Toro 30639 User manual

FormNo.3392-727RevA
EULightKit
2015andAfterGroundsmaster®5910SeriesRotaryMowerwith
Cab
ModelNo.30639
InstallationInstructions
Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Disconnectthebattery.
Flasherbracket1
Flangeheadscrew,1/4x1/2inch2
Flangenut,1/4inch2
Flashermodule1
2
wiringharness1
Installtheashermodule.
Switch,hazard1
3Cabletie2
Installthesignalcontrollerandhazard
switch.
Headlampbracket,lefthand(formodel
withoutcab)1
Headlampbracket,righthand(formodel
withoutcab)1
Headlampbracket,righthand(formodel
withcab)1
Headlampbracket,lefthand(formodel
withcab)1
Headlamprighthand1
Headlamplefthand1
Flangeheadbolt,1/21–1/4inch2
Flangenut,1/2inch2
Headlightwiringcover(formodel
withoutcab)2
Plasticplug8
4
Cableties6
Installtheheadlights.
Fuse,10amp1
Fuseblock1
5Decal,turnsignalfuse1
Installthefuseblock.
Rearlampassembly2
Cabletiemount2
6Cabletie4
Installtherearlamps.
MediaandAdditionalParts
DescriptionQty.Use
Partscatalog1
Installationinstructions1
©2014—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.OriginalInstructions(EN)
PrintedintheUSA.
AllRightsReserved*3392-727*A

1
DisconnectingtheBattery
NoPartsRequired
Procedure
1.Positionthemachineonalevelsurface,settheparking
brake,lowerthecuttingunits,turntheignitionoff,and
removethekey.
CAUTION
Ifyouleavethekeyintheignitionswitch,
someonecouldaccidentlystarttheengineand
seriouslyinjureyouorbystanders.
Removethekeyfromtheignitionswitch
beforeyoudoanymaintenance.
2.Removetheaccesspanel,behindtheseat,toexpose
thebatteries.
3.Disconnectthenegativebatterycablefrombothof
thebatteries.
2
InstallingtheFlasherModule
Partsneededforthisprocedure:
1Flasherbracket
2Flangeheadscrew,1/4x1/2inch
2Flangenut,1/4inch
1Flashermodule
1wiringharness
Procedure
1.Removethescrewssecuringthesteeringtowercover
tothesteeringtower(Figure1).Removethesteering
towercover.
Figure1
1.Steeringtowercover2.Mountingscrew
2.Mounttheashermoduletothebracketwitha#10
x5/8inchscrew2atwashers(0.216x0.500inch)
anda#10nut,positioningthecomponentsasshown
inFigure2.
Figure2
1.Screw4.Flashermodule
2.Washer5.Flasherbracket
3.Nut6.Flangescrewandnut
3.Mounttheasherbrackettothesteeringcolumn
mountwith2angeheadscrews(1/4x5/8inch)and
1/4angenuts(Figure2).
4.Routetheendoftheenclosedwiringharnessunderthe
steeringtoweropeningintheoperator'splatform.
5.Plugthewiringharnessconnector,labeledFlasher
Module,intotheashermodule.
2

Figure3
3

3
InstallingtheHazardSwitch
Partsneededforthisprocedure:
1Switch,hazard
2Cabletie
Procedure
1.Removetheplugfromtheholeinthetopofthe
steeringtower(Figure4).
g016658
12
3
Figure4
1.Turnsignalswitch3.Plug
2.Hazardswitch
2.Installthehazardswitchintotheholeinthesteering
tower(Figure4).
3.Unplugthewiringharnessconnectorfromtheturn
signalswitch(Figure4).
4.Plugthewiringharnessconnector,labeledTurnSignal,
intotheturnsignalswitchandtheconnector,labeled
Hazard,intothehazardswitch.
5.Securethewiringharnesstotheexistingwiringharness
withthe2cableties.
Note:Whenroutingthewiring,ensurethatthe
operationofthetiltsteeringdoesnotdamagethe
harnessorpullonthewires.
4
InstallingtheHeadlights
Partsneededforthisprocedure:
1Headlampbracket,lefthand(formodelwithoutcab)
1Headlampbracket,righthand(formodelwithoutcab)
1Headlampbracket,righthand(formodelwithcab)
1Headlampbracket,lefthand(formodelwithcab)
1Headlamprighthand
1Headlamplefthand
2Flangeheadbolt,1/21–1/4inch
2Flangenut,1/2inch
2Headlightwiringcover(formodelwithoutcab)
8Plasticplug
6Cableties
ForTractionUnitsNotEquippedWith
aCab
1.Unplugthewiringharnessconnectorfromeach
existingheadlight.
2.Removethefastenerssecuringeachheadlightbracket
totheoperator'splatform.Retainthemounting
fasteners(Figure5).
Figure5
1.Headlightbracket
3.Usingthefastenerspreviouslyremoved,mountthe
R.HandL.Hheadlightbracketstotheexistingholes
inthefrontoftheoperator'splatform.Positionthe
bracketsasshowninFigure6andFigure7.Torqueto
95to115ft-lbs(129to156N-m).
4

Figure6
1.Headlightassembly,right
hand
6.Washer,large
2.Headlightwiringcover7.Operator'splatform
3.Bolt8.Cabletie
4.Washer,small9.Headlightbracket,right
hand
5.Flangenut
Figure7
1.Headlightbracket,right
hand
6.Headlightwiringcover
2.Cabletie7.Headlightassembly,left
hand
3.Washer,small8.Operator'splatform
4.Bolt9.Washer,large
5.Plasticplug10.Flangenut
4.Securetherighthandandlefthandheadlightassemblies
totheheadlightbrackets(Figure6)withthefasteners
suppliedwiththelights.Makesuretheturnsignallens
ontheheadlightispositionedtowardtheoutsideof
themachine.
5.Routetheheadlightwiringharnessendsunderneath
thefrontedgeoftheoperator'splatform,thruthe
headlightbracketsandtotheheadlights(Figure3).
6.Plugoneoftheharnessconnectorsintothepreviously
unpluggedharnessconnectorandoneintothe
headlight.Theheadlightconnectionshouldbemade
insidetheheadlightbracket.Repeatthisprocedureon
theotherheadlight.
7.Usingtheholeineachheadlightbracket,securethe
harness,tothebracketwithacabletieasshownin
Figure7.
8.Mounttheheadlightwiringcovertotheheadlight
bracketwithplasticplugs.
9.Installthesteeringtowercoverwiththescrews
previouslyremoved.
Fortractionunitsequippedwithacab
1.Unplugthewiringharnessconnectorfromeach
existingheadlight.
2.Removethefastenerssecuringtheheadlightsto
bracketsonthefrontofthecab(Figure8).
Figure8
1.Headlight2.Bracket
3.Looselyinstallthelefthandheadlightbrackettothe
topofthelefthandcabbracketwitha1/2x1-1/4inch
angeheadboltand1/2inchangenut.Positionthe
bracketasshowninFigure9.
5

g028605
7
Figure9
1.Flangeheadbolt,1/4x3/4
inch
5.Flangenut,1/4inch
2.Cabbracket6.Cableties
3.Flangenut,1/2inch7.Flangeheadbolt,1/2x
1-1/4inch
4.Headlightassembly,left
hand
4.Looselymounttheendoftheheadlightbrackettothe
sideofthecabbracketwitha1/4x3/4inchange
headboltand1/4inchangenut(Figure9).
5.Tightenthefastenerssecuringtheheadlightbracket.
6.Repeattheproceduretoinstalltherighthandheadlight
brackettotherighthandcabbracket(Figure10).
7.Fastentherighthandandlefthandheadlightassemblies
totheheadlightbrackets(Figure9andFigure10)with
thefastenerssuppliedwiththelights.Makesurethe
turnsignallensontheheadlightispositionedtoward
theoutsideofthemachine.
g028606
Figure10
1.Headlightassembly,right
hand
5.Flangenut,1/2inch
2.Headlightbracket,right
hand
6.Flangenut,1/4inch
3.Flangeheadbolt,1/4x3/4
inch
7.Tab
4.Cabbracket8.Flangeheadbolt,1/2x
1-1/4inch
8.Routetheheadlightwiringharnessunderneaththe
frontedgeoftheoperator'splatformanduptothe
headlights(Figure3).
9.Plugoneoftheharnessconnectorsintothepreviously
unpluggedharnessconnectorandoneintothe
headlight.Securetheharnessconnectorstothetab
onthebracketwithacabletie(Figure10).Repeatthis
procedureontheotherheadlight.
10.Usingtheholesineachheadlightbracket,securethe
harness,tothebracketwithcabletiesasshownin
Figure9.
11.Installthesteeringtowercoverwiththescrews
previouslyremoved.
Note:Theexistingfrontandrearcablightscannotbe
usedforCEapplications.Disablethefrontandrear
cablightsasfollows:
•Front-Popthelightsoutofthecabroofand
disconnectthewiresfromthelights.Reinstallthe
lightsintothecab.
•Rear-Removethescrewssecuringthelensesto
lights.Removethebulbsfromthelightsand
reinstallthelensestothelights.
6

5
InstallingtheFuseBlock
Partsneededforthisprocedure:
1Fuse,10amp
1Fuseblock
1Decal,turnsignalfuse
Procedure
1.Afxandconnectthenewfuseblocktotheexisting
fuseblocks(Figure11).Thismaynotnecessaryifa
newfuseblockwaspreviouslyinstalledforanother
attachment.
Note:The2screwsandnutsfromtheadjoiningfuse
blockmayberemovedandreusedtosecurethenew
fuseblocktothemachine.
2.Insertthe10ampfuseintotheopenslotonthefuse
block(Figure11).
Figure11
1.Fuseblock
3.Afxthenewfusedecaltotheexistingfusedecalon
thepowercentercover.
4.Routethesectionoftheharnesswiththe2ring
terminalconnectorsandthefuseblockconnectorup
thruthefrontholeintheplatform,underthestarting
post.
5.Connectthewiringharnessringterminal,labeled12
VDCEUPWR,tothepositivestartingpost(Figure
12).
Figure12
1.Groundingblock3.Positivestartingpost
2.Fuseblock
6.Connectthewiringharnessringterminal,labeled
Ground,tothegroundingblock(Figure12).
7.Plugthewiringharnessterminal,labeled12VDC,into
thefuseblock(Figure12).
6
InstallingtheRearLamps
Partsneededforthisprocedure:
2Rearlampassembly
2Cabletiemount
4Cabletie
Procedure
1.Removethe2rearboltsandnutssecuringtherear
bumperbrackettotheleftframerail(Figure13).Retain
theboltsandnuts.
7

Figure13
1.Rearbumperbracketboltsandnuts
2.Usingtheboltsandnutspreviouslyremoved,securea
lampassemblytothebracketandframe(Figure14).
G016538
1
2
3
4
5
Figure14
1.Nutspreviouslyremoved4.Rearlampassembly
2.Rearbumperbracket5.Boltspreviouslyremoved
3.Cabletie
3.Repeattheprocedureontheothersideofthemachine.
4.Followingthetractionunitmainwiringharness,route
therearlightwiringharnesstotherightrearlampas
follows:
•Underthehoodsupportbracket(Figure15).
•Underthevalve(Figure15).
•Alongtheexistinghardlineandwiringharnessto
theradiatorsupport(Figure15).
•Overtheradiatorhose(Figure15)
•Downundertheframeshroud(Figure15)
Figure15
1.Hoodsupportbracket4.Radiatorhose
2.Valve5.Frameshroud
3.Radiatorsupport
•Afxacabletiemountingpadtotheundersideof
theframe,behindtherearaxleandapproximately
7inches(17.8cm)fromtherightframerail(Figure
16).
Important:Makesurethemountingsurfaceis
cleanedwithrubbingalcoholbeforeinstalling
themountingpad.Pressandholdthe
mountingpadfor15secondswheninstalling.
8

Figure16
1.Atleast7inches(17.8cm)2.Cabletiemountingpad
•Securetheharnesstothemountingpadwitha
cabletie.
Important:Whenroutingtheharness,ensure
thattheoperationoftherearaxledoesnot
damagetheharnessorpullonthewires.
•Routetheharnessdownovertheaxlesupportto
therearlight(Figure15).
•Plugtheharnessconnectorintothelampspigtail
connector.
5.Followingthetractionunitmainwiringharness,route
therearlightwiringharnesstotheleftrearlampas
follows:
•Acrossthehoodsupportframetotheleftsideof
themachine(Figure17).
•Throughthecornershroud(Figure17).
•Alongtheframeoutsideofthemuferheatshield
(Figure17).
Important:Keepthewiringharnessaway
fromthesideandrearofthemufer.
•Alongtheexistinghardlinetotheradiatorsupport
(Figure17).
Figure17
1.Hoodsupportframe3.Muferheatshield
2.Cornershroud4.Radiatorsupport
•Overthehardlinesdownthroughtheframe
(Figure17).
•Afxacabletiemountingpadtotheundersideof
theframe,behindtherearaxleandapproximately7
inches(17.8cm)fromtheleftframerail(Figure16).
•Securetheharnesstothemountingpadwitha
cabletie.
Important:Whenroutingtheharness,ensure
thattheoperationoftherearaxledoesnot
damagetheharnessorpullonthewires.
•Routetheharnessdownovertheaxlesupportto
therearlight(Figure15).
•Plugtheharnessconnectorintothelampspigtail
connector.
6.Usingtheholeineachrearlamp,securethelamppig
tailswithcabletiesatthelocationshowninFigure14.
Note:The2remainingwiresaretobeusedwhenthe
registrationplatelightsareinstalledontherearofthe
machine.
7.Usingcableties,securetheremainderofthewiring
harnesstothetractionunitwiringharness(Figure3).
Note:Makesurethewiringharnessisroutedaway
fromanyhot,sharpormovingparts.
9

7
ConnectingtheBattery
NoPartsRequired
Procedure
1.Connectthenegativebatterycabletobothbatteries.
2.Installtheaccesspanel.
Operation
UsingtheLightandHazard
Switches
•TurnthekeyswitchONandpressthelightswitchtothe
ONpositiontoactivatetheheadlamps.
•PressthehazardswitchtotheOnpositiontoactivatethe
frontandrearashinghazardlights.
•TurnthekeyswitchONandpresstheleftsideofthe
turnsignalswitchtoactivatetheleftturnsignalandthe
rightsideoftheswitchtoactivatetherightturnsignal.
Thecenterpositionisoff.
Note:Checktheoperationofthelights.Makesurethe
correctlightsareashingwhenoperatingtheturnsignal
switch.
AimingtheHeadlights
1.Loosenthemountingnutstoadjustthelights.
2.Adjustthelightsperlocalstandards.
10