Medallion Bagger Manuel de service

WALK BEHIND POWER MOWER DRIVE SYSTEMSSERVICE MANUAL

vi WPM Drive Systems ManualTABLE OF CONTENTSModel Trans Trans Wheel Handle Blade R&R Internal Pinion Repair Clutch Repair 10331 CD SB RK 2B

6-14 WPM Drive Systems ManualBBC / BOS / BCS5. Hook the end of the control link into the brake plate lever, then slip the BBC control cable onto the

6-15WPM Drive Systems ManualBBC / BOS / BCSUnder Deck Components Disassembly (Toro Vacu Power/Lawn-Boy Medallion)1. Stop the engine and disconnect th

6-16 WPM Drive Systems ManualBBC / BOS / BCS7. Again, pivot the brake plate counterclockwise and remove the BBC fl ywheel.8. BBC Belt or Idler Pulley

6-17WPM Drive Systems ManualBBC / BOS / BCSUnder Deck Components Assembly (Toro Vacu Power/Lawn-Boy Medallion)1. Check to make sure that the brake pl

6-18 WPM Drive Systems ManualBBC / BOS / BCS6. Install the BBC fl ywheel onto the crankshaft, making certain that the slots in the BBC fl ywheel align

6-19WPM Drive Systems ManualBBC Cable Removal (Toro Vacu Power/Lawn-Boy Medallion)BBC / BOS / BCS11. Complete BBC service by checking BBC and self-pr

6-20 WPM Drive Systems ManualBBC / BOS / BCSBBC Cable Installation (Toro Vacu Power/Lawn-Boy Medallion)1. Slide a new BBC cable into the BBC cable le

6-21WPM Drive Systems ManualBBC / BOS / BCSENGINE AND BLADE ASSEMBLY (Toro Recycler / Rear Bagger) Fig 182 engineandbladeassyRef. No. Qty Description

6-22 WPM Drive Systems ManualBBC / BOS / BCSTORO RECYCLER/REAR BAGGER BBCIdler Arm System Disassembly (Recycler/Rear Bagger) Fig 183 1350-001 a1. Dr

6-23WPM Drive Systems ManualBBC / BOS / BCS4. Turn the mower on its side. Remove the blade and the BBC cover. Brush any grass clippings out of the ar

viiWPM Drive Systems ManualTABLE OF CONTENTSModel Trans Trans Wheel Handle Blade R&R Internal Pinion Repair Clutch Repair 10546 CD 3S RK 2B

6-24 WPM Drive Systems ManualBBC / BOS / BCS6. Now, disassemble the components on the crankshaft. If you have an impact wrench, the large nut on the

6-25WPM Drive Systems ManualBBC / BOS / BCSIdler Arm System Assembly (Recycler/Rear Bagger)1. Start by installing the key and self-propel pulley. The

6-26 WPM Drive Systems Manual They are noise dampeners. Without them, when the brake pad hits the drum, the drum will ring like a bell. Also look at

6-27WPM Drive Systems ManualBBC Cable Removal (Recycler/Rear Bagger) Fig 199 3428-01929. Start the shaft into the hole in the housing. Rotate the idl

6-28 WPM Drive Systems ManualBBC / BOS / BCSBBC Cable Installation (Recycler/Rear Bagger)6. Slip the end of the BBC cable from the cable lever and re

6-29WPM Drive Systems Manual6. Slip end of cable under screw. See page 7-16.BBC / BOS / BCS Fig 206 MVC-1973. Remove the blade and blade stiffener

6-30 WPM Drive Systems ManualBBC / BOS / BCS Fig 210 MVC-2037. Unhook both springs from the slot in the brake arm (Fig. 210). Fig 209 MVC-2006. Re

6-31WPM Drive Systems Manual8. Lift the brake assembly and blade drive belt from the mower (Fig. 211).9. To replace the blade drive belt, remove the

6-32 WPM Drive Systems ManualBBC / BOS / BCS Fig 218 MVC-22415. The anchor plate contains a pivot screw with a bushing. Remove the locknut (Fig. 218

6-33WPM Drive Systems ManualBrake Arm AssemblyBBC / BOS / BCSA. Tab B. Notch16. The bushing has a notch removed from the fl ange end. Align that notc

viii WPM Drive Systems ManualTABLE OF CONTENTSModel Trans Trans Wheel Handle Blade R&R Internal Pinion Repair Clutch Repair 16212 W Worm N

6-34 WPM Drive Systems ManualBBC / BOS / BCSBOS/BCS System AssemblyAssemble all other parts in reverse order.Bolt torque as follows:Blade nuts: 350 -

7-1WPM Drive Systems Manual234568HANDLES AND CONTROL CABLESWorm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . .

7-2 WPM Drive Systems ManualHANDLES AND CONTROL CABLESToro 2 Bail HandleThere are four types of handle and control assemblies on mowers not covered in

7-3WPM Drive Systems ManualHANDLES AND CONTROL CABLESThis is the original Toro Personal Pace/ Lawn Boy Easy Stride system. The handle is telescoping a

7-4 WPM Drive Systems ManualHANDLES AND CONTROL CABLES3. Remove 6 screws from the traction rod retainer (Fig. 228). Fig 228 DSC-48104. Remove the t

7-5WPM Drive Systems ManualReassemblyHANDLES AND CONTROL CABLES7. Slide the handle up and off (Fig. 232). Fig 232 DSC-4819a8. If you need to replac

7-6 WPM Drive Systems ManualHANDLES AND CONTROL CABLESAdjusting the Personal Pace CableEnsure the transmission belt is disengaged, transmission tilted

7-7WPM Drive Systems ManualHANDLES AND CONTROL CABLES2. Install the tool over the stop in the handle guides as shown, one on each side. Push the hand

7-8 WPM Drive Systems ManualHANDLES AND CONTROL CABLESAdjusting the Personal Pace/Easy Stride CableEnsure the transmission belt is disengaged, transmi

7-9WPM Drive Systems ManualHANDLES AND CONTROL CABLES Fig 245 DSC-4864aThe Lawn-Boy Sens-a-Speed handle is made in two forms, zone start and blade cl

ixWPM Drive Systems ManualTABLE OF CONTENTSModel Trans Trans Wheel Handle Blade R&R Internal Pinion Repair Clutch Repair 20041 22stl B SR P

7-10 WPM Drive Systems ManualHANDLES AND CONTROL CABLES2. Squeeze the ends of the upper bail to disengage them from the handle. On some models the ri

7-11WPM Drive Systems ManualHANDLES AND CONTROL CABLESThe engine brake cable is not adjustable. If it fails to function it will need to be replaced.

7-12 WPM Drive Systems ManualHANDLES AND CONTROL CABLES Fig 254 DSC-4899a3. Slide the pivot assembly, bail and the brake cable to the right until th

7-13WPM Drive Systems ManualHANDLES AND CONTROL CABLESThe shift cables are not adjustable. To install the shift cable, insert the end of the cable in

7-14 WPM Drive Systems ManualHANDLES AND CONTROL CABLESThe objective is to have the wheels begin to drive when the bail is about 1” (25mm) below the u

7-15WPM Drive Systems ManualHANDLES AND CONTROL CABLES1. Remove the two fl anged head self-tapping screws securing the screen panel to the housing and

7-16 WPM Drive Systems ManualHANDLES AND CONTROL CABLESThe cable adjustment is the clamp on top of the housing on the left side of the mower. Loosen t

7-17WPM Drive Systems ManualHANDLES AND CONTROL CABLESOn BBC models, the control bail also controls the transmission belt engagement. The adjustment p

7-18 WPM Drive Systems ManualHANDLES AND CONTROL CABLESThe blade clutch control is adjusted by removing the cover between the engine and bag door. Loo

7-19WPM Drive Systems ManualHANDLES AND CONTROL CABLESLawn-Boy Insight Platimun:1. Remove the gas and oil and tip the mower on its side with the air

x WPM Drive Systems ManualTABLE OF CONTENTSModel Trans Trans Wheel Handle Blade R&R Internal Pinion Repair Clutch Repair 20439 CD 3SP RK BBC

7-20 WPM Drive Systems ManualHANDLES AND CONTROL CABLESTHIS PAGE INTENTIONALLY LEFT BLANK.

8-1WPM Drive Systems Manual234567SELF-PROPEL BELT REPLACEMENTWorm Drive Transmission . . . . . . . . . . . . . . . . . . . . . .

8-2 WPM Drive Systems ManualSELF-PROPEL BELT REPLACEMENTThere are several different procedures for replacing the self propelled belt. Mowers with a bl

8-3WPM Drive Systems ManualSELF-PROPEL BELT REPLACEMENTThe Zone Start models use a basic self propel system. See Transmission Remove and Replace, page

8-4 WPM Drive Systems ManualSELF-PROPEL BELT REPLACEMENTTHIS PAGE INTENTIONALLY LEFT BLANK.

xiWPM Drive Systems ManualTABLE OF CONTENTSModel Trans Trans Wheel Handle Blade R&R Internal Pinion Repair Clutch Repair 20666 CD 3SP RK 1B

xii WPM Drive Systems ManualTABLE OF CONTENTSModel Trans Trans Wheel Handle Blade R&R Internal Pinion Repair Clutch Repair 20833 CD SB RK PP

xiiiWPM Drive Systems ManualTABLE OF CONTENTSModel Trans Trans Wheel Handle Blade R&R Internal Pinion Repair Clutch Repair 26633 CD VP 3 S

xiv WPM Drive Systems ManualTABLE OF CONTENTSTHIS PAGE INTENTIONALLY LEFT BLANK.

1-1WPM Drive Systems ManualWorm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . .Single Speed Spur/Bevel Gear

1-2 WPM Drive Systems ManualWORM DRIVE TRANSMISSIONGENERALThere are two versions of the worm drive transmission. The fi rst is a clutch type and is use

1-3WPM Drive Systems ManualThis transmission requires 90 wt. gear oil. A variable weight such as 85w90 is acceptable as long as the range includes 90

1-4 WPM Drive Systems ManualWORM DRIVE TRANSMISSION4. Remove both front wheels and wheel covers (Fig. 005). Fig 005 3428-01295. Pivot (both) front

1-5WPM Drive Systems Manual Fig 008 3428-01377. The wheel pinion, thrust washer, pivot, and spring arm will now slide off the end of the axle (Fig.

1-6 WPM Drive Systems ManualWORM DRIVE TRANSMISSION5. Push the worm shaft out of the cover. This may require a little pressure.6. To remove the axle

1-7WPM Drive Systems ManualAssembly Fig 014 3428-01579. Clean the old gasket material from the mating surfaces of the case and cover.10. A hook or s

1-8 WPM Drive Systems ManualWORM DRIVE TRANSMISSION3. Note: Some replacement axles have more than one hole that can be used to pin the sleeve to the

1-9WPM Drive Systems ManualControls6. Install worm shaft in bearing.7. Use a new gasket. Install the cover on the bottom case and start the 4 self-t

1-10 WPM Drive Systems ManualWORM DRIVE TRANSMISSION Fig 021 3428-0127The transmission cable is a standard lever type. Since the spring and pin on to

1-11WPM Drive Systems ManualCONSTANT MESHDescriptionThis transmission is very similar to the “INTERNALLY CLUTCHED” on page 1 – 1. However, the helical

This service manual was written expressly for Toro servicing dealers. The Toro Company has made every effort to make the information in this manual co

1-12 WPM Drive Systems ManualWORM DRIVE TRANSMISSION Fig 023 20911B sprearaxleassyRemoval and InstallationRef. No. Qty Description1234567910111213141

1-13WPM Drive Systems ManualWORM DRIVE TRANSMISSIONTo remove the transmission from the mower proceed as follows:1. Remove both rear wheels.2. Remove

1-14 WPM Drive Systems ManualWORM DRIVE TRANSMISSIONWHEEL CLUTCH4. If loss of traction or improper engagement still occurs after adjustment, repeat s

2-1WPM Drive Systems Manual345678SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSIONWorm Drive Transmission . . . . . . . . . . . . . . . . . .

2-2 WPM Drive Systems ManualSINGLE SPEED SPUR/BEVEL GEAR TRANSMISSIONGEAR CASE ASSEMBLY Fig 026 snglspspurbvlgearboxRef. No. Qty Description123456789

2-3WPM Drive Systems ManualThis basic transmission has been in use for several years. There are minor variations, such as different shafts on the beve

2-4 WPM Drive Systems ManualOn some models, removing these 2 screws makes transmission removal easier (Fig. 032).SINGLE SPEED SPUR/BEVEL GEAR TRANSMIS

2-5WPM Drive Systems Manual Fig 035 3428-0018Remove the axle and intermediate shaft with the gears. The bearing in the cover should be sealed on both

2-6 WPM Drive Systems ManualSINGLE SPEED SPUR/BEVEL GEAR TRANSMISSIONPrior to installation of oil impregnated bushings, it is wise to apply a light co

3-1WPM Drive Systems Manual245678SINGLE SPEED BEVEL GEAR TRANSMISSIONWorm Drive Transmission . . . . . . . . . . . . . . . . . . .

THIS PAGE INTENTIONALLY LEFT BLANK.

3-2 WPM Drive Systems ManualSINGLE SPEED BEVEL GEAR TRANSMISSIONEXPLODED VIEW - SINGLE SPEED BEVEL GEAR TRANSMISSIONA. Nut H. BushingB. Washer I. T

3-3WPM Drive Systems ManualGENERAL INFORMATIONThis transmission was fi rst used on 22” steel deck models for 2002. It is used in both front wheel and r

3-4 WPM Drive Systems ManualSINGLE SPEED BEVEL GEAR TRANSMISSIONFRONT AXLE AND TRANSMISSION ASSEMBLY3354-613 Rev A Fig 041 3354-613(5)Ref. No. Qty De

3-5WPM Drive Systems Manual22” FRONT WHEEL DRIVE MODELS1. Block the front of the mower up. There are two screws that secure the belt cover to the hou

3-6 WPM Drive Systems ManualSINGLE SPEED BEVEL GEAR TRANSMISSION9. Remove the two bolts and nuts securing each pivot arm to the housing. There is a n

3-7WPM Drive Systems ManualTransmission Disassembly The snap ring can now be removed. Loosen the clamps with care due to the spring arm tension. Sepa

3-8 WPM Drive Systems Manual1. The same axle is used for both front and rear drive versions. There are two holes in the axle about one inch apart. Fr

3-9WPM Drive Systems Manual7. Coat the axle, key, and spring with #2 molybendum disulfi de base grease or anti-seize compound before installing the pi

3-10 WPM Drive Systems ManualSINGLE SPEED BEVEL GEAR TRANSMISSION22” TORO & LAWN-BOY REAR WHEEL DRIVE MODELSTransmission Removal and Belt Replacem

3-11WPM Drive Systems ManualSINGLE SPEED BEVEL GEAR TRANSMISSION3. Remove the plug from the hole next to where the self propel cable goes through the

iWPM Drive Systems ManualTABLE OF CONTENTSQUICK REFERENCETransmission Remove and Replace 3 speed transmission . . . . . . . . . .

3-12 WPM Drive Systems ManualSINGLE SPEED BEVEL GEAR TRANSMISSION12. Tip the mower onto its right side (carburetor up) and remove the blade.13. Remo

3-13WPM Drive Systems Manual14. Place the mower right side up and remove the three hex head and one Allen head cap screws on each side that hold the

3-14 WPM Drive Systems ManualSINGLE SPEED BEVEL GEAR TRANSMISSION21. Pull the belt towards the crankshaft and remove.If only the belt is to be replac

3-15WPM Drive Systems ManualSINGLE SPEED BEVEL GEAR TRANSMISSIONRear Axle Disassembly1. Remove the klip rings and thrust washers that secure the pini

3-16 WPM Drive Systems ManualSINGLE SPEED BEVEL GEAR TRANSMISSION2. Since the pulley was previously removed, the input shaft will now slip out of the

3-17WPM Drive Systems Manual Fig 084 MVC-4691. The same axle is used for both front and rear wheel drive models. There are two holes in the axle abo

3-18 WPM Drive Systems ManualSINGLE SPEED BEVEL GEAR TRANSMISSION Fig 087 MVC-4726. Coat the axle, key, and spring with #2 molybendum disulfi de grea

3-19WPM Drive Systems ManualSINGLE SPEED BEVEL GEAR TRANSMISSIONLAWN-BOY INSIGHT TRANSMISSION REMOVE AND REPLACE3352-960 Rev BRear Axle and Transmissi

3-20 WPM Drive Systems ManualSINGLE SPEED BEVEL GEAR TRANSMISSIONTransmission Removal & Belt ReplacementThe following steps will show one method o

3-21WPM Drive Systems ManualSINGLE SPEED BEVEL GEAR TRANSMISSION7. Lift the top half of the transmission pulley off. If just replacing the belt, push

ii WPM Drive Systems ManualTABLE OF CONTENTSWORM DRIVE TRANSMISSION GENERAL INTERNALLY CLUTCHED Description . . . . . . . . .

3-22 WPM Drive Systems ManualSINGLE SPEED BEVEL GEAR TRANSMISSION13. Push the bearings and bearing retainers inward, towards the transmission (Fig. 1

3-23WPM Drive Systems ManualSINGLE SPEED BEVEL GEAR TRANSMISSION Fig 103 PICT-192615. Remove the nut, washer, 2 pulley halves, and spacer from the t

3-24 WPM Drive Systems ManualSINGLE SPEED BEVEL GEAR TRANSMISSIONTransmission Disassembly Fig 106 MVC-4621. Remove the 4 screws holding the cover on

3-25WPM Drive Systems ManualSINGLE SPEED BEVEL GEAR TRANSMISSION Fig 111 MVC-4721. Reconnect the cable to the belt guide and install the washer and

3-26 WPM Drive Systems ManualSINGLE SPEED BEVEL GEAR TRANSMISSION7. When installing the rear cover, note the bosses on the back side of the cover. Th

4-1WPM Drive Systems Manual235678THREE SPEED TRANSMISSIONWorm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . .

4-2 WPM Drive Systems ManualTHREE SPEED TRANSMISSIONGEARCASE ASSEMBLY Fig 114 gearcaseassyRef. No. Qty Description12345891112131415171819201112211111

4-3WPM Drive Systems ManualTHREE SPEED TRANSMISSIONOPERATIONInput System:Power is transferred from the engine to the transmission by a belt. The self-

4-4 WPM Drive Systems ManualTHREE SPEED TRANSMISSIONThere are also three gears on the output shaft. These three gears rotate freely on the gear sleeve

4-5WPM Drive Systems ManualTHREE SPEED TRANSMISSIONRemoval - Toro Vacu Power/Lawn-Boy Medallion ModelsComplete transmission removal on the Toro Vacu P

iiiWPM Drive Systems ManualTABLE OF CONTENTS Speed Reduction System . . . . . . . . . . . . . . . . . . . .

4-6 WPM Drive Systems ManualTHREE SPEED TRANSMISSIONRemoval - Recycler/Rear Bagger ChassisTo remove the transmission from the chassis, raise the rear

4-7WPM Drive Systems ManualTHREE SPEED TRANSMISSION3. Removal of the input shaft and pulley assembly can be diffi cult because the input pinion has a

4-8 WPM Drive Systems ManualTHREE SPEED TRANSMISSIONOutput Shaft Assembly1. Slide the output bushing onto the output shaft, fl anged side last. Assemb

4-9WPM Drive Systems ManualTHREE SPEED TRANSMISSIONInput Shaft Assembly8. If the left pivot arm was removed for servicing, reassemble now as describe

4-10 WPM Drive Systems ManualTHREE SPEED TRANSMISSIONIntermediate Shaft AssemblyNote: Before assembling, coat the intermediate shaft with No. 2 lithi

4-11WPM Drive Systems ManualTHREE SPEED TRANSMISSIONSpecial Assembly Notes for Toro Vacu Power/Lawn-Boy Medallion1. Slip the gear selection cable int

4-12 WPM Drive Systems ManualTHREE SPEED TRANSMISSIONTROUBLESHOOTING TIPS - 3 SPEED TRANSMISSIONHard ShiftingA raised boss molded into each gear cause

5-1WPM Drive Systems Manual234678WHEEL PINION CLUTCHWorm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . .Sing

5-2 WPM Drive Systems ManualWHEEL PINION CLUTCHGEARCASE AND WHEEL ASSEMBLY, ROCKING KEY STYLE Fig 135 gearcase wheel assyRef. No. Qty Description123

5-3WPM Drive Systems ManualThe wheel pinion clutch has a three-fold purpose. One, when the transmission is engaged, it causes the pinions to move with

iv WPM Drive Systems ManualTABLE OF CONTENTS BBC Cable Removal (Recycler/Rear Bagger) . . . . . . . . . . . . . . .

5-4 WPM Drive Systems ManualWHEEL PINION CLUTCHTest for Function17. Compression Spring – provides the light, constant, inward force necessary for pro

5-5WPM Drive Systems ManualWHEEL PINION CLUTCH2. Remove the special retaining clip at the end of the output shaft and pull off the following six whee

5-6 WPM Drive Systems ManualWHEEL PINION CLUTCH4. Assemble the spring arm and pivot arm as shown in Figure 138. Fig 138 3428-00285. To increase ser

5-7WPM Drive Systems ManualWHEEL PINION CLUTCH13. Place the wheel pinion onto the output shaft. It is symmetrical and can be put on either way.14. I

5-8 WPM Drive Systems ManualWHEEL PINION CLUTCHGEARCASE AND WHEEL ASSEMBLY, SPRING RATCHET STYLE3354-613 Rev A Fig 141 3354-613(5)Ref. No. Qty Descri

5-9WPM Drive Systems ManualWHEEL PINION CLUTCHThe Spring Ratchet type wheel clutch system has been used on a wide variety of models. It consists of a

5-10 WPM Drive Systems ManualWHEEL PINION CLUTCH Fig 144 MVC-8504. Slide the wheel pinion off the axle.Note: There is a spring-loaded key under the

6-1WPM Drive Systems Manual234578BBC / BOS / BCSWorm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . .Single S

6-2 WPM Drive Systems ManualBBC / BOS / BCSDescriptionThere are two basic blade clutching system designs. The fi rst is commonly referred to as the BBC

6-3WPM Drive Systems ManualBBC / BOS / BCSThe normal or “at rest” position of the control bar is indicated by the number 1 in the Figure 148. In order

vWPM Drive Systems ManualTABLE OF CONTENTSModel Trans Trans Wheel Handle Blade R&R Internal Pinion Repair Clutch Repair 10301 CD SB RK 2B No

6-4 WPM Drive Systems ManualBBC / BOS / BCSe. Traction Lever: provides input to the traction cable since the end of the traction cable is retained in

6-5WPM Drive Systems ManualBBC / BOS / BCSWhen the control bar is cocked to its lowest position as in Figure 151. The buckling spring is fl exed and mo

6-6 WPM Drive Systems ManualBBC / BOS / BCSControl Box DisassemblyWhen the control bar is released, the tip of the control hook catches on the leaf sp

6-7WPM Drive Systems Manual A better method is to make a special cut-away version of the right control box housing half as shown in Figure 154. When

6-8 WPM Drive Systems ManualBBC / BOS / BCS3. Place a piece of duct tape over the heads of the carriage bolts that slide through the handle and the l

6-9WPM Drive Systems Manual8. Slip the white nylon washer onto the J end of the buckling spring. The slotted side of the washer should face away from

6-10 WPM Drive Systems ManualBBC / BOS / BCSTORO BBC SERVICE GUIDE Fig 160 bbc scanDisassembly Sequence

6-11WPM Drive Systems ManualBBC / BOS / BCSBLADE BRAKE CLUTCH ASSEMBLY (Toro Vacu Power/Lawn-Boy Medallion BBC) Fig 161 bladebrakeclutchassyRef. No.

6-12 WPM Drive Systems Manual1. Remove the fl anged head self-tapping capscrews securing the upper BBC cover to the housing and remove the upper BBC c

6-13WPM Drive Systems Manual4. Remove the bushing from inside the bellcrank.5. Using the control link to hold the control pin, remove the fl anged he