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TimeCutter™ Z Service Manual

TRANSAXLE

5

IMPORTANT:

Before installing a new transaxle,

check the oil level and check the torque on the
nut retaining the input pulley. Torque to 30 - 35
ft. lbs. (40.7 N·m - 47.5 N·m).

Use a jack to lift the transaxle into the chassis.
Carefully guide it into position so that the cooling
fan does not catch on the chassis and the
bypass rod is properly positioned in the lever.
Insert the vent hose through the slot provided for
it in the frame.

Install the two axle bolts, washer, and nuts to the
frame. Do not tighten the bolts. Reinstall the
rest of the bolts, washers, and nuts in the lower
hydro plate. If the plate was completely
removed, make sure the lip of the plate is
pointing to the front and down. Tighten the
transaxle bolts and nuts following the sequence
shown in the photo. Torque the bolts and nuts to
200 in. lbs. (22.6 N·m)

5

3

1

4

2

0702-0516

0702-0515

0702-0513

Reassembly

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Summary of Contents for TimeCutter Z Series

Page 1: ...ON POINTS ENGINE BRIGGS STRATTON ENGINE KOHLER ENGINE KAWASAKI ENGINE BRIGGS STRATTON AIR CLEANER KOHLER AIR CLEANER KAWASAKI AIR CLEANER SPARK PLUG ENGINE REMOVE AND REPLACE TRANSAXLE TROUBLESHOOTING CHECKLIST FLUIDS REMOVE AND REPLACE TRANSAXLE REASSEMBLY CONTROL HANDLE RETURN TO NEUTRAL ADJUSTMENT PURGING THE SYSTEM NEUTRAL ADJUSTMENT TRACKING ADJUSTMENT CONTROL HANDLE ADJUSTMENT CHASSIS REMOVE...

Page 2: ...REMOVAL AND REPLACEMENT MOWER DECK REMOVE AND REPLACE MOWER DECK SIDE TO SIDE ADJUSTMENT MOWER DECK FRONT TO REAR ADJUSTMENT SPINDLE BEARING REPLACEMENT ELECTRICAL SYSTEMS SAFETY INTERLOCK SYSTEM INTERLOCK COMPONENTS ELECTRICAL COMPONENTS ELECTRIC CLUTCH ELECTRICAL SCHEMATICS BRIGGS STRATTON KAWASAKI KOHLER ...

Page 3: ...TimeCutter Z TimeCutter ZX Service Manual ...

Page 4: ... refer to the appropriate engine manufacturer s service and repair instructions 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 Consumer Service Training Department 8111 Lyndale Avenue South Bloomington MN 55420 The Toro Company reserves the...

Page 5: ...Z Service Manual 1 1 QUICK REFERENCE SECTION Safety Information Specifications Maintenance SERVICE SECTION Model Serial Number Greasing and Lubrication Engine Transaxle Chassis Mower Decks Electrical Systems 1a 1b 1c 2 3 4 5 6 7 8 ...

Page 6: ...le of Contents SAFETY INFORMATION General Information 1 3 Think Safety First 1 3 SPECIFICATIONS Engine Specifications Z16 44 Z17 44 1 4 Engine Specifications Z17 52 Z18 52 1 5 BOLT TORQUES 1 6 MAINTENANCE SCHEDULE Z16 44 1 7 Z17 44 Z17 52 1 8 Z18 52 1 9 ...

Page 7: ...e in temperature during operation while the unit is running or shortly after it has been running Avoid fires and explosions Avoid spilling fuel and never smoke while working with any type of fuel or lubricant Wipe up any spilled fuel or oil immediately Never remove the fuel cap or add fuel when the engine is running Always use approved labeled containers for storing or transporting fuel and lubric...

Page 8: ...ve Tires 18x10 8 4 ply with Multitrac CS Tread 18x10 8 4 ply with Multitrac CS Tread Front Caster Tires 410 350 x 4 4 25 IS with sawtooth tread 410 350 x 4 4 25 IS with sawtooth tread Tire Pressure 13 psi 90 kPa rear 35 psi 241 kPa front 13 psi 90 kPa rear 35 psi 241 kPa front ELECTRICAL SYSTEM Battery Voltage 12 volt negative ground 12 volt negative ground Battery Type BCI Group U1 BCI Group U1 D...

Page 9: ...res 18x10 10 10 5 4 ply with Multitrac CS Tread 18x10 10 10 5 4 ply with Multitrac CS Tread Front Caster Tires 410 350 x 4 4 25 IS with sawtooth tread 410 350 x 4 4 25 IS with sawtooth tread Tire Pressure 13 psi 90 kPa rear 35 psi 241 kPa front 13 psi 90 kPa rear 35 psi 241 kPa front ELECTRICAL SYSTEM Battery Voltage 12 volt negative ground 12 volt negative ground Battery Type BCI Group U1 BCI Gro...

Page 10: ...ported Right side discharge 44 in cut three blade mid mounted rotary Drawn 13 gauge steel with welded mounting brackets and gauge wheel brackets Frame supported Fuel System Single fuel tank fender type mounted on the left side Single fuel tank fender type mounted on the left side Capacity 5 Gallons 18 9 L Fuel tank shut off In line fuel ﬁlter 5 Gallons 18 9 L Fuel tank shut off In line fuel ﬁlter ...

Page 11: ... center of castor wheel to center of drive tires Width 43 109 2cm outside rear tires 43 109 2cm outside rear tires Overall Width 55 139 7cm with deck deﬂector down 46 6 188 4cm Gate width with deck deﬂector up 55 139 7cm with deck deﬂector down 46 6 188 4cm Gate width with deck deﬂector up Overall Length 77 5 196 9cm 77 5 196 9cm Overall Height 40 101 6cm 40 101 6cm Track Width 35 2 89 4cm center ...

Page 12: ...ackets Frame supported Right side discharge 52 in cut three blade mid mounted rotary Drawn 12 gauge steel with welded mounting brackets and gauge wheel brackets Frame supported Fuel System Single fuel tank fender type mounted on the left side Single fuel tank fender type mounted on the left side Capacity 5 Gallons 18 9 L Fuel tank shut off In line fuel ﬁlter 5 Gallons 18 9 L Fuel tank shut off In ...

Page 13: ...52 1 132 3cm center of castor wheel to center of drive tires Width 47 6 120 9cm outside rear tires 47 6 120 9cm outside rear tires Overall Width 65 165 1cm with deck deﬂector down 58 147 3cm Gate width with deck deﬂector up 65 165 1cm with deck deﬂector down 58 147 3cm Gate width with deck deﬂector up Overall Length 77 5 196 9cm 77 5 196 9cm Overall Height 41 104 1cm 41 104 1cm Track Width 37 5 95...

Page 14: ...and gauge wheel brackets Frame supported Right side discharge 52 cut three blade mid mounted rotary Drawn 12 gauge steel with welded mounting brackets and gauge wheel brackets Frame supported Fuel System Single fuel tank fender type mounted on the left side Single fuel tank fender type mounted on the left side Capacity 5 Gallons 18 9 L Fuel tank shut off In line fuel ﬁlter 5 Gallons 18 9 L Fuel ta...

Page 15: ... 132 3cm center of castor wheel to center of drive tires Width 47 6 120 9cm outside rear tires 47 6 120 9cm outside rear tires Overall Width 65 165 1cm with deck deﬂector down 58 147 3cm Gate width with deck deﬂector up 65 165 1cm with deck deﬂector down 58 147 3cm Gate width with deck deﬂector up Overall Length 77 5 196 9cm 77 5 196 9cm Overall Height 41 104 1cm 41 104 1cm Track Width 37 5 95 3cm...

Page 16: ...rame supported Right side discharge 44 cut three blade mid mounted rotary Drawn 13 gauge steel with welded mounting brackets and gauge wheel brackets Frame supported Fuel System Single fuel tank fender type mounted on the left side Single fuel tank fender type mounted on the left side Capacity 5 Gallons 18 9 L Fuel tank shut off In line fuel ﬁlter 5 Gallons 18 9 L Fuel tank shut off In line fuel ﬁ...

Page 17: ...of castor wheel to center of drive tires Width 43 109 2cm outside rear tires 43 109 2cm outside rear tires Overall Width 55 139 7cm with deck deﬂector down 46 6 188 4cm Gate width with deck deﬂector up 60 139 7cm with deck deﬂector down 49 118 4cm Gate width with deck deﬂector up Overall Length 77 5 196 9cm 77 5 196 9cm Overall Height 40 101 6cm 40 101 6cm Track Width 35 2 89 4cm center to center ...

Page 18: ...ut three blade mid mounted rotary Drawn 12 gauge steel with welded mounting brackets and gauge wheel brackets Frame supported Fuel System Single fuel tank fender type mounted on the left side Single fuel tank fender type mounted on the left side Capacity 5 Gallons 18 9 L Fuel tank shut off In line fuel ﬁlter 5 Gallons 18 9 L Fuel tank shut off In line fuel ﬁlter Traction System Transaxles Twin Hyd...

Page 19: ...r of castor wheel to center of drive tires Width 43 109 2cm outside rear tires 47 6 120 9cm outside rear tires Overall Width 62 5 158 8cm with deck deﬂector down 53 5 135 9cm Gate width with deck deﬂector up 68 165 1cm with deck deﬂector down 55 147 3cm Gate width with deck deﬂector up Overall Length 77 5 196 9cm 77 5 196 9cm Overall Height 40 101 6cm 41 101 6cm Track Width 35 2 89 4cm center to c...

Page 20: ...60 ft lb 54 82 N m Caster Bolts 77 95 ft lb 105 130 N m 77 95 ft lb 105 130 N m Clutch Bolt 50 60 ft lb 68 82 N m 50 60 ft lb 68 82 N m Engine Mounting Bolts 120 180 ft lb 164 246 N m 120 180 ft lb 164 246 N m Spindle Pulley Nuts 80 100 ft lb 109 136 N m 50 75 ft lb 68 102 N m Wheel Lug Nuts 70 90 ft lb 95 5 123 N m 70 90 ft lb 95 5 123 N m ...

Page 21: ...m air cleaner1 Check the belts for wear cracks Check the battery electrolyte Check the tire pressure Change the engine oil2 Every 50 hours Clean the cooling system1 Every 100 hours Service the paper air cleaner1 Change the oil filter2 Replace the fuel filter Replace the spark plug s Before Storage Perform all maintenance procedures listed above Drain the fuel tank Charge the battery and disconnect...

Page 22: ...ck the belts for wear cracks Check the battery electrolyte Check the tire pressure Change the engine oil1 Every 100 hours Replace the paper air cleaner1 Change the oil filter1 Every 200 hours Replace the fuel filter Check the spark plug s Before Storage Perform all maintenance procedures listed above Drain the fuel tank Charge the battery and disconnect the battery cables Paint any chipped surface...

Page 23: ... electrolyte Check the tire pressure Service the paper air cleaner1 Every 50 hours Change the engine oil Every 100 hours Check the spark plug s Change the oil filter Every 200 hours Replace the fuel filter Replace the paper air cleaner1 Clean the engine shrouds and cooling fins1 Every 300 hours Before Storage Perform all maintenance procedures listed above Drain the fuel tank Charge the battery an...

Page 24: ...1 10 TimeCutter Z Service Manual THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 25: ...utter Z Service Manual 2 1 QUICK REFERENCE SECTION Safety Information Specifications Maintenance SERVICE SECTION Model Serial Number Greasing and Lubrication Engine Transaxle Chassis Mower Decks Electrical Systems 1a 1b 1c 2 3 4 5 6 7 8 ...

Page 26: ...2 2 TimeCutter Z Service Manual MODEL SERIAL NUMBER LOCATION Table of Contents MODEL SERIAL NUMBER LOCATION 2 3 ...

Page 27: ... shown in the illustration The engine has its own model and serial number identification Consult the appropriate engine manufacturer s service literature for the location and translation of the engine model and serial number information Transaxles also have their own model serial number MODEL SERIAL NUMBER LOCATION 0702 0201 0702 0202 ...

Page 28: ...THIS PAGE INTENTIONALLY LEFT BLANK 2 4 TimeCutter Z Service Manual ...

Page 29: ...ter Z Service Manual 3 1 3 QUICK REFERENCE SECTION Safety Information Specifications Maintenance SERVICE SECTION Model Serial Number Greasing and Lubrication Engine Transaxle Chassis Mower Decks Electrical Systems 1a 1b 1c 2 4 5 6 7 8 ...

Page 30: ...3 2 TimeCutter Z Service Manual GREASING AND LUBRICATION Table of Contents Service Interval Specification 3 3 Lubrication Points 3 4 ...

Page 31: ...t should be greased every 25 hours more often when operating in dirty dusty or sandy conditions A decal located under the seat shows the location of all the grease zerks Grease Type General purpose lithium base grease 0702 0301 Service Interval Specification 0702 0302 ...

Page 32: ... AND LUBRICATION 3 There is a grease fitting on the mower for right and left outer spindle The grease zerk for the center mower spindle There is a grease fitting for the deck idler arm bushing 0702 0303 0702 0304 0702 0305 Lubrication Points ...

Page 33: ...re are 2 grease fittings for the deck raising pivot bushings one on each side of the unit The grease zerk for the deck height adjustment lever is on the right side of the machine There are grease fittings for each front castor bushing 0702 0306 0702 0307 0702 0308 ...

Page 34: ...ATION 3 as well as the castor wheel bearings The zerk fitting for the traction belt idler bushing is located under the seat Also under the seat are the fittings for the motion control lever pivot bushings one for each lever 0702 0309 0702 0310 0702 0311 ...

Page 35: ...vice Manual 4 1 QUICK REFERENCE SECTION Safety Information Specifications Maintenance SERVICE SECTION Model Serial Number Greasing and Lubrication Engine Transaxle Chassis Mower Decks Electrical Systems 1a 1b 1c 2 3 4 5 6 7 8 ...

Page 36: ...ce Manual ENGINE Table of Contents Briggs Stratton Engine 4 3 Kohler Engine 4 3 Kawasaki Engine 4 3 Briggs Stratton Air Cleaner 4 4 Kohler Air Cleaner 4 4 Kawasaki Air Cleaner 4 4 Spark Plug 4 5 Engine Remove and Replace 4 6 ...

Page 37: ...5W 30 Oil Type Detergent oil API service SG SH SJ or higher Crankcase Capacity with filter 2 1 qt 2 l Viscosity See table Change Oil Kohler Every 50 hours Change oil filter every 100 hours 10W 30 5W 20 5W 30 Oil Type Detergent oil API service SC SD SE SF SG or SH Crankcase Capacity with filter 1 6 qt 1 5 l Viscosity See table Change Oil Kawasaki After the first use Every 100 hours Change oil filte...

Page 38: ... a flat surface to remove dust and dirt Inspect the element for tears oil contamination and damage to the rubber seal NOTE Never clean the paper element with compressed air or solvents If the element is dirty or damaged replace it immediately A Paper Element B Foam Precleaner C Cover A B C The air cleaner assembly consists of a paper filter element and a foam precleaner To clean the paper element ...

Page 39: ... Kawasaki engines replace the spark plug s every 100 operating hours On Kohler engines check the spark plug s every 200 operating hours If the insulator on the spark plug s is light brown or gray the engine is running properly A black coating on the insulator indicates the air cleaner may be dirty IMPORTANT Never clean the spark plug s Always replace the spark plug s when it has a black coating wo...

Page 40: ...TimeCutter Z Service Manual ENGINE 4 Disconnect the negative battery cable NEW PHOTO Close the fuel shut off Remove the fuel line from the fuel filter 0702 0408 0702 0409 0702 0410 Engine Remove and Replace ...

Page 41: ...ter Z Service Manual 4 7 4 Disconnect the clutch PTO wiring Disconnect the engine wiring harness plug Loosen the throttle choke cable clamp and remove the cable from the governor linkage 0702 0411 0702 0412 0702 0413 ...

Page 42: ...utter Z Service Manual ENGINE 4 Remove the ground cable from the engine block On Kohler engines loosen the oil filter base bolts and remove the filter base Remove the starter cable 0702 0414 0702 0415 0702 0416 ...

Page 43: ...pter 8 Remove the clutch bolt and lower the clutch assembly Remove traction drive belt Move the idler pulley to lessen the tension on the traction drive belt and slip the belt up off the engine drive pulley Then remove the clutch and drive pulley from the crankshaft 0702 0417 0702 0418 0702 0419 ...

Page 44: ...4 10 TimeCutter Z Service Manual ENGINE 4 Remove the 4 engine mounting bolts Lift the engine from the chassis Reverse the above steps to replace 0702 0420 0702 0421 ...

Page 45: ...vice Manual 5 1 QUICK REFERENCE SECTION Safety Information Specifications Maintenance SERVICE SECTION Model Serial Number Greasing and Lubrication Engine Transaxle Chassis Mower Decks Electrical Systems 1a 1b 1c 2 3 4 5 6 7 8 1c ...

Page 46: ... Contents Troubleshooting Checklist 5 3 Fluids 5 4 Remove and Replace Transaxle 5 5 Reassembly 5 10 Control Handle Return To Neutral Adjustment 5 14 Purging the System 5 16 Neutral Adjustment 5 18 Tracking Adjustment 5 22 Control Handle Adjustment 5 24 ...

Page 47: ... replace loose parts Repair or replace valve or linkage Purge hydraulic system UNIT HAS NO LOW POWER Engine speed low Control linkage bent or out of adjustment Brake setting incorrect Drive belt slipping or pulley damaged Oil level low or contaminated oil Excessive loading Bypass assembly sticking Air trapped in hydraulic system Adjust to correct setting Repair or replace linkage Adjust brake to p...

Page 48: ...e oil has been selected for use by the factory and is recommended for normal operating temperatures Check oil level when cold To check the transaxle fluid level remove the vent Oil level should be 1 7 8 2 3 16 4 8 cm 5 56 cm from the top of the vent port The oil level can only be checked when the transaxle is removed from the machine 0702 0501 0702 0502 Fluids ...

Page 49: ...NSAXLE TimeCutter Z Service Manual 5 5 5 Disconnect the battery Close the fuel shut off Raise the rear of the unit and support it with jack stands 0702 0408 0702 0409 0702 0505 Remove and Replace Transaxle ...

Page 50: ...ter Z Service Manual TRANSAXLE 5 Remove the clip that secures the vent hose to the chassis If necessary engage the parking brake to facilitate wheel removal Remove the wheel assembly 0702 0506 0702 0507 0702 0508 ...

Page 51: ...Manual 5 7 5 Remove the parking brake link from the brake arm Disconnect the motion control link from the transaxle Remove the hairpin cotter and washer from the bypass valve lever Leave the rod in place 0702 0509 0702 0510 0702 0511 ...

Page 52: ... the belt up off the engine drive pulley Remove the belt from the transaxle being removed Loosen and remove the 6 bolts and washer between both transaxles Remove the hydro lower plate Note the orientation of the hydro lower plate It must be reinstalled with the lip facing down toward the front 0702 0419 0702 0512 0702 0513 ...

Page 53: ...TimeCutter Z Service Manual 5 9 5 Support the transaxle with a jack while removing the last bolts Guide the transaxle as it is lowered Make sure the cooling fan and vent hose clear the chassis 0702 0514 0702 0515 ...

Page 54: ...the bypass rod is properly positioned in the lever Insert the vent hose through the slot provided for it in the frame Install the two axle bolts washer and nuts to the frame Do not tighten the bolts Reinstall the rest of the bolts washers and nuts in the lower hydro plate If the plate was completely removed make sure the lip of the plate is pointing to the front and down Tighten the transaxle bolt...

Page 55: ... the traction belt on the pulley Check for correct belt routing A Engine Pulley B Idler Pulley C Right Hydro D Left Hydro Install the hairpin cotter pin and washer on the bypass valve lever Reinstall the motion control link 1s 0802 0702 0511 0702 0517 ...

Page 56: ...t at the factory and should not normally require adjustment in the field If the link has been tampered with the distance between bolt centers is Left side 3 6 9 14 cm Right side 3 1 7 9 cm Install the parking brake linkage Replace the wheel assembly 0702 0517 0702 0509 0702 0508 ...

Page 57: ...RANSAXLE TimeCutter Z Service Manual 5 13 5 Secure the vent hose to the chassis Recheck to make sure the brake arm clears the teeth of the brake cog when the park brake is disengaged 0702 0506 0702 0518 ...

Page 58: ...ion 2 Let the handles go They should return to the neutral position which means the handle should line up with the neutral slot neutral lockout position 3 If adjustment is needed A Lift the seat and located the adjusters Loosen the jam nut on the yoke 0702 0519 0702 0520 0702 0521 Control Handle Return To Neutral Adjustment ...

Page 59: ... lined up with the neutral slot Neutral Lockout Position C Tighten the jam nut and then test the directional control handle by pulling the handle in reverse and then let the handle go It should return to the neutral slot D Before starting the unit follow the procedures on Purging the System 0702 0522 0702 0520 ...

Page 60: ...han that of the oil normally approved for use in hydrostatic drive systems The following procedures should be performed with the vehicle drive wheels off the ground the seat switch temporarily bypassed and the brake arm completely disengaged from the brake cog see Parking Brake Adjustment page 6 18 The procedure may need to be repeated under normal operating conditions 1 With the bypass valves ope...

Page 61: ...the engine running slowly move the directional control handles through the forward and reverse directions 5 to 6 times 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 0702 0524 ...

Page 62: ... the transaxle 2 Operate the unit to determine which transaxle needs adjustment 3 Raise the unit and place it on jack stands 4 Warm the transaxle fluid by running for at least 10 minutes 5 Unplug the seat switch and temporarily connect a jumper wire across the plug connector 0702 0525 0702 0505 2001 050 Neutral Adjustment ...

Page 63: ... half throttle 7 The rear traction wheels should remain stationary or creep slightly in reverse 8 If necessary loosen the jam nuts A and turn the control rod until the wheel stops between forward and reverse In some cases you may have a slight creep in reverse When you lower the unit to the ground it should stop A 0702 0526 0702 0527 0702 05028 ...

Page 64: ...e neutral lock out position 10 Run the engine at full throttle Check neutral again by moving the directional control handles in reverse then let go of the handles The handles should move to the neutral position and the drive wheels should not move A slight creep could be observed when the machine is elevated However when lowering the unit to the ground the weight of the unit should stop the creep ...

Page 65: ...TRANSAXLE TimeCutter Z Service Manual 5 21 5 12 Remove the jumper wire on the seat switch and plug the switch into the harness Lower the unit to the ground 0702 0532 ...

Page 66: ... kPa rear 35 psi 241 kPa front Tire pressure has a great influence on the tracking of these units It is advisable to check for a large deviation in outside diameter of the tires side to side if the tracking error is severe Also check that the front casters rotate freely and the front wheel bearings are in good condition 2 You may be able to make a slight tracking adjustment by turning the neutral ...

Page 67: ...up for forward motion It is not unusual to have a large tracking error when going a distance in reverse Do not try to adjust reverse tracking If you do it will misadjust the forward linkage 3 After attempting any tracking change with the unit make sure it is still neutralized 0702 0527 ...

Page 68: ...l handles do not line up with each other they require adjustment 1 Loosen the bolts attaching the handles to the control linkage 2 Adjust the position of the handles so that they are aligned Tighten the bolts after adjustment 0702 0534 0702 0535 Control Handle Adjustment ...

Page 69: ...ce Manual 5 TRANSAXLE Transaxle Identification Model Year 2001 2004 Hydro Gear Model 310 2400 IZT Transaxles Transaxle Identification Model Year 2005 and Later Hydro Gear Model 310 2600 IZT with a Charge Pump PICT 6171 MVC 353X ...

Page 70: ...A5 26 TimeCutter ZX Service Manual 5 TRANSAXLE THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 71: ...vice Manual 6 1 QUICK REFERENCE SECTION Safety Information Specifications Maintenance SERVICE SECTION Model Serial Number Greasing and Lubrication Engine Transaxle Chassis Mower Decks Electrical Systems 1a 1b 2 3 4 5 6 7 8 1c ...

Page 72: ...2 Table of Contents Remove and Replace Dampers 6 3 Remove and Replace Control Linkage 6 4 Replace Control Linkage 6 8 Remove and Replace Brake Linkage 6 11 Replace Brake Linkage 6 15 Parking Brake Adjustment 6 18 Replace Traction Belt 6 20 ...

Page 73: ...SSIS TimeCutter Z Service Manual 6 3 6 Remove the E clip and washer at the bottom of the damper Remove the bolt at the top of the damper and remove the damper 0702 0601 0702 0602 Remove and Replace Dampers ...

Page 74: ... Manual CHASSIS 6 Remove the control arm Remove the electrical connector from the motion control switch NEW PHOTO Remove the pin from the return to neutral yoke 0702 0603 0702 0604 0702 0605 Remove and Replace Control Linkage ...

Page 75: ... Manual 6 5 6 Remove the link between the front and rear bellcranks NOTE All the ball joint assemblies are installed with a flat washer between the ball joint and lever Disconnect the steering damper 0702 0606 0702 0607 0702 0608 ...

Page 76: ...ASSIS 6 Remove the bolts securing the bushings at each end of the control shaft Remove the control shaft Disconnect the link between the transaxle and the bellcrank NOTE Do not change the length of the link 0702 0609 0702 0610 0702 0611 ...

Page 77: ...meCutter Z Service Manual 6 7 6 Use a small punch to drive the roll pin out of the upper bellcrank lever then remove the lever and thrust washer Pull the lower lever and shaft from the bushing 0702 0612 0702 0613 ...

Page 78: ...and install in bushing The lever welded to the shaft goes on the underside of the chassis Carefully position the top lever on the shaft and secure with roll pin Install the link between the transaxle and bellcrank lever 0702 0613 0702 0614 0702 0517 Replace Control Linkage ...

Page 79: ...tion control shaft in position in the console and secure with nuts and bolts NOTE Make sure shaft is rotating freely after installation Reconnect the steering damper Replace the link connecting the control shaft and bellcrank 0702 0609 0702 0608 0702 0606 ...

Page 80: ...vice Manual CHASSIS 6 Attach the return to neutral adjustment yoke to the control shaft lever Connect the wiring to the neutral switch Position the motion control handle and secure with 2 bolts 0702 0605 0702 0604 0702 0603 ...

Page 81: ...link from the brake arm Remove the clip and yoke from the brake shaft lever Remove the cotter pin and washer from the actuator rod NOTE The actuator rod cannot be removed from the lever at this time 0702 0509 0702 0615 0702 0616 Remove and Replace Brake Linkage ...

Page 82: ...ng the brake shaft NOTE During reassembly the wiring harness is routed below the brake shaft throttle cable is routed above Remove the brake shaft from the chassis and actuator rod To remove the front brake shaft first remove the brake handle 0702 0617 0702 0618 0702 0619 ...

Page 83: ...TimeCutter Z Service Manual 6 13 6 Remove the brake switch Remove the cotter pin and washer from the brake rod and remove the rod Remove the two bolts and nuts securing the bushing 0702 0620 0702 0621 0702 0622 ...

Page 84: ...6 14 TimeCutter Z Service Manual CHASSIS 6 Remove the E clip from the brake shaft To remove the bellcrank first slide it to the operator s left then down 0702 0623 0702 0624 ...

Page 85: ...e shaft Position the brake shaft in the console Secure with nuts and bolts Install bolts from the outside NOTE Make sure shaft rotates freely after installation Connect the brake rod to the brake shaft lever Secure with the cotter pin and washer 0702 0625 0702 0626 0702 0621 Replace Brake Linkage ...

Page 86: ...e the brake switch and install wiring Install the brake handle on the brake shaft Position the rear brake shaft on the chassis with the upper brake rod through the hole in the lever and secure with a washer and cotter pin 0702 0620 0702 0619 0702 0616 ...

Page 87: ...d below the brake shaft and the throttle cable above Then secure the brake shaft with the two clamps Install the brake links to the brake arms with a washer and cotter pin Install the adjustment yokes to the brake shaft levers with clevis pins and hairpins 0702 0617 0702 0509 0702 0615 ...

Page 88: ...e is disengaged there must be clearance between the brake arm and the brake cog or severe damage could occur to the transaxle A Brake Linkage B Brake Cog C Brake Arm A B C When the parking brake is released the brake arm pivots away from the brake cog allowing the brake shaft to turn The brake arm is held in place by spring tension The nut at the bottom of the spring should have approximately two ...

Page 89: ...ve the clevis pin and turn the yoke to adjust the length of the rod until the brake arm engages and disengages the cog completely 3 Reconnect the brake rod clevis and tighten the jam nut Recheck to make sure the brake arm clears the teeth of the brake cog when the park brake is disengaged 0702 0629 0702 0630 0702 0518 ...

Page 90: ...ical connection for the PTO clutch Remove the mower deck drive belt from the left side pulley and clutch pulley Place the rear of the unit on jack stands Remove the PTO clutch bolt and the electric clutch assembly 0702 0411 0702 0417 0702 0631 Replace Traction Belt ...

Page 91: ...e traction drive belt and slip the belt up off the engine drive pulley Remove the traction belt from the transaxle pulleys Install the traction belt following the belt routing Reconnect the idler bracket spring and tighten the eye bolt A Engine Pulley B Idler Pulley C Right Hydro D Left Hydro 0702 0632 0702 0512 1S 0802 ...

Page 92: ... 6 Reinstall the electric PTO clutch apply Loctite 271 to the bolt Torque the clutch bolt to 50 60 ft lbs 68 3 81 8 N m It will be necessary to remove the flywheel screen and hold the flywheel nut to achieve proper torque 0702 0633 0702 0634 ...

Page 93: ...ervice Manual 7 1 QUICK REFERENCE SECTION Safety Information Specifications Maintenance SERVICE SECTION Model Serial Number Greasing and Lubrication Engine Transaxle Chassis Mower Decks Electrical Systems 1a 1b 1c 2 3 4 5 6 7 8 ...

Page 94: ...WER DECKS Table of Contents 44 48 AND 52 DECK ASSEMBLIES Belt Removal and Replacement 7 3 Mower Deck Remove and Replace 7 5 Mower Deck Side to Side Adjustment 7 8 Mower Deck Front to Rear Adjustment 7 9 Spindle Bearing Replacement 7 11 ...

Page 95: ...l 7 3 7 Place the deck height lever in its lowest position Remove the pulley covers Remove the hairpin and washers on left and rear mower pork chop bracket 44 48 52 DECK ASSEMBLIES 0702 0701 0702 0702 0702 0703 Belt Removal and Replacement ...

Page 96: ...ce Manual MOWER DECKS 7 Place a length of 3 4 pipe over the idler pulley rod and remove the belt tension Remove the belt from the pulley Reverse the steps above to reassemble Route the drive belt as shown 0702 0417 0702 0716 ...

Page 97: ...KS TimeCutter Z Service Manual 7 5 7 Place the mower deck in its lowest position Remove the pulley covers Remove the belt as described in this section 0702 0701 0702 0702 0702 0417 Mower Deck Remove and Replace ...

Page 98: ...7 6 TimeCutter Z Service Manual MOWER DECKS 7 Remove the mower pork chop brackets Remove the rear trunion rods Remove the front trunion rods 0702 0704 0702 0705 0702 0706 ...

Page 99: ...MOWER DECKS TimeCutter Z Service Manual 7 7 7 Tie the rear trunion rods to the frame Slide the deck out from under the right side of the unit 0702 0707 0702 0708 ...

Page 100: ...he blade tips and the surface on both sides of the deck If the difference is greater than 3 16 4 72 mm adjustment is required 1 Remove the spring clip and washers from the pork chop bracket 2 Rotate the bracket toward the front to lower or toward the rear to raise that side of the deck 3 Replace the spring clip NOTE Each adjustment hole changes the dimension by 1 8 inch 0702 0725 0702 0703 Mower D...

Page 101: ...n rods The distance between centers should be 11 5 29 3 cm If necessary loosen the jam nut Remove the spring clip and washer and turn the rod to achieve the correct length Reinstall the trunion rods and raise the deck to the 3 7 6 cm position Rotate the blades until the ends face forward and backward 0702 0709 0702 0710 0702 0711 Mower Deck Front to Rear Adjustment ...

Page 102: ...blade height gauge to measure the blade height at the front of the center blade and at the rear of the side blades Adjust the front trunion rods until the front blade tip is 1 16 5 16 1 6 7 9 mm lower than the rear Tighten the jam nuts 0702 0712 0702 0713 ...

Page 103: ...vice Manual 7 11 7 Remove the nut and washer securing the spindle pulley Slide the pulley off the shaft Remove the shaft washer and blade assembly from the spindle housing 0702 0714 0702 0726 0702 0715 Spindle Bearing Replacement ...

Page 104: ...the spindle housing assembly from the deck Use a long punch to drive the bearings from the spindle housing There is a spacer between the two bearings The spindle housing assembly consists of a casting two bearings and a spacer 0702 0717 0702 0718 0702 0720 ...

Page 105: ...ld to the outside A Open Side B Shielded Side A B On 52 decks the bearings are a line to line fit in the spindle housings and can be installed by hand On 44 decks the bearings must be installed with a press On the blade side of the spindle housing locate the bearing flush with the counterbore 0702 0719 0702 0727 0702 0721 ...

Page 106: ...ual MOWER DECKS 7 Install the spacer between the two bearings On the pulley side of the spindle housing the bearing is located flush with the top of the bore Grease bearings with 2 lithium base grease 0702 0722 0702 0723 0702 0724 ...

Page 107: ... Z Service Manual 8 1 QUICK REFERENCE SECTION Safety Information Specifications Maintenance SERVICE SECTION Model Serial Number Greasing and Lubrication Engine Transaxle Chassis Mower Decks Electrical Systems 1a 1b 1c 2 3 4 5 6 7 8 ...

Page 108: ... Z Service Manual ELECTRICAL SYSTEMS Table of Contents SAFETY INTERLOCK SYSTEM Interlock Components 8 3 Electrical Components 8 5 Electric Clutch 8 7 ELECTRICAL SCHEMATICS Briggs Stratton 8 8 Kawasaki 8 9 Kohler 8 10 ...

Page 109: ...itch One pair gray and violet is wired in series with the PTO switch When the PTO switch is in the off position power from the I terminal of the ignition switch flows through the PTO switch then through this pair of brake switch contacts to energize the kill relay The second pair of contacts yellow and violet are wired in series with the seat switch When the operator is on the seat power from the ...

Page 110: ...8 4 TimeCutter Z Service Manual ELECTRICAL SYSTEMS 8 The seat switch is closed when the operator is on the seat 0702 0804 ...

Page 111: ... clutch when in the on position and to the kill relay through the brake switch when in the off position The start solenoid connects the battery to the starter motor The kill relay connects the engine magneto to ground whenever it is not energized 0702 0805 0702 0812 0702 0812 Electrical Components ...

Page 112: ...6 TimeCutter Z Service Manual ELECTRICAL SYSTEMS 8 There are two fuses in the system The 30 amp fuse is in the main power supply from the battery The 25 amp fuse is in the battery charge circuit 0702 0808 ...

Page 113: ...the resistance across the clutch plug terminals The resistance should be 2 9 ohms 20 Connect a 12 volt power source across the clutch plug The clutch should click when it engages The clutch uses a magnetic brake to stop the mower blades when disengaged Test this function when mounted on the vehicle with mower installed Blade stopping time should be 3 seconds or less 0702 0809 0702 0810 0702 0811 E...

Page 114: ...8 8 TimeCutter Z Service Manual ELECTRICAL SYSTEMS 8 Electrical Schematic Briggs Stratton ...

Page 115: ...ELECTRICAL SYSTEMS TimeCutter Z Service Manual 8 9 8 Electrical Schematic Kawasaki ...

Page 116: ...8 10 TimeCutter Z Service Manual ELECTRICAL SYSTEMS 8 Electrical Schematic Kohler ...

Page 117: ......

Page 118: ...492 4736 Revised 5 07 ...

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