Toro 98-9240, 98-9230 Installation Instructions
FORM NO. 3321–190
GTS 200 CONVERSION KIT
For ProLine BBC Mowers Model Year 1992 and Up and
For ProLine Zone Start Mowers Model Year 1995 and Up
PART NO. 98–9230
PART NO. 98–9240
Loose Parts
Note: Use the chart below to identify parts used for assembly.
DESCRIPTION QTY. USE
Discharge Chute
Latch Plate
Discharge Door Assembly
Door Retainer
Self-tapping Screw – 1/4-10 x .60
Screw – 3/8-16 x 1.5 3
Engine Decal – 98-2002 1 Replace old engine
ProLine Decal – 84-4960 1
Casing Clamp 1 Install on engine
1
1
1
1
2
Install new discharge chute and door assembly
INSTALLATION
INSTRUCTIONS
Clamp Screw 1
Throttle Control
Throttle Cable
E-Ring
Primer Guard 1 Install on right front quadrant
Cable Tie (Zone Start models only) 2 Fasten cables to lower handle
Cable Tie (BBC models only) 3
Rope Stop 1 Install on recoil rope
Traction Control Decal (Self-propelled zone
start models only)
Control Panel Decal (BBC models only) 1 Replace old decal
Control Bar (BBC models only) 1 Replace old control bar
Printed in USA
The Toro Company – 1998
All Rights Reserved
1
1
2
1 Replace old decal
Replace old throttle cable
Installation
DESCRIPTION USEQTY.
Rope Guide (BBC models only) 1
Curved Washer (BBC models only) 1 Install new rope guide
Hex Head Screw – 1/4-20 x 1.5 (BBC models
only)
Hex Lock Nut (BBC models only) 1
Before Installing
POTENTIAL HAZARD
• If you leave the wire on the spark plug,
someone could accidentally start the engine.
WHAT CAN HAPPEN
• Accidental starting of engine could
seriously injure you or other bystanders.
HOW TO AVOID THE HAZARD
• Pull wire off spark plug before you install
kit. Also push wire aside so it does not
accidentally contact spark plug.
1. Disconnect spark plug wire from spark plug.
1
3. Reconnect spark plug wire.
4. Even though the gasoline has been drained from
the engine, enough fuel should be left in the
carburetor bowl and fuel line to start the engine.
Start the engine and let it run until it runs out of
fuel. Briefly running engine will warm up the
oil.
5. Disconnect spark plug wire from spark plug.
6. Drain oil from engine. Refer to your operator’s
manual for proper oil draining procedure.
Disassemble Old Components
Remove Starter Rope
1. Zone Start Models Only – Remove starter rope
from rope guide (Fig. 1).
POTENTIAL HAZARD
• If gasoline is spilled on a hot engine, it
could ignite.
WHAT CAN HAPPEN
• Contact with burning gasoline could cause
serious personal injury.
HOW TO AVOID THE HAZARD
• Drain gasoline from a cold engine only.
2. Make sure engine is cool. Remove cap from fuel
tank and use a pump-type syphon to drain fuel
into a clean gas can.
Note: This is the only procedure
recommended for draining fuel.
EN–2
1
2
m–2705
Figure 1
1. Rope guide 2. Starter rope
Installation
Remove Cable Ties
1. Cut cable ties holding cables to lower handle.
Remove Gas Tank
1. Disconnect fuel line from engine (Fig. 2).
2. Remove gas tank from tank bracket (Fig. 2).
Carefully set tank aside.
4
2
3
Figure 3
1. Belt cover 2. Self-tapping screw (2)
2. Loosen cable clamp screw and disconnect
throttle cable from throttle lever (Fig. 4).
m-224
1
Figure 2
1. Fuel line clamp
2. Fuel line
3. Tank bracket
4. Gas tank
Disconnect Throttle Cable
1. Remove (2) self-tapping screws securing belt
cover to deck (Fig. 3). Set cover and fasteners
aside for reinstallation.
1. Cable clamp screw
2. Throttle cable
Figure 4
3. Throttle lever
m-286
EN–3
Installation
Disconnect Brake Cable
(Zone Start Models Only)
1. Disconnect brake cable from brake arm (Fig. 5).
2. Using a pliers, squeeze tabs on top and bottom
of brake cable fitting, and slide brake cable out
of brake assembly (Fig. 5).
4
1 3
2
Figure 5
1. Brake cable
2. Brake arm
3. Brake cable fitting
4. Brake assembly
7
6
4
3
2
1
1. Blade bolt
2. Lock washer
3. Blade stiffener/accelerator
4. Blade
5. Blade retainer
6. Spacer
11
10
9
8
5
Figure 6
7. Square key
8. Self-tapping screw (3)
9. Internal lock washer (3)
10. Crankshaft protector
11. Engine drive pulley
(self-propelled model only)
Remove Blade Assembly
Zone Start Models
1. Remove blade bolt, lock washer, blade
stiffener/accelerator, blade, blade retainer, spacer,
square key and crankshaft protector (Fig. 6).
To remove the crankshaft protector, remove (3)
self-tapping screws and (3) internal lock
washers. Retain all of these items for
reinstallation.
EN–4
BBC Models
1. Remove (2) blade nuts, anti-scalp cup, blade
stiffener/accelerator, blade, lock nut and blade
spacer. Then loosen tabs securing BBC shield to
housing by loosening nuts or bolts on tabs.
Rotate tabs 180_ out of the way. Remove BBC
shield, hub assembly, brake drum, (2) blade
bolts, flywheel, pulley driver and woodruff key
(Fig. 7). Retain all of these items for
reinstallation.
15
Installation
1
16
14
13
8
9
11
8
7
4
5
3
2
1
1. Blade nut (2)
2. Anti-scalp cup
3. Blade stiffener/accelerator
4. Blade
5. Lock nut
6. Blade spacer
7. Lock nut (2)
8. Tab (3)
Figure 7
12
6
9. Screw
10. BBC shield
11. Hub assembly
12. Brake drum
13. Blade bolt (2)
14. Flywheel
15. Pulley driver
16. Woodruff key
10
8
2
7
Figure 8
1. Engine 2. Engine screw (3)
Remove Discharge Tunnel Assembly
(Fig. 9)
1. Remove (2) capscrews, (2) flat washers, (2) lock
nuts, 1/2” hex head washer screw and 3/4” hex
head washer screw securing discharge tunnel
assembly to housing. Retain all of these items
for reinstallation.
2. Lift off discharge tunnel assembly.
3. Remove spring bracket and spring extension.
Retain these items for reinstallation.
Remove Old Engine
1. Remove three (3) engine screws and carefully
lift engine off housing (Fig. 8). Discard screws
and engine.
4. Remove (2) self-tapping screws and latch plate
from old tunnel and discard them.
5. Remove door retainer and discharge door
assembly and discard them.
EN–5
Installation
11
8
1
5
1. Discharge tunnel
2. Capscrew (2)
3. Flat washer (2)
4. Lock nut (2)
5. Hex head washer screw
(1/2” long)
6. Hex head washer screw
(3/4” long)
6
Figure 9
12
9
10
2
3
7
4
7. Spring bracket
8. Spring extension
9. Latch plate
10. Self-tapping screw (2)
11. Door retainer
12. Discharge door assembly
3. Install new discharge door assembly and secure
with new door retainer.
4. Install new latch plate to tunnel using (2) new
self-tapping screws.
5. Hook one end of spring extension through hole
on spring bracket and the other end onto the
discharge door handle.
6. Open and close discharge door to ensure that
discharge tunnel door closes when handle is
released.
Install New Engine
1. Carefully set new engine onto housing.
2. Install and tighten (3) new engine screws
(Fig. 10). Torque the engine screws to 250-400
in-lbs (28-45 NSm).
1
6. Discard discharge tunnel.
Install Conversion Kit
Install New Discharge Tunnel (Fig. 9)
1. Position new discharge tunnel on deck. Align
holes in discharge tunnel with holes in deck.
2. Fasten rear-left and rear-rights corners of tunnel
to deck using (2) capscrews, (2) flat washers and
(2) lock nuts previously removed. Fasten
front-right side of tunnel to deck using 1/2” hex
head washer screw previously removed. Fasten
front-left corner of tunnel and spring bracket to
deck using 3/4” hex head washer screw
previously removed.
EN–6
2
Figure 10
1. Engine 2. Engine screw (3)
Installation
Reinstall Blade Assembly
Reinstall blade assembly in reverse order of
disassembly. Refer to Remove Blade Assembly
procedures.
Zone Start Models - When reinstalling crankshaft
protector, install but do not tighten mounting screws.
Insert a shim (a business card works well) between
protector and hub on blade retainer which helps
center protector. Tighten mounting screws and
remove shim. Continue installing blade assembly.
Torque blade bolt to 50 ft.-lbs. (68 Nm).
BBC Models – Torque blade nuts to 15-27 ft.-lbs.
(20-37 Nm).
Install Primer Guard
1. Remove (2) hex head screws from right front
quadrant (Fig. 11). Leave quadrant in place.
2. Install new primer guard on top of right front
quadrant with (2) hex head screws (Fig. 11).
Install New Throttle Control
Zone Start Models
1. HP Models Only – Disconnect brake cable from
throttle control by removing E-ring (Fig. 12).
Discard E-ring.
2. SP Models Only - Disconnect traction cable
from throttle control by removing E-ring
(Fig. 12). Discard E-ring.
1
6
2
1
1. Right front quadrant
2. Hex head screw (2)
Figure 11
3. Primer guard
4
3
3
1. Throttle control
2. Brake cable (HP model)
Traction cable (SP model)
3. Throttle cable
Figure 12
4. E-ring
5. Hex head screw (2)
6. Curved washer (2)
7. Seal
7
2
6
5
3. Remove (2) hex head screws and (2) curved
washers securing throttle control to handle
(Fig. 12). Retain screws and washers. Discard
throttle control and throttle cable.
4. Install new throttle control using (2) hex head
screws and (2) curved washers previously
removed.
5. Connect new throttle cable to throttle control
using new E-ring.
EN–7
Installation
6. HP Models Only – Reconnect brake cable to
throttle control using new E-ring. Then
reconnect brake cable to engine (Fig. 5).
7. SP Models Only – Reconnect traction cable to
throttle control using new E-ring. Then
reconnect brake cable to engine (Fig. 5).
8. Make sure seals on cables are pushed down tight
(Fig. 12).
9. Route throttle cable across top of transmission
(Fig. 13).
11. Move throttle to (FAST) position.
12. Push throttle arm to rear of engine as far as it
will go.
13. Install new cable clamp and cable clamp screw
to engine (Fig. 14). Tighten cable clamp screw to
lock throttle cable in place.
14. Reinstall belt cover using fasteners previously
removed (Fig. 3).
BBC Models
1. Remove (4) Phillips head screws and (4) lock
nuts securing throttle control to control panel
(Fig. 15). Retain screws and lock nuts. Discard
throttle control, throttle control retainer and
throttle cable.
1
7
1
Figure 13
1. Throttle cable
10. Connect throttle cable to throttle arm on engine
(Fig. 14).
3
1
2
4
m-3638
Figure 14
1. Cable clamp screw
2. Cable clamp
3. Throttle cable
4. Throttle arm
1. Phillips head screw (4)
2. Lock nut (4)
3. Throttle control
4. Throttle control retainer
2
3
4
6
5
Figure 15
5. Throttle cable
6. Seal
7. Decal P/N 98-2003
EN–8
Installation
2. Remove and discard old control panel decal.
Install new control panel decal (Fig. 15).
3. Install new throttle control using (4) Phillips
head screws and (4) lock nuts previously
removed. Install new throttle control retainer.
Note: Make sure seal on throttle cable is
pushed down tight.
4. Connect throttle cable to throttle arm on engine.
5. Move throttle to
(FAST) position.
6. Push throttle arm to rear of engine as far as it
will go.
7. Install new cable clamp and cable clamp screw
to engine (Fig. 14). Tighten cable clamp screw to
lock throttle cable in place.
Install New Control Bar
(BBC Models Only)
2
7
1. Control bar
2. Handle screw
3. Support spacer
4. Hex flange nut
3
8
4
1
6
5
Figure 16
5. Hex head cap screw
6. Spacer
7. Lock nut
8. Control bracket
1. Remove handle screw, support spacer and hex
flange nut securing right side of control bar to
handle (Fig. 16). Retain these items for
reinstallation.
2. Carefully remove hex head cap screw, spacer and
lock nut securing left side of control bar and top
portion of control bracket to handle (Fig. 16).
Retain these items for reinstallation. Leave other
parts loosely assembled in control bracket for
reinstallation.
3. Remove and discard old control bar.
4. Attach new control bar by reversing order of
disassembly.
Reinstall Gas Tank
Reinstall gas tank in reverse order of disassembly
(Fig. 2). Connect fuel line to engine.
EN–9
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