Toro Groundsmaster 4000 Series User manual

FormNo.3458-361RevA
EULightKit
Groundsmaster®4000SeriesRotaryMower
ModelNo.31694
InstallationInstructions
ThisproductcomplieswithallrelevantEuropeandirectives.Fordetails,pleaseseetheDeclarationof
Incorporation(DOI)atthebackofthispublication.
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,MN55420
Registeratwww.T oro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3458-361*

Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachine.
2Nopartsrequired–Disconnectthebattery.
Rightheadlight—PartNo.140-6772
(light,mount,washer,andnut)1
Leftheadlight—PartNo.140-6773
(light,mount,washer,andnut)1
Leftlightmount(Groundsmaster4000
Machines)1
Rightlightmount(Groundsmaster4000
Machines)1
Leftlightmount(Groundsmaster4100
Machines)1
Rightlightmount(Groundsmaster4100
Machines)1
Leftlightmount(machineswithacab)1
Rightlightmount(machineswithacab)1
Grommet(Groundsmaster4000
Machinesandmachineswithacab)2
Carriagebolt(1/2x5/8inch—machines
withacab)2
Carriagebolt(1/2x5/8inch—machines
withacab)2
Carriagebolt(1/4x5/8inch—machines
withacab)2
Flangelocknut(1/4inch—machines
withacab)2
3
Cabletie2
Assembletheheadlightstothebrackets.
4Nopartsrequired–Installtheheadlights.
2

ProcedureDescriptionQty.Use
Consoleharness1
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.
Horn1
Capscrew(5/16x3/4inch)1
Flangelocknut(5/16inch)1
6Cabletie1
Installthehornandconnecttheconsole
harness.
Tape(double-faceadhesive)1
7Identityplate1
Installtheidentityplate(machinessold
inGermany).
Fuse(10A)2
Fuse(15A)1
8Relay1
Installthefuseandrelay.
3

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
9
Flangelocknut(3/8inch)4
Installthetaillights.
Bumper1
Spacer1
Flange-headlocknut(1/4inch)1
Slowmovingvehiclemount1
Speeddecal3
Nutclip(#10)2
License-platelight1
10
Socket-headscrews(#10x3/4inch)2
Installthelicenseplateandsidedecals.
11Nopartsrequired–Connectthetaillightharnesses.
12Nopartsrequired–Connectthebatterycables.
4

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
AssemblingtheHeadlights
totheBrackets
Partsneededforthisprocedure:
1Rightheadlight—PartNo.140-6772(light,mount,
washer,andnut)
1Leftheadlight—PartNo.140-6773(light,mount,
washer,andnut)
1Leftlightmount(Groundsmaster4000Machines)
1Rightlightmount(Groundsmaster4000Machines)
1Leftlightmount(Groundsmaster4100Machines)
1Rightlightmount(Groundsmaster4100Machines)
1Leftlightmount(machineswithacab)
1Rightlightmount(machineswithacab)
2Grommet(Groundsmaster4000Machinesand
machineswithacab)
2Carriagebolt(1/2x5/8inch—machineswithacab)
2Carriagebolt(1/2x5/8inch—machineswithacab)
2Carriagebolt(1/4x5/8inch—machineswithacab)
2Flangelocknut(1/4inch—machineswithacab)
2Cabletie
5

IdentifyingtheHeadlights
Atthebracketsideoftheheadlight,lookatthe
informationprintedonthehousing(Figure4).Note
thepartnumberandthe“RH”or“LH”information.
g350385
Figure4
IdentifyingtheHeadlightMounts
UseFigure5,Figure6,andFigure7toidentifythe
headlightmountsforyourmachine.
g350857
Figure5
Groundsmaster4000Machines
1.Leftlightmount2.Rightlightmount
g350858
Figure6
Groundsmaster4100Machines
1.Leftlightmount2.Rightlightmount
g350858
Figure7
MachineswithaCab
1.Leftlightmount2.Rightlightmount
RemovingtheFloorPanel
Hardware
MachineswithaRollBar
Removethe2capscrewsand2thinwashers,2thick
washers,and2angelocknutsthatsecurethefrontof
theoorpaneltotheframeofthemachine(Figure8).
Note:Retainthehardware.
g350418
Figure8
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)
AssemblingtheHeadlights
Groundsmaster4000Machines
Important:Ensurethatyouassemblethe
headlightmarkedleftandtheleftlightmount,
andtheheadlightmarkedrightandtherightlight
mount.
1.Ifassembled,removethelocknut(12mm)and
lockwasher(12mm)fromthecapscrewinthe
headlightbracket.
6

2.Assemblethecapscrew(12mm)tothelight
mountfortheGroundsmaster4000machines
(Figure9)withthelocknut(12mm)andlock
washer(12mm).
g350742
Figure9
Rightheadlightshown.
1.Headlight3.Lockwasher
2.Lightmount
(Groundsmaster4000
machines)
4.Locknut
3.Tightenthelocknutandcapscrew.
4.Assemblethegrommettothe38mm(1-1/2
inch)holeinthelightmount(Figure10).
g350743
Figure10
1.Headlight3.Grommet
2.Headlightbracket
5.Repeatstepsthrough4fortheotherheadlight
andtheGroundsmaster4100lightmount.
AssemblingtheHeadlights
Groundsmaster4100Machines
Important:Ensurethatyouassemblethe
headlightmarkedleftandtheleftlightmount,
andtheheadlightmarkedrightandtherightlight
mount.
1.Ifassembled,removethelocknut(12mm)and
lockwasher(12mm)fromthecapscrewinthe
headlightbracket.
2.Assemblethecapscrew(12mm)tothelight
mountfortheGroundsmaster4100machines
(Figure11)withthelocknut(12mm)andlock
washer(12mm).
g350745
Figure11
Rightheadlightshown.
1.Headlight3.Lockwasher
2.Lightmount
(Groundsmaster4100
machines)
4.Locknut
3.Tightenthelocknutandcapscrew.
4.Repeatsteps1through3fortheotherheadlight
andtheGroundsmaster4100lightmount.
AssemblingtheHeadlights
MachineswithaCab
Important:Ensurethatyouassemblethe
headlightmarkedleftandtheleftlightmount,
andtheheadlightmarkedrightandtherightlight
mount.
1.Ifassembled,removethelocknut(12mm)and
lockwasher(12mm)fromthecapscrewinthe
headlightbracket.
2.Assemblethecapscrew(12mm)tothelight
mount(Figure12)withthelocknut(12mm)and
lockwasher(12mm).
7

g350618
Figure12
Rightheadlightshown.
1.Headlight3.Lockwasher
2.Lightmount(machines
withacab)
4.Locknut
3.Assemblethegrommettothe38mm(1-1/2
inch)holeinthelightmount(Figure13).
g350619
Figure13
1.Grommet2.Cabheadlightbracket
4.Repeatsteps1through3fortheotherheadlight
andlightmount.
4
InstallingtheHeadlights
NoPartsRequired
InstallingtheHeadlightsandLight
Mounts
MachineswithaRollBar
1.Assembletheheadlightandlightmounttothe
oorpanelandframeofthemachinewiththe
capscrew(1/2x4-1/2inches),thinwasher(1/2x
1-3/8inch),thickwasher(1/2x2-1/4x3/8inch),
andangelocknut(1/2inch)thatyouremoved
inRemovingtheFloorPanelHardware(page6)
asshowninFigure14orFigure15.
8

g350744
Figure14
Groundsmaster4000Machines
1.Capscrew(1/2x4-1/2
inches)
4.Frontframe
2.Thinwasher(1/2x1-3/8
inch)
5.Thickwasher(1/2x2-1/4
x3/8inch)
3.Headlightandlight
mount(Groundsmaster
4000machines)
6.Flangelocknut(1/2inch)
g350746
Figure15
Groundsmaster4100Machines
1.Capscrew(1/2x4-1/2
inches)
4.Frontframe
2.Thinwasher(1/2x1-3/8
inch)
5.Thickwasher(1/2x2-1/4
x3/8inch)
3.Headlightandlightmount
(Groundsmaster4000
machines)
6.Flangelocknut(1/2inch)
2.Torquelocknutandcapscrewandlocknutto91
to113N∙m(67to83ft-lb).
3.Removethecabletiesecuringthe6-socket
connectorlabeledHEADLIGHTLHandthe
6-socketconnectorlabeledHEADLIGHTRHof
themachinewireharnesstothechassisofthe
machine(Figure16).
9

g350888
Figure16
Groundsmaster4000shown;theGroundsmaster4100is
similar.
4.ForGroundsmaster4000machines,routethe
6-socketconnector(labeledHEADLIGHTLHor
HEADLIGHTRHofthemachinewireharness
throughthegrommetasshowninFigure17.
g350903
Figure17
Groundsmaster4000Machines
1.6-socketconnector
(labeledHEADLIGHTLHor
HEADLIGHTRH—machine
wireharness)
2.Grommet
5.Removethecapfromthe6-socketconnector
labeledHEADLIGHTLHorthe6-socketconnector
labeledHEADLIGHTRH,andplugtheconnector
intotheheadlight(Figure18).
g350820
Figure18
1.6-socketconnector
(labeledHEADLIGHTLHor
HEADLIGHTRH—machine
wireharness)
3.Headlight
2.Cap
6.Bundletheexcesswireharnessandsecureitto
thechassiswithacabletie.
7.Repeatsteps1through6fortheheadlightand
lightmountattheothersideofthemachine.
InstallingtheHeadlightsandLight
Mounts
MachineswithaCab
1.Assembletheheadlightandlightmounttothe
headlightbracketonthecabframe(Figure19)
withaange-headcapscrew(1/2x1inch),
angelocknut(1/2inch),carriagebolt(1/4x5/8
inch),andangelocknut(1/4inch).
10

g350620
Figure19
1.Cabheadlightbracket4.Flangelocknut(1/2inch)
2.Flange-headcapscrew
(1/2x1inch)
5.Carriagebolt(1/4x5/8
inch)
3.Headlightbracket6.Flangelocknut(1/4inch)
2.Tightenthelocknutandcarriagebolt.
3.Torquelocknutandcapscrewandlocknutto91
to113N∙m(67to83ft-lb).
4.Routethe6-socketconnector(labeled
HEADLIGHTLHorHEADLIGHTRHofthemachine
wireharnessthroughthegrommetasshownin
Figure21.
g350900
Figure20
g350904
Figure21
1.6-socketconnector
(labeledHEADLIGHTLHor
HEADLIGHTRH—machine
wireharness)
2.Grommet
5.Removethecapfromthe6-socketconnector
labeledHEADLIGHTLHorthe6-socketconnector
labeledHEADLIGHTRH,andplugtheconnector
intotheheadlight(Figure22).
11

g350820
Figure22
1.6-socketconnector
(labeledHEADLIGHTLHor
HEADLIGHTRH—machine
wireharness)
3.Headlight
2.Cap
6.Repeatsteps1through3fortheheadlightand
lightmountattheothersideofthemachine.
5
InstallingtheControl
Console
Partsneededforthisprocedure:
1Consoleharness
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)
PreparingtheSteeringCoverand
RoutingtheControlHarness
1.Removethebootfromthesteeringcover,and
slidethebootup(Figure23).
12

g350969
Figure23
1.Boot3.Steeringcover
2.Flange-headscrews
2.Removethe4ange-headscrewsthatsecure
thesteeringcovertothecovermounts,andlift
thecover(Figure23).
3.Grindanotchinthesteeringcoverasshowin
Figure24.
g350968
Figure24
1.Notch(steeringcover)3.11mm(7/16inch)
2.6mm(1/4inch)
4.Alignthe12-pinconnectorendofthecontrol
harnessthroughnotchinthesteeringcover
(Figure25).
g350970
Figure25
1.12-pinconnector(control
harness)
2.Notch(steeringcover)
5.Assemblethesteeringcovertothecovermounts
withthe4ange-headscrews.
6.Pullthebootdownandassemblethebottomof
itintothesteeringcover(Figure26).
g350967
Figure26
13

AssemblingtheFuseMountPlate
1.Assembletheclipnut(#10)ontothefusemount
plate(Figure27).
g350763
Figure27
1.Clipnut(#10)4.Flangeheadscrew(#10x
3/8inch)
2.Fusemountplate5.Cabletie
3.Flasher
2.Assembletheashertothemountplate(Figure
27)withaangeheadscrew(#10x3/8inch).
3.Securetheashertothemountplatewitha
cabletie(Figure27).
4.Plugthe12-socketconnectoroftheconsole
harnessintothe12-pinconnectoroftheasher
(Figure28).
g350765
Figure28
1.12-pinconnector(asher)2.12-socketconnector
(consoleharness)
5.Insertpush-inanchoroftheconsoleharness
intothe6.4mm(1/4inch)holeinthebracket
mount(Figure29).
14

g350766
Figure29
1.Bracketmount2.Push-inanchor(console
harness)
AssemblingtheSwitchMount
1.Assemblethe8clipnut(1/4inch)totheswitch
mountasshowninFigure30.
g350767
Figure30
1.Switchmount2.Clipnut(1/4inch)
2.Insertthemulti-functionswitchintothe100mm
(2inch)holeintheswitchmountasshownin
Figure31.
g350769
Figure31
1.Switchmount2.Multi-functionswitch
15

3.Securethemulti-functionswitchtotheswitch
mountwiththethickandthinswitchclips(Figure
32).
g350778
Figure32
1.Tab(multi-functionswitch)3.Switchclip(thin)
2.Switchclip(thick)
4.Insertthe3switchplugsintotheswitchmount
asshowninFigure33.
g350770
Figure33
1.Switchplug
5.Aligntherockerswitchtotheswitchmountwith
thelensofthelighttothefrontoftheswitch
plate(Figure34).
g350768
Figure34
1.Rockerswitch2.Frontoftheswitchplate
6.Assemblethe2knobsintothefusecover,and
securetheknobswith2boltretainers(Figure
35).
g350764
Figure35
1.Boltretainer3.Knob
2.Fusecover
7.Assemblethefusecovertotheswitchplate,and
tightentheknobs(Figure35).
16

InstallingtheSwitchPlatetothe
SteeringColumn
1.Aligntheswitchplatetotherearwardsideorthe
steeringcolumn(Figure37).
g350762
Figure36
1.Carriagebolt(1/4x2
inches)
2.Bracketmount
2.Attheupper6.4mm(1/4inch)holes,assemble
2carriageboltsbolt(1/4x2inches)throughthe
switchplateandtheotherbracketmount(Figure
36).
3.Assemblethefusemountplatetotheupper
bracketmountandcarriagebolts(Figure37)
with2angelocknuts(1/4inch).
g350772
Figure37
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(Figure37)with2carriagebolts(1/4x2
inches)and2angelocknuts(1/4inch).
5.Aligntheswitchplatetotheoperator’sseat,and
tightenthe4angelocknuts.
ConnectingtheConsoleHarness
totheSwitches
1.Plugthe8-socketconnectorofthecontrol
harnesslabeledHAZARDSWITCHintothe8-pin
connectoroftherockerswitch(Figure38).
g350776
Figure38
1.8-pinconnector(rocker
switch)
2.8-socketconnector
(labeledHAZARD
SWITCH—console
harness)
17

2.Plugthe9-pinconnectorofthemulti-function
switchharnessintothe9-socketconnectorof
theconsoleharness(Figure39).
g350777
Figure39
1.9-pinconnector
(multi-functionswitch
harness)
2.9-socketconnector
(consoleharness)
3.Securetheconsoleharnesstothesteering
columnwith2cableties.
InstallingtheControlCover
1.Aligntheholesinthecontrolcovertotheholes
intheswitchmount(Figure40).
g350789
Figure40
1.Switchmount3.Controlcover
2.Push-infastener
2.Usingthemiddleholes,securethecoverto
themountwith2push-infastenersasshown
inFigure40.
3.Securethecovertothemountwith4
ange-headsscrews(1/4x3/4)asshownin
Figure41.
g350771
Figure41
1.Flange-headsscrew(1/4
x3/4inch)
2.Controlcover
6
InstallingtheHornand
ConnectingtheConsole
Harness
Partsneededforthisprocedure:
1Horn
1Capscrew(5/16x3/4inch)
1Flangelocknut(5/16inch)
1Cabletie
AssemblingtheHorn
1.Aligntheholeinthebracketofthehornwiththe
holeinthecolumnbraceasshowninFigure43.
18

g351028
Figure42
g351025
Figure43
1.Hornandbracket4.Capscrew(5/16x3/4inch)
2.Flangelocknut(5/16inch)5.Rightsideofthemachine
3.Columnbrace
2.Securethehornbrackettothecolumnbrace
(Figure43)withacapscrew(5/16x3/4inch)
andangelocknut(5/16inch).
3.Connectthe2spade-socketconnectorsofthe
machinewireharnesstotheelectricalterminals
ofthehorn(Figure44).
g351026
Figure44
1.Horn3.Cabletie
2.Spade-socketconnector
4.Securethehornwireswithacabletie.
ConnectingtheHarness
1.Removethecapfromthe12-socketconnector
ofthemachinewireharness(Figure45).
g351027
Figure45
1.12-socketconnector
(machinewireharness)
3.12-pinconnector(console
harness)
2.Cap
19

2.Plugthe12-pinconnectoroftheconsole
harnessintothe12-socketconnectorofthe
machinewireharness(Figure45).
7
InstallingtheIdentityPlate
MachinesOperatedinGermany
Partsneededforthisprocedure:
1Tape(double-faceadhesive)
1Identityplate
Procedure
1.Removethebackingfromthedouble-face
adhesivetape(Figure46).
g351074
Figure46
1.Tape(double-face
adhesive)
3.Identityplate
2.Backinglm
2.Adherethetapetotheidentityplate(Figure46).
3.Cleantherightsupportchannelbelowthe
operator’splatform,andallowthechanneltodry
(Figure47andFigure48).
g350944
Figure47
g350945
Figure48
1.Identityplate3.3mm(1/8inch)
2.Supportchannel4.22mm(7/8inch)
4.Removethebackinglmfromtheidentityplate
(Figure46)andadheretheplatetothesupport
channelasshowninFigure48.
20