1. Manuals
  2. Brands
  3. Toro Manuals
  4. Lawn Mower
  5. Lawn-Boy TimeCutter Z
  6. Service manual

Toro Lawn-Boy TimeCutter Z Service Manual

Zero radius turn riding mower
Hide thumbs
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading

Related Manuals for Toro Lawn-Boy TimeCutter Z

Summary of Contents for Toro Lawn-Boy TimeCutter Z

  • Page 2 ABOUT THIS MANUAL This service manual was written expressly for Toro and Lawn-Boy service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of contents lists the systems and the related topics covered in this manual.
  • Page 3 ABOUT THIS MANUAL THIS PAGE INTENTIONALLY LEFT BLANK.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Safety Information .......................................................................................................................................................................................... Dimensions & Weight ........................Dimensions & Weight cont..............................................................................................................................................................................Chassis ........................................... Front Castor Fork Replacement ..............................................
  • Page 5 TABLE OF CONTENTS Engine Engine Replacement ........................Engine Removal............................................................................................................Hydrostatic Drive System ................................................................ Transaxle Replacement........................ Transaxle Removal ............................................Actuator Arm Replacement......................Actuator Arm Removal ..........................................Activator Arm Assembly Replacement..................Activator Arm Assembly Removal .....................................
  • Page 6 TABLE OF CONTENTS Electrical ............................................................................Location ....................................................Testing ..................................................................................Location ....................................................Testing ................................................................................Location ....................................................Testing ................................................................................Location ....................................................Testing ..............................................................................Location ....................................................Testing ............................Coil Resistance Measurement ....................
  • Page 7 TABLE OF CONTENTS THIS PAGE INTENTIONALLY LEFT BLANK.

  • Page 8: Safety Information

    – read the instruction because it has to for safe operating practices. Operator’s manuals are do with your safety. Failure to comply available online through your Toro parts source or: with the instruction may result in The Toro Company personal injury or even death.
  • Page 9 SAFETY INFORMATION THIS PAGE INTENTIONALLY LEFT BLANK. TimeCutter® Z/Precision® Z Service Manual...
  • Page 10 SPECIFICATIONS Z4200 Kohler, Overhead Valve, Twin Cam, 19.0 hp (14.2kW) @ 3600 RPM High Idle: 3300 + 100 RPM Z4200 (CE) Kohler, Overhead Valve, Twin Cam, 19.0 hp (14.2kW) @ 3600 RPM High Idle: 2650 + 100 RPM Z4220 Kohler, Overhead Valve, Twin Cam, 21.0 hp (15.7kW) @ 3600 RPM High Idle: 3300 + 100 RPM Z4202 (CE) Kohler, Overhead Valve, Twin Cam, 20.0 hp (14.9kW) @ 3600 RPM...
  • Page 11 SPECIFICATIONS Frame: drawn 11 gauge steel Electric Clutch Levers: Dual wrap-around levers control hydraulic pump Dampening: Dual hydraulic dampeners Turning Radius: Zero Radius Turn (ZRT) Seat: Operator presence switch Control Lever/Brake: Dual position switch Power Take Off: Position switch Battery Voltage: 12 volt negative ground Twin Hydro-Gear EZT Hydrostatic Transaxles Belt drive with self-tensioning system TimeCutter®...
  • Page 12 SPECIFICATIONS Z4200 0 to 3.5 mph (5.6km/hr) reverse Z4200 (CE) 0 to 2.8 mph (4.5km/hr) reverse Z4220 0 to 3.5 mph (5.6km/hr) reverse Z4202 (CE) 0 to 2.8 mph (4.5km/hr) reverse Z5000 0 to 3.5 mph (5.6km/hr) reverse Z5000 (CE) 0 to 3.0 mph (4.9km/hr) reverse Z5020 0 to 3.5 mph (5.6km/hr) reverse...
  • Page 13 SPECIFICATIONS rotary. Drawn 13 gauge steel deck with Frame supported. Left and right front mounted, Left, center and right front mounted, Two height positions Four height positions Adjusts from 1.5” to 4.5” (7 positions) 17,290 ft (5,270m)/min @ 3300 RPM nominal 17,730 ft (5,404m)/min @ 3300 RPM nominal 17,810 ft (5,428m)/min @ 3400 RPM max 18,330 ft (5,587m)/min @ 3400 RPM max...
  • Page 14 SPECIFICATIONS Z4200 48.1” 40.5” 53.75” 73.1” 37.25” (122.2cm) (102.9cm) (136.5cm) (185.7cm) (94.6cm) Z4200 (CE) 48.1” 40.5” 53.75” 73.1” 37.25” (122.2cm) (102.9cm) (136.5cm) (185.7cm) (94.6cm) Z4220 48.1” 40.5” 53.75” 73.1” 37.25” (122.2cm) (102.9cm) (136.5cm) (185.7cm) (94.6cm) Z4202 (CE) 48.1” 40.5” 53.75” 73.1”...
  • Page 15 SPECIFICATIONS Z4200 32.9” 29.5” 53.75” (83.6cm) (74.9cm) (226.8cm) (226.8kg) Z4200 (CE) 32.9” 29.5” 53.75” (83.6cm) (74.9cm) (226.8cm) (231kg) Z4220 32.9” 29.5” 53.75” (83.6cm) (74.9cm) (226.8cm) (226.8kg) Z4202 (CE) 32.9” 29.5” 53.75” (83.6cm) (74.9cm) (226.8cm) (231kg) Z5000 34.6” 29.5” 63” (160cm) (87.9cm) (74.9cm) (250.4kg)
  • Page 16 SPECIFICATIONS PICT-9625 Oil Capacity 1.6 to 1.7 qt. (1.5 to 1.6 liters) Oil Level Fluid Change PICT-9626 PICT-9629a TimeCutter® Z/Precision® Z Service Manual...
  • Page 17 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 18 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 19 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 20 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 21 SPECIFICATIONS Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals Fractions Decimals 1/64 0.015625 0.397 33/64 0.515625 13.097 1/32 0.03125 0.794 16/32 0.53125 13.484 3/64 0.046875 1.191 35/64 0.546875 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.078125 1.984 37/64 0.578125 14.684 3/32...
  • Page 22 SPECIFICATIONS U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Linear Feet Centimeters 30.48 Measurement Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.0929 Area...
  • Page 23 SPECIFICATIONS 2-14 TimeCutter® Z/Precision® Z Service Manual...
  • Page 24 CHASSIS (Fig. 006). The unit model and serial number plate is located on the frame under the seat as shown (Fig. 004): Fig. 006 PICT-9157 Fig. 004 PICT-9150 1. Park the unit on a level surface, disengage the blade control (PTO), and turn the ignition key to “Off” to stop the engine.
  • Page 25 CHASSIS Style A - Front Axle Assembly Caster Fork Note: There are two different style front axle as- Removal Style A (Fig. 008): 1. Remove the hex head bolt and washer located on top of the caster fork assembly (Fig. 010). Fig.
  • Page 26 CHASSIS 3. Using a drift punch, tap the bottom ball bearing out Style A caster fork assembly (Fig. 014) of the front axle assembly (Fig. 012). B C D E Fig. 014 PICT-9167a Fig. 012 PICT-9164 A. Caster fork assembly D.
  • Page 27 CHASSIS Style A - Front Axle Assembly Caster Fork 3. Install the washer and bolt and tighten the bolt (Fig. Installation 017). 1. Tap the bottom and top ball bearings into the front axle assembly (Fig. 015). Fig. 017 PICT-9175 Fig.
  • Page 28 CHASSIS Style B - Front Axle Assembly Caster Fork Style B - Front Axle Assembly Caster Fork Removal Installation 1. Remove the plastic dust cover, e-ring and washer. Slide the caster fork down, out of the front axle front axle assembly (Fig. 020). assembly (Fig.

  • Page 29: Caster Wheel Assembly Removal

    CHASSIS Caster Wheel Assembly Removal 3. Install the washer and the e-ring on the caster fork assembly (Fig. 022). 1. Park the unit on a level surface, disengage the blade control (PTO), and turn the ignition key to “Off” to stop the engine.
  • Page 30 CHASSIS Castor Wheel Assembly Installation 4. Remove the wheel spanner from the wheel as- sembly (Fig. 026). 028). Fig. 026 PICT-9197 Fig. 028 PICT-9200a the wheel rims (Fig. 027). 2. Install the wheel spanner into the wheel assembly (Fig. 029). Fig.

  • Page 31: Front Axle Assembly Removal

    CHASSIS 3. Install the bolt and nut retaining the wheel assembly 4. Remove the front footrest plate (Fig. 032). to the caster fork, then tighten the bolt and nut (Fig. 030). Fig. 032 PICT-9202 Fig. 030 PICT-9195 5. Remove the footrest from the frame (Fig. 033). Front Axle Assembly Removal 1.
  • Page 32 CHASSIS 6. Remove the lift rod from the front axle (Fig. 034). 8. Remove the 4 bolts, washers, and nuts retaining the front axle assembly to the frame (Fig. 036). Fig. 034 PICT-9205 Fig. 036 PICT-9207 7. Remove both the right and left castor fork assemb- 9.
  • Page 33 CHASSIS 10. Remove the castor fork bearings by using a drift 2. Install the front axle assembly into the frame (Fig. punch and tapping the bearings out of the front axle 040). assembly (Fig. 038). Fig. 040 PICT-9208 Fig. 038 PICT-9209a 3.
  • Page 34 CHASSIS 4. Install thrust washers onto the caster forks, then 6. Install the lift rod, washer and nut to the front axle install the castor fork assemblies into the front axle assembly (Fig. 044). assembly (Fig. 042). Fig. 044 PICT-9205 Fig.

  • Page 35: Fuel Tank Removal

    CHASSIS 8. Install the footrest plate to the frame with two bolts and washers (Fig. 046). Fuel Tank Removal 1. Remove the negative battery cable from the battery (Fig. 047). Fig. 046 PICT-9217 Fig. 047 PICT-9219 10. Install the mower deck; refer to “Mower Deck Installation”...
  • Page 36 CHASSIS 3. Remove the fuel cap (Fig. 049). 5. Remove the 3 shoulder screws that retain the RH pod to the frame (Fig. 051). Fig. 049 PICT-9226 Fig. 051 PICT-9230 6. Remove the RH pod from the frame (Fig. 052). of the fuel tank (Fig.
  • Page 37 CHASSIS 7. Move the hose clamp and disconnect the fuel line 9. Remove the fuel tank (Fig. 055). (Fig. 053). Fig. 055 PICT-9236 Fig. 053 PICT-9234 Fuel Tank Installation 8. Cut and remove the cable tie running through the 1. Install fuel tank onto the frame (Fig. 056). retention tabs located on the seat/pod bracket (Fig.
  • Page 38 CHASSIS 2. Install a cable tie through the retention tabs located on the seat/pod bracket (Fig. 057). install the hose clamp (Fig. 059). Fig. 059 Fig. 057 PICT-9234 PICT-9238 5. Install the RH pod to the frame (Fig. 060). 3. Install the seal foam on the neck of the fuel tank (Fig.
  • Page 39 CHASSIS 6. Install 3 shoulder screws that retain the RH pod to 8. Install 4 screws in the control panel and tighten (Fig. the frame (Fig. 061). 063). Fig. 063 Fig. 061 PICT-9241 PICT-9230 9. Install the battery negative cable onto the battery (Fig.
  • Page 40 CHASSIS Seat Pivot/Control Assembly 3. Remove the wire harness retainer located on the seat base (Fig. 067). Seat Pivot/Control Assembly Removal 1. Remove the negative battery cable from the battery (Fig. 065). Fig. 067 PICT-9251 4. Remove the hairpin and the clevis pin holding the retaining cable stop for the seat (Fig.
  • Page 41 CHASSIS 5. Remove the shoulder bolts and nuts retaining the 7. Remove the LH pod from the unit (Fig. 071). seat base to the seat pivot/control assembly and remove seat assembly (Fig. 069). Fig. 071 PICT-9260 Fig. 069 PICT-9257 8. Remove the four screws on the control panel and move the control panel away from the side panel 6.
  • Page 42 CHASSIS 9. Remove the fuel cap and the rubber washer. 12. Cut and remove the tie cable running through the retention tabs located on the seat/pods bracket (Fig. 10. Remove the 3 shoulder screws retaining the RH pod 075). to the frame (Fig. 073). Fig.
  • Page 43 CHASSIS 14. Remove the right and left control covers (Fig. 077). 16. Remove the z-bend of the parking brake cable from the RH and LH gear control (Fig. 079). Fig. 077 PICT-9275 Fig. 079 PICT-9282 15. Remove the screw securing the parking brake cable to the RH and LH activator arm assembly (Fig.
  • Page 44 CHASSIS 19. Remove the RH and LH neutral switch and pull the wire assembly out of the control linkage area (Fig. yokes for both the right hand and left hand hydro 081). links (Fig. 083). Fig. 081 Fig. 083 PICT-9342a PICT-9286 20.
  • Page 45 CHASSIS 23. Remove the 2 bolts and nuts that retain the lift arm 25. Remove the two bolts and nuts located in the front of assembly to the lift lever assembly (Fig. 085). the seat pivot/control assembly (Fig. 087). Fig. 087 Fig.
  • Page 46 CHASSIS 27. On the left side remove the 2 bolts and nuts retain- 29. Remove the seat pivot/control assembly from the ing the seat pivot/control assembly to the frame (Fig. frame (Fig. 091). 089). Note: The right handle assembly is being removed. The left hand side is removed the same way.
  • Page 47 CHASSIS 31. Pull back on the actuator arm and install a small 33. With a 1/4” Allen wrench and a 7/16” wrench, punch in the hole located on the return plate (Fig. remove the nut from the end of the eccentric (Fig. 093).
  • Page 48 CHASSIS Seat Pivot/Control Assembly Installation 35. Remove the activator arm and actuator from the seat pivot/control assembly (Fig. 097). Note: Perform the same installation on the RH and LH side. 1. Install the activator and actuator arm assembly into the seat pivot/control assembly using a shoulder bolt (Fig.
  • Page 49 CHASSIS 3. Install an eccentric screw through the eccentric. 5. With a punch installed on the end of the return plate and spring, install the bracket return onto the seat the seat pivot/control assembly (Fig. 100). pivot/control assembly (Fig. 102). Fig.
  • Page 50 CHASSIS 7. Install 2 bolts and washers in the handle assembly 9. On the right side install one bolt and nut retaining the and the actuator arm and tighten (Fig. 104). seat pivot/control assembly to the frame; tighten the bolt and nut (Fig. 106). Fig.
  • Page 51 CHASSIS 11. Install the two bolts and nuts located on the backside 13. Install a bolt and nut on the top of the HOC sector of the seat pivot/control assembly; tighten the bolts and a bolt, washer and nut on the bottom of the and nuts (Fig.
  • Page 52 CHASSIS 15. Install the lift lever assembly to the lift arm assembly 17. Install a washer between each motion control damp - and install nuts and tighten (Fig. 112). er and the activator arm and secure with a shoulder screw (Fig. 114). Fig.
  • Page 53 CHASSIS Install in the slot located below the actuator arm (Fig. 20. Install the z-bend of the parking brake cable into the 116). right and left gear controls (Fig. 118). Fig. 116 Fig. 118 PICT-9344 PICT-9353 19. Route the parking brake cable to the inside of the motion control damper under the RH and LH activa- the activator arm assembly and tighten (Fig.
  • Page 54 CHASSIS 22. Check the operation of both the right and left park 24. Install the right and left control covers (Fig. 122). brake. Move the handle assembly to the neutral park position (Fig. 120). Fig. 122 PICT-9368 Fig. 120 PICT-9360 25.
  • Page 55 CHASSIS 26. Install a cable tie through the retention tabs located 28. Install the rubber washer and fuel cap (Fig. 126). on the seat pivot/control assembly (Fig. 124). Fig. 126 PICT-9226 Fig. 124 PICT-9370 29. Install the 4 screws retaining the control panel to the right hand pod (Fig.
  • Page 56 CHASSIS 30. Install the left hand pod with 3 shoulder screws (Fig. 32. Install the hairpin and clevis pin holding the retaining 128). cable stop for the seat (Fig. 130). Fig. 128 Fig. 130 PICT-9259 PICT-9256 31. Install the two shoulder bolts and nuts retaining the 33.
  • Page 57 CHASSIS 34. Install the wire plug harness to the seat switch (Fig. 132). 1. Remove the negative battery cable from the battery (Fig. 134). Fig. 132 PICT-9246 35. Install the negative battery cable to the battery (Fig. 133). Fig. 134 PICT-9219 2.
  • Page 58 CHASSIS 4. Remove the left hand pod from the unit. (Fig. 136). 6. Remove the fuel cap and the rubber washer. 7. Remove the 3 shoulder screws retaining the right hand pod to the frame (Fig. 138). Fig. 136 PICT-9260 Fig.
  • Page 59 CHASSIS 9. Remove the wire plug of the harness from the seat 11. Cut and remove the cable tie running through the switch (Fig. 140). retention tabs located on the seat/pods bracket (Fig. 142). Fig. 140 PICT-9246 Fig. 142 PICT-9235 10.
  • Page 60 CHASSIS 13. Remove the battery positive cable from the battery. 16. Remove the right and left neutral safety switches by 14. Remove the battery hold down and remove the pushing the clip that retains the neutral switch to the battery from the battery tray (Fig. 144). seat pivot/control assembly (Fig.
  • Page 61 CHASSIS 18. Remove the left and right spring clip retaining the 20. Remove the cotter pin and washer from the lift lever brake cable to the brake arm (Fig. 148). assembly (Fig. 150). Fig. 150 PICT-9392 Fig. 148 PICT-9385 21. Remove the 4 bolts and nuts retaining the seat/pods bracket to the frame (Fig.
  • Page 62 CHASSIS 22. Pull the neutral wiring harness out of the hole 24. Remove the screw from the relay base and remove located on the backside of the seat/pods bracket. the base from the seats/pods bracket (Fig. 154). There is one on the left side and one on the right side (Fig.
  • Page 63 CHASSIS 26. Open the wire harness clamp located on the right 28. Remove the seat/pods bracket from the frame (Fig. side of the seat/pods bracket and remove the wire 158). harness (Fig. 156). Fig. 158 PICT-9425 Fig. 156 PICT-9422 29. Remove the lift plate from the frame (Fig. 159). 27.
  • Page 64 CHASSIS 30. Remove the two bolts and nuts retaining the lift arm assembly to the lift lever assembly (Fig. 160). 1. Install the lift lever assembly to the lift link (Fig. 162). Fig. 160 PICT-9430 Fig. 162 PICT-9436 31. Remove the lift lever assembly from the lift link (Fig. 161).
  • Page 65 CHASSIS 3. Install the bolts and nuts to the lift arm assembly and 5. Install the seat/pods bracket to the frame (Fig. 166). the lift lever assembly and tighten (Fig. 164). Fig. 166 PICT-9425 Fig. 164 PICT-9430 6. Install the two screws in the fuse block to the seat/ pods bracket (Fig.
  • Page 66 CHASSIS 7. Install the relay base with one screw and tighten it 9. Install the throttle/choke cable and the wiring har- down to the seat/pods bracket (Fig. 168). ness in the wire clamp located on the right side of the seat/pods bracket (Fig. 170). Fig.
  • Page 67 CHASSIS 11. Install the right and left neutral wiring harnesses 13. Install the washer and cotter pin on the lift lever through the hole on the back side of the seat/pods assembly (Fig. 174). bracket (Fig. 172). Fig. 174 PICT-9392 Fig.
  • Page 68 CHASSIS 15. Install the brake cable eyelet to the brake arm and 17. Route the left and right neutral switches, with har- install the spring clip (Fig. 176). ness attached, and clip them into the side of the seat pivot/control assembly (Fig. 178). Fig.
  • Page 69 CHASSIS 19. Install the battery to the battery tray with the battery 22. Install cable tie through the retention tabs located on hold down (Fig. 180). the seat/pods bracket (Fig. 182). Fig. 182 Fig. 180 PICT-9370 PICT-9372 23. Install the wire seat switch harness retainer to the 20.
  • Page 70 CHASSIS 24. Install the seat switch wiring harness plug to the seat 26. Install the 3 shoulder screws into the right hand pod switch (Fig. 184). and tighten (Fig. 186). Fig. 184 Fig. 186 PICT-9246 IMG-0455a 25. Install the right hand pod to the frame (Fig. 185). install the fuel cap.

  • Page 71: Arm-Lift, Rear, Removal

    CHASSIS 29. Install the left pod onto the frame (Fig. 188). 31. Install the mower deck; see “Mower Deck Installation” on page 6-13. 32. Install the negative battery cable to the battery (Fig. 190). Fig. 188 PICT-9457 Fig. 190 30. Install the 3 shoulder screws that retain the left hand PICT-9219 pod to the frame and tighten (Fig.
  • Page 72 CHASSIS 2. Remove the mower deck; see “Mower Deck 6. Remove the right hand pod from the frame (Fig. Removal” on page 6-12. 194). 3. Remove the four screws on the control panel and move the control panel away from the pod (Fig. 192).
  • Page 73 CHASSIS 7. Remove the wire harness retainer located on the 9. Remove the fuel tank from the frame (Fig. 198). seat base (Fig. 196). Fig. 198 PICT-9265a Fig. 196 PICT-9251 10. Remove the cotter pin and washer from the lift lever 8.
  • Page 74 CHASSIS Arm-Lift, Rear, Installation 11. Remove the bolt, washer and nut retaining the pivot block for the arm-lift on either the right or left side of the frame (Fig. 200). Loosen the bolt, washer, and 1. Loosely install the pivot block with the round tab nut on the other side.
  • Page 75 CHASSIS 2. Install the end of the arm-lift into the pivot block 3. Install the lift link of the arm-lift to the lift lever as- (Fig. 204) and install the other pivot block to the sembly with washer and cotter pin (Fig. 206). other side of the frame (Fig.
  • Page 76 CHASSIS 5. Install a cable tie through the retention tabs located 7. Install the wire plug on the wire harness to the seat on the seat/pods bracket (Fig. 208). switch (Fig. 210). Fig. 208 Fig. 210 PICT-9238 PICT-9246 6. Install the wire harness retainer to the seat base 8.
  • Page 77 CHASSIS 9. Install the 3 shoulder screws that retain the right 11. Install the control panel to the right hand pod using 4 hand pod to the frame (Fig. 212). screws and tighten (Fig. 214). Fig. 212 Fig. 214 IMG-0455a PICT-9241 10.

  • Page 78: Rear Bumper Removal

    CHASSIS Rear Bumper Installation Rear Bumper Removal 1. Install the rear bumper to the frame (Fig. 218). 1. Remove the 4 bolts, washers and nuts (Fig. 216). Fig. 218 PICT-9492 Fig. 216 PICT-9484 2. Install washers under each bolt head. On the two outside bolts, install a large hardened washer be- tween the bolt and the nut;...
  • Page 79 CHASSIS THIS PAGE INTENTIONALLY LEFT BLANK. 3-56 TimeCutter® Z/Precision® Z Service Manual...

  • Page 80: Engine

    ENGINE Engine Replacement 4. Remove the bolt retaining the electric PTO clutch to the engine crankshaft (Fig. 222). Engine Removal 1. Remove the negative battery cable from the battery. 2. Release the mower drive belt tension and remove the mower drive belt from the electric PTO clutch (Fig.
  • Page 81 ENGINE 6. Release the spring tension on the idler arm using a 8. Remove the two screws retaining the heat shield to spring tool (Toro p/n 92-5771). Remove the drive belt from the engine pulley (Fig. 224). Fig. 226 PICT-9510a Fig.
  • Page 82 ENGINE 10. Remove the 4 engine bolts going through the hydro- 12. Loosen the throttle/choke cable clamp screw and supports of the frame and up into the engine block remove the cable (Fig. 230). (Fig. 228). Fig. 230 PICT-9517a Fig. 228 PICT-9514 13.
  • Page 83 ENGINE 14. Remove the engine wire harness plug (Fig. 232). 16. Remove the negative battery cable and the negative wire from the wiring harness from the top of the starter (Fig. 234). Fig. 232 PICT-9522a Fig. 234 PICT-9525 15. Remove the positive starter cable from the bottom of the starter (Fig.
  • Page 84 ENGINE Engine Installation 3. Install the negative battery cable and the negative wire to the wiring harness to the top of the starter terminal (Fig. 238). 1. Install the engine into the frame (Fig. 236). Fig. 238 PICT-9525 Fig. 236 PICT-9529 4.
  • Page 85 ENGINE 5. Plug the engine wire harness into the main wiring 7. Install the throttle/choke cable into the cable clamp, harness (Fig. 240). before tightening the clamp, make sure the throttle control is in the low idle setting (Fig. 242). Also, make sure the throttle linkage on the engine carbur- etor is pushed to far left stop position (Fig.
  • Page 86 ENGINE hose clamp (Fig. 244). Fig. 246 PICT-9537 Fig. 244 PICT-9515 10. Install the 2 screws retaining the heat shield to the 9. Install the 4 engine mounting bolts through the hydro-supports of the frame and into the engine (Fig. 245).
  • Page 87 ENGINE 11. Apply anti-seize lubricant to the engine crankshaft 13. Install the drive belt around the engine drive pulley (Fig. 248). by releasing the spring tension on the idler arm. Make sure the belt is routed around both transmis- then around the engine drive pulley (Fig. 250). Fig.
  • Page 88 ENGINE 15. Install the electric PTO clutch onto the crankshaft. 17. Install the plug connector into the electric PTO clutch Make sure the slot of the PTO clutch engages with (Fig. 254). the clutch stop bracket (Fig. 252). Fig. 254 PICT-9500a Fig.
  • Page 89 ENGINE Fig. 258 PICT-9562 Fig. 256 PICT-9510 2. Remove the 4 screws, washers and 2 gaskets re- Fig. 259 PICT-9552 Fig. 257 PICT-9560 4-10 TimeCutter® Z/Precision® Z Service Manual...
  • Page 90 ENGINE TimeCutter® Z/Precision® Z Service Manual 4-11...
  • Page 91 ENGINE THIS PAGE INTENTIONALLY LEFT BLANK. 4-12 TimeCutter® Z/Precision® Z Service Manual...

  • Page 124: Mower Deck

    MOWER DECK Mower Spindle Replacement 4. With a rag or thickly-padded glove hold the blade end and remove the nut on the spindle pulley with a 15/16” wrench (Fig. 370). Mower Spindle Removal 1. Remove the mower deck from the unit; see “Mower Deck Removal”...
  • Page 125 MOWER DECK 6. Remove the mower spindle assembly from the deck 8. Remove the blade screw and washer from the (Fig. 372). spindle shaft (Fig. 374). Fig. 372 Fig. 374 PICT-9865a PICT-9872a 7. Loosen the blade screw on the spindle (Fig. 373). 9.
  • Page 126 MOWER DECK 10. Remove the mower blade (Fig. 376). 12. Remove the spacer (Fig. 378). Fig. 376 Fig. 378 PICT-9874a PICT-9876 11. Remove the spindle shaft and bearing shield (Fig. 13. With a punch, drive one of the bearings out of the 377).
  • Page 127 MOWER DECK 14. Remove the spacer from the housing (Fig. 380). Housing, spacer, and bearings (Fig. 382) Fig. 380 Fig. 382 PICT-9881a PICT-9884 A. Housing C. Bearing (2) B. Spacer 15. Turn the housing over and drive the other bearing out the other side with a punch (Fig.
  • Page 128 MOWER DECK Mower Spindle Installation 3. Press another bearing in until it seats (Fig. 385). 1. Starting at the top of the spindle housing, press bearing into the housing until it seats (Fig. 383). Fig. 385 PICT-9889 Fig. 383 PICT-9885 4.
  • Page 129 MOWER DECK 5. Install the mower blade onto the spindle shaft (Fig. 7. Install blade bolt and washer (Fig. 389). 387). Fig. 389 PICT-9895a Fig. 387 PICT-9892a 8. Torque the blade bolt to 35 – 65 ft-lbs. (47 – 88 Nm) 6.
  • Page 130 MOWER DECK 9. Install the mower spindle assembly with blade onto 10. Install the spindle pulley with large hub of the pulley the deck (Fig. 391). facing down toward the deck (Fig. 393). Fig. 391 Fig. 393 PICT-9865 PICT-9897 10. Install the 4 screws retaining the spindle assembly 11.
  • Page 131 MOWER DECK Idler Arm Replacement 12. Install the mower drive belt around the spindle pulley (Fig. 395). Idler Arm Removal 1. Remove the mower deck from the unit; see “Mower Deck Removal” on page 6-12. 2. Remove the spring extension from the spring return hook (Fig.
  • Page 132 MOWER DECK 4. Remove the screw retaining the idler arm to the Idler arm assembly (Fig. 401) mower deck (Fig. 399). Fig. 401 PICT-9905a Fig. 399 PICT-9902 A. Plain Washer (2) D. Screw B. Friction Washer- E. Idler Arm Composite (2) F.
  • Page 133 MOWER DECK Idler Arm Installation Idler arm and pulley assembly (Fig. 403) 1. Install the screw through the idler arm and install the (Fig. 404). Fig. 403 PICT-9909a A. Nut D. Idler Arm B. Washer E. Screw C. Flat Idler Pulley Fig.
  • Page 134 MOWER DECK 3. Install a plain washer on the screw for the idler 5. Install one end of the extension spring to the idler arm, friction washer-composite, spacer through the arm (Fig. 408). idler arm; on the other side install a friction washer- composite, plain washer (Fig.

  • Page 135: Mower Deck Replacement

    MOWER DECK Fixed Flat Idler Pulley Replacement Mower Deck Replacement Fixed Flat Idler Pulley Removal Mower Deck Removal 1. Park the machine on a level surface and disengage of the mower deck. They are both replaced the PTO switch. the same way. 2.
  • Page 136 MOWER DECK Mower Deck Installation 5. Lift the mower deck and hanger brackets clear of the rear lift rod and lower the mower carefully to the ground (Fig. 413). 1. Park the machine on a level surface and disengage the blade control switch. 2.

  • Page 137: Leveling The Mower Deck

    MOWER DECK Leveling the Mower Deck 6. Attach the front support rod to the mower deck with the clevis pin and hairpin cotter (Fig. 415). Check to ensure the mower deck is level whenever the mower is installed or there is poor cutting performance. The mower deck must be checked for bent blades prior to leveling;...
  • Page 138 MOWER DECK Side-to-Side Leveling 1. Park the machine on a level surface and disengage the PTO switch. 2. Move the motion control levers outward to the park position, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
  • Page 139 MOWER DECK Adjusting the Front-to-Rear Blade Slope 6. Move to the left side of the machine. Loosen, but do not remove, the rear locking nut on the hanger bracket (Fig. 418). Check the front-to-rear blade level any time you install the mower.
  • Page 140 MOWER DECK 4. Carefully rotate the blades so they are facing front to rear (Fig. 419 and Fig. 420). (Fig. 419 and Fig. 420). If the front blade tip is not 1/16 - 5/16” (1.6 - 7.9mm) lower than the rear blade tip, adjust the front locknut.

  • Page 141: Mower Belt Maintenance

    MOWER DECK Mower Belt Maintenance Inspecting the Belts Mower Belt Routing Service Interval: Every 25 hours - Check the belts for wear/cracks. Belt routing decals: Check the belts for cracks, frayed edges, burn marks, or For models with 42” decks: any other damage.
  • Page 142 MOWER DECK 5. Pull the idler pulley in the direction shown (Fig. 424) 6. Route the new belt around the engine pulley and and roll the belt off of the pulleys. mower pulleys (Fig. 425). Fig. 425 Fig. 424 Mower Decks with 2 Blades Mower Decks with 3 Blades A.

  • Page 143: Checking For Bent Blades

    MOWER DECK Checking for Bent Blades here (Fig. 427). Note: The machine must be on a level surface for the following procedure. 1. Raise the mower deck to the highest height-of-cut position; also considered the ’transport’ position. 2. While wearing thickly padded gloves or other adequate hand protection slowly rotate blade to be measure into a position that allows effective measurement of the distance between the cutting...
  • Page 144 Removing the Blades and Installing the Blades. Note: If a bent blade is replaced with a new one and the dimension obtained continues to exceed Contact an Authorized Toro Dealer for service. b. If the variance is within constraints, move to the next blade.
  • Page 145 MOWER DECK THIS PAGE INTENTIONALLY LEFT BLANK. 6-22 TimeCutter® Z/Precision® Z Service Manual...
  • Page 146 ELECTRICAL Electrical System How It Works Two things happen when turning the ignition switch to A relay is an electrically actuated switch. switch to the starter solenoid coil terminal. (2) At the 1. Coil: Terminals 85 and 86 are connected to a coil. Applying 12 volts to these terminals energizes the coil turning it into an electromagnet.
  • Page 147 ELECTRICAL Solenoid Testing Purpose 1. Disconnect the relay from the harness. 2. Verify the coil resistance between terminals 85 and The solenoid’s purpose is simply to connect the battery 86 with a multimeter (ohms setting). Resistance to the starter motor on the engine when the ignition should be from 70 to 90 ohms.
  • Page 148 ELECTRICAL How It Works Testing 1. Disconnect the solenoid from the wiring harness. is wrapped around an iron core. Whenever 12 volts is applied to the coil, it becomes a magnet. The other part 2. With a multimeter (ohms setting), check to ensure is a bar type switch.
  • Page 149 ELECTRICAL Ignition Switch How It Works Purpose and START. The START position is spring loaded so the cylinder automatically returns to RUN once the key is The ignition switch provides the proper switching for the released (Fig. 438). starter, ignition, accessories, and safety circuits. Location The ignition switch is located on the control panel, to the right side of the operator (Fig.
  • Page 150 ELECTRICAL PTO Switch How It Works Purpose contacts inside the switch electrically connect various the safety interlock system. electric clutch and it engages. Location Testing right side of the operator (Fig. 439). 3. Press in on the locking tabs, on each side of the switch, and pull the switch out of the control panel.
  • Page 151 ELECTRICAL (“IN” POSITION) (“OUT” POSITION) Cont. Open Open Open Open Cont. (“IN” POSITION) (“OUT” POSITION) Cont. Open Open Open Open Cont. Fig. 440 TimeCutter® Z/Precision® Z Service Manual...
  • Page 152 ELECTRICAL Electric (PTO) Clutch How It Works Purpose This clutch electrically controls the engagement and coil of wire on an iron core, which becomes an electro- magnet when power is applied. The friction plate is the only piece that can slide up and down on the crankshaft axis.
  • Page 153 ELECTRICAL Coil Resistance Measurement Measuring Clutch Current Draw 2. Disconnect clutch wire connector. 2. Disconnect the clutch wire connector. 3. Set the multimeter or volt/ohm meter to check 3. Set the multimeter to check amps (10 amp scale). resistance (ohms). 4.
  • Page 154 ELECTRICAL Park Brake Switch How It Works Purpose This single pole plunger type switch has two terminals. When the forward/reverse control levers are in the park position (handles in the out position), it pushes on Used to ensure the transaxles are in neutral and the park the plunger, closing the contact, and connecting the brakes are engaged.
  • Page 155 ELECTRICAL Switch, Seat How It Works Purpose When the seat is vacated, the switch is open and there When the seat is occupied, the switch closes and there The switch is in the safety circuit. If the engine is running should be continuity between the two terminals (Fig.
  • Page 156 ELECTRICAL FlyBack Diode How It Works Purpose you go to restart the engine, it could feed enough cur- FlyBack diode blocks this from happening. The FlyBack from interfering with the starting of the engine. diode is located on 2009 and later TimeCutter Z (Fig. 449).
  • Page 157 ELECTRICAL Toro TimeCutter Z 2007-2008 Models Schematic Fig. 450 74360 _2007-2008 scheme 7-12 TimeCutter® Z/Precision® Z Service Manual...
  • Page 158 ELECTRICAL Toro TimeCutter Z 2009 Models Schematic Fig. 451 74360_2009 scheme TimeCutter® Z/Precision® Z Service Manual 7-13...
  • Page 159 ELECTRICAL Lawn-Boy Precision Z (Single Cylinder Engines) 2008 Models Schematic Fig. 452 81270_2008 scheme 7-14 TimeCutter® Z/Precision® Z Service Manual...
  • Page 160 ELECTRICAL Lawn-Boy Precision Z (Twin Cylinder Engines) 2008 Models Schematic Fig. 453 81271_2008 scheme TimeCutter® Z/Precision® Z Service Manual 7-15...
  • Page 161 ELECTRICAL THIS PAGE INTENTIONALLY LEFT BLANK. 7-16 TimeCutter® Z/Precision® Z Service Manual...

This manual is also suitable for:

Lawn-boy precision z

Table of Contents