Residential Products Garden Tractor GT Series Service Manual
ABOUT THIS MANUAL This service manual was written expressly for Toro 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.
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TABLE OF CONTENTS SAFETY INFORMATION *HQHUDO ,QIRUPDWLRQ......................................................................................................................1-1 Think Safety First..........................................................................................................................1-1 SPECIFICATIONS 7RUTXH 6SHFL¿FDWLRQV ...................................................................................................................2-1 6WDQGDUG 7RUTXH IRU 'U\ =LQF 3ODWH
TABLE OF CONTENTS CHASSIS cont. Deck Lift Handle & Shaft Assembly Replacement......................................................................3-93 Deck Lift Handle & Shaft Assembly Removal ......................................................................3-93 'HFN /LIW +DQGOH 6KDIW $VVHPEO\ ,QVWDOODWLRQ ...................................................................3-97 )URQW :KHHO 7RH ,Q 0HDVXUHPHQW $GMXVWPHQW......................................................................
TABLE OF CONTENTS MOWER DECK 50” Mower Deck Belt Replacement ..............................................................................................7-1 50” Mower Deck Belt Removal ..............................................................................................7-1 ´ 0RZHU 'HFN %HOW ,QVWDOODWLRQ ...........................................................................................7-2 ´ 0RZHU 'HFN )L[HG ,GOHU 5HSODFHPHQW ............................................................
TABLE OF CONTENTS THIS PAGE INTENTIONALLY LEFT BLANK.
SAFETY INFORMATION *HQHUDO ,QIRUPDWLRQ 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. $YRLG ¿UHV DQG H[SORVLRQV Avoid spilling fuel and never smoke while working with any type of fuel or lubricant. Wipe up any spilled fuel or oil immediately. Never remove the fuel cap or add fuel when the engine is running.
SAFETY INFORMATION 1 +\GUDXOLFV 6DIHW\ ,QVSHFW DOO K\GUDXOLF OLQH FRQQHFWRUV DQG ¿WWLQJV 0DNH sure all hydraulic hoses and lines are in good condition before applying pressure to the system. .HHS ERG\ DQG KDQGV DZD\ IURP SLQ KROH OHDNV RU QR]]OHV WKDW HMHFW KLJK SUHVVXUH K\GUDXOLF ÀXLG 8VH FDUGERDUG RU SDSHU WR ¿QG K\GUDXOLF OHDNV +\GUDXOLF ÀXLG HVFDSLQJ XQGHU SUHVVXUH FDQ SHQHWUDWH WKH VNLQ and cause injury.
SPECIFICATIONS 7RUTXH 6SHFL¿FDWLRQV 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.
SPECIFICATIONS 6WDQGDUG 7RUTXH IRU 'U\ =LQF 3ODWHG DQG 6WHHO )DVWHQHUV ,QFK 6HULHV 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 Stronge
SPECIFICATIONS 6WDQGDUG 7RUTXH IRU 'U\ =LQF DQG 6WHHO )DVWHQHUV 0HWULF 6HULHV 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 640 ± 60 N-cm 78 ± 7 in-lb 885 ± 80 N-cm M6 X 1.0 96 ± 9 in-lb 1018 ± 100 N-cm 133 ± 13 in-lb 1500 ± 150 N-cm M8 X 1.
SPECIFICATIONS 2WKHU 7RUTXH 6SHFL¿FDWLRQV Other Torque Specifications Wheel Bolts and Lug Nuts SAE Grade 8 Steel Set Screws 2 Recommended Torque Thread Size 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
SPECIFICATIONS (TXLYDOHQWV DQG &RQYHUVLRQV Equivalents and Conversions Decimal and Millimeter Equivalents Fractions 1/64 1/32 mm 0.015625 0.397 0.03125 0.794 3/64 0.046875 1.191 0.0625 1.588 5/64 0.078125 1.984 1/16 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 Decimals 0.9375 2.381 0.1250 3.175 0.140625 3.572 0.15625 3.969 0.171875 4.366 0.1875 4.762 0.203125 5.159 0.21875 5.
SPECIFICATIONS 8 6 WR 0HWULF &RQYHUVLRQV U.S. to Metric Conversions 2 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.
SPECIFICATIONS 3URGXFW 6SHFL¿FDWLRQV GT2100 GT2200 GT2300 23HP Twin Cylinder Kohler Courage 25HP Twin Cylinder Kohler Courage 26HP Twin Cylinder Kohler Courage 1DPH (QJLQH +LJK 530 6HWWLQJ 3375 /RZ 530 6HWWLQJ 1200 + 75 &RQVWUXFWLRQ 12 Gauge Steel Frame )XHO &DSDFLW\ 3.0 gallons (11.4 liters) :KHHO %DVH 46.0” (116.8cm) 2YHUDOO /HQJWK 68.0” (172.7cm) 54.0” (137.2cm) 2YHUDOO :LGWK 54.0” (137.2cm) 2 60.0” (152.4cm) 43.0” (109.2cm) 2YHUDOO +HLJKW :HLJKW DSSUR[ 575 lbs.
SPECIFICATIONS 2 7+,6 3$*( ,17(17,21$//< /()7 %/$1.
CHASSIS Front Pivot Axle Replacement 5HPRYH WKH GHFN KDQJHU EUDFNHW DQG URG DVVHPEO\ IURP WKH IUDPH )LJ Front Pivot Axle Removal 1. Disconnect the negative and then the positive battery cable. 2. Remove the mower deck. Refer to: ³ ´ 0RZHU 'HFN 5HPRYDO´ RQ SDJH ³ ´ 0RZHU 'HFN 5HPRYDO´ RQ SDJH 3.
CHASSIS 8QSOXJ WKH KHDGOLJKWV IURP WKH ZLUH KDUQHVV )LJ 8. Apply the parking brake. /LIW DQG VHFXUH WKH IURQW HQG RI WKH PDFKLQH VR WKH front axle can be accessed. 5HPRYH WKH KXEFDSV IURP ERWK IURQW ZKHHOV )LJ 3 Fig 004 3,&7 5HPRYH WKH KRRG IURP WKH IUDPH )LJ Fig 006 3,&7 11.
CHASSIS 5HPRYH WKH ZDVKHUV IURP WKH D[OHV )LJ Note: There is an inner and an outer bushing included with the wheel assembly: ,QQHU EXVKLQJ )LJ 3 Fig 008 3,&7 D Fig 010 3,&7 D Fig 011 3,&7 D 5HPRYH WKH ZKHHOV IURP WKH D[OHV )LJ 2XWHU EXVKLQJ )LJ Fig 009 GT Series Tractors Service Manual 3,&7 3-3
CHASSIS 5HPRYH WKH QXW VHFXULQJ WKH EDOO MRLQW WR WKH D[OH DVVHPEO\ )LJ 5HPRYH WKH FDS IURP WKH D[OH DVVHPEO\ )LJ 3 Fig 014 Fig 012 5HPRYH WKH EDOO MRLQW IURP WKH D[OH DVVHPEO\ )LJ 5HPRYH WKH SXVK QXW IURP WKH D[OH DVVHPEO\ )LJ Fig 015 Fig 013 3,&7 3,&7 3,&7 3,&7 GT Series Tractors Service Manual
CHASSIS 18. Remove the axle assembly from the front pivot axle )LJ 6XSSRUW WKH IURQW SLYRW D[OH ZLWK MDFNVWDQGV 22. Remove the 2 screws securing the bumper to the IUDPH EROW RQ WKH OHIW DQG RQ WKH ULJKW )LJ 3 Fig 016 3,&7 Fig 018 3,&7 5HSHDW VWHSV WR UHPRYH WKH D[OH DVVHPEO\ from the opposite side of the pivot axle.
CHASSIS 5HPRYH WKH VFUHZV VHFXULQJ WKH OHIW DQG ULJKW VLGH EXPSHU EUDFNHWV WR WKH PXIÀHU EUDFNHW RQ WKH OHIW DQG RQ WKH ULJKW )LJ 5HPRYH WKH EROWV RQ WKH ULJKW RQ WKH OHIW securing the left and right pivot supports to the frame )LJ Fig 020 Fig 022 3 3,&7 6OLGH WKH PXIÀHU DQG KHDW VKLHOG DVVHPEO\ RII WKH PDQLIROG SLSHV )LJ Fig 021 5HPRYH WKH QXWV IURP WKH EROWV VHFXULQJ WKH SLYRW bar and pivot support brackets to the frame (Fig.
CHASSIS 8QWKUHDG DQG UHPRYH RQH RI WKH EROWV DQG SLYRW VXSSRUWV IURP WKH SLYRW D[OH DQG IUDPH )LJ 5HPRYH WKH SLYRW EDU EUDFNHW IURP WKH IUDPH )LJ 3 Fig 024 3,&7 8QWKUHDG DQG UHPRYH WKH RWKHU EROW DQG SLYRW VXS SRUW IURP WKH SLYRW D[OH DQG IUDPH )LJ Fig 026 5HPRYH WKH IURQW SLYRW D[OH )LJ Fig 027 Fig 025 GT Series Tractors Service Manual 3,&7 3,&7 3,&7
CHASSIS Front Pivot Axle Installation 1. Position and support the front pivot axle to the frame. 3. Position the pivot support to the frame and loosely LQVWDOO D EROW WKURXJK WKH SLYRW VXSSRUW SLYRW EUDFNHW DQG SLYRW D[OH )LJ 1RWH 7KH JUHDVH ¿WWLQJV VKRXOG IDFH IRUZDUG )LJ 3 Fig 030 Fig 028 3,&7 3,&7 3RVLWLRQ WKH RWKHU SLYRW VXSSRUW EUDFNHW WR WKH IUDPH and loosely install the other bolt through the pivot VXSSRUW SLYRW EUDFNHW DQG SLYRW D[OH )LJ 2.
CHASSIS /RRVHO\ LQVWDOO D QXW RQWR HDFK RI WKH EROWV VHFXULQJ the pivot support bracket and pivot bar bracket to the IUDPH )LJ 7LJKWHQ WKH QXWV DQG EROWV VHFXULQJ WKH SLYRW VXS port bracket and axle pivot bar to the frame (Fig. 3 Fig 032 3,&7 ,QVWDOO EROWV VHFXULQJ WKH OHIW DQG ULJKW SLYRW VXS SRUWV WR WKH IUDPH RQ WKH ULJKW RQ WKH OHIW )LJ Fig 034 6OLGH WKH PXIÀHU DQG KHDW VKLHOG DVVHPEO\ RQWR WKH PDQLIROG SLSHV DQG SRVLWLRQ LW WR WKH IUDPH
CHASSIS ,QVWDOO VFUHZV VHFXULQJ WKH OHIW DQG ULJKW VLGH SLYRW VXSSRUW EUDFNHWV WR WKH PXIÀHU KHDW VKLHOG DVVHPEO\ RQ WKH OHIW DQG RQ WKH ULJKW )LJ 11.
CHASSIS 13. Slide the axle assemblies into the front pivot axle )LJ ,QVWDOO D QXW RQWR HDFK EDOO MRLQW VHFXULQJ WKH EDOO MRLQWV WR WKH D[OH DVVHPEO\ )LJ 3 Fig 040 3,&7 3RVLWLRQ WKH EDOO MRLQWV LQWR WKH D[OH DVVHPEO\ )LJ Fig 042 6OLGH WKH ZKHHO DVVHPEOLHV RQWR WKH D[OHV )LJ Fig 043 Fig 041 GT Series Tractors Service Manual 3,&7 3,&7 3,&7 3-11
CHASSIS Note: There is an inner and an outer bushing included with the wheel assembly: ,QVWDOO D ZDVKHU RQWR HDFK D[OH )LJ ,QQHU EXVKLQJ )LJ 3 Fig 046 Fig 044 3,&7 D 3,&7 D 18.
CHASSIS ,QVWDOO D KXEFDS RQWR WKH ZKHHO DVVHPEOLHV )LJ 22. Position the hood onto the hood support brackets )LJ 3 Fig 048 3,&7 /RZHU WKH IURQW HQG RI WKH PDFKLQH WR WKH JURXQG Fig 050 3,&7 3OXJ WKH KHDGOLJKWV LQWR WKH ZLUH KDUQHVV )LJ 21.
CHASSIS /RZHU WKH KRRG )LJ 3 Fig 054 Fig 052 3,&7 D 3,&7 3RVLWLRQ WKH GHFN KDQJHU EUDFNHW DQG URG DVVHPEO\ WR WKH IUDPH )LJ $SSO\ JUHDVH WR WKH D[OH SLYRW EDU JUHDVH ¿WWLQJV DQG to the bushings on the inside of the wheel assembly )LJ DQG )LJ Fig 055 Fig 053 3,&7 3,&7 GT Series Tractors Service Manual
CHASSIS ,QVWDOO FOHYLV SLQV DQG KDLUSLQV WR VHFXUH WKH GHFN KDQJHU EUDFNHW WR WKH IUDPH )LJ Axle Assembly Replacement 1RWH 7KH IROORZLQJ SURFHGXUH LV WKH VDPH IRU ULJKW VLGH DQG OHIW VLGH D[OH DVVHPEO\ UHSODFHPHQW 1RWH 7KH IROORZLQJ SURFHGXUHV ZHUH GRQH ZLWK WKH PRZHU GHFN UHPRYHG ,W LV QRW UHTXLUHG WKDW WKH PRZHU GHFN EH UHPRYHG Axle Assembly Removal 3 1. Disconnect the negative and then the positive battery cable. 5DLVH WKH KRRG )LJ Fig 056 3,&7 28.
CHASSIS 8QSOXJ WKH KHDGOLJKWV IURP WKH ZLUH KDUQHVV )LJ $SSO\ WKH SDUNLQJ EUDNH /LIW DQG VHFXUH WKH IURQW HQG RI WKH PDFKLQH VR WKH front axle can be accessed. 5HPRYH WKH KXEFDS IURP WKH IURQW ZKHHO )LJ 3 Fig 058 3,&7 5HPRYH WKH KRRG IURP WKH IUDPH )LJ Fig 060 3,&7 8.
CHASSIS 5HPRYH WKH ZDVKHU IURP WKH D[OH )LJ Note: There is an inner and an outer bushing included with the wheel assembly: ,QQHU EXVKLQJ )LJ 3 Fig 062 3,&7 D Fig 064 3,&7 D Fig 065 3,&7 D 5HPRYH WKH ZKHHO DVVHPEO\ IURP WKH D[OH )LJ 2XWHU EXVKLQJ )LJ Fig 063 GT Series Tractors Service Manual 3,&7
CHASSIS 5HPRYH WKH QXW VHFXULQJ WKH EDOO MRLQW WR WKH D[OH DVVHPEO\ )LJ 5HPRYH WKH FDS IURP WKH D[OH DVVHPEO\ )LJ 3 Fig 068 Fig 066 5HPRYH WKH EDOO MRLQW IURP WKH D[OH DVVHPEO\ )LJ 5HPRYH WKH SXVK QXW IURP WKH D[OH DVVHPEO\ )LJ Fig 069 Fig 067 3-18 3,&7 3,&7 3,&7 3,&7 GT Series Tractors Service Manual
CHASSIS 5HPRYH WKH D[OH DVVHPEO\ IURP WKH IURQW SLYRW D[OH )LJ 3RVLWLRQ WKH EDOO MRLQW LQWR WKH D[OH DVVHPEO\ )LJ 3 Fig 070 3,&7 Axle Assembly Installation Fig 072 3,&7 ,QVWDOO D QXW RQWR WKH EDOO MRLQW VHFXULQJ LW WR WKH D[OH DVVHPEO\ )LJ 1. Slide the axle assembly into the front pivot axle (Fig.
CHASSIS 6OLGH WKH ZKHHO DVVHPEO\ RQWR WKH D[OH )LJ 2XWHU EXVKLQJ )LJ 3 Fig 074 3,&7 Note: There is an inner and an outer bushing included with the wheel assembly: Fig 076 3,&7 ,QVWDOO D ZDVKHU RQWR WKH D[OH )LJ ,QQHU EXVKLQJ )LJ Fig 077 Fig 075 3,&7 D 3,&7 D GT Series Tractors Service Manual
CHASSIS ,QVWDOO D QHZ FRWWHU SLQ LQWR WKH D[OH WR VHFXUH WKH ZKHHO )LJ /RZHU WKH IURQW HQG RI WKH PDFKLQH WR WKH JURXQG ,QVWDOO D SXVK QXW FDS RQWR WKH D[OH DVVHPEO\ )LJ 3 Fig 078 3,&7 D Fig 080 3,&7 ,QVWDOO D KXEFDS RQWR WKH ZKHHO DVVHPEO\ )LJ 3RVLWLRQ WKH KRRG RQWR WKH KRRG VXSSRUW EUDFNHWV )LJ Fig 079 3,&7 Fig 081 GT Series Tractors Service Manual 3,&7 3-21
CHASSIS 3OXJ WKH KHDGOLJKWV LQWR WKH ZLUH KDUQHVV )LJ $SSO\ JUHDVH WR WKH D[OH SLYRW EDU JUHDVH ¿WWLQJV DQG to the bushings on the inside of the wheel assembly )LJ DQG )LJ 3 Fig 082 3,&7 Fig 084 3,&7 Fig 085 3,&7 D /RZHU WKH KRRG )LJ Fig 083 3-22 3,&7 GT Series Tractors Service Manual
CHASSIS Steering Wheel Replacement 3. Remove the washer from the steering wheel (Fig. Steering Wheel Removal 5HPRYH WKH VWHHULQJ ZKHHO FRYHU )LJ 3 Fig 088 Fig 086 3,&7 3,&7 5HPRYH WKH VWHHULQJ ZKHHO IURP WKH VWHHULQJ VKDIW )LJ 2.
CHASSIS Steering Wheel Installation 3. Install a screw to secure the steering wheel to the VWHHULQJ VKDIW )LJ 1. Slide the steering wheel onto the steering shaft (Fig.
CHASSIS 6WHHULQJ 6KDIW 5HSODFHPHQW 6WHHULQJ 6KDIW 5HPRYDO 5HPRYH WKH VWHHULQJ ZKHHO 5HIHU WR ³6WHHULQJ :KHHO 5HPRYDO´ RQ SDJH 5HPRYH WKH IXHO FDS 6OLGH WKH KRVH FODPS GRZQ WKH IXHO OLQH 5HPRYH WKH IXHO OLQH IURP WKH IXHO ¿OWHU DQG drain the fuel into a suitable container. Slide the fuel OLQH EDFN RQWR WKH IXHO ¿OWHU DQG SRVLWLRQ WKH KRVH clamp to secure. Replace the fuel cap onto the fuel WDQN )LJ 5DLVH WKH KRRG )LJ 3 Fig 095 Fig 094 3,&7 3.
CHASSIS /LIW WKH IXHO WDQN RXW RI WKH WRZHU )LJ 5HPRYH WKH SLQLRQ IURP WKH VWHHULQJ VKDIW )LJ 3 Fig 097 3,&7 D 5DLVH DQG VXSSRUW WKH PDFKLQH WR DFFHVV WKH steering gear assembly. Fig 099 3,&7 3XVK XS RQ WKH VWHHULQJ VKDIW DQG UHPRYH WKH ZDVK HU IURP WKH HQG RI WKH VWHHULQJ VKDIW )LJ 8.
CHASSIS /RZHU WKH PDFKLQH 6WHHULQJ 6KDIW ,QVWDOODWLRQ 3XOO WKH VWHHULQJ VKDIW XS DQG RXW RI WKH KH[ ÀDQJH bearing.
CHASSIS 3. Raise the machine to access the steering gear assembly. /RRVHO\ LQVWDOO D QXW RQWR WKH VWHHULQJ VKDIW 6HFXUH the steering gear in place with a punch and tighten WKH QXW )LJ 3XVK XS RQ WKH VWHHULQJ VKDIW WR LQVWDOO D ZDVKHU RQWR WKH VWHHULQJ VKDIW )LJ Note: The washer is installed above the steering JHDU 3 Fig 107 Fig 105 3,&7 3,&7 *UHDVH WKH SLQLRQ JHDU ZLWK JHQHUDO SXUSRVH JUHDVH )LJ 6OLGH WKH SLQLRQ RQWR WKH VWHHULQJ VKDIW )LJ
CHASSIS /RZHU WKH PDFKLQH Electric PTO Clutch Replacement 3RVLWLRQ WKH IXHO WDQN LQWR WKH WRZHU )LJ Electric PTO Clutch Removal 1. Remove the mower deck. Refer to: ³ ´ 0RZHU 'HFN 5HPRYDO´ RQ SDJH ³ ´ 0RZHU 'HFN 5HPRYDO´ RQ SDJH 8QSOXJ WKH FOXWFK IURP WKH ZLUH KDUQHVV )LJ 3 Fig 109 3,&7 D 3RVLWLRQ WKH IXHO WDQN VXSSRUW URGV DQG LQVWDOO a screw securing each support rod to the dash VXSSRUWV )LJ Fig 111 3,&7 3.
CHASSIS 5HPRYH WKH EROW DQG ORFN ZDVKHU VHFXULQJ WKH FOXWFK WR WKH FUDQNVKDIW )LJ Electric PTO Clutch Installation 1. Apply anti-seize compound to the crankshaft (Fig.
CHASSIS 3. Align the clutch keyway with the key on the crankshaft and slide the clutch and spacer assembly onto WKH FUDQNVKDIW )LJ 5RXWH WKH FOXWFK FRQQHFWRU WKURXJK WKH VORW LQ WKH frame.
CHASSIS Fuel Tank Replacement /RRVHQ WKH VFUHZV VHFXULQJ WKH IXHO WDQN VXSSRUW URGV WR WKH GDVK VXSSRUWV /D\ WKH VXSSRUW URGV WR WKH VLGH )LJ Fuel Tank Removal 5DLVH WKH KRRG )LJ 3 Fig 121 Fig 119 3,&7 3,&7 /LIW WKH IXHO WDQN RXW RI WKH WRZHU )LJ 2. Remove the fuel cap. Slide the hose clamp down the IXHO OLQH 5HPRYH WKH IXHO OLQH IURP WKH IXHO ¿OWHU DQG drain the fuel into a suitable container.
CHASSIS Fuel Tank Installation 6OLGH WKH IXHO OLQH EDFN RQWR WKH IXHO ¿OWHU DQG SRVL WLRQ WKH KRVH FODPS WR VHFXUH )LJ 3RVLWLRQ WKH IXHO WDQN LQWR WKH WRZHU )LJ 3 Fig 125 Fig 123 3,&7 3,&7 D /RZHU WKH KRRG )LJ 2.
CHASSIS Hood Replacement 5HPRYH WKH KRRG IURP WKH IUDPH )LJ Hood Removal 5DLVH WKH KRRG )LJ 3 Fig 129 Fig 127 3,&7 3,&7 Hood Installation 1.
CHASSIS 3OXJ WKH KHDGOLJKWV LQWR WKH ZLUH KDUQHVV )LJ Fender Replacement Fender Removal /LIW WKH VHDW WR DFFHVV WKH EDWWHU\ FRPSDUWPHQW 2. Disconnect the battery cable from the negative EDWWHU\ WHUPLQDO )LJ 3 Fig 131 3,&7 /RZHU WKH KRRG )LJ Fig 133 3,&7 3. Disconnect the battery cable from the positive EDWWHU\ WHUPLQDO )LJ Fig 132 3,&7 Fig 134 GT Series Tractors Service Manual 3,&7 D
CHASSIS 5HPRYH WKH EDWWHU\ KROG GRZQ URG )LJ 5HPRYH WKH EDWWHU\ WUD\ )LJ 3 Fig 135 3,&7 5HPRYH WKH EDWWHU\ IURP WKH EDWWHU\ WUD\ )LJ Fig 136 3,&7 Fig 137 3,&7 8QSOXJ WKH VHDW VZLWFK ZLUHV )LJ Fig 138 3,&7 GT Series Tractors Service Manual
CHASSIS /RRVHQ WKH EROW DQG QXW VHFXULQJ WKH OHIW VHDW PRXQW EUDFNHW WR WKH VHDW EUDFNHW )LJ 5HPRYH WKH EROWV VHFXULQJ WKH VHDW PRXQW EUDFN HWV WR WKH IHQGHU )LJ 3 Fig 139 3,&7 Fig 141 8VLQJ D VSULQJ WRRO 7RUR SDUW QR UHOHDVH the extension spring from the seat mount bracket )LJ 5HPRYH WKH VHDW )LJ Fig 142 Fig 140 GT Series Tractors Service Manual 3,&7 3,&7 3,&7
CHASSIS 12. Remove the height-of-cut grip from the height-of-cut OHYHU )LJ 5HPRYH WKH FDUULDJH EROW ZDVKHU DQG QXW VHFXULQJ WKH IHQGHU WR WKH IUDPH )LJ 3 Fig 143 3,&7 13. Pry up the front portion of the left hand foot pad (Fig. Fig 144 3-38 3,&7 Fig 145 3,&7 3U\ XS WKH IURQW SRUWLRQ RI WKH ULJKW KDQG IRRW SDG )LJ Fig 146 3,&7 GT Series Tractors Service Manual
CHASSIS 5HPRYH WKH FDUULDJH EROW ZDVKHU DQG QXW VHFXULQJ WKH IHQGHU WR WKH IUDPH )LJ 5HPRYH WKH VFUHZV )LJ 3 Fig 149 Fig 147 3,&7 3,&7 /RFDWH WKH VFUHZV XQGHU WKH GDQJHU GHFDO RQ WKH fender. Cut the decal to expose the screw heads )LJ 5HPRYH WKH IDVWHQHUV VHFXULQJ WKH EUDNH SHGDO OHYHU WR WKH EUDNH FRQWURO DVVHPEO\ )LJ 1RWH 7KH IRRW SDG KDV EHHQ UHPRYHG IRU SKRWR SXUSRVHV A B Fig 148 3,&7 Fig 150 3,&7 A.
CHASSIS 5HPRYH WKH EUDNH SHGDO )LJ 5HPRYH WKH VSHHG FRQWURO SHGDO )LJ 3 Fig 151 3,&7 21. Remove the 2 bolts securing the speed control lever WR WKH VSHHG FRQWURO DVVHPEO\ )LJ Fig 153 5HPRYH WKH IHQGHU )LJ Fig 154 Fig 152 3,&7 3,&7 3,&7 GT Series Tractors Service Manual
CHASSIS Fender Installation 3. Install 2 bolts securing the speed control lever to the VSHHG FRQWURO DVVHPEO\ )LJ 3RVLWLRQ WKH IHQGHU RQWR WKH IUDPH )LJ 3 Fig 157 Fig 155 3,&7 2. Position the speed control pedal to the speed control DVVHPEO\ )LJ 3RVLWLRQ WKH EUDNH SHGDO WR WKH EUDNH FRQWURO DV VHPEO\ )LJ Fig 158 Fig 156 GT Series Tractors Service Manual 3,&7 3,&7 3,&7
CHASSIS ,QVWDOO IDVWHQHUV VHFXULQJ WKH EUDNH SHGDO WR WKH EUDNH FRQWURO DVVHPEO\ )LJ $SSO\ D UHSODFHPHQW GDQJHU GHFDO )LJ 1RWH 7KH IRRW SDG KDV EHHQ UHPRYHG IRU SKRWR SXUSRVHV A 3 B Fig 161 Fig 159 3,&7 A. TORX screw and washer B.
CHASSIS /LIW WKH OHIW IRRW SDG DQG LQVWDOO D FDUULDJH EROW ZDVK er and nut securing the fender to the frame (Fig. 11. Position the seat assembly onto the fender (Fig.
CHASSIS ,QVWDOO WKH WK EROW DQG H[WHUQDO ORFN ZDVKHU VHFXULQJ WKH VHDW PRXQW EUDFNHWV WR WKH IHQGHU )LJ 7LJKWHQ WKH EROW DQG QXW VHFXULQJ WKH OHIW VHDW PRXQW EUDFNHW WR WKH VHDW EUDFNHW )LJ Fig 167 Fig 169 3 3,&7 8VLQJ D VSULQJ UHPRYDO WRRO 7RUR SDUW QR install an extension spring onto the seat mount EUDFNHW )LJ 3OXJ WKH VHDW VZLWFK ZLUHV LQWR WKH VHDW VZLWFK )LJ Fig 170 Fig 168 3,&7 3,&7 3,&7 GT
CHASSIS 3RVLWLRQ WKH EDWWHU\ WUD\ LQWR WKH IHQGHU )LJ ,QVWDOO WKH EDWWHU\ KROG GRZQ URG )LJ 3 Fig 171 3,&7 3ODFH WKH EDWWHU\ LQWR WKH EDWWHU\ WUD\ )LJ Fig 172 Fig 173 &RQQHFW WKH UHG EDWWHU\ FDEOH WR WKH SRVLWLYH EDWWHU\ WHUPLQDO )LJ 3,&7 Fig 174 GT Series Tractors Service Manual 3,&7 3,&7 D
CHASSIS 21. Connect the black battery cable to the negative EDWWHU\ WHUPLQDO )LJ Tower Replacement Tower Removal 5HPRYH WKH IHQGHU 5HIHU WR ³)HQGHU 5HPRYDO´ RQ SDJH 5HPRYH WKH VWHHULQJ ZKHHO 5HIHU WR ³6WHHULQJ :KHHO 5HPRYDO´ RQ SDJH 5HPRYH WKH KRRG 5HIHU WR ³+RRG 5HPRYDO´ RQ SDJH 3 5HPRYH WKH IXHO FDS 6OLGH WKH KRVH FODPS GRZQ WKH IXHO OLQH 5HPRYH WKH IXHO OLQH IURP WKH IXHO ¿OWHU DQG drain the fuel into a suitable container.
CHASSIS /RRVHQ WKH VFUHZV VHFXULQJ WKH IXHO WDQN VXSSRUW URGV WR WKH GDVK VXSSRUWV /D\ WKH VXSSRUW URGV WR WKH VLGH )LJ 8QSOXJ WKH KRXU PHWHU IURP WKH ZLUH KDUQHVV )LJ 3 Fig 179 Fig 177 3,&7 3,&7 8QSOXJ WKH HOHFWULF 372 VZLWFK SOXJ )LJ /LIW WKH IXHO WDQN RXW RI WKH WRZHU )LJ Fig 180 Fig 178 GT Series Tractors Service Manual 3,&7 3,&7 D
CHASSIS 8QSOXJ WKH ZLUH KDUQHVV IURP WKH LJQLWLRQ PRGXOH )LJ 11.
CHASSIS 13. Remove the bolt and nut securing the control knob WR WKH WKURWWOH DVVHPEO\ )LJ 5HPRYH WKH VFUHZV VHFXULQJ WKH WKURWWOH DVVHPEO\ WR WKH WRZHU )LJ 3 Fig 185 3,&7 5HPRYH WKH FRQWURO NQRE )LJ Fig 186 Fig 187 3XOO WKH WKURWWOH DVVHPEO\ RXW IURP WKH UHDU RI WKH WRZHU )LJ 3,&7 Fig 188 GT Series Tractors Service Manual 3,&7 3,&7
CHASSIS 5HPRYH WKH VFUHZV VHFXULQJ WKH EXPSHU WR WKH IUDPH EROW RQ WKH OHIW DQG RQ WKH ULJKW )LJ 5HPRYH WKH VFUHZV VHFXULQJ WKH OHIW DQG ULJKW VLGH PXIÀHU EUDFNHWV WR WKH IUDPH RQ WKH OHIW DQG RQ WKH ULJKW )LJ 3 Fig 189 3,&7 5HPRYH WKH EXPSHU )LJ Fig 190 Fig 191 6OLGH WKH PXIÀHU DQG KHDW VKLHOG DVVHPEO\ RII WKH PDQLIROG SLSHV )LJ 3,&7 Fig 192 3,&7 3,&7 GT Series Tractors Service Manual
CHASSIS 21. Position the throttle in the slow position and fully SXVK WKH FKRNH LQ )LJ 23.
CHASSIS 5HPRYH WKH FKRNH DVVHPEO\ IURP WKH WRZHU )LJ 5HPRYH WKH FUXLVH FRQWURO URG DQG SDUN EUDNH URG IURP WKH OHYHUV )LJ 3 Fig 197 3,&7 D 5HPRYH WKH KDLUSLQV IURP WKH FUXLVH FRQWURO URG DQG WKH SDUN EUDNH OLQNDJH )LJ Fig 198 Fig 199 28. Remove the 2 screws and washers securing the top of the tower to the top of the support brackets (Fig.
CHASSIS 5HPRYH WKH EROWV DQG VFUHZV VHFXULQJ WKH ERWWRP RI WKH WRZHU WR WKH IUDPH RQ WKH OHIW VLGH RQ WKH ULJKW VLGH )LJ 31. Remove the 2 screws securing the left tower support WR WKH IUDPH )LJ 3 Fig 203 Fig 201 32. Remove the left tower support from the frame (Fig.
CHASSIS 33. Repeat steps 31 and 32 to remove the right tower support. 5HPRYH WKH FOLS IURP EDFN VLGH RI WKH 372 VZLWFK )LJ 5HPRYH WKH KRXU PHWHU IURP WKH WRZHU E\ VTXHH]LQJ WKH WDEV )LJ 3 Fig 207 Fig 205 3,&7 3,&7 5HPRYH WKH 372 VZLWFK IURP WKH WRZHU )LJ 5HPRYH WKH LJQLWLRQ VZLWFK PRGXOH IURP WKH WRZHU E\ GHSUHVVLQJ WKH WDEV )LJ Fig 208 Fig 206 3,&7 3,&7 GT Series Tractors Service Manual
CHASSIS 38. Remove the screw securing the bent lever rod to the WRZHU )LJ Tower Installation 3RVLWLRQ WKH EHQW OHYHU URG FUXLVH FRQWURO OHYHU DQG parking brake lever assembly into the tower (Fig.
CHASSIS 2.
CHASSIS ,QVHUW WKH LJQLWLRQ VZLWFK PRGXOH LQWR WKH WRZHU )LJ 3RVLWLRQ WKH OHIW WRZHU VXSSRUW RQWR WKH IUDPH )LJ 3 Fig 217 3,&7 ,QVWDOO WKH KRXU PHWHU LQWR WKH WRZHU )LJ Fig 218 GT Series Tractors Service Manual Fig 219 3,&7 8.
CHASSIS 5HSHDW VWHSV DQG WR LQVWDOO WKH ULJKW WRZHU support. 12. Install 2 screws and washers securing the top of the WRZHU WR WKH WRS RI WKH VXSSRUW EUDFNHWV )LJ 3RVLWLRQ WKH WRZHU RQWR WKH IUDPH )LJ 3 Fig 223 Fig 221 3,&7 D 3,&7 13.
CHASSIS ,QVWDOO D KDLUSLQ LQWR WKH FUXLVH FRQWURO URG DQG WKH park brake rod securing them to the levers (Fig. 5RXWH WKH FKRNH FDEOH DURXQG WKH OHIW VLGH RI WKH HQJLQH SODFLQJ WKH FDEOH LQWR WKH 5 FODPS )LJ DQG WKURXJK WKH FDEOH WLH )LJ 3 Fig 225 3,&7 Fig 227 3,&7 Fig 228 3,&7 ,QVHUW WKH FKRNH DVVHPEO\ WKURXJK WKH WRZHU )LJ Fig 226 GT Series Tractors Service Manual 3,&7
CHASSIS ,QVWDOO D QXW VHFXULQJ WKH FKRNH KDQGOH WR WKH WRZHU )LJ 3ODFH WKH FKRNH FDEOH LQWR WKH FDEOH FODPS )LJ 3 Fig 229 3,&7 18. Insert the choke cable z-bend into the choke lever RQ WKH IURQW RI WKH HQJLQH )LJ Fig 230 3,&7 Fig 231 3,&7 ,QVHUW WKH WKURWWOH DVVHPEO\ IURP WKH UHDU RI WKH WRZHU )LJ Fig 232 3,&7 GT Series Tractors Service Manual
CHASSIS 21. Install 2 screws securing the throttle assembly to the WRZHU )LJ 23. Install a bolt and nut securing the control knob to the WKURWWOH DVVHPEO\ )LJ 3 Fig 233 3,&7 22. Push the knob onto the throttle control lever (Fig. Fig 235 $SSO\ D WKURWWOH GHFDO RQWR WKH WRZHU )LJ Fig 236 Fig 234 GT Series Tractors Service Manual 3,&7 3,&7 3,&7
CHASSIS ,QVWDOO WKH IXVH KROGHU LQWR WKH ULJKW KDQG WRZHU VXSSRUW )LJ 3OXJ WKH ZLUH KDUQHVV LQWR WKH LJQLWLRQ PRGXOH )LJ 3 Fig 237 3,&7 3OXJ WKH ZLUH KDUQHVV LQWR WKH LJQLWLRQ VZLWFK )LJ Fig 238 3,&7 Fig 239 3,&7 28.
CHASSIS 3OXJ WKH ZLUH KDUQHVV LQWR WKH KRXU PHWHU )LJ 31.
CHASSIS ,QVWDOO WKH VWHHULQJ ZKHHO 5HIHU WR ³6WHHULQJ :KHHO ,QVWDOODWLRQ´ RQ SDJH ,QVWDOO VFUHZV VHFXULQJ WKH OHIW DQG ULJKW VLGH PXIÀHU EUDFNHWV WR WKH IUDPH RQ WKH OHIW DQG RQ WKH ULJKW )LJ ,QVWDOO WKH IHQGHU 5HIHU WR ³)HQGHU ,QVWDOODWLRQ´ RQ SDJH $GMXVW WKH WKURWWOH DQG FKRNH FDEOHV 5HIHU WR ³7KURWWOH DQG &KRNH &DEOH $GMXVWPHQW´ RQ SDJH 6OLGH WKH PXIÀHU DQG KHDW VKLHOG DVVHPEO\ RQWR WKH PDQLIROG SLSHV )LJ 3 Fig 246 3,&7
CHASSIS ,QVWDOO VFUHZV VHFXULQJ WKH EXPSHU WR WKH IUDPH EROW RQ WKH OHIW DQG RQ WKH ULJKW )LJ Throttle Cable Replacement Throttle Cable Removal /LIW WKH VHDW WR DFFHVV WKH EDWWHU\ FRPSDUWPHQW 2. Disconnect the battery cable from the negative EDWWHU\ WHUPLQDO )LJ 3 Fig 248 3,&7 ,QVWDOO WKH KRRG 5HIHU WR ³+RRG ,QVWDOODWLRQ´ RQ SDJH 2SHUDWH WKH WUDFWRU WR HQVXUH DOO FRQWUROV DQG WKH seat switch operate properly.
CHASSIS 5HPRYH WKH KRRG 5HIHU WR ³+RRG 5HPRYDO´ RQ SDJH 5HPRYH WKH VFUHZV VHFXULQJ WKH OHIW DQG ULJKW VLGH PXIÀHU EUDFNHWV WR WKH IUDPH RQ WKH OHIW DQG RQ WKH ULJKW )LJ 5HPRYH WKH VFUHZV VHFXULQJ WKH EXPSHU WR WKH IUDPH EROW RQ WKH OHIW DQG RQ WKH ULJKW )LJ 3 Fig 252 Fig 250 3,&7 3,&7 6OLGH WKH PXIÀHU DQG KHDW VKLHOG DVVHPEO\ RII WKH PDQLIROG SLSHV )LJ 5HPRYH WKH EXPSHU )LJ Fig 253 Fig 251 3,&7
CHASSIS 8. Remove the fuel cap. Slide the hose clamp down the IXHO OLQH 5HPRYH WKH IXHO OLQH IURP WKH IXHO ¿OWHU DQG drain the fuel into a suitable container. Replace the IXHO FDS RQWR WKH IXHO WDQN )LJ /LIW WKH IXHO WDQN RXW RI WKH WRZHU )LJ 3 Fig 256 Fig 254 3,&7 D 3,&7 5HPRYH WKH WKURWWOH GHFDO IURP WKH WRZHU )LJ /RRVHQ WKH VFUHZV VHFXULQJ WKH IXHO WDQN VXSSRUW URGV WR WKH GDVK VXSSRUWV /D\ WKH VXSSRUW URGV WR WKH VLGH )LJ Fig 257
CHASSIS 12. Remove the bolt and nut securing the control knob WR WKH WKURWWOH DVVHPEO\ )LJ 5HPRYH WKH VFUHZV VHFXULQJ WKH WKURWWOH DVVHPEO\ WR WKH WRZHU )LJ 3 Fig 258 3,&7 5HPRYH WKH FRQWURO NQRE )LJ Fig 259 Fig 260 3XOO WKH WKURWWOH DVVHPEO\ RXW IURP WKH UHDU RI WKH WRZHU )LJ 3,&7 Fig 261 3,&7 3,&7 GT Series Tractors Service Manual
CHASSIS /RRVHQ WKH FDEOH FODPS 725; VFUHZ VHFXULQJ WKH throttle and choke cables to the engine bracket (Fig. 18.
CHASSIS Throttle Cable Installation 2. Install the throttle cable z-bend into engine throttle EUDFNHW DQG LQVHUW LW LQWR WKH FDEOH FODPS )LJ 1. Slide the throttle cable assembly through the cable tie located on the left front corner of the engine. Place the cable into the R-clamp located on the left UHDU VLGH RI WKH HQJLQH )LJ DQG )LJ 3 Fig 268 Fig 266 3,&7 ,QVHUW WKH WKURWWOH DVVHPEO\ LQWR WKH WRZHU )LJ Fig 269 Fig 267 3,&7 3,&7 3,&7
CHASSIS ,QVWDOO VFUHZV WR VHFXUH WKH WKURWWOH DVVHPEO\ WR WKH WRZHU )LJ ,QVWDOO D EROW DQG QXW WR VHFXUH WKH FRQWURO NQRE WR WKH WKURWWOH DVVHPEO\ )LJ 3 Fig 270 3,&7 6OLGH WKH FRQWURO NQRE RQWR WKH WKURWWOH DVVHPEO\ OHYHU )LJ Fig 272 ,QVWDOO D WKURWWOH GHFDO RQWR WKH WRZHU )LJ Fig 273 Fig 271 GT Series Tractors Service Manual 3,&7 3,&7 3,&7
CHASSIS 3RVLWLRQ WKH IXHO WDQN LQWR WKH WRZHU )LJ 6OLGH WKH IXHO OLQH EDFN RQWR WKH IXHO ¿OWHU DQG SRVL WLRQ WKH KRVH FODPS WR VHFXUH )LJ 3 Fig 274 3,&7 D Fig 276 3RVLWLRQ WKH IXHO WDQN VXSSRUW URGV DQG LQVWDOO a screw securing each support rod to the dash VXSSRUWV )LJ 3,&7 $GMXVW WKH WKURWWOH DQG FKRNH FDEOHV 5HIHU WR ³7KURWWOH DQG &KRNH &DEOH $GMXVWPHQW´ RQ SDJH 6OLGH WKH PXIÀHU DQG KHDW VKLHOG DVVHPEO\ RQWR WKH PDQLIROG SLSHV D
CHASSIS ,QVWDOO VFUHZV VHFXULQJ WKH OHIW DQG ULJKW VLGH PXIÀHU EUDFNHWV WR WKH IUDPH RQ WKH OHIW DQG RQ WKH ULJKW )LJ ,QVWDOO VFUHZV VHFXULQJ WKH EXPSHU WR WKH IUDPH EROW RQ WKH OHIW DQG RQ WKH ULJKW )LJ 3 Fig 280 Fig 278 3,&7 3,&7 3RVLWLRQ WKH EXPSHU WR WKH IUDPH )LJ ,QVWDOO WKH KRRG 5HIHU WR ³+RRG ,QVWDOODWLRQ´ RQ SDJH &RQQHFW WKH EDWWHU\ FDEOH WR WKH QHJDWLYH EDWWHU\ WHUPLQDO )LJ Fig 279 3,&7 F
CHASSIS Choke Cable Replacement 5HPRYH WKH KRRG 5HIHU WR ³+RRG 5HPRYDO´ RQ SDJH Choke Cable Removal /LIW WKH VHDW WR DFFHVV WKH EDWWHU\ FRPSDUWPHQW 5HPRYH WKH VFUHZV VHFXULQJ WKH EXPSHU WR WKH IUDPH EROW RQ WKH OHIW DQG RQ WKH ULJKW )LJ 2. Disconnect the battery cable from the negative EDWWHU\ WHUPLQDO )LJ 3 Fig 283 Fig 282 3,&7 3,&7 5HPRYH WKH EXPSHU )LJ Fig 284 3,&7 GT Series Tractors Service Manual
CHASSIS 5HPRYH WKH VFUHZV VHFXULQJ WKH OHIW DQG ULJKW VLGH PXIÀHU EUDFNHWV WR WKH IUDPH RQ WKH OHIW DQG RQ WKH ULJKW )LJ 8. Remove the fuel cap. Slide the hose clamp down the IXHO OLQH 5HPRYH WKH IXHO OLQH IURP WKH IXHO ¿OWHU DQG drain the fuel into a suitable container. Replace the IXHO FDS RQWR WKH IXHO WDQN )LJ 3 Fig 285 3,&7 Fig 287 6OLGH WKH PXIÀHU DQG KHDW VKLHOG DVVHPEO\ RII WKH PDQLIROG SLSHV )LJ Fig 286 /RRVHQ WKH VFUHZV VHFXULQJ WKH I
CHASSIS 12. Remove the choke cable from the cable clamp and remove the z-bend from the engine control lever )LJ /LIW WKH IXHO WDQN RXW RI WKH WRZHU )LJ 3 Fig 289 3,&7 D Fig 291 /RRVHQ WKH FDEOH FODPS 725; VFUHZ VHFXULQJ WKH throttle and choke cables to the engine bracket (Fig. Fig 290 13.
CHASSIS 5HPRYH WKH FKRNH FDEOH DVVHPEO\ IURP WKH PD FKLQH E\ SXOOLQJ LW RXW WKURXJK WKH WRZHU )LJ 2. Route the choke cable around the left side of the HQJLQH SODFLQJ WKH FDEOH LQWR WKH 5 FODPS )LJ DQG WKURXJK WKH FDEOH WLH )LJ 3 Fig 293 3,&7 D Fig 295 3,&7 Fig 296 3,&7 Choke Cable Installation 1.
CHASSIS 3.
CHASSIS 8. Position the 2 fuel tank support rods and install a screw securing each support rod to the dash VXSSRUWV )LJ 6OLGH WKH PXIÀHU DQG KHDW VKLHOG DVVHPEO\ RQWR WKH PDQLIROG SLSHV DQG LQWR SRVLWLRQ )LJ 3 Fig 303 Fig 301 6OLGH WKH IXHO OLQH EDFN RQWR WKH IXHO ¿OWHU DQG SRVLWLRQ WKH KRVH FODPS WR VHFXUH )LJ Fig 302 GT Series Tractors Service Manual 3,&7 3,&7 3,&7 ,QVWDOO VFUHZV VHFXULQJ WKH OHIW DQG ULJKW VLGH PXI ÀHU EUDFNHWV WR WKH
CHASSIS 3RVLWLRQ WKH EXPSHU WR WKH IUDPH )LJ ,QVWDOO WKH KRRG 5HIHU WR ³+RRG ,QVWDOODWLRQ´ RQ SDJH &RQQHFW WKH EDWWHU\ FDEOH WR WKH QHJDWLYH EDWWHU\ WHUPLQDO )LJ 3 Fig 305 3,&7 13. Install 2 screws securing the bumper to the frame (1 EROW RQ WKH OHIW DQG RQ WKH ULJKW )LJ Fig 307 3,&7 /RZHU WKH VHDW 2SHUDWH WKH WUDFWRU WR HQVXUH DOO FRQWUROV RSHUDWH properly.
CHASSIS 'HFN /LIW /LQN 5HSODFHPHQW 'LVFRQQHFW WKH UHG EDWWHU\ FDEOH IURP WKH SRVLWLYH EDWWHU\ WHUPLQDO )LJ The following procedures were done on the right side of the tractor. The procedure is the same for the left side unless noted. The rear wheel assembly has been removed for photo purposes. 'HFN /LIW /LQN 5HPRYDO 1. Remove mower deck. Refer to: ³ ´ 0RZHU 'HFN 5HPRYDO´ RQ SDJH ³ ´ 0RZHU 'HFN 5HPRYDO´ RQ SDJH 3 2.
CHASSIS 5HPRYH WKH EDWWHU\ IURP WKH EDWWHU\ WUD\ )LJ 5HPRYH WKH FRWWHU SLQ VHFXULQJ WKH OLIW FDEOH WR WKH OLIW OLQN )LJ 3 Fig 311 3,&7 Fig 313 3,&7 5HPRYH WKH EDWWHU\ WUD\ )LJ 5HPRYH WKH VKRXOGHU EROW DQG QXW VHFXULQJ WKH IURQW HQG RI WKH OLIW OLQN WR WKH IUDPH )LJ Fig 312 3,&7 Fig 314 3-82 3,&7 GT Series Tractors Service Manual
CHASSIS 5HPRYH WKH OLIW OLQN IURP WKH PDFKLQH )LJ 2. Install a shoulder bolt and nut to secure the front end RI WKH OLIW OLQN WR WKH IUDPH )LJ 3 Fig 315 3,&7 Fig 317 'HFN /LIW /LQN ,QVWDOODWLRQ 3,&7 3.
CHASSIS /HIW VLGH OLIW FDEOH The lift cable must be positioned between the transmission drive belt and the frame )LJ 3 A 3ODFH WKH EDWWHU\ LQWR WKH EDWWHU\ WUD\ )LJ B Fig 321 Fig 319 $ /LIW FDEOH 3,&7 3,&7 % 7UDQVPLVVLRQ GULYH EHOW ,QVWDOO WKH EDWWHU\ KROG GRZQ URG )LJ 3RVLWLRQ WKH EDWWHU\ WUD\ LQWR WKH IHQGHU )LJ Fig 322 Fig 320 3,&7 3,&7 GT Series Tractors Service Manual
CHASSIS &RQQHFW WKH UHG EDWWHU\ FDEOH WR WKH SRVLWLYH EDWWHU\ WHUPLQDO )LJ 'HFN /LIW &DEOH 5HSODFHPHQW The following procedures were performed on the right side lift cable. The procedure is the same for the left side lift cable unless noted. The wheel assembly has been removed for photo purposes. 'HFN /LIW &DEOH 5HPRYDO 1. Remove the mower deck. Refer to: ³ ´ 0RZHU 'HFN 5HPRYDO´ RQ SDJH ³ ´ 0RZHU 'HFN 5HPRYDO´ RQ SDJH 3 2.
CHASSIS 'LVFRQQHFW WKH UHG EDWWHU\ FDEOH IURP WKH SRVLWLYH EDWWHU\ WHUPLQDO )LJ 5HPRYH WKH EDWWHU\ IURP WKH EDWWHU\ WUD\ )LJ 3 Fig 328 Fig 326 3,&7 3,&7 D 5HPRYH WKH EDWWHU\ WUD\ )LJ 5HPRYH WKH EDWWHU\ KROG GRZQ URG )LJ Fig 327 Fig 329 3,&7 3,&7 GT Series Tractors Service Manual
CHASSIS 8VLQJ D VSULQJ WRRO 7RUR SDUW QR XQKRRN WKH GHFN OLIW VSULQJ IURP WKH PDFKLQH )LJ 11. Place the deck lift handle in the lowest height-of cut position. 12. Remove the e-clip from the end of the lift shaft DVVHPEO\ )LJ 3 Fig 330 3,&7 Fig 332 3,&7 5HPRYH WKH KDLUSLQ FRWWHU VHFXULQJ WKH XSSHU HQG RI WKH OLIW FDEOH WR WKH IUDPH )LJ 13.
CHASSIS 5HPRYH WKH FRWWHU SLQ VHFXULQJ WKH OLIW FDEOH WR WKH lift link. Remove the end of cable from the lift link )LJ 5HPRYH WKH UROOHU SXOOH\ DQG VKRXOGHU EROW )LJ 3 Fig 336 Fig 334 3,&7 3,&7 5HPRYH WKH OLIW FDEOH IURP WKH PDFKLQH )LJ 5HPRYH WKH QXW IURP WKH VKRXOGHU EROW WKDW VHFXUHV WKH UROOHU SXOOH\ DQG OLIW FDEOH WR WKH IUDPH )LJ Fig 337 Fig 335 3-88 3,&7 3,&7 GT Series Tractors Service Manual
CHASSIS 'HFN /LIW &DEOH ,QVWDOODWLRQ ,QVWDOO WKH H FOLS RQWR WKH HQG RI WKH OLIW VKDIW DVVHPEO\ )LJ 1. Place the deck lift handle in the lowest height-of cut position. 3RVLWLRQ WKH OLIW FDEOH LQWR WKH PDFKLQH )LJ 3 Fig 340 Fig 338 3,&7 :LWK WKH H FOLS UHPRYHG VOLGH WKH OLIW VKDIW RYHU DV far as possible and install the upper end of the cable LQWR WKH OLIW VKDIW DVVHPEO\ )LJ 3ODFH WKH GHFN OLIW KDQGOH LQ WKH KLJKHVW KHLJKW RI FXW position.
CHASSIS +RRN WKH GHFN OLIW VSULQJ RQWR WKH IUDPH )LJ ,QVHUW WKH VKRXOGHU EROW LQWR WKH UROOHU SXOOH\ 3ODFH the lift cable into the groove of the roller pulley. Insert WKH VKRXOGHU EROW UROOHU DVVHPEO\ LQWR WKH SXOOH\ EUDFNHW ORFDWHG RQ WKH IUDPH )LJ Note: Make sure the cable stays inside the guides RQ WKH IUDPH 3 Fig 342 3,&7 8. Place the deck lift handle in the lowest height-of cut position.
CHASSIS 12. Insert the lower end of the lift cable into the lift link and install a cotter pin securing the lift cable to the OLIW OLQN )LJ 3RVLWLRQ WKH EDWWHU\ WUD\ LQ WKH IHQGHU )LJ Right side lift cable: The lift cable must be positioned on the outside of the brake rod. A 3 B Fig 348 3,&7 3ODFH WKH EDWWHU\ LQWR WKH EDWWHU\ WUD\ )LJ Fig 346 $ /LIW FDEOH 3,&7 % %UDNH 5RG /HIW VLGH OLIW FDEOH The lift cable must be positioned between the transmi
CHASSIS ,QVWDOO WKH EDWWHU\ KROG GRZQ URG )LJ &RQQHFW WKH EODFN EDWWHU\ FDEOH WR WKH QHJDWLYH EDWWHU\ WHUPLQDO )LJ 3 Fig 350 3,&7 Fig 352 &RQQHFW WKH UHG EDWWHU\ FDEOH WR WKH SRVLWLYH EDWWHU\ WHUPLQDO )LJ 3,&7 /RZHU WKH VHDW ,QVWDOO WKH PRZHU GHFN 5HIHU WR ´ 0RZHU 'HFN ,QVWDOODWLRQ RQ SDJH ´ 0RZHU 'HFN ,QVWDOODWLRQ RQ SDJH 2SHUDWH WKH WUDFWRU WR HQVXUH DOO FRQWUROV RSHUDWH properly.
CHASSIS 'HFN /LIW +DQGOH 6KDIW $VVHPEO\ Replacement 'HFN /LIW +DQGOH 6KDIW $VVHPEO\ 5HPRYDO /LIW WKH VHDW WR DFFHVV WKH EDWWHU\ FRPSDUWPHQW 'LVFRQQHFW WKH EODFN EDWWHU\ FDEOH IURP WKH QHJDWLYH EDWWHU\ WHUPLQDO )LJ 1. Remove the mower deck. Refer to: ³ ´ 0RZHU 'HFN 5HPRYDO´ RQ SDJH ³ ´ 0RZHU 'HFN 5HPRYDO´ RQ SDJH 2. Place the deck lift handle in the highest height-of-cut position. 3 3.
CHASSIS 5HPRYH WKH EDWWHU\ KROG GRZQ URG )LJ 5HPRYH WKH EDWWHU\ WUD\ )LJ 3 Fig 356 3,&7 5HPRYH WKH EDWWHU\ IURP WKH EDWWHU\ WUD\ )LJ Fig 357 Fig 358 5HPRYH WKH KDLUSLQ FRWWHU VHFXULQJ WKH XSSHU HQG RI WKH OLIW FDEOH WR WKH OLIW VKDIW DVVHPEO\ )LJ 3,&7 Fig 359 3,&7 3,&7 GT Series Tractors Service Manual
CHASSIS 8VLQJ D VSULQJ WRRO 7RUR SDUW QR UHPRYH WKH GHFN OLIW VSULQJ IURP WKH PDFKLQH )LJ 6OLGH WKH OLIW VKDIW RYHU DV IDU DV SRVVLEOH DQG UH move the upper end of the cable from the lift shaft DVVHPEO\ )LJ 3 Fig 360 3,&7 Fig 362 12. Place the deck lift handle in the lowest height-of-cut position. 13. Remove the e-clip from the end of the lift shaft DVVHPEO\ )LJ 5HPRYH WKH EXVKLQJ IURP WKH HQG RI WKH OLIW VKDIW DVVHPEO\ )LJ Fig 363
CHASSIS 5HSHDW VWHSV WKUX RQ WKH RSSRVLWH VLGH RI WKH machine. 6OLGH WKH HQGV RI WKH GHFN OLIW VKDIW RXW RI WKH VLGHV of the frame. Move the wire harness from above the deck lift shaft assembly. Slide the assembly back to the left and remove the lift handle from the slot in the fender. Remove the assembly through the right side RI WKH PDFKLQH )LJ DQG )LJ 18. Remove the torsion spring from the handle and shaft DVVHPEO\ )LJ B A 3 C Fig 366 A. Torsion spring B.
CHASSIS 'HFN /LIW +DQGOH 6KDIW $VVHPEO\ Installation ,QVWDOO WKH KDQGOH LQWR WKH VKDIW DVVHPEO\ )LJ 3. Insert the deck lift shaft and handle assembly in to the frame from under the right side of the fender. Insert the handle into the slot in the fender. Position the wire harness on top of the shaft assembly. Insert the ends of the shaft into the sides of the frame (Fig. DQG )LJ 3 Fig 368 3,&7 D Fig 370 3,&7 Fig 371 3,&7 2.
CHASSIS ,QVWDOO D EXVKLQJ RYHU WKH HQG RI WKH OLIW VKDIW )LJ ,QVWDOO DQ H FOLS RQWR WKH HQG RI WKH OLIW VKDIW DV VHPEO\ )LJ 3 Fig 372 3,&7 6OLGH WKH OLIW VKDIW RYHU DV IDU DV SRVVLEOH DQG LQVHUW the upper end of the cable assembly into the hole on WKH VLGH RI WKH OLIW VKDIW DVVHPEO\ )LJ Fig 374 3,&7 5HSHDW VWHSV WKUX RQ WKH RSSRVLWH VLGH RI WKH machine. 8. Place the deck lift handle in the highest height-of-cut position.
CHASSIS ,QVWDOO D KDLU SLQ WR VHFXUH WKH XSSHU HQG RI ERWK OLIW FDEOHV WR WKH OLIW VKDIW DVVHPEO\ )LJ 3ODFH WKH EDWWHU\ LQWR WKH EDWWHU\ WUD\ )LJ 3 Fig 378 Fig 376 3,&7 3,&7 ,QVWDOO WKH EDWWHU\ KROG GRZQ URG )LJ 3RVLWLRQ WKH EDWWHU\ WUD\ )LJ Fig 379 Fig 377 GT Series Tractors Service Manual 3,&7 3,&7
CHASSIS &RQQHFW WKH UHG EDWWHU\ FDEOH WR WKH SRVLWLYH EDWWHU\ WHUPLQDO )LJ /RZHU WKH VHDW ,QVWDOO WKH KDQGOH JULS RQWR WKH GHFN OLIW KDQGOH )LJ 3 Fig 380 3,&7 D Fig 382 &RQQHFW WKH EODFN EDWWHU\ FDEOH WR WKH QHJDWLYH EDWWHU\ WHUPLQDO )LJ 3,&7 D 18. Place the deck lift handle in the highest height-of-cut position.
CHASSIS )URQW :KHHO 7RH ,Q 0HDVXUHPHQW Adjustment %HKLQG WKH D[OH PHDVXUH WKH GLVWDQFH KRUL]RQWDOO\ from the inside of the left rim to the inside of the right ULP )LJ 1RWH WKH GLVWDQFH ,I WKHUH LV XQHYHQ WLUH ZHDU ODZQ VFXI¿QJ RU KDUG VWHHU LQJ WRH LQ PD\ QHHG WR EH DGMXVWHG 7KH IURQW WRH LQ PHDVXUHPHQW VKRXOG EH ´ WR ´ WR PP 7KLV VKRXOG EH FKHFNHG HYHU\ KRXUV RU RQFH D \HDU ZKLFKHYHU RFFXUV ¿UVW 1.
CHASSIS $GMXVW LI QHFHVVDU\ /RRVHQ WKH MDP QXW IRXQG RQ WKH GUDJ OLQN DW WKH UHDU RI WKH EDOO MRLQW )LJ 3 Fig 385 ¿J 5HPRYH WKH KH[ QXW RQ WKH WRS RI EDOO MRLQW )LJ 7KUHDG WKH EDOO MRLQW WRZDUG WKH MDP QXW WR VKRUWHQ WKH GUDJ OLQN 7KUHDG WKH EDOO MRLQW DZD\ IURP WKH MDP QXW WR OHQJWKHQ WKH GUDJ OLQN )LJ 8.
ENGINE Engine Replacement 4. Remove the electric PTO clutch. Refer to “Electric PTO Clutch Removal” on page 3-29. Engine Removal 1. Lift the seat to access the battery compartment. 2. Disconnect the battery cable from the negative battery terminal (Fig. 386). 5. Release tension from the idler spring and slide the engine pulley off the crank shaft. Remove the transmission drive belt from the engine pulley and remove the pulley from the machine (Fig. 388). 4 Fig 388 Fig 386 PICT-7497 PICT-7349 6.
ENGINE 7. Lower the machine to the ground. 8. Remove the hood. Refer to “Hood Removal” on page 3-34. 11. Remove the 4 screws securing the left and right side bumper brackets to the frame (2 on the left and 2 on the right) (Fig. 392). 9. Remove the 2 screws securing the bumper to the frame (1 bolt on the left and 1 on the right) (Fig. 390). 4 Fig 392 Fig 390 PICT-7245 PICT-7423 6OLGH WKH PXIÀHU DQG KHDW VKLHOG DVVHPEO\ RII WKH manifold pipes and remove it from the machine (Fig. 393). 10.
ENGINE 13. Mark either the throttle or choke cable and corresponding engine bracket to more easily identify them upon installation (the choke is marked with tape in the photo below) (Fig. 394). 15. Unhook the throttle and choke cable z-bends from the engine brackets (Fig. 396). A B Fig 394 Fig 396 PICT-7597 PICT-7591 A. Choke (outside linkage plate) B. Throttle (inside linkage plate) 16.
ENGINE 17. Remove the fuel cap. Slide the hose clamp down the IXHO OLQH 5HPRYH WKH IXHO OLQH IURP WKH IXHO ¿OWHU DQG drain the fuel into a suitable container. Slide the fuel OLQH EDFN RQWR WKH IXHO ¿OWHU DQG SRVLWLRQ WKH KRVH clamp to secure. Replace the fuel cap onto the fuel tank (Fig. 398). 4 19. Disconnect the wire harness from the engine (Fig. 400). Fig 400 Fig 398 PICT-7300 PICT-7605 20. Remove the nut securing the positive wire to the starter assembly.
ENGINE 21. Loosen the oil dipstick. Remove the oil drain cap and LQVWDOO WKH GUDLQ KRVH RQWR WKH RLO GUDLQ ¿WWLQJ 7ZLVW WKH RLO GUDLQ ¿WWLQJ FRXQWHU FORFNZLVH DQG SXOO WR drain the oil from the engine (Fig. 402). 25. Attach chains/straps and a hoist to the lift points on the engine. Raise and remove the engine from the frame (Fig. 403). Fig 403 Fig 402 PICT-7613 PICT-7612 22. Loosen the engine oil dipstick. $IWHU WKH RLO KDV GUDLQHG WXUQ WKH RLO GUDLQ ¿WWLQJ clockwise to close.
ENGINE Engine Installation 3. Plug the wire harness into the engine harness (Fig. 406). 1. Attach chains/straps and a hoist to the lift points on the engine. Lower the engine into place on the frame (Fig. 404). Note: Take care to ensure the throttle and choke cables are not caught between the engine and the frame. 4 Fig 406 PICT-7605 6OLGH WKH IXHO OLQH RQWR WKH IXHO ¿OWHU DQG SRVLWLRQ WKH clamp to secure (Fig. 407). Fig 404 PICT-7613 2. Slide the positive wire onto the starter post.
ENGINE 5. Slide the throttle and choke cables through cable tie and position them into the r-clamp located on the left side of the engine (Fig. 408). 7. Place the throttle and choke cables into the cable clamp. Tighten screw only enough to hold the cables in place (Fig. 410). Fig 408 Fig 410 PICT-7614 6. Hook the throttle and choke cable z-bends into the engine brackets (Fig. 409). Note the marked cable and the marked bracket. Fig 409 8. Remove the cable markers. 9. Raise the machine. 10.
ENGINE 11. Apply anti-seize compound to the crankshaft. Slide the engine pulley onto crankshaft and install the transmission drive belt around engine pulley (Fig. 412). 4 14. Connect the battery cable to the negative battery terminal (Fig. 414). Fig 414 Fig 412 PICT-7349 PICT-7497 15. Lower the seat. 12. Install the Electric PTO clutch. Refer to Electric PTO Clutch Installation on page 3-30. 16. Adjust the throttle and choke cables. Refer to: “Throttle & Choke Cable Adjustment” on page 4-10. 13.
ENGINE 18. Install 4 screws securing the left and right side bumper brackets to the frame (2 on the left and 2 on the right) (Fig. 416). 20. Install 2 screws securing the bumper to the frame (1 bolt on the left and 1 on the right) (Fig. 418). Fig 418 Fig 416 PICT-7245 PICT-7423 19. Position the bumper to the frame (Fig. 417). 21. Install the hood Refer to “Hood Installation” on page 3-34. 22. Operate the tractor to ensure all controls operate properly.
ENGINE Throttle & Choke Cable Adjustment 3. Remove the bumper (Fig. 420). 7KH KRRG IURQW EXPSHU DQG PXIÀHU DVVHPEO\ PXVW EH removed to make this adjustment. To remove them, follow steps 1 – 5. If they have already been removed, begin at step 6. 1. Remove the hood. Refer to “Hood Removal” on page 3-34. 2. Remove the 2 screws securing the bumper to the frame (1 bolt on the left and 1 on the right) (Fig. 419). 4 Fig 420 PICT-7417 4.
ENGINE 6OLGH WKH PXIÀHU DQG KHDW VKLHOG DVVHPEO\ RII WKH manifold pipes and remove it from the machine (Fig. 422). 7. Position the choke control so it is fully pushed in and the throttle control so it is in the fast position (Fig. 423 and Fig. 424). Fig 422 Fig 423 PICT-7993 Fig 424 PICT-7992 PICT-7425 Adjustment: 6. The cable clamp securing the throttle and choke cables must be loose.
ENGINE 8. Push the engine throttle bracket over to the full throttle position (Fig. 425). 4 Fig 425 PICT-7995 9. Tighten the cable clamp TORX screw to secure the throttle and choke cables in position (Fig. 426). Fig 426 PICT-7998 10. Move both the throttle control and the choke control in through the full range of motion to ensure the cables are properly adjusted.
GEAR DRIVE SYSTEM Transmission Drive Belt Replacement 4. Remove the battery hold down rod (Fig. 429). Transmission Drive Belt Removal 1. Lift the seat to access the battery compartment. 2. Disconnect the battery cable from the negative battery terminal (Fig. 427). Fig 429 PICT-7352 5. Remove the battery from the battery tray (Fig. 430). Fig 427 5 PICT-7349 3. Disconnect the battery cable from the positive battery terminal (Fig. 428).
GEAR DRIVE SYSTEM 6. Remove the battery tray (Fig. 431). Fig 431 8. Remove the transmission belt from the machine (Fig. 433). PICT-7354 Fig 433 5 PICT-7628 0RYH WKH ÀDW LGOHU SXOOH\ LQ WKH GLUHFWLRQ RI WKH DUURZ to remove the transmission drive belt from the transmission pulley and variable speed pulley (Fig. 432). A B Fig 432 A. Direction to move ÀDW LGOHU SXOOH\ 5-2 PICT-7627a B.
GEAR DRIVE SYSTEM Transmission Drive Belt Installation 2. Position the battery tray (Fig. 435). 1. Route the transmission drive belt around the pulleys (Fig. 434). A D C B E Fig 434 A. Variable speed pulley B. Transmission pulley C. Idler pulley Fig 435 PICT-7354 3. Place the battery into the battery tray (Fig. 436). 5 belt routing iso D. Transmission drive belt E.
GEAR DRIVE SYSTEM 4. Install the battery hold down rod (Fig. 437). Fig 437 6. Connect the black battery cable to the negative battery terminal (Fig. 439). PICT-7352 Fig 439 5 5. Connect the red battery cable to the positive battery terminal (Fig. 438). Fig 438 5-4 PICT-7349 7. Lower the seat.
GEAR DRIVE SYSTEM Variable Speed Drive Belt Replacement 4. Remove the shift cover plate from the frame and lay it to the side (Fig. 442). Variable Speed Drive Belt Removal 1. Remove the transmission drive belt. Refer to “Transmission Drive Belt Removal” on page 5-1. 2. Remove the shift knob (Fig. 440). Fig 442 PICT-7636 5. Remove the Electric PTO clutch. Refer to “Electric PTO Clutch Removal” on page 3-29. Fig 440 PICT-7632 6.
GEAR DRIVE SYSTEM 7. Remove the 4 bolts securing the variable speed pulley assembly to the transmission (Fig. 444). Fig 444 5 PICT-7640a 8. Tilt the variable speed pulley forward and remove the belt from it (Fig. 445). 9. Route the belt forward and remove it from around the shift rod (Fig. 446). Fig 446 10. Pull the belt downward (Fig. 447).
GEAR DRIVE SYSTEM 5HPRYH WKH EHOW IURP DURXQG WKH WZR ÀDW LGOHU pulleys (Fig. 448). Variable Speed Drive Belt Installation 1. Route the transmission drive belt through the steering support bracket and frame. Install the transmission drive belt around the crankshaft (Fig. 450). Note: The belt routes between the steering shaft and left side of the frame. Fig 448 PICT-7649 12. Remove the transmission drive belt from around the crankshaft and remove it from above the steering support bracket (Fig.
GEAR DRIVE SYSTEM 3. Route the belt up toward the top of the transmission (Fig. 452). Fig 452 5 PICT-7648 4. Route the belt so that it is positioned around the shift rod (Fig. 453). Fig 453 5-8 PICT-7644 5. Tilt the variable speed pulley forward and route the belt around it into the lower pulley groove (Fig. 454). Fig 454 PICT-7642 6. Install 4 bolts securing the variable speed pulley assembly to the transmission (Fig. 455).
GEAR DRIVE SYSTEM 7. Apply anti-seize compound to the crankshaft. Slide the engine pulley onto the crankshaft and route the transmission drive belt around the engine pulley (Fig. 456). 10. Install 4 screws securing the shift cover to the frame (Fig. 458). Fig 458 Fig 456 PICT-7635 PICT-7497 11. Slide the shift knob onto the shift lever (Fig. 459). 5 8. Install the Electric PTO clutch. Refer to “Electric PTO Clutch Installation” on page 3-30. 9. Slide the shift cover plate into the frame (Fig. 457).
GEAR DRIVE SYSTEM CVT Transmission Replacement 4. Remove the 4 screws securing the shift cover to the frame (Fig. 461). CVT Transmission Removal 1. Remove the mower deck. Refer to “50 inch Mower Deck Removal” on page 7-6. 2. Remove the transmission drive belt. Refer to “Transmission Drive Belt Removal” on page 5-1. 3. Remove the shift knob (Fig. 460). Fig 461 PICT-7635 5. Remove the shift cover plate and lay it to the side (Fig. 462).
GEAR DRIVE SYSTEM 6. Remove the nut securing the shift rod assembly to the transmission (Fig. 463). Fig 463 PICT-7710a 7. Remove the spring washer from the shift rod assembly (Fig. 464). Fig 464 GT Series Tractors Service Manual PICT-7709a 8. Remove the shift rod assembly from the machine (Fig. 465). Fig 465 PICT-7708a 9. Remove the washer from the shift rod assembly (Fig. 466).
GEAR DRIVE SYSTEM 10. Loosen the 8 bolts securing the rear wheels to the wheel hub assemblies (4 on the left and 4 on the right) (Fig. 467). Fig 467 13. Raise the machine. 14. Remove the 4 bolts securing the variable speed pulley assembly to the transmission (Fig. 469). PICT-7502a Fig 469 5 11. Raise and support the rear of the machine. 12. Remove the 8 lug nuts and remove the 2 wheel assemblies from the wheel hubs (Fig. 468). 15.
GEAR DRIVE SYSTEM 16. Pull the belt downward (Fig. 471). Fig 471 18. Remove the cotter pin securing the front end of the brake control rod to the brake linkage (Fig. 473). PICT-8530 Fig 473 5HPRYH WKH EHOW IURP WKH WZR ÀDW LGOHU SXOOH\V )LJ 472). Fig 472 19. Remove the brake control rod from the linkage (Fig. 474).
GEAR DRIVE SYSTEM 20. Unhook the spring from the rear end of the brake control rod (Fig. 475). 22. Remove the bolt, nut and self tapping screw securing the front of the transmission to the transmission bracket (Fig. 477). A B Fig 475 PICT-7662 Fig 477 5 A. Bolt and nut 21. Remove the brake control rod (Fig. 476). Fig 476 5-14 PICT-7668 B.
GEAR DRIVE SYSTEM 23. Support the transmission. 24. Remove the 4 bolts and nuts securing the sides of the transmission to the frame (2 bolts and 2 nuts on each side) (Fig. 478). 26. Remove the variable speed pulley from the transmission (Fig. 480). Fig 480 Fig 478 PICT-7670 25. Carefully lower the transmission from the machine (Fig. 479). PICT-7676 27. Remove the bolt and washer securing the wheel hub assembly to the transmission axle shaft. Remove the wheel hub from the axle shaft (Fig. 481).
GEAR DRIVE SYSTEM 28. Repeat step 28 to remove the opposite wheel hub assembly. 29. Remove the nut securing the transmission pulley to the transmission (Fig. 482). Fig 482 5 PICT-7682 5-16 1. Position the transmission pulley onto the transmission (Fig. 484). Fig 484 PICT-7684 2. Install the nut securing the transmission pulley to the transmission (Fig. 485). 30. Remove the transmission pulley (Fig. 483).
GEAR DRIVE SYSTEM 3. Slide the wheel hub onto the axle shaft. Install a bolt and washer to secure the wheel hub assembly to the transmission axle shaft (Fig. 486). 6. Carefully raise and support the transmission in the machine (Fig. 488). Fig 488 Fig 486 PICT-7677 PICT-7679a 4. Repeat step 2 to install the opposite wheel hub assembly. 7. Install 4 bolts and nuts securing the sides of the transmission to the frame (2 bolts and 2 nuts on each side) (Fig. 489). 5 5.
GEAR DRIVE SYSTEM 8. Install a bolt, nut and a self tapping screw to secure the front of the transmission to the transmission bracket (Fig. 490). 10. Hook the brake control spring to the rear end of the brake control rod (Fig. 492). A B Fig 492 Fig 490 A. Bolt and nut 5 PICT-7662 PICT-7667 B. Self tapping screw 11. Insert the front end of the brake control rod into the brake linkage (Fig. 493). 9. Insert the brake control rod through the hole in the transmission bracket (Fig. 491).
GEAR DRIVE SYSTEM 12. Install a cotter pin securing the front end of the brake control rod to the brake linkage (Fig. 494). Fig 494 14. Lower the machine. 15. Tighten the 8 lug nuts securing the rear wheels to the wheel hub assemblies (Fig. 496). PICT-7659 Fig 496 13. Install the 2 rear wheel assemblies onto the wheel hubs. Install 8 lug nuts to secure (Fig. 495). Fig 495 16. Route the transmission drive belt between the two ÀDW LGOHU SXOOH\V RQ WKH FHQWHU GRXEOH LGOHU EUDFNHW (Fig. 497).
GEAR DRIVE SYSTEM 17. Route the belt up in front of the transmission toward the top of the transmission (Fig. 498). Fig 498 5 Fig 500 PICT-7648 18. Tilt the variable speed pulley forward and route the drive belt around it into the lower pulley groove (Fig. 499). Fig 499 19. Install 4 bolts securing the variable speed pulley assembly to the transmission (Fig. 500). 20. Lower the machine. 6OLGH D ÀDW ZDVKHU ZLWK DQ REORQJ FHQWHU KROH RQWR the transmission shift lever (Fig. 501).
GEAR DRIVE SYSTEM 22. Slide the shift rod assembly onto the transmission shift lever. Ensure the rod is in between the variable speed drive belt (Fig. 502). 24. Install a nut securing the shift rod assembly to the transmission shift lever (Fig. 504). Fig 504 Fig 502 23. Slide a spring washer (center of the washer up, OD of the washer down) onto the shift rod assembly (Fig. 503). 25. Position the shift cover plate into the fender (Fig. 505).
GEAR DRIVE SYSTEM 26. Install 4 screws securing the shift cover to the frame (Fig. 506). CVT Transmission Service CVT Transmission Housing Teardown Note: Transaxle shown does not have grease, for photo clarity. Clean and inspect all parts after disassembly. Apply a small amount of grease to all moving parts and needle bearings prior to reassembly. 1. Remove the 23 bolts securing the housing halves together (Fig. 508). Fig 506 5 PICT-7712 27. Slide the shift knob onto the shift rod (Fig. 507).
GEAR DRIVE SYSTEM 3. Remove the 2 bolts securing the brake assembly to the transmission housing (Fig. 510). Fig 510 PICT-8277a 4. Remove the brake assembly from the transmission (Fig. 511). 5. Remove the brake disc from the transmission shaft (Fig. 512). Fig 512 PICT-8280a 6. Remove the puck from the transmission housing (Fig. 513). 5 Note: Some transmissions have 2 washers (1 on each bolt) between the brake assembly and transmission housing.
GEAR DRIVE SYSTEM 7. Remove the shift fork assembly from the transmission housing (Fig. 514). Fig 514 5 PICT-8283 8. Remove the drive shaft and right hand output shaft assemblies from the housing (Fig. 515). 9. Remove the differential axle assembly from the housing (Fig. 516). Fig 516 10. Remove the e-ring from the input shaft (Fig. 517).
GEAR DRIVE SYSTEM 11. Remove the washers from the input shaft (Fig. 518). Fig 518 PICT-8288 12. Remove the input shaft assembly from the housing (Fig. 519). Fig 519 GT Series Tractors Service Manual PICT-8289 13. Remove the washer from the input shaft (Fig. 520). Fig 520 PICT-8290a 14. Remove the snap ring that secures the bevel gear to the input shaft (Fig. 521).
GEAR DRIVE SYSTEM 15. Remove the bevel gear from the input shaft (Fig. 522). Fig 522 5 PICT-8295a 16. Remove the 2 screws securing the lockout plate from the housing (Fig. 523). Fig 523 5-26 PICT-8296 17. Remove the lockout plate from the housing (Fig. 524). Fig 524 PICT-8298 18. Turn the housing over and remove the 3 screws that secure the shift cover to the housing (Fig. 525).
GEAR DRIVE SYSTEM 19. Remove the shift cover from the housing (Fig. 526). Fig 526 21. Remove the shifter insert from the housing (Fig. 528). PICT-8301a Fig 528 20. Remove the shift lever assembly from the housing (Fig. 527). Fig 527 22. If the bearings are being replaced, drive out the upper and lower needle bearings from the housing for the input shaft through the hole (Fig. 529).
GEAR DRIVE SYSTEM Differential Axle Assembly Service 25. Repeat steps 23 and 24 to remove the opposite bearings and wheel hub assembly. Note: Differential is serviced as an assembly. 23. Remove the bolt and washer securing the wheel hub assembly to the transmission axle shaft. Remove the wheel hub from the axle shaft (Fig. 530). 26. Inspect the 4 bearings. Replace if worn or damaged (Fig. 532). Note: Discard the bolt. It is a patch bolt and must be replaced upon installation.
GEAR DRIVE SYSTEM 28. Slide the wheel hub onto the axle shaft. Install a patch bolt (new) and washer securing the wheel hub assembly to the transmission axle shaft (Fig. 534). Fig 534 Drive Shaft Assembly Service 5HPRYH WKH ÀDQJH EHDULQJ DQG ÀDW ZDVKHU IURP WKH drive shaft (Fig. 535). PICT-8314a Fig 535 29. Repeat steps 27 and 28 to install the opposite bearings and wheel hub assembly. 31. Remove the 9 tooth sprocket from the drive shaft (Fig. 536).
GEAR DRIVE SYSTEM 32. Remove the collar assembly from the drive shaft (Fig. 537). Fig 537 5 PICT-8323a 33. Remove the 41 tooth spur gear from the drive shaft (Fig. 538). Fig 538 5-30 PICT-8324a 34. Remove the 20 tooth spur gear from the drive shaft (Fig. 539). Fig 539 PICT-8326a 35. Remove the hi-lo collar assembly from the drive shaft (Fig. 540).
GEAR DRIVE SYSTEM 5HPRYH WKH ÀDQJH EHDULQJ DQG ÀDW ZDVKHU IURP WKH opposite end of the drive shaft (Fig. 541). Fig 541 38. Remove the 10 tooth spur gear from the drive shaft (Fig. 543). Fig 543 PICT-8329a 37. Remove the snap ring from the drive shaft (Fig. 542). ,QVSHFW WKH GULYH VKDIW ÀDQJH EHDULQJV ZDVKHUV sprocket, spur gears, snap ring and collars. Replace if worn or damaged (Fig. 544): B A F B E D C G Fig 542 A H I PICT-8331a Fig 544 A. B. C. D. E.
GEAR DRIVE SYSTEM 40. Slide a 10 tooth spur gear onto the drive shaft (Fig. 545). Fig 545 5 PICT-8333a 41. Install a snap ring onto the drive shaft securing the 10 tooth spur gear (Fig. 546). Fig 546 5-32 PICT-8331a 6OLGH D ZDVKHU DQG ÀDQJH EHDULQJ RQWR WKH HQG RI the drive shaft (Fig. 547). Fig 547 PICT-8329 43. Slide a hi-lo collar assembly onto the drive shaft (Fig. 548).
GEAR DRIVE SYSTEM 44. Slide a 20 tooth spur gear onto drive shaft (Fig. 549). Fig 549 46. Slide a collar assembly onto the drive shaft (Fig. 551). PICT-8326a Fig 551 45. Slide a 41 tooth spur gear onto the drive shaft (Fig. 550). Fig 550 47. Slide a 9 tooth sprocket onto the drive shaft (Fig. 552).
GEAR DRIVE SYSTEM 6OLGH D ZDVKHU DQG ÀDQJH EHDULQJ RQWR WKH GULYH shaft (Fig. 553). 50. Remove the bearing from the output shaft (Fig. 555). Fig 555 Fig 553 5 PICT-8340a PICT-8321a Right Hand Output Shaft Assembly Service 51. Remove the 16 tooth sprocket and chain from the output shaft (Fig. 556). 49. Remove the seal from the output shaft (Fig. 554).
GEAR DRIVE SYSTEM 5HPRYH WKH ÀDQJHG EHDULQJ IURP WKH RXWSXW VKDIW (Fig. 557). Fig 557 PICT-8343a 53. Remove the 2 washers from the output shaft (Fig. 558). Fig 558 GT Series Tractors Service Manual PICT-8344a 54. Remove the 37 tooth spur gear from the output shaft (Fig. 559). Fig 559 PICT-8346a 55. Remove the shifter cover from the output shaft (Fig. 560).
GEAR DRIVE SYSTEM 5 56. Remove the 27 tooth spur gear from the output shaft (Fig. 561). 58. Slide a 27 tooth spur gear onto the output shaft (Fig. 563). Fig 561 Fig 563 PICT-8349a ,QVSHFW WKH ÀDQJHG EHDULQJ ZDVKHUV VKLIWHU FRYHU output shaft, seal, ball bearing, spur gears and chain. Replace if worn or damaged Fig. 562): BC D G H A E I 59. Slide a shifter cover onto the output shaft (Fig. 564). F J Fig 564 Fig 562 A. B. C. D. E.
GEAR DRIVE SYSTEM 60. Slide a 37 tooth spur gear onto the output shaft (Fig. 565). Fig 565 PICT-8346a 61. Slide 2 washers onto the output shaft (Fig. 566). Fig 566 6OLGH D ÀDQJHG EHDULQJ RQWR WKH RXWSXW VKDIW )LJ 567). Fig 567 63. Slide a 16 tooth sprocket and chain onto the output shaft (Fig. 568).
GEAR DRIVE SYSTEM 64. Slide a bearing onto the output shaft (Fig. 569). Fig 569 66. Position the 9 tooth sprocket on the drive shaft assembly into the chain with the right hand output shaft assembly (Fig. 571). PICT-8340a Fig 571 PICT-8351a 65. Slide a new seal onto the output shaft (Fig. 570). 5 CVT Transmission Housing Rebuild 67. If applicable, press 2 new input shaft needle bearings into the housing (Fig. 572).
GEAR DRIVE SYSTEM 68. Slide the shifter insert into the housing (Fig. 573). Fig 573 70. Turn the housing over and position the shift cover to the housing (Fig. 575). PICT-8305a Fig 575 69. Slide the shift lever assembly into the housing (Fig. 574). Fig 574 71. Install 3 screws to secure the shift cover to the housing (Fig. 576).
GEAR DRIVE SYSTEM 72. Position the lockout plate to the housing (Fig. 577). Fig 577 5 PICT-8298 73. Install 2 screws to secure the lockout plate to the housing (Fig. 578). Fig 578 5-40 PICT-8296 74. Slide a bevel gear onto the input shaft (Fig. 579). Fig 579 PICT-8295a 75. Install a snap ring to secure the bevel gear to the input shaft (Fig. 580).
GEAR DRIVE SYSTEM 76. Slide a washer onto the input shaft (Fig. 581). Fig 581 PICT-8290a 77. Slide the input shaft assembly into the housing (Fig. 582). Fig 582 GT Series Tractors Service Manual PICT-8289 78. Slide 2 washers onto the input shaft (Fig. 583). Fig 583 PICT-8288 79. Install an e-ring onto the input shaft to secure it to the housing (Fig. 584).
GEAR DRIVE SYSTEM 80. Position the differential axle assembly into the housing (Fig. 585). Fig 585 5 1RWH 0DNH VXUH WKH WDEV RI DOO ÀDQJH EHDULQJV are seated in their V notches in the housing (Fig. 587 and Fig. 588). PICT-8285 Fig 587 PICT-8352a Fig 588 PICT-8354a 81. Position the drive shaft and right hand output shaft assemblies into the housing (Fig. 586).
GEAR DRIVE SYSTEM 82. Place the shift fork assembly into the housing (Fig. 589). Fig 589 PICT-8283 83. Replace the brake pucks and brake disc if worn or damaged. Install the puck into the transmission housing (Fig. 590). 84. Slide the brake disc onto the transmission shaft (Fig. 591). Fig 591 PICT-8280a Note: Some transmissions have 2 washers (1 on each bolt) between the brake assembly and transmission housing. 85. Position the brake assembly to the transmission (Fig. 592).
GEAR DRIVE SYSTEM 86. Install 2 bolts to secure the brake assembly to the transmission housing (Fig. 593). Fig 593 5 PICT-8277a 89. Install 23 bolts in a crisscross pattern to secure the housing halves together (Fig. 595). Fig 595 PICT-8272a 87. Pack the transmission with grease: 55 oz. of Shell Darina “O” Type Grease. Variable Speed Pulley Service 88. Position the upper housing onto the lower housing (Fig. 594).
GEAR DRIVE SYSTEM 2. Remove the bracket assembly from the variable speed pulley (Fig. 597). 4. Remove the bearing cup from the bracket (Fig. 599). Fig 599 Fig 597 3. Remove the 3 nuts and bolts securing the bearing cup to the pulley bracket (Fig. 598). 5. Remove the 2 ball bearings from the bearing cup (Fig. 600).
GEAR DRIVE SYSTEM 6. Inspect the bearings. Replace if worn or damaged. 7. Insert 2 bearings into the bearing cup (Fig. 601). 9. Install 3 bolts and nuts to secure the bearing cup assembly to the bracket (Fig. 603). Fig 603 Fig 601 5 8. Position the bearing cup assembly onto the bracket (Fig. 602). 10. With the pulley secure in a vise, position the bracket assembly onto the pulley (Fig. 604).
GEAR DRIVE SYSTEM 11. Install a bolt and washer securing the bracket assembly to the pulley (Fig. 605). Fig 605 2. Raise and support the rear of the machine. 3. Remove the 4 lug nuts and remove the wheel assembly from the wheel hub (Fig. 607). PICT-7685a Fig 607 PICT-7503a Brake Puck Replacement 4. Remove the 2 bolts securing the brake assembly to the transmission housing (Fig. 608). Brake Puck Removal 1. Loosen the 4 lug nuts securing the rear wheel to the wheel hub assembly (Fig. 606).
GEAR DRIVE SYSTEM 5. Remove the brake assembly from the transmission (Fig. 609). 7. Remove the puck from the brake assembly (Fig. 611). Note: Some transmissions have 2 washers between the brake assembly and the transmission (1 for each bolt). Fig 611 5 Fig 609 PICT-7719a PICT-7721 8. Remove the brake disc from the transmission (Fig. 612). 6. Remove the brake assembly from the spring (Fig. 610).
GEAR DRIVE SYSTEM 9. Remove the puck from the transmission housing (Fig. 613). Brake Puck Installation 1. Install a puck into the transmission housing (Fig. 615). Fig 613 PICT-7723a Fig 615 PICT-7723a 10. Inspect the brake disc and 2 brake pucks. Replace if damaged or worn (Fig. 614). 2. Slide the brake disc onto the transmission shaft (Fig. 616).
GEAR DRIVE SYSTEM 3. Install the puck into the brake assembly (Fig. 617). Fig 617 PICT-7721 4. Hook the brake assembly onto the spring (Fig. 618). 5 Fig 618 5-50 5. Insert 2 bolts into the brake assembly (Fig. 619). Fig 619 PICT-7728 6. If washers are present, slide a washer onto each of the bolts (Fig. 620).
GEAR DRIVE SYSTEM 7. Position the brake assembly to the transmission and install the 2 bolts to secure it (Fig. 621). Fig 621 9. Lower the machine. 10. Tighten the 4 lug nuts to secure the rear wheel to the wheel hub assembly (Fig. 623). PICT-7717a Fig 623 PICT-7502a 8. Slide the wheel onto the wheel hub assembly and install 4 lug nuts (Fig. 622).
GEAR DRIVE SYSTEM Brake Adjustment 1. Loosen, but do NOT remove, the hex nut found on the right side of the brake assembly (Fig. 000 abov). ! WARNING ! Never attempt to adjust the brakes while the engine is running. Always disengage PTO, move shift lever into neutral position, stop engine and remove key to prevent unintended starting. 2. Insert a feeler gauge set at .011” (.028mm) between the brake disc and the brake puck (Fig. 625).
GEAR DRIVE SYSTEM Autodrive Pedal Adjustment 3. If adjustment is needed: 1. Remove the mower deck. Refer to “50” Mower Deck Removal” on page 7-6. 4. Locate the speed control assembly on the underside of the steering support bracket (Fig. 628). 2. The Autodrive pedal is properly adjusted when the hole found in the double idler bracket has approximately 1-3/8” (3.5cm) of travel with 10 lbs. (4.5kg) of pressure applied to the Autodrive pedal (Fig. 626 and Fig. 627). Fig 628 PICT-7682a 5.
GEAR DRIVE SYSTEM 6. Remove the washer from the speed control assembly (Fig. 630). 8. Remove the lock nut from the main pin (Fig. 632). Fig 632 Fig 630 5 7. Remove the Autodrive pedal return spring (Fig. 631). Fig 631 5-54 PICT-7691 PICT-7683 PICT-7684 9. Remove the main pin from the speed control assembly (Fig. 633).
GEAR DRIVE SYSTEM 10. Loosen the jam nut on the idler adjustment rod. Turn the idler adjustment rod clockwise or counterclockwise to obtain the 1-3/8” (3.5cm) idler bracket travel (Fig. 634). 12. Install the main pin through the adjustment rod, back into the lockout bracket, then through the speed control assembly. Install the jam nut onto the pin (Fig. 635). Note: Ensure the main pin is oriented so the hairpin holes are positioned vertically. B A B A E C D Fig 634 A. Jam nut PICT-7693 B.
GEAR DRIVE SYSTEM 14. Install 2 hairpin cotters into the main pin (Fig. 637). Fig 637 16. Install the other end of the Autodrive pedal return spring to the tab on the frame (Fig. 639). PICT-7682a Fig 639 5 15. Install the Autodrive pedal return spring into the notch on the speed control bracket (Fig. 638). PICT-7704 17. Check the travel distance on the idler bracket (approximately 1-3/8” (3.5cm) of travel with 10 lbs. (4.5kg) of pressure applied to the Autodrive pedal).
HYDROSTATIC DRIVE SYSTEM Transmission Drive Belt Replacement 4. Remove the battery hold down rod (Fig. 642). Transmission Drive Belt Removal 1. Lift the seat to access the battery compartment. 2. Disconnect the battery cable from the negative battery terminal (Fig. 640). Fig 642 PICT-7352 5. Remove the battery from the battery tray (Fig. 643). Fig 640 PICT-7349 3. Disconnect the battery cable from the positive battery terminal (Fig. 641).
HYDROSTATIC DRIVE SYSTEM 6. Remove the battery tray (Fig. 644). 9. Remove the Electric PTO clutch. Refer to Electric PTO Clutch Removal on page 3-29. 10. Slide the engine pulley off the crankshaft and remove the transmission drive belt from the engine pulley (Fig. 646). Fig 644 PICT-7354 7. Raise the machine so the transmission drive belt can be accessed. 8. With a small pry bar, release tension from the idler VSULQJ 5HPRYH WKH EHOW IURP WKH ¿[HG 9 LGOHU SXOOH\ and the idler pulley (Fig. 645).
HYDROSTATIC DRIVE SYSTEM 12. Route the transmission drive belt back and remove it from above the steering support bracket (Fig. 648). Transmission Drive Belt Installation 1. Route the transmission drive belt around the transmission fan and pulley (Fig. 650). Fig 648 PICT-7499 Fig 650 13. Remove the transmission drive belt from around the transmission pulley and fan. Remove the belt from the machine (Fig. 649). PICT-7501 2.
HYDROSTATIC DRIVE SYSTEM 3. Position the transmission drive belt around the crankshaft (Fig. 652). Fig 652 :LWK D VPDOO SU\ EDU H[WHQG WKH LGOHU VSULQJ EUDFNHW 5RXWH WKH ULJKW KDQG EHOW UXQ EHWZHHQ WKH ¿[HG LGOHU DQG WKH ÀDW LGOHU 5RXWH WKH OHIW KDQG EHOW UXQ RQ WKH RXWVLGH RI WKH RWKHU ¿[HG LGOHU SXOOH\ )LJ PICT-7585a Fig 654 4. Apply anti-seize compound to crankshaft. Slide the engine pulley onto crankshaft and install the transmission drive belt around engine pulley (Fig. 653).
HYDROSTATIC DRIVE SYSTEM 6. Install the Electric PTO clutch. Refer to “Electric PTO Clutch Installation” on page 3-30. 9. Install the battery hold down rod (Fig. 658). 7. Install the battery tray (Fig. 656). Fig 658 Fig 656 PICT-7354 PICT-7352 10. Connect the battery cable to the positive battery terminal (Fig. 659). 8. Install the battery to the battery tray (Fig. 657).
HYDROSTATIC DRIVE SYSTEM 11. Connect the battery cable to the negative battery terminal (Fig. 660). Hydrostatic Transmission Replacement Hydrostatic Transmission Removal 1. Remove the transmission drive belt. Refer to “Transmission Drive Belt Removal” on page 5-1. 2. Loosen the 8 lug nuts securing the rear wheels to the wheel hub assemblies (Fig. 661). Fig 660 PICT-7349 12. Lower the seat.
HYDROSTATIC DRIVE SYSTEM 3. Raise and support the rear of the machine. 4. Remove the 8 lug nuts and remove the 2 wheel assemblies from the wheel hubs (Fig. 662). 6. Remove the brake control rod from the linkage (Fig. 664). Fig 664 Fig 662 PICT-7513 PICT-7503a 5. Remove the cotter pin securing the front end of the brake control rod to the brake linkage (Fig. 663). 7. Unhook the spring from the rear end of the brake control rod (Fig. 665).
HYDROSTATIC DRIVE SYSTEM 8. Remove the brake control rod (Fig. 666). Fig 666 10. Remove the speed control rod trunnion from the speed control linkage (Fig. 668). PICT-7521 Fig 668 9. Remove the hairpin cotter securing the front end of the speed control rod to the speed control linkage (Fig. 667). PICT-7523 11. Remove the cotter pin from the rear end of the speed control rod (Fig. 669).
HYDROSTATIC DRIVE SYSTEM 12. Remove the spring from the speed control rod and transmission (Fig. 670). Fig 670 PICT-7529 13. Remove the speed control rod from the transmission linkage and remove it from the machine (Fig. 671). 14. Remove the washer from the speed control rod (Fig. 672). Fig 672 PICT-7532 15. Unplug the harness wire from actuator bracket spring switch (Fig. 673).
HYDROSTATIC DRIVE SYSTEM 16. Remove the actuator bracket/spring switch (Fig. 674). Fig 674 PICT-7546 17. Remove the screw securing the harness ground (Fig. 675). 18. Remove the hairpin cotter securing the bypass lever to the bypass bracket on the transmission (Fig. 676). Fig 676 PICT-7556 19. Remove the return spring from the bypass lever (Fig. 677).
HYDROSTATIC DRIVE SYSTEM 20. Remove the bypass lever from the bypass bracket on the transmission and remove the lever from the machine (Fig. 678). Fig 678 22. Secure and support the transmission. 23. Remove the 2 bolts securing the front of the hydrostatic transmission to the frame (Fig. 680). PICT-7559a Fig 680 21. Remove the cable tie securing the transmission vent hose to the frame (Fig. 679). PICT-7551 24.
HYDROSTATIC DRIVE SYSTEM 25. Carefully lower the hydrostatic transmission from the machine (Fig. 682). Fig 682 PICT-7564a 26. Remove the bolt and washer securing the wheel hub DVVHPEO\ WR WKH WUDQVPLVVLRQ D[OH VKDIW )LJ 27. Remove the wheel hub assembly from the transPLVVLRQ D[OH VKDIW )LJ Fig 684 PICT-7568a 28. Repeat steps 26 and 27 to remove the opposite wheel hub assembly.
HYDROSTATIC DRIVE SYSTEM Hydrostatic Transmission Installation 1. Slide a wheel hub assembly onto each transmission D[OH VKDIW )LJ 3. Carefully position the hydrostatic transmission under the machine. Secure and support the transmission (Fig. 687). Fig 687 Fig 685 PICT-7564a PICT-7568a 2. Install a bolt and washer to secure each wheel hub DVVHPEO\ WR WKH WUDQVPLVVLRQ D[OH VKDIWV )LJ 4.
HYDROSTATIC DRIVE SYSTEM 5. Install 2 bolts securing the front of the hydrostatic transmission to the frame (Fig. 689). Fig 689 7. Insert the bypass lever into the slot on the rear of the machine. Slide the bypass lever onto the bypass bracket on the transmission (Fig. 691). PICT-7551 Fig 691 PICT-7559a 6. Position the transmission vent tube along the left side of the frame and install a plastic push mount tie to secure it to the frame and wire harness (Fig. 690). 8.
HYDROSTATIC DRIVE SYSTEM 9. Install a hairpin cotter securing the bypass lever and spring to the bypass bracket on the transmission (Fig. 693). 11. Position the actuator bracket with the spring switch to the slot in the transmission (Fig. 695). Fig 695 Fig 693 PICT-7574 PICT-7556 10. Position the ground wire to the transmission bracket and install a screw to secure it (Fig. 694). 12. Plug the harness wire into the actuator bracket spring switch (Fig. 696).
HYDROSTATIC DRIVE SYSTEM 13. Slide a washer onto the rear end of the speed control rod (Fig. 697). Fig 697 PICT-7532 14. Position the rear end of the speed control rod into the machine and slide the speed control rod into the transmission linkage (Fig. 698). +RRN WKH VSULQJ RQWR WKH VSHHG FRQWURO URG )LJ 699). Fig 699 PICT-7529 16. Install a cotter pin securing the spring, actuator bracket and speed control rod to the transmission (Fig. 700).
HYDROSTATIC DRIVE SYSTEM 17. Insert the trunnion on the front end of the speed control rod into the speed control linkage (Fig. 701). Fig 701 19. Position the rear end of the brake control rod through the hole in the frame and up to the transmission (Fig. 703). PICT-7523 Fig 703 18. Install a hairpin cotter securing the front end of the speed control rod to the speed control linkage (Fig. 702). PICT-7521 +RRN WKH VSULQJ WR WKH UHDU HQG RI WKH EUDNH FRQWURO rod (Fig. 704).
HYDROSTATIC DRIVE SYSTEM 21. Position the front end of the brake control rod into the brake control linkage (Fig. 705). Fig 705 PICT-7580 23. Slide the wheel assembly onto the wheel hub assembly (Fig. 707). Fig 707 PICT-7503a 22. Install a cotter pin securing the front end of the brake control rod to the brake control linkage (Fig. 706). 24. Install 4 lug nuts securing the wheel assembly to the wheel hub assembly (Fig. 708).
HYDROSTATIC DRIVE SYSTEM 25. Repeat steps 23 and 24 to install the second wheel assembly to the opposite wheel hub. 26. Install the transission drive belt. Refer to “Transmission Drive Belt Installation” on page 5-3. 27. Tighten the 8 lug nuts securing the rear wheels to the wheel hub assemblies (Fig. 709). Fig 709 PICT-7502a 28. If a new transmission was installed, purge the system, adjust the brake and adjust neutral. Refer to: ³3XUJLQJ WKH 6\VWHP´ RQ SDJH ³%UDNH $GMXVWPHQW´ RQ SDJH
HYDROSTATIC DRIVE SYSTEM 3XUJLQJ WKH 6\VWHP 'XH WR WKH HIIHFW DLU KDV RQ HI¿FLHQF\ LQ K\GURVWDWLF drive applications, it is critical that it be purged from the system. These purge procedures should be implemented any time a hydrostatic system has been opened to facilitate maintenance or any additional oil has been added to the system. $LU FUHDWHV LQHI¿FLHQF\ EHFDXVH LWV FRPSUHVVLRQ DQG H[SDQVLRQ UDWH LV KLJKHU WKDQ WKH RLO LQ K\GURVWDWLF GULYH systems.
HYDROSTATIC DRIVE SYSTEM )OXLG &KDQJH 7KH +\GUR *HDU WUDQVD[OH LV IDFWRU\ ¿OOHG DQG GRHV QRW require periodic oil change. In the event of oil contamination or degradation, oil replacement may correct certain performance problems: 5HPRYH WKH WUDQVD[OH IURP WKH PDFKLQH 5HIHU WR ³+\GURVWDWLF 7UDQVPLVVLRQ 5HPRYDO´ RQ SDJH &RPSOHWHO\ GUDLQ WKH RLO IURP WKH WUDQVD[OH WKURXJK WKH WRS ÀXLG ¿OO SRUW 3RUW $ )LJ )LOO XQLW XQWLO RLO LV ÀRZLQJ RXW RI 3RUW % )LJ Fluid Description Vo
HYDROSTATIC DRIVE SYSTEM Neutral Adjustment Before making a neutral adjustment, the transmission must be warmed up for at least 10 minutes. 4. Locate the neutral adjusting puck and loosen the $OOHQ KHDG EROW ,I LW¶V GLI¿FXOW WR ORRVHQ KHDW WKH aluminum housing near the bolt with a propane torch (Fig. 714). 1. Loosen the 4 lug nuts securing the right rear wheel to the wheel hub assembly (Fig. 712). Fig 714 Fig 712 PICT-7502a 2. Raise and support the rear of the machine. 6 3.
HYDROSTATIC DRIVE SYSTEM 8. Operate the foot control in forward and reverse. Allow the pedal to return to the neutral position to test the adjustment. 11. Lower the machine to the ground. 12. Tighten the 4 lug nuts (Fig. 718). 9. Slide the wheel assembly onto the wheel hub assembly (Fig. 716). Fig 718 Fig 716 PICT-7502a PICT-7503a 10. Install 4 lug nuts securing the wheel assembly to the wheel hub assembly (Fig. 717).
HYDROSTATIC DRIVE SYSTEM %UDNH 3XFN 5HSODFHPHQW 2. Raise and support the rear of the machine. %UDNH 3XFN 5HPRYDO 3. Remove the 4 lug nuts and remove the wheel assembly from the wheel hub (Fig. 720). 1. Loosen the 4 lug nuts securing the right rear wheel to the wheel hub assembly (Fig. 719). Fig 720 Fig 719 PICT-7503a PICT-7502a 4. Loosen the lower bolt securing the brake assembly to the transmission housing (Fig. 721).
HYDROSTATIC DRIVE SYSTEM 5. Remove the brake arm spring (Fig. 722). Fig 722 7. Remove the upper bolt securing the brake assembly to the transmission housing (Fig. 724). PICT-7734 Fig 724 6. Remove the lower bolt, washer, and spacer from the brake assembly (Fig. 723). PICT-7737 8. Remove the brake assembly from the transmission (Fig. 725).
HYDROSTATIC DRIVE SYSTEM 9. Remove the brake assembly from the spring (Fig. 726). Fig 726 PICT-7739 10. Remove the puck from the brake assembly (Fig. 727). 11. Remove the disc brake from the transmission (Fig. 728). Fig 728 PICT-7742a 12. Remove the puck from the transmission housing (Fig. 729).
HYDROSTATIC DRIVE SYSTEM 13. Inspect the disc brake and 2 brake pucks. Replace if damaged or worn (Fig. 730). 2. Slide the disc brake onto the transmission shaft (Fig. 732). Fig 730 Fig 732 PICT-7744a PICT-7745 3. Install the puck into the brake assembly (Fig. 733). %UDNH 3XFN ,QVWDOODWLRQ 1. Install a puck into the transmission housing (Fig. 731).
HYDROSTATIC DRIVE SYSTEM +RRN WKH EUDNH DVVHPEO\ RQWR WKH VSULQJ )LJ Fig 734 6. Install the lower bolt, washer and spacer to secure the brake assembly to the transmission housing (Fig. 736). PICT-7747 Fig 736 PICT-7736 5. Position the brake assembly to the transmission and install the top bolt to secure it (Fig. 735). +RRN WKH EUDNH DUP VSULQJ RQWR WKH EUDNH DUP )LJ 737).
HYDROSTATIC DRIVE SYSTEM +RRN WKH EUDNH DUP VSULQJ RQWR WKH ORZHU EROW )LJ 738). Fig 738 11. Lower the machine. 12. Tighten the 4 lug nuts securing the rear wheel to the wheel hub assembly (Fig. 740). PICT-7733 Fig 740 PICT-7502a 9. Adjust the parking brake. See “Parking Brake Adjustment” on page 6-30. 10. Slide the wheel onto the wheel hub assembly and install 4 lug nuts (Fig. 739).
HYDROSTATIC DRIVE SYSTEM 1. Remove and discard the cotter pin which secures the crown nut to the assembly (Fig. 741). 3DUNLQJ %UDNH $GMXVWPHQW ! WARNING ! 1HYHU DWWHPSW WR DGMXVW WKH EUDNHV ZKLOH WKH HQJLQH is running. Always disengage PTO, stop engine and remove key to prevent unintended starting. If the tractor does not come to a complete stop when the brake pedal is completely depressed, or if the tractor’s rear wheels can roll with the parking brake applied, the brake is in need of adjustment.
MOWER DECK 50” Mower Deck Belt Replacement 50” Mower Deck Belt Removal 1. Remove the mower deck from the tractor. Refer to “50” Mower Deck Removal” on page 7-6. 4. Remove the 4 screws securing the right hand spindle cover to the mower deck (Fig. 000). Note: There is a hook retainer bracket located under one of the screws securing the right spindle cover to the mower deck (Fig. 745). 2. Remove the 3 screws securing the left hand spindle cover to the mower deck (Fig. 743).
MOWER DECK 6. Loosen the nut from the bolt securing the pulley to the spring loaded idler assembly (Fig. 747). 50” Mower Deck Belt Installation 1. Route the mower deck belt around the spindles and idlers. Refer to the belt routing decal (Fig. 749): Fig 747 PICT-7952 Fig 749 decal 1 3354-977 7. Tilt the spring loaded idler pulley and remove the mower deck belt from the mower deck (Fig. 748). 2. Tilt the spring loaded idler pulley to route the belt around it (Fig. 750).
MOWER DECK 3. Tighten the nut onto the bolt securing the pulley to the spring loaded idler assembly (Fig. 751). 5. Install 4 screws to secure the right hand spindle cover to the mower deck (Fig. 753). Note: There is a hook retainer bracket located under one of the screws securing the spindle cover to the mower deck. Fig 751 PICT-7952 4. Position the right hand spindle cover onto the mower deck (Fig. 752). Fig 753 PICT-7947 6. Position the left hand spindle cover onto the mower deck (Fig. 754).
MOWER DECK 7. Install 3 screws to secure the left hand spindle cover to the mower deck (Fig. 755). 50” Mower Deck Fixed Idler Replacement The mower deck has been removed from the tractor for photo purposes. 50” Mower Deck Fixed Idler Removal 5HPRYH WKH EROW ZDVKHU DQG QXW VHFXULQJ WKH ¿[HG LGOHU SXOOH\ WR WKH ¿[HG LGOHU PRXQWLQJ EUDFNHW )LJ 756). Fig 755 PICT-7946 8. Install the mower deck onto the tractor. Refer to “50” Mower Deck Installation” on page 7-8.
MOWER DECK 5HPRYH WKH ¿[HG LGOHU SXOOH\ IURP WKH PRXQWLQJ bracket (Fig. 757). 50” Mower Deck Fixed Idler Installation 3RVLWLRQ WKH ¿[HG LGOHU SXOOH\ RQWR WKH ¿[HG LGOHU mounting bracket (Fig. 758). Fig 757 PICT-7984 Fig 758 PICT-7984 ,QVWDOO D EROW ZDVKHU DQG QXW WR VHFXUH WKH ¿[HG LGOHU SXOOH\ WR WKH ¿[HG LGOHU PRXQWLQJ EUDFNHW )LJ 7 Fig 759 GT Series Tractors Service Manual PICT-7982 7-5
MOWER DECK 50” Mower Deck Removal 1. Place the PTO/Blade Engage knob in the disengaged (OFF) position and engage the parking brake. 3. Using a breaker bar or ratchet, rotate the idler bracket forward and remove the deck belt from around the electric PTO clutch (Fig. 761 and Fig. 762). 2. Lower the deck by moving the deck lift lever into the bottom notch on the right fender (Fig. 760). D C E A B Fig 761 Fig 760 PICT-7829 A. Idler bracket B. Spring C. Pivoting idler pulley ¿J D.
MOWER DECK 4. From the left side of the tractor, locate the deck support pin on the rear left side of the deck. Pull the deck support pin outward to release the deck from the deck lift arm. Rotate the pin so it rests on the deck hanger bracket (Fig. 763). 7. Move the deck lift lever into the top notch to raise the deck lift arms up and out of the way (Fig. 765). Fig 765 Fig 763 PICT-7988 5. Repeat the above step on the tractor’s right side. PICT-7839 8. Turn the tractor’s front wheels fully left.
MOWER DECK 50” Mower Deck Installation 1. Place the PTO/Blade Engage knob in the disengaged (OFF) position and engage the parking brake. 4. Slide the cutting deck toward the front of the tractor allowing the hooks on the deck to catch on the deck stabilizer rod (Fig. 769). 2. Move the deck lift lever into the top notch to raise the deck lift arms up and out of the way (Fig. 767). Fig 769 Fig 767 PICT-7839 PICT-7987 5.
MOWER DECK 6. From the left side of the tractor, locate the deck support pin on the rear left side of the deck. Pull the deck support pin outward. Lift the deck into position and release the deck support pin so that the deck is hanging and supported by the deck support pin (Fig. 771). 7. Repeat the above step on the tractor’s right side. 8. Using a breaker bar or ratchet, rotate the idler bracket forward and route the mower deck belt around the electric PTO clutch (Fig. 772 and Fig. 773).
MOWER DECK 9. Raise the deck by moving the deck lift lever into the top notch on the right fender (Fig. 774). 50” Mower Deck Spindle Replacement The following procedure was performed on the center spindle assembly. The process is the same for all three VSLQGOH DVVHPEOLHV H[FHSW ZKHUH QRWHG 50” Mower Deck Spindle Removal 1. Remove the mower deck from the tractor. Refer to “50” Mower Deck Removal” on page 7-6. 2. If servicing a left or right spindle, remove the deck belt from the mower deck.
MOWER DECK 5. Remove the mower deck blade from the spindle shaft (Fig. 776). Fig 776 PICT-7978 7. Remove the spindle assembly from the mower deck (Fig. 778). Fig 778 PICT-012a 6. Remove the 4 screws securing the spindle assembly to the mower deck (Fig 777).
MOWER DECK 50” Mower Deck Spindle Installation 3. Install 4 screws securing the spindle assembly to the mower deck (Fig 780). 1. As necessary, apply grease to all three mower deck spindles. Note: The screws are installed from the bottom side of the mower deck. 2. Position the spindle assembly onto the top side of the mower deck (pulley side facing up) (Fig. 779). 1RWH 7KH VSLQGOH JUHDVH ¿WWLQJ VKRXOG EH SRVL tioned so that it is facing toward the front of the mower deck.
MOWER DECK 5. Block the mower deck blade and install a nut securing the mower deck blade to the spindle shaft (Fig. 782). Torque the blade nut to 80 + 10 ft-lbs. (108 + 13.5 Nm). 50” Mower Deck Spindle Service 1. Secure the mower deck spindle into a vise. 2. Secure the spindle shaft and remove the nut securing the pulley to the mower deck spindle (Fig. 783). Fig 782 PICT-019 Fig 783 PICT-8046a 6. Install the pulley onto the spindle. Refer to “Mower Deck Pulley Installation” on page 7-50. 7.
MOWER DECK 4. Remove the pulley (Fig. 785). Fig 785 6. Remove the shoulder spacer from the spindle shaft (Fig. 787). PICT-8048a Fig 787 5. Remove the spindle shaft/shoulder spacer assembly from the spindle housing (Fig. 786). PICT-8050a 7. Remove the bearing and 2 spacers from the pulley side of the housing (Fig. 788).
MOWER DECK 8. Press the second bearing out of the blade side of the housing (Fig. 789). 11. Secure the housing assembly into a vise and stake the housing to retain the bearing (Fig. 791). Note: Since this bearing is staked in place it WILL be damaged if removed. Fig 791 Fig 789 PICT-7745a PICT-7748a 12. Insert 2 spacers into the spindle housing (Fig. 792). 9. Inspect the bearings and spacers and replace if worn or damaged. 10. Press the blade side bearing into the housing (Fig. 790).
MOWER DECK 13. Install a bearing into the pulley side of the spindle housing (Fig. 793). Fig 793 PICT-7750a 14. Install a shoulder spacer onto the spindle shaft cupped side down (Fig. 794). 15. Install the spindle shaft and shoulder spacer assembly into the spindle housing (Fig. 795). Fig 795 PICT-8049a 16. Place the spindle housing into a vise. 17. Install the pulley (Fig. 796).
MOWER DECK 18. Install a washer onto the spindle shaft (Fig. 797). 50” Mower Deck Spring Loaded Idler Replacement 50” Mower Deck Spring Loaded Idler Removal 1. Remove the Mower Deck from the Tractor. Refer to “50” Mower Deck Removal” on page 7-6. 2. Remove the mower deck belt. Refer to “50” Mower Deck Belt Removal” on page 7-1. 3. Remove the bolt, washer and nut securing the pulley to the spring loaded idler (Fig. 799). Fig 797 PICT-8047a 19.
MOWER DECK 4. Remove the pulley from the idler bracket (Fig. 800). Fig 800 6. Using a spring tool (Toro part no. 92-5771), unhook the idler spring from the spring post on the mower deck (Fig. 802). PICT-7956 Fig 802 PICT-7960 5. Remove the spacer from the idler bracket (Fig. 801). 7. Remove the idler spring from the idler bracket (Fig. 803).
MOWER DECK 8. Remove the nut from the shoulder bolt securing the idler bracket to the mower deck (Fig. 804). Fig 804 PICT-7963 9. Remove the idler bracket from the mower deck (Fig. 805). 10. Remove the washer from below the idler assembly mounting bracket (Fig. 806). Fig 806 PICT-7967 11. Remove the spacer from on top of the idler assembly mounting bracket (Fig. 807).
MOWER DECK 12. Remove the shoulder bolt from the idler bracket (Fig. 808). Fig 808 PICT-7972 50” Mower Deck Spring Loaded Idler Installation 2. Position the spacer on top of the idler assembly mounting bracket (Fig. 810). Fig 810 PICT-7969 3. Position a washer on the underside of the idler assembly mounting bracket (Fig. 811). 1. Insert the shoulder bolt into the idler bracket (Fig. 809).
MOWER DECK 4. Insert the idler bracket shoulder bolt through the idler assembly mower mounting bracket and washer (Fig. 812). 6. Hook the idler spring onto the idler bracket (Fig. 814). Fig 814 Fig 812 PICT-7962 PICT-7966 5. Install a nut onto the shoulder bolt securing the idler bracket to the mower deck (Fig. 813). 7. Using a spring tool (Toro part no. 92-5771), hook the idler spring to the spring post on the mower deck (Fig. 815).
MOWER DECK 8. Position a spacer onto the idler bracket (Fig. 816). Fig 816 10. Loosely install a bolt, washer and nut to secure the pulley to the spring loaded idler (Fig. 818). PICT-7957 Fig 818 9. Position the pulley onto the idler bracket (Fig. 817). PICT-7955 11. Apply grease to the idler assembly shoulder bolt (Fig. 819). Note: Check and apply grease to each of the mower deck spindles as needed. 7 Fig 817 PICT-7956 Fig 819 PICT-7975 12. Install the mower deck belt.
MOWER DECK 54” Mower Deck Belt Replacement The following procedures were done with the mower deck removed from the mower for photo purposes. To replace the mower deck belt the mower deck can remain on the tractor. 3. Using a breaker bar or ratchet, rotate the idler bracket forward and remove the deck belt from around the electric PTO clutch (Fig. 821 and Fig. 822). A 54” Mower Deck Belt Removal 1. Place the PTO/Blade Engage knob in the disengaged (OFF) position and engage the parking brake. B 2.
MOWER DECK 4. Remove the 5 screws securing the left hand spindle cover to the mower deck (Fig. 823). Fig 823 PICT-7845 5. Remove the left hand spindle cover (Fig. 823). 6. Remove the 5 screws securing the right hand spindle cover to the mower deck (Fig. 824). Fig 824 PICT-7847 7. Remove the right hand spindle cover (Fig. 825).
MOWER DECK 8. Remove the mower deck belt from the mower deck (Fig. 826). Fig 826 PICT-7851 2. Install 5 screws to secure the right hand spindle cover to the mower deck (Fig. 828). Fig 828 PICT-7847 3. Position the left hand spindle cover onto the mower deck (Fig. 829). 54” Mower Deck Belt Installation 1. Position the right hand spindle cover onto the mower deck (Fig. 827).
MOWER DECK 4. Install 5 screws to secure the left hand spindle cover to the mower deck (Fig. 831). 54” Mower Deck Fixed Idler Replacement 54” Mower Deck Fixed Idler Removal 1. Remove the mower deck from the tractor. Refer to “54” Mower Deck Removal” on page 7-29. 2. Remove the deck belt from the mower deck. Refer to “54” Mower Deck Belt Removal” on page 7-23. 5HPRYH WKH EROW ZDVKHU DQG QXW VHFXULQJ WKH ¿[HG LGOHU SXOOH\ WR WKH ¿[HG LGOHU EUDFNHW )LJ Fig 831 PICT-7845 Fig 832 PICT-7869 7
MOWER DECK 5HPRYH WKH ¿[HG LGOHU SXOOH\ )LJ Fig 833 5HPRYH WKH VFUHZV VHFXULQJ WKH ¿[HG LGOHU bracket from the bottom side of the mower deck (Fig. 835). PICT-7871 Fig 835 PICT-7875 5. Remove the spacer (Fig. 834).
MOWER DECK 54” Mower Deck Fixed Idler Installation 3RVLWLRQ D VSDFHU RQWR WKH ¿[HG LGOHU EUDFNHW )LJ 839). 3RVLWLRQ WKH ¿[HG LGOHU EUDFNHW RQWR WKH PRZHU GHFN (Fig. 837). Fig 839 Fig 837 PICT-7873 PICT-7878 3RVLWLRQ WKH ¿[HG LGOHU SXOOH\ RQWR WKH VSDFHU )LJ 840). 2.
MOWER DECK ,QVWDOO D EROW ZDVKHU DQG QXW WR VHFXUH WKH ¿[HG LGOHU SXOOH\ WR WKH ¿[HG LGOHU EUDFNHW )LJ 54” Mower Deck Removal 1. Place the PTO/Blade Engage knob in the disengaged (OFF) position and engage the parking brake. 2. Lower the deck by moving the deck lift lever into the bottom notch on the right fender (Fig. 842). Fig 841 PICT-7869 6. Install the mower deck belt onto the mower deck. Refer to “54” Mower Deck Belt Installation” on page 7-25. Fig 842 PICT-7829 7.
MOWER DECK 3. Using a breaker bar or ratchet, rotate the idler bracket forward and remove the deck belt from around the electric PTO clutch (Fig. 843 and Fig. 844). 4. From the left side of the tractor, locate the deck support pin on the rear left side of the deck. Pull the deck support pin outward to release the deck from the deck lift arm. Rotate the pin so it rests on the deck hanger bracket (Fig. 845). A B Fig 843 A. Idler pulley ¿J B. 3/8” Square hole Fig 845 PICT-7833 5.
MOWER DECK 7. Move the deck lift lever into the top notch to raise the deck lift arms up and out of the way (Fig. 847). 54” Mower Deck Installation 1. Place the PTO/Blade Engage knob in the disengaged (OFF) position and engage the parking brake. 2. Move the deck lift lever into the top notch to raise the deck lift arms up and out of the way (Fig. 849). Fig 847 PICT-7839 8. Turn the tractor’s wheels fully left. Slide the cutting deck (from the right side) out from underneath the tractor (Fig. 848).
MOWER DECK 4. Slide the cutting deck toward the front of the tractor allowing the hooks on the deck to catch on the deck stabilizer rod (Fig. 851). Fig 851 6. From the left side of the tractor, locate the deck support pin on the rear left side of the deck. Pull the deck support pin outward. Lift the deck into position and release the deck support pin so that the deck is hanging and supported by the deck support pin (Fig. 853). PICT-7836 5.
MOWER DECK 9. Using a breaker bar or ratchet, rotate the idler bracket forward and route the mower deck belt around the electric PTO clutch (Fig. 855 and Fig. 856). 10. Raise the deck by moving the deck lift lever into the top notch on the right fender (Fig. 857). A B Fig 857 Fig 855 A. Idler pulley PICT-7837 ¿J B.
MOWER DECK 54” Mower Deck Roller Replacement 54” Mower Deck Roller Removal 3. Support the lift bracket and remove the lift bracket pin from the lift bracket on both sides of the mower. Gently lower the roller assembly to the ground (Fig. 860). 1. Raise the deck by moving the deck lift lever into the top notch on the right fender. Raise and support the rear of the tractor to allow clearance for the deck roller to be removed from the mower deck roller brackets (Fig. 858).
MOWER DECK 5. Remove the cotter pin from end of the roller shaft (Fig. 862). Fig 862 PICT-7940 6. Remove the height adjuster from the end of the roller shaft (Fig. 863). 7. Remove the spacer from the end of the roller shaft (Fig. 864). Fig 864 PICT-7944a 8. Repeat steps 5 – 7 to remove the height adjuster from the other end of the roller shaft. 9. Remove the 4 deck rollers from the roller shaft (Fig. 865).
MOWER DECK 54” Mower Deck Roller Installation 3. Slide the height adjuster onto the end of the roller shaft (Fig. 868). 1. Slide 4 deck rollers onto the roller shaft (Fig. 866). Fig 868 Fig 866 PICT-7943 PICT-7945 2. Slide a spacer onto the end of the roller shaft (Fig. 867). 4. Install a cotter pin into end of the roller shaft (Fig. 869).
MOWER DECK 5. Repeat steps 2 – 4 to install the height adjuster onto the other end of the roller shaft. 6. Raise the deck by moving the deck lift lever into the top notch on the right fender. Raise and support the rear of the tractor to allow clearance for the deck roller to be installed into the mower deck roller brackets (Fig. 870). 8. Slide the height adjuster into the mower deck roller bracket. Support the lift bracket and install the lift bracket pin into the lift bracket (Fig. 872).
MOWER DECK 54” Mower Deck Roller Adjustment 1. Place the deck lift lever in the lowest position. 2. Remove the clevis pin and hairpin cotter from the deck roller brackets on the left and right sides of the cutting deck (Fig. 874). 54” Mower Deck Spindle Replacement The following procedure was performed on the left hand spindle assembly. The process is the same for all three spindle assemblies. 54” Mower Deck Spindle Removal 1. Remove the mower deck from the tractor.
MOWER DECK 5. Remove the mower deck blade from the spindle shaft (Fig. 876). Fig 876 PICT-7883 7. Remove the spindle assembly from the mower deck (Fig. 878). Fig 878 PICT-7889 6. Remove the 4 screws securing the spindle assembly to the mower deck (Fig 877).
MOWER DECK 54” Mower Deck Spindle Installation 3. Install 4 screws securing the spindle assembly to the mower deck (Fig. 880). 1. Check and apply grease to all three mower deck spindles as needed. Note: The screws are installed from the bottom side of the mower deck. 2. Position the spindle assembly onto the top side of the mower deck (pulley side facing up) (Fig. 879). 1RWH 7KH VSLQGOH JUHDVH ¿WWLQJ VKRXOG EH SRVL tioned so that it is facing toward the front of the mower deck.
MOWER DECK 4. Slide mower deck blade onto the spindle shaft (Fig. 881). Ensure the center of the blade is seated onto machined star end of the spindle shaft. 54” Mower Deck Spindle Service Note: Make sure the blade sails face the deck. 2. Remove the nut from the spindle shaft (Fig. 882). Fig 881 PICT-7926 5. Block the mower deck blade and install a nut securing the mower deck blade to the spindle shaft (Fig. 000). Torque the blade nut to 80 + 10 ft-lbs. (108 + 13.5 Nm). 1.
MOWER DECK 4. Remove the spindle assembly from the vise and remove the spindle shaft and spacer from the spindle housing (Fig. 884). 6. Remove the second bearing from the blade side of the spindle housing (Fig. 886). Fig 886 Fig 884 PICT-7904 PICT-7901 5. Remove the bearing and two spacers from the pulley side of the housing (Fig. 885). 7. Inspect the bearings and spacers. Replace if worn or damaged. 8. Install a bearing into the blade side of the spindle housing (Fig. 887).
MOWER DECK 9. Insert 2 spacers into the pulley side of the spindle housing (Fig. 888). 11. Slide the spacer onto the spindle shaft (Fig. 890). Fig 890 Fig 888 PICT-7912a PICT-7908a 10. Install a bearing into the pulley side of the spindle housing (Fig. 889). 12. Slide the spindle shaft into the spindle housing by LQVHUWLQJ LW LQWR WKH EODGH VLGH RI WKH KRXVLQJ ¿UVW (Fig. 891).
MOWER DECK 13. Secure the spindle housing into a vise with the pulley side up. 14. Slide a spacer onto the spindle shaft (Fig. 892). Note: Slide the pulley onto the spindle shaft so WKDW WKH ÀDQJHG VLGH RI WKH SXOOH\ LV LQVWDOOHG blade side down (Fig. 894). Fig 894 Fig 892 PICT-7919 PICT-7916a 15. Slide the pulley onto the spindle shaft. Ensure the center of the pulley is seated onto machined star end of the shaft (Fig. 893). 16. Install a nut securing the pulley to the spindle assembly (Fig. 895).
MOWER DECK 17. Apply grease to the spindle until it begins to appear at the weep hole (Fig. 896). 54” Mower Deck Spring Loaded Idler Replacement 54” Mower Deck Spring Loaded Idler Removal 1. Remove the mower deck from the tractor. Refer to “54” Mower Deck Removal” on page 7-29. 2. Remove the mower deck belt form the mower deck. Refer to “54” Mower Deck Belt Removal” on page 7-23. 3. Remove the bolt, washer and nut securing the idler pulley to the idler bracket (Fig. 897).
MOWER DECK 4. Remove the idler pulley from the idler bracket (Fig. 898). Fig 898 6. Using a spring removal tool (Toro part no. 92-5771), remove the idler spring from the idler bracket and mower deck (Fig. 900). PICT-7854 Fig 900 5. Remove the spacer from the idler bracket (Fig. 899). PICT-7859 7. Remove the nut and lock washer from the shoulder bolt securing the idler bracket to the mower deck (Fig. 901).
MOWER DECK 8. Remove the shoulder bolt, idler bracket and stabilizer bracket from the mower deck (Fig. 902). Fig 902 2. Install a lock washer and nut onto the shoulder bolt to secure the idler bracket to the mower deck (Fig. 904). PICT-7868 Fig 904 54” Mower Deck Spring Loaded Idler Installation 1. Position the stabilizer bracket and idler bracket to the mower deck. Insert a shoulder bolt through the idler and stabilizer brackets and then through the mower deck (Fig. 903). PICT-7863 3.
MOWER DECK 4. Position a spacer onto the idler bracket (Fig. 906). Fig 906 6. Insert a bolt and washer through the idler pulley, spacer and idler bracket. Install a nut to secure the pulley to the idler bracket (Fig. 908). PICT-7856 Fig 908 PICT-7853 5. Place the idler pulley onto the spacer (Fig. 907). 7. Install the deck belt. Refer to “54” Mower Deck Belt Installation” on page 7-25. 8. Install the mower deck onto the tractor. Refer to “54” Mower Deck Installation” on page 7-31.
MOWER DECK Mower Deck Pulley Replacement (50” & 54” Mower Decks) 2. Remove the pulley and the spacer from the spindle shaft (54” mower spindle shown) (Fig. 910). The following procedure was performed on the left hand spindle pulley. The process is the same for all spindle pulley replacement. Depending on which pulley is being replaced, the spindle covers and mower deck belt may have to be removed: Remove the mower deck from the tractor.
MOWER DECK Mower Deck Pulley Installation If the mower deck, spindle covers and mower deck belt have to been removed: 1. Slide the pulley and the spacer onto the spindle shaft (54” mower spindle shown) (Fig. 911). Install the mower deck belt onto the mower deck. Refer to: ´ 0RZHU 'HFN %HOW ,QVWDOODWLRQ RQ SDJH ´ 0RZHU 'HFN %HOW ,QVWDOODWLRQ RQ SDJH Install the mower deck onto the tractor.
ELECTRICAL Electrical System The GT2000 Series tractor electrical components and electrical troubleshooting topics can be found in the 2006 LX Series Lawn Tractors / GT2000 Series Garden 7UDFWRUV 'HP\VWL¿FDWLRQ *XLGH )RUP 1R along with complete wiring diagrams to help diagnose HOHFWULFDO SUREOHPV (OHFWULFDO 7URXEOHVKRRWLQJ '9' 3DUW 1R DOVR FRQWDLQV ZLULQJ GLDJUDPV DQG component troubleshooting information for GT2000 6HULHV WUDFWRUV 8 GT Series Tractors Service Manual 8-1
ELECTRICAL GT2100, GT2200, GT2300 Wiring Diagram IGNITION SWITCH OFF RUN 1 RUN 2 START G M A1 B A1 AND L A2 B A1 B S A1 G M GN GN Y L S B A1 A2 HEADLIGHT HARNESS GN BU GN R OR R/W R PUR R/W R BRAKE SWITCH GN BRAKE SWITCH IS SHOWN WITH BRAKE APPLIED Y OR Y/W OR/BK GN Y BU/W BU/W PTO CLUTCH R/W R W Relay W W/BK R 3 4 5 GN 1 2 Y/BK Y/BK W/BK BRAKE + OR BRAKE OR/BK OR/BK PTO OR/W OR/W PTO + OR/BK R 8 PUR N/C + 12V GND R GN GN SYSTEMS INDICATOR MONITOR / HOUR MET
ELECTRICAL GT2100, GT2200, GT2300 Wiring Diagram cont.
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Garden Tractor GT Series Service Manual Form No.
