Toro 4100 Boxer Parts List & Mounting Instructions
Jodale • Perry Printed: 2004/04
Toro 4100 Mounting Instructions Prior to installing cab, please note the following which must be adhered to for safe vehicle operation.
WARNING: Counter balance pressure should be adjusted per tractor’s operator’s manual recommendations. Do not exceed 550 psi with cab installed or machine stability will be adversely affected.
WARNING: When cutting deck is put into service position, there is a chance of the deck contacting the cab if the deck is raised.
WARNING: Tractor must have a 125 lb counter-weight installed on rear bumper for stability.
Toro 4100 Mounting Instructions Standard Parts List Qty
Description
L&R
Rear Brackets
1
Platform Cover Plate
1
Step Bracket
L&R
Deck Pads w/UMHW Installed
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)
8 FT
¼” Fuel Hose
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.
Electrical Connectors List Qty
Description
1
Connectors, Loop, 10GA, ½”
1
Connectors, Loop, 10GA, 3/8”
1
Connector, Wire Splitter, (ELE1136) Ignition
Power/Ground
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 4100 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”, Plated
4
Nut, Hex, Nylon Locking, 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)
2
Button, Plug 1 3/16” (245-035)
4
Bolt, Flange, ¼” x ¾”, Yellow Dichrome
4
Nut, Flange, ¼”, Macro-black
4
Button, Plug, ½” (245-044)
4
Washer, Flat, ½”, Yellow Dichrome
4
Bolt, Carriage, 3/8” x 1”, Yellow Dichrome
8
Nut, Flange, 3/8”, Yellow Dichrome
4
Bolt, Flange, 3/8” x ¾”, Yellow Dichrome
4
Bolt, Hex, 3/8” x 4”, Yellow Dichrome
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 4100 Mounting Instructions
Optional Parts Lists Heater Option (if equipped) Qty
Description
1
Splicer, Rad Hose, 1 3/8”
2
Clamp, Hose, HS-24
28 LF
Hose, Heater, 5/8”
2
Fitting, 3/8NPT x 5/8” Barb, 180°
2
Clamp, Hose, HS-10
Photo
Washer Option (if equipped) Qty
Description
6
Bolt, Flange, ¼” x ¾”, Yellow Dichrome
4
Nut, Flange, ¼”, Macroblack
1
Tank, Washer, Bottle
1
Washer Tank Bottle Mount
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 4100 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.
is installed. See Figure 2. Repeat for the right side. (Right Side has Extra Sheet Metal welded at top of bracket). 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 toolbox on the left side of the operator platform. It will be remounted inside of the cab in a new location 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 clean, then peal back the mylar backing 4. Take the platform cover plate and and glue into place. See Figure 1. install it where the toolbox used to be with the original toolbox fasteners. See Figure 1 Figure 3. Take the toolbox and place it onto the mounting brackets that are on the left side of the cab. Take the ¼” x ¾” flange bolts and ¼” flange nuts and bolt the toolbox to the brackets. Take the two 1 3/16” plug buttons and install into the bottom of the toolbox. Figure 3
3. Take the left rear bracket, the mount support will be on the outside and rear of the bracket when installed, and slide it into the left 2-post ROPS mount slot. Take the 5/8” x 1 ½” hex bolts, re-use the flat washers, and the 5/8” lock washers and loosely fasten the bracket into place. Do NOT torque brackets until after cab 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 4100 Mounting Instructions 5. Move to the cab now. Remove the left Figure 5 door, right escape 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 Crossmember just in front of the b-post. Using a chain or lifting strip, attach to the left brackets and prepare to lift the cab off the shipping pallet. Un-bolt the shipping bracket and lift the cab and begin installing cab weatherstrip. Figure 4
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
on the opposite side of the cab. See Figure 7. 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 stop. See Figures 5 & 6. Repeat for the right side. 8. Take the 180° O-rubber, and clip onto the rear shield starting from where you left off on the previous step and ending
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
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 4100 Mounting Instructions isolators on the front operator platform Figure 8 crossmember where the holes are located. Place the other two isolators on the rear brackets. Ensure that the 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 radiator hose on the right side of the torqued. engine at the base of the radiator. Cut out a short section of the hose and take 10. Re-install the front plastic fascia. the 1 3/8” rad splicer and place it into the cut-out portion of the rad hose. Use the 11. Electrical Hook-up: Locate the heavy two HS-24 hose clamps provided. red wire coming out of the rear of the cab REMEMBER to use a water sealant and connect to 12V on the starter material around the threads of the B-terminal. Locate the heavy black wire fitting. Take the other 3/8NPT - 5/8” coming out of the rear of the cab and Barb 180° fitting and screw it into the connect to tractor ground. Locate the splicer (suction fitting) See Figure 9. orange wire coming out of the rear of the cab and connect to the I terminal on the Figure 9 ignition. See electrical connection photos. If cab is equipped with a heater option, please proceed with steps 12-14. 12. Drain the engine antifreeze before proceeding. Locate the pressure port with the thermostat sending unit on the right side of the thermostat housing and the plug just beneath it. Unscrew the plug and insert one of the 3/8NPT - 5/8” Barb 180° fittings (pressure fitting). REMEMBER to use a water sealant material around the threads of the fitting. See Figure 8. Locate the lower 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 4100 Mounting Instructions 13. Route the 5/8” ID heater hose above the lift arm and into the engine bay. Ensure that no moving parts will interfere with the hose, and clamp down hose as necessary. Take the heater hose labeled pressure and route towards pressure fitting. Ensure that there is adequate length to reach other the fitting BEFORE you cut the hose, and then cut the hose. Use the HS-10 hose clamps to clamp the hose onto the fittings.
16. Locate the fuel breather. Disconnect the hose clamp at the fuel tank and take provided 8 LF of fuel hose. Bend the hose in half and route down the top of the channel on the C-post. Use a tie to secure at the top of the channel and do not kink hose. Route one end of the hose into the hole in the rear bracket and route the other through the U-bracket on the right rear bracket to the connection on the fuel tank. Re-connect with factory hose clamp. See Figure 11.
14. Ensure that all connections are tight, and re-fill engine antifreeze. Open Figure 11 the water valve using the rotary control 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. Figure 10
17. Take the four ½” snap caps and install on the operator platform tubular members on the left and right sides of the platform. 18. 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. 15. Take the main cab floormat and place onto the operator platform. Ensure that there is adequate clearance around all the pedals, and then glue into place. See Figure 10.
19. Ensure that all decks are lowered to mowing height. Take the left deck stop bracket and position it onto the left wing deck. Remove the two deck mounting hardware. Place the bracket onto 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 4100 Mounting Instructions deck arm, and fasten in place with the 3/8” x 4” hex bolts and nuts provided. See Figure 12. Figure 12
22. Take the washer tank bracket and position it over the two tapped holes on the engine housing behind the air filter. Attach with the two provided ¼” x ¾” flange bolts. 23. Bolt the washer tank bottle to the bracket with the provided ¼” x ¾” nuts Figure 14
20. Repeat for the right side pad. 21. Take the step bracket, ½” flat washers, 3/8” flange nuts, 3/8” x 1” carriage bolts and go to the step on the tractor. Place the bracket over the step pad and use the fasteners and install the bracket as shown in Figure 12. Figure 13
and bolts. See Figure 14. 24. Locate the ground loop wire on the washer bottle and connect to a grounding source. 25. Locate the loose blue wire at the bottom of the cab C-post and connect it to the washer bottle motor.
If tractor is equipped with washer kit, then proceed with steps 22-25.
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.