Service Manual

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LCE Products

Toro GrandStand

Stand-on Mower

Service Manual

Summary of content (454 pages)

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LCE Products Toro GrandStand Stand-on Mower Service Manual
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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 Demystification Guide (4924761) and subsequent.
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ABOUT THIS MANUAL THIS PAGE INTENTIONALLY LEFT BLANK.
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TABLE OF CONTENTS Safety Information General Information �� 1-1 Think Safety First �� 1-1 Specifications Torque Specifications ��
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TABLE OF CONTENTS Controls LH Motion Control Lever Replacement ��4-1 LH Motion Control Lever Removal ��4-1 LH Motion Control Lever Installation ��4-3 RH Motion Control Lever Replacement ��
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TABLE OF CONTENTS Hydraulic Drive System cont.
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TABLE OF CONTENTS Electrical Component Testing ��8-1 Ignition Switch ��8-1 Purpose ��
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TABLE OF CONTENTS Electrical cont.
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TABLE OF CONTENTS THIS PAGE INTENTIONALLY LEFT BLANK.
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SAFETY INFORMATION General Information ! This symbol means WARNING or PERSONAL SAFETY INSTRUCTION read the instruction because if has to do with your safety. Failure to comply with the instruction may result in personal injury or even death. This manual is intended as a service and repair manual only. The safety instructions provided herein are for troubleshooting, service, and repair of the Toro GrandStand Stand-on Mower.
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SPECIFICATIONS SPECIFICATIONS Torque Specifications Torque Specifications Fastener Identification Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual.
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SPECIFICATIONS Standard Torque for Dry, Zinc Plated & Steel Fasteners (Inch Series) Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size 2 Grade 1, 5, & SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 8 with Thin Studs, & Sems with Regular Studs, & Sems with Regular Studs, & Sems with Regular Height Nuts Height Nuts (SAE J995 Height Nuts (SAE J995 Height Nuts (SAE J995 Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) Grade 2 or Stronger Nu
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SPECIFICATIONS Standard Torque for Dry, Zinc & Steel Fasteners (Metric Fasteners) Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) 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 or Strong Nuts) M5 X 0.8 57 ± 5 in-lb 644 ± 68 N-cm 78 ± 8 in-lb 881 ± 90 N-cm M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N-cm 133 ± 14 in-lb 1503 ± 158 N-cm M8 X 1.
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SPECIFICATIONS OtherTorque TorqueSpecifications Specifications Other Wheel Bolts and Lug Nuts SAE Grade 8 Steel Set Screws Recommended Torque Thread Size 2 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 Thread Size Recommended Torque** 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb 88 ± 14 N-m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb 108 ± 14 N-m M12 X 1.
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SPECIFICATIONS Equivalents & Conversions Equivalents and Conversions Decimal & Millimeter Equivalents Decimal and Millimeter Equivalents Fractions Decimals 1/64 1/32 3/64 1/16 5/64 3/32 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 mm 0.015625 0.397 0.03125 0.794 0.046875 1.191 0.0625 1.588 0.078125 1.984 0.9375 2.381 0.1250 3.175 0.140625 3.572 0.15625 3.969 0.171875 4.366 0.1875 4.762 0.
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SPECIFICATIONS U.S. to Metric Conversions 2 U.S. to Metric Conversions To Convert Into Linear Measurement Miles Yards Feet Feet Inches Inches Inches Kilometers Meters Meters Centimeters Meters Centimeters Millimeters Area Square Miles Square Feet Square Inches Acre Square Kilometers Square Meters Square Centimeters Hectare Volume Cubic Yards Cubic Feet Cubic Inches Cubic Meters Cubic Meters Cubic Centimeters 0.7646 0.02832 16.
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SPECIFICATIONS Domestic GrandStand Specifications Engines: Output (Max. @ 3600 RPM’s) 18 hp (13.4kW) 19 hp (14.2kW) 20 hp (14.9kW) 23 hp (17.2kW) 24 hp (17.9kW) 26 hp (19.
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SPECIFICATIONS Domestic GrandStand Specifications cont. 2 Mower Engagement: Engine Mounted Electric Clutch Clutch Adjustment: Periodic Air Gap Adjustment Required - .018” + .003” (0.45 + 0.
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SPECIFICATIONS International GrandStand Specifications Engines: Output (Max. @ 3000 RPM’s) 19 hp (14.2 kW) 20 hp (17.2 kW) 23 hp (17.2 kW) Make Kawasaki Kawasaki Kawasaki Model FH580V FS600V FH680V Hi-Idle 2900 ± 100 RPM 2900 ± 100 RPM 2900 ± 100 RPM Starter Electric Electric Electric Champion RCJ8Y NGK BPR4ES NGK BPR4ES SAE 10w-30 / SAE10w-40 SAE 10w-30 / SAE10w-40 SAE 10w-30 / SAE10w-40 1.8 L (3.8 pint) 1.9 L (4.0 pint) 1.9 L (4.
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SPECIFICATIONS International GrandStand Specifications cont. Mower Drive: 2 Mower Engagement: Engine Mounted Electric Clutch Clutch Adjustment: Periodic Air Gap Adjustment Required - 0.45 ± 0.0762 mm (.018” ± .
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CHASSIS Parking Brake Assembly Replacement 2. Remove the hairpin cotter and clevis pin securing the linkage yoke at the lower end of the brake rod to the brake assembly (Fig. 0002). Parking Brake Assembly Removal 1. Move the parking brake lever to the “OFF” position (Fig. 0001). 3 Fig. 0002 Fig. 0001 IMG-1302a 3. Move the parking brake lever to the “ON” position (Fig. 0003). Fig.
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CHASSIS 4. Remove the hairpin cotter from the top end of the parking brake rod. Slide the top end of the rod out of the handle (Fig. 0004). 5. Remove the hairpin cotter and clevis pin securing the top and bottom brake arms to the brake lever (Fig. 0006). 3 Fig. 0004 IMG-9347a Note: 2010 models use a nut to secure the upper end of the parking brake rod (Fig. 0005). Fig. 0005 3-2 DSCN-0261a Fig. 0006 DSCN-0268a 6. Disconnect the wire harness from the brake switch (Fig. 0007). Fig.
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CHASSIS 7. Remove the carriage bolt and nut securing the brake lever and brake switch plate to the control tower, then remove the brake lever and brake switch plate (Fig. 0008). 9. Remove the shoulder bolt, thick washer and nut securing the LH side of the brake assembly to the chassis, then remove the brake assembly (Fig. 0010). 3 Fig. 0008 DSCN-0255a Fig. 0010 IMG-1325a 8. Remove the bolt and nut securing the RH side of the brake assembly and torsion spring assembly to the chassis (Fig. 0009). Fig.
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CHASSIS Parking Brake Assembly Installation 1. Secure the LH side of the brake assembly to the chassis using the shoulder bolt, thick washer and nut (Fig. 0011). 3. Position the bolt and spacer through the chassis mount and brake assembly. The spacer must be nested in the chassis mount (Fig. 0013). 3 Fig. 0013 Fig. 0011 IMG-1332a IMG-1325a 4. Position the large spacer onto the bolt (Fig. 0014). 2. Place the small spacer onto the bolt that secures the RH side of the brake assembly (Fig. 0012). Fig.
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CHASSIS 5. Position the torsion spring over the spacer and bolt. The straight end of the spring is secured by the chassis, the curved end hooks under the brake assembly (Fig. 0015). 7. Position the carriage bolt through the RH side of the control tower (Fig. 0017). 3 Fig. 0017 Fig. 0015 IMG-1336a 6. Secure the RH assembly using the washer and nut (Fig. 0016). Fig. 0016 8. Position the switch plate onto the carriage bolt (Fig. 0018).
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CHASSIS 9. Position one of the large washers onto the carriage bolt (Fig. 0019). 11. Position the brake lever through the control panel and onto the shouldered spacer (Fig. 0021). 3 Fig. 0019 IMG-1348a 10. Position the shouldered spacer onto the carriage bolt (Fig. 0020). Fig. 0020 3-6 IMG-1351a Fig. 0021 IMG-1355a 12. Secure the brake lever assembly with the large washer and nut (Fig. 0022). Fig.
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CHASSIS 13. Position the clevis pin through the bottom brake arm (Fig. 0023). 15. Position the top brake arm onto the clevis pin (Fig. 0025). 3 Fig. 0023 IMG-1365a 14. Insert the clevis pin through the brake lever (Fig. 0024). Fig. 0025 16. Install the hairpin cotter to the clevis pin (Fig. 0026). Fig. 0026 Fig.
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CHASSIS 17. Plug the wire harness into the brake switch (Fig. 0027). 18. Feed the brake rod up through the fuel tank base and secure the upper end to the brake arm using a hairpin cotter (Fig. 0028). 3 Fig. 0027 DSCN-0265a Fig. 0028 IMG-9347a Note: 2010 models use a nut to secure the upper end of the parking brake rod (Fig. 0029). Fig.
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CHASSIS 19. Secure the yoke on the lower end of the brake rod to the brake assembly using a clevis pin and hairpin cotter (Fig. 0030). 21. If adjustment is needed, remove the clevis pin secur ing the yoke to the brake arm. Rotate the yoke to obtain the desired gap (Fig. 0032). 3 Fig. 0030 DSCN-0264a Fig. 0032 DSCN-0264a 20. The brake assembly should contact the tires when there is approximately 3/4” (1.
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CHASSIS Height of Cut (HOC) Handle Assembly Replacement 3. 2010 only: Remove the dampener assembly from the base of the lift bar (Fig. 0035). HOC Handle Assembly Removal 1. Lower the deck onto two boards to support the weight of the deck assembly (Fig. 0033). 3 Fig. 0035 Fig. 0033 IMG-1373a DSCN-0272a 4. Remove the shoulder bolt, washer and spring securing the height of cut (HOC) lever to the HOC handle assembly (Fig. 0036). 2. 2009 only: Remove the nut at the base of the lift bar (Fig. 0034). Fig.
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CHASSIS 5. Remove the HOC lever through the slot in the control panel (Fig. 0037). 7. Remove the two sets of bolts, nuts and spacers securing the HOC bracket to the side of the control tower (Fig. 0039). 3 Fig. 0037 DSCN-0283a Fig. 0039 6. Remove the “E” clip that secures the pivot hub in the HOC handle assembly (Fig. 0038). Fig. 0038 8. Remove the carriage bolt and nut securing the HOC handle assembly to the control tower (Fig. 0040). DSCN-0285a Fig.
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CHASSIS 9. Move the HOC handle assembly from its frame mount; then remove the lift bar pivot hub (Fig. 0041). HOC Handle Assembly Installation 1. Install the plastic bushing into the upper end of the lift bar (Fig. 0043). 3 Fig. 0041 DSCN-0292a Fig. 0043 DSCN-0297a 10. Remove the lift bar by lowering it down through the fuel tank base. 11. Remove the HOC handle assembly from the control tower. 12. Remove the plastic bushing from the upper end of the lift bar (Fig. 0042). Fig.
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CHASSIS 2. Position the lift bar up through the slot in the fuel tank base, to the approximate mounting location Fig. 0044). 3. Install the lift arm pivot hub into the HOC handle assembly (Fig. 0046). Note: Do not install the “E” clip. It will be installed in a later step. 3 Fig. 0044 DSCN-0307a Fig. 0046 Note: 2010 only: The tube welded to the base of the lift bar must face to the right (Fig. 0045). Fig. 0045 4. Position the HOC handle assembly in the control tower, just above its mounting bracket.
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CHASSIS 5. Secure the pivot hub with the “E” clip (Fig. 0048). 7. Place the two HOC bracket bolts through the side of the control panel. The carriage bolt goes into the upper hole (Fig. 0050). 3 Fig. 0048 DSCN-0285a Fig. 0050 6. Secure the HOC handle assembly to the control tower using the carriage bolt and nut (Fig. 0049). Note: Do not over-tighten. The HOC handle assem bly must move freely. 8. Place a spacer over each of the bolts (Fig. 0051). Fig. 0051 Fig.
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CHASSIS 9. Place the HOC bracket onto the two bolts and secure with nuts (Fig. 0052). 11. Place the washer, then the spring onto the HOC lever shoulder bolt (Fig. 0054). 3 Fig. 0052 DSCN-0330a 10. Position the HOC lever in through the control panel, then onto the HOC handle assembly (Fig. 0053). Fig. 0053 Toro GrandStand Service Manual DSCN-0333a Fig. 0054 DSCN-0335a 12. Secure the HOC lever with the shoulder bolt assembly (Fig. 0055). Fig.
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CHASSIS 13. 2009 only: Secure the lower end of the lift bar to the rear cross shaft assembly using a nut. Thread the nut onto the bolt until there are 3 threads protruding (Fig. 0056). 15. Remove the boards supporting the deck (Fig. 0058). 3 Fig. 0058 Fig. 0056 DSCN-0274a 14. 2010 only: Secure the lower end of the lift bar to the rear cross shaft assembly using the dampener assembly and nut. Thread the dampener assembly bolt into the nut until there are 3 threads protruding (Fig. 0057). 16.
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CHASSIS Caster Wheel Assembly Replacement 3. Remove the caster fork and wheel assembly. Caster Wheel Assembly Removal 4. Remove the three Bellville washers from the caster wheel pivot tube (Fig. 0062). 1. Remove the grease cap from the top of the caster wheel pivot tube (Fig. 0060). 3 Fig. 0062 Fig. 0060 DSCN-0362a DSCN-0357a 5. Remove the upper tapered roller bearing from the caster wheel pivot tube (Fig. 0063). 2. Remove the nut from the caster fork shaft (Fig. 0061). Fig. 0063 Fig.
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CHASSIS 6. Remove the grease seal from the bottom of the caster wheel pivot tube (Fig. 0064). 8. If replacing the wheel bearings, use a blunt punch to remove the upper and lower bearing cups from the caster wheel pivot tube (Fig. 0066). 3 Fig. 0064 DSCN-0370a Fig. 0066 7. Remove the lower tapered roller bearing (Fig. 0065). Fig. 0065 9. Remove the nut securing the caster wheel axle bolt, then remove the axle bolt (Fig. 0067). DSCN-0416a Fig.
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CHASSIS 10. Remove the caster wheel assembly from the caster fork. 12. Remove the spacer nut from the caster axle (Fig. 0069). 11. Remove the seal guard from both sides of the wheel hub (Fig. 0068). 3 Fig. 0069 Fig. 0068 DSCN-0377a 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. 0070). Fig.
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CHASSIS 13. Remove the grease seal from both sides of the caster wheel (Fig. 0071). Caster Wheel Assembly Installation 1. Pack the caster wheel tapered roller bearing with high temperature grease (Fig. 0073). 3 Fig. 0071 DSCN-0387a Fig. 0073 DSCN-0407a 14. Remove the LH and RH tapered bearings (Fig. 0072). 2. Install the bearing into the wheel hub (Fig. 0074). Fig. 0072 DSCN-0389a Fig.
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CHASSIS 3. Install grease seal into the wheel hub (Fig. 0075). 6. Position the caster axle through the bearing and seal assembly (Fig. 0077). 3 Fig. 0075 DSCN-0393a Fig. 0077 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 tempera ture grease (Fig. 0076). Fig. 0076 7. Install a spacer nut onto both ends of the caster axle (Fig. 0078).
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CHASSIS 8. Position the seal guard onto both sides of the caster wheel hub (Fig. 0079). 10. Install the upper and lower bearing cups into the pivot tube (Fig. 0081). 3 Fig. 0079 DSCN-0377a 9. Secure the caster wheel assembly to the caster fork using the axle bolt and nut (Fig. 0080). Fig. 0080 3-22 DSCN-0376a Fig. 0081 DSCN-0410a Note: A socket can be used as a driver. Take care not to scar the race surface (Fig. 0082). Fig.
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CHASSIS 11. Pack the pivot tube tapered roller bearings with high temperature grease (Fig. 0083). 13. Install grease seal into the base of the pivot tube (Fig. 0085). 3 Fig. 0083 DSCN-0407a 12. Install the lower bearing into the pivot tube (Fig. 0084). Fig. 0084 Toro GrandStand Service Manual DSCN-0416a Fig. 0085 DSCN-0414a 14. Install the upper bearing into the pivot tube (Fig. 0086). Fig.
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CHASSIS 15. Install the 3 Bellville washers into the pivot tube (Fig. 0087). 16. Insert the caster wheel and fork assembly through the pivot hub (Fig. 0089). 3 Fig. 0087 DSCN-0428a Note: Bottom: Crown Up / Middle: Crown Down / Top: Crown up (Fig. 0088). Fig. 0088 3-24 DSCN-0423a Fig. 0089 DSCN-0431a 17. Secure the caster wheel and fork assembly with the nut (Fig. 0090). Fig.
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CHASSIS 18. Tighten locknut until spring washers are flat (15 ftlbs./20 Nm) and then back off a 1/4 turn to properly set the pre-load on the bearings. 21. Fill the pivot hub cavity until grease is purging out through the upper bearing (Fig. 0093). 19. Remove the plug from the side of the pivot hub (Fig. 0091). 3 Fig. 0093 Fig. 0091 DSCN-0436a DSCN-0438a 22. Replace the grease zerk with the plug (Fig. 0094). 20. Install a grease zerk into the port on the side of the pivot hub (Fig. 0092). Fig.
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CHASSIS 23. Install the grease cap onto the top of the pivot hub (Fig. 0095). Fuel Tank Assembly Replacement Fuel Tank Assembly Removal 1. Turn the fuel shutoff valve to the “OFF” position (Fig. 0096). 3 Fig. 0095 DSCN-0357a Fig. 0096 DSCN-0457a 2. Siphon the fuel from the fuel tank. Note: The only recommended way to remove the fuel from the tank is by using a siphon pump. 3. Remove the height of cut (HOC) pin and lower the deck (Fig. 0097). Fig.
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CHASSIS 4. 2009 only: Remove the 90 degree fuel line vent fitting from the fuel tank (Fig. 0098). 6. 2009 only: Slide the hose clamp back from the fuel tank fitting, then slide the fuel line off the fuel tank fitting (Fig. 0100). 3 Fig. 0098 IMG-9299a Fig. 0100 5. 2009 only: Remove the rubber grommet from the fuel tank (Fig. 0099). Fig. 0099 7. 2009 only: Remove the carriage bolt and nut securing the fuel tank bracket to the frame bracket, then remove the fuel tank support (Fig. 0101). IMG-9530b Fig.
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CHASSIS 8. 2010 only: Remove the vent line from the 90 degree vent fitting (Fig. 0102). 10. 2010 only: Slide the hose clamp off the fuel pick-up tube fitting, then remove the fuel line from the fitting (Fig. 0104). 3 Fig. 0102 DSCN-0461a Fig. 0104 9. 2010 only: Remove the 90 degree vent fitting, then rubber grommet from the fuel tank (Fig. 0103). Fig. 0103 11. 2010 only: Remove the four thread forming screws securing the tank bracket to the control panel (Fig. 0105). DSCN-0463a Fig.
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CHASSIS 12. Remove the fuel tank from the control tower Fig. 0106). Fuel Tank Assembly Installation 1. Position the fuel tank into the control tower (Fig. 0107). 3 Fig. 0106 IMG-9307a Fig. 0107 IMG-9307a 2. 2009 only: Secure the fuel tank bracket to the frame bracket using the carriage bolt and nut (Fig. 0108). Fig.
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CHASSIS 3. 2009 only: Position the fuel line onto the pick-up tube fitting and secure with the hose clamp (Fig. 0109). 5. 2009 only: Install the 90 degree fuel line vent fitting into the fuel tank (Fig. 0111). 3 Fig. 0111 Fig. 0109 4. 2009 only: Install the rubber grommet into the fuel tank (Fig. 0110). 6. 2010 only: Secure the tank bracket using four thread forming screws (Fig. 0112). Fig. 0112 Fig.
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CHASSIS 7. 2010 only: Slide the fuel line onto the pick-up tube fitting and secure with the hose clamp (Fig. 0113). 9. 2010 only: Install the 90 degree fitting into the rubber grommet (Fig. 0115). Note: A thin film of oil will ease installation of the fitting barb. 3 Fig. 0113 DSCN-0466a 8. 2010 only: Install the rubber grommet into the fuel tank (Fig. 0114). Fig. 0115 DSCN-0463a 10. Install the vent hose onto vent fitting (Fig. 0116). Fig. 0114 DSCN-0469a Fig.
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CHASSIS Platform & Cushion Assembly Replacement 3. Remove the four sets of bolts and washers securing the upper and lower pad hinges to the cushion pad (Fig. 0119). Platform & Cushion Assembly Removal 1. Remove both hairpin cotters securing the cushion pad to the control tower, then lower the operator cushion onto the operator platform (Fig. 0117). 3 Fig. 0119 Fig. 0117 DSCN-0478a DSCN-0488a 4.
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CHASSIS 5. Remove the RH and LH carriage bolts, washers, spacers, and nuts securing the platform to the carrier frame (Fig. 0121). 7. Remove the knob from the platform latch pin (Fig. 0123). 3 Fig. 0123 Fig. 0121 6. Remove the carriage bolts, friction washers, spacers and nuts securing the LH and RH pad links to the platform (Fig. 0122). 8. Remove the latch pin and spring from the platform (Fig. 0124). Fig. 0124 Fig.
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CHASSIS 9. Remove the four nuts securing the four rubber bumpers to the platform (Fig. 0125). Platform & Cushion Assembly Installation 1. Secure the four rubber bumpers to the platform using four nuts (Fig. 0126). 3 Fig. 0125 DSCN-0505a Fig. 0126 DSCN-0505a 2. Position the spring on the latch pin (Fig. 0127). Fig.
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CHASSIS 3. Position the latch pin and spring assembly into the platform (Fig. 0128). 5. Install the knob onto the latch pin (Fig. 0130). 3 Fig. 0130 Fig. 0128 4. Apply thread-locking compound to the threads of the knob (Fig. 0129). 6. Position the carriage bolt and spacer into the tab on the platform (Fig. 0131). Fig. 0131 Fig.
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CHASSIS 7. Position the friction washer, then the pad link over the spacer (Fig. 0132). 9. Repeat steps 6, 7, and 8 on the other side. 10. Position the carriage bolt through the brake support and the carrier frame (Fig. 0134). 3 Fig. 0132 DSCN-0549a Fig. 0134 8. Secure the assembly with a washer and nut (Fig. 0133). Fig. 0133 11. Position a washer over the carriage bolt (Fig. 0135). DSCN-0555a Fig.
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CHASSIS 12. Position the platform so the carriage bolt protrudes through the platform pivot hole (Fig. 0136). 14. Secure the assembly with a washer and nut (Fig. 0138). 3 Fig. 0136 DSCN-0557a 13. Position the spacer over the carriage bolt and into the platform pivot hole (Fig. 0137). Fig. 0138 DSCN-0493a 15. Repeat steps 10 through 14 on the other side of the machine. 16. Secure the shield, foot mat bracket, and foot mat to the platform using two thread forming screws (Fig. 0139). Fig.
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CHASSIS 17. Secure the shield and lower hinge bracket to the operator cushion using two screws and washers (Fig. 0140). 19. Align the pad link with the lower hinge bracket (Fig. 0142). 3 Fig. 0142 Fig. 0140 18. Secure the upper hinge bracket to the operator cushion using two screws and washers (Fig. 0141). 20. Place a friction washer between the pad link and lower hinge bracket (Fig. 0143). Fig. 0143 Fig.
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CHASSIS 21. Insert a carriage bolt through the pad link assembly (Fig. 0144). 23. Secure the assembly with a nut and washer (Fig. 0146). 3 Fig. 0144 DSCN-0572a 22. Position the spacer over the carriage bolt and into the friction washer and lower hinge bracket (Fig. 0145). Fig. 0145 Fig. 0146 24. Repeat steps 19 through 23 on the other side of the machine. 25. Raise the operator cushion assembly into the oper ating position and secure with the hairpin cotters and slide bushings (Fig. 0147).
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CHASSIS Lift Assist Cylinder Replacement (2009 only) 5. Remove the spring cover (Fig. 0149). Lift Assist Cylinder Removal (2009 only) 1. Turn the engine off and remove the key from the ignition. 2. Set the parking brake. 3 3. Place Height-of-Cut lever in the transport position. 4. Unlatch cover clamp at front end of gas spring cover (Fig. 0148). Fig. 0149 IMG-9688a 6. Remove the retaining clip from the front end of the gas spring assembly (Fig. 0150). Fig. 0148 IMG-9686a Fig.
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CHASSIS 7. Repeat steps 4 through 6 on the other side if replacing both gas spring assemblies. 9. Spin the upper nut approximately 1/2” (1.27cm) up the lift bar (Fig. 0153). 8. Loosen the lower lock nut on the lift bar 1/2 turn (Fig. 0151 and Fig. 0152). 3 Fig. 0153 Fig. 0151 IMG-9705a Fig. 0152 IMG-0088a 10. Tighten the lower nut on the lift bar until the compression force on the gas spring assembly has been relieved and the gas spring assembly can easily be removed from the ball stud (Fig. 0154).
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CHASSIS 11. Repeat step 10 on the other side if replacing both gas spring assemblies. 14. Remove the retaining clip from the rear end of the gas spring assembly (Fig. 0157). 12. Loosen the lower nut on the lift bar approximately 2 turns until the Height-Of-Cut handle can be moved from the transport position (Fig. 0155). 3 Fig. 0157 Fig. 0155 IMG-9749a IMG-9711a 15. Remove the gas spring assembly (Fig. 0158). 13. Lower the Height-Of-Cut handle to the 1” (2.54cm) height-of-cut setting (Fig. 0156).
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CHASSIS Lift Assist Cylinder Installation (2009 only) 1. Ensure both retaining clips are in the position shown (Fig. 0159) and (Fig. 0160). 2. Install the large cylinder end of the gas spring assembly onto the rear ball stud by pressing the gas spring socket onto the ball stud until it is secured by the spring clip (Fig. 0161). 3 Fig. 0159 IMG-9718a Fig. 0161 IMG-9724a 3. Repeat step 2 on the other side if replacing both gas spring assemblies. 4. Raise the mower deck to the transport position (Fig.
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CHASSIS 5. Tighten the lower nut on the lift bar until the front end of the gas spring aligns with the ball stud (Fig. 0163 and Fig. 0164). 6. Snap the front end of the gas spring onto the ball stud (Fig. 0165). 3 Fig. 0165 Fig. 0163 IMG-9735a IMG-9749a 7. Slide the spring cover onto the gas spring assembly (Fig. 0166). Fig. 0164 IMG-9729a Fig.
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CHASSIS 8. Secure the spring cover with the cover clamp (Fig. 0167). 11. Lower the Height-of-Cut lever to the 3” (7.62cm) Height-Of-Cut position (Fig. 0169). 3 Fig. 0167 IMG-9686a 9. Repeat steps 5 thru 8 on the other side if replacing both gas spring assemblies. 10. Loosen the lower nut on the lift bar assembly ap proximately 3 turns until the Height-Of-Cut handle can be taken out of the transport position (Fig. 0168). Fig. 0169 12. Position the center blade in the front-to-back position.
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CHASSIS 13. Turn the upper nut on the lift bar assembly down to the height-of-cut pin (Fig. 0171). Lift Assist Spring Replacement (2010 only) Lift Assist Spring Removal (2010 only) 1. Move the height of cut (HOC) lever to the transport position (Fig. 0173). 3 Fig. 0171 IMG-9705 14. Tighten the lower nut on the lift bar assembly to secure the HOC adjustment (Fig. 0172). Fig. 0173 DSCN-0441a 2. Support the deck with a floor jack (Fig. 0174). Fig. 0172 IMG-9705 Fig.
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CHASSIS 3. Move the HOC lever to the 1” (2.54cm) position (Fig. 0175). 5. Remove the spring and chain assembly (Fig. 0177). 3 Fig. 0177 Fig. 0175 DSCN-0451a DSCN-0445a 4. Remove the bolt and washer securing the lift assist spring to the control tower (Fig. 0176). Fig.
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CHASSIS Lift Assist Springs Installation (2010 only) 1. Position the chain between the spring hook and pivot shaft assembly (Fig. 0178). 3. Install the bolt until the gap between the control tower mount and spring cap is 1-1/2” (3.8cm) for 60” decks / 2” (5cm) 48” or 52” decks (Fig. 0180). A 3 Fig. 0180 Fig. 0178 DSCN-0453a 2. Secure the spring and chain assembly to the control tower using the bolt and washer (Fig. 0179). Fig. 0179 3-48 DSCN-1527a A. 1-1/2” (3.
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CHASSIS Wheel Motor Housing Assembly Replacement 3. Break the torque of the wheel motor shaft nut (Fig. 0182). Wheel Motor Housing Assembly Removal Note: Only slightly loosen the wheel motor shaft nut, do not remove at this time. 1. Apply the parking brake. 2. Break the torque of the four lug nuts securing the tire assembly to the wheel hub (Fig. 0181). Note: Only slightly loosen the lug nuts, do not remove at this time. 3 Fig. 0182 DSCN-0608a 4. Repeat steps 2 and 3 on the other side of the machine.
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CHASSIS 6. Remove both tires by removing the four lug nuts securing each tire to it’s hub (Fig. 0184). 8. Remove both wheel hubs by using a puller (Toro P/N TOR6006) and four lug nuts (Fig. 0186). 3 Fig. 0184 DSCN-0608a 7. Remove the wheel motor nut from both wheel motors (Fig. 0185). Fig. 0185 3-50 DSCN-0611a Fig. 0186 DSCN-0614a Note: Install the lug nut with the taper facing out ward (Fig. 0187). Fig.
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CHASSIS 9. Remove the woodruff key from both of the wheel motor shafts (Fig. 0188). 12. Position a drain pan under the wheel motor (Fig. 0190). 3 Fig. 0188 DSCN-0628a 10. Thoroughly clean the area around the hydraulic fittings to prevent debris from entering the system. Fig. 0190 DSCN-0634a 13. Disconnect both hydraulic hoses from the wheel motor fittings (Fig. 0191). 11. Mark the hoses, corresponding fittings, and motor ports to ensure the hoses are reconnected in their original positions (Fig.
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CHASSIS 14. Remove both sets of hydraulic fittings from the wheel motor (Fig. 0192). 16. Remove the four bolts and washers securing the wheel motor to the wheel motor housing (Fig. 0194). 3 Fig. 0192 DSCN-0670a 15. Cap the wheel motor ports and hydraulic hoses to prevent debris from entering the system (Fig. 0193). Fig. 0194 DSCN-0647a 17. Remove the wheel motor from the wheel motor housing. 18. Repeat steps 6 through 17 on the other side of the machine. 19.
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CHASSIS 20. Remove the four sets (2 per side) of fasteners se curing the wheel motor housing assembly to the carrier frame (Fig. 0196). Wheel Motor Housing Assembly Installation 1. Secure the motor mount center section to the motor mounts using eight carriage bolts and nuts (Fig. 0198). 3 Fig. 0196 DSCN-0652a Fig. 0198 DSCN-0658a 21. Remove the wheel motor housing assembly. 22. Remove the eight carriage bolts and nuts securing the motor mount center section to the RH and LH motor mounts (Fig. 0197).
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CHASSIS 2. Position the motor mount/axle assembly under the carrier frame (Fig. 0200). 4. Tighten the four sets of fasteners. 5. Position the wheel motor into the wheel motor housing (Fig. 0202). 3 Fig. 0200 DSCN-0649a Fig. 0202 3. Loosely install the four sets of bolts (2 per side), spacers, and nuts that secure the motor mount/axle assembly to the carrier frame (Fig. 0201). DSCN-0664a 6. Secure the wheel motor to the wheel motor housing using four bolts and Belleville washers.
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CHASSIS 7. Replace the fitting o-rings. Install the two motor fittings so they point towards the machine. Secure the position of the fittings with the fitting jam nut (Fig. 0204). 9. Repeat steps 5 through 8 on the other side of the machine. 10. Position the woodruff key in the wheel motor shaft (Fig. 0206). 3 Fig. 0204 DSCN-0670a Fig. 0206 8. Install the hydraulic hoses to the hydraulic fittings (Fig. 0205). Fig. 0205 11. Position the wheel hub onto the motor shaft (Fig. 0207). DSCN-0673a Fig.
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CHASSIS 12. Apply thread-locking compound to the wheel motor shaft threads (Fig. 0208). 14. Secure the tire assembly to the wheel hub using four lug nuts (Fig. 0210). Note: The lug nuts will have the proper torque applied in a later step. 3 Fig. 0208 DSCN-0679a 13. Install the wheel motor nut to the wheel motor shaft (Fig. 0209). Note: The wheel motor nut will have the proper torque applied in a later step. Fig. 0210 DSCN-0683a 15. Repeat steps 10 through 14 on the other side of the machine. 16.
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CHASSIS 18. Tighten the wheel motor nut and lug nuts (Fig. 0211). B B Cross Shaft & Lift Assembly Replacement Cross Shaft & Lift Assembly Removal 1. 2009 only: Remove the lift assist cylinder. See “Lift Assist Cylinder Removal (2009 only)” on page 3-40. B B Fig. 0211 2. Place two boards under the deck and lower the deck onto them (Fig. 0212). A Note: The boards need to be long enough to sup port the front and rear of the deck. DSCN-0683a A. 200 ± 25 ft-lbs. (271 ± 33 Nm) B. 80 ± 10 ft-lbs.
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CHASSIS 4. 2010 only: Remove the dampener assembly that secures the lift bar to the rear cross shaft assembly (Fig. 0214). 7. Mark the hydraulic fittings and hoses so they can be correctly installed upon reassembly (Fig. 0216). 3 Fig. 0214 DSCN-0793a 5. Remove the fuel tank. See “Fuel Tank Assembly Removal” on page 3-26. 6. Remove the cable ties securing the high pressure hoses (Fig. 0215). Fig. 0215 3-58 DSCN-0689a Fig. 0216 DSCN-0691a 8.
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CHASSIS 9. 2010 only: Remove the bolts and washers securing the extension spring assemblies and chains to the RH and LH sides of the control tower (Fig. 0218). 11. 48” and 52” decks only: Remove the nuts from the end of the lift rods and remove the RH and LH lift rods (Fig. 0220). Note: Leave the inside nuts in their location to minimize deck leveling adjustments at the end of this procedure. 3 Fig. 0218 DSCN-0700a 10.
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CHASSIS 13. 2009 only: Remove the bolts, spacers, washers and nuts securing the cross shaft assembly to the carrier frame (Fig. 0222). 15. 2010 only: Remove the LH and RH pivot shafts from the rear cross shaft assembly and carrier frame hub (Fig. 0224). Note: 48” and 52” decks are set to a narrow stance. Remove the wheels to remove the pivot shafts. 3 Fig. 0222 DSCN-1602a 14.
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CHASSIS 17. Remove the lift plates (Fig. 0226). 19. Remove the “E” clip securing the height of cut (HOC) pin to the rear cross shaft assembly (Fig. 0228). 3 Fig. 0226 DSCN-0723a Fig. 0228 18. Remove the rear cross shaft from the machine (Fig. 0227). Fig. 0227 20. Remove the HOC pin from the rear cross shaft assembly (Fig. 0229). DSCN-0730a Fig.
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CHASSIS 21. Remove the two 45 degree grease fittings from the LH and RH grease blocks (Fig. 0230). Cross Shaft & Lift Assembly Installation 1. Install the 45 degree grease fitting into the LH and RH grease blocks. Position the fitting so it faces upward (Fig. 0231). 3 Fig. 0230 DSCN-0744a Fig. 0231 DSCN-0747a 2. Position the HOC pin in the rear cross shaft assembly (Fig. 0232). Fig.
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CHASSIS 3. Secure the position of the HOC pin with the “E” clip (Fig. 0233). 4. Position the rear cross shaft onto the engine base (Fig. 0234). 3 Fig. 0233 DSCN-0751a Fig. 0234 DSCN-0752a Note: Position the grease blocks so the grease fittings are pointing upwards (Fig. 0235). Fig.
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CHASSIS 5. Position the right hand lift plate over the grease block with the bolt hole pattern aligned with the mating pattern on the engine base (Fig. 0236). 7. 2009 only: Tighten the four sets of fasteners. 8. 2010 only: The right side lift plate is secured with three long carriage bolts and one short (Fig. 0238). 3 Fig. 0236 DSCN-0758a Fig. 0238 6. 2009 only: Loosely install four carriage bolts, Belleville washers, nuts (Fig. 0237). Fig. 0237 9.
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CHASSIS 10. 2010 only: Loosely install the remaining three carriage bolts, Belleville washers, and nuts (Fig. 0240). 13. Loosely install four carriage bolts, Belleville washers, nuts (Fig. 0242). 3 Fig. 0242 Fig. 0240 11. 2010 only: Tighten the four sets of fasteners. 12. Position the left hand lift plate over the grease block with the bolt hole pattern aligned with the mating pattern on the engine base (Fig. 0241). 14. Tighten the four sets of fasteners. 15.
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CHASSIS 16. 2009 only: Install the bolt through the carrier frame, then through the spacer and hub assembly (Fig. 0244). 18. 2009 only: Repeat steps 15, 16 and 17 on the other side of the unit. 19. 2010 only: Position the RH pivot shaft through the carrier frame hub and rear cross shaft assembly (Fig. 0246). 3 Fig. 0244 DSCN-1606a 17. 2009 only: Secure the assembly using a washer and nut (Fig. 0245). Fig. 0245 3-66 Fig.
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CHASSIS 20. 2010 only: Rotate the pivot shaft so the spiral pin hole of the pivot shaft aligns with the spiral pin hole of the rear cross shaft assembly, then secure the assembly with the spiral pin (Fig. 0247). 21. 2010 only: Repeat steps 19 and 20 on the LH side of the machine. 22. 48” and 52” decks: Install the lift rod through the lift rod bracket and secure with nut (Fig. 0249). 3 Fig. 0247 DSCN-0791a Fig. 0249 Note: The spiral pin ends need to be flush to the lift arm hub (Fig. 0248). Fig.
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CHASSIS 24. Position the opposite end of the lift rod over the stud on the rear cross shaft assembly (Fig. 0251). 25. Position the large washer over the rear cross shaft stud (Fig. 0253). 3 Fig. 0251 DSCN-0801a Note: Ensure the flange bearing is still in place (Fig. 0252). Fig. 0253 26. Secure the assembly using the “E” clip (Fig. 0254). Fig. 0254 Fig.
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CHASSIS 27. Repeat steps 24 through 26 on the other side of the machine. 28. Replace the fitting o-rings. Install the high pressure hoses to the pumps in their original positions (Fig. 0255). 30. 2009 only: Install the lift assist cylinder. See “Lift Assist Cylinder Installation (2009 only)” on page 3-43. 31. 2010 only: Position the chain between the pivot shaft and extension spring assembly (Fig. 0257). 3 Fig. 0255 DSCN-0810a 29. Secure the hose routings using three cable ties (Fig. 0256). Fig.
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CHASSIS 33. 2010 only: Install the bolt until the gap between the control tower mount and spring cap is 1-1/2” (3.8cm) for 60” decks / 2” (5cm) 48” or 52” decks (Fig. 0259). 37. 2010 only: Secure the lower end of the lift bar to the rear cross shaft assembly using the dampener assembly and nut. Thread the dampener assembly bolt into the nut until there are 3 threads protruding (Fig. 0261). A 3 Fig. 0259 DSCN-0820a A. 1-1/2” (3.8cm) for 60” decks 2” (5cm) for 48” for 52” decks Fig.
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CHASSIS Engine Base Replacement 4. 2010 only: Remove the dampener assembly that secures the lift bar to the rear cross shaft assembly (Fig. 0265). Engine Base Removal 1. 2009 only: Remove the lift assist cylinder. See “Lift Assist Cylinder Removal (2009 only)” on page 3-40. 2. Place two boards under the deck and lower the deck onto them (Fig. 0263). Note: The boards need to be long enough to sup port the front and rear of the deck. 3 Fig. 0265 DSCN-0793a 5. Remove the fuel tank.
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CHASSIS 7. Mark the hydraulic fittings and hoses so they can be correctly installed upon reassembly (Fig. 0267). 9. 2010 only: Remove the bolts and washers securing the extension spring assemblies and chains to the RH and LH sides of the control tower (Fig. 0269). 3 Fig. 0267 DSCN-0691a Fig. 0269 8. Remove the high-pressure hoses from the pump fittings (Fig. 0268). Note: Cap the pump and hose fittings to prevent debris from entering the hydraulic system. 10.
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CHASSIS 11. 48” and 52” decks only: Remove the nuts from the end of the lift rods and remove the RH and LH lift rods (Fig. 0271). 13. 2009 only: Remove the bolts, spacers, washers and nuts securing the cross shaft assembly to the carrier frame (Fig. 0273). Note: Leave the inside nuts in their location to minimize deck leveling adjustments at the end of this procedure. 3 Fig. 0273 Fig. 0271 DSCN-0707a DSCN-1602a 14.
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CHASSIS 15. 2010 only: Remove the LH and RH pivot shafts from the rear cross shaft assembly and carrier frame hub (Fig. 0275). 16. Remove the four carriage bolts and nuts securing the muffler guard and guard panel to the carrier frame, then remove both (Fig. 0276). Note: 48” and 52” decks are set to a narrow stance. Remove the wheels to remove the pivot shafts. Reinstall the wheels after removing the pivot shafts. 3 Fig. 0276 Fig.
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CHASSIS 17. Remove the shoulder bolts, washers, and nuts securing the LH and RH lift links to the deck (Fig. 0278). 19. Remove the “Z” bend from the engine choke lever (Fig. 0280). 3 Fig. 0280 Fig. 0278 18. Loosen the cable clamp securing the choke cable to the engine throttle plate, then remove the cable from the clamp (Fig. 0279). 20. Loosen the cable clamp securing the throttle cable to the engine throttle plate, then remove the cable from the clamp (Fig. 0281). Fig. 0281 Fig.
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CHASSIS 21. Remove the “Z” bend from the engine throttle lever (Fig. 0282). 23. Remove the nut and bolt securing the negative cable to the battery (Fig. 0284). 3 Fig. 0282 DSCN-0950a 22. Remove the two sets of wing nuts and hold down bolts securing the battery cover to the battery tray, then remove the cover (Fig. 0283). Fig. 0284 24. Remove the nut and bolt securing the positive cable to the battery (Fig. 0285). Fig. 0285 Fig.
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CHASSIS 25. Slide the hose clamp back on the fuel line and remove the fuel line from the fuel filter (Fig. 0286). 26. Slide the hose clamp back on the low-pressure re turn hose, then remove the hose from the “T” fitting (Fig. 0288). 3 Fig. 0286 DSCN-0959a Fig. 0288 Note: Position a pan under the fuel hose to catch any fuel remaining in the fuel hose (Fig. 0287). Fig. 0287 27. Slide the hose clamp back on the low-pressure suction hose, then remove the hose from the “T” fitting (Fig. 0289).
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CHASSIS 28. Disconnect the wire harness from the neutral switch (Fig. 0290). 30. Unplug the pink wire from the green fuel solenoid wire (Fig. 0292). 3 Fig. 0290 DSCN-0974a 29. Disconnect the violet wire from the voltage regulator (Fig. 0291). Fig. 0291 3-78 DSCN-0977a Fig. 0292 DSCN-0978a 31. Unplug the white wire from the black magneto wire (Fig. 0293). Fig.
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CHASSIS 32. Remove nut and lock washer securing the positive battery cable and red wire eyelet to the solenoid post (Fig. 0294). 34. Remove the bolt and washer securing the ground wires to the engine block (Fig. 0296). 3 Fig. 0296 Fig. 0294 33. Remove the green and blue bullet connectors from the two small studs on the solenoid (Fig. 0295). 35. Disconnect the clutch wires from the wiring harness (Fig. 0297). Fig. 0297 Fig.
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CHASSIS 36. Remove both sets of bolts, nuts, and spacers securing the lower end of the control cables to the control fork assemblies (Fig. 0298). 38. Remove the two cable ties securing the speed control cable to the RH control cable and the lower LH side of the linkage mount (Fig. 0300). 3 Fig. 0298 DSCN-0996a 37. Remove the spring clip securing the motion control cables to the linkage mount (Fig. 0299). Fig. 0299 3-80 DSCN-0999a Fig. 0300 DSCN-1000a 39.
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CHASSIS 40. Remove the speed control cable clip from the speed control handle assembly (Fig. 0302). 42. Remove the four sets of bolts, spacers and nuts (two sets per side) that secure the axle and wheel assembly to the carrier frame (Fig. 0304). 3 Fig. 0302 DSCN-1010a Fig. 0304 41. Remove the “Z” bend of the speed control cable from the speed control handle assembly (Fig. 0303). Fig. 0303 Toro GrandStand Service Manual DSCN-1019a 43.
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CHASSIS 44. Walk the carrier frame and tower assembly forward, over the engine and deck assembly (Fig. 0306). 46. Remove the two thread forming screws securing the solenoid to the engine base (Fig. 0308). 3 Fig. 0306 DSCN-1028a 45. Remove the nut and lock washer securing the starter cable to the solenoid post (Fig. 0307). Fig. 0307 Fig. 0308 47. Remove the four sets of carriage bolts, washers and nuts securing the lift plate to the engine base (Fig. 0309). DSCN-1030a Fig.
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CHASSIS 51. 2009 only: Remove the hairpin cotter and washer securing the front ends of the shifter links to the shifter bracket (Fig. 0312). 48. Remove the lift plate (Fig. 0310). 3 Fig. 0310 DSCN-1035a Fig. 0312 49. Repeat steps 46 and 47 on the other side of the engine base. 50. Remove the rear cross shaft assembly from the engine base (Fig. 0311). Fig. 0311 Toro GrandStand Service Manual DSCN-1036a IMG-0348a 52.
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CHASSIS 53. Remove the hairpin cotter and washer from the rear end of the shifter links (Fig. 0314). 55. 2009 only: Serial range 290000210 - 290999999: There are 3 rollers located on the rear end of the RH shifter link rod inside the control fork assembly and pump control arm. Slide the left hand roller off the rear end of the RH shifter link rod (Fig. 0316). 3 Fig. 0314 IMG-9424a 54.
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CHASSIS 57. 2009 only: Serial range 290000210 - 290999999: Push down on the control fork assembly and remove the center roller from the pump control arm slot (Fig. 0318). Shifter Link and Roller Configurations (Fig. 0320): A. 2009: Serial range 290000001-290000210; 3 rollers, all thin and same size B. 2009: Serial range 290000211-290999999; 3 rollers, large center roller C. 2010: Serial range 310000001-310999999; 3 rollers, all large and same size 3 Fig. 0318 IMG-9436a 58.
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CHASSIS 61. Remove the two thread forming screws and washers securing the shifter and speed control cable assem bly to the engine base (Fig. 0322). 63. Remove the three thread forming screws securing the drive linkage mount assembly to the engine base (Fig. 0324). Fig. 0322 Fig. 0324 3 DSCN-1042a 62. Remove the shifter and speed control cable as sembly (Fig. 0323). DSCN-1049a 64. Remove the drive linkage mount assembly from the engine base. 65.
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CHASSIS 66. Remove the deck belt from the clutch pulley (Fig. 0326). 68. Remove the drive belt. 69. Remove the two set screws securing the pump pulley to the pump input shaft (Fig. 0328). 3 Fig. 0326 DSCN-1053a Fig. 0328 67. Using a spring tool, remove the hydro drive idler spring from the spring anchor (Fig. 0327). Note: On 2009 machines the extension spring hooks to the rear of the engine base. Fig. 0327 Toro GrandStand Service Manual DSCN-1059a DSCN-1066a 70. Remove the pump pulley. 71.
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CHASSIS 72. Repeat steps 69 through 71 on the other pump. 73. Remove the two sets of carriage bolts, washers and nuts securing the pump to the engine base (Fig. 0330). 76. Remove the bolt and nut securing the idler assembly to the engine base, then remove the assembly (Fig. 0332). 3 Fig. 0332 Fig. 0330 DSCN-1086a DSCN-1078a 77. 2010 only: Remove the cable tie securing the clutch wires to the clutch stop (Fig. 0333). 74. Repeat step 73 on the other pump. 75. Remove both pumps from the engine base (Fig.
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CHASSIS 78. Push the clutch wire and frame grommet down through the engine base (Fig. 0334). 80. 2010 only: Remove the nut securing the thread forming screw used to secure the clutch anchor (Fig. 0336). 3 Fig. 0334 DSCN-1092a Fig. 0336 79. 2009 only: Remove the bolt, washers, spacer and nut securing the clutch brake strap to the engine base (Fig. 0335). Fig. 0335 81. 2010 only: Remove the thread forming screw securing the clutch anchor to the engine base (Fig. 0337). IMG-9755 Fig.
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CHASSIS 82. Using a hoist, support the weight of the engine and engine base (Fig. 0338). 84. Remove the two sets of carriage bolts and nuts securing the rear of the engine base to the rear of the mower deck (Fig. 0340). 3 Fig. 0338 DSCN-1102a Fig. 0340 83. Remove the bolt and nut securing the front engine base mounting tab to the top of the mower deck (Fig. 0339). DSCN-1112a 85. Repeat step 84 on the other side of the engine base. 86. Raise the engine and engine base off the mower deck. 87.
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CHASSIS 88. Remove the bolt, spring washer and washer secur ing the clutch to the engine crankshaft (Fig. 0342). 90. Remove the hydro drive pulley from the engine crankshaft (Fig. 0344). 3 Fig. 0342 DSCN-1114a 89. Remove the clutch from the engine crankshaft (Fig. 0343). Fig. 0343 Toro GrandStand Service Manual DSCN-1116a Fig. 0344 DSCN-1119a 91. Remove the key from the keyway in the engine crankshaft (Fig. 0345). Fig.
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CHASSIS 92. Remove the four engine mounting bolts and Belle ville washers securing the engine to the engine base (Fig. 0346). Engine Base Installation 1. Secure the engine base to the engine using four sets of bolts and Belleville washers. Install the Belleville washers with the crown facing the bolt head. Torque to 200 ± 25 in-lbs. (22.6 + 2.8 Nm) (Fig. 0348). 3 Fig. 0346 DSCN-1126a Note: Support the engine base.
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CHASSIS 2. Install the square key in the crankshaft and apply anti-seize around the crankshaft (Fig. 0350). 4. Apply thread locking compound to clutch bolt threads (Fig. 0352). 3 Fig. 0350 DSCN-1142a 3. Install the hydro drive pulley onto the engine crank shaft (Fig. 0351). Note: Install the pulley with the long hub facing the engine. Fig. 0352 5. Secure the electric clutch onto the engine crankshaft using the clutch bolt, spring washer and washer (Fig. 0353). Fig. 0353 Fig.
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CHASSIS 6. Torque the clutch bolt to 55 ± 5 ft-lbs. (75 ± 7 Nm). 7. Remove the rope from the engine cylinder and install the spark plug (Fig. 0354). 9. 2010 only: Secure the clutch anchor to the engine base using the thread forming screw (Fig. 0356). 3 Fig. 0356 Fig. 0354 IMG-9634a 8. 2009 only: Secure the clutch brake strap to the engine base using the bolt, washers, spacer and nut (Fig. 0355).
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CHASSIS 10. 2010 only: Secure the thread forming screw using the nut (Fig. 0358). 12. 2010 only: Secure the clutch wires to the clutch stop using a cable tie (Fig. 0360). 3 Fig. 0358 DSCN-1161a 11. Feed the clutch wires up through the engine base and install the rubber grommet into the engine base (Fig. 0359). Fig. 0360 13. Position the engine and engine base plate assembly onto the mower deck (Fig. 0361). Fig. 0361 Fig.
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CHASSIS 14. Loosely install the bolt and nut securing the engine plate front mounting tab to the top of the mower deck (Fig. 0362). 16. Repeat step 15 on the other side of the engine plate. 17. Tighten all five sets of nuts and bolts securing the engine base to the mower deck. 18. Remove the hoist from the engine assembly. 19. Place the idler pivot bolt down through the engine base (Fig. 0364). 3 Fig. 0362 DSCN-1169a 15.
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CHASSIS 21. Place the idler assembly onto the pivot bolt (Fig. 0366). 23. Secure the idler assembly with a nut (Fig. 0368). 3 Fig. 0368 Fig. 0366 22. Place one friction composite washer and steel washer onto the pivot bolt (Fig. 0367). 24. Position the pumps on the engine base (Fig. 0369). Fig. 0369 Fig.
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CHASSIS 25. Secure the pump to the engine base using two car riage bolts, washers and nuts (Fig. 0370). 28. Position the pulley on the pump shaft and secure with the two set screws (Fig. 0372). Note: The face of the pulley hub should be flush with the end of the pump shaft. 3 Fig. 0370 DSCN-1194a Fig. 0372 26. Repeat step 25 on the other pump. DSCN-1199a 27. Install the square key in the pump input shaft and apply anti-seize around the shaft (Fig. 0371). Fig.
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CHASSIS 29. Position the pump drive belt around the engine, idler and pump pulleys (Fig. 0373). 30. Using a spring tool, secure the pump drive belt idler spring to the anchor (Fig. 0374). Note: On 2009 machines, the idler spring is anchored to the back of the engine plate. A 3 B E D C Fig. 0373 A. Hydraulic pumps B. Idler pulley C. Clutch pulley fig. 66 G012686 Fig. 0374 DSCN-1059a 31. Place the mower deck belt around the clutch pulley (Fig. 0375). D. Clutch retainer E. Pump drive belt Fig.
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CHASSIS 32. Using a spring tool, secure the mower deck idler spring to the spring anchor (Fig. 0376). 33. Secure the drive linkage mount assembly to the engine base using three thread forming screws (Fig. 0377). 3 Fig. 0376 DSCN-1206a Fig. 0377 DSCN-1047a Note: The pump control arm must nest in the center of the control forks (Fig. 0378). Fig.
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CHASSIS 34. Route the speed control cable along the left side of the LH pump (Fig. 0379). 35. Secure the shifter and speed control cable assembly to the engine base using two thread forming screws and washers (Fig. 0381). 3 Fig. 0379 DSCN-1214a Fig. 0381 Note: The speed control cable must route up the front side of the drive linkage mount assem bly (Fig. 0380). Fig. 0380 Toro GrandStand Service Manual DSCN-1215a DSCN-1218a 36.
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CHASSIS Shifter Link and Roller Configurations (Fig. 0383): A. 2009: Serial range 290000001 - 290000210; 3 rollers, all thin and same size B. 2009: Serial range 290000211 - 290999999; 3 rollers, large center roller C. 2010: Serial range 310000001 - 310999999; 3 rollers, all large and same size 38. 2009 only: Serial range 290000210 - 290999999: Push down on the control fork assembly and slide the center roller into the slot of the pump control arm (Fig. 0385). 3 A B Fig. 0383 C Fig.
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CHASSIS 40. 2009 only: Serial range 290000210 - 290999999: Slide the right hand roller onto the rear end of the right hand shifter link rod. Slide the rear end of the shifter link rod (with roller) through the control fork assembly following the Allen wrench through to capture the center roller on the shifter link rod (Fig. 0387). 42. 2009 only: Secure the front end of the RH shifter link to the shifter bracket using a hairpin cotter and washer (Fig. 0389). 3 Fig. 0389 Fig. 0387 IMG-9432a 41.
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CHASSIS 45. 2010 only: Place a spacer into the front end of the shifter link (Fig. 0391). 47. Install the washer and hairpin cotter to the end of the speed control linkage (Fig. 0393). 3 Fig. 0391 IMG-0946a 46. 2010 only: Secure the shifter link to the shifter bracket with a bolt, two washers and nut (Fig. 0392). Fig. 0392 3-104 IMG-0905a Fig. 0393 IMG-9424a 48. Secure the solenoid to the engine base using two thread forming screws (Fig. 0394). Fig.
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CHASSIS 49. Secure the starter cable to the solenoid post using the nut and lock washer (Fig. 0395). 50. Position the rear cross shaft assembly onto the engine base (Fig. 0396). 3 Fig. 0395 DSCN-1224a Fig. 0396 DSCN-1228a Note: The grease blocks must be positioned with the grease zerk facing upward (Fig. 0397). Fig.
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CHASSIS 51. Position the right hand lift plate over the grease block with the bolt hole pattern aligned with the mating pattern on the engine base (Fig. 0398). 53. 2009 only: Tighten the four sets of fasteners. 54. 2010 only: The right side lift plate is secured with three long carriage bolts and one short (Fig. 0400). 3 Fig. 0398 DSCN-1233a Fig. 0400 52. 2009 only: Loosely install four carriage bolts, Belleville washers and nuts (Fig. 0399). Fig. 0399 55.
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CHASSIS 56. 2010 only: Loosely install the remaining three carriage bolts, Belleville washers, and nuts (Fig. 0402). 59. Loosely install four carriage bolts, Belleville washers, nuts (Fig. 0404). 3 Fig. 0404 Fig. 0402 57. 2010 only: Tighten the four sets of fasteners. 58. Position the left hand lift plate over the grease block with the bolt hole pattern aligned with the mating pattern on the engine base (Fig. 0403). 60. Tighten the four sets of fasteners. 61.
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CHASSIS 62. Using two people or a hoist, lift the rear end of the carrier frame and tower assembly (Fig. 0406). 64. Loosely install the four sets of bolts, spacers and nuts (two sets per side) that secure the axle and wheel assembly to the carrier frame (Fig. 0408). 3 Fig. 0406 DSCN-1382a Fig. 0408 63. Walk the carrier frame and tower assembly rear ward, over the engine and deck assembly (Fig. 0407). Fig.
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CHASSIS 65. Tighten all four sets of fasteners. 66. 2009 only: Install the spacer into the rear cross shaft hub (Fig. 0410). 68. 2009 only: Secure the assembly using a washer and nut (Fig. 0412). 3 Fig. 0412 Fig. 0410 DSCN-1607a DSCN-1603a 67. 2009 only: Install the bolt through the carrier frame, then through the spacer and hub assembly (Fig. 0411). 69. 2009 only: Repeat steps 66 through 68 on the other side of the unit. 70.
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CHASSIS 71. 2010 only: Rotate the pivot shaft so the spiral pin hole of the pivot shaft aligns with the spiral pin hole of the rear cross shaft assembly, then secure the assembly with the spiral pin (Fig. 0414). 72. 2010 only: Repeat steps 70 and 71 on the LH side of the machine. 73. Connect the “Z” bend of the speed control cable to the speed control handle assembly (Fig. 0416). 3 Fig. 0414 DSCN-1395a Fig. 0416 Note: The spiral pin ends need to be flush to the lift arm hub (Fig. 0415). Fig. 0415 74.
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CHASSIS 75. Install the motion control cable adjustment nuts into the linkage mount (Fig. 0418). 77. Secure the speed control cable to the RH control cable and the lower LH side of the linkage mount using cable ties (Fig. 0420). 3 Fig. 0418 DSCN-1409a Fig. 0420 76. Secure the motion control cables to the linkage mount using the spring clip (Fig. 0419). Fig. 0419 78. Secure the rod ends at the base of the control cables to the control forks using the bolts, spacers and nuts (Fig. 0421).
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CHASSIS 79. Connect the wire harness to the neutral switch (Fig. 0422). 81. Connect the black wire eyelet and battery ground cable to the engine block using a bolt and washer (Fig. 0424). 3 Fig. 0422 DSCN-1421a Fig. 0424 80. Connect the wire harness to the clutch harness (Fig. 0423). Fig. 0423 82. Connect the green and blue wire bullet connectors to the two small studs on the solenoid (Fig. 0425). DSCN-1423a Fig.
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CHASSIS 83. Connect the white wire connector to the black magneto wire (Fig. 0426). 85. Connect the purple wire connector to the rectifier (Fig. 0428). 3 Fig. 0426 DSCN-1449a Fig. 0428 DSCN-1453a 84. Connect the pink wire connector to the green fuel solenoid wire (Fig. 0427). Fig.
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CHASSIS 86. Secure the red wire eyelet and battery positive cable to the solenoid post using a nut and lock washer (Fig. 0429). 87. 48” and 52” decks: Install the lift rod through the lift rod bracket and secure with nut (Fig. 0431). 3 Fig. 0431 Fig. 0429 Note: Position the red boot over the solenoid post after installing cables (Fig. 0430). 88. 60” decks: Install the lift rod to the turnbuckle and secure with jam nut (Fig. 0432). Fig. 0432 Fig.
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CHASSIS 89. Position the opposite end of the lift rod over the stud on the rear cross shaft assembly (Fig. 0433). 90. Position the large washer over the rear cross shaft stud (Fig. 0435). 3 Fig. 0433 DSCN-0801a Note: Ensure the flange bearing is still in place (Fig. 0434). Fig. 0435 91. Secure the assembly using the “E” clip (Fig. 0436). Fig. 0436 Fig.
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CHASSIS 92. Repeat steps 87 through 91 on the other side of the machine. 93. Secure the lower ends of the lift links using the shoulder bolts, washers and nuts (Fig. 0437). 94. 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. 0439). 3 Fig. 0439 Fig. 0437 Note: Install the thin washer between the lift link and deck bracket (Fig. 0438). 95. Move the throttle lever to the “Fast” position (Fig. 0440).
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CHASSIS 96. With the engine throttle control lever in the “Fast” position, pull the slack from the cable jacket and tighten the throttle cable clamp (Fig. 0441). 98. Push the choke knob in so it is in the “Open” position (Fig. 0443). 3 Fig. 0443 Fig. 0441 97. 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 cable clamp (Fig. 0442). 99.
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CHASSIS 100. Position the muffler guard assembly and loosely install the four carriage bolts, two guard mounting brackets and nuts (Fig. 0445). 101. Make sure the muffler exhaust pipe is centered in the muffler guard assembly, then tighten all four bolts and nuts (Fig. 0447). 3 Fig. 0445 IMG-0586a Fig. 0447 DSCN-0589a Note: 60” models have a guard panel, not the two guard mounting brackets (Fig. 0446). Fig.
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CHASSIS 102. Secure the low-pressure suction line to the “T” fitting using the hose clamp (Fig. 0448). 103. Secure the low-pressure return line to the “T” fitting using the hose clamp (Fig. 0450). 3 Fig. 0448 DSCN-1473a Note: The opposite end of the low-pressure suction line is connected to the hydraulic oil filter (Fig. 0449). Fig. 0449 Toro GrandStand Service Manual DSCN-1475a Fig.
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CHASSIS 104. Replace the fitting o-rings. Install the highpressure hoses to the pumps in their original positions (Fig. 0452). 106. Secure the fuel hose to the fuel filter using the hose clamp (Fig. 0454). 3 Fig. 0454 Fig. 0452 DSCN-1484a DSCN-0810a 105. Secure the hose routings using three cable ties (Fig. 0453). 107. 2009 only: Install the lift assist cylinder. See “Lift Assist Cylinder Installation (2009 only)” on page 3-43. 108.
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CHASSIS 109. 2010 only: Secure the extension spring assembly and chain to the control tower using the bolt and washer (Fig. 0456). 111. 2010 only: Repeat steps 108 through 110 on the other side of the machine. 112. Install the fuel tank. See “Fuel Tank Assembly Installation” on page 3-29. 113. 2009 only: Secure the lower end of the lift bar to the rear cross shaft assembly using a nut. Thread the nut onto the bolt until there are 3 threads protruding. Secure the position with the jam nut (Fig. 0458).
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CHASSIS 114. 2010 only: Secure the lower end of the lift bar to the rear cross shaft assembly using the dampener assembly and nut. Thread the dampener assembly bolt into the nut until there are 3 threads protruding (Fig. 0459). 116. Secure the red positive cable to the positive terminal on the battery using a bolt, washer and nut (Fig. 0461). 3 Fig. 0461 Fig. 0459 DSCN-0793a 115. Position the battery on the battery tray (Fig. 0460).
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CHASSIS 117. Secure the black ground cable to the negative terminal on the battery using the bolt, washer and nut (Fig. 0463). Carrier Frame Replacement Carrier Frame Removal 1. 2009 only: Remove the lift assist cylinder. See “Lift Assist Cylinder Removal (2009 only)” on page 3-40. 2. Place two boards under the deck and lower the deck onto them (Fig. 0465). Note: The boards need to be long enough to sup port the front and rear of the deck. Fig. 0463 DSCN-1499a 118.
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CHASSIS 4. 2010 only: Remove the dampener assembly that secures the lift bar to the rear cross shaft assembly (Fig. 0467). 7. Mark the hydraulic fittings and hoses so they can be correctly installed upon reassembly (Fig. 0469). 3 Fig. 0469 Fig. 0467 5. Remove the fuel tank. See “Fuel Tank Assembly Removal” on page 3-26. 6. Remove the cable ties securing the high-pressure hoses (Fig. 0468). 8. Remove the high-pressure hoses from the pump fittings (Fig. 0470).
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CHASSIS 9. 2010 only: Remove the bolts and washers securing the extension spring assemblies and chains to the RH and LH sides of the control tower (Fig. 0471). 11. 48” and 52” decks only: Remove the nuts from the end of the lift rods and remove the RH and LH lift rods (Fig. 0473). Note: Leave the inside nuts in their location to minimize deck leveling adjustments at the end of this procedure. 3 Fig. 0471 DSCN-0700a 10.
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CHASSIS 13. 2009 only: Remove the bolts, spacers and washers securing the cross shaft assembly to the carrier frame (Fig. 0475). 15. 2010 only: Remove the LH and RH pivot shafts from the rear cross shaft assembly and carrier frame hub (Fig. 0477). Note: 48” and 52” decks are set to a narrow stance. Remove the wheels to remove the pivot shafts. Reinstall the wheels after removing the pivot shafts. 3 Fig. 0475 DSCN-1602a 14.
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CHASSIS 16. Remove the four carriage bolts and nuts securing the muffler guard and guard panel to the carrier frame, then remove both (Fig. 0478). 17. Remove the shoulder bolts, washers and nuts securing the LH and RH lift links to the deck (Fig. 0480). 3 Fig. 0478 DSCN-0932a Note: 48” and 52” models use two guard mounting brackets instead of the single guard panel (Fig. 0479). Fig. 0479 Toro GrandStand Service Manual IMG-0586a Fig. 0480 DSCN-0935a 18.
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CHASSIS 19. Remove the “Z” bend from the engine choke lever (Fig. 0482). 21. Remove the “Z” bend from the engine throttle lever (Fig. 0484). 3 Fig. 0482 DSCN-0945a 20. Loosen the cable clamp securing the throttle cable to the engine throttle plate, then remove the cable from the clamp (Fig. 0483). Fig. 0483 3-128 DSCN-0946a Fig. 0484 DSCN-0950a 22. Remove the two sets of wing nuts and hold down bolts securing the battery cover to the battery tray, then remove the cover (Fig. 0485). Fig.
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CHASSIS 23. Remove the nut and bolt securing the negative cable to the battery (Fig. 0486). 25. Slide the hose clamp back on the fuel line and remove the fuel line from the fuel filter (Fig. 0488). 3 Fig. 0486 DSCN-0953a Fig. 0488 DSCN-0959a 24. Remove the nut and bolt securing the positive cable to the battery (Fig. 0487). Note: Position a pan under the fuel hose to catch any fuel remaining in the fuel hose (Fig. 0489). Fig. 0487 Fig.
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CHASSIS 26. Slide the hose clamp back on the low-pressure return hose, then remove the hose from the “T” fitting (Fig. 0490). 28. Disconnect the wire harness from the neutral switch (Fig. 0492). 3 Fig. 0492 Fig. 0490 27. Slide the hose clamp back on the low-pressure suction hose, then remove the hose from the “T” fitting (Fig. 0491). 29. Disconnect the violet wire from the voltage regulator (Fig. 0493). Fig. 0493 Fig.
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CHASSIS 30. Unplug the pink wire from the green fuel solenoid wire (Fig. 0494). 32. Remove nut and lock washer securing the positive battery cable and red wire eyelet to the solenoid post (Fig. 0496). 3 Fig. 0494 DSCN-0978a Fig. 0496 31. Unplug the white wire from the black magneto wire (Fig. 0495). Fig. 0495 33. Remove the green and blue bullet connectors from the two small studs on the solenoid (Fig. 0497). DSCN-0980a Fig.
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CHASSIS 34. Remove the bolt and washer securing the ground wires to the engine block (Fig. 0498). 36. Remove both sets of bolts, nuts and spacers secur ing the lower end of the control cables to the control fork assemblies (Fig. 0500). 3 Fig. 0498 DSCN-0991a Fig. 0500 35. Disconnect the clutch wires from the wiring harness (Fig. 0499). Fig. 0499 37. Remove the spring clip securing the motion control cables to the linkage mount (Fig. 0501). DSCN-0993a Fig.
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CHASSIS 38. Remove the two cable ties securing the speed control cable to the RH control cable and the lower LH side of the linkage mount (Fig. 0502). 40. Remove the speed control cable clip from the speed control handle assembly (Fig. 0504). 3 Fig. 0504 Fig. 0502 39. Remove the motion control cables from the linkage mount (Fig. 0503). 41. Remove the “Z” bend of the speed control cable from the speed control handle assembly (Fig. 0505). Fig. 0505 Fig.
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CHASSIS 42. Remove the four sets of bolts, spacers and nuts (two sets per side) that secure the axle and wheel assembly to the carrier frame (Fig. 0506). 44. Walk the carrier frame and tower assembly forward, over the engine and deck assembly (Fig. 0508). 3 Fig. 0508 Fig. 0506 DSCN-1028a DSCN-1019a 43. Using two people or a hoist, lift the rear end of the carrier frame and tower assembly (Fig. 0507). 45.
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CHASSIS 46. Remove bolt and nut securing the “R” clamp (secur ing choke and throttle cables) to the LH side of the carrier frame (Fig. 0510). 48. Remove the hairpin cotter and clevis pin securing the brake rod yoke to the brake assembly (Fig. 0512). 3 Fig. 0510 DSCN-1249a 47. Remove the cable tie securing the choke cable to the LH rear side of the carrier frame (Fig. 0511). Fig. 0511 Fig. 0512 49.
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CHASSIS 50. Remove the platform assembly from the carrier frame (Fig. 0514). 52. 2010 only: Remove the cable tie securing the fuel vent hose to the RH side of the carrier frame (Fig. 0516). 3 Fig. 0514 DSCN-1260a Fig. 0516 51. Remove the brake assembly from the carrier frame (Fig. 0515). Fig. 0515 53. Remove the four sets (one set in each corner) of bolts, spacers and nuts securing the tower assembly to the carrier frame (Fig. 0517). DSCN-1263a Fig.
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CHASSIS 54. Remove the tower assembly from the carrier frame (Fig. 0518). 56. Slide the hose clamp back on the low-pressure suction line where it connects to the filter inlet fitting (Fig. 0520). 3 Fig. 0518 DSCN-1271a Fig. 0520 55. Remove bolt and nut securing the “R” clamp (secur ing the low-pressure return line) to the hydraulic reservoir (Fig. 0519). Fig. 0519 57. Remove the two sets of bolts, washers, spacers and nuts securing the hydraulic reservoir to the tank mount (Fig. 0521).
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CHASSIS 58. Place an oil drain pan below the reservior. Remove the reservoir from the tank mount (Fig. 0522). 59. Remove the two sets of bolts and washers securing the hydraulic filter head assembly (Fig. 0524). 3 Fig. 0522 DSCN-1276a Note: While lifting the tank from the tank bracket, remove the low-pressure hose from the filter inlet fitting (Fig. 0523). Fig. 0524 60. Remove the “E” clip and washer securing the lift assembly (Fig. 0525). Fig. 0525 Fig.
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CHASSIS 61. Remove the lift assembly from the carrier frame (Fig. 0526). 62. Repeat step 60 and 61 on the other side of the carrier frame. 63. Remove the grease zerk from the LH & RH rear pivot hubs (Fig. 0528). 3 Fig. 0526 DSCN-1294a Note: Ensure the thin washer is removed with the lift assembly (Fig. 0527). Fig. 0528 DSCN-1297a 64. Remove the grease zerk from the LH & RH front pivot hubs (Fig. 0529). Fig. 0527 DSCN-1308a Fig.
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CHASSIS 65. Remove the two front caster wheel assemblies. See “Caster Wheel Assembly Removal” on page 3-17. 66. Using a drill, carefully remove the two pop rivets securing the model/serial plate (Fig. 0530). Carrier Frame Installation 1. Using pop rivets, secure the original model/serial plate to the carrier frame (Fig. 0531). 3 Fig. 0530 DSCN-1306a Fig. 0531 DSCN-1306a 2. Install the two front caster wheel assemblies. See “Caster Wheel Assembly Installation” on page 3-20. 3.
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CHASSIS 4. Install the grease zerk into the LH & RH rear pivot hubs (Fig. 0533). 5. Install the lift assembly to the carrier frame (Fig. 0534). 3 Fig. 0533 DSCN-1297a Fig. 0534 DSCN-1311a Note: Ensure the thin washer is in place on the lift assembly pivot post (Fig. 0535). Fig.
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CHASSIS 6. Secure the lift assembly to the carrier frame using the large washer and “E” clip (Fig. 0536). 9. Position the hydraulic reservoir in the hydraulic reservoir mount (Fig. 0538). 3 Fig. 0536 DSCN-1287a 7. Repeat steps 5 and 6 on the other side. 8. Secure the hydraulic filter head assembly to the hydraulic reservoir mount using two bolts and washers (Fig. 0537). Fig.
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CHASSIS 10. Position the two spacers between the hydraulic reservoir and the hydraulic reservoir mount (Fig. 0540). 12. Secure the low-pressure suction line to the hydraulic filter inlet fitting using the hose clamp (Fig. 0542). 3 Fig. 0542 Fig. 0540 11. Secure the hydraulic reservoir and spacers to the hydraulic reservoir mount using two bolts, washers and nuts (Fig. 0541). Fig. 0541 13.
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CHASSIS 14. Position the tower assembly onto the carrier frame (Fig. 0544). 15. Loosely install the two sets of bolts, spacers and nuts that secure the front of the tower to the carrier frame using (Fig. 0545). 3 Fig. 0544 DSCN-1271a Fig. 0545 DSCN-1325a Note: The bolt is installed upwards though the carrier frame, then up through the tower assembly (Fig. 0546). Fig.
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CHASSIS 16. Loosely install the two sets of bolts, spacers and nuts that secure the rear of the tower to the carrier frame (Fig. 0547). 17. Tighten all four sets of fastener assemblies. 18. 2010 only: Secure the fuel vent hose to the RH side of the carrier frame using a cable tie (Fig. 0549). 3 Fig. 0547 DSCN-1328a Fig. 0549 DSCN-1269a Note: The bolt is installed downwards though the tower, then down through the carrier frame (Fig. 0548). Fig.
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CHASSIS 19. Position the brake arm assembly in the carrier frame (Fig. 0550). 20. Position the platform assembly onto the carrier frame (Fig. 0552). 3 Fig. 0550 DSCN-1332a Note: Align the square bolt hole in the end of the brake support with the square bolt hole in the side of the carrier frame (Fig. 0551). Fig. 0552 DSCN-1258a Note: The pivot hole in the platform aligns with the square hole in the carrier frame (Fig. 0553). Note: The brake arm torsion spring will be set in a later step. Fig.
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CHASSIS 21. Position the carriage bolt through the brake support and the carrier frame (Fig. 0554). 23. Position the platform so carriage bolt protrudes through the platform pivot hole (Fig. 0556). 3 Fig. 0554 DSCN-1340a 22. Position a washer over the carriage bolt (Fig. 0555). Fig. 0555 Fig. 0556 24. Position the spacer over the carriage bolt and into the platform pivot hole (Fig. 0557). DSCN-1342a Fig.
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CHASSIS 25. Secure the assembly with a washer and nut (Fig. 0558). 28. Remove the nut and washer securing the brake arm torsion spring, then remove the spring (Fig. 0560). 3 Fig. 0558 DSCN-1255a 26. Repeat steps 21 through 25 on the other side of the machine. 27. Move the platform to the “Up” position (Fig. 0559). Fig. 0559 3-148 DSCN-1359a Fig. 0560 DSCN-1362a 29. Position the torsion spring over the spacer and bolt.
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CHASSIS 30. Secure the torsion spring assembly using the washer and nut (Fig. 0562). 32. Secure the brake rod to the brake arm assembly using the clevis pin and hairpin cotter (Fig. 0564). 3 Fig. 0562 DSCN-1362a 31. Lower the platform assembly to the “Down” position (Fig. 0563). Fig. 0564 DSCN-1367a 33. Secure the fuel hose bracket (securing the fuel hose) to the RH side of the carrier frame using the bolt and nut (Fig. 0565).
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CHASSIS 34. Route the choke cable between the brake rod and the carrier frame (Fig. 0566). 36. Secure the “R” clamp (securing the throttle and choke cables) to the LH side of the carrier frame using a bolt and nut (Fig. 0568). 3 Fig. 0566 DSCN-1371a Fig. 0568 35. Secure the choke cable to the carrier frame using a cable tie (Fig. 0567). Fig. 0567 37. Place the platform assembly in the “UP” position (Fig. 0569). DSCN-1373a Fig.
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CHASSIS 38. Position the rear axle assembly behind the engine base assembly (Fig. 0570). 40. Walk the carrier frame and tower assembly rear ward, over the engine and deck assembly (Fig. 0572). 3 Fig. 0570 DSCN-1378a Fig. 0572 DSCN-1385a 39. Using two people or a hoist, lift the rear end of the carrier frame and tower assembly (Fig. 0571). Fig.
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CHASSIS 41. Loosely install the four sets of bolts, spacers, and nuts (two sets per side) that secure the axle and wheel assembly to the carrier frame using (Fig. 0573). 42. Tighten all four sets of fasteners. 43. 2009 only: Install the spacer into the rear cross shaft hub (Fig. 0575). 3 Fig. 0573 DSCN-1386a Fig. 0575 DSCN-1603a Note: The bolts are installed downwards though the carrier frame, then down through the wheel motor mounts (Fig. 0574). 44.
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CHASSIS 45. 2009 only: Secure the assembly using a washer and nut (Fig. 0577). 48. 2010 only: Rotate the pivot shaft so the spiral pin hole of the pivot shaft aligns with the spiral pin hole of the rear cross shaft assembly, then secure the assembly with the spiral pin (Fig. 0579). 3 Fig. 0577 DSCN-1607a Fig. 0579 46. 2009 only: Repeat steps 43 through 45 on the other side of the unit. 47. 2010 only: Position the RH pivot shaft through the carrier frame hub and rear cross shaft assembly (Fig. 0578).
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CHASSIS 49. 2010 only: Repeat steps 47 and 48 on the LH side of the machine. 52. Install the motion control cable adjustment nuts into the linkage mount (Fig. 0583). 50. Install the “Z” bend of the speed control cable to the speed control handle assembly (Fig. 0581). 3 Fig. 0583 Fig. 0581 DSCN-1015a DSCN-1409a 53. Secure the motion control cables to the linkage mount using the spring clip (Fig. 0584). 51.
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CHASSIS 54. Secure the speed control cable to the RH control cable and the lower LH side of the linkage mount using cable ties (Fig. 0585). 56. Connect the wire harness to the neutral switch (Fig. 0587). 3 Fig. 0587 Fig. 0585 55. Secure the rod ends at the base of the control cables to the control forks using the bolts, spacers and nuts (Fig. 0586). 57. Connect the wire harness to the clutch harness (Fig. 0588). Fig. 0588 Fig.
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CHASSIS 58. Connect the black wire eyelet and battery ground cable to the engine block using a bolt and washer (Fig. 0589). 60. Connect the white wire connector to the black mag neto wire (Fig. 0591). 3 Fig. 0591 Fig. 0589 59. Connect the green and blue wire bullet connectors to the two small studs on the solenoid (Fig. 0590). 61. Connect the pink wire connector to the green fuel solenoid wire (Fig. 0592). Fig. 0592 Fig.
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CHASSIS 62. Connect the purple wire connector to the rectifier (Fig. 0593). 63. Secure the red wire eyelet and battery positive cable to the solenoid post using a nut and lock washer (Fig. 0594). 3 Fig. 0593 DSCN-1453a Fig. 0594 DSCN-1456a Note: Position the red boot over the solenoid post after installing cables (Fig. 0595). Fig.
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CHASSIS 64. 48” and 52” Decks: Install the lift rod through the lift rod bracket and secure with nut (Fig. 0596). 66. Position the opposite end of the lift rod over the stud on the rear cross shaft assembly (Fig. 0598). 3 Fig. 0596 DSCN-1459a 65. 60” Decks: Install the lift rod to the turnbuckle and secure with jam nut (Fig. 0597). Fig. 0597 3-158 DSCN-1462a Fig. 0598 DSCN-0801a Note: Ensure the flange bearing is still in place (Fig. 0599). Fig.
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CHASSIS 67. Position the large washer over the rear cross shaft stud (Fig. 0600). 69. Repeat steps 64 through 68 on the other side of the machine. 70. Secure the lower ends of the lift links using the shoulder bolts, washers, and nuts (Fig. 0602). 3 Fig. 0600 DSCN-0807a 68. Secure the assembly using the “E” clip (Fig. 0601). Fig. 0602 DSCN-1467a Note: Install the thin washer between the lift link and deck bracket (Fig. 0603). Fig. 0601 DSCN-0808a Fig.
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CHASSIS 71. 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. 0604). 73. With the engine throttle control lever in the “Fast” position, pull the slack from the cable jacket and tighten the throttle cable clamp (Fig. 0606). 3 Fig. 0606 Fig. 0604 72. Move the throttle lever to the “Fast” position (Fig. 0605). Fig. 0605 3-160 IMG-0576a IMG-0575a DSCN-1478a 74.
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CHASSIS 75. Push the choke knob in so it is in the “Open” position (Fig. 0608). 77. Position the muffler guard assembly and loosely install the four carriage bolts, two guard mounting brackets and nuts (Fig. 0610). 3 Fig. 0608 DSCN-1479a Fig. 0610 76. While holding the engine choke control lever in the “Open” position, pull the slack from the cable jacket and tighten the choke cable clamp (Fig. 0609). Fig.
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CHASSIS 78. Make sure the muffler exhaust pipe is centered in the muffler guard assembly, then tighten all four bolts and nuts (Fig. 0612). 79. Secure the low-pressure suction line to the “T” fitting using the hose clamp (Fig. 0613). 3 Fig. 0613 Fig. 0612 DSCN-1473a IMG-0589a Note: The opposite end of the low-pressure suction line is connected to the hydraulic oil filter (Fig. 0614). Fig.
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CHASSIS 80. Secure the low-pressure return line to the “T” fitting using the hose clamp (Fig. 0615). 81. Replace fitting o-rings. Install the high-pressure hoses to the pumps in their original positions (Fig. 0617). 3 Fig. 0615 DSCN-1485a Fig. 0617 Note: The opposite end of the low-pressure return line is connected to the base of the hydraulic reservoir (Fig. 0616). Fig. 0616 Toro GrandStand Service Manual DSCN-1489a DSCN-0810a 82. Secure the hose routings using three cable ties (Fig. 0618). Fig.
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CHASSIS 83. Secure the fuel hose to the fuel filter using the hose clamp (Fig. 0619). 86. 2010 only: Secure the extension spring assembly and chain to the control tower using the bolt and washer (Fig. 0621). 3 Fig. 0619 DSCN-1484a Fig. 0621 84. 2009 only: Install the lift assist cylinder. See “Lift Assist Cylinder Installation (2009 only)” on page 3-43. 85. 2010 only: Position the chain between the pivot shaft and extension spring assembly (Fig. 0620). DSCN-0818a 87.
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CHASSIS 88. 2010 only: Repeat steps 85 and 86 on the other side of the machine. 89. Install the fuel tank. See “Fuel Tank Assembly Installation” on page 3-29. 91. 2010 only: Secure the lower end of the lift bar to the rear cross shaft assembly using the dampener assembly and nut. Thread the dampener assembly bolt into the nut until there are 3 threads protruding (Fig. 0624). 90. 2009 only: Secure the lower end of the lift bar to the rear cross shaft assembly using a nut.
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CHASSIS 93. Secure the red positive cable to the positive terminal on the battery using a bolt, washer, and nut (Fig. 0626). 94. Secure the black ground cable to the negative terminal on the battery using the bolt, washer and nut (Fig. 0628). 3 Fig. 0626 DSCN-1495a Note: Position the red protective boot over the terminal once the cable is secured (Fig. 0627). Fig. 0627 Fig. 0628 DSCN-1499a 95. Secure the battery to the battery tray using the battery cover, hold down bolts and wing nuts (Fig. 0629).
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CONTROLS LH Motion Control Lever Replacement LH Motion Control Lever Removal 1. Remove the bolt, nut & spacer securing the end of the control cable to the LH motion control lever (Fig. 0630). Fig. 0632 IMG-0956a 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. 0633). Fig. 0630 IMG-0953a 2.
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CONTROLS 3. Remove the LH control lever assembly from the control tower (Fig. 0634). 4 Fig. 0634 IMG-0964a 5. Remove the two plastic bearings from the ends of the control handle (Fig. 0636). Fig. 0636 IMG-0973a 4. Remove the pivot rod from the motion control handle (Fig. 0635). Fig.
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CONTROLS LH Motion Control Lever Installation 3. Secure the control handle assembly in the control tower using two bolts (Fig. 0639 & 0640). 1. Install a plastic bearing into each end of the control handle (Fig. 0637). Fig. 0637 Fig. 0639 IMG-0955a Fig. 0640 IMG-0956a IMG-0973a 2. Install the pivot rod into the center of the control handle (Fig. 0638). Fig.
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CONTROLS 4. Secure the control cable to the motion control lever using a bolt, nut and spacer (Fig. 0641). RH Motion Control Lever Replacement RH Motion Control Lever Removal 1. Remove the bolt, nut & spacer securing the end of the control cable to the RH motion control lever (Fig. 0642). Fig. 0641 4 IMG-0953a Fig. 0642 IMG-0974a 2. Unplug the wire harness from the OPC switch (Fig. 0643). Fig.
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CONTROLS 3. Remove the two screws securing the pivot shaft in side the RH motion control lever (Fig. 0644 & 0645). Fig. 0644 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. 0646). IMG-0977a Fig. 0646 IMG-0980a 4. Remove the RH control lever assembly from the control tower (Fig. 0647). Fig. 0645 IMG-0979a Fig.
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CONTROLS 5. Remove the pivot rod from the motion control handle (Fig. 0648). 4 Fig. 0648 7. Remove the two screws and tapped plate securing the OPC switch to the control handle assembly (Fig. 0650). IMG-0986a Fig. 0650 6. Remove the extension spring from the assembly (Fig. 0649). Fig. 0649 8. Remove the bolt and nut securing the RH handle to the motion control assembly (Fig. 0651). IMG-0987a Fig.
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CONTROLS 9. Remove the nut and washer securing the adjustment cam to the RH control lever (Fig. 0652). RH Motion Control Lever Installation 1. Install the four plastic bearings to the motion control assembly (Fig. 0654). Fig. 0652 IMG-0999a Fig. 0654 IMG-1002a 10. Remove the four plastic bearings from the motion control assembly (Fig. 0653). 2. Loosely secure the adjustment cam to the RH control lever (Fig. 0655). Note: This nut will be tightened later in the process. Fig. 0653 IMG-1002a Fig.
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CONTROLS 3. Secure the RH control lever to the motion control assembly with the shoulder bolt and nut (Fig. 0656). 4 Fig. 0656 IMG-0996a 4. Loosely secure the OPC switch to the motion control assembly (Fig. 0657). 5. Install the extension spring to the motion control assembly (Fig. 0658). Fig. 0658 IMG-0987a 6. Install the pivot rod into the motion control assembly (Fig. 0659). Note: These will be tightened later in the process. Fig. 0659 Fig.
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CONTROLS 7. Secure the control handle assembly in the control tower using two bolts (Fig. 0660 & 0661). Fig. 0660 IMG-0977a 8. Install the wire harness onto the OPC switch (Fig. 0662). Fig. 0662 IMG-0976a 9. Position the RH control handle so it is horizontally aligned with the LH lever (Fig. 0663). Fig. 0661 IMG-0979a Fig.
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CONTROLS 10. Secure the position of the RH lever by tightening the nut on the adjustment cam on the RH control assembly (Fig. 0664). 12. Secure the position of the switch by tightening the two mounting screws (Fig. 0666). Fig. 0666 4 Fig. 0664 11. 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. 0665). A Fig. 0665 IMG-8390a IMG-059a 13.
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CONTROLS RH Control Linkage Replacement RH Control Linkage Removal 3. Remove the cable tie securing the speed control cable to the RH motion control cable, then remove the motion control cable from the linkage mount (Fig. 0670). 1. Remove the bolt, nut and spacer securing the lower end of the control cable to the RH control fork assembly (Fig. 0668). Fig. 0670 Fig. 0668 IMG-1008a IMG-1011a 4.
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CONTROLS 5. 2010 Only: Remove the bolt, nut, washers and spacer securing the front end of the RH shifter link to the shifter bracket (Fig. 0672). 4 Fig. 0672 7. 2009 Only: Serial range 290000001 - 290000209: Remove the right hand shifter link rod and the 3 rollers located on the rear end of the shifter link rod from the inside of the control fork assembly and pump control arm (Fig. 0674). IMG-0905a Fig. 0674 6. Remove the hairpin cotter and washer from the rear end of the shifter link (Fig. 0673).
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CONTROLS 9. 2009 Only: Serial range 290000210 - 290999999: Remove the rear end of the RH shifter link and the right hand roller (Fig. 0676). Fig. 0676 11. 2010 Only: Remove the RH shifter link and the 3 rollers located on the rear end of the shifter link inside of the control fork assembly (Fig. 0678). Fig. 0678 IMG-9432a 10. 2009 Only: Serial range 290000210 - 290999999: Push down on the control fork assembly and remove the center roller from the pump control arm slot (Fig. 0677).
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CONTROLS 12. Remove the nut and large washer securing the control fork assembly (Fig. 0680). 4 Fig. 0680 IMG-1013a 13. Remove the bolt and washer from the shoulder hub (Fig. 0681). Fig. 0681 14. Remove the shoulder hub and control fork assembly (Fig. 0682). Fig. 0682 15. Remove the two sets of bolts and nuts securing the pump control arm to the pump RTN (Return to Neutral) mechanism (Fig. 0683). IMG-1015a Fig.
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CONTROLS RH Control Linkage Installation 1. Secure the pump control arm to the pump RTN mechanism using two bolts and nuts (Fig. 0684). 3. Position the control fork on the shoulder hub with the forked end straddling the pump control arm (Fig. 0686). Fig. 0686 Fig. 0684 IMG-1018a 2. Position the shoulder hub into the two neutral switch levers (Fig. 0685). 4. Install the bolt with washer through the center of the shoulder hub (Fig. 0687). Fig. 0687 Fig.
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CONTROLS 5. Loosely install the large washer and nut securing the control fork and shoulder hub assembly to the linkage mount (Fig. 0688). Note: This will be tightened later in this procedure. 4 6. 2009 Only: Serial range 290000001 – 290000209: Slide 3 rollers onto the rear end of the RH shifter link rod. Slide the rear end of the shifter link rod (with 3 rollers) into the control fork assembly (Fig. 0690). Fig. 0690 Fig. 0688 Shifter Link and Roller Configurations (Fig. 0689): A.
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CONTROLS 8. 2009 Only: Serial range 290000210 -290999999: Using an Allen wrench, locate the center roller and slide the Allen wrench through it (Fig. 0692). Fig. 0692 10. 2009 Only: Serial range 290000210 and up: Slide the left hand roller onto the rear end of the right hand shifter link rod and into the outside of the control fork assembly (Fig. 0694). IMG-9492a Fig. 0694 9. 2009 Only: Serial range 290000210 -290999999: Slide the right hand roller onto the rear end of the right hand shifter link rod.
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CONTROLS 12. 2010 Only: Slide 3 rollers onto the rear end of the RH shifter link. Slide the rear end of the shifter link (with three rollers) into the control fork assembly (Fig. 0696). 14. 2010 Only: Secure the shifter link to the shifter bracket with a bolt two washers and nut (Fig. 0698). Fig. 0698 4 Fig. 0696 IMG-0948a 13. 2010 Only: Place a spacer into the front end of the shifter link (Fig. 0697). 15.
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CONTROLS 16. While pulling the control fork assembly rearward (not so hard that the speed control linkage moves) tighten the screw that goes through the center of the shoulder hub (Fig. 0700). 17. Install the washer and hairpin cotter to the end of the speed control linkage (Fig. 0702). Fig. 0702 Fig. 0700 IMG-1013a Note: It is important to keep the pump control arm and control fork slots aligned with each other.
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CONTROLS 19. Secure the cable to the linkage mount with the spring clip (Fig. 0704). LH Control Linkage Replacement LH Control Linkage Removal 1. Remove the bolt, nut & spacer securing the lower end of the control cable to the LH control fork assembly (Fig. 0706). 4 Fig. 0704 IMG-1022a 20. Secure the end of the control cable to the control fork using the bolt, nut and spacer (Fig. 0705). Fig. 0706 IMG-1033a 2. Remove the spring clip securing the motion control cable to the linkage mount (Fig. 0707).
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CONTROLS 3. Remove the LH motion control cable from the link age mount (Fig. 0708). Fig. 0708 5. 2010 Only: Remove the bolt, nut, washers, and spacer securing the front end of the LH shifter link to the shifter bracket (Fig. 0710). IMG-1035a Fig. 0710 4. 2009 Only: Remove the hairpin cotter and washer securing the front end of the LH shifter link to the shifter bracket (Fig. 0709). Fig. 0709 Toro GrandStand Service Manual IMG-9358a IMG-0346_b 6.
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CONTROLS 7. 2009 Only: Serial range 290000001 - 290000209: Remove the LH shifter link rod and the 3 rollers located on the rear end of the shifter link rod from the inside of the control fork assembly and pump control arm (Fig. 0712). 4 9. 2009 Only: Serial range 290000210 - 290999999: Remove the rear end of the LH shifter link and the right hand roller (Fig. 0714). Fig. 0714 Fig. 0712 IMG-9373a 8.
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CONTROLS 11. 2010 Only: Remove the LH shifter link and the 3 rollers located on the rear end of the shifter link inside of the control fork assembly (Fig. 0716). 12. Remove the nut and switch stop arm securing the control fork assembly (Fig. 0718). Fig. 0718 Fig. 0716 Shifter Link and Roller Configurations (Fig. 0717): D. 2009: Serial range 290000001-290000210; 3 rollers, all thin and same size E. 2009: Serial range 290000211-290999999; 3 rollers, large center roller F.
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CONTROLS 14. Remove the shoulder hub and control fork assembly (Fig. 0720). LH Control Linkage Installation 1. Secure the pump control arm to the pump RTN mechanism using two bolts and nuts (Fig. 0722). 4 Fig. 0720 IMG-1045a Fig. 0722 15. Remove the two sets of bolts and nuts securing the pump control arm to the pump RTN (Return to Neutral) mechanism (Fig. 0721). Fig. 0721 2. Position the shoulder hub into the two neutral switch levers (Fig. 0723). IMG-1047a Fig.
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CONTROLS 3. Position the control fork on the shoulder hub with the forked end straddling the pump control arm (Fig. 0724). 5. Loosely install the switch stop arm and nut securing the control fork and shoulder hub assembly to the linkage mount (Fig. 0726). Note: This will be tightened later in this procedure. Fig. 0724 IMG-1050a Fig. 0726 4. Install the bolt with washer through the center of the shoulder hub (Fig. 0725). Fig. 0725 IMG-1044a Shifter Link and Roller Configurations (Fig. 0727): D.
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CONTROLS 6. 2009 Only: Serial range 290000001 - 290000209: Slide 3 rollers onto the rear end of the LH shifter link rod. Slide the rear end of the shifter link rod (with 3 rollers) into the control fork assembly (Fig. 0728). 4 8. 2009 Only: Serial range 290000210 - 290999999: Using an Allen wrench, locate the center roller and slide the Allen wrench through it (Fig. 0730). Fig. 0730 Fig. 0728 7.
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CONTROLS 10. 2009 only: Serial range 290000210 and up: Slide the left hand roller onto the rear end of the LH shifter link rod and into the outside of the control fork as sembly (Fig. 0732). Fig. 0732 IMG-9365a 11. 2009 Only: Secure the front end of the LH shifter link to the shifter bracket using a hairpin cotter and washer (Fig. 0733). 12. 2010 Only: Slide 3 rollers onto the rear end of the LH shifter link.
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CONTROLS 14. 2010 Only: Secure the shifter link to the shifter bracket with a bolt two washers and nut (Fig. 0736). 4 Fig. 0736 16. Insert a 7/32nd Allen wrench into the slots of the control fork and control arm in front of the speed control linkage rollers (Fig. 0738). IMG-0346_b Fig. 0738 DSC-0504a 15. Using a cable tie, secure the neutral switch plates with the switch stop arm nested between them (Fig. 0737). Fig.
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CONTROLS 17. While pulling the control fork assembly rearward (not so hard that the speed control linkage moves) tighten the screw that goes through the center of the shoulder hub (Fig. 0739). 18. Install the washer and hairpin cotter to the end of the speed control linkage (Fig. 0741). Fig. 0741 Fig. 0739 IMG-1057a Note: It is important to keep the pump control arm and control fork slots aligned with each other.
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CONTROLS 20. Position the motion control cable adjustment nut into the slot on the linkage mount (Fig. 0743). 4 Fig. 0743 IMG-1058a 22. Secure the end of the control cable to the control fork using the bolt, nut and spacer (Fig. 0745). Fig. 0745 IMG-1061a 21. Secure the cable to the linkage mount with the spring clip (Fig. 0744). Fig.
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CONTROLS Speed Control Cable & Shifter Replacement 3. Remove the two cable ties securing the speed control cable to the RH control cable and the left side of the linkage mount (Fig. 0748). Speed Control Cable & Shifter Removal 1. Remove the speed control handle knob and then the two screws and nuts securing the handle assembly to the control tower (Fig. 0746). Fig. 0748 Fig. 0746 IMG-0145a IMG-1089a 4.
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CONTROLS 5. 2010 Only: Remove the bolt, nut, washers, and spacer securing the front end of the RH & LH shifter links to the shifter bracket (Fig. 0750). 7. Remove the two screws securing the shifter bracket assembly to the engine base (Fig. 0752). Fig. 0752 4 Fig. 0750 6. Using a spring tool, unhook the “J” end of the torsion spring from the lower shifter bracket (Fig. 0751). 8. Remove the shifter bracket assembly and speed control cable from the chassis (Fig. 0753). Fig. 0753 Fig.
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CONTROLS 9. Remove the screw and cable clamp securing the speed control cable to the shifter bracket assembly (Fig. 0754). 11. Remove the hairpin cotter and washer from both ends of the hinge pin (Fig. 0756). Fig. 0756 Fig. 0754 10. Remove the “Z” bend of the speed control cable from the shifter assembly (Fig. 0755). 12. Remove the hinge pin and torsion spring from the shifter assembly (Fig. 0757). Fig. 0757 Fig.
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CONTROLS 13. Remove the two plastic bushings from the lower shifter bracket (Fig. 0758). Speed Control Cable & Shifter Installation 1. Install two plastic bushings into the upper shift bracket (Fig. 0760). 4 Fig. 0758 IMG-1077a Fig. 0760 IMG-1078a 14. Remove the two plastic bushings from the upper shifter bracket (Fig. 0759). 2. Install two plastic bushings into the lower shift bracket (Fig. 0761). Fig. 0759 IMG-1078a Fig.
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CONTROLS 3. Install the hinge pin through one side of the upper and lower shifter brackets, though the torsion spring, then through the opposite end of the shifter brackets (Fig. 0762). 5. Hook the “Z” bend of the speed control cable to the shifter bracket assembly (Fig. 0764). Fig. 0764 Fig. 0762 IMG-1125a 4. Secure the hinge pin with a hairpin cotter and wash er on both ends (Fig. 0763). Fig. 0763 6. Loosely install the screw and cable clamp to the shifter assembly (Fig. 0765).
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CONTROLS 7. Secure the shifter bracket assembly to the engine base using two thread forming screws (Fig. 0766). 4 Fig. 0766 IMG-0153a Note: The speed control cable must be routed be tween the LH pump RTN (Return to Neutral) mechanism, then upward behind the linkage mount (Fig. 0767). 8. Using a spring tool, hook the “J” end of the torsion spring to the lower shifter bracket (Fig. 0768). Fig. 0768 9.
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CONTROLS 10. 2010 Only: Place a spacer into the front end of the shifter links (Fig. 0770). 12. 2010 Only: Repeat steps 10 & 11 on the opposite shifter link. 13. Hook the “Z” bend of the speed control cable to the speed control lever assembly and secure with the cable clip (Fig. 0772). Fig. 0770 IMG-0946a 11. 2010 Only: Secure the shifter links to the shifter bracket with a bolt two washers and nut (Fig. 0771). 4 Fig. 0772 IMG-0150a 14.
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CONTROLS 15. Move the speed control lever to the “FAST” position (Fig. 0774). 4 Fig. 0774 17. Using cable ties, secure the speed control cable to the RH control cable and the left side of the linkage mount (Fig. 0776). PICT-9749a Fig. 0776 IMG-1089a 16. Pull rearward on the cable jacket to remove any slack, then tighten the cable clamp securing the cable jacket to the shifter bracket (Fig. 0775). Fig.
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CONTROLS Speed Control Adjustment 4. Remove the hairpin cotter and washer from the LH speed control linkage (Fig. 0779). 1. Set the HOC lever to 2” (5cm), and then move the speed control lever to the “FAST” position. 2. Loosen the cable clamp securing the speed control cable jacket to the shifter bracket (Fig. 0777). Fig. 0779 Fig. 0777 DSC-0488a DSC-0513a 5. Insert a 7/32” (approx. 5.
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CONTROLS 6. Push the speed control linkage forward (Fig. 0781). The Allen wrench establishes the intended air gap between the rollers and end of the control linkage slots. 8. The switch stop arm must be aligned with the cable end of the control forks. Using a cable tie, secure the neutral assembly to align the components (Fig. 0783). A 4 Fig. 0781 B C Fig. 0783 DSC-0522a A. LH control fork B. Switch stop arm D DSC-0508a C. Cable tie D. RH control fork 7.
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CONTROLS 9. While pulling the control fork assembly rearward (not so hard that the speed control linkage moves) tighten the screw that goes through the center of the LH shoulder hub (Fig. 0784). Fig. 0786 Fig. 0784 DSC-0504a Note: It is important to keep the pump control arm and control fork slots aligned with each other (Fig. 0785). This can be achieved by making sure the top of the pump control arm and control fork are parallel to each other (Fig. 0786). DSC-0527a 4 10.
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CONTROLS Control Cable Replacement 2. Remove the spring clip securing the motion control cable to the linkage mount (Fig. 0789). This procedure was written using the left hand control cable. This procedure is the same for either side. Control Cable Removal 1. Remove the bolt, nut & spacer securing the lower end of the control cable to the control fork assembly (Fig. 0788). Fig. 0789 4 IMG-1009a 3. Remove the motion control cable from the linkage mount (Fig. 0790). Fig. 0788 IMG-1033a Fig.
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CONTROLS 4. Remove the bolt, nut and spacer securing the upper end of the control cable to the motion control handle assembly (Fig. 0791). Control Cable Installation 1. Position the control cable with the cable’s locating groove in line with the bolt holes in the cable bar (Fig. 0793). Note: Ensure the dust cover boot is covering the joint between the cable sleeve and jacket. Fig. 0791 4 IMG-1093a 5.
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CONTROLS 3. Position the cable clamp on the control cable (Fig. 0795). Note: Ensure the dimple in the cable clamp is nested in the locating slot of the control cable. 4 5. Secure the upper end of the control cable to the motion control handle assembly using a bolt, spacer and nut (Fig. 0797). Fig. 0797 Fig. 0795 IMG-1113a 4. Secure the cable, cable clamp, and spacer to the cable bar using two thread forming screws (Fig. 0796). 6.
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CONTROLS 7. Position the adjustment nut of the control cable in the linkage mount (Fig. 0799). Fig. 0799 IMG-1035a 9. Secure the lower end of the control cable to the con trol fork using a bolt, spacer, and nut (Fig. 0801). Fig. 0801 IMG-1033a 8. Secure the control cable to the linkage mount using the spring clip (Fig. 0800). Fig.
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CONTROLS Choke Cable Replacement 3. Cut the cable tie securing the choke cable to the frame, then pull the cable rearward from the frame (Fig. 0804). Choke Cable Removal 1. Remove the bolt and cable clamp securing the choke cable to the engine throttle plate (Fig. 0802). 4 Fig. 0804 Fig. 0802 IMG-1127a IMG-1132a 4. Remove the nut securing the choke cable to the control panel (Fig. 0805). 2. Remove the “Z” bend of the choke cable from the engine choke arm (Fig. 0803). Fig. 0805 Fig.
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CONTROLS 5. Remove the choke cable from the control panel (Fig. 0806). Choke Cable Installation 1. Feed the choke cable through the mounting hole in the control panel (Fig. 0807). Fig. 0806 IMG-1137a Fig. 0807 IMG-1137a 2. Secure the choke cable to the control panel using a nut (Fig. 0808). Fig.
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CONTROLS 3. Feed the cable through the frame, to the left of the brake linkage (Fig. 0809). 4 Fig. 0809 IMG-1142a 4. Feed the choke cable through the ”R” clamp located on the front, lower corner of the control tower (Fig. 0810). Fig. 0810 4-48 IMG-1143a 5. Install the choke cable “Z” bend into the engine choke lever (Fig. 0811). Fig. 0811 IMG-1129a 6. Position the choke cable to the engine throttle plate and loosely install the screw and cable clamp (Fig. 0812). Fig.
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CONTROLS 7. Secure the choke cable to the frame using a cable tie (Fig. 0813). Fig. 0813 IMG-1132a 8. Ensure the choke knob is in the “OPEN” position (Fig. 0814). Fig. 0814 9. Ensure the choke is fully open in the throat of the carburetor (Fig. 0815). Fig. 0815 10. While holding the engine choke lever in the “OPEN” position, pull the slack from the cable jacket (Fig. 0816). IMG-1302a Fig.
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CONTROLS 11. Secure the position of the choke cable with the screw and cable clamp (Fig. 0817). Throttle Cable Replacement Throttle Cable Removal 1. Remove the bolt and cable clamp securing the throttle cable to the engine throttle plate (Fig. 0818). 4 Fig. 0817 IMG-1127a 12. Ensure the choke is functioning correctly by moving the choke knob in and out while observing the choke plate in the carburetor throat. Fig. 0818 IMG-1127a 2.
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CONTROLS 3. From the rear of the machine, pull the cable rear ward from the frame. 4. Remove the throttle knob from the throttle lever (Fig. 0820). 6. Remove the cable clip and then the “Z” bend of the cable from the throttle control lever assembly (Fig. 0822). Fig. 0822 Fig. 0820 IMG-1160a IMG-1156a 5. Remove the two screws and nuts securing the throttle lever assembly to the control panel (Fig. 0821). Fig.
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CONTROLS Throttle Cable Installation 3. Apply medium strength thread-locking material to the threads of the handle knob (Fig. 0825). 1. Hook the “Z” bend of the speed control cable to the speed control lever assembly and secure with the cable clip (Fig. 0823). Fig. 0825 4 Fig. 0823 IMG-1160a IMG-1161a 4. Install the handle knob to the throttle lever (Fig. 0826). 2. Secure the lever assembly to the control tower using two screws and nuts (Fig. 0824). Fig. 0826 Fig.
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CONTROLS 5. Route the throttle cable downward between the con trol cables and fuel tank, then forward under the fuel tank shelf (Fig. 0827). 7. Feed the throttle cable through the muffler mount (Fig. 0829). Fig. 0829 Fig. 0827 6. Feed the throttle cable through the ”R” clamp located on the front, lower corner of the control tower (Fig. 0828). 8. Install the throttle cable “Z” bend into the engine throttle lever (Fig. 0830). Fig. 0830 Fig.
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CONTROLS 9. Position the throttle cable to the engine throttle plate and loosely install the screw and cable clamp (Fig. 0831). 4 Fig. 0831 IMG-1127a 10. Move the throttle lever to the “FAST” position (Fig. 0832). Fig. 0832 IMG-1172a 11. While holding the engine throttle lever in the “Fast” position, pull the slack from the cable jacket (Fig. 0833). Fig. 0833 DSCN-1578a 12. Secure the position of the throttle cable with the screw and cable clamp (Fig. 0834). Fig. 0834 IMG-1127a 13.
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ENGINE Engine Replacement 4. Remove the negative and then the positive battery cables and remove the battery (Fig. 0837). Engine Removal 1. Turn the engine off and remove the key from the ignition. 2. Turn the fuel shutoff valve to the “OFF” position (Fig. 0835). Fig. 0837 IMG-0453a 5. Slide the hose clamp off the fuel line where it con nects to the fuel pump (Fig. 0838). Fig. 0835 5 IMG-0447a 3. Remove the two hold down bolts and wing nuts securing the battery cover. Then remove the cover (Fig.
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ENGINE 6. Remove the fuel line from the fuel pump. Drain the fuel into suitable container (Fig. 0839). Fig. 0839 IMG-0458a 7. Remove the violet wire from the voltage regulator (Fig. 0840). 8. Unplug the pink wire from the green fuel solenoid wire (Fig. 0841). Fig. 0841 IMG-0464a 9. Unplug the white wire from the black magneto wire (Fig. 0842). 5 Fig. 0840 5-2 IMG-0462a Fig.
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ENGINE 10. Remove the bolt and washer securing the ground wires to the engine block (Fig. 0843). Fig. 0843 IMG-0467a 11. Remove nut and lock washer securing the starter wire to the solenoid (Fig. 0844). 12. Unplug the clutch wires from the wiring harness (Fig. 0845). Fig. 0845 IMG-0474a 13. Push the grommet and the electrical plug connector down through the engine base (Fig. 0846). 5 Fig. 0844 Toro GrandStand Service Manual IMG-0470a Fig.
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ENGINE 14. Remove the four nuts, two mounting guard brackets, and four carriage bolts retaining the muffler guard assembly to the front frame (Fig. 0847). 16. Loosen the screw on the choke cable clamp and remove the choke cable from the engine panel control (Fig. 0849). Note: 60” models have a guard panel, not the two guard mounting brackets Fig. 0849 Fig. 0847 5 IMG-0475a 15. Remove the muffler guard assembly (Fig. 0848). 17.
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ENGINE 18. Remove the right hand mower belt cover (Fig. 0851). 20. Raise the machine so the underside of the chassis can be accessed. 21. 2009 ONLY: Remove the bolt, washers, spacer and nut securing the clutch brake strap to the engine base (Fig. 0853). Fig. 0851 IMG-0485a 19. With a spring tool, remove the extension spring from the spring anchor bracket (Fig. 0852). Fig. 0853 IMG-9755a 5 22. Remove the mower belt from around the PTO electric clutch (Fig. 0854). Fig. 0852 IMG-0487a Fig.
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ENGINE 23. With a spring tool, remove the extension spring from the spring anchor bracket (Fig. 0855). Note: On 2009 machines the extension spring hooks to the back of the engine base. 25. Remove the 3 carriage bolts and 3 nuts securing the skid plate to the mower deck and remove the skid plate (Fig. 0857). Fig. 0857 Fig. 0855 5 IMG-0496a 24. Remove the hydraulic drive belt from around the engine and hydraulic pump pulleys (Fig. 0856). Fig. 0856 26.
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ENGINE 27. Remove the bolt, spring washer and washer secur ing the clutch to the engine crankshaft (Fig. 0859). Fig. 0859 29. Remove the four engine mounting bolts and Belle ville washers securing the engine to the engine base (Fig. 0861). IMG-0506a Fig. 0861 28. Lower the clutch onto the top of the mower deck (Fig. 0860). IMG-0516a 30. Remove the engine from the engine base (Fig. 0862).
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ENGINE 31. Remove the square key from the engine crankshaft (Fig. 0863). Fig. 0863 5 IMG-0520a 32. Remove the two bolts, spacers and nuts securing the left and right side muffler brackets to the muffler (Fig. 0864). Fig. 0864 5-8 IMG-0542a 33. Remove four nuts and lock washers securing the muffler to the engine (Fig. 0865). Fig. 0865 IMG-0522a 34. Remove the four bolts and lock washers (2 per side) securing the right and left hand muffler brackets to the engine (Fig. 0866). Fig.
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ENGINE Engine Installation 1. Secure the RH and LH muffler brackets to the en gine using four bolts and lock washers (Fig. 0867). 3. Secure the muffler to the engine using four nuts and lock washers. Torque to 19 ± 2 ft-lbs. (26 ± 3 Nm) (Fig. 0869). Fig. 0869 Fig. 0867 IMG-0528a 2. Position a new exhaust gasket on the exhaust studs for both exhaust ports (Fig. 0868). Fig. 0868 Toro GrandStand Service Manual IMG-0532a IMG-0531a 4.
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ENGINE 5. Install the square key in the crankshaft and apply anti-seize around the crankshaft (Fig. 0871). Fig. 0871 5 IMG-0545a 8. Apply thread locking compound to clutch bolt threads (Fig. 0873). Fig. 0873 IMG-0563a 6. Lower the engine into the chassis until the base of the engine is approximately 1-1/2” (3.81cm) from the engine base. 9. Install the electric clutch onto the engine crankshaft and loosely install the clutch bolt, spring washer and washer (Fig. 0874). 7.
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ENGINE 10. Install the 4 screws and Belleville washers securing the engine to the engine base. Torque the screws to 30 ± 4 ft-lbs. (41 ± 5 Nm) (Fig. 0875). 12. Torque the clutch bolt to 55 ± 5 ft-lbs. (75 ± 7 Nm) (Fig. 0877). Fig. 0877 Fig. 0875 IMG-0566a IMG-0511a 11. Remove one spark plug and feed a minimum of 2 feet (61cm) of 3/8” (.95cm) rope into the cylinder to prevent engine rotation (Fig. 0876). Note: Rotate crankshaft as needed to permit feeding the rope into the cylinder. 13.
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ENGINE 15. Feed the clutch wire through the hole in the engine base and install the rubber grommet (Fig. 0879). 17. Install the extension spring from the idler bracket to the spring anchor bracket (Fig. 0881). Note: On 2009 machines the extension spring hooks to the back of the engine base. Fig. 0879 5 IMG-0567a 16. Install the pump drive belt around the engine drive pulley, the two hydraulic pump pulleys and the idler pulley (Fig. 0880). Fig. 0880 Fig. 0881 18.
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ENGINE 19. Install the deck drive belt. Ensure the deck drive belt is routed properly around the mower deck pulleys. Refer to belt routing decal 117-0486 (Fig. 0883). 21. Install the right hand mower belt cover (Fig. 0885). Fig. 0885 Fig. 0883 fig. 1 117-0486 IMG-0485a 22. 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. 0886). 20.
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ENGINE 23. Move the throttle lever to the “Fast” position (Fig. 0887). Fig. 0887 25. 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 cable clamp (Fig. 0889). DSC-4512a Fig. 0889 5 24. With the engine throttle control lever in the “Fast” position, pull the slack from the cable jacket and tighten the throttle cable clamp (Fig. 0888). Fig. 0888 5-14 IMG-0576a IMG-0579a 26.
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ENGINE 27. While holding the engine choke control lever in the “Open” position, pull the slack from the cable jacket and tighten the choke cable clamp (Fig. 0891). Fig. 0891 IMG-0584a 28. Position the muffler guard assembly and loosely install the four carriage bolts, two mounting guard brackets and nuts (Fig. 0892). 29. Make sure the muffler exhaust is centered in the muffler guard assembly, then tighten all four bolts and nuts (Fig. 0893). Fig. 0893 IMG-0589a 30.
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ENGINE 31. Install the battery ground wire and the wiring har ness ground wire to the engine block (Fig. 0895). Fig. 0895 IMG-0593a 32. Install the starter wire to the solenoid using a lock washer and nut (Fig. 0896). 33. Connect the white wire to the black magneto wire (Fig. 0897). Fig. 0897 IMG-0465a 34. Connect the pink wire to the green fuel solenoid wire (Fig. 0898). 5 Fig. 0896 5-16 IMG-0594a Fig.
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ENGINE 35. Connect the violet wire to the voltage regulator (Fig. 0899). Fig. 0899 37. Position the battery on the battery tray and 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. 0901). IMG-0462a 36. Secure the fuel line to the fuel pump using the hose clamp (Fig. 0900). Fig. 0901 IMG-0453a 38. Install the battery cover with the two hold down bolts and wing nuts (Fig. 0902). Fig.
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ENGINE 39. Turn the fuel shutoff valve to the “ON” position (Fig. 0903). Fig.
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HYDRAULIC DRIVE SYSTEM Pump Drive Belt Replacement 3. Remove the mower deck belt from around the clutch pulley (Fig. 0906). Pump Drive Belt Removal 1. Remove the RH belt cover (Fig. 0904). Fig. 0906 Fig. 0904 IMG-0796a 2. Using a spring tool, remove the mower deck idler spring from the spring anchor (Fig. 0905). IMG-0799a 4. Using a spring tool, remove the pump drive belt idler spring from the spring anchor (Fig. 0907).
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HYDRAULIC DRIVE SYSTEM 5. 2010 Only: The spring anchor is held in place by spring tension. Once the spring is removed, the anchor can be removed (Fig. 0908). Pump Drive Belt Installation 1. Position the pump drive belt around the engine, idler and pump pulleys (Fig. 0909). A Fig. 0908 IMG-0803b 6. Remove the pump drive belt from around the engine and pump pulleys. B E D C F Fig. 0909 A. Hydraulic pumps B. Idler pulley C. Clutch pulley 6 6-2 fig. 66 G012686 D. Clutch retainer E.
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HYDRAULIC DRIVE SYSTEM 2. 2010 Only: Position the spring anchor into the engine base (Fig. 0910). Fig. 0910 IMG-0803b 3. Using a spring tool, secure the pump drive belt idler spring to the anchor (Fig. 0911). 4. Place the mower deck belt around the clutch pulley (Fig. 0912). Fig. 0912 IMG-0799a 5. Using a spring removal tool, secure the mower deck idler spring to the spring anchor (Fig. 0913). Note: On 2009 machines, the idler spring is an chored to the back of the engine base. 6 Fig. 0913 Fig.
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HYDRAULIC DRIVE SYSTEM Pump Drive Belt Idler Replacement 6. Install the RH belt cover (Fig. 0914). Pump Drive Belt Idler Removal 1. Using a spring tool, remove the pump drive belt idler spring from the spring anchor (Fig. 0915). Note: On 2009 machines, the idler spring is an chored to the back of the engine base. Fig. 0914 IMG-0796a Fig. 0915 IMG-0801a 2. 2010 Only: The spring anchor is held in place by spring tension. Once the spring is removed, the anchor can be removed (Fig. 0916). 6 Fig.
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HYDRAULIC DRIVE SYSTEM 3. Remove the idler spring from the idler plate (Fig. 0917). Fig. 0917 5. Remove the bolt and nut securing the idler assembly to the engine base, then remove the assembly (Fig. 0919). IMG-0804a Fig. 0919 4. Remove the belt from around the pump and idler pulleys (Fig. 0918). IMG-0806a 6. Remove the large spacer, two friction composite washers, spacer and washer (Fig. 0920). 6 A B CD B E Fig. 0918 IMG-0805a Fig. 0920 A. Steel washer B.
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HYDRAULIC DRIVE SYSTEM 7. Remove the bolt, washers and nut securing the idler pulley to the idler plate (Fig. 0921). Pump Drive Belt Idler Installation 1. Secure the idler pulley to the idler plate using bolt, washers and nut (Fig. 0922). Note: The pulley hub needs to face the idler plate. A B B C E A B D Fig. 0921 A. Bolt B. Washer (2) C. Idler pulley B C IMG-0810a E D D. Idler plate E. Nut Fig. 0922 A. Bolt B. Washer (2) C. Idler pulley IMG-0810a D. Idler plate E. Nut 2.
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HYDRAULIC DRIVE SYSTEM 3. Place the large spacer, one friction composite wash er and bushing onto the pivot bolt (Fig. 0924). 5. Place one friction composite washer and steel wash er onto the pivot bolt (Fig. 0926). Fig. 0924 Fig. 0926 IMG-0818a 4. Place the idler assembly onto the pivot bolt (Fig. 0925). IMG-0820a 6. Secure the idler assembly with a nut (Fig. 0927). 6 Fig. 0927 Fig.
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HYDRAULIC DRIVE SYSTEM 7. Position the pump drive belt around the engine, idler and pump pulleys (Fig. 0928). 8. 2010 Only: Position the spring anchor into the engine base (Fig. 0929). A B E D C F Fig. 0928 A. Hydraulic pumps B. Idler pulley C. Clutch pulley Fig. 0929 IMG-0803b 9. Using a spring tool, secure the pump drive belt idler spring to the anchor (Fig. 0930). fig. 66 G012686 Note: On 2009 machines, the idler spring is an chored to the back of the engine plate. D. Clutch retainer E.
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HYDRAULIC DRIVE SYSTEM Left Hydraulic Pump Replacement 5. Remove the pump belt from around the pump pulleys (Fig. 0932). Note: Cleanliness is a key factor in a successful repair of any hydraulic system. 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.
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HYDRAULIC DRIVE SYSTEM 7. Remove the left pump pulley from the pump shaft (Fig. 0934). 9. Lower the machine to the ground. 10. Lower the operator cushion assembly and lay it on the platform. 11. Turn the fuel shut-off valve to the OFF position (Fig. 0936). Fig. 0934 IMG-9465a 8. Remove the key from the pump shaft keyway (Fig. 0935). Fig. 0936 IMG-9283a 6 Fig.
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HYDRAULIC DRIVE SYSTEM 12. Siphon the fuel from the fuel tank: Note: The only recommended way to remove fuel from the tank is with a siphon pump. 13. 2009 only: Remove the 90 degree fuel line vent fitting from the fuel tank (Fig. 0938). A. Clean around the fuel cap to prevent debris from getting into the fuel tank. B. Remove the fuel cap. C. Insert a siphon pump hose into the fuel tank (Fig. 0937). Fig. 0938 IMG-9299a 14. 2009 only: Remove the rubber grommet from the fuel tank (Fig. 0939). Fig.
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HYDRAULIC DRIVE SYSTEM 15. Slide the hose clamp back from the fuel tank fitting. Slide the fuel line off the fuel tank fitting (Fig. 0940). 17. 2009 only: Remove the fuel tank support bracket (Fig. 0942). Note: There may be some fuel leakage. Fig. 0942 Fig. 0940 IMG-9305a IMG-9292a 16. 2009 only: Remove the carriage bolt and nut secur ing the fuel tank support to the frame bracket (Fig. 0941). 18. 2010 only: Remove the fuel vent hose from the tank fitting (Fig. 0943). 6 Fig. 0943 Fig.
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HYDRAULIC DRIVE SYSTEM 19. 2010 only: Remove the four self-tapping screws securing the tank bracket to the control tower (Fig. 0944). 21. Remove the fuel tank from the machine (Fig. 0946). Fig. 0946 Fig. 0944 IMG-9307a IMG-0897a 20. Position the deck height adjustment to 1” (2.54cm) (Fig. 0945). 22. Remove the 3 push cable ties by driving them through the tower frame (Fig. 0947). 6 Fig. 0947 Fig.
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HYDRAULIC DRIVE SYSTEM 23. Loosen the bolt and nut securing the strike plate to the tower two full turns to gain access to the bolt below it (Fig. 0948). 25. Raise the deck to the transport position and secure the deck in position with straps (Fig. 0950). Fig. 0950 Fig. 0948 IMG-9339a IMG-9316a 24. Remove the bolt and nut securing the fuel line r-clamp to the frame (Fig. 0949). 26. Raise and support the machine. 27. 2009 only: Remove the lock nut from the lower end of the lift bar (Fig. 0951).
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HYDRAULIC DRIVE SYSTEM 28. 2010 only: Remove the nut securing the lift damp ener assembly to the base of the HOC lift bar (Fig. 0952). Fig. 0952 IMG-0901a 29. 2010 only: Remove the adjustment bolt and washer from the upper end of the lift assist springs on both sides of the control tower (Fig. 0953). 30. Remove the hairpin cotter from the top end of the parking brake rod. Slide the top end of the rod out of the handle (Fig. 0954). Fig.
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HYDRAULIC DRIVE SYSTEM 31. Remove the nuts from the 4 self-tapping screws securing the tower to the frame (Fig. 0956). Fig. 0956 IMG-9516a 32. Remove the 4 self-tapping screws securing the tower to the frame (Fig. 0957). 33. Remove the spring clip from the drive linkage mount (Fig. 0958). Fig. 0958 IMG-9350a 34. Remove the 2 traction control cables from the drive linkage mount slots (Fig. 0959). 6 Fig. 0957 6-16 IMG-9516a Fig.
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HYDRAULIC DRIVE SYSTEM 35. Lift the tower assembly up off the frame and lay it back as shown, taking care that the lift bar is routed out from under the right hand lift cylinder and the brake rod is routed out from under the control panel (Fig. 0960). A 37. 2009 only: Remove the hairpin cotter and washer from the front end of the left hand shifter link rod (Fig. 0962). B Fig. 0962 Fig. 0960 A. Lift rod IMG-9358a IMG-9352a B. Brake rod 38.
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HYDRAULIC DRIVE SYSTEM 39. Remove the hairpin cotter and washer from the rear end of the left hand shifter link rod (Fig. 0964). Fig. 0964 41. Serial range 290000210 - 290999999: Remove the front end of the left hand shifter link rod. There are 3 rollers located on the rear end of the left hand shifter link rod inside the control fork assembly. Slide the left hand roller off the rear end of the left hand shifter link rod (Fig. 0966). IMG-9361a 40.
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HYDRAULIC DRIVE SYSTEM 43. Serial range 290000210 - 290999999: Push down on the control fork assembly and remove the center roller from the pump control arm slot (Fig. 0968). Fig. 0968 IMG-9371a 44. 2010 only: Remove the LH shifter link and the 3 rollers located on the rear end of the shifter link inside of the control fork assembly (Fig. 0969). Shifter Link and Roller Configurations (Fig. 0970): A. 2009: Serial range 290000001-290000210; 3 rollers, all thin and same size B.
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HYDRAULIC DRIVE SYSTEM 46. Slide the hose clamp back from the fitting and re move the charge line (Fig. 0972). 48. Remove the 2 high pressure hoses (Fig. 0974). Fig. 0974 Fig. 0972 IMG-9383a IMG-9380a 47. Slide the hose clamp back from the fitting and re move the return line (Fig. 0973). 49. Remove the 2 carriage bolts, nuts, and washers securing the pump to the frame (Fig. 0975). 6 Fig. 0975 Fig.
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HYDRAULIC DRIVE SYSTEM 50. Remove the left hand pump (Fig. 0976). 52. If you are servicing the pump, refer to the HydroGear P Series Hydrostatic Pumps Service and Repair Manual (Form No. BLN 52503). 53. If you are installing a new pump, transfer all markings and all 4 fittings to the new pump (Fig. 0978). Fig. 0976 IMG-9387a 51. Remove the 2 bolts and nuts securing the pump control arm to the pump. Remove the pump control arm (Fig. 0977). Fig. 0978 IMG-9394a 6 Fig.
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HYDRAULIC DRIVE SYSTEM Left Hydraulic Pump Installation 3. Install 2 carriage bolts, nuts and washers securing the pump to the frame (Fig. 0981). 1. Position the Pump Control Arm to the pump linkage and install 2 bolts and nuts to secure (Fig. 0979). Fig. 0981 Fig. 0979 IMG-9386a IMG-9391a 2. Position the left hand pump into the frame. Align the mounting flange on the pump with the mounting holes in the frame (Fig. 0980). 4. Install the hoses/fittings to the fittings located on the pump.
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HYDRAULIC DRIVE SYSTEM b. Install the return line and secure with the hose clamp (Fig. 0983) Fig. 0983 c. IMG-9397a Install the charge line and secure with the hose clamp (Fig. 0984) Shifter Link and Roller Configurations (Fig. 0985): A. 2009: Serial range 290000001-290000210; 3 rollers, all thin and same size B. 2009: Serial range 290000211-290999999; 3 rollers, large center roller C. 2010: Serial range 310000001-310999999; 3 rollers, all large and same size A B Fig. 0985 C IMG-0941a 5.
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HYDRAULIC DRIVE SYSTEM 6. Serial range 290000210 - 290999999: Push down on the control fork assembly and slide the center roller into the slot of the pump control arm (Fig. 0987). Fig. 0987 8. Serial range 290000210 - 290999999: Slide the right hand roller onto the rear end of the left hand shifter link rod. Slide the rear end of the shifter link rod (with roller) through the control fork assembly following the Allen wrench through to capture the center roller on the shifter link rod (Fig. 0989).
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HYDRAULIC DRIVE SYSTEM 10. 2010 only: Slide 3 rollers onto the rear end of the left hand shifter link. Slide the rear end of the shifter link (with three rollers) into the control fork assembly (Fig. 0991). Fig. 0991 IMG-0936a 11. Slide a washer onto the rear end of the shifter link rod. Install a hairpin cotter to secure (Fig. 0992). 12. 2009 only: Slide the front end of the left hand shifter link rod into the left side of the dual shifter arm. Slide a washer onto the front end of the shifter link rod.
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HYDRAULIC DRIVE SYSTEM 14. 2010 only: Secure the shifter link to the shifter bracket with a bolt two washers and nut (Fig. 0995). Fig. 0995 16. Lift the tower assembly up and lower it onto the frame, taking care that the lift bar is routed between the right hand lift cylinder and the RH Lift Rod assembly. Also ensure the top end of the brake rod is routed under the control panel and up to the brake handle lever (Fig. 0997). IMG-0904a 15.
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HYDRAULIC DRIVE SYSTEM 18. Position the choke cable R-clamp onto the selftapping screw located on the left hand rear corner where the tower meets the main frame. Install a nut to secure (Fig. 0999). 20. Install 3 push cable ties through the holes located in the base of the tower (Fig. 1001). Fig. 1001 Fig. 0999 IMG-9524a PICT-8609a 19. Install 3 nuts to the remaining 3 self-tapping screws securing the tower to the frame (Fig. 1000). 6 Fig.
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HYDRAULIC DRIVE SYSTEM 21. Slide the top end of the brake rod into the brake handle. Install a hairpin cotter to secure the top end of the parking brake rod to the brake handle (Fig. 1002). 22. Position the fuel line r-clamp to the frame and install a bolt and nut to secure (Fig. 1004). Fig. 1004 Fig. 1002 IMG-9329a IMG-9347 Note: 2010 models use a nut to secure the upper end of the parking brake rod (Fig. 1003). 23.
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HYDRAULIC DRIVE SYSTEM 24. Slide the 2 traction control cables into the drive linkage mount slots (Fig. 1006). Fig. 1006 26. 2010 only: Secure the upper end of the lift assist springs to the control tower with the adjustment screw and washer (Fig. 1008). IMG-9351a Fig. 1008 25. Install the spring clip into the drive linkage mount (Fig. 1007). IMG-0902a 27. 2010 only: Adjust the gap between the upper spring bracket and the top of the spring nut insert (Fig. 1009). 6 A Fig. 1007 IMG-9350a Fig.
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HYDRAULIC DRIVE SYSTEM 28. 2009 only: Install a lock nut onto the lower end of the lift bar securing it to the height-of-cut pin (Fig. 1010). Fig. 1010 30. Lower the machine. 31. Remove the straps securing the mower deck (Fig. 1012). Lower the deck to the 1” (2.54cm) height-ofcut position (Fig. 1012 and Fig. 1013). IMG-9345a Fig. 1012 IMG-9339a Fig. 1013 IMG-9306a 29. 2010 only: Secure the lift bar to the HOC pin using the lift dampener and nut (Fig. 1011). 6 Fig.
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HYDRAULIC DRIVE SYSTEM 32. Position the fuel tank into the tower (Fig. 1014). Fig. 1014 34. 2009 only: Install a carriage bolt and nut securing the fuel tank support bracket to the frame bracket (Fig. 1016). IMG-9307a Fig. 1016 33. 2009 only: Position the fuel tank support bracket (Fig. 1015). IMG-9304a 35. 2010 only: Secure the tank bracket to the control tower using 4 self tapping screws (Fig. 1017). 6 Fig. 1015 IMG-9305a Fig.
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HYDRAULIC DRIVE SYSTEM 36. 2010 only: Install the vent hose to the tank fitting (Fig. 1018). Fig. 1018 DSC-4530a 37. Slide the fuel outlet line onto the fuel tank fitting. Position the hose clamp to secure (Fig. 1019). 38. 2009 only: Install the fuel tank vent fitting grommet into the fuel tank opening (Fig. 1020). Fig. 1020 IMG-9530a 39. 2009 only: Install the 90 degree fuel line vent fitting into the grommet (Fig. 1021). 6 Fig. 1019 6-32 IMG-9292a Fig.
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HYDRAULIC DRIVE SYSTEM 40. Install the operator cushion assembly to the tower. 45. Install a key into the pump shaft keyway (Fig. 1023). 41. Move the HOC lever to the transport level. 42. Move the platform to the up position. 43. Raise the machine to access the pump pulley. 44. Apply anti-seize compound to the left hand pump shaft (Fig. 1022). Fig. 1023 IMG-9463a 46. Apply thread locking compound to 2 pulley set screws (Fig. 1024). Fig. 1022 IMG-9460a 6 Fig.
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HYDRAULIC DRIVE SYSTEM 47. Slide the left pump pulley onto the pump shaft (Fig. 1025). Fig. 1025 IMG-9464a 48. Install the 2 left pump pulley set screws (Fig. 1026). 49. Route the pump belt around the pump pulleys (Fig. 1027). Fig. 1027 IMG-9543a 50. Using a spring tool (Toro Part No. 92-5771), install the pump idler extension spring (Fig. 1028). Note: 2010 machines have the end of the extension spring connected to an anchor, not the back side of the engine base. 6 Fig. 1026 IMG-9471a Fig.
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HYDRAULIC DRIVE SYSTEM 51. Lower the machine. Right Hydraulic Pump Replacement 52. Turn the fuel shut-off valve to the ON position (Fig. 1029). Note: Cleanliness is a key factor in a successful repair of any hydraulic system. 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.
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HYDRAULIC DRIVE SYSTEM 5. Remove the pump belt from around the pump pulleys (Fig. 1031). Fig. 1031 IMG-9274a 6. Remove the 2 set screws from the right pump pulley (Fig. 1032). 7. Remove the right pump pulley from the pump shaft (Fig. 1033). Fig. 1033 IMG-9480a 8. Remove the key from the pump shaft keyway (Fig. 1034). 6 Fig. 1032 6-36 IMG-9475a Fig.
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HYDRAULIC DRIVE SYSTEM 9. Lower the machine to the ground. 12. Siphon the fuel from the fuel tank: 10. Lower the operator cushion assembly and lay it on the platform. Note: The only way to remove fuel from the tank is with a siphon pump. 11. Turn the fuel shut-off valve to the OFF position (Fig. 1035). A. Clean around the fuel cap to prevent debris from getting into the fuel tank. B. Remove the fuel cap. C. Insert a siphon pump hose into the fuel tank (Fig. 1036). Fig. 1035 IMG-9283a Fig.
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HYDRAULIC DRIVE SYSTEM 13. 2009 only: Remove the 90 degree fuel line vent fitting from the fuel tank (Fig. 1037). 15. Slide the hose clamp back from the fuel tank fitting. Slide the fuel line off the fuel tank fitting (Fig. 1039). Note: There may be some fuel leakage. Fig. 1037 IMG-9299a Fig. 1039 14. 2009 only: Remove the rubber grommet from the fuel tank (Fig. 1038). IMG-9292a 16. 2009 only: Remove the carriage bolt and nut securing the fuel tank support to the frame bracket (Fig. 1040). 6 Fig.
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HYDRAULIC DRIVE SYSTEM 17. 2009 only: Remove the fuel tank support bracket (Fig. 1041). Fig. 1041 19. 2010 only: Remove the four self-tapping screws securing the tank bracket to the control tower (Fig. 1043). IMG-9305a Fig. 1043 18. 2010 only: Remove the fuel vent hose from the tank fitting (Fig. 1042). IMG-0897a 20. Position the deck height adjustment to 1” (2.54cm) (Fig. 1044). 6 Fig. 1042 IMG-0896a Fig.
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HYDRAULIC DRIVE SYSTEM 21. Remove the fuel tank from the machine (Fig. 1045). Fig. 1045 23. Loosen the nut and bolt securing the strike plate to the tower 2 full turns to gain access to the bolt below it (Fig. 1047). IMG-9307a Fig. 1047 22. Remove the 3 push cable ties by driving them through the tower frame (Fig. 1046). IMG-9316a 24. Remove the bolt and nut securing the fuel line r-clamp to the frame (Fig. 1048). 6 Fig. 1046 IMG-9314a Fig.
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HYDRAULIC DRIVE SYSTEM 25. Raise the deck to the transport position and secure the deck in position with straps (Fig. 1049). Fig. 1049 28. 2010 only: Remove the nut securing the lift damp ener assembly to the base of the HOC lift bar (Fig. 1051). IMG-9339a Fig. 1051 26. Raise and support the machine. 27. 2009 only: Remove the lock nut from the lower end of the lift bar (Fig. 1050). IMG-0901a 29.
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HYDRAULIC DRIVE SYSTEM 30. Remove the hairpin cotter from the top end of the parking brake rod. Slide the top end of the rod out of the handle (Fig. 1053). 31. Remove the nuts from the 4 self-tapping screws securing the tower to the frame (Fig. 1055). Fig. 1055 Fig. 1053 IMG-9516a IMG-9347a Note: 2010 models use a nut to secure the upper end of the parking brake rod (Fig. 1054). 32. Remove the 4 self-tapping screws securing the tower to the frame (Fig. 1056). 6 Fig. 1056 Fig.
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HYDRAULIC DRIVE SYSTEM 33. Remove the spring clip from the drive linkage mount (Fig. 1057). 35. Lift the tower assembly up off the frame and lay it back as shown, taking care that the lift bar is routed out from under the right hand lift cylinder and the brake rod is routed out from under the control panel (Fig. 1059). A Fig. 1057 B IMG-9350a 34. Remove the 2 traction control cables from the drive linkage mount slots (Fig. 1058). Fig. 1059 A. Lift bar IMG-9352a B. Brake rod 36.
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HYDRAULIC DRIVE SYSTEM 37. 2009 only: Remove the hairpin cotter and washer from the front end of the right hand shifter link rod and slide the front end of the rod out of the shifter arm (Fig. 1061). 39. Remove the hairpin cotter and washer from the rear end of the right hand shifter link rod (Fig. 1063). Fig. 1063 Fig. 1061 IMG-9424a IMG-9422a 38. 2010 only: Remove the bolt, nut, washers and spacer securing the RH shifter link to the shifter bracket (Fig. 1062). 40.
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HYDRAULIC DRIVE SYSTEM 41. Serial range 290000210 - 290999999: There are 3 rollers located on the rear end of the right hand shifter link rod inside the control fork assembly and pump control arm. Slide the left hand roller off the rear end of the right hand shifter link rod (Fig. 1065). 43. Serial range 290000210 - 290999999: Push down on the control fork assembly and remove the center roller from the pump control arm slot (Fig. 1067). Fig. 1067 Fig. 1065 IMG-9436a IMG-9430a 42.
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HYDRAULIC DRIVE SYSTEM Shifter Link and Roller Configurations (Fig. 1069): A. 2009: Serial range 290000001-290000210; 3 rollers, all thin and same size B. 2009: Serial range 290000211-290999999; 3 rollers, large center roller C. 2010: Serial range 310000001-310999999; 3 rollers, all large and same size A B Fig. 1069 6 46. Slide the hose clamp back from the fitting and remove the return line (Fig. 1071). Fig. 1071 C IMG-0941a IMG-9442a 47.
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HYDRAULIC DRIVE SYSTEM 48. Remove both high pressure hoses (Fig. 1073). Fig. 1073 IMG-9448a 49. Remove the 2 carriage bolts, nuts, and washers securing the pump to the frame (Fig. 1074). 50. Remove the right hand pump (Fig. 1075). Fig. 1075 IMG-9483a 51. Remove the 2 bolts and nuts securing the pump control arm to the pump. Remove the pump control arm (Fig. 1076). 6 Fig. 1074 IMG-9457a Fig.
PAGE 307
HYDRAULIC DRIVE SYSTEM 52. If you are servicing the pump, refer to the HydroGear P Series Hydrostatic Pumps Service and Repair Manual (Form No. BLN 52503). 53. If you are installing a new pump, transfer all markings and all 4 fittings to the new pump (Fig. 1077). Right Hydraulic Pump Installation 1. Position the Pump Control Arm to the pump linkage and install 2 bolts and nuts to secure (Fig. 1078). Fig. 1078 Fig. 1077 IMG-9391a PICT-8870a 2. Position the right hand pump into the frame.
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HYDRAULIC DRIVE SYSTEM 3. Install 2 carriage bolts, nuts and washers securing the pump to the frame (Fig. 1080). Fig. 1080 b. Install the charge line and secure with the hose clamp (Fig. 1082). Fig. 1082 IMG-9457a 4. Install the hoses to the fittings located on the pump. Ensure the markings on the hoses match the markings on the fittings and pump: a. Install the high pressure hoses (Fig. 1081). c. IMG-9446a Install the return line and secure with the hose clamp (Fig. 1083). 6 Fig. 1083 Fig.
PAGE 309
HYDRAULIC DRIVE SYSTEM Shifter Link and Roller Configurations (Fig. 1084): A. 2009: Serial range 290000001-290000210; 3 rollers, all thin and same size B. 2009: Serial range 290000211-290999999; 3 rollers, large center roller C. 2010: Serial range 310000001-310999999; 3 rollers, all large and same size A B Fig. 1084 6 C 6. Serial range 290000210 - 290999999: Push down on the control fork assembly and slide the center roller into the slot of the pump control arm (Fig. 1086). Fig. 1086 IMG-0941a 5.
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HYDRAULIC DRIVE SYSTEM 8. Serial range 290000210 - 290999999: Slide the right hand roller onto the rear end of the right hand shifter link rod. Slide the rear end of the shifter link rod (with roller) through the control fork assembly following the Allen wrench through to capture the center roller on the shifter link rod (Fig. 1088). 10. 2010 only: Slide 3 rollers onto the rear end of the left hand shifter link.
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HYDRAULIC DRIVE SYSTEM 12. 2009 only: Slide the front end of the right hand shifter link rod into the left side of the dual shifter arm. Slide a washer onto the front end of the shifter link rod. Install a hairpin to secure (Fig. 1092). 14. 2010 only: Secure the shifter link to the shifter bracket with a bolt two washers and nut (Fig. 1094). Fig. 1094 Fig. 1092 IMG-0905a IMG-9423a 13. 2010 only: Place a spacer into the front end of the shifter link (Fig. 1093). 15.
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HYDRAULIC DRIVE SYSTEM 16. Lift the tower assembly up and lower it onto the frame, taking care that the lift bar is routed between the right hand lift cylinder and the RH Lift Rod assembly. Also ensure the top end of the brake rod is routed under the control panel and up to the brake handle lever (Fig. 1096). 18. Position the choke cable R-clamp onto the selftapping screw located on the left hand rear corner where the tower meets the main frame. Install a nut to secure (Fig. 1098). Fig. 1098 Fig.
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HYDRAULIC DRIVE SYSTEM 20. Install 3 push cable ties through the holes located in the base of the tower (Fig. 1100). Fig. 1100 21. Slide the top end of the brake rod into the brake handle. Install a hairpin cotter to secure the top end of the parking brake rod to the brake handle (Fig. 1101). IMG-9524a Fig. 1101 IMG-9347a Note: 2010 models use a nut to secure the upper end of the parking brake rod (Fig. 1102). 6 Fig.
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HYDRAULIC DRIVE SYSTEM 22. Position the fuel line r-clamp to the frame and install a bolt and nut to secure (Fig. 1103). Fig. 1103 IMG-9329a 23. Tighten the bolt and nut securing the strike plate to the tower (Fig. 1104). 24. Slide the 2 traction control cables into the drive linkage mount slots (Fig. 1105). Fig. 1105 IMG-9351a 25. Install the spring clip into the drive linkage mount (Fig. 1106). 6 Fig. 1104 Toro GrandStand Service Manual IMG-9316a Fig.
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HYDRAULIC DRIVE SYSTEM 26. 2009 only: Install a lock nut onto the lower end of the lift bar securing it to the height-of-cut pin (Fig. 1107). 28. 2010 only: Adjust the gap between the upper spring bracket and the top of the spring nut insert (Fig. 1109). A Fig. 1107 IMG-9345a Fig. 1109 IMG-0902a A. 1.5” (3.8cm) for 60” decks 2” (5cm) for 48” & 52” decks 27. 2010 only: Secure the upper end of the lift assist springs to the control tower with the adjustment screw and washer (Fig. 1108). 6 Fig.
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HYDRAULIC DRIVE SYSTEM 29. Lower the machine. 31. Position the fuel tank into the tower (Fig. 1112). 30. Remove the straps securing the mower deck (Fig. 1110). Lower the deck to the 1” (2.54cm) height-ofcut position (Fig. 1111). Fig. 1112 Fig. 1110 IMG-9339a IMG-9307a 32. 2009 only: Position the fuel tank support bracket (Fig. 1113). 6 Fig. 1111 Toro GrandStand Service Manual IMG-9306a Fig.
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HYDRAULIC DRIVE SYSTEM 33. 2009 only: Install a carriage bolt and nut securing the fuel tank support bracket to the frame bracket (Fig. 1114). 35. 2010 only: Install the vent hose onto the tank fitting (Fig. 1116). Fig. 1116 Fig. 1114 DSC-4530a IMG-9304a 34. 2010 only: Secure the tank bracket to the control tower using 4 self tapping screws (Fig. 1115). 36. Slide the fuel outlet line onto the fuel tank fitting. Position the hose clamp to secure (Fig. 1117). 6 Fig. 1117 Fig.
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HYDRAULIC DRIVE SYSTEM 37. 2009 only: Install the fuel tank vent fitting grommet into the fuel tank opening (Fig. 1118). 39. Install the operator cushion assembly to the tower. 40. Move the HOC lever to the transport level. 41. Move the platform to the up position. 42. Raise the machine to access the pump pulley. 43. Apply anti-seize compound to the right hand pump shaft (Fig. 1120). Fig. 1118 IMG-9530a 38. 2009 only: Install the 90 degree fuel line vent fitting into the grommet (Fig. 1119). Fig.
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HYDRAULIC DRIVE SYSTEM 45. Slide the right hand pump pulley onto pump shaft (Fig. 1122). 47. Install the 2 pump pulley set screws (Fig. 1124). Fig. 1124 Fig. 1122 IMG-9475a IMG-9540a 46. Apply thread locking compound to the 2 pump pulley set screws (Fig. 1123). 48. Route the pump belt around the pump pulleys (Fig. 1125). 6 Fig. 1125 Fig.
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HYDRAULIC DRIVE SYSTEM 49. Using a spring tool (Toro Part No. 92-5771), install the pump idler extension spring (Fig. 1126). Note: 2010 machines have the end of the extension spring connected to an anchor, not the back side of the engine base. 50. Lower the machine. 51. Turn the fuel shut-off valve to the ON position (Fig. 1127). Fig. 1127 Fig. 1126 IMG-9284a IMG-9545a 52. Refill the hydraulic oil as needed. Remove air from the hydraulic system.
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HYDRAULIC DRIVE SYSTEM Wheel Motor Replacement 5. Loosen the four wheel lug nuts (Fig. 1129). The following procedure was done on the left hand wheel motor. The procedure is the same for the right hand wheel motor. Note: Cleanliness is a key factor in a successful repair of any hydraulic system. 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.
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HYDRAULIC DRIVE SYSTEM 7. Support the machine with two jackstands just behind the deck (Fig. 1131). 9. Remove lug nuts (Fig. 1133). Fig. 1133 Fig. 1131 IMG-9917a IMG-9909a 10. Remove the wheel (Fig. 1134). 8. Release the parking brake (Fig. 1132). 6 Fig. 1134 Fig.
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HYDRAULIC DRIVE SYSTEM 11. Remove the wheel motor axle nut (Fig. 1135). Fig. 1135 13. Advance the forcing screw through the hub until it firmly contacts the wheel motor shaft (Fig. 1137). IMG-9921a Fig. 1137 IMG-9929a 12. Install a hub puller (Toro p/n: TOR6006) onto the wheel studs. Note: The lug nuts should be installed backwards so the flat side is against the puller (Fig. 1136). 6 Fig.
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HYDRAULIC DRIVE SYSTEM 14. Tighten the lug nuts evenly (approximately 1/4 to 1/2 turn at a time) until the hub pops off the wheel motor shaft (Fig. 1138 and Fig. 1139). Fig. 1138 15. Remove the hub puller from the hub. 16. Remove the woodruff key from the keyway (Fig. 1140). IMG-9932a Fig. 1140 IMG-9938a 17. Thoroughly clean the area around the hydraulic fittings to prevent debris from entering the system. 18. Mark the hose and wheel motor fittings to identify the upper and lower hoses (Fig. 1141).
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HYDRAULIC DRIVE SYSTEM 19. Position a drain pan under the wheel motor (Fig. 1142). Fig. 1142 IMG-9944a 20. Disconnect both hydraulic hoses from the wheel motor (Fig. 1143). 21. Cap the hose ends and wheel motor fittings so that debris does not enter the system (Fig. 1144). Fig. 1144 IMG-9885a 22. Loosen the jam nuts on the upper wheel motor fitting (Fig. 1145). 6 Fig. 1143 6-66 IMG-9879a Fig.
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HYDRAULIC DRIVE SYSTEM 23. Remove the upper fitting from the wheel motor. Cap the wheel motor port so that debris does not enter the system. (Fig. 1146). Fig. 1146 IMG-9897a 24. Repeat steps 22 and 23 to remove the lower wheel motor fitting. 26. Remove the upper carriage bolt and nut from the center motor mount closest to the wheel motor being removed (Fig. 1148). Fig. 1148 IMG-9949a 27. Loosen the remaining nut until it is flush with the end of the carriage bolt (Fig. 1149). 25.
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HYDRAULIC DRIVE SYSTEM 28. 2009 only: While supporting the motor mount assembly, remove the two nuts (leave the bolts) attaching the motor mount assembly to the frame assembly (Fig. 1150). Fig. 1150 IMG-9956a Note: 2010 models use bolts, spacers and nuts to secure the motor mount to the frame (Fig. 1151). 29. Lower the motor mount assembly just enough to allow the bolts to clear the holes in the frame assembly and then remove the motor mount assembly out to the side of the machine (Fig. 1152). Fig.
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HYDRAULIC DRIVE SYSTEM Wheel Motor Installation 31. Remove the wheel motor (Fig. 1154). 1. Position the wheel motor into the motor mount assembly (Fig. 1155). Fig. 1154 IMG-9969a 32. To service the wheel motor, refer to the Parker/Ross Wheel Motor Service Manual (Toro Form No. HY131521-M2/US). Fig. 1155 IMG-9969a 2. Loosely install 4 bolts securing the wheel motor to the motor mount (Fig. 1156). 6 Fig.
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HYDRAULIC DRIVE SYSTEM 3. Slide the wheel motor mount assembly in from the side of the machine and raise it into position (Fig. 1157). Fig. 1157 IMG-9961a 4. While supporting the motor mount assembly, loosely install two nuts onto the bolts securing it to the frame (Fig. 1158). Fig. 1158 IMG-9979a Note: 2010 models use bolts, spacers and nuts to secure the motor mount to the frame (Fig. 1159). 6 Fig.
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HYDRAULIC DRIVE SYSTEM 5. Loosely install 3 carriage bolts and nuts fastening the center motor mount to the motor mount assemblies (Fig. 1160). 7. Tighten the two nuts attaching the motor mount assembly to the frame assembly (Fig. 1162). Fig. 1162 Fig. 1160 IMG-9989a IMG-9986a 6. Tighten the 4 nuts fastening the center motor mount to the motor mount assemblies (Fig. 1161). 8. Tighten the four bolts securing the wheel motor to the motor mount assembly (Fig. 1163). 6 Fig. 1163 Fig.
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HYDRAULIC DRIVE SYSTEM 9. Install the two fittings into the wheel motor ports (Fig. 1164). Fig. 1164 11. Install both hydraulic hoses to the wheel motor. Make sure the hoses are routed to the correct fitting (marked earlier) (Fig. 1166). IMG-9999a Fig. 1166 10. Position the fittings as shown and tighten the jam nuts (Fig. 1165). IMG-9877a 12. Install the woodruff key into the wheel motor shaft keyway (Fig. 1167). 6 Fig. 1165 IMG-9892a Fig.
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HYDRAULIC DRIVE SYSTEM 13. Install the wheel hub onto the wheel motor shaft (Fig. 1168). 15. Loosely install a wheel motor nut (Fig. 1170). Fig. 1170 Fig. 1168 IMG-0013a IMG-0008a 14. Apply thread locking compound to the threads on the wheel motor shaft (Fig. 1169). 16. Slide the wheel onto the wheel hub (Fig. 1171). 6 Fig. 1171 Fig.
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HYDRAULIC DRIVE SYSTEM 19. Apply the parking brake (Fig. 1174). 17. Loosely install 4 lug nuts (Fig. 1172). Fig. 1172 IMG-0015a 18. Ensure wheel motor hoses are not in contact with tire (Fig. 1173). Fig. 1174 PICT-8610a 20. Remove the two jackstands and lower the machine to the floor (Fig. 1175). 6 Fig. 1173 6-74 IMG-0031a Fig.
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HYDRAULIC DRIVE SYSTEM 21. Torque the four wheel lug nuts to 85 + 5 ft-lbs. (115 + 6.8 Nm) (Fig. 1176). Reservoir Tank Replacement Note: Cleanliness is a key factor in a successful repair of any hydraulic system. 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.
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HYDRAULIC DRIVE SYSTEM 2. Move the hose clamp from the tank fitting so the low pressure return hose can be removed (Fig. 1179). 4. Move the hose clamp from the filter fitting so the hose can be removed (Fig. 1181). Note: Due to the short length, remove the hose from the filter fitting as the tank is removed. Fig. 1179 IMG-0822a 3. Position a drain pan under the reservoir tank. Re move the low pressure return line from the tank fitting and drain the fluid into the pan (Fig. 1180). Fig.
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HYDRAULIC DRIVE SYSTEM 6. While lifting the tank from the bracket, slide the suction line off the filter fitting (Fig. 1183). Fig. 1183 IMG-0836a 7. Move the hose clamp from the tank fitting so the low pressure return hose can be removed (Fig. 1184). 8. Remove the low pressure hose from the tank fitting (Fig. 1185). Fig. 1185 IMG-0840a 9. Loosen the jam nut securing the position of the 45 degree fitting (Fig. 1186). 6 Fig. 1184 Toro GrandStand Service Manual IMG-0838a Fig.
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HYDRAULIC DRIVE SYSTEM 10. Remove the fitting from the reservoir tank (Fig. 1187). Fig. 1187 IMG-0843a 11. Remove the o-ring from the fitting (Fig. 1188). 12. Loosen the jam nut securing the position of the 90 degree fitting (Fig. 1189). Fig. 1189 IMG-0844a 13. Remove the fitting from the reservoir tank (Fig. 1190). 6 Fig. 1188 IMG-0854a Fig.
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HYDRAULIC DRIVE SYSTEM 14. Remove the o-ring from the fitting (Fig. 1191). Reservoir Tank Installation 1. Install new o-rings onto the reservoir fittings (Fig. 1192). Fig. 1191 IMG-0855a Fig. 1192 IMG-0883a 2. Install the 90 degree fitting into the base of the reservoir (Fig. 1193). 6 Fig.
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HYDRAULIC DRIVE SYSTEM 3. Orient the fitting so it is pointing straight rearward. Secure the position with the fitting jam nut (Fig. 1194). 5. Orient the fitting so it is at a 1 o’clock position. Se cure the position with the fitting jam nut (Fig. 1196). Fig. 1196 Fig. 1194 IMG-0888a IMG-0886a 4. Install the 45 degree fitting into the base of the reservoir (Fig. 1195). 6. Install the low pressure suction line to the 90 degree fitting and secure with hose clamp (Fig. 1197). 6 Fig. 1197 Fig.
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HYDRAULIC DRIVE SYSTEM 7. Position the reservoir into the reservoir bracket. While lowering the reservoir into place, install the low pressure hose onto the filter mount bracket fitting (Fig. 1198). 9. Position the two spacers between the reservoir mounting surface and the reservoir bracket (Fig. 1200). Fig. 1200 Fig. 1198 IMG-0891a IMG-0836a 8. Secure the hose to the fitting with the hose clamp (Fig. 1199). 10.
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HYDRAULIC DRIVE SYSTEM 11. Install the low pressure return line to the 45 degree fitting and secure with the hose clamp (Fig. 1202). 13. Fill the reservoir to the “COLD” fluid level (Fig. 1204). DA C B Fig. 1202 IMG-0892a Fig. 1204 A. Cap B. Baffle fig. 68 G001045 C. Cold fluid level-full D. Hot fluid level-full 12. Secure the hose to the reservoir bracket using the “R” clamp, bolt, washer and nut (Fig. 1203). 14. Bleed the hydraulic system. See “Bleeding the Hydraulic System” on page 6-95.
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HYDRAULIC DRIVE SYSTEM Hydraulic Filter Mount Replacement 2. Move the hose clamp from the tank fitting so the low pressure return hose can be removed (Fig. 1206). Note: Cleanliness is a key factor in a successful repair of any hydraulic system. 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.
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HYDRAULIC DRIVE SYSTEM 4. Move the hose clamp from the filter fitting so the hose can be removed (Fig. 1208). 6. While lifting the tank from the bracket, slide the suction line off the filter fitting (Fig. 1210). Note: Due to the short length, remove the hose from the filter fitting as the tank is removed. Fig. 1210 Fig. 1208 IMG-0832a IMG-0836a 7. Remove the hydraulic filter (Fig. 1211). 5. Remove the two sets of bolts, nuts, washers and spacers securing the reservoir tank to the tank bracket (Fig.
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HYDRAULIC DRIVE SYSTEM 8. Move the hose clamp from the filter mount fitting so the hose can be removed (Fig. 1212). Fig. 1212 IMG-0857a 9. Remove the low pressure suction line from the filter mount fitting (Fig. 1213). 10. Remove the two bolts and washers securing the filter mount to the tank bracket (Fig. 1214). Fig. 1214 IMG-0879a 11. Loosen the jam nuts securing the position of the 90 degree fittings (Fig. 1215). 6 Fig. 1213 Toro GrandStand Service Manual IMG-0859a Fig.
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HYDRAULIC DRIVE SYSTEM 12. Remove the fittings from the filter mount (Fig. 1216). Hydraulic Filter Mount Installation 1. Install new o-rings onto the fittings (Fig. 1218). Fig. 1216 IMG-0867a Fig. 1218 IMG-0869a 13. Remove the o-rings from the fittings (Fig. 1217). 2. Install a fitting into the filter mount “OUT” port (Fig. 1219). 6 Fig. 1217 IMG-0866a Fig.
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HYDRAULIC DRIVE SYSTEM 3. Orient the fitting so it is pointing rearward, towards the filter mounting face. Secure the position with the fitting jam nut (Fig. 1220). 5. Orient the fitting so it is pointing forward, away from the filter mounting face. Secure the position with the fitting jam nut (Fig. 1222). Fig. 1220 Fig. 1222 IMG-0875a 4. Install a fitting onto the filter mount “IN” port (Fig. 1221). IMG-0877a 6. Position the filter mount so the “FLOW” arrow is pointing up (Fig. 1223). 6 Fig.
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HYDRAULIC DRIVE SYSTEM 7. Secure the filter mount to the hydraulic reservoir using two bolts and washers (Fig. 1224). Fig. 1224 IMG-0879a 8. Install the low pressure suction hose to the filter mount fitting and secure with hose clamp (Fig. 1225). 9. Apply a thin layer of oil to the filter’s rubber seal (Fig. 1226). Fig. 1226 IMG-0881a 10. Install the oil filter to the filter mount (Fig. 1227). 6 Fig. 1227 Fig.
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HYDRAULIC DRIVE SYSTEM 11. Position the reservoir into the reservoir bracket. While lowering the reservoir into place, install the low pressure hose onto the filter mount bracket fitting (Fig. 1228). 13. Position the two spacers between the reservoir mounting surface and the reservoir bracket (Fig. 1230). Fig. 1230 Fig. 1228 IMG-0891a IMG-0836a 12. Secure the hose to the fitting with the hose clamp (Fig. 1229). 14.
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HYDRAULIC DRIVE SYSTEM 15. Install the low pressure return line to the 45 degree fitting and secure with the hose clamp (Fig. 1232). 17. Fill the reservoir to the “COLD” fluid level (Fig. 1234). DA C B Fig. 1232 Fig. 1234 IMG-0892a A. Cap B. Baffle 16. Secure the hose to the reservoir bracket using the “R” clamp, bolt, washer and nut (Fig. 1233). fig. 68 G001045 C. Cold fluid level-full D. Hot fluid level-full 18. Bleed the hydraulic system. See “Bleeding the Hydraulic System” on page 6-95.
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HYDRAULIC DRIVE SYSTEM Hydraulic Testing 1. Apply the parking brake. Note: Cleanliness is a key factor in a successful repair of any hydraulic system. 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. 2. Loosen the 4 lug nuts.
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HYDRAULIC DRIVE SYSTEM 6. Thoroughly clean the area around the hydraulic fittings to prevent debris from entering the system. 10. Cap the wheel motor fittings so debris does not enter the system. 7. Mark the hoses and corresponding wheel motor fitting ports to ensure the hoses are connected to their original locations (Fig. 1236). 11. Attach the hydraulic hoses to the flow test gauge (Fig. 1238). Fig. 1236 IMG-0911a Fig. 1238 8. Position a drain pain under the wheel motor. 9.
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HYDRAULIC DRIVE SYSTEM 13. Run the machine for 2 minutes in forward (no load) to purge air from the system. 14. Run the machine at full throttle (no load). Verify the RPM with a tachometer: 3200 + 150 RPM. Do not exceed 3600 RPM. 16. Record the flow reading from the bi-directional flow meter. Make a second flow reading at 1100 PSI and record that reading (Fig. 1241). Subtract the first reading from the second reading and determine if it is an acceptable GPM. 15.
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HYDRAULIC DRIVE SYSTEM 17. After all necessary repairs have been made, reconnect the hydraulic hoses to the wheel motor fittings. 18. Slide the wheel and tire assembly onto the hub and snug fit the 4 lug nuts on the wheel hub studs. 19. Lower the machine so the rear tires are resting on the ground. 20. Apply the parking brake. 21. Tighten and torque the 4 lug nuts to 85 + 8 ft-lbs. (115 + 10.8 Nm) (Fig. 1242). 22. Fill the reservoir with hydraulic fluid as specified.
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HYDRAULIC DRIVE SYSTEM Bleeding the Hydraulic System 1. Disengage the PTO. Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that air is purged from the system. 2. Stop the engine and wait for all moving parts to stop before leaving the operating position. These purge procedures should be implemented anytime a hydrostatic system has been opened for maintenance or any additional oil has been added to the system.
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HYDRAULIC DRIVE SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK.
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MOWER DECK Mower Deck Belt Replacement Mower Deck Belt Installation Mower Deck Belt Removal 1. Install the deck drive belt. Ensure the deck drive belt is routed properly around the mower deck and clutch pulleys. Refer to belt routing decal 117-0486 (Fig. 1246). 1. Turn the ignition off and remove the key. 2. Move the mower deck to the 1” (25mm) HOC. 3. Remove the RH and LH belt covers (Fig. 1244). Fig. 1244 IMG-0485a Fig. 1246 4.
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MOWER DECK 3. Verify the idler pulley spring is stretched to 5-3/4” (14.6 cm) from hook to hook (Fig. 1248). 4. If the idler pulley spring requires adjustment, loosen the front idler pulley by loosening the nut (Fig. 1248). 5. Using a ratchet in the front idler arm, tighten the idler pulley until the spring is stretched to 5-3/4” (14.6 cm) from hook to hook (Fig. 1248). B C A 6. Secure the front idler arm by tightening the nut (Fig. 1248). 7. Install the RH and LH mower belt covers (Fig. 1249).
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MOWER DECK Spindle Replacement & Service 6. Loosen the front idler by loosening the nut (Fig. 1251). Mower Deck Spindle Removal 1. Disengage the PTO and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Engage the parking brake. 4. Lower the mower deck to the lowest height-of-cut position. 5. Remove the belt covers (Fig. 1250). Fig. 1251 IMG-9550a 7. Remove the mower deck belt from the mower deck pulleys (Fig.
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MOWER DECK 8. Raise the mower deck to the transport position (highest height-of-cut) and pin it to secure (Fig. 1253). 10. Remove the battery hold down bolt (Fig. 1255). Fig. 1255 Fig. 1253 IMG-9570a IMG-9557a 9. Remove the wingnut from the battery hold down bolt (Fig. 1254). 11. Repeat steps 8 and 9 to remove the battery hold down on the other side of the battery cover. 12. Remove the battery cover (Fig. 1256). 7 Fig. 1254 7-4 IMG-9568a Fig.
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MOWER DECK 13. Disconnect the negative battery cable from the negative (-) battery terminal (Fig. 1257). 15. Remove the battery (Fig. 1259). Fig. 1259 Fig. 1257 IMG-9585a IMG-9575a 14. Slide the red boot off the positive (red) battery terminal. Remove the positive (red) battery cable from the positive (+) battery terminal (Fig. 1258). 16. Clean around the hydraulic tank cap to prevent debris from getting into the tank. 17.
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MOWER DECK 18. Siphon the fuel from the fuel tank. Note: The only recommended way to remove fuel from the tank is to use a siphon pump. 19. With two people, raise the front of the mower so it rests on the drive tires and the platform (Fig. 1262). A. Clean around the fuel cap to prevent debris from getting into the fuel tank. B. Remove the fuel cap. C. Insert a siphon pump hose into the fuel tank (Fig. 1261). Fig. 1262 IMG-9752a 20. Block the mower deck blade (Fig. 1263). Fig. 1261 IMG-9592a D.
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MOWER DECK 21. Remove the 3 bolts securing the pulley to the spin dle pulley hub (Fig. 1264). Fig. 1264 23. Block the mower deck blade and remove the blade bolt, washer and blade from the spindle (Fig. 1266 and Fig. 1267). IMG-9765a Fig. 1266 IMG-9775a Fig. 1267 IMG-9779a 22. Remove the pulley from the spindle (Fig. 1265). Fig.
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MOWER DECK 24. Remove the 6 bolts and nuts securing the spindle housing to the mower deck (Fig. 1268). Fig. 1268 IMG-9780a Note: 2010 machines have the spindle housing mounted to the top of the deck. From the underside of the deck, remove the 6 nuts securing the spindle housing (Fig. 1269). 25. Remove the spindle assembly from the mower deck (Fig. 1270). Fig. 1270 IMG-9816a 26. To service the spindle, refer to “Spindle Service” on page 7-14. 7 Fig.
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MOWER DECK Mower Deck Spindle Installation 1. Position the spindle assembly to the deck. Orient the spindle so that the grease fitting is easily accessible (Fig. 1271). Note: 2010 machines have the spindle housing mounted to the top of the deck. From the underside of the deck, install the 6 nuts securing the spindle housing (Fig. 1273). Fig. 1273 Fig. 1271 IMG-0794a IMG-9822a 2. Install 6 bolts and nuts to secure the spindle assembly to the mower deck (Fig. 1272). 3.
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MOWER DECK 4. Slide the blade bolt through the blade (Fig. 1275). Fig. 1275 6. Block the blade and torque the blade bolt to 85 110 ft-lbs. (115 - 149 Nm) (Fig. 1277). IMG-9827a Fig. 1277 5. Install the blade, blade bolt and washer onto the spindle assembly (Fig. 1276). 7 Fig. 1276 7. Position the pulley on the spindle housing assembly (Fig. 1278). IMG-9830a Fig.
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MOWER DECK 8. With the blade blocked, secure the belt pulley to the top of the spindle housing assembly with the 3 bolts (Fig. 1279). Fig. 1279 10. With two people, lower the front of the mower to the ground. 11. Position the battery onto the battery tray (Fig. 1281). IMG-9770a Fig. 1281 9. Grease the spindle assembly with No. 2 general purpose lithium base or molybdenum base grease until grease begins to ooze out of the bearings. (Fig. 1280). IMG-9660a 12.
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MOWER DECK 13. Install the negative battery cable to the negative (-) battery terminal (Fig. 1283). Fig. 1283 IMG-9665a 14. Position the battery cover over the battery (Fig. 1284). 7 Fig. 1284 15. Install the two battery hold down bolts and wing nuts to secure (Fig. 1285). Fig. 1285 16. Remove the hydraulic tank cap and remove the piece of plastic over the tank opening. Reinstall the hydraulic cap (Fig. 1286). IMG-9667a Fig.
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MOWER DECK 17. Lower the mower deck to the lowest height-of-cut (Fig. 1287). 19. Using a ratchet in the idler arm, tension the arm until the spring is stretched 5-3/4” (14.6cm) from hook to hook, then tighten the nut (Fig. 1289): B C A Fig. 1287 IMG-9676a D EF 18. Route the mower deck belt around the mower deck pulleys and clutch pulley. Refer to the belt routing decal (Fig. 1288): Fig. 1289 A. 5-3/4” (14.6cm) from hook to hook B. Spring C. Spring loaded idler fig. 61 G009460 D. Ratchet E.
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MOWER DECK 20. Install the LH and RH belt covers onto the mower deck (Fig. 1290). Spindle Service 1. Remove the hex nut from the end of the spindle shaft (Fig. 1291). Fig. 1290 IMG-9548a Fig. 1291 22. Add fuel to the fuel tank. IMG-9789a 2. Remove the washer from the end of the spindle shaft (Fig. 1292). 7 Fig.
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MOWER DECK 3. Remove the pulley hub from the end of the spindle shaft (Fig. 1293). Fig. 1293 IMG-9791a 4. Remove the square key from the spindle shaft keyway (Fig. 1294). Fig. 1294 Toro GrandStand Service Manual IMG-9792a 5. Remove the bearing shield from the spindle assembly (Fig. 1295). Fig. 1295 IMG-9793a 6. Remove the thrust washer from the spindle assembly (Fig. 1296). Fig.
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MOWER DECK 7. Remove the spindle housing assembly from the spindle shaft (Fig. 1297). Fig. 1297 IMG-9795a 8. Remove the thrust washer from the spindle shaft. (It may stick to the bottom of the spindle housing.) (Fig. 1298) 7 9. Remove the bearing shield from the spindle shaft (Fig. 1299). Fig. 1299 10. Drive out one of the bearings from the spindle housing (Fig. 1300). Fig. 1300 Fig.
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MOWER DECK 11. Remove the bearing spacer from the spindle housing (Fig. 1301). Fig. 1301 IMG-9799a 12. Turn the housing over and drive the second bearing out of the spindle housing (Fig. 1302). 13. Remove the grease fitting from the spindle housing (Fig. 1303). Fig. 1303 IMG-9802a 14. Inspect the spindle assembly components. Replace if damaged or worn. Note: Spindle shaft keyway can be significantly damaged before the spindle shaft requires replacement. 15.
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MOWER DECK 16. Press a new bearing into one end of the spindle housing hub (Fig. 1305). Fig. 1305 IMG-9804a 17. Turn the spindle housing over and slide a bearing spacer into the spindle hub (Fig. 1306). 7 Fig. 1306 7-18 IMG-9807a 18. Press a new bearing into the end of the spindle housing hub (Fig. 1307). Fig. 1307 IMG-9809a 19. Slide the bearing shield onto the spindle shaft (Fig. 1308). Fig.
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MOWER DECK 20. Slide the thrust washer onto the spindle shaft (Fig. 1309). Fig. 1309 IMG-9797a 21. Slide the spindle housing assembly onto the spindle shaft (Fig. 1310). Fig. 1310 Toro GrandStand Service Manual IMG-9795a 22. Slide the thrust washer onto the spindle shaft (Fig 1311). Fig. 1311 IMG-9794a 23. Slide the bearing shield onto the spindle shaft (Fig. 1312). Fig.
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MOWER DECK 24. Insert the square key into the spindle shaft keyway (Fig. 1313). Fig. 1313 IMG-9792a 25. Slide the pulley hub onto the end of the spindle shaft (hub side up) aligning it with the square key (Fig. 1314). 26. Slide the washer onto the end of the spindle shaft (Fig. 1315). Fig. 1315 IMG-9790a 27. Install the hex nut onto the end of the spindle shaft and torque to 100 + 10 ft-lbs. (135.5 + 13.5 Nm) (Fig. 1316). 7 Fig. 1314 7-20 IMG-9791a Fig.
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MOWER DECK Spring Idler & Adjustment Idler Replacement 3. Remove the spring idler assembly (Fig. 1318). Spring Idler Removal 1. Remove the mower deck belt. Refer to “Mower Deck Belt Removal” on page 7-1. 2. Remove the carriage bolt and nut securing the spring idler assembly to the deck (Fig. 1317). Fig. 1318 IMG-0599a 4. Remove the spring from the idler plate (Fig. 1319). Fig. 1317 IMG-0597a Fig.
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MOWER DECK 5. Remove the two plain washers, two friction compo site washers, and bushing (Fig. 1320). 1. Install the carriage bolt, nut, and washers securing the pulley (hub down) to the idler plate (Fig. 1322). A B C B A Fig. 1320 A. Plain washer (2) B. Friction composite washer (2) Spring Idler Installation A IMG-0601a C. Bushing B C E D Fig. 1322 A. Nut B. Idler Pulley C. Washer (2) IMG-0603a D. Idler Plate E. Carriage Bolt 6.
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MOWER DECK 3. Install a friction composite washer, idler plate, friction composite washer, plain washer, and secure with nut (Fig. 1324). Adjustment Idler Removal 1. Remove the mower deck belt. Refer to “Mower Deck Belt Removal” on page 7-1. 2. Remove the carriage bolt, nut, washer and spacer securing the slotted end of the idler plate (Fig. 1326). Fig. 1324 IMG-0623a 4. Install extension spring on the idler plate with the hook of the spring coming from the bottom of the idler plate upwards (Fig. 1325).
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MOWER DECK 4. Remove the idler adjust assembly from the mower deck (Fig. 1328). Adjustment Idler Installation 1. Install the carriage bolt, nut, and washers securing the pulley (hub down) to the idler plate (Fig. 1330). A B Fig. 1328 E C D IMG-0608a Fig. 1330 5. Remove the carriage bolt, nut, and washers securing the pulley to the idler plate (Fig. 1329). A B 7 E C D. Idler Plate E. Carriage Bolt 2. Place the carriage bolt up through the mower and install a spacer (Fig. 1331). D Fig. 1329 A.
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MOWER DECK 3. Install idler adjust assembly and secure with nut (Fig. 1332). Fig. 1332 5. Install carriage bolt through the mower deck, spacer, idler plate, Belleville washer, and loosely install the nut (Fig. 1334). IMG-0614a Fig. 1334 4. Position spacer between the mower deck and the idler adjust assembly (Fig. 1333). Fig. 1333 Toro GrandStand Service Manual IMG-0620a 6. Install the mower deck belt. Refer to “Mower Deck Belt Installation” on page 7-1.
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MOWER DECK Baffles & Skid Plate Replacement 3. Remove the two self-tapping screws securing the fixed baffle to the deck (Fig. 1337). Fixed Baffle Removal 1. Remove the two nuts from the self-tapping screws located on the top of the mower deck for the fixed baffle (Fig. 1335). Fig. 1337 IMG-0634a 4. Remove the baffle from the mower deck (Fig. 1338). Fig. 1335 IMG-0627a 2. Remove the carriage bolt and nut for the fixed baffle located on the left side of the mower deck (Fig. 1336). 7 Fig. 1338 Fig.
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MOWER DECK Fixed Baffle Installation 3. Install the two self-tapping screws through the fixed baffle to the mower deck (Fig. 1341). 1. Position the fixed baffle into the mower deck (Fig. 1339). Fig. 1341 Fig. 1339 IMG-0634a IMG-0638a 4. Tighten the carriage bolt and nut on the fixed baffle and left hand side of the mower deck (Fig. 1342). 2. Loosely install the carriage bolt and nut through the hole located on the left side of the mower deck (Fig. 1340). Fig. 1342 Fig.
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MOWER DECK 5. Install two nuts on the self-tapping screws retaining the fixed baffle (Fig. 1343). Adjustable Baffle Removal 1. Remove the nut from the thread forming screw located on the top of the mower for the adjustable baffle (Fig. 1344). Fig. 1343 IMG-0627a Fig. 1344 IMG-0787a 2. Remove the lever assembly from the adjustable baffle by unscrewing the lever from the adjustable baffle (Fig. 1345). 7 Fig.
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MOWER DECK 3. Remove the thread forming screw from the adjust able baffle assembly (Fig. 1346). Fig. 1346 IMG-0790a 4. Remove the adjustable baffle from the mower deck (Fig. 1347). 5. Remove the nut that secures the lock lever to the lock cap (Fig. 1348). Fig. 1348 6. Disassemble the lock lever assembly (Fig. 1349). Fig. 1349 Fig.
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MOWER DECK Adjustable Baffle Installation 3. Secure the adjustable baffle to the mower deck with a thread forming screw (Fig. 1352). 1. Secure the lock screw in the lock cap with the lock lever (Fig. 1350). Fig. 1352 Fig. 1350 IMG-0790a IMG-0681a 4. Install a nut on the thread forming screw (Fig. 1353). 2. Secure the lock lever with nut (Fig. 1351). 7 Fig. 1353 Fig.
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MOWER DECK 5. Apply anti-seize compound onto the lock screw threads (Fig. 1354). Discharge Baffle Removal 1. Remove the right hand belt cover (Fig. 1356). Fig. 1354 IMG-0687a Fig. 1356 6. Thread the lever assembly in the adjustable baffle (Fig. 1355). Fig. 1355 2. Remove the two nuts from the thread forming screws that secure the discharge baffle (Fig. 1357). 7 IMG-0689a Fig.
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MOWER DECK 3. Remove the two thread forming screws retaining the discharge baffle to the deck (Fig. 1358). Discharge Baffle Installation 1. Secure the discharge baffle with two thread forming screws (Fig. 1360). Fig. 1358 IMG-0791a Fig. 1360 IMG-0791a 4. Remove the discharge baffle from the underside of the mower deck (Fig. 1359). 2. Install two nuts to the thread forming screws retaining the discharge baffle to the mower deck (Fig. 1361). 7 Fig. 1359 IMG-0680a Fig.
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MOWER DECK Skid Plate Removal 3. Install the RH belt cover (Fig. 1362). 1. Remove the three nuts and carriage bolts securing the skid plate to the mower deck (Fig. 1363). Fig. 1362 IMG-0671a Fig. 1363 IMG-0503a 2. Remove the skid plate from the mower deck (Fig. 1364). 7 Fig.
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MOWER DECK Skid Plate Installation 1. Position the skid plate into the mower deck (Fig. 1365). Anti-Scalp Roller Replacement (60” Models Only) Single Anti-Scalp Roller Removal 1. Remove the nut from the roller axle bolt (Fig. 1367). Fig. 1365 IMG-0504a Fig. 1367 IMG-0692a 2. Secure the skid plate to the mower deck with three carriage bolts and nuts (Fig. 1366). 2. Remove the axle bolt and roller assembly from the wheel bracket (Fig. 1368). 7 Fig. 1366 IMG-0503a Fig.
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MOWER DECK 3. Remove the spacer from the spanner tube (Fig. 1369). Fig. 1369 5. Remove the thread forming screw securing the wheel bracket to the deck and remove the bracket (Fig. 1371). IMG-0694a Fig. 1371 IMG-0696a 4. Remove the spanner tube from the roller (Fig. 1370). Fig.
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MOWER DECK Single Anti-Scalp Roller Installation 3. Insert the spanner tube through the roller (Fig. 1374). 1. Position the wheel bracket on the deck so the wheel bracket tabs are aligned with the slots on the deck (Fig. 1372). Fig. 1374 Fig. 1372 IMG-0698a IMG-0695a 4. Place the spacer onto the spanner tube (Fig. 1375). 2. Secure the wheel bracket to the deck with a thread forming screw (Fig. 1373). 7 Fig. 1375 Fig.
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MOWER DECK 5. Secure the roller assembly to the wheel bracket with the axle bolt and nut (Fig. 1376). Double Anti-Scalp Roller Removal 1. Remove the nut from the roller axle bolt (Fig. 1377). Fig. 1376 IMG-0691a Fig. 1377 IMG-0700a 2. Remove the axle bolt and roller assembly from the wheel bracket (Fig. 1378). 7 Fig.
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MOWER DECK 3. Remove the spanner tube from the rollers (Fig. 1379). Double Anti-Scalp Roller Installation 1. Position the wheel bracket on the deck so the wheel bracket tabs are aligned with the slots on the deck (Fig. 1381). Fig. 1379 IMG-0704a 4. Remove the two thread forming screws securing the wheel bracket to the deck and remove the bracket (Fig. 1380). Fig. 1381 IMG-0709a 2. Secure the wheel bracket to the deck with two thread forming screws (Fig. 1382). 7 Fig. 1380 IMG-0707a Fig.
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MOWER DECK 3. Insert the spanner tube through the rollers with the roller hubs facing outward (Fig. 1383). Belt Cover Brackets Replacement Early 2009 Belt Cover Bracket Removal 1. Remove the knob securing the belt cover (Fig. 1385). Fig. 1383 IMG-0711a 4. Secure the roller assembly to the wheel bracket with the axle bolt and nut (Fig. 1384). Fig. 1385 IMG-0714a 2. Remove the belt cover (Fig. 1386). Fig. 1384 7 IMG-0700a Fig.
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MOWER DECK 3. Remove the self-tapping screw securing the belt cover bracket to the deck (Fig. 1387). Early 2009 Belt Cover Bracket Installation 1. Position the belt cover bracket on the deck so the dimple on the deck is aligned with the dimple on the bracket (Fig. 1388). Fig. 1387 IMG-0718a Fig. 1388 IMG-0717a 2. Secure the bracket to the deck using a self-tapping screw (Fig. 1389). 7 Fig.
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MOWER DECK Mid 2009 & Later Belt Cover Brackets Removal 3. Install the belt cover (Fig. 1390). 1. Remove the belt cover (Fig. 1392). Fig. 1390 IMG-0715a 4. Secure the belt cover with the belt cover knob (Fig. 1391). Fig. 1392 IMG-0720a 2. Remove the self-tapping screws securing the cover brackets to the mower deck (Fig. 1393). Fig. 1391 7 IMG-0714a Fig.
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MOWER DECK 3. From the underside of the deck, remove the two nuts securing the wire form bracket to the deck, then remove the wire form bracket (Fig. 1394). Mid 2009 & Later Belt Cover Brackets Installation 1. Position the wire form bracket through the holes in the top of the deck (Fig. 1395). Fig. 1394 IMG-0722a Fig. 1395 IMG-0724a 2. Using two nuts, secure the wire form bracket to the deck (Fig. 1396). 7 Fig.
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MOWER DECK 3. Position the cover bracket on the deck so the cover bracket tab engages the slot in the deck (Fig. 1397). Fig. 1397 5. Repeat steps 3 and 4 for second bracket. 6. Install the belt cover (Fig. 1399). IMG-0728a Fig. 1399 IMG-0720a 4. Secure the cover bracket with a thread forming screw (Fig. 1398). Fig.
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MOWER DECK Grass Deflector Replacement 3. Remove the pivot bolt, spacer and spring. Then remove the deflector assembly (Fig. 1402). Grass Deflector Removal 1. Unhook the spring from the deflector assembly (Fig. 1400). Fig. 1402 Fig. 1400 IMG-0729a IMG-0731a 4. Remove the four carriage bolts and nuts securing the hinge brackets and discharge strap to the rubber deflector (Fig. 1403). 2. Remove the nut securing the deflector pivot bolt (Fig. 1401). 7 Fig. 1403 Fig.
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MOWER DECK Grass Deflector Installation 3. Secure the front hinge bracket to the assembly using two nuts (Fig. 1406). 1. Insert the four carriage bolts into the discharge strap (Fig. 1404). Note: The bolt pattern is oriented so that the two bolt holes that are closer to each other are on the left. Fig. 1406 IMG-0762a 4. Secure the rear hinge bracket to the assembly using two nuts (Fig. 1407). Fig. 1404 IMG-0755a 2. Position and press the rubber deflector onto the four carriage bolts (Fig. 1405).
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MOWER DECK 5. Slide the spring onto the spacer (Fig. 1408). 7. Secure the deflector assembly, spacer and spring with the pivot bolt and nut (Fig. 1410). Note: The spring “J” hooks must be mounted so one is on each side of the mounting plate. Fig. 1408 IMG-0764a 6. Position the deflector assembly to the mower deck (Fig. 1409). Fig. 1410 IMG-0766a 8. Hook the end of the spring on the deflector’s rear hinge bracket (Fig. 1411). 7 Fig. 1409 IMG-0765a Fig.
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MOWER DECK Mower Deck Replacement 4. Remove the four bolts and nuts securing the engine base to the rear of the deck (Fig. 1414). Mower Deck Removal 1. Remove the mower deck belt. Refer to “Mower Deck Belt Removal” on page 7-1. Note: The rear of the deck is now free from the engine base and can be lowered to the ground. 2. Use a strap to secure the engine base to the frame on both sides (Fig. 1412). Fig. 1414 Fig. 1412 IMG-0772a IMG-0781a 5.
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MOWER DECK 6. Remove the shoulder bolt, nut and washer securing the other front lift link to the mower deck. Note: The front of the deck is now free from the lift assembly and can be lowered to the ground. 7. Slide the mower deck assembly out from under the chassis. Mower Deck Installation 1. Position the mower deck under the chassis. 2. Insert the shoulder bolt through the deck lift link and add the steel washer (Fig. 1416). Fig. 1416 IMG-0783a 3.
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MOWER DECK 4. Repeat steps 2 and 3 on the other side. 5. Loosely install four bolts and nuts to secure the engine base to the rear of the deck (Fig. 1418). 7. Tighten the four bolts and nuts securing the engine base to the rear of the deck (Fig. 1420). Fig. 1420 Fig. 1418 IMG-0781a IMG-0781a 8. Remove the strap from the engine base (Fig. 1421). 6. Secure the front engine base tab to the top of the deck using a nut and bolt (Fig. 1419). Fig. 1421 Fig.
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MOWER DECK Mower Deck Adjustments Correcting the Mower Quality of Cut Checking the Mower Deck Side-to-Side Height If one deck blade cuts lower than the other, correct as follows. 1. Adjust the rear tire pressure to 12-14 psi (83-97kPa). Note: Tire air pressure is critical in these pro cedures. 1. Disengage the PTO and set the parking brake. 2. Ensure the blades are not bent. Refer to Checking for Bent Blades. 3. Position the blades side-to-side.
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MOWER DECK Changing the Mower Deck Side-to-Side Height Checking the Mower Deck Front-to-Rear Pitch Changing the side-to-side height is done by adjusting the rear tire pressure and U-plates on the side of the engine deck. 1. Adjust the rear tire pressure to 12-14 psi (83-97kPa). 1. Change the rear tire pressure. Do this to the corres ponding side that needs adjustment. 2. Position one blade front-to-rear. Measure at A and B locations from a level surface to the cutting edge of the blade tips (Fig.
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MOWER DECK Changing the Mower Deck Front-to-Rear Pitch 2. Loosen both the front and rear nuts on the adjust ment rods (Fig. 1426). Changing the front-to-rear pitch is done by adjusting the front height-of-cut posts. 1. Place 3 pieces of 2x4 wood under the mower deck as shown in Fig. 1425. Stand the 2x4’s on the 4” part. 1 1 2 3 Fig. 1425 fig. 85 G012190 1. 2x4 piece of wood under mower deck Fig. 1426 1. Adjustment rods 2. Rear nuts fig. 86 G0012191 3. Front nuts 3.
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MOWER DECK Matching Height-of-Cut 4. The measurement should be 3” (7.6cm). 1. Check the rear tire pressure. 5. If it does not measure correctly, locate the height-ofcut rod on the right side of the machine (Fig. 1428). 2. Set the height-of-cut to the 3” (7.6cm) position. 3. With the machine on level surface, position one blade front-to-rear. Measure at A and from level sur face to the cutting edge of the blade tips (Fig. 1427). 2 1 2 Fig. 1428 1. Height-of-cut rod 1 Fig. 1427 fig. 88 G013167 2.
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MOWER DECK THIS PAGE INTENTIONALLY LEFT BLANK.
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ELECTRICAL Additional information can be found in the LCE Electrical Troubleshooting DVD #492-9193, available through your Toro parts supplier. CAUTION Before performing any tests with a continuity light or ohmmeter, disconnect the component from the wire harness. This ensures you are testing the component rather than another circuit. How It Works Detents inside the switch gives it 3 positions: OFF, RUN and START.
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ELECTRICAL Power Take Off (PTO) Switch Testing Purpose 1. Disengage the PTO, set the parking brake, turn the ignition to OFF and remove the key. The Power Take Off (PTO) Switch is used to turn on the Electric PTO Clutch and function as part of the safety interlock system. 2. Disconnect the wire harness from the PTO switch. Location The PTO switch is located on the control panel (Fig. 1431). 3. Press in on the locking tabs on each side of the switch and pull the switch out of the control panel. 4.
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ELECTRICAL Electric (PTO) Clutch Testing Purpose This clutch electrically controls the engagement and disengagement of the Power Take Off (PTO) pulley, which drives the mower deck belt. If the electric PTO clutch is not engaging or is suspected as a cause of electrical problems, use the trouble shooting procedures below. These procedures will help you determine if the clutch has failed or is the cause of the electrical problem.
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ELECTRICAL Measuring Clutch Current Draw Solenoid 1. Disengage the PTO, set the parking brake, turn the ignition OFF, and remove the key. Purpose 2. Disconnect the clutch wire connector from the wire harness. 3. Set the multimeter to check amps (10 amp scale). The purpose of the solenoid is to connect the battery to the starter motor on the engine when the ignition switch is turned to “START”.
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ELECTRICAL How It Works Testing The solenoid has two primary parts. One, a coil wire is wrapped around an iron core. Whenever 12 volts is applied to the coil, it becomes a magnet. The other part is a bar type switch. Because it has a large contact area with contact terminals, it can easily handle the high current loads required by the starter motor of the engine. 1. Disconnect the solenoid from the wire harness. When 12 volts is applied to the coil, it becomes an elec tromagnet.
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ELECTRICAL Operator Presence Control (OPC) Switch Purpose The Operator Presence Control (OPC) Switch is part of the safety circuit. If the PTO is engaged and the operator vacates the machine, the PTO will shut down (Fig. 1439). How It Works This is a “Normally Closed (NC)” switch. The letters “NC” will be stamped on the terminals. When the RH control lever is in the “UP” position, the switch is open and there is no continuity between the switch terminals.
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ELECTRICAL Neutral Switch How It Works Purpose This is a “Normally Closed (NC)” switch. The letters “NC” will be stamped on the terminals. When the control levers are in the neutral position, the switch is open and there is no continuity between the switch terminals. The Neutral Switch is part of the safety circuit. The neutral switch is used to ensure the motion control levers are in the neutral position allowing the machine to start (Fig. 1441).
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ELECTRICAL Parking Brake Switch How It Works Purpose This is a “Normally Closed (NC)” switch. The letters “NC” will be stamped on the terminals. When the parking brake is engaged, the switch is closed and there is continuity between the switch terminals. The Parking Brake Switch is part of the safety circuit. The parking brake switch is used to shut down the engine if the machine leaves neutral with the parking brake on (Fig. 1443).
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ELECTRICAL Fuse Block & Fuses How It Works Purpose The fuse block houses the fuses that protect the electrical system from electrical surges. The fuse block houses the electrical system fuses. Testing Location The fuse block is located on the rear, LH side of the control tower (Fig. 1445). Fig. 1445 IMG-1209a 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. 1446). Fig.
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ELECTRICAL Hour Meter/Control Module How It Works Purpose 1. Hour Meter – Hours are accumulated when 12.8 volts are generated by the engine. Battery voltage is not great enough to engage the hour meter function (Fig. 1448). The hour meter/control module keeps track of the actual running hours of the engine. It has safety interlock indicators to let the operator know the position of the corresponding component. It also provides the operator with the battery output voltage.
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ELECTRICAL Component Replacement 3. Remove the switch through the front of the control panel (Fig. 1451). Ignition Switch Removal 1. Remove the wire harness and spade connector from the back of the ignition switch (Fig. 1449). Fig. 1451 Fig. 1449 IMG-1230a IMG-1220a 2. Depress the two tabs on the sides of the switch (Fig. 1450). Fig.
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ELECTRICAL Ignition Switch Installation 2. Install the spade connector with the two pink wires to the “I” terminal of the switch (Fig. 1454). 1. Install the switch into the control panel. Ensure that the mounting clips have secured the switch in the control panel (Fig. 1452). Fig. 1454 Fig. 1452 IMG-1230a IMG-1234a 3. Install the wire harness to the switch (Fig. 1455). Note: The switch must be orientated so it can be read from the operator position (Fig. 1453). Fig. 1455 8 Fig.
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ELECTRICAL Power Take Off (PTO) Switch Removal 3. Remove the switch through the front of the control panel (Fig. 1458). 1. Remove the wire harness from the back of the PTO switch (Fig. 1456). Fig. 1458 Fig. 1456 IMG-1246a IMG-1240a 2. Depress the four tabs securing the switch to the control panel (Fig. 1457). Fig.
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ELECTRICAL Power Take Off (PTO) Switch Installation Electric PTO Clutch Removal 1. Install the switch into the control panel. Ensure that the mounting clips have secured the switch in the control panel (Fig. 1459). 1. Turn the engine off and remove the key from the ignition. 2. Set the parking brake. 3. Lower the mower deck to the lowest height-of-cut position. 4. Remove the LH and RH belt covers (Fig. 1461). Fig. 1459 IMG-1246a 2. Install the wire harness to the back of the switch (Fig. 1460). Fig.
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ELECTRICAL 6. Remove the mower deck belt from the mower deck (Fig. 1463). Fig. 1463 IMG-9553a 7. Raise the mower deck to the transport position (highest height-of-cut) and pin it to secure (Fig. 1464). 8. Remove the wingnut from the battery hold down bolt (Fig. 1465). Fig. 1465 9. Remove the battery hold down bolt (Fig. 1466). Fig. 1466 Fig.
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ELECTRICAL 10. Repeat steps 8 and 9 to remove the battery hold down on the other side of the battery cover. 11. Remove the battery cover (Fig. 1467). 13. Slide the red boot off the positive (red) battery terminal. Remove the positive (red) battery cable from the positive (+) battery terminal (Fig. 1469). Fig. 1469 Fig. 1467 12. Disconnect the negative battery cable from the negative (-) battery terminal (Fig. 1468). 14. Remove the battery (Fig. 1470). Fig. 1470 Fig.
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ELECTRICAL 15. Clean around the hydraulic tank cap to prevent debris from getting into the tank. C. Insert a siphon pump hose into the fuel tank (Fig. 1472). 16. Remove the cap from the hydraulic tank and place a piece of plastic wrap over the opening. Reinstall the hydraulic tank cap (Fig. 1471). Fig. 1472 Fig. 1471 IMG-9587a 17. Siphon the fuel from the fuel tank: Note: The only recommended way to remove fuel from the tank is with a siphon pump. IMG-9592a D.
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ELECTRICAL 19. Remove the 3 carriage bolts and 3 nuts securing the skid plate to the mower deck (Fig. 1474). Fig. 1474 21. Disconnect the clutch wire connector from the wire harness and push the clutch connector and grommet through to the bottom side of the engine base (Fig. 1476). IMG-9600a Fig. 1476 IMG-9599a 20. Remove the skid plate (Fig. 1475). Fig.
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ELECTRICAL 22. 2009 only: Remove the bolt, washers, spacer and nut securing the clutch brake strap to the mower deck (Fig. 1477). 23. Remove only the nuts from the 5 bolts securing the mower deck to the engine base (Fig. 1479). Fig. 1479 Fig. 1477 Note: On 2010 models the clutch is secured by an anchor bracket (Fig. 1478). 24. Remove the upper bolt securing the engine base to the mower deck (Fig. 1480). Fig. 1480 Fig.
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ELECTRICAL 25. Remove 1 of the 4 lower bolts securing the engine base to the mower deck and replace it with a screwdriver to keep the deck in position (Fig. 1481). 27. Remove the screwdriver and slide the rear of the mower deck 2” (5cm) away from the engine base so that the top mower deck hole aligns with the bottom hole in the engine base. Insert the screwdriver to secure the alignment. This will provide enough clearance to slide the clutch off the crankshaft (Fig. 1483).
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ELECTRICAL 29. Remove the clutch bolt, spring washer and flat washer (Fig. 1485). Fig. 1485 31. 2009 only: Remove the nut and spring washer from the bolt securing the brake clutch strap to the clutch (Fig. 1487). IMG-9611a Fig. 1487 IMG-9617a 30. Slide the clutch off the crankshaft and remove it from the machine (Fig. 1486). 32. 2009 only: Remove the strap assembly (Fig. 1488). Fig. 1486 Fig.
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ELECTRICAL 33. 2009 only: Remove the flat washer (Fig. 1489). Fig. 1489 35. 2009 only: Remove the 2 spacers from the 2 grommets in the clutch brake strap (Fig. 1491). IMG-9619a Fig. 1491 34. 2009 only: Remove the bolt and washer from the clutch (Fig. 1490). Fig. 1490 IMG-9621a 36. 2009 only: Remove the 2 grommets from the clutch brake strap (Fig. 1492). Renew worn parts as needed. IMG-9620a Fig.
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ELECTRICAL Electric PTO Clutch Installation 3. 2009 only: Slide 2 spacers into the 2 grommets in the clutch brake strap (Fig. 1495). 1. Using a feeler gauge, check the clutch air gap at each of the 3 adjustment slots. The gap should be set to 0.015” (0.381mm). Make sure the gauge is inserted between the armature and the rotor friction surfaces. Adjust the clutch as necessary (Fig. 1493). Fig. 1495 Fig. 1493 PICT-0554a IMG-9621a 4. 2009 only: Install a bolt and washer into the clutch plate (Fig.
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ELECTRICAL 5. 2009 only: Slide a flat washer onto the bolt (Fig. 1497). Fig. 1497 IMG-9619a 6. 2009 only: Slide the strap assembly onto the bolt (Fig. 1498). Fig. 1498 7. 2009 only: Slide a spring washer (crown side up) onto the bolt (Fig. 1499). Fig. 1499 IMG-9623a 8. 2009 only: Install a nut onto the bolt securing the brake clutch strap assembly to the clutch (Fig. 1500). IMG-9618a Fig.
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ELECTRICAL 9. Apply anti-seize to the crankshaft (Fig. 1501). Fig. 1501 10. Slide the clutch onto the crankshaft aligning the keyway with the key in the crankshaft (Fig. 1502). IMG-9627a Fig. 1502 IMG-9614a Note: On 2010 models, the clutch stop bracket must be nested in the slot on the clutch (Fig. 1503). Fig.
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ELECTRICAL 11. Install the spring washer (crown toward the bolt head) and flat washer to the clutch bolt (Fig. 1504). Fig. 1504 13. Torque the clutch bolt to 55 ft-lbs. (75 Nm) (Fig. 1506). IMG-9630a 12. Apply thread-locking compound to the threads of the clutch bolt (Fig. 1505). Fig. 1506 IMG-9645a 14. Install the bolt, washers, spacer and nut securing the clutch brake strap to the mower deck (Fig. 1507). C A Fig. 1505 PICT-8700a 8-26 B D E F Fig. 1507 A. Bolt B. Washers (2) C.
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ELECTRICAL 15. Insert the clutch connector through the engine base. Install the rubber grommet into the hole in the engine base (Fig. 1508). Fig. 1508 IMG-9758a 16. Connect the clutch wire connector to the wire harness (Fig. 1509). 17. Remove the rope from the spark plug hole and reinstall the spark plug (Fig. 1510). Fig. 1510 IMG-9633a 18. Remove the screwdriver securing the deck and slide the rear of the mower deck towards the engine base.
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ELECTRICAL 19. Install 3 of the 4 lower bolts securing the mower deck to the engine base. Remove the screwdriver (Fig. 1512). 21. Install the upper bolt securing the engine base to the mower deck (Fig. 1514). Fig. 1514 Fig. 1512 22. Install the nuts on the 5 bolts securing the mower deck to the engine base (Fig. 1515). 20. Install the remaining (4th) bolt (Fig. 1513). Fig. 1513 IMG-9605a IMG-9651a IMG-9608a Fig.
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ELECTRICAL 23. Position the skid plate to the mower deck (Fig. 1516). 25. With two people, lower the front of the mower, returning it to the upright position. 26. Position the battery onto the battery tray (Fig. 1518). Fig. 1516 IMG-9658a Fig. 1518 24. Install the 3 carriage bolts and 3 nuts securing the skid plate to the mower deck (Fig. 1517). Fig. 1517 27.
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ELECTRICAL 28. Install the negative battery cable to the negative (-) battery terminal (Fig. 1520). Fig. 1520 IMG-9665a 29. Position the battery cover over the battery (Fig. 1521). Fig. 1521 30. Install the two battery hold down bolts and wing nuts to secure (Fig. 1522). Fig. 1522 IMG-9672a 31. Remove the hydraulic tank cap and remove the piece of plastic over the tank opening. Reinstall the hydraulic cap (Fig. 1523). IMG-9667a Fig.
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ELECTRICAL 32. Lower the mower deck to the lowest height-of-cut (Fig. 1524). 34. Using a ratchet in the idler arm, tension the arm until the spring is stretched 5-3/4” (14.6cm) hook to hook and then tighten the nut (Fig. 1526). A Fig. 1524 B C IMG-9676a D EF 33. Route the mower deck belt around the mower deck pulleys and clutch pulley. Refer to the belt routing decal (Fig. 1525): Fig. 1526 A. 5-3/4” (14.6cm) from hook to hook B. Spring C. Spring loaded idler fig. 61 G009460 D. Ratchet E.
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ELECTRICAL 35. Install the LH and RH belt covers onto the mower deck (Fig. 1527). Electric PTO Clutch Burnishing Procedure Note: This procedure needs to be done only when installing a new clutch. The clutch should be burnished as part of the predelivery service, or whenever a new clutch is installed. Burnish ing ensures full contact between the armature and rotor friction surfaces, for smooth clutch engagement and maximum power transfer. With deck drive belt installed, run the engine at half throttle.
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ELECTRICAL Solenoid Removal 3. Remove the nut and lock washer securing the positive cable that goes to the starter (Fig. 1531). 1. Disconnect the black ground cable from the battery (Fig. 1529). Fig. 1531 Fig. 1529 IMG-1294a IMG-1287a 4. Remove the green and blue bullet connectors from the two small studs on the solenoid (Fig. 1532). 2.
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ELECTRICAL 5. Remove the two thread forming screws securing the solenoid the engine base plate (Fig. 1533). Solenoid Installation 1. Secure the solenoid to the engine base using two thread forming screws (Fig. 1534). Fig. 1533 IMG-1297a Fig. 1534 IMG-1297a 2. Install the blue and green wires to the two small studs on the solenoid using the wire’s bullet con nectors (Fig. 1535). 8 Fig.
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ELECTRICAL 3. Secure the starter positive cable to the LH solenoid stud with a nut and lock washer (Fig. 1536). Fig. 1536 IMG-1294a 4. Secure the positive battery cable and red wire eyelet to the solenoid using a nut and lock washer (Fig. 1537). 5. Position the positive cable terminal cover over the terminal connection (Fig. 1538). Fig. 1538 6. Secure the black ground cable to the battery nega tive terminal (Fig. 1539). Fig. 1539 Fig.
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ELECTRICAL Operator Presence Control (OPC) Switch Removal Operator Presence Control (OPC) Switch Installation 1. Remove the wire harness from the switch (Fig. 1540). 1. Loosely install the two screws and threaded plate that secure the switch to the control handle assembly (Fig. 1542). Fig. 1540 IMG-1262a Fig. 1542 2. Remove the two screws and threaded plate that secure the switch to the control handle assembly and remove the switch (Fig. 1541). 8 Fig. 1541 8-36 IMG-1264a IMG-1264a 2.
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ELECTRICAL 3. Position the switch so there is an 1/8” (3mm) gap between the switch plunger and the tab on the handle assembly (Fig. 1544). 5. Plug the wire harness into the switch (Fig. 1546). Fig. 1546 Fig. 1544 IMG-1262a IMG-1267a 4. Secure the position of the switch by tightening the two mounting screws (Fig. 1545). Fig.
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ELECTRICAL Neutral Switch Removal Neutral Switch Installation 1. Remove the wire harness from the switch (Fig. 1547). 1. Loosely install the two screws and threaded plate that secure the switch to the control handle assem bly (Fig. 1549). 2. With the controls in the neutral position, position the switch so there is an 1/8” (3mm) gap between the switch plunger and the tab on the neutral plate (Fig. 1549). 3. Secure the position of the switch by tightening the two mounting screws (Fig. 1549). Fig.
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ELECTRICAL Parking Brake Switch Removal Parking Brake Switch Installation 1. Remove the wire harness from the switch (Fig. 1551). 1. Loosely install the two screws and threaded plate that secure the switch to the brake assembly (Fig. 1553). Fig. 1551 IMG-1281a Fig. 1553 IMG-1283a 2. Remove the two screws and threaded plate that secure the switch to the brake assembly and remove the switch (Fig. 1552). Fig.
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ELECTRICAL 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. 1554). 3. Secure the position of the switch by tightening the two mounting screws (Fig. 1555). A B Fig. 1555 C C Fig. 1554 E B D A IMG-1283a 4. Plug the wire harness into the switch (Fig. 1556). fig. 64 G012873 A. 1/8” (3mm) gap needed C. Switch between switch and D. Switch button brake lever E. Face of the switch B. Brake lever Fig.
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ELECTRICAL Hour Meter/Control Module Removal 3. Remove the hour meter through the front of the control panel (Fig. 1559). 1. Remove the wire harness from the back of the hour meter (Fig. 1557). Fig. 1559 Fig. 1557 IMG-1252a IMG-1247a 2. Depress the two tabs securing the hour meter to the control panel (Fig. 1558). Fig.
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ELECTRICAL Hour Meter/Control Module Installation 2. Install the wire harness to the back of the hour meter (Fig. 1562). 1. Install the hour meter into the control panel. Ensure that the mounting clips have secured the switch in the control panel (Fig. 1560). Fig. 1562 Fig. 1560 IMG-1247a IMG-1252a Note: The hour meter must be orientated so it can be read from the front of the machine (Fig. 1561). 8 Fig.
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SCHEMATICS GrandStand Hydraulic Schematic Fig.
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SCHEMATICS GrandStand Electrical Schematic 9 Fig.
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Toro GrandStand Stand-on Mower Service Manual Form No.