Toro 31527 User manual

FormNo.3459-502RevA
FlowDividerKit
Groundsmaster®4500-Dor4700-DTractionUnit
ModelNo.31527
InstallationInstructions
ThisproductcomplieswithallrelevantEuropeandirectives.Fordetails,pleaseseetheDeclarationof
Incorporation(DOI)atthebackofthispublication.
Safety
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea
ofpotentialdanger.Replaceanydecalthatisdamagedormissing.
decal132-6104
132-6104
1.4WDLock2.4WDUnlock
decal132-6185
132-6185
1.4WDLock(10A)
©2022—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3459-502*

Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachine.
2Nopartsrequired–Removethehydrauliclines.
Plug1
Valve2
Coil(12V)2
3Coilnut2
Installthecoilsontheow-divider
manifoldassembly(4WDswitch
installationonly).
Flow-dividermanifold1
Pressurehose1
Manifoldtube1
Traction-motortube1
Dividertube1
Tankhose1
Bolt2
4
Flangenut2
Installthehydrauliccomponents.
Fuse(10A)1
5Fusedecal1
Installthefuse(4WDswitchinstallation
only).
Toggleswitch1
Wireharness1
64WDfunctiondecal1
Installtheswitch.
Wireharness1
Relay1
7Self-tappingscrew1
Installthewireharnesstothemachine
(4WDswitchinstallationonly).
8Nopartsrequired–Completingtheinstallation.
Important:ThiskitisonlyintendedforusewithGroundsmasterModels30881,30882,30873,30873TE,
30874,and30874TEserialnumbers40000000andup.
Note:Theproceduresforinstallingthiskitrequirethatyouworkfromunderthemachine.
2

1
PreparingtheMachine
NoPartsRequired
Procedure
Note:Youcanuseahoistforbetteraccessunder
themachine.
Important:Caporpluganydisconnected
hydraulichoses,tubes,orcomponentportsto
preventcontaminatingthesystem.
1.Parkonalevelsurface,engagetheparking
brake,ensurethatthetractionpedalisinthe
neutralposition.
2.EnsurethatthePTObuttonisintheOFF
position.
3.Shutofftheengine,removethekey,andallow
themachinetocool.
CAUTION
Ifyouleavethekeyintheignition
switch,someonecouldaccidentlystart
theengineandseriouslyinjureyouor
bystanders.
Removethekeyfromtheswitchbefore
youdoanymaintenance.
4.Bleedthepressurefromthehydraulicsystem
byturningthehydraulicpumpbypassvalve;
refertotheinstructionsforpushingortowingthe
machineintheOperator’sManual.
5.Ifyouarenotinstallingthe4WDswitch,skip
to2RemovingtheHydraulicLines(page4).If
youareinstallingthe4WDswitch,continuethis
procedure.
6.Opentherighttoolboxcoveranddisconnectthe
negativecablefromthebatterypost;refertothe
Operator’sManualforyourmachine.
WARNING
Incorrectbattery-cableroutingcould
damagethemachineandcablescausing
sparks.Sparkscancausethebattery
gassestoexplode,resultinginpersonal
injury.
•Alwaysdisconnectthenegative
(black)batterycablebefore
disconnectingthepositive(red)
cable.
•Alwaysconnectthepositive(red)
batterycablebeforeconnectingthe
negative(black)cable.
7.Disconnectthepositivebatterycablefromthe
battery;refertotheOperator’sManualforyour
machine.
8.Removetherightconsolecoverasshownin
Figure1.
g204998
Figure1
1.Righttoolboxcover2.Rightconsolecover
3

2
RemovingtheHydraulic
Lines
NoPartsRequired
RemovingthePressureHose
1.Alignadrainpanbelowtheforwardendofthe
pressurehose(Figure2).
g021275
Figure2
BottomViewShown
1.Tractionmotor7.Crosstube(rear-traction
manifold)
2.T-tting8.Hydraulicpump
3.Dividertube9.Rear-tractiontube
4.Pressurehose10.Clamp
5.Hydraulic-ltertube11.Tubebracket
6.Rear-tractionmanifold12.Forward
2.Removetheforwardendofthepressurehose
fromthettinginthedividertube,andallowthe
hydraulicuidtodrainfromthehoseandtube
(Figure3).
g021282
Figure3
SideViewShown
1.Bolts6.Tubebracket
2.Chassisbracket7.Pressurehose
3.Dividertube8.Up
4.Nut9.Forward
5.Clamp
3.Removetherearendofthepressurehosefrom
thettinginthehydraulicpump,andremovethe
pressurehose;refertoFigure2andFigure3.
4.Temporarilycapthepumpandthedividertube.
Note:Discardtheoriginalpressurehose.
RemovingtheCrossTube
1.Alignthedrainpanbelowtherear-traction
manifold.
2.Removethetubenutforthecrosstubefromthe
ttingintherear-tractionmanifold(Figure2or
Figure3).
3.Removethetubenutfortheltertubefromthe
ttinginthecrosstube,andremovethecross
tube(Figure2orFigure3).
Important:Retaintheltertubefor
installationinInstallingtheFilterTubeand
theDividerTube(page9).
Note:Discardthecrosstube.
4.Temporarilycapthettingintherear-traction
manifold.
4

RemovingtheTubeBracketand
Clamp
1.Removetheboltandthenutthatsecurethe
dividertubetothetubebracket,andremovethe
clamp(Figure3orFigure2).
2.Removethe2boltsandthe2nutsthatsecure
thetubebrackettothechassisbracket(Figure3
orFigure2).
Note:Discardthetubebracket,clamp,and
hardware.
RemovingtheDividerTube
1.Removethetubenutfortherear-tractiontube
fromthettingofthedividertube.
2.Removethetubenutofthedividertubefrom
theT-ttinginthefront-lefttractionmotor,and
removethetubefromthemachine(Figure2or
Figure3).
Note:Discardthedividertube.
3.Ifyouareinstallingthe4WDswitch,continue
thisprocedure.Ifyouarenotinstallingthe
4WDswitch,skipto4InstallingtheHydraulic
Components(page7).
RemovingtheTankHose
Important:Thisprocedureisnecessaryifyou
installthe4WDswitch.
1.Alignadrainpanbelowtheforward,straightend
ofthetankhose.
2.Removetheforwardendofthetankhosefrom
thettinginthehydraulicuidtank,capthe
ttingonthetank,andallowthehydraulicuid
todrainfromthehose.
g205311
Figure4
BottomView
1.Hydraulic-tanktting3.Bulkheadtting
2.Tankhose
3.Removetherear,angledendofthetankhose
fromthebulkheadttingandremovethetank
hose.
4.Temporarilycapthebulkheadtting.
Note:Discardtheoriginaltankhose.
5

3
InstallingtheCoilson
theFlow-DividerManifold
Assembly
4WDSwitchOnly
Partsneededforthisprocedure:
1Plug
2Valve
2Coil(12V)
2Coilnut
Procedure
Important:Themanifoldcomespre-assembled
forusewithouttheswitch;thisprocedureis
necessaryifyouinstallthe4WDswitch.
1.Removethe2existingvalvesfromtheCV1and
CV2portsofthemanifold.
2.Installtheappropriatepartstotheow-divider
manifoldasshowninFigure5.
g230515
Figure5
1.Coilnut4.Existingorice(removed)
2.Coil(12V)5.Plug
3.Valve6.Neworice
3.Torquethecoilnutsto6.8to9.5N∙m(5to7
ft-lb).
4.Torquethevalvesto34N∙m(25ft-lb).
5.Installtheplugovertheneworice.
Note:Youmaydiscardtheremovedoriceand
valves.
6

4
InstallingtheHydraulic
Components
Partsneededforthisprocedure:
1Flow-dividermanifold
1Pressurehose
1Manifoldtube
1Traction-motortube
1Dividertube
1T ankhose
2Bolt
2Flangenut
InstallingtheFlow-Divider
Manifold
1.Aligntheholesintheow-dividermanifoldwith
theholesinthechassisbracket.
Note:Ensurethatthe45°ttingispointing
downandtowardthebackofthemachine.
g205001
Figure6
BottomViewShown
1.Front,righttire4.Coils(forusewith4WD
switchonly)
2.Flangenuts5.Flow-dividermanifold
3.Chassisbracket6.Bolts
2.Securetheow-dividermanifoldtothechassis
bracketwiththe2boltsand2angenuts.
Tightentheboltsto37to45N∙m(27to33ft-lb).
InstallingtheRear-TractionTube
andthePressureHose
1.Aligntheforwardtubenutfortherear-traction
tubewiththeelbowttingintheow-divider
manifold(Figure7andFigure8).
g205002
Figure7
1.Traction-motortube7.Hydraulicpump
2.Dividertube8.Rear-tractiontube
3.Hydraulic-ltertube9.Flow-dividermanifold
4.Rear-tractionmanifold10.Tractionmotor
5.Cross-manifoldtube11.Forward
6.Pressurehose
2.Threadtheforwardtubenutontotheelbow,and
tightenthenutto51to63N∙m(37to47ft-lb).
7

g205014
Figure8
1.Flow-dividermanifold4.Pressurehose(pump
tting)
2.Pressurehose(divider
tting)
5.Hydraulicpump
3.Rear-tractiontube
(forwardtting)
6.Forward
3.Removethetemporarycapfromthehydraulic
pump.
4.Threadonestraightendofthepressurehose
intothettinginthehydraulicpump(Figure8).
5.Removethetemporarycapfromtheow-divider
manifold.
6.Threadtheotherstraightendofthepressure
hoseintothettinginthesideoftheow-divider
manifold(Figure8).
7.Tightenthehosettingsto150to184N∙m(110
to136ft-lb).
InstallingtheCrossTube
1.Removethecaponthettingoftherear-traction
manifoldthatyoupreviouslyinstalled.
2.Alignthetubenutsforthecross-manifoldtubeto
thettingsintherear-tractionmanifoldandthe
ow-dividermanifold(Figure9).
g205016
Figure9
1.Rear-tractionmanifold4.Flow-dividermanifold
2.Cross-manifoldtube
(rear-tractionmanifold
tting)
5.Forward
3.Cross-manifoldtube
(dividertting)
3.Threadthetubenutsontothettingsinthe
ow-dividermanifoldandtherear-traction
manifold,andtightenthenutsto51to63N∙m
(37to47ft-lb).
8

InstallingtheFilterTubeandthe
DividerTube
1.Preparethehydraulic-ltertuberetainedfrom
RemovingtheCrossTube(page4).Alignthe
tubenutforthehydraulic-ltertubetothetting
inthecross-manifoldtubeasshowninFigure
10.
g205017
Figure10
1.Dividertube(ow-divider
tting)
5.Dividertube
(cross-manifoldtube
tting)
2.Hydraulic-ltertube(lter
basetting)
6.Hydraulic-ltertube
(cross-manifoldtube
tting)
3.Flow-dividermanifold7.Forward
4.Cross-manifoldtube
2.Threadthetubenutforthehydraulic-ltertube
ontothettinginthecross-manifoldtube,and
tightenthenutto51to63N∙m(37to47ft-lb).
3.Alignthetubenutsforthedividertubetothe
ttingsinthecross-manifoldtubeandthe
ow-dividermanifold(Figure10).
4.Threadthetubenutsforthedividertubeonto
thettingsinthecross-manifoldtubeandthe
ow-dividermanifold,andtightenthenutsto37
to45N∙m(27to33ft-lb).
InstallingtheTraction-MotorTube
1.Alignthetubenutsforthetraction-motortube
tothettingsinthetractionmotorandthe
ow-dividermanifold(Figure11).
g205018
Figure11
1.Tractionmotor4.Traction-motortube
(ow-dividertting)
2.T-tting5.Flow-dividermanifold
3.Traction-motortube
(traction-motortting)
6.Forward
2.Threadthetubenutsforthetraction-motortube
ontothettingsinthetractionmotorandthe
ow-dividermanifold,andtightenthenutsto116
to142N∙m(85to105ft-lb).
9

InstallingtheTankHose
Important:Thisprocedureisnecessaryifyou
installthe4WDswitch.
1.Removethetemporarycapfromthebulkhead
ttingandthreadtheangledendofthetank
hoseontothebulkheadtting.
g205309
Figure12
BottomView
1.Hydraulictanktting3.Bulkheadtting
2.Tankhose
Note:Ensureclearanceforthecoilsbyfacing
theangledendandhoseouttowardtheright
sideofthemachine,perpendiculartotheframe.
2.Removethetemporarycapfromthettingon
thehydraulicuidtank,andthreadthestraight
endofthetankhoseontothetting.
3.Tightentheforward,straightendattachedtothe
tankto50to64N∙m(37to47ft-lb).
4.Tightentheangledendattachedtothebulkhead
to81to100N∙m(60to74ft-lb).
10

5
InstallingtheFuse
4WDSwitchOnly
Partsneededforthisprocedure:
1Fuse(10A)
1Fusedecal
Procedure
Important:Thisprocedureisnecessaryifyou
installthe4WDswitch.
1.InstallthefuseintotheC4slotinthefusebox
(Figure13).
Note:Ifanotherfuseisalreadyoccupyingthe
C4slot,placethefuseinanyopenauxiliaryslot.
g205019
Figure13
1.C4Slot3.Auxiliaryslot
2.Fuse
Important:Notewhichfuseslot
correspondstowhichauxiliarypowerwire.
Iftheswitchisconnectedtoawirewithouta
fuse,itwillnotfunction.
2.Placethefusedecalinthecorrespondingpanel
ofthefusemapdecallocatedunderthetoolbox
cover.
g206710
Figure14
FusedecalinC4slot
1.C5Auxiliaryslot2.C4Auxiliaryslotwithdecal
11

6
InstallingtheSwitch
Partsneededforthisprocedure:
1T oggleswitch
1Wireharness
14WDfunctiondecal
Procedure
1.Drilla13mm(1/2inch)holeinthecenter
console;refertoFigure15fortheappropriate
orientation.
Important:Usecautiontonothitany
componentsorwiresunderneaththe
consolewiththedrillbit.
g034547
Figure15
1.13mm(1/2inch)diameter3.25mm(1inch)
2.13mm(1/2inch)from
thecenterofholetothe
rightedgeofthehigh-low
speedcontrolswitch
2.Placethe4WDfunctiondecaloverthedrilled
hole(Figure16).
g205310
Figure16
3.Identifytheswitchterminallocations,wire
harnesslabels,andwireharnesscolors(Figure
17).
Theswitchterminalsareidentiedbythe
numbersimprintedintothebottomoftheswitch.
Note:Theswitchisspring-loadedtotherearof
theswitch(Figure18).Theswitchisnormally
openbetweenterminals1and2(Figure17).
g273505
Figure17
Installedswitchorientation
1.Terminal1—rear3.Terminal3—front
2.Terminal2—center
12

4.SecuretheredwirelabeledBYPASSENGAGE
SWITCH2totheoverrideswitchcenterterminal
number2(Figure17andFigure18).
5.SecurethegraywirelabeledBYPASSENGAGE
SWITCH1totheoverrideswitchrearterminal
number1(Figure17andFigure18).
Important:Incorrectswitchwiringcan
resultindamagetothehydraulicsystem.
Verifythatthewiringisinstalledcorrectly;
refertoTestingtheFour-WheelDrive(page
18).
g273521
Figure18
1.Spring-loadedtotherear
oftheswitch
5.Frontterminal
2.Toggleswitch6.Centerterminal
3.Graywire7.Rearterminal
4.Redwire
6.Routethetoggleswitchwiththeconnected
wireharnessintotherearofthecenterconsole
(Figure19).
g035968
Figure19
1.Toggleswitch2.Rearofcenterconsole
7.Pullthetoggleswitch/wireharnessthroughthe
centerconsoleuptothedrilledhole(Figure20).
g035969
Figure20
1.Rearofcenterconsole2.Toggleswitch
8.Installthetoggleswitchintothe13mm(1/2
inch)holefromthebottomoftheconsole;refer
toFigure21forthecorrecthexlocknutand
washerorientation.
Note:Installtheswitchspring-loadedtoward
therearofthemachine.
Discardthetabbedwasherincludedwiththe
toggleswitch.
13

g274109
Figure21
1.Hexlocknut3.Hexlocknut
2.Washer(15/32inch)4.Toggleswitch
7
InstallingtheWireHarness
totheMachine
4WDSwitchOnly
Partsneededforthisprocedure:
1Wireharness
1Relay
1Self-tappingscrew
Procedure
Important:Thisprocedureisnecessaryifyou
installthe4WDswitch.
1.Routethewireharnessalongtheexisting
harnessintotheopeningintheframebehindthe
seat(Figure22).
g205030
Figure22
Toolboxshellremovedforclarity
1.Entranceintorighttoolbox4.Existingwireharness
2.Openinginframe5.Rearofrightconsole
3.Newwireharness
2.Securethenewwireharness,intheconsole,to
theexistingwireharness.
3.Routetheterminalplugandtheeyelet
connectionintotherighttoolbox(Figure23).
14

g205036
Figure23
1.Entranceintorighttoolbox3.Rearofrightconsole
2.Newwireharness
4.Plugthewireharnessterminalintotheauxiliary
powerwireleavingthefuseblockasshownin
Figure24.
Important:Ensurethatthechosenauxiliary
powerwireisassociatedwiththenewfuse,
ortheswitchwillnotfunction.Performa
continuitytestwithamulti-metertoconrm
thattheintendedslotandwirematch.
g205031
Figure24
1.Auxiliaryslots3.Newwireharnessterminal
2.Auxiliarypowerwire
5.Connecttheeyeletconnectiontotheground
terminalblockasshowninFigure25.
g205032
Figure25
6.Unlatchtheseat;refertotheOperator’sManual
foryourmachine.
7.Connecttherelaytotherelaymountwiththe
providedself-tappingscrewasshowninFigure
26.
g205033
Figure26
1.Bottomofseatplatform2.Relay
8.Plugtherelayconnectorintotherelayasshown
inFigure27.
15

g205034
Figure27
1.Relay3.Wireharnesscontinuing
downtoow-divider
manifold
2.Relayconnector
9.Routethe2remainingwiresthatarenotdirectly
attachedtotherelayhalfwayalongtheexisting
wireharnessundertheframeuntildirectlyabove
the3-waymanifold(Figure28).
g205054
Figure28
1.Wireharnessleading
downtoow-divider
manifold
3.Wireharnessendsat
3-waymanifold
2.Wireharnessroutedalong
frame
4.3-waymanifoldlocation
beneathlowerframe
10.Unplugthecoilfromthe3-waymanifold(Figure
29).
g205037
Figure29
BottomView
1.Coilfromexistingwire
harness
3.3-waymanifold
2.Connection3-way
manifold
4.Frontofmachine
11.Connecttheplugyoujustremovedintothefree
socketonthenewwireharness(Figure30).
g205039
Figure30
BottomView
1.Freesocket2.Existingplug
12.Connecttheangledplugfromthenewwire
harnessintothecoilonthe3-waymanifold
Figure31.
16

g205040
Figure31
BottomView
1.Angledplug3.3-waymanifold
2.3-waymanifoldcoil
13.Routetheremaininglooseharnessendsdown
aroundthelowerframeandconnectthemto2
coilsontheow-dividermanifoldjustinsideof
theright,fronttire(Figure28andFigure32).
g205041
Figure32
BottomView
1.Rightofmachine2.Frontofmachine
8
CompletingtheInstallation
NoPartsRequired
CompletingtheInstallation(4WD
SwitchOnly)
1.Connectthepositivebatterycabletothepositive
postofthebattery;refertotheOperator’s
Manualforyourmachine.
WARNING
Incorrectbattery-cableroutingcould
damagethemachineandcablescausing
sparks.Sparkscancausethebattery
gassestoexplode,resultinginpersonal
injury.
•Alwaysdisconnectthenegative
(black)batterycablebefore
disconnectingthepositive(red)
cable.
•Alwaysconnectthepositive(red)
batterycablebeforeconnectingthe
negative(black)cable.
2.Connectthenegativebatterycabletothe
negativepostofthebattery;refertothe
Operator’sManualforyourmachine.
3.Closetherighttoolboxcoverandinstalltheright
consolecover(Figure1).
17

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
injectedintotheskin.
1.Checkandtightenallttingsandhydraulic
connections.
2.Ensurethatthehydraulicpumpbypassvalveis
intheoperationposition;refertothepushingor
towingthemachineinstructionsintheOperator’s
Manual.
3.Checkthehydraulic-uidlevelandreplenishit
asrequired;refertotheOperator’sManualfor
yourmachine.
4.Startthemachineandallowthehydraulic
systemtopressurize.
5.Shutofftheengineandcheckthehydraulic
tubes,hoses,andttingsforleaks.
Note:Repairallleaksbeforeoperatingthe
machine.
Important:Thiscompletestheinstallation.
TestingtheFour-WheelDrive
1.Placethekeyintotheswitch,turnthekeytothe
ONposition,anddisengagetheparkingbrake.
2.Drivethemachineforwardandpressthe4WD
toggleswitchforward.
Note:Youshouldhearthesolenoidsshiftifthe
kitisinstalledproperly.Ifyoudonot,checkthe
wireharnessconnectionsandfuseplacement.
3.Makeatightturnwiththeswitchpressed
forward.
Note:Youshouldfeelthe4WDifthekitis
installedproperly.Ifyoudonot,checkthewire
harnessconnectionsandfuseplacement.
18

Operation
OperatingTips
Theowdividerkitsplitsthetractionowbetweenthe
frontandrearwheels.Thiswillrequirebothafrontand
areartiretospinbeforethemachinelosestraction.
Usethefollowinginformationtobestoperatethe
machinewiththeowdividerkitinstalled:
•Theowdividerkitisforuseinthelow-speed
rangeonly.Thesystemdoesnotallowittooperate
inthehigh-speedrange.
•Ifbothafrontwheelandarearwheelspin,itmay
behelpfultousethesteeringbrakes.Applythe
brakepedalcorrespondingtothespinningfront
wheelinordertotransfertorquetothewheelthat
stillhastraction.
Thisowdividerkitevenlysplitstractionowbetween
thefrontandrearwheelmotors.Thismeansthat
bothafrontandareartirewillneedtospinbefore
themachinelosestraction.
Note:Whentheowdividerisactive,thetraction
systemperformanceismoreaggressive,particularly
whilethemachineisturning.Becarefulandpractice
operationinaninconspicuousareatounderstand
tractionperformanceonyourmachine.
The2optionalinstallationshaveslightlydifferent
operationalcharacteristics:
•AutomaticFlowDividerOption:Theowdivider
isALWAYSactivewhenthemachineisdriving
forward.Therearenoelectronicsorswitches
involved.
•Manually-activatedFlowDividerOption:Aswitch
isinstalledontheoperatorcontrolpanel.When
notmanually-activated,thetractionbehavioris
identicaltoamachinewithoutaowdivider.The
operatorcanengagetheswitchwhendesired,
activatingtheowdivider,evenlysplittingow
betweenthefrontandreartractionmotorswhile
themachineisdrivingforward.
Note:Themanually-activatedoptionisonlyfunctional
whenthemachineisintheLOWspeedrange.
Thehigh-lowspeedcontrolswitchonthemachine
mustbeintheLOWsettingfortheowdividerto
activate.
19

Notes: