Toro 31526 User manual

FormNo.3413-563RevC
FlowDividerKit
SerialNumber400000000andAfterGroundsmaster®4100Series
TractionUnit
ModelNo.31526
InstallationInstructions
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
Safety
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea
ofpotentialdanger.Replaceanydecalthatisdamagedormissing.
decal132-6104
132-6104
1.4WDLock2.4WDUnlock
©2018—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3413-563*C

Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachine.
2Nopartsrequired–Removethehydrauliclines.
Flowdivider1
Hex-headbolt2
Flangenut2
Traction-motortube1
Tubemanifold1
Returnhose1
Crosshose1
3
Reartractionhose1
Installthehydrauliccomponents.
Toggleswitch1
Wireharness1
44WDfunctiondecal1
Installtheswitch.
Relay1
5Cabletie1Installthekittothewireharness.
6Nopartsrequired–Completetheinstallation.
Note:Theproceduresforinstallingthiskitrequirethatyouworkfromunderthemachine.
2

1
PreparingtheMachine
NoPartsRequired
Procedure
CAUTION
Ifyouleavethekeyintheignitionswitch,
someonecouldaccidentlystarttheengine
andseriouslyinjureyouorotherbystanders.
Removethekeyfromtheignitionswitch
beforeyouperformanymaintenance.
Important:Useliftingandsupportequipment
withacapacityof1300kg(5,000lb)orgreater.
Important:Caporpluganydisconnected
hydraulichoses,tubes,orcomponentportsto
preventcontaminatingthesystem.
1.Parkthemachineonalevelsurface,engagethe
parkingbrake,besurethatthetractionpedalis
intheNEUTRALposition.
2.EnsurethatthePTObuttonisintheOFF
position.
3.Shuttheengineoff,removethekeyfromthe
switch,andallowthemachinetocool.
4.Disconnectthenegativecablefromthebattery
post;refertotheOperator’sManualforyour
machine.
WARNING
Incorrectbatterycableroutingcould
damagethemachineandcables,causing
sparks.Sparkscancausethebattery
gassestoexplode,resultinginpersonal
injury.
•Alwaysdisconnectthenegative
(black)batterycablebefore
disconnectingthepositive(red)
cable.
•Alwaysconnectthepositive(red)
batterycablebeforeconnectingthe
negative(black)cable.
5.Disconnectthepositivebatterycablefromthe
battery;refertotheOperator’sManualforyour
machine.
6.Removethecontrollercoverandtheright
consolecoverasshowninFigure1.
g034560
Figure1
1.Controllercover2.Rightconsolecover
7.Raisethemachineusingahoist(preferred)or
onjacks.
Note:Usejackstandsorblockthemachineto
preventitfromfalling.
8.Bleedthepressurefromthehydraulicsystemby
turningthehydraulicpumpbypassvalve;referto
thepushingortowingthemachineinstructions
intheOperator’sManual.
3

2
RemovingtheHydraulic
Lines
NoPartsRequired
RemovingtheHydraulicHoses
1.Alignadrainpanbelowtheforwardendofthe
hydraulic-pressurehose(Figure2).
g212935
Figure2
1.Reartractionmanifold5.Reartractionhose
2.Traction-controlhose6.Tractionmotor
3.Hydraulicpump7.Dividertube
4.Hydraulic-pressurehose8.Combinationmanifold
2.Removetheforwardttingofthe
hydraulic-pressurehosefromthemiddle
ttingofthedividertube,andallowthehydraulic
uidtodrainfromthehoseandtube(Figure3).
g212936
Figure3
1.Bulkheadtting4.Reartting(dividertube)
2.Reartting(reartraction
hose)
5.Middletting(dividertube)
3.Forwardtting(rear
tractionhose)
6.Forwardtting(pressure
hose)
3.Temporarilyplugthehydraulic-pressurehose.
4.Removetheforwardttingofthereartraction
hosefromtherearttingofthedividertube
(Figure3).
5.Removetherearttingofthereartractionhose
fromthebulkheadttinginthebulkheadnear
thesteeringaxle(Figure3).
4

6.Pullthereartractionhosethroughthehose
supportbracket,andremovethehosefromthe
machine(Figure4).
Note:Discardthereartractionhose.
g212933
Figure4
1.Hosesupportbracket2.Reartractionhose
7.Temporarilycapthebulkheadtting.
RemovingtheTubeBracketand
Clamp
1.Removethebolt,nut,andclampplatesecuring
theclamp-blockhalvesanddividertubetothe
supportbracket(Figure5).
g212988
Figure5
1.Dividertube4.Clamp-blockhalf
2.Carriagebolt5.Clampplate
3.Supportbracket6.Flangenut
2.Removetheclamp-blockhalves(Figure5).
3.Removethe2boltsand2angenutsthatsecure
thesupportbrackettothechassisbracket,and
removethesupportbracket(Figure6).
Note:Discardthebolts,nuts,clamp-block
halves,andsupportbracket.
g212938
Figure6
1.Flangenuts3.Chassisbracket
2.Supportbracket4.Bolts
5

RemovingtheDividerTube
1.Removethetubenutofthedividertubefrom
theT-ttinginthefront,righttractionmotor,and
removethetubefromthemachine(Figure7).
g212934
Figure7
1.Tubenut(dividertube)2.T-tting(tractionmotor)
Note:Discardthedividertube.
2.TemporarilycaptheT-ttinginthetractionmotor.
RemovingtheTraction-Control
Hose
1.Removetheinboard-hosettingforthe
traction-controlhosefromthehydraulicttingin
port(CH1)ofthecombinationmanifold(Figure
8).
g212937
Figure8
1.Hydraulictting(rear
tractionmanifold)
4.Hydraulictting
(combinationmanifold)
2.Outboard-hosetting
(traction-controlhose)
5.Combinationmanifold
3.Inboard-hosetting
(traction-controlhose)
6.Reartractionmanifold
2.Removetheoutboard-hosettingforthe
traction-controlhosefromthe45°hydraulic
ttinginport(CH)ofthereartractionmanifold.
3.Temporarilycapthestraighthydraulicttingsin
thecombinationmanifoldandthe45°hydraulic
ttinginthereartractionmanifold.
Note:Discardthetraction-controlhose.
6

3
InstallingtheHydraulic
Components
Partsneededforthisprocedure:
1Flowdivider
2Hex-headbolt
2Flangenut
1Traction-motortube
1Tubemanifold
1Returnhose
1Crosshose
1Reartractionhose
InstallingtheFlow-Divider
Manifold
1.Aligntheholesintheow-dividermanifoldwith
theholesinthechassisbracket(Figure9).
Note:Ensurethatthe45ºttinginthe
ow-dividermanifoldistowardthecenterlineof
themachine.
g021371
Figure9
1.Flangenuts3.Flow-dividermanifold
2.Chassisbracket4.Hex-headbolts
2.Securetheow-dividermanifoldtothechassis
bracketwiththe2hex-headboltsand2ange
nuts(Figure9).
7

InstallingtheTraction-MotorTube
1.Alignthetubenutsforthetraction-motortube
totheT-ttinginthetractionmotorandthe90º
ttingintheowdivider(Figure10).
Note:Ensurethatthetraction-motortubeis
routedabovethehydraulic-pressurehoseofthe
hydraulicpump;refertostep2ofRemovingthe
HydraulicHoses(page4).
Note:Rotatethe90ºttingasnecessaryto
alignthettingwiththereartubenutofthe
traction-motortube.
g212932
Figure10
1.Reartubenut
(traction-motortube)
5.T-tting
2.90°hydraulictting6.Forwardtubenut(T-tting)
3.Jamnut7.Forwardtubenut
(traction-motortube)
4.Tractionmotor
2.RemovethecapfromtheT-ttingofthetraction
motorthatyouinstalledstep2ofRemovingthe
Traction-ControlHose(page6).
3.Threadthetubenutsforthetraction-motortube
ontothettingsinthetractionmotorandthe
owdivider(Figure10).
4.Tightenthejamnutforthe90ºtting(Figure10).
5.Tightenthetubenutsofthetraction-motortube
to116to142N∙m(85to105ft-lb).
Note:Ensurethatthereisclearancebetween
allthehardlines,ortheywillrattleagainsteach
otherduringoperation.
InstallingtheTubeManifold
1.Aligntheforwardtubenutforthetubemanifold
withthecheckadapterlocatedinportCH1of
theowdivider(Figure11).
g212810
Figure11
1.Flow-dividermanifold4.90°threadedtting
(T-tting)
2.Tubenut(T-tting)5.Forwardtubenut(tube
manifold)
3.Checkadapter(9/16inch)6.Reartubenut(tube
manifold)
2.Alignthereartubenutforthetubemanifoldwith
the90°threadedttingoftheT-tting(Figure
11).
Note:RotatetheT-ttingnecessarytoalignthe
ttingwiththereartubenutofthetubemanifold.
3.Threadthetubenutsofthetubemanifoldonto
thecheckadapterandtheT-tting(Figure11).
4.TightenthetubenutoftheT-ttingto51to63
N∙m(37to47ft-lb).
5.Tightenthetubenutofthetubemanifoldto51
to63N∙m(37to47ft-lb).
8

InstallingtheReturnHose
1.Alignthestraightttingofthereturnhosewith
thethreadedttingofthetubemanifold(Figure
12).
Note:Ensurethatthereturnhoseisrouted
abovethehydraulic-pressurehoseofthe
hydraulicpump;refertostep2ofRemovingthe
HydraulicHoses(page4).
g212931
Figure12
1.Straighttting(return
hose)
4.90ºtting(returnhose)
2.Threadedtting(tube
manifold)
5.Hydraulictting
(combinationmanifold)
3.Flow-dividermanifold6.Combinationmanifold
2.Alignthe90°ttingofthereturnhosewiththe
threadedttinginthecombinationmanifold
(Figure12).
3.Removethecapfromthehydraulicttinginthe
combinationmanifoldthatyouinstalledinstep3
ofRemovingtheTraction-ControlHose(page6).
4.Threadthehosettingsontothettingsofthe
returnmanifoldandthecombinationmanifold,
andtightenthehosettingsto51to63N∙m(37
to47ft-lb).
5.Torquethe90°ttingofthereturnhoseto51to
63N∙m(37to47ft-lb).
6.Torquethestraightttingofthereturnhoseto
37to44N∙m(27to33ft-lb).
InstallingtheCrossHose
1.Alignthe90°ttingofthecrosshosethrough
thecushionedguideinthesupportbracket,and
slidethehosethroughthebracket(Figure13).
g212925
Figure13
1.Reartractionmanifold4.Cushionedguide
2.45°hydraulictting(rear
tractionmanifold)
5.Supportbracket
3.Crosshose6.Straight-threadedtting
(T-tting)
2.Alignthe90°ttingofthecrosshosewiththe
straight-threadedttingoftheT-tting(Figure
14).
Note:Ensurethatthecrosshoseisrouted
abovethehydraulic-pressurehoseofthe
hydraulicpump;refertostep2ofRemovingthe
HydraulicHoses(page4).
g212975
Figure14
1.Straighttting(crosshose)4.90°tting(crosshose)
2.45°hydraulictting(rear
tractionmanifold)
5.Straight-threadedtting
(T-tting)
3.Flow-dividermanifold6.Reartractionmanifold
9

3.Alignthestraightttingofthecrosshosewith
the45°hydraulicttinginthereartraction
manifold(Figure14).
4.Removethecapfromthe45°hydraulicttingin
thereartractionmanifoldthatyouinstalledin
step3ofRemovingtheTraction-ControlHose
(page6).
5.Threadthehosettingsofthecrosshoseonto
thettingsoftheT-ttingandthereartraction
manifold,andtightenthettingsto51to63N∙m
(37to47ft-lb).
InstallingtheRearTractionHose
1.Alignthettingofthereartractionhosethrough
thecushionedguideofthesupportbracket,and
slidethehosethroughthebracket(Figure15).
g212930
Figure15
1.Bulkhead4.Cushionedguide
2.Bulkheadtting5.Reartractionhose
3.Supportbracket
2.Aligntherearttingofthereartractionhosewith
thebulkheadtting(Figure16).
g212974
Figure16
1.Bulkhead4.Forwardtting(rear
tractionhose)
2.Bulkheadtting5.Straighthydraulictting
3.Reartting(reartraction
hose)
6.Flow-dividermanifold
3.Aligntheforwardttingofthereartractionhose
withthestraighthydraulicttinglocatedinport
M3oftheow-dividermanifold(Figure16).
4.Removethecapfromthebulkheadttingthat
youinstalledinstep3ofRemovingtheHydraulic
Hoses(page4).
5.Threadthehosettingsofthereartractionhose
ontothettingsintheow-dividermanifoldand
thebulkheadtting,andtightenthettingsto
116to142N∙m(85to105ft-lb).
10

InstallingtheHydraulic-Pressure
Hose
1.Removetheplugfromtheendofthe
hydraulic-pressurehosethatyouinstalledin
step3ofRemovingtheHydraulicHoses(page
4).
2.Removethe45°ttingofthepressurehosefrom
thestraightttinginthehydraulicpump(Figure
17).
g212927
Figure17
1.Hydraulicpump4.45°hydraulictting
2.Straighthydraulictting5.Flow-dividermanifold
3.45°tting
(hydraulic-pressurehose)
6.Straighttting
(hydraulic-pressurehose)
3.Alignthestraightttingofthehydraulic-pressure
hosewiththe45°hydraulicttinginthe
ow-dividermanifold(Figure18).
g212973
Figure18
1.Straighttting
(hydraulic-pressurehose)
3.Flow-dividermanifold
2.45°hydraulictting
4.Threadthestraightttingofthe
hydraulic-pressurehoseontothe45°
hydraulicttingintheow-dividermanifold
(Figure18).
5.Alignthe45°ttingofthepressurehosewiththe
straightttinginthehydraulicpump(Figure19).
g212962
Figure19
1.Hydraulicpump4.Flow-dividermanifold
2.Straighthydraulictting5.Jamnut
3.45°tting
(hydraulic-pressurehose)
6.45°hydraulictting
6.Threadthe45°ttingofthepressurehoseonto
thestraightttinginthehydraulicpump(Figure
19).
7.Tightenthejamnutofthe45°hydraulictting
ontotheow-dividermanifold(Figure19).
8.Torquethestraightand45°ttingsofthe
pressure-hoseto150to184N∙m(110to136
ft-lb).
11

4
InstallingtheSwitch
Partsneededforthisprocedure:
1Toggleswitch
1Wireharness
14WDfunctiondecal
Procedure
1.Drilla13mm(1/2inch)holeinthecenter
console;refertoFigure20fortheappropriate
orientation.
Important:Usecautiontonothitany
componentsorwiresunderneaththe
consolewiththedrillbit.
g034559
Figure20
1.13mm(1/2inch)diameter3.25mm(1inch)
2.13mm(1/2inch)from
thecenterofholetothe
rightedgeofthehigh-low
speedcontrolswitch
2.Placethe4WDfunctiondecaloverthedrilled
hole(Figure21).
g205310
Figure21
3.Identifytheswitchterminallocations,wire
harnesslabels,andwireharnesscolors(Figure
22).
Theswitchterminalsareidentiedbythe
numbersimprintedintothebottomoftheswitch.
Note:Theswitchisspring-loadedtotherearof
theswitch(Figure23).Theswitchisnormally
openbetweenterminals1and2(Figure22).
g273505
Figure22
Installedswitchorientation
1.Terminal1—rear3.Terminal3—front
2.Terminal2—center
12

4.SecuretheredwirelabeledBYPASSENGAGE
SWITCH2totheoverrideswitchcenterterminal
number2(Figure22andFigure23).
5.SecurethegraywirelabeledBYPASSENGAGE
SWITCH1totheoverrideswitchrearterminal
number1(Figure22andFigure23).
Important:Incorrectswitchwiringcan
resultindamagetothehydraulicsystem.
Verifythatthewiringisinstalledcorrectly;
refertoTestingtheFlow-DividerManifold
(page16).
g273521
Figure23
1.Spring-loadedtotherear
oftheswitch
5.Frontterminal
2.Toggleswitch6.Centerterminal
3.Graywire7.Rearterminal
4.Redwire
6.Routethetoggleswitchwiththeconnected
wireharnessintotherearofthecenterconsole
(Figure24).
g035968
Figure24
1.Toggleswitch2.Rearofcenterconsole
7.Pullthetoggleswitch/wireharnessthroughthe
centerconsoleuptothedrilledhole(Figure25).
g212799
Figure25
1.Rearofcenterconsole2.T oggleswitch
8.Installthetoggleswitchintothe13mm(1/2
inch)holefromthebottomoftheconsole;refer
toFigure26forthecorrecthexlocknutand
washerorientation.
Note:Installtheswitchspring-loadedtoward
therearofthemachine.
13

Discardthetabbedwasherincludedwiththe
toggleswitch.
g274109
Figure26
1.Hexlocknut3.Hexlocknut
2.Washer(15/32inch)4.Toggleswitch
5
InstallingtheKittotheWire
Harness
Partsneededforthisprocedure:
1Relay
1Cabletie
Procedure
1.Plugtherelayconnectorintotherelayasshown
inFigure27.
g035962
Figure27
2.Connecttherelaytotherelaymountwitha
cabletieasshowninFigure28.
14

g035966
Figure28
3.Unlatchtheseatandlocatetheremainingloose
wireharnessendsbelowthebackrightcorner
ofthenowexposedframecrossbar.
4.Plugthelooseharnessendsintothe4WD
manifoldjustinsideoftheright,fronttire(Figure
29).
g035292
Figure29
6
CompletingtheInstallation
NoPartsRequired
CheckingforHydraulicLeaks
WARNING
Hydraulicuidescapingunderpressurecan
penetrateskinandcauseinjury.
•Makesurethatallhydraulicuidhoses
andlinesareingoodconditionandall
hydraulicconnectionsandttingsaretight
beforeapplyingpressuretothehydraulic
system.
•Keepyourbodyandhandsawayfrom
pinholeleaksornozzlesthateject
high-pressurehydraulicuid.
•Usecardboardorpapertondhydraulic
leaks.
•Safelyrelieveallpressureinthehydraulic
systembeforeperforminganyworkonthe
hydraulicsystem.
•Getimmediatemedicalhelpifuidis
injectedintoskin.
1.Checkandtightenallttingsandhydraulic
connections.
2.Ensurethatthehydraulicpumpbypassvalveis
intheoperationposition;refertothepushingor
towingthemachineinstructionsintheOperator’s
Manual.
3.Checkthehydraulicuidlevelandreplenishit
asrequired.
4.Connectthepositivebatterycabletothepositive
postofthebattery;refertotheOperator’s
Manualforyourmachine.
15

WARNING
Incorrectbatterycableroutingcould
damagethemachineandcablescausing
sparks.Sparkscancausethebattery
gassestoexplode,resultinginpersonal
injury.
•Alwaysdisconnectthenegative
(black)batterycablebefore
disconnectingthepositive(red)
cable.
•Alwaysconnectthepositive(red)
batterycablebeforeconnectingthe
negative(black)cable.
5.Connectthenegativebatterycabletothe
negativepostofthebattery;refertothe
Operator’sManualforyourmachine.
6.Closetherighttoolboxcoverandinstalltheright
consolecover(Figure1).
7.Startthemachineandallowthehydraulic
systemtopressurize.
8.Stoptheengineandcheckthehydraulictubes,
hoses,andttingsforleaks.
Note:Repairallleaksbeforeoperatingthe
machine.
TestingtheFlow-DividerManifold
1.Placethekeyintotheswitch,turnthekeytothe
ONposition,anddisengagetheparkingbrake.
2.Drivethemachineforwardandpressthe4WD
toggleswitchforward.
Note:Youshouldhearthesolenoidsshiftifthe
kitisinstalledproperly.Ifyoudonot,checkthe
wireharnessconnectionsandfuseplacement.
3.Makeatightturnwiththeswitchpressed
forward.
Note:Youshouldfeelthe4WDifthekitis
installedproperly.Ifyoudonot,checkthewire
harnessconnectionsandfuseplacement.
Operation
4WDSwitch
Pressandholdthe4WDtoggleswitchforwardto
momentarilyactivatethe4WDfunctionofthemachine.
g035443
Figure30
1.4WDactive2.Normalposition
OperatingTips
Theowdividerkitenhancesthetractiondrive
performanceincompromisedoperatingconditions.
Important:Ifboththefrontandrearwheelsspin,
featherthesteeringbraketocontrolthetransfer
ofthetorquefromthespinningwheelstothe
oppositefrontwheel.
16

Schematics
g212898
HydraulicSchematic(Rev.A)
17

Notes:

Notes: