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Toro GT series Service Manual
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Toro GT series Service Manual

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Summary of Contents for Toro GT series

  • Page 1 Residential Products Garden Tractor Garden Tractor GT Series GT Series Service Manual Service Manual...

  • Page 2: About This 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.
  • Page 3 THIS PAGE INTENTIONALLY LEFT BLANK. GT Series Tractors Service Manual...

  • Page 4: Table Of Contents

    Throttle Cable Replacement.......................3-65 Throttle Cable Removal .......................3-65 ....................3-70 Choke Cable Replacement......................3-74 Choke Cable Removal ......................3-74 ......................3-77 Deck Lift Link Replacement......................3-81 Deck Lift Link Removal ......................3-81 .....................3-83 Deck Lift Cable Replacement .....................3-85 Deck Lift Cable Removal .....................3-85 ....................3-89 GT Series Tractors Service Manual...
  • Page 5 Transmission Drive Belt Replacement ..................6-1 Transmission Drive Belt Removal ..................6-1 ..................6-3 Hydrostatic Transmission Replacement ..................6-6 Hydrostatic Transmission Removal..................6-6 ...................6-13 Purging the System ........................6-20 Fluid Change ..........................6-21 ........................6-22 Brake Puck Replacement ......................6-24 Brake Puck Removal ......................6-24 ......................6-27 ......................6-30 GT Series Tractors Service Manual...
  • Page 6 54” Mower Deck Spindle Service ....................7-41 ..............7-45 ..............7-45 ..............7-47 Mower Deck Pulley Replacement (50” & 54” Mower Decks)............7-49 Mower Deck Pulley Removal ....................7-49 ....................7-50 Electrical Electrical System ..........................8-1 GT2100, GT2200, GT2300 Wiring Diagram.................8-2 GT2100, GT2200, GT2300 Wiring Diagram cont.................8-3 GT Series Tractors Service Manual...
  • Page 7 TABLE OF CONTENTS THIS PAGE INTENTIONALLY LEFT BLANK. GT Series Tractors Service Manual...

  • Page 8: Safety Information

    Always test the safety interlock system after making while the unit is running or shortly after it has been adjustments or repairs on the machine. Refer to the running. Electrical section in this manual for more information. GT Series Tractors Service Manual...
  • Page 9 GT Series Tractors Service Manual...
  • Page 10 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.
  • Page 11 Note: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. GT Series Tractors Service Manual...
  • Page 12 Note: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. GT Series Tractors Service Manual...
  • Page 13 200 ± 100 in-lb torque values. All torque values are based on non- lubricated fasteners. Conversion Factors in-lb X 11.2985 - N-cm N-cm X - 0.08851 = in-lb ft-lb X 1.3558 = N-m N-cm X 0.73776 - ft-lb GT Series Tractors Service Manual...

  • Page 14: Equivalents And Conversions

    15/16 0.9375 23.812 29/64 0.453125 11.509 61/64 0.953125 24.209 15/32 0.46875 11.906 31/32 0.96875 24.606 31/64 0.484375 12.303 63/64 0.984375 25.003 0.5000 12.700 1.000 25.400 1 mm = 0.03937 in. 0.001 in. = 0.0254 mm GT Series Tractors Service Manual...

  • Page 15: U.s. To Metric Conversions

    Kilopascal Pressure 1.356 Foot-pounds Newton-Meters Foot-pounds Kilogram-Meters Work 0.1383 Inch-pounds Kilogram-Centimeters 1.152144 Quarts Liters 0.9463 Liquid Volume Gallons Liters 3.785 Gallons/Minute Liters/Minute 3.785 Liquid Flows Fahrenheit Celsius 1. Subtract 32° Temperature 2. Multiply by 5/9 GT Series Tractors Service Manual...
  • Page 16 Alternator: 15 amp regulated Fuse: 20 amp 50” (127cm) Three Blade 50” (127cm) Three Blade 54” (138cm) Three Blade 12 Gauge Steel (2.7mm) 12 Gauge Steel (2.7mm) 12 Gauge Steel (2.7mm) 1.5” to 4” (3.8 to 10cm) GT Series Tractors Service Manual...
  • Page 17 SPECIFICATIONS GT Series Tractors Service Manual...

  • Page 18: Chassis

    Front Pivot Axle Removal 1. Disconnect the negative and then the positive battery cable. 2. Remove the mower deck. Refer to: 3. Remove the 2 hairpin cotters and clevis pins secur- Fig 002 Fig 001 Fig 003 GT Series Tractors Service Manual...
  • Page 19 CHASSIS 8. Apply the parking brake. front axle can be accessed. Fig 004 Fig 006 11. Remove and discard the cotter pin from the 2 axles Fig 005 Fig 007 GT Series Tractors Service Manual...
  • Page 20 CHASSIS Note: There is an inner and an outer bushing in- cluded with the wheel assembly: Fig 008 Fig 010 Fig 009 Fig 011 GT Series Tractors Service Manual...
  • Page 21 CHASSIS Fig 014 Fig 012 Fig 015 Fig 013 GT Series Tractors Service Manual...
  • Page 22 18. Remove the axle assembly from the front pivot axle 22. Remove the 2 screws securing the bumper to the Fig 016 Fig 018 from the opposite side of the pivot axle. Fig 017 Fig 019 GT Series Tractors Service Manual...
  • Page 23 CHASSIS securing the left and right pivot supports to the frame Fig 020 Fig 022 bar and pivot support brackets to the frame (Fig. Fig 021 Fig 023 GT Series Tractors Service Manual...
  • Page 24 CHASSIS Fig 024 Fig 026 Fig 027 Fig 025 GT Series Tractors Service Manual...
  • Page 25 1. Position and support the front pivot axle to the frame. Fig 030 Fig 028 and loosely install the other bolt through the pivot 2. Position the pivot bar bracket onto the frame (Fig. Fig 031 Fig 029 GT Series Tractors Service Manual...
  • Page 26 CHASSIS the pivot support bracket and pivot bar bracket to the port bracket and axle pivot bar to the frame (Fig. Fig 034 Fig 032 Fig 035 Fig 033 GT Series Tractors Service Manual...
  • Page 27 CHASSIS 11. Install 2 screws securing the bumper to the frame (1 Fig 038 Fig 036 Fig 039 Fig 037 GT Series Tractors Service Manual...
  • Page 28 CHASSIS 13. Slide the axle assemblies into the front pivot axle Fig 040 Fig 042 Fig 043 Fig 041 GT Series Tractors Service Manual 3-11...
  • Page 29 Note: There is an inner and an outer bushing in- cluded with the wheel assembly: Fig 046 Fig 044 18. Install a new cotter pin into each axle to secure the Fig 047 Fig 045 3-12 GT Series Tractors Service Manual...
  • Page 30 CHASSIS 22. Position the hood onto the hood support brackets Fig 048 Fig 050 21. Install push nut caps onto each of the axle Fig 051 Fig 049 GT Series Tractors Service Manual 3-13...
  • Page 31 CHASSIS Fig 054 Fig 052 to the bushings on the inside of the wheel assembly Fig 055 Fig 053 GT Series Tractors Service Manual...

  • Page 32: Axle Assembly Replacement

    CHASSIS Axle Assembly Replacement Axle Assembly Removal 1. Disconnect the negative and then the positive battery cable. Fig 056 28. Install the mower deck. Refer to: Fig 057 GT Series Tractors Service Manual...
  • Page 33 CHASSIS front axle can be accessed. Fig 058 Fig 060 8. Remove and discard the cotter pin from the axle Fig 059 Fig 061 GT Series Tractors Service Manual...
  • Page 34 CHASSIS Note: There is an inner and an outer bushing in- cluded with the wheel assembly: Fig 062 Fig 064 Fig 063 Fig 065 GT Series Tractors Service Manual...
  • Page 35 CHASSIS Fig 068 Fig 066 Fig 069 Fig 067 3-18 GT Series Tractors Service Manual...
  • Page 36 CHASSIS Fig 070 Fig 072 Axle Assembly Installation 1. Slide the axle assembly into the front pivot axle (Fig. Fig 073 Fig 071 GT Series Tractors Service Manual...
  • Page 37 CHASSIS Fig 074 Fig 076 Note: There is an inner and an outer bushing in- cluded with the wheel assembly: Fig 077 Fig 075 GT Series Tractors Service Manual...
  • Page 38 CHASSIS Fig 078 Fig 080 Fig 079 Fig 081 GT Series Tractors Service Manual 3-21...
  • Page 39 CHASSIS to the bushings on the inside of the wheel assembly Fig 082 Fig 084 Fig 085 Fig 083 3-22 GT Series Tractors Service Manual...

  • Page 40: Steering Wheel Replacement

    CHASSIS Steering Wheel Replacement 3. Remove the washer from the steering wheel (Fig. Steering Wheel Removal Fig 088 Fig 086 2. Remove the screw securing the steering wheel to Fig 089 Fig 087 GT Series Tractors Service Manual 3-23...
  • Page 41 CHASSIS Steering Wheel Installation 3. Install a screw to secure the steering wheel to the 1. Slide the steering wheel onto the steering shaft (Fig. Fig 092 Fig 090 Fig 093 Fig 091 GT Series Tractors Service Manual...
  • Page 42 CHASSIS drain the fuel into a suitable container. Slide the fuel clamp to secure. Replace the fuel cap onto the fuel Fig 095 Fig 094 3. Remove the mower deck. Refer to: Fig 096 GT Series Tractors Service Manual...
  • Page 43 CHASSIS Fig 097 Fig 099 steering gear assembly. 8. Secure the steering gear in place with a punch and remove the nut from the end of the steering shaft Fig 100 Fig 098 GT Series Tractors Service Manual...
  • Page 44 Fig 101 Fig 103 2. Slide the steering shaft up into the tower from below. Insert the lower end of the steering shaft into the hex Fig 104 Fig 102 GT Series Tractors Service Manual...
  • Page 45 3. Raise the machine to access the steering gear assembly. the steering gear in place with a punch and tighten Note: The washer is installed above the steering Fig 107 Fig 105 Fig 108 Fig 106 3-28 GT Series Tractors Service Manual...

  • Page 46: Electric Pto Clutch Replacement

    1. Remove the mower deck. Refer to: Fig 109 a screw securing each support rod to the dash Fig 111 3. Raise the machine so the electric PTO clutch can be accessed. the frame. Fig 110 GT Series Tractors Service Manual...
  • Page 47 CHASSIS Electric PTO Clutch Installation 1. Apply anti-seize compound to the crankshaft (Fig. Fig 112 Fig 114 Fig 113 Fig 115 GT Series Tractors Service Manual...
  • Page 48 3. Align the clutch keyway with the key on the crank- shaft and slide the clutch and spacer assembly onto frame. Fig 116 Fig 118 8. Install the mower deck. Refer to: Fig 117 GT Series Tractors Service Manual 3-31...

  • Page 49: Fuel Tank Replacement

    Fuel Tank Replacement Fuel Tank Removal Fig 121 Fig 119 2. Remove the fuel cap. Slide the hose clamp down the drain the fuel into a suitable container. Replace the Fig 122 Fig 120 3-32 GT Series Tractors Service Manual...
  • Page 50 CHASSIS Fuel Tank Installation Fig 125 Fig 123 2. Position the 2 fuel tank support rods and install a screw securing each support rod to the dash sup- Fig 126 Fig 124 GT Series Tractors Service Manual 3-33...

  • Page 51: Hood Replacement

    CHASSIS Hood Replacement Hood Removal Fig 129 Hood Installation Fig 127 1. Position the hood onto the hood support brackets Fig 130 Fig 128 GT Series Tractors Service Manual...

  • Page 52: Fender Replacement

    CHASSIS Fender Replacement Fender Removal 2. Disconnect the battery cable from the negative Fig 131 Fig 133 3. Disconnect the battery cable from the positive Fig 132 Fig 134 GT Series Tractors Service Manual...
  • Page 53 CHASSIS Fig 135 Fig 137 Fig 136 Fig 138 GT Series Tractors Service Manual...
  • Page 54 CHASSIS Fig 139 Fig 141 the extension spring from the seat mount bracket Fig 142 Fig 140 GT Series Tractors Service Manual...
  • Page 55 CHASSIS 12. Remove the height-of-cut grip from the height-of-cut Fig 143 Fig 145 13. Pry up the front portion of the left hand foot pad (Fig. Fig 144 Fig 146 3-38 GT Series Tractors Service Manual...
  • Page 56 CHASSIS Fig 149 Fig 147 fender. Cut the decal to expose the screw heads Fig 148 Fig 150 A. TORX screw and washer B. Hex head bolt and lock washer GT Series Tractors Service Manual...
  • Page 57 CHASSIS Fig 151 Fig 153 21. Remove the 2 bolts securing the speed control lever Fig 154 Fig 152 GT Series Tractors Service Manual...
  • Page 58 CHASSIS Fender Installation 3. Install 2 bolts securing the speed control lever to the Fig 157 Fig 155 2. Position the speed control pedal to the speed control Fig 158 Fig 156 GT Series Tractors Service Manual...
  • Page 59 CHASSIS Fig 161 Fig 159 A. TORX screw and washer B. Hex head bolt and lock washer Fig 162 Fig 160 GT Series Tractors Service Manual...
  • Page 60 CHASSIS 11. Position the seat assembly onto the fender (Fig. er and nut securing the fender to the frame (Fig. Fig 165 Fig 163 Fig 166 Fig 164 GT Series Tractors Service Manual...
  • Page 61 CHASSIS Fig 167 Fig 169 install an extension spring onto the seat mount Fig 170 Fig 168 GT Series Tractors Service Manual...
  • Page 62 CHASSIS Fig 171 Fig 173 Fig 172 Fig 174 GT Series Tractors Service Manual...

  • Page 63: Tower Replacement

    21. Connect the black battery cable to the negative Tower Removal drain the fuel into a suitable container. Replace the Fig 175 23. Operate the tractor to ensure all controls and the seat switch operate properly. Fig 176 GT Series Tractors Service Manual...
  • Page 64 CHASSIS Fig 179 Fig 177 Fig 180 Fig 178 GT Series Tractors Service Manual...
  • Page 65 CHASSIS 11. Remove the fuse holder from the tower support by Fig 181 Fig 183 Fig 184 Fig 182 GT Series Tractors Service Manual...
  • Page 66 CHASSIS 13. Remove the bolt and nut securing the control knob Fig 185 Fig 187 Fig 186 Fig 188 GT Series Tractors Service Manual...
  • Page 67 CHASSIS Fig 189 Fig 191 Fig 190 Fig 192 GT Series Tractors Service Manual...
  • Page 68 21. Position the throttle in the slow position and fully 23. Remove the choke cable from the cable clamp and remove the z-bend from the engine control lever Fig 193 Fig 195 Fig 194 Fig 196 GT Series Tractors Service Manual...
  • Page 69 CHASSIS Fig 197 Fig 199 28. Remove the 2 screws and washers securing the top of the tower to the top of the support brackets (Fig. Fig 198 Fig 200 GT Series Tractors Service Manual...
  • Page 70 CHASSIS 31. Remove the 2 screws securing the left tower support Fig 203 Fig 201 32. Remove the left tower support from the frame (Fig. Fig 204 Fig 202 GT Series Tractors Service Manual...
  • Page 71 CHASSIS 33. Repeat steps 31 and 32 to remove the right tower support. Fig 207 Fig 205 Fig 208 Fig 206 GT Series Tractors Service Manual...
  • Page 72 CHASSIS Tower Installation 38. Remove the screw securing the bent lever rod to the parking brake lever assembly into the tower (Fig. Fig 209 Fig 211 Fig 210 Fig 212 GT Series Tractors Service Manual...
  • Page 73 CHASSIS 2. Install the screw securing the bent lever rod to the Fig 213 Fig 215 Fig 214 Fig 216 GT Series Tractors Service Manual...
  • Page 74 CHASSIS Fig 217 Fig 219 8. Install 2 screws securing the left tower support to the Fig 218 Fig 220 GT Series Tractors Service Manual...
  • Page 75 CHASSIS 12. Install 2 screws and washers securing the top of the support. Fig 223 Fig 221 13. Insert the cruise control rod and park brake rod into Fig 224 Fig 222 GT Series Tractors Service Manual...
  • Page 76 CHASSIS park brake rod securing them to the levers (Fig. Fig 225 Fig 227 Fig 228 Fig 226 GT Series Tractors Service Manual...
  • Page 77 CHASSIS Fig 229 Fig 231 18. Insert the choke cable z-bend into the choke lever Fig 230 Fig 232 GT Series Tractors Service Manual...
  • Page 78 21. Install 2 screws securing the throttle assembly to the 23. Install a bolt and nut securing the control knob to the Fig 233 Fig 235 22. Push the knob onto the throttle control lever (Fig. Fig 236 Fig 234 GT Series Tractors Service Manual...
  • Page 79 CHASSIS Fig 237 Fig 239 28. Plug the wire harness into the electric PTO switch Fig 238 Fig 240 GT Series Tractors Service Manual...
  • Page 80 CHASSIS 31. Position the 2 fuel tank support rods and install a screw securing each support rod to the dash Fig 241 Fig 243 Fig 242 Fig 244 GT Series Tractors Service Manual...
  • Page 81 CHASSIS Fig 246 Fig 245 Fig 247 GT Series Tractors Service Manual...

  • Page 82: Throttle Cable Replacement

    CHASSIS Throttle Cable Replacement Throttle Cable Removal 2. Disconnect the battery cable from the negative Fig 248 Fig 249 seat switch operate properly. GT Series Tractors Service Manual...
  • Page 83 CHASSIS Fig 252 Fig 250 Fig 253 Fig 251 GT Series Tractors Service Manual...
  • Page 84 CHASSIS 8. Remove the fuel cap. Slide the hose clamp down the drain the fuel into a suitable container. Replace the Fig 256 Fig 254 Fig 257 Fig 255 GT Series Tractors Service Manual...
  • Page 85 CHASSIS 12. Remove the bolt and nut securing the control knob Fig 258 Fig 260 Fig 259 Fig 261 GT Series Tractors Service Manual...
  • Page 86 18. Remove the throttle cable assembly from the cable throttle and choke cables to the engine bracket (Fig. tie and R-clamp located on the left side of the engine Fig 262 Fig 264 Fig 265 Fig 263 GT Series Tractors Service Manual...

  • Page 87: Throttle Cable Installation

    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 Fig 268 Fig 266 Fig 269 Fig 267 GT Series Tractors Service Manual...
  • Page 88 CHASSIS Fig 270 Fig 272 Fig 273 Fig 271 GT Series Tractors Service Manual...
  • Page 89 CHASSIS Fig 274 Fig 276 a screw securing each support rod to the dash Fig 275 Fig 277 GT Series Tractors Service Manual...
  • Page 90 CHASSIS Fig 280 Fig 278 Fig 279 Fig 281 properly. GT Series Tractors Service Manual...

  • Page 91: Choke Cable Replacement

    CHASSIS Choke Cable Replacement Choke Cable Removal 2. Disconnect the battery cable from the negative Fig 283 Fig 282 Fig 284 GT Series Tractors Service Manual...
  • Page 92 CHASSIS 8. Remove the fuel cap. Slide the hose clamp down the drain the fuel into a suitable container. Replace the Fig 285 Fig 287 Fig 286 Fig 288 GT Series Tractors Service Manual...
  • Page 93 Fig 289 Fig 291 throttle and choke cables to the engine bracket (Fig. 13. Remove the nut securing the choke control to the Fig 290 Fig 292 GT Series Tractors Service Manual...
  • Page 94 CHASSIS 2. Route the choke cable around the left side of the Fig 293 Fig 295 Choke Cable Installation 1. Insert the choke cable assembly through the tower Fig 296 Fig 294 GT Series Tractors Service Manual...
  • Page 95 CHASSIS 3. Install a nut securing the choke cable control to the Fig 297 Fig 299 Fig 298 Fig 300 GT Series Tractors Service Manual...
  • Page 96 CHASSIS 8. Position the 2 fuel tank support rods and install a screw securing each support rod to the dash Fig 303 Fig 301 Fig 302 Fig 304 GT Series Tractors Service Manual...
  • Page 97 CHASSIS Fig 305 13. Install 2 screws securing the bumper to the frame (1 Fig 307 properly. Fig 306 GT Series Tractors Service Manual...
  • Page 98 The rear wheel assembly has been removed for photo purposes. 1. Remove mower deck. Refer to: 2. Place the deck lift handle in the lowest height-of cut position. Fig 309 Fig 308 Fig 310 GT Series Tractors Service Manual 3-81...
  • Page 99 CHASSIS Fig 311 Fig 313 Fig 312 Fig 314 3-82 GT Series Tractors Service Manual...
  • Page 100 3. Insert the lower end of the lift cable into the lift link and install a cotter pin securing the lift cable to the Right side lift cable: The lift cable must be positioned on the outside of the brake rod. Fig 316 Fig 318 GT Series Tractors Service Manual 3-83...
  • Page 101 CHASSIS The lift cable must be positioned between the transmission drive belt and the frame Fig 321 Fig 319 Fig 322 Fig 320 GT Series Tractors Service Manual...
  • Page 102 2. Place the deck lift handle in the highest height-of-cut position. Fig 323 8. Connect the black battery cable to the negative Fig 325 Fig 324 11. Operate the tractor to ensure all controls operate properly. GT Series Tractors Service Manual...
  • Page 103 CHASSIS Fig 328 Fig 326 Fig 329 Fig 327 GT Series Tractors Service Manual...
  • Page 104 12. Remove the e-clip from the end of the lift shaft Fig 330 Fig 332 13. Slide the lift shaft over as far as possible and re- move the upper end of the cable from the lift shaft Fig 331 Fig 333 GT Series Tractors Service Manual...
  • Page 105 CHASSIS lift link. Remove the end of cable from the lift link Fig 336 Fig 334 Fig 337 Fig 335 3-88 GT Series Tractors Service Manual...
  • Page 106 CHASSIS 1. Place the deck lift handle in the lowest height-of cut position. Fig 340 Fig 338 position. far as possible and install the upper end of the cable Fig 341 Fig 339 GT Series Tractors Service Manual...
  • Page 107 8. Place the deck lift handle in the lowest height-of cut position. Fig 344 hole in the frame located in front of the roller pulley 11. Install a nut onto the shoulder bolt to secure the Fig 343 Fig 345 GT Series Tractors Service Manual...
  • Page 108 Right side lift cable: The lift cable must be posi- tioned on the outside of the brake rod. Fig 348 Fig 346 The lift cable must be positioned between the transmission drive belt and the frame Fig 349 Fig 347 GT Series Tractors Service Manual...
  • Page 109 CHASSIS Fig 350 Fig 352 properly. Fig 351 GT Series Tractors Service Manual...
  • Page 110 Replacement 1. Remove the mower deck. Refer to: 2. Place the deck lift handle in the highest height-of-cut position. 3. Remove the handle grip from the deck lift handle Fig 354 Fig 353 Fig 355 GT Series Tractors Service Manual...
  • Page 111 CHASSIS Fig 358 Fig 356 Fig 357 Fig 359 GT Series Tractors Service Manual...
  • Page 112 Fig 360 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 Fig 363 Fig 361 GT Series Tractors Service Manual...
  • Page 113 Remove the assembly through the right side Fig 366 A. Torsion spring C. Shaft assembly B. Handle Fig 364 Fig 367 Fig 365 GT Series Tractors Service Manual...
  • Page 114 (Fig. Fig 368 Fig 370 2. Install the torsion spring securing the handle to the Fig 371 Fig 369 A. Torsion spring C. Shaft assembly B. Handle GT Series Tractors Service Manual...
  • Page 115 CHASSIS Fig 372 Fig 374 the upper end of the cable assembly into the hole on machine. 8. Place the deck lift handle in the highest height-of-cut position. Fig 373 Fig 375 GT Series Tractors Service Manual...
  • Page 116 CHASSIS Fig 378 Fig 376 Fig 379 Fig 377 GT Series Tractors Service Manual...
  • Page 117 CHASSIS Fig 380 Fig 382 18. Place the deck lift handle in the highest height-of-cut position. properly. Fig 381 GT Series Tractors Service Manual...
  • Page 118 1. Place the steering wheel in position for straight ahead travel. from the inside of the left rim to the inside of the right Fig 384 less than the measurement taken behind the axle. Fig 383 GT Series Tractors Service Manual...
  • Page 119 CHASSIS Fig 385 8. Replace hex nut and lock washer and retighten the GT Series Tractors Service Manual...

  • Page 120: Engine

    (Fig. 386). Fig 388 PICT-7497 Fig 386 PICT-7349 6. Remove the 4 engine mounting bolts (Fig. 389). 3. Disconnect the battery cable from the positive battery terminal (Fig. 387). Fig 389 PICT-7620 Fig 387 PICT-7351a GT Series Tractors Service Manual...
  • Page 121 (1 bolt on the left and 1 on the right) (Fig. 390). Fig 392 PICT-7423 manifold pipes and remove it from the machine (Fig. Fig 390 PICT-7245 393). 10. Remove the bumper (Fig. 391). Fig 393 PICT-7425 Fig 391 PICT-7417 GT Series Tractors Service Manual...
  • Page 122 (Fig. 397). 14. Loosen the cable clamp securing the throttle and choke cable to the engine bracket (Fig. 395). Fig 397 PICT-7601 Fig 395 PICT-7596 GT Series Tractors Service Manual...
  • Page 123 20. Remove the nut securing the positive wire to the Fig 398 PICT-7300 starter assembly. Remove the positive wire from the starter assembly (Fig. 401). 18. Slide the other hose clamp down the fuel line and Fig 401 PICT-7610 Fig 399 PICT-7603a GT Series Tractors Service Manual...
  • Page 124 Tighten the oil dipstick. to the bracket on the new engine. 24. Remove the drain hose and reinstall the oil drain cap. throttle/choke cables through. cables get routed through to the new engine. GT Series Tractors Service Manual...

  • Page 125: Engine Installation

    (Fig. 407). Fig 404 PICT-7613 2. Slide the positive wire onto the starter post. Install a nut securing the positive wire to the starter assembly (Fig. 405). Fig 407 PICT-7603 Fig 405 PICT-7610 GT Series Tractors Service Manual...
  • Page 126 10. Align the engine mounting holes with the holes in the frame. Install the 4 engine mounting bolts and torque to 16 + 2 ft-lbs. (21.7 + 2.7 Nm) (Fig. 411). Fig 409 PICT-7617 Fig 411 PICT-7620 GT Series Tractors Service Manual...
  • Page 127 “Throttle & Choke Cable Adjustment” on page 4-10. Clutch Installation on page 3-30. 13. Connect the battery cable to the positive battery terminal (Fig. 413). manifold pipes and into position (Fig. 415). Fig 415 PICT-7425 Fig 413 PICT-7351a GT Series Tractors Service Manual...
  • Page 128 Fig 416 PICT-7423 21. Install the hood Refer to “Hood Installation” on page 19. Position the bumper to the frame (Fig. 417). 3-34. 22. Operate the tractor to ensure all controls operate properly. Fig 417 PICT-7417 GT Series Tractors Service Manual...
  • Page 129 PICT-7417 4. 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. 421). Fig 419 PICT-7245 Fig 421 PICT-7423 4-10 GT Series Tractors Service Manual...
  • Page 130 (Fig. 422). 423 and Fig. 424). Fig 422 PICT-7425 Fig 423 PICT-7993 Adjustment: 6. The cable clamp securing the throttle and choke cables must be loose. Fig 424 PICT-7992 GT Series Tractors Service Manual 4-11...
  • Page 131 (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. 4-12 GT Series Tractors Service Manual...

  • Page 132: Gear Drive System

    Fig 429 PICT-7352 5. Remove the battery from the battery tray (Fig. 430). Fig 427 PICT-7349 3. Disconnect the battery cable from the positive bat- tery terminal (Fig. 428). Fig 430 PICT-7353 Fig 428 PICT-7351a GT Series Tractors Service Manual...
  • Page 133 (Fig. 433). Fig 431 PICT-7354 Fig 433 PICT-7628 to remove the transmission drive belt from the trans- mission pulley and variable speed pulley (Fig. 432). Fig 432 PICT-7627a A. Direction to move B. Transmission belt GT Series Tractors Service Manual...
  • Page 134 3. Place the battery into the battery tray (Fig. 436). Fig 434 belt routing iso A. Variable speed pulley D. Transmission drive belt B. Transmission pulley E. Idler spring C. Idler pulley Fig 436 PICT-7353 GT Series Tractors Service Manual...
  • Page 135 6. Connect the black battery cable to the negative battery terminal (Fig. 439). Fig 437 PICT-7352 Fig 439 PICT-7349 5. Connect the red battery cable to the positive battery terminal (Fig. 438). 7. Lower the seat. Fig 438 PICT-7351a GT Series Tractors Service Manual...

  • Page 136: Variable Speed Drive Belt Replacement

    6. Slide the engine pulley off the crankshaft and remove the transmission drive belt from the engine Fig 440 PICT-7632 pulley (Fig. 443). 3. Remove the 4 screws securing the shift cover to the frame (Fig. 441). Fig 443 PICT-7497 Fig 441 PICT-7635 GT Series Tractors Service Manual...
  • Page 137 (Fig. 446). Fig 444 Fig 446 PICT-7640a PICT-7644 8. Tilt the variable speed pulley forward and remove 10. Pull the belt downward (Fig. 447). the belt from it (Fig. 445). Fig 447 PICT-7648 Fig 445 PICT-7642 GT Series Tractors Service Manual...
  • Page 138 (Fig. 449). Fig 450 PICT-7622 2. Route the belt between the two idler pulleys on the center double idler bracket (Fig. 451). Fig 449 PICT-7498 Fig 451 PICT-7649 GT Series Tractors Service Manual...
  • Page 139 4. Route the belt so that it is positioned around the shift 6. Install 4 bolts securing the variable speed pulley rod (Fig. 453). assembly to the transmission (Fig. 455). Fig 453 PICT-7644 Fig 455 PICT-7640a GT Series Tractors Service Manual...
  • Page 140 Clutch Installation” on page 3-30. 9. Slide the shift cover plate into the frame (Fig. 457). Fig 459 PICT-7632 12. Install the transmission drive belt. Refer to “Trans- mission Drive Belt Installation” on page X-XX. Fig 457 PICT-7636 GT Series Tractors Service Manual...

  • Page 141: Cvt Transmission Replacement

    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). Fig 460 PICT-7632 Fig 462 PICT-7636 5-10 GT Series Tractors Service Manual...
  • Page 142 Fig 465 PICT-7710a PICT-7708a 7. Remove the spring washer from the shift rod as- 9. Remove the washer from the shift rod assembly sembly (Fig. 464). (Fig. 466). Fig 464 PICT-7709a Fig 466 PICT-7705a GT Series Tractors Service Manual 5-11...
  • Page 143 15. Tilt the variable speed pulley forward and remove the belt from it (Fig. 470). 12. Remove the 8 lug nuts and remove the 2 wheel assemblies from the wheel hubs (Fig. 468). Fig 470 PICT-7642 Fig 468 PICT-7503a 5-12 GT Series Tractors Service Manual...
  • Page 144 18. Remove the cotter pin securing the front end of the brake control rod to the brake linkage (Fig. 473). Fig 471 PICT-8530 Fig 473 PICT-7659 472). 19. Remove the brake control rod from the linkage (Fig. 474). Fig 472 PICT-7649 Fig 474 PICT-7660 GT Series Tractors Service Manual 5-13...
  • Page 145 (Fig. 477). Fig 475 PICT-7662 Fig 477 PICT-7668 A. Bolt and nut B. Self tapping screw 21. Remove the brake control rod (Fig. 476). Fig 476 PICT-7666 5-14 GT Series Tractors Service Manual...
  • Page 146 Remove the wheel hub from the axle shaft (Fig. 481). 25. Carefully lower the transmission from the machine (Fig. 479). Note: Variable speed pulley will be unsecured. Fig 481 PICT-7679a Fig 479 PICT-7677 GT Series Tractors Service Manual 5-15...
  • Page 147 (Fig. 482). Fig 484 PICT-7684 Fig 482 PICT-7682 2. Install the nut securing the transmission pulley to the 30. Remove the transmission pulley (Fig. 483). transmission (Fig. 485). Fig 483 PICT-7684 Fig 485 PICT-7682 5-16 GT Series Tractors Service Manual...
  • Page 148 (2 bolts and 2 nuts on 4. Repeat step 2 to install the opposite wheel hub each side) (Fig. 489). assembly. 5. Position the variable speed pulley onto the trans- mission (Fig. 487). Fig 489 PICT-7669 Fig 487 PICT-7696 GT Series Tractors Service Manual 5-17...
  • Page 149 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). Fig 493 PICT-7698 Fig 491 PICT-7666 5-18 GT Series Tractors Service Manual...
  • Page 150 13. Install the 2 rear wheel assemblies onto the wheel hubs. Install 8 lug nuts to secure (Fig. 495). 16. Route the transmission drive belt between the two (Fig. 497). Fig 495 PICT-7503a Fig 497 PICT-7702 GT Series Tractors Service Manual 5-19...
  • Page 151 18. Tilt the variable speed pulley forward and route the 20. Lower the machine. drive belt around it into the lower pulley groove (Fig. 499). the transmission shift lever (Fig. 501). Fig 499 PICT-7642 Fig 501 PICT-7705a 5-20 GT Series Tractors Service Manual...
  • Page 152 25. Position the shift cover plate into the fender (Fig. 23. Slide a spring washer (center of the washer up, OD 505). of the washer down) onto the shift rod assembly (Fig. 503). Fig 505 PICT-7636 Fig 503 PICT-7709a GT Series Tractors Service Manual 5-21...

  • Page 153: Cvt Transmission Service

    Drive Belt Installation” on page 5-3. 29. Install the mower deck. Refer to “50” Mower Deck Installation” on page 7-8. 30. Operate the tractor to ensure all controls operate properly. Fig 509 PICT-8274a 5-22 GT Series Tractors Service Manual...
  • Page 154 6. Remove the puck from the transmission housing (Fig. 511). (Fig. 513). Note: Some transmissions have 2 washers (1 on each bolt) between the brake assembly and transmission housing. Fig 513 PICT-8281 Fig 511 PICT-8278a GT Series Tractors Service Manual 5-23...
  • Page 155 PICT-8283 PICT-8285 8. Remove the drive shaft and right hand output shaft 10. Remove the e-ring from the input shaft (Fig. 517). assemblies from the housing (Fig. 515). Fig 517 PICT-8286 Fig 515 PICT-8284 5-24 GT Series Tractors Service Manual...
  • Page 156 PICT-8290a 12. Remove the input shaft assembly from the housing 14. Remove the snap ring that secures the bevel gear to (Fig. 519). the input shaft (Fig. 521). Fig 519 PICT-8289 Fig 521 PICT-8293a GT Series Tractors Service Manual 5-25...
  • Page 157 16. Remove the 2 screws securing the lockout plate 18. Turn the housing over and remove the 3 screws that from the housing (Fig. 523). secure the shift cover to the housing (Fig. 525). Fig 523 PICT-8296 Fig 525 PICT-8299 5-26 GT Series Tractors Service Manual...
  • Page 158 22. If the bearings are being replaced, drive out the (Fig. 527). upper and lower needle bearings from the housing for the input shaft through the hole (Fig. 529). Fig 527 PICT-8304a Fig 529 PICT-8306 GT Series Tractors Service Manual 5-27...

  • Page 159: Differential Axle Assembly Service

    Fig 532 PICT-8318a 27. Slide 2 bearings onto the axle shaft (Fig. 533). Fig 530 PICT-8314a 24. Slide the 2 bearings off the axle (Fig. 531). Fig 533 PICT-8315a Fig 531 PICT-8315a 5-28 GT Series Tractors Service Manual...

  • Page 160: Drive Shaft Assembly Service

    PICT-8314a Fig 535 PICT-8321 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). Fig 536 PICT-8322a GT Series Tractors Service Manual 5-29...
  • Page 161 Fig 539 PICT-8323a PICT-8326a 33. Remove the 41 tooth spur gear from the drive shaft 35. Remove the hi-lo collar assembly from the drive (Fig. 538). shaft (Fig. 540). Fig 538 PICT-8324a Fig 540 PICT-8327a 5-30 GT Series Tractors Service Manual...
  • Page 162 A. Flange bearing (2) F. 10 tooth spur gear B. Flat washer (2) G. Collar assembly C. Drive shaft H. 20 tooth spur gear D. 9 tooth sprocket 41 tooth spur gear E. Hi-Lo Collar GT Series Tractors Service Manual 5-31...
  • Page 163 41. Install a snap ring onto the drive shaft securing the 43. Slide a hi-lo collar assembly onto the drive shaft 10 tooth spur gear (Fig. 546). (Fig. 548). Fig 546 PICT-8331a Fig 548 PICT-8327a 5-32 GT Series Tractors Service Manual...
  • Page 164 Fig 551 PICT-8323 45. Slide a 41 tooth spur gear onto the drive shaft (Fig. 550). 47. Slide a 9 tooth sprocket onto the drive shaft (Fig. 552). Fig 550 PICT-8324a Fig 552 PICT-8322 GT Series Tractors Service Manual 5-33...

  • Page 165: Right Hand Output Shaft Assembly Service

    51. Remove the 16 tooth sprocket and chain from the Right Hand Output Shaft Assembly Service output shaft (Fig. 556). 49. Remove the seal from the output shaft (Fig. 554). Fig 556 PICT-8342a Fig 554 PICT-8339a 5-34 GT Series Tractors Service Manual...
  • Page 166 Fig 557 Fig 559 PICT-8343a PICT-8346a 53. Remove the 2 washers from the output shaft (Fig. 55. Remove the shifter cover from the output shaft (Fig. 558). 560). Fig 558 PICT-8344a Fig 560 PICT-8347a GT Series Tractors Service Manual 5-35...
  • Page 167 A. Flanged bearing F. Ball bearing B. Washer (2) G. 37 tooth spur gear C. Shifter cover H. 27 tooth spur gear D. Output shaft 16 tooth spur gear E. Seal J. 22 link chain 5-36 GT Series Tractors Service Manual...
  • Page 168 Fig 567 PICT-8346a PICT-8343a 61. Slide 2 washers onto the output shaft (Fig. 566). 63. Slide a 16 tooth sprocket and chain onto the output shaft (Fig. 568). Fig 566 PICT-8344a Fig 568 PICT-8342a GT Series Tractors Service Manual 5-37...

  • Page 169: Cvt Transmission Housing Rebuild

    65. Slide a new seal onto the output shaft (Fig. 570). CVT Transmission Housing Rebuild 67. If applicable, press 2 new input shaft needle bear- ings into the housing (Fig. 572). Fig 570 PICT-8339a Fig 572 PICT-8310a 5-38 GT Series Tractors Service Manual...
  • Page 170 Fig 575 PICT-8301a 69. Slide the shift lever assembly into the housing (Fig. 71. Install 3 screws to secure the shift cover to the 574). housing (Fig. 576). Fig 574 PICT-8304a Fig 576 PICT-8299 GT Series Tractors Service Manual 5-39...
  • Page 171 73. Install 2 screws to secure the lockout plate to the 75. Install a snap ring to secure the bevel gear to the housing (Fig. 578). input shaft (Fig. 580). Fig 578 PICT-8296 Fig 580 PICT-8293a 5-40 GT Series Tractors Service Manual...
  • Page 172 PICT-8288 77. Slide the input shaft assembly into the housing (Fig. 79. Install an e-ring onto the input shaft to secure it to 582). the housing (Fig. 584). Fig 582 PICT-8289 Fig 584 PICT-8286 GT Series Tractors Service Manual 5-41...
  • Page 173 V notches in the housing (Fig. 587 and Fig. 588). Fig 585 PICT-8285 Fig 587 PICT-8352a 81. Position the drive shaft and right hand output shaft assemblies into the housing (Fig. 586). Fig 588 PICT-8354a Fig 586 PICT-8284 5-42 GT Series Tractors Service Manual...
  • Page 174 Install the puck into the transmission each bolt) between the brake assembly and housing (Fig. 590). transmission housing. 85. Position the brake assembly to the transmission (Fig. 592). Fig 590 PICT-8281 Fig 592 PICT-8278a GT Series Tractors Service Manual 5-43...

  • Page 175: Variable Speed Pulley Service

    88. Position the upper housing onto the lower housing transmission, refer to “CVT Transmission Removal” on (Fig. 594). page 5-10. 1. Remove the center bolt and washer securing the bearings to the pulley shaft (Fig. 596). Fig 594 PICT-8355a Fig 596 PICT-7685a 5-44 GT Series Tractors Service Manual...
  • Page 176 5. Remove the 2 ball bearings from the bearing cup 3. Remove the 3 nuts and bolts securing the bearing (Fig. 600). cup to the pulley bracket (Fig. 598). Fig 600 PICT-7692a Fig 598 PICT-7688a GT Series Tractors Service Manual 5-45...
  • Page 177 10. With the pulley secure in a vise, position the bracket assembly onto the pulley (Fig. 604). 8. Position the bearing cup assembly onto the bracket (Fig. 602). Fig 604 PICT-7686a Fig 602 PICT-7695a 5-46 GT Series Tractors Service Manual...

  • Page 178: Brake Puck Replacement

    4. Remove the 2 bolts securing the brake assembly to Brake Puck Removal the transmission housing (Fig. 608). 1. Loosen the 4 lug nuts securing the rear wheel to the wheel hub assembly (Fig. 606). Fig 608 PICT-7717a Fig 606 PICT-7502a GT Series Tractors Service Manual 5-47...
  • Page 179 Fig 611 PICT-7721 8. Remove the brake disc from the transmission (Fig. Fig 609 PICT-7719a 612). 6. Remove the brake assembly from the spring (Fig. 610). Fig 612 PICT-7722 Fig 610 PICT-7720a 5-48 GT Series Tractors Service Manual...
  • Page 180 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). Fig 614 PICT-7724a Fig 616 PICT-7725 GT Series Tractors Service Manual 5-49...
  • Page 181 Fig 619 PICT-7728 6. If washers are present, slide a washer onto each of 4. Hook the brake assembly onto the spring (Fig. 618). the bolts (Fig. 620). Fig 618 PICT-7727 Fig 620 PICT-7730 5-50 GT Series Tractors Service Manual...
  • Page 182 10. Tighten the 4 lug nuts to secure the rear wheel to the wheel hub assembly (Fig. 623). Fig 621 PICT-7717a Fig 623 PICT-7502a 8. Slide the wheel onto the wheel hub assembly and install 4 lug nuts (Fig. 622). Fig 622 PICT-7503a GT Series Tractors Service Manual 5-51...

  • Page 183: Brake Adjustment

    3. Retighten the hex nut loosened earlier, leaving a .011” (.028mm) gap between the brake disc and the brake puck. Fig 624 A. Brake disc C. Spring B. Hex nut D. Brake puck (2) 5-52 GT Series Tractors Service Manual...
  • Page 184 5. Remove both hairpin cotters from the main pin on the speed control assembly (Fig. 629). Fig 626 PICT-7670 Fig 629 PICT-7682a Fig 627 PICT-7673a A. Double idler bracket B. 1-3/8” (3.5cm) travel distance GT Series Tractors Service Manual 5-53...
  • Page 185 Fig 632 PICT-7691 Fig 630 PICT-7683 9. Remove the main pin from the speed control as- 7. Remove the Autodrive pedal return spring (Fig. 631). sembly (Fig. 633). Fig 633 PICT-7692 Fig 631 PICT-7684 5-54 GT Series Tractors Service Manual...
  • Page 186 A. Main pin D. Speed control assembly B. Adjustment rod E. Jam nut 11. Tighten the jam nut. C. Lockout bracket 13. Install a washer onto the main pin (Fig. 636). Fig 636 PICT-7683 GT Series Tractors Service Manual 5-55...
  • Page 187 (4.5kg) of pressure applied to the Autodrive pedal). If additional adjustment is needed, go back to step 3 and repeat adjustment. 18. Install the mower deck. Refer to “50” Mower Deck Installation” on page 7-8. Fig 638 PICT-7687a 5-56 GT Series Tractors Service Manual...

  • Page 188: Hydrostatic Drive System

    (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). Fig 643 PICT-7353 Fig 641 PICT-7351a GT Series Tractors Service Manual...
  • Page 189 8. With a small pry bar, release tension from the idler and the idler pulley (Fig. 645). 11. Remove the transmission drive belt from around the crankshaft (Fig. 647). Fig 645 PICT-7496 Fig 647 PICT-7498 GT Series Tractors Service Manual...
  • Page 190 13. Remove the transmission drive belt from around the transmission pulley and fan. Remove the belt from the machine (Fig. 649). 2. Route the transmission drive belt between the steer- ing support bracket and frame (Fig. 651). Fig 649 PICT-7501 Fig 651 PICT-7584 GT Series Tractors Service Manual...
  • Page 191 4. Apply anti-seize compound to crankshaft. Slide the engine pulley onto crankshaft and install the trans- mission drive belt around engine pulley (Fig. 653). Transmission drive belt routing (Fig. 655). Fig 653 PICT-7497 Fig 655 PICT-7586 GT Series Tractors Service Manual...
  • Page 192 7. Install the battery tray (Fig. 656). Fig 658 PICT-7352 Fig 656 PICT-7354 10. Connect the battery cable to the positive battery terminal (Fig. 659). 8. Install the battery to the battery tray (Fig. 657). Fig 659 PICT-7351a Fig 657 PICT-7353 GT Series Tractors Service Manual...

  • Page 193: Hydrostatic Transmission Replacement

    1. Remove the transmission drive belt. Refer to “Trans- mission 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. Fig 661 PICT-7502a GT Series Tractors Service Manual...
  • Page 194 7. Unhook the spring from the rear end of the brake control rod (Fig. 665). 5. Remove the cotter pin securing the front end of the brake control rod to the brake linkage (Fig. 663). Fig 665 PICT-7518 Fig 663 PICT-7512 GT Series Tractors Service Manual...
  • Page 195 9. Remove the hairpin cotter securing the front end of the speed control rod to the speed control linkage 11. Remove the cotter pin from the rear end of the (Fig. 667). speed control rod (Fig. 669). Fig 667 PICT-7522 Fig 669 PICT-7527 GT Series Tractors Service Manual...
  • Page 196 13. Remove the speed control rod from the transmission 15. Unplug the harness wire from actuator bracket linkage and remove it from the machine (Fig. 671). spring switch (Fig. 673). Fig 671 PICT-7530 Fig 673 PICT-7534 GT Series Tractors Service Manual...
  • Page 197 (Fig. 676). Fig 674 PICT-7546 Fig 676 PICT-7556 17. Remove the screw securing the harness ground 19. Remove the return spring from the bypass lever (Fig. (Fig. 675). 677). Fig 675 PICT-7544 Fig 677 PICT-7558 6-10 GT Series Tractors Service Manual...
  • Page 198 24. Remove the 4 bolts and nuts securing the sides of hose to the frame (Fig. 679). the hydrostatic transmission to the frame (2 bolts on each side) (Fig. 681). Fig 679 PICT-7561 Fig 681 PICT-7554 GT Series Tractors Service Manual 6-11...
  • Page 199 (Fig. 682). Fig 682 PICT-7564a Fig 684 PICT-7568a 26. Remove the bolt and washer securing the wheel hub 28. Repeat steps 26 and 27 to remove the opposite wheel hub assembly. Fig 683 PICT-7567a 6-12 GT Series Tractors Service Manual...
  • Page 200 4. Install 4 bolts and nuts securing the sides of the hydrostatic transmission to the frame (2 bolts on 2. Install a bolt and washer to secure each wheel hub each side) (Fig. 688). Fig 688 PICT-7554 Fig 686 PICT-7567a GT Series Tractors Service Manual 6-13...
  • Page 201 8. Slide the return spring onto the bypass bracket (Fig. side of the frame and install a plastic push mount tie 692). to secure it to the frame and wire harness (Fig. 690). Fig 692 PICT-7558 Fig 690 PICT-7561 6-14 GT Series Tractors Service Manual...
  • Page 202 12. Plug the harness wire into the actuator bracket 10. Position the ground wire to the transmission bracket spring switch (Fig. 696). and install a screw to secure it (Fig. 694). Fig 696 PICT-7534 Fig 694 PICT-7544 GT Series Tractors Service Manual 6-15...
  • Page 203 16. Install a cotter pin securing the spring, actuator the machine and slide the speed control rod into the bracket and speed control rod to the transmission transmission linkage (Fig. 698). (Fig. 700). Fig 698 PICT-7577 Fig 700 PICT-7527 6-16 GT Series Tractors Service Manual...
  • Page 204 PICT-7523 Fig 703 PICT-7521 18. Install a hairpin cotter securing the front end of the speed control rod to the speed control linkage (Fig. 702). rod (Fig. 704). Fig 704 Fig 702 PICT-7522 PICT-7518 GT Series Tractors Service Manual 6-17...
  • Page 205 22. Install a cotter pin securing the front end of the brake 24. Install 4 lug nuts securing the wheel assembly to the control rod to the brake control linkage (Fig. 706). wheel hub assembly (Fig. 708). Fig 706 PICT-7512 Fig 708 PICT-7502a 6-18 GT Series Tractors Service Manual...
  • Page 206 (Fig. 709). Fig 709 PICT-7502a 28. If a new transmission was installed, purge the sys- tem, adjust the brake and adjust neutral. Refer to: 29. Operate the tractor to ensure all controls operate properly. GT Series Tractors Service Manual 6-19...
  • Page 207 3. It may be necessary to repeat Steps 1 and 2 until all the air is completely purged from the system. When 2. Lack of power or drive after short term operation speed purging is complete. sion of oil Fig 710 port 6-20 GT Series Tractors Service Manual...

  • Page 208: Purging The System

    Fluid Description Volume 20W-50 engine oil 0.95 gal (116.5oz) Fig 711 port X-XX. 5. Purge the system. Refer to “Purging the System” on page X-XX. GT Series Tractors Service Manual 6-21...

  • Page 209: Neutral Adjustment

    (Fig. 713). 7. Once in neutral, hold the puck with an adjustable wrench so it won’t move. Tighten the Allen head bolt (Fig. 715). Fig 713 PICT-7503a Fig 715 PICT-7823 6-22 GT Series Tractors Service Manual...
  • Page 210 9. Slide the wheel assembly onto the wheel hub as- sembly (Fig. 716). Fig 718 PICT-7502a Fig 716 PICT-7503a 10. Install 4 lug nuts securing the wheel assembly to the wheel hub assembly (Fig. 717). Fig 717 PICT-7502a GT Series Tractors Service Manual 6-23...
  • Page 211 1. Loosen the 4 lug nuts securing the right rear wheel to the wheel hub assembly (Fig. 719). Fig 720 PICT-7503a Fig 719 PICT-7502a 4. Loosen the lower bolt securing the brake assembly to the transmission housing (Fig. 721). Fig 721 PICT-7733 6-24 GT Series Tractors Service Manual...
  • Page 212 PICT-7734 Fig 724 PICT-7737 6. Remove the lower bolt, washer, and spacer from the brake assembly (Fig. 723). 8. Remove the brake assembly from the transmission (Fig. 725). Fig 723 PICT-7736 Fig 725 PICT-7738 GT Series Tractors Service Manual 6-25...
  • Page 213 726). 728). Fig 726 PICT-7739 Fig 728 PICT-7742a 10. Remove the puck from the brake assembly (Fig. 12. Remove the puck from the transmission housing 727). (Fig. 729). Fig 727 PICT-7741a Fig 729 PICT-7743a 6-26 GT Series Tractors Service Manual...
  • Page 214 (Fig. 730). 732). Fig 730 PICT-7744a Fig 732 PICT-7745 3. Install the puck into the brake assembly (Fig. 733). 1. Install a puck into the transmission housing (Fig. 731). Fig 733 PICT-7741a Fig 731 PICT-7743a GT Series Tractors Service Manual 6-27...
  • Page 215 (Fig. 736). Fig 734 PICT-7747 Fig 736 PICT-7736 5. Position the brake assembly to the transmission and install the top bolt to secure it (Fig. 735). 737). Fig 735 PICT-7748 Fig 737 PICT-7749 6-28 GT Series Tractors Service Manual...
  • Page 216 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). Fig 739 PICT-7503a GT Series Tractors Service Manual 6-29...
  • Page 217 .011” (.28mm) gap between the brake disc and each of the brake pucks. 5. Insert a new cotter pin to secure the crown nut in Fig 741 A. Brake puck (2) C. Crown nut B. Cotter pin D. Brake disc 6-30 GT Series Tractors Service Manual...

  • Page 218: Mower Deck

    (Fig. 743). Fig 745 PICT-7947 Fig 743 PICT-7946 5. Remove the right hand spindle cover (Fig. 746). 3. Remove the left hand spindle cover (Fig. 744). Fig 746 PICT-7950a Fig 744 PICT-7949 GT Series Tractors Service Manual...
  • Page 219 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). Fig 748 PICT-7953a Fig 750 PICT-7953a GT Series Tractors Service Manual...
  • Page 220 4. Position the right hand spindle cover onto the mower Fig 753 PICT-7947 deck (Fig. 752). 6. Position the left hand spindle cover onto the mower deck (Fig. 754). Fig 752 PICT-7950 Fig 754 PICT-7949 GT Series Tractors Service Manual...
  • Page 221 The mower deck has been removed from the tractor for photo purposes. 50” Mower Deck Fixed Idler Removal 756). Fig 755 PICT-7946 8. Install the mower deck onto the tractor. Refer to “50” Mower Deck Installation” on page 7-8. Fig 756 PICT-7982 GT Series Tractors Service Manual...
  • Page 222 MOWER DECK 50” Mower Deck Fixed Idler Installation bracket (Fig. 757). mounting bracket (Fig. 758). Fig 757 PICT-7984 Fig 758 PICT-7984 Fig 759 PICT-7982 GT Series Tractors Service Manual...

  • Page 223: 50" Mower Deck Removal

    2. Lower the deck by moving the deck lift lever into the bottom notch on the right fender (Fig. 760). Fig 761 A. Idler bracket D. Belt guard B. Spring E. 3/8” Square hole C. Pivoting idler pulley Fig 760 PICT-7829 Fig 762 PICT-7830 GT Series Tractors Service Manual...
  • Page 224 5. Repeat the above step on the tractor’s right side. 6. Slide the cutting deck toward the front of the tractor allowing the hooks on the deck to release them- selves from the deck stabilizer rod (Fig. 764). Fig 766 PICT-7986 Fig 764 PICT-7987 GT Series Tractors Service Manual...
  • Page 225 (Fig. 770). 3. Turn the tractor’s front wheels fully left. Slide the cutting deck (from the right side) underneath the tractor (Fig. 768). Fig 770 PICT-7829 Fig 768 PICT-7986 GT Series Tractors Service Manual...
  • Page 226 PTO clutch (Fig. 772 and Fig. 773). 771). Fig 772 Fig. 20 3354-975 Fig 771 PICT-7988 A. Idler bracket D. Belt guard B. Spring E. 3/8” Square hole C. Pivoting idler pulley Fig 773 PICT-7990 GT Series Tractors Service Manual...

  • Page 227: 50" Mower Deck Spindle Replacement

    3. Turn the mower deck over to access the underside Fig 774 PICT-7837 of the mower deck. 4. Block the mower deck blade and remove the nut securing the mower deck blade to the spindle shaft (Fig. 775). Fig 775 PICT-7976 7-10 GT Series Tractors Service Manual...
  • Page 228 7. Remove the spindle assembly from the mower deck shaft (Fig. 776). (Fig. 778). Fig 776 PICT-7978 Fig 778 PICT-012a 6. Remove the 4 screws securing the spindle assembly to the mower deck (Fig 777). Fig 777 PICT-7980 GT Series Tractors Service Manual 7-11...
  • Page 229 4. Slide mower deck blade onto the spindle shaft (Fig. 781). Ensure the center of the blade is seated onto machined star end of the spindle shaft. Fig 779 PICT-012a Note: Make sure the blade sails face the deck. Fig 781 PICT-7978 7-12 GT Series Tractors Service Manual...

  • Page 230: 50" Mower Deck Spindle Service

    7. If applicable, install the mower deck belt onto the mower deck. Refer to “50” Mower Deck Belt Instal- lation” on page 7-2. 8. Install the mower deck onto the tractor. Refer to “50” Mower Deck Installation” on page 7-8. Fig 784 PICT-8047a GT Series Tractors Service Manual 7-13...
  • Page 231 5. Remove the spindle shaft/shoulder spacer assembly from the spindle housing (Fig. 786). 7. Remove the bearing and 2 spacers from the pulley side of the housing (Fig. 788). Fig 786 PICT-8049a Fig 788 PICT-7742a 7-14 GT Series Tractors Service Manual...
  • Page 232 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). Fig 792 PICT-7749a Fig 790 PICT-7740 GT Series Tractors Service Manual 7-15...
  • Page 233 14. Install a shoulder spacer onto the spindle shaft 16. Place the spindle housing into a vise. cupped side down (Fig. 794). 17. Install the pulley (Fig. 796). Fig 794 PICT-8050a Fig 796 PICT-8048a 7-16 GT Series Tractors Service Manual...
  • Page 234 19. Secure the spindle shaft and install a nut to secure the pulley to the mower deck spindle (Fig. 798). Fig 799 PICT-7955 Fig 798 PICT-8046a 20. Remove the mower deck spindle from the vise. GT Series Tractors Service Manual 7-17...
  • Page 235 MOWER DECK 4. Remove the pulley from the idler bracket (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). Fig 800 PICT-7956 Fig 802 PICT-7960 5.
  • Page 236 PICT-7967 9. Remove the idler bracket from the mower deck (Fig. 11. Remove the spacer from on top of the idler as- 805). sembly mounting bracket (Fig. 807). Fig 805 PICT-7966 Fig 807 PICT-7969 GT Series Tractors Service Manual 7-19...
  • Page 237 3. Position a washer on the underside of the idler as- sembly mounting bracket (Fig. 811). Installation 1. Insert the shoulder bolt into the idler bracket (Fig. 809). Fig 811 PICT-7967 Fig 809 PICT-7972 7-20 GT Series Tractors Service Manual...
  • Page 238 PICT-7962 Fig 812 PICT-7966 7. Using a spring tool (Toro part no. 92-5771), hook the 5. Install a nut onto the shoulder bolt securing the idler idler spring to the spring post on the mower deck bracket to the mower deck (Fig. 813).
  • Page 239 PICT-7975 12. Install the mower deck belt. Refer to “50” Mower Deck Belt Installation” on page 7-2. 13. Install the Mower Deck onto the Tractor. Refer to “50” Mower Deck Installation” on page 7-8. 7-22 GT Series Tractors Service Manual...

  • Page 240: 54" Mower Deck Belt Replacement

    2. Lower the deck by moving the deck lift lever into the bottom notch on the right fender (Fig. 820). Fig 821 A. Idler pulley B. 3/8” Square hole Fig 820 PICT-7829 Fig 822 PICT-7830 GT Series Tractors Service Manual 7-23...
  • Page 241 (Fig. 824). Fig 823 PICT-7845 Fig 824 PICT-7847 5. Remove the left hand spindle cover (Fig. 823). 7. Remove the right hand spindle cover (Fig. 825). Fig 825 PICT-7849 Fig 823 PICT-7848 7-24 GT Series Tractors Service Manual...
  • Page 242 3. Position the left hand spindle cover onto the mower 54” Mower Deck Belt Installation deck (Fig. 829). 1. Position the right hand spindle cover onto the mower deck (Fig. 827). Fig 830 PICT-7848 Fig 827 PICT-7849 GT Series Tractors Service Manual 7-25...
  • Page 243 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. Fig 831 PICT-7845 Fig 832 PICT-7869 7-26 GT Series Tractors Service Manual...
  • Page 244 MOWER DECK bracket from the bottom side of the mower deck (Fig. 835). Fig 833 PICT-7871 Fig 835 PICT-7875 5. Remove the spacer (Fig. 834). Fig 834 PICT-7873 Fig 836 PICT-7878 GT Series Tractors Service Manual 7-27...
  • Page 245 MOWER DECK 54” Mower Deck Fixed Idler Installation 839). (Fig. 837). Fig 839 PICT-7873 Fig 837 PICT-7878 840). 2. Install 4 screws from the underside of the mower Fig 840 PICT-7871 Fig 838 PICT-7875 7-28 GT Series Tractors Service Manual...

  • Page 246: 54" Mower Deck Removal

    6. Install the mower deck belt onto the mower deck. Refer to “54” Mower Deck Belt Installation” on page Fig 842 PICT-7829 7-25. 7. Install the mower deck onto the tractor. Refer to “54” Mower Deck Installation” on page 7-31. GT Series Tractors Service Manual 7-29...
  • Page 247 6. Gently slide the cutting deck toward the front of the tractor allowing the hooks on the deck to release themselves from the deck stabilizer rod (Fig. 846). Fig 844 PICT-7830 Fig 846 PICT-7836 7-30 GT Series Tractors Service Manual...
  • Page 248 (from the right side) out from underneath the Fig 849 PICT-7839 tractor (Fig. 848). 3. Turn the tractor’s wheels fully left. Slide the cutting deck (from the right side) underneath the tractor (Fig. 850). Fig 848 PICT-7842 Fig 850 PICT-7842 GT Series Tractors Service Manual 7-31...
  • Page 249 7. Repeat the above step on the tractor’s right side. 8. Route the mower deck belt around the spindles and idlers. Refer to the belt routing decal (Fig. 854): Fig 852 PICT-7829 Fig 854 decal 1 3354-977 7-32 GT Series Tractors Service Manual...
  • Page 250 (Fig. 857). electric PTO clutch (Fig. 855 and Fig. 856). Fig 857 PICT-7837 Fig 855 A. Idler pulley B. 3/8” Square hole Fig 856 PICT-7990 GT Series Tractors Service Manual 7-33...

  • Page 251: 54" Mower Deck Roller Replacement

    (Fig. 861). Fig 858 PICT-7837 2. Remove the hairpin cotter from the lift bracket pin on both sides of the mower deck (Fig. 859). Fig 861 PICT-7935 Fig 859 PICT-7929 7-34 GT Series Tractors Service Manual...
  • Page 252 8. Repeat steps 5 – 7 to remove the height adjuster shaft (Fig. 863). from the other end of the roller shaft. 9. Remove the 4 deck rollers from the roller shaft (Fig. 865). Fig 863 PICT-7943a Fig 865 PICT-7945 GT Series Tractors Service Manual 7-35...
  • Page 253 Fig 866 PICT-7945 4. Install a cotter pin into end of the roller shaft (Fig. 869). 2. Slide a spacer onto the end of the roller shaft (Fig. 867). Fig 869 PICT-7940 Fig 867 PICT-7944a 7-36 GT Series Tractors Service Manual...
  • Page 254 7. Slide the deck roller assembly under the rear end of the mower deck (Fig. 871). Fig 873 PICT-7929 10. Repeat steps 8 and 9 on the other side of the deck roller. Fig 871 PICT-7935 GT Series Tractors Service Manual 7-37...

  • Page 255: 54" Mower Deck Spindle Replacement

    IMPORTANT: Be certain that the left roller bracket and the right roller bracket are set in the same position. Fig 875 PICT-7882 7-38 GT Series Tractors Service Manual...
  • Page 256 7. Remove the spindle assembly from the mower deck shaft (Fig. 876). (Fig. 878). Fig 876 PICT-7883 Fig 878 PICT-7889 6. Remove the 4 screws securing the spindle assembly to the mower deck (Fig 877). Fig 877 PICT-7884 GT Series Tractors Service Manual 7-39...
  • Page 257 (pulley side facing up) (Fig. 879). tioned so that it is facing toward the front of the mower deck. This will allow for easier greasing of the spindles. Fig 880 PICT-7884 Fig 879 PICT-7925 7-40 GT Series Tractors Service Manual...

  • Page 258: 54" Mower Deck Spindle Service

    6. Install the mower deck belt onto the mower deck. Refer to “54” Mower Deck Belt Installation” on page 7-25. 7. Install the mower deck onto the tractor. Refer to “54” Mower Deck Installation” on page 7-31. Fig 883 PICT-7897 GT Series Tractors Service Manual 7-41...
  • Page 259 5. Remove the bearing and two spacers from the pulley side of the housing (Fig. 885). 8. Install a bearing into the blade side of the spindle housing (Fig. 887). Fig 885 PICT-7903 Fig 887 PICT-7906 7-42 GT Series Tractors Service Manual...
  • Page 260 Fig 888 PICT-7908a 12. Slide the spindle shaft into the spindle housing by 10. Install a bearing into the pulley side of the spindle housing (Fig. 889). (Fig. 891). Fig 889 PICT-7910a Fig 891 PICT-7913a GT Series Tractors Service Manual 7-43...
  • Page 261 15. Slide the pulley onto the spindle shaft. Ensure the assembly (Fig. 895). center of the pulley is seated onto machined star end of the shaft (Fig. 893). Fig 895 PICT-7894 Fig 893 PICT-7918 7-44 GT Series Tractors Service Manual...
  • Page 262 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). Fig 896 PICT-7923 Fig 897 PICT-7853 GT Series Tractors Service Manual 7-45...
  • Page 263 MOWER DECK 4. Remove the idler pulley from the idler bracket (Fig. 6. Using a spring removal tool (Toro part no. 92-5771), 898). remove the idler spring from the idler bracket and mower deck (Fig. 900). Fig 898 PICT-7854 Fig 900 PICT-7859 5.
  • Page 264 3. Hook the idler spring to the idler bracket and using Installation a spring removal tool (Toro part no. 92-5771), hook the idler spring to the spring post on the mower deck 1. Position the stabilizer bracket and idler bracket to (Fig.
  • Page 265 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. Fig 907 PICT-7854 7-48 GT Series Tractors Service Manual...

  • Page 266: Mower Deck Pulley Replacement (50" & 54" Mower Decks)

    Remove the mower deck belt from the mower deck. Refer to: Fig 910 PICT-7880 Mower Deck Pulley Removal 1. Block the blade and remove the nut from the spindle shaft (Fig. 909). Fig 909 PICT-7879 GT Series Tractors Service Manual 7-49...
  • Page 267 (54” mower spindle shown) (Fig. 911). Install the mower deck onto the tractor. Refer to: Fig 911 PICT-7880 2. Block the blade and install a nut onto the spindle shaft (Fig. 912). Fig 912 PICT-7879 7-50 GT Series Tractors Service Manual...

  • Page 268: 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 along with complete wiring diagrams to help diagnose component troubleshooting information for GT2000 GT Series Tractors Service Manual...

  • Page 269: Gt2100, Gt2200, Gt2300 Wiring Diagram

    WITH BRAKE APPLIED OR/BK BU/W BU/W CLUTCH Relay W/BK Y/BK Y/BK W/BK BRAKE + OR/BK OR/BK BRAKE OR/W OR/W OR/BK PTO + + 12V SYSTEMS INDICATOR MONITOR / HOUR METER Fig 913 GT wiring diag 1 GT Series Tractors Service Manual...

  • Page 270: Gt2100, Gt2200, Gt2300 Wiring Diagram Cont

    SEAT SWITCH IS SHOWN WITH OPERATOR PRESENT W/BK A1 POWER OR/BK SEAT SW OR/W REVERSE SWITCH Y/BK E-PTO REVERSE SWITCH IS SHOWN IN FORWARD A2 POWER REV SW R/BK GROUND RMC MODULE Fig 914 GT wiring diag 2 GT Series Tractors Service Manual...
  • Page 271 ELECTRICAL THIS PAGE INTENTIONALLY LEFT BLANK. GT Series Tractors Service Manual...

  • Page 273: Service Manual

    Garden Tractor GT Series Service Manual Form No. 492-9194...

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