Toro 4000 Boxer Parts List & Mounting Instructions
Jodale • Perry Printed: 2004/01
Toro 4000 Mounting Instructions Standard Parts List Qty
Description
L&R
Rear Brackets
1
Fuse Block Mount Plate
2
Cab Lift Brackets (2” Tube)
2
3/8” Black Snap Caps
9 LF
180° O-rubber
8.5 LF
90° O-rubber
1
Floormat (pre-cut)
1
Mylar (pre-cut)
L&R
Deck Stop Brackets
L&R
Control Rods
2
Neoprene Pads
Photo
NOTE: All references to left and right are taken from the operator’s point of view when he/she is sitting in the driver’s seat.
Toro 4000 Mounting Instructions Standard Bolts List Qty
Description
2
Bolt, Hex, ½” x 3”, Gr. 8, Yellow Dichrome
2
Bolt, Hex, ½” x 6 ½”, Gr. 8, Yellow Dichrome
4
Bolt, Hex, 5/8” x 1 ½”, Gr. 8, Yellow Dichrome
4
Washer, Lock, 5/8”
4
Washer, Lock, ½”
4
Nut, Hex, ½”, Gr. 8, Yellow Dichrome
4
Washer, Flat, Rubber, 9/16” x 2 ½”
4
Washer, Flat, Steel, 9/16” x 2 ½”, Yellow Dichrome
2
Isolator, Rubber, 9/16” x 3”
2
Isolator, Rubber, 9/16” x 3” (Trimmed 2 opposite sides)
1
Screw, Pan-Head, #8 x ½”, Marco-black
2
Pin, Cotter, 1/8”
2
Washer, Flat, 5/16”
4
Bolt, Step, ¼” x 1”, Macro-black
4
Nut, Flange, ¼”, Macro-black
NOTE: All references to left and right are taken from the operator’s point of view when he/she is sitting in the driver’s seat.
Toro 4000 Mounting Instructions
Optional Parts Lists Heater Option (if equipped) Qty
Description
Photo
1
Splicer, Rad Hose, 1 3/8”
2
Clamp, Hose, HS-24
28 LF
Hose, Heater, 5/8”
1
Adaptor, 3/8NPT x 3/8NPT x 3/8NPT (JDPPRT0194)
2
Fitting, 3/8NPT x 5/8” Barb, 180°
2
Clamp, Hose, HS-10
NOTE: All references to left and right are taken from the operator’s point of view when he/she is sitting in the driver’s seat.
Toro 4000 Mounting Instructions NOTE: Use the following torque specifications for all hardware: ½” hardware 73 ft-lbs, 3/8” hardware 42 ft-lbs, 5/8” hardware 177 ft-lbs.
Do NOT torque brackets until after cab is installed. See Figure 2. Repeat for the right side. Figure 2
1. Prior to installing the cab, remove the overflow/breather pipe from the 2-post ROPS, then remove the 2-post ROPS from the machine. It will be necessary to remove the top deck lift pin on the side decks to access the mounts and move the cylinder out of the way. Save flatwashers to be re-used later. 2. Take the under-seat mylar and tilt the seat plate forward. Place the mylar against the seat plate to ensure that all necessary openings have been cut and so that there is no interference with moving parts. Ensure that the seat plate is 4. Remove the right black plastic clean, then peal back the mylar backing console. Locate the fuse blocks mounted and glue into place. See Figure 1. at the rear of the console and remove from the rear panel mount. Take the Figure 1 supplied fuse block mount and bolt the fuse blocks onto the mount plate. Install the fuse block mount plate at the rear of the console with the fuse blocks facing the rear, to provide access for checking fuses. Peel off the fuse location sticker and mount onto the rear plastic shroud. See Figure 3. Reinstall the black plastic shroud. 5. Move to the cab now. Remove the left door, right escape window, lower right window, and red front plastic fascia panel prior to proceeding. Take the provided cab lift brackets and bolt through the holes in the upper A-C 3. Take the left rear bracket, the mount Crossmember just in front of the b-post. support will be on the outside and rear of Using a chain or lifting strip, attach to the bracket when installed, and slide it the left brackets and prepare to lift the into the left 2-post ROPS mount slot. cab off the shipping pallet. Un-bolt the Take the 5/8” x 1 ½” hex bolts, re-use the shipping bracket and lift the cab and flat washers, and the 5/8” lock washers begin installing cab weatherstrip. and loosely fasten the bracket into place. NOTE: All references to left and right are taken from the operator’s point of view when he/she is sitting in the driver’s seat.
Toro 4000 Mounting Instructions Figure 3
stop. See Figures 5 & 6. Repeat for the right side. Figure 5
6. Take the 180° O-rubber and move to the lower windshield crossmember. Attach the o-rubber to the sheetmetal extension panel from the left a-post to the right a-post except where the mount plates are located. See Figure 4.
Figure 6
Figure 4
8. Take the 180° O-rubber, and clip onto the rear shield starting from where you left off on the previous step and ending on the opposite side of the cab. See Figure 7. 7. Take the 90° O-rubber and move to the left side of the cab, on the inside of the a-post where you left off previously. Install the O-rubber onto the sheetmetal edge with the bulb down and move to the rear panel where the shield notch is and
9. NOW YOU ARE READY TO MOUNT THE CAB. Lift the cab over the machine and slowly lower towards the mounting plates. Place the two notched rubber isolators on the front operator platform crossmember where the holes are located. Place the other two isolators on the rear brackets. Ensure that the
NOTE: All references to left and right are taken from the operator’s point of view when he/she is sitting in the driver’s seat.
Toro 4000 Mounting Instructions protrusion of the isolator fits into the cab mount plate when bolting the cab down. For the rear mounts, use one ½” x 3” hex bolt, steel flatwasher, rubber flatwasher, ½” lock washer, and ½” hex nut. Use the ½” x 6 ½” hex bolts for the front mounts. Lower the cab down onto the isolators and start all four fasteners. Use the torque specifications for the rear brackets, and for all cab mounts torque the mounts until the rubber compresses to a 7/8” gap between steel mounting plates. Re-install deck lift arm pins for the side decks after rear bracket is torqued.
with the thermostat sending unit on the right side of the thermostat housing. Unscrew the sending unit and take the 3/8NPTx3/8NPTx3/8NPT sensor adaptor and screw it into the sending unit port. Screw the sending unit into the end of the sensor adaptor. Take one of the 3/8NPT - 5/8” Barb 180° fittings, and screw it into the other port on the sensor adaptor (pressure fitting). REMEMBER to use a water sealant material around the threads of the fitting. See Figure 8. Figure 8
Figure 7
10. Re-install the front plastic fascia.
If cab is equipped with a heater option, please proceed with steps 12-14.
Locate the lower radiator hose on the right side of the engine at the base of the radiator. Cut out a short section of the hose and take the 1 3/8” rad splicer and place it into the cut-out portion of the rad hose. Use the two HS-24 hose clamps provided. REMEMBER to use a water sealant material around the threads of the fitting. Take the other 3/8NPT - 5/8” Barb 180° fitting and screw it into the splicer (suction fitting) See Figure 9.
12. Drain the engine antifreeze before proceeding. Locate the pressure port
13. Route the 5/8” ID heater hose above the lift arm and into the engine bay.
11. Connect cab wiring before proceeding. Take the heavy red wire from cab and connect to 12V on tractor. Take the heavy black wire from cab and connect to main tractor ground. Take the orange wire from cab and connect to switched source on tractor.
NOTE: All references to left and right are taken from the operator’s point of view when he/she is sitting in the driver’s seat.
Toro 4000 Mounting Instructions Figure 9
the pedals, and then glue into place. See Figure 10. Figure 10
16. Locate the fuel breather. It will be necessary to bend the breather in order Ensure that no moving parts will interfere with the hose, and clamp down to properly locate it on the C-post at the hose as necessary. Take the heater hose back of the cab. Use Figure 11 as a guide and note that the tube is bent labeled pressure and route towards around the rear mount plate as needed, pressure fitting. Ensure that there is adequate length to reach other the fitting and around the rear window up until the BEFORE you cut the hose, and then cut hole in the C-post. Insert the end of the the hose. Use the HS-10 hose clamps to breather into the C-post, then use the #8 x ½” screw provided and attach one of clamp the hose onto the fittings. the hose clamps into the hole in the rear shield. 14. Ensure that all connections are tight, and re-fill engine antifreeze. Open the water valve using the rotary control Figure 11 cable in the left switchplate of the cab, and turn on the fan. Start the unit and run at PTO RPM for five minutes while the engine coolant builds up heat. Check the engine for leaks and add antifreeze as required. Continue running the engine until the heater produces HOT AIR. HINT: open the radiator cap while the engine is running to help purge air from the coolant system. 15. Take the cab floormat and place onto the operator platform. Ensure that there is adequate clearance around all
NOTE: All references to left and right are taken from the operator’s point of view when he/she is sitting in the driver’s seat.
Toro 4000 Mounting Instructions 17. To ensure maximum protection against sound and moisture penetration, use a black urethane sealant to fill all cracks and small openings around the floormat and silicone sealant around the various sealants.
Figure 13
18. Lower the wing decks before proceeding. Remove the factory wing deck transport release. 19. Take the rubber neoprene pad and place it on the outside of the left deck stop bracket. Use 2 - ¼” flange nuts and ¼” x 1” step bolts provided and bolt onto the bracket. See Figure 12. Figure 12
20. Take the left deck stop and mount in the location of the factory part with the factory hardware. 21. Take the left control rod and slide through the slot in the rear shield and towards the deck stop bracket. Use the provided flat washer and cotter pin and install the rod. See Figure 13. 22. Repeat for the right side.
NOTE: All references to left and right are taken from the operator’s point of view when he/she is sitting in the driver’s seat.
ADDENDUM ALL Mounting Instructions Electrical Connectors List Qty
Description
2
Connectors, Loop, 10GA, ¼”
1
Connectors, Loop, 10GA, ½”
1
Connectors, Loop, 10GA, 3/8”
1
Splicer, Wire, Blue
NOTE: All references to left and right are taken from the operator’s point of view when he/she is sitting in the driver’s seat.