Page 1 WALK BEHIND POWER MOWER DRIVE SYSTEMS SERVICE MANUAL...
Page 3: About This Manual
This manual was written with the assumption that the reader has basic mechanical knowledge and skills. This book contains material covering the Toro and Lawn-Boy Walk Behind Mower Drive Systems models from 1990 through 2006, and may be speciﬁ ed for use on products built after 2006 that are similar in design.
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Page 5: Table Of Contents
......Mowers with Toro Blade Override System ......
Page 6 Belt Service - Front Wheel Drive Models ......22” TORO & LAWN-BOY REAR WHEEL DRIVE MODELS Transmission Removal & Belt Replacement .
Page 7 Control Box Assembly ....... TORO BBC SERVICE GUIDE ......
Page 8 HANDLES AND CONTROL CABLES Toro 2 Bail Handle ....... . .
Page 9 TABLE OF CONTENTS Using this manual Following each model number in the list below are codes identifying the type of deck material, transmission, wheel pinion clutch, hand controls, and if it has a blade clutch system. Use this information to select the correct sections of the service manual for the mower being serviced.
Page 10 TABLE OF CONTENTS Code List 1B - one bail CDVP - cast deck Vacu Power 2B - two bail ES1 - Easy Stride 1st generation 3S- 3 speed ES2 - Easy Stride 2nd generation 21” stl - 21” steel deck Ins - Insight 22”...
Page 11 TABLE OF CONTENTS Code List 1B - one bail CDVP - cast deck Vacu Power 2B - two bail ES1 - Easy Stride 1st generation 3S- 3 speed ES2 - Easy Stride 2nd generation 21” stl - 21” steel deck Ins - Insight 22”...
Page 12 TABLE OF CONTENTS Code List 1B - one bail CDVP - cast deck Vacu Power 2B - two bail ES1 - Easy Stride 1st generation 3S- 3 speed ES2 - Easy Stride 2nd generation 21” stl - 21” steel deck Ins - Insight 22”...
Page 13 TABLE OF CONTENTS Code List 1B - one bail CDVP - cast deck Vacu Power 2B - two bail ES1 - Easy Stride 1st generation 3S- 3 speed ES2 - Easy Stride 2nd generation 21” stl - 21” steel deck Ins - Insight 22”...
Page 14 TABLE OF CONTENTS Code List 1B - one bail CDVP - cast deck Vacu Power 2B - two bail ES1 - Easy Stride 1st generation 3S- 3 speed ES2 - Easy Stride 2nd generation 21” stl - 21” steel deck Ins - Insight 22”...
Page 15 TABLE OF CONTENTS Code List 1B - one bail CDVP - cast deck Vacu Power 2B - two bail ES1 - Easy Stride 1st generation 3S- 3 speed ES2 - Easy Stride 2nd generation 21” stl - 21” steel deck Ins - Insight 22”...
Page 16 TABLE OF CONTENTS Code List 1B - one bail CDVP - cast deck Vacu Power 2B - two bail ES1 - Easy Stride 1st generation 3S- 3 speed ES2 - Easy Stride 2nd generation 21” stl - 21” steel deck Ins - Insight 22”...
Page 17 TABLE OF CONTENTS Code List 1B - one bail CDVP - cast deck Vacu Power 2B - two bail ES1 - Easy Stride 1st generation 3S- 3 speed ES2 - Easy Stride 2nd generation 21” stl - 21” steel deck Ins - Insight 22”...
Page 18 TABLE OF CONTENTS THIS PAGE INTENTIONALLY LEFT BLANK. WPM Drive Systems Manual...
Page 19 WORM DRIVE TRANSMISSION Worm Drive Transmission ......Single Speed Spur/Bevel Gear Transmission ... . . Single Speed Bevel Gear Transmission .
Page 20: Worm Drive Transmission
WORM DRIVE TRANSMISSION GENERAL the mower housing, pivots the transmission forward to maintain tension on the belt. There are two versions of the worm drive transmission. The worm is in constant mesh with the helical gear. The The ﬁ rst is a clutch type and is used on 21” front wheel clutching action is provided by a sliding clutch jaw.
Page 21: Lubrication
WORM DRIVE TRANSMISSION Lubrication The shift rod has a roll pin protruding through the top of the transmission. This pin goes through a latch plate with an L shaped slot in it. The slot guides the pin in its This transmission requires 90 wt. gear oil. A variable travel from engagement to disengagement.
Page 22: Removal & Installation (Front Wheel Drive Applications)
WORM DRIVE TRANSMISSION Removal & Installation (front wheel drive 4. Remove both front wheels and wheel covers (Fig. 005). applications) 1. Remove the belt cover and unhook the spring on the front of the transmission. Slip the belt off the transmission pulley (Fig.
Page 23: Disassembly
WORM DRIVE TRANSMISSION 6. Place a block of wood under the wheel pinion for 8. Remove the transmission from the chassis. support and drive the roll pin out of the axle (Fig. 007). Repeat the process on the other side. 9.
Page 24 WORM DRIVE TRANSMISSION 2. Drive the roll pins out of the ﬂ anges in the front 5. Push the worm shaft out of the cover. This may and rear of the case. (These pins align the top and require a little pressure. bottom parts of the case) (Fig.
Page 25: Assembly
WORM DRIVE TRANSMISSION 9. Clean the old gasket material from the mating 14. Remove the screw from the shift arm and remove surfaces of the case and cover. the shift arm, dust cover, and wear plate (Fig. 015). If the ball bearing is to be replaced, press it out at this 10.
Page 26 WORM DRIVE TRANSMISSION Note: The bushings are two different lengths. The 3. Note: Some replacement axles have more than one side of the case with the thicker boss uses hole that can be used to pin the sleeve to the axle. a longer busing to support the axle.
Page 27: Controls
WORM DRIVE TRANSMISSION 5. If the bearing in the cover is being replaced, use tool 9. Fill the transmission with gear oil AFTER it is P/N 27-0490 to press it in place. This bearing only installed in the mower. The top of this transmission is has one seal.
Page 28: Adjustment
WORM DRIVE TRANSMISSION Adjustment The transmission cable is a standard lever type. Since the spring and pin on top of the transmission pushes the shift fork towards the engaged position, the cable pulls the shift arm to the rear to disengage the transmission. The adjustment point is on the mower housing just to the rear of the transmission.
Page 29: Constant Mesh Description
WORM DRIVE TRANSMISSION CONSTANT MESH 1. Jam nut 13. Oil Seal 2. Lock washer 14. Output shaft 3. Half pulley 15. Traction bracket Description 4. V Belt 16. Thread forming screw 5. Pulley spacer 17. Gearbox case This transmission is very similar to the “INTERNALLY 6.
Page 30: Removal & Installation
WORM DRIVE TRANSMISSION Removal and Installation Fig 023 20911B sprearaxleassy Ref. No. Description Ref. No. Description Rear Pivot Assembly RH Keyed Thrust Washer (incl. Ref. #2, 4, 5 & 14) Retaining Ring Grease Fitting LH Rocking Key Washer Pinion Gear Sleeve Bushing Compression Spring Grease Seal...
Page 31: Controls
WORM DRIVE TRANSMISSION To remove the transmission from the mower proceed as 2. Rotate the adjustment knob under the lower left- follows: hand side of the control panel ½ turn clockwise to tighten the belt, or ½ turn counterclockwise to loosen 1.
Page 32: Wheel Clutch
WORM DRIVE TRANSMISSION 4. If loss of traction or improper engagement still occurs after adjustment, repeat steps 2 – 3 until properly adjusted. WHEEL CLUTCH See Rocking Key Wheel Clutch, page 5-3. 1-14 WPM Drive Systems Manual...
Page 33: Single Speed Spur/Bevel Gear Transmission
SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION Worm Drive Transmission ......Single Speed Spur/Bevel Gear Transmission ... . . Single Speed Bevel Gear Transmission .
Page 34: Gear Case Assembly
SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION GEAR CASE ASSEMBLY Fig 026 snglspspurbvlgearbox Ref. No. Description Ref. No. Description Gear Case Casting Output Bushing Gear Case Cover Intermediate Shaft HWH Screw Pulley Half Retaining Ring Ball Bearing Flat Washer Pulley Spacer Groove Pin Bevel Gear 15t Spur, 37t Lock Nut NI Pinion Gear Bevel...
Page 35: Description
SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION Description 2. Remove transmission belt cover. 3. Remove both rear wheels. This basic transmission has been in use for several years. There are minor variations, such as different 4. Remove retaining ring, spring, thrust washer, and shafts on the bevel pinion gear to accommodate belt pinion from both axles (Fig.
Page 36: Transmission Internal Repair
SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION 6. Remove the belt guide. Note the location of the On some models, removing these 2 screws makes spacer under the front mounting screw (Fig. 030). transmission removal easier (Fig. 032). Do not try to force the belt off the pulley without removing the belt guide.
Page 37: Assembly
SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION Before removing the parts from the case, note the Clean the gears in solvent and inspect carefully. Any quantity and location of the thrust washers (Fig. 034). damaged gear must be replaced. Also replace the mate for the damaged gear.
Page 38 SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION Prior to installation of oil impregnated bushings, it is Insert the transmission back into the chassis. Refer wise to apply a light coating of engine oil to the running to the section on the wheel pinion clutch for assembly surface (Fig.
Page 39: Single Speed Bevel Gear Transmission
SINGLE SPEED BEVEL GEAR TRANSMISSION Worm Drive Transmission ......Single Speed Spur/Bevel Gear Transmission ... . . Single Speed Bevel Gear Transmission .
Page 40: Bevel Gear Transmission
SINGLE SPEED BEVEL GEAR TRANSMISSION EXPLODED VIEW - SINGLE SPEED BEVEL GEAR TRANSMISSION Fig 039 single speedtrans a A. Nut H. Bushing B. Washer Thrust washer C. Pulley J. Bevel Gear D. Spacer K. Bushing E. Housing L. Roll pin F.
Page 41: General Information
SINGLE SPEED BEVEL GEAR TRANSMISSION GENERAL INFORMATION This transmission was ﬁ rst used on 22” steel deck models for 2002. It is used in both front wheel and rear wheel drive conﬁ gurations. The bevel gear is reversed when used in the front drive versus the rear drive to change axle shaft direction of rotation.
Page 42: Front Axle & Transmission Assembly
SINGLE SPEED BEVEL GEAR TRANSMISSION FRONT AXLE AND TRANSMISSION ASSEMBLY 3354-613 Rev A Fig 041 3354-613(5) Ref. No. Description Ref. No. Description Bolt-Shoulder Spring-Compression Wheel Gear ASM Bushing Transmission ASM Klipring-Locking Gasket-Gearbox Gear-Pinion, 13T Screw-HWH Washer-Thrust Bracket-Pivot, Fwd Cover-Wheel Screw-HWH Cover Spacer Washer-Stepped...
Page 43: 22" Front Wheel Drive Models
SINGLE SPEED BEVEL GEAR TRANSMISSION 22” FRONT WHEEL DRIVE MODELS 4. Remove the nut, washer, transmission pulley halves, and spacer. Remove Transmission 5. Remove the belt guide. 1. Block the front of the mower up. There are two 6. Remove both front wheels; note there is a washer screws that secure the belt cover to the housing.
Page 44 SINGLE SPEED BEVEL GEAR TRANSMISSION 9. Remove the two bolts and nuts securing each pivot 10. Remove the klip ring and thrust washer from each arm to the housing. There is a notch in the pivot arm end of the axle (the left side has 2 thrust washers, for clearance of a socket (Fig.
Page 45: Transmission Disassembly
SINGLE SPEED BEVEL GEAR TRANSMISSION The snap ring can now be removed. Loosen the 2. Since the pulley was previously removed, the input clamps with care due to the spring arm tension. shaft will now slip out of the transmission case. Separate the spring arm components (Fig.
Page 46: Assembly Tips
SINGLE SPEED BEVEL GEAR TRANSMISSION Assembly Tips 3. Install the transmission bearings with the ﬂ ange facing the gear (Fig. 054). 1. The same axle is used for both front and rear drive versions. There are two holes in the axle about one inch apart.
Page 47: To Replace Self-Propelled Drive Belt
SINGLE SPEED BEVEL GEAR TRANSMISSION 7. Coat the axle, key, and spring with #2 molybendum Belt Service - Front Wheel Drive Models disulﬁ de base grease or anti-seize compound before installing the pinion (Fig. 055). To replace the self-propelled drive belt, proceed as follows: 1.
Page 48: 22" Toro & Lawn-Boy Rear Wheel Drive Models
SINGLE SPEED BEVEL GEAR TRANSMISSION 4. Remove one of the mounting screws for the belt 22” TORO & LAWN-BOY REAR guide and loosen the other. DO NOT bend the belt WHEEL DRIVE MODELS guide (Fig. 059). Transmission Removal and Belt...
Page 49 SINGLE SPEED BEVEL GEAR TRANSMISSION 3. Remove the plug from the hole next to where the 5. The cable tool (P/N 105-6819) will compress the self propel cable goes through the chassis (Fig. locking tabs on the cable so it can be removed from 062).
Page 50 SINGLE SPEED BEVEL GEAR TRANSMISSION 8. Push it into the larger hole (Fig. 066). 11. Pinch the ends of the lower handle together to disengage them from the pins on the HOC plates (Fig. 068). Fig 066 PICT-1897 Fig 068 MVC-737 9.
Page 51 SINGLE SPEED BEVEL GEAR TRANSMISSION 14. Place the mower right side up and remove the three 16. The belt cover must be removed in order to remove hex head and one Allen head cap screws on each the belt (Fig. 072). side that hold the height of cut plates to the chassis (Fig.
Page 52 SINGLE SPEED BEVEL GEAR TRANSMISSION 18. Pull the belt cover out from under the rear wall and 20. The cable may be unhooked from the arm on the the belt is exposed (Fig. 074). transmission to help prevent cable damage (Fig. 076).
Page 53: Rear Axle Disassembly
SINGLE SPEED BEVEL GEAR TRANSMISSION Rear Axle Disassembly 4. The pivot assembly will slide off the axle. This includes the bearing, bearing retainer, HOC plate, spring arm, and pivot arm (Fig. 079). 1. Remove the klip rings and thrust washers that secure the pinions to the axle (Fig.
Page 54: Transmission Disassembly
SINGLE SPEED BEVEL GEAR TRANSMISSION 6. You can now release the clamps and separate the 2. Since the pulley was previously removed, the input HOC plate, spring arm, and pivot arm (Fig. 081). shaft will now slip out of the transmission case. 3.
Page 55: Axle Assembly Tips
SINGLE SPEED BEVEL GEAR TRANSMISSION Axle Assembly Tips 3. Install the transmission bearings with the ﬂ ange facing the gear (Fig. 085). 1. The same axle is used for both front and rear wheel drive models. There are two holes in the axle about one inch apart.
Page 56 SINGLE SPEED BEVEL GEAR TRANSMISSION 6. Coat the axle, key, and spring with #2 molybendum disulﬁ de grease or anti-seize compound before installing the pinion (Fig. 087). Fig 087 MVC-472 7. The wheel pinion is marked with an R and L for right and left.
Page 57: Lawn-Boy Insight Transmission Remove & Replace
SINGLE SPEED BEVEL GEAR TRANSMISSION LAWN-BOY INSIGHT TRANSMISSION REMOVE AND REPLACE 3352-960 Rev B Rear Axle and Transmission Assembly Fig 089 3352-960(6) Ref. No. Description Ref. No. Description Bolt-Shoulder Spring-Compression Rear Wheel ASM Klipring-Locking Transmission ASM Gear-Pinion, 15T Washer-Shield Washer-Thrust Bracket-Transmission Wheel Cover ASM Screw-HWH...
Page 58: Tranmission Removal & Belt Replacement
SINGLE SPEED BEVEL GEAR TRANSMISSION Transmission Removal & Belt Replacement 4. The belt cover will drop off the bottom (Fig. 092). The following steps will show one method of replacing the belt or removing the transmission on the Lawn-Boy Insight mowers. 1.
Page 59 SINGLE SPEED BEVEL GEAR TRANSMISSION 7. Lift the top half of the transmission pulley off. If just 9. Bend the trailing shield slightly in the middle and replacing the belt, push the belt into the cutting remove it from the mower. Rotate both rear spring chamber and slip the belt over the blade.
Page 60 SINGLE SPEED BEVEL GEAR TRANSMISSION 11. Remove klip ring, keyed thrust washer, and standard 13. Push the bearings and bearing retainers inward, thrust washer (left side of mower has the standard towards the transmission (Fig. 100). thrust washer, right side does not) (Fig. 098). Fig 100 MVC-297 Fig 098...
Page 61 SINGLE SPEED BEVEL GEAR TRANSMISSION 16. Push the transmission to the left, as shown, and rotate to clear the tunnel. Drop the left side down, then pull the assembly out to the left side (Fig. 104). Fig 102 MVC-211x1 15. Remove the nut, washer, 2 pulley halves, and Fig 104 MVC-300 spacer from the transmission input shaft.
Page 62: Transmission Disassembly
SINGLE SPEED BEVEL GEAR TRANSMISSION Transmission Disassembly Transmission Assembly & Installation 1. Remove the 4 screws holding the cover on the Assemble in reverse order. See Axle Assembly and transmission. The axle, bearings, and bevel gear Installation Tips following. can be lifted out (Fig. 106). Axle Assembly Tips 1.
Page 63: Transmission Installation Tips
SINGLE SPEED BEVEL GEAR TRANSMISSION 2. Install the thrust washer on the side of the gear with Transmission Installation Tips the shortest hub, away from the gear teeth (Fig. 108). 1. Reconnect the cable to the belt guide and install the washer and spacer before installing the guide on the 3.
Page 64 SINGLE SPEED BEVEL GEAR TRANSMISSION 4. The wheel pinion is marked with an R and L for right 7. When installing the rear cover, note the bosses on and left. Identify right and left from the operator’s the back side of the cover. They must go behind the position (Fig.
Page 65: Three Speed Transmission
THREE SPEED TRANSMISSION Worm Drive Transmission ......Single Speed Spur/Bevel Gear Transmission ... . . Single Speed Bevel Gear Transmission .
Page 66: Gear Case Assembly
THREE SPEED TRANSMISSION GEARCASE ASSEMBLY Fig 114 gearcaseassy Ref. No. Description Ref. No. Description Pinion-25T Bushing - Yoke Pinion-20T Retainer - Fork, Shift Gear-15t Spur, 37t Bevel Shaft - Output Washer - Thrust Yoke - Shift Bushing Spacer Bushing - Output Pulley - Half Washer Gear - Pinion, Bevel...
Page 67: Operation
THREE SPEED TRANSMISSION OPERATION Speed Reduction System: Speed reduction is accomplished by two sets of gears Input System: – one set on the intermediate shaft and the other set on the output shaft. The gears on the intermediate shaft Power is transferred from the engine to the transmission are powdered metal and ride on a hexagonal shaft by a belt.
Page 68: Gear Selection System
THREE SPEED TRANSMISSION There are also three gears on the output shaft. These The shift keys are retained on one end by the shift three gears rotate freely on the gear sleeve. The gear collar. Movement of the shift fork positions the shift collar sleeve is coupled to the output shaft with a roll pin so and shift key.
Page 69: Removal - Toro Vacu Power/Lawn-Boy Medallion Models
Medallion Models 5. Remove the two ﬂ anged head self-tapping Complete transmission removal on the Toro Vacu screws securing the belt cover to the top of the Power/Lawn-Boy Medallion mower is quite easy and is transmission.
Page 70: Removal - Recycler/Rear Bagger Chassis
THREE SPEED TRANSMISSION Removal - Recycler/Rear Bagger Chassis Disassembly To remove the transmission from the chassis, raise the Inspection of this transmission can be accomplished rear and support it with blocks. without removing the pivot arm assembly from the output shaft.
Page 71: Transmission - Assembly
THREE SPEED TRANSMISSION 3. Removal of the input shaft and pulley assembly can 5. Remove the cotter pin from the top of the shift fork be difﬁ cult because the input pinion has a tendency and remove the shift lever. to turn as the pulley nut is loosened.
Page 72: Output Shaft Assembly
THREE SPEED TRANSMISSION Output Shaft Assembly 5. Coat the shift key sleeve with grease and prepare the shift keys, shift collar, and spring clip for assembly as shown in Figure 124. 1. Slide the output bushing onto the output shaft, ﬂ...
Page 73: Input Shaft Assembly
THREE SPEED TRANSMISSION 8. If the left pivot arm was removed for servicing, 3. The input pulley nut can be tightened after complete reassemble now as described under “Rear Height- transmission assembly, or at this point using the of-Cut and Wheel Pinion Clutch – Assembly” on process in step 3, under Disassembly, page 4-7.
Page 74: Intermediate Shaft Assembly
THREE SPEED TRANSMISSION Intermediate Shaft Assembly 2. Slide the intermediate shaft gears onto the intermediate shaft in this order: a. 25 tooth gear Note: Before assembling, coat the intermediate b. 20 tooth gear shaft with No. 2 lithium-based grease. Apply a c.
Page 75: Special Assembly Notes For Toro Vacu Power/Lawn-Boy Medallion
THREE SPEED TRANSMISSION Special Assembly Notes for Toro Vacu 4. Slip the two rear end cap fasteners through the safety shield guide wires then install. Tighten all four Power/Lawn-Boy Medallion end cap fasteners (Fig. 131). 1. Slip the gear selection cable into the shift fork lever Note: End cap fastener torque: 225 in-lbs.
Page 76: Troubleshooting Tips - 3 Speed Transmission
THREE SPEED TRANSMISSION TROUBLESHOOTING TIPS - 3 SPEED Look at the key and the notch in the gear that it engages. Excessive wear to the tip of the key or the notch in the TRANSMISSION gear may be the problem (Fig. 133). Hard Shifting A raised boss molded into each gear causes the leading edge of the key to depress before it can enter the next...
Page 77: Wheel Pinion Clutch
WHEEL PINION CLUTCH Worm Drive Transmission ......Single Speed Spur/Bevel Gear Transmission ... . . Single Speed Bevel Gear Transmission .
Page 78: Gear Case & Wheel Assembly, Rocking Key Style
WHEEL PINION CLUTCH GEARCASE AND WHEEL ASSEMBLY, ROCKING KEY STYLE Fig 135 gearcase wheel assy Ref. No. Description Ref. No. Description V-Belt Washer-Clutch Lever-Shift Key-Rocking, LH Pin-Cotter Key-Rocking, RH Clamp-Cable Gear-Pinion Cap-End Spring-Compression O-Ring Cover-Wheel Spring Arm ASM Spacer-Cover, Wheel Pivot Arm ASM Wheel ASM Bushing...
Page 79: Wheel Pinion Clutch
WHEEL PINION CLUTCH Wheel Pinion Clutch 10. Keyed Thrust Washer – internal tab ﬁ ts in the keyway on the output shaft. This washer rotates with the output shaft and protects outboard clutch The wheel pinion clutch has a three-fold purpose. One, components from wear.
Page 80: Test For Function
WHEEL PINION CLUTCH 17. Compression Spring – provides the light, constant, To operate this system, practice the following. Walk inward force necessary for proper clutch washer and along at a normal pace. When you stop walking, keep friction ring engagement. your elbows at your sides.
Page 81: Rear Height-Of-Cut & Wheel Pinion Clutch - Assembly
WHEEL PINION CLUTCH 2. Remove the special retaining clip at the end of the 6. Press the needle bearing and the oil impregnated output shaft and pull off the following six wheel bushing from the pivot arm using an arbor press. pinion clutch components: •...
Page 82 WHEEL PINION CLUTCH 4. Assemble the spring arm and pivot arm as shown in 9. Slide the externally tabbed thrust washer and the Figure 138. internally tabbed thrust washer onto the output shaft. Make sure that the tab on the internally tabbed thrust washer enters the keyway.
Page 83 WHEEL PINION CLUTCH 13. Place the wheel pinion onto the output shaft. It is symmetrical and can be put on either way. 14. Install the internally tabbed thrust washer onto the output shaft making sure that the tab enters the keyway.
Page 84 WHEEL PINION CLUTCH GEARCASE AND WHEEL ASSEMBLY, SPRING RATCHET STYLE 3354-613 Rev A Fig 141 3354-613(5) Ref. No. Description Ref. No. Description Bolt-Shoulder Spring-Compression Wheel Gear ASM Bushing Transmission ASM Klipring-Locking Gasket-Gearbox Gear-Pinion, 13T Screw-HWH Washer-Thrust Bracket-Pivot, Fwd Cover-Wheel Screw-HWH Cover Spacer Washer-Stepped...
Page 85: Spring Ratchet Style
WHEEL PINION CLUTCH Spring Ratchet Style WHEEL PINION SERVICE The Spring Ratchet type wheel clutch system has been The steps to service the wheel pinions are the same for used on a wide variety of models. It consists of a spring both front and rear wheel drive models.
Page 86 WHEEL PINION CLUTCH 4. Slide the wheel pinion off the axle. Reassemble in reverse order: Note: There is a spring-loaded key under the pinion 1. Install one thrust washer, then the ﬁ rst retaining ring (Fig. 144). with the sharp edge facing the chassis (Fig. 145). Fig 145 MVC-472 Fig 144...
Page 87 BBC / BOS / BCS Worm Drive Transmission ......Single Speed Spur/Bevel Gear Transmission ... . . Single Speed Bevel Gear Transmission .
Page 88: Blade Brake Clutch System
The ﬁ rst is commonly referred to as the BBC or Blade Brake Clutch. It has two versions which have been used on many Toro models as well as Lawn-Boy Medallion BBC Clutch Operation mowers. The second design was introduced in 2005 and is used on Toro (Blade Override System) and Lawn-Boy (Blade Clutch System) (Fig.
Page 89: Handle Controls
BBC / BOS / BCS The normal or “at rest” position of the control bar is Handle Controls indicated by the number 1 in the Figure 148. In order to engage the blade, the operator must ﬁ rst “cock” the The control box components and their functions (Fig.
Page 90 BBC / BOS / BCS e. Traction Lever: provides input to the traction cable These components interact to provide control to the BBC since the end of the traction cable is retained in it. deck mechanism. Notice in Figure 150 the position of It also pivots on the upper shoulder bolt when the the traction cable lever and the BBC cable lever.
Page 91 BBC / BOS / BCS When the control bar is cocked to its lowest position as When the control bar is raised to a point 5” (12.7cm) in Figure 151. The buckling spring is ﬂ exed and moved below the handle, the BBC cable has been tightened to the right end of the rocker arm slot.
Page 92: Control Box Disassembly
BBC / BOS / BCS When the control bar is released, the tip of the control 2. Bend the locking tab securing the throttle control to hook catches on the leaf spring causing it to rotate. This the control panel, then tap the throttle control out releases the BBC cable lever, thereby causing the BBC using a rubber mallet.
Page 93: Control Box Assembly
BBC / BOS / BCS A better method is to make a special cut-away 12. Pull the tape from the outside of the handle. Remove version of the right control box housing half as the upper carriage bolt along with the cable lever shown in Figure 154.
Page 94 BBC / BOS / BCS 3. Place a piece of duct tape over the heads of the 6. Slide the rocker arm assembly over the upper carriage bolts that slide through the handle and the carriage bolt and sleeve making sure that the sleeve left control box housing.
Page 95 BBC / BOS / BCS 8. Slip the white nylon washer onto the J end of the 10. Before installing the right control housing, check buckling spring. The slotted side of the washer to make sure that both cable sheath ends are fully should face away from the end of the spring.
Page 96: Toro Bbc Service Guide
BBC / BOS / BCS TORO BBC SERVICE GUIDE Disassembly Sequence Fig 160 bbc scan 6-10 WPM Drive Systems Manual...
Page 97 BBC / BOS / BCS BLADE BRAKE CLUTCH ASSEMBLY (Toro Vacu Power/Lawn-Boy Medallion BBC) Fig 161 bladebrakeclutchassy Ref. No. Description Ref. No. Description Brake Shoe HH Screw Plate Hub Compression Spring V Belt Spring Retainer Pulley Hub Woodruff Key Lock Nut...
Page 98: Toro Vacu Power/Lawn-Boy Medallion Bbc
3428-0082 Fig 162 DSC-068a 3. Remove the shoulder bolt and ﬂ anged nut securing Bellcrank System Disassembly (Toro Vacu the bellcrank to the control cable bracket. Once Power/Lawn-Boy Medallion) loose, remove the bellcrank assembly complete with control link from the unit (Fig. 165).
Page 99: Bellcrank System Assembly (Toro Vacu Power/Lawn-Boy Medallion)
4. Slide a ﬂ at washer and a bushing onto the shoulder bolt and slide into the front side of the bellcrank as shown in Figure 000. (3428-0088) Complete Bellcrank System Assembly (Toro Vacu reassembly of the bell crank system by sliding Power/Lawn-Boy Medallion) another ﬂ...
Page 100: Bbc Cover And Screen
BBC / BOS / BCS 5. Hook the end of the control link into the brake plate BBC Cover and Screen: lever, then slip the BBC control cable onto the bellcrank. Finally, slip the shoulder bolt through the The BBC cover and screen are two important com- hole in the cable bracket support and secure with the ponents that keep dirt and debris out of the BBC ﬂ...
Page 101: Under Deck Components Disassembly (Toro Vacu Power/Lawn-Boy Medallion)
5. If further disassembly is required, begin by removing the crankshaft nut. An impact wrench works best. (Toro Vacu Power/Lawn-Boy Medallion) However, if you must remove it manually, use a large screwdriver or bar to wedge the BBC ﬂ ywheel while 1.
Page 102 BBC / BOS / BCS 7. Again, pivot the brake plate counterclockwise and 11. Remove the brake plate and hub assembly from the remove the BBC ﬂ ywheel. housing and disassemble the seal/oil impregnated bushing, the hub, self-tapping capscrew, and washer 8.
Page 103: Under Deck Components Assembly (Toro Vacu Power/Lawn-Boy Medallion)
BBC / BOS / BCS Under Deck Components Assembly (Toro 3. Loosely secure the brake plate, complete with brake pad, to the brake lever and brake hub as shown in Vacu Power/Lawn-Boy Medallion) Figure 174. Note that the bolt should go through the brake plate ﬁ...
Page 104 BBC / BOS / BCS 6. Install the BBC ﬂ ywheel onto the crankshaft, making 7. Press the bearings into the bearing block, using an certain that the slots in the BBC ﬂ ywheel align with arbor press. Press only on the outer race, otherwise the bumps on the bottom of the self-propel pulley bearing damage will result (use an appropriately (Fig.
Page 105: Bbc Cable Removal (Toro Vacu Power/Lawn-Boy Medallion)
BBC control box. This will prevent the control box components from falling out of the handle during disassembly. BBC Cable Removal (Toro Vacu Power/ 4. Remove the three ﬂ anged head screws securing the Lawn-Boy Medallion) control box halves.
Page 106: Bbc Cable Installation (Toro Vacu Power/Lawn-Boy Medallion)
BBC / BOS / BCS BBC Cable Installation (Toro Vacu Power/ 3. Install the three ﬂ anged head screws securing the control box halves. Lawn-Boy Medallion) 4. Bend the throttle control locking tab forward so that 1. Slide a new BBC cable into the BBC cable lever.
Page 107 BBC / BOS / BCS ENGINE AND BLADE ASSEMBLY (Toro Recycler / Rear Bagger) Fig 182 engineandbladeassy Ref. No. Description Ref. No. Description Gts Ohv 200 Engine Lock Nut Gas Cap ASM HH Screw Toro Nameplate Flat Washer Recoil Decal...
Page 108: Toro Recycler/Rear Bagger Bbc
BBC / BOS / BCS TORO RECYCLER/REAR BAGGER 2. On the left side of the mower next to the rear wheel, loosen the clamp that secures the BBC cable to the mower housing. Near the left front wheel, unhook the spring end of the cable from the bellcrank.
Page 109 BBC / BOS / BCS 4. Turn the mower on its side. Remove the blade and Slide the lever off the shaft and the idler/brake shaft the BBC cover. Brush any grass clippings out of the can be pulled down and out of the housing (Fig. area.
Page 110 BBC / BOS / BCS 6. Now, disassemble the components on the 8. Roll the self-propel belt off the pulley and remove the crankshaft. If you have an impact wrench, the large pulley and the key in the crankshaft. nut on the crankshaft can be spun off. If you must remove it manually, wedge a bar or large screwdriver 9.
Page 111: Idler Arm System Assembly (Recycler/Rear Bagger)
BBC / BOS / BCS Idler Arm System Assembly (Recycler/Rear The ﬂ ywheel must be installed with the side that looks like 1/2 of a pulley facing the brake drum Bagger) (Fig. 194). Push the ﬂ ywheel ﬁ rmly on the taper of the crankshaft.
Page 112 BBC / BOS / BCS They are noise dampeners. Without them, when the CAUTION! The two bumps on the pulley MUST brake pad hits the drum, the drum will ring like a bell. engage the ﬂ ywheel. If you do not have an Also look at the two blade mounting bolts.
Page 113: Bbc Cable Removal (Recycler/Rear Bagger)
BBC / BOS / BCS 8. Slip the spring over the shaft. One tang of the spring 10. Hold the idler/brake arm in place. Slip the spring must engage the tab as shown (Fig. 198). over the end on top of the deck as shown. Install the lever and install the screw through the lever and idler/brake arm shaft (Fig.
Page 114: Bbc Cable Installation (Recycler/Rear Bagger)
BBC / BOS / BCS 2. Unhook the spring and cable from the bellcrank (Fig. 6. Slip the end of the BBC cable from the cable lever 202). and remove the cable (Fig. 203). Fig 203 ﬁ g 36 Fig 202 3428-0173 A.
Page 115 3. Remove the blade and blade stiffener (Fig. 206). Both Toro and Lawn-Boy use the same blade clutching system on some models. On Toro it is named the Blade Override System. On Lawn-Boy it is named the Blade Clutch System.
Page 116 BBC / BOS / BCS 4. Remove the blade support and disc (Fig. 207). 6. Remove the brake pivot bolt. You will need a second wrench to hold the bolt head (Fig. 209). Fig 207 MVC-198 Fig 209 MVC-200 5. Remove the 3 capscrews and lift off the belt cover (Fig.
Page 117 BBC / BOS / BCS 8. Lift the brake assembly and blade drive belt from the 10. The components of the idler assembly are shown mower (Fig. 211). here (Fig. 213). Fig 213 MVC-209 Fig 211 MVC-205 A. Belt E. Washer B.
Page 118 BBC / BOS / BCS 12. Rock the pulley half slightly and lift it off. The blade 14. Remove the two bolts holding the anchor plate to the bolts will now drop out of their pockets (Fig. 215). chassis (Fig. 217). Fig 217 MVC-223 Fig 215...
Page 119: Brake Arm Assembly
BBC / BOS / BCS 16. The bushing has a notch removed from the ﬂ ange 2. Place the bearing with the ﬂ ange side down on the end. Align that notch in the bushing with the tab in spacer and place the washer on top of the bearing the anchor plate (Fig.
Page 120: Bos/Bcs System Assembly
BBC / BOS / BCS BOS/BCS System Assembly Assemble all other parts in reverse order. Bolt torque as follows: Blade nuts: 350 - 400 in-lbs. (39.5 – 45.2 Nm) Crankshaft Bolt: 45 - 55 ft-lbs. (60.9 – 74.5 Nm) 6-34 WPM Drive Systems Manual...
Page 121: Blade Override System (Bos), Blade Clutch System (Bcs)
HANDLES AND CONTROL CABLES Worm Drive Transmission ......Single Speed Spur/Bevel Gear Transmission ... . . Single Speed Bevel Gear Transmission .
Page 122: Handle Disassembly
Loosen this clamp and push the cable jacket up or down to adjust. When the bail is lowered about 1” (25mm) the Toro 2 Bail Handle drive should disengage. This is a gap that is comfortable for most operators.
Page 123: Personal Pace Easy Stride (Generation 1)
Disconnect the cable from the bail Generation 1 and set aside (Fig. 226). This is the original Toro Personal Pace/ Lawn Boy Easy Stride system. The handle is telescoping and as it slides, it tensions the transmission drive belt.
Page 124 HANDLES AND CONTROL CABLES 3. Remove 6 screws from the traction rod retainer (Fig. 5. Disconnect the cable from the traction lever (Fig. 228). 230). Fig 230 DSC-4815 Fig 228 DSC-4810 6. Unhook the springs from each side of the handle 4.
Page 125: Reassembly
HANDLES AND CONTROL CABLES 7. Slide the handle up and off (Fig. 232). Reassembly Reassemble in reverse order. 1. There are 3 bosses on the inside of the guide. The top and bottom ones receive the mounting screws. The boss in the photo must line up with the end of the control rod.
Page 126: Adjusting The Personal Pace Cable
HANDLES AND CONTROL CABLES Adjusting the Personal Pace Cable This is the second generation of the personal pace/ easy stride handle assembly. It works the same as the original in the sense that the handle is telescoping. As Ensure the transmission belt is disengaged, transmission the handle is depressed it tightens the self propelled belt tilted forward.
Page 127 HANDLES AND CONTROL CABLES 2. Install the tool over the stop in the handle guides as 4. Continue pushing the handle down until it slides off shown, one on each side. Push the handle down. the end of the upper handle (Fig. 241). The tool will allow the handle to slide over the stop built into the handle guide (Fig.
Page 128: Adjusting The Personal Pace/Easy Stride Cable
HANDLES AND CONTROL CABLES Adjusting the Personal Pace/Easy Stride Lawn-Boy 2 Bail Handle Cable The 2 bail style is shown here (Fig. 244). The top bail is the engine stop. Release it and the ignition is grounded Ensure the transmission belt is disengaged, transmission and a brake comes on to help stop the ﬂ...
Page 129: Lawn-Boy Sens-A-Speed
HANDLES AND CONTROL CABLES Lawn-Boy Sens-a-Speed On blade clutch models, the engine on and off is controlled by a switch on the left hand handle. The bail engages and disengages the blade. The Sens-a-Speed handle controls the self propel the same way as on a zone start model.
Page 130: Assembly
HANDLES AND CONTROL CABLES 2. Squeeze the ends of the upper bail to disengage 4. Slide the pin out of the left hand handle and pull the them from the handle. On some models the right upper handle up and out. side of the bail may be connected to the pin by a push nut.
Page 131: Cable Adjustment
HANDLES AND CONTROL CABLES Cable Adjustment The engine brake cable is not adjustable. If it fails to function it will need to be replaced. Self-Propel Cable To properly adjust the self propel cable, loosen the cable clamp, pull the cable downward to remove all the slack (Fig.
Page 132 HANDLES AND CONTROL CABLES 2. Remove the e-clip on the left side pivot pin (Fig. 4. Continue sliding the pivot assembly and brake cable 253). off the pin. 5. Remove the shoulder bolt that the traction lever pivots on and remove the traction lever. 6.
Page 133: Speed Transmission Models
HANDLES AND CONTROL CABLES 7. Slide the upper handle out of the top slide. 3 Speed Control Cables Reverse the process to assemble. The shift cables are not adjustable. To install the shift cable, insert the end of the cable in the shift arm and slip Note how the switch assembly, bail and control cable the end of the cable jacket into the bracket (Fig.
Page 134 HANDLES AND CONTROL CABLES The adjustment point for this cable is a knob, jam nuts, The objective is to have the wheels begin to drive when or a clamp to the handle (Fig. 259 and Fig. 260). the bail is about 1” (25mm) below the upper handle, yet be able to lower the bail enough to stop the wheels without releasing the bail (Fig.
Page 135: Bbc Cable Adjustment (Toro Vacu Power/Lawn-Boy Medallion)
HANDLES AND CONTROL CABLES BBC Cable Adjustment (Toro Vacu Power/ 2. With the engine off and the spark plug wire discon- nected, cock and lift the control bar to engage the Lawn-Boy Medallion) blade. Tape the control bar to the handle with the blade engaged, then measure the length of the over- 1.
Page 136: Toro Bbc Cable Adjustment (Recycler/Rear Bagger)
HANDLES AND CONTROL CABLES 5. Install the screen panel with the two ﬂ anged head Toro BBC Cable Adjustment (Recycler/Rear self-tapping screws. Make sure that the top edge Bagger) of the screen panel is under the lip at the top of the housing.
Page 137: Toro Bos Control
HANDLES AND CONTROL CABLES On BBC models, the control bail also controls the Toro BOS Control transmission belt engagement. The adjustment point is a knob about halfway between the control panel and The BOS control is the upper bail on the handle. For the transmission.
Page 138: Toro Bos Control Cable Adjustment
HANDLES AND CONTROL CABLES Toro BOS Control Cable Adjustment Lawn-Boy BCS Control Cable Adjustment The blade clutch control is adjusted by removing the Lawn-Boy Insight and Insight Gold: cover between the engine and bag door. Loosen the cable clamp and draw the cable to the rear to remove 1.
Page 139 HANDLES AND CONTROL CABLES Lawn-Boy Insight Platimun: 1. Remove the gas and oil and tip the mower on its side with the air ﬁ lter up. 2. Remove the BCS cover and belt cover. 3. Loosen the 2 cap-screws securing the bracket to the housing.
Page 140 HANDLES AND CONTROL CABLES THIS PAGE INTENTIONALLY LEFT BLANK. 7-20 WPM Drive Systems Manual...
Page 141 SELF-PROPEL BELT REPLACEMENT Worm Drive Transmission ......Single Speed Spur/Bevel Gear Transmission ... . . Single Speed Bevel Gear Transmission .
Page 142: Toro 21" Front Wheel Drive
Mowers with a blade clutch mechanism are the most complex as parts of that will These are steel deck mowers, made in both Toro and need to be removed to access the self propel belt. Lawn-Boy brands.
Page 143: Toro & Lawn-Boy Mowers With Blade Brake Clutch
SELF-PROPEL BELT REPLACEMENT 21” Toro and Lawn-Boy Mowers with Blade Brake Clutch Part of the blade clutch must be disassembled to access the self propel belt. See the BBC section starting on page 6-1 for more information. 21” Toro Mowers with Blade Override...
Page 144 SELF-PROPEL BELT REPLACEMENT THIS PAGE INTENTIONALLY LEFT BLANK. WPM Drive Systems Manual...

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Toro 20330 - Low Wheel Walk Power Mower Service Manual

Worm Drive Transmission

Single Speed Spur/Bevel Gear Transmission

Single Speed Bevel Gear Transmission

Three Speed Transmission

Wheel Pinion Clutch

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