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

Figure9
1.Manifold3.Leftframebulkheadbracket5.Hydraulictube,partno.
108-7626
7.Bulkheadnut
2.Rightframebulkhead
bracket
4.Hydraulictube,partno.
108-7624
6.Hydraulictube,partno.
108-7625
8.Tubeclamp
6

5
RemovetheFrontTubeand
theHydraulicHose
NoPartsRequired
Procedure
1.Raisethefrontoftheunitandsupportitonjackstands.
2.Removethelugnutssecuringthewheelassembliesand
removethewheels.
3.Removethecapscrewsandnutssecuringthewheel
shieldstothefrontaxleanges(Figure10).
4.Disconnectthehydraulictubefromthetopttingon
thefrontleftwheelmotorandthebottomttingon
thefrontrightwheelmotor(Figure10).
5.RemovetheR-clampssecuringthetubetotheframe
(Figure10)andthecabletiessecuringthebrakecables
tothehydraulictubes.
LH
RH
Figure10
1.Wheelshields3.Screw5.Locknut
2.Hydraulictube4.Hoseconnectiontting6.R-clamp
6.Disconnectthelefthandhosefromthevariablepump
andthehydraulictube(Figure10).Also,removethe45
degreettingfromthebottomofthevariablepump
(Figure10).
Note:Therighthandhosecanalsoberemovedto
improveclearancefortheremovalandinstallationof
thefronttube.Thisisnotnecessarybutcanaidinthe
installationofthiskit.
7

6
InstalltheFrontTubesandthe
HydraulicHose
Partsneededforthisprocedure:
1Hydraulictube,partno.108-7622
1Hydraulictube,partno.108-7623
1Hydraulictting,90degrees
1Hydraulichose
3Cabletie
Procedure
1.Connecthydraulictube,partno.108-7622,totheright
wheelmotorttingandtotherighthydraulictubein
therightframebulkhead(Figure11).
2.Connecthydraulictube,partno.108-7623,totheleft
wheelmotorttingandtothelefthydraulictubeinthe
rightframebulkhead(Figure11).
3.Installa90degreehydraulicttingintothebottomof
thevariablepump(Figure11).
4.Connectthehydraulichosetothelefthandpump
ttingandtothehydraulictubeatleftframebulkhead.
Iftherighthandhosewasremoved,connectitatthis
time.
5.Securethehydraulichosetothebottomofthebattery
traywithacabletie(Figure11).
6.Installthewheelshieldstothefrontaxleangeswith
thecapscrewsandnutspreviouslyremoved(Figure
10).
7.Installthecabletiestosecurethebrakecablestothe
hydraulictubes.
Figure11
1.Rightwheelmotor4.Leftwheelmotor7.Variablepump10.Batterytray
2.Rightframebulkhead5.Hydraulictube,partno.
108-7623
8.90degreetting11.Cabletie
3.Hydraulictube,partno.
108-7622
6.Leftframebulkhead9.Hydraulichose
8

7
ChecktheHydraulicHoses
andTubes
NoPartsRequired
Procedure
Checkthehydraulictubesandhosesforleaks,loosettings,
kinkedlines,andloosemountingsupports.Makenecessary
repairsbeforeoperating.
Note:Keepareasaroundthehydraulicsystemcleanfrom
grassanddebrisbuildup.
WARNING
Hydraulicuidescapingunderpressurecan
penetrateskinandcauseinjury.Fluidaccidentally
injectedintotheskinmustbesurgicallyremoved
withinafewhoursbyadoctorfamiliarwiththis
formofinjuryorgangrenemayresult.
•Keepbodyandhandsawayfrompinholeleaks
ornozzlesthatejecthighpressurehydraulic
uid.
•Usecardboardorpapertondhydraulicleaks.
1.InstalltheR-clampsremovedpreviouslyusing2screws
andlocknutstosecurethehydraulictubestothe
machineframeshowninFigure12.
Figure12
1.Machineframe4.Screw
2.Hydraulictubes5.Locknut
3.R-clamp
2.Installthefronttiresusingthefastenersremoved
previously.Torquethelugnutsto85-100ft-lb.
3.Removethemachinefromthejackstandsandlower
theunittotheoor.
4.Checkthehydraulicoillevel.Ifnecessary,adduid
tothebringtheleveltothefullmarkonthedipstick.
RefertotheOperator'sManualformoreinformation.
5.Operatethemachinetotestforleaks.Shutdownthe
machineasspeciedintheOperator'sManualandcheck
forleaksinthehydraulicsystem.
6.Checkthehydraulicoillevelonemoretime.If
necessary,adduidtothebringtheleveltothefull
markonthedipstick.RefertotheOperator'sManual
formoreinformation.
9

8
InstalltheDecals
Partsneededforthisprocedure:
2Decal
1Decal110–8869,danger
1Decal110–8973,CEdanger(Europeonly)
Procedure
1.Installeachdecalatlocationsbelowasfollows:
A.Thoroughlycleantheareawhereyouwillinstall
thedecal.
B.Dampentheareawithwaterormildlysoapywater.
C.Peelthedecalfromthebackingandinstallitin
place.
D.Squeegeeacrossthesurfaceofthedecal,starting
atthecenterofthedecalandworkingtowardthe
edges,usingoverlappingstrokes.
2.UsingthedimensionsshowninFigure13,locateand
afxaCROSSTRAXdecaltothelowerrearcorner
ofeachsideofthehood.
Figure13
1.4.00inches2.1.00inch
3.Afxtheappropriatedangerdecalovertheexisting
decalontheoperatorplatform(Figure14):
•Fordomesticunitsapplydecal110-8869.
•ForCE(European)unitsapplydecal110-89673.
Figure14
1.Dangerdecal
10

Schematics
HydraulicSchematic(Rev.A)
11

DeclarationofIncorporation
TheT oroCompany,8111LyndaleAve.South,Bloomington,MN,USAdeclaresthatthefollowingunit(s)
conform(s)tothedirectiveslisted,wheninstalledinaccordancewiththeaccompanyinginstructionsontocertain
ToromodelsasindicatedontherelevantDeclarationsofConformity.
ModelNo.SerialNo.ProductDescriptionInvoiceDescriptionGeneralDescriptionDirective
03655—CrossTraxAll-WheelDriveKitCROSSTRAXAWDKIT
[F15ANDNEWER]CrossTraxAll-WheelDriveKit2006/42/EC,
2000/14/EC
RelevanttechnicaldocumentationhasbeencompiledasrequiredperPartBofAnnexVIIof2006/42/EC.
Wewillundertaketotransmit,inresponsetorequestsbynationalauthorities,relevantinformationonthispartly
completedmachinery.Themethodoftransmissionshallbeelectronictransmittal.
ThismachineryshallnotbeputintoserviceuntilincorporatedintoapprovedT oromodelsasindicatedonthe
associatedDeclarationofConformityandinaccordancewithallinstructions,wherebyitcanbedeclaredin
conformitywithallrelevantDirectives.
Certied:EUTechnicalContact:
PeterTetteroo
ToroEuropeNV
B-2260Oevel-Westerloo
Belgium
DavidKlisTel.003214562960
Sr.EngineeringManagerFax003214581911
8111LyndaleAve.South
Bloomington,MN55420,USA
September26,2013
12