Toro 139-6040 User manual

FormNo.3446-110RevA
FuelCoolerKit
Reelmaster®5410/5510/5610-DSeriesorGroundsmaster®4300-D
TractionUnit
ModelNo.139-6040
InstallationInstructions
Installation
1
PreparingtheMachine
NoPartsRequired
Procedure
1.Parkthemachineonalevelsurface.
2.Engagetheparkingbrake.
3.Lowerthecuttingunits.
4.Shutofftheengine,removethekey,andwaitfor
allmovingpartstostop
5.Allowtheenginetocool.
2
RemovingtheHoodand
Screen
NoPartsRequired
Procedure
1.Unlatchthehoodatbothsides.
g356307
Figure1
1.Clevispin3.Bowpin
2.Pivotbracket
2.Removethebowpinandtheclevispinthat
securesthehoodtothepivotbracketsofthe
machine(Figure1).
3.Carefullyliftthehood,andremoveitfromthe
machine(Figure1).
4.Removetheballpinthatsecuresthescreen
latch(Figure2).
©2021—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3446-110*

g356310
Figure2
1.Ballpin3.Hinge
2.Latch(screen)4.Pivotpin(radiatorframe)
5.Unlatchthescreen(Figure2).
6.Liftthescreenfromthepivotpinsoftheradiator
frame(Figure2).
3
DisconnectingtheNegative
BatteryCable
NoPartsRequired
Procedure
1.Pressthetabsthebatterycovertoreleasethe
coverfromtheslotsinthebatterytray,and
removethecover(Figure3).
g356303
Figure3
1.Batterycover3.Clamp(negativebattery
cable)
2.Slot(batterytray)
2.Removetheclampofthenegativebatterycable
fromthenegativebatterypost(Figure3).
Note:Movethebatterycableawayfromthe
battery.
2

4
AssemblingtheFuelCooler
Partsneededforthisprocedure:
2Fuelhose9.5x559mm(3/8x22inches)
1Fuelcooler
Hoseclamp
4Clipnut
1Fuel-coolerbracket
2Push-incabletie/anchor
4Flangecapscrew(1/4x5/8inch)
2Foamstrip12.7x12.7x127mm(1/2x1/2x5inches)
2Foamstrip12.7x12.7x152mm(1/2x1/2x6inches)
Procedure
1.Assemblethe2fuelhoses9.5x559mm(3/8x
22inches)intothettingsofthefuelcoolerwith
the2spring-typehoseclamps(Figure4).
g356300
Figure4
1.Fittings(fuelcooler)3.Fuelhoses9.5x559mm
(3/8x22inches)
2.Hoseclamp(spring-type)
2.Assemblethe4clipnutstotheholes9.5mm
(3/8inch)inthefuelcoolerbracket(Figure5).
g356299
Figure5
1.Fuel-coolerbracket4.Flangecapscrew(1/4x
5/8inch)
2.Clipnut5.Fuelcooler
3.Push-incabletie/anchor
3.Assemblethe2push-incabletie/anchorsinto
the2holes6.4mm(1/4inch)inthefuel-cooler
bracket(Figure5).
4.Securethefuelcoolertothefuel-coolerbracket
(Figure5)withthe4angecapscrews(1/4x5/8
inch).
5.Securethe2fuelhosestothefuel-coolerbracket
with2push-incabletie/anchor(Figure6).
3

g356312
Figure6
1.Push-incableties/anchors
6.Removetheadhesivebackingfromthe4foam
strips(Figure7).
g356295
Figure7
1.Foamstrip—vertical12.7
x12.7x127mm(1/2x1/2
x5inches)
3.Foamstrip—horizontal
12.7x12.7x152mm(1/2
x1/2x6inches)
2.Fuel-coolerbracket
7.Attheothersideofthefuel-coolerbracket,apply
toverticalandhorizontalfoamstripsasshown
inFigure7.
5
InstallingtheFuelCoolerto
theRadiatorBracket
Partsneededforthisprocedure:
1Grommet
2Capscrew(5/16x5/8inch)
MachineswithaRadiatorBracket
Knock-OutPlug
1.Attheleftsideofthebatterytray,removethe
knock-outplugfromtheradiatorbracket(Figure
8).
g356308
Figure8
1.Knock-outplug(radiatorbracket)
2.Removeallburrsfromtheholeinthebracket.
4

MachineswithoutaRadiator
BracketKnock-OutPlug
1.Attheleftsideofthebatterytray,measure51
mm(2inches)fromthecenterlineoftheholefor
thebatterycableandmarktheradiatorbracket
(Figure9).
g356304
Figure9
1.64mm(2-1/2inches)
measurement
3.Drillbit38mm(1-1/2
inches)
2.51mm(2inches)
measurement
2.Measure64mm(2-1/2inches)fromthetop
radiatorbracket,andmarkthebracket(Figure
9).
3.Centerpunchtheradiatorbracketatthe
intersectionofthe2marks.
4.Drillapilotholeatthecenterpunchmark.
5.Drilla38mm(1-1/2inches)holeinthebracket
atthepilothole(Figure9).
6.Removeallburrsfromtheholeinthebracket.
InstallingtheGrommet
Installthegrommetintotheholeintheradiatorbracket
(Figure10).
g356305
Figure10
1.Hole2.Grommet
5

AssemblingtheFuelCoolertothe
RadiatorBracket
1.Removethe2Flangecapscrews(5/16x1/2
inch)thatsecuretheradiatortotheradiator
bracket(Figure11).
Note:Discardthe2capscrews.
g356309
Figure11
1.Capscrews(5/16x1/2inch)
2.Assemblethe2fuelhosesofthefuelcooler
throughthegrommetintheradiatorbracket
(Figure12).
g356298
Figure12
1.Grommet4.Capscrew(5/16x5/8inch)
2.Fuelhoses(fuelcooler)5.Fuel-coolerbracket
3.Radiatorbracket
3.Alignthehoesinthefuel-coolerbracketwiththe
holesintheradiatorbracket(Figure12).
4.Securethefuel-coolerbrackettotheradiator
bracket(Figure12)withthe2capscrews(5/16
x5/8inch).
6

6
ConnectingtheFuel-Cooler
Hoses
Partsneededforthisprocedure:
2Barbhoseconnector
2Hoseclamp(worm-type)
1Fuelhose6.4x457mm(1/4x18inches)
2Hoseclamp(spring-type)
1Cabletie
AssemblingtheFuelCoolerHose
Fittings
1.Assembleabarbhoseconnectorintoeachof
thefuel-coolerhoses(Figure13).
g356294
Figure13
1.Fuel-coolerhose3.Barbhoseconnector
2.Hoseclamp(worm-type)
2.Securethehoseconnectortoeachofthehoses
withtheworm-typehoseclamps(Figure13).
ConnectingtheFuelTankandFuel
CoolerHoses
1.Removethespring-typehoseclampand
fuel-tankhoseattherearmostttingofthefuel
lterhead(Figure14).
Note:Retainthehoseclamp.
g356306
Figure14
1.Fitting—fuellterhead
(rearmostposition)
3.Fuel-tankhose
2.Hoseclamp(spring-type)
2.Plugtheendofthehose.
3.Whilemaintaininghoserouting,placethefuel
tankhosenexttotheinboardfuel-coolerhose
(Figure15).
Note:Ensurethatthefuel-tankhoseroutes
closetotheleftframerailofthemachine.
7

g356302
Figure15
4.Markthefuel-tankhoseatthebarbhosetting
(Figure15).
5.Cutthefuel-tankhoseatthemark(Figure15).
6.Assemblethespring-typehoseclampthatyou
removedinstep1ontothefuel-tankhoseon
themachine(Figure16).
g356301
Figure16
1.Fuel-tankhose3.Fuel-coolerhose(inboard
position)
2.Hoseclamp(spring-type)
7.Assemblethefuel-tankhoseandhoseclamp
ontothebarbhoseconnectoroftheinboard
fuel-coolerhose(Figure16).
8

ConnectingtheFuelFilterand
FuelCoolerHoses
1.Assemblethefuelhose6.4x457mm(1/4x18
inches)ontotherearmostttingofthefuellter
headwithaspring-typehoseclamp(Figure17).
g356297
Figure17
1.Fitting—fuellterhead
(rearmostposition)
3.Fuelhose6.4x457mm
(1/4x18inches)
2.Hoseclamp(spring-type)
2.Routetheotherendofthefuellterhosetothe
otherfuel-coolerhose(Figure18).
g356296
Figure18
1.Fuellterhose3.Barbhoseconnector
(outboardfuel-cooler
hose)
2.Hoseclamp(spring-type)
3.Assemblethefuellterhoseandaspring-type
hoseclampontothebarbhoseconnectorofthe
outboardfuel-coolerhose(Figure18).
4.Securethe2fuel-coolerhosestogetherwitha
cabletie(Figure19).
g356311
Figure19
1.Fuelcoolerhose(inboard)3.Fuelcoolerhose
(outboard)
2.Cabletie
7
CompletingtheKit
Installation
NoPartsRequired
ConnectingtheNegativeBattery
Cable
1.Cleananycorrosiononthenegativebattery
cableclampandthebatterypost.
2.Assembletheclampofthenegativebattery
cableontothebatterypost,andtightenthe
T-boltandnutoftheclamp(Figure20).
9

g356366
Figure20
1.Negativebatterycable3.Batterycover
2.Slot(batterytray)
3.Applyathincoatofbatteryterminalprotectorto
thebattery-cableclamp.
4.Assemblethebatterycoveroverthebattery,
aligningthetabsofthecoverintotheslotsinthe
batterytray(Figure20).
PurgingAirfromtheFuelSystem
1.RotatetheignitionkeytotheRUNorONposition.
2.Allowtheelectricfuelpumptorunfor10
seconds.
3.RotatetheignitionkeytotheSTOPposition.
4.Waitfor35to40seconds.
5.Repeatsteps1through4again2moretimes.
6.Starttheengine,andpreformthestepsin
CheckingforFuelLeaks(page10).
CheckingforFuelLeaks
1.Checkthefuelhoses,ttings,andfuelcooler
forleaks.
Important:Repairallfuelleaks.
2.Shutofftheengineandremovethekey.
InstallingtheScreen
1.Assemblethehingeofthescreenontothepivot
pinsiftheradiatorframe(Figure21).
g356361
Figure21
1.Hinge(screen)3.Ballpin
2.Pivotpin(radiatorframe)4.Latch
2.Closethescreenandsecureittotheradiator
framewiththelatch(Figure21).
3.Inserttheballpinthroughtheholesinthelatch
(Figure21).
10

InstallingtheHood
1.Alignthehoodtothebackofthemachine
(Figure22).
g356365
Figure22
1.Clevispin3.Bowpin
2.Hood-frametubeandpivot
bracket
2.Aligntheholesinthehood-frametubewith
theholesinthepivotbracketsofthemachine
(Figure22).
3.Assemblethehood-frametubetothepivot
bracketswiththe2clevispinsand2bowpins
(Figure22).
4.Latchthehoodatbothsides.
11