Toro GrandStand 74534 Service Manual Download

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ABOUT THIS MANUAL

This service manual was written expressly for Toro and Lawn-Boy service technicians. The Toro Company has made

every effort to make the information in this manual complete and correct.

Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems

and the related topics covered in this manual.

For additional information on the electrical system, please refer to the Toro Electrical Troubleshooting DVD (492-

9193) and subsequent. For service information on drive systems, please refer to the Hydro-Gear BDP service manual

(BLN-52503). For information specific to the engines used on this unit, refer to the appropriate engine manufacturer’s

service and repair instructions.

36” & 40” Toro GrandStand model years 2010, 2011 & 2012 are covered in this manual. The manual may also be

specified for use on later model products.

Both 36” and 40” models were used during the writing of this manual. You may see slight differences in the photos

depending on which model you are servicing.

Due to the compact design, parts were removed for photographic purposes when necessary.

The hydraulic components are sophisticated pieces of machinery. Maintain strict cleanliness control during all stages

of service and repair. Cover or cap all hose ends and fittings whenever they are exposed. Even a small amount of dirt

or other contamination can severely damage the system.

We are hopeful that you will find this manual a valuable addition to your service shop. If you have any questions or

comments regarding this manual, please contact us at the following address:

The Toro Company

Residential and Landscape Contractor Service Training Department

8111 Lyndale Avenue South

Bloomington, MN 55420

The Toro Company reserves the right to change product specifications or this manual without notice.

Summary of Contents for GrandStand 74534

Page 1: ...Toro 36 40 GrandStand Service Manual LCE Products ...

Page 2: ...ified for use on later model products Both 36 and 40 models were used during the writing of this manual You may see slight differences in the photos depending on which model you are servicing Due to the compact design parts were removed for photographic purposes when necessary The hydraulic components are sophisticated pieces of machinery Maintain strict cleanliness control during all stages of se...

Page 3: ...ABOUT THIS MANUAL THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 4: ...Assembly Replacement 3 13 Platform Cushion Assembly Removal 3 13 Platform Cushion Assembly Installation 3 15 Engine Base Replacement 3 21 Engine Base Removal 3 21 Engine Base Installation 3 32 4 Controls LH Motion Control Lever Replacement 4 1 LH Motion Control Lever Removal 4 1 LH Motion Control Lever Installation 4 2 RH Motion Control Lever Replacement 4 4 RH Motion Control Lever Removal 4 4 RH ...

Page 5: ... Installation 6 21 Reservoir Tank Replacement 6 23 Reservoir Tank Removal 6 23 Reservoir Tank Installation 6 25 Hydraulic Filter Mount Replacement 6 27 Hydraulic Filter Mount Removal 6 27 Hydraulic Filter Mount Installation 6 29 Hydraulic Testing 6 31 Bleeding the Hydraulic System 6 35 7 Mower Deck 36 Mower Deck Belt Replacement 7 1 36 Mower Deck Belt Removal 7 1 36 Mower Deck Belt Installation 7 ...

Page 6: ... 7 34 Grass Deflector Installation 7 35 Deck Strut Replacement 7 37 Rear Strut Removal 7 37 Rear Strut Installation 7 38 Front Strut Removal 7 39 Front Strut Installation 7 40 Mower Deck Replacement 7 42 Mower Deck Removal 7 42 Mower Deck Installation 7 45 Mower Deck Adjustments 7 49 Leveling the Mower 7 49 Preparing the Machine 7 49 Adjusting the Left Side Front to Rear Mower Pitch 7 50 Leveling ...

Page 7: ...8 10 How It Works 8 10 Testing 8 10 Component Replacement 8 11 Ignition Switch 8 11 Ignition Switch Removal 8 11 Ignition Switch Installation 8 12 Power Take Off PTO Switch 8 13 Power Take Off PTO Switch Removal 8 13 Power Take Off PTO Switch Installation 8 14 Electric PTO Clutch Switch 8 14 Electric PTO Clutch Removal 8 14 Electric PTO Clutch Installation 8 22 Electric PTO Clutch Burnishing Proce...

Page 8: ...8 40 Parking Brake Switch Removal 8 40 Parking Brake Switch Installation 8 41 Hour Meter Control Module 8 42 Hour Meter Control Module Removal 8 42 Hour Meter Control Module Installation 8 43 9 Schematics 36 40 Toro GrandStand Hydraulic Schematic 9 1 36 40 Toro GrandStand Electrical Schematic 9 2 ...

Page 9: ...TABLE OF CONTENTS vi 36 40 Toro GrandStand Service Manual THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 10: ...ng or testing powered equipment Avoid injury due to projectiles Always clear the area of sticks rocks or any other debris that could be picked up and thrown by the powered equipment Avoid modifications Never alter or modify any part unless it is a factory approved procedure Avoid unsafe operation Always test the safety interlock system after making adjustments or repairs on the machine Refer to th...

Page 11: ...SAFETY INFORMATION 1 2 36 40 Toro GrandStand Service Manual 1 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 12: ... e g Loctite degree of lubrication on the fastener presence of a prevailing torque feature hardness of the surface underneath of the fastener s head or similar condition which affects the installation As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fast...

Page 13: ...Grade 8 Bolts Screws Studs Sems with Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts In lb In lb N cm In lb N cm In lb N cm 6 32 UNC 10 2 13 2 147 23 15 2 169 23 23 2 260 34 6 40 UNF 17 2 190 20 25 2 280 20 8 32 UNC 13 2 25 5 282 30 29 3 330 30 41 4 460 45 8 36 UNF 31 3 350 30 43 4 31 3 10 24 UNC 18 2 30 5 339 56 42 4 475 45 60 6 674 70 10 32 UNF 48 4 540 45 68 6 765 70 1 4 20 UNC 48 7 53 7 ...

Page 14: ...th length of thread engagement etc Note The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 10 of the nominal torque value Thin height nuts include jam nuts Thread Size Class 8 8 Bolts Screws and Studs with Regular Height Nuts Class 8 or Strong Nuts Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10...

Page 15: ... 73776 ft lb Thread Size Recommended Torque Square Head Hex Socket 1 4 20 UNC 140 20 in lb 73 12 in lb 5 16 18 UNC 215 35 in lb 145 20 in lb 3 8 16 UNC 35 10 ft lb 18 3 ft lb 1 2 13 UNC 75 15 ft lb 50 10 ft lb Type 1 Type 23 or Type F Thread Size Baseline Torque No 6 32 UNC 20 5 in lb No 8 32 UNC 30 5 in lb No 10 24 UNC 38 7 in lb 1 4 20 UNC 85 15 in lb 5 16 18 UNC 110 20 in lb 3 8 16 UNC 200 100 ...

Page 16: ... 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 16 0 3125 7 541 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0...

Page 17: ...s Square Meters Square Centimeters Hectare 2 59 0 0929 6 452 0 4047 Volume Cubic Yards Cubic Feet Cubic Inches Cubic Meters Cubic Meters Cubic Centimeters 0 7646 0 02832 16 39 Weight Tons Short Pounds Ounces Metric Tons Kilograms Grams 0 9078 0 4536 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Work Foot pounds Foot pounds Inch pounds Newton Meters Kilogram Meters Kilogram Centimeters 1 356 0 138...

Page 18: ...ump Two Hydro Gear Model PG 10cc Hydraulic Wheel Motor Two Parker TEO 195 Hydraulic Oil Filter 25 Micron Automotive Spin On Type Hydraulic Fluid Toro Hypr Oil or Equivelant Synthetic 15w50 Motor Oil Hydraulic Fluid Capacity 2 1 quarts 1 9 liters Parking Brake Standard Equipment Ground Speed Hydro MPH Variable 0 to 8 13 kph MPH Fwd 0 to 3 5 kph MPH Rev Hourmeter with Service Indicator Standard Equi...

Page 19: ...Ductile Cast Iron 9 3 8 24cm Diameter Mounted with Six Bolts Bearings Greasable Ball Bearings with Grease Fitting for Lubrication Construction 7 gauge 179 inch 4 5mm Steel Welded Construction Blade Tip Speed Dom Int l 36 91cm 18 420 ft m calculated 3600 engine RPM 15 288 ft m calculated 3000 engine RPM 40 102cm 18 278 ft m calculated 3600 engine RPM 15 625 ft m calculated 3000 engine RPM Skid Plat...

Page 20: ...l pivot tube Fig 001 3 The caster fork and wheel assembly is now free to be removed 4 Remove the three Bellville washers from the caster wheel pivot tube Fig 003 Fig 001 DSCN 3918a 2 Remove the nut from the caster fork shaft Fig 002 Fig 002 DSCN 3921a Fig 003 DSCN 3924a 5 Remove the upper tapered roller bearing from the caster wheel pivot tube Fig 004 Fig 004 DSCN 3927a ...

Page 21: ...el pivot tube Fig 007 Fig 005 DSCN 3930a 7 The lower tapered roller bearing is now free to be removed Fig 006 Fig 006 DSCN 3933a Fig 007 DSCN 3936a 9 Remove the nut securing the caster wheel axle bolt then remove the axle bolt Fig 008 Fig 008 DSCN 0376a 6 Remove the grease seal from the bottom of the caster wheel pivot tube Fig 005 ...

Page 22: ...heel hub Fig 009 Note The spacer nuts are both threaded onto the caster axle One of the spacer nuts will need to be removed after it has been removed from the caster wheel Fig 011 Fig 009 DSCN 0377a 12 Remove the spacer nut from the caster axle Fig 010 Fig 010 DSCN 0379a Fig 011 DSCN 0383a 13 Remove the grease seal from both sides of the caster wheel Fig 012 Fig 012 DSCN 0387a ...

Page 23: ...mbly Installation 14 The LH and RH tapered bearings are now free to be removed Fig 013 1 Pack the caster wheel tapered roller bearing with high temp grease Fig 014 Fig 013 DSCN 0389a Fig 014 DSCN 0407a 2 Install the bearing into the wheel hub Fig 015 Fig 015 DSCN 0389a ...

Page 24: ...6 DSCN 0393a 4 Repeat steps 1 2 and 3 on the other side of the caster wheel 5 Fill the center of the wheel hub with high temp grease Fig 017 Fig 017 DSCN 0406a Fig 018 DSCN 0398a 7 Install a spacer nut onto both ends of the caster axle Fig 019 Note There should be approximately 3 internal spacer nut threads visible on both sides indicating the axle is centered Fig 019 DSCN 0379a ...

Page 25: ...Fig 020 DSCN 0377a 9 Secure the caster wheel assembly to the caster fork using the axle bolt and nut Fig 021 Fig 021 DSCN 0376a Fig 022 DSCN 0410a Note A socket can be used as a driver Take care not to scar the race surface Fig 023 Fig 023 DSCN 0413a 8 Position the seal guard onto both sides of the caster wheel hub Fig 020 ...

Page 26: ...ings with high temperature grease Fig 024 13 Install grease seal into the base of the pivot tube Fig 026 Fig 024 DSCN 0407a 12 Install the lower bearing into the pivot tube Fig 025 Fig 025 DSCN 3933a Fig 026 DSCN 3930a 14 Install the upper bearing into the pivot tube Fig 027 Fig 027 DSCN 3927a ...

Page 27: ...g 028 DSCN 3924a Note Bottom Crown Up Middle Crown Down Top Crown up Fig 029 Fig 029 DSCN 0423a Fig 030 DSCN 0360a 18 Tighten locknut until spring washers are flat 15 ft lbs 20 Nm and then back off a 1 4 turn to properly set the pre load on the bearings 19 Remove the plug from the side of the pivot hub Fig 031 Fig 031 DSCN 0436a 15 Install the 3 Bellville washers into the pivot tube Fig 028 ...

Page 28: ...of the pivot hub Fig 032 22 Replace the grease zerk with the plug Fig 034 Fig 032 DSCN 0434a 21 Fill the pivot hub cavity until grease is purging out through the upper bearing Fig 033 Fig 033 DSCN 0438a Fig 034 DSCN 0436a 23 Install the grease cap onto the top of the pivot hub Fig 035 Fig 035 DSCN 3918a ...

Page 29: ...rom the fuel tank Note The only recommended way to remove the fuel from the tank is by using a siphon pump 3 Place the deck into the 1 HOC position 4 Remove the vent line from the 90 degree vent fitting Fig 037 Fig 037 DSCN 3941a Fig 038 DSCN 3946a 6 Slide the hose clamp off the fuel pick up tube fitting then remove the fuel line from the fitting Fig 039 Fig 039 DSCN 3949a 1 Turn the fuel shutoff ...

Page 30: ...ecuring the tank bracket to the control panel Fig 040 1 Position the fuel tank into the control tower Fig 042 Fig 040 DSCN 3952a 8 Remove the fuel tank from the control tower Fig 041 Fig 041 DSCN 3955a Fig 042 DSCN 3955a 2 Secure the tank bracket to the control tower using four thread forming screws Fig 043 Fig 043 DSCN 3952a ...

Page 31: ... film of oil will ease installation of the fitting barb Fig 044 DSCN 3949a 4 Install the rubber grommet into the fuel tank Fig 045 Fig 045 DSCN 3958a Fig 046 DSCN 3946a 6 Install the vent hose onto vent fitting Fig 047 Fig 047 DSCN 3941a 3 Slide the fuel line onto the pick up tube fitting and secure with the hose clamp Fig 044 ...

Page 32: ...tor cushion onto the operator platform 4 Remove the carriage bolts spacers friction washers washers and nuts securing the pad hinge to the pad links Fig 050 Fig 048 DSCN 3962a 2 Remove the four sets of bolts and flange nuts that secure the brake assembly to the frame Fig 049 Fig 049 DSCN 3965a Fig 050 DSCN 0577a 5 Remove the four sets of bolts and washers securing the upper and lower pad hinges to...

Page 33: ...se the rear of the machine and remove the tires 8 Remove the RH and LH carriage bolts washers spacers and nuts securing the platform to the carrier frame Fig 053 Fig 053 DSCN 3974a Fig 054 DSCN 3978a 10 Remove the knob from the platform latch pin Fig 055 Fig 055 DSCN 0500a 6 Remove the two thread forming screws securing the shield foot mat bracket and foot mat to the platform Fig 052 ...

Page 34: ...n and spring from the platform Fig 056 1 Secure the four rubber bumpers to the platform using four nuts Fig 058 Fig 056 DSCN 0501a 12 Remove the four nuts securing the four rubber bumpers to the platform Fig 057 Fig 057 DSCN 0505a Fig 058 DSCN 0505a 2 Position the spring on the latch pin Fig 059 Fig 059 DSCN 0512a ...

Page 35: ... 062 Fig 060 DSCN 0517a 4 Apply thread locking compound to the threads of the knob Fig 061 Fig 061 DSCN 0521a Fig 062 DSCN 0498a 6 Position the carriage bolt and spacer into the tab on the platform Fig 063 Fig 063 DSCN 0548a 3 Position the latch pin and spring assembly into the platform Fig 060 ...

Page 36: ...r the spacer Fig 064 9 Repeat steps 6 7 and 8 on the other side 10 Position the platform assembly onto the frame Fig 066 Fig 064 DSCN 0549a 8 Secure the assembly with a washer and nut Fig 065 Fig 065 DSCN 0555a Fig 066 DSCN 3979a 11 Place the washer and spacer onto the bolt Fig 067 Fig 067 DSCN 3982a ...

Page 37: ...her side of the machine 15 Install the tires 16 Secure the shield foot mat bracket and foot mat to the platform using two thread forming screws Fig 070 Fig 068 DSCN 3984a 13 Secure the platform assembly to the frame using the bolt washer spacer and flange nut Fig 069 Fig 069 DSCN 3974a Fig 070 DSCN 0490a Fig 071 DSCN 0564a 12 Position the large washer between the platform pivot and frame Fig 068 ...

Page 38: ...ing two screws and washers Fig 072 20 Place a friction washer between the pad link and lower hinge bracket Fig 074 Fig 072 DSCN 0566a 19 Align the pad link with the lower hinge bracket Fig 073 Fig 073 DSCN 0568a Fig 074 DSCN 0571a 21 Insert a carriage bolt through the pad link assembly Fig 075 Fig 075 DSCN 0572a ...

Page 39: ...ets of bolts and flange nuts Fig 078 Fig 076 DSCN 0576a 23 Secure the assembly with a nut and washer Fig 077 Fig 077 DSCN 0577a Fig 078 DSCN 3965a 26 Secure the brake link rod to the brake assembly using the hairpin cotter and clevis pin Fig 079 Fig 079 DSCN 3962a 22 Position the spacer over the carriage bolt and into the friction washer and lower hinge bracket Fig 076 ...

Page 40: ...le Fig 080 3 Remove the deck belt extension spring from the deck anchor post then remove the belt from around the clutch pulley Fig 082 Fig 080 DSCN 3989a 2 Remove the two sets of hold down bolts and wing nuts securing the battery cover Fig 081 Fig 081 DSCN 4011a Fig 082 DSCN 3995a 4 Remove the bolt washer and nut securing the front strut to the carrier frame Fig 083 Fig 083 DSCN 3998a ...

Page 41: ...N 4057a 8 Remove the four sets of nuts and lock washers securing the muffler pipes to the engine Fig 087 Fig 087 DSCN 4061a 5 Remove the four carriage bolts and nuts securing the muffler guard to the carrier frame Fig 084 6 Loosen the cable clamps securing the choke and throttle cables to the engine throttle plate then remove the Z bend of the cables from the engine control arms Fig 085 Fig 085 DS...

Page 42: ...k then lower the deck onto the boards Fig 090 Fig 088 DSCN 2683a 10 Raise the rear of the machine so the underside can be accessed 11 Remove the four sets of bolts washers and nuts securing the rear struts to engine base and carrier frame Fig 089 Fig 089 DSCN 4215a Fig 090 DSCN 3990a 14 Remove the four sets of bolts and nuts securing the deck lift chains to the mower deck Fig 091 Fig 091 DSCN 4179...

Page 43: ...filter outlet fitting Fig 093 Fig 093 DSCN 4007a Fig 094 DSCN 4009a 18 Remove the fuel line from the fuel pump Drain the fuel into a suitable container 19 Remove the violet wire from the voltage regulator Fig 095 Fig 095 DSCN 4012a 15 Position an oil pan under the reservoir Move the hose clamp from the reservoir tank fitting then remove the low pressure return hose from the base of the reservoir F...

Page 44: ...6 22 Remove the bolt and washer securing the ground wires to the engine block Fig 098 Fig 096 DSCN 4015a 21 Unplug the white wire from the black magneto wire Fig 097 Fig 097 DSCN 4017a Fig 098 DSCN 4026a 23 Remove the green and blue bullet connectors from the two small studs on the solenoid Fig 099 Fig 099 DSCN 4028a ...

Page 45: ...move the tires 28 Thoroughly clean the area around the hydraulic fittings then mark the motor fittings and hoses to ensure they are returned to their original location upon assembly Fig 102 Fig 100 DSCN 4030a Fig 101 DSCN 4035a Fig 102 DSCN 4043a 29 Remove the four high pressure hoses from the motors Cap the hose ends and motor fittings to prevent debris from entering the system Fig 103 Fig 103 DS...

Page 46: ...olts and flange nuts securing the cable clamp bracket to the engine base Fig 107 30 Thoroughly clean the area around the hydraulic fittings then mark the pumps and fittings to ensure they are returned to their original location upon assembly Fig 104 32 Remove the bolts and nuts securing the control cable ends to the pump control arms Fig 106 Fig 104 DSCN 4039a Fig 105 DSCN 4054a Fig 106 DSCN 4048a...

Page 47: ...Remove the extension spring from the pump idler assembly and anchor bolt Fig 109 Fig 109 DSCN 4070a Fig 110 DSCN 4075a 38 Remove the nut securing the spring anchor post to the engine base Fig 111 Fig 111 DSCN 4072a 34 Using two people or a hoist lift the rear of the carrier frame and tower assembly Walk the carrier frame and tower assembly forward over the engine and deck assembly Fig 108 ...

Page 48: ...s from the pump shaft keyways Fig 112 41 Remove both pumps with hoses attached from the engine base Fig 114 Fig 112 DSCN 4080a Fig 114 DSCN 4083a 42 Remove the nut and lock washer securing the red starter cable to the solenoid Fig 115 Fig 115 DSCN 4084a 40 Remove the four sets of carriage bolts washers and nuts securing the pumps to the engine base Fig 113 Fig 113 DSCN 4079a ...

Page 49: ...ig 118 Fig 116 DSCN 4087a 44 Remove the cable tie securing the clutch wires to the clutch stop Fig 117 Fig 117 DSCN 4088a Fig 118 DSCN 4091a 46 Secure a lift to the engine to support the engine and engine base Fig 119 Fig 119 DSCN 4093a 43 Remove the two thread forming screws securing the solenoid to the engine base Fig 116 ...

Page 50: ...he engine and engine base from the mower deck 50 Remove the four sets of bolts and Belleville washers securing the engine to the engine base The engine base is now free to be removed Fig 122 Fig 120 DSCN 4098a 48 Remove the two flange nuts securing the sides of the engine base to the deck Fig 121 Note Do not remove the thread forming screws from the deck Fig 121 DSCN 4101a Fig 122 DSCN 4108a ...

Page 51: ...7 4 Nm Fig 123 Note The crown of the Belleville washer must face the head of the bolt 4 Secure the rear of the engine base to the rear of the deck using two carriage bolts and flange nuts Fig 125 Fig 123 DSCN 4108a 2 Lower the engine and engine base onto the mower deck 3 Secure the sides of the engine base to the mower deck using the flange nuts Fig 124 Fig 124 DSCN 4101a Fig 125 DSCN 4098a ...

Page 52: ... 6 Push the clutch connector up through the engine base and position the grommet into the engine base hole Fig 128 Fig 126 DSCN 4112a Note The clutch stop must be nested into the slot on the clutch Fig 127 Fig 127 DSCN 4114a Fig 128 DSCN 4117a 7 Secure the clutch wires to the clutch stop using a cable tie Fig 129 Fig 129 DSCN 4118a ...

Page 53: ...the pivot bolt Fig 132 Fig 130 DSCN 4120a 9 Place the large spacer one friction composite washer and bushing onto the pivot bolt Fig 131 Fig 131 DSCN 4124a Fig 132 DSCN 4126a 11 Secure the idler assembly with a flange nut Fig 133 Fig 133 DSCN 4129a 8 Place the pivot bolt with washer down through the engine base Fig 130 ...

Page 54: ...age bolts washers and nuts Fig 134 14 Apply anti seize to the pump shaft Fig 136 Fig 134 DSCN 4132a 13 Install the key into the keyway on the pump shaft Fig 135 Fig 135 DSCN 4139a Fig 136 DSCN 4146a 15 Apply thread locking material to the threads of the pump pulley set screws Fig 137 Fig 137 DSCN 4142a ...

Page 55: ...a 17 Install the pulley onto the pump shaft The base of the pulley hub should be flush with the base of the pump shaft Secure the position with the set screws Fig 139 Fig 139 DSCN 4159a Fig 140 fig 67 G012686 19 Install the extension spring from the idler bracket to the spring anchor Fig 141 Fig 141 DSCN 4155 16 Install the set screws into the pump pulley Fig 138 Note Ensure the set screws have no...

Page 56: ... a hoist lift the rear of the carrier frame and tower assembly Walk the carrier frame and tower assembly rearward over the engine and deck assembly Fig 144 Fig 142 DSCN 4157a 21 Secure the red cable from the starter to the solenoid post Fig 143 Fig 143 DSCN 4163a Fig 144 DSCN 4067a 23 Position exhaust gaskets on the exhaust manifold Fig 145 Fig 145 DSCN 4173a ...

Page 57: ...muffler to the RH and LH muffler brackets using the bolts thick washers and flange nuts Fig 147 Fig 147 DSCN 4178a Fig 148 DSCN 4179a 27 Secure the front strut to the carrier frame using a bolt large washer and flange nut Fig 149 Fig 149 DSCN 4183a 24 Secure the muffler to the exhaust manifold using nuts and lock washers Torque to 21 2 ft lbs 28 4 2 7 Nm Fig 146 ...

Page 58: ...te the belt around the deck and clutch pulleys Fig 150 40 Belt Routing Fig 150 decal 119 0187 Fig 151 36 Belt Routing Fig 151 decal 119 0186 Fig 152 DSCN 4185a 30 Hook the Z bend of the throttle cable into the throttle control lever and loosely clamp the outer housing of the throttle cable with the cable clamp Fig 153 Fig 153 DSCN 2672a ...

Page 59: ...ble with the cable clamp Fig 156 Fig 154 DSCN 2674a 32 With the engine throttle control lever in the Fast position pull the slack from the cable jacket and tighten the throttle cable clamp Fig 155 Fig 155 IMG 0576a Fig 156 DSCN 2676a 34 Push the choke knob in so it is in the Open position Fig 157 Fig 157 DSCN 2677a 31 Move the throttle lever to the Fast position Fig 154 ...

Page 60: ...ighten the choke cable clamp Fig 158 37 Secure the low pressure return line to the reservoir fitting using the hose clamp Fig 160 Fig 158 IMG 0584a 36 Secure the throttle and choke cable to the oil drain assemble using a cable tie Fig 159 Fig 159 DSCN 2683a Fig 160 DSCN 4187a 38 Secure the low pressure suction line to the filter fitting Fig 161 Fig 161 DSCN 4190a ...

Page 61: ...the muffler exhaust is centered in the muffler guard assembly then tighten all four bolts and nuts Torque the nuts to 19 2 ft lbs 25 76 2 7 Nm Fig 163 Fig 163 DSCN 2680a Fig 164 DSCN 2686a 43 Install the battery ground cable and the wiring harness ground wire to the engine block Fig 165 Fig 165 DSCN 2688a 39 Position the muffler guard assembly and loosely install the four carriage bolts two mounti...

Page 62: ... nut Torque the nut to 35 in lbs 4 Nm Fig 166 Fig 166 DSCN 4030a 45 Connect the green and blue bullet connectors to the two small studs on the solenoid Fig 167 46 Connect the white wire to the black magneto wire Fig 168 Fig 167 DSCN 4028a Fig 168 DSCN 2691a 47 Connect the pink wire to the green fuel solenoid wire Fig 169 Fig 169 DSCN 2692a ...

Page 63: ...age bolts and flange nuts Fig 172 Fig 172 DSCN 4193a 51 Secure the control cables to the pump link using the bolts and nuts Fig 173 Fig 173 DSCN 4047a 48 Connect the violet wire to the voltage regulator Fig 170 Fig 170 DSCN 2695a Fig 171 DSCN 4009a 49 Secure the fuel line to the fuel pump using the hose clamp Fig 171 ...

Page 64: ...installed to the correct wheel motor fitting by using the identification markings If installed incorrectly wheel direction will be reversed Fig 175 DSCN 4222a 54 Loop the hoses around the control cables Fig 176 Fig 176 DSCN 4224a 55 Install the hoses to the wheel motor Fig 177 Note Ensure the hose is installed to the correct wheel motor fitting by using the identification markings If installed inc...

Page 65: ...to the correct pump fittings by using the identification markings If installed incorrectly wheel direction will be reversed Loop the hoses around the control cables and opposite side pump hoses Fig 179 Fig 179 DSCN 4231a Fig 180 DSCN 4236a 58 Position the battery on the battery tray Using the bolt nut and washer secure the positive battery cable to the battery Using the bolt nut and washer secure ...

Page 66: ...GrandStand Service Manual 3 60 Install both tires 61 Bleed the hydraulic system See Bleeding the Hydraulic System on page 6 35 59 Install the battery cover with the two hold down bolts and wing nuts Fig 182 Fig 182 DSCN 2700a ...

Page 67: ...CHASSIS 3 48 36 40 Toro GrandStand Service Manual 3 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 68: ...er rod A 4 easy out can be used to secure the pivot rod The bolt on the opposite side can then be removed Fig 185 Fig 183 DSCN 3570 2 Remove the two bolts securing the pivot shaft inside the LH motion control lever One bolt is located on the outside of the control tower The second is located at the opposite end of the control handle Fig 184 Fig 184 DSCN 3573 Fig 185 DSCN 3584a 3 Remove the LH cont...

Page 69: ...g 187 1 Install a plastic bearing into each end of the control handle Fig 189 Fig 187 DSCN 3595a 6 Remove the two plastic bearings from the ends of the control handle Fig 188 Fig 188 DSCN 3597a Fig 189 DSCN 3597a 2 Loosely install the bolt and jam nut to the handle assembly Fig 190 Note The nut will be tightened in a later step Fig 190 DSCN 3599a ...

Page 70: ...g the shoulder bolt and flange nut Fig 193 Fig 191 DSCN 3591a 4 Secure the control handle assembly in the control tower using two bolts Fig 192 A 05 to 09 1 27 to 2 29mm Fig 192 DSCN 3573a Fig 193 DSCN 3570 6 Position the neutral switch bolt so the gap between it and the switch is between 05 and 09 1 27 and 2 29mm Secure the position using the jam nut Fig 194 Fig 194 DSCN 3603a A ...

Page 71: ...ntrol Lever Replacement RH Motion Control Lever Removal 1 Remove the shoulder bolt and flange nut securing the end of the control cable to the RH motion control lever Fig 195 Fig 195 DSCN 3610a 2 Unplug the wire harness from the OPC switch Fig 196 Fig 196 DSCN 3612a ...

Page 72: ...198 DSCN 3653a Note Only one bolt will typically back out due to both threading into the same inner rod A 4 easy out can be used to secure the pivot rod The bolt on the opposite side can then be removed Fig 199 Fig 199 DSCN 3647a 4 Remove the RH control lever assembly from the control tower 5 Remove the pivot rod from the motion control handle Fig 200 Fig 200 DSCN 3616a ...

Page 73: ... and tapped plate securing the OPC switch to the control handle assembly Fig 202 8 Remove the bolt and nut securing the RH handle to the motion control assembly Fig 203 Fig 201 DSCN 3617a Fig 202 DSCN 3622a Fig 203 DSCN 3626a 9 Remove the nut and washer securing the adjustment cam to the RH control lever Fig 204 Fig 204 DSCN 3629a ...

Page 74: ...ig 205 1 Install the four plastic bearings to the motion control assembly Fig 207 Fig 205 DSCN 3634a 11 Remove the four plastic bearings from the motion control assembly Fig 206 Fig 206 DSCN 3637a Fig 207 DSCN 3637a 2 Loosely secure the adjustment cam to the RH control lever Fig 208 Note This nut will be tightened later in the process Fig 208 DSCN 3629a ...

Page 75: ...5 Loosely secure the OPC switch to the motion control assembly Fig 211 Note The bolts will be tightened later in the process Fig 209 DSCN 3634a 4 Secure the RH control lever to the motion control assembly with the shoulder bolt and nut Fig 210 Fig 210 DSCN 3626a Fig 211 DSCN 3644a 6 Install the extension spring to the motion control assembly Fig 212 Fig 212 DSCN 3646a ...

Page 76: ...Stand Service Manual 4 8 Secure the control handle assembly in the control tower using two bolts Fig 214 215 7 Install the pivot rod into the motion control assembly Fig 213 Fig 213 DSCN 3616a Fig 214 DSCN 3649a Fig 215 DSCN 3653a ...

Page 77: ...am on the RH control assembly to correct Fig 218 Fig 216 DSCN 3656a 10 Position the RH control handle so it is horizontally aligned with the LH lever Fig 217 A 125 3mm Fig 217 DSCN 3657a Fig 218 DSCN 3661a 12 Adjust the OPC switch so there is 125 3mm gap between the switch plunger and the control handle tab when the control handle is in the operating position Fig 219 Fig 219 DSCN 3665a A ...

Page 78: ...mounting screws Fig 220 15 Position the neutral switch bolt so the gap between it and the switch is between 05 and 09 1 27 and 2 29mm Secure the position using the jam nut Fig 222 Fig 220 DSCN 3666a 14 Secure the control cable to the motion control lever using a shoulder bolt and flange nut Fig 221 Fig 221 DSCN 3610a Fig 222 DSCN 3668a A ...

Page 79: ...he end of the control cable to the motion control lever Fig 223 4 Remove the two thread forming screws and cable clamp securing the lower cable to the cable bracket Fig 226 3 Remove the cable adjustment nut from the cross bracket Fig 225 Fig 223 DSCN 3671a 2 Remove the spring clip from the cross bracket Fig 224 Fig 224 DSCN 3672a Fig 225 DSCN 3674a Fig 226 DSCN 3679a ...

Page 80: ...d flange nut securing the cable to the pump assembly Fig 227 1 Secure the cable rod end to the pump assembly using the bolt and flange nut Fig 228 Fig 227 DSCN 3682a Fig 228 DSCN 3682a 2 Secure the lower cable to the cable bracket using the two thread forming screws and cable clamp Fig 229 Fig 229 DSCN 3679a ...

Page 81: ...ing clip Fig 232 Fig 230 DSCN 3685a 4 Position the cable adjustment nut into the slot on the cross bracket Fig 231 Fig 231 DSCN 3688a Fig 232 DSCN 3690a 6 Secure the control cable to the motion control lever using a shoulder bolt and flange nut Fig 233 Fig 233 DSCN 3671a 7 Verify the tracking of the machine See Adjusting the Tracking on page 4 41 ...

Page 82: ...e yoke at the lower end of the link rod to the brake assembly Fig 234 3 Remove the grip from the brake handle Fig 236 Fig 234 DSCN 3815a 2 Remove the nut securing the upper end of the link rod to the brake handle Fig 235 Fig 235 DSCN 3817a Fig 236 DSCN 3822a 4 Remove the bolt washer and nut securing the brake handle to the control tower Fig 237 Fig 237 DSCN 3819a ...

Page 83: ...the brake assembly to the chassis Fig 239 1 Secure the LH side of the brake assembly to the chassis using the shoulder bolt spacer and nut Fig 240 Fig 238 DSCN 3826a Fig 239 DSCN 3825a Fig 240 DSCN 3825a 2 Secure the RH side of the brake and torsion spring assemblies to the chassis using the bolt spacers and washers Fig 241 Note Position one end of the torsion spring under the brake assembly posit...

Page 84: ...ure the handle to the tower using the bolt washer and nut Fig 242 Note Do not over tighten The handle needs to move freely 5 Secure the upper end of the brake rod to the brake handle using the flange nut Fig 244 Fig 242 DSCN 3819a 4 Install the grip onto the brake lever Fig 243 Fig 243 DSCN 3822a Fig 244 DSCN 3817a ...

Page 85: ...re the yoke at the lower end of the brake rod to the brake assembly using the clevis pin Fig 245 Fig 245 DSCN 3834a Note With the brake handle in the off position measure the distance between the brake bar and tire The distance needs to be between 3 16 and 5 16 5 and 8mm If adjustment is needed remove the clevis pin and rotate the yoke accordingly Fig 246 Fig 246 fig 60 G012699 A C B ...

Page 86: ...he deck onto the boards Fig 248 3 Remove the snap ring and washer securing the HOC handle assembly to the frame Fig 250 Fig 248 DSCN 3839a 2 Remove the bolt and nut securing the lift link assembly to the lower end of the HOC handle Fig 249 Fig 249 DSCN 3841a Fig 250 DSCN 3843a 4 Remove the nuts securing the HOC anchor bolt to the HOC plate assembly Fig 251 Fig 251 DSCN 3848a ...

Page 87: ... Fig 252 7 Remove the latch rod assembly spring and washer out through the top of the HOC handle Fig 254 Fig 252 DSCN 3852a 6 Remove the shoulder bolt and nut securing the latch rod to the HOC latch Fig 253 Fig 253 DSCN 3855a Fig 254 DSCN 3857a 8 Remove the shoulder bolt washer and nut securing the HOC latch to the HOC handle Fig 255 Fig 255 DSCN 3877a ...

Page 88: ...houlder bolt washer and nut Fig 256 3 Position the latch rod assembly into the HOC handle Fig 258 Fig 256 DSCN 3877a 2 Position the spring and washer onto the latch rod Fig 257 Fig 257 DSCN 3880a Fig 258 DSCN 3857a 4 Secure the lower end of the latch rod assembly to the HOC latch using the shoulder bolt and nut Fig 259 Fig 259 DSCN 3886a ...

Page 89: ...washer and spacers into the rear of the HOC plates Fig 260 7 Position the HOC handle pivot shaft through the frame hub Fig 262 Fig 260 DSCN 3891a 6 Loosely secure the HOC plates assembly to the control tower using the flange nut Fig 261 Fig 261 DSCN 3895a Fig 262 DSCN 3900a ...

Page 90: ...ghten the rear fastener assembly Fig 263 9 Secure the HOC handle latch bolt to the control tower using the two nuts Fig 265 Fig 263 DSCN 3902a Note The HOC handle must be nested in between the HOC plates Fig 264 Fig 264 DSCN 3908a Fig 265 DSCN 3912a 10 Install the washer and snap ring that secure the HOC handle to the frame Fig 266 Fig 266 DSCN 3843a ...

Page 91: ...andle Fig 267 1 Remove the bolt and cable clamp securing the choke cable to the engine throttle plate Fig 269 Fig 267 DSCN 3841a 12 Pump high temp grease into the HOC handle pivot hub Fig 268 Fig 268 DSCN 3915a Fig 269 DSCN 3505a 2 Remove the Z bend of the choke cable from the engine choke arm Fig 270 Fig 270 DSCN 3509a 13 Raise the deck and remove the boards ...

Page 92: ...nd throttle cable to the oil drain Fig 271 6 Remove the choke cable from the control panel Fig 273 Fig 271 DSCN 3511a 4 From the rear of the machine pull the cable rear ward from the frame 5 Remove the nut securing the choke cable to the control panel Fig 272 Fig 272 DSCN 3515a Fig 273 DSCN 3518a ...

Page 93: ... in the control panel Fig 274 3 Feed the cable through the frame to the left of the brake linkage Fig 276 Fig 274 DSCN 3518a 2 Secure the choke cable to the control panel using a nut Fig 275 Fig 275 DSCN 3515a Fig 276 DSCN 3519a 4 Feed the choke cable through the R clamp located on the carrier frame Fig 277 Fig 277 DSCN 3522a ...

Page 94: ...ely install the screw and cable clamp Fig 279 5 Install the choke cable Z bend into the engine choke lever Fig 278 7 Position the choke knob in the OPEN position Fig 280 Fig 278 DSCN 3509a Fig 279 DSCN 3505a Fig 280 DSCN 3525a 8 Ensure the choke is fully open in the throat of the carburetor Fig 281 Fig 281 DSCN 3528a ...

Page 95: ...g 282 1 Remove the bolt and cable clamp securing the throttle cable to the engine throttle plate Fig 284 Fig 282 DSCN 3530a 10 Secure the choke and throttle cable to the oil drain using a cable tie Fig 283 Fig 283 DSCN 3511a Fig 284 DSCN 3505a 2 Remove the Z bend of the throttle cable from the engine throttle arm Fig 285 Fig 285 DSCN 3535a 11 Ensure the choke is functioning correctly by moving the...

Page 96: ... tie securing the choke and throttle cable to the oil drain Fig 286 6 Remove the two carriage bolts and nuts securing the throttle lever assembly to the control panel Fig 288 Fig 286 DSCN 3511a 4 From the rear of the machine pull the cable rearward from the frame 5 Remove the throttle knob from the throttle lever Fig 287 Fig 287 DSCN 3536a Fig 288 DSCN 3541a Fig 289 DSCN 3545a ...

Page 97: ...ever assembly and secure with the cable clip Fig 290 3 Apply thread locking material to the threads of the handle knob Fig 292 Fig 290 DSCN 3552a 2 Secure the lever assembly to the control tower using two carriage bolts and nuts Fig 291 Fig 291 DSCN 3541a Fig 292 DSCN 3554a 4 Install the handle knob to the throttle lever Fig 293 Fig 293 DSCN 3536a ...

Page 98: ...tle cable through the R clamp located on the carrier frame Fig 294 7 Position the throttle cable to the engine throttle plate and loosely install the screw and cable clamp Fig 296 Fig 294 DSCN 3556a 6 Install the throttle cable Z bend into the engine throttle lever Fig 295 Fig 295 DSCN 3535a Fig 296 DSCN 3505a 8 Move the throttle lever to the FAST position Fig 297 Fig 297 DSCN 3536a ...

Page 99: ...cket and tighten the throttle cable clamp Fig 298 10 Ensure the throttle is functioning correctly by moving the throttle lever from FAST to SLOW while observing the engine throttle lever 1 Remove the shoulder bolts and flange nuts securing the ends of the control cables to the motion control levers Fig 299 Fig 298 DSCN 3561a Fig 299 DSCN 3671a 2 Remove the spring clip Fig 300 Fig 300 DSCN 3692a ...

Page 100: ...01 DSCN 3674a 4 Remove the cable tie securing the fuel vent hose to the speed control base assembly Fig 302 Fig 302 DSCN 3698a Fig 303 DSCN 3705a 6 Remove the two sets of bolts and nuts securing the cross bracket to the control tower Fig 304 Note Do not remove the wire harness from the cross bracket The clearance needed is gained by removing the mounting hardware Fig 304 DSCN 3707a ...

Page 101: ...he four sets of bolts nuts and spacers securing the slider plates to the slider assembly Fig 308 9 Remove the bolt nut and clamp washer securing the slider assembly to the cable Fig 307 Fig 305 DSCN 3701a Fig 306 DSCN 3711a Fig 307 DSCN 3718a Fig 308 DSCN 3720a 7 Remove the two sets of carriage bolts and nuts securing the speed control assembly to the control panel Fig 305 ...

Page 102: ...stener assembly securing the speed control handle to the control assembly Fig 311 Fig 309 DSCN 3726a 12 Remove the bolt spacer washer and nut securing the link assembly to the control assembly Fig 310 Fig 310 DSCN 3729a Fig 311 DSCN 3732a 14 Remove the nuts and washers securing the pulleys to the control assembly Fig 312 Fig 312 DSCN 3741a ...

Page 103: ... spacer and wave washers onto the control assembly Fig 314 Fig 314 DSCN 3753a Fig 315 DSCN 3748a 3 Secure the handle to the control assembly using the retainer lock washer and flange nut Fig 316 Note The speed control handle must move freely yet have adequate drag to keep it from moving during operation Fig 316 DSCN 3757a 1 Secure the three pulleys to the control assembly using washers and nuts Fi...

Page 104: ...later step Fig 317 DSCN 3763a 5 Secure the link assembly to the control handle using a flange nut Fig 318 Fig 318 DSCN 3766a Fig 319 DSCN 3770a 7 Route the cable around the pulleys and secure to the link assembly using the nut and jam nut then tighten the nut securing the cable eyelet Fig 320 Note Do not over tension the cable The speed control handle must move freely without the cable binding on ...

Page 105: ...Fig 323 Fig 321 DSCN 3779 Fig 322 DSCN 3788a Fig 323 DSCN 3790a 10 Loosely install the bolt nut and cable clamp to the slide assembly Fig 324 Note This assembly will be tightened in a later step Fig 324 DSCN 3796a 8 Secure the slider plates to the slider assembly using the four sets of bolts spacers and flange nuts Fig 321 Note The base of the slider plates and the base of the slider assembly MUST...

Page 106: ...and flange nuts Fig 325 13 Install the grip onto the speed control lever Fig 327 Fig 325 DSCN 3800a 12 Secure the control assembly to the control tower using two sets of carriage bolts and nuts Fig 326 Fig 326 DSCN 3701a Fig 327 DSCN 3705a 14 Secure the cross brace to the control tower using two bolts and flange nuts Fig 328 Fig 328 DSCN 3707a ...

Page 107: ...e spring clip Fig 330 17 Secure the control cables to the motion control levers using a shoulder bolt and flange nut Fig 331 Fig 329 DSCN 3803a Fig 330 DSCN 3804a Fig 331 DSCN 3671a 18 Place the speed control lever into the FAST position Fig 332 Fig 332 DSCN 3806a 15 Secure the fuel vent hose to the control assembly using a cable tie Fig 329 ...

Page 108: ... the same distance 2 Check if the machine tracks to one side If it does stop the machine and set the parking brake 3 Release the operator cushion from the rear of the machine 4 Rotate the right cable adjustment to position the right motion control in the center of the control panel neutral lock slot Then rotate the left cable adjustment in quarter turn increments until the machine tracks straight ...

Page 109: ...able Fig 336 Fig 336 DSC 0534a 2 Move the speed control lever to the Fast position Fig 337 Fig 337 DSC 0539a 5 Check for proper tracking 5 Repeat adjustment until the tracking is correct 7 Check that the machine does not creep from neutral with the park brakes disengaged Important Do not rotate the linkage too far as this may cause the machine to creep in neutral ...

Page 110: ...d LH idler spacers rearward as far as possible Fig 338 4 Tighten the clamp assembly securing the speed control cable to the speed control assembly Fig 339 5 Verify that the speed control lever and motion control levers operate smoothly Fig 338 DSC 0540a Fig 339 DSC 0534a ...

Page 111: ...CONTROLS 4 44 36 40 Toro GrandStand Service Manual 4 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 112: ...he engine off and remove the key from the ignition 2 Turn the fuel shutoff valve to the OFF position Fig 340 5 Remove the bolt washer and nut securing the black ground cable to the battery terminal Fig 342 Fig 340 DSCN 2516a 3 Drain the engine oil 4 Remove the two sets of wingnuts and hold down bolts securing the battery cover then remove the cover Fig 341 Fig 341 DSCN 2263a Fig 342 DSCN 2265a Fig...

Page 113: ...the fuel pump Fig 344 9 Remove the violet wire from the voltage regulator Fig 346 Fig 344 DSCN 2517a 8 Remove the fuel line from the fuel pump Drain the fuel into a suitable container Fig 345 Fig 345 DSCN 2521a Fig 346 DSCN 2522a 10 Unplug the pink wire from the green fuel solenoid wire Fig 347 Fig 347 DSCN 2526a ...

Page 114: ...ig 348 13 Remove nut and lock washer securing the starter wire to the solenoid Fig 350 Fig 348 DSCN 2527a 12 Remove the bolt and washer securing the ground wires to the engine block Fig 349 Fig 349 DSCN 2530a Fig 350 DSCN 2533a 14 Unplug the clutch wires from the wiring harness Fig 351 Fig 351 DSCN 2536a ...

Page 115: ...throttle cable from the engine throttle lever Fig 355 17 Loosen the screw on the choke cable clamp and disconnect the choke cable from the engine choke lever Fig 354 Fig 352 DSCN 2547a 16 Remove the four nuts two mounting guard brackets and four carriage bolts securing the muffler guard assembly to the front frame then remove the muffler guard Fig 353 Fig 353 DSCN 2549a Fig 354 DSCN 2551a Fig 355 ...

Page 116: ... throttle and choke cable to the engine oil drain Fig 356 23 40 Deck Using a spring tool remove the exten sion spring from the deck anchor post Fig 358 Fig 356 DSCN 2561a 20 Lower the HOC height of cut to the lowest HOC 21 Remove the belt covers 22 36 Deck Using a spring tool remove the exten sion spring from the deck anchor post Fig 357 Fig 357 DSCN 2562a Fig 358 DSCN 2564a Fig 359 DSCN 2582a ...

Page 117: ...cable tie securing the clutch wire harness to the clutch anchor Fig 360 28 Remove the extension spring from the drive idler pulley assembly Fig 362 Fig 360 DSCN 2566a 27 Remove the deck belt from the clutch pulley Fig 361 Fig 361 DSCN 2569a Fig 362 DSCN 2574a 29 Remove the drive belt from the engine pulley Fig 363 Fig 363 DSCN 2575a ...

Page 118: ... Fig 364 DSCN 2578a 31 Remove the four bolts and Belleville washers secur ing the engine to the engine base Fig 365 Fig 365 DSCN 2581a Fig 366 DSCN 2587a 33 Remove one spark plug and feed a minimum of two feet 61cm of 3 8 95cm rope into the cylinder to prevent engine crankshaft rotation Fig 367 Note Rotate the crankshaft as needed to permit feeding the rope into the cylinder Fig 367 IMG 9634a ...

Page 119: ...37 Remove the key from the engine crankshaft keyway Fig 370 Fig 368 DSCN 2589a 35 Remove the clutch from the engine crankshaft 36 Remove the drive pulley from the engine crankshaft Fig 369 Fig 369 DSCN 2594a Fig 370 DSCN 2597a 38 Loosen the jam nut securing the position of the oil drain assembly then remove the oil drain Fig 371 Fig 371 DSCN 2602a ...

Page 120: ...eft and right side muffler brackets to the muffler Fig 372 41 Remove the four bolts and lock washers securing the right and left hand muffler brackets to the engine Fig 374 Fig 372 IMG 0542a 40 Remove four nuts and lock washers securing the muffler to the engine Fig 373 Fig 373 IMG 0522a Fig 374 IMG 0528a ...

Page 121: ...Install the two bolts spacers and nuts securing the left and right side muffler brackets to the muffler Fig 378 3 Secure the muffler to the engine using four nuts and lock washers Torque to 19 2 ft lbs 26 3 Nm Fig 377 Fig 375 IMG 0528a 2 Position an exhaust gasket on the exhaust studs for both exhaust ports Fig 376 Fig 376 IMG 0531a Fig 377 IMG 0532a Fig 378 IMG 0542a ...

Page 122: ...rankshaft keyway and apply anti seize around the crankshaft Fig 381 Fig 379 DSCN 2602a 6 Remove one spark plug and feed a minimum of two feet 61cm of 3 8 95cm rope into the cylinder to prevent engine crankshaft rotation Fig 380 Note Rotate the crankshaft as needed to permit feeding the rope into the cylinder Fig 380 IMG 9634a Fig 381 DSCN 2603a 8 Install the drive pulley onto the engine crankshaft...

Page 123: ...gauge is inserted between the armature and the rotor friction surfaces Fig 383 11 Apply thread locking compound to the threads of the clutch bolt Fig 385 Fig 383 PICT 0554a 10 Install the spring washer crown toward the bolt head and flat washer to the clutch bolt Fig 384 Fig 384 IMG 9630a Fig 385 PICT 8700a 12 Torque the clutch bolt to 55 ft lbs 75 Nm Fig 386 Fig 386 DSCN 2612a ...

Page 124: ...nd replace the spark plug Fig 387 15 Secure the engine to the engine base using the four sets of bolts and Belleville washers Torque the bolts to 30 35 ft lbs 41 47 Nm Fig 389 Fig 387 IMG 9634a 14 Using a hoist position the engine onto the engine base Fig 388 Fig 388 DSCN 2587a Fig 389 DSCN 2581a ...

Page 125: ... a bolt and nut Fig 390 17 Feed the clutch wire harness up through the engine base Fig 392 Fig 390 DSCN 2642a Note Ensure the PTO stop bracket is nested in the slot on the clutch plate Fig 391 Fig 391 DSCN 2645a Fig 392 DSCN 2647a 18 Install the rubber grommet into the engine base Fig 393 Fig 393 DSCN 2649a ...

Page 126: ...ler pulley E Pump drive belt C Clutch pulley F Pump drive pulley 19 Secure the wire harness to the PTO stop bracket using a cable tie Fig 394 21 Install the extension spring from the idler bracket to the spring anchor Fig 396 Fig 394 DSCN 2658a Fig 395 fig 67 G012686 Fig 396 DSCN 2660a 22 36 Deck Route the deck belt around the deck spindle pulleys Refer to decal 119 0186 Fig 397 Fig 397 decal 119 ...

Page 127: ...ck Install the extension spring to the LH idler bracket and spring anchor Fig 400 Fig 398 DSCN 2666a 24 40 Deck Route the deck belts around the deck spindle pulleys Refer to decal 119 0187 Fig 399 Fig 399 decal 119 0187 Fig 400 DSCN 2670a 26 40 Deck Install the extension spring to the RH idler bracket and spring anchor Fig 401 Fig 401 DSCN 2667a ...

Page 128: ... Hook the Z bend of the throttle cable into the throttle control lever and loosely clamp the outer housing of the throttle cable with the cable clamp Fig 402 30 With the engine throttle control lever in the Fast position pull the slack from the cable jacket and tighten the throttle cable clamp Fig 404 Fig 402 DSCN 2672a 29 Move the throttle lever to the Fast position Fig 403 Fig 403 DSCN 2674a Fig...

Page 129: ...e cable clamp Fig 407 35 Position the muffler guard assembly and loosely install the four carriage bolts two mounting guard brackets and nuts Fig 409 34 Secure the throttle and choke cable to the oil drain assemble using a cable tie Fig 408 Fig 406 DSCN 2677a Fig 407 IMG 0584a Fig 408 DSCN 2683a Fig 409 DSCN 2678a 32 Push the choke knob in so it is in the Open position Fig 406 ...

Page 130: ...ffler exhaust is centered in the muffler guard assembly then tighten all four bolts and nuts Torque the nuts to 19 2 ft lbs 25 76 2 7 Nm Fig 410 38 Install the battery ground wire and the wiring harness ground wire to the engine block Fig 412 Fig 410 DSCN 2680a 37 Connect the clutch wire harness to the wire harness Fig 411 Fig 411 DSCN 2686a Fig 412 DSCN 2688a Fig 413 DSCN 2533a ...

Page 131: ...magneto wire Fig 414 42 Connect the violet wire to the voltage regulator Fig 416 Fig 414 DSCN 2691a 41 Connect the pink wire to the green fuel solenoid wire Fig 415 Fig 415 DSCN 2692a Fig 416 DSCN 2695a 43 Secure the fuel line to the fuel pump using the hose clamp Fig 417 Fig 417 DSCN 2517a ...

Page 132: ... cable to the battery Using the bolt nut and washer secure the negative battery cable to the battery Fig 418 46 Fill the engine with oil to the specified level 47 Turn the fuel shutoff valve to the ON position Fig 420 Fig 418 DSCN 2698a 45 Install the battery cover with the two hold down bolts and wing nuts Fig 419 Fig 419 DSCN 2700a Fig 420 DSCN 2702a ...

Page 133: ...ENGINE 5 22 36 40 Toro GrandStand Service Manual 5 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 134: ...deck anchor post Fig 422 1 36 Deck Using a spring tool remove the exten sion spring from the deck anchor post Fig 421 3 Raise the machine so the underside of the chassis can be accessed 4 Remove the deck belt from the clutch pulley Fig 423 Fig 421 DSCN 2562a Fig 422 DSCN 2564a Fig 423 DSCN 2569a 5 Remove the extension spring from the drive idler pulley assembly Fig 424 Fig 424 DSCN 2574a ...

Page 135: ...ion the pump drive belt around the engine drive pulley the two hydraulic pump pulleys and the idler pulley Fig 426 A Hydraulic pumps D Clutch retainer B Idler pulley E Pump drive belt C Clutch pulley F Pump drive pulley Fig 425 DSCN 2575a Fig 426 fig 67 G012686 2 Install the extension spring from the idler bracket to the spring anchor Fig 427 Fig 427 DSCN 2660a A B C F D E ...

Page 136: ...428 5 40 Deck Route the deck belts around the deck spindle pulleys Refer to decal 119 0187 Fig 430 Fig 428 decal 119 0186 4 36 Deck Install the extension spring to the idler bracket and spring anchor Fig 429 Fig 429 DSCN 2666a Fig 430 decal 119 0187 6 40 Deck Install the extension spring to the LH idler bracket and spring anchor Fig 431 Fig 431 DSCN 2670a ...

Page 137: ... Idler Plate Washer 2 E Large Spacer 5 Remove the large spacer two friction composite washers spacer and washer Fig 434 Fig 432 DSCN 2574a 3 Remove the belt from around the idler and pump pulleys 4 Remove the bolt and nut securing the idler assembly to the engine base then remove the assembly Fig 433 Fig 433 DSCN 2799a Fig 434 DSCN 2779a 6 Remove the bolt washers and nut securing the idler pulley ...

Page 138: ...ey hub needs to face the idler plate 3 Place the large spacer one friction composite washer and bushing onto the pivot bolt Fig 438 2 Place the pivot bolt with washer down through the engine base Fig 437 Fig 437 DSCN 2789a Fig 438 DSCN 2793a 4 Place the idler assembly onto the pivot bolt Fig 439 Fig 439 DSCN 2797a Fig 436 DSCN 2784a A Bolt D Idler Plate B Washer 2 E Nut C Idler Pulley A B C D B E ...

Page 139: ...lt around the engine idler and pump pulleys Fig 442 Fig 440 DSCN 2795a B Secure the idler assembly with a nut Fig 441 Fig 441 DSCN 2799a 7 Install the extension spring from the idler bracket to the spring anchor Fig 443 Fig 443 DSCN 2660a A Hydraulic pumps D Clutch retainer B Idler pulley E Pump drive belt C Clutch pulley F Pump drive pulley Fig 442 fig 67 G012686 A B C F D E ...

Page 140: ...otect all exposed sealing areas and open cavities from damage and foreign material Upon removal all seals o rings and gaskets should be replaced During installation lightly lubricate all seals o rings and gaskets with clean petroleum jelly prior to assembly 4 Raise the rear of the machine 5 Release the parking brake 6 Remove the four lug nuts and then the tire assembly Fig 445 1 Place the deck in ...

Page 141: ... 9 Remove the two set screws securing the pump pulley to the pulley shaft then remove the pulley Fig 448 10 Remove the key from the pulley shaft keyway Fig 449 Fig 447 DSCN 2962a Fig 448 DSCN 2965a Fig 449 DSCN 2971a 11 Remove the bolt and nut securing the control cable to the pump control arm Fig 450 Fig 450 DSCN 2978a ...

Page 142: ...rectly Fig 451 14 Place a drain pan under the wheel motor and dis connect both hydraulic hoses from the wheel motor fittings Fig 453 Fig 451 DSCN 2986a 13 Mark the high pressure hoses and pump to ensure they are re installed correctly Fig 452 Fig 452 DSCN 2980a Fig 453 DSCN 2989a 15 Remove the two high pressure hoses from the pump Fig 454 Fig 454 DSCN 2990a ...

Page 143: ...of bolts washers and nuts securing the pump to the engine base Fig 457 Fig 455 DSCN 2992a Fig 457 DSCN 3045a 19 Remove the pump 20 Loosen the jam nut securing the return hose fitting then remove the fitting Fig 458 Fig 458 DSCN 3029a 17 Move the hose clamp securing the low pressure return hose to the pump fitting then remove the hose Fig 456 Fig 456 DSCN 2995a ...

Page 144: ...to the replacement pump 2 Secure the pump control arm to the RTN Return to Neutral assembly using the bolts and nuts Fig 461 21 Loosen the jam nut securing the suction hose fitting then remove the fitting Fig 459 Fig 459 DSCN 3032a Fig 460 DSCN 3038a Fig 461 DSCN 3038a 23 To service the pump refer to the HydroGear Pump Service Manual BLN 52503 3 Install the suction hose fitting to the pump Fig 462...

Page 145: ...nut Fig 463 Fig 463 DSCN 3029a 6 Secure the return hose to the pump fitting using the hose clamp Fig 465 Fig 465 DSCN 3049a 5 Secure the pump to the engine base using the carriage bolts washers and nuts Fig 464 Fig 464 DSCN 3045a 7 Secure the suction hose to the pump fitting Fig 466 Note Secure the position of the fitting using the jam nut Fig 466 DSCN 3051a ...

Page 146: ...ark ings If installed incorrectly wheel direction will be reversed Fig 467 DSCN 3052a 9 Loop the hose around the control cables and opposite side pump hoses Fig 468 Fig 468 DSCN 3055a 10 Install the hose to the wheel motor Fig 469 Note Ensure the hose is installed to the correct wheel motor fitting by using the identification markings If installed incorrectly wheel direction will be reversed Fig 4...

Page 147: ...pressure hose to the pump Fig 470 13 Install the hose to the wheel motor Fig 472 Fig 470 DSCN 3059a 12 Loop the hose around the control cables and opposite side pump hoses Fig 471 Fig 471 DSCN 3061a Fig 472 DSCN 3063a 14 Secure the control cable to the pump control arm Fig 473 Fig 473 DSCN 2978a ...

Page 148: ...ly thread locking material to the threads of the pump pulley set screws Fig 476 Fig 474 DSCN 2971a 16 Apply anti seize to the pump shaft Fig 475 Fig 475 DSCN 3079a Fig 476 DSCN 3069a 18 Install the set screws into the pump pulley Fig 477 Note Ensure the set screws have not protruded into the center of the pulley hub Fig 477 DSCN 3071a ...

Page 149: ...e idler bracket to the spring anchor Fig 480 Fig 478 DSCN 3081a 20 Position the pump drive belt around the engine idler and pump pulleys Fig 479 Fig 480 DSCN 2660a 22 Secure the tire assembly to the wheel motor hub using the four wheel lug nuts Fig 481 Note The four wheel lug nuts will be torqued in a later step Fig 481 DSCN 2805a A Hydraulic pumps D Clutch retainer B Idler pulley E Pump drive bel...

Page 150: ... Thoroughly clean all exposed surfaces prior to any type of maintenance Cleaning all parts by using a solvent wash and air drying is usually adequate As with any precision equipment all parts must be kept free of foreign material and chemicals Protect all exposed sealing areas and open cavities from damage and foreign material Upon removal all seals o rings and gaskets should be replaced During in...

Page 151: ...84 DSCN 2805a 4 Raise the rear of the machine 5 Release the parking brake 6 Remove the four lug nuts and remove the tire Fig 485 Fig 485 DSCN 2805 Fig 486 DSCN 2806a 8 Install a hub puller Toro p n TOR6006 onto the wheel lug bolts Fig 487 Note The lug bolts need to be installed backwards so the flat side is against the puller Fig 487 DSCN 2813a ...

Page 152: ...haft Fig 489 9 Advance the forcing screw through the wheel hub until it firmly contacts the wheel motor shaft Fig 488 11 Remove the hub puller from the hub 12 Remove the woodruff key from the wheel motor shaft keyway Fig 490 Fig 488 DSCN 2817a Fig 489 DSCN 2822a Fig 490 DSCN 2827a 13 Mark the hose and motor ports to ensure they are installed correctly Fig 491 Fig 491 DSCN 2829a ...

Page 153: ...2 17 Remove the four bolts and nuts securing the wheel motor to the frame then remove the wheel motor Fig 495 16 Loosen the jam nut securing the position of the fit tings then remove the hydraulic fittings Fig 494 Fig 492 DSCN 2834a 15 Cap the hose ends to prevent debris from entering the system Fig 493 Note If the wheel motor is going to be reused cap the hydraulic fittings to prevent debris from...

Page 154: ...fication markings to the new motor Fig 496 3 Install the two hydraulic fittings into the motor Fig 498 Note Do not tighten the jam nuts until the hoses are connected Fig 496 DSCN 2854a Fig 497 DSCN 2843a Fig 498 DSCN 2836a 4 Install the two hydraulic hoses then secure the position of the hose fittings using the jam nuts Fig 499 Note Ensure the hoses are connected to the cor rect port by using the ...

Page 155: ...t using the wheel motor nut Fig 502 Note The wheel motor nut will be torqued in a later step Fig 500 DSCN 2827a 6 Apply thread locking material to the threads of the wheel motor nut Fig 501 Fig 501 DSCN 2871a Fig 502 DSCN 2806a 8 Secure the tire to the wheel motor hub using the four wheel lug nuts Fig 503 Note The four wheel lug nuts will be torqued in a later step Fig 503 DSCN 2805a ...

Page 156: ...g a solvent wash and air drying is usually adequate As with any precision equipment all parts must be kept free of foreign material and chemicals Protect all exposed sealing areas and open cavities from damage and foreign material Upon removal all seals o rings and gaskets should be replaced During installation lightly lubricate all seals o rings and gaskets with clean petroleum jelly prior to ass...

Page 157: ...into the pan Fig 507 4 Remove the two sets of bolts washers and nuts securing the reservoir tank to the tank bracket then remove the reservoir tank Fig 509 Fig 507 DSCN 2887a 3 Remove the low pressure suction hose from the reservoir fitting Fig 508 Fig 508 DSCN 2887a Fig 509 DSCN 2890a 5 Loosen the jam nut securing the return hose fitting then remove the fitting Fig 510 Fig 510 DSCN 2898a ...

Page 158: ...e suction hose fitting then remove the fitting Fig 511 1 Install the suction hose fitting into the reservoir tank and secure the position using the jam nut Fig 512 Fig 511 DSCN 2901a Fig 512 DSCN 2905a 2 Install the return hose fitting into the reservoir tank and secure the position using the jam nut Fig 513 Fig 513 DSCN 2903a ...

Page 159: ...ic fluid See your Operator s Manual for the specified fluid Fig 517 5 Secure the return hose to the return fitting using the hose clamp Fig 516 Fig 514 DSCN 2890a 4 Install the suction hose to the suction fitting Fig 515 Fig 515 DSCN 2887a Fig 516 DSCN 2906a Fig 517 fig 71 G012685 7 Purge the air from the hydraulic system See Bleeding the Hydraulic System on page 6 35 A Cap C Cold fluid level full...

Page 160: ...l parts must be kept free of foreign material and chemicals Protect all exposed sealing areas and open cavities from damage and foreign material Upon removal all seals O rings and gaskets should be replaced During installation lightly lubricate all seals O rings and gaskets with clean petroleum jelly prior to assembly 2 Remove the suction hose from the filter mount inlet fitting Fig 519 1 Place an...

Page 161: ...oosen the jam nut and remove the inlet fitting Fig 521 6 Remove the two bolts and washers securing the hydraulic filter mount to the filter bracket Fig 523 Fig 521 DSCN 2916a 5 Loosen the jam nut and remove the outlet fitting Fig 522 Fig 522 DSCN 2919a Fig 523 DSCN 2921a ...

Page 162: ...am nut Fig 527 1 Secure the hydraulic filter mount to the filter bracket using the two bolts and nuts Fig 524 2 Install the outlet fitting into the filter mount outlet port Fig 526 Note Do not tighten the jam nut at this time Fig 524 DSCN 2921a Note Position the filter mount so the FLOW arrow aligns with the arrow in the filter bracket Fig 525 Fig 525 DSCN 2928a Fig 526 DSCN 2919a Fig 527 DSCN 293...

Page 163: ...am nut at this time 6 Apply a thin coat of hydraulic fluid to the rubber gasket on the replacement filter Fig 530 Fig 528 DSCN 2916a 5 Secure the suction hose to the inlet fitting then secure the position of the fitting with the jam nut Fig 529 Fig 529 DSCN 2913a Fig 530 DSCN 2956a 7 Install the replacement filter to the filter mount Fig 531 Fig 531 DSCN 2910a ...

Page 164: ...ny precision equipment all parts must be kept free of foreign material and chemicals Protect all exposed sealing areas and open cavities from damage and foreign material When using a Bi Directional Flow Test Kit determining directional flow is not necessary The flow meter may be connected in either direction into the forward and reverse high pressure system lines Caution Ensure all fittings and ho...

Page 165: ...from the wheel motor Fig 537 7 Thoroughly clean the area around the hydraulic fittings to prevent debris from entering the system 8 Mark the hoses and corresponding wheel motor fitting ports so the hoses get connected back in their original locations Fig 536 Fig 534 DSCN 2811a 5 Release the parking brake 6 Remove the 4 lug nuts and the wheel assembly Fig 535 Fig 535 DSCN 2805a Fig 536 DSCN 2830a F...

Page 166: ...tes in forward no load to purge air from the system 15 Run the machine at full throttle no load Verify the RPM with a tachometer 3200 150 RPMs Do not exceed 3600 RPM 16 With the drive control fully forward slowly tighten the restriction valve until the gauge indicates 300 PSI 21 bar Fig 540 Fig 538 IMG 0916a 13 Open the restriction valve all the way counter clockwise Fig 539 Fig 539 IMG 0917a Fig ...

Page 167: ...cond reading and determine if it is an acceptable GPM Example 1st Reading 300 psi 21 bar reading 7 gpm 26 l m 2nd Reading 1100 psi 76 bar reading 3 gpm 11 l m 7 gpm 1st reading 3 gpm 2nd reading 4 gpm the difference Refer to the Hydro Gear pump service manual for maximum acceptable flow droop or difference 18 After all necessary repairs have been made re connect the hydraulic hoses to the wheel mo...

Page 168: ...g conditions 1 Disengage the PTO 2 Stop the engine and wait for all moving parts to stop before leaving the operating position 3 Support the rear of the machine on jack stands high enough to raise the drive wheels off the ground 4 With the bypass valve open and the engine running slowly move the directional control in both forward and reverse directions 5 to 6 times As air is purged from the unit ...

Page 169: ...HYDRAULIC DRIVE SYSTEM 6 36 36 40 Toro GrandStand Service Manual 6 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 170: ...eys 1 Turn the ignition off and remove the key 2 Move the mower deck to the 1 25mm HOC 3 Remove the belt covers 4 Remove the extension spring from the anchor post Fig 544 1 Route the belt around the deck and clutch pulleys Fig 545 Fig 544 DSCN 3449a Fig 545 fig 119 0186 2 Install the extension spring to the idler bracket and spring anchor Fig 546 Fig 546 DSCN 3449a 3 Install the belt covers ...

Page 171: ... to the 1 25mm HOC 3 Remove the RH belt cover 4 Remove the RH extension spring from the anchor post Fig 547 1 Route the RH belt around the deck pulleys Fig 549 Form 3368 755 Page 10 Belt Routing Fig 547 DSCN 3117a 5 Remove the RH belt from the deck pulleys Fig 548 Fig 548 DSCN 3119a Fig 549 fig 119 0187 2 Install the extension spring to the RH idler bracket and spring anchor Fig 550 Fig 550 DSCN 3...

Page 172: ... the 1 25mm HOC 3 Remove the belt covers 4 Remove the RH extension spring from the anchor post Fig 551 6 Remove the LH extension spring from the anchor post Fig 553 Fig 551 DSCN 3117a 5 Remove the RH belt from the deck pulleys Fig 552 Fig 552 DSCN 3119a Fig 553 DSCN 3121a 7 Remove the LH belt from around the deck and clutch pulleys Fig 554 Fig 554 DSCN 3124a ...

Page 173: ...pulleys Fig 555 3 Route the RH belt around the deck pulleys Fig 557 Fig 555 fig 119 0187 2 Install the extension spring to the LH idler bracket and spring anchor Fig 556 Fig 556 DSCN 3121a Fig 557 fig 119 0187 4 Install the extension spring to the RH idler bracket and spring anchor Fig 558 Fig 558 DSCN 3117a 5 Install the belt covers ...

Page 174: ...ion spring from the anchor post Fig 559 5 Raise the machine so the underside of the deck can be accessed 6 Block the mower deck blade and remove the blade bolt washer and blade from the spindle Fig 561 Fig 559 DSCN 3121a 4 Remove the belt from the mower deck pulleys Fig 560 Fig 560 DSCN 3124a Fig 561 DSCN 3147a 7 Remove the six nuts securing the thread forming screws Fig 562 Fig 562 DSCN 3152a ...

Page 175: ...screws securing the spindle assembly to the deck Fig 563 To service the spindle assembly refer to Spindle Service on page 7 8 1 Secure the spindle assembly to the deck using six thread forming screws Fig 564 Fig 563 DSCN 3153a Fig 564 DSCN 3153a 2 Secure the thread forming screws with nuts Fig 565 Fig 565 DSCN 3152a ...

Page 176: ...lade bolt and washer With the mower blade blocked torque the blade bolt to 85 110 ft lbs 115 149 Nm Fig 566 4 Route the belt around the deck pulleys Fig 568 40 deck and Fig 569 36 deck Fig 566 DSCN 3220a Note The crown of the washer faces the bolt head Fig 567 Fig 567 DSCN 3216a Fig 568 fig 119 0187 Fig 569 fig 119 0186 ...

Page 177: ...spindle assembly 1 With the blade firmly secured in a vise remove the nut and washer securing the pulley to the spindle shaft Fig 571 Fig 571 DSCN 3171a 2 Remove the bearing shield from the spindle assembly Fig 572 Fig 572 DSCN 3178a 5 Install the extension spring to the idler bracket and spring anchor Fig 570 Fig 570 DSCN 3121a 6 Install the belt covers ...

Page 178: ...firmly secured in a vise remove the nut and washer securing the blade to the spindle shaft Fig 574 Fig 574 DSCN 3184a 5 Remove the upper and lower bearings from the spindle housing Fig 575 Fig 575 DSCN 3185a 6 Remove the bearing spacer from the spindle housing Fig 576 Note Inspect all spindle assembly components Replace any that are damaged or worn Fig 576 DSCN 3191a ...

Page 179: ... temp grease Fig 579 8 Position the bearing spacer in the spindle housing Fig 578 Fig 578 DSCN 3195a Fig 579 DSCN 3198a 10 Install the lower bearing into the spindle housing and add a couple of pumps of high temp grease to the center of the bearing spacer Fig 580 Fig 580 DSCN 3202a 7 Install the upper bearing into the spindle housing Fig 577 Fig 577 DSCN 3193a ...

Page 180: ...e the pulley to the spindle shaft using the washer and nut The torque will be applied in a later step Fig 583 Note The welded side of the pulley hub faces upward Fig 583 DSCN 3158a 11 Install the spindle shaft into the spindle housing Fig 581 Note Rotate the spindle shaft as it is inserted through the spindle housing to spread the grease Fig 581 DSCN 3205a ...

Page 181: ...lley to the spindle shaft Fig 586 Fig 586 DSCN 3171a 16 Secure the spindle assembly to the deck using six thread forming screws Fig 587 Fig 587 DSCN 3153a Note The crown of the washer faces the bolt head Fig 585 Fig 585 DSCN 3216a 14 Secure the blade to the spindle shaft using the washer and blade bolt The torque will be applied in a later step Fig 584 Fig 584 DSCN 3212a ...

Page 182: ...orming screws with nuts Fig 588 Fig 588 DSCN 3152a 18 With the mower blade blocked torque the blade bolt to 85 110 ft lbs 115 149 Nm Fig 589 Fig 589 DSCN 3220a 19 Route the belt around the deck pulleys Fig 590 40 deck and Fig 591 36 deck Fig 590 fig 119 0187 Fig 591 fig 119 0186 ...

Page 183: ... 2 Move the mower deck to the 1 25mm HOC 3 Remove the belt covers 4 Remove the extension spring from the anchor post Fig 593 20 Install the extension spring to the idler bracket and spring anchor Fig 592 Fig 592 DSCN 3121a Fig 593 DSCN 3449a 22 Install the belt covers 5 Remove the belt from the idler pulley 6 Raise the machine to access to underside of the mower deck ...

Page 184: ...ring the idler assembly to the mower deck Fig 594 9 Remove the grease fitting from the idler arm hub Fig 596 Fig 594 DSCN 3452a 8 Remove the spacer from the idler arm assembly Fig 595 Fig 595 DSCN 3455a Fig 596 DSCN 3457a 10 Using a punch remove the upper and lower bushings Fig 597 Fig 597 DSCN 3459a ...

Page 185: ... bolt washer and flange nut securing the idler pulley to the idler arm Fig 598 1 Install the upper and lower bushings into the idler arm hub Fig 599 Fig 598 DSCN 3462a Fig 599 DSCN 3465a 2 Install the grease fitting into the idler arm hub Fig 600 Note Install the fitting so it is pointing upwards Fig 600 DSCN 3468a ...

Page 186: ...olt washer and flange nut Fig 601 4 Install the spacer into the idler arm assembly Fig 603 Fig 601 DSCN 3480a Note The taller side of the idler pulley hub faces the idler arm Fig 602 Fig 602 DSCN 3239a Fig 603 DSCN 3482a 5 Position the bolt upper and lower washers onto the idler arm assembly Fig 604 Fig 604 DSCN 3487a ...

Page 187: ...nto the mower deck Fig 605 8 Route the belt around the deck pulleys Fig 607 Fig 605 DSCN 3489a 7 Secure the assembly using the flange nut Fig 606 Fig 606 DSCN 3492a Fig 607 fig 119 0186 9 Install the extension spring to the idler bracket and spring anchor Fig 608 Fig 608 DSCN 3449a ...

Page 188: ... Removal 10 Pump high temp grease into the idler hub Fig 609 11 Install the belt cover 1 Turn the ignition off and remove the key 2 Remove the belt cover 3 Remove the extension spring from the anchor post Fig 610 Fig 609 DSCN 3495a Fig 610 DSCN 3121a 4 Remove the belt from the mower deck pulleys Fig 611 Fig 611 DSCN 3125a ...

Page 189: ... bolt washers and flange nut securing the idler assembly to the mower deck Fig 612 8 Using a punch remove the upper and lower bushings Fig 614 Fig 612 DSCN 3225a 7 Remove the spacer from the idler arm assembly Fig 613 Fig 613 DSCN 3255a Fig 614 DSCN 3233a 9 Remove the grease fitting from the idler arm hub Fig 615 Fig 615 DSCN 3235a ...

Page 190: ...dler pulley to the idler arm using the carriage bolt washer and flange nut Fig 617 Fig 616 DSCN 3237a Fig 617 DSCN 3243a Note The taller side of the idler pulley hub faces the idler arm Fig 618 Fig 618 DSCN 3239a 10 Remove the carriage bolt washer and flange nut securing the idler pulley to the idler arm Fig 616 ...

Page 191: ...e idler arm hub Fig 619 4 Install the spacer into the idler arm assembly Fig 621 Fig 619 DSCN 3235a 3 Install the upper and lower bushings into the idler arm hub Fig 620 Fig 620 DSCN 3248a Fig 621 DSCN 3255a 5 Position the bolt with washer up through the mower deck Fig 622 Fig 622 DSCN 3257a ...

Page 192: ...ace a large washer onto the bolt Fig 623 8 Place a large washer onto the bolt Fig 625 Fig 623 DSCN 3260a 7 Place the idler assembly onto the bolt Fig 624 Fig 624 DSCN 3262a Fig 625 DSCN 3263a 9 Secure the assembly using the flange nut Fig 626 Fig 626 DSCN 3266a ...

Page 193: ...nstall the belt cover 10 Route the belt around the deck pulleys Fig 627 12 Pump high temp grease into the idler hub Fig 629 Fig 627 fig 119 0187 11 Install the extension spring to the idler bracket and spring anchor Fig 628 Fig 628 DSCN 3121a Fig 629 DSCN 3269a ...

Page 194: ...ion spring from the anchor post Fig 630 5 Remove the spacer two washers and two friction washers from the assembly Fig 632 Fig 630 DSCN 3117a 4 Remove the bolt and nut securing the idler assembly to the idler mount Fig 631 Fig 631 DSCN 3271a Fig 632 DSCN 3274a 6 Remove the carriage bolt washer and flange nut securing the idler pulley to the idler arm Fig 633 Fig 633 DSCN 3275a ...

Page 195: ... bolt washer and flange nut Fig 634 2 Place the bolt through the two washers two friction washers spacer and idler arm Fig 636 Fig 634 DSCN 3275a Note The taller side of the idler pulley hub faces the idler arm Fig 635 Fig 635 DSCN 3239a Fig 636 DSCN 3277a Note The two friction washers must have the spacer nested into their center Fig 637 Fig 637 DSCN 3280a ...

Page 196: ...move the carriage bolt and nut securing the LH side of the baffle Fig 640 Fig 638 DSCN 3271a 4 Install the extension spring to the idler bracket and spring anchor Fig 639 Fig 639 DSCN 3117a Fig 640 DSCN 3288a 3 36 Deck Only Remove the carriage bolt and nut securing the RH side of the baffle Fig 641 Fig 641 DSCN 3300a 5 Install the belt cover Baffles Skid Plate Replacement Fixed Baffle Removal ...

Page 197: ...ck Only Secure the RH side of the baffle using the carriage bolt and nut then tighten the LH carriage bolt and nut Fig 645 1 36 Deck Only Loosely install the carriage bolt and nut that secure the LH side of the baffle Fig 644 Fig 642 DSCN 3292a 5 40 Deck Only Remove the thread forming screw securing the RH side of the baffle Fig 643 Fig 643 DSCN 3296a Fig 644 DSCN 3288a Fig 645 DSCN 3300a ...

Page 198: ...ing the thread forming screw then tighten the LH carriage bolt and nut Fig 647 3 40 Deck Only Loosely install the carriage bolt and nut that secure the LH side of the baffle Fig 646 5 40 Deck Only Secure the thread forming screw using the nut Fig 648 Fig 646 DSCN 3288a Fig 647 DSCN 3296a Fig 648 DSCN 3292a ...

Page 199: ...orming screw on the LH side of the baffle Fig 649 4 Remove the carriage bolt and flange nut securing the RH side of the baffle Fig 651 Fig 649 DSCN 3302a 2 Raise the machine to access the underside of the mower deck 3 Remove the thread forming screw securing the LH side of the baffle Fig 650 Fig 650 DSCN 3307a Fig 651 DSCN 3308a ...

Page 200: ...lange nut securing the RH side of the baffle Fig 652 3 Secure the thread forming screw using a nut Fig 654 Fig 652 DSCN 3308a 2 Secure the LH side of the baffle using the thread forming screw Fig 653 Fig 653 DSCN 3307a Fig 654 DSCN 3302a 4 Secure the desired position of the baffle by tighten ing the flange nut Fig 655 Fig 655 DSCN 3308a ...

Page 201: ...g screws Fig 656 1 Secure the discharge baffle using two thread forming screws Fig 658 Fig 656 DSCN 3284a 2 Raise the machine to access the underside of the mower deck 3 Remove the two thread forming screws securing the discharge baffle Fig 657 Fig 657 DSCN 3286a Fig 658 DSCN 3286a 2 Secure the two thread forming screws using two nuts Fig 659 Fig 659 DSCN 3284a ...

Page 202: ...e underside of the mower deck 2 36 Deck Only Remove the four sets of carriage bolts and nuts securing the skid plate to the mower deck Fig 660 1 36 Deck Only Secure the skid plate to the mower deck using the four sets of carriage bolts and nuts Fig 662 Fig 660 DSCN 3502a 3 40 Deck Only Remove the three sets of carriage bolts and nuts securing the skid plate to the mower deck Fig 661 Fig 661 DSCN 3...

Page 203: ...torsion spring from the deflector mount Fig 664 3 Remove the four sets of carriage bolts and nuts securing the deflector mount deflector and deflector strap to the rubber deflector Fig 666 Fig 664 DSCN 3315a 2 Remove the bolt nut and spacer securing the deflector assembly to the mower deck Fig 665 Fig 665 DSCN 3317a Fig 666 DSCN 3320a ...

Page 204: ...charge strap Fig 667 3 Secure the deflector using the two outmost carriage bolts and nuts Fig 669 Fig 667 DSCN 3322a 2 Position the rubber deflector onto the four carriage bolts Fig 668 Fig 668 DSCN 3325a Fig 669 DSCN 3334a 4 Secure the deflector mount to the assembly using the two carriage bolts and nuts Fig 670 Fig 670 DSCN 3336a ...

Page 205: ...ote The torsion spring J hooks must straddle the deck plate 7 Hook the J hook of the torsion spring onto the defector mount Fig 673 Fig 671 DSCN 3338a 6 Secure the deflector assembly to the deck using the bolt and nut Fig 672 Note Do not over tighten the bolt and nut The deflector assembly must move freely Fig 672 DSCN 3340a Fig 673 DSCN 3342a ...

Page 206: ...ote If the bolt must be replaced loosen the wheel motor to gain the clearance needed to remove 4 Remove the spacer from the suspension bushing Fig 676 Fig 674 DSCN 3352a 3 Remove the bolt nut and washer securing the strut to the engine base and deck Fig 675 Fig 675 DSCN 3347a Fig 676 DSCN 3354a 5 Using an arbor press remove the suspension bushing from the strut Fig 677 Fig 677 DSCN 3358a 6 Repeat ...

Page 207: ... 3 Install the spacer into the suspension bushing Fig 680 Fig 678 DSCN 3362a 2 Using an arbor press install the suspension bushing into the strut Fig 679 Fig 679 DSCN 3363a Fig 680 DSCN 3366a 4 Repeat steps 1 through 3 on the other end of the strut 5 Loosely install the bolt washer and nut securing the rear of the strut to the frame Fig 681 Fig 681 DSCN 3352a ...

Page 208: ...ut 6 Secure the front end of the strut to the engine base and deck using the bolt washer and nut Fig 682 1 Remove the bolt nut and washer securing the strut to the frame Fig 683 Fig 682 DSCN 3347a Fig 683 DSCN 3370a 2 Remove the bolt washer and nut securing the strut to the deck Fig 684 Fig 684 DSCN 3367a ...

Page 209: ...n layer of grease to the outer lip of the suspension bushing Fig 687 Fig 685 DSCN 3373a 4 Using an arbor press remove the suspension bushing from the strut Fig 686 Fig 686 DSCN 3375a Fig 687 DSCN 3362a 2 Using an arbor press install the suspension bushing into the strut Fig 688 Fig 688 DSCN 3375a 5 Repeat steps 3 and 4 on the other end of the strut ...

Page 210: ... the spacer into the suspension bushing Fig 689 6 Secure the other end of the strut to the deck using the bolt washer and nut Fig 691 Fig 689 DSCN 3373a 4 Repeat steps 1 through 3 on the other end of the strut 5 Loosely install the bolt washer and nut securing the strut to the frame Fig 690 Fig 690 DSCN 3370a Fig 691 DSCN 3367a ...

Page 211: ...the extension spring from the anchor post Fig 692 Fig 692 DSCN 3121a 3 Raise the machine to access the underside of the mower 4 Remove the deck belt from the PTO clutch Fig 693 Fig 693 DSCN 3379a 5 Remove the two sets of bolts washers and nuts securing the RH and LH rear struts to the engine base and deck Fig 694 Fig 694 DSCN 3384a ...

Page 212: ... the rear of the engine base Fig 695 to the cable retainer Fig 696 8 Using a strap secure the front of the engine base to the carrier frame Fig 697 Fig 695 DSCN 3388a Fig 696 DSCN 3392a Fig 697 DSCN 3399a 9 Remove the two sets of carriage bolts and flange nuts securing the engine base to the rear of the deck Fig 698 Fig 698 DSCN 3405a ...

Page 213: ...curing the front strut to the mower deck Fig 701 Fig 699 DSCN 3412a 11 Place a 2 x4 under each side of the mower deck then lower the deck onto the boards Fig 700 Fig 700 DSCN 3414a Fig 701 DSCN 3415a 13 Remove the four flange nuts securing the lift chains to the mower deck Fig 702 Note The HOC handle will spring to the transport position once the deck is unsecured Fig 702 DSCN 3419a ...

Page 214: ...703 Note The rear of the machine can be raised to ease removal 1 Position the mower deck under the chassis 2 Secure the four lift chains to the mower deck using the flange nuts Fig 704 Fig 703 DSCN 3429a Fig 704 DSCN 3419a 3 Secure the front strut to the mower deck using the bolt washer and flange nut Fig 705 Fig 705 DSCN 3415a ...

Page 215: ...rotruding through the deck Fig 706 5 Loosely install the flange nuts onto the two screws Fig 708 Fig 706 DSCN 3430a Note The rear deck mounts must be to the inside of the engine base mounts Fig 707 Fig 707 DSCN 3437a Fig 708 DSCN 3442a 6 Loosely install the two sets of carriage bolts through the deck and engine base Fig 709 Fig 709 DSCN 3440a ...

Page 216: ... flange nuts securing the engine base to the rear of the deck Fig 711 7 Secure the two rear struts using the two sets of bolts washers and flange nuts Fig 710 9 Tighten the two flange nuts securing the engine base to the top of the deck Fig 712 Fig 710 DSCN 3384a Fig 711 DSCN 3384a Fig 712 DSCN 3412a ...

Page 217: ...ront and rear of the engine base 11 Route the belt around the deck and clutch pulleys Fig 713 40 deck and Fig 714 36 deck 13 Install the belt covers 12 Install the extension spring to the idler bracket and spring anchor Fig 715 Fig 713 fig 119 0187 Fig 714 fig 119 0186 Fig 715 DSCN 3121a ...

Page 218: ...until the deck has been leveled Refer to Adjusting the Height of Cut on page 7 52 6 Check the distance between the swivels measure at the center of the swivels center to center length on the threaded rod This length needs to be 19 1 2 49 5cm for 36 mower decks and 17 3 16 43 7cm for 40 mower decks Fig 716 7 Inspect the four chains The chains need to have tension 8 If either rear chain is loose the...

Page 219: ...wer at position A than at position B Fig 717 If it is not correct proceed to the following steps 1 Measure here from the 2 Measure at A B blade to a hard surface 5 Loosen the nut on the upper chain bolt and the jam nut on the adjustment bolt Fig 718 6 Use the adjustment bolt to achieve 1 4 to 3 8 6 to 10mm lower in front at A than in the rear at B Fig 718 7 Tighten the nut on the upper chain bolt ...

Page 220: ...he C location from a level surface to the cutting edge of the blade tip and record this measurement Fig 720 3 Measure the right blade at the D location from a level surface to the cutting edge of the blade tip and record this measurement Fig 720 4 The mower blade should be a 1 4 to 3 8 6 to 10mm lower at position C than at position D Fig 720 If it is not correct proceed to the following steps 5 Th...

Page 221: ...p and record this measurement Fig 721 6 The measurement between location A and C needs to be within an 1 8 of the 3 76mm height of cut setting If it is not correct proceed to the following steps 7 Loosen the jam nuts at both ends of the turnbuckle Fig 722 Note The end of the turnbuckle with the groove machined in it has left hand threads Fig 722 8 Adjust the turnbuckle to raise or lower the deck h...

Page 222: ...he component rather than another circuit Interlock modules MUST be removed from the circuit before performing any tests with an ohmmeter or continuity light Battery voltage can damage these modules if applied to the wrong terminals Ignition Switch Component Testing Purpose How It Works 1 Disconnect the switch from the wire harness 2 Verify that continuity exists between the terminals listed for th...

Page 223: ...ated on the control panel Fig 725 Fig 725 DSCN 2194a Testing 1 Disengage the PTO set the parking brake turn the ignition to OFF and remove the key 2 Disconnect the wire harness from the PTO switch 3 Press in on the locking tabs on each side of the switch and pull the switch out of the control panel 4 Verify that there is continuity between the appro priate terminals in the ON and OFF positions Fig...

Page 224: ...plate and the two rotate as one Location The electric clutch is located on the PTO end of the engine crankshaft under the machine Fig 727 Fig 727 DSCN 2195a Coil Resistance Measurement 1 Disengage the PTO set the parking brake turn the ignition OFF and remove the key 2 Disconnect clutch wire connector from the wire harness 3 Set the multimeter or volt ohm meter to check resistance ohms 4 Connect t...

Page 225: ...ose of the solenoid is to connect the battery to the starter motor on the engine when the ignition switch is turned to START The solenoid is used to protect the ignition switch from the high current drawn from by the starter motor Fig 730 Fig 729 clutch current draw Fig 730 IMG 1198a Location The solenoid is located between the RH hydraulic pump and the engine on the RH side of the machine Fig 731...

Page 226: ...ntact bar toward the contacts and closes the switch When power is removed from the coil the spring loaded bar returns to its normal open position The solenoid closes and opens the switch very quickly This minimizes the arcing that can damage other kinds of switches The ignition switch is protected because only a small amount of current is needed to activate the coil 1 Disconnect the solenoid from ...

Page 227: ...he machine While observing the black triangle for the OPC indicator on the hour meter move the RH control lever up and down If the black triangle turns on and off the switch is good If the black triangle for the OPC indicator fails to turn on when the RH control lever is moved up and down the switch needs to be checked for continuity 1 Disconnect the switch from the wire harness 2 With a multimete...

Page 228: ...ated in the control tower Fig 736 Fig 736 DSCN 2209a Testing Turn the ignition key to the run position do not start the machine While observing the black triangle for the Neutral indicator on the hour meter move one of the control levers in and out of the neutral position If the black triangle turns on and off the switch is good If the black triangle for the neutral indicator fails to turn on when...

Page 229: ...nel as part of the parking brake control lever assembly Fig 738 Fig 738 DSCN 2213a Testing Turn the ignition key to the run position do not start the machine While observing the black triangle for the parking brake indicator on the hour meter engage and disengage the parking brake If the black triangle turns on and off the switch is good If the black triangle for the parking brake indicator fails ...

Page 230: ...he fuses that protect the electrical system from electrical surges Location The fuse block is located on the rear LH side of the control tower Fig 739 Fig 739 DSCN 2216a Testing The fuses used in this application can be visually inspected A failed fuse can be identified by the broken melted element inside the fuse cover or a damaged spade Fig 740 Fig 740 IMG 1214a ...

Page 231: ...ery voltage will be displayed in the area the hours are normally displayed The battery light turns on when the battery charge is below 12 volts Fig 742 3 Safety Interlock Indicators The display uses black triangles to indicate the position of an interlock system component Fig 742 Note The neutral indicator is the only triangle that MUST be on for the unit to start Location The hour meter is locate...

Page 232: ...ition Switch Removal 1 Remove the wire harness and spade connector from the back of the ignition switch Fig 743 3 Remove the switch out through the front of the control panel Fig 745 Fig 743 DSCN 2219a 2 Depress the two tabs on the sides of the switch Fig 744 Fig 744 DSCN 2223a Fig 745 DSCN 2224a ...

Page 233: ...2 Install the spade connector with the two pink wires to the I terminal of the switch Fig 748 Fig 748 DSCN 2232a 3 Install the wire harness to the switch Fig 749 Fig 749 DSCN 2234a Ignition Switch Installation 1 Install the switch in through the control panel En sure that the mounting clips have secured the switch in the control panel Fig 746 Fig 746 DSCN 2224a ...

Page 234: ... Remove the wire harness from the back of the PTO switch Fig 750 3 Remove the switch out through the front of the control panel Fig 752 Fig 750 DSCN 2248a 2 Depress the four tabs securing the switch to the control panel Fig 751 Fig 751 DSCN 2257a Fig 752 DSCN 2258a Power Take Off PTO Switch ...

Page 235: ...tch in the control panel Fig 753 1 Turn the engine off and remove the key from the ignition 2 Turn the fuel shutoff valve to the OFF position Fig 755 Fig 753 DSCN 2258a 2 Install the wire harness to the back of the switch Fig 754 Fig 754 DSCN 2248a Fig 755 DSCN 2516a 3 Remove the two sets of wingnuts and hold down bolts securing the battery cover then remove the cover Fig 756 Fig 756 DSCN 2263a El...

Page 236: ...he hose clamp off the fuel line where it connects to the fuel pump Fig 759 Fig 757 DSCN 2265a 5 Remove the bolt washer and nut securing the red positive cable to the battery terminal then remove the battery Fig 758 Fig 758 DSCN 2270a Fig 759 DSCN 2517a 7 Remove the fuel line from the fuel pump Drain the fuel into a suitable container Fig 760 Fig 760 DSCN 2521a ...

Page 237: ...gulator Fig 761 10 Unplug the white wire from the black magneto wire Fig 763 Fig 761 DSCN 2522a 9 Unplug the pink wire from the green fuel solenoid wire Fig 762 Fig 762 DSCN 2526a Fig 763 DSCN 2527a 11 Remove the bolt and washer securing the ground wires to the engine block Fig 764 Fig 764 DSCN 2530a ...

Page 238: ...securing the starter wire to the solenoid Fig 765 14 Push the grommet and the electrical plug connector down through the engine base Fig 767 Fig 765 DSCN 2533a Fig 767 DSCN 2547 15 Remove the four nuts two mounting guard brackets and four carriage bolts securing the muffler guard assembly to the front frame then remove the muffler guard Fig 768 Fig 768 DSCN 2549 ...

Page 239: ...e and choke cable to the engine oil drain Fig 771 Fig 769 DSCN 2551a 17 Loosen the screw on the throttle cable clamp and disconnect the throttle cable from the engine throttle lever Fig 770 Fig 770 DSCN 2556a Fig 771 DSCN 2561a 19 Lower the HOC height of cut to the lowest HOC 20 Remove the belt covers 21 36 Deck Using a spring tool remove the exten sion spring from the deck anchor post Fig 772 Fig...

Page 240: ... 40 Deck Using a spring tool remove the RH spindle extension spring from the RH deck anchor post Fig 774 Fig 774 DSCN 2582a 24 Raise the machine so the underside of the chassis can be accessed 25 Remove the cable tie securing the clutch wire harness to the clutch anchor Fig 775 Fig 775 DSCN 2566a 26 Remove the deck belt from the clutch pulley Fig 776 Fig 776 DSCN 2569a ...

Page 241: ...mbly Fig 777 Fig 777 DSCN 2574a 28 Remove the drive belt from the engine pulley Fig 778 Fig 778 DSCN 2575a 29 Remove the bolt and nut securing the clutch anchor to the engine base Fig 779 Fig 779 DSCN 2578a 30 Remove the four bolts and Belleville washers securing the engine to the engine base Fig 780 Fig 780 DSCN 2581a ...

Page 242: ...imum of two feet 61cm of 3 8 95cm rope into the cylinder to prevent engine crankshaft rotation Fig 782 Note Rotate the crankshaft as needed to permit feeding the rope into the cylinder Fig 782 IMG 9634a 33 Remove the bolt spring washer and washer securing the clutch to the engine crankshaft Fig 783 Fig 783 IMG 9630a 34 Remove the clutch from the engine crankshaft ...

Page 243: ...rted between the armature and the rotor friction surfaces Fig 784 Fig 784 PICT 0554a 2 Install the spring washer crown toward the bolt head and flat washer to the clutch bolt Fig 785 Fig 785 IMG 9630a Electric PTO Clutch Installation 3 Apply thread locking compound to the threads of the clutch bolt Fig 786 Fig 786 PICT 8700a 4 Torque the clutch bolt to 55 ft lbs 75 Nm Fig 787 Fig 787 DSCN 2612a ...

Page 244: ...ark plug Fig 788 Fig 788 IMG 9634a 6 Position the engine onto the engine base Fig 789 Fig 789 DSCN 2587a 7 Secure the engine to the engine base using the four sets of bolts and Belleville washers Torque the bolts to 30 35 ft lbs 41 47 Nm Fig 790 Note The crown of the washer must face the bolt head Fig 790 DSCN 2581a ...

Page 245: ...ot on the clutch plate Fig 792 Fig 792 DSCN 2645a 9 Feed the clutch wire harness up through the engine base Fig 793 Fig 793 DSCN 2647a 10 Install the rubber grommet into the engine base Fig 794 Fig 794 DSCN 2649a 8 Secure the PTO stop bracket to the engine base using a bolt and nut Fig 791 Fig 791 DSCN 2642a ...

Page 246: ...ing anchor Fig 797 Fig 797 DSCN 2660a 14 36 Deck Route the deck belt around the deck spindle pulleys Refer to decal 119 0186 Fig 798 Fig 798 decal 119 0186 12 Position the pump drive belt around the engine drive pulley the two hydraulic pump pulleys and the idler pulley Fig 796 A Hydraulic pumps D Clutch retainer B Idler pulley E Pump drive belt C Clutch pulley F Pump drive pulley Fig 796 fig 67 G...

Page 247: ...9 DSCN 2666a 16 40 Deck Route the deck belts around the deck spindle pulleys Refer to decal 119 0187 Fig 800 Fig 800 decal 119 0187 18 40 Deck Install the extension spring to the RH idler bracket and spring anchor Fig 802 Fig 802 DSCN 2667a 17 40 Deck Install the extension spring to the LH idler bracket and spring anchor Fig 801 Fig 801 DSCN 2670a ...

Page 248: ... Fig 803 Fig 803 DSCN 2672a 22 With the engine throttle control lever in the Fast position pull the slack from the cable jacket and tighten the throttle cable clamp Fig 805 Fig 805 IMG 0576a 21 Move the throttle lever to the Fast position Fig 804 Fig 804 DSCN 2674a 23 Hook the Z bend of the choke cable into the choke control lever and loosely clamp the outer housing of the choke cable with the cab...

Page 249: ... lever in the Open position pull the slack from the cable jacket and tighten the choke cable clamp Fig 808 Fig 808 IMG 0584a 26 Secure the throttle and choke cable to the oil drain assemble using a cable tie Fig 809 Fig 809 DSCN 2683a Fig 810 DSCN 2678a 27 Position the muffler guard assembly and loosely install the four carriage bolts two mounting guard brackets and nuts Fig 810 ...

Page 250: ...ure the muffler exhaust is centered in the muffler guard assembly then tighten all four bolts and nuts Torque the nuts to 19 2 ft lbs 25 76 2 7 Nm Fig 811 Fig 811 DSCN 2680a 29 Connect the clutch wire harness to the wire harness Fig 812 Fig 812 DSCN 2686a 31 Install the starter wire to the solenoid using a lock washer and nut Torque nut to 35 in lbs 4 Nm Fig 814 Fig 814 DSCN 2533a ...

Page 251: ...ck magneto wire Fig 815 Fig 815 DSCN 2691 34 Connect the violet wire to the voltage regulator Fig 817 Fig 817 DSCN 2695a 33 Connect the pink wire to the green fuel solenoid wire Fig 816 Fig 816 DSCN 2692a 35 Secure the fuel line to the fuel pump using the hose clamp Fig 818 Fig 818 DSCN 2517a ...

Page 252: ...o Electric PTO Clutch Burnishing Procedure following Fig 821 DSCN 2702a 36 Position the battery on the battery tray Using the bolt nut and washer secure the positive battery cable to the battery Using the bolt nut and washer secure the negative battery cable to the battery Fig 819 Fig 819 DSCN 2698a 37 Install the battery cover with the two hold down bolts and wing nuts Fig 820 Fig 820 DSCN 2700a ...

Page 253: ...0 seconds on 10 seconds off Increase engine RPM to 3 4 to full throttle Engage and disengage mower 5 times 10 seconds on 10 seconds off Using a feeler gauge check the clutch air gap at each of the 3 adjustment slots The gap should be between 0 015 0 381mm Make sure the gauge is inserted between the armature and the rotor friction surfaces Adjust the clutch as necessary Fig 822 Fig 822 PICT 0554a S...

Page 254: ...ing the positive cable that goes to the starter Fig 827 Fig 825 DSCN 2270a Fig 827 DSCN 2276a 6 Remove the green and blue bullet connectors from the two small studs on the solenoid Fig 828 Fig 828 DSCN 2278a 4 Move the terminal cover off the positive cable com ing from the battery then remove the nut and lock washer securing the positive battery cable and red wire eyelet to the solenoid Fig 826 Fi...

Page 255: ...rews securing the solenoid the engine base plate Fig 829 1 Secure the solenoid to the engine base using two thread forming screws Fig 830 Fig 829 DSCN 2280a Fig 830 DSCN 2280a 2 Install the blue and green wires to the two small studs on the solenoid using the wire s bullet con nectors Fig 831 Fig 831 DSCN 2278a ...

Page 256: ...ttery positive terminal using the bolt washer and nut Fig 834 Fig 832 DSCN 2276a Fig 834 DSCN 2270a 8 Secure the positive battery cable and the wire harness red wire eyelet to the solenoid using a nut and lock washer torque to 35 in lbs 4 Nm then position the positive cable terminal cover over the terminal connection Fig 833 Fig 833 DSCN 2353a 10 Secure the black ground cable to the battery negati...

Page 257: ...using the two sets of wingnuts and hold down bolts Fig 836 1 Remove the wire harness from the switch Fig 837 Fig 836 DSCN 2263a Fig 837 DSCN 2285a 2 Remove the two screws and threaded plate that secure the switch to the control handle assembly and remove the switch Fig 838 Fig 838 DSCN 2291a Operator Presence Control OPC Switch ...

Page 258: ...e control handle as sembly Fig 839 Fig 839 DSCN 2291a 2 Move the RH control lever to the operating position Fig 840 A 1 8 3mm Fig 840 DSCN 2294a 3 Position the switch so there is an 1 8 3mm gap between the switch plunger and the tab on the handle as sembly Fig 841 Fig 841 DSCN 2295a A 4 Secure the position of the switch by tightening the two mounting screws Fig 842 Fig 842 DSCN 2291a ...

Page 259: ...mity Switch Removal 1 Disconnect the wire harness from the switch Fig 844 2 Remove the two screws and nuts that secure the switch to the switch mounting bracket and remove the switch Fig 845 Fig 844 DSCN 2304a Fig 845 DSCN 2305a 5 Plug the wire harness into the switch Fig 843 Fig 843 DSCN 2285a ...

Page 260: ...the controls in the neutral position position the switch so the target printed on the body of the switch is aligned with the bolt attached to the control lever assembly Fig 847 Fig 847 DSCN 2308a 3 Secure the position of the switch by tightening the two mounting screws Fig 848 Fig 848 DSCN 2305a Note Ensure the end of the bolt is within 070 020 1 8 0 5mm of the switch body Fig 849 Fig 849 DSCN 232...

Page 261: ... Remove the wire harness from the switch Fig 851 Fig 851 DSCN 2345a 2 Remove the two screws and threaded plate that secure the switch to the switch bracket Fig 852 Fig 852 DSCN 2326a 4 Plug the wire harness into the switch Fig 850 Fig 850 DSCN 2304a Parking Brake Switch Removal ...

Page 262: ... harness into the switch Fig 856 A 1 8 3mm Fig 856 DSCN 2345a 1 Loosely install the two screws and threaded plate that secure the switch to the brake assembly Fig 853 Fig 853 DSCN 2326a 2 With the brake engaged position the switch so there is an 1 8 3mm gap between the switch body and the tab on the brake arm Fig 854 Fig 854 DSCN 2213a Parking Brake Switch Installation A ...

Page 263: ... wire harness from the back of the hour meter Fig 857 Fig 857 DSCN 2328a 2 Depress the two tabs securing the hour meter to the control panel Fig 858 Fig 858 DSCN 2330a 3 Remove the hour meter out through the front of the control panel Fig 859 Fig 859 DSCN 2333a Hour Meter Control Module Removal ...

Page 264: ...ont of the machine Fig 861 1 Install the hour meter in through the control panel Ensure that the mounting clips have secured the switch in the control panel Fig 860 2 Install the wire harness to the back of the hour meter Fig 862 Fig 860 DSCN 2333a Fig 861 DSCN 2338a Fig 862 DSCN 2328a Hour Meter Control Module Installation ...

Page 265: ...ELECTRICAL 8 44 36 40 Toro GrandStand Service Manual 8 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 266: ...SCHEMATICS 9 1 36 40 Toro GrandStand Service Manual 9 36 40 Toro GrandStand Hydraulic Schematic Fig 863 fig G009494 ...

Page 267: ...SCHEMATICS 9 2 36 40 Toro GrandStand Service Manual 9 36 40 Toro GrandStand Electrical Schematic Fig 864 fig G015606 elec scheme G015606 63 ...

Page 268: ...Toro 36 40 GrandStand Service Manual Form Number 492 9236 ...

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