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Toro XL Series Service Manual

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TORO XL LAWN TRACTOR SERVICE MANUAL
Table of Contents – Page 1 of 3
SPECIFICATIONS
DIMENSIONS
HYDRO-GEAR HYDROSTATIC TRANSAXLE USAGE
TURNING RADIUS
ELECTRICAL SYSTEM
TECUMSEH PEERLESS TRANSAXLES
1993 - 1995
1996 - PRESENT
TORQUE SPECIFICATIONS
FASTENER IDENTIFICATION
STANDARD TORQUE FOR DRY, ZINC PLATED, AND STEEL FASTENERS (INCH SERIES)
STANDARD TORQUE FOR DRY, ZINC, AND STEEL FASTENERS (METRIC FASTENERS)
OTHER TORQUE SPECIFICATIONS
SAE GRADE 8 STEEL SET SCREWS
THREAD CUTTING SCREWS (ZINC PLATED STEEL)
CONVERSION FACTORS
WHEEL BOLTS AND LUG NUTS
THREAD CUTTING SCREWS (ZINC PLATED STEEL)
EQUIVALENTS AND CONVERSIONS
DECIMAL AND MILLIMETER EQUIVALENTS
U.S. TO METRIC CONVERSIONS
XL GEAR DRIVE
XL GEAR DRIVE TRANSAXLE REMOVAL - 915 TRANSAXLE
XL GEAR DRIVE TRANSAXLE INSTALLATION - 915 TRANSAXLE
XL GEAR DRIVE TRACTION DRIVE BELT REPLACEMENT PROCEDURE - 915 TRANSAXLE
XL GEAR DRIVE SHIFT LEVER ADJUSTMENT - 915 TRANSAXLE
XL GEAR DRIVE BRAKE ADJUSTMENT -915 TRANSAXLE
XL GEAR DRIVE MST-205 TRANSAXLE REMOVAL
XL GEAR DRIVE MST-205 TRANSAXLE INSTALLATION
XL GEAR DRIVE SHIFT LEVER ADJUSTMENTS, MST-205 TRANSAXLE
XL GEAR DRIVE BRAKE ADJUSTMENT, MST-205 TRANSAXLE
CHECKING THE BRAKE
ADJUSTING THE BRAKE
XL GEAR DRIVE TRACTION DRIVE BELT REPLACEMENT PROCEDURE, MST-205 TRANSAXLE
CABLE ADJUSTMENT, SHIFT-ON-THE-GO, 915 AND MST-205 TRANSAXLE
XL HYDROSTATIC TRANSAXLES
IDENTIFICATION
HYDRO-GEAR 0500/0750 TRANSAXLE
HYDRO-GEAR 0510 TRANSAXLE
INTERNAL SERVICE
TROUBLESHOOTING CHART
PURGING PROCEDURES
FLUID CHANGE
HXL HYDRO TRANSAXLE REMOVAL - 2000 AND PRIOR
NEUTRAL ADJUSTMENT - HXL HYDRO- 2000 AND PRIOR
BRAKE ADJUSTMENT - HXL HYDRO - 2000 AND PRIOR
TRACTION DRIVE BELT REPLACEMENT ON HXL HYDRO - 2000 AND PRIOR
HXL HYDRO TRANSAXLE REMOVAL - 2001 AND LATER
HXL HYDRO TRANSAXLE INSTALLATION - 2001 AND LATER

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  • Page 1 TORO XL LAWN TRACTOR SERVICE MANUAL Table of Contents – Page 1 of 3 SPECIFICATIONS DIMENSIONS HYDRO-GEAR HYDROSTATIC TRANSAXLE USAGE TURNING RADIUS ELECTRICAL SYSTEM TECUMSEH PEERLESS TRANSAXLES 1993 - 1995 1996 - PRESENT TORQUE SPECIFICATIONS FASTENER IDENTIFICATION STANDARD TORQUE FOR DRY, ZINC PLATED, AND STEEL FASTENERS (INCH SERIES)
  • Page 2 TORO XL LAWN TRACTOR SERVICE MANUAL Table of Contents – Page 2 of 3 XL HYDROSTATIC TRANSAXLES -CONTINUED NEUTRAL ADJUSTMENT - HXL HYDRO - 2001 AND LATER BRAKE ADJUSTMENT - HXL HYDRO - 2001 AND LATER TRACTION DRIVE BELT REPLACEMENT - HXL HYDRO - 2001 AND LATER...
  • Page 3 TORO XL LAWN TRACTOR SERVICE MANUAL Table of Contents – Page 3 of 3 ELECTRICAL SYSTEM - CONTINUED KEYCHOICE™ REVERSE OPERATING SYSTEM SWITCH PURPOSE HOW IT WORKS TESTING REVERSE SWITCH PURPOSE LOCATION HOW IT WORKS TESTING KEYCHOICE™ REVERSE OPERATING SYSTEM MODULE...
  • Page 4 XL Lawn Tractor...
  • Page 5 PREFACE This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS SPECIFICATIONS Specifi cations ........Dimensions .
  • Page 7 TABLE OF CONTENTS XL HYDROSTATIC TRANSAXLES cont. HXL Hydro Transaxle Removal - 2000 and Prior ..... . Neutral Adjustmnet - HXL Hydro - 2000 and Prior ..... . 3-10 Brake Adjustment - HXL Hydro - 2000 and Prior .
  • Page 8 TABLE OF CONTENTS ELECTRICAL SYSTEM cont. Neutral Switch (Used on 2000 and Later Lawn Tractors) ....Purpose ........Location .
  • Page 9 TABLE OF CONTENTS MOWER cont. 38” Mower ........Removing 38”...

  • Page 10: Specifications

    SPECIFICATIONS Specifications Fuel Engines Steering Capacity All tractors since 1993 were manufactured with Briggs & Stratton engines 7 qts (6.65l) Sector and Pinion ranging from 10 to 17 Horsepower. For more information on servicing the engines, please contact Briggs & Stratton. Dimensions 32”...

  • Page 11: Turning Radius

    SPECIFICATIONS Turning Radius Model Turning Radius 32” (81.3cm) XL 21.5” (54.6cm) - Left 22” (55.8cm) - Right 38” (96.5cm) HXL and XL 20” (50.8cm) - Left 22” (55.8cm)- Right 44” (111.8cm) HXL 20” (50.8cm) - Left 22” (55.8cm) - Right Electrical System Engine Battery...

  • Page 12: Torque Specifi Cations

    Fastener Identification Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual.

  • Page 13: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch Series)

    SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Grade 1, 5, & SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 8 with Thin Studs, & Sems with Regular Studs, & Sems with Regular Studs, &...

  • Page 14: Standard Torque For Dry, Zinc, And Steel Fasteners (Metric Fasteners)

    SPECIFICATIONS Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Class 10.9 Bolts, Screws, and Studs with Thread Size Regular Height Nuts Regular Height Nuts ( (Class 8 or Strong Nuts) Class 10 or Strong Nuts) M5 X 0.8 57 ±...

  • Page 15: Other Torque Specifi Cations

    SPECIFICATIONS Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Square Head Hex Socket 7/16 - 20 UNF 65 ± 10 ft-lb 88 ± 14 N-m Grade 5 1/4 - 20 UNC 140 ±...

  • Page 16: Equivalents And Conversions

    SPECIFICATIONS Equivalents and Conversions XL Lawn Tractor Service Manual 1 - 7...
  • Page 17 THIS PAGE INTENTIONALLY LEFT BLANK 1 - 8 XL Lawn Tractor Service Manual...

  • Page 18: Xl Gear Drive

    XL GEAR DRIVE XL Gear Drive Transaxle Removal - Loosen the left transaxle belt guide and move it away from the belt. The right transaxle belt guide 915 Transaxle needs to be removed (Figure 5). Disconnect battery cables and remove the battery and battery tray.
  • Page 19 XL GEAR DRIVE Remove the nut on the shift tie rod (Figure 7). Remove the nut and washer holding the left side torque strap leaving the torque strap bolted to the frame (Figure 9). Figure 7 mvc-800 Remove the bolt and nut on the left side shift pivot Figure 9 mvc-803 clamp and slide the shift pivot rod so you can...
  • Page 20 XL GEAR DRIVE 10. Remove the brake return spring (Figure 11). 12. Before removing the 4 transaxle bolts, put a floor jack under the transaxle so you can lower it from the frame. Remove the 4 bolts, washers, and nuts (Figure 13).

  • Page 21: Xl Gear Drive Transaxle Installation - 915 Transaxle

    XL GEAR DRIVE 14. The transaxle should be free from the frame now Install the right and left torque straps to the frame (Figure 15). and the transaxle, do not tighten. Install the 4 axle bolts, washers, and nuts and tighten first. Then tighten the torque straps (Figure 17).
  • Page 22 XL GEAR DRIVE Install brake spring to the clutch/brake rod (Figure Install the right and left belt guides and adjust so 19). they are within 1/8” (3mm) of the transaxle pulley and drive belt (Figure 21). Note direction of belt guide installation, right hand points forward, left hand points rearward.
  • Page 23 XL GEAR DRIVE Install the rear hitch panel. There are two bolts, 10. Check the following items: washers, and nuts on each side of the plate and 2 bolts, washers, and nuts for the seat springs A. The Shift-On-The-Go for proper adjustment. If (Figure 23).
  • Page 24 XL GEAR DRIVE Loosen and move the right and left engine belt Remove the idler spring on the idler assembly. guides (Figure 26). Remove the idler pulley and belt guide (Figure 28). Remove the drive belt. Figure 26 mvc-821 Figure 28 mvc-824 Loosen the left side transaxle belt guide.
  • Page 25 XL GEAR DRIVE Route belt back over the pedal pivot rod, the idler Hook the idler spring to the idler bracket (Figure pivot bracket, and around the transaxle pulley 32). (Figure 30). Figure 32 mvc-829 Figure 30 mvc-826 10. Install the right side belt guide and adjust to within Install the idler pulley to the idler bracket.

  • Page 26: Xl Gear Drive Shift Lever Adjustment - 915 Transaxle

    XL GEAR DRIVE 11. Recheck the routing of the belt (Figure 34). 14. Check the following: A. The Shift-On-The-Go for proper adjustment. If adjustment is needed, (refer to “Cable Adjustment, Shift-On-The-Go, 915 and MST- 205 Transaxle” on page 2 - 19). B.
  • Page 27 XL GEAR DRIVE Remove the rear hitch panel by removing the two Shift the transaxle through each gear to verify the bolts and nuts holding the seat springs and two gear shift lever centers in each gate as the internal bolts and nuts located on each side of the hitch transaxle detents are felt.

  • Page 28: Xl Gear Drive Brake Adjustment - 915 Transaxle

    XL GEAR DRIVE XL Gear Drive Brake Adjustment - If the shifter still does not go into 5th gear, loosen the jam nut on the tie rod end of the shift arm and 915 Transaxle remove the nut. Rotate the tie rod end until the gear shift lever is centered in the 5th gear gate.

  • Page 29: Xl Gear Drive Mst-205 Transaxle Removal

    XL GEAR DRIVE XL Gear Drive MST-205 Transaxle Remove the right and left transaxle belt guides. Put the park brake on and then slip the traction Removal drive belt off the transaxle pulley (Figure 44). Disconnect battery cables and remove battery and battery tray.

  • Page 30: Xl Gear Drive Mst-205 Transaxle Installation

    XL GEAR DRIVE XL Gear Drive MST-205 Transaxle Disconnect the shift link at the transaxle shift lever (Figure 46). Installation Raise the transaxle up to the frame and install the 4 axle bolts and 2 torque strap bolts. Tighten all 6 bolts (Figure 48).

  • Page 31: Xl Gear Drive Shift Lever Adjustment, Mst-205 Transaxle

    XL GEAR DRIVE Place the traction drive belt around the transaxle Install the rear hitch panel (Figure 52). input pulley. Install the right and left belt guides. Figure 52 mvc-0037 Figure 50 mvc-0002 Re-install the mower deck (“Mower” section on page 6 - 1).

  • Page 32: Checking The Brake

    XL GEAR DRIVE XL Gear Drive Brake Adjustment, Loosen the bolt between the shift pivot and the shift pivot lever (Figure 54). MST-205 Transaxle The brake is located on the right side of the rear axle, inside the rear tire. If the brake does not hold securely or stopping power is insufficient, an adjustment is required (Figure 56).

  • Page 33: Xl Gear Drive Traction Drive Belt Replacement Procedure, Mst-205 Transaxle

    XL GEAR DRIVE Important: With the parking brake released, the rear Remove the right and left belt guides located on wheels must rotate freely when you push the tractor. If each side of the transaxle pulley (Figure 58). the brake seems to drag, loosen the adjusting nut slightly until the wheels rotate freely.
  • Page 34 XL GEAR DRIVE Loosen the right and left belt guides located on Install belt on the idler pulley and tighten the pulley each side of the engine drive pulley (Figure 60). bolt (Figure 62). Remove the drive belt. Figure 62 mvc-0010 Figure 60 mvc-000D...
  • Page 35 XL GEAR DRIVE 10. Reinstall the idler spring on bolt holding the idler 12. Install rear hitch plate and seat springs (Figure pulley to the idler assembly (Figure 64). 66). Figure 64 Figure 66 mvc-000a mvc-0037 11. Adjust both the right and left engine belt guides so 13.

  • Page 36: Cable Adjustment, Shift-On-The-Go, 915 And Mst-205 Transaxle

    XL GEAR DRIVE Cable Adjustment, Shift-On-The-Go, A. Loosen the fastener securing the forward cable guide. It is located just above and behind the 915 and MST-205 Transaxle mower deck pulley (Figure 70). Adjustment is required if the gearshift lever is not pulled firmly under spring tension toward the numbers on the shift plate or if it is difficult to shift on-the-go (Figure 68).
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  • Page 38: Xl Hydrostatic Transaxles

    XL HYDROSTATIC TRANSAXLES Identification Hydro-Gear 0510 Transaxle Used: 2001 and later Hydro-Gear 0500/0750 Transaxle Model: 318-0510 Used: 1993 - 2000 Models: 316-0500, 321-0500, 323-0500, 316-0750, and 326-0750 mvc-660 Lubrication: 20W50 Motor Oil Oil Level: Oil level should not be more than 1¼” (3.17cm) below the top fill port.

  • Page 39: Internal Service

    Refer to the Tractor Parts Catalog for available The Hydro-Gear 310-0500/0700 Service Manual is transaxle service parts. available from Toro under Form #492-4712. For 1993 - 1995 model year tractors, refer to the The Hydro-Gear 310-0510 Service Manual is available comparable 1996 model, as spare parts were not from Toro under Form #492-4735.

  • Page 40: Purging Procedures

    XL HYDROSTATIC TRANSAXLES Purging Procedures Fluid Change The Hydro-Gear transaxle is factory filled, sealed and Due the effects air has on efficiency in hydrostatic drive does not require oil maintenance. However, in the applications, it is critical that it be purged from the event of oil contamination or degradation, oil system.
  • Page 41 XL HYDROSTATIC TRANSAXLES Remove the rear hitch panel. There are 2 bolts Loosen the right and left belt guides located on and nuts holding the seat springs and 2 bolts and each side of the engine drive pulley (Figure 75). nuts on each side of the rear panel (Figure 73).
  • Page 42 XL HYDROSTATIC TRANSAXLES Slip the traction belt down off the engine pulley Remove the hairpin and washer on the bypass and move the slack of the belt back toward the lever rod (Figure 79). rear of the tractor. You should now be able to slip the traction belt up off the transaxle drive pulley.
  • Page 43 XL HYDROSTATIC TRANSAXLES 11. Unhook the brake spring from the clutch/brake 13. Support the transaxle with a jack. Remove the 4 rod. bolts, washers, and nuts holding the transaxle to the frame (Figure 83). Figure 81 iso3 Figure 83 MVC-0042 (A) Brake Spring (B) Unhook from clutch/ 14.
  • Page 44 XL HYDROSTATIC TRANSAXLES HXL Hydro Lawn Tractor Transaxle Reconnect the brake spring to the clutch/brake rod (Figure 87). Installation – 2000 and Prior Raise the transaxle to the frame and install the 4 axle bolts, washers, and nuts (Figure 85). Figure 87 iso3 (A) Spring...
  • Page 45 XL HYDROSTATIC TRANSAXLES Install the washer and hairpin on the speed control Install the traction drive belt around the transaxle rod (Figure 89). input pulley (Figure 91). Figure 89 Figure 91 MVC-003B MVC-003A Install the washer and hairpin that holds the Install the traction drive belt around the engine bypass lever (Figure 90).
  • Page 46 XL HYDROSTATIC TRANSAXLES Reconnect the idler spring to the idler bracket 11. Adjust and tighten the right and left rear transaxle assembly (Figure 93). belt guides. Adjust the guides so they are within 1/8” (3mm) of the belt and pulley (Figure 95). 1/8”...

  • Page 47: Neutral Adjustmnet - Hxl Hydro - 2000 And Prior

    XL HYDROSTATIC TRANSAXLES 13. Install the battery and battery tray. Note: If the 17. Install the right rear tire and check the brake battery uses a drain tube, make sure the tube adjustments. If adjustment is needed, follow the is reinstalled through the rear hole in the procedures in the “Brake Adjustment - HXL Hydro frame (Figure 97).

  • Page 48: Brake Adjustment - Hxl Hydro - 2000 And Prior

    XL HYDROSTATIC TRANSAXLES Loosen the locknut (Figure 100). Tighten the locknut. Move the motion control pedal forward and reverse and allow it to recenter. Verify that there is still no creep with the wheels on the ground. When operating the foot control, if you find too much ground speed in forward and not enough in reverse or too much ground speed in reverse and not enough in froward, the pivot block which the speed control pedal...
  • Page 49 XL HYDROSTATIC TRANSAXLES To adjust the brake, loosen the brake adjusting nut slightly (Figure 103). Check to see if the brake lever returns to the “OFF” position when the pedal is released (Figure 105). Figure 103 mvc-654 Insert a 0.020” (.5mm) feeler gauge between the Figure 105 4017-09 outer discs, if the clearance is not correct make...

  • Page 50: Traction Drive Belt Replacement On Hxl Hydro - 2000 And Prior

    XL HYDROSTATIC TRANSAXLES Traction Drive Belt Replacement On If the battery drain tube is installed improperly through the frame, the battery will drain in this HXL Hydro - 2000 and Prior area and corrode the pins and linkage (Figure 107). Remove the mower deck from the tractor, refer to "Mower"...
  • Page 51 XL HYDROSTATIC TRANSAXLES Unhook the idler spring on the idler spring bracket Install belt around the engine drive pulley and feed (Figure 111). the drive belt up over the pedal pivot rod (Figure 113). Figure 111 mvc-001C Figure 113 mvc-0021 Unbolt the idler pulley assembly with belt guide and remove assembly (Figure 112).
  • Page 52 XL HYDROSTATIC TRANSAXLES Install the belt around the flat idler pulley 11. Adjust and tighten both the right and left engine assembly with the belt guide and tighten the bolt belt guides. They should be adjusted so they are and nut (Figure 115). within 1/8”...

  • Page 53: Hxl Hydro Transaxle Removal - 2001 And Later

    XL HYDROSTATIC TRANSAXLES HXL Hydro Transaxle Removal - 13. Before installing the mower deck on the tractor, check the routing of the drive belt (Figure 119). 2001 and Later Disconnect the battery cables and remove the battery and battery tray. Remove the mower deck (refer to the "Mower"...
  • Page 54 XL HYDROSTATIC TRANSAXLES Loosen the right and left belt guides located Move the slack of the traction drive belt to the rear around the engine pulley and slip the belt down off of the tractor and slip the belt off the transaxle the engine drive pulley (Figure 123).

  • Page 55: Hxl Hydro Transaxle Installation - 2001 And Later

    XL HYDROSTATIC TRANSAXLES HXL Hydro Transaxle Installation - Unhook the small spring on the brake arm. Pull the cotter pin out of the crown nut on the brakes 2001 and Later and remove nut to disconnect the brake arm from the transaxle (Figure 127).
  • Page 56 XL HYDROSTATIC TRANSAXLES Reconnect the speed control link and the speed Adjust and tighten both the right and left engine control rod with washers and hairpins (Figure belt guides. They should be adjusted so they are 131). within 1/8” (3mm) of the engine pulley (Figure 133).

  • Page 57: Neutral Adjustment - Hxl Hydro - 2001 And Later

    XL HYDROSTATIC TRANSAXLES Install the left rear tire only and lower the unit until Jack-up and support the right rear end of the the tire just touches the ground. Install the battery tractor, allowing enough clearance to remove the and the battery tray and reconnect the battery right rear tire.

  • Page 58: Brake Adjustment - Hxl Hydro - 2001 And Later

    XL HYDROSTATIC TRANSAXLES Once you are in neutral, hold the puck with an Adjusting the Brake: adjustable wrench so it won't move when you retighten the Allen bolt (Figure 138). Jack-up and support the right rear end of the tractor. Operate the foot control in forward and reverse and allow pedal to return to the neutral position to Remove the right rear tire.

  • Page 59: Traction Drive Belt Replacement - Hxl Hydro - 2001 And Later

    XL HYDROSTATIC TRANSAXLES Install tire and check the brake operation again. If Loosen the transaxle belt guide located on the left satisfactory brake adjustment/operation cannot be side of the transaxle pulley and swing the guide attained, the brake pads or disc require service. away from the pulley (Figure 142).
  • Page 60 XL HYDROSTATIC TRANSAXLES Unhook the idler spring on the idler spring bracket Loosen the left side idler pulley and slide the (Figure 144). assembly toward the center of the tractor away from the frame (Figure 146). Remove the belt from the engine and transaxle pulleys. Figure 144 MVC-001C Unbolt the idler pulley assembly with belt guide...
  • Page 61 XL HYDROSTATIC TRANSAXLES Continue feeding the belt back up over the idler 11. Reconnect the idler spring to the idler bracket pivot bracket and around the transaxle drive pulley (Figure 150). (Figure 148). Figure 150 MVC-001c Figure 148 MVC-0022 12. On the other side of the idler pivot, is a V-idler 10.
  • Page 62 XL HYDROSTATIC TRANSAXLES 13. Adjust and tighten both the right and left engine 15. Before installing the mower deck on the tractor, belt guides. They should be adjusted so they are check the routing of the drive belt (Figure 154). within 1/8”...

  • Page 63: Chassis

    CHASSIS Front Axle Removal Upper Steering Shaft Removal (No Tilt Steering) If the tractor is equipped with headlights, disconnect the wiring to the headlights. Follow steps #1 and #2 in the procedure for Steering Tower Removal, (refer to “Steering Tower Unbolt the 2 shoulder bolts, located on the right Removal”...

  • Page 64: Steering Assembly

    CHASSIS Steering Assembly Figure 156 (1) Front Axle (15) Flat Washer (29) Cotter Pin (2) E-Ring (16) Cotter Pin (30) Bearing Washer (3) Tie Rod Steering (17) LH Spindle (31) Lock Nut (4) Drag Link (18) Screw (32) Pivot Washer (5) RH Spindle (19) Screw (33) Lock Nut...

  • Page 65: Tilt Steering

    CHASSIS Tilt Steering Figure 157 (1) Steering Short Shaft (9) Curved Washer (17) Roll Pin (2) Flange Bushing (10) Thrust Washer (18) Sliding Bushing (3) Thrust Washer (11) Steering Upper Shaft (19) Release Button (4) Plastite Screw (12) Lock Nut (20) Flat Washer (5) E-Ring (13) Leaf Spring...

  • Page 66: Steering Shaft Removal (Tilt Steering)

    CHASSIS Steering Shaft Removal (Tilt Steering Tower Removal Steering) Using a drift punch and hammer, drive the steering wheel roll pin out and remove the Disconnect the battery cables. steering wheel (Figure 159). Remove mower deck (refer to the Mower section). Drain the gas tank and remove the tank by removing the left screw that holds the support bracket in and swing the bracket so you can...

  • Page 67: Steering Tower Installation

    CHASSIS Unplug the ignition switch, PTO safety switch, light Remove the two bolts that are located on the switch, and Key Choice™ Reverse Operating underside of the tractor that hold the rear portion System light (Figure 161), if so equipped. of the steering tower (Figure 163).

  • Page 68: Rear Body/Fender Assembly Removal

    CHASSIS Rear Body/Fender Assembly Remove the 2 bolts and nuts holding the seat to the right and left pivot brackets. Unscrew the Removal Height-of Cut knob (Figure 166). On gear shift models, unscrew the knob. Remove the steering tower, refer to ”Steering Tower Removal"...
  • Page 69 CHASSIS Remove the upper steering shaft by removing the Remove the mower engagement cable from the E-ring around the bottom of the shaft and slide the brake lever bracket (Figure 170). shaft out the bottom of the frame (Figure 168). Figure 170 MVC-0032 Figure 168...

  • Page 70: Installation Of The Rear Body

    CHASSIS 11. Remove the rubber grip from the brake pedal (Figure 172). Figure 172 MVC-0030 12. Carefully lift the rear body off the frame of the tractor (Figure 173). Figure 173 MVC-0034 Installation Of The Rear Body Reverse the order of rear body removal. XL Lawn Tractor Service Manual 4 - 8...
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  • Page 72: Electric Pto Clutch Removal

    CHASSIS Electric PTO Clutch Removal 5. Disconnect and remove the electrical plug to the electric PTO clutch (Fig. A4 003). 1. Disconnect the positive battery cable from the battery. 2. Remove the mower from the tractor (follow the procedure in Section 6). 3.

  • Page 73: Electric Pto Clutch Installation

    CHASSIS 7. Remove the electric PTO clutch from the crankshaft 2. Install the electric PTO clutch on the crankshaft, (Fig. A4 005). making sure the key on the clutch aligns with the keyway on the crankshaft. Also, make sure the slot on the electric PTO clutch slides onto the clutch stop bracket (Fig.
  • Page 74 CHASSIS 4. Route the electric PTO clutch wire through the frame and reconnect the plug connector to the wiring harness (Fig. A4 009). Fig A4 009 PICT-4452 5. Install the gas tank (Fig. A4 010). Fig A4 010 PICT-4449 6. Install the mower deck and mower drive belt, (refer to Mower Installation in Section 6).
  • Page 75 CHASSIS THIS PAGE INTENTIONALLY LEFT BLANK. A4-4 XL Lawn Tractor Service Manual...

  • Page 76: Electrical System

    ELECTRICAL SYSTEM Electrical System Relay The electrical systems in all the XL Lawn Tractors are Purpose similar when starting the tractor. Two things happen when turning the ignition switch to the “START” The relay (or kill relay) is in the safety circuit and the position.

  • Page 77: Testing

    ELECTRICAL SYSTEM Switch: Terminals 30, 87, and 87a are actually Connect multimeter (ohms setting) leads to relay part of a single pole, double throw (SPDT) switch. terminals 30 and 87. Ground terminal 86 and Terminal 30 is the common lead. The switch is apply +12 VDC to terminal 85.

  • Page 78: Location

    ELECTRICAL SYSTEM How It Works You should be able to hear the solenoid switch “click” when you make the connection. The solenoid has two primary parts. One is a coil of (1) 1999 & prior models (2) 2000 & later models wire wrapped around an iron core.

  • Page 79: Neutral Switch (Used On 1999 And Prior Lawn Tractors)

    ELECTRICAL SYSTEM Neutral Switch (Used on 1999 and Testing Prior Lawn Tractors) Disconnect the switch from the harness. Purpose Verify the conditions from the table. Used to ensure the transmission is in neutral when Button Condition starting the unit. It is actuated when the clutch/brake pedal is depressed.

  • Page 80: Location

    ELECTRICAL SYSTEM Neutral Switch (Used on 2000 and Location Later Lawn Tractors) The PTO switch is located under the gas tank, inside of the steering tower, below the PTO lever (Figure 182). Purpose Used to ensure the transmission is in neutral when starting the unit.

  • Page 81: Seat Switch

    ELECTRICAL SYSTEM How It Works Location This single pole plunger type switch has two terminals. The seat switch is located in the bottom of the seat When the cluch/brake pedal is depressed, it pushes on between the seat cushion and the seat plate (Figure the plunger, closing the contact, and connecting the 186).

  • Page 82: Keychoice™ Reverse Operating System - Used On 1999 And Later Xl Lawn Tractors

    ELECTRICAL SYSTEM With weight or pressure on the seat, check the While the engine is running, move the PTO lever continuity again on the two terminals. There to the “engage” position, on gear shift models, should be continuity. move the gear shift lever in reverse and on Hydro models move the forward/reverse pedal to reverse.

  • Page 83: Keychoice™ Reverse Operating System Switch

    ELECTRICAL SYSTEM A red light on the front console turns on, indicating How It Works that the interlock (No-Mow-In-Reverse) is disabled (Figure 189). The switch is basically an on/off switch spring-loaded to return to the off position. When turned to the On position with the PTO engaged, it activates circuits in the Key Choice™...

  • Page 84: Location

    ELECTRICAL SYSTEM Location Depress the plunger on the switch and check the continuity across the terminals, there should be The switch is located under the tractor, near the NO continuity (Figure 192). traction idler (Figure 191). Figure 192 mvc-685 Figure 191 mvc-686 KeyChoice™...

  • Page 85: Location

    ELECTRICAL SYSTEM Location * NOTE: If multimeter does not have a diode scale, this test can not be done. This is not a problem if The Key Choice™ Reverse Operating System module powered tests are done. Powered test must be done to is located under the gas tank (Figure 194).

  • Page 86: How It Works

    ELECTRICAL SYSTEM Electric PTO Switch Testing 1. Disengage the PTO, set the parking brake, turn the Purpose ignition to the “OFF” position and remove the key. The PTO (Power Take Off) switch is typically used to 2. Remove the gas tank from the steering tower. turn on the Electric PTO Clutch and to function as part of the safety interlock system.

  • Page 87: How It Works

    ELECTRICAL SYSTEM Electric PTO Clutch Testing If the electric PTO clutch is not engaging or is suspected Purpose as a cause of electrical problems, use the following troubleshooting steps. These procedures will help you This clutch electrically controls the engagement and determine if the clutch has failed or is the cause of the disengagement of the Power Take Off (PTO) pulley.

  • Page 88: Measuring Clutch Current Draw

    ELECTRICAL SYSTEM Measuring Clutch Current Draw 1. Disengage the PTO, set the parking brake, turn the ignition key to OFF, and remove the key. 2. Disconnect the clutch wire connector. 3. Set the multimeter to check amps (10 amp scale). 4.
  • Page 89 ELECTRICAL SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK. A5-4 XL Lawn Tractor Service Manual...

  • Page 90: Mower

    1Mower MOWER 32” Mower Remove the hairpin cotter and washer from the blade control arm on the left side of the mower (Figure 197). Slide the rod off of the arm. Removing 32” Mower Park the machine on a level surface, disengage the PTO, shift into neutral, set the parking brake, stop the engine, and remove the ignition key.

  • Page 91: Installing 32" Mower

    MOWER Remove the hairpin cotter and washer at the top Important: Do not bend the belt guide(s) away from of the mower leveling bracket (Figure 199). Slide the pulley because the belt will not operate properly the bracket off of the mounting pin. Repeat this when the mower is installed later.
  • Page 92 MOWER Important: Do not bend the belt guide(s) away from Slide the end of the long rod through the hole in the pulley. There must be a maximum 1/8” (3mm) the mower mount (Figure 202). Install the washer between the belt guide(s) and the edge of the pulley to and hairpin cotter to secure the rod in place.

  • Page 93: Blade Drive Belt

    MOWER Blade Drive Belt Install the blade control rod onto the blade control arm and secure it with the washer and hairpin cotter (Figure 203). Removing the Blade Drive Belt Remove the mower; refer to "32” Mower" on page 6 - 1. Loosen the belt guide mounting bolts and move the belt guides away from the pulley.

  • Page 94: Side-To-Side Mower Leveling

    MOWER Side-to-Side Mower Leveling Remove the hairpin cotter and washer from the leveling bracket (Figure 207). To level the blade(s), reposition the leveling bracket in a The mower blades must be level from side to side. different hole and install the washer and hairpin Check the side-to-side level any time you install the cotter.
  • Page 95 MOWER Pull the wire off of the spark plug. Measure the length of the rod extending out of the front of the adjusting block on the sides of the chassis (Figure 209). If the rod length is not 5/8 in. Check and adjust side-to-side blade level if you (16mm), remove the hairpin cotter and washer have not checked the setting;...

  • Page 96: 38" Mower

    MOWER rotate the right side slope adjusting nut until 14. Repeat front-to-rear blade slope adjustment; refer Slowly both adjusting nuts are in the same position to steps 8-10. Important: If the slope adjustment does not stay in position after you adjust it, tighten the center bolt and locknut and repeat step 9.
  • Page 97 MOWER Unhook the blade control (PTO) cable ring end Remove the height-of-cut lift assist spring from from the idler spring (Figure 213). the retaining bolt (Figure 212), using the spring tool provided with the machine. The spring Remove rubber wiper and jam nut from blade is between the frame and the right rear wheel.
  • Page 98 MOWER Remove the bolts and lock nuts and pull the two 13. Move the height-of-cut lever (deck lift) into the “D” mower pivot mount brackets down from the front notch. Hook lift assist spring onto retaining bolt for axle (Figure 214). storage (Figure 212).

  • Page 99: Installing 38" Mower

    MOWER 14. Remove the mower belt from the lower engine Turn the front wheels fully to the left. Slide the pulley (Figure 216). If you are careful, you can flex mower under the chassis from the right side. the belt guide(s) just far enough away from the pulley to remove the belt.
  • Page 100 MOWER Slide the end of the long rod through the hole in 11. Hook end of blade control (PTO) cable onto idler the mower mount (Figure 218). Install the washer spring (Figure 219). and hairpin cotter to secure the rod in place. Repeat this step on the opposite side of the mower.

  • Page 101: Blade Drive Belt

    MOWER 14. Move the height-of-cut lever (deck lift) into the “D” Install the mower; refer to "Installing 38” Mower" notch to make it easier to install the height-of-cut on page 6 - 10. lift assist spring. 15. Hook the height-of-cut lift assist spring onto the retaining bolt (Figure 212), using the spring tool provided with the machine.

  • Page 102: Front-To-Rear Blade Slope

    MOWER Carefully rotate blade(s) side to side (Figure 222). Remove the hairpin cotter and washer from the Measure between the outside cutting edges and leveling bracket (Figure 223). To level the the flat surface (Figure 222). If both blade(s), reposition the leveling bracket in a measurements are not within 3/16”...
  • Page 103 MOWER Move the height-of-cut lever (deck lift) into the “C” notch. Measure the length of the rod extending out the front of the adjusting block on the sides of the chassis (Figure 224). If the rod length is not 5/8” (16mm), remove the hairpin cotter and washer from the end of the rod (Figure 224), and turn the rod until the 5/8”...

  • Page 104: 44" Mower

    MOWER 10. When front-to-rear slope is correct, tighten the Remove the height-of-cut lift assist spring from the pivot plate mounting bolts (Figure 226). retaining bolt (Figure 227), using the spring tool provided with the machine. The spring is between the frame and the right rear wheel. Figure 226 m-4634 Figure 227...
  • Page 105 MOWER Move the cable out of the way and lay inside 11. Remove the hairpin cotter and washer at the frame rail so it can not get caught in drive belts or mower leveling bracket (Figure 230). Slide the pulleys. bracket off the mounting pin.

  • Page 106: Installing 44" Mower

    MOWER 15. Remove the mower belt from the engine pulley Installing 44” Mower (Figure 231). If you are careful, you can flex the belt guide(s) just far enough away from the pulley DANGER to remove the belt. If it is too difficult to remove the belt, loosen the bolts and nuts securing the belt guides.
  • Page 107 MOWER Install mower belt onto the lower engine pulley Install the mower pivot mount brackets onto the (Figure 232). If you are careful, you can flex the front axle with bolts and lock nuts (Figure 233). belt guide(s) just far enough away from the pulley Tighten fasteners.
  • Page 108 MOWER Move the height-of-cut lever (deck lift) into the “A” 11. Mount the slotted mower leveling bracket onto the notch. pin on the mower mount (Figure 235). Install the thick washer and hairpin cotter to secure the mower. Repeat this step on the opposite side of the mower.

  • Page 109: Installing 44" Recycler Baffl E

    MOWER 17. Check that blade brake pads contact pulleys and 19. Hook the lift assist spring between the mower right actuating rods are loose when blade control (PTO) side lift bracket and the retaining bolt (Figure 237) is disengaged, and that brake pads are away from Use the spring tool provided with the machine.

  • Page 110: Removing 44" Recycler Baffl E

    MOWER Rotate blades to assure there is at least 1/8” Install 3/8-16 x 3/4” carriage bolts, 3/8” washer (3mm) clearance between blades and baffle. and 3/8” lock nuts, from loose parts package, in open holes of mower for safety. DANGER POTENTIAL HAZARD •...

  • Page 111: Adjusting Blade Brakes

    MOWER Install the mower; refer to "Installing 44” Mower" Disengage blade control (PTO) lever, check that on page 6 - 17. blade brake pads contact pulleys and actuating rods are loose when blade control (PTO) is disengaged, and that brake pads are away from pulleys when blade control (PTO) is engaged.

  • Page 112: Front-To-Rear Blade Slope

    MOWER Carefully rotate blade(s) side to side (Figure 241). Check the front-to-rear blade slope; refer to Measure between the outside cutting edges and "Front-to-Rear Blade Slope" on page 6 - 23. the flat surface (Figure 241). If both measurements are not within 3/16” (5mm), an Front-to-Rear Blade Slope adjustment is required;...
  • Page 113 MOWER Measure the length of the rod extending out the Measure between the tip of the front blade (Figure front of the adjusting block on the sides of the 244) and the tip of the rear blade to the flat chassis (Figure 243).
  • Page 114 MOWER 10. When front-to-rear slope is correct, tighten the pivot plate mounting bolts (Figure 245). Figure 245 1792 (A) Pivot Mounting Bolt (B) Eyebolt Lock Nut 11. When front-to-rear blade slope is correct, recheck the side-to-side level of the mower; refer to "Side- to-Side Mower Leveling"...
  • Page 115 THIS PAGE INTENTIONALLY LEFT BLANK 6 - 26 XL Lawn Tractor Service Manual...

  • Page 116: 32" Mower

    MOWER 32” Mower 38” Mower with Manual PTO Clutch 32” Mower Brake Adjustment 38” Mower Brake Adjustment 1. Lower the mower to the lowest height of cut position. 1. Lower the mower to the lowest height of cut position. 2. With the engine OFF, engage the mower (PTO) 2.

  • Page 117: 44" Mower With Manual Pto Clutch

    MOWER 44” Mower with Manual PTO Clutch 38” Mower with Electric PTO Clutch 44” Mower Brake Adjustment Removing 38” Mower with Electric PTO Clutch 1. Lower the mower to the lowest height of cut position. 1. Park the tractor on a level surface. 2.
  • Page 118 MOWER 6. Move the height-of-cut lever into the A notch. 9. Remove the hairpin cotter and washer from the end of the long rod (Fig. A6 007). Slide the rod out of the 7. Unhook the spring on the idler pulley arm from the mower mount.

  • Page 119: Installing 38" Mower With Electric Pto Clutch

    MOWER 14. Remove the mower belt from the electric clutch Installing 38” Mower with Electric PTO pulley (Fig. A6 008). Clutch DANGER Without the grass defl ector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris.
  • Page 120 MOWER 4. Install the mower pivot mount brackets onto the front 7. Move the height-of-cut lever into the A notch. axle with the bolts and locknuts (Fig. A6 009). 8. Slide the end of the long rod through the hole in the mower mount (Fig.
  • Page 121 MOWER 13. Hook the idler spring from the idler pulley arm to the 15. Hook the lift assist spring between the mower right eyebolt on the mower (Fig. A6 012). side lift bracket and the retaining bolt (Fig. A6 013). Note: Use the spring tool provided with the machine.

  • Page 122: Replacing The Blade Drive Belt

    MOWER Replacing the Blade Drive Belt Installing the Blade Drive Belt, 38” Mower with Electric PTO Clutch Removing the Blade Drive Belt, 38” Mower 1. Install the new belt around the blade pulleys and with Electric PTO Clutch under the belt guide on the idler pulley. 1.
  • Page 123 MOWER 5. Carefully rotate the blades side to side (Fig. A6 015). 6. Remove the hairpin cotter and washer from the Measure between the outside cutting edges and the leveling bracket. To level the blades, reposition fl at surface. If both measurements are not within the leveling bracket in a different hole and install 3/16”...

  • Page 124: Adjusting 38" Mower Front-To-Rear Blade Slope

    MOWER Adjusting 38” Mower Front-to-Rear 6. Install the end of the rod into the hole in the mower mount and secure it with the washer and hairpin Blade Slope cotter. Repeat this procedure on the opposite side of the mower. Check the front-to-rear blade slope any time you install the mower.

  • Page 125: 44" Mower With Electric Pto Clutch

    MOWER 8. To adjust the front-to-rear blade slope, loosen the 44” Mower with Electric PTO Clutch front pivot plate mounting bolts slightly (Fig. A6 019). Removing 44” Mower with Electric PTO Clutch 1. Park the machine on a level surface, disengage the PTO, set the parking brake, stop the engine, and remove the ignition key.
  • Page 126 MOWER 5. Unhook the spring on the idler pulley arm from the 7. Remove the hairpin cotter and washer from the end bracket on the mower (Fig. A6 021 viewed from the of the long rod (Fig. A6 023). Slide the rod out of the left side).

  • Page 127: Installing 44" Mower With Electric Pto Clutch

    MOWER 12. Remove the mower belt from the electric clutch Installing 44” Mower with Electric PTO pulley (Fig. A6 024 top view). Clutch DANGER Without the grass defl ector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris.
  • Page 128 MOWER 3. Install the mower belt onto the electric clutch pulley 5. Move the height-of-cut lever into the D notch. (Fig. A6 025 top view). 6. Remove the lift assist spring between the mower right side lift bracket and the retaining bolt (Fig. A6 027).
  • Page 129 MOWER 8. Ensure that both rods extend 5/8” (16mm) beyond 14. Hook the spring from the idler pulley arm to the the adjustment block (Fig. A6 028). bracket on the mower (Fig. A6 029 viewed from the left side). Fig A6 028 fi...

  • Page 130: Replacing The Blade Drive Belt, 44" Mower With Electric Pto Clutch

    MOWER 16. Hook the lift assist spring between the mower right Replacing the Blade Drive Belt, 44” side lift bracket and the retaining bolt (Fig. A6 030). Mower with Electric PTO Clutch Note: Use the spring tool provided with the Removing the Blade Drive Belt, 44”...

  • Page 131: Installing The Blade Drive Belt, 44" Mower With Electric Pto Clutch

    MOWER Installing the Blade Drive Belt, 44” Mower 4. Carefully rotate the blades side to side.Measure between the outside cutting edges and the fl at with Electric PTO Clutch surface. If both measurements are not within 3/16” (5mm), an adjustment is required; refer to steps 5 1.

  • Page 132: Adjusting 44" Mower Front-To-Rear Blade Slope

    MOWER 6. To level the blades, reposition the leveling bracket 4. Measure the length of the rod extending out of in a different hole and install the washer and hairpin the front of the adjusting block on the sides of the cotter (Fig.
  • Page 133 MOWER 9. Check the front-to-rear slope by measuring between 10. To adjust the front-to-rear blade slope, loosen the the bottom of the mower (front center and rear front pivot plate mounting bolts slightly (Fig. A6 036). center) and the fl at surface (Fig. A6 035). If the front blade tip is not within a range of 0 to 5/16”...
  • Page 135 492-4734 Revised 4-07...

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