Toro 30667 User manual

FormNo.3437-339RevA
HomologationKit
Groundsmaster®4500-D,4700-DorReelmaster®7000-DTraction
Unit
ModelNo.30667
InstallationInstructions
Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Disconnectthebattery.
2Nopartsrequired–Drillthemountingholes.
Rightheadlightbracket1
Leftheadlightbracket1
Bolt(3/8x2-1/2inches)6
Flangenut(3/8inch)6
Washer(3/8x7/8inches)8
Rubberhanger2
Spacer4
Bolt(5/16x1-5/8inches)4
Flangenut(5/16inch)4
Rightheadlightassembly1
Leftheadlightassembly1
3
Bent-platebracket2
Installtheheadlights.
Horn1
Hornbracket1
Bolt(3/8x5/8inch)1
Flangenut(3/8inch)1
Bolt(1/4x2inches)2
4
Nut(1/4inch)2
Installthehorn.
Relayswitch1
Serratedhex-headangebolt(#8x1/2
inch)1
5Locknut(#8)1
Installtherelayswitchanddecal.
Columnbracket1
Flashermodule1
On-Off-Onrockerswitch1
Beaconswitch1
Paddleswitch1
Hornswitch1
Hornbutton1
Horndecal(PartNo.104-6957)1
Hexsocketbutton-headscrew1
6
Speednut2
Installtheashermoduleandswitches
onthecolumnbracket.
©2019—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3437-339*A

ProcedureDescriptionQty.Use
Steering-columnbracket1
Columnmountbracket1
Carriagebolt(3/8x3/4inch)2
Flangenut(3/8inch)2
Foamstrip1
7
Cabletie1
Installthecolumn-bracketassembly
ontothesteering-column.
Carriagebolt(#10x5/8inch)1
Locknut(#10)1
Sensorplate1
Flangenut(1/4inch)2
Brake-sensorbracket1
Bolts(1/4x3/4inch)2
Slottedscrew(#6x1inch)2
Washer(#6)4
Brakesensor1
8
Locknut(#6)2
Installthebrakesensorbracket.
Leftlightbracket1
Rightlightbracket1
Screw(5/8x3inches)4
Flatwasher4
Jamnut(5/8inch)2
9
Rear-lampassembly2
Installtherearlamps.
Platelight1
Platebracket1
Screw(#10x5/8inch)2
Locknut(#10)2
10
Self-tappingscrew(5/16x1/2inch)2
Installthelicense-platebracket.
Wireharness1
Switch-panel-enclosurecover1
Screw(#10x1/2inch)3
Mountingpad3
Cabletie11
11
Jumperwireharness(LEDheadlights
only)2
Installthewireharness.
Fuse(10A)3
Fuse(15A)1
12Fuse-boxdecal1
Installthefusesintothefusebox.
Plate2
Decal4
Hex-headscrew(1/4x2-1/2inches)4
13Locknut(1/4inch)4
Installthedecal-mountingplates.
1
DisconnectingtheBattery
NoPartsRequired
Procedure
1.Parkthemachineonalevelsuface.
2.Engagetheparkingbrake.
3.Lowerthecuttingunits.
4.Shutofftheengineandremovethekey.
5.Disconnectthebattery;refertoyourmachine
Operator’sManual.
2

2
DrillingtheMountingHoles
NoPartsRequired
DrillingtheHolesforthe
HeadlightsandtheWireHarness
1.Removethenutsfromthe2carriagebolts
securingtheheadlightstothetraction-unitframe
(Figure1).
2.Removethe2self-tappingboltssecuringthetop
oftheplatformshroudtotheframe(Figure1).
3.Unplugtheheadlightconnectorsandremove
theplatformshroudfromtheframe(Figure1).
g034758
Figure1
1.Platformshroud4.Self-tappingbolt(2)
2.Headlightassembly
(halogenshown)
5.Headlightconnector
3.Carriagebolt(2)6.Drilla38mm(1-1/2inch)
holehere.
4.Drilla38mm(1-1/2inch)holeintheplatform
shroudinthelocationshowninFigure1.
5.UsingthedimensionsinFigure2,locateand
drill6holes(1.0cm)throughbothwallsofthe
roller-supporttube.
g029586
Figure2
1.6.4cm(2-1/2inches)4.1.0cm(13/32inch)diameter
2.8.9cm(3-1/2inches)5.1.9cm(3/4inch)
3.14.0cm(5-1/2inches)
3

DrillingtheHolesfortheHorn
Bracket
UsingthedimensionsinFigure3,locateanddrill2
holes(7mm)throughbothwallsoftheroller-support
tube.
g029796
Figure3
1.1.9cm(3/4inch)3.25.4cm(10inches)
2.3.8cm(1-1/2inches)4.7mm(9/32inch)diameter
DrillingtheHolesintheFront
FootrestfortheBrake-Pedal
Switch
UsingthedimensionsinFigure4,locateanddrill2
holes(7mm)throughthefrontfootrest.
g029663
Figure4
1.15.5cm(6-7/64inches)4.17mm(11/16inch)
2.32mm(1-1/4inches)5.7mm(9/32inch)diameter
3.19mm(3/4inch)
4

DrillingtheMountingHolesinthe
RearBumperfortheLicensePlate
UsingthedimensionsshowninFigure5,locateand
drill2holes(9/32inch)throughtheoutsidewallofthe
rearbumper.
g029755
Figure5
1.8.3cm(3-1/3inches)3.52.07cm(20-1/2inches)
2.13.3cm(5-1/4inches)4.Drillahole(9/32inch)
here.
3
InstallingtheHeadlights
Partsneededforthisprocedure:
1Rightheadlightbracket
1Leftheadlightbracket
6Bolt(3/8x2-1/2inches)
6Flangenut(3/8inch)
8Washer(3/8x7/8inches)
2Rubberhanger
4Spacer
4Bolt(5/16x1-5/8inches)
4Flangenut(5/16inch)
1Rightheadlightassembly
1Leftheadlightassembly
2Bent-platebracket
InstallingtheHeadlightBracketto
aROPSModel
1.Fastentheleftandrightheadlightbracketsto
thefrontoftheroller-supporttubewith6bolts
(3/8x2-1/2inches)and6angenuts(3/8inch)
asshowninFigure6.
g029788
Figure6
1.Installedheadlightbracket3.Headlightbracket
2.Bolts(3/8x2-1/2inches)4.Flangenuts(3/8inch)
Note:Positiontheboltssothattheangenuts
aretowardthefrontofthetractionunit.
2.Fastentheleftandrightheadlightstothe
headlightbrackets(Figure7)withthefasteners
suppliedwiththelights.
5

Note:Ensurethattheturn-signallensonthe
headlightispositionedtowardtheoutsideofthe
tractionunit.
g029778
Figure7
Rightheadlightassemblyshown
1.Rightheadlightbracket4.Headlightarm
2.Articulated-jointshell5.Locknut(10mm)
3.Articulatedjoint
3.Tightenthelocknuttormlyholdtheheadlight
assemblytotheheadlightbracket.
Note:Donotovertightenthelocknut.
InstallingtheHeadlightBracketto
aCabModel
1.Installabent-platebracketontoeachofthe
uppercornersofthelowerfrontpanelofthecab
withtheexistingscrewsasshowninFigure8.
g034337
Figure8
1.Bolt(5/16x1-5/8inches)5.Rubberhanger
2.Washer6.Flangenut(5/16inch)
3.Bent-platebracket7.Screw(existing)
4.Spacer
2.Looselyinstallarubberhangertoeach
bent-platebracketwithabolt(5/16x1-5/8inch),
2washers(3/8inch),aspacer,andaangenut
(5/16inch)asshowninFigure8.
3.Looselyinstalltheleftandrightheadlight
bracketstothefrontoftheroller-supporttube
with6bolts(3/8x2-1/2inches)andangenuts
(3/8inch).Positionthebracketsasshownin
Figure9.
Note:Ensurethattheholesinthebent-plate
bracketsalignwiththeholesintherubber
hangers.
6

g034338
Figure9
1.Nut(5/16inch)4.Headlightbracket
2.Washer5.Brackettab
3.Spacer6.Bolt(5/16x1-5/8inch)
4.Fastentheleftandrightheadlightassemblies
totheheadlightbrackets(Figure7)withthe
fastenerssuppliedinthekit.
Note:Ensurethattheturn-signallensonthe
headlightispositionedtowardtheoutsideofthe
tractionunit.
5.Tightenthelocknuttormlyholdtheheadlight
assemblytotheheadlight-assemblybracket.
Note:Donotovertightenthelocknut.
Note:Youcannotusethefrontandrearcablightsfor
CEapplications.Disablethefrontandrearcablights
asfollows:
•Front—Removethelightsfromthecabroofand
disconnectthewiresfromthelights.Installthe
lightsintothecab.
•Rear—Removethescrewssecuringthelensesto
thelights.Removethebulbsfromthelightsand
installthelensestothelights.
4
InstallingtheHorn
Partsneededforthisprocedure:
1Horn
1Hornbracket
1Bolt(3/8x5/8inch)
1Flangenut(3/8inch)
2Bolt(1/4x2inches)
2Nut(1/4inch)
Procedure
1.Securethehornstraptothehornbracketwitha
bolt(3/8x5/8inch)andaangenut(3/8inch)
asshowninFigure10.
g023184
Figure10
1.Hornbracket2.Hornstrap
2.Mountthehornbrackettothebacksideofthe
roller-supporttubewith2bolts(1/4x2inches)
andnuts(1/4inch).Rotatethehornsothatit
facesdown(Figure10).
7

5
InstallingtheRelaySwitch
Partsneededforthisprocedure:
1Relayswitch
1Serratedhex-headangebolt(#8x1/2inch)
1Locknut(#8)
Procedure
Securetherelayswitchunderthebatterycoverwith
aserratedhex-headangebolt(#8x1/2inch)anda
locknut(#8)atthelocationshowninFigure11.
Note:Donotovertightenthebolt.
g034581
Figure11
1.Serratedhex-headange
bolt(#8x1/2inch)
3.Locknut
2.Relayswitch
6
InstallingtheFlasher
ModuleandSwitcheson
theColumnBracket
Partsneededforthisprocedure:
1Columnbracket
1Flashermodule
1On-Off-Onrockerswitch
1Beaconswitch
1Paddleswitch
1Hornswitch
1Hornbutton
1Horndecal(PartNo.104-6957)
1Hexsocketbutton-headscrew
2Speednut
Procedure
1.InstallthecomponentsasshowninFigure12.
8

g034342
Figure12
1.On-Off-Onrockerswitch6.Columnbracket
2.Hornbutton7.Speednut(2)
3.Locknut8.Flashermodule
4.Paddleswitch9.Hornswitch
5.Beaconswitch10.Hexsocketbutton-head
screw
2.Installthehorndecal(PartNo.104-6957)as
showninFigure13.
g034344
Figure13
1.Horndecal(PartNo.104-6957)
7
Installingthe
Column-BracketAssembly
ontotheSteeringColumn
Partsneededforthisprocedure:
1Steering-columnbracket
1Columnmountbracket
2Carriagebolt(3/8x3/4inch)
2Flangenut(3/8inch)
1Foamstrip
1Cabletie
Procedure
1.Installthefoamstriponthesteeringcolumnas
showninFigure14.
g034582
Figure14
1.Steeringcolumn5.Thecabletiegoesthrough
theseslots.
2.Foamstrip6.Carriagebolt—3/8x3/4
inch(2)
3.Columnmountbracket7.Column-bracketassembly
4.Locknut—3/8inch(2)
9

2.Insertthecabletiethroughtheslotsinthe
columnmountbracketsothattheendsare
outward,butdonottiethem.
3.Installthesteering-columnbracketontothe
steeringcolumnwiththemountingbracket,2
carriagebolts,and2angenuts(Figure14).
Important:Ensurethatthetopofthe
steering-columnbracketis21mm(0.83inch)
belowthetopofthesteeringcolumn.
Important:Torquethefastenersto19to24
N∙m(14to18ft-lb).Donotovertightenthe
carriagebolts;otherwise,youmaydeform
thesteering-columnbracket.
8
InstallingtheBrake-Sensor
Bracket
Partsneededforthisprocedure:
1Carriagebolt(#10x5/8inch)
1Locknut(#10)
1Sensorplate
2Flangenut(1/4inch)
1Brake-sensorbracket
2Bolts(1/4x3/4inch)
2Slottedscrew(#6x1inch)
4Washer(#6)
1Brakesensor
2Locknut(#6)
Procedure
Note:Thisprocedureisonlyformachineswith
halogenheadlights.UseFigure15todetermineifyou
havehalogenheadlights.
g312027
Figure15
1.Halogenheadlight2.LEDheadlight
1.Disassembletheproximity-sensorassemblyon
thebrake-pedallever(Figure16)andsetaside
allthepartsexcepttheproximitysensor.
g029761
Figure16
1.Forwardfootrest4.Proximitysensor
2.Carriagebolt(#10x5/8
inch)
5.Brake-pedallever
3.Brake-sensorplate6.Locknut(#10)
2.Assembletheproximity-sensorassemblytothe
brakeleverusingthecarriagebolt(#10x5/8
inch),brake-sensorplate,proximitysensor,and
locknut(#10)asshowninFigure16.
Note:Ensurethatyoudonotovertightenthe
bolts.Overtighteningtheboltswilldamagethe
sensor.
3.Locatethebrake-sensorbracketmountingholes
onthefrontfootrestandlooselyinstallthe
brake-sensorbrackettothefrontfootrestusing2
bolts(1/4x3/4inch)and2angenuts(1/4inch).
Note:Youwillneedtomovethebrake-sensor
bracketupordowntoalignthebrakesensorto
thebrake-sensorplate(Figure17).
10

g029762
Figure17
1.Forwardfootrest5.Brake-sensorbracket
2.Slottedscrew(#6x1inch)6.Locknut(#6)
3.Washer(#6)7.Bolts(1/4x3/4inch)
4.Brakesensor8.Flangenut(1/4inch)
4.Looselyinstallthebrakesensortothe
brake-sensorbracketwiththe2slottedscrews
(#6x1inch),2washers,and2angenuts
(Figure17).
5.Alignthebrakesensorinoroutandthe
brake-sensorbracketupordownsothatthe
switchonthebrakesensorispressingagainst
thesensorplate.
6.Completethebrake-sensorassemblyinstallation
bytighteningallofthemountinghardware.
•Tightenthe2slottedscrews(#6x1inch)
and2angenutstormlysecurethebrake
sensortothebrake-sensorbracket.
Note:Ensurethatyoudonotovertighten
thescrews.Overtighteningthescrewswill
damagethesensor.
•Tightenthebolts(1/4x3/4inch)and2ange
nuts(1/4inch)holdingthebrake-sensor
brackettothefrontfootrestto1,017to1,243
N∙cm(90to110in-lb).
Important:Afteryoucompletetheinstallationof
thelightkit,verifythatthebrakesensoractivates
thebrakelightswhenthebrakepedalispressed.
Realignthebrakesensorifnecessary.
9
InstallingtheRearLamps
Partsneededforthisprocedure:
1Leftlightbracket
1Rightlightbracket
4Screw(5/8x3inches)
4Flatwasher
2Jamnut(5/8inch)
2Rear-lampassembly
Procedure
1.Removethe2bolts,2washers,and2nuts
securingthereservoir-mountingbrackettothe
leftframerail(Figure18).
Note:Stabilizethereservoirandbracketto
preventthemfromfalling.
g023193
Figure18
1.Reservoirbracketmountingbolts,washers,andnuts
2.Securetheleftlightbrackettothebracketand
framewith2bolts(5/8x3inches),2atwashers
and2jamnutsasshownin(Figure19).
11

Note:Theleftandrightlightbracketsare
different.Ensurethatyouusethecorrectmount.
g023194
Figure19
1.Leftlightbracket3.Rearlamp
2.Rightlightbracket
3.Mounttherearlamptolightbracketwiththe
boltsandnutsincludedwiththelight(Figure19).
Note:Ensurethatthelightispositionedsothat
theplugisthroughtheholeinthelightbracket
andtheamberendistowardtheoutsideofthe
tractionunit.
4.Removethe2rearboltsand2washersfromthe
rightframerail(Figure20).
g023195
Figure20
1.Boltsandwashers
5.Securetherightlightbrackettotheframewith2
bolts(5/8x3inches)and2atwashers(Figure
19).
10
InstallingtheLicense-Plate
Bracket
Partsneededforthisprocedure:
1Platelight
1Platebracket
2Screw(#10x5/8inch)
2Locknut(#10)
2Self-tappingscrew(5/16x1/2inch)
Procedure
1.Securetheplatelighttothelicense-platebracket
with2screws(#10x5/8inch)and2locknuts
(Figure21).
Note:Donotovertightenthescrews.Ensure
thatthelenspointsdownwardandthewiresare
insertedthroughtheholeinthelicense-plate
bracket.
g023197
Figure21
1.Locknut(#10)4.Screw(#10x5/8inch)
2.License-platebracket5.Self-tappingscrew(5/16x
1/2inch)
3.Platelight
2.Mountthelicense-platebrackettotherear
bumperwith2self-tappingscrews(5/16x1/2
inch)asshowninFigure21.
Note:Positionthelicense-platebracketas
showninFigure21.
12

11
InstallingtheWireHarness
Partsneededforthisprocedure:
1Wireharness
1Switch-panel-enclosurecover
3Screw(#10x1/2inch)
3Mountingpad
11Cabletie
2Jumperwireharness(LEDheadlightsonly)
Procedure
Usethefollowinginstructionsandillustrationstoroute
andconnectthewireharness.
g034565
Figure22
1.Removetheange-headscrewsecuringthe
compartmentclampandsealtothetractionunit
(Figure23).
Note:Removetheclampandsealtogain
accesstothefusecompartment.
g023198
Figure23
1.Compartmentclamp2.Seal
2.Fromundertherightsideofthetraction
unit,routethefuse-blocksectionofthewire
harnessuptoandintotheopeninginthefuse
compartment(Figure24).
g029803
Figure24
Important:Whenroutingthewireharness,
donotpullitacrosssharpedges,whichmay
damagethewires.Wiresmustnotcontact
hotormovingparts.Securethewireharness
withcableties.
3.Mountthewire-harness-fuseblocknexttothe
existingfuseblockwiththe2self-tappingscrews
(#8x1/2inch)includedwiththewireharness
(Figure25).
Note:Donotovertightenthescrews.
4.Connectthesmall-ringterminalfromthewire
harnessto1ofthescrewsontheground-block
terminal(Figure25).
13

g023200
Figure25
1.Self-tappingscrews(#8x
1/2inch)
3.Junctionblock
2.Ground-blockterminal4.Wireharnessfuseblock
5.Connectthelarge-ringterminal,fromthewire
harness,tothestudonthejunctionblock(Figure
25).
6.Installthecompartmentclampandsealtothe
tractionunitwiththeange-headscrew(Figure
23).
7.Routethefrontendofthewireharnessunder
theoperatorplatformtothefrontofthetraction
unit(Figure26).
g311790
Figure26
1.Jumperwireharness
formachineswithLED
headlights
3.Connectorsforheadlights
2.Brakeconnectorfor
machineswithhalogen
headlights
4.Hornconnectors
Note:UseFigure27orFigure15todetermine
whichheadlightyouhave.
8.FormachineswithLEDheadlights,installthe
jumperwireharnessesshowninFigure26.
9.Threadeachharnessconnectorthroughthe
appropriateheadlightbracketandconnectitto
theheadlight(Figure26).
10.Plugthewireharnesslead,withthe2
connectors,intothehorn(Figure26).
11.Positiontheplatformshroudontopoftheframe
(Figure27).
12.Plugthelight-kitwireharnessconnectorsinto
theshroudheadlights(Figure27).
14

g312120
Figure27
1.Platformshroud5.Headlightwireconnectors
2.Halogenheadlight6.Holeforwireharness
3.Carriageboltandnut7.LEDheadlight
4.Washer-headscrewsand
nuts
13.Securetheshroudandtheheadlightstothe
framewiththe2carriageboltsandnutsyou
previouslyremoved(Figure27).
14.Routethewireharnesstothecolumn-bracket
assemblyonthesteeringcolumn.
15.Plugtheconnectorsintotheashermodule,
horn,turnsignal,andhazardswitches(Figure
28).
g312684
Figure28
1.Turnsignalconnector3.Hazardconnector
2.Hornconnector4.Beaconconnector
16.Installthecoverontothecolumn-bracket
assemblywith2hexsocketbutton-headscrews
asshowninFigure29.
g034566
Figure29
1.Cover2.Hexsocketbutton-head
screws
17.Securethewireharnesstothecolumnusingthe
cabletieinsertedintotheslotsinthecolumn
mountbracket;refertoFigure14.
18.Routetherightrearwireharnessundertheright
sideofthetractionunittotheright,rearlight
(Figure30).
15

g034579
Figure30
19.Plugthewire-harnessconnectorintothelight
connector.
20.Routetheleft,rearwireharnessundertheleft
sideofthetractionunittotheleft,rearlight
(Figure30).
g029801
Figure31
21.Plugthewire-harnessconnectorintothelight
connector.
22.Routethewireharnesstotheregistration-plate
lightandplugthewire-harnessconnectorinto
thelightconnector(Figure31).
Important:Securethewireharnesswith
cabletiessothatitdoesnotcontactanyhot
ormovingparts.
23.Installanypartsthatwereremovedfromthe
tractionunittoroutethewireharness.
12
InstallingtheFusesand
Decal
Partsneededforthisprocedure:
3Fuse(10A)
1Fuse(15A)
1Fuse-boxdecal
Procedure
1.Insertthe3(10A)and1(15A)fusesintothe
fuseblockslot(Figure32).
g029811
Figure32
1.Fuse(10A)3.Fuse(10A)
2.Fuse(10A)4.Fuse(15A)
2.Installthefuse-boxdecaltothestorage-box
cover(Figure33).
16

g034580
Figure33
1.6mm(1/4inch)2.Fuse-boxdecal
13
Installingthe
Decal-MountingPlates
Partsneededforthisprocedure:
2Plate
4Decal
4Hex-headscrew(1/4x2-1/2inches)
4Locknut(1/4inch)
Procedure
1.Aligntheplateswiththeexistingholesinthe
light-kitbrackets(Figure34).
g032309
Figure34
Rightsideshown
1.Plate3.Holes
2.Light-kitbracket
2.Securetheplatestothelight-kitbracketswith
the4hex-headscrews(1/4x2-1/2inches)and
4locknuts(1/4inch)asshowninFigure35.
g032310
Figure35
Rightsideshown
1.Plate3.Light-kitbracket
2.Locknuts(1/4inch)4.Hex-headscrews(1/4x
2-1/2inches)
3.Applythedecalstotheoutward-facingsurface
oftheplates(Figure36).
17

g032311
Figure36
Rightsideshown
1.Plate2.Decals
14
ConnectingtheBattery
NoPartsRequired
Procedure
Connectthebattery;refertoyourmachineOperator’s
Manual.
Operation
Controls
HazardSwitch
Pressthehazardswitch(Figure37)totheONposition
toactivatethefrontandrearashinghazardlights.
g034583
Figure37
1.Turnsignalswitch3.Hazardswitch
2.Hornbutton4.Beaconswitch(optional)
Turn-SignalSwitch
Pressdownontheleftsideoftheturn-signalswitch
(Figure37)toactivatetheleft-turnsignal.Thecenter
positionisoff.
Pressdownontherightsideoftheturn-signalswitch
(Figure37)toactivatetheright-turnsignal.Thecenter
positionisoff.
BeaconSwitch(Optional)
Pressthebeaconswitch(Figure37)toactivatethe
beacon.
HornButton
Pressthehornbutton(Figure37)toactivatethehorn.
18

AimingtheHeadlights
1.Loosenthemountingnutsandpositioneach
headlightsothatitpointsstraightahead.
2.Tighteneachmountingnutjustenoughtohold
theheadlightinposition.
3.Placeaatpieceofsheetmetaloverthefaceof
theheadlight.
4.Mountamagneticprotractorontotheplate.
5.Whileholdingtheassemblyinplace,carefullytilt
theheadlightdownward3degrees,thentighten
thenut.
6.Repeattheprocedurefortheotherheadlight.
19