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Toro TIMECUTTER HD 75202 User Manual

Toro TIMECUTTER HD 75202
153 pages
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Residential Products
Service Manual
TIMECUTTER® HD
Issued: April 2017

Table of Contents

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Toro TIMECUTTER HD 75202 Specifications

General IconGeneral
BrandToro
ModelTIMECUTTER HD 75202
CategoryLawn Mower
LanguageEnglish

Summary

About This Manual

Manual Scope and Introduction

Provides introductory information about the service manual's purpose and scope.

Icon Legend

Symbol and Icon Explanations

Explains the meaning of symbols and icons used throughout the manual for clarity.

Safety

General Safety Information

Essential safety guidelines and precautions to prevent injury and equipment damage.

Think Safety First

Specific safety advice and warnings covering potential hazards during operation.

Specifications

General Specifications Overview

Key operational and dimensional data for various TIMECUTTER HD models.

Unit Dimensions

Physical measurements and weight of different TIMECUTTER HD models.

Mower Deck Specifications

Specifications related to the mower deck, including width and configuration.

Engine Model Specifications

Specifications for models equipped with Toro and Kawasaki engines.

Mower Deck Specifications (Cont.)

Further details on mower deck specifications for specific models.

Toro Engine Specifications

Specifications for models equipped with Toro engines.

Mower Deck Specifications (Cont. 2)

Additional mower deck specifications for specific models.

Unit Dimensions (Detailed)

Detailed measurements and weight for all TIMECUTTER HD models.

Torque Specifications

Guidelines for applying torque to fasteners to ensure proper assembly and safety.

Fastener Identification

Identification of different grades and classes for bolts and screws.

US Standard Torque Specifications

Torque values for US standard fasteners, including various grades and thread sizes.

Metric Standard Torque Specifications

Torque values for metric fasteners, including various classes and thread sizes.

Additional US Torque Specifications

Torque specifications for wheel bolts, lug nuts, and thread cutting screws.

Equivalents and Conversions

Tables for converting between decimal, millimeter, and fractional measurements.

US to Metric Conversion Factors

Factors for converting linear, area, volume, weight, pressure, work, and liquid measurements.

Maintenance

Recommended Maintenance Schedule(s)

Overview of maintenance tasks and their recommended service intervals.

Recommended Maintenance Chart

Detailed chart outlining maintenance tasks based on operating hours or time intervals.

Servicing the Toro Engine

Procedures for maintaining the Toro engine, including air cleaner and oil servicing.

Servicing the Air Cleaner

Steps for cleaning and replacing the air cleaner foam and paper elements.

Removing Air Cleaner Elements

Step-by-step instructions for removing the air cleaner foam and paper elements.

Cleaning Foam and Paper Elements

Methods for cleaning the foam and inspecting the paper air filter elements.

Servicing the Engine Oil

Procedures for checking and changing the engine oil and oil filter.

Checking the Engine Oil Level

Instructions for checking the engine oil level before each use or daily.

Checking Engine Oil Level (Cont.)

Detailed steps for checking and adding engine oil to maintain proper levels.

Changing Engine Oil and Oil Filter

Procedure for draining old oil and replacing the engine oil filter.

Changing Engine Oil and Oil Filter (Cont.)

Steps for completing the oil filter change and filling with new oil.

Servicing the Spark Plug

Information on checking and replacing spark plugs at specified intervals.

Removing the Spark Plug

Procedure for safely removing the spark plug from the engine.

Checking the Spark Plug

Instructions for inspecting spark plug condition and gap.

Installing the Spark Plug

Procedure for correctly installing a new or cleaned spark plug.

Cleaning the Cooling System

Steps for cleaning the engine's cooling system for optimal performance.

Fuel System Maintenance

Procedures for maintaining the fuel system, including filter replacement.

Replacing the In-line Fuel Filter

Step-by-step guide for replacing the inline fuel filter.

Electrical System Maintenance

Procedures for maintaining the electrical system, focusing on the battery.

Servicing the Battery

Instructions for charging and testing the battery.

Belt Maintenance

Procedures for inspecting and replacing mower and hydrostatic drive belts.

Inspecting the Belts

Guidelines for identifying worn or damaged belts.

Servicing the Cutting Blades

Safety precautions and procedures for maintaining cutting blades.

Inspecting the Blades

Steps for inspecting cutting edges, curved areas, and checking for wear or cracks.

Checking for Bent Blades

Method for checking if the cutting blades are bent using a level surface.

Changing the Blades

Procedure for removing and replacing mower blades.

Blade Removal

Steps to safely remove the blade bolt, washer, and blade from the spindle.

Blade Installation

Procedure for installing new mower blades, including torque specifications.

Sharpening the Blades

Instructions for sharpening and balancing mower blades for optimal performance.

Troubleshooting

Troubleshooting Table

A table listing common problems, their potential causes, and recommended solutions.

Starter Not Cranking

Troubleshooting steps for when the starter motor does not crank the engine.

Engine Not Starting or Running Rough

Steps to diagnose why the engine fails to start or run smoothly.

Engine Loses Power

Troubleshooting steps for when the engine experiences a loss of power.

Engine Overheats

Troubleshooting steps for an engine that is overheating.

Uneven Cutting Height

Troubleshooting steps for producing an uneven cutting height.

Blades Do Not Rotate

Troubleshooting steps for when the mower blades fail to rotate.

Chassis

Caster Tires Exploded View

Exploded view illustrating the components of the caster tire assembly.

Motion Control Assembly

Procedures for removing and installing the motion control assembly.

Caster Tires Exploded View (Detailed)

Detailed diagram of the caster tire and wheel assembly.

Caster Assembly and Bearing

Instructions for removing and installing the caster assembly and its bearings.

Caster Wheel Bearing

Procedure for removing and installing the caster wheel bearing.

Left Console Removal

Procedure for removing the left console assembly from the machine.

Left Console Installation

Steps for reinstalling the left console assembly onto the machine.

Right Console Removal

Procedure for removing the right console assembly from the machine.

Right Console Removal (Cont.)

Continuation of steps for removing the right console assembly.

Right Console Installation

Steps for reinstalling the right console assembly onto the machine.

Seat Removal (ZX Models)

Procedure for removing the seat assembly from ZX model TIMECUTTER HD.

Seat Installation (ZX Models)

Procedure for installing the seat assembly onto ZX model TIMECUTTER HD.

Seat & MyRIDE™ Platform Removal (MR Models)

Procedure for removing the seat and MyRIDE™ platform from MR models.

Seat & MyRIDE™ Platform Removal (Cont.)

Continuation of steps for removing the seat and MyRIDE™ platform.

Seat & MyRIDE™ Platform Removal (Cont. 2)

Further steps for removing the seat and MyRIDE™ platform assembly.

Seat & MyRIDE™ Platform Removal (Cont. 3)

Final steps for removing the seat and MyRIDE™ platform assembly.

Seat & MyRIDE™ Platform Removal (Cont. 4)

Final procedures for lifting the MyRIDE™ assembly off the machine.

Seat & MyRIDE™ Platform Installation

Procedure for installing the seat and MyRIDE™ platform assembly onto the machine.

Seat & MyRIDE™ Platform Installation (Cont.)

Continuation of steps for installing the seat and MyRIDE™ platform.

Seat & MyRIDE™ Platform Installation (Cont. 2)

Final steps for connecting components and verifying function.

Fuel Tank Removal

Procedure for removing the fuel tank assembly from the machine.

Fuel Tank Installation

Procedure for installing the fuel tank assembly onto the machine.

Throttle Control Assembly Removal

Steps for removing the throttle control assembly from the console.

Throttle Control Assembly Installation

Steps for installing the throttle control assembly onto the console.

Throttle Control Assembly Installation (Cont.)

Continuation of steps for installing the throttle control assembly.

Choke Control Assembly Removal

Steps for removing the choke control assembly from the console.

Choke Control Assembly Installation

Steps for installing the choke control assembly onto the console.

Choke Control Assembly Installation (Cont.)

Continuation of steps for installing the choke control assembly.

Park Brake Handle Assembly Removal

Procedure for removing the park brake handle assembly.

Park Brake Handle Assembly Installation

Procedure for installing the park brake handle assembly.

Park Brake Handle Assembly Installation (Cont.)

Continuation of steps for installing the park brake handle assembly.

Motion Control Assembly Removal

Steps for removing the motion control assembly from the machine frame.

Motion Control Assembly Removal (Cont.)

Final steps for disconnecting the motion control assembly from the frame.

Motion Control Assembly Installation

Procedure for installing the motion control assembly and connecting linkage.

Adjusting Motion Control Handle Position

Instructions for adjusting the position of the motion control handles for operator comfort.

Engine

Engine Mounting Exploded View

Exploded view of the engine mounting for Toro twin cylinder engines.

Toro Twin Cylinder Engine Exploded View

Diagram showing exploded view of Toro twin cylinder engine mounting components.

Toro Twin Cylinder Engine Removal

Steps for safely removing the Toro twin cylinder engine from the machine.

Toro Twin Cylinder Engine Removal (Cont.)

Continuation of steps for disconnecting electrical and fuel connections.

Toro Twin Cylinder Engine Removal (Cont. 2)

Final steps for disconnecting cables, removing clutch, pulley, and mounting bolts.

Toro Twin Cylinder Engine Installation

Procedure for preparing the frame and lowering the engine into place.

Toro Twin Cylinder Engine Installation (Cont.)

Steps for installing the clutch, washer, and clutch bolt, and torquing.

Toro Twin Cylinder Engine Installation (Cont. 2)

Connecting ground wire and starter wire for Toro engine installation.

Toro Twin Cylinder Engine Installation (Cont. 3)

Connecting wire harnesses and fuel/vent lines for Toro engine installation.

Toro Twin Cylinder Engine Installation (Cont. 4)

Final steps: installing belts, muffler, guard, filling oil, and verifying function.

Kawasaki Engine Removal

Steps for safely removing the Kawasaki engine from the machine.

Kawasaki Engine Installation

Procedure for preparing the frame and lowering the Kawasaki engine into place.

Kawasaki Engine Installation (Cont.)

Final steps: connecting wiring, belts, muffler, guard, filling oil, and verifying function.

Hydrostatic Drive System

Hydrostatic Drive Exploded View

Exploded view of the hydrostatic drive system components.

Hydrostatic Drive Exploded View (Detailed)

Detailed diagram of the hydrostatic drive system components.

Using Drive Wheel Release Valves

Instructions for using the bypass valves to allow manual movement of the machine.

Neutral Adjustment

Procedure for adjusting the neutral setting of the motion control levers.

Neutral Adjustment (Cont.)

Continuation of steps for adjusting the neutral setting and verifying.

Tracking Adjustment

Procedure for adjusting the machine's tracking to ensure straight-line movement.

Hydro Change Procedure

Steps for changing the hydraulic oil in the hydrostatic drive system.

Purging Procedure

Procedure for removing air from the hydrostatic drive system after maintenance.

Hydrostatic Drive Belt Removal

Steps for safely removing the hydrostatic drive belt.

Hydrostatic Drive Belt Removal (Cont.)

Final steps for removing the drive belt from the pulleys.

Hydrostatic Drive Belt Installation

Procedure for installing the hydrostatic drive belt around the pulleys.

Hydrostatic Drive Belt Installation (Cont.)

Final steps for installing the idler spring and connecting the battery.

Hydrostatic Drive Transmission Removal

Procedure for removing the hydrostatic drive transmission from the right side.

Hydrostatic Drive Transmission Removal (Cont.)

Disconnection of bypass arm and brake linkage from the transmission.

Hydrostatic Drive Transmission Removal (Cont. 2)

Notes on overflow tubes and their orientation during transmission removal.

Hydrostatic Drive Transmission Removal (Cont. 3)

Steps for removing bolts securing the transmission to the frame.

Hydrostatic Drive Transmission Installation

Procedure for installing the hydrostatic drive transmission and its mounting hardware.

Hydrostatic Drive Transmission Installation (Cont.)

Connecting brake linkage and bypass arm to the transmission.

Hydrostatic Drive Transmission Installation (Cont. 2)

Connecting motion control linkage, installing drive belt, and drive wheel.

Hydrostatic Drive Transmission Installation (Cont. 3)

Adding hydraulic oil, purging air, and adjusting settings.

Mower Deck

Mower Deck Exploded View

Exploded view of the mower deck components.

Mower Deck Exploded View (Detailed)

Detailed diagram of mower deck components and their labels.

Deck Lift Assembly Exploded View

Exploded view of the deck lift assembly components.

Mower Belt Replacement

Procedure for replacing the mower deck belt.

Mower Belt Replacement (Cont.)

Continuation of steps for routing and installing the new mower belt.

Mower Deck Removal

Steps for safely removing the mower deck from the machine.

Mower Deck Removal (Cont.)

Final steps for unhooking chains and sliding the deck out.

Mower Deck Installation

Procedure for positioning and attaching the mower deck to the machine.

Mower Deck Installation (Cont.)

Final steps for installing the mower belt, covers, and verifying function.

Mower Spindle Removal

Steps for removing the mower spindle assembly.

Mower Spindle Disassembly

Procedure for disassembling the mower spindle components.

Mower Spindle Assembly

Procedure for assembling the mower spindle components.

Leveling the Mower Deck

Procedure for leveling the mower deck for optimal cutting performance.

Leveling the Mower Deck (Cont.)

Continuation of steps for measuring and adjusting blade height for deck leveling.

Leveling the Mower Deck (Cont. 2)

Using blocks and adjustment bolts to level the mower deck.

Leveling the Mower Deck (Cont. 3)

Final checks and adjustments for mower deck leveling.

Electric PTO Clutch Removal

Steps for safely removing the electric PTO clutch.

Electric PTO Clutch Installation

Procedure for installing the electric PTO clutch.

Electric PTO Clutch Installation (Cont.)

Final steps for connecting wires and verifying PTO clutch function.

Electrical

Electrical System Exploded View

Exploded view of the electrical system components.

Electrical System Exploded View (Detailed)

Diagram of the electrical system components and their connections.

General Electrical Information

General guidelines for electrical testing and troubleshooting.

Fuse Block and Fuses

Information about the fuse block, its function, and how to test fuses.

Key/Ignition Switch

Description of the ignition switch function and wiring connections.

Key/Ignition Switch Testing

Procedure for testing the ignition switch continuity in different positions.

Hourmeter

Description of the hourmeter's function and testing procedure.

Operator Presence Switch (Seat Switch)

Information on the seat switch function and testing its continuity.

Neutral Switch - Left and Right

Description and testing procedure for the neutral switches.

Parking Brake Switch

Description and testing procedure for the parking brake switch.

Starter Solenoid

Description of the starter solenoid and procedure for testing it.

PTO Switch

Description of the PTO switch function and its role in safety interlocks.

PTO Switch Testing

Procedure for testing the PTO switch continuity in different positions.

Electric PTO Clutch

Description of the electric PTO clutch and its components.

Electric PTO Clutch Coil Resistance Measurement

Procedure for measuring the coil resistance of the electric PTO clutch.

Electric PTO Clutch Continuity to Ground Check

Procedure to check for continuity to ground for the PTO clutch.

Measuring Clutch Current Draw

Procedure for measuring the current draw of the electric PTO clutch.

TVS Diode

Information on the TVS Diode's function and testing.

Kill Relay

Description of the kill relay's function in grounding the magneto.

Electrical Schematic

Diagram illustrating the electrical system wiring and connections.

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