Toro 03655 Bedienungsanleitung

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.

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

Lockwasher(1/2inch)8

Mountthewheelmotorassemblies.

Manifold1

Hydraulictting,straight7

Diagnostictting2

Dustcap2

Bolt(3/8x1-3/4inches)3

Lockwasher(3/8inch)3

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

Locknut(5/16inch)1

Installingthemanifoldtubes.

5Nopartsrequired–Removingthefronttubeandthe

hydraulichose.

Hydraulictube,partno.108-76221

Hydraulictube,partno.108-76231

Hydraulictting,90degrees1

Hydraulichose1

Cabletie3

Installingthefronttubesandthe

hydraulichose.

7Nopartsrequired–Checkingthehydraulichosesandtubes.

Decal2

Decal110–8869,danger1

8Decal110–8973,CEdanger(Europe

only)1

Installingthedecals.

MediaandAdditionalParts

DescriptionQty.Use

Installationinstructions1Usetoinstallthekit

Partscatalog1Usetoreferencepartnumbers

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

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

InstallingtheWheelMotor

Hoses

Partsneededforthisprocedure:

4Hydraulichose

Procedure

1.Looselythreadthe45degreettingendofeach

hydraulichoseontothestraightttingsattherearof

themanifold(Figure6).

Figure6

1.LHtting,at10degrees2.RHtting,at10degrees

2.Routethe2lefthosestotheleftwheelmotor.Connect

theuppermanifoldhosetotheupperwheelmotor

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).

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).

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

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.

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.

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

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.

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

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