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Toro 20016

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2. Raise the front of the mower off the bench and support it with blocks. 3. Disconnect the shift cable.

Fig 006

3428-0131
6. Place a block of wood under the wheel pinion for support and drive the roll pin out of the axle (Fig. 007). Repeat the process on the other side. 8. Remove the transmission from the chassis. 9. Reverse the procedure to install. NOTE: Support the wheel pinions with the wood block while driving the roll pins in. This will prevent the axle from being bent. Fill the transmission with oil after it is installed in the mower (Fig. 009). Note the front of the transmission is identied by the oil ll/check screw and the at tab which is part of the lower case.

Fig 007 3428-0135

A. Wood Block
7. The wheel pinion, thrust washer, pivot, and spring arm will now slide off the end of the axle (Fig. 008). Repeat the process on the other side.

Fig 009

3428-0166

A. Fill/Check B. Plug

C. Tab

Disassembly

1. Cut and discard the push-on retainer on top of the transmission pulley. Remove the belt and pulley.

Fig 008

3428-0137
2. Drive the roll pins out of the anges in the front and rear of the case. (These pins align the top and bottom parts of the case) (Fig. 010). 5. Push the worm shaft out of the cover. This may require a little pressure. 6. To remove the axle, slide the clutch jaw to the side and drive the roll pin out of the sleeve and axle (Fig. 012).

Fig 010

3428-0146

Fig 012

3428-0151
3. Remove the 4 self-tapping screw that connect the top and bottom cases. Note: If you turn this transmission on its side or upside down, oil may leak out of the top. This is not a sealed case. 4. Remove the transmission cover. The shift fork may come with the cover or may fall into the bottom of the case (Fig. 011). 7. If the axle bearings are to be re-used, clean the end of the axle before drawing it out of the case. 8. Remove the sleeve, clutch jaw, helical gear, and thrust washer (Fig. 013)

A B C D

Fig 013 Fig 011 3428-0148

3428-0153

A. Helical Gear B. Thrust Washer

C. Sleeve D. Clutch Jaw

9. Clean the old gasket material from the mating surfaces of the case and cover. 10. A hook or small screwdriver can be used to pry the seals out of the case. 11. An arbor press or large vise will be needed when removing and replacing the bushings. 12. Clean the oil residue and any metal shavings from the case. 13. Worm and helical gears are sold as a set. Even after a short run time, they will develop a wear pattern. Replacing only one gear will result in rapid failure (Fig. 014). 14. Remove the screw from the shift arm and remove the shift arm, dust cover, and wear plate (Fig. 015). If the ball bearing is to be replaced, press it out at this time.

Fig 015

A. B. C. D. Roll Pin Latch Plate Dust Filter Dust Cover

Fig 014 3428-0157

15. Remove the roll pin and pull shifter rod out of the cover. Clean the cover.

A. Worm Shaft

B. Helical Gear

Assembly

1. Use bushing installation tool P/N 27-0460, to press in new axle bushings. This tool helps keep the bushing straight and keeps the inner diameter of the bushing correctly sized.
Note: The bushings are two different lengths. The side of the case with the thicker boss uses a longer busing to support the axle. The bushings should be ush with the inside of the case (Fig. 016). 3. Note: Some replacement axles have more than one hole that can be used to pin the sleeve to the axle. Refer to the original axle to identify the correct hole to use. Then drive a roll pin through the sleeve and axle (Fig. 017).

Fig 016

3428-0158

Fig 017

A. Tool P/N 27-0460 4. Using a seal protector, slide new seals down each side of the axle, Install the seal with the lip facing the transmission. The outer edge of the seal should be ush with the outside of the case. If a seal protector is not available, wrap a piece of cellophane around the axle (Fig. 018).
2. Clean the rust and dirt from the both ends of the axle. Wipe the inner diameter of the bushings with a clean cloth. Lightly oil the axle and insert it into the gearcase. When facing the front of the gearbox, insert the short end of the axle from left to right. Install the thrust washer, helical gear, and the sleeve and clutch jaw. Then push the axle through the other side of the case.

Fig 018

3428-0170
A. Seal protector or Cellophane

B. Seal

5. If the bearing in the cover is being replaced, use tool P/N 27-0490 to press it in place. This bearing only has one seal. Install the bearing such that the seal is visible from the top of the cover and the open side faces the gears. Press the bearing in until it is fully seated in the case (Fig. 019). 9. Fill the transmission with gear oil AFTER it is installed in the mower. The top of this transmission is not sealed. It will leak if tipped on its side (Fig. 020).

Fig 020 3428-0166

A. Fill/Check

Fig 019 3428-0159

B. Plug

A. Tool P/N 27-0490

Controls
6. Install worm shaft in bearing. 7. Use a new gasket. Install the cover on the bottom case and start the 4 self-tapping screws. Do not fully tighten them. 8. Install the front and rear roll pins to align the cover and case. Then secure the 4 self-tapping screws. There are two control cables used with this system. One cable operates the engine kill switch and ywheel brake; the other controls the transmission.

Adjustment

The transmission cable is a standard lever type. Since the spring and pin on top of the transmission pushes the shift fork towards the engaged position, the cable pulls the shift arm to the rear to disengage the transmission. The adjustment point is on the mower housing just to the rear of the transmission. To adjust, pull the control to the rear (disengage). Go to the cable clamp/adjustment. Loosen the clamp, pull the cable to the rear until the shift lever is as far back as it will go. Hold it there and tighten the clamp (Fig. 021).

Fig 021

3428-0127

A. Cable Clamp

CONSTANT MESH
This transmission is very similar to the INTERNALLY CLUTCHED on page 1 1. However, the helical gear is different as there is no internal clutching (Fig. 022). Engagement and disengagement is accomplished by pivoting the transmission to tighten or loosen the belt. Internal repair procedures are the same, as is the lubrication requirement, 90 wt. gear oil rated GL-5 or higher. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Jam nut Lock washer Half pulley V Belt Pulley spacer Gearbox cover Shaft & worm Ball bearing Gearbox gasket Check plug Gasket check plug Bushing 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Oil Seal Output shaft Traction bracket Thread forming screw Gearbox case Thrust washer Roll pin Helical gear Thrust washer Bushing Roll pin
The constant mesh type transmission is used in a 48cm rear wheel drive application.

Fig 022

g 18-A

Removal and Installation

Fig 023

20911B sprearaxleassy

Ref. No. 14 15

Qty 2 2

Description Rear Pivot Assembly RH (incl. Ref. #2, 4, 5 & 14) Grease Fitting Washer Sleeve Bushing Grease Seal Rear Pivot Assembly LH (incl. Ref. #3, 4, 5 & 14) Locknut Thread Forming Screw Trigger Return Spring H.O.C. Saddle Thread Forming Screw Push Nut Needle Bearing Friction Washer

Ref. No. 35

Description Keyed Thrust Washer Retaining Ring LH Rocking Key Pinion Gear Compression Spring Wheel Cover Tire & Gear Assy Wheel (incl. Ref. #24) Wheel Bolt Wheel Bushing Wheel Spacer Clutch Washer Rear Suspension Plate Thread Forming Screw Roll Pin Gearbox Assembly
To remove the transmission from the mower proceed as follows: 1. Remove both rear wheels. 2. Remove the retaining rings, springs, gears, keys, clutches, and pivot arms on both sides (Wheel Pinion Clutch on page 5-2). 3. Remove the belt. 4. There is a suspension bracket on each side that secures the transmission and pivot arms to the chassis. Each bracket has 2 screws. Once they are removed, the transmission will drop out. To install, reverse the above process. Fill the transmission level with the ll plug opening after it is installed in the chassis. The top of the transmission is not sealed, so it may leak if lled and tipped.

Fig 032

3428-0121

A. End cap

Fig 030 PICT-1880a
Transmission Internal Repair
7. The transmission can be moved to the right until the short end of the axle clears the housing and the transmission can be removed (Fig. 031). Some models have the axle shaft retained by an end cap. The nut on the pulley can be removed now. The spacer under the pulley varies with the chassis and the length of the shaft on the pinion (Fig. 033). Remove the selftapping screws holding the cover on the transmission.

Fig 031

3128-0074

Fig 033

3428-0008
Before removing the parts from the case, note the quantity and location of the thrust washers (Fig. 034). Clean the gears in solvent and inspect carefully. Any damaged gear must be replaced. Also replace the mate for the damaged gear. When gears run together, they develop a wear pattern that will result in premature failure if only one gear is replaced. The exception for this is if the transmission has VERY little running time before failure. The axle has two roll pins through it. One connects the single spur gear to the axle (Fig. 036). The other pin aligns the axle and transmission case.

Fig 034

108-8140-1b
Remove the axle and intermediate shaft with the gears. The bearing in the cover should be sealed on both sides. Inspect the bearing and its seals for damage (Fig. 035). Replace as necessary. The bearing is pressed into the cover. Make sure bearing is fully seated.

Fig 036 3428-0016

Assemble with the correct number of thrust washers. Refer to the parts manual if there is any doubt at all. It is not possible to locate the shafts and bearings in the wrong location, due to differences in sizes.

Fig 035

3428-0018
Prior to installation of oil impregnated bushings, it is wise to apply a light coating of engine oil to the running surface (Fig. 037). Add grease and install the cover. Insert the transmission back into the chassis. Refer to the section on the wheel pinion clutch for assembly instructions. Install self propel cable. Adjust as needed; see Handles and Control Cables Section 7.

Fig 037

3428-0019
Finally, install the spacer and pulley on the input shaft. The internal gears will help hold the pinion while the nut is tightened (Fig. 038).

Fig 038

3428-0022
EXPLODED VIEW - SINGLE SPEED BEVEL GEAR TRANSMISSION
A B C D E F I H L G J K M

Fig 039

single speedtrans a

A. B. C. D. E. F. G.

Nut Washer Pulley Spacer Housing Bearing Pinion

H. I. J. K. L. M.

Bushing Thrust washer Bevel Gear Bushing Roll pin Axle

GENERAL INFORMATION

This transmission was rst used on 22 steel deck models for 2002. It is used in both front wheel and rear wheel drive congurations. The bevel gear is reversed when used in the front drive versus the rear drive to change axle shaft direction of rotation. In both cases, the gears are in constant mesh. Clutching is done by rocking the transmission to tighten or loosen the drive belt (Fig. 040). The control cable will move the transmission to tighten the belt. When released, the weight of the transmission causes it to rock towards the engine to disengage.

Fig 040

MVC-485
FRONT AXLE AND TRANSMISSION ASSEMBLY

3354-613 Rev A

Fig 041

3354-613(5)

Ref. No. 2:7 7:1 7:13
Description Bolt-Shoulder Wheel Gear ASM Bushing Klipring-Locking Gear-Pinion, 13T Washer-Thrust Cover-Wheel Cover Washer-Stepped Arm-Pivot, Front Arm-Spring Knob-Lever, HOC Ring-Retaining Retainer-Bearing, HOC Bearing-Ball

Ref. No. 26 27

Description Spring-Compression Key Transmission ASM Gasket-Gearbox Screw-HWH Bracket-Pivot, Fwd Screw-HWH Spacer V-Belt Pulley-Half, Front Washer-Flat Nut-Lock Cover-Belt, Front Washer
22 FRONT WHEEL DRIVE MODELS

Remove Transmission

1. Block the front of the mower up. There are two screws that secure the belt cover to the housing. They are accessed from the bottom (Fig. 042). 4. Remove the nut, washer, transmission pulley halves, and spacer. 5. Remove the belt guide. 6. Remove both front wheels; note there is a washer between the wheel and wheel cover. 7. To remove the wheel pinions, remove the klip ring and thrust washer. The pinion will now slide off the axle (Fig. 044). Note: The spring-loaded drive key is under the pinion.

Fig 042 MVC-482

2. Slip the belt out between the transmission pulley and belt guide. 3. Grip the axle with locking pliers and remove the locknut on the transmission pulley (Fig. 043)

Fig 044 MVC-472

A. Key

B. Wheel cover

8. Remove the wheel cover.

Fig 043

MVC-486
9. Remove the two bolts and nuts securing each pivot arm to the housing. There is a notch in the pivot arm for clearance of a socket (Fig. 045). 10. Remove the klip ring and thrust washer from each end of the axle (the left side has 2 thrust washers, the right side, one). The bearing, bearing retainer, HOC plate, spring arm and pivot arm all come off as one unit (Fig. 047).

Fig 045

MVC-475 Fig 047 PICT-1858a
The axle assembly will now drop out of the chassis (Fig. 046). 11. To disassemble the pivot arm assembly, compress the components with two clamps or locking pliers (Fig. 048).

Fig 075

MVC-740

Rear Axle Disassembly

1. Remove the klip rings and thrust washers that secure the pinions to the axle (Fig. 077). 4. The pivot assembly will slide off the axle. This includes the bearing, bearing retainer, HOC plate, spring arm, and pivot arm (Fig. 079).

Fig 079 Fig 077 MVC-746

MVC-747
2. When removing the pinions, note that there is a spring-loaded key under them. 3. Remove the other thrust washer and retaining ring holding the pivot assembly to the axle (Fig. 078).
5. Clamp the pivot assembly with 2 pairs of locking pliers or other clamps and remove the snap ring (Fig. 080).

Fig 080

MVC-748

Fig 078

MVC-850
6. You can now release the clamps and separate the HOC plate, spring arm, and pivot arm (Fig. 081). 2. Since the pulley was previously removed, the input shaft will now slip out of the transmission case. 3. If the input bearing is to be removed, press it out now. 4. Slide the bearings and thrust washer off the axle. Drive the roll pin out and the bevel gear can be removed (Fig. 083).

Fig 081

MVC-750
1. Remove the 4 screws holding the cover on the transmission. The axle, bearings, and bevel gear can be lifted out (Fig. 082).

Fig 083 MVC-470

Assemble in reverse order.

Fig 082

Axle Assembly Tips
1. The same axle is used for both front and rear wheel drive models. There are two holes in the axle about one inch apart. Rear wheel drive models use the hole about 4-3/4 (12cm) from the end. Slip the gear on such that the teeth and the longest hub face the short end of the axle. Drive the pin into place. A double check is that neither of the pin holes should be visible when the gear is installed (Fig. 084). 3. Install the transmission bearings with the ange facing the gear (Fig. 085).

Fig 085

4. Fill the transmission approximately 2/3 full with #2 Lithium base grease (1.5 oz or 43gm). 5. Assemble the bearing, bearing retainer, HOC plate, spring arm, and pivot arm. Use two vise grips or clamps to compress the assembly so the snap ring can be installed (Fig. 086). Note: Install the snap ring with the sharp edge facing away from the spring arm.

Fig 117 3428-0065

The shift keys are retained on one end by the shift collar. Movement of the shift fork positions the shift collar and shift key. The shift fork is supported, both top and bottom, by nylon bushings for smooth operation and long wear (Fig. 117).

C. Keys

The operator controls movement of the shift fork by means of the gear selection control and cable. Note: There are no shift detents in or on the transmission on 1988 and newer mowers.
Removal - Toro Vacu Power/Lawn-Boy Medallion Models
Complete transmission removal on the Toro Vacu Power/Lawn-Boy Medallion mower is quite easy and is recommended for most self-propel system repairs. 1. Remove the spark plug lead from the engine to prevent accidental starting. Drain the fuel and oil. 2. Place the ground speed selector in neutral. This will make it easier to remove the speed selection cable later. 3. Remove the two anged head self-tapping screws securing the screen panel to the housing and remove the panel (Fig. 118). 4. Remove the black plastic transmission cover from the top rear of the housing. 5. Remove the two anged head self-tapping screws securing the belt cover to the top of the transmission. Pull the cable from belt guide and remove the belt guide. 6. Remove the transmission access cover from the rear of the housing by pressing from underneath. 7. Loosen the gear selection control cable clamp screw until the cable comes free. Do not attempt to remove the gear selection cable from the control arm at this time. 8. Turn the mower onto its right side and remove the four anged head self-tapping screws securing the end caps to the housing (Fig. 119).

Fig 118

g 94 Fig 119 3428-0121
A. Screen panel B. Screws
C. Transmission access cover A. End cap
9. Slowly pull the transmission from the housing being very careful not to damage the gear selection cable. Once clear of the housing, rotate the assembly until the cable can be safely removed.
Removal - Recycler/Rear Bagger Chassis
To remove the transmission from the chassis, raise the rear and support it with blocks. 1. Remove both rear wheels and wheel covers. 2. Remove the rocking key clutches (see Wheel Pinion Clutch on page 5-3). 3. Slide the pivot arm and spring arm off the axles. 4. Remove the belt cover. Loosen the belt guide and slip the belt off the pulley. Disconnect shift and clutch cables. 5. Slide the transmission to the right to slip the short end of the axle out of the chassis.

Fig 140

3428-0040
16. Slip the wheel, the original number of spacers, and the wheel cover onto the shoulder bolt and secure to the pivot arm using the nylon locknut. 17. Grease with No. 2 lithium-based grease. Use a hand grease gun to avoid excess pressure that may prevent the friction parts from working. As a rule, use two pumps to ensure that you do not over-grease. Be sure to grease after every 25 hours of use for maximum service life.
GEARCASE AND WHEEL ASSEMBLY, SPRING RATCHET STYLE

Fig 141

Spring Ratchet Style
The Spring Ratchet type wheel clutch system has been used on a wide variety of models. It consists of a spring supporting a drive key which engages the pinion. When the mower drive is engaged the axle turns the key which is engaged with an internal tooth on the pinion. The pinion turns the wheel gear. When the mower is pushed or turned, the pinion must rotate faster than the axle. As the pinion rotates it depresses the key, allowing the differential action. The axle drives both keys and pinions equally but they will ratchet individually. When the mower is pulled backwards, this type of clutch does not disengage. It will require the axle and transmission to turn backwards. It is critical to easy backing to make sure the self propel belt properly disengages.

WHEEL PINION SERVICE

The steps to service the wheel pinions are the same for both front and rear wheel drive models. 1. Raise the mower until the wheel is off the ground. Support with a block. 2. Remove the wheel bolt, wheel and wheel cover (Fig. 142).

Servicing the System

The things that can impede the function are dirt, rust or wear. The owners manual requires that ordinary engine oil be added to each side of the pinion periodically. This is to keep the anti seize from drying up. If that is not done, it will be necessary to remove the pinion, key and spring to clean and re-lubricate with anti-seize compound. On the left side there will be two keyed thrust washers and one regular thrust washer. Clean the end of the axle, keyway, and the parts removed. Inspect the key; if worn, replace. Make sure the thrust washers have the key tab on them. If the tab is broken, the pinion will tend to push the retaining rings out of their grooves. Lubricate the key, spring, and axle with anti-seize compound and reassemble. Note the pinion has the letter R stamped on one side and L on the other. If you are on the right side of the mower, the letter R should face you when you install the pinion. The letter L should be visible on the left side of the mower.

Fig 142

MVC-739
3. Remove the retaining ring and thrust washer (Fig. 143).

Fig 143

MVC-746
4. Slide the wheel pinion off the axle. Note: There is a spring-loaded key under the pinion (Fig. 144). Reassemble in reverse order: 1. Install one thrust washer, then the rst retaining ring with the sharp edge facing the chassis (Fig. 145).
Fig 144 MVC-850 Fig 145 MVC-472
A. Retaining ring and thrust washer
B. Key 2. Lubricate with anti-seize and assemble in the original order.
5. Behind the pinion should be another thrust washer and retaining ring (Fig. 000). (MVC-850)

BBC / BOS / BCS

BLADE BRAKE CLUTCH SYSTEM (BBC)
There are two basic blade clutching system designs. The rst is commonly referred to as the BBC or Blade Brake Clutch. It has two versions which have been used on many Toro models as well as Lawn-Boy Medallion mowers. The second design was introduced in 2005 and is used on Toro (Blade Override System) and Lawn-Boy (Blade Clutch System) (Fig. 146 and Fig. 147). The blade clutch system offers the customer convenience to stop the blade while allowing the engine to continue to run. Before troubleshooting the BBC deck mechanism, be sure that it is adjusted properly. Refer to the BBC cable adjustment section for proper adjustments.

BBC Clutch Operation

The clutch operates by using a ywheel which turns with the engine crankshaft and a brake drum and blade that are free to turn separately from the ywheel. The two are connected by tensioning a drive belt between the ywheel and brake drum. The combination idler arm and brake controls the belt. When the control is engaged, the idler with the brake pad backs away from the brake drum and tightens the belt. When the control is released, a spring causes the idler to pivot towards the brake drum releasing the belt and engaging the brake. This stops the blade but allows the ywheel and crankshaft to continue to turn.
BBC Control Box Operation

Fig 146 3428-0001

The BBC control mechanisms purpose is to actuate the deck mechanism. It does this by tensioning and loosening the BBC cable. The control mechanism meets the federal governments 2-step blade engagement procedure. The traction drive can also be integrated with this control system.

Fig 147

3428-0004
The normal or at rest position of the control bar is indicated by the number 1 in the Figure 148. In order to engage the blade, the operator must rst cock the control bar down to position 2, then raise the control bar to position 3.

Handle Controls

The control box components and their functions (Fig. 149) are described below.

Fig 148

Fig 157

A. BBC cable lever

Fig 156 g 35

B. BBC cable
A. Control hook B. Roll pin ush with this side

C. Cable lever

8. Slip the white nylon washer onto the J end of the buckling spring. The slotted side of the washer should face away from the end of the spring. Slip the spring into position in the rocker arm and the left control housing as shown in Figure 158. 10. Before installing the right control housing, check to make sure that both cable sheath ends are fully seated in their slots in the left housing. Also make sure that the sleeve passes through all components including the left control housing. Finally, make sure that the roll pin passes through the rocker arm and control bar. Install the right control housing and secure with the 2 nylon locknuts or 1 locknut and 1 ange nut.
11. Install the 3 anged head screws that retain the two control box halves. 12. Check for proper operation of the entire BBC system. Correct as required. 13. Bend the throttle control locking tab forward to provide positive lock with the throttle control and install the throttle control. 14. Adjust the BBC cable and traction cables as needed. See page 7-16.

Fig 158

3428-0281

A. Nylon washer

B. Buckling spring
9. Assemble the right control housing by installing the leaf spring and pin to retain the leaf spring (Fig. 159).

Fig 159

MVC-488
TORO BBC SERVICE GUIDE Disassembly Sequence

Fig 160

bbc scan
BLADE BRAKE CLUTCH ASSEMBLY (Toro Vacu Power/Lawn-Boy Medallion BBC)

Fig 161

bladebrakeclutchassy

Ref. No. 21

Description Brake Shoe Plate Hub V Belt Pulley Hub Lock Nut Spring Rod Shoulder Bolt Compression Spring Flange Bushing Lever Wa Bushing Ring Seal HWH Screw TAP Screw Flange Nut Cable Bracket Support Flat Washer Bellcrank Bushing Crank Spring Pin Control Link

Ref. No. 46

Description HH Screw Compression Spring Spring Retainer Woodruff Key Driver Pulley BBC Flywheel Blade Bolt Brake Drum Hub ASM BBC Shield Blade Spacer 21 Blade Anti Scalp Cup Lock Nut Lock Nut BBC Screen Vibration Damper Idler Pulley HH Screw Thd Forming Screw Flat Washer
TORO VACU POWER/LAWN-BOY MEDALLION BBC
2. Pull the black plastic transmission cover up to remove it from the housing (Fig. 164).

Fig 162

DSC-068a

Fig 164

3428-0082
Bellcrank System Disassembly (Toro Vacu Power/Lawn-Boy Medallion)
1. Remove the anged head self-tapping capscrews securing the upper BBC cover to the housing and remove the upper BBC cover (Fig. 163).
3. Remove the shoulder bolt and anged nut securing the bellcrank to the control cable bracket. Once loose, remove the bellcrank assembly complete with control link from the unit (Fig. 165).
Fig 165 3428-0090 Fig 163 3428-0079

Ensure the transmission belt is disengaged, transmission tilted forward. Loosen the cable clamp on the handle. When you pull the cable down the Personal Pace/Easy Stride handle should raise to the stop. Hold the cable and secure the clamp (Fig. 243).

Lawn-Boy 2 Bail Handle

The 2 bail style is shown here (Fig. 244). The top bail is the engine stop. Release it and the ignition is grounded and a brake comes on to help stop the ywheel. The lower bail is the self propel bail. Squeeze it to tension the belt and drive the transmission.

Fig 244 Fig 243 DSC-4829

The engine stop cable is not adjustable. If it does not function, it must be replaced. The self propel cable is adjustable through a clamp. It should be adjusted so that lowering the bail about 1 (25mm) disengages the self propel. This is a gap that is comfortable for most operators.

Lawn-Boy Sens-a-Speed

On blade clutch models, the engine on and off is controlled by a switch on the left hand handle. The bail engages and disengages the blade. The Sens-a-Speed handle controls the self propel the same way as on a zone start model.
Handle Disassembly, Zone Start Models
1. Loosen the cable clamp and disconnect the Sens-aSpeed cable (Fig. 246).

Fig 245

DSC-4864a

A. Top bail

The Lawn-Boy Sens-a-Speed handle is made in two forms, zone start and blade clutch. The basic function is the same but the addition of the blade clutch mechanism makes the handle for those models a little more complex.

Fig 246 DSC-4869a

The top mounted bail is the engine stop control on zone start models and the blade control on blade clutch models. On a zone start model, pull the top bail down and hold to keep the engine running. The Sens-a-Speed handle telescopes and as it is depressed tensions the transmission drive belt. To operate this keep your elbows at your sides, hold your hands straight out in front of you and walk. If you want to go faster, walk faster. Do not push the Sens-a-Speed handle down. That will activate the drive too aggressively and the mower will jump forward.
2. Squeeze the ends of the upper bail to disengage them from the handle. On some models the right side of the bail may be connected to the pin by a push nut. The push nut can be removed or the bail removed with the pin attached (Fig. 247). 4. Slide the pin out of the left hand handle and pull the upper handle up and out. 5. The plastic sleeves will slide off the upper handle. 6. The springs can be removed from the top slides if necessary.
If the handle has been binding, clean the top slides and the sleeves before assembling. Dirt and grit in the sliding part of the handle can cause a bind. Assemble in reverse order. When you install the upper handle, line up the holes and install the pivot pins (Fig. 249).

Fig 265

348-0172

Fig 264

On BBC models, the control bail also controls the transmission belt engagement. The adjustment point is a knob about halfway between the control panel and transmission. Ideally, the cable should be set so that the transmission drive will disengage when the bail is lowered about 1 (25mm). This allows the bail to be lowered so that the wheels stop driving and the BBC remains engaged, but the gap isnt so large that the handle is hard to hold (Fig. 266). This measurement is not an exact requirement. It can be varied to accommodate a customer with small hands, etc.

Toro BOS Control

The BOS control is the upper bail on the handle. For the required 2 step engagement, there is a pivoting stop on the right hand handle. Rotate it out of the way and then pull the bail down for blade engagement (Fig. 267).

Fig 267

MVC-102

A. Pivoting stop

Fig 266 g 20
Toro BOS Control Cable Adjustment
The blade clutch control is adjusted by removing the cover between the engine and bag door. Loosen the cable clamp and draw the cable to the rear to remove the slack. Now push the cable outer jacket forward 5/8 (1.5cm) and secure. This will create 5/8 (1.5cm) slack in the cable (Fig. 268).
Lawn-Boy BCS Control Cable Adjustment
Lawn-Boy Insight and Insight Gold: 1. Remove the grass bag and tunnel (Fig. 270).

Fig 270

DSC-5360a

Fig 268

MVC-BOS457x

Lawn-Boy BCS Control

To engage the blade clutch, press the control button. Then pull the control bar to the handle. To disengage the blade, release the control bar. (Fig. 269).
2. Loosen cable clamp. Draw cable to rear to remove slack. Now push outer jacket of cable forward 5/8 (1.5cm) and secure. This will create 5/8 (1.5cm) slack in the cable (Fig. 271).

Fig 271

DSC-5357a

Fig 269

lwpm_10797a
Lawn-Boy Insight Platimun: 1. Remove the gas and oil and tip the mower on its side with the air lter up. 2. Remove the BCS cover and belt cover. 3. Loosen the 2 cap-screws securing the bracket to the housing. Pull the cable to the rear to remove the slack. Push the cable forward 5/8 (1.5cm) and secure. This will create 5/8 (1.5cm) of slack (Fig. 272).

21 Cast Deck Mowers with 3 Speed Transmission
Made in both Toro and Lawn-Boy brands. To replace the belt, drain both the gasoline and oil from the engine. Remove the belt cover, just behind the engine on top of the mower, to access the transmission. Loosen or remove the belt guides so the belt can be replaced without forcing. See the section on the three speed transmission starting on page 4-1.
21 Toro and Lawn-Boy Mowers with Blade Brake Clutch
Part of the blade clutch must be disassembled to access the self propel belt. See the BBC section starting on page 6-1 for more information.
21 Toro Mowers with Blade Override System and Lawn-Boy Mower with Blade Clutch System
Part of the BOS or BCS must be removed to replace the self propel belt. (See page 6-18 for more information.) The Lawn-Boy Insight has a black access cover just to the rear of the engine on top of the chassis. Remove it for easy access to the top of the transmission.
21 Lawn-Boy Insight Mowers
The Zone Start models use a basic self propel system. See Transmission Remove and Replace, page 3-19, which also explains the belt replacement process.

doc1

Purchase a Toro Recycler Mower from March 30 through July 5, 2006 and get an extra year of FULL coverage warranty

Valid Recycler Models:

20005, 20016, 20017, 20041, 20047, 20070.
To ensure that you receive this additional coverage free, follow these easy steps:
Retain this form/warranty statement amendment with your original proof of purchase. Should warranty coverage be necessary, you will need to provide a dated proof of purchase to your service outlet.
We strongly encourage you to register your product on-line at www.toro.com or use the registration card that came with the mower.

490-7507

Amendment to the Toro Total Coverage Guarantee and The Toro Starting Guarantee on GTS-2 (Guaranteed to Start) Engines
The warranty period for the above noted warranty is hereby amended as follows:
Conditions and products covered under the Toro Total Coverage Guarantee
The Toro Company and its affiliate, Toro Warranty Company, promise to repair any Toro products used for residential purposes* if defective in materials or workmanship or if it stops functioning due to the failure of components. The following time periods apply from the date of purchase: Products Recycler Walk Mowers Batteries Warranty Period 3 Year full warranty 1 Year full warranty
This warranty covers the cost of parts and labor, but you must pay transportation costs. Conditions and products covered under the Toro Starting Guarantee
The Toro Company and its affiliate, Toro Warranty Company, guarantee that your Toro GTS-2 Engine, when used for residential purposes*, will start on the first or second pull for three years from the date of purchase, if you provide the routine maintenance it requires, or we will fix it free of charge. This warranty covers the cost of parts and labor, but you must pay transportation costs. All other terms and conditions of the above noted warranty remain unchanged. This amendment is valid only for Toro Recycler models: 20005, 20016, 20017, 20041, 20047, 20070 purchased during the time period of March 30 - July 5, 2006. * Residential purposes means use of the product on the same lot as your home. Use at more than one location is considered commercial use, and the commercial use warranty would apply. 490-7507

 

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