Toro 121-7480 Installation Instructions

HydraulicSystemCoolingKit

GrandStand

ModelNo.121-7480

®

Installation

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

FormNo.3373-396RevB

Mower

InstallationInstructions

ProcedureDescription

1
2

3

4

5
6

Nopartsrequired

Nopartsrequired

Hydraulicsystemcoolingassembly1
Bolt(5/16x3/4inch)
Nut(5/16inch)
61cm(24inch)hose
HoseassemblywiththeT-connector1
Cabletie
Hoseclamps
Wireharness1
Cabletie

Nopartsrequired

Qty.

10

Use

–

–

2
2
1

2
5

–

Preparingtheunit.

Removingthelowpressurehoses.

Installingthehydraulicsystemcooling
assembly.

Installingthelowpressurehoses.

Routingthewireharness.

Bleedingthehydraulicsystem.

©2012—TheT oro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Registeratwww.T oro.com.

OriginalInstructions(EN)

PrintedintheUSA.

AllRightsReserved

*3373-396*B

1

1

2

3

g018697

1

2 3

1

g018698

PreparingtheUnit

NoPartsRequired

Procedure

WARNING

Hydraulicuidescapingunderpressurecan
penetrateskinandcauseinjury.

Figure1

•Makesureallhydraulicuidhosesandlinesare
ingoodconditionandallhydraulicconnections
andttingsaretightbeforeapplyingpressureto
thehydraulicsystem.

•Keepyourbodyandhandsawayfrompin
holeleaksornozzlesthatejecthighpressure
hydraulicuid.

•Usecardboardorpapertondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulicsystem
beforeperforminganyworkonthehydraulic
system.

•Seekimmediatemedicalattentionifuidis
injectedintoskin.

1.Positionmachineonalevelsurface.

2.Disengagethepowertakeoff(PTO)andsetthe
parkingbrake.

3.Stoptheengineandwaitforallmovingpartstostop
beforeleavingtheoperatingposition.

4.Removethekey.

1.Platformup

2.Platformdown

9.Removethehairpincottersecuringtherearcushion
bracket(Figure2).

10.Slidethebushingnexttothemachine(Figure2).

11.Lowertherearcushionbracketontotheplatform
(Figure1andFigure2).

3.Pulltheknobouttorelease
theplatform

Figure1).

Figure33).

Figure2

1.Hairpincotter3.Rearcushionbracket

2.Bushing

5.Removethebatterycover(

6.Removethenegativebatterycablefromthebattery.

7.Lowerthemowerdecktothelowestheight-of-cut
setting.

8.Lowertheplatform(

2

2

1

g01842 5

2

3

g018420

1

2

g018419

1

2

RemovingtheLowPressure
Hoses

NoPartsRequired

Procedure

1.Removethebolt,nut,andR-clampsecuringthehose
connectingtheright-handpumptothehydraulic
reservoirbracket(Figure3).

Note:DiscardtheR-clamp.

Figure4

Yourmodelmayvaryfromthisdiagram.

Figure3

1.Boltsecuringthehose3.Frontconnectoron
hydraulicreservoirtank

2.Hydraulicreservoirbracket

2.Removethelowpressurehosefromthefronttting
underthehydraulicreservoirtank(Figure3).

Note:Draintheoilintoanoilpan.

1.Cabletie

1.Cabletie

2.Hoses

Figure5

Yourmodelmayvaryfromthisdiagram.

2.Lowpressurehoses

3.Removeanddiscardthecabletiessecuringthelow
pressurehoses(

Figure4andFigure5).

3

4.Removethelowpressurehosefromtheright-hand

1

g018421

1

g018422

1

g018424

pump(Figure6).

Figure6

1.Disconnecthere

5.Removethelowpressurehosefromtheleft-hand
pump(Figure7).

Figure8

1.Removehose

3

InstallingtheHydraulic SystemCoolingAssembly

Partsneededforthisprocedure:

1Hydraulicsystemcoolingassembly

2

Bolt(5/16x3/4inch)

2

Nut(5/16inch)

Procedure

1.Usinga5/16inchdrillbit,reamtheholeinthe
reservoirbracket(Figure9).

Figure7

1.Disconnecthere

6.Removethehosefromtheunit(Figure8).

4

1

g018426

g018327

1

g018427

1

2

2

Figure11

1.Hole

2.Locatetheserialnumberdecal.

Figure10

1.Locationofthemodelandserialnumbers

Figure9

1.Uppersetoftheholesfor
2011models.

2.Lowersetofholesfor
2009and2010models.

3.Determineyourmodelyearfromtheserialnumber.

•2009—serialnumberrange290000001andup

•2010—serialnumberrange310000001andup

•2011—serialnumberrange311000001andup

4.Locatethemountingholesinthecoolingassemblythat
willberequiredforyourunit.

Note:Usetheuppersetoftheholesfor2011models.
Usethelowersetofholesfor2009and2010models.

5

5.Alignthecoolingassemblytothereservoirbracket

g018429

1

g018428

1

1

g018451

(Figure12).

Figure12

1.Coolingassembly

6.Usingthecorrectsetofholesforyourunit,secure
therightsideofthecoolingassemblytothehydraulic
reservoirbracketusingabolt(5/16x1inch)andnut
(5/16inch)(Figure12andFigure13).

Figure14

1.Boltandnut

8.Securethecoolerassemblyusingtheboltandnut
(Figure14).

4

Figure13

1.Boltandnut

7.Usingthecoolerbracketasatemplate,drillthesecond
5/16inchholeintothereservoirbracket(Figure12,
Figure13,andFigure14).

InstallingtheLowPressure Hoses

Partsneededforthisprocedure:

1

61cm(24inch)hose

1HoseassemblywiththeT-connector

2

Cabletie

5

Hoseclamps

Procedure

Note:Thehosefromtheleft-handpumpconnectstothe

radiatorinletport(Figure15).

6

1

2

3

g018473

1.Coolingassemblyinlet

g018472

1

2

3

4

5

6

7

g018452

1

2

1

g018690

2

3

4

5

port

2.Hosefromleft-handpump
connectingtocooling
assemblyinletport

Figure15

3.Left-handpump

Note:Securethehosewithahoseclampsothatthe
tabsoftheclamparepointingdownwardasshown.

Figure17

1.Left-handpump

2.Returnport

2.Routethehoseandinstalltheotherendtothecooling
assemblyinlet.

Note:Thehosefromtheright-handpumpconnectstoa
T-connector.TheshorthosecomingofftheT-connector
goestotheradiatorexitport.Theotherhoseconnectsto
thehydraulicreservoirtank

1.Hydraulicreservoirtank5.Right-handpump

2.Coolingassembly

3.Shorthose

4.Hosefromtheright-hand
pumpconnectingtothe
T-connector

Figure16

6.T-connector

7.Hoseconnectingtothe
hydraulicreservoir

Note:Rotatetabsonhoseclampasshownin
Figure18.

Figure18

1.CoolingAssemblyoutlet

2.CoolingAssemblyInlet

3.Hosecomingfromthe
left-handpump

4.Hosegoingtothe
T-connector

5.Tabsonclamp

1.Installthe61cm(24inch)hosetoleft-handpump
(Figure17.

3.InstallthehoseconnectingtheT-connectortothe
coolingassemblyoutlet(Figure16andFigure19).

7

Note:Rotatetabsonhoseclampasshownin

1

g018454

2

g018455

1

2

g018456

1

g018457

1

Figure18.

Figure19

1.Hosegoingtothe
hydraulicreservoirtank

2.T-connector

4.InstallthehoseconnectingtheT-connectortothe
right-handpump(Figure16andFigure20).

Note:Rotatethetabsofthehoseclampsotheyare
pointingdownward.

Figure21

1.Cabletie

Figure22

Figure20

1.Right-handpump2.Hoseclamp

1.Cabletie

6.Movethedeckfromthehighestheightofcuttothe
lowestheightofcut.

5.Securethehosesusing2cableties(Figure21and

•Repeatthisstepwhileobservingthehoses.

Figure22).

•Verifythatthehosesdonotcontacthotsurfaces,

sharpedges,ormovingcontrolslinkage.

•Adjustthecabletiesandhoseroutingifneededto

avoidcontactforallheightofcutpositions.

8

5

g018478

1

2

3

4

g018458

1

1

g018459

RoutingtheWireHarness

Partsneededforthisprocedure:

1Wireharness

10

Cabletie

Procedure

1.Beforestartingthisprocedure,observehowyouwill
routethewireharness.

Figure24

1.Coolingassemblyconnector

3.Routethecoolingassemblywireharnessunderneath
allthehosesandthroughthepumpcompartment
(

Figure25).

Figure23

1.Routingthewireharness
tothebattery

2.Relay4.Wireharnesstothe

2.Connectthecoolingassemblyconnectortothewire
harness(Figure24).

3.Relaysocket

coolingassembly

Figure25

1.Coolingassemblywireharness

4.Continueroutingthecoolingassemblywireharness
betweenthebrakerodandframe(Figure26).

9

1

g018460

Figure26

1

2

g018475

1

g018461

1

g018691

2

1.Coolingassemblywireharness

5.Removetherelayfromthewireharnessrelaysocket
(ifinstalled).

7.Installtherelayintotherelaysocket.

8.Removeanddiscardtheprotectivecapfromtheend
oftheAUXconnectoronthewireharnessnearthe
fusebox.

9.Connectthecoolingassemblywireharnesstothe
wireharnessAUXconnectorlocatedatthefuseblock
(Figure28).

6.Installtherelaysockettotheframecrossbrace.

•For2011modelssecuretherelaysockettothe

crossbraceusinganutandbolt(Figure27).

•For2009and2010modelssecuretherelaysocket

tothecrossbraceand/orwireharness,usinga
cabletie.

Note:Thereisnoholeinthecrossbraceon2009
and2010modelsforsecuringtherelaysocketto
thecrossbrace.

Figure28

1.Wireharnesses

10.Securethewireharnesstothehosegoingtothe
coolingassemblyinletwithacabletie(

Figure29).

Figure27

2011modelshown

1.Relaysocket2.Nut

Figure29

1.Cabletie

2.Wireharness

11.Securetheclipattachedtothewireharnesstothe
frame(Figure30).

10

1

g018689

Figure30

1

g018463

g018464

1

g018477

3

1.Attachthecliponthewireharnesstotheframe

Figure32

1.Cabletie

12.Securethecoolingassemblywireharnesstothe
R-clamplocatedinthelowerleftfrontcornerofthe
controltower,usingacabletie(Figure31).

Figure31

1.Cabletie

13.Removetheslackfromthewireharnesswhereitpasses
throughthepumpcompartment.

14.Securethecoolingassemblywireharnesstothemain
wireharnessusingacabletie(Figure32).

15.Routetheotherendofthewireharnesstothebattery
(Figure23)and(Figure33).

Figure33

1.Wingnut4.Positivebattery
connection

2.Batterycover5.Battery

3.Wireharnesstothe

positivebatteryterminal

16.Opentheredcapcoveringthepositivebatteryterminal.

17.Installtheconnectoronthecoolingassemblywire
harnesstothepositivebatteryterminal(Figure33).

18.Installtheredcap.

19.Installthenegativebatterycabletothebattery.

11

20.Securethepathofthecoolingassemblywireharness

1

g018465

G012005

4 1 3

2

usingthecableties.

21.Installthebatterycover.

22.Installthe15ampfuseintothefuseblock(Figure34).

Figure34

1.Fuse

23.TurnthekeytotheRunpositionandverifytheelectric
fanisrunning,thenturnthekeytothestopposition.

24.Installtherearcushionbracket(Figure2).

Figure35

1.Cap3.Colduidlevel-full

2.Bafe4.Hotuidlevel-full

2.Removecapfromllerneck.(Figure35).

3.Adduidtothereservoiruntilitreachesthecoldlevel
ofthebafe(Figure35).

4.Raisetherearofthemachineupontojackstandshigh
enoughtoraisethedrivewheelsofftheground.

5.Disengagetheparkingbrake.

6.Starttheengineandmovethethrottlecontroltoidle
position.

Note:Ifthedrivewheeldoesnotrotate,itispossible
toassistthepurgingofthesystembycarefullyrotating
thetireintheforwarddirection.

6

BleedingtheHydraulicSystem

NoPartsRequired

Procedure

Note:HydraulicOilType:Toro®HYPR-OIL™500

hydraulicoilorMobil®115W -50syntheticmotoroil.

1.Cleanareaaroundcapandllerneckofhydraulictank
(Figure35).

7.Checkthehydraulicuidlevelasitdropsadduidas
requiredtomaintaintheproperlevel.

8.Repeatthisprocedurefortheoppositewheel.

9.Installthecaponthellerneck.

10.Thoroughlycleantheareaaroundeachofthecharge
pumphousings.

11.Checkthecoolingsystemconnectionsforanyleaks.

12