Toro 10301, 10307, 10309, 10310, 10311 Service Manual

...
WALK BEHIND POWER
MOWER DRIVE SYSTEMS
SERVICE MANUAL
ABOUT THIS MANUAL
This service manual was written expressly for Toro servicing dealers. The Toro Company has made every effort to make the information in this manual complete and correct.
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.
We are hopeful that you will fi nd this manual a valuable addition to your service shop. If you have any questions or comments regarding this manual, please contact us at the following address:
The Toro Company
LCE Service Training Department 8111 Lyndale Avenue South Bloomington, MN 55420
The Toro Company reserves the right to change product specifi cations or this manual without notice.
Copyright© All Rights Reserved
©2006 The Toro Company
THIS PAGE INTENTIONALLY LEFT BLANK.
TABLE OF CONTENTS
QUICK REFERENCE
Transmission Remove and Replace
3 speed transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21” steel & cast deck Personal Pace, Easy Stride transmission . . . . . . . . . . . . . . . .
22” steel deck transmission, Toro and Lawn-Boy . . . . . . . . . . . . . . . . . . . . . .
21” Lawn-Boy Insight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Internal Repair
3 speed transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spur/Bevel gear transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bevel gear transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Clutch Troubleshooting & Repair
Rocking Key style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring Ratchet style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blade Clutch System Troubleshooting & Repair
Blade Brake Clutch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blade Override System (Toro - BOS) Blade Clutch System (Lawn-Boy - BCS) . . . . . . . . . . .
4-5 2-3 3-10 3-20
4-6 2-4 3-16
5-2 5-9
6-2 6-28
Handle Disassembly
Toro 2 Bail handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personal Pace Easy Stride (Generation 1) . . . . . . . . . . . . . . . . . . . . . . . . .
Personal Pace Easy Stride (Generation 2) . . . . . . . . . . . . . . . . . . . . . . . . .
Lawn-Boy Sens-a-Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Replacement
Mowers with Toro Blade Brake Clutch . . . . . . . . . . . . . . . . . . . . . . . . . .
Mowers with Toro Blade Override System . . . . . . . . . . . . . . . . . . . . . . . . .
Zone start 21” Rear Wheel Drive Toro & Lawn-Boy (except Insight) . . . . . . . . . . . . . . .
Zone start 22” Toro Rear Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . .
Zone start 22” Toro Front Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . .
Lawn-Boy Insight Zone Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lawn-Boy Insight with Blade Clutch System . . . . . . . . . . . . . . . . . . . . . . . .
7-2 7-3 7-6 7-9
8-3 8-3 8-2 3-10 3-5 3-19 8-3
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TABLE OF CONTENTS
WORM DRIVE TRANSMISSION
GENERAL INTERNALLY CLUTCHED
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Shifting Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal & Installation (front wheel drive applications) . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONSTANT MESH
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEEL CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION
GEAR CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Remove & Replace . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Internal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2 1-3 1-3 1-4 1-5 1-7 1-9 1-10
1-11 1-12 1-13 1-14
2-2 2-3 2-3 2-3 2-4 2-5
SINGLE SPEED BEVEL GEAR TRANSMISSION
EXPLODED VIEW - SINGLE SPEED BEVEL GEAR TRANSMISSION . . . . . . . . . . . . . .
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT AXLE & TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .
22” FRONT WHEEL DRIVE MODELS
Remove Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Service - Front Wheel Drive Models . . . . . . . . . . . . . . . . . . . . . . . .
22” TORO & LAWN-BOY REAR WHEEL DRIVE MODELS
Transmission Removal & Belt Replacement . . . . . . . . . . . . . . . . . . . . . .
Rear Axle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Assembly Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LAWN-BOY INSIGHT TRANSMISSION REMOVE & REPLACE . . . . . . . . . . . . . . . .
Tranmission Removal & Belt Replacement . . . . . . . . . . . . . . . . . . . . . . .
Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Assembly Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Installation Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THREE SPEED TRANSMISSION
GEAR CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION
Input System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2 3-3 3-4
3-5 3-7 3-7 3-8 3-9
3-10 3-15 3-16 3-16 3-17 3-19 3-20 3-24 3-24 3-24 3-25
4-2
4-3
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TABLE OF CONTENTS
Speed Reduction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Selection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal - Toro Vacu Power/Lawn-Boy Medallion Models . . . . . . . . . . . . . . . . .
Removal - Recycler/Rear Bagger Chassis . . . . . . . . . . . . . . . . . . . . . . .
Alternate Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermediate Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Assembly Notes for Toro Vacu Power/Lawn-Boy Medallion . . . . . . . . . . . . .
TROUBLESHOOTING TIPS - 3 SPEED TRANSMISSION
Hard Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slipping Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEEL PINION CLUTCH
GEAR CASE & WHEEL ASSEMBLY, ROCKING KEY STYLE . . . . . . . . . . . . . . . . .
Wheel Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Defi nitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test for Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Height-of-Cut & Wheel Pinion Clutch - Disassembly . . . . . . . . . . . . . . . . .
Rear Height-of-Cut & Wheel Pinion Clutch - Assembly . . . . . . . . . . . . . . . . . .
GEAR CASE & WHEEL ASSEMBLY SPRING RATCHET STYLE . . . . . . . . . . . . . . . .
Spring Ratchet Key Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEEL PINION SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3 4-4 4-5 4-6 4-6 4-6 4-7 4-8 4-9 4-10 4-10 4-11
4-12 4-12
5-2 5-3 5-3 5-4 5-4 5-4 5-5 5-8 5-9 5-9 5-9
BLADE BRAKE CLUTCH SYSTEMS (BBC), BLADE OVERRIDE SYSTEM (BOS), BLADE CLUTCH SYSTEM (BCS) BLADE BRAKE CLUTCH SYSTEM
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BBC Clutch Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Box Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handle Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Box Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TORO BBC SERVICE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLADE BRAKE CLUTCH ASSEMBLY (Toro Vacu Power/Lawn-Boy Medallion) . . . . . . . . . .
TORO VACU POWER/LAWN-BOY MEDALLION BBC . . . . . . . . . . . . . . . . . . . .
Bellcrank System Disassembly (Toro Vacu Power/Lawn-Boy Medallion) . . . . . . . . . . .
Bellcrank System Assembly (Toro Vacu Power/Lawn-Boy Medallion) . . . . . . . . . . . . .
BBC Cover and Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Under Deck Components Disassembly (Toro Vacu Power/Lawn-Boy Medallion) . . . . . . . .
Under Deck Components Assembly (Toro Vacu Power/Lawn-Boy Medallion) . . . . . . . . . .
BBC Cable Removal (Toro Vacu Power/Lawn-Boy Medallion) . . . . . . . . . . . . . . .
BBC Cable Installation (Toro Vacu Power/Lawn-Boy Medallion) . . . . . . . . . . . . . . .
ENGINE & BLADE ASSEMBLY (Toro Recycler/Rear Bagger) . . . . . . . . . . . . . . . . .
TORO RECYCLER/REAR BAGGER BBC . . . . . . . . . . . . . . . . . . . . . . . . .
Idler Arm System Disassembly (Recycler/Rear Bagger) . . . . . . . . . . . . . . . . . .
Idler Arm System Assembly (Recycler/Rear Bagger) . . . . . . . . . . . . . . . . . . .
6-2 6-2 6-2 6-3 6-6 6-7 6-10 6-11 6-12 6-12 6-13 6-14 6-15 6-17 6-19 6-20 6-21 6-22 6-22 6-25
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TABLE OF CONTENTS
BBC Cable Removal (Recycler/Rear Bagger) . . . . . . . . . . . . . . . . . . . . . .
BBC Cable Installation (Recycler/Rear Bagger) . . . . . . . . . . . . . . . . . . . . .
BLADE OVERRIDE SYSTEM (BOS), BLADE CLUTCH SYSTEM (BCS) . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOS/BCS System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLES AND CONTROL CABLES
Toro 2 Bail Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personal Pace Generation 1/Easy Stride Generation 1 . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Personal Pace Cable . . . . . . . . . . . . . . . . . . . . . . . . . .
Personal Pace Generation 2/Easy Stride Generation 2 . . . . . . . . . . . . . . . . . .
Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Personal Pace/Easy Stride Cable . . . . . . . . . . . . . . . . . . . . .
Lawn-Boy 2 Bail Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lawn-Boy Sens-a-Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handle Disassembly, Zone Start Models . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Self-Propel Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handle Disassembly, Lawn-Boy Blade Clutch System (BCS) Models . . . . . . . . . . . . .
3 Speed Transmission Models . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Speed Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BBC Cable Adjustment (Toro Vacu Power/Lawn-Boy Medallion) . . . . . . . . . . . . . . .
Toro BBC Cable Adjustment (Recycler/Rear Bagger) . . . . . . . . . . . . . . . . . . .
Toro BOS Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toro BOS Control Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .
Lawn-Boy BCS Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lawn-Boy BCS Control Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . .
6-27 6-28 6-28 6-28 6-32 6-33
7-2 7-3 7-3 7-3 7-5 7-6 7-6 7-6 7-8 7-8 7-9 7-9 7-9 7-10 7-11 7-11 7-11 7-13 7-13 7-15 7-16 7-17 7-18 7-18 7-18
SELF-PROPEL BELT REPLACEMENT
Toro 21” Front Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22” Front Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22” Rear Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21” Steel & Cast Deck Toro & Lawn-Boy Mowers Belt Replacement . . . . . . . . . . . . .
21” Cast Deck Mowers with 3 Speed Transmission . . . . . . . . . . . . . . . . . . . .
21” Toro & Lawn-Boy Mowers with Blade Brake Clutch . . . . . . . . . . . . . . . . . .
21” Toro Mowers with Blade Override System & Lawn-Boy Mower
with Blade Brake Clutch System . . . . . . . . . . . . . . . . . . . . . . . . .
21” Lawn-Boy Insight Mowers . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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8-2 8-2 8-2 8-2 8-2 8-3
8-3 8-3
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.
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” stl - 22” steel deck PP1 - Personal Pace 1st generation B- bevel gear PP2 - Personal Pace 2nd generation BBC - blade brake clutch RK - rocking key BBC VP - blade brake clutch SB - spur bevel for Vacu Power SR - spring ratchet BOS - blade override system SS - Sens-a-Speed CD - cast deck W - worm
Model Trans Trans Wheel Handle Blade R&R Internal Pinion Repair Clutch Repair
10301 CD SB RK 2B None 10302 CD SB RK 2B None 10304 CD SB RK 2B None 10305 CD SB RK 2B None 10307 CD SB RK 2B None 10309 CD SB RK 2B None 10310 CD SB RK 2B None 10311 CD SB RK 2B None 10312 CD SB RK 2B None 10313 CD SB RK 2B None 10314 CD SB RK 2B None 10316 CD SB RK 2B None 10317 CD SB RK 2B None 10318 CD SB RK 2B None 10319 CD SB RK 2B None 10320 CD SB RK 2B None 10321 CD SB RK 2B None 10323 CD SB RK 2B None 10324 CD SB RK 2B None 10324C CD SB RK 2B None 10327 CD SB RK 2B None 10328 CD SB RK 2B None 10329 CD SB RK 2B None 10330 CD SB RK 2B None
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TABLE OF CONTENTS
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” stl - 22” steel deck PP1 - Personal Pace 1st generation B- bevel gear PP2 - Personal Pace 2nd generation BBC - blade brake clutch RK - rocking key BBC VP - blade brake clutch SB - spur bevel for Vacu Power SR - spring ratchet BOS - blade override system SS - Sens-a-Speed CD - cast deck W - worm
Model Trans Trans Wheel Handle Blade R&R Internal Pinion Repair Clutch Repair
10331 CD SB RK 2B None 10332 CD SB RK 2B None 10334 CD SB RK 2B None 10335 CD SB RK 2B None 10342 CD SB RK 2B None 10343 CD SB RK 2B None 10344 CD SB RK 2B None 10345 CD SB RK 2B None 10356 CD SB RK 2B None 10357 CD SB RK 2B None 10358 CD SB RK 2B None 10359C CD SB RK 2B None 10360 CD SB RK 2B None 10360C CD SB RK 2B None 10361 CD SB RK 2B None 10362 CD SB RK 2B None 10363 CD SB RK 2B None 10515 CD 3S RK 2B None 10516 CD 3S RK 2B None 10517 CD 3S RK 2B None 10518 CD 3S RK 2B None 10519 CD 3S RK 2B None 10520 CD 3S RK 2B None 10521 CD 3S RK 2B None 10522 CD 3S RK 2B None 10523 CD 3S RK 2B None 10524 CD 3S RK 2B None 10525 CD 3S RK 2B None 10527 CD 3S RK 2B None 10528 CD 3S RK 2B None 10533 CD 3S RK BBC BBC VP 10545 CD 3S RK 2B None
Code List
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TABLE OF CONTENTS
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” stl - 22” steel deck PP1 - Personal Pace 1st generation B- bevel gear PP2 - Personal Pace 2nd generation BBC - blade brake clutch RK - rocking key BBC VP - blade brake clutch SB - spur bevel for Vacu Power SR - spring ratchet BOS - blade override system SS - Sens-a-Speed CD - cast deck W - worm
Model Trans Trans Wheel Handle Blade R&R Internal Pinion Repair Clutch Repair
10546 CD 3S RK 2B None 10547 CD 3S RK 2B None 10548 CD 3S RK 2B None 10550 CD SB RK ES1 None 10551 CD SB RK ES1 None 10552 CD SB RK ES1 None 10655 22stl B SR ES2 None 10656 22stl B SR ES2 None 10672 Ins B SR SS None 10673 Ins B SR SS None 10682 Ins B SR 2B None 10684 Ins B SR 2B None 10684C Ins B SR 2B None 10685 Ins B SR SS None 10686 Ins B SR SS None 10686C Ins B SR SS None 10687 Ins B SR SS BCS 10695 Ins B SR SS None 10696 Ins B SR SS None 10696C Ins B SR SS None 10697 Ins B SR SS BCS 10910 CD SB RK 2B None 10910B CD SB RK 2B None 10926 CD SB RK 2B None 10927 CD SB RK 2B None 10928 CD 3S RK ? None 10929 CD SB RK 2B None 10995 Ins B SR SS None 10997 CD B SR SS BCS 11001 CD 3S RK 2B None 11001B CD 3S RK 2B None 11003 CD 3S RK 2B None
Code List
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TABLE OF CONTENTS
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” stl - 22” steel deck PP1 - Personal Pace 1st generation B- bevel gear PP2 - Personal Pace 2nd generation BBC - blade brake clutch RK - rocking key BBC VP - blade brake clutch SB - spur bevel for Vacu Power SR - spring ratchet BOS - blade override system SS - Sens-a-Speed CD - cast deck W - worm
Model Trans Trans Wheel Handle Blade R&R Internal Pinion Repair Clutch Repair
16212 W Worm None None None 16212B W Wom None None None 16212W W Worm None None None 16212WG W Worm None None None 16401 W Worm None None None 16402 W Worm None None None 16404 W Worm None None None 16411 W Worm None None None 16775 W Worm None None None 16776 W Worm None None None 16785 W Worm None None None 16793 W Worm None None None 20001 22stl B SR 2B None 20003 22stl B SR 2B None 20005 22stl B SR 2B None 20007 22stl B SR 2B None 20011 22stl SB RK 2B None 20012 22stl B SR 2B None 20013 22stl B SR PP2 None 20014 22stl B SR PP2 None 20016 22stl B SR 2B None 20017 22stl B SR PP2 None 20018 22stl B SR PP2 None 20019 22stl B SR 2B None 20020 CD SB RK 2B None 20021 CD SB RK 2B None 20028 CD SB RK 2B None 20031 22stl B SR PP2 None 20036 CD SB RK PP2 None 20037 CD SB RK PP2 None 20038 CD SB RK PP2 None 20039 CD SB RK PP2 None
Code List
viii WPM Drive Systems Manual
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” stl - 22” steel deck PP1 - Personal Pace 1st generation B- bevel gear PP2 - Personal Pace 2nd generation BBC - blade brake clutch RK - rocking key BBC VP - blade brake clutch SB - spur bevel for Vacu Power SR - spring ratchet BOS - blade override system SS - Sens-a-Speed CD - cast deck W - worm
Model Trans Trans Wheel Handle Blade R&R Internal Pinion Repair Clutch Repair
20041 22stl B SR PP2 None 20044 CD 3SP RK 1B None 20047 22stl B RK PP2 None 20049 22stl B SR PP2 None 20051 22stl B SR PP2 None 20054 CD SB RK PP2 None 20055 CD SB RK PP2 None 20056 CD SB RK PP2 BOS 20057 CD SB RK PP2 None 20058 CD SB RK PP2 BOS 20070 22stl B SR PP2 None 20079 22stl B SR PP2 None 20106 CD 3SP RK 1B BBC 20107 CD 3SP RK 1B BBC 20210 CD 3SP RK 1B BBC 20211 CD 3SP RK 1B BBC 20214 CD 3SP RK 1B None 20216 CD 3SP RK 1B None 20218 CD 3SP RK 1B None 20219 CD 3SP RK 1B BBC 20320 CD 3SP RK 1B None 20321 CD 3SP RK 1B None 20322 CD 3SP RK 1B None 20324 CD 3SP RK 1BBC BBC 20325 CD 3SP RK BBC BBC 20327B CD 3SP RK 1B None 20328B CD 3SP RK 1B None 20436 CD 3SP RK 1B None 20436WF CD 3SP RK 1B None 20437 CD 3SP RK 1B None 20438 CD 3SP RK BBC BBC 20438WF CD 3SP RK BBC BBC
ixWPM Drive Systems Manual
TABLE OF CONTENTS
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” stl - 22” steel deck PP1 - Personal Pace 1st generation B- bevel gear PP2 - Personal Pace 2nd generation BBC - blade brake clutch RK - rocking key BBC VP - blade brake clutch SB - spur bevel for Vacu Power SR - spring ratchet BOS - blade override system SS - Sens-a-Speed CD - cast deck W - worm
Model Trans Trans Wheel Handle Blade R&R Internal Pinion Repair Clutch Repair
20439 CD 3SP RK BBC BBC 20439WF CD 3SP RK BBC BBC 20462 CD 3SP RK 1B None 20463 CD 3SP RK 1B None 20464 CD 3SP RK 1B None 20465 CD 3SP RK BBC BBC 20466 CD 3SP RK BBC BBC 20470 CD 3SP RK 1B None 20472 CD 3SP RK 1B None 20473 CD 3SP RK 1B None 20474 CD 3SP RK 1B None 20475 CD 3SP RK BBC BBC 20476 CD 3SP RK BBC BBC 20478 CD 3SP RK 1B None 20479 CD 3SP RK 1B None 20480 CD 3SP RK 1B None 20481 CD 3SP RK 1B None 20482 CD 3SP RK BBC BBC 20483 CD 3SP RK BBC BBC 20486 CD 3SP RK 1B None 20487 CD 3SP RK BBC BBC 20488 CD 3SP RK 1B None 20489 CD 3SP RK 1B None 20490 CD 3SP RK BBC BBC 20494 CD 3SP RK 1B None 20495 CD 3SP RK 1B None 20622 CD 3SP RK BBC BBC 20632 CD 3SP RK BBC BBC 20652 21” stl SB RK PP1 None 20654 21” stl SB RK PP2 None 20655 22” stl B SR PP2 None 20656 22” stl B SR PP2 None
Code List
x WPM Drive Systems Manual
TABLE OF CONTENTS
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” stl - 22” steel deck PP1 - Personal Pace 1st generation B- bevel gear PP2 - Personal Pace 2nd generation BBC - blade brake clutch RK - rocking key BBC VP - blade brake clutch SB - spur bevel for Vacu Power SR - spring ratchet BOS - blade override system SS - Sens-a-Speed CD - cast deck W - worm
Model Trans Trans Wheel Handle Blade R&R Internal Pinion Repair Clutch Repair
20666 CD 3SP RK 1B None 20667 CD 3SP RK BBC BBC 20668 CD 3SP RK 1B None 20677 CD 3SP RK 1B None 20680 CD 3SP RK 1B None 20692 CD 3SP RK 1B None 20695 CD 3SP RK BBC BBC 20761B CD 3SP RK 1B None 20763B CD 3SP RK 1B None 20764B CD 3SP RK 1B None 20764BC CD 3SP RK 1B None 20766B CD 3SP RK 1B None 20766BC CD 3SP RK 1B None 20767B CD 3SP RK 1B None 20768B CD 3SP RK 1B None 20776 CD 3SP RK 1B None 20777 CD 3SP RK 1B None 20778 CD 3SP RK 1B None 20781 CD SB RK PP2 None 20783 CD SB RK PP2 None 20784 CD SB RK PP2 None 20786 CD 3SP RK 1B None 20787 CD 3SP RK 1B None 20792 CD SB RK PP2 None 20793 CD SB RK PP2 None 20795 CD SB RK PP2 None 20796 CD SB RK PP2 None 20817 CD SB RK PP2 None 20819 CD SB RK PP2 None 20828 CD SB RK PP2 None 20831 CD SB RK PP2 None 20832 CD SB RK PP2 None
Code List
xiWPM Drive Systems Manual
TABLE OF CONTENTS
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” stl - 22” steel deck PP1 - Personal Pace 1st generation B- bevel gear PP2 - Personal Pace 2nd generation BBC - blade brake clutch RK - rocking key BBC VP - blade brake clutch SB - spur bevel for Vacu Power SR - spring ratchet BOS - blade override system SS - Sens-a-Speed CD - cast deck W - worm
Model Trans Trans Wheel Handle Blade R&R Internal Pinion Repair Clutch Repair
20833 CD SB RK PP2 None 20905 CD Worm RK 1B None 20905B CD Worm RK 1B None 20906B CD Worm RK 1B None 20911B CD Worm RK 1B None 20915 CD Worm RK 1B None 20916B CD Worm RK 1B None 20920 CD Worm RK 1B None 20920B CD Worm RK 1B None 20921B CD Worm RK 1B None 20925 CD Worm RK 1B None 20925B CD Worm RK 1B None 20926B CD Worm RK 1B None 20927B CD Worm RK 1B None 26620B CD VP 3 SP RK 1B None 26620BF CD VP 3 SP RK 1B None 26620BG CD VP 3 SP RK 1B None 26621 CD VP 3 SP RK BBC BBC VP 26621B CD VP 3 SP RK BBC BBC VP 26622 CD VP 3 SP RK BBC BBC VP 26623 CD VP 3 SP RK BBC BBC VP 26624 CD VP 3 SP RK BBC BBC VP 26625B CD VP 3 SP RK 1B None 26625BG CD VP 3 SP RK 1B None 26626 CD VP 3 SP RK BBC BBC VP 26630B CD VP 3 SP RK 1B None 26630BC CD VP 3 SP RK 1B None 26630BG CD VP 3 SP RK 1B None 26631B CD VP 3 SP RK BBC BBC VP 26631BC CD VP 3 SP RK BBC BBC VP 26632 CD VP 3 SP RK 1B None 26632B CD VP 3 SP RK 1B None
Code List
xii WPM Drive Systems Manual
TABLE OF CONTENTS
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” stl - 22” steel deck PP1 - Personal Pace 1st generation B- bevel gear PP2 - Personal Pace 2nd generation BBC - blade brake clutch RK - rocking key BBC VP - blade brake clutch SB - spur bevel for Vacu Power SR - spring ratchet BOS - blade override system SS - Sens-a-Speed CD - cast deck W - worm
Model Trans Trans Wheel Handle Blade R&R Internal Pinion Repair Clutch Repair
26633 CD VP 3 SP RK BBC BBC VP 26633B CD VP 3 SP RK BBC BBC VP 26635B CD VP 3 SP RK 1B None 26635BC CD VP 3 SP RK 1B None 26635BG CD VP 3 SP RK 1B None 26636 CD VP 3 SP RK 1B None 26636B CD VP 3 SP RK 1B None 26637 CD VP 3 SP RK 1B None 26638 CD VP 3 SP RK BBC BBC VP 26639 CD VP 3 SP RK 1B None 26640B CD VP 3 SP RK 1B None 26640BC CD VP 3 SP RK 1B None 26643 CD VP 3 SP RK 1B None 26643B CD VP 3 SP RK 1B None 26680 CD VP 3 SP RK 1B None 26680WG CD VP 3 SP RK 1B None 26682 CD VP 3 SP RK BBC BBC VP 26683 CD VP 3 SP RK BBC BBC VP 27500 CD VP 3 SP RK BBC BBC VP 27501 CD VP 3 SP RK BBC BBC VP 27502 CD VP 3 SP RK BBC BBC VP 20442 CD SB RK 1B None 20444 CD SB RK 1B None 20711 CD SB RK 1B None
Code List
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TABLE OF CONTENTS
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xiv WPM Drive Systems Manual
WORM DRIVE TRANSMISSION
Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . .
Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . .
Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . .
Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . .
Wheel Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
3
4
5
Blade Brake Clutch Systems (BBC), Blade Override
System (BOS), Blade Clutch Systems (BCS) . . . . . . . . . . . . .
Handles and Control Cables . . . . . . . . . . . . . . . . . . . . . .
Self-Propel Belt Replacement . . . . . . . . . . . . . . . . . . . . . .
6
7
8
1-1WPM Drive Systems Manual
WORM DRIVE TRANSMISSION
GENERAL
There are two versions of the worm drive transmission. The fi rst is a clutch type and is used on 21” front wheel drive mowers. The second version is constant mesh and is used on International 48cm rear wheel drive mowers.
INTERNALLY CLUTCHED
Description
This is a worm and helical gear transmission. The worm shaft (input shaft) is driven by a belt from the engine crankshaft. A spring which hooks into the tab on the front of the transmission (where the roll pin is) and to
the mower housing, pivots the transmission forward to maintain tension on the belt.
The worm is in constant mesh with the helical gear. The clutching action is provided by a sliding clutch jaw. A shift fork moves the clutch jaw to engage and disengage the transmission. When the clutch jaw engages the helical gear, power is transferred from the clutch jaw to the sleeve inside the clutch jaw. The sleeve is pinned to the axle. The axle then begins to rotate (Fig. 001).
A. Belt E. Shift Fork B. Spring F. Sleeve C. Helical Gear G. Input Shaft D. Clutch Jaw (worm shaft)
A
C
B
E
G
D
F
1-2 WPM Drive Systems Manual
Fig 001g 1
WORM DRIVE TRANSMISSION
Lubrication
This transmission requires 90 wt. gear oil. A variable weight such as 85w90 is acceptable as long as the range includes 90 weight. The second part of the requirement is an EP rating of GL 5 or higher.
The transmission has a fi ll/check plug in the front. With the transmission level, fi ll until level with the hole. NOTE: This is equal to about the center of the axle.
Unless the case is cracked, oil can not leak out. Even if a seal fails, oil will leak out only to the bottom of the seal on the axle.
If gear failure occurs, the resulting friction can cook the oil down to a smear in the bottom of the case. This does not indicate a lack of lubrication.
This type of transmission will last less than 30 minutes with no lubrication. If a transmission lasts even a few weeks in consumer use, it had lubrication to start.
The Shifting Process
The upper end of the clutch fork slides over a groove in a spring loaded rod. This spring pushes the shift fork and clutch jaw towards the engaged position (Fig. 002).
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 travel from engagement to disengagement. Above the latch plate is a dust fi lter and a dust cover. The shift arm on top of the transmission holds all these parts in place (Fig. 003).
G
A
B C
D
E
F
Fig 003 3428-0165
A. Roll Pin E. Shift Arm B. Latch Plate F. Screw C. Dust Filter G. Shift Rod D. Dust Cover
A
B
Fig 002 3428-0150
A. Shift Rod B. Shift Fork
When the shift arm is pulled to the rear by the shift cable, the pin moves to the left side of the mower, then to the rear. This moves the shift pin, the shift fork, and the clutch jaw to the disengage position.
NOTE: Dirt packed in the latch plate can prevent
disengagement. The dust fi lter and dust cover help prevent this failure.
When the shift cable is engaged, tension on the shift arm is released. The spring on the shift rod applies pressure to the rod, fork, and clutch jaw to engage the transmission.
1-3WPM Drive Systems Manual
WORM DRIVE TRANSMISSION
C
Removal & Installation (front wheel drive applications)
1. Remove the belt cover and unhook the spring on the front of the transmission. Slip the belt off the transmission pulley (Fig. 004).
A
B
C
Fig 004 3428-0127
A. Cable Clamp C. Spring B. Shift Cable
4. Remove both front wheels and wheel covers (Fig.
005).
Fig 005 3428-0129
5. Pivot (both) front spring arms forward until they point straight down. (This removes the tension from the pivot arms so the roll pin can be removed) (Fig.
006).
2. Raise the front of the mower off the bench and support it with blocks.
3. Disconnect the shift cable.
Fig 006 3428-0131
1-4 WPM Drive Systems Manual
WORM DRIVE TRANSMISSION
A
6. Place a block of wood under the wheel pinion for
support and drive the roll pin out of the axle (Fig.
007). Repeat the process on the other side.
A
Fig 007 3428-0135
A. Wood Block
8. Remove the transmission from the chassis.
9. Reverse the procedure to install.
NOTE: Support the wheel pinions with the wood
block while driving the roll pins in. This will prevent the axle from being bent. Fill the transmission with oil after it is installed in the mower (Fig. 009).
Note the front of the transmission is identifi ed by the oil fi ll/check screw and the fl at tab which is part of the lower case.
7. The wheel pinion, thrust washer, pivot, and spring
arm will now slide off the end of the axle (Fig. 008). Repeat the process on the other side.
Fig 008 3428-0137
A
C
B
Fig 009 3428-0166
A. Fill/Check C. Tab B. Plug
Disassembly
1. Cut and discard the push-on retainer on top of the transmission pulley. Remove the belt and pulley.
1-5WPM Drive Systems Manual
WORM DRIVE TRANSMISSION
2. Drive the roll pins out of the fl anges in the front and rear of the case. (These pins align the top and bottom parts of the case) (Fig. 010).
Fig 010 3428-0146
3. Remove the 4 self-tapping screw that connect the top and bottom cases.
5. Push the worm shaft out of the cover. This may require a little pressure.
6. To remove the axle, slide the clutch jaw to the side and drive the roll pin out of the sleeve and axle (Fig.
012).
Fig 012 3428-0151
Note: If you turn this transmission on its side or
upside down, oil may leak out of the top. This is not a sealed case.
4. Remove the transmission cover. The shift fork may come with the cover or may fall into the bottom of the case (Fig. 011).
Fig 011 3428-0148
7. If the axle bearings are to be re-used, clean the end of the axle before drawing it out of the case.
8. Remove the sleeve, clutch jaw, helical gear, and thrust washer (Fig. 013)
A
BC
D
Fig 013 3428-0153
A. Helical Gear C. Sleeve B. Thrust Washer D. Clutch Jaw
1-6 WPM Drive Systems Manual
WORM DRIVE TRANSMISSION
9. Clean the old gasket material from the mating surfaces of the case and cover.
10. A hook or small screwdriver can be used to pry the seals out of the case.
11. An arbor press or large vise will be needed when removing and replacing the bushings.
12. Clean the oil residue and any metal shavings from the case.
13. Worm and helical gears are sold as a set. Even after a short run time, they will develop a wear pattern. Replacing only one gear will result in rapid failure (Fig. 014).
A
14. Remove the screw from the shift arm and remove the shift arm, dust cover, and wear plate (Fig. 015). If the ball bearing is to be replaced, press it out at this time.
G
A
B C
D
E
F
Fig 015 3428-0165
A. Roll Pin E. Shift Arm B. Latch Plate F. Screw C. Dust Filter G. Shift Rod D. Dust Cover
B
A. Worm Shaft B. Helical Gear
Fig 014 3428-0157
15. Remove the roll pin and pull shifter rod out of the cover. Clean the cover.
Assembly
1. Use bushing installation tool P/N 27-0460, to press in new axle bushings. This tool helps keep the bushing straight and keeps the inner diameter of the bushing correctly sized.
1-7WPM Drive Systems Manual
WORM DRIVE TRANSMISSION
Note: The bushings are two different lengths. The
side of the case with the thicker boss uses a longer busing to support the axle. The bushings should be fl ush with the inside of the case (Fig. 016).
A
Fig 016 3428-0158
A. Tool P/N 27-0460
3. Note: Some replacement axles have more than one hole that can be used to pin the sleeve to the axle. Refer to the original axle to identify the correct hole to use. Then drive a roll pin through the sleeve and axle (Fig. 017).
Fig 017 3428-0151
2. Clean the rust and dirt from the both ends of the axle. Wipe the inner diameter of the bushings with a clean cloth. Lightly oil the axle and insert it into the gearcase. When facing the front of the gearbox, insert the short end of the axle from left to right. Install the thrust washer, helical gear, and the sleeve and clutch jaw. Then push the axle through the other side of the case.
4. Using a seal protector, slide new seals down each side of the axle, Install the seal with the lip facing the transmission. The outer edge of the seal should be fl ush with the outside of the case. If a seal protector is not available, wrap a piece of cellophane around the axle (Fig. 018).
A
B
Fig 018 3428-0170
1-8 WPM Drive Systems Manual
A. Seal protector or B. Seal Cellophane
WORM DRIVE TRANSMISSION
5. If the bearing in the cover is being replaced, use tool P/N 27-0490 to press it in place. This bearing only has one seal. Install the bearing such that the seal is visible from the top of the cover and the open side faces the gears. Press the bearing in until it is fully seated in the case (Fig. 019).
A
Fig 019 3428-0159
9. Fill the transmission with gear oil AFTER it is installed in the mower. The top of this transmission is not sealed. It will leak if tipped on its side (Fig. 020).
A
B
Fig 020 3428-0166
A. Fill/Check B. Plug
A. Tool P/N 27-0490
6. Install worm shaft in bearing.
7. Use a new gasket. Install the cover on the bottom case and start the 4 self-tapping screws. Do not fully tighten them.
8. Install the front and rear roll pins to align the cover and case. Then secure the 4 self-tapping screws.
Controls
There are two control cables used with this system. One cable operates the engine kill switch and fl ywheel brake; the other controls the transmission.
1-9WPM Drive Systems Manual
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. To adjust, pull the control to the rear (disengage). Go to the cable clamp/adjustment. Loosen the clamp, pull the cable to the rear until the shift lever is as far back as it will go. Hold it there and tighten the clamp (Fig. 021).
A
Fig 021 3428-0127
A. Cable Clamp
1-10 WPM Drive Systems Manual
WORM DRIVE TRANSMISSION
CONSTANT MESH
Description
This transmission is very similar to the “INTERNALLY CLUTCHED” on page 1 – 1. However, the helical gear is different as there is no internal clutching (Fig. 022). Engagement and disengagement is accomplished by pivoting the transmission to tighten or loosen the belt.
Internal repair procedures are the same, as is the lubrication requirement, 90 wt. gear oil rated GL-5 or higher.
1. Jam nut 13. Oil Seal
2. Lock washer 14. Output shaft
3. Half pulley 15. Traction bracket
4. V Belt 16. Thread forming screw
5. Pulley spacer 17. Gearbox case
6. Gearbox cover 18. Thrust washer
7. Shaft & worm 19. Roll pin
8. Ball bearing 20. Helical gear
9. Gearbox gasket 21. Thrust washer
10. Check plug 22. Bushing
11. Gasket check plug 23. Roll pin
12. Bushing
The constant mesh type transmission is used in a 48cm rear wheel drive application.
Fig 022g 18-A
1-11WPM Drive Systems Manual
WORM DRIVE TRANSMISSION
Removal and Installation
Fig 023 20911B sprearaxleassy
Ref. No. Qty Description
1
2 3 4 5 6
7
9 10 11 12 13 14 15
1-12 WPM Drive Systems Manual
1
2 2 2 2 1
2 1 2 1 2 1 2 2
Rear Pivot Assembly RH (incl. Ref. #2, 4, 5 & 14) Grease Fitting Washer Sleeve Bushing Grease Seal Rear Pivot Assembly LH (incl. Ref. #3, 4, 5 & 14) Locknut Thread Forming Screw Trigger Return Spring H.O.C. Saddle Thread Forming Screw Push Nut Needle Bearing Friction Washer
Ref. No. Qty Description
16 17 18 19 20 21 22
23 24 25 26 27 28 34 35
4 4 1 2 2 2 2
2 4 2 2 2 4 2 1
Keyed Thrust Washer Retaining Ring LH Rocking Key Pinion Gear Compression Spring Wheel Cover Tire & Gear Assy Wheel (incl. Ref. #24) Wheel Bolt Wheel Bushing Wheel Spacer Clutch Washer Rear Suspension Plate Thread Forming Screw Roll Pin Gearbox Assembly
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