Toro 115-8492 User manual

FormNo.3365-152RevA
AccessoryWiringKit
Groundsmaster®4000-Dand4100-DSeriesTractionUnit
ModelNo.115-8492
InstallationInstructions
Installation
ForModels30412and30413
1.Positionthemachineonalevelsurface,lowerthe
cuttingunit,stoptheengine,engagetheparking
brakeandremovethekeyfromtheignition.
2.Disconnectthenegativebatterycablefromthe
battery.
3.Removethecontrolpanelcover(Figure1)togain
accesstothefuseblockarea.
G009954
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Figure1
1.Controlpanelcover
4.Locatetheholesunderthedecalonthetopofthe
controlconsole.Removethedecalmaterialcovering
theholes(Figure2).
5.Cleanthemountingsurfaceandapplythecontrol
decalovertheholesonthecontrolconsole(Figure2).
6.Looselymountatoggleswitchineachholewiththe
washersandnutssupplied(Figure2).
G009955
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2
3
Figure2
1.Consoledecal3.Harnessconnectors
2.Toggleswitches
7.Plugthe(2)connectorsfromtheaccessorywire
harnessontothetoggleswitchterminals(Figure2).
8.Removethe(3)screwsandnutssecuringthefuse
blocktotheinsideofthecontrolconsole(Figure3).
9.Movethefuseblockdowntothenextsetof
mountingholesandreinstallwiththescrewsand
nutspreviouslyremoved(Figure3).
G009956
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1
Figure3
1.Fuseblock2.Groundingbolt
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Registeratwww.Toro.com.OriginalInstructions(EN)
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10.Securethegroundwires(ringterminals)fromthe
accessoryandpowerharness’tothegroundingbolt
locatedbeneaththefuseblocks(Figure2).
Important:Whenroutingtheharness,donot
pullitacrosssharpedgeswhichmaydamage
thewires.Wiresmustnotcontactanyhotor
movingparts.Securethewireharnesswithwire
ties.
11.Connectthe(2)spadeterminalsfromtheaccessory
wireharnesstothe(2)spadeterminalsonthefuse
blockwires(Figure4).
G009957
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2
2
3
4
5
5
6
Figure4
1.Accessorywireharness4.Powerrelay
2.Powerwireharness5.5ampfuse
3.Tractionunitwireharness6.30ampthermalbreaker
12.Plugtheconnectorfromthepowerwireharness
intotheexistingfuseblockconnector(locatedatthe
fuseblock(Figure4).
13.Plugtheconnectorfromthepowerwireharnessinto
thenewfuseblockconnector(Figure4).
14.Installthefuses(Figure4)asfollows:
Forsnowthrowerapplications,use(1)10ampfuse
suppliedwiththesnowthrowerand(1)30amp
thermalbreakerfurnishedwiththekit.
Note:The30ampthermalbreakerisusedforthe
chuterotatingcircuit.
Forrotarybroomapplications,use(2)5ampfuses
furnishedwiththekit(Donotusea30ampthermal
breaker).
Note:Makesurethefusesareinstalledinthe
correspondingslotsthathavethewireconnected
totheharness.
15.Afxthefusedecalstothecorrespondinglocations
onthefuseblockdecal(Figure5).Makesurethe
decalsurfaceiscleananddrybeforeafxingthe
decals.
G009958
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Figure5
1.Decals
16.Plugthepowerrelayintotheconnectoronthe
powerwireharness(Figure4).
17.Securethewireandrelaytothecontrolconsolewith
acabletie(Figure4).
18.Unplugthespadeterminalfromthe“I”terminal
(standaloneterminal)ontheignitionswitch
(Figure6).
G009959
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2
Figure6
1.Ignitionswitch2.Accessorywireharness
19.Plugthespadeterminalfromthepowerwireharness
ontotheswitchterminal(Figure6).
20.Plugtheremainingconnectorintothewireconnector
disconnectedfromtheswitch(Figure6).
21.Afxthemountingpadstoundersideofoperator
platformatlocationsshowninFigure7.Cleanthe
mountingsurfacewellbeforeafxingthepads.
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G009960
1
Figure7
1.Mountingpads
22.Insertacabletiethrougheachoftheplastic
mountingpads.
23.Inserttheendoftheharnessthroughtheholeinthe
operatorplatformandsecureitwiththecableties.
Note:Checkswitchoperationandreversetheir
locationincontrolconsoleiftheydon’toperatein
directionshownondecals.Tightentoggleswitch
nuts.
24.Reinstallthecontrolpanelcover.
25.Connectthenegativebatterycabletothebattery.
ForModels30446,30447,30448and
30449
1.Positionthemachineonalevelsurface,lowerthe
cuttingunit,stoptheengine,engagetheparking
brakeandremovethekeyfromtheignition.
2.Disconnectthenegativebatterycablefromthe
battery.
3.Removethehydrauliclinecoverfromthebaseofthe
steeringtowercover(Figure8).
4.Removethesteeringtowercoverfromthesteering
tower(Figure8).
Figure8
1.Hydrauliclinecover2.Steeringtowercover
5.Frominsidethesteeringtower,presstheplugoutof
theholeinthetopofthetower(Figure9).
g012990
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23
Figure9
1.Plug3.Decal
2.Switch
6.Presstheswitchintothecontrolpanelmounting
holeasshowninFigure9.
7.Cleanthetowermountingsurfacearoundtheswitch.
Applythecontroldecalnexttoswitch(Figure9).
8.Routetheswitchconnectorendofharnessup
throughtheplatformandtowertotheswitch.Plug
theconnectorintotheswitch.
Note:Routetheharnessawayfromanyhotor
rotatingcomponentsandavoidanypossiblepinch
points.
9.Reinstallthesteeringtowercoverandhydraulicline
cover.
3

10.Openthehoodandroutethepowerandground
connectorendoftheharnessbackalongtheright
sideofthemachinetothepowercenter(Figure10).
g011539
1
Figure10
1.Powercenter
11.Openthecoveronpowercentertoexposethefuse
blocks(Figure11).
G01 1542
1
2210 20
7.5 7.5 10
7.5 7.5 10
7.5 7.5 10
Figure11
1.Fuseblocks
12.Fromtherearofthepowercenter,insertthenew
fuseblockintothebottomslot(Figure12).
Note:Thepowercentermayremovedtoaid
installation.
13.Securethefuseblocktothepowercenterwith(2)
#10x5/8inchscrewsandlocknuts(Figure12).
14.Plugthefuseblockpowercableintooneofthe
availablesources.
15.Hookthepowersideoftheharnesstothenewfuse
blockandtheharnessgroundtothegroundblock.
Figure12
1.Screw(2)4.Locknut
2.Fuseblock5.Fuse
3.Powercenter
16.Installthefuses(Figure12)asfollows:
Forsnowthrowerapplications,use(1)10ampfuse
suppliedwiththesnowthrowerand(1)30amp
thermalbreakerfurnishedwiththekit.
Note:The30ampthermalbreakerisusedforthe
chuterotatingcircuit.
Forrotarybroomapplications,use(2)5ampfuses
furnishedwiththekit(Donotusea30ampthermal
breaker).
Note:Makesurethefusesareinstalledinthe
correspondingslotsthathavethewireconnected
totheharness.
17.Afxthefusedecalstothecorrespondinglocations
onthefuseblockdecal(Figure12).Makesurethe
decalsurfaceiscleananddrybeforeafxingthe
decal.
18.Closeandsecurethepowercentercover.
19.Routetheattachmentendoftheharnessalongthe
liftarmtotheattachmentsolenoids.Connectthe
harnesstothesolenoids.
Note:Routeandcabletietheharnessawayfrom
anyhotorrotatingcomponentsandavoidany
possiblepinchpoints.
20.Connectthenegativebatterycabletothebattery.
21.Testtheswitchoperation.Reversetheconnections
ontheattachmentsolenoidsifthedirectionof
operationisoppositetheswitchanddecal.
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