Toro 71140, 71180, 71181, 71182, 71184 Service Manual

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TORO XL LAWN TRACTOR SERVICE MANUAL

Table of Contents – Page 1 of 3

SPECIFICATIONS DIMENSIONS

HYDRO-GEAR HYDROSTATIC TRANSAXLE USAGE TURNING RADIUS

ELECTRICAL SYSTEM

TECUMSEH PEERLESS TRANSAXLES 1993 - 1995

1996 - PRESENT TORQUE SPECIFICATIONS

FASTENER IDENTIFICATION

STANDARD TORQUE FOR DRY, ZINC PLATED, AND STEEL FASTENERS (INCH SERIES) STANDARD TORQUE FOR DRY, ZINC, AND STEEL FASTENERS (METRIC FASTENERS) OTHER TORQUE SPECIFICATIONS

SAE GRADE 8 STEEL SET SCREWS

THREAD CUTTING SCREWS (ZINC PLATED STEEL) CONVERSION FACTORS

WHEEL BOLTS AND LUG NUTS

THREAD CUTTING SCREWS (ZINC PLATED STEEL) EQUIVALENTS AND CONVERSIONS

DECIMAL AND MILLIMETER EQUIVALENTS U.S. TO METRIC CONVERSIONS

XL GEAR DRIVE

XL GEAR DRIVE TRANSAXLE REMOVAL - 915 TRANSAXLE

XL GEAR DRIVE TRANSAXLE INSTALLATION - 915 TRANSAXLE

XL GEAR DRIVE TRACTION DRIVE BELT REPLACEMENT PROCEDURE - 915 TRANSAXLE XL GEAR DRIVE SHIFT LEVER ADJUSTMENT - 915 TRANSAXLE

XL GEAR DRIVE BRAKE ADJUSTMENT -915 TRANSAXLE XL GEAR DRIVE MST-205 TRANSAXLE REMOVAL

XL GEAR DRIVE MST-205 TRANSAXLE INSTALLATION

XL GEAR DRIVE SHIFT LEVER ADJUSTMENTS, MST-205 TRANSAXLE XL GEAR DRIVE BRAKE ADJUSTMENT, MST-205 TRANSAXLE

CHECKING THE BRAKE

ADJUSTING THE BRAKE

XL GEAR DRIVE TRACTION DRIVE BELT REPLACEMENT PROCEDURE, MST-205 TRANSAXLE CABLE ADJUSTMENT, SHIFT-ON-THE-GO, 915 AND MST-205 TRANSAXLE

XL HYDROSTATIC TRANSAXLES IDENTIFICATION

HYDRO-GEAR 0500/0750 TRANSAXLE HYDRO-GEAR 0510 TRANSAXLE INTERNAL SERVICE

TROUBLESHOOTING CHART PURGING PROCEDURES

FLUID CHANGE

HXL HYDRO TRANSAXLE REMOVAL - 2000 AND PRIOR

NEUTRAL ADJUSTMENT - HXL HYDRO2000 AND PRIOR

BRAKE ADJUSTMENT - HXL HYDRO - 2000 AND PRIOR

TRACTION DRIVE BELT REPLACEMENT ON HXL HYDRO - 2000 AND PRIOR HXL HYDRO TRANSAXLE REMOVAL - 2001 AND LATER

HXL HYDRO TRANSAXLE INSTALLATION - 2001 AND LATER

TORO XL LAWN TRACTOR SERVICE MANUAL

Table of Contents – Page 2 of 3

XL HYDROSTATIC TRANSAXLES -CONTINUED

NEUTRAL ADJUSTMENT - HXL HYDRO - 2001 AND LATER

BRAKE ADJUSTMENT - HXL HYDRO - 2001 AND LATER

TRACTION DRIVE BELT REPLACEMENT - HXL HYDRO - 2001 AND LATER

CHASSIS

FRONT AXLE REMOVAL

UPPER STEERING SHAFT REMOVAL (NO TILT STEERING)

STEERING RACK REMOVAL

STEERING ASSEMBLY

TILT STEERING

STEERING SHAFT REMOVAL (TILT STEERING)

STEERING TOWER REMOVAL

STEERING TOWER INSTALLATION

REAR BODY/FENDER ASSEMBLY REMOVAL

INSTALLATION OF THE REAR BODY

ELECTRICAL SYSTEM RELAY

PURPOSE

LOCATION HOW IT WORKS TESTING

SOLENOID PURPOSE HOW IT WORKS TESTING LOCATION

NEUTRAL SWITCH (USED ON 1999 AND PRIOR LAWN TRACTORS) PURPOSE

LOCATION HOW IT WORKS TESTING

PTO SWITCH PURPOSE LOCATION HOW IT WORKS TESTING

NEUTRAL SWITCH (USED ON 2000 AND LATER LAWN TRACTORS) PURPOSE

LOCATION HOW IT WORKS TESTING

SEAT SWITCH PURPOSE LOCATION HOW IT WORKS TEST

KEYCHOICE™ REVERSE OPERATING SYSTEM – USED ON 1999 AND LATER XL LAWN TRACTORS TESTING THE KEY CHOICE™ REVERSE OPERATING SYSTEM

CHECKING THE KEYCHOICE™ SYSTEM

TORO XL LAWN TRACTOR SERVICE MANUAL

Table of Contents – Page 3 of 3

ELECTRICAL SYSTEM - CONTINUED

KEYCHOICE™ REVERSE OPERATING SYSTEM SWITCH PURPOSE

HOW IT WORKS TESTING

REVERSE SWITCH

PURPOSE

LOCATION HOW IT WORKS TESTING

KEYCHOICE™ REVERSE OPERATING SYSTEM MODULE PURPOSE

LOCATION HOW IT WORKS TESTING

MOWER

32" MOWER

REMOVING 32" MOWER

INSTALLING 32" MOWER BLADE DRIVE BELT

REMOVING THE BLADE DRIVE BELT INSTALLING THE BLADE DRIVE BELT

SIDE-TO-SIDE MOWER LEVELING

FRONT-TO-REAR BLADE SLOPE 38" MOWER

REMOVING 38" MOWER

INSTALLING 38" MOWER BLADE DRIVE BELT

REMOVING THE BLADE DRIVE BELT INSTALLING THE BLADE DRIVE BELT

SIDE-TO-SIDE MOWER LEVELING

FRONT-TO-REAR BLADE SLOPE 44" MOWER

REMOVING 44" MOWER

INSTALLING 44" MOWER INSTALLING 44" RECYCLER BAFFLE REMOVING 44" RECYCLER BAFFLE BLADE DRIVE BELT

REMOVING THE BLADE DRIVE BELT INSTALLING THE BLADE DRIVE BELT

ADJUSTING BLADE BRAKES SIDE-TO-SIDE MOWER LEVELING FRONT-TO-REAR BLADE SLOPE

XL Lawn Tractor

PREFACE

This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to make the information in this manual complete and correct.

Basic mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual.

For additional information on the electrical system, please refer to the Toro Electrical Demystification Guide (4924404). For information specific to the engines used on this unit, refer to the appropriate engine manufacturer’s service and repair instructions.

We are hopeful that you will find 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

Consumer Service Training Department

8111 Lyndale Avenue South

Bloomington, MN 55420

The Toro Company reserves the right to change product specifications or this manual without notice.

The hydrostatic transaxle is a sophisticated piece of machinery. Maintain strict cleanliness control during all stages of service and repair. Cover or cap all hose ends and fittings whenever they are exposed. Even a small amount of dirt or other contamination can severely damage the system.

Copyright© All Rights Reserved

©2001 The Toro Company

TABLE OF CONTENTS

SPECIFICATIONS

 

 

 

 

Specifi cations . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

. . .

. 1-1

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

. . . .

1-1

Hydro-Gear Hydrostatic Transaxle Usage . . . . . . . . . . . . . . .

. . . . . .

. . . .

1-1

Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . 1-2

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

Tecumseh Peerless Transaxles . . . . . . . . . . . . . . . . . . .

. . . . . .

. . . .

1-2

1993 - 1995 . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

1-2

1996 - Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

Torque Specifi cations . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

. . .

. 1-3

Fastener Identifi cation . . . . . . . . . . . . . . . . . . . . .

. . . . . .

. . . .

1-3

Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) . . .

. . . . . .

. . . .

1-4

Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) . . . .

. . . . . .

. . .

. 1-5

Other Torque Specifi cations . . . . . . . . . . . . . . . . . . . . .

. . . . . .

. . . .

1-6

SAE Grade 8 Steel Set Screws . . . . . . . . . . . . . . . . . .

. . . . . .

. . . .

1-6

Thread Cutting Screws (Zinc Plated Steel) . . . . . . . . . . . . .

. . . . . .

. . . .

1-6

Wheel Bolts and Lug Nuts . . . . . . . . . . . . . . . . . . . .

. . . . . .

. . . .

1-6

Thread Cutting Screws (Zinc Plated Steel) . . . . . . . . . . . . .

. . . . . . . . . .

1-6

Equivalents and Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-7

Decimal and Millimeter Equivalents . . . . . . . . . . . . . . . .

. . . . . .

. . . .

1-7

U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . .

. . . . . .

. . .

. 1-7

XL GEAR DRIVE

 

 

 

 

XL Gear Drive Transaxle Removal - 915 Transaxle . . . . . . . . . . .

. . . . . .

. . .

. 2-1

XL Gear Drive Transaxle Installation - 915 Transaxle . . . . . . . . . . .

. . . . . .

. . .

. 2-4

XL Gear Drive Traction Drive Belt Replacement Procedure - 915 Transaxle . .

. . . . . .

. . . .

2-6

XL Gear Drive Shift Lever Adjustment - 915 Transaxle . . . . . . . . . .

. . . . . .

. . . .

2-9

XL Gear Drive Brake Adjustment - 915 Transaxle . . . . . . . . . . . .

. . . . . .

. . . .

2-11

XL Gear Drive MST-205 Transaxle Removal . . . . . . . . . . . . . .

. . . . . .

. . . .

2-12

XL Gear Drive MST-205 Transaxle Installation . . . . . . . . . . . . .

. . . . . .

. . . .

2-13

XL Gear Drive Shift Lever Adjustment, MST-205 Transaxle . . . . . . . .

. . . . . .

. . . .

2-14

XL Gear Drive Brake Adjustment, MST-205 Transaxle . . . . . . . . . .

. . . . . .

. . . .

2-15

Checking the Brake . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

. . . .

2-15

Adjusting the Brake . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

. . . .

2-15

XL Gear Drive Traction Drive Belt Replacement Procedure, MST-205 Transaxle

. . . . . .

. . . .

2-16

Cable Adjustment, Shift-On-The-Go, 915 and MST-205 Transaxle . . . . . .

. . . . . .

. . . .

2-19

XL HYDROSTATIC TRANSAXLES

 

 

 

 

Identifi cation . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

. . .

. 3-1

Hydro-Gear 0500/0750 Transaxle . . . . . . . . . . . . . . . . .

. . . . . .

. . . .

3-1

Hydro-Gear 0510 Transaxle . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

3-1

Internal Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

. . . .

3-2

Purging Procedures . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

. . . .

3-3

Fluid Change . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

. . . .

3-3

XL Lawn Tractor Service Manual

i

TABLE OF CONTENTS

XL HYDROSTATIC TRANSAXLES cont.

 

 

HXL Hydro Transaxle Removal - 2000 and Prior . . . . . . . . . . . . . . . . . . . . . .

3-3

Neutral Adjustmnet - HXL Hydro - 2000 and Prior . . . . . . . . . . . . . . . . . . . . . .

3-10

Brake Adjustment - HXL Hydro - 2000 and Prior . . . . . . . . . . . . . . . . . . . . . .

3-11

Traction Drive Belt Replacement on HXL Hydro - 2000 and Prior . . . . . . . . . . . . . . . .

3-13

HXL Hydro Transaxle Removal - 2001 and Later . . . . . . . . . . . . . . . . . . . . . .

3-16

HXL Hydro Transaxle Installation - 2001 and Later . . . . . . . . . . . . . . . . . . . . . .

3-18

Neutral Adjustment - HXL Hydro - 2001 and Later . . . . . . . . . . . . . . . . . . . . . .

3-20

Brake Adjustment - HXL Hydro - 2001 and Later . . . .

. . . . . . . . . . . . . . . . . . . 3-21

Traction Drive Belt Replacement - HXL Hydro - 2001 and Later . . . . . . . . . . . . . . . . .

3-22

CHASSIS

 

 

Front Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

Upper Steering Shaft Removal (No Tilt Steering) . . . . . . . . . . . . . . . . . . . . . .

4-1

Steering Rack Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2

Tilt Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3

Steering Shaft Removal (Tilt Steering) . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4

Steering Tower Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4

Steering Tower Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5

Rear Body/Fender Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6

Installation of the Rear Body . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . 4-8

Electric PTO Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A4-1

Electric PTO Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A4-2

ELECTRICAL SYSTEM

 

 

Relay . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . 5-1

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2

Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3

How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3

Neutral Switch (Used on 1999 and Prior Lawn Tractors)

. . . . . . . . . . . . . . . . . . . 5-4

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4

How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4

PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5

How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5

ii

XL Lawn Tractor Service Manual

TABLE OF CONTENTS

ELECTRICAL SYSTEM cont.

 

Neutral Switch (Used on 2000 and Later Lawn Tractors) . . . . . . . . . . . . . . . . . . .

5-5

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5

How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6

Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6

How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6

KeyChoice™ Reverse Operating System - Used on 1999 and Later XL Lawn Tractors . . . . . . . .

5-7

Testing The KeyChoice™ Reverse Operating System . . . . . . . . . . . . . . . . . . . .

5-7

Checking the KeyChoice™ System . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7

KeyChoice™ Reverse Operating System Switch . . . . . . . . . . . . . . . . . . . . . .

5-8

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8

How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8

Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9

How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9

KeyChoice™ Reverse Operating System Module . . . . . . . . . . . . . . . . . . . . . .

5-9

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10

How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10

Electric PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A5-1

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A5-1

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A5-1

How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A5-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A5-1

Electric PTO Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A5-2

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A5-2

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A5-2

How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A5-2

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A5-2

Coil Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A5-2

Measuring Clutch Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . .

A5-3

MOWER

 

32” Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

Removing 32” Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

Installing 32” Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2

Blade Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Removing the Blade Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4

Installing the Blade Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4

Side-to-Side Mower Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5

Front-to-Rear Blade Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5

XL Lawn Tractor Service Manual

iii

TABLE OF CONTENTS

MOWER cont.

 

 

38” Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

6-7

Removing 38” Mower . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

6-7

Installing 38” Mower . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

6-10

Blade Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . 6-12

Removing the Blade Drive Belt . . . . . . . . . . . . . . . . . . . .

. . . . . .

6-12

Installing the Blade Drive Belt . . . . . . . . . . . . . . . . . . . . .

. . . . . .

6-12

Side-to-Side Mower Leveling . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

6-12

Front-to-Rear Blade Slope . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

6-13

44” Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

6-15

Removing 44” Mower . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

6-15

Installing 44” Mower . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

6-17

Installing 44” Recycler Baffl e . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

6-20

Removing 44” Recycler Baffl e . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

6-21

Blade Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Removing the Blade Drive Belt . . . . . . . . . . . . . . . . . . . .

. . . . . .

6-21

Installing the Blade Drive Belt . . . . . . . . . . . . . . . . . . . . .

. . . . . .

6-21

Adjusting Blade Brakes . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

6-22

Side-to-Side Mower Levleing . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

6-22

Front-to-Rear Blade Slope . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

6-23

32” Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

A6-1

32” Mower Brake Adjustment . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

A6-1

38” Mower with Manual PTO Clutch . . . . . . . . . . . . . . . . . . . . .

. . . . . .

A6-1

38” Mower Brake Adjustment . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

A6-1

44” Mower with Manual PTO Clutch . . . . . . . . . . . . . . . . . . . . .

. . . . . .

A6-2

44” Mower Brake Adjustment . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

A6-2

38” Mower with Electric PTO Clutch . . . . . . . . . . . . . . . . . . . . .

. . . . . .

A6-2

Removing 38” Mower with Electric PTO Clutch . . . . . . . . . . . . . . .

. . . . . .

A6-2

Installing 38” Mower with Electric PTO Clutch . . . . . . . . . . . . . . . .

. . . . . .

A6-4

Replacing the Blade Drive Belt . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

A6-7

Removing the Blade Drive Belt, 38” Mower with Electric PTO Clutch . . . . . . .

. . . . . . A6-7

Installing the Blade Drive Belt, 38” Mower with Electric PTO Clutch . . . . . . . .

. . . . . . A6-7

Leveling 38” Mower from Side-to-Side . . . . . . . . . . . . . . . . . . . .

. . . . . .

A6-7

Adjusting 38” Mower Front-to-Rear Blade Slope . . . . . . . . . . . . . . . . .

. . . . . .

A6-9

44” Mower with Electric PTO Clutch . . . . . . . . . . . . . . . . . . . . .

. . . . . .

A6-10

Removing 44” Mower with Electric PTO Clutch . . . . . . . . . . . . . . .

. . . . . .

A6-10

Installing 44” Mower with Electric PTO Clutch . . . . . . . . . . . . . . . .

. . . . . .

A6-12

Replacing the Blade Drive Belt, 44” Mower with Electric PTO Clutch . . . . . . . . .

. . . . . .

A6-15

Removing the Blade Drive Belt, 44” Mower with Electric PTO Clutch . . . . . . .

. . . . . . A6-15

Installing the Blade Drive Belt, 44” Mower with Electric PTO Clutch . . . . . . . .

. . . . . . A6-16

Leveling 44” Mower from Side-to-Side . . . . . . . . . . . . . . . . . . . .

. . . . . .

A6-16

Adjusting 44” Mower Front-to-Rear Blade Slope . . . . . . . . . . . . . . . . .

. . . . . .

A6-17

iv

XL Lawn Tractor Service Manual

 

 

 

 

 

 

 

 

 

 

SPECIFICATIONS

 

Specifications

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Engines

 

 

 

 

 

Fuel

 

 

Steering

 

 

 

 

 

 

 

 

 

 

Capacity

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

All tractors since 1993 were manufactured with Briggs & Stratton engines

 

7 qts (6.65l)

Sector and Pinion

 

ranging from 10 to 17 Horsepower. For more information on servicing the

 

 

 

 

 

 

 

 

engines, please contact Briggs & Stratton.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Dimensions

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

32” (81.3cm) XL

 

38” (96.5cm) XL and HXL

 

44” (111.8cm) HXL

 

 

 

 

 

Lawn Tractors

 

Lawn Tractors

 

 

 

 

Lawn Tractors

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Wheel Base:

 

 

48.5” (123.2cm)

 

47” (119.4cm)

 

 

 

 

47.5” (120.7cm)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Length:

 

 

 

66.5” (168.9cm)

 

66.5” (168.9cm)

 

 

 

 

 

68” (172.7cm)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Height:

 

 

 

39.3” (99.8cm)

 

 

40” (101.6cm)

 

 

 

 

 

42” (106.7cm)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Width (includes mower):

 

39.3” (99.8cm)

 

 

45” (114.3cm)

 

 

 

 

 

55” (139.7cm)

 

 

 

 

 

 

 

 

 

 

 

Weight:

 

 

 

375 lbs. Net (168.9kg)

 

412 lbs. Net (185.6kg)

 

468 lbs. Net (210.8kg)

 

 

 

 

 

 

 

 

 

 

 

Hydro-Gear Hydrostatic Transaxle Usage

 

 

 

 

 

 

 

Year

12-38 XHL - 16-38 HXL

 

15-44 XHL, 16-44HXL,

 

16-38 HXL and 17-44 HXL

 

 

 

and 17-44 HXL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1993

 

316-0500

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1994

 

316-0500

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1995

 

321-0500

 

 

 

316-0750

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1996

 

323-0500

 

 

 

316-0750

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1997

 

323-0500

 

 

 

326-0750

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1998

 

323-0500

 

 

 

326-0750

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1999

 

323-0500

 

 

 

326-0750

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2000

 

323-0500

 

 

 

326-0750

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2001

 

 

 

 

 

 

 

 

 

 

 

 

 

318-0510

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

XL Lawn Tractor Service Manual

1 - 1

SPECIFICATIONS

Turning Radius

Model

Turning Radius

 

 

 

 

32” (81.3cm) XL

21.5” (54.6cm) - Left

 

22” (55.8cm) - Right

 

 

38” (96.5cm) HXL and XL

20” (50.8cm) - Left

 

22” (55.8cm)- Right

 

 

44” (111.8cm) HXL

20” (50.8cm) - Left

 

22” (55.8cm) - Right

 

 

Electrical System

Engine

Battery

 

 

 

 

3 amp unregulated / 80 watt A.C. Alternator

12 volt - 160 CCA

 

 

Tecumseh Peerless Transaxles

1993 - 1995 1996 - Present

 

 

 

mvc-667

 

mvc-668

Tecumseh Peerless

 

Tecumseh Peerless

Model: 915-020

 

Model: MST-205

Lubrication: Bentonite grease (available through

 

Lubrication: 80W90 gear lube

Tecumseh)

 

 

NOTE: Tractor may have been converted to current MST-205 transaxle.

For further information on servicing Peerless transaxles, contact Tecumseh Products.

1 - 2

XL Lawn Tractor Service Manual

SPECIFICATIONS

Torque Specifications

Fastener Identification

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

These torque specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in the service manual. The following factors shall be considered when applying torque: cleanliness of the fastener, use of a thread sealant (Loctite), degree of lubrication on the fastener, presence of a prevailing torque feature, hardness of the surface underneath of the fastener’s head, or similar condition which affects the installation.

As noted in the following tables, torque values should be reduced by 25% for lubricated fasteners to achieve the similar stress as a dry fastener. Torque values may also have to be reduced when the fastener is threaded into aluminum or brass. The specific torque value should be determined based on the aluminum or brass material strength, fastener size, length of thread engagement, etc.

The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut) and mating part, then back off fastener 1/4 of a turn. Measure the torque required to tighten the fastener until the lines match up.

 

 

 

 

Figure 1

 

Inch Series Bolts and Screws

 

 

 

(A) Grade 1

 

(C) Grade 8

(B) Grade 5

 

 

 

 

 

Figure 2

Metric Bolts and Screws

(A) Class 8.8

(B) Class 10.9

 

 

XL Lawn Tractor Service Manual

1 - 3

SPECIFICATIONS

Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)

 

Grade 1, 5, &

SAE Grade 1 Bolts, Screws,

SAE Grade 5 Bolts, Screws,

SAE Grade 8 Bolts, Screws,

Thread Size

8 with Thin

Studs, & Sems with Regular

Studs, & Sems with Regular

Studs, & Sems with Regular

Height Nuts

Height Nuts (SAE J995 Grade

Height Nuts (SAE J995 Grade

Height Nuts (SAE J995 Grade

 

 

 

 

2 or Stronger Nuts)

2 or Stronger Nuts)

 

2 or Stronger Nuts)

 

 

 

 

 

 

 

 

 

 

 

In-lb

In-lb

N-cm

In-lb

N-cm

In-lb

N-cm

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

# 6 - 32 UNC

10

± 2

13

± 2

147

± 23

 

15

± 2

170

±

20

23

± 2

260

±

20

 

 

 

 

 

 

 

 

 

 

 

 

# 6 - 40 UNF

 

17

± 2

190

±

20

25

± 2

280

±

20

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

# 8 - 32 UNC

13

± 2

25

± 5

282

± 30

 

29

± 3

330

±

30

41

± 4

460

±

45

 

 

 

 

 

 

 

 

 

 

 

 

# 8 - 36 UNF

 

31 ± 3

350 ± 30

43

± 4

31 ± 3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

# 10 - 24 UNC

18

± 2

30

± 5

339

± 56

 

42

± 4

475

±

45

60

± 6

674

± 70

 

 

 

 

 

 

 

 

 

 

 

 

#10 - 32 UNF

 

48

± 4

540

±

45

68

± 6

765

± 70

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1/4 - 20 UNC

48

± 7

53

± 7

599

± 79

 

100

± 10

1125 ± 100

140

± 15

1580

± 170

 

 

 

 

 

 

 

 

 

 

 

 

 

1/4 - 28 UNF

53

± 7

65 ± 10

734 ± 113

 

115 ± 10

1300

± 100

160

± 15

1800

± 170

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5/16 - 18 UNC

115 ± 15

105

± 17

1186

± 169

 

200

± 25

2250

± 280

300

± 30

3390

± 340

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5/16 - 24 UNF

138

± 17

128

± 17

1446

± 192

 

225

± 25

2540

± 280

325

± 30

3670

± 340

 

 

 

 

 

 

 

 

 

ft-lb

ft-lb

N-m

ft-lb

N-m

ft-lb

N-m

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3/8 - 16 UNC

16

± 2

16

± 2

22

± 3

 

30

± 3

41

± 4

43

± 4

58

± 5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3/8 - 24 UNF

17

± 2

18

± 2

24

± 3

 

35

± 3

47

± 4

50

± 4

68

± 5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7/16 - 14 UNC

27

± 3

27

± 3

37

± 4

 

50

± 5

68

± 7

70

± 7

68

± 9

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7/16 - 20 UNF

29

± 3

29

± 3

39

± 4

 

55

± 5

75

± 7

77

± 7

104 ± 9

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1/2 - 13 UNC

30

± 3

48

± 7

65

± 9

 

75

± 8

102 ± 11

105

± 10

142

± 14

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1/2 - 20 UNF

32

± 3

53

± 7

72

± 9

 

85

± 8

115

± 11

120

± 10

163

± 14

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5/8 - 11 UNC

65 ± 10

88 ± 12

119

± 16

 

150

± 15

203

± 20

210

± 20

285

± 27

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5/8 - 18 UNF

75 ± 10

95 ± 15

129

± 20

 

170

± 15

230

± 20

240

± 20

325

± 27

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3/4 - 10 UNC

93 ± 12

140

± 20

190

± 27

 

265

± 25

359

± 34

374

± 35

508

± 47

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3/4 - 16 UNF

115 ± 15

165

± 25

224

± 34

 

300

± 25

407

± 34

420

± 35

569

± 47

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7/8 - 9 UNC

140

± 20

225

± 25

305

± 34

 

430

± 45

583

± 61

600

± 60

813

± 81

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7/8 - 14 UNF

155

± 25

260

± 30

353

± 41

 

475

± 45

644

± 61

660

± 60

895

± 81

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Note: Reduce torque values listed in the table above by 25% for lubricated fasteners. Lubricated fasteners are defined as threads coated with a lubricant such as oil, graphite, or thread sealant such as Loctite.

Note: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc.

Note: The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is approximately ± 10% of the nominal torque value. Thin height nuts include jam nuts.

1 - 4

XL Lawn Tractor Service Manual

SPECIFICATIONS

Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners)

 

 

Class 8.8 Bolts, Screws, and Studs with

Class 10.9 Bolts, Screws, and Studs with

Thread Size

 

Regular Height Nuts

 

 

Regular Height Nuts (

 

 

 

(Class 8 or Strong Nuts)

 

Class 10 or Strong Nuts)

M5

X 0.8

57 ± 5 in-lb

640 ± 60 N-cm

78 ± 7 in-lb

885 ± 80 N-cm

 

 

 

 

 

 

M6

X 1.0

96 ± 9 in-lb

1018 ± 100 N-cm

133 ± 13 in-lb

1500 ± 150 N-cm

 

 

 

 

 

 

 

 

 

 

M8 X 1.25

19

± 2 ft-lb

26

±

3 N-m

27

± 2 ft-lb

36

± 3 N-m

 

 

 

 

 

 

 

 

 

 

M10 X 1.5

38

± 4 ft-lb

52

±

5 N-m

53

± 5 ft-lb

72

± 7 N-m

 

 

 

 

 

 

 

 

 

M12

X 1.75

66

± 7 ft-lb

90 ± 10 N-m

92

± 9 ft-lb

125

± 12 N-m

 

 

 

 

 

 

 

 

 

 

M16 X 2.0

166

± 15 ft-lb

225

±

20 N-m

229

± 22 ft-lb

310

± 30 N-m

 

 

 

 

 

 

 

 

 

 

M20 X 2.5

325

± 33 ft-lb

440

±

45 N-m

450

± 37 ft-lb

610

± 50 N-m

 

 

 

 

 

 

 

 

 

 

 

Note: Reduce torque values listed in the table above by 25% for lubricated fasteners. Lubricated fasteners are defined as threads coated with a lubricant such as oil, graphite, or thread sealant such as Loctite.

Note: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc.

Note: The nominal torque values listed above are based on 75% of the minimum proof load specified in SAE J1199. The tolerance is approximately ± 10% of the nominal torque value. Thin height nuts include jam nuts.

XL Lawn Tractor Service Manual

1 - 5

SPECIFICATIONS

Other Torque Specifications

SAE Grade 8 Steel Set Screws

Thread Size

Recommended Torque

 

 

Square Head

Hex Socket

 

 

 

 

1/4 - 20 UNC

140 ± 20 in-lb

73 ± 12 in-lb

 

 

 

5/16 - 18 UNC

215 ± 35 in-lb

145 ± 20 in-lb

 

 

 

3/8 - 16 UNC

35 ± 10 ft-lb

18 ± 3 ft-lb

 

 

 

1/2 - 13 UNC

75 ± 15 ft-lb

50 ± 10 ft-lb

 

 

 

Wheel Bolts and Lug Nuts

Thread Size

Recommended Torque**

 

 

 

7/16 - 20 UNF

65 ± 10 ft-lb

88 ± 14 N-m

Grade 5

 

 

 

 

 

1/2 - 20 UNF

80 ± 10 ft-lb

108 ± 14 N-m

Grade 5

 

 

 

 

 

M12 X 1.25

80 ± 10 ft-lb

108 ± 14 N-m

Class 8.8

 

 

 

 

 

M12 X 1.5

80 ± 10 ft-lb

108 ± 14 N-m

Class 8.8

 

 

 

 

 

** For steel wheels

and non-lubricated

fasteners.

Thread Cutting Screws

(Zinc Plated Steel)

Type 1, Type 23, or Type F

Thread Size

Baseline Torque*

 

 

 

No. 6 - 32 UNC

20

± 5 in-lb

 

 

 

No. 8 - 32 UNC

30

± 5 in-lb

 

 

 

No.10 - 24 UNC

38

± 7 in-lb

 

 

1/4 - 20 UNC

85 ± 15 in-lb

 

 

 

5/16 - 18 UNC

110

± 20 in-lb

 

 

3/8 - 16 UNC

200 ± 100 in-lb

 

 

 

Conversion Factors

in-lb X 11.2985 - N-cm

ft-lb X 1.3558 = N-m

Thread Cutting Screws

(Zinc Plated Steel)

Thread

Threads per Inch

Baseline Torque*

 

 

Size

 

 

Type A

Type B

 

 

 

 

 

 

 

No. 6

18

20

20 ± 5 in-lb

 

 

 

 

No. 8

15

18

30 ± 5 in-lb

 

 

 

 

No. 10

12

16

38 ± 7 in-lb

 

 

 

 

No. 12

11

14

85 ± 15 in-lb

* Hole size, material strength, material thickness and finish must be considered when determining specific torque values. All torque values are based on nonlubricated fasteners.

N-cm X - 0.08851 = in-lb

N-cm X 0.73776 - ft-lb

1 - 6

XL Lawn Tractor Service Manual

Toro 71140, 71180, 71181, 71182, 71184 Service Manual

SPECIFICATIONS

Equivalents and Conversions

XL Lawn Tractor Service Manual

1 - 7

THIS PAGE INTENTIONALLY LEFT BLANK

1 - 8

XL Lawn Tractor Service Manual

XL GEAR DRIVE

XL Gear Drive Transaxle Removal -

915 Transaxle

1.Disconnect battery cables and remove the battery and battery tray. Remove the mower deck (refer to “Mower” section on page 6 - 1).

2.Raise the rear of the tractor and remove the right and left rear tires. Put jack-stands under the frame, just in front of the transaxle (Figure 3).

 

 

Figure 3

mvc-794

3.Remove the rear hitch panel. There are 2 bolts and nuts holding the seat springs and 2 bolts and nuts on each side of the rear panel (Figure 4).

 

 

Figure 4

mvc-795

4.Loosen the left transaxle belt guide and move it away from the belt. The right transaxle belt guide needs to be removed (Figure 5).

 

 

Figure 5

mvc-796

5.Unhook the idler spring from the idler assembly (Figure 6).

 

 

Figure 6

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6.Remove the nut on the shift tie rod (Figure 7).

 

 

Figure 7

mvc-800

7.Remove the bolt and nut on the left side shift pivot clamp and slide the shift pivot rod so you can remove the shift tie rod (Figure 8).

8.Remove the nut and washer holding the left side torque strap leaving the torque strap bolted to the frame (Figure 9).

 

 

Figure 9

mvc-803

9.Remove both the top and bottom washer and nut from the right side torque strap (Figure 10).

 

 

Figure 8

mvc-802

Figure 10

mvc-806

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10. Remove the brake return spring (Figure 11).

 

 

Figure 11

mvc-808

11.Unhook the brake spring from the clutch/brake rod (Figure 12).

A

B

 

Figure 12

iso3

 

 

 

(A) Spring

(B) Clutch/brake rod

 

 

 

 

12.Before removing the 4 transaxle bolts, put a floor jack under the transaxle so you can lower it from the frame. Remove the 4 bolts, washers, and nuts (Figure 13).

 

 

Figure 13

mvc-810

13.Lower the transaxle slightly so you can free it from the two front torque straps. Unhook the brake spring from the transaxle brake arm (Figure 14).

 

 

Figure 14

mvc-811

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14.The transaxle should be free from the frame now (Figure 15).

 

 

Figure 15

mvc-813

XL Gear Drive Transaxle Installation

- 915 Transaxle

1.Raise the transaxle to the frame making sure the brake lever fits through the slot in the frame. Reinstall the brake spring on the brake lever (Figure 14 and Figure 16).

 

 

Figure 16

mvc-814

2.Install the right and left torque straps to the frame and the transaxle, do not tighten. Install the 4 axle bolts, washers, and nuts and tighten first. Then tighten the torque straps (Figure 17).

 

 

Figure 17

mvc-816

3.Install the left side shift pivot clamp on the shift pivot rod before securing the clamp to the frame. Make sure the shift tie rod is reinstalled in the hole in the shift pivot rod. Tighten the shift pivot clamp and the shift tie rod (Figure 18).

 

 

Figure 18

mvc-817

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4.Install brake spring to the clutch/brake rod (Figure 19).

A

B

 

Figure 19

iso3

 

 

 

(A) Spring

(B) Clutch/brake rod

 

 

 

 

5.Install belt around the transaxle pulley. Reinstall the idler spring to the idler assembly (Figure 20).

 

 

Figure 20

mvc-798

6.Install the right and left belt guides and adjust so they are within 1/8” (3mm) of the transaxle pulley and drive belt (Figure 21). Note direction of belt guide installation, right hand points forward, left hand points rearward.

1/8” (3mm)

1/8” (3mm)

Figure 21

mvc-818

7.Connect the brake return spring to the brake lever (Figure 22).

 

 

Figure 22

mvc-819

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8.Install the rear hitch panel. There are two bolts, washers, and nuts on each side of the plate and 2 bolts, washers, and nuts for the seat springs (Figure 23).

 

 

Figure 23

mvc-795

9.Install the right and left rear tires. Install the battery and battery box. Note: Make sure the battery drain tube is installed through the rear hole of the frame (Figure 24; rear hitch panel removed for clarity).

 

 

Figure 24

mvc-639

10.Check the following items:

A.The Shift-On-The-Go for proper adjustment. If adjustment is needed, (refer to “Cable Adjustment, Shift-On-The-Go, 915 and MST205 Transaxle” on page 2 - 19).

B.Brake Adjustment. If adjustment is needed, (refer to “XL Gear Drive Brake Adjustment -915 Transaxle” on page 2 - 11).

C.Shift Lever Adjustment. If adjustment is needed, (Refer to “XL Gear Drive Shift Lever Adjustment - 915 Transaxle” on page 2 - 9).

11.Install mower deck; see instructions in the Mower section.

12.Check all safety switches to make sure they are operating properly.

XL Gear Drive Traction Drive Belt

Replacement Procedure - 915

Transaxle

1.Disconnect battery and remove battery and battery tray. Remove mower deck. (Refer to Mower section.)

2.Remove the rear hitch panel. There are 2 bolts and nuts holding the seat springs and 2 bolts and nuts on each side of the rear panel (Figure 25).

 

 

Figure 25

mvc-795

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3.Loosen and move the right and left engine belt guides (Figure 26).

5.Remove the idler spring on the idler assembly. Remove the idler pulley and belt guide (Figure 28). Remove the drive belt.

 

 

Figure 26

mvc-821

4.Loosen the left side transaxle belt guide. Remove the right side transaxle belt guide (Figure 27).

 

 

Figure 28

mvc-824

6.Install new belt around the engine drive pulley (Figure 29).

 

 

Figure 27

mvc-796

Figure 29

mvc-825

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7.Route belt back over the pedal pivot rod, the idler pivot bracket, and around the transaxle pulley (Figure 30).

9.Hook the idler spring to the idler bracket (Figure 32).

 

 

Figure 30

mvc-826

8.Install the idler pulley to the idler bracket. Note the correct hole location of the bolt and nut retaining the pulley and belt guide bracket (Figure 31).

 

 

Figure 32

mvc-829

10.Install the right side belt guide and adjust to within 1/8” (3mm) of the transaxle pulley and belt. Adjust and tighten the left belt guide so it is within 1/8” (3mm) of the transaxle pulley and belt (Figure 21 and Figure 33).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 31

mvc-828

 

 

 

1/8” (3mm)

Figure 33

mvc-796

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11. Recheck the routing of the belt (Figure 34).

 

 

Figure 34

mvc-833

12.Install the mower deck. (Refer to Mower Deck section). Make sure the engine belt guides are adjusted so they are within 1/8” (3mm) of both the engine and mower drive pulley.

13.Install battery and battery tray making sure the battery drain tube is installed in the rear hole of the frame (Figure 35). Install the rear hitch panel (Figure 25).

 

 

Figure 35

mvc-639

14.Check the following:

A.The Shift-On-The-Go for proper adjustment. If adjustment is needed, (refer to “Cable Adjustment, Shift-On-The-Go, 915 and MST205 Transaxle” on page 2 - 19).

B.Brake Adjustment. If adjustment is needed, (refer to “XL Gear Drive Brake Adjustment -915 Transaxle” on page 2 - 11).

C.Shift Lever Adjustment. If adjustment is needed, (refer to “XL Gear Drive Shift Lever Adjustment - 915 Transaxle” on page 2 - 9).

15.Check all safety switches to make sure they are operating properly.

XL Gear Drive Shift Lever

Adjustment - 915 Transaxle

It is VERY important the shift lever is properly aligned with the shift gates.

If the gear shift lever and shift gates do not properly align, you may encounter the following symptoms:

1.No reverse.

2.No fifth gear.

3.Jumping out of gear.

If the misalignment is ignored for a period of time, severe transaxle damage will result.

Adjust using the following procedure:

1.Disconnect the battery cables and remove the battery and battery tray.

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2.Remove the rear hitch panel by removing the two bolts and nuts holding the seat springs and two bolts and nuts located on each side of the hitch panel. Loosen the fastener securing the front cable guide to remove tension from the shift cable (Figure 36).

4.Shift the transaxle through each gear to verify the gear shift lever centers in each gate as the internal transaxle detents are felt. The lever should also “detent” into 5th gear and reverse (Figure 38). That is, the shift lever should not contact the side of the metal “fingers” of each gate as the lever enters the gate.

 

 

Figure 36

mvc-834

3.Remove the rubber shift gate cover (Figure 37).

 

 

Figure 37

mvc-835

 

 

Figure 38

mvc-836

5.If the shifter does not align with the gates, loosen the bolt and nut between the shift pivot and the shift pivot lever and adjust (Figure 39).

 

 

Figure 39

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6.If the shifter still does not go into 5th gear, loosen the jam nut on the tie rod end of the shift arm and remove the nut. Rotate the tie rod end until the gear shift lever is centered in the 5th gear gate. Place the shift arm on the gear selector shaft and verify that neutral, reverse, and fifth gears properly align. Reinstall the shift arm fastener and tighten the jam nut (Figure 40).

XL Gear Drive Brake Adjustment -

915 Transaxle

The brake is located on the right side of the rear axle, inside the rear tire. If the brake does not hold securely or stopping power is insufficient, an adjustment is required (Figure 41).

 

 

 

 

 

 

 

Figure 40

HL11014

 

 

 

 

 

 

(1) Jam Nut

(3) Shift Arm

 

 

(2)Fastener

7.Reassembly:

A.Ensure the transaxle and engine pulley belt guides are positioned 1/8” (3mm) away from the drive belt.

B.Adjust the transaxle shift cable (refer to “Cable Adjustment, Shift-On-The-Go, 915 and MST205 Transaxle” on page 2 - 19.)

C.Reinstall the shift gate cover, rear hitch panel, battery, and battery tray. Note: Make sure the battery drain tube is installed in rear hole of the frame (Figure 35). Reconnect the battery cables.

D.Test drive the tractor and verify all adjustments and safety switches are operating properly.

 

 

Figure 41

mvc-847

1.Park the machine on a level surface, disengage the blade control (PTO), shift into neutral, set the parking brake, and turn the ignition key to “OFF” to stop the engine.

2.If the rear wheels lock and skid when you push the tractor forward, no adjustment is required. An adjustment is required if the wheels turn and do not lock.

3.To increase braking resistance, tighten the brake adjusting nut (Figure 41) 1/8 turn clockwise; then check the brake again. Continue this adjusting and checking process until the brake is set properly.

If the brake system does not respond to adjustment, the brake pads and possibly the brake disc, require replacement.

4.Push down on the clutch/brake pedal to release the parking brake.

IMPORTANT: With the parking brake released, the rear wheels must rotate freely when you push the tractor. If the brake seems to “drag”, loosen the adjusting nut slightly until the wheels rotate freely.

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XL Gear Drive MST-205 Transaxle

Removal

1.Disconnect battery cables and remove battery and battery tray. Remove mower deck (refer to “Mower” section on page 6 - 1). Lift the rear of the tractor and remove both the right and left rear tires (Figure 42).

 

 

Figure 42

mvc-0001

2.Remove the rear hitch panel, removing the two bolts and nuts holding the seat springs and two bolts and nuts located on each side of the hitch panel (Figure 43).

 

 

Figure 43

mvc-0037

3.Remove the right and left transaxle belt guides. Put the park brake on and then slip the traction drive belt off the transaxle pulley (Figure 44).

A

Figure 44

mvc-0002

(A)Belt Guides

4.Release the park brake and disconnect the brake spring (A) at the idler arm assembly. Remove the brake return spring (B) (Figure 45).

A

B

 

Figure 45

mvc-0005

 

 

(A) Brake Spring

(B) Brake Return Spring

 

 

 

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5.Disconnect the shift link at the transaxle shift lever (Figure 46).

 

 

Figure 46

mvc-0003

6.Use a floor jack to support and lower the transaxle from the frame. Unbolt and remove the two torque strap bolts located in the front of the transaxle.

Remove the 4 axle bolts holding the transaxle to the frame (Figure 47).

 

 

Figure 47

mvc-0004

XL Gear Drive MST-205 Transaxle

Installation

1.Raise the transaxle up to the frame and install the 4 axle bolts and 2 torque strap bolts. Tighten all 6 bolts (Figure 48).

A

Figure 48

mvc-0011

(A)Torque Straps

2.Connect the brake spring between the clutch/ brake rod and the transaxle brake lever. Install the brake return spring, located between the transaxle brake lever and the axle frame bracket.

A

B

 

Figure 49

mvc-0005

 

 

(A) Brake Spring

(B) Brake Return Spring

 

 

 

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