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Toro Hydraulic System Cooling Kit, GrandStand Mower Installation guide

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FormNo.3373-396RevB
HydraulicSystemCoolingKit
GrandStand
®
Mower
ModelNo.121-7480
InstallationInstructions
Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescription
Qty.
Use
1
Nopartsrequired
–
Preparingtheunit.
2
Nopartsrequired
–
Removingthelowpressurehoses.
Hydraulicsystemcoolingassembly1
Bolt(5/16x3/4inch)
2
3
Nut(5/16inch)
2
Installingthehydraulicsystemcooling
assembly.
61cm(24inch)hose
1
HoseassemblywiththeT-connector1
Cabletie
2
4
Hoseclamps
5
Installingthelowpressurehoses.
Wireharness1
5
Cabletie
10
Routingthewireharness.
6
Nopartsrequired
–
Bleedingthehydraulicsystem.
©2012—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.
OriginalInstructions(EN)
PrintedintheUSA.
AllRightsReserved
*3373-396*B
1
PreparingtheUnit
NoPartsRequired
Procedure
WARNING
Hydraulicuidescapingunderpressurecan
penetrateskinandcauseinjury.
•Makesureallhydraulicuidhosesandlinesare
ingoodconditionandallhydraulicconnections
andttingsaretightbeforeapplyingpressureto
thehydraulicsystem.
•Keepyourbodyandhandsawayfrompin
holeleaksornozzlesthatejecthighpressure
hydraulicuid.
•Usecardboardorpapertondhydraulicleaks.
•Safelyrelieveallpressureinthehydraulicsystem
beforeperforminganyworkonthehydraulic
system.
•Seekimmediatemedicalattentionifuidis
injectedintoskin.
1.Positionmachineonalevelsurface.
2.Disengagethepowertakeoff(PTO)andsetthe
parkingbrake.
3.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.
4.Removethekey.
5.Removethebatterycover(
Figure33).
6.Removethenegativebatterycablefromthebattery.
7.Lowerthemowerdecktothelowestheight-of-cut
setting.
8.Lowertheplatform(
Figure1).
1
2
3
g018697
Figure1
1.Platformup
3.Pulltheknobouttorelease
theplatform
2.Platformdown
9.Removethehairpincottersecuringtherearcushion
bracket(Figure2).
10.Slidethebushingnexttothemachine(Figure2).
11.Lowertherearcushionbracketontotheplatform
(Figure1andFigure2).
1
2 3
1
g018698
Figure2
1.Hairpincotter3.Rearcushionbracket
2.Bushing
2
2
RemovingtheLowPressure
Hoses
NoPartsRequired
Procedure
1.Removethebolt,nut,andR-clampsecuringthehose
connectingtheright-handpumptothehydraulic
reservoirbracket(Figure3).
Note:DiscardtheR-clamp.
1
g01842 5
2
3
Figure3
1.Boltsecuringthehose3.Frontconnectoron
hydraulicreservoirtank
2.Hydraulicreservoirbracket
2.Removethelowpressurehosefromthefronttting
underthehydraulicreservoirtank(Figure3).
Note:Draintheoilintoanoilpan.
3.Removeanddiscardthecabletiessecuringthelow
pressurehoses(
Figure4andFigure5).
g018420
1
2
Figure4
Yourmodelmayvaryfromthisdiagram.
1.Cabletie
2.Hoses
g018419
1
2
Figure5
Yourmodelmayvaryfromthisdiagram.
1.Cabletie
2.Lowpressurehoses
3
4.Removethelowpressurehosefromtheright-hand
pump(Figure6).
1
g018421
Figure6
1.Disconnecthere
5.Removethelowpressurehosefromtheleft-hand
pump(Figure7).
1
g018422
Figure7
1.Disconnecthere
6.Removethehosefromtheunit(Figure8).
1
g018424
Figure8
1.Removehose
3
InstallingtheHydraulic
SystemCoolingAssembly
Partsneededforthisprocedure:
1Hydraulicsystemcoolingassembly
2
Bolt(5/16x3/4inch)
2
Nut(5/16inch)
Procedure
1.Usinga5/16inchdrillbit,reamtheholeinthe
reservoirbracket(Figure9).
4
1
g018426
Figure9
1.Hole
2.Locatetheserialnumberdecal.
g018327
Figure10
1.Locationofthemodelandserialnumbers
3.Determineyourmodelyearfromtheserialnumber.
•2009—serialnumberrange290000001andup
•2010—serialnumberrange310000001andup
•2011—serialnumberrange311000001andup
4.Locatethemountingholesinthecoolingassemblythat
willberequiredforyourunit.
Note:Usetheuppersetoftheholesfor2011models.
Usethelowersetofholesfor2009and2010models.
1
g018427
1
2
2
Figure11
1.Uppersetoftheholesfor
2011models.
2.Lowersetofholesfor
2009and2010models.
5
5.Alignthecoolingassemblytothereservoirbracket
(Figure12).
g018429
1
Figure12
1.Coolingassembly
6.Usingthecorrectsetofholesforyourunit,secure
therightsideofthecoolingassemblytothehydraulic
reservoirbracketusingabolt(5/16x1inch)andnut
(5/16inch)(Figure12andFigure13).
g018428
1
Figure13
1.Boltandnut
7.Usingthecoolerbracketasatemplate,drillthesecond
5/16inchholeintothereservoirbracket(Figure12,
Figure13,andFigure14).
1
g018451
Figure14
1.Boltandnut
8.Securethecoolerassemblyusingtheboltandnut
(Figure14).
4
InstallingtheLowPressure
Hoses
Partsneededforthisprocedure:
1
61cm(24inch)hose
1HoseassemblywiththeT-connector
2
Cabletie
5
Hoseclamps
Procedure
Note:Thehosefromtheleft-handpumpconnectstothe
radiatorinletport(Figure15).
6
1
2
3
g018473
Figure15
1.Coolingassemblyinlet
port
3.Left-handpump
2.Hosefromleft-handpump
connectingtocooling
assemblyinletport
Note:Thehosefromtheright-handpumpconnectstoa
T-connector.TheshorthosecomingofftheT-connector
goestotheradiatorexitport.Theotherhoseconnectsto
thehydraulicreservoirtank
g018472
1
2
3
4
5
6
7
Figure16
1.Hydraulicreservoirtank5.Right-handpump
2.Coolingassembly
6.T-connector
3.Shorthose
7.Hoseconnectingtothe
hydraulicreservoir
4.Hosefromtheright-hand
pumpconnectingtothe
T-connector
1.Installthe61cm(24inch)hosetoleft-handpump
(Figure17.
Note:Securethehosewithahoseclampsothatthe
tabsoftheclamparepointingdownwardasshown.
g018452
1
2
Figure17
1.Left-handpump
2.Returnport
2.Routethehoseandinstalltheotherendtothecooling
assemblyinlet.
Note:Rotatetabsonhoseclampasshownin
Figure18.
1
g018690
2
3
4
5
Figure18
1.CoolingAssemblyoutlet
4.Hosegoingtothe
T-connector
2.CoolingAssemblyInlet
5.Tabsonclamp
3.Hosecomingfromthe
left-handpump
3.InstallthehoseconnectingtheT-connectortothe
coolingassemblyoutlet(Figure16andFigure19).
7
Note:Rotatetabsonhoseclampasshownin
Figure18.
1
g018454
2
Figure19
1.Hosegoingtothe
hydraulicreservoirtank
2.T-connector
4.InstallthehoseconnectingtheT-connectortothe
right-handpump(Figure16andFigure20).
Note:Rotatethetabsofthehoseclampsotheyare
pointingdownward.
g018455
1
2
Figure20
1.Right-handpump2.Hoseclamp
5.Securethehosesusing2cableties(Figure21and
Figure22).
g018456
1
Figure21
1.Cabletie
g018457
1
Figure22
1.Cabletie
6.Movethedeckfromthehighestheightofcuttothe
lowestheightofcut.
•Repeatthisstepwhileobservingthehoses.
•Verifythatthehosesdonotcontacthotsurfaces,
sharpedges,ormovingcontrolslinkage.
•Adjustthecabletiesandhoseroutingifneededto
avoidcontactforallheightofcutpositions.
8
5
RoutingtheWireHarness
Partsneededforthisprocedure:
1Wireharness
10
Cabletie
Procedure
1.Beforestartingthisprocedure,observehowyouwill
routethewireharness.
g018478
1
2
3
4
Figure23
1.Routingthewireharness
tothebattery
3.Relaysocket
2.Relay4.Wireharnesstothe
coolingassembly
2.Connectthecoolingassemblyconnectortothewire
harness(Figure24).
g018458
1
Figure24
1.Coolingassemblyconnector
3.Routethecoolingassemblywireharnessunderneath
allthehosesandthroughthepumpcompartment
(
Figure25).
1
g018459
Figure25
1.Coolingassemblywireharness
4.Continueroutingthecoolingassemblywireharness
betweenthebrakerodandframe(Figure26).
9
1
g018460
Figure26
1.Coolingassemblywireharness
5.Removetherelayfromthewireharnessrelaysocket
(ifinstalled).
6.Installtherelaysockettotheframecrossbrace.
•For2011modelssecuretherelaysockettothe
crossbraceusinganutandbolt(Figure27).
•For2009and2010modelssecuretherelaysocket
tothecrossbraceand/orwireharness,usinga
cabletie.
Note:Thereisnoholeinthecrossbraceon2009
and2010modelsforsecuringtherelaysocketto
thecrossbrace.
1
2
g018475
Figure27
2011modelshown
1.Relaysocket2.Nut
7.Installtherelayintotherelaysocket.
8.Removeanddiscardtheprotectivecapfromtheend
oftheAUXconnectoronthewireharnessnearthe
fusebox.
9.Connectthecoolingassemblywireharnesstothe
wireharnessAUXconnectorlocatedatthefuseblock
(Figure28).
1
g018461
Figure28
1.Wireharnesses
10.Securethewireharnesstothehosegoingtothe
coolingassemblyinletwithacabletie(
Figure29).
1
g018691
2
Figure29
1.Cabletie
2.Wireharness
11.Securetheclipattachedtothewireharnesstothe
frame(Figure30).
10
1
g018689
Figure30
1.Attachthecliponthewireharnesstotheframe
12.Securethecoolingassemblywireharnesstothe
R-clamplocatedinthelowerleftfrontcornerofthe
controltower,usingacabletie(Figure31).
1
g018463
Figure31
1.Cabletie
13.Removetheslackfromthewireharnesswhereitpasses
throughthepumpcompartment.
14.Securethecoolingassemblywireharnesstothemain
wireharnessusingacabletie(Figure32).
g018464
1
Figure32
1.Cabletie
15.Routetheotherendofthewireharnesstothebattery
(Figure23)and(Figure33).
g018477
3
Figure33
1.Wingnut4.Positivebattery
connection
2.Batterycover5.Battery
3.Wireharnesstothe
positivebatteryterminal
16.Opentheredcapcoveringthepositivebatteryterminal.
17.Installtheconnectoronthecoolingassemblywire
harnesstothepositivebatteryterminal(Figure33).
18.Installtheredcap.
19.Installthenegativebatterycabletothebattery.
11
20.Securethepathofthecoolingassemblywireharness
usingthecableties.
21.Installthebatterycover.
22.Installthe15ampfuseintothefuseblock(Figure34).
1
g018465
Figure34
1.Fuse
23.TurnthekeytotheRunpositionandverifytheelectric
fanisrunning,thenturnthekeytothestopposition.
24.Installtherearcushionbracket(Figure2).
6
BleedingtheHydraulicSystem
NoPartsRequired
Procedure
Note:HydraulicOilType:Toro®HYPR-OIL™500
hydraulicoilorMobil®115W-50syntheticmotoroil.
1.Cleanareaaroundcapandllerneckofhydraulictank
(Figure35).
G012005
4 1 3
2
Figure35
1.Cap3.Colduidlevel-full
2.Bafe4.Hotuidlevel-full
2.Removecapfromllerneck.(Figure35).
3.Adduidtothereservoiruntilitreachesthecoldlevel
ofthebafe(Figure35).
4.Raisetherearofthemachineupontojackstandshigh
enoughtoraisethedrivewheelsofftheground.
5.Disengagetheparkingbrake.
6.Starttheengineandmovethethrottlecontroltoidle
position.
Note:Ifthedrivewheeldoesnotrotate,itispossible
toassistthepurgingofthesystembycarefullyrotating
thetireintheforwarddirection.
7.Checkthehydraulicuidlevelasitdropsadduidas
requiredtomaintaintheproperlevel.
8.Repeatthisprocedurefortheoppositewheel.
9.Installthecaponthellerneck.
10.Thoroughlycleantheareaaroundeachofthecharge
pumphousings.
11.Checkthecoolingsystemconnectionsforanyleaks.
12
/