Toro 31102 User manual

FormNo.3383-962RevD
AdapterKit
100inRearDischargeMowerfor2-WheelDriveor2013andBefore
4-WheelDriveGroundsmaster®360TractionUnit
ModelNo.31102
InstallationInstructions
WARNING
CALIFORNIA
Proposition65Warning
ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato
causecancer,birthdefects,orreproductiveharm.
Note:Thisadapterkitisusedtomountthe100-inchRearDischargeDeckontoallGroundsmaster®360Series2WD
TractionUnits,2013andbeforeGroundsmaster®360Series4WDTractionUnits,and2014Groundsmaster®360Series
Tractionunitsinthefollowingserialranges:
ModelSerialrange
31223314000101to314000104
30536314000101to314000105
30539314000101to314000116
©2017—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3383-962*D

Safety
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential
danger.Replaceanydecalthatisdamagedormissing.
decal121-5463
121-5463
1.Height-of-cutselection
decal121-5498
121-5498
2

Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
DescriptionQty.Use
Nopartsrequired–Removetheexistingdeck.
Height-of-cutdecal1
Bolt(1/2x2-3/4inches)1
Flatwasher1
Flangenut(1/2inch)1
Belt-routingdecal1
Orice1
Teetting1
Adaptertting1
Hydraulichose—28inches1
Hydraulichose—67inches1
Hydraulichose—13-1/2inches1
Teetting1
Cabletie4
R-clamp1
Bolt(3/8x1inch)1
Sheet-metalnut1
Wireharness1
Relay3
Washer-headscrew(#10x3/4inch)4
Nut(#10)4
Step1
Screw(5/16x7/8inch)2
Flangenut(5/16inch)2
Fuseblockandfuse1
Shuntwireharness1
Installtheadapterkit.
MediaandAdditionalParts
DescriptionQty.Use
Installationinstructions1Readtheinstructionsbeforeinstallingthekit.
Partscatalog1Referencethecatalogforpartnumbers.
3

RemovingtheExisting
Deck
Note:Ifthemachineisnotequippedwithadeck,skipthis
procedureandproceedtoInstallingtheAdapterKit(page5).
CAUTION
Thepulllinktorsionspringsmaycausesome
rotationofthepulllinksduringinstallation.
Becarefulwhenconnectingthepulllinkstothe
machine.
1.Parkthemachineonalevelsurfacewiththedeckinthe
fullyraisedposition.Shutofftheengine,engagethe
parkingbrake,andremovethekey.
Note:Whenthedeckisintheraisedposition,the
pulllinktorsionspringtension(Figure1)isreduced,
makingitmucheasiertodisconnectthepulllinksfrom
themachine.
g017279
1
2
3
4
5
6
7
g017279
Figure1
1.Pulllink(deckraised)5.Deckliftchain
2.Shoulderscrew6.Clevispin
3.Retainerpin7.Adjustmentclevis
4.Torsionspring
2.Disconnectthepulllinkfromeachsideofthemachine
(Figure1).
A.Removetheshoulderscrewthatsecuresthe
retainerpintothecarrierframe(Figure1).
B.Carefullyslidetheretainerpinfromthecarrier
frameandthepulllink(Figure1).
3.Notethelocationoftheheight-of-cut(HOC)pinin
theHOCbracketforassemblypurposes(Figure2),
andremovetheHOCpinfromtheHOCbracket.
1
2
G017278
g017278
Figure2
1.HOCpin2.HOCbracket
4.Starttheengineandfullylowerthedeck.Stopthe
engineandremovethekeyfromtheignitionswitch.
Note:Loweringthedeckontofurnituredollieseases
theremovalofthedeck.
Note:Elevatethefrontofthemachinetomovethe
deckawayfromthemachine.
5.Removetheboltsandnutsthatsecurethe4liftchains
totheliftarmsonthedeck(Figure1).
6.DisconnecttheendyokeofthePTOdriveshaftfrom
thedeckgearboxshaftasfollows:
A.Removetherollpinfromtheendyokeandthe
gearboxshaft(Figure3).
Note:Retaintherollpin.
g012230
Figure3
1.Driveshaft3.Rollpin
2.Capscrewsandlocknuts4.Gearbox
B.Loosenthe2capscrewsandlocknuts(Figure3).
4

C.Slidethedriveshaftendyokefromthegearbox
shaft.
D.Raisethedriveshaftandtieittotheframe.
7.Slidethedeckawayfromthemachine.
InstallingtheAdapterKit
ApplyingtheDecals
1.Removetheexistingheight-of-cutdecalfromthe
height-of-cutbracketonthemachine(Figure4).
g025286
Figure4
1.Height-of-cutdecal2.Height-of-cutbracket
2.Makesurethatthedecalmountingsurfaceofthe
height-of-cutbracketisfreeofallgreaseandgrime.
3.Afxthenewheight-of-cutdecaltothebracket
(Figure5).
g025287
Figure5
1.Locknut3.Bolt
2.Newheight-of-cutdecal4.Washer
4.Installthe1/2x2-3/4inchbolt,atwasher,and1/2
inchangenutintothelowerrearholeofthenew
decalasshowninFigure5.
Note:Thiskeepsthedeckfromloweringand
contactingthegroundiftheheight-of-cutpinis
removed.
5.Pivotopentheoorplate(Figure6).
g025288
Figure6
1.Belt-routingdecal2.Floorplate
6.Afxthenewbelt-routingdecalovertheexistingdecal
(Figure6).
Note:Makesurethatthemountingsurfaceisclean
beforeinstallingthenewdecal.
5

RemovingtheFender
Removethe3self-tappingscrewssecuringtheleftfront
fendertothemachineframe(Figure7),andremovethe
fender.
Note:Astepwillbeinstalledinplaceofthefenderafterthe
deckisinstalled.
g025289
Figure7
1.Self-tappingscrews2.Leftfrontfender
AssemblingtheDeckLiftManifold
Block
1.Raisetheseatplate.
2.Installtheoriceintothedeckliftvalvemanifoldas
follows:
CAUTION
Ifyouperformmaintenanceonthedecklift
manifoldwhilethedeckisraised,thepressure
ofthehydraulicsystemcouldcauseserious
injury.
Lowerthedecktorelievethepressureinthe
hydraulicsystem.
WARNING
Hydraulicuidescapingunderpressurecan
penetrateskinandcauseinjury.Fluidinjected
intotheskinmustbesurgicallyremoved
withinafewhoursbyadoctorfamiliarwith
thisformofinjuryorgangrenemayresult.
•Keepyourbodyandhandsawayfrom
pinholeleaksornozzlesthateject
high-pressurehydraulicuid.
•Usecardboardorpapertondhydraulic
leaks;neveruseyourhands.
Note:Haveadrainpanoraragavailabletocatchthe
hydraulicuid.
A.Removethenutsecuringthespacer/coilassembly
tothesolenoidvalveinport“A”onthelift
valvemanifoldblock(Figure8),andremovethe
spacer/coilassembly.
B.Removethesolenoidvalvefromtheliftvalve
manifoldblock(Figure8)
g025290
Figure8
1.Liftvalvemanifoldblock4.Solenoidvalve
2.Orice5.Spacer
3.Coil6.Nut
6

C.Inserttheoriceintotheopeningofthemanifold
block,positioningitsothatthechamferedendis
inward(Figure8).
D.Threadthesolenoidvalveintotheliftvalve
manifoldblock,andtorquethevalveto27N-m
(20ft-lb).
Note:Donotovertightenthenut.
E.Insertthecoil/spacerassemblyontothesolenoid
valve(Figure8).
F.Securethecoil/spacerassemblytothevalvewith
thenut(Figure8),andtorquethenutto7N-m
(5ft-lb).
Note:Donotovertightenthenut.
3.Disconnectthehydraulichosefromthe90degree
ttingonthefrontoftheliftvalvemanifoldblock
(Figure9).
Note:Haveadrainpanoraragavailabletocatchthe
hydraulicuid.
g025291
Figure9
1.90degreetting3.Hydraulichose
2.Liftvalvemanifoldblock
4.Removethe90degreettingfromthefrontofthe
manifoldblock(Figure9)anddiscardthetting.
Note:Togainadditionalaccesstothettingsonthe
frontofthevalve,disconnectthehardhydraulicline
fromthevalveand/orremovethevalvemountingnuts
(Figure9).
5.Installtheteettingintothevacatedportonthefront
ofthemanifoldblock.
Note:PositiontheteettingasshowninFigure10.
g025598
Figure10
1.Teetting3.Hydraulichose
2.Frontofmanifoldblock4.Adaptertting
6.Installtheadapterttingtothenewlyinstalledtee
tting(Figure10).
7.Installtheendofthehydraulichose,disconnectedin
step3,totheadaptertting(Figure10).
7

MountingtheDecktotheMachine
1.RemovethenutssecuringtheliftchainU-boltstothe
undersideofthedeck(Figure11).
g025293
Figure11
1.U-bolt2.Nut(2)
2.Remove1ofthetopnutsfromtheU-bolts,insertthe
liftchainsontotheU-bolts,andtheninstallthetopnut.
3.InstalltheU-boltstothedeckwiththenutspreviously
removed(Figure11).
4.Slidethenewdeckunderthecarrierframeofthe
machine.
Note:Elevatethefrontofthemachinetoslidethe
newdeckunderthecarrierframeofthemachine.
5.ConnecttheendyokeofthePTOdriveshafttothe
deckgearboxasfollows:
A.Alignthesplineandrollpinholesofthedriveshaft
yokewiththegearboxshaft.
B.SlidethePTOdriveshaftendyokeontothe
gearboxshaft.
C.SecuretheendyokeofthePTOdriveshafttothe
gearboxshaftwiththerollpin(Figure3).
D.Tightenthelocknutstosecuretheendyoketothe
gearboxshaft(Figure3),andtorquethelocknuts
to20to25N-m(15to18ft-lb).
6.Removeandinstallthereardeckliftchainstothelift
bracketsasfollows:
Note:Wheninstallingtherearliftchainstothe
liftbrackets,usethesecondlinkfromthetop.This
providestherecommendedrakeforthedeck.
A.Securetherightrearliftchaintotheinboardside
oftheliftbracketwithaboltand2nuts(Figure
12).
B.Securetheleftrearliftchaintotheoutboardside
oftheliftbracketwithaboltand2nuts.
C.Usingthetopchainlinks,securethefrontlift
chainstotheoutboardsideoftheliftbrackets.
g025273
Figure12
1.Leftrearliftchain2.Rightrearliftchain
8

InstallingtheHoses
1.Looselyinstallthemid-lengthhydraulichosetothe
outboardportoftheright-handwingcylinder(Figure
13).
Note:Donottightenthetting.
g025303
Figure13
1.Longhose3.Right-handwingcylinder
2.Mid-lengthhose4.Deckliftcylinder
2.Routethehoseunderthehydraulictankbracketand
totheteettingonthefrontofthemanifoldblock
(Figure14).
g025294
Figure14
1.Longhose3.Shorthose
2.Deckliftvalveteetting4.Deckliftcylinder
Note:Makesurethatthehoseisnottwistedanddoes
notcontactanyhot,sharp,ormovingparts.
9

ConnectingtheLongHose
(4WDModels)
Forasimplermethodofconnectingthelonghoseon
2WDmodels,refertoConnectingtheLongHose(2WD
ModelsOnly)(page11).
1.Disconnectthehosefromthehydrauliclineontheleft
sideofthemachineandfromtheteettingonthetop
ofthepump(Figure15).Discardthehose.
Note:Haveadrainpanoraragavailabletocatchthe
hydraulicuid.
2
G025597
1
g025597
Figure15
Asviewedfromunderthemachine
1.Hydraulicline2.Newhose
2.Installateettingtothehydraulicline(Figure16).
3.Connectthe90degreettingendofthenewshort
hosetothehydrauliclineteettingandthestraight
ttingendtotheteettingonthepump(Figure16)
andtightenbothendsofthehose.
4
2
G025295
31
g025295
Figure16
Asviewedfromunderthemachine
1.Hydraulicline3.Shorthose
2.Teetting4.Longhose
4.Installtheendofthelonghydraulichosetotheinboard
portoftherightwingcylinderandtightenthetting.
5.Routethehosefromtherightwingcylinderalongthe
mid-lengthhose,underthehydraulictankbracketand
tothenewteetting(Figure16)andtightenthetting.
Note:Makesurethatthehoseisnottwistedanddoes
notcontactanyhot,sharp,ormovingparts.
10

ConnectingtheLongHose
(2WDModelsOnly)
Thisproceduredoesnotapplyto4WDmodels.
1.Installtheendofthelonghydraulichosetotheinboard
portoftherightwingcylinderandtightenthetting.
2.Routethehosefromtherightwingcylinderalongthe
mid-lengthhose,underthehydraulictankbracket,
abovetheliftshaft,andbelowtheoorboardsupport
tothecappedttingonthehydraulichardline(Figure
17andFigure18).
g027153
Figure17
1.Cappedtting
g027154
Figure18
Somepartsnotshown
1.Floorboardsupport3.Rightwingcylinderhose
2.Liftshaft4.Hydrauliclinetting
3.Removeanddiscardthecapfromthetting(Figure
17).
4.Connecttherightwingcylinderhosetothettingon
thehydraulicline(Figure18)andtightenthetting.
Note:Makesurethatthehoseisnottwistedandwill
notcontactanyhot,sharp,ormovingparts.
11

ConnectingthePullLinkstothe
Machine
1.Securethe2liftcylinderhosestotheundersideofthe
hydraulictankwithacabletieortheR-clamp,the3/8
x1inchbolt,andthesheet-metalnutsupplied.
Note:Makesurethehosesarenottwistedandwill
notcontactanyhot,sharp,ormovingparts.
g025296
Figure19
1.Sheet-metalnut3.Bolt(3/8x1inch)
2.R-clamp
2.Starttheengineandfullyraisethedeck.Stopthe
engineandremovethekeyfromtheignitionswitch.
Note:Placeawoodblockorsimilarshimundereach
linktoholditintheraisedposition(Figure20).
3.Alignthepulllinktothecarrierframeandattach
thelinkwiththeretainerpin(Figure20).Securethe
retainerpintotheframewiththeshoulderscrew
(Figure20).
g025301
Figure20
1.Pulllink(deckraised)4.Deckliftchain
2.Torsionspring5.Retainerpin
3.U-bolts6.Shoulderscrew
4.Slightlyraisethefrontofthemachinetoremovethe
woodblockorsimilarshimfromundereachpulllink.
InstallingtheWireHarness
1.Locatethefuseblockandthegroundblock(Figure21).
g025297
Figure21
1.Fuseblock2.Groundblock
2.Attachthenewwireharnessasfollows:
•Attachtheredwiretoanavailableconnectoron
thefuseblock.
Note:Ifthereisnotanavailableconnectoronthe
fuseblock,installanadditionalblock.Afuseblock,
fuseandmountingnutsandboltsareincludedin
thelooseparts.
•Attachtheblackwiretothenearbygroundblock.
3.Locatethe2holesatthebottomofthefuseblock
mountingplate(Figure22).
4.Mountthe3relaystothefuseblockmountingplate
with2washer-headscrews(#10x3/4inch)and2nuts
(#10);refertoFigure22.
g025298
Figure22
1.Relay(3)3.Nut—#10(2)
2.Washer-headscrew—#10
x3/4inch(2)
5.Plugthewireharnessconnectorsintotherelays.
6.Unplugtheconnectorsatthefrontofthetransmission
neartheoillter(Figure23).
12

g025299
Figure23
1.Transmissionconnectors2.Wireharnessconnectors
7.Routethewireharnesstothetransmissionandplugthe
2matingwireharnessconnectorsintotheunplugged
connectors(Figure23).
8.Routetheremaininglengthofwireharnesstotheleft
sideofthemachine,undertheoorandtowardthe
frontofthemachine.
9.Plugtheharnessconnectorintotheharnessonthe
frontcenterofthedeck.
10.Securetheharnesstotheexistingharnesswithtie
wraps,andsecureanyexcessharnessawayfromany
hot,sharp,ormovingparts.
11.Plugtheshuntwireharnessintothedeckwireharness
asshowningure.
Note:Usetheshuntwireharnessonlywhenthedecks
areremovedfromthemachine.
g206087
Figure24
1.Shuntwireharness
InstallingtheStep
1.Usingthe3existingfender-mountingholes,securethe
frontofthesteptothemachinewiththe3self-tapping
screwspreviouslyremoved(Figure25).
g025300
Figure25
1.Step
2.Usingtherearofthestepasatemplate,locate,mark,
anddrill2holes—8.3mm(0.328inch)diameter—in
theframeofthemachine.
3.Mounttherearofthesteptothemachinewith2
screws(5/16x7/8inch)and2angenuts(5/16);refer
toFigure25.
13

CompletingtheInstallation
1.InstalltheHOCpinintotheHOCbracketatthe
desiredheightofcut(Figure26).
g025302
Figure26
1.HOCpin2.HOCbracket
2.Checkthehydraulic-oillevelandreplenishtheoilas
required;refertothetractionunitOperator’sManual.
3.Levelthecuttingunit;refertotheCuttingUnit
OperatorsManual.
4.LubricatethecuttingunitandPTOdriveshaftgrease
ttings;refertothecuttingunitOperator’sManual.
14

Notes: