“F” SERIES GEAR DRIVE SELF-PROPELLED - Toro F” SERIES GEAR DRIVE SELF PROPELLED...

“F” SERIES GEAR DRIVE SELF-PROPELLED

GROUND SPEED SELECTION

Combinations of the various drive roller sizes and transmission gear ratios are available to change the ground speed.

Refer to the following specifications and informa- tion to obtain the desired ground speed.

Drive Rollers .88” Dia. 607657 L.H. Drive Roller .88” Dia. 607658 R.H. Drive Roller

1.00” Dia. 610844 L.H. Drive Roller 1.00” Dia. 610845 R.H. Drive Roller 1.12” Dia. 610440 L.H. Drive Roller 1.12” Dia. 610441 R.H. Drive Roller

Transmissions 15 Tooth 607663 Gear Drive 15 Tooth 607664 Gear Driven

16 Tooth 610687 Gear Driven 14 Tooth 610688 Gear Drive

Ratio Drive Roller Speed MPH 3200 RPM 15:15 .88 2.7 3200 RPM 14:16 .88 2.4 3200 RPM 14:16 1.00 2.8 3200 RPM 14:16 1.12 3.1

14:16 Gear ratio transmission will fit all 679699 (metal) and plastic gear cases.

NOTE

To change ground speed on mowers manu- factured prior to 1980, it would be necessary to replace the axle bracket part number 608934 with part number 610500 bracket. This includes all D-600 series, 1978 and 1979 “F” series.

NOTE

.

Do not use the 1.00” and 1.12” diameter drive rollers with a 15:15 ratio transmission. Ground speed would be excessive with poor cutting results.

10-20 ..SERVICE BULLETIN REFERENCE

“F” SERIES GEAR DRIVE SELF PROPELLED SERVlClNG CLUTCH ADJUSTMENT

The clutch control rod must be adjusted to provide a 3/16 inch space between the drive rollers and rear wheels.

Place mower in “OUT-OF-DRIVE” position, Adjustment is performed by placing lower end of control rod into groove of clutch control lever assembly. Pull up clutch control lever and down on control rod as far as possible and tighten clamp screw securely. This procedure should provide the required 3/16 inch spacing. However, if it cannot be attained, remove right rear wheel and loosen shoulder bolt and adjust axle ac- cordingly.

SAFETY WARNING I M P R O P E R T I G H T E N I N G O F CLUTCH ROD AND LEVER CON- NECTION MAY RESULT IN OPERA- TOR LOSS OF DRIVE CONTROL MECHANISM.

Whenever wheel height o r handle height is changed, clutch control rod and lever must be readjusted. Loosen clamp, lock drive unit in out- of-drive position. Pull up clutch control lever and down on control rod as far as possible and tighten clamp securely

SERVICE BULLETIN REFERENCES 10-21

“F” SERIES GEAR DRIVE SELF PROPELLED SERVICING

DRlVE ROLLER INSTALLATION

The drive rollers must be properly installed to uti- lize the self-cleaning feature. Proper installation is with the vee pointing toward the wheel.

Always replace the roll pin with a new one. Drive it into place with 5/32” or larger drift punch. Neither end of pin should protrude beyond surface of roller.

STARTER INTERLOCK-SELF PROPELLED MODELS

The starter interlock is a safety feature on self-propelled models. This system prevents starting the engine when the control handle is in the “DRIVE” position. The interlock cable is attached to the rear axle and an interlock lever. When the control handle is placed in “DRIVE” position the cable rotates the interlock lever upwards into a position

that prevents the starter pinion from engaging the flywheel. When the control handle is placed in “NEUTRAL” position the interlock cable pulls the interlock lever downward, allowing the starter pinion to engage flywheel as shown. This permits starting the engine with the control handle in the “NEUTRAL position only.

10-22 SERVICE BULLETIN REFERENCES

"F" SERIES GEAR DRIVE SELF PROPELLED SERVICING A SAFETY WARNING

INTERLOCK OPERATING SPRING MUST BE IN PLACE ON BOTH THE ELECTRIC AND MANUAL START MODELS TO PREVENT STARTING OF ENGINE WHILE IN DRIVE POSITION.

NOTE

Do not replace spring with other than original equipment to assure correct operation.

INTERLOCK SPRING P/N 302993

INTERLOCK

CABLE CLIP "NEUTRAL"

INTERLOCK SPRING I

609571 CLIP CABLE

Misadjustment of the interlock system will eliminate the safety feature it was designed for and may permit starting the engine with control handle in "DRIVE" position causing possible injury to operator.

Proper adjustment is accomplished as follows:

1. Place control handle in "NEUTRAL" position. Adjust clutch control rod by loosening clamp and pulling up on lower lower clutch lever and down, on upper clutch rod until a gap of 3/16" appears between the drive rollers and the rear wheels. Tighten clamp as tight as possible with hand pressure.


“F” SERIES GEAR DRIVE SELF PROPELLED SERVICING This procedure should provide the required 3/16 inch spacing. However, if it cannot be attained, remove right rear wheel and loosen shoulder bolt and adjust axle ac- cordingly.

NOTE

Check felt wheel washers and replace if necessary. Do not lubricate wheel and axle assembly.

3. MANUAL START MODELS: Place control handle in “NEUTRAL” position. Observe movement of interlock lever. The lever should be in a position that allows the starter pinion to engage the flywheel when the starter handle is in neutral. To adjust: remove spring clip and position interlock cable until a clearance of .090” is obtained between starter pinion and interlock lever as shown to allow necessary movement of starter pinion. Hold interlock cable in position, DO NOT allow cable to move, and secure interlock cable to starter bracket with spring clip as shown with a pair of pliers.

SAFETY WARNING I M P R O P E R T I G H T E N I N G OF CLUTCH ROD AND LEVER CON- NECTION MAY RESULT IN OPERA- TOR LOSS OF DRIVE CONTROL MECHANISM.

Remove left drive roller guard and left rear wheel. Loosen cable retainer clip and position end of cable housing (with rubber grommet installed on cable) 1-1/2 inches from nearest edge of retainer clip as shown. Secure clip and reinstall drive roller guard and wheel.

NOTE If .090” measurement between starter pinion and interlock lever can not be obtained using procedure #3 above then remove cable clip from rear axle bracket and position cable until .090” clearance is obtained. Secure cable to rear axle bracket and clip with pliers.


"F" SERIES GEAR ELECTRIC START MODELS: Place control handle in "NEUTRAL" position. Observe movement of interlock lever when manual starter handle is pulled and when key is turned to "START" position. The interlock lever should be in a position that allows the starter pinion to engage the flywheel. To adjust; remove spring clip and position interlock cable to allow necessary movement of starter pinion. Hold interlock cable in position, DO NOT allow cable to move, and secure interlock cable with spring clip with a pair of pliers.

NOTE

If necessary clearance can not be obtained by using above procedure then remove cable clip from rear cable clip from rear axle bracket and position cable until clearance is obtained. Secure cable to rear axle bracket with clip.

Place control handle in "DRIVE"position. Observe movement of interlock lever. When properly adjusted interlock lever will move upward preventing starter pinion from engaging flywheel. To adjust; remove spring clip and position cable so interlock lever prevents starter pinion from engaging flywheel. Secure cable with spring clip.

DRIVE SELF PROPELLED SERVlClNG 5.

6.

Check movement of interlock lever in "NEUTRAL" and "DRIVE" position. Check to be certain mower will start with control handle locked in "NEUTRAL" position ONLY. Mower should NOT start with control handle locked in "DRIVE" position. If additional adjustment is required repeat steps 3 & 4.

A I SAFETY WARNING

Check interlock operation whenever drive roller engagement or- rear axle adjustment is changed. It is NOT necessary to check interlock adjustment when cutting height or handle height has been changed. Clutch control rod will require adjustment when handle or cutting height is changed.

To replace interlock cable; remove left side drive roller cover and rear wheel. Remove spring clip securing the cable to the deck and remove cable from rear axle. The interlock lever is designed with a "quick disconnect" feature that allows the cable to be easily removed. Remove spring clip securing cable to starter bracket. Rotate cable approxi- mately 45° counterclockwise and remove cable from interlock lever as shown. Reverse procedure when installing new cable. The washer located on the end of the cable must be installed next to the cable loop to secure cable tointerlock lever. DO NOT lubricate interlock cable if cable movement is restricted or cable damaged replace cable. For adjusting procedure follow steps 1, 2 and 3.



To remove the rear wheels remove retainer ring with expansion pliers # 603596.

SAFETY WARNING

DO NOT OVER EXTEND (STRESS) RETAINING RING WHILE REMOV- ING OR INSTALLING. WHEN IN- STALLING RETAINING RING PO- SITION THE SIDE WITH THE ROUND OR BEVELED EDGES IN TOWARDS THE WHEEL. MAKE CERTAIN RETAINING RING IS NESTED IN GROOVE OF AXLE. LOSS OF WHEEL MAY ALLOW BLADE TO CONTACT GROUND SURFACE AND PICK UP OBJECTS THAT MAY BE THROWN BY THE BLADE.

The rear wheels are adjusted with one lever at the rear of mower deck.

SAFETY WARNING

MAKE SURE COTTER PIN AND ALL

PONENTS ARE IN PLACE. LOSS OF COTTER PIN MAY CAUSE REAR OF MOWER TO DROP PERMITTING BLADE TO PICK UP OBJECTS THAT MAY BE THROWN.

REAR HEIGHT ADJUSTMENT COM-


“F” SERIES GEAR DRIVE SELF PROPELLED SERVICING REPAIR OR REPLACE DRIVEN GEAR, SHAFT, THRUST WASHER AND/OR SEAL

Remove spark plug lead. Electric start models remove battery and disconnect starter lead wires.

1. Remove blade, blade stiffener, and adapter.

2. Remove muffler.

3. Remove transmission mounting screw from underside of deck as shown.

4. Remove engine mounting fasteners.

When reinstalling transmission mounting screw torque to 70 inch pounds.

5. Remove drive shaft cover.

SAFETY WARNING

DRIVE SHAFT COVER AND ROLLER GUARDS MUST BE IN PLACE A T

TOR EXPOSURE TO ROTATING PARTS.

ALL TIMES TO PREVENT OPERA-

6. Remove engine from mower housing.

Do not remove shaft from crankcase gear housing.

7. Loosen four screws securing gear cover assembly to crankcase. DO NOT remove the four screws a t this time.



8. Carefully remove driveshaft from gear box assembly. Sharp spline edges will cut seal. Al- ways replace seal. To replace seal, remove by in- serting screwdriver under one side and prying up. Seal may be reinstalled by placing squarely on seal seat and tamping in by using 5/8 inch socket and soft headed (leather or plastic) hammer.

10-28

NOTE

Driven shaft should be installed in lower unit before seal is installed to safeguard against damage to seal.

Remove four screws and remove gear cover assembly from engine. Remove bronze gear and thrust washer. Inspect for wear and/or damage. Also inspect spiral gear of crankshaft for wear and damage. Replace any part that is questionable.

SERVICE BULLETIN REFERENCES

"F" SERIES GEAR DRIVE SELF PROPELLED SERVICING

DRIVE TUBE END PLAY

1. Using a feeler gauge check for excessive end play as shown. If end play measurement is .035 to .135, no "0" ring required. If measurement is .136 to .235, add one "0" ring to transmission driver gearshaft as shown. If measurement is .236 or higher, add one "0" ring to transmission driven gearshaft and one "0" ring to engine driveshaft as shown. Replacement part no. for "0" ring is 303067.

2. Check position of bushings in drive tube. They must be installed with chamfered end inserted in drive tube as illustrated. Always replace worn bushings.

3. A sintered metal bushing must be installed on end next to engine.

CHAMFERED END OF BUSHING

DRIVE TUBE

REPAIR OR REPLACE TRANSMISSION

1. Remove transmission cover plate and drive

2. Remove blade, blade stiffener, and adapter. 3. Remove muffler. 4. Remove transmission mounting screw from

5. Remove engine mounting bolts.

roller covers.

underside of deck.

NOTE If a failure of the drive tube or bushings occurs on any gear driven self-propelled mower, it is to be replaced with the new spring loaded assembly shown here. Also remove and discard all "0" rings used with the old tube. Refer to the parts book and master parts price list for the part numbers.

SERVICE BULLETIN REFERENCES 10-29 REVISED 1983


6. Remove engine from mower housing carefully to avoid pulling P.T.O. shaft from lower crankcase gear housing.

NOTE

If P.T.O. shaft is removed, the driven gear will drop off end of shaft. Refer to steps 6 thru 9, REPAIR OR REPLACE DRIVEN GEAR, SHAFT, THRUST WASHER AND/OR SEAL.

7. Remove drive rollers and drive shaft roller bearings.

NOTE When reinstalling drive rollers place one washer between roller bearing and drive roller on both sides. This will provide correct end play of .062 inch or less. If end play exceeds this, install additional washer, part no. 603037, between right roller bearing and drive roller.

NOTE The sleeve has a flat surface that matches the flat surface of the bracket. When re-assembling, flat surfaces must match.

8. Remove two “C” clamps securing top and bottom gear covers.

9. Remove drive shaft and transmission assembly complete.

10. Drive roll pin out of bevel gear and drive shaft, and slide shaft out of bearing housing.

NOTE

Replace gears in sets. Do not replace individually.


"F" SERIES GEAR DRIVE SELF PROPELLED SERVICING

11. To replace bearing, press out damaged or worn bearing with special Lawn- Boy removal tool, part number 608361, and press in replacement with special installer tool, part number 608360.

Do not drive bearings in or out with a hammer. They must be removed or replaced using arbor press as illustrated.

LEFT SURFACE RIGHT

REMOVAL INSTALLATION TOOL TOOL

NOTE

In servicing the drive shaft, there is one very important consideration; there is a left and a right-hand side. The reason for this is that the bearing surface side (left of center) is hardened to prevent wear.

When facing the rear of the mower (operator's position) measure the distance from end of shaft to the first hole. A measurement of 1-1/32 inch is the left end. The other end will measure 1-5/16 inch to the first hole as illustrated.


“F” SERIES GEAR DRIVE SELF PROPELLED SERVICING LUBRICATION

25 Hours

1.

2.

3.

DRIVE GEAR BEARINGS-Remove cross- shaft cover on rear of mower housing (secured by two screws). Remove inner top cover to ex- pose gears (secured by two clamps). Apply grease through each grease fitting until grease appears a t point “A.” USE LAWN-BOY “A” GREASE.

DRIVE GEARS-Apply a liberal amount of lubricant on all surfaces of teeth on both gears a t point “B.” USE LAWN-BOY “A” GREASE.

DRIVE ROLLER BEARINGS-Unscrew plug from end of each drive roller. Fill exposed cav- ity with LAWN-BOY “A” GREASE. Replace plug and tighten until snug. Point “C.” Repeat procedure until lubricant appears on cross- shaft a t Point “D.”

NOTE

Do not lubricate the wheels or axle bolts. The lubricant can accumulate dirt and debris accelerating wear.

AS REQUIRED

4. CLUTCH LINKAGE-Apply several drops of light machine oil on clutch at Point “E” as shown.

TOP COVER REMOVED FOR ILLUSTRA- TION


“F” SERIES GEAR DRIVE SELF-PROPELLED - Toro F” SERIES GEAR DRIVE SELF PROPELLED...

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