Toro 107-3080 Installation Instructions

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Hydraulic Tank Relocation Kit

100 Series Z Master Mowers

Model No. 107-3080

Installation Instructions

Loose Parts

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

DESCRIPTION QTY. USE

Form No. 3350-460

Template, hydraulic tank Bolt, 1/4 x 1 inch Flat washer, 1/4 inch Tank stand Bolt, 5/16 x 3/4 inch Bolt, 5/16 x 1 inch Flange nut, 5/16 inch

Swivel head hydraulic line assembly, model year 2001 and before

R-clamp Open end hydraulic line assembly, model year

2002 Hydraulic filter 1

1 2 2 1 1 1 2

1 1 1

Installing the hydraulic tank

Installing the new hydraulic line

Replacing the hydraulic filter and filling the hydraulic tank

 2003 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Original Instructions (EN)

Printed in the USA

Draining the Hydraulic Tank

Warning

Removing the Rear Wheels

1. Loosen the wheel nuts from the both sides of the

vehicle.

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.

1. Position machine on a level surface, disengage the PTO,

move the motion control levers to the neutral locked position, 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. Place a pan under the hydraulic filter. The filter is

located toward the rear, on the underside of the unit (Fig. 1).

Note: Most units have nuts securing the wheel to the unit; however, some older models have bolts in place of the nuts.

2. Raise the back of the machine up and support it with

jack-stands.

3. Remove the wheel fasteners from both sides of the

vehicle (Fig. 2).

Figure 2

Right wheel shown

1. Wheel nuts 2. Left rear wheel

4. Remove the rear wheels (Fig. 2).

m–7026

m–7142

Figure 1

1. Pan 2. Hydraulic filter

Important Clean the hydraulic lines and filter, as well

as the surrounding areas, before draining the hydraulic oil.

4. Remove the hydraulic filter and let the fluid drain into

the pan (Fig. 1).

5. Discard the hydraulic filter. Note: Dispose of the used oil at a certified recycling center.

Relocating the Hydraulic Tank for Model Year 2001 and Before

Important If you are relocating the hydraulic tank on a

2002 unit, turn to the Relocating the Hydraulic Tank for Model Year 2002 section on page 7.

The hydraulic tank is moved from the right side to the left side (Fig. 3). Once the tank is moved, the hydraulic lines are rerouted to accommodate the new tank location.

3. Locate the hydraulic line that runs from the tank to the

hydraulic pumps.

4. Disconnect the line at the elbow fitting on the tank.

5. Remove the two bolts and two nuts securing the

hydraulic tank to the engine guard.

6. Remove the hydraulic tank assembly.

7. Install the hydraulic tank template on the tank as shown

in figure 5, using the fasteners removed previously.

m–7139

Figure 3

Kohler engine shown

1. Old tank location 2. New tank location

Removing the Hydraulic Tank

1. Locate the hydraulic line that runs from the tank to the

filter.

2. Disconnect the line first at the elbow fitting on the tank,

and then at the filter bracket. Discard the hydraulic line.

m–7143

Figure 5

1. Tank template

2. Hydraulic tank

3. Fastener holes

4. Center punch holes

8. Use a center punch to mark the drill holes designated by

the template (Fig. 5).

9. Remove the bolts and nuts securing the template to the

tank. Discard the fasteners and template.

10.Drill two, 5/16 inch holes into the tank at the marked

drill points (Fig. 6).

A. For units with Kawasaki engines, remove the screw

and R-clamp securing the hydraulic line to the engine (Fig. 4). Save the screw for later use.

Figure 4

1. Screw

2. R-clamp

3. Hydraulic line

m–7177

1. Tank template

2. Hydraulic tank

m–7144

Figure 6

3. Drill points

11. Remove the hydraulic tank cap and flush out the empty

tank to remove any foreign debris.

12.Replace the tank cap.

Installing the Hydraulic Tank

5. Install the tank stand in the upright position as shown in

figure 8, using one bolt (5/16 x 1 inch), one bolt (5/16 x 3/4 inch), and two flange nuts (5/16 inch).

A hole must be drilled in the left engine guard to accommodate the new tank stand. Use the tank stand to mark the location of the drill hole.

1. Install the tank stand upside down to the left engine

guard as shown in figure 7, using a bolt (5/16 x 1 inch) and a flange nut (5/16 inch).

Important Verify the rear bolt hole is used when

attaching the tank stand (Fig. 7).

m–7145

Figure 7

1. Tank stand, upside down

2. Left engine guard

3. Bolt, 5/16 x 1 inch

4. Flange nut, 5/16 inch

5. Rear bolt hole

6. Drill point

m–7146

1. Tank stand, upright position

2. Bolt, 5/16 x 1 inch

Figure 8

3. Bolt, 5/16 x 3/4 inch

4. Flange nut, 5/16 inch

5. Drilled hole

6. Position the hydraulic tank assembly on the tank stand, lining up the newly drilled holes to the tank stand posts (Fig. 9).

2. Use a center punch to mark the location of the second

hole to be drilled.

3. Remove the tank stand and fasteners. Set them aside for

later use.

4. Drill a hole in the engine guard, 5/16 inch in diameter,

at the point marked previously (Fig. 7).

Figure 9

1. Tank assembly

2. Tank stand post

3. Drilled holes

4. Bolt, 1/4 x 1 inch

5. Washer, 1/4 inch

7. Install the tank to the tank stand using two bolts (1/4 x 1 inch) and two washers (1/4 inch) as shown in figure 9.

m–7160

Rerouting the Hydraulic Pump Lines

The hydraulic lines that connect the pump to the tank need to be rerouted to reach the new tank position.

1. Loosen the swivel nuts of the threaded elbow

connections at both the left and right pumps and disconnect the hydraulic lines (Fig. 10).

2. Flip the hydraulic line assembly, as shown in

figures 10 and 11, so the lines reach the new tank location.

m–7155

Figure 10

1. Hydraulic pump line

2. T-connection, old location

3. T-connection, new location

4. Hydraulic tank

5. Threaded connection, right pump

6. Threaded connection, left pump

Important Do not disconnect the hydraulic lines at the

T–connection.

After Before

m–7156

Figure 11

3. Connect the hydraulic lines to the respective pumps

(Fig. 11).

4. Connect the remaining hydraulic line to the hydraulic

tank.

Installing the New Hydraulic Line

1. Locate the swivel head hydraulic line assembly, for

model year 2001 and before, and apply thread sealer tape to the pipe thread end of the line (Fig. 12).

1. Hydraulic line assembly, model year 2001 and before

Figure 12

2. Swivel head end

3. Pipe thread end

m–7167

2. Connect the pipe thread end of the new hydraulic line assembly to the hydraulic filter bracket.

3. Route the new line around the engine and to the hydraulic tank (Fig. 13).

A. For units with Kawasaki engines, use the screw

removed previously and the R-clamp to secure the new hydraulic line to the engine (Fig. 4).

4. Install the swivel head end of the new hydraulic line to

the hydraulic tank at the elbow fitting as shown in figure 13.

3. Install the replacement hydraulic filter onto the filter

adapter (Fig. 14). Do not tighten.

Figure 13

1. New hydraulic line

2. Hydraulic tank

3. Filter location

Replacing the Filter and Filling the Hydraulic Tank

m–7159

m–1256

Figure 14

1. Hydraulic filter

2. Gasket

3. Adapter

4. Remove the cap from the filler neck.

5. Fill the hydraulic tank with hydraulic fluid until the

fluid overflows the filter and then turn it clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 14).

6. Clean up any spilled fluid.

7. Add fluid to the top of the baffle in the hydraulic tank (Fig. 15). Do not overfill.

Fluid T ype: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil.

Important Use oil specified or equivalent. Other fluids

could cause system damage.

1. Change the hydraulic filter with the filter included in

the loose parts before the hydraulic fluid is replaced.

2. Apply a thin coat hydro fluid to the rubber gasket on the

replacement filter (Fig. 14).

M-4280

Figure 15

1. Cap

2. Baffle

3. Hot fluid level—full

8. Clean the area around the filler neck of hydraulic tank.

9. Install cap on filler neck.

Restart Original Maintenance Schedule

After changing the hydraulic fluid or working on the system, it is necessary to restart the maintenance schedule. This includes changing the hydraulic fluid after the first 8 hours of use. Refer to the Maintenance Section in your Operator’s Manual for more information.

Relocating the Hydraulic Tank for Model Year 2002

The hydraulic tank is moved from the right side to the left side (Fig. 16). Once the tank is moved, the hydraulic lines are rerouted to accommodate the new tank location.

4. Locate the hydraulic line that runs from the tank to the

hydraulic pumps.

5. Disconnect the line at the tank by removing the spring

lock securing the line to the tank. Keep the spring lock from the line for later use.

6. Remove the two bolts, two washers, and two flange nuts

securing the hydraulic tank to the engine guard and discard.

7. Remove the hydraulic tank assembly.

Installing the Hydraulic Tank

A hole must be drilled in the left engine guard to accommodate the new tank stand. Use the tank stand to mark the location of the drill hole.

1. Install the tank stand upside down to the left engine

guard as shown in figure 7, using a bolt (5/16 x 1 inch) and a flange nut (5/16 inch).

m–7141

Figure 16

1. Old tank location 2. New tank location

Removing the Hydraulic Tank

1. Locate the hydraulic line that runs from the tank to the

filter.

2. Disconnect the line at the tank by removing the spring

lock securing the line to the tank. Remove the spring lock from the line and save for later use.

3. Disconnect the line at the filter bracket. Discard the

hydraulic line. A. For units with Kawasaki engines, remove the screw

and R-clamp securing the hydraulic line to the engine (Fig. 17). Save the screw for later use.

Important Verify the rear bolt hole is used when

attaching the tank stand (Fig. 18).

m–7145

Figure 18

1. Tank stand, upside down

2. Left engine guard

3. Bolt, 5/16 x 1 inch

4. Flange nut, 5/16 inch

5. Rear bolt hole

6. Drill point

2. Use a center punch to mark the location of the second

hole to be drilled.

3. Remove the tank stand and fasteners. Set them aside for

later use.

1. Screw

2. R-clamp

4. Drill a hole in the engine guard, 5/16 inch in diameter,

at the point marked previously.

m–7177

Figure 17

3. Hydraulic line

5. Install the tank stand in the upright position as shown in

figure 19, using one bolt (5/16 x 1 inch), one bolt (5/16 x 3/4 inch), and two flange nuts (5/16 inch).

m–7146

Figure 19

1. Tank stand, upright position

2. Bolt, 5/16 x 1 inch

3. Bolt, 5/16 x 3/4 inch

4. Flange nut, 5/16 inch

5. Drilled hole

Rerouting the Hydraulic Pump lines

The hydraulic lines that connect the pump to the tank need to be rerouted to reach the new tank position.

1. Loosen the swivel nuts of the threaded elbow

connections at both the left and right pumps and disconnect the hydraulic lines (Fig. 21).

6. Position the hydraulic tank assembly on the tank stand, lining up the existing holes in the tank to the tank stand posts (Fig. 20).

m–7161

Figure 20

1. Tank assembly

2. Tank stand post

3. Bolt, 1/4 x 1 inch

4. Washer, 1/4 inch

m–7155

Figure 21

1. Hydraulic pump line

2. T-connection, old location

3. T-connection, new location

4. Hydraulic tank

5. Right hydraulic pump

6. Left hydraulic pump

Important Do not disconnect the hydraulic lines at the

T–connection.

7. Install the tank to the tank stand using two bolts

(1/4 x 1 inch) and two washers (1/4 inch) as shown in figure 20.

2. Flip the hydraulic line assembly, as shown in

figures 21 and 22, so the lines reach the new tank location.

After Before

m–7156

Figure 22

3. Connect the hydraulic lines to the respective pumps

(Fig. 22).

4. Connect the remaining hydraulic line to the hydraulic

tank.

Installing the New Hydraulic Line

1. Locate the open end hydraulic line assembly, for model

year 2002, and apply thread sealer tape to the pipe thread end of the line (Fig. 23).

1. Hydraulic line assembly, model year 2002

2. Open end

2. Place the spring lock, removed previously, over the open end of the hydraulic line assembly.

3. Connect the pipe thread end of the new hydraulic line to the hydraulic filter bracket.

Figure 23

3. Pipe thread end

4. Spring lock

m–7180

m–7158

Figure 24

Kawasaki Engine Shown

1. New hydraulic line

2. Hydraulic tank

3. Filter location

4. Screw

Replacing the Filter and Filling the Hydraulic Tank

Fluid T ype: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil.

Important Use oil specified or equivalent. Other fluids

could cause system damage.

1. Change the hydraulic filter with the filter included in

the loose parts before the hydraulic fluid is replaced.

2. Apply a thin coat hydro fluid to the rubber gasket on the

replacement filter (Fig. 25).

3. Install the replacement hydraulic filter onto the filter

adapter (Fig. 25). Do not tighten.

4. Route the new line around the engine and to the hydraulic filter (Fig. 24).

A. For units with Kawasaki engines, use the screw

removed previously and the R-clamp to secure the new hydraulic line to the engine (Fig. 17).

5. Install the open end of the new hydraulic line to the hydraulic tank as shown in figure 24. Use the spring lock to secure the line to the tank.

Figure 25

1. Hydraulic filter

2. Gasket

4. Remove the cap from the filler neck.

m–1256

3. Adapter

5. Fill the hydraulic tank with hydraulic fluid until the

fluid overflows the filter and then turn it clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 25).

6. Clean up any spilled fluid.

7. Add fluid to the cold level of the baffle in the hydraulic tank (Fig. 26). Do not overfill.

Installing the Rear Wheels

1. Mount the wheels with the valve stem to the outside and

secure it with the nuts previously removed (Fig. 27).

Note: Most units have nuts securing the wheel to the unit; however, some older models have bolts in place of the nuts.

2. Torque the nuts to 95 ft-lb (128 N⋅m).

m–5615

Figure 26

1. Cap

2. Baffle

3. Cold fluid level—full

4. Hot fluid level—full

8. Clean the area filler neck of hydraulic tank.

9. Install cap on filler neck.

Restart Original Maintenance Schedule

m–6917

Figure 27

Right wheel shown

1. Wheel nuts 2. Left rear wheel

Bleeding the Hydraulic System

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.

After changing the hydraulic fluid or working on the system, it is necessary to bleed the system.

1. Raise the rear of the machine so wheels are off the

ground and support with jack stands, if not already raised.

2. Start the engine and run at low idle speed. Engage the

lever and traction on one side and spin the wheel by hand.

3. When the wheel begins to spin on its own, keep it

engaged until wheel drives smoothly. Approximately 15 minutes.

4. Recheck the fluid level while the fluid is warm. The

fluid should be between cold and hot.

5. If required, add fluid to the hydraulic tank. Do not overfill.

Note: The fluid level should be to the top of the hot level

of the baffle, when the fluid is hot.

6. Install cap on filler neck.

Toro 107-3080 Installation Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual