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Toro 74161 Service Manual

Mid-mount z
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TORO MID-MOUNT Z SERVICE MANUAL
Table of Contents – Page 1 of 3
SPECIFICATIONS
ENGINE
Z100 SERIES
Z250 SERIES
Z280 SERIES
UNIT DIMENSIONS
Z100 SERIES
Z250 SERIES
Z280 SERIES
HYDRAULIC SYSTEM
TORQUE SPECIFICATIONS
HYDRAULIC HOSES & FITTINGS
CHASSIS
MAINTENANCE
RECOMMENDED MAINTENANCE SCHEDULE
CHECKING THE OIL LEVEL
CHANGING OIL AND FILTER
SERVICING THE AIR CLEANER
REMOVING THE FILTERS
INSTALLING THE FILTERS
SERVICING MODELS EQUIPPED WITH THE HEAVY-DUTY AIR CLEANER
USING THE FILTER MINDER
REMOVING THE AIR CLEANER
CLEANING THE PRIMARY FILTER
INSTALLING THE FILTERS
SERVICING THE AIR CLEANER LIQUID-COOLED MODELS
REMOVING THE PAPER ELEMENT
CLEANING THE PAPER ELEMENTS
INSTALLING THE PAPER ELEMENTS
CLEANING THE ENGINE FINS
SERVICING THE COOLING SYSTEM
CHECKING THE RADIATOR COOLANT
CLEANING THE COOLING SYSTEM
CHANGING THE ENGINE COOLANT
INSPECTING THE COOLING SYSTEM
SERVICING THE FUEL FILTER
REPLACING THE FUEL FILTER
SERVICING THE SPARK PLUG
REMOVING THE SPARK PLUG(S)
CHECKING THE SPARK PLUG
INSTALLING THE SPARK PLUG(S)
CHECK VALVE CLEARANCE
GREASING AND LUBRICATION
HOW TO GREASE
GREASING THE FRONT CASTOR PIVOTS
WHERE TO ADD GREASE
WHERE TO ADD LIGHT OIL OR SPRAY LUBRICATION
GREASING THE BEARINGS

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  • Page 1 TORO MID-MOUNT Z SERVICE MANUAL Table of Contents – Page 1 of 3 SPECIFICATIONS ENGINE Z100 SERIES Z250 SERIES Z280 SERIES UNIT DIMENSIONS Z100 SERIES Z250 SERIES Z280 SERIES HYDRAULIC SYSTEM TORQUE SPECIFICATIONS HYDRAULIC HOSES & FITTINGS CHASSIS MAINTENANCE RECOMMENDED MAINTENANCE SCHEDULE...
  • Page 2 TORO MID-MOUNT Z SERVICE MANUAL Table of Contents – Page 2 of 3 ENGINE EXTERNAL ALTERNATOR REMOVE & REPLACE ENGINE REMOVE & REPLACE AIR-COOLED ENGINE REMOVE & REPLACE LIQUID-COOLED RADIATOR REMOVE & REPLACE LIQUID-COOLED MOWERS MODELS EQUIPPED WITH ELECTRONIC FUEL INJECTION (EFI)
  • Page 3 TORO MID-MOUNT Z SERVICE MANUAL Table of Contents – Page 3 of 3 ELECTRICAL SYSTEMS - CONTINUED ELECTRIC PTO CLUTCH REMOVAL SOLENOID PURPOSE HOW IT WORKS TESTING STARTER, ELECTRIC PURPOSE HOW IT WORKS TESTING SWITCH, PTO/CLUTCH PURPOSE HOW IT WORKS...
  • Page 4 Mid-Mount Z Service Manual...

  • Page 5: About This Manual

    PREFACE ABOUT THIS MANUAL This service manual was written expressly for the Toro Mid-Mount Z product line. The Toro Company has made every effort to make the information in this manual complete and correct. This manual was written for the service technician; 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 Engine ............. . .1 - 1 Z100 Series.
  • Page 7 TABLE OF CONTENTS Servicing the Spark Plug ..........2 - 10 Removing the Spark Plug(s) .
  • Page 8 TABLE OF CONTENTS CHASSIS Motion Control Linkage - Remove and Replace .......5 - 1 Adjusting the Handle Neutral .
  • Page 9 TABLE OF CONTENTS ELECTRICAL SYSTEMS (cont’d) Solenoid ............7 - 24 Purpose .
  • Page 10 TABLE OF CONTENTS ELECTRICAL SYSTEMS (cont’d) Mercury Switch ............7 - 33 Purpose .
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  • Page 12: Specifications

    SPECIFICATIONS ENGINE Z100 Series Model Manufacturer Oil Capacity High Idle Low Idle Cooling System 74170 Kawasaki 1.9 Qts. 3600 ± 100 1500 Air-Cooled 74171 Kohler 2 Qts. 3600 ± 100 1500 Air-Cooled 74172 Kohler 2 Qts. 3600 ± 100 1500 Air-Cooled 74173 Kawasaki...

  • Page 13: Unit Dimensions

    SPECIFICATIONS UNIT DIMENSIONS Z100 Series Model Wheel Length Width Height Weight Tires Tire Pressure Base Rear Front Rear Front 74176 50” 78” 55” 40” 23” x 9.50-12” 13” x 5.00”-6” 13 PSI 13 PSI 74178 50” 78” 65” 40” 23” x 9.50-12” 13”...

  • Page 14: Hydraulic System

    SPECIFICATIONS HYDRAULIC SYSTEM Model Pumps Motors Fluid Type Fluid Capacity Z100 Mobil 1 15W20 (2) Hydro-Gear BDP10A (2) Ross MB15 Torquemotors 2.1 Qts. Series Synthetic Z250 (2) Hydro-Gear BDP10A (2) Ross MB15 Torquemotors Mobil 1 15W20 2.1 Qts. Series Synthetic Z280 (2) Hydro-Gear BDP10A (2) Ross MB15 Torquemotors...
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  • Page 16: Maintenance

    MAINTENANCE Recommended Maintenance Schedule Maintenance Service Maintenance Procedure Interval • Hydraulic fluid—check level After first 5 hours • Engine Oil—check • Hydraulic filter—change • Oil—check level • Safety System—check Each Use • Mower Housing—clean • Engine Cooling System—clean • Cutting Blades—check •...

  • Page 17: Checking The Oil Level

    MAINTENANCE Checking the Oil Level Place a pan below the oil drain. Rotate oil drain valve to allow oil to drain (Figure 2). Note: Check oil when engine is cold. Disengage the power take off (PTO) and turn the ignition key to off. Move levers to neutral locked position and apply parking brake.

  • Page 18: Servicing The Air Cleaner

    MAINTENANCE Viscosity: See table below Release the latches on the air cleaner and pull the air cleaner cover off of the air cleaner body (Figure Servicing the Air Cleaner Figure 3 m-3214 Primary Filter: Clean or replace after every 200 operating hours.

  • Page 19: Installing The Filters

    MAINTENANCE Installing the Filters Start by visually checking the condition of the primary element. If the element is visually dirty, replace the primary element. Do not attempt to To prevent engine damage, always Important clean it. operate the engine with both air filters and cover installed.

  • Page 20: Removing The Air Cleaner

    MAINTENANCE Removing the Air Cleaner Do not exceed 100 psi and keep the Important hose at least 2 inches from the filter. Replace air filters if they are damaged or cannot be cleaned. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off.

  • Page 21: Cleaning The Paper Elements

    MAINTENANCE Clean around the air cleaner to prevent dirt from Never clean the paper element with Important getting into the engine and causing damage. pressurized air or liquids, such as solvent, gas, or Loosen the retaining clips and remove the air kerosene.

  • Page 22: Servicing The Cooling System

    MAINTENANCE Servicing the Cooling System With the engine cool, remove the radiator cap (Figure 8). Checking the Radiator Coolant If the coolant level is low, add a 50/50 mixture of permanent antifreeze and water until the radiator is completely full without overflowing. Danger Install the radiator cap.

  • Page 23: Changing The Engine Coolant

    MAINTENANCE Remove debris from the screen on the engine With the engine cool, drain the coolant by cover. loosening the drain cock in the right rear corner (Figure 9). Tilt the engine cover forward. The engine block must be drained by removing Remove debris from the radiator core and engine the drain plug from the engine block (Figure 10).

  • Page 24: Inspecting The Cooling System

    MAINTENANCE Drain the coolant from the overflow bottle. Inspecting the Cooling System Remove the radiator cap and add a 50/50 mixture Inspect the radiator and the hoses initially and after the of permanent antifreeze and water until the first 8 operating hours. radiator is completely full.

  • Page 25: Servicing The Spark Plug

    MAINTENANCE Install a new filter and move the hose clamps Remove the spark plug(s) and metal washer. close to the filter (Figure 12). Checking the Spark Plug Wipe up any spilled fuel. Look at the center of the spark plug(s) (Figure 14). Open fuel shut-off valve on console.

  • Page 26: Greasing And Lubrication

    MAINTENANCE Greasing and Lubrication Remove grease zerk in hole. Reinstall hex plug and cap. Lubricate the machine when shown on the Check Where to Add Grease Service Reference Aid decal (Figure 15). Grease more frequently when operating conditions are Lubricate the grease fittings as shown on the Check extremely dusty or sandy.
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  • Page 28: Engine

    ENGINE External Alternator Remove & Replace Remove the alternator adjustment bolt and pivot bolt. Disconnect the battery negative cable. Figure 18 0508-003 Figure 16 0507-001 Remove the alternator belt and rotate the alternator to gain access to the wiring. Remove the lower engine protection bracket and set the coolant recovery bottle off to the side.

  • Page 29: Engine Remove & Replace Air-Cooled

    ENGINE Engine Remove & Replace Disconnect the PTO clutch electrical plug and main wiring harness connector (Figure 21). Air-Cooled Release the tension from the drive belt by raising Disconnect the negative battery cable. the lever against the spring tension and remove the belt from the PTO pulley (Figure 22).

  • Page 30: Engine Remove & Replace Liquid-Cooled

    ENGINE Using a suitable pry bar, release the idler pulley Remove the pins from the radiator cover and lift spring tension and remove the hydraulic pump off the cover. drive belt. Figure 26 0507-002 Figure 24 1023-012 Remove the radiator cap and open the drain 10.
  • Page 31 ENGINE To drain the block, remove the drain bolts. Remove the bolts securing the overflow bottle to NOTE: apply sealant to the bolt threads during the engine guard. reassembly. Figure 30 0507-006 Figure 28 0507-004 Remove the 7 bolts securing the radiator support Loosen the radiator hose clamps at the water to the engine guard.
  • Page 32 ENGINE 10. Remove the hose clamp from the air cleaner duct 12. Remove the 6 bolts securing the rear bumper to at the carburetor. the engine guard. Figure 32 Figure 34 0507-008 0507-010 11. Remove the 2 bolts securing the air cleaner to the 13.
  • Page 33 ENGINE 14. Remove the bolts holding the engine guard to the 16. Remove the alternator output and ground wires. frame, and then remove the guard. Figure 38 0507-014 Figure 36 0507-012 17. Lift the lever on the deck belt tension pulley and 15.
  • Page 34 ENGINE 18. Remove the control wires for the carburetor choke 20. Make sure the fuel selector is in the off position. and throttle control. Then remove the fuel line from the carburetor. CAUTION: Gasoline is extremely flammable. Drain into a suitable container and keep away from any source of combustion.

  • Page 35: Radiator Remove & Replace Liquid-Cooled Mowers

    ENGINE Radiator Remove & Replace Remove the radiator cap and open the drain petcock to drain the coolant into a suitable Liquid-Cooled Mowers container. Disconnect the negative battery cable. Figure 46 0507-003 Figure 44 To drain the block, remove the drain bolts. 0507-001 NOTE: Apply sealant to the bolt threads during Remove the pins from the radiator cover and lift...
  • Page 36 ENGINE Unplug the electrical connections from the Carefully lift the radiator assembly from the unit. temperature sender and fan motor. Figure 50 0507-007 Figure 48 0507-005 10. Remove the hose clamps from the radiator fittings. Remove the overflow hose from the radiator. Figure 51 0507-021 Figure 49...
  • Page 37 ENGINE 11. Remove the 6 bolts securing the lower radiator 13. Turn the radiator over. Remove the 6 bolts support to the radiator, and then lift off the support. securing the upper radiator support to the radiator and remove the support. Figure 52 0507-022 Figure 54...

  • Page 38: Models Equipped With Electronic Fuel Injection (Efi)

    ENGINE Models Equipped With Electronic Fuel The diagnostic plug is installed on the right side of the machine near the starter. Injection (EFI) For engine specific service or diagnostics procedures consult the engine manufacture’s service manuals. The following are the locations of components which are EFI related but mounted to the unit’s chassis.
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  • Page 40: Hydraulic Systems

    HYDRAULIC SYSTEMS Hydraulic System, Typical Ref. No. Qty. Description Ref. No. Qty. Description Upper Hose Hose ASM Hydraulic Tank ASM Hose ASM Head Filter Hose ASM Cap (Hydraulic Reservoir) Sheave Hyd Filter Sheave Winter Hyd Filter Pump Drive Belt 90 Deg Fitting Idler Sheave Low Pressure Hose ASM Lower Pressure Hose...

  • Page 41: Description

    HYDRAULIC SYSTEMS Description Replacing the Pump Drive Belt The hydraulic system consists of a fluid reservoir Check pump drive belt for wear after every 50 hours of supplying 2 Hydro-Gear BDP-10L hydrostatic pumps operation. through a spin-on filter. The pumps are controlled by adjustable wrap around handles through a bellcrank Using a suitable pry bar, release the spring and linkage to the pump control lever.

  • Page 42: Pump Removal

    HYDRAULIC SYSTEMS Pump Removal Mark the location of the wheel motor supply hoses as to which fitting they go on the wheel motor. Remove the hose fittings to the pump and install Clean the pump of any dirt and debris that may be caps to keep dirt out.
  • Page 43 HYDRAULIC SYSTEMS Refer to "Replacing the Parking Brake and Linkage" on Loosen locknut at ball joint on pump control rod (Figure 65). page 5 - 4 DANGER Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. •...

  • Page 44: Wheel Motor R & R

    HYDRAULIC SYSTEMS Open throttle to fast. Make sure wheel remains Remove the cotter pin (A) (Figure 67) from the stopped or slightly creeps in reverse, re-adjust if wheel motor output shaft. Then loosen the nut (B) necessary. (Figure 67) securing the hub to the output shaft. Release the parking brake.
  • Page 45 HYDRAULIC SYSTEMS Remove the front two wheel motor mounting bolts and swing the brake linkage out of the way (Figure 70). Remove the rear two wheel motor mounting bolts and then remove the wheel motor from the chassis (Figure 70). Figure 70 4 - 6 Mid-Mount Z Service Manual...

  • Page 46: Chassis

    CHASSIS Motion Control Linkage - Remove and Remove the control link from the bell crank (Figure 73). Replace Remove the 6 bolts securing the console to the rear frame assembly. Then, carefully lower the console to gain access to the motion control linkage (Figure 71).

  • Page 47: Adjusting The Handle Neutral

    CHASSIS Carefully remove the bell crank from the chassis Check where lever is relative to notch in console (Figure 75). (should be centered allowing lever to pivot outward to the neutral lock position) (Figure 76). If adjustment is needed, loosen the nut against the yoke.
  • Page 48 CHASSIS Control Linkage, Typical Ref. No. Qty. Description Ref. No. Qty. Description Adjustable Yoke HH Screw Belleville Washer HH Screw Control Damper HH Screw RH Ball Joint HH Screw Nylon Flanged Bushing Screw Neutral Return Bolt Lock Nut Neutral Return Spring Hex Nut HH Screw RH Lever/Grip ASM...

  • Page 49: Replacing The Parking Brake And Linkage

    CHASSIS Replacing the Parking Brake and Linkage Using the special puller, remove the brake hub from the wheel motor (Figure 79). Remove the negative battery cable. Raise the drive wheels and place the unit on safety stands. Remove the tire and wheel assemblies. Remove the 3 bolts securing the brake band to the brake pivot (Figure 77).
  • Page 50 CHASSIS To remove the brake brackets, remove the 2 bolts 10. Then remove the brake shaft bearing bolts at at the front of the wheel motor and remove the either end of the shaft (Figure 83). bracket (Figure 81). Figure 83 1030-009 Figure 81 1227-001...
  • Page 51 CHASSIS 13. To remove the brake handle, remove the cotter pin from the brake handle pivot shaft (Figure 85). Figure 85 1030-003 14. Then, pull the brake handle out of the brass bearing (Figure 86). Figure 86 1030-007 5 - 6 Mid-Mount Z Service Manual...
  • Page 52 CHASSIS Parking Brake, Typical Ref. No. Qty. Description Ref. No. Qty. Description Control Bearing HH Screw Brake Spring Clevis Pin Brake Rod HH Screw Brake Lever/Grip ASM Grease Fitting Brake Shaft Square Nut Brake Bracket HH Nut Spacer Washer Flange Nut Brake Bank Lock Washer Brake Bracket...

  • Page 53: Adjusting The Parking Brake

    CHASSIS Adjusting the Parking Brake Engage parking brake. A. Measure the distance between the trunnion Check parking brake for proper adjustment. roller and the collar on brake rod. Measurement should be 3/16 - 1/4 in. Disengage brake lever (lever down). (5 -7mm) (Figure 88).

  • Page 54: Description - Fuel System

    CHASSIS Description - Fuel System The Z Master fuel system consists of dual fuel tanks with a total capacity of 12 gallon for the 200 Series and 10 gallons for the 100 Series. Fuel is routed to a 3 position selector valve, then to a fuel filter and the engine fuel pump.

  • Page 55: Fuel Tank - Remove And Replace

    CHASSIS Fuel Tank - Remove and Replace If the left tank is to be removed, remove the electrical control panel from the tank (Figure 91). Remove the battery negative cable. Drain the fuel tank. To do this, first place the fuel selector valve in the off position.
  • Page 56 CHASSIS Remove the bolt securing the front of the fuel tank Remove the fuel line from the fitting at the front of to the frame (Figure 93). the tank (Figure 95). Figure 93 Figure 95 1030-033 1030-032 Remove the nut and spring assembly securing the Reverse these steps to reinstall.

  • Page 57: Replace Front Wheel Bearings

    CHASSIS Replace Front Wheel Bearings Remove the 2 wheel spacers (Figure 99). Raise the front of the unit so that the front wheels are off the ground. Remove the through bolt holding the wheel to the caster assembly (Figure 97). Figure 99 1030-024 Remove the bearing seal (Figure 100).
  • Page 58 CHASSIS Remove the wheel bearing (Figure 101). Clean the bearing and bearing race and inspect for signs of pitting or other damage (Figure 103). Figure 101 1030-020 Figure 103 1030-017 Drive the bearing race out from the opposite side of the wheel using a long drift (Figure 102). Press a new race into the wheel hub (Figure 104).

  • Page 59: Front Caster Bearings - Remove & Replace

    CHASSIS Front Caster Bearings - Remove & Replace 10. Pack the bearing with grease and install it on the race (Figure 105). Remove the dust cap at the top of the caster assembly (Figure 107). Figure 105 1030-025 11. Press a new bearing seal into the hub (Figure Figure 107 1030-011 106).
  • Page 60 CHASSIS Inspect the tapered caster bearings and races for pitting or other damage (Figure 109). Figure 109 1030-017 Pack the bearings with grease and reinstall in the housing. Press in a new seal. Reassemble the caster into the bearings (Figure 110).
  • Page 61 CHASSIS Wheel and Caster Assembly Ref. No. Qty. Description Grease Cap Lock Nut Belleville Washer Tapered Roller Bearing Cup Bearing Grease Seal Caster Caster Wheel Assembly HH Screw Lock Nut 5 - 16 Mid-Mount Z Service Manual...

  • Page 62: Mower Decks

    MOWER DECKS Replacing the PTO Drive Belt Remove PTO drive belt from pulley and front idler pulley assembly. Remove the PTO drive belt (Figure 112). Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn drive belt.
  • Page 63 MOWER DECKS Install clutch retaining strap and plug clutch Check belt tension again. The center bolt of spring terminal into main wire harness (Figure 111). loaded idler must be between the two alignment holes in left support plate (Figure 114). Adjust, if Check belt tension.

  • Page 64: Mower Deck Removal

    MOWER DECKS Mower Deck Removal Remove the struts from the deck by first removing the nut and bolt that holds the pin to the deck. Slide the pin out of the strut to release it from the Raise the handle on the mower deck drive belt deck (Figure 120).

  • Page 65: Spindle Repair

    MOWER DECKS Spindle Repair Remove the spindle shaft from the spindle housing. It may need to be pressed out of the housing. Note: The lower bearing spacer will Stop the engine, remove the key and engage the remain on the spindle shaft. parking brake.
  • Page 66 MOWER DECKS 11. Remove the seals, note the direction of the seals. B. Look for dirt in the grease. Dirt in the grease This will be important during reassembly. The indicates a bad seal or a worn lower bearing upper seal faces inward, and the lower seal faces spacer.

  • Page 67: Assembly

    MOWER DECKS 14. A large snap ring is still inside the spindle housing. E. Pulley assembly - If the shaft shows signs of It locates the matched bearing set in the bore of wear, inspect the pulley for excessive wear in the spindle housing.
  • Page 68 MOWER DECKS 19. Pack both bearings with grease. Smearing 26. Slide the pulley down onto the shaft and secure grease on the outside of the bearing is not enough with the washer and nut. Be certain to only use lubrication. Pack the bearing by hand or use a the washer specified because it is hardened.
  • Page 69 MOWER DECKS (A) Zerk (B) Nut (C) Pulley (D) Spindle Housing (E) Bearing Cup (F) Small Spacer (G) Snap Ring (H) Bearing Cone (I) Bearing Spacer (J) Grease Axis Hole (K) Blade Bolt (L) Spring Washer (M) Blade (N) Spindle Shaft (O) Seal (P) Bearing Cup (Q) Machined “C”...

  • Page 70: Deck Mounting, Typical

    MOWER DECKS Deck Mounting, Typical Ref. No. Qty. Description HF Nut HH Cap Screw Deck Lift Chain Grease Fitting Hex Nut Lock Washer HH Screw Spherical Balljoint Hex Nut Deck Strut Deck Strut Pin HH Screw Lock Nut Mid-Mount Z Service Manual 6 - 9...

  • Page 71: Leveling The Mower

    MOWER DECKS Leveling the Mower Place two 1-1/2 in. (38mm) thick blocks under rear left and right lower edge of mower. Place one 2-1/4 in. (57mm) block under front center lower Position mower on a flat surface. Stop the engine, edge of mower (Figure 129).

  • Page 72: Checking For Bent Blades

    MOWER DECKS Lift up on four top chain attachment bolts, in the slots, to take slack out of chains and tighten flange lock nuts. (Deck is still supported by two rear and one front blocks under mower.) If bolts contact the end of slots, shorten or lengthen rod/swivel assemblies as required, for extra clearance, adjust each side same amount.

  • Page 73: Adjusting The Compression Spring

    MOWER DECKS Adjusting the Compression Spring Raise deck lift lever to the transport position, (Figure 133). Figure 133 1228-005 Springs are compressed so the distance between the two large washers should be 11 in. (279mm) (Figure 134). 11 in. (279mm) Figure 134 Adjust by turning nut in front of each spring (Figure 134).

  • Page 74: Spindle Assemblies, Typical

    MOWER DECKS Spindle Assemblies, Typical Ref. No. Qty. Description Ref. No. Qty. Description Cap Screw Spring Washer Torsion Spring Blade Belt Guide Flat Washer ASM Deflector HF Nut Lock Nut Outer Spindle ASM HH Screw Middle Spindle ASM Flat Washer Carr Screw Flange Lock Nut Deflector Mounting...
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  • Page 76: Electrical Systems

    ELECTRICAL SYSTEMS Mid-Mount Z Service Manual 7 - 1...
  • Page 77 ELECTRICAL SYSTEMS Models 74170 74200 74171 74201 74172 74202 74173 74203 74174 74204 74175 74205 74209 Start Circuit 7 - 2 Mid-Mount Z Service Manual...
  • Page 78 ELECTRICAL SYSTEMS Models 74170 74200 74171 74201 74172 74202 74173 74203 74174 74204 74175 74205 74209 Run Circuit Mid-Mount Z Service Manual 7 - 3...
  • Page 79 ELECTRICAL SYSTEMS 7 - 4 Mid-Mount Z Service Manual...
  • Page 80 ELECTRICAL SYSTEMS Models 74211 74212 Start Circuit Mid-Mount Z Service Manual 7 - 5...
  • Page 81 ELECTRICAL SYSTEMS Models 74211 74212 Run Circuit 7 - 6 Mid-Mount Z Service Manual...
  • Page 82 ELECTRICAL SYSTEMS Mid-Mount Z Service Manual 7 - 7...
  • Page 83 ELECTRICAL SYSTEMS Models 74218 74219 Start Circuit 7 - 8 Mid-Mount Z Service Manual...
  • Page 84 ELECTRICAL SYSTEMS Models 74218 74219 Run Circuit Mid-Mount Z Service Manual 7 - 9...
  • Page 85 ELECTRICAL SYSTEMS 7 - 10 Mid-Mount Z Service Manual...
  • Page 86 ELECTRICAL SYSTEMS Mid-Mount Z Service Manual 7 - 11...
  • Page 87 ELECTRICAL SYSTEMS 7 - 12 Mid-Mount Z Service Manual...
  • Page 88 ELECTRICAL SYSTEMS Mid-Mount Z Service Manual 7 - 13...
  • Page 89 ELECTRICAL SYSTEMS 7 - 14 Mid-Mount Z Service Manual...
  • Page 90 ELECTRICAL SYSTEMS Mid-Mount Z Service Manual 7 - 15...
  • Page 91 ELECTRICAL SYSTEMS 7 - 16 Mid-Mount Z Service Manual...
  • Page 92 ELECTRICAL SYSTEMS Mid-Mount Z Service Manual 7 - 17...
  • Page 93 ELECTRICAL SYSTEMS 7 - 18 Mid-Mount Z Service Manual...
  • Page 94 ELECTRICAL SYSTEMS Mid-Mount Z Service Manual 7 - 19...

  • Page 95: Alternator, Kohler

    ELECTRICAL SYSTEMS Purpose Alternator (Kohler) The stator generates 25 amps of alternating current to charge the battery. How It Works Whenever a magnet passes by a coil of wire on an iron core, electricity is produced. The amount will depend on the thickness of wire, the number of windings on each coil, the strength of the magnet, and the speed at which the magnet is moving.

  • Page 96: Regulator/Rectifior

    ELECTRICAL SYSTEMS Purpose Regulator/Rectifier The regulator/rectifier prevents battery boiling by shutting off the current when the battery has reached 14.7 volts. How It Works The voltage regulator rectifies the current so that the battery sees only positive current and voltage. The voltage level across the battery is very near constant because the battery has very low impedance.

  • Page 97: Clutch,Electric

    ELECTRICAL SYSTEMS Purpose Clutch Electric This clutch electrically controls the engagement and disengagement of the PTO pulley. How It Works The PTO clutch is composed of three major components: the field, the clutch plate, and the friction plate. The clutch plate always turns with the engine. The field is a coil of wire on an iron core which becomes an electro-magnet when power is applied.

  • Page 98: Electric Pto Clutch Removal

    ELECTRICAL SYSTEMS Electric PTO Clutch Removal Rotate the clutch assembly until the anchor will clear the lower clutch guard. Then, slide the clutch assembly off of the crankshaft while holding Remove the PTO clutch anchor bolt. the 2 clutch halves together (Figure 137). Remove the 4 bolts securing the PTO clutch guard and remove the guard (Figure 135).

  • Page 99: Solenoid

    ELECTRICAL SYSTEMS Purpose Solenoid The solenoid’s purpose is simply to protect the ignition switch from the high current drawn by the starter motor. How It Works The solenoid has really only two parts. One is a coil of wire wrapped around an iron core. Whenever 12 volts is applied to the coil, it becomes a magnet.

  • Page 100: Starter Electric

    ELECTRICAL SYSTEMS Purpose Starter Electric The starter motor pushes the starter pinion into engagement with the flywheel, then rotates the starter motor to start the engine. How It Works The starter motor is really just a collection of simple parts: FIELD: A coil of wire on an iron core that becomes an electromagnet when current is applied.

  • Page 101: Switch Pto/Clutch

    ELECTRICAL SYSTEMS Purpose Switch PTO/Clutch Typically used to turn on the electric blade clutch and to function as part of the safety interlock system. How It Works Contacts inside this DPDT switch electrically connect various terminals. It is actually just two SPDT switches tripped by a single lever.

  • Page 102: Brake Switch

    ELECTRICAL SYSTEMS Purpose Brake Switch Senses the position of the parking brake handle. Insures that the parking brake is applied on start up and that the parking brake is released before operating the unit. How It Works When the brake is applied, both sets of contacts are closed.

  • Page 103: Interlock Module

    ELECTRICAL SYSTEMS Purpose Interlock Module The interlock module monitors the status of the safety switch and prevents the engine from running if an unsafe condition exists. How It Works When the ignition switch is in the “ON” or “START” position, B+ to power the module is supplied to the blue wire from the “A”...

  • Page 104: Hourmeter

    ELECTRICAL SYSTEMS Purpose Hourmeter The hourmeter keeps track of the amount of hours the engine has been running. How It Works When the ignition switch is in the “ON” position, power is supplied to the + terminal of the hourmeter from the “A”...

  • Page 105: Motion Control Switch

    ELECTRICAL SYSTEMS Purpose Motion Control Switch There are two motion control switches - one for each lever. They sense the position of the motion control levers. How It Works Each motion control switch has two pairs of contacts - one normally open, one normally closed. When the control handles are out, the contacts connected to the light blue wires are closed providing a ground for the start solenoid.

  • Page 106: Key Switch

    ELECTRICAL SYSTEMS Key Switch Purpose The key switch provides proper switching of the start, run, stop, and interlock circuits. How It Works Detents inside the switch give it three positions: “OFF”, “RUN”, and “START”. The “START” position is spring loaded so the switch returns to the “RUN” position when the key is released.

  • Page 107: Seat Switch

    ELECTRICAL SYSTEMS Purpose Seat Switch To sense when the operator is in position on the seat. How It Works The seat switch is mounted to a spring loaded link so that the switch contacts are open when there is no operator on the seat.

  • Page 108: Mercury Switch

    ELECTRICAL SYSTEMS Purpose Mercury Switch To shut the engine down when the tilt limit has been exceeded. How It Works A small amount of mercury is contained in the switch. When the tilt angle of the unit is less than 60°, the mercury connects the contacts in the switch.

  • Page 109: Amp Fuse

    ELECTRICAL SYSTEMS Purpose 20 Amp Fuse Fuses are electrical safety valves that protect wiring and electrical components from damage from high current flow by creating an open circuit. Fuses are rated for specific currents (amps). Never connect a jumper wire across a fuse. Never connect additional fuses in parallel.

  • Page 110: Wiring Harness, Typical

    ELECTRICAL SYSTEMS Wiring Harness, Typical Ref. No. Qty. Description Ref. No. Qty. Description Battery Holddown Strap Switch 230 CCA Battery Normally Open Switch Wing Nut Plastic Tie Ground Wire Seat Delay Module Battery Insulator Key Switch ASM HH Screw Hourmeter Flat Washer Delta Switch HF Nut...
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  • Page 113 492-4758...

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