Toro Groundsmaster 4000 Series User manual

FormNo.3444-718RevD
NALightKit
Groundsmaster®4000SeriesRotaryMower
ModelNo.31693
InstallationInstructions
Safety
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedormissing.
decal140-1531
140-1531
1.Snowchute—left4.Hazardlight—off
2.Snowchute—right5.Attachment—down
3.Hazardlight—on6.Attachment—up
decal140-1623
140-1623
1.Beacon—off2.Beacon—on
©2022—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420Registeratwww.T oro.com.
OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3444-718*

Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachine.
2Nopartsrequired–Disconnectthebattery.
Reectordecal(front—yellow)2
3Reectordecal(back—red)2Installthefrontreectordecals.
Rightheadlight—PartNo.140-6772
(light,mount,washer,andnut)1
Leftheadlight—PartNo.140-6773
(light,mount,washer,andnut)1
Lightmount(machineswitharollbar)2
Leftlightmount(machineswithacab)1
Rightlightmount(machineswithacab)1
Flange-headcapscrew(1/2x1inch)2
FlangeLocknut(1/2inch)2
4
Cabletie2
Assembletheheadlightstothebrackets.
Consoleharness1
Capplug1
Fusemountplate1
Clipnut(#10)1
Flasher1
Flangeheadscrew(#10x3/8inch)1
Cabletie1
Bracketmount2
Clipnut(1/4inch)8
Switchmount1
Multi-functionswitch1
Switchclip(thick)1
Switchclip(thin)1
Switchplug3
Rockerswitch1
Knob2
Fusecover1
Boltretainer2
Carriagebolt(1/4x2inches)4
Flangelocknuts4
Cableties2
Push-infastener2
5
Flange-headsscrew(1/4x3/4inch)4
Installthecontrolconsole.
6Nopartsrequired–Connecttheconsoleharness.
Fuse(10A)1
7Fuse(15A)1Installthefuses.
2

ProcedureDescriptionQty.Use
Leftlighthousing1
Leftlight-housingmount1
Rightlighthousing1
Rightlight-housingmount1
Carriagebolt(1/4x5/8inch)4
Flangelocknut(1/4inch)4
Lefttaillightandlicenseplateharness1
Righttaillightharness1
Clipnut(1/4inch)4
Innermount2
Socket-headscrew(1/4x3/4inch)8
Taillight2
Phillips-headscrew(#10x1-1/4inches)4
Pivotbracket2
Capscrew(1/4x3/4inch)6
Locknut(1/4inch)6
Leftmountcover1
Rightmountcover1
Push-infasteners8
Swivel-adaptermount2
Carriagebolt(1/4x1-1/4inches)4
8
Flangelocknut(3/8inch)4
Installthetaillights.
Slowmovingvehicleemblem1
Slowmovingvehiclemount1
Capscrew(1/4x3/4inch)3
Washer(1/4x3/4inch)3
9
Locknut(1/4inch)3
Installtheslow-movingvehiclesign.
10Nopartsrequired–Connectthetaillightharnesses.
11Nopartsrequired–Connectthebatterycables.
3

1
PreparingtheMachine
NoPartsRequired
Procedure
1.Parkthemachineonalevelsurfaceandlower
thecuttingunits.
2.Engagetheparkingbrake.
3.Shutofftheengineandremovethekey.
g351500
Figure1
2
DisconnectingtheBattery
NoPartsRequired
Procedure
1.Openthebatterycoveronthesideoftheshroud
(Figure2).
Note:Pressdownontheatsurfaceabovethe
batterycovertoeasetheremovalofthecover.
g020758
Figure2
1.Batterycover2.Pressdownhere.
2.Disconnectthenegative(black)batterycable.
g020451
Figure3
1.Battery
3.Sliptherubberbootoffthepositiveterminal,and
disconnectthecable.
3
InstallingtheReector
Decals
Partsneededforthisprocedure:
2Reectordecal(front—yellow)
2Reectordecal(back—red)
InstallingtheFrontReector
MachineswithaRollBar
1.Cleanthefrontedgeoftheplatformwithalcohol,
andallowittodry(Figure4).
4

g351079
Figure4
1.Reectordecal(yellow)
2.Removethebackinglmfromtheyellow
reectordecal.
3.Alignthereectortothebottomedgeofthe
platformasshowninFigure4,andadhereitto
theplatform.
4.Wraptheedgeofthereectoroverthetopof
theplatform.
5.Repeatsteps1through4fortheotheryellow
reectordecal.
InstallingtheFrontReector
MachineswithaCab
1.Cleanthefrontcabpillarabovetheheadlight
bracketwithalcohol,andallowittodry(Figure
5).
g351129
Figure5
1.Frontcabpillar3.23.8cm(9-3/8inches)
2.Reectordecal(yellow)4.Headlightbracket
2.Removethebackinglmyellowreectordecal.
3.Alignthedecal23.8cm(9-3/8inches)above
theheadlightbracket,andadherethedecalto
thecabpillar(Figure5).
InstallingtheRearReector
1.Cleanthefaceofthebumperwithalcohol,and
allowittodry(Figure6).
g351117
Figure6
2.Removethebackinglmfromtheredreector
decal.
3.Alignthereectortothebumperasshownin
Figure6,andadhereittothebumper.
5

4.Repeatsteps1through3fortheotherred
reectordecal.
4
AssemblingtheHeadlights
totheBrackets
Partsneededforthisprocedure:
1Rightheadlight—PartNo.140-6772(light,mount,
washer,andnut)
1Leftheadlight—PartNo.140-6773(light,mount,
washer,andnut)
2Lightmount(machineswitharollbar)
1Leftlightmount(machineswithacab)
1Rightlightmount(machineswithacab)
2Flange-headcapscrew(1/2x1inch)
2FlangeLocknut(1/2inch)
2Cabletie
IdentifyingtheHeadlights
Atthebracketsideoftheheadlight,lookatthe
informationprintedonthehousing(Figure7).Note
thepartnumberandthe“RH”or“LH”information.
g350385
Figure7
IdentifyingtheHeadlightMounts
UseFigure8andFigure9toidentifytheheadlight
mountsforyourmachine.
g350863
Figure8
MachineswithaRollBar
1.Lightmounts
g350864
Figure9
MachineswithaCab
1.Leftlightmount2.Rightlightmount
RemovingtheFloorPanel
Hardware
MachineswithaRollBar
Removethe2capscrewsand2thinwashers,2thick
washers,and2angelocknutsthatsecurethefrontof
theoorpaneltotheframeofthemachine(Figure10).
Note:Retainthehardware.
6

g350418
Figure10
1.Capscrew(1/2x4-1/2
inches)
4.Flangelocknut(1/2inch)
2.Floorpanel5.Thickwasher(1/2x2-1/4
x3/8inch)
3.Thinwasher(1/2x1-3/8
inch)
InstallingtheLightMountstothe
Machine
MachineswithaRollBar
1.Assemblethelightmounttotheoorpaneland
frameofthemachinewiththecapscrew(1/2x
4-1/2inches),thinwasher(1/2x1-3/8inch),
thickwasher(1/2x2-1/4x3/8inch),andange
locknut(1/2inch)thatyouremovedinRemoving
theFloorPanelHardware(page6).
g350530
Figure11
1.Capscrew(1/2x4-1/2
inches)
4.Thickwasher(1/2x2-1/4
x3/8inch)
2.Thinwasher(1/2x1-3/8
inch)
5.Flangelocknut(1/2inch)
3.Lightmount(machines
withacab)
2.Torquelocknutandcapscrewandlocknutto91
to113N∙m(67to83ft-lb).
3.Repeatsteps1and2forthelightmountatthe
othersideofthemachine.
AssemblingtheHeadlights
MachineswithaCab
Important:Ensurethatyouassemblethe
headlightmarkedleftandtheleftlightmount,
andtheheadlightmarkedrightandtherightlight
mount.
1.Ifassembled,removethelocknut(12mm)and
lockwasher(12mm)fromthecapscrewinthe
headlightbracket.
2.Alignthelighttothelightmountasfollows:
7

•Groundsmaster4010Machines:Usethe
outsidelight-mounthole.
•Groundsmaster4110Machines:Usethe
insidelight-mounthole.
g350532
Figure12
Rightheadlightshown.
1.Capscrew(headlight)4.Lockwasher
2.Outsidelight-mounthole
(GroundsmasterGM4010
machines)
5.Locknut
3.Insidelightmounthole
(GroundsmasterGM4110
machines)
3.Assemblethecapscrew(12mm)tothelight
mount(Figure12)withthelocknut(12mm)and
lockwasher(12mm).
4.Tightenthelocknutandcapscrew.
5.Repeatsteps1through4fortheheadlightand
lightmountfortheothersideofthemachine.
InstallingtheHeadlights
MachineswithaRollBar
Important:Ensurethatyouassemblethe
headlightmarkedleftattheleftsideofthe
machine,andtheheadlightmarkedrightatthe
rightsideofthemachine.
1.Removethecabletiesecuringthe6-socket
connectorlabeledHEADLIGHTLHandthe
6-socketconnectorlabeledHEADLIGHTRHof
themachinewireharnesstothechassisofthe
machine(Figure13).
g350877
Figure13
2.Removethecapfromthe6-socketconnector
labeledHEADLIGHTLHorthe6-socketconnector
labeledHEADLIGHTRHofthemachinewire
harness,andplugtheconnectorintothe
headlight(Figure14).
8

g350820
Figure14
1.6-socketconnector
(labeledHEADLIGHTLHor
HEADLIGHTRH—machine
wireharness)
3.Headlight
2.Cap
3.Ifassembled,removethelocknut(12mm)and
lockwasher(12mm)fromthecapscrewinthe
headlightbracket.
4.Assemblethecapscrew(12mm)tothelight
mount(Figure15)withthelocknut(12mm)and
lockwasher(12mm).
g350531
Figure15
Rightheadlightshown.
1.Headlight3.Lockwasher
2.Lightmount(machines
witharollbar)
4.Locknut
5.Tightenthelocknutandcapscrew.
6.Bundletheexcesswireharnessandsecureitto
thechassiswithacabletie.
7.Repeatsteps2through5fortheotherheadlight
attheothersideofthemachine.
9

InstallingtheHeadlightsandLight
Mounts
MachineswithaCab
1.Assembletheheadlightandlightmounttothe
headlightbracket(Figure16)withaange-head
capscrew(1/2x1inch)andangelocknut(1/2
inch).
g350533
Figure16
1.Flange-headcapscrew
(1/2x1inch)
3.Headlightbracket
2.Lightmount4.FlangeLocknut(1/2inch)
2.Torquelocknutandcapscrewandlocknutto91
to113N∙m(67to83ft-lb).
3.Repeatsteps1and2fortheotherheadlightand
lightmountattheothersideofthemachine.
4.Removethecapfromthe6-socketconnector
labeledHEADLIGHTLHorthe6-socketconnector
labeledHEADLIGHTRHofthemachinewire
harness,andplugtheconnectorintothe
headlight(Figure17).
g350820
Figure17
1.6-socketconnector
(labeledHEADLIGHTLHor
HEADLIGHTRH—machine
wireharness)
3.Headlight
2.Cap
5.Repeatstep4fortheotherheadlightattheother
sideofthemachine.
10

5
InstallingtheControl
Console
Partsneededforthisprocedure:
1Consoleharness
1Capplug
1Fusemountplate
1Clipnut(#10)
1Flasher
1Flangeheadscrew(#10x3/8inch)
1Cabletie
2Bracketmount
8Clipnut(1/4inch)
1Switchmount
1Multi-functionswitch
1Switchclip(thick)
1Switchclip(thin)
3Switchplug
1Rockerswitch
2Knob
1Fusecover
2Boltretainer
4Carriagebolt(1/4x2inches)
4Flangelocknuts
2Cableties
2Push-infastener
4Flange-headsscrew(1/4x3/4inch)
InstallingtheConsoleHarness
ConnectorPlug
1.Disconnectthesingle-pinconnectorfromthe
single-socketconnectorlabeledNA/EUMODE
SELECTOR(Figure18).
g350773
Figure18
1.Capplug3.Single-pinconnector
2.Single-socketconnector
(labeledNA/EUMODE
SELECTOR)
2.Plugthesingle-pinconnectorandthe
single-socketconnectorintothecapplug(Figure
18).
11

PreparingtheSteeringCoverand
RoutingtheControlHarness
1.Removethebootfromthesteeringcover,and
slidethebootup(Figure19).
g350969
Figure19
1.Boot3.Steeringcover
2.Flange-headscrews
2.Removethe4ange-headscrewsthatsecure
thesteeringcovertothecovermounts,andlift
thecover(Figure19).
3.Grindanotchinthesteeringcoverasshowin
Figure20.
g350968
Figure20
1.Notch(steeringcover)3.11mm(7/16inch)
2.6mm(1/4inch)
4.Alignthe12-pinconnectorendofthecontrol
harnessthroughnotchinthesteeringcover
(Figure21).
12

g350970
Figure21
1.12-pinconnector(control
harness)
2.Notch(steeringcover)
5.Assemblethesteeringcovertothecovermounts
withthe4ange-headscrews.
6.Pullthebootdownandassemblethebottomof
itintothesteeringcover(Figure22).
g350967
Figure22
AssemblingtheFuseMountPlate
1.Assembletheclipnut(#10)ontothefusemount
plate(Figure23).
g350763
Figure23
1.Clipnut(#10)4.Flangeheadscrew(#10x
3/8inch)
2.Fusemountplate5.Cabletie
3.Flasher
2.Assembletheashertothemountplate(Figure
23)withaangeheadscrew(#10x3/8inch).
3.Securetheashertothemountplatewitha
cabletie(Figure23).
4.Plugthe12-socketconnectoroftheconsole
harnessintothe12-pinconnectoroftheasher
(Figure24).
13

g350765
Figure24
1.12-pinconnector(asher)2.12-socketconnector
(consoleharness)
5.Insertpush-inanchoroftheconsoleharness
intothe6.4mm(1/4inch)holeinthebracket
mount(Figure25).
g350766
Figure25
1.Bracketmount2.Push-inanchor(console
harness)
14

AssemblingtheSwitchMount
1.Assemblethe8clipnuts(1/4inch)totheswitch
mountasshowninFigure26.
g350767
Figure26
1.Switchmount2.Clipnut(1/4inch)
2.Insertthemulti-functionswitchintothe100mm
(2inch)holeintheswitchmountasshownin
Figure27.
g350769
Figure27
1.Switchmount2.Multi-functionswitch
3.Securethemulti-functionswitchtotheswitch
mountwiththethickandthinswitchclips(Figure
28).
g350778
Figure28
1.Tab(multi-functionswitch)3.Switchclip(thin)
2.Switchclip(thick)
4.Insertthe3switchplugsintotheswitchmount
asshowninFigure29.
15

g350770
Figure29
1.Switchplug
5.Aligntherockerswitchtotheswitchmountwith
thelensofthelighttothefrontoftheswitch
plate(Figure30).
g350768
Figure30
1.Rockerswitch2.Frontoftheswitchplate
6.Assemblethe2knobsintothefusecover,and
securetheknobswith2boltretainers(Figure
31).
g350764
Figure31
1.Boltretainer3.Knob
2.Fusecover
7.Assemblethefusecovertotheswitchplate,and
tightentheknobs(Figure31).
InstallingtheSwitchPlatetothe
SteeringColumn
1.Aligntheswitchplatetotherearwardsideorthe
steeringcolumn(Figure33).
g350762
Figure32
1.Carriagebolt(1/4x2
inches)
2.Bracketmount
16

2.Attheupper6.4mm(1/4inch)holes,assemble
2carriageboltsbolt(1/4x2inches)throughthe
switchplateandtheotherbracketmount(Figure
32).
3.Assemblethefusemountplatetotheupper
bracketmountandcarriagebolts(Figure33)
with2angelocknuts(1/4inch).
g350772
Figure33
1.Bracketmount4.Fusemountplate
2.Carriagebolt(1/4x2
inches)
5.Flangelocknut(1/4inch)
3.Switchmount
4.Atthelower6.4mm(1/4inch)holes,assemble
2carriageboltsbolt(1/4x2inches)throughthe
switchplate,bracketmount,andfusemount
plate(Figure33)with2carriagebolts(1/4x2
inches)and2angelocknuts(1/4inch).
5.Aligntheswitchplatetotheoperator’sseat,and
tightenthe4angelocknuts.
ConnectingtheConsoleHarness
totheSwitches
1.Plugthe8-socketconnectorofthecontrol
harnesslabeledHAZARDSWITCHintothe8-pin
connectoroftherockerswitch(Figure34).
g350776
Figure34
1.8-pinconnector(rocker
switch)
2.8-socketconnector
(labeledHAZARD
SWITCH—console
harness)
2.Plugthe9-pinconnectorofthemulti-function
switchharnessintothe9-socketconnectorof
theconsoleharness(Figure35).
g350777
Figure35
1.9-pinconnector
(multi-functionswitch
harness)
2.9-socketconnector
(consoleharness)
3.Securetheconsoleharnesstothesteering
columnwith2cableties.
InstallingtheControlCover
1.Aligntheholesinthecontrolcovertotheholes
intheswitchmount(Figure36).
17

g350789
Figure36
1.Switchmount3.Controlcover
2.Push-infastener
2.Usingthemiddleholes,securethecoverto
themountwith2push-infastenersasshown
inFigure36.
3.Securethecovertothemountwith4
ange-headsscrews(1/4x3/4)asshownin
Figure37.
g350771
Figure37
1.Flange-headsscrew(1/4
x3/4inch)
2.Controlcover
6
ConnectingtheConsole
Harness
NoPartsRequired
Procedure
1.Removethecapfromthe12-socketconnector
ofthemachinewireharness(Figure38and
Figure39).
g351028
Figure38
18

g351027
Figure39
1.12-socketconnector
(machinewireharness)
3.12-pinconnector(console
harness)
2.Cap
2.Plugthe12-pinconnectoroftheconsole
harnessintothe12-socketconnectorofthe
machinewireharness(Figure39).
7
InstallingtheFuses
Partsneededforthisprocedure:
1Fuse(10A)
1Fuse(15A)
RemovingtheElectricalCover
MachineswithaRollBar
Attheooralongrightsideoftheoperator’sseat,
removethe2socket-headscrewsand2washersthat
securethecontrollercovertotheelectrical-component
mount,andremovethecover(Figure40).
g351012
g351093
Figure40
1.Electricalcover3.Washer
2.Socket-headscrew4.Clipnut
(electrical-component
mount)
RemovingtheElectricalCover
MachineswithaCab
Attheooralongrightsideoftheoperator’sseat,
removethe2socket-headscrewsthatsecurethe
controllercovertotheelectrical-componentmount,
andremovethecover(Figure41).
19

g351105
g351092
Figure41
1.Electricalcover3.Clipnut
(electrical-component
mount)
2.Socket-headscrew
InsertingtheFuses
Insertthefuses(Figure42)intothefollowing
fuse-blockslots:
FuseFuse-blockslot
10AA3
15AA4
g351014
Figure42
1.Fuse(10A)andfuse-block
slotA3
2.Fuse(15A)andfuse-block
slotA4
InstallingtheElectricalCover
MachineswithaRollBar
1.Alignholesinthecontrollercoverwithclipnuts
ontheelectrical-componentmount(Figure43).
g351093
Figure43
1.Electricalcover3.Washer
2.Socket-headscrew4.Clipnut
(electrical-component
mount)
2.Installthecontrollercovertothe
electrical-componentmount(Figure43)
withthe2socket-headscrewsand2washers
thatyouremovedinRemovingtheElectrical
Cover(page19).
InstallingtheElectricalCover
MachineswithaCab
1.Alignholesinthecontrollercoverwithclipnuts
ontheelectrical-componentmount(Figure44).
g351092
Figure44
1.Electricalcover3.Clipnut
(electrical-component
mount)
2.Socket-headscrew
2.Installthecontrollercovertothe
electrical-componentmount(Figure44)
20