Service Manual
Page 5
... Easy Stride (Generation 1 7-3 Personal Pace Easy Stride (Generation 2 7-6 Lawn-Boy Sens-a-Speed 7-9 Belt Replacement Mowers with Toro Blade Brake Clutch 8-3 Mowers with Toro Blade Override System 8-3 Zone start 21" Rear Wheel Drive Toro & Lawn-Boy (except Insight 8-2 Zone start 22" Toro Rear Wheel Drive 3-10 Zone start 22" Toro Front Wheel Drive 3-5 Lawn-Boy Insight Zone Start 3-19 Lawn-Boy Insight with Blade Clutch...
... Easy Stride (Generation 1 7-3 Personal Pace Easy Stride (Generation 2 7-6 Lawn-Boy Sens-a-Speed 7-9 Belt Replacement Mowers with Toro Blade Brake Clutch 8-3 Mowers with Toro Blade Override System 8-3 Zone start 21" Rear Wheel Drive Toro & Lawn-Boy (except Insight 8-2 Zone start 22" Toro Rear Wheel Drive 3-10 Zone start 22" Toro Front Wheel Drive 3-5 Lawn-Boy Insight Zone Start 3-19 Lawn-Boy Insight with Blade Clutch...
Service Manual
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Front Wheel Drive Models 3-9 22" TORO & LAWN-BOY REAR WHEEL DRIVE MODELS Transmission Removal & Belt Replacement 3-10 Rear Axle Disassembly 3-15 Transmission Disassembly 3-16 Transmission Assembly 3-16 Axle Assembly Tips 3-17 LAWN-BOY INSIGHT TRANSMISSION REMOVE & REPLACE 3-19 Tranmission Removal & Belt Replacement 3-20 Transmission Disassembly 3-24 Transmission Assembly 3-24 Axle Assembly Tips 3-24 Transmission Installation Tips 3-25 THREE...
Front Wheel Drive Models 3-9 22" TORO & LAWN-BOY REAR WHEEL DRIVE MODELS Transmission Removal & Belt Replacement 3-10 Rear Axle Disassembly 3-15 Transmission Disassembly 3-16 Transmission Assembly 3-16 Axle Assembly Tips 3-17 LAWN-BOY INSIGHT TRANSMISSION REMOVE & REPLACE 3-19 Tranmission Removal & Belt Replacement 3-20 Transmission Disassembly 3-24 Transmission Assembly 3-24 Axle Assembly Tips 3-24 Transmission Installation Tips 3-25 THREE...
Service Manual
Page 8
... Adjustment (Toro Vacu Power/Lawn-Boy Medallion 7-15 Toro BBC Cable Adjustment (Recycler/Rear Bagger 7-16 Toro BOS Control 7-17 Toro BOS Control Cable Adjustment 7-18 Lawn-Boy BCS Control 7-18 Lawn-Boy BCS Control Cable Adjustment 7-18 SELF-PROPEL BELT REPLACEMENT Toro 21" Front Wheel Drive 8-2 22" Front Wheel Drive 8-2 22" Rear Wheel Drive 8-2 21" Steel & Cast Deck Toro & Lawn-Boy Mowers Belt Replacement 8-2 21...
... Adjustment (Toro Vacu Power/Lawn-Boy Medallion 7-15 Toro BBC Cable Adjustment (Recycler/Rear Bagger 7-16 Toro BOS Control 7-17 Toro BOS Control Cable Adjustment 7-18 Lawn-Boy BCS Control 7-18 Lawn-Boy BCS Control Cable Adjustment 7-18 SELF-PROPEL BELT REPLACEMENT Toro 21" Front Wheel Drive 8-2 22" Front Wheel Drive 8-2 22" Rear Wheel Drive 8-2 21" Steel & Cast Deck Toro & Lawn-Boy Mowers Belt Replacement 8-2 21...
Service Manual
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WORM DRIVE TRANSMISSION 1 Worm Drive Transmission 2 Single Speed Spur/Bevel Gear Transmission 3 Single Speed Bevel Gear Transmission 4 Three Speed Transmission 5 Wheel Pinion Clutch 6 Blade Brake Clutch Systems (BBC), Blade Override System (BOS), Blade Clutch Systems (BCS 7 Handles and Control Cables 8 Self-Propel Belt Replacement WPM Drive Systems Manual 1-1
WORM DRIVE TRANSMISSION 1 Worm Drive Transmission 2 Single Speed Spur/Bevel Gear Transmission 3 Single Speed Bevel Gear Transmission 4 Three Speed Transmission 5 Wheel Pinion Clutch 6 Blade Brake Clutch Systems (BBC), Blade Override System (BOS), Blade Clutch Systems (BCS 7 Handles and Control Cables 8 Self-Propel Belt Replacement WPM Drive Systems Manual 1-1
Service Manual
Page 20
...worm shaft (input shaft) is provided by a belt from the clutch jaw to the axle. A spring which hooks into the tab on the front of the worm drive transmission. The sleeve is used on 21" front wheel drive mowers. Spring C. The second version is constant mesh... Gear D. Clutch Jaw E. INTERNALLY CLUTCHED Description This is used on the belt. Belt B. Input Shaft (worm shaft) A B E CDF G 1-2 Fig 001 fig 1 WPM Drive Systems Manual When the clutch jaw engages the helical gear, power is in constant mesh with the helical gear. Shift Fork F. The fi...
...worm shaft (input shaft) is provided by a belt from the clutch jaw to the axle. A spring which hooks into the tab on the front of the worm drive transmission. The sleeve is used on 21" front wheel drive mowers. Spring C. The second version is constant mesh... Gear D. Clutch Jaw E. INTERNALLY CLUTCHED Description This is used on the belt. Belt B. Input Shaft (worm shaft) A B E CDF G 1-2 Fig 001 fig 1 WPM Drive Systems Manual When the clutch jaw engages the helical gear, power is in constant mesh with the helical gear. Shift Fork F. The fi...
Service Manual
Page 22
... front of the transmission. Pivot (both front wheels and wheel covers (Fig. 005). A B C A. WORM DRIVE TRANSMISSION Removal & Installation (front wheel drive applications) 1. Spring Fig 005 3428-0129 3428-0127 5. Fig 006 3428-0131 1-4 WPM Drive Systems Manual Remove the belt cover and unhook the spring on the front of the mower off the transmission pulley (Fig. 004). 4. Remove...
... front of the transmission. Pivot (both front wheels and wheel covers (Fig. 005). A B C A. WORM DRIVE TRANSMISSION Removal & Installation (front wheel drive applications) 1. Spring Fig 005 3428-0129 3428-0127 5. Fig 006 3428-0131 1-4 WPM Drive Systems Manual Remove the belt cover and unhook the spring on the front of the mower off the transmission pulley (Fig. 004). 4. Remove...
Service Manual
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... discard the push-on retainer on the other side. Remove the belt and pulley. Fig 008 3428-0137 WPM Drive Systems Manual 1-5 Repeat the process on top of the lower case. Wood Block A 7. NOTE: Support the wheel pinions with oil after it is part of the transmission pulley. ...Plug C B Fig 009 C. WORM DRIVE TRANSMISSION 6. Fill the transmission with the wood block while driving the roll pins in the mower...
... discard the push-on retainer on the other side. Remove the belt and pulley. Fig 008 3428-0137 WPM Drive Systems Manual 1-5 Repeat the process on top of the lower case. Wood Block A 7. NOTE: Support the wheel pinions with oil after it is part of the transmission pulley. ...Plug C B Fig 009 C. WORM DRIVE TRANSMISSION 6. Fill the transmission with the wood block while driving the roll pins in the mower...
Service Manual
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Engagement and disengagement is used in a 48cm rear wheel drive application. Lock washer 3. Half pulley 4. Shaft & worm 8. Check plug 11. Thread forming screw 17. Bushing 23. Oil Seal 14. WPM Drive Systems Manual Fig 022 fig 18-A 1-11 Jam nut 2. Pulley spacer 6. Thrust washer 22. Internal repair procedures ... "INTERNALLY CLUTCHED" on page 1 - 1. However, the helical gear is different as is very similar to tighten or loosen the belt. V Belt 5. WORM DRIVE TRANSMISSION CONSTANT MESH Description This transmission is the lubrication requirement, 90 wt.
Engagement and disengagement is used in a 48cm rear wheel drive application. Lock washer 3. Half pulley 4. Shaft & worm 8. Check plug 11. Thread forming screw 17. Bushing 23. Oil Seal 14. WPM Drive Systems Manual Fig 022 fig 18-A 1-11 Jam nut 2. Pulley spacer 6. Thrust washer 22. Internal repair procedures ... "INTERNALLY CLUTCHED" on page 1 - 1. However, the helical gear is different as is very similar to tighten or loosen the belt. V Belt 5. WORM DRIVE TRANSMISSION CONSTANT MESH Description This transmission is the lubrication requirement, 90 wt.
Service Manual
Page 31
... clockwise to tighten the belt, or ½ turn counterclockwise to loosen the belt. To check the adjustment... the retaining rings, springs, gears, keys, clutches, and pivot arms on both rear wheels. 2. There is not sealed, so it is approximately 1" (25mm) from the upper... when the control bar is installed in the chassis. WORM DRIVE TRANSMISSION To remove the transmission from turning (Fig. 024). Hold the...;g 19 Adjusting Wheel Traction Drive 1. WPM Drive Systems Manual Fig 025 fig 20 1-13 Each bracket has 2 screws. Remove both sides ("Wheel Pinion Clutch" on...
... clockwise to tighten the belt, or ½ turn counterclockwise to loosen the belt. To check the adjustment... the retaining rings, springs, gears, keys, clutches, and pivot arms on both rear wheels. 2. There is not sealed, so it is approximately 1" (25mm) from the upper... when the control bar is installed in the chassis. WORM DRIVE TRANSMISSION To remove the transmission from turning (Fig. 024). Hold the...;g 19 Adjusting Wheel Traction Drive 1. WPM Drive Systems Manual Fig 025 fig 20 1-13 Each bracket has 2 screws. Remove both sides ("Wheel Pinion Clutch" on...
Service Manual
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SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION 1 Worm Drive Transmission 2 Single Speed Spur/Bevel Gear Transmission 3 Single Speed Bevel Gear Transmission 4 Three Speed Transmission 5 Wheel Pinion Clutch 6 Blade Brake Clutch Systems (BBC), Blade Override System (BOS), Blade Clutch Systems (BCS 7 Handles and Control Cables 8 Self-Propel Belt Replacement WPM Drive Systems Manual 2-1
SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION 1 Worm Drive Transmission 2 Single Speed Spur/Bevel Gear Transmission 3 Single Speed Bevel Gear Transmission 4 Three Speed Transmission 5 Wheel Pinion Clutch 6 Blade Brake Clutch Systems (BBC), Blade Override System (BOS), Blade Clutch Systems (BCS 7 Handles and Control Cables 8 Self-Propel Belt Replacement WPM Drive Systems Manual 2-1
Service Manual
Page 35
...in use a bevel pinion input gear which drives a final spur gear. 2. There are minor variations, such as different shafts on the bevel pinion gear to "Wheel Pinion Clutch" on different chassies. All use for several years. Remove transmission belt cover. 3. Raise the rear of lithium... based No. 2 grease. A. Refer to accommodate belt alignment on page 5-3 for this transmission is 2.5 - 3 fluid ounces (7.1cc - 9.0cc) of the mower and ...
...in use a bevel pinion input gear which drives a final spur gear. 2. There are minor variations, such as different shafts on the bevel pinion gear to "Wheel Pinion Clutch" on different chassies. All use for several years. Remove transmission belt cover. 3. Raise the rear of lithium... based No. 2 grease. A. Refer to accommodate belt alignment on page 5-3 for this transmission is 2.5 - 3 fluid ounces (7.1cc - 9.0cc) of the mower and ...
Service Manual
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SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION 6. This often results in damage to force the belt off the pulley without removing the belt guide. A. Fig 031 3128-0074 2-4 Fig 033 3428-0008 WPM Drive Systems Manual On some models, removing these 2 screws makes transmission removal easier (Fig. 032). Remove the selftapping screws holding the cover...
SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION 6. This often results in damage to force the belt off the pulley without removing the belt guide. A. Fig 031 3128-0074 2-4 Fig 033 3428-0008 WPM Drive Systems Manual On some models, removing these 2 screws makes transmission removal easier (Fig. 032). Remove the selftapping screws holding the cover...
Service Manual
Page 41
... front wheel and rear wheel drive configurations. Clutching is used in both cases, the gears are in the front drive versus the rear drive to change axle shaft direction of the transmission causes it to rock towards the engine to disengage. It is done by rocking the transmission to tighten the belt. When... GENERAL INFORMATION This transmission was first used in constant mesh. The control cable will move the transmission to tighten or loosen the drive belt (Fig. 040). The bevel gear is reversed when used on 22" steel deck models for 2002. Fig 040 MVC-485 WPM...
... front wheel and rear wheel drive configurations. Clutching is used in both cases, the gears are in the front drive versus the rear drive to change axle shaft direction of the transmission causes it to rock towards the engine to disengage. It is done by rocking the transmission to tighten the belt. When... GENERAL INFORMATION This transmission was first used in constant mesh. The control cable will move the transmission to tighten or loosen the drive belt (Fig. 040). The bevel gear is reversed when used on 22" steel deck models for 2002. Fig 040 MVC-485 WPM...
Service Manual
Page 47
...the housing (Fig. 057). The letter L should face out. WPM Drive Systems Manual Fig 058 MVC-487 3-9 Front Wheel Drive Models To replace the self-propelled drive belt, proceed as follows: 1. Fig 055 MVC-472 8. The wheel pinion is marked with #2 molybendum disulfide base grease or ...and tip the mower on the wheel clutch see Section 5, Wheel Pinion Clutch. On the right side, the letter R should face out on the left . If the wheel pinions are reversed, the wheels will not drive. SINGLE SPEED BEVEL GEAR TRANSMISSION 7. Remove the two screws securing the belt cover from ...
...the housing (Fig. 057). The letter L should face out. WPM Drive Systems Manual Fig 058 MVC-487 3-9 Front Wheel Drive Models To replace the self-propelled drive belt, proceed as follows: 1. Fig 055 MVC-472 8. The wheel pinion is marked with #2 molybendum disulfide base grease or ...and tip the mower on the wheel clutch see Section 5, Wheel Pinion Clutch. On the right side, the letter R should face out on the left . If the wheel pinions are reversed, the wheels will not drive. SINGLE SPEED BEVEL GEAR TRANSMISSION 7. Remove the two screws securing the belt cover from ...
Service Manual
Page 48
...The blade can be removed, but it is not required for belt replacement. 5. Drain fuel and oil from the mower housing in order to change the drive belt. 1. Fig 059 MVC-490 Note: Blade removed for the belt guide and loosen the other. Remove the single retaining screw from ... Fig 061 MVC-733 Fig 060 MVC-491 3-10 WPM Drive Systems Manual SINGLE SPEED BEVEL GEAR TRANSMISSION 4. DO NOT bend the belt guide (Fig. 059). 22" TORO & LAWN-BOY REAR WHEEL DRIVE MODELS Transmission Removal and Belt Replacement On rear wheel drive models, it is necessary to one of the mounting screws...
...The blade can be removed, but it is not required for belt replacement. 5. Drain fuel and oil from the mower housing in order to change the drive belt. 1. Fig 059 MVC-490 Note: Blade removed for the belt guide and loosen the other. Remove the single retaining screw from ... Fig 061 MVC-733 Fig 060 MVC-491 3-10 WPM Drive Systems Manual SINGLE SPEED BEVEL GEAR TRANSMISSION 4. DO NOT bend the belt guide (Fig. 059). 22" TORO & LAWN-BOY REAR WHEEL DRIVE MODELS Transmission Removal and Belt Replacement On rear wheel drive models, it is necessary to one of the mounting screws...
Service Manual
Page 88
...BBC or Blade Brake Clutch. This stops the blade but allows the flywheel and crankshaft to continue to as Lawn-Boy Medallion mowers. The control mechanism meets the federal government's "2-step" blade engagement procedure. The two are connected by tensioning and loosening the BBC cable...basic blade clutching system designs. When the control is used on Toro (Blade Override System) and Lawn-Boy (Blade Clutch System) (Fig. 146 and Fig. 147). It has two versions which turns with this by tensioning a drive belt between the flywheel and brake drum. The second design...
...BBC or Blade Brake Clutch. This stops the blade but allows the flywheel and crankshaft to continue to as Lawn-Boy Medallion mowers. The control mechanism meets the federal government's "2-step" blade engagement procedure. The two are connected by tensioning and loosening the BBC cable...basic blade clutching system designs. When the control is used on Toro (Blade Override System) and Lawn-Boy (Blade Clutch System) (Fig. 146 and Fig. 147). It has two versions which turns with this by tensioning a drive belt between the flywheel and brake drum. The second design...
Service Manual
Page 117
... bolt securing the pulley to keep the pulley from the mower (Fig. 211). 10. To replace the blade drive belt, remove the idler pulley bolt (Fig. 212). Fig 212 MVC-207 WPM Drive Systems Manual Fig 214 MVC-218 6-31 B A F E C D G H Fig 211 MVC-205 9. Belt guard Fig 213 MVC-209 E. Bolt 11. BBC / BOS / BCS...
... bolt securing the pulley to keep the pulley from the mower (Fig. 211). 10. To replace the blade drive belt, remove the idler pulley bolt (Fig. 212). Fig 212 MVC-207 WPM Drive Systems Manual Fig 214 MVC-218 6-31 B A F E C D G H Fig 211 MVC-205 9. Belt guard Fig 213 MVC-209 E. Bolt 11. BBC / BOS / BCS...
Service Manual
Page 123
... Toro Personal Pace/ Lawn Boy Easy Stride system. If you just push the handle down it will engage too rapidly and the mower ...will jump forward. Turn the handle over and remove the cable clamp, screw and the cable from the bail and set aside (Fig. 226). The handle is keeping your elbows at your sides and your sides. Squeeze the ends of pressure to the handle to disengage it tensions the transmission drive belt...). Operation The best way to go faster, walk faster. Fig 225 DSC-4801 Fig 227 DSC-4808 WPM Drive Systems Manual 7-3 HANDLES AND CONTROL CABLES Personal...
... Toro Personal Pace/ Lawn Boy Easy Stride system. If you just push the handle down it will engage too rapidly and the mower ...will jump forward. Turn the handle over and remove the cable clamp, screw and the cable from the bail and set aside (Fig. 226). The handle is keeping your elbows at your sides and your sides. Squeeze the ends of pressure to the handle to disengage it tensions the transmission drive belt...). Operation The best way to go faster, walk faster. Fig 225 DSC-4801 Fig 227 DSC-4808 WPM Drive Systems Manual 7-3 HANDLES AND CONTROL CABLES Personal...
Service Manual
Page 129
... for those models a little more complex. That will activate the drive too aggressively and the mower will jump forward. Fig 246 DSC-4869a WPM Drive Systems Manual 7-9 Handle Disassembly, Zone Start Models 1. If you and walk. Lawn-Boy Sens-a-Speed HANDLES AND CONTROL CABLES On blade clutch models... start and blade clutch. The Sens-a-Speed A handle controls the self propel the same way as it is depressed tensions the transmission drive belt. On a zone start models and the blade control on blade clutch models. To operate this keep the engine running. The bail ...
... for those models a little more complex. That will activate the drive too aggressively and the mower will jump forward. Fig 246 DSC-4869a WPM Drive Systems Manual 7-9 Handle Disassembly, Zone Start Models 1. If you and walk. Lawn-Boy Sens-a-Speed HANDLES AND CONTROL CABLES On blade clutch models... start and blade clutch. The Sens-a-Speed A handle controls the self propel the same way as it is depressed tensions the transmission drive belt. On a zone start models and the blade control on blade clutch models. To operate this keep the engine running. The bail ...
Service Manual
Page 142
... be replaced without forcing. SELF-PROPEL BELT REPLACEMENT There are several different procedures for belt jumping and damage. 21" Steel and Cast Deck Toro and Lawn-Boy Mowers Belt Replacement Drain the gasoline and oil before tipping the mower to avoid fuel spillage. Toro 21" Front Wheel Drive See Worm Drive Transmission page 1-1. These mowers usually have a larger tendency to jump...
... be replaced without forcing. SELF-PROPEL BELT REPLACEMENT There are several different procedures for belt jumping and damage. 21" Steel and Cast Deck Toro and Lawn-Boy Mowers Belt Replacement Drain the gasoline and oil before tipping the mower to avoid fuel spillage. Toro 21" Front Wheel Drive See Worm Drive Transmission page 1-1. These mowers usually have a larger tendency to jump...