Service Manual

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Toro

36” & 40” GrandStand

Service Manual

LCE Products

Summary of content (268 pages)

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LCE Products Toro 36” & 40” GrandStand 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 Troubleshooting DVD (4929193) and subsequent.
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ABOUT THIS MANUAL THIS PAGE INTENTIONALLY LEFT BLANK.
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TABLE OF CONTENTS 1 - Safety Information General Information �� 1-1 Think Safety First �� 1-1 2 - Specifications Torque Specifications ��
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TABLE OF CONTENTS 4 - Controls cont.
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TABLE OF CONTENTS 7 - Mower Deck cont.
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TABLE OF CONTENTS 8 - Electrical cont.
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TABLE OF CONTENTS 8 - 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 it 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 36” and 40” Toro GrandStand Stand-on Mower.
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SAFETY INFORMATION 1 THIS PAGE INTENTIONALLY LEFT BLANK.
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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. These torque specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified 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 GrandStand Specifications Engine: Output (Max. @ 3600 RPM’s) 15 hp (11.2kW) Make Kawasaki Model FS541V Hi-Idle (Dom) 3600 RPM Hi-Idle (Int’l) 3000 RPM Starter Electric Spark Plug NGK BPR4ES Oil SAE 10w-30 / SAE10w-40 2 Oil Capacity 2.1 qt. (2.0 L) Fuel System: Fuel Tank Capacity 7 Gallons (26.
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SPECIFICATIONS GrandStand Specifications cont. Mower Drive: 2 Mower Engagement Engine Mounted Electric Clutch Clutch Adjustment Periodic Air Gap Adjustment Required - .018” + .003” (0.45 + 0.
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CHASSIS Caster Wheel Assembly Replacement Caster Wheel Assembly Removal 1. Remove the grease cap from the top of the caster wheel pivot tube (Fig. 001). 3. The caster fork and wheel assembly is now free to be removed. 4. Remove the three Bellville washers from the caster wheel pivot tube (Fig. 003). 3 Fig. 003 Fig. 001 DSCN-3918a 2. Remove the nut from the caster fork shaft (Fig. 002). Fig. 002 36” & 40” Toro GrandStand Service Manual DSCN-3924a DSCN-3921a 5.
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CHASSIS 6. Remove the grease seal from the bottom of the caster wheel pivot tube (Fig. 005). 8. Using a blunt punch, remove the upper and lower bearing cups from the caster wheel pivot tube (Fig. 007). 3 Fig. 005 DSCN-3930a Fig. 007 7. The lower tapered roller bearing is now free to be removed (Fig. 006). Fig. 006 9. Remove the nut securing the caster wheel axle bolt, then remove the axle bolt (Fig. 008). DSCN-3933a Fig.
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CHASSIS 10. The caster wheel assembly is now free to be re moved from the caster fork. 11. Remove the seal guard from both sides of the wheel hub (Fig. 009). Note: The spacer nuts are both threaded onto the caster axle. One of the spacer nuts will need to be removed after it has been removed from the caster wheel (Fig. 011). 3 Fig. 011 Fig. 009 12. Remove the spacer nut from the caster axle (Fig. 010). 13. Remove the grease seal from both sides of the caster wheel (Fig. 012). Fig. 012 Fig.
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CHASSIS 14. The LH and RH tapered bearings are now free to be removed (Fig. 013). Caster Wheel Assembly Installation 1. Pack the caster wheel tapered roller bearing with high-temp grease (Fig. 014). 3 Fig. 013 DSCN-0389a Fig. 014 DSCN-0407a 2. Install the bearing into the wheel hub (Fig. 015). Fig.
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CHASSIS 3. Install grease seal into the wheel hub (Fig. 016). 6. Position the caster axle through the bearing and seal assembly (Fig. 018). 3 Fig. 016 DSCN-0393a Fig. 018 4. Repeat steps 1, 2, and 3 on the other side of the caster wheel. 5. Fill the center of the wheel hub with high-temp grease (Fig. 017). Fig. 017 7. Install a spacer nut onto both ends of the caster axle (Fig. 019).
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CHASSIS 8. Position the seal guard onto both sides of the caster wheel hub (Fig. 020). 10. Install the upper and lower bearing cups into the pivot tube (Fig. 022). 3 Fig. 020 DSCN-0377a 9. Secure the caster wheel assembly to the caster fork using the axle bolt and nut (Fig. 021). Fig. 021 3-6 DSCN-0376a Fig. 022 DSCN-0410a Note: A socket can be used as a driver. Take care not to scar the race surface (Fig. 023). Fig.
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CHASSIS 11. Pack the pivot tube tapered roller bearings with high temperature grease (Fig. 024). 13. Install grease seal into the base of the pivot tube (Fig. 026). 3 Fig. 024 DSCN-0407a 12. Install the lower bearing into the pivot tube (Fig. 025). Fig. 025 36” & 40” Toro GrandStand Service Manual DSCN-3933a Fig. 026 DSCN-3930a 14. Install the upper bearing into the pivot tube (Fig. 027). Fig.
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CHASSIS 15. Install the 3 Bellville washers into the pivot tube (Fig. 028). 16. Position the caster wheel and fork assembly up through the pivot hub. 17. Secure the caster wheel and fork assembly with the nut (Fig. 030). 3 Fig. 028 DSCN-3924a Note: Bottom: Crown Up / Middle: Crown Down / Top: Crown up (Fig. 029). Fig. 030 DSCN-0360a 18. Tighten locknut until spring washers are flat (15 ft-lbs / 20 Nm) and then back off a 1/4 turn to properly set the pre-load on the bearings. 19.
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CHASSIS 20. Install a grease zerk into the port on the side of the pivot hub (Fig. 032). 22. Replace the grease zerk with the plug (Fig. 034). 3 Fig. 034 Fig. 032 21. Fill the pivot hub cavity until grease is purging out through the upper bearing (Fig. 033). 23. Install the grease cap onto the top of the pivot hub (Fig. 035). Fig. 035 Fig.
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CHASSIS Fuel Tank Assembly Replacement 5. Remove the 90 degree vent fitting, then rubber grommet from the fuel tank (Fig. 038). Fuel Tank Assembly Removal 1. Turn the fuel shutoff valve to the “OFF” position (Fig. 036). 3 Fig. 038 Fig. 036 DSCN-3940a DSCN-3946a 6. Slide the hose clamp off the fuel pick-up tube fitting, then remove the fuel line from the fitting (Fig. 039). 2. Siphon the fuel from the fuel tank.
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CHASSIS 7. Remove the four thread forming screws securing the tank bracket to the control panel (Fig. 040). Fuel Tank Assembly Installation 1. Position the fuel tank into the control tower (Fig. 042). 3 Fig. 040 DSCN-3952a Fig. 042 DSCN-3955a 8. Remove the fuel tank from the control tower (Fig. 041). 2. Secure the tank bracket to the control tower using four thread forming screws (Fig. 043). Fig. 041 DSCN-3955a Fig.
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CHASSIS 3. Slide the fuel line onto the pick-up tube fitting and secure with the hose clamp (Fig. 044). 5. Install the 90 degree fitting into the rubber grommet (Fig. 046). Note: A thin film of oil will ease installation of the fitting barb. 3 Fig. 044 DSCN-3949a 4. Install the rubber grommet into the fuel tank (Fig. 045). Fig. 046 DSCN-3946a 6. Install the vent hose onto vent fitting (Fig. 047). Fig. 045 DSCN-3958a Fig.
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CHASSIS Platform & Cushion Assembly Replacement 3. Lower the operator cushion onto the operator platform. Platform & Cushion Assembly Removal 4. Remove the carriage bolts, spacers, friction washers, washers, and nuts securing the pad hinge to the pad links (Fig. 050). 1. Remove the hairpin cotter and clevis pin securing the brake link rod to the brake assembly (Fig. 048). 3 Fig. 050 Fig. 048 DSCN-3962a 2. Remove the four sets of bolts and flange nuts that secure the brake assembly to the frame (Fig.
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CHASSIS 6. Remove the two thread forming screws securing the shield, foot mat bracket, and foot mat to the platform (Fig. 052). 9. Remove the carriage bolts, friction washers, spacers, and nuts securing the pad link to the platform (Fig. 054). 3 Fig. 052 DSCN-0490a 7. Raise the rear of the machine and remove the tires. 8. Remove the RH and LH carriage bolts, washers, spacers, and nuts securing the platform to the carrier frame (Fig. 053). Fig. 054 10. Remove the knob from the platform latch pin (Fig.
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CHASSIS 11. Remove the latch pin and spring from the platform (Fig. 056). Platform & Cushion Assembly Installation 1. Secure the four rubber bumpers to the platform using four nuts (Fig. 058). 3 Fig. 056 DSCN-0501a Fig. 058 DSCN-0505a 12. Remove the four nuts securing the four rubber bumpers to the platform (Fig. 057). 2. Position the spring on the latch pin (Fig. 059). Fig. 057 DSCN-0505a Fig.
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CHASSIS 3. Position the latch pin and spring assembly into the platform (Fig. 060). 5. Install the knob onto the latch pin (Fig. 062). 3 Fig. 062 Fig. 060 4. Apply thread-locking compound to the threads of the knob (Fig. 061). 6. Position the carriage bolt and spacer into the tab on the platform (Fig. 063). Fig. 063 Fig.
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CHASSIS 7. Position the friction washer then pad link over the spacer (Fig. 064). 9. Repeat steps 6, 7, and 8 on the other side. 10. Position the platform assembly onto the frame (Fig. 066). 3 Fig. 064 DSCN-0549a Fig. 066 8. Secure the assembly with a washer and nut (Fig. 065). Fig. 065 11. Place the washer and spacer onto the bolt (Fig. 067). DSCN-0555a Fig.
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CHASSIS 12. Position the large washer between the platform pivot and frame (Fig. 068). 14. Repeat steps 11 through 13 on the other side of the machine. 15. Install the tires. 16. Secure the shield, foot mat bracket, and foot mat to the platform using two thread forming screws (Fig. 070). 3 Fig. 068 DSCN-3984a 13. Secure the platform assembly to the frame using the bolt, washer, spacer, and flange nut (Fig. 069). Fig. 070 DSCN-0490a 17.
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CHASSIS 18. Secure the upper hinge bracket to the operator cushion using two screws and washers (Fig. 072). 20. Place a friction washer between the pad link and lower hinge bracket (Fig. 074). 3 Fig. 072 DSCN-0566a 19. Align the pad link with the lower hinge bracket (Fig. 073). Fig. 073 36” & 40” Toro GrandStand Service Manual DSCN-0568a Fig. 074 DSCN-0571a 21. Insert a carriage bolt through the pad link assembly (Fig. 075). Fig.
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CHASSIS 22. Position the spacer over the carriage bolt and into the friction washer and lower hinge bracket (Fig. 076). 24. Repeat steps 19 through 23 on the other side of the machine. 25. Secure the brake assembly to the frame using four sets of bolts and flange nuts (Fig. 078). 3 Fig. 076 DSCN-0576a Fig. 078 23. Secure the assembly with a nut and washer (Fig. 077). Fig. 077 26. Secure the brake link rod to the brake assembly using the hairpin cotter and clevis pin (Fig. 079). DSCN-0577a Fig.
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CHASSIS Engine Base Replacement 3. Remove the deck belt extension spring from the deck anchor post, then remove the belt from around the clutch pulley (Fig. 082). Engine Base Removal 1. Remove the negative (black) battery cable from the battery, then remove the positive (red) cable (Fig. 080). 3 Fig. 082 Fig. 080 DSCN-3989a DSCN-3995a 4. Remove the bolt, washer, and nut securing the front strut to the carrier frame (Fig. 083). 2.
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CHASSIS 5. Remove the four carriage bolts and nuts securing the muffler guard to the carrier frame (Fig. 084). 7. Remove the two sets of bolts, washers, and flange nuts securing the RH and LH muffler mount brackets to the muffler (Fig. 086). 3 Fig. 084 DSCN-4000a Fig. 086 6. Loosen the cable clamps securing the choke and throttle cables to the engine throttle plate, then remove the “Z” bend of the cables from the engine control arms (Fig. 085). 8.
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CHASSIS 9. Remove the cable tie securing the choke and throttle cables to the oil drain (Fig. 088). 12. Lower the machine. 13. Place two boards under the mower deck, then lower the deck onto the boards (Fig. 090). 3 Fig. 088 DSCN-2683a Fig. 090 10. Raise the rear of the machine so the underside can be accessed. 11. Remove the four sets of bolts, washers, and nuts securing the rear struts to engine base and carrier frame (Fig. 089). 14.
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CHASSIS 15. Position an oil pan under the reservoir. Move the hose clamp from the reservoir tank fitting, then remove the low pressure return hose from the base of the reservoir (Fig. 092). 17. Slide the hose clamp off the fuel line where it connects to the fuel pump (Fig. 094). 3 Fig. 094 Fig. 092 DSCN-4004a 16. Remove the low pressure suction hose from the filter outlet fitting (Fig. 093). Fig. 093 18. Remove the fuel line from the fuel pump. Drain the fuel into a suitable container . 19.
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CHASSIS 20. Unplug the pink wire from the green fuel solenoid wire (Fig. 096). 22. Remove the bolt and washer securing the ground wires to the engine block (Fig. 098). 3 Fig. 096 DSCN-4015a 21. Unplug the white wire from the black magneto wire (Fig. 097). Fig. 097 36” & 40” Toro GrandStand Service Manual DSCN-4017a Fig. 098 DSCN-4026a 23. Remove the green and blue bullet connectors from the two small studs on the solenoid (Fig. 099). Fig.
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CHASSIS 24. Move the terminal cover off the positive cable com ing from the battery, then remove the nut and lock washer securing the positive battery cable and red wire eyelet to the solenoid (Fig. 100). 26. Remove the two wire harness clamps securing the wire harness to the engine base. They are located next to the clutch connector and under the starter. 27. Raise the rear of the machine just enough to remove the tires. 28.
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CHASSIS 30. Thoroughly clean the area around the hydraulic fittings, then mark the pumps and fittings to ensure they are returned to their original location upon assembly (Fig. 104). 32. Remove the bolts and nuts securing the control cable ends to the pump control arms (Fig. 106). 3 Fig. 106 Fig. 104 DSCN-4039a 31. Remove the four high pressure hoses from the pumps. Cap the hose ends and pump fittings to prevent debris from entering the system (Fig. 105). 33.
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CHASSIS 34. Using two people or a hoist, lift the rear of the carrier frame and tower assembly. Walk the carrier frame and tower assembly forward over the engine and deck assembly (Fig. 108). 36. Remove the pump drive belt. 37. Remove the bolt and nut securing the idler arm assembly to the engine base (Fig. 110). 3 Fig. 108 DSCN-4067a 35. Remove the extension spring from the pump idler assembly and anchor bolt (Fig. 109). Fig. 109 3-28 DSCN-4070a Fig. 110 DSCN-4075a 38.
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CHASSIS 39. Remove the two set screws securing the pump pullies to the pump output shafts. Remove the pump pullies, then remove the keys from the pump shaft keyways (Fig. 112). 41. Remove both pumps, with hoses attached, from the engine base (Fig. 114). 3 Fig. 114 Fig. 112 DSCN-4080a 40. Remove the four sets of carriage bolts, washers, and nuts securing the pumps to the engine base (Fig. 113). 42. Remove the nut and lock washer securing the red starter cable to the solenoid (Fig. 115). Fig. 115 Fig.
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CHASSIS 43. Remove the two thread forming screws securing the solenoid to the engine base (Fig. 116). 45. Remove the bolt and nut securing the clutch stop to the engine base (Fig. 118). 3 Fig. 116 DSCN-4087a Fig. 118 DSCN-4091a 44. Remove the cable tie securing the clutch wires to the clutch stop (Fig. 117). 46. Secure a lift to the engine to support the engine and engine base (Fig. 119). Fig. 117 Fig.
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CHASSIS 47. Remove the two sets of carriage bolts and flange nuts securing the engine base to the rear of the deck (Fig. 120). 49. Using the hoist, raise the engine and engine base from the mower deck. 50. Remove the four sets of bolts and Belleville washers securing the engine to the engine base. The engine base is now free to be removed. (Fig. 122). 3 Fig. 120 DSCN-4098a 48. Remove the two flange nuts securing the sides of the engine base to the deck (Fig. 121). Fig.
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CHASSIS Engine Base Installation 1. Secure the engine to the engine base using four bolts and Belleville washers. Torque bolts to 30-35 ft-lbs (40.6-47.4 Nm) (Fig. 123). 4. Secure the rear of the engine base to the rear of the deck using two carriage bolts and flange nuts (Fig. 125). Note: The crown of the Belleville washer must face the head of the bolt. 3 Fig. 125 Fig. 123 DSCN-4098a DSCN-4108a 2. Lower the engine and engine base onto the mower deck. 3.
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CHASSIS 5. Secure the clutch stop to the engine base using a bolt and flange nut (Fig. 126). 6. Push the clutch connector up through the engine base and position the grommet into the engine base hole (Fig. 128). 3 Fig. 126 DSCN-4112a Fig. 128 Note: The clutch stop must be nested into the slot on the clutch (Fig. 127). Fig. 127 7. Secure the clutch wires to the clutch stop using a cable tie (Fig. 129). DSCN-4114a Fig.
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CHASSIS 8. Place the pivot bolt with washer down through the engine base (Fig. 130). 10. Place the idler assembly, friction washer, then steel washer onto the pivot bolt (Fig. 132). 3 Fig. 130 DSCN-4120a 9. Place the large spacer, one friction composite washer and bushing onto the pivot bolt (Fig. 131). Fig. 131 3-34 DSCN-4124a Fig. 132 DSCN-4126a 11. Secure the idler assembly with a flange nut (Fig. 133). Fig.
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CHASSIS 12. Secure the pumps to the engine base using carriage bolts, washers, and nuts (Fig. 134). 14. Apply anti-seize to the pump shaft (Fig. 136). 3 Fig. 136 Fig. 134 13. Install the key into the keyway on the pump shaft (Fig. 135). 15. Apply thread-locking material to the threads of the pump pulley set screws (Fig. 137). Fig. 137 Fig.
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CHASSIS 16. Install the set screws into the pump pulley (Fig. 138). Note: Ensure the set screws have not protruded into the center of the pulley hub. 18. Position the pump drive belt around the engine, idler and pump pulleys (Fig. 140). A 3 Fig. 138 DSCN-4150a 17. Install the pulley onto the pump shaft. The base of the pulley hub should be flush with the base of the pump shaft. Secure the position with the set screws (Fig. 139). B E D C F Fig. 140 A. Hydraulic pumps B. Idler pulley C.
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CHASSIS 20. Secure the solenoid to the engine base using the two thread forming screws (Fig. 142). 22. Using two people or a hoist, lift the rear of the carrier frame and tower assembly. Walk the carrier frame and tower assembly rearward over the engine and deck assembly (Fig. 144). 3 Fig. 142 DSCN-4157a Fig. 144 21. Secure the red cable from the starter to the solenoid post (Fig. 143). Fig. 143 23. Position exhaust gaskets on the exhaust manifold (Fig. 145). DSCN-4163a Fig.
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CHASSIS 24. Secure the muffler to the exhaust manifold using nuts and lock washers. Torque to 21 ± 2 ft-lbs (28.4 ± 2.7 Nm) (Fig. 146). 26. Secure the deck to the lift chains using the bolts and flange nuts (Fig. 148). 3 Fig. 148 Fig. 146 25. Secure the muffler to the RH and LH muffler brackets using the bolts, thick washers, and flange nuts (Fig. 147). 27. Secure the front strut to the carrier frame using a bolt, large washer, and flange nut (Fig. 149). Fig. 149 Fig.
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CHASSIS 28. Route the belt around the deck and clutch pulleys (Fig. 150) 40” Belt Routing. 29. Install the extension spring to the idler bracket and spring anchor (Fig. 152). 3 Fig. 152 Fig. 150 decal 119-0187 DSCN-4185a 30. Hook the “Z” bend of the throttle cable into the throttle control lever and loosely clamp the outer housing of the throttle cable with the cable clamp (Fig. 153). (Fig. 151) 36” Belt Routing Fig. 153 Fig.
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CHASSIS 31. Move the throttle lever to the “Fast” position (Fig. 154). 33. 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. 156). 3 Fig. 154 DSCN-2674a Fig. 156 32. With the engine throttle control lever in the “Fast” position, pull the slack from the cable jacket and tighten the throttle cable clamp (Fig. 155). Fig. 155 3-40 IMG-0576a DSCN-2676a 34.
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CHASSIS 35. 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. 158). 37. Secure the low pressure return line to the reservoir fitting using the hose clamp (Fig. 160). 3 Fig. 160 Fig. 158 36. Secure the throttle and choke cable to the oil drain assemble using a cable tie (Fig. 159). Fig. 159 36” & 40” Toro GrandStand Service Manual DSCN-4187a IMG-0584a 38.
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CHASSIS 39. Position the muffler guard assembly and loosely install the four carriage bolts, two mounting guard brackets and nuts (Fig. 162). 41. Secure the wire harness to the engine base using the wire harness plastic anchors. 42. Connect the clutch wire harness to the wire harness (Fig. 164). 3 Fig. 162 DSCN-2678a Fig. 164 40. Make sure the muffler exhaust is centered in the muffler guard assembly, then tighten all four bolts and nuts. Torque the nuts to 19 ± 2 ft-lbs (25.76 ± 2.7 Nm) (Fig. 163).
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CHASSIS 44. Secure the battery cable and red wire eyelet to the solenoid using a lock washer and nut. Torque the nut to 35 in-lbs. (4 Nm) (Fig. 166). 46. Connect the white wire to the black magneto wire (Fig. 168). 3 Fig. 168 Fig. 166 45. Connect the green and blue bullet connectors to the two small studs on the solenoid (Fig. 167). 47. Connect the pink wire to the green fuel solenoid wire (Fig. 169). Fig. 169 Fig.
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CHASSIS 48. Connect the violet wire to the voltage regulator (Fig. 170). 50. Secure the cable clamp bracket to the engine base using carriage bolts and flange nuts (Fig. 172). 3 Fig. 170 DSCN-2695a 49. Secure the fuel line to the fuel pump using the hose clamp (Fig. 171). Fig. 171 3-44 DSCN-4009a Fig. 172 DSCN-4193a 51. Secure the control cables to the pump link using the bolts and nuts (Fig. 173). Fig.
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CHASSIS 52. Secure the rear struts to the frame and engine base using the bolts, large washers, and flange nuts (Fig. 174). 54. Loop the hoses around the control cables (Fig. 176). 3 Fig. 176 Fig. 174 DSCN-4224a DSCN-4215a 55. Install the hoses to the wheel motor (Fig. 177). 53. Secure the high pressure hoses to the pump (Fig. 175). Note: Ensure the hose is installed to the correct wheel motor fitting by using the identification markings. If installed incorrectly, wheel direction will be reversed.
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CHASSIS 56. Install the high pressure hoses to the opposite pump (Fig. 178). 57. Install the hoses to the wheel motor fittings (Fig. 180). Note: Ensure the hoses are installed to the correct wheel motor fittings by using the identification markings. If installed incorrectly, wheel direction will be reversed. 3 Fig. 178 DSCN-4229a Note: Ensure the hoses are installed to the correct pump fittings by using the identification markings. If installed incorrectly, wheel direction will be reversed.
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CHASSIS 59. Install the battery cover with the two hold down bolts and wing nuts (Fig. 182). 3 Fig. 182 DSCN-2700a 60. Install both tires. 61. Bleed the hydraulic system. See “Bleeding the Hydraulic System” on page 6-35.
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CHASSIS 3 THIS PAGE INTENTIONALLY LEFT BLANK.
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CONTROLS LH Motion Control Lever Replacement 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. 185). LH Motion Control Lever Removal 1. Remove the shoulder bolt and flange nut securing the end of the control cable to the LH motion control lever (Fig. 183). Fig. 185 Fig. 183 DSCN-3570 2.
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CONTROLS 5. Remove the bolt and jam nut from the handle assembly (Fig. 187). LH Motion Control Lever Installation 1. Install a plastic bearing into each end of the control handle (Fig. 189). 4 Fig. 187 DSCN-3595a Fig. 189 DSCN-3597a 6. Remove the two plastic bearings from the ends of the control handle (Fig. 188). 2. Loosely install the bolt and jam nut to the handle assembly (Fig. 190). Note: The nut will be tightened in a later step. Fig. 188 DSCN-3597a Fig.
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CONTROLS 3. Install the pivot rod into the center of the control handle (Fig. 191). Fig. 191 DSCN-3591a 4. Secure the control handle assembly in the control tower using two bolts (Fig. 192). 5. Secure the control cable to the motion control lever using the shoulder bolt and flange nut (Fig. 193). Fig. 193 DSCN-3570 6. Position the neutral switch bolt so the gap between it and the switch is between .05” and .09” (1.27 and 2.29mm). Secure the position using the jam nut (Fig. 194). A Fig.
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CONTROLS RH Motion Control Lever Replacement 2. Unplug the wire harness from the OPC switch (Fig. 196). RH Motion Control Lever Removal 1. Remove the shoulder bolt and flange nut securing the end of the control cable to the RH motion control lever (Fig. 195). Fig. 196 4 Fig.
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CONTROLS 3. Remove the two screws securing the pivot shaft inside the LH motion control lever (Fig. 197 & 198). Fig. 197 Note: Only one bolt will typically back out due to both threading into the same inner rod. A #4 easy-out can be used to secure the pivot rod. The bolt on the opposite side can then be removed (Fig. 199). DSCN-3649a Fig. 199 DSCN-3647a 4. Remove the RH control lever assembly from the control tower. 5. Remove the pivot rod from the motion control handle (Fig. 200). Fig.
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CONTROLS 6. Remove the extension spring from the assembly (Fig. 201). 4 Fig. 201 DSCN-3617a 7. Remove the two screws and tapped plate securing the OPC switch to the control handle assembly (Fig. 202). 8. Remove the bolt and nut securing the RH handle to the motion control assembly (Fig. 203). Fig. 203 9. Remove the nut and washer securing the adjustment cam to the RH control lever (Fig. 204). Fig. 204 Fig.
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CONTROLS 10. Remove the bolt and jam nut from the motion control assembly (Fig. 205). RH Motion Control Lever Installation 1. Install the four plastic bearings to the motion control assembly (Fig. 207). Fig. 205 DSCN-3634a Fig. 207 DSCN-3637a 11. Remove the four plastic bearings from the motion control assembly (Fig. 206). 2. Loosely secure the adjustment cam to the RH control lever (Fig. 208). Note: This nut will be tightened later in the process. Fig. 206 DSCN-3637a Fig.
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CONTROLS 3. Loosely install the bolt and jam nut to the handle assembly (Fig. 209). 5. Loosely secure the OPC switch to the motion control assembly (Fig. 211). Note: The nut will be tightened in a later step. Note: The bolts will be tightened later in the process. 4 Fig. 209 DSCN-3634a Fig. 211 4. Secure the RH control lever to the motion control assembly with the shoulder bolt and nut (Fig. 210). Fig. 210 6. Install the extension spring to the motion control assembly (Fig. 212). DSCN-3626a Fig.
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CONTROLS 7. Install the pivot rod into the motion control assembly (Fig. 213). Fig. 213 36” & 40” Toro GrandStand Service Manual DSCN-3616a 8. Secure the control handle assembly in the control tower using two bolts (Fig. 214 & 215). Fig. 214 DSCN-3649a Fig.
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CONTROLS 9. Install the wire harness onto the OPC switch (Fig. 216). 4 Fig. 216 11. Secure the position of the RH lever by tightening the nut on the adjustment cam on the RH control assembly to correct (Fig. 218). DSCN-3656a Fig. 218 10. Position the RH control handle so it is horizontally aligned with the LH lever (Fig. 217). DSCN-3661a 12. Adjust the OPC switch so there is .
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CONTROLS 13. Secure the position of the switch by tightening the two mounting screws (Fig. 220). 15. Position the neutral switch bolt so the gap between it and the switch is between .05” and .09” (1.27 and 2.29mm). Secure the position using the jam nut (Fig. 222). A Fig. 220 DSCN-3666a Fig. 222 14. Secure the control cable to the motion control lever using a shoulder bolt and flange nut (Fig. 221). Fig. 221 36” & 40” Toro GrandStand Service Manual DSCN-3668a A. .05” to .09” (1.27 to 2.
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CONTROLS Motion Control Cable Replacement 3. Remove the cable adjustment nut from the cross bracket (Fig. 225). Motion Control Cable Removal 1. Remove the shoulder bolt and flange nut securing the end of the control cable to the motion control lever (Fig. 223). Fig. 225 4 Fig. 223 DSCN-3671a DSCN-3674a 4. Remove the two thread forming screws and cable clamp securing the lower cable to the cable bracket (Fig. 226). 2. Remove the spring clip from the cross bracket (Fig. 224). Fig. 226 Fig.
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CONTROLS 5. Remove the bolt and flange nut securing the cable to the pump assembly (Fig. 227). Motion Control Cable Installation 1. Secure the cable rod end to the pump assembly using the bolt and flange nut (Fig. 228). Fig. 227 DSCN-3682a Fig. 228 DSCN-3682a 2. Secure the lower cable to the cable bracket using the two thread forming screws and cable clamp (Fig. 229). Fig.
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CONTROLS 3. Route the cable upwards, inside of the cable retainer (Fig. 230). 5. Secure the nut using the spring clip (Fig. 232). Fig. 232 4 Fig. 230 4. Position the cable adjustment nut into the slot on the cross bracket (Fig. 231). 6. Secure the control cable to the motion control lever using a shoulder bolt and flange nut (Fig. 233). Fig. 233 Fig. 231 DSCN-3690a DSCN-3685a DSCN-3671a DSCN-3688a 7. Verify the tracking of the machine. See “Adjusting the Tracking” on page 4-41.
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CONTROLS Parking Brake Replacement 3. Remove the grip from the brake handle (Fig. 236). Parking Brake Removal 1. Remove the hairpin cotter and clevis pin securing the linkage yoke, at the lower end of the link rod, to the brake assembly (Fig. 234). Fig. 236 DSCN-3822a 4. Remove the bolt, washer, and nut securing the brake handle to the control tower (Fig. 237). Fig. 234 DSCN-3815a 2. Remove the nut securing the upper end of the link rod to the brake handle (Fig. 235). Fig. 237 Fig.
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CONTROLS 5. Remove the bolt and nut securing the RH side of the brake and torsion spring assemblies to the chassis (Fig. 238). 4 Fig. 238 Parking Brake Installation 1. Secure the LH side of the brake assembly to the chassis using the shoulder bolt, spacer, and nut (Fig. 240). DSCN-3826a Fig. 240 6. Remove the shoulder bolt, spacer, and nut securing the LH side of the brake assembly to the chassis (Fig. 239). DSCN-3825a 2.
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CONTROLS 3. Position the brake handle through the control tower and secure the handle to the tower using the bolt, washer, and nut (Fig. 242). 5. Secure the upper end of the brake rod to the brake handle using the flange nut (Fig. 244). Note: Do not over tighten. The handle needs to move freely. Fig. 244 Fig. 242 DSCN-3817a DSCN-3819a 4. Install the grip onto the brake lever (Fig. 243). Fig.
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CONTROLS 6. Secure the yoke at the lower end of the brake rod to the brake assembly using the clevis pin (Fig. 245). 4 Fig. 245 DSCN-3834a 7. Secure the clevis pin using the hairpin cotter (Fig. 247). Fig. 247 DSCN-3837a Note: With the brake handle in the off position, measure the distance between the brake bar and tire. The distance needs to be between 3/16” and 5/16” (5 and 8mm). If adjustment is needed, remove the clevis pin and rotate the yoke accordingly (Fig. 246). C B A Fig. 246 A.
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CONTROLS Height-of-Cut (HOC) Handle Assembly Replacement 3. Remove the snap ring and washer securing the HOC handle assembly to the frame (Fig. 250). HOC Handle Assembly Removal 1. Position two boards under the deck, then lower the deck onto the boards (Fig. 248). Fig. 250 DSCN-3843a 4. Remove the nuts securing the HOC anchor bolt to the HOC plate assembly (Fig. 251). Fig. 248 DSCN-3839a 2. Remove the bolt and nut securing the lift link assembly to the lower end of the HOC handle (Fig. 249). Fig.
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CONTROLS 5. Remove the two sets of bolts, washers, spacers, and nuts securing the HOC plates to the control tower (Fig. 252). 7. Remove the latch rod assembly, spring and washer out through the top of the HOC handle (Fig. 254). Fig. 254 4 Fig. 252 6. Remove the shoulder bolt and nut securing the latch rod to the HOC latch (Fig. 253). 8. Remove the shoulder bolt, washer, and nut securing the HOC latch to the HOC handle (Fig. 255). Fig. 255 Fig.
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CONTROLS HOC Handle Assembly Installation 3. Position the latch rod assembly into the HOC handle (Fig. 258). 1. Secure the HOC latch to the HOC handle using the shoulder bolt, washer, and nut (Fig. 256). Fig. 258 Fig. 256 DSCN-3877a 2. Position the spring and washer onto the latch rod (Fig. 257). 4. Secure the lower end of the latch rod assembly to the HOC latch using the shoulder bolt and nut (Fig. 259). Fig. 259 Fig.
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CONTROLS 5. Position the bolt, washer, and spacers into the rear of the HOC plates (Fig. 260). 4 Fig. 260 DSCN-3891a 7. Position the HOC handle pivot shaft through the frame hub (Fig. 262). Fig. 262 DSCN-3900a 6. Loosely secure the HOC plates assembly to the control tower using the flange nut (Fig. 261). Fig.
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CONTROLS 8. Secure the front of the HOC plates to the control tower using the bolt, washer, spacers, and nut. Tighten the rear fastener assembly. (Fig. 263). 9. Secure the HOC handle latch bolt to the control tower using the two nuts (Fig. 265). Fig. 265 Fig. 263 Note: The HOC handle must be nested in between the HOC plates (Fig. 264). 10. Install the washer and snap ring that secure the HOC handle to the frame (Fig. 266). Fig. 266 Fig.
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CONTROLS 11. Secure the lift link assembly to the lower end of the HOC handle (Fig. 267). Choke Cable Replacement Choke Cable Removal 1. Remove the bolt and cable clamp securing the choke cable to the engine throttle plate (Fig. 269). 4 Fig. 267 DSCN-3841a 12. Pump high temp grease into the HOC handle pivot hub (Fig. 268). Fig. 269 DSCN-3505a 2. Remove the “Z” bend of the choke cable from the engine choke arm (Fig. 270). Fig. 268 DSCN-3915a 13. Raise the deck and remove the boards. Fig.
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CONTROLS 3. Remove the cable tie securing the choke and throttle cable to the oil drain (Fig. 271). 6. Remove the choke cable from the control panel (Fig. 273). Fig. 271 Fig. 273 DSCN-3511a DSCN-3518a 4. From the rear of the machine, pull the cable rear ward from the frame. 5. Remove the nut securing the choke cable to the control panel (Fig. 272). Fig.
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CONTROLS Choke Cable Installation 3. Feed the cable through the frame, to the left of the brake linkage (Fig. 276). 1. Feed the choke cable through the mounting hole in the control panel (Fig. 274). Fig. 276 4 Fig. 274 DSCN-3519a DSCN-3518a 4. Feed the choke cable through the ”R” clamp located on the carrier frame (Fig. 277). 2. Secure the choke cable to the control panel using a nut (Fig. 275). Fig. 277 Fig.
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CONTROLS 5. Install the choke cable “Z” bend into the engine choke lever (Fig. 278). Fig. 278 DSCN-3509a 6. Position the choke cable to the engine throttle plate and loosely install the screw and cable clamp (Fig. 279). 7. Position the choke knob in the “OPEN” position (Fig. 280). Fig. 280 8. Ensure the choke is fully open in the throat of the carburetor (Fig. 281). Fig. 281 Fig.
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CONTROLS 9. While holding the engine choke lever in the “OPEN” position, pull the slack from the cable jacket, then secure the position of the choke cable with the screw and cable clamp (Fig. 282). Throttle Cable Replacement Throttle Cable Removal 1. Remove the bolt and cable clamp securing the throttle cable to the engine throttle plate (Fig. 284). 4 Fig. 282 DSCN-3530a Fig. 284 DSCN-3505a 10. Secure the choke and throttle cable to the oil drain using a cable tie (Fig. 283). 2.
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CONTROLS 3. Remove the cable tie securing the choke and throttle cable to the oil drain (Fig. 286). Fig. 286 6. Remove the two carriage bolts and nuts securing the throttle lever assembly to the control panel (Fig. 288). DSCN-3511a Fig. 288 4. From the rear of the machine, pull the cable rearward from the frame. 5. Remove the throttle knob from the throttle lever (Fig. 287). 7. Remove the cable clip and then the “Z” bend of the cable from the throttle control lever assembly (Fig. 289). Fig. 289 Fig.
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CONTROLS Throttle Cable Installation 3. Apply thread-locking material to the threads of the handle knob (Fig. 292). 1. Hook the “Z” bend of the speed control cable to the speed control lever assembly and secure with the cable clip (Fig. 290). Fig. 292 4 Fig. 290 DSCN-3552a DSCN-3554a 4. Install the handle knob to the throttle lever (Fig. 293). 2. Secure the lever assembly to the control tower using two carriage bolts and nuts (Fig. 291). Fig. 293 Fig.
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CONTROLS 5. Route the throttle cable downward between the control cables and fuel tank, then forward under the fuel tank shelf. Feed the throttle cable through the ”R” clamp located on the carrier frame (Fig. 294). 7. Position the throttle cable to the engine throttle plate and loosely install the screw and cable clamp (Fig. 296). Fig. 296 Fig. 294 6. Install the throttle cable “Z” bend into the engine throttle lever (Fig. 295). 8. Move the throttle lever to the “FAST” position (Fig. 297). Fig.
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CONTROLS 9. With the engine throttle control lever in the “Fast” position, pull the slack from the cable jacket and tighten the throttle cable clamp (Fig. 298). Speed Control Replacement Speed Control Removal 1. Remove the shoulder bolts and flange nuts securing the ends of the control cables to the motion control levers (Fig. 299). 4 Fig. 298 DSCN-3561a 10. Ensure the throttle is functioning correctly by moving the throttle lever from “FAST” to “SLOW” while observing the engine throttle lever. Fig.
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CONTROLS 3. Remove the two cable adjustment nuts from the cross bracket (Fig. 301). Fig. 301 DSCN-3674a 4. Remove the cable tie securing the fuel vent hose to the speed control base assembly (Fig. 302). 5. Remove the grip from the speed control lever (Fig. 303). Fig. 303 DSCN-3705a 6. Remove the two sets of bolts and nuts securing the cross bracket to the control tower (Fig. 304). Note: Do not remove the wire harness from the cross bracket.
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CONTROLS 7. Remove the two sets of carriage bolts and nuts securing the speed control assembly to the control panel (Fig. 305). 9. Remove the bolt, nut, and clamp washer securing the slider assembly to the cable (Fig. 307). Fig. 307 4 Fig. 305 8. Remove the two sets of carriage bolts and nuts securing the slider bracket to the control assembly (Fig. 306). 10. Remove the four sets of bolts, nuts, and spacers securing the slider plates to the slider assembly (Fig. 308). Fig. 308 Fig.
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CONTROLS 11. Remove the nuts securing the cable to the control assembly (Fig. 309). Fig. 309 DSCN-3726a 12. Remove the bolt, spacer, washer, and nut securing the link assembly to the control assembly (Fig. 310). Fig. 310 36” & 40” Toro GrandStand Service Manual DSCN-3729a 13. Remove the fastener assembly securing the speed control handle to the control assembly (Fig. 311). Fig. 311 DSCN-3732a 14. Remove the nuts and washers securing the pulleys to the control assembly (Fig. 312). Fig.
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CONTROLS Speed Control Installation Note: The wave washers must be nested together, not alternating (Fig. 315). 1. Secure the three pulleys to the control assembly using washers and nuts (Fig. 313). Fig. 315 4 Fig. 313 DSCN-3748a DSCN-3741a 3. Secure the handle to the control assembly using the retainer, lock washer, and flange nut (Fig. 316). 2. Position the carriage bolt, washer, spacer, and wave washers onto the control assembly (Fig. 314). Fig.
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CONTROLS 4. Position the bolt, spacer, and washer into the control handle (Fig. 317). 6. Loosely install the cable eyelet to the link assembly stud (Fig. 319). Note: This nut will be tightened in a later step. Fig. 317 DSCN-3763a Fig. 319 5. Secure the link assembly to the control handle using a flange nut (Fig. 318). DSCN-3770a 7. Route the cable around the pulleys and secure to the link assembly using the nut and jam nut, then tighten the nut securing the cable eyelet (Fig. 320).
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CONTROLS 8. Secure the slider plates to the slider assembly using the four sets of bolts, spacers, and flange nuts (Fig. 321). Note: The cable tab must be located to the inside of the cable (Fig. 323). Note: The base of the slider plates and the base of the slider assembly MUST be level to each other. Fig. 323 4 Fig. 321 DSCN-3779 DSCN-3790a 10. Loosely install the bolt, nut, and cable clamp to the slide assembly (Fig. 324). Note: This assembly will be tightened in a later step. 9.
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CONTROLS 11. Secure the slider bracket to the control assembly using the two sets of carriage bolts and flange nuts (Fig. 325). 13. Install the grip onto the speed control lever (Fig. 327). Fig. 327 Fig. 325 12. Secure the control assembly to the control tower using two sets of carriage bolts and nuts (Fig. 326). 14. Secure the cross-brace to the control tower using two bolts and flange nuts (Fig. 328). Fig. 328 Fig.
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CONTROLS 15. Secure the fuel vent hose to the control assembly using a cable tie (Fig. 329). 4 Fig. 329 17. Secure the control cables to the motion control levers using a shoulder bolt and flange nut (Fig. 331). DSCN-3803a Fig. 331 16. Position the cable adjustment nuts in the slots on the cross brace and secure using the spring clip (Fig. 330). Fig. 330 4-40 DSCN-3804a DSCN-3671a 18. Place the speed control lever into the “FAST” position (Fig. 332). Fig.
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CONTROLS 19. Pull the RH and LH slider spacers rearward as far as possible (Fig. 333). Adjusting the Tracking Note: Determine the left and right sides of the machine from the normal operating position. 1. While driving the machine, push both control levers forward the same distance. 2. Check if the machine tracks to one side. If it does, stop the machine and set the parking brake. 3. Release the operator cushion from the rear of the machine. Fig. 333 DSCN-3812a 20.
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CONTROLS 5. Check for proper tracking Speed Control Adjustment 5. Repeat adjustment until the tracking is correct. 1. Loosen the clamp assembly securing the speed control assembly to the speed control cable (Fig. 336). 7. Check that the machine does not creep from neutral with the park brakes disengaged. Important Do not rotate the linkage too far, as this may cause the machine to creep in neutral. 4 Fig. 336 DSC-0534a 2. Move the speed control lever to the “Fast” position (Fig. 337). Fig.
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CONTROLS 3. Pull the RH and LH idler spacers rearward as far as possible (Fig. 338). Fig. 338 DSC-0540a 4 4. Tighten the clamp assembly securing the speed control cable to the speed control assembly (Fig. 339). Fig. 339 DSC-0534a 5. Verify that the speed control lever and motion control levers operate smoothly.
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CONTROLS 4 THIS PAGE INTENTIONALLY LEFT BLANK.
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ENGINE Engine Replacement 5. Remove the bolt, washer, and nut securing the black ground cable to the battery terminal (Fig. 342). 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. 340). Fig. 342 DSCN-2265a 6. Remove the bolt, washer, and nut securing the red positive cable to the battery terminal, then remove the battery (Fig. 343). Fig. 340 DSCN-2516a 3. Drain the engine oil. 4.
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ENGINE 7. Slide the hose clamp off the fuel line where it con nects to the fuel pump (Fig. 344). Fig. 344 DSCN-2517a 8. Remove the fuel line from the fuel pump. Drain the fuel into a suitable container (Fig. 345). 9. Remove the violet wire from the voltage regulator (Fig. 346). Fig. 346 DSCN-2522a 10. Unplug the pink wire from the green fuel solenoid wire (Fig. 347). 5 Fig. 345 5-2 DSCN-2521a Fig.
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ENGINE 11. Unplug the white wire from the black magneto wire (Fig. 348). Fig. 348 DSCN-2527a 12. Remove the bolt and washer securing the ground wires to the engine block (Fig. 349). 13. Remove nut and lock washer securing the starter wire to the solenoid (Fig. 350). Fig. 350 DSCN-2533a 14. Unplug the clutch wires from the wiring harness (Fig. 351). 5 Fig. 349 36” & 40” Toro GrandStand Service Manual DSCN-2530a Fig.
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ENGINE 15. Push the grommet and the electrical plug connector down through the engine base (Fig. 352). Fig. 352 17. Loosen the screw on the choke cable clamp and disconnect the choke cable from the engine choke lever (Fig. 354). DSCN-2547a Fig. 354 5 DSCN-2551a 16. Remove the four nuts, two mounting guard brackets, and four carriage bolts securing the muffler guard assembly to the front frame, then remove the muffler guard (Fig. 353). 18.
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ENGINE 19. Remove the cable clamp securing the throttle and choke cable to the engine oil drain (Fig. 356). Fig. 356 DSCN-2561a 20. Lower the HOC (height of cut) to the lowest HOC. 21. Remove the belt covers. 23. 40” Deck: Using a spring tool, remove the exten sion spring from the deck anchor post (Fig. 358). Fig. 358 DSCN-2564a 24. 40” Deck: Using a spring tool, remove the RH spindle extension spring from the RH deck anchor post (Fig. 359). 22.
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ENGINE 25. Raise the machine so the underside of the chassis can be accessed. 28. Remove the extension spring from the drive idler pulley assembly (Fig. 362). 26. Remove the cable tie securing the clutch wire harness to the clutch anchor (Fig. 360). Fig. 362 Fig. 360 5 DSCN-2566a DSCN-2574a 29. Remove the drive belt from the engine pulley (Fig. 363). 27. Remove the deck belt from the clutch pulley (Fig. 361). Fig. 363 Fig.
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ENGINE 30. Remove the bolt and nut securing the clutch anchor to the engine base (Fig. 364). Fig. 364 DSCN-2578a 31. Remove the four bolts and Belleville washers secur ing the engine to the engine base (Fig. 365). 32. Using a hoist, remove the engine from the engine base (Fig. 366). Fig. 366 DSCN-2587a 33. Remove one spark plug and feed a minimum of two feet (61cm) of 3/8” (.95cm) rope into the cylinder to prevent engine crankshaft rotation (Fig. 367).
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ENGINE 34. Remove the bolt, spring washer, and washer secur ing the clutch to the engine crankshaft. (Fig. 368). Fig. 368 DSCN-2589a 35. Remove the clutch from the engine crankshaft. 5 36. Remove the drive pulley from the engine crankshaft (Fig. 369). 37. Remove the key from the engine crankshaft keyway (Fig. 370). Fig. 370 38. Loosen the jam nut securing the position of the oil drain assembly, then remove the oil drain (Fig. 371). Fig. 371 Fig.
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ENGINE 39. Remove the two bolts, spacers and nuts securing the left and right side muffler brackets to the muffler (Fig. 372). Fig. 372 IMG-0542a 41. Remove the four bolts and lock washers securing the right and left hand muffler brackets to the engine (Fig. 374). Fig. 374 IMG-0528a 40. Remove four nuts and lock washers securing the muffler to the engine (Fig. 373). Fig.
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ENGINE Engine Installation 1. Secure the RH and LH muffler brackets to the engine using four bolts and lock washers (Fig. 375). 3. Secure the muffler to the engine using four nuts and lock washers. Torque to 19 ± 2 ft-lbs. (26 ± 3 Nm) (Fig. 377). Fig. 377 Fig. 375 5 IMG-0528a 2. Position an exhaust gasket on the exhaust studs for both exhaust ports (Fig. 376). Fig. 376 5-10 IMG-0532a IMG-0531a 4.
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ENGINE 5. Install the oil drain assembly into the engine sump (Fig. 379). 7. Install the key into the engine crankshaft keyway and apply anti seize around the crankshaft (Fig. 381). Note: Position the oil drain assembly with the exit port pointing downward, then secure the position with the jam nut. Fig. 381 Fig. 379 DSCN-2602a DSCN-2603a 8. Install the drive pulley onto the engine crankshaft with the large hub towards the engine (Fig. 382). 5 6.
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ENGINE 9. Using a feeler gauge, check the clutch air gap at each of the three adjustment slots. Set the gap to .015” (0.381mm). Make sure the gauge is inserted between the armature and the rotor friction surfaces (Fig. 383). 11. Apply thread locking compound to the threads of the clutch bolt (Fig. 385). Fig. 385 Fig. 383 5 PICT-0554a PICT-8700a 12. Torque the clutch bolt to 55 ft-lbs. (75 Nm) (Fig. 386). 10.
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ENGINE 13. Remove the rope from the engine cylinder and replace the spark plug (Fig. 387). Fig. 387 15. Secure the engine to the engine base using the four sets of bolts and Belleville washers. Torque the bolts to 30 - 35 ft-lbs. (41 - 47 Nm) (Fig. 389). IMG-9634a Fig. 389 DSCN-2581a 14. Using a hoist, position the engine onto the engine base (Fig. 388). 5 Fig.
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ENGINE 16. Secure the PTO stop bracket to the engine base using a bolt and nut (Fig. 390). Fig. 390 DSCN-2642a Note: Ensure the PTO stop bracket is nested in the slot on the clutch plate (Fig. 391). 17. Feed the clutch wire harness up through the engine base (Fig. 392). Fig. 392 DSCN-2647a 18. Install the rubber grommet into the engine base (Fig. 393). 5 Fig. 391 5-14 DSCN-2645a Fig.
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ENGINE 19. Secure the wire harness to the PTO stop bracket using a cable tie (Fig. 394). Fig. 394 DSCN-2658a 20. Position the pump drive belt around the engine drive pulley, the two hydraulic pump pulleys, and the idler pulley (Fig. 395). 21. Install the extension spring from the idler bracket to the spring anchor (Fig. 396). Fig. 396 DSCN-2660a 22. 36” Deck: Route the deck belt around the deck spindle pulleys. Refer to decal 119-0186 (Fig. 397). 5 A B E D C F Fig. 395 A. Hydraulic pumps B.
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ENGINE 23. 36” Deck: Install the extension spring to the idler bracket and spring anchor (Fig. 398). Fig. 398 DSCN-2666a 24. 40” Deck: Route the deck belts around the deck spindle pulleys. Refer to decal 119-0187 (Fig. 399). 25. 40” Deck: Install the extension spring to the LH idler bracket and spring anchor (Fig. 400). Fig. 400 DSCN-2670a 26. 40” Deck: Install the extension spring to the RH idler bracket and spring anchor (Fig. 401). 5 Fig. 401 Fig.
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ENGINE 27. Install the belt covers. 28. Hook the “Z” bend of the throttle cable into the throttle control lever and loosely clamp the outer housing of the throttle cable with the cable clamp (Fig. 402). 30. With the engine throttle control lever in the “Fast” position, pull the slack from the cable jacket and tighten the throttle cable clamp (Fig. 404). Fig. 404 Fig. 402 DSCN-2672a 29. Move the throttle lever to the “Fast” position (Fig. 403). 31.
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ENGINE 32. Push the choke knob in so it is in the “Open” position (Fig. 406). Fig. 406 5 DSCN-2677a 33. 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. 407). Fig. 407 5-18 IMG-0584a 34. Secure the throttle and choke cable to the oil drain assemble using a cable tie (Fig. 408). Fig. 408 DSCN-2683a 35.
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ENGINE 36. Make sure the muffler exhaust is centered in the muffler guard assembly, then tighten all four bolts and nuts. Torque the nuts to 19 ± 2 ft-lbs. (25.76 ± 2.7 Nm) (Fig. 410). 38. Install the battery ground wire and the wiring harness ground wire to the engine block (Fig. 412). Fig. 412 Fig. 410 DSCN-2680a 37. Connect the clutch wire harness to the wire harness (Fig. 411). Fig. 411 36” & 40” Toro GrandStand Service Manual DSCN-2688a DSCN-2686a 39.
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ENGINE 40. Connect the white wire to the black magneto wire (Fig. 414). Fig. 414 DSCN-2691a 41. Connect the pink wire to the green fuel solenoid wire (Fig. 415). 42. Connect the violet wire to the voltage regulator (Fig. 416). Fig. 416 DSCN-2695a 43. Secure the fuel line to the fuel pump using the hose clamp (Fig. 417). 5 Fig. 415 5-20 DSCN-2692a Fig.
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ENGINE 44. Position the battery on the battery tray. Using the bolt nut and washer, secure the positive battery cable to the battery. Using the bolt nut and washer, secure the negative battery cable to the battery (Fig. 418). 46. Fill the engine with oil to the specified level. 47. Turn the fuel shutoff valve to the “ON” position (Fig. 420). Fig. 420 Fig. 418 DSCN-2702a DSCN-2698a 5 45. Install the battery cover with the two hold down bolts and wing nuts (Fig. 419). Fig.
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ENGINE THIS PAGE INTENTIONALLY LEFT BLANK.
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HYDRAULIC DRIVE SYSTEM Pump Drive Belt Replacement 3. Raise the machine so the underside of the chassis can be accessed. Pump Drive Belt Removal 1. 36” Deck: Using a spring tool, remove the exten sion spring from the deck anchor post (Fig. 421). 4. Remove the deck belt from the clutch pulley (Fig. 423). Fig. 423 Fig. 421 DSCN-2569a DSCN-2562a 2. 40” Deck: Using a spring tool, remove the LH extension spring from the deck anchor post (Fig. 422). 5.
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HYDRAULIC DRIVE SYSTEM 6. Remove the drive belt from the engine pulley and pump pulleys (Fig. 425). Pump Drive Belt Installation 1. Position the pump drive belt around the engine drive pulley, the two hydraulic pump pulleys, and the idler pulley (Fig. 426). A Fig. 425 DSCN-2575a B E D C F Fig. 426 A. Hydraulic pumps B. Idler pulley C. Clutch pulley 6 fig. 67 G012686 D. Clutch retainer E. Pump drive belt F. Pump drive pulley 2.
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HYDRAULIC DRIVE SYSTEM 3. 36” Deck: Route the deck belt around the deck spindle pulleys. Refer to decal 119-0186 (Fig. 428). Fig. 428 decal 119-0186 4. 36” Deck: Install the extension spring to the idler bracket and spring anchor (Fig. 429). Fig. 429 36” & 40” Toro GrandStand Service Manual DSCN-2666a 5. 40”Deck: Route the deck belts around the deck spindle pulleys. Refer to decal 119-0187 (Fig. 430). Fig. 430 decal 119-0187 6.
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HYDRAULIC DRIVE SYSTEM Pump Drive Belt Idler Replacement 5. Remove the large spacer, two friction composite washers, spacer and washer (Fig. 434). Pump Drive Belt Idler Removal 1. Raise the machine so the underside of the chassis can be accessed. 2. Remove the extension spring from the drive idler pulley assembly (Fig. 432). A B C D B E Fig. 434 A. Steel Washer B. Friction Composite Washer (2) Fig. 432 6 DSCN-2574a C. Bushing D. Idler Plate E. Large Spacer 6.
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HYDRAULIC DRIVE SYSTEM Pump Drive Belt Idler Installation 3. Place the large spacer, one friction composite washer and bushing onto the pivot bolt (Fig. 438). 1. Secure the idler pulley to the idler plate using a bolt, washers and a nut (Fig. 436). Note: The pulley hub needs to face the idler plate. A B D C B E Fig. 438 Fig. 436 A. Bolt B. Washer (2) C. Idler Pulley DSCN-2784a DSCN-2793a 4. Place the idler assembly onto the pivot bolt (Fig. 439). D. Idler Plate E. Nut 2.
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HYDRAULIC DRIVE SYSTEM 5. Place one friction composite washer and steel washer onto the pivot bolt (Fig. 440). 6. Position the pump drive belt around the engine, idler and pump pulleys (Fig. 442). A Fig. 440 DSCN-2795a B E D C F B. Secure the idler assembly with a nut (Fig. 441). Fig. 442 A. Hydraulic pumps B. Idler pulley C. Clutch pulley 6 fig. 67 G012686 D. Clutch retainer E. Pump drive belt F. Pump drive pulley 7.
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HYDRAULIC DRIVE SYSTEM Pump Replacement 4. Raise the rear of the machine. 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. 5.
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HYDRAULIC DRIVE SYSTEM 8. Remove the belt from around the pump pulley (Fig. 447). Fig. 447 DSCN-2962a 9. Remove the two set screws securing the pump pulley to the pulley shaft, then remove the pulley (Fig. 448). 10. Remove the key from the pulley shaft keyway (Fig. 449). Fig. 449 DSCN-2971a 11. Remove the bolt and nut securing the control cable to the pump control arm (Fig. 450). 6 Fig. 450 Fig.
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HYDRAULIC DRIVE SYSTEM 12. Mark the high pressure hoses and wheel motor fittings to ensure they are re-installed correctly (Fig. 451). Fig. 451 DSCN-2986a 13. Mark the high pressure hoses and pump to ensure they are re-installed correctly (Fig. 452). 14. Place a drain pan under the wheel motor and dis connect both hydraulic hoses from the wheel motor fittings (Fig. 453). Fig. 453 DSCN-2989a 15. Remove the two high pressure hoses from the pump (Fig. 454). 6 Fig.
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HYDRAULIC DRIVE SYSTEM 16. Remove the low pressure suction line from the pump fitting (Fig. 455). Fig. 455 18. Remove the two sets of bolts, washers and nuts securing the pump to the engine base (Fig. 457). Fig. 457 DSCN-2992a 17. Move the hose clamp securing the low pressure return hose to the pump fitting, then remove the hose (Fig. 456). DSCN-3045a 19. Remove the pump. 20. Loosen the jam nut securing the return hose fitting, then remove the fitting (Fig. 458). 6 Fig. 456 DSCN-2995a Fig.
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HYDRAULIC DRIVE SYSTEM 21. Loosen the jam nut securing the suction hose fitting, then remove the fitting (Fig. 459). Pump Installation 1. Transfer the high pressure hose identification marks to the replacement pump. 2. Secure the pump control arm to the RTN (Return to Neutral) assembly using the bolts and nuts (Fig. 461). Fig. 459 DSCN-3032a 22. Remove the two sets of bolts and nuts securing the pump control arm to the pump RTN (Return to Neutral) assembly (Fig. 460). Fig. 461 DSCN-3038a 3.
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HYDRAULIC DRIVE SYSTEM 4. Install the return hose fitting, orientate as shown, then secure the position using the jam nut (Fig. 463). Fig. 463 DSCN-3029a 5. Secure the pump to the engine base using the carriage bolts, washers and nuts (Fig. 464). 6. Secure the return hose to the pump fitting using the hose clamp (Fig. 465). Fig. 465 DSCN-3049a 7. Secure the suction hose to the pump fitting (Fig. 466). Note: Secure the position of the fitting using the jam nut. 6 Fig. 464 DSCN-3045a Fig.
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HYDRAULIC DRIVE SYSTEM 8. Install the high pressure hose to the pump (Fig. 467). Note: Ensure the hose is installed to the correct pump fitting by using the identification mark ings. If installed incorrectly, wheel direction will be reversed. 10. Install the hose to the wheel motor (Fig. 469). Note: Ensure the hose is installed to the correct wheel motor fitting by using the identification markings. If installed incorrectly, wheel direction will be reversed. Fig. 469 Fig. 467 DSCN-3057a DSCN-3052a 9.
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HYDRAULIC DRIVE SYSTEM 11. Install the second high pressure hose to the pump (Fig. 470). 13. Install the hose to the wheel motor (Fig. 472). Fig. 472 Fig. 470 DSCN-3063a DSCN-3059a 14. Secure the control cable to the pump control arm (Fig. 473). 12. Loop the hose around the control cables and opposite side pump hoses (Fig. 471). 6 Fig. 473 Fig.
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HYDRAULIC DRIVE SYSTEM 15. Install the key into the keyway on the pump shaft (Fig. 474). Fig. 474 DSCN-2971a 16. Apply anti-seize to the pump shaft (Fig. 475). 17. Apply thread-locking material to the threads of the pump pulley set screws (Fig. 476). Fig. 476 DSCN-3069a 18. Install the set screws into the pump pulley (Fig. 477). Note: Ensure the set screws have not protruded into the center of the pulley hub. 6 Fig. 475 DSCN-3079a Fig.
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HYDRAULIC DRIVE SYSTEM 19. Install the pulley onto the pump shaft. The base of the pulley hub should be flush with the base of the pump shaft. Secure the position with the set screws (Fig. 478). 21. Install the extension spring from the idler bracket to the spring anchor (Fig. 480). Fig. 480 Fig. 478 DSCN-2660a DSCN-3081a 20. Position the pump drive belt around the engine, idler and pump pulleys (Fig. 479). A 22. Secure the tire assembly to the wheel motor hub using the four wheel lug nuts (Fig.
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HYDRAULIC DRIVE SYSTEM 23. Lower the machine to the ground. Wheel Motor Replacement 24. 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.
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HYDRAULIC DRIVE SYSTEM 3. Loosen the four lug nuts (Fig. 484). Fig. 484 7. Remove the wheel motor nut (Fig. 486). DSCN-2805a 4. Raise the rear of the machine. Fig. 486 DSCN-2806a 8. Install a hub puller (Toro p/n: TOR6006) onto the wheel lug bolts (Fig. 487). 5. Release the parking brake. 6. Remove the four lug nuts and remove the tire (Fig. 485). Note: The lug bolts need to be installed backwards so the flat side is against the puller. 6 Fig. 485 6-18 DSCN-2805 Fig.
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HYDRAULIC DRIVE SYSTEM 9. Advance the forcing screw through the wheel hub until it firmly contacts the wheel motor shaft (Fig. 488). Fig. 488 11. Remove the hub puller from the hub. 12. Remove the woodruff key from the wheel motor shaft keyway (Fig. 490). DSCN-2817a Fig. 490 10. 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. 489). DSCN-2827a 13. Mark the hose and motor ports to ensure they are installed correctly (Fig. 491).
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HYDRAULIC DRIVE SYSTEM 14. Place a drain pan under the wheel motor and disconnect both hydraulic hoses from the wheel motor (Fig. 492). 16. Loosen the jam nut securing the position of the fit tings, then remove the hydraulic fittings (Fig. 494). Fig. 494 Fig. 492 DSCN-2836a DSCN-2834a 15. Cap the hose ends to prevent debris from entering the system (Fig. 493). 17. Remove the four bolts and nuts securing the wheel motor to the frame, then remove the wheel motor (Fig. 495).
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HYDRAULIC DRIVE SYSTEM Wheel Motor Installation 3. Install the two hydraulic fittings into the motor. (Fig. 498). 1. Transfer the port identification markings to the new motor (Fig. 496). Fig. 496 DSCN-2854a 2. Secure the wheel motor to the frame using the four bolts and nuts. Torque the fasteners to 86 ± 9 ft-lbs. (117 ± 12 Nm) (Fig. 497). Note: Do not tighten the jam nuts until the hoses are connected. Fig. 498 DSCN-2836a 4.
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HYDRAULIC DRIVE SYSTEM 5. Install the woodruff key into the wheel motor shaft keyway (Fig. 500). 7. Secure the wheel hub onto the wheel motor shaft using the wheel motor nut (Fig. 502). Note: The wheel motor nut will be torqued in a later step. Fig. 500 DSCN-2827a 6. Apply thread-locking material to the threads of the wheel motor nut (Fig. 501). Fig. 502 DSCN-2806a 8. Secure the tire to the wheel motor hub using the four wheel lug nuts (Fig. 503).
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HYDRAULIC DRIVE SYSTEM 9. Lower the machine to the ground. Reservoir Tank Replacement 10. 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.
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HYDRAULIC DRIVE SYSTEM 2. Position a drain pan under the reservoir tank. Re move the low pressure return hose from the fitting and drain the fluid into the pan (Fig. 507). Fig. 507 DSCN-2887a 3. Remove the low pressure suction hose from the reservoir fitting (Fig. 508). 4. Remove the two sets of bolts, washers and nuts securing the reservoir tank to the tank bracket, then remove the reservoir tank (Fig. 509). Fig. 509 DSCN-2890a 5.
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HYDRAULIC DRIVE SYSTEM 6. Loosen the jam nut securing the suction hose fitting, then remove the fitting (Fig. 511). Reservoir Tank Installation 1. Install the suction hose fitting into the reservoir tank and secure the position using the jam nut (Fig. 512). Fig. 511 DSCN-2901a Fig. 512 DSCN-2905a 2. Install the return hose fitting into the reservoir tank and secure the position using the jam nut (Fig. 513). 6 Fig.
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HYDRAULIC DRIVE SYSTEM 3. Secure the reservoir tank to the tank bracket using the two sets of bolts, washers and nuts (Fig. 514). Fig. 514 5. Secure the return hose to the return fitting using the hose clamp (Fig. 516). Fig. 516 DSCN-2890a 4. Install the suction hose to the suction fitting (Fig. 515). DSCN-2906a 6. Fill the reservoir to the “COLD” fluid level with the specified hydraulic fluid. See your Operator’s Manual for the specified fluid (Fig. 517). A C D 6 Fig. 515 B DSCN-2887a Fig.
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HYDRAULIC DRIVE SYSTEM Hydraulic Filter Mount Replacement 2. Remove the suction hose from the filter mount inlet fitting (Fig. 519). 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. Loosen the jam nut and remove the inlet fitting (Fig. 521). Fig. 521 DSCN-2916a 6. Remove the two bolts and washers securing the hydraulic filter mount to the filter bracket (Fig. 523). Fig. 523 DSCN-2921a 5. Loosen the jam nut and remove the outlet fitting (Fig. 522). 6 Fig.
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HYDRAULIC DRIVE SYSTEM Hydraulic Filter Mount Installation 2. Install the outlet fitting into the filter mount outlet port (Fig. 526). 1. Secure the hydraulic filter mount to the filter bracket using the two bolts and nuts (Fig. 524). Note: Do not tighten the jam nut at this time. Fig. 524 DSCN-2921a Note: Position the filter mount so the “FLOW” arrow aligns with the arrow in the filter bracket (Fig. 525). Fig. 526 DSCN-2919a 3.
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HYDRAULIC DRIVE SYSTEM 4. Install the inlet fitting into the filter mount inlet port (Fig. 528). 6. Apply a thin coat of hydraulic fluid to the rubber gasket on the replacement filter (Fig. 530). Note: Do not tighten the jam nut at this time. Fig. 530 Fig. 528 DSCN-2956a DSCN-2916a 5. Secure the suction hose to the inlet fitting, then secure the position of the fitting with the jam nut (Fig. 529). 7. Install the replacement filter to the filter mount (Fig. 531). 6 Fig. 531 Fig.
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HYDRAULIC DRIVE SYSTEM 8. Fill the reservoir to the “COLD” fluid level with the specified hydraulic fluid. See your Operator’s Manual for the specified fluid (Fig. 532). A C D A. Cap B. Baffle 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 4. Raise the rear of the machine and secure with jack stands (Fig. 534). 7. Thoroughly clean the area around the hydraulic fittings to prevent debris from entering the system. 8. Mark the hoses and corresponding wheel motor fitting ports so the hoses get connected back in their original locations (Fig. 536). Fig. 534 DSCN-2811a 5. Release the parking brake. Fig. 536 6. Remove the 4 lug nuts and the wheel assembly (Fig. 535). DSCN-2830a 9.
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HYDRAULIC DRIVE SYSTEM 11. Cap the wheel motor fittings so debris does not enter the system. 14. Run the machine for 2 minutes in forward (no load) to purge air from the system. 12. Attach the hydraulic hoses to the flow test gauge (Fig. 538). 15. Run the machine at full throttle (no load). Verify the RPM with a tachometer: 3200 + 150 RPMs. Do not exceed 3600 RPM. Note: When using a flow test gauge that is not bidirectional, damage to the flow tester could occur if the machine is operated in reverse.
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HYDRAULIC DRIVE SYSTEM Subtract the first reading from the second reading and determine if it is an acceptable GPM. Example: 1st Reading: 300 psi (21 bar) reading 7 gpm (26 l/m) 2nd Reading: 1100 psi (76 bar) reading 3 gpm (11 l/m) 7 gpm (1st reading) - 3 gpm (2nd reading) 20. Lower the machine onto the ground. 21. Apply the parking brake. 22. Torque the wheel lug nuts to 85 ± 8 ft-lbs. (115 ± 10.8 Nm) (Fig. 543).
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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 36” Mower Deck Belt Replacement 36” Mower Deck Belt Installation 36” Mower Deck Belt Removal 1. Route the belt around the deck and clutch pulleys (Fig. 545). 1. Turn the ignition off and remove the key. 2. Move the mower deck to the 1” (25mm) HOC. 3. Remove the belt covers. 4. Remove the extension spring from the anchor post (Fig. 544). Fig. 545 Fig. 544 fig. 119-0186 DSCN-3449a 5. Remove the belt from the deck and clutch pulleys. 2.
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MOWER DECK 40” Mower Deck Belts Replacement 40” Mower Deck RH Spindle Belt Removal 1. Turn the ignition off and remove the key. 40” Mower Deck RH Spindle Belt Installation 1. Route the RH belt around the deck pulleys (Fig. 549). Form 3368-755, Page 10, Belt Routing 2. Move the mower deck to the 1” (25mm) HOC. 3. Remove the RH belt cover. 4. Remove the RH extension spring from the anchor post (Fig. 547). Fig. 549 Fig. 547 fig. 119-0187 DSCN-3117a 2.
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MOWER DECK 40” Mower Deck LH Spindle Belt Removal 6. Remove the LH extension spring from the anchor post (Fig. 553). 1. Turn the ignition off and remove the key. 2. Move the mower deck to the 1” (25mm) HOC. 3. Remove the belt covers. 4. Remove the RH extension spring from the anchor post (Fig. 551). Fig. 553 DSCN-3121a 7. Remove the LH belt from around the deck and clutch pulleys (Fig. 554). Fig. 551 DSCN-3117a 5. Remove the RH belt from the deck pulleys (Fig. 552). Fig. 554 Fig.
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MOWER DECK 40” Mower Deck LH Spindle Belt Installation 3. Route the RH belt around the deck pulleys (Fig. 557). 1. Route the LH belt around the deck pulleys (Fig. 555). Fig. 557 Fig. 555 fig. 119-0187 fig. 119-0187 4. Install the extension spring to the RH idler bracket and spring anchor (Fig. 558). 2. Install the extension spring to the LH idler bracket and spring anchor (Fig. 556). 7 Fig. 558 Fig. 556 7-4 DSCN-3121a DSCN-3117a 5. Install the belt covers.
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MOWER DECK Spindle Assembly Replacement Spindle Assembly Removal 5. Raise the machine so the underside of the deck can be accessed. 6. Block the mower deck blade and remove the blade bolt, washer, and blade from the spindle (Fig. 561). 1. Turn the ignition off and remove the key. 2. Remove the belt cover. 3. Remove the extension spring from the anchor post (Fig. 559). Fig. 561 Fig. 559 DSCN-3121a DSCN-3147a 7. Remove the six nuts securing the thread forming screws (Fig. 562). 4.
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MOWER DECK 8. Remove the six thread forming screws securing the spindle assembly to the deck (Fig. 563). Spindle Assembly Installation 1. Secure the spindle assembly to the deck using six thread forming screws (Fig. 564). Fig. 563 DSCN-3153a To service the spindle assembly, refer to “Spindle Service” on page 7-8. Fig. 564 DSCN-3153a 2. Secure the thread forming screws with nuts (Fig. 565). 7 Fig.
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MOWER DECK 3. Secure the mower deck blade to the spindle assembly using the blade bolt, and washer. With the mower blade blocked, torque the blade bolt to 85110 ft. lbs. (115-149 Nm). (Fig. 566). Fig. 566 4. Route the belt around the deck pulleys (Fig. 568, 40” deck and Fig. 569, 36” deck). DSCN-3220a Note: The crown of the washer faces the bolt head (Fig. 567). Fig. 568 fig. 119-0187 7 Fig. 567 DSCN-3216a Fig. 569 36” & 40” Toro GrandStand Service Manual fig.
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MOWER DECK 5. Install the extension spring to the idler bracket and spring anchor (Fig. 570). Spindle Service Note: Once the spindle is removed, the following procedure can be used to rebuild the spindle assembly. 1. With the blade firmly secured in a vise, remove the nut and washer securing the pulley to the spindle shaft (Fig. 571). Fig. 570 DSCN-3121a 6. Install the belt covers. Fig. 571 DSCN-3171a 2. Remove the bearing shield from the spindle assembly (Fig. 572). 7 Fig.
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MOWER DECK 3. Remove the spindle shaft and blade from the spindle housing (Fig. 573). Fig. 573 DSCN-3179a 4. With the spindle shaft firmly secured in a vise, remove the nut and washer securing the blade to the spindle shaft (Fig. 574). 5. Remove the upper and lower bearings from the spindle housing (Fig. 575). Fig. 575 DSCN-3185a 6. Remove the bearing spacer from the spindle housing (Fig. 576). Note: Inspect all spindle assembly components. Replace any that are damaged or worn. 7 Fig.
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MOWER DECK 7. Install the upper bearing into the spindle housing (Fig. 577). Fig. 577 9. With the bearing spacer centered in the housing, fill the cavity between the spacer and housing with high temp grease (Fig. 579). DSCN-3193a Fig. 579 8. Position the bearing spacer in the spindle housing (Fig. 578). 7 Fig. 578 10. Install the lower bearing into the spindle housing and add a couple of pumps of high temp grease to the center of the bearing spacer. (Fig. 580). DSCN-3195a Fig.
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MOWER DECK 11. Install the spindle shaft into the spindle housing (Fig. 581). Note: Rotate the spindle shaft as it is inserted through the spindle housing to spread the grease. Fig. 581 DSCN-3205a 13. Secure the pulley to the spindle shaft using the washer and nut. The torque will be applied in a later step (Fig. 583). Note: The welded side of the pulley hub faces upward. Fig. 583 DSCN-3158a 12. Position the bearing shield onto the top of the spindle housing (Fig. 582). 7 Fig.
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MOWER DECK 14. Secure the blade to the spindle shaft using the washer and blade bolt. The torque will be applied in a later step (Fig. 584). Fig. 584 DSCN-3212a Note: The crown of the washer faces the bolt head (Fig. 585). 15. With the spindle shaft firmly secured in a vise, apply 100-130 ft-lbs. (135-176 Nm) torque to the nut securing the pulley to the spindle shaft (Fig. 586). Fig. 586 DSCN-3171a 16. Secure the spindle assembly to the deck using six thread forming screws (Fig. 587). 7 Fig.
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MOWER DECK 17. Secure the thread forming screws with nuts (Fig. 588). Fig. 588 19. Route the belt around the deck pulleys (Fig. 590, 40” deck and Fig. 591, 36” deck). DSCN-3152a 18. With the mower blade blocked, torque the blade bolt to 85-110 ft. lbs. (115-149 Nm). (Fig. 589). Fig. 590 Fig. 589 7 DSCN-3220a Fig. 591 36” & 40” Toro GrandStand Service Manual fig. 119-0187 fig.
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MOWER DECK 20. Install the extension spring to the idler bracket and spring anchor (Fig. 592). 36” Mower Deck Belt Idler Replacement 36” Mower Deck Belt Idler Removal 1. Turn the ignition off and remove the key. 2. Move the mower deck to the 1” (25mm) HOC. 3. Remove the belt covers. 4. Remove the extension spring from the anchor post (Fig. 593). Fig. 592 DSCN-3121a 22. Install the belt covers. Fig. 593 DSCN-3449a 5. Remove the belt from the idler pulley. 6.
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MOWER DECK 7. Remove the bolt, washers, and flange nut securing the idler assembly to the mower deck (Fig. 594). Fig. 594 DSCN-3452a 8. Remove the spacer from the idler arm assembly (Fig. 595). Fig. 595 36” & 40” Toro GrandStand Service Manual DSCN-3455a 9. Remove the grease fitting from the idler arm hub (Fig. 596). Fig. 596 DSCN-3457a 10. Using a punch, remove the upper and lower bushings (Fig. 597). Fig.
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MOWER DECK 11. Remove the carriage bolt, washer, and flange nut securing the idler pulley to the idler arm (Fig. 598). 36” Mower Deck Belt Idler Installation 1. Install the upper and lower bushings into the idler arm hub (Fig. 599). Fig. 598 DSCN-3462a Fig. 599 DSCN-3465a 2. Install the grease fitting into the idler arm hub (Fig. 600). Note: Install the fitting so it is pointing upwards. 7 Fig.
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MOWER DECK 3. Secure the idler pulley to the idler arm using the carriage bolt, washer, and flange nut (Fig. 601). Fig. 601 DSCN-3480a 4. Install the spacer into the idler arm assembly (Fig. 603). Fig. 603 DSCN-3482a Note: The taller side of the idler pulley hub faces the idler arm (Fig. 602). 5. Position the bolt, upper and lower washers, onto the idler arm assembly (Fig. 604). Fig. 602 Fig.
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MOWER DECK 6. Position the assembly onto the mower deck (Fig. 605). Fig. 605 8. Route the belt around the deck pulleys (Fig. 607). DSCN-3489a 7. Secure the assembly using the flange nut (Fig. 606). Fig. 607 fig. 119-0186 9. Install the extension spring to the idler bracket and spring anchor (Fig. 608). 7 Fig. 606 DSCN-3492a Fig.
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MOWER DECK 10. Pump high temp grease into the idler hub (Fig. 609). 40” Mower Deck Belts Idler Replacement 40” Mower Deck Belts LH Idler Removal 1. Turn the ignition off and remove the key. 2. Remove the belt cover. 3. Remove the extension spring from the anchor post (Fig. 610). Fig. 609 DSCN-3495a 11. Install the belt cover. Fig. 610 DSCN-3121a 4. Remove the belt from the mower deck pulleys (Fig. 611). 7 Fig.
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MOWER DECK 5. Raise the machine so the underside of the deck can be accessed. 8. Using a punch, remove the upper and lower bushings (Fig. 614). 6. Remove the bolt, washers, and flange nut securing the idler assembly to the mower deck (Fig. 612). Fig. 614 Fig. 612 DSCN-3225a DSCN-3233a 9. Remove the grease fitting from the idler arm hub (Fig. 615). 7. Remove the spacer from the idler arm assembly (Fig. 613). 7 Fig. 615 Fig.
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MOWER DECK 10. Remove the carriage bolt, washer, and flange nut securing the idler pulley to the idler arm (Fig. 616). 40” Mower Deck Belts LH Idler Installation 1. Secure the idler pulley to the idler arm using the carriage bolt, washer, and flange nut (Fig. 617). Fig. 616 DSCN-3237a Fig. 617 DSCN-3243a Note: The taller side of the idler pulley hub faces the idler arm (Fig. 618). 7 Fig.
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MOWER DECK 2. Install the grease fitting into the idler arm hub (Fig. 619). Fig. 619 DSCN-3235a 3. Install the upper and lower bushings into the idler arm hub (Fig. 620). 7 Fig. 620 7-22 DSCN-3248a 4. Install the spacer into the idler arm assembly (Fig. 621). Fig. 621 DSCN-3255a 5. Position the bolt with washer up through the mower deck (Fig. 622). Fig.
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MOWER DECK 6. Place a large washer onto the bolt (Fig. 623). Fig. 623 DSCN-3260a 7. Place the idler assembly onto the bolt (Fig. 624). Fig. 624 36” & 40” Toro GrandStand Service Manual DSCN-3262a 8. Place a large washer onto the bolt (Fig. 625). Fig. 625 DSCN-3263a 9. Secure the assembly using the flange nut (Fig. 626). Fig.
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MOWER DECK 10. Route the belt around the deck pulleys (Fig. 627). 12. Pump high temp grease into the idler hub (Fig. 629). Fig. 629 DSCN-3269a 13. Install the belt cover. Fig. 627 fig. 119-0187 11. Install the extension spring to the idler bracket and spring anchor (Fig. 628). 7 Fig.
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MOWER DECK 40” Mower Deck Belts RH Idler Removal 5. Remove the spacer, two washers, and two friction washers from the assembly (Fig. 632). 1. Turn the ignition off and remove the key. 2. Remove the belt cover. 3. Remove the extension spring from the anchor post (Fig. 630). Fig. 632 DSCN-3274a 6. Remove the carriage bolt, washer, and flange nut securing the idler pulley to the idler arm (Fig. 633). Fig. 630 DSCN-3117a 4. Remove the bolt and nut securing the idler assembly to the idler mount (Fig.
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MOWER DECK 40” Mower Deck Belts RH Idler Installation 2. Place the bolt through the two washers, two friction washers, spacer, and idler arm (Fig. 636). 1. Secure the idler pulley to the idler arm using the carriage bolt, washer, and flange nut (Fig. 634). Fig. 636 Fig. 634 DSCN-3277a DSCN-3275a Note: The two friction washers must have the spacer nested into their center (Fig. 637). Note: The taller side of the idler pulley hub faces the idler arm (Fig. 635). 7 Fig. 637 Fig.
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MOWER DECK 3. Secure the idler assembly to the idler mount using the bolt and nut (Fig. 638). Baffles & Skid Plate Replacement Fixed Baffle Removal 1. Raise the machine to access the underside of the deck. 2. Remove the carriage bolt and nut securing the LH side of the baffle (Fig. 640). Fig. 638 DSCN-3271a 4. Install the extension spring to the idler bracket and spring anchor (Fig. 639). Fig. 640 DSCN-3288a 3. 36” Deck Only: Remove the carriage bolt and nut securing the RH side of the baffle (Fig.
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MOWER DECK 4. 40” Deck Only: Remove the nut securing the thread forming screw on the RH side of the baffle (Fig. 642). Fig. 642 Fixed Baffle Installation 1. 36” Deck Only: Loosely install the carriage bolt and nut that secure the LH side of the baffle (Fig. 644). DSCN-3292a Fig. 644 5. 40” Deck Only: Remove the thread forming screw securing the RH side of the baffle (Fig. 643). DSCN-3288a 2.
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MOWER DECK 3. 40” Deck Only: Loosely install the carriage bolt and nut that secure the LH side of the baffle (Fig. 646). Fig. 646 DSCN-3288a 5. 40” Deck Only: Secure the thread forming screw using the nut (Fig. 648). Fig. 648 DSCN-3292a 4. 40” Deck Only: Secure the RH side of the baffle using the thread forming screw, then tighten the LH carriage bolt and nut (Fig. 647). 7 Fig.
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MOWER DECK Adjustable Discharge Baffle Removal 4. Remove the carriage bolt and flange nut securing the RH side of the baffle (Fig. 651). 1. Remove the nut securing the thread forming screw on the LH side of the baffle (Fig. 649). Fig. 651 Fig. 649 DSCN-3308a DSCN-3302a 2. Raise the machine to access the underside of the mower deck. 3. Remove the thread forming screw securing the LH side of the baffle (Fig. 650). 7 Fig.
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MOWER DECK Adjustable Discharge Baffle Installation 3. Secure the thread forming screw using a nut (Fig. 654). 1. Loosely install the carriage bolt and flange nut securing the RH side of the baffle (Fig. 652). Fig. 654 Fig. 652 DSCN-3302a DSCN-3308a 4. Secure the desired position of the baffle by tighten ing the flange nut (Fig. 655). 2. Secure the LH side of the baffle using the thread forming screw (Fig. 653). Fig. 655 Fig.
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MOWER DECK Discharge Baffle Removal Discharge Baffle Installation 1. Remove the two nuts securing the two thread forming screws (Fig. 656). 1. Secure the discharge baffle using two thread forming screws (Fig. 658). Fig. 656 DSCN-3284a 2. Raise the machine to access the underside of the mower deck. Fig. 658 DSCN-3286a 2. Secure the two thread forming screws using two nuts (Fig. 659). 3. Remove the two thread forming screws securing the discharge baffle (Fig. 657). 7 Fig. 659 Fig.
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MOWER DECK Skid Plate Removal Skid Plate Installation 1. Raise the machine to access the underside of the mower deck. 1. 36” Deck Only: Secure the skid plate to the mower deck using the four sets of carriage bolts and nuts (Fig. 662). 2. 36” Deck Only: Remove the four sets of carriage bolts and nuts securing the skid plate to the mower deck (Fig. 660). Fig. 662 Fig. 660 DSCN-3502a 3. 40” Deck Only: Remove the three sets of carriage bolts and nuts securing the skid plate to the mower deck (Fig. 661).
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MOWER DECK Grass Deflector Replacement 3. Remove the four sets of carriage bolts and nuts securing the deflector mount, deflector, and deflector strap to the rubber deflector (Fig. 666). Grass Deflector Removal 1. Remove the “J” hook of the torsion spring from the deflector mount (Fig. 664). Fig. 666 Fig. 664 DSCN-3320a DSCN-3315a 2. Remove the bolt, nut and spacer securing the deflector assembly to the mower deck (Fig. 665). 7 Fig.
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MOWER DECK Grass Deflector Installation 3. Secure the deflector using the two outmost carriage bolts and nuts (Fig. 669). 1. Position the four carriage bolts into the discharge strap (Fig. 667). Fig. 669 Fig. 667 DSCN-3334a DSCN-3322a 4. Secure the deflector mount to the assembly using the two carriage bolts and nuts (Fig. 670). 2. Position the rubber deflector onto the four carriage bolts (Fig. 668). Fig. 670 Fig.
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MOWER DECK 5. Position the deflector assembly, spacer, and torsion spring onto the mower deck (Fig. 671). 7. Hook the “J” hook of the torsion spring onto the defector mount (Fig. 673). Note: The torsion spring “J” hooks must straddle the deck plate. Fig. 673 Fig. 671 DSCN-3342a DSCN-3338a 6. Secure the deflector assembly to the deck using the bolt and nut (Fig. 672). Note: Do not over tighten the bolt and nut. The deflector assembly must move freely. 7 Fig.
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MOWER DECK Deck Strut Replacement 4. Remove the spacer from the suspension bushing (Fig. 676). Rear Strut Removal 1. Raise the machine to access the underside of the mower deck. 2. Remove the bolt, nut and washer securing the strut to the frame assembly (Fig. 674). Note: If the bolt must be replaced, loosen the wheel motor to gain the clearance needed to remove. Fig. 676 DSCN-3354a 5. Using an arbor press, remove the suspension bushing from the strut (Fig. 677). Fig. 674 DSCN-3352a 3.
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MOWER DECK Rear Strut Installation 3. Install the spacer into the suspension bushing (Fig. 680). 1. Apply a thin layer of grease to the outer lip of the suspension bushing (Fig. 678). Fig. 680 Fig. 678 DSCN-3366a DSCN-3362a 4. Repeat steps 1 through 3 on the other end of the strut. 2. Using an arbor press, install the suspension bushing into the strut (Fig. 679). 5. Loosely install the bolt, washer, and nut securing the rear of the strut to the frame (Fig. 681). 7 Fig.
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MOWER DECK 6. Secure the front end of the strut to the engine base and deck using the bolt, washer and nut (Fig. 682). Front Strut Removal 1. Remove the bolt, nut and washer securing the strut to the frame (Fig. 683). Fig. 682 7. Tighten the rear bolt and nut. DSCN-3347a Fig. 683 DSCN-3370a 2. Remove the bolt, washer and nut securing the strut to the deck (Fig. 684). 7 Fig.
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MOWER DECK 3. Remove the spacer from the suspension bushing (Fig. 685). Front Strut Installation 1. Apply a thin layer of grease to the outer lip of the suspension bushing (Fig. 687). Fig. 685 DSCN-3373a Fig. 687 DSCN-3362a 4. Using an arbor press, remove the suspension bushing from the strut (Fig. 686). 2. Using an arbor press, install the suspension bushing into the strut (Fig. 688). 7 Fig. 686 DSCN-3375a 5. Repeat steps 3 and 4 on the other end of the strut. 7-40 Fig.
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MOWER DECK 3. Install the spacer into the suspension bushing (Fig. 689). Fig. 689 DSCN-3373a 4. Repeat steps 1 through 3 on the other end of the strut. 6. Secure the other end of the strut to the deck using the bolt, washer and nut (Fig. 691). Fig. 691 DSCN-3367a 7. Tighten the bolt and nut securing the other end of the strut. 5. Loosely install the bolt, washer and nut securing the strut to the frame (Fig. 690). 7 Fig.
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MOWER DECK Mower Deck Replacement 3. Raise the machine to access the underside of the mower. Mower Deck Removal 4. Remove the deck belt from the PTO clutch (Fig. 693). 1. Remove the belt covers. 2. Remove the extension spring from the anchor post (Fig. 692). Fig. 693 Fig. 692 DSCN-3121a DSCN-3379a 5. Remove the two sets of bolts, washers and nuts securing the RH and LH rear struts to the engine base and deck (Fig. 694). 7 Fig.
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MOWER DECK 6. Place the HOC (Height of Cut) into the transport position. 8. Using a strap, secure the front of the engine base to the carrier frame (Fig. 697). 7. Using a strap, secure the rear of the engine base (Fig. 695) to the cable retainer (Fig. 696). Fig. 697 Fig. 695 DSCN-3388a Fig. 696 DSCN-3392a 9. Remove the two sets of carriage bolts and flange nuts securing the engine base to the rear of the deck (Fig. 698). 7 Fig.
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MOWER DECK 10. Remove the two flange nuts securing the engine base to the top of the mower deck (Fig. 699). Fig. 699 DSCN-3412a 11. Place a 2”x4” under each side of the mower deck, then lower the deck onto the boards (Fig. 700). 12. Remove the bolt, washer and nut securing the front strut to the mower deck (Fig. 701). Fig. 701 DSCN-3415a 13. Remove the four flange nuts securing the lift chains to the mower deck (Fig. 702).
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MOWER DECK 14. Slide the deck out from under the chassis (Fig. 703). Mower Deck Installation Note: The rear of the machine can be raised to ease removal. 1. Position the mower deck under the chassis. 2. Secure the four lift chains to the mower deck using the flange nuts (Fig. 704). Fig. 703 DSCN-3429a Fig. 704 DSCN-3419a 3. Secure the front strut to the mower deck using the bolt, washer, and flange nut (Fig. 705). 7 Fig.
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MOWER DECK 4. Raise the HOC handle to the transport position. Guide the engine base onto the screws protruding through the deck (Fig. 706). 5. Loosely install the flange nuts onto the two screws (Fig. 708). Fig. 708 Fig. 706 Note: The rear deck mounts must be to the inside of the engine base mounts (Fig. 707). 7 6. Loosely install the two sets of carriage bolts through the deck and engine base (Fig. 709). Fig. 709 Fig.
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MOWER DECK 7. Secure the two rear struts using the two sets of bolts, washers and flange nuts (Fig. 710). Fig. 710 DSCN-3384a 9. Tighten the two flange nuts securing the engine base to the top of the deck (Fig. 712). Fig. 712 DSCN-3412a 8. Tighten the two sets of carriage bolts and flange nuts securing the engine base to the rear of the deck (Fig. 711). 7 Fig.
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MOWER DECK 10. Remove the straps from the front and rear of the engine base. 12. Install the extension spring to the idler bracket and spring anchor (Fig. 715). 11. Route the belt around the deck and clutch pulleys (Fig. 713, 40” deck and Fig. 714, 36” deck). Fig. 715 DSCN-3121a 13. Install the belt covers. Fig. 713 fig. 119-0187 Fig. 714 fig.
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MOWER DECK Mower Deck Adjustments Leveling the Mower Preparing the Machine 1. Position mower on a flat surface. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 10. If either front chain is loose, loosen the nut on the upper chain bolt and the jam nut on the adjustment bolt. 11. Use the adjustment bolt to get equal tension on both front chains (Fig. 716). 12. Tighten the nut on the upper chain bolt and the jam nut on the adjustment bolt. A 3.
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MOWER DECK Adjusting the Left Side Front-to-Rear Mower Pitch 1. Position the left blade front-to-rear. 2. Measure the left blade at the A location, from a level surface to the cutting edge of the blade tip and record this measurement (Fig. 717). 5. Loosen the nut on the upper chain bolt and the jam nut on the adjustment bolt (Fig. 718). 6. Use the adjustment bolt to achieve 1/4” to 3/8” (6 to 10mm) lower in front at A than in the rear at B (Fig. 718). 7.
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MOWER DECK Leveling the Mower Side-to-Side 1. Position the left blade front-to-rear (Fig. 719). 2. Measure the left blade at the A location, from a level surface to the cutting edge of the blade tip and record this measurement (Fig. 719). 3. Position the right blade front-to-rear (Fig. 719). 4. Measure the right blade at the C location, from a level surface to the cutting edge of the blade tip and record this measurement (Fig. 719). 5. The measurement between location A and C needs to be within 1/8”.
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MOWER DECK Adjusting the Height of Cut 7. Loosen the jam nuts at both ends of the turnbuckle (Fig. 722). 1. Lower the mower to the 3” (76mm) height-of-cut position. 2. Position the left blade front-to-rear (Fig. 721). 3. Measure the left blade at the A location, from a level surface to the cutting edge of the blade tip and record this measurement (Fig. 721). 4. Position the right blade front-to-rear (Fig. 721). 5.
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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. 725). 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. 733). 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 (Proximity) Switch How It Works Purpose The neutral (proximity) switch is a “normally open” switch. The contacts close when a piece of steel (bolt) is placed close to the switch. The specified gap between the bolt and the face of the switch is .070” ± .020” (1.8 ± .5mm). The switch will open when the bolt is moved away. The switches are wired in series. The Neutral Switch is part of the safety circuit.
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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. 737).
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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. 739). Fig. 739 DSCN-2216a The fuses used in this application can be visually inspected. A failed fuse can be identified by the broken/ melted element inside the fuse cover or a damaged spade (Fig. 740). Fig.
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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. 742). 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 out through the front of the control panel (Fig. 745). Ignition Switch Ignition Switch Removal 1. Remove the wire harness and spade connector from the back of the ignition switch (Fig. 743). Fig. 745 Fig. 743 DSCN-2224a DSCN-2219a 2. Depress the two tabs on the sides of the switch (Fig. 744). 8 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. 748). 1. Install the switch in through the control panel. En sure that the mounting clips have secured the switch in the control panel (Fig. 746). Fig. 748 Fig. 746 DSCN-2224a DSCN-2232a 3. Install the wire harness to the switch (Fig. 749). Note: The switch must be orientated so it can be read from the operator position (Fig. 747). Fig. 749 8 Fig.
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ELECTRICAL Power Take Off (PTO) Switch 3. Remove the switch out through the front of the control panel (Fig. 752). Power Take Off (PTO) Switch Removal 1. Remove the wire harness from the back of the PTO switch (Fig. 750). Fig. 752 Fig. 750 DSCN-2258a DSCN-2248a 2. Depress the four tabs securing the switch to the control panel (Fig. 751). Fig.
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ELECTRICAL Power Take Off (PTO) Switch Installation Electric (PTO) Clutch Switch 1. Install the switch in through the control panel. Ensure that the mounting clips have secured the switch in the control panel (Fig. 753). Electric (PTO) Clutch Removal 1. Turn the engine off and remove the key from the ignition. 2. Turn the fuel shutoff valve to the “OFF” position (Fig. 755). Fig. 753 DSCN-2258a 2. Install the wire harness to the back of the switch (Fig. 754). Fig. 755 DSCN-2516a 3.
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ELECTRICAL 4. Remove the bolt, washer, and nut securing the black ground cable to the battery terminal (Fig. 757). Fig. 757 DSCN-2265a 5. Remove the bolt, washer, and nut securing the red positive cable to the battery terminal, then remove the battery (Fig. 758). 6. Slide the hose clamp off the fuel line where it connects to the fuel pump (Fig. 759). Fig. 759 7. Remove the fuel line from the fuel pump. Drain the fuel into a suitable container (Fig. 760). Fig. 760 Fig.
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ELECTRICAL 8. Remove the violet wire from the voltage regulator (Fig. 761). Fig. 761 DSCN-2522a 9. Unplug the pink wire from the green fuel solenoid wire (Fig. 762). Fig. 762 DSCN-2526a 10. Unplug the white wire from the black magneto wire (Fig. 763). Fig. 763 DSCN-2527a 11. Remove the bolt and washer securing the ground wires to the engine block (Fig. 764). Fig.
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ELECTRICAL 12. Remove nut and lock washer securing the starter wire to the solenoid (Fig. 765). Fig. 765 DSCN-2533a 13. Unplug the clutch wires from the wiring harness (Fig. 766). Fig. 766 14. Push the grommet and the electrical plug connector down through the engine base (Fig. 767). Fig. 767 15. Remove the four nuts, two mounting guard brackets and four carriage bolts securing the muffler guard assembly to the front frame, then remove the muffler guard (Fig. 768). DSCN-2536a Fig.
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ELECTRICAL 16. Loosen the screw on the choke cable clamp and disconnect the choke cable from the engine choke lever (Fig. 769). Fig. 769 DSCN-2551a 17. Loosen the screw on the throttle cable clamp and disconnect the throttle cable from the engine throttle lever (Fig. 770). 18. Remove the cable clamp securing the throttle and choke cable to the engine oil drain (Fig. 771). Fig. 771 DSCN-2561a 19. Lower the HOC (height of cut) to the lowest HOC. 20. Remove the belt covers. 21.
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ELECTRICAL 22. 40” Deck: Using a spring tool, remove the exten sion spring from the deck anchor post (Fig. 773). 24. Raise the machine so the underside of the chassis can be accessed. 25. Remove the cable tie securing the clutch wire harness to the clutch anchor (Fig. 775). Fig. 773 DSCN-2564a 23. 40” Deck: Using a spring tool, remove the RH spindle extension spring from the RH deck anchor post (Fig. 774). Fig. 774 Fig. 775 26. Remove the deck belt from the clutch pulley (Fig. 776). DSCN-2582a Fig.
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ELECTRICAL 27. Remove the extension spring from the drive idler pulley assembly (Fig. 777). Fig. 777 DSCN-2574a 28. Remove the drive belt from the engine pulley (Fig. 778). Fig. 778 DSCN-2575a 29. Remove the bolt and nut securing the clutch anchor to the engine base (Fig. 779). Fig. 779 DSCN-2578a 30. Remove the four bolts and Belleville washers securing the engine to the engine base (Fig. 780). Fig.
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ELECTRICAL 31. Remove the engine from the engine base (Fig. 781). Fig. 781 33. Remove the bolt, spring washer, and washer securing the clutch to the engine crankshaft (Fig. 783). DSCN-2587a Fig. 783 32. Remove one spark plug and feed a minimum of two feet (61cm) of 3/8” (.95cm) rope into the cylinder to prevent engine crankshaft rotation (Fig. 782). IMG-9630a 34. Remove the clutch from the engine crankshaft. Note: Rotate the crankshaft as needed to permit feeding the rope into the cylinder. Fig.
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ELECTRICAL Electric (PTO) Clutch Installation 3. Apply thread locking compound to the threads of the clutch bolt (Fig. 786). 1. Using a feeler gauge, check the clutch air gap at each of the three adjustment slots. Set the gap to .015” (0.381mm). Make sure the gauge is inserted between the armature and the rotor friction surfaces (Fig. 784). Fig. 786 Fig. 784 PICT-0554a PICT-8700a 4. Torque the clutch bolt to 55 ft-lbs. (75 Nm) (Fig. 787). 2.
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ELECTRICAL 5. Remove the rope from the engine cylinder and replace the spark plug (Fig. 788). 7. Secure the engine to the engine base using the four sets of bolts and Belleville washers. Torque the bolts to 30 - 35 ft-lbs. (41 - 47 Nm) (Fig. 790). Note: The crown of the washer must face the bolt head. Fig. 788 IMG-9634a 6. Position the engine onto the engine base (Fig. 789). Fig. 789 Fig.
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ELECTRICAL 8. Secure the PTO stop bracket to the engine base using a bolt and nut (Fig. 791). Fig. 791 DSCN-2642a Note: Ensure the PTO stop bracket is nested in the slot on the clutch plate (Fig. 792). Fig. 792 DSCN-2645a 9. Feed the clutch wire harness up through the engine base (Fig. 793). Fig. 793 DSCN-2647a 10. Install the rubber grommet into the engine base (Fig. 794). Fig.
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ELECTRICAL 11. Secure the wire harness to the PTO stop bracket using a cable tie (Fig. 795). Fig. 795 DSCN-2658a 12. Position the pump drive belt around the engine drive pulley, the two hydraulic pump pulleys, and the idler pulley (Fig. 796). 13. Install the extension spring from the idler bracket to the spring anchor (Fig. 797). Fig. 797 DSCN-2660a 14. 36” Deck: Route the deck belt around the deck spindle pulleys. Refer to decal 119-0186 (Fig. 798). A B E D C F Fig. 796 A. Hydraulic pumps B.
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ELECTRICAL 15. 36” Deck: Install the extension spring to the idler bracket and spring anchor (Fig. 799). Fig. 799 DSCN-2666a 16. 40”Deck: Route the deck belts around the deck spindle pulleys. Refer to decal 119-0187 (Fig. 800). 17. 40” Deck: Install the extension spring to the LH idler bracket and spring anchor (Fig. 801). Fig. 801 18. 40” Deck: Install the extension spring to the RH idler bracket and spring anchor (Fig. 802). Fig. 802 8 Fig.
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ELECTRICAL 19. Install the belt covers. 20. 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. 803). 22. With the engine throttle control lever in the “Fast” position, pull the slack from the cable jacket and tighten the throttle cable clamp (Fig. 805). Fig. 805 Fig. 803 DSCN-2672a 21. Move the throttle lever to the “Fast” position (Fig. 804). 23.
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ELECTRICAL 24. Push the choke knob in so it is in the “Open” position (Fig. 807). Fig. 807 DSCN-2677a 25. 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. 808). 26. Secure the throttle and choke cable to the oil drain assemble using a cable tie (Fig. 809). Fig. 809 27. Position the muffler guard assembly and loosely install the four carriage bolts, two mounting guard brackets and nuts (Fig. 810). Fig.
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ELECTRICAL 28. Make sure the muffler exhaust is centered in the muffler guard assembly then tighten all four bolts and nuts. Torque the nuts to 19 ± 2 ft-lbs. (25.76 ± 2.7 Nm) (Fig. 811). 30. Install the battery ground wire and the wiring har ness ground wire to the engine block (Fig. 813). Fig. 813 Fig. 811 DSCN-2680a 29. Connect the clutch wire harness to the wire harness (Fig. 812). 31. Install the starter wire to the solenoid using a lock washer and nut. Torque nut to 35 in-lbs. (4 Nm) (Fig. 814).
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ELECTRICAL 32. Connect the white wire to the black magneto wire (Fig. 815). Fig. 815 DSCN-2691 33. Connect the pink wire to the green fuel solenoid wire (Fig. 816). Fig. 816 DSCN-2692a 34. Connect the violet wire to the voltage regulator (Fig. 817). Fig. 817 DSCN-2695a 35. Secure the fuel line to the fuel pump using the hose clamp (Fig. 818). Fig.
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ELECTRICAL 36. Position the battery on the battery tray. Using the bolt nut and washer, secure the positive battery cable to the battery. Using the bolt nut and washer, secure the negative battery cable to the battery (Fig. 819). Fig. 819 38. Turn the fuel shutoff valve to the “ON” position (Fig. 821). Note: If a new electric PTO clutch was installed, the clutch must be burnished. Refer to “Electric PTO Clutch Burnishing Procedure” following. DSCN-2698a Fig. 821 DSCN-2702a 37.
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ELECTRICAL Electric PTO Clutch Burnishing Procedure Solenoid Note: This procedure needs to be done only when installing a new clutch. Solenoid Removal The clutch should be burnished as part of the predelivery service, or whenever a new clutch is installed. Burnishing polishes the clutch plate, allowing for smooth clutch engagement. 1. Remove the two sets of wingnuts and hold down bolts securing the battery cover then remove the cover (Fig. 823).
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ELECTRICAL 3. Remove the bolt, washer, and nut securing the red positive cable to the battery terminal, then remove the battery (Fig. 825). 5. Remove the nut and lock washer securing the positive cable that goes to the starter (Fig. 827). Fig. 827 Fig. 825 4. Move the terminal cover off the positive cable com ing from the battery, then remove the nut and lock washer securing the positive battery cable and red wire eyelet to the solenoid (Fig. 826). 6.
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ELECTRICAL 7. Remove the two thread forming screws securing the solenoid the engine base plate (Fig. 829). Solenoid Installation 1. Secure the solenoid to the engine base using two thread forming screws (Fig. 830). Fig. 829 DSCN-2280a Fig. 830 DSCN-2280a 2. Install the blue and green wires to the two small studs on the solenoid using the wire’s bullet con nectors (Fig. 831). 8 Fig.
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ELECTRICAL 3. Secure the starter positive cable to the LH solenoid stud with a nut and lock washer. Torque to 35 in-lbs. (4 Nm) (Fig. 832). Fig. 832 DSCN-2276a 8. Secure the positive battery cable and the wire harness red wire eyelet to the solenoid using a nut and lock washer, torque to 35 in-lbs. (4 Nm), then position the positive cable terminal cover over the terminal connection (Fig. 833). 9.
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ELECTRICAL 11. Secure the battery cover using the two sets of wingnuts and hold down bolts (Fig. 836). Operator Presence Control (OPC) Switch Operator Presence Control (OPC) Switch Removal 1. Remove the wire harness from the switch (Fig. 837). Fig. 836 DSCN-2263a Fig. 837 DSCN-2285a 2. Remove the two screws and threaded plate that secure the switch to the control handle assembly and remove the switch (Fig. 838). 8 Fig.
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ELECTRICAL Operator Presence Control (OPC) Switch Installation 3. Position the switch so there is an 1/8” (3mm) gap between the switch plunger and the tab on the handle assembly (Fig. 841). 1. Loosely install the two screws and threaded plate that secure the switch to the control handle as sembly (Fig. 839). A Fig. 841 DSCN-2295a A. 1/8” (3mm) Fig. 839 DSCN-2291a 2. Move the RH control lever to the operating position (Fig. 840). 4.
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ELECTRICAL 5. Plug the wire harness into the switch (Fig. 843). Neutral (Proximity) Switch Neutral (Proximity) Switch Removal 1. Disconnect the wire harness from the switch (Fig. 844). Fig. 843 DSCN-2285a Fig. 844 DSCN-2304a 2. Remove the two screws and nuts that secure the switch to the switch mounting bracket and remove the switch (Fig. 845). 8 Fig.
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ELECTRICAL Neutral (Proximity) Switch Installation 3. Secure the position of the switch by tightening the two mounting screws (Fig. 848). 1. Loosely install the two screws and nuts that secure the switch to the switch mounting bracket (Fig. 846). Fig. 848 Fig. 846 DSCN-2305a DSCN-2305a 2. With the controls in the neutral position, position the switch so the target printed on the body of the switch is aligned with the bolt attached to the control lever assembly (Fig. 847).
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ELECTRICAL 4. Plug the wire harness into the switch (Fig. 850). Parking Brake Switch Parking Brake Switch Removal 1. Remove the wire harness from the switch (Fig. 851). Fig. 850 DSCN-2304a Fig. 851 DSCN-2345a 2. Remove the two screws and threaded plate that secure the switch to the switch bracket (Fig. 852). 8 Fig.
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ELECTRICAL Parking Brake Switch Installation 3. Secure the position of the switch by tightening the two mounting screws (Fig. 855). 1. Loosely install the two screws and threaded plate that secure the switch to the brake assembly (Fig. 853). Fig. 855 Fig. 853 DSCN-2326a DSCN-2326a 4. Plug the wire harness into the switch (Fig. 856). 2. With the brake engaged, position the switch so there is an 1/8” (3mm) gap between the switch body and the tab on the brake arm (Fig. 854). Fig. 856 A Fig.
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ELECTRICAL Hour Meter/Control Module 3. Remove the hour meter out through the front of the control panel (Fig. 859). Hour Meter/Control Module Removal 1. Remove the wire harness from the back of the hour meter (Fig. 857). Fig. 859 Fig. 857 DSCN-2333a DSCN-2328a 2. Depress the two tabs securing the hour meter to the control panel (Fig. 858). 8 Fig.
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ELECTRICAL Hour Meter/Control Module Installation 2. Install the wire harness to the back of the hour meter (Fig. 862). 1. Install the hour meter in through the control panel. Ensure that the mounting clips have secured the switch in the control panel (Fig. 860). Fig. 862 Fig. 860 DSCN-2328a DSCN-2333a Note: The hour meter must be orientated so it can be read from the front of the machine (Fig. 861). Fig.
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SCHEMATICS 36” & 40” Toro GrandStand Hydraulic Schematic Fig. 863 fig.
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SCHEMATICS 36” & 40” Toro GrandStand Electrical Schematic 9 G015606 Fig. 864 9-2 fig.
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Toro 36” & 40” GrandStand Service Manual Form Number 492-9236