Toro 106-2053 Installation Instructions

Shock Valve Kit

100 and 200 Series Z Masters

Part No. 106–2053

Form No. 3327–812

Installation Instructions

This service kit is designed for the replacement or the addition of the Hydro–Gear Shock Valve relief valve cartridges in the hydro pumps on Toro 100 and 200 Series Z Master units.

Note: This kit contains the parts required for one pump. Two kits are needed when updating both pumps on a machine.

Loose Parts

Note: Use the chart below to identify parts for assembly.

DESCRIPTION QTY. USE

Shock valve, .024 in. orifice Shock valve, no orifice Spring Valve cap

Note: Determine the left and right sides of the machine from the normal operating position.

Before Installing this Kit

Important Use extreme care to ensure the hydraulic

system is not contaminated. Particles as small as lint, dust, or human hair have the

potential to cause failure of the hydraulic system. Take care removing and installing these components to

protect the integrity of the system.

1. Thoroughly clean the area around both hydraulic

pumps.

1 1

Installing the shock valves

2 2

Warning

Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

• Always Disconnect the negative (black) battery

cable before disconnecting the positive (red) cable.

• Always Reconnect the positive (red) battery

cable before reconnecting the negative (black) cable .

Note: Up to 4 fl. oz. of hydraulic oil can be lost per pump

while installing this kit.

2. Place a pan under each hydraulic pump.

Important Wear protective equipment while installing

this kit. Avoid any contact of the hydraulic oil with eyes or continuous contact with skin.

 2002 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Printed in the USA

Warning

Hydraulic fluid escaping under pressure can penetrate skin and cause injury.

• If hydraulic fluid is injected into the skin it

must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done.

• Keep body and hands away from pin hole leaks

or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic leaks.

• Safely relieve all pressure in the hydraulic

system before performing any work on the hydraulic system.

• Make sure all hydraulic fluid hoses and lines

are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system.

Using the Correct Shock Valve

There are two types of shock valves for this installation.

• One has no orifice or hole and text markings of 200

and 000 (Fig. 1).

• One has a very small .024 in. hole or orifice and text

markings of 200 and 024 (Fig. 1).

1. Shock valve with an orifice

2. Shock valve with no orifice

3. 200 and 000 markings

Figure 1

4. 200 and 024 markings

5. .024 in. orifice

6. No orifice

m–6100

Finding the Correct Machine and Pump in the following Table

This instruction sheet provides separate instructions for the installation of the shock valves in Z Masters listed in the following table.

1. Determine if you have a 100 or 200 series Z Master.

2. Identify the serial number on the Z Master.

3. Identify the the pump model number.

Hydro–Gear Pumps

BDP–10L–121P BDP–10A–414 BDP–10A–433 BDP–10A–427

100 Series Z Master

Z Master Serial Number 210999999 and Lower

Z Master Serial number 220000001 and Up with Hydro–Gear pump date

See page 4 for

code 1275 and Up

instructions.

See page 6 for instructions.

200 Series Z Master

Z Master Serial Number 210999999 and Lower

See page 8 for instructions.

N/A

4. Identify the serial number on the pumps. See

Identifying the Pumps on page 3.

5. If needed, identify the date code in the pump serial

number. See Identifying the Pumps on page 3.

6. Refer to the appropriate instruction page, as listed in

the table section, for your machine and pump.

N/A N/A

Z Master Serial number 210000001

Z Master Serial number

22000XXXX and Up –22000XXXX and Lower with Hydro– Gear pump date code 1275 and Up

See page 12 for correct

models and serial

numbers. See page 10 for correct

models and serial numbers.

only BDP–10A pumps with a date code 1275 and greater are compatible with Shock Valves. The date code is the first four digits of the four–part

number in the lower left corner of the Hydro–Gear label. Ex) 0 131 P1 476 – the date code of this pump would be 0131.

Indentifying the Pumps

The following is an example of the Hydro–Gear label. The information on this label is needed for determining which pump you have on your machine (Fig. 2).

The date code is the first four digits of the four–part

Hydro–Gear Model Number

Year Built

Serial Number

number in the lower left corner of the Hydro–Gear label. An example is 0 131 P1 476. The date code of this pump

Date

would be 0131 (Fig. 2).

1. Locate this label on one of the pumps in your machine.

Type of Product and Build Information

m–6084

Figure 2

1. Label

2. Model Number

3. Date code—first four digits

Installing the Shock Valves on a 100 Series Z Master with Serial Number 210999999 and Lower

These machines are equipped with the Hydro–Gear BDP–10L–121P pumps. This model number can be found on the label on the side of the pump (Fig. 2).

Installing the Shock Valve on the Control Arm Side

1. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

3. Raise the seat and locate the battery.

4. Disconnect the negative battery cable.

Danger

Mechanical or hydraulic jacks may fail to support machine and cause a serious injury.

• Use jack stands when supporting machine.

• Do not use hydraulic jacks.

5. For the left–hand pump only, remove the left rear tire. Note: An extension on an Allen wrench socket may be

needed to gain access to the system check plug on the left pump.

1. Left side of pump

2. Check plug

3. Spring

4. Ball

Figure 3

5. Blank shock valve—no orifice

6. Valve cap

7. Control arm

m–6033

Installing the Shock Valve on the Side Opposite the Control Arm

1. Remove the system check plug in the pump, on the

side opposite of the control arm (Fig. 4).

Note: This assembly will contain a spring and poppet rather than a spring and ball.

2. Use a magnetic screwdriver to remove the spring and

poppet (Fig. 4).

3. Insert the shock valve with the 0.024 in. orifice

(Figures 1 and 4).

6. Remove the system check plug from the control

arm–side of the pump (Fig. 3).

7. Use a magnetic screwdriver to remove the spring and

ball (Fig. 3).

8. Insert the blank shock valve (no orifice)

(Figures 1 and 3).

9. Tighten and torque the valve cap for the shock valve

assembly to 15–20 ft.–lb.

10.Install the left rear tire. Torque lugnuts to 95 ft.–lb.

(128 NM).

4. Tighten and torque the valve cap for the shock valve

assembly to 15–20 ft.–lb.

5. Fill the hydraulic reservoir with Mobil 1 15W–50, or

equivalent oil, to the top of the baffle in the tank.

6. Connect the negative battery cable, lower the seat,

start the engine, and drive the unit for 5 to 10 minutes to purge the air out of the hydraulic system.

7. Shut the machine off and allow system to cool for 15

minutes.

8. Check the hydraulic oil level and add hydraulic oil if

necessary.

1. Pump—non–control a r m side

2. Check plug

3. Spring

Figure 4

m–6034

4. Poppet

5. Shock valve—.024 in. orifice

6. Valve cap

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