Toro 03655 User manual

FormNo.3385-758RevB
CrossTraxAll-WheelDriveKit
2015andAfterReelmaster®5010SeriesTractionUnit
ModelNo.03655
InstallationInstructions
Note:Thiskit,wheninstalledtoReelmaster5010seriesTractionUnits,iscoveredbyPatent#7,017,703.
WARNING
Bodilyinjurycouldoccurifthetractionunitrollsover.
Whenoperatingmachine,alwaysusetheseatbeltandROPStogether.
Safety
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential
danger.Replaceanydecalthatisdamagedorlost.
110-8869
1.Warning—readtheOperator'sManual,donotoperatethis
machineunlessyouaretrained.
2.Thrownobjecthazard—keepbystandersasafedistance
fromthemachine.
3.Tippinghazard—slowmachinebeforeturning,donotturn
athighspeeds;lowerthecuttingunitwhendrivingdown
slopes;usearolloverprotectionsystemandweartheseat
belt.AlwayswearaseatbeltwhenaROPSisinplace.
4.Warning—donotparkthemachineonslopes;engagethe
parkingbrake,lowerthecuttingdecks,stoptheengineand
removetheignitionkeybeforeleavingthemachine.
5.Warning—readtheOperator'sManual,donottowthe
machine.
110-8973
(Afxoverpartno.110–8869forCE*)
*Thissafetydecalincludesaslopewarningrequiredonthemachinefor
compliancetotheEuropeanLawnMowerSafetyStandardEN836:1997.The
conservativemaximumslopeanglesindicatedforoperationofthismachineare
prescribedbyandrequiredbythisstandard.
1.Warning—readtheOperator'sManual,donotoperatethis
machineunlessyouaretrained.
2.Thrownobjecthazard—keepbystandersasafedistance
fromthemachine.
3.Tippinghazard—donotoperateonslopesgreaterthan15°;
lowerthecuttingdeckswhenoperatingonslopes;wear
thesafetybelt.
4.Warning—donotparkthemachineonslopes;engagethe
parkingbrake,lowerthecuttingdecks,stoptheengineand
removetheignitionkeybeforeleavingthemachine
5.Warning—readtheOperator'sManualbeforetowingthe
machine.
©2014—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.OriginalInstructions(EN)
PrintedintheUSA.
AllRightsReserved*3385-758*B

Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
RHwheelmotor1
LHwheelmotor1
Hydraulictting,45degrees4
Bolt(1/2x2-1/4inch)8
1
Lockwasher(1/2inch)8
Mountthewheelmotorassemblies.
Manifold1
Hydraulictting,straight7
Diagnostictting2
Dustcap2
Bolt(3/8x1-3/4inches)3
Lockwasher(3/8inch)3
2
Spacer3
Installthemanifold.
3Hydraulichose4Installthewheelmotorhoses.
Hydraulictube,partno.108-76241
Hydraulictube,partno.108-76251
Hydraulictube,partno.108-76261
Bulkheadlocknut3
Tubeclamphalves2
Capscrew(5/16x1-1/2inches)1
Flatwasher(.344x.688)1
4
Locknut(5/16inch)1
Installingthemanifoldtubes.
5Nopartsrequired–Removingthefronttubeandthe
hydraulichose.
Hydraulictube,partno.108-76221
Hydraulictube,partno.108-76231
Hydraulictting,90degrees1
Hydraulichose1
6
Cabletie3
Installingthefronttubesandthe
hydraulichose.
7Nopartsrequired–Checkingthehydraulichosesandtubes.
Decal2
Decal110–8869,danger1
8Decal110–8973,CEdanger(Europe
only)1
Installingthedecals.
MediaandAdditionalParts
DescriptionQty.Use
Installationinstructions1Usetoinstallthekit
Partscatalog1Usetoreferencepartnumbers
2

1
MountingtheWheelMotor
Assemblies
Partsneededforthisprocedure:
1RHwheelmotor
1LHwheelmotor
4Hydraulictting,45degrees
8Bolt(1/2x2-1/4inch)
8Lockwasher(1/2inch)
Procedure
1.Jackuptherearofthemachineandsupportitwith
jackstands.
2.Removethe5lugnutssecuringeachreartiretothe
wheelspindlehub(Figure1).Removethetires.
Figure1
1.Reartire3.Wheelspindle
2.Wheelspindlehub4.Wheelhousing
3.Removethe4angeboltssecuringeachwheelspindle
toeachwheelhousing(Figure1).Removethewheel
spindles.Thewheelhubdoesnotneedtoberemoved
fromthespindle.
4.Installtwo45degreehydraulicttingsintoeachwheel
motorassembly(Figure2).Positionthettingssothey
pointstraighttotherear.
Note:MakesuretheO-ringsarelubricatedandin
positiononallofthettingsbeforeinstallation.
Figure2
Righthandsidewheelmotorshown
1.Wheelmotor3.Identicationgrooves
2.45degreettings
5.IdentifytheLeftandRighthandwheelmotors.The
wheelmotorfortheRighthandsideofthemachine
isidentiedwithgroovesintheoutersurfaceofthe
motorhousing.Forfurtherverication,theleft-hand
motorcanbeidentiedbyasmallyellowstickeror
paintmarkonthemotorhousing.
6.Mounttherespectivewheelmotorassemblytoeach
wheelhousingwith4bolts(1/2x2-1/4inch)andlock
washers(1/2inch)(Figure3).Torquetheboltsto
70-80ft-lb.
Figure3
1.Wheelmotor3.Wheelmotorbolt
2.Wheelhousing4.Lockwasher
3

2
InstallingtheManifold
Partsneededforthisprocedure:
1Manifold
7Hydraulictting,straight
2Diagnostictting
2Dustcap
3Bolt(3/8x1-3/4inches)
3Lockwasher(3/8inch)
3Spacer
Procedure
1.Install4straighthydraulicttingsintotherearofthe
manifold(Figure4).
Figure4
1.Manifold4.Dustcap(2)
2.Straighttting,rearinstall
(4)
5.Straighttting,underside
install(3)
3.Diagnostictting(2)
2.Install2diagnosticttingsintoeithersideofthe
manifoldalongwithdustcaps(Figure4).
3.Install3straighthydraulicttingsintothebottomof
themanifold(Figure4).
4.Mountthemanifoldassemblytotheundersideofthe
manifoldbracketwith3bolts(3/8x1-3/4inches),
lockwashers(3/8inch)andspacers.Positionthe
spacersbetweenthemanifoldbracketandthetopof
themanifold.Themanifoldistobepositionedsothe
ttingspointtotherear,anddown(Figure5).
Note:MakesuretheO-ringsarelubricatedandin
positiononallofthettingsbeforeinstallation.
Figure5
1.Manifoldassembly4.Bolt(3/8x1-3/4inches)
2.Machineframe5.Lockwashers(3/8inch)
3.Spacer
3
InstallingtheWheelMotor
Hoses
Partsneededforthisprocedure:
4Hydraulichose
Procedure
1.Looselythreadthe45degreettingendofeach
hydraulichoseontothestraightttingsattherearof
themanifold(Figure6).
Figure6
1.LHtting,at10degrees2.RHtting,at10degrees
2.Routethe2lefthosestotheleftwheelmotor.Connect
theuppermanifoldhosetotheupperwheelmotor
4

ttingandthelowermanifoldhosetothelowerwheel
motortting(Figure7).Ifthehosesarenotproperly
routedtheymaycomeincontactwiththetiresorrear
bumperwhichwillcausedamagetothehoses.
Important:Donotcrossthehydraulichosesas
theyareroutedfromthemanifoldtothewheel
motors.
Figure7
1.90degrees2.10degrees
3.Repeattheprocedurefortherightwheelmotor.
PositionthehosesasshowninFigure8andtighten
allthehosettings.
Figure8
1.90degrees2.10degrees
4.Reinstallthereartiresandtorquethelugnutsto85-100
ft-lb.
Important:Checkthehoseroutingtoensure
thereisproperclearancewhentheaxleisoscillated
andwhenthesteeringwheelisoperatedinafull
rightandleftlockturn.Theminimumtiretoaxle
clearanceshouldbe1/2inch(13mm).
4
InstalltheManifoldTubes
Partsneededforthisprocedure:
1Hydraulictube,partno.108-7624
1Hydraulictube,partno.108-7625
1Hydraulictube,partno.108-7626
3Bulkheadlocknut
2Tubeclamphalves
1Capscrew(5/16x1-1/2inches)
1Flatwasher(.344x.688)
1Locknut(5/16inch)
Procedure
1.Routethehydraulictube,partno.108-7624,fromthe
leftmanifoldttinglabeled“RF”totherightholein
therightframebulkheadbracket(Figure9).
2.Securetherearofthehydraulictubetothemanifold
ttingandthefronttothebulkheadwithabulkhead
locknut(Figure9).
3.Routehydraulictube,partno.108-7626,fromthe
centermanifoldttinglabeled“REV”totheholein
theleftframebulkheadbracket(Figure9).
4.Securetherearofthehydraulictubetothemanifold
ttingandthefronttothebulkheadbracketwitha
bulkheadlocknut.
5.Routehydraulictube,partno.108-7625,fromtheright
manifoldttinglabeled“LF”totheleftholeinthe
rightframebulkheadbracket(Figure9).
6.Securetherearofthehydraulictubetothemanifold
ttingandthefronttothebulkheadwithabulkhead
locknut.
7.Securethe2rightbulkheadlinestogetherwiththetube
clamphalves,capscrew(5/16x1-1/2inches),at
washer(.344x.688)andalocknut(5/16inch)(Figure
9).
5