Toro 100-4252 Idler Kit Installation Instructions PDF

The Toro Company 1999 Printed in USA All Rights Reserved

FORM NO. 3322-899

INSTALLATION INSTRUCTIONS

Part No. 1004252

62 Deck Idler Kit High Speed For Model 74212 Serial No. 994001 to 995000 For Model 74203 Serial No. 990001 to 991000

Loose Parts

Note: Use the chart below to identify parts for assembly.

DESCRIPTION QTY. USE

Bracket

Bolt (5/1618 x 3/4)

Flange Nut

1

4

4

Install Front Idler Pulley Bracket

Pulley

Spacer

Belt Guide Plate

Spring Disk

Bolt (3/8 16 x 21/4)

Bolt (3/8 16 x 33/4)

Spacer Bracket

1

1

1

2

1

1

1

Install Front Idler Pulley

Belt Guide

Bolt

Washer

Nut

1

1

1

1

Install Belt Guide

Installation Instructions

2

Removing Drive Belt

1. Stop the engine, set the parking brake, remove the key and disconnect the spark plug wire(s) from the spark plug(s).

2. Remove the clutch retaining strap from machine frame and unplug clutch terminal from wire harness (Fig. 1).

Note: Leave clutch retaining strap attached to the clutch.

3. Remove the drive belt (Fig. 1).

1

4

m4451

3 2

5

Figure 1

1. Clutch 2. Clutch retaining strap 3. Clutch Terminal

4. Drive belt 5. Machine Frame

Removing Deck

1. Lower the deck on to wood blocks.

2. Remove the four bolts at the bottom of chains that are attached to deck (Fig. 2).

3. Remove the nuts and bolts holding pins in the push arm (Fig. 2).

4. Remove pins (Fig. 2).

5. Raise height of cut lever and slide deck out (Fig. 2).

2

1

3

4

7

5

6

Figure 2

1. Deck 2. Chain 3. Chain Bolt 4. Push Arm

5. Push Arm Bolt 6. Push Arm Nut 7. Push Arm Pin

Installation Instructions

3

Installing Front Idler Pulley Bracket

1. Remove existing belt guide and hardware and discard (Fig. 3).

2. Align hole in bracket to the hole the belt guard was installed in (Fig. 3).

3. Position belt idler bracket rear edge parallel to the rear edge of deck (Fig. 3).

4. Install one bolt through the bracket and where the belt guide was installed in deck. Install nut and tighten (Fig. 3).

5. Using bracket as a template, drill three 21/64 holes into deck (Fig. 3).

6. Install bolts into bracket and securely tighten bracket to the deck with nuts (Fig. 3).

3

2

1

4

5

6

Figure 3

1. Idler Pulley Bracket 2. Existing Belt Guide 3. Bolt

4. Nut 5. Holes to Drill 6. Align Holes

Installing Front Idler Pulley

1. Install pulley onto the idler bracket mounting stud (Fig. 4).

2. Install bolt (3/8 x 21/4) into spring disk washer, belt guide plate and short spacer. Install into the center of mounting stud. Do not tighten (Fig. 4).

3. Place belt into idler assembly with back side of belt toward idler pulley.

4. Install bolt (3/8 x 33/4) into spring disk washer, belt guide plate, long bracket spacer and hole in idler bracket. Install nut onto bolt (Fig. 4).

5. Tighten both bolts (Fig. 4).

9

3

1

6

5

4

3 2

7

10

8

Figure 4

1. Pulley 2. Bolt (3/8 x 21/4) 3. Spring Disk Washer 4. Belt Guide Plate 5. Short Spacer

6. Mounting Stud 7. Long Bracket Spacer 8. Hole in Idler Bracket 9. Bolt (3/8 x 33/4) 10. Nut

Installation Instructions

4

Install Belt Guide

1. Remove existing belt guide, carriage bolt, washer, nut and discard (Fig. 5).

1

2

3 4

Figure 5

1. Existing Belt guide 2. Carriage Bolt

3. Nut 4. Washer

2. Remove existing carriage bolt and nut (Fig. 6).

IMPORTANT: Remove only this specific bolt to install belt guide (Fig. 6).

3. Install removed carriage bolt and nut into where the existing belt finger was installed (Fig. 6).

4. Install new bolt, washer, nut and belt guide (Fig. 6).

5. Adjust belt guide. Refer to Adjusting Belt Guide section on page 6.

1

3

2 4

5

Figure 6

1. New Belt guide 2. New Bolt 3. Nut

4. Washer 5. Old Belt Finger Hole

Installing Deck

1. Remove push arms from machine frame.

2. Adjust push arms. Loosen jam nut and rotate ball joint counterclockwise, one turn at a time. Adjust each side the same amount. Adjust the length of push arms to 155/16 (389mm) (Fig. 10).

3. Reinstall push arms to machine frame.

4. Install pins into the deck and push arms.

5. Install the nut and bolt to secure pin to the push arm and deck.

6. Install the four bolts at the bottom of chains that attached to deck.

7. Grease the push arms.

Mower Leveling

When finished installing deck, the deck must be leveled (see Operators Manual for instructions).

Installation Instructions

5

Installing Drive Belt

1. Place new drive belt over clutch, around rear idler pulley, installed into rear idler arm assembly, installed into front idler pulley assembly and onto mower top center pulley.

IMPORTANT: Check the amount of twist in belt between pulleys. Make sure it is only what is specified in figure 7.

2. Install clutch retaining strap and plug clutch terminal into main wire harness (Fig. 7).

1

4

m4451

3 2

5

7

6 6

Figure 7

1. Clutch 2. Clutch retaining strap 3. Clutch Terminal 4. Drive belt

5. Machine Frame 6. 1/4 Belt Twist 7. 1/8 Belt Twist

3. Check belt tension. The center bolt of spring loaded idler must be between the two alignment holes in left support plate (Fig 8).

Note: Check position of center bolt in Low Height of Cut. The center bolt must be at or below the top alignment hole. Check position of center bolt in a High Height of Cut. The center bolt must be at or above the lower adjustment hole (Fig 8).

1

2

Figure 8

1. Center bolt, spring loaded idler

2. Alignment hole

4. If adjustment is required, loosen the fixed idler on right support plate and move up or down in adjustment slot. To relieve belt tension lift up on spring loaded idler (Fig. 9).

m3746

1 2

Figure 9

1. Fixed Idler 2. Adjustment slot

5. Check belt tension again. The center bolt of spring loaded idler must be between the two alignment holes in left support plate (Fig 8). Adjust, if necessary, and tighten all hardware securely.

6. If the fixed idler contacts the end of the adjustment slot and more belt tension is required, a small change in the length of the push arms can be made (Fig. 10).

Installation Instructions

6

7. To adjust push arms, remove push arms from machine frame, remove drive belt, loosen jam nut and rotate ball joint counterclockwise, one turn at a time. Adjust each side the same amount (Fig. 10).

Note: Increase tension by lengthening the push arms and decrease tension by shortening push arms.

m3740

4 3

2

1

Figure 10

1. Push arm 2. 155/16 (389 mm)

nominal

3. Jam nut 4. Ball joint

8. Install drive belt (Fig. 6).

Adjusting Belt Guide

1. Loosen belt guide (Fig. 11).

2. Rotate the belt guide, so it is 1/81/4 (37 mm) away from the vertical side of the PTO belt (Fig.11).

2

1

3

Figure 11

1. Belt guide 2. Drive belt

3. 1/81/4 (37 mm)

Installation Instructions

7