Toro 02917 User manual

FormNo.3373-375RevA
RoadLightswithBrakeLightsKit
Groundsmaster®3400-DTractionUnit
ModelNo.02917—SerialNo.312000001andUp
InstallationInstructions
Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Initialpreparation
Rearlightbracket,L.H.1
Rearlightbracket,R.H.1
Bolt,M16x110mm2
Nut,M162
2
Fuse,15amp2
Installtherearlights
Dowtyseal,1/4inch1
Pressureswitchadapter1
Pressureswitch1
3Pressureswitchcable1
Installthepressureswitch
Numberplatebracket1
PM2ConnectorGothic1
Flasherrelay1
4Standardshorterrelay1
Installthenumberplatebracket
Centerheadlightmount1
R.H.Headlightmount1
L.H.Headlightmount1
Screw,M6x20mm8
Nut,nylocM68
Screw,M10x25mm4
Nut,nylocM104
Washer,3/8inch8
Mountingbracket2
5
PM4Connector2
Installthefrontlights
Instrumentpanelconnectorlead1
Switch,hazardwarning1
Switch,lights1
Switch,indicator1
Button,horn1
Decal,horn1
Cabletie10
6
Cabletie14
Installthecontrolpanelswitches
7Reector2Installthereectors
8Seriallabel1Installtheseriallabel
©2012—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.OriginalInstructions(EN)
PrintedintheUK.
AllRightsReserved

MediaandAdditionalParts
DescriptionQty.Use
InstallationInstructions1Readbeforeinstallingandoperatingkit
PartsCatalog1Usetoreferencepartnumbers
1
InitialPreparation
NoPartsRequired
Procedure
1.Parkthemachineonalevelsurface,lowerthecutting
unit,stoptheengine,engagetheparkingbrakeand
removethekeyfromtheignitionswitch.
2.Disconnectthenegative(–)batterycablefromthe
battery.
WARNING
Wearsafetygogglesandrubbergloveswhen
workingwithbatteries.Sincethegasesare
explosive,keepopenamesandelectricalspark
awayfrombatteries.Donotsmoke.
2
InstallingtheRearLights
Partsneededforthisprocedure:
1Rearlightbracket,L.H.
1Rearlightbracket,R.H.
2Bolt,M16x110mm
2Nut,M16
2Fuse,15amp
Procedure
TherearlightsattachtotheoutsideoftheROPSpost
ontheleftandrightsidesandusetheexistingboltholes
intheROPS.
1.Opentheenginecover.
2.Lifttheoperatorplatform.
3.Removethebulkheadbyunscrewingthe4bolts
(Figure1).Thisistoenableaccesstothemain
wiringloom.
g018276
1
2
Figure1
1.Bulkhead2.Screws(4)
4.EnsurethatROPSpivotboltsandclampboltsarein
placeandaretight.
5.RemovetheROPSpivotboltontheleftsideofthe
mower.
6.AligntheupperholeintheL.H.rearlightbracket
withtheholeintheROPSandinsertthenewM16x
110mmbolt(Figure2).Re-usetheexistingwashers.
2

g018241
1234
5
2
Figure2
1.Bolt,M16x110mm4.L.H.rearlightbracket
2.Existingwashers5.Nut,M16
3.Orangeindicatorsideup
7.InstallthenewM16nutontotheboltandtightento
atorqueof15N-m(11ft-lbs).Donotovertighten
asthiswillmaketheROPSdifculttofold.
8.RemovetheROPSpivotboltontherightsideof
themower.
9.AligntheupperholeintheR.H.rearlightbracket
withtheholeintheROPSandinsertthenewM16x
110mmbolt(Figure3).Re-usetheexistingwashers.
g018242
1
2
34
5
2
Figure3
1.Nut,M164.Orangeindicatorsideup
2.Existingwashers5.Bolt,M16x110mm
3.R.H.rearlightbracket
10.InstallthenewM16nutontotheboltandtightento
atorqueof15N-m(11ft-lbs).Donotovertighten
asthiswillmaketheROPSdifculttofold.
Note:Ifthereisalreadyabeaconkitttedtothe
rightsideorawastebinkitttedtoleftside,itis
allowabletousethesameboltfortheinstallation.It
isadvisabletousethenewM16nylocnutsprovided
withthiskit.
11.FeedallelectricalcablesdownthefrontoftheROPS
frameandontotheelectricalmountpanel.
12.Thecablesmustnowbeconnectedtothemain
wiringloomofthemachinewhichislocatedonthe
electricalbulkhead(Figure4).Connectthe4-pin
L.H.rearlightassemblywiringconnectortothe
corresponding4-pinelectricalconnectorontheL.H.
sideofthemainwiringloom.Connectthe4-pin
R.H.rearlightassemblywiringconnectortothe
corresponding4-pinelectricalconnectorontheR.H.
sideofthemainwiringloom.The2-pinelectrical
connectorsontheL.H.andR.H.rearlightassembly
isrequiredforthenumberplatelight.Onlyoneof
the2-Pinelectricalconnectorsareused.
g018243
1
23
Figure4
1.4-pinL.H.rearlight
assemblyconnectormain
wiringloom
3.4-pinR.H.rearlight
assemblyconnectormain
wiringloom
2.3-pinelectricalpressure
switchcableconnector
mainwiringloom
13.Install(2)15ampfusesintothefuseblock.Usethe
1stand3rdreceptaclesfromtheleftendofthefuse
block(Figure5).
3

g018244
1
Figure5
1.Fuse,15amp(2)
3
InstallingthePressureSwitch
Partsneededforthisprocedure:
1Dowtyseal,1/4inch
1Pressureswitchadapter
1Pressureswitch
1Pressureswitchcable
Procedure
Thepressureswitchcontrolsthebrakelights.The
switchisscrewedintothemaintransmissionline.
1.Locatethethreehoseconnectionsontheright
sideofthetransmissionpump.Thelowerfront
connectiontothepumphasateettingwitha
blankingcap.
2.Removethisblankingcapfromtheteetting.
3.Screwthepressureswitchadapterintotheteetting
usinga1/4inchdowtyseal(Figure6).
g018247
123
Figure6
1.Dowtyseal,1/4inch3.Pressureswitch
2.Pressureswitchadapter
4.Screwthepressureswitchintothisadapter(Figure6).
Torquetheswitchto34N-m(25ft-lbs).
5.Workingontheelectricalbulkhead,plugthe3-pin
connectoroftheelectricalpressureswitchcableto
thecorrespondingconnectorlocatedonthemain
wiringloomofthemachine(Figure4andFigure7).
g018248
1
2
3
4
5
61
7
Figure7
1.Green/Yellow5.Blue
2.Yellow6.Pressureswitch
connector,mainwiring
loom
3.Black7.Pressureswitchcable
connector
4.Brown
6.Runtheelectricalpressureswitchcablefromthe
electricalbulkhead,downtheR.H.ROPSpost
forwardalongthechassisrailtothepressureswitch.
7.Plugtheconnectorontothepressureswitchand
securetheconnector.
4

4
InstallingtheNumberPlate
Bracket
Partsneededforthisprocedure:
1Numberplatebracket
1PM2ConnectorGothic
1Flasherrelay
1Standardshorterrelay
Procedure
Thenumberplatewithlightattachestothebulkhead.
1.Inthecenteroftheplasticbulkheadcover,
approximately40mm(1–1/2inches)fromthefront,
drilla8mmdiameterhole(Figure8).
g018245
1
2
Figure8
1.Drill8mmholehere2.Numberplatebracket
WARNING
Whendrillingorcarryingoutotheroperations,
alwaysweareyeprotection.
2.Feedthenumberplatecablethroughthe8mmhole
intheplasticbulkheadcover.Installthenumber
platebracketandthebulkheadwiththebulkhead
fastenerspreviouslyremoved.
3.PushthePM2connectorontotheterminalsofthe
numberplatecable(Figure9).
g018277
1
2
3
Figure9
1.Redwire3.PM2connector
2.Blackwire
4.Connectthenumberplatelightwiringtoeither
theL.H.orR.H.rearlightassemblywiring2-Pin
electricalconnector.
5.PlugtheasherrelayintotheL.H.vacantrelay
socketandthestandardshorterrelayintotheR.H.
vacantreplaysocket(Figure10).
g018246
1
2
Figure10
1.Flasherrelay2.Standardshorterrelay
5

5
InstallingtheFrontLights
Partsneededforthisprocedure:
1Centerheadlightmount
1R.H.Headlightmount
1L.H.Headlightmount
8Screw,M6x20mm
8Nut,nylocM6
4Screw,M10x25mm
4Nut,nylocM10
8Washer,3/8inch
2Mountingbracket
2PM4Connector
Procedure
Theheadlightsandindicatorattachtothebracketsat
thefrontofthemachine.
1.Thefrontlightassembliesattachtothecenter
headlightmountwhichattachestothemachineusing
twomountingbrackets(Figure11).
2.Installthetwomountingbracketstothefrontof
themachineusingM10x25mmscrews,3/8inch
washers,M10nylocnuts(Figure11).
3.Installthecenterheadlightmounttothemounting
bracketsusingM10x25mmscrews,3/8inch
washers,M10nylocnuts(Figure11).
4.Applyanti-seizegreasetofullycoattheinsidewall
ofthetubeendsandallthesurfacesofthesprings
andtubeendproles(Figure11).
5.Thelightassembliesarenowreadytoinstall.While
holdingtheR.H.headlightmount,threadthewiring
cabledownthroughtheendtubesandoutthecenter
cutoutofthecenterheadlightmount(Figure11).
6.SecuretheR.H.frontlightassemblytothecenter
headlightmountusingtheM6x20mmscrewsand
M6nylocnuts(Figure11).
g018249
9
7
4
8
5
6
1
2
3
4
56
7
8
8
8
10
10
11
Figure11
1.Centerheadlightmount7.Nut,nylocM10
2.R.H.Headlightmount8.Washer,3/8inch
3.L.H.Headlightmount9.Mountingbracket
4.Screw,M6x20mm10.Applyanti-seizehere
5.Nut,nylocM611.Centercutofheadlight
mount
6.Screw,M10x25mm
7.InstallthePM4wiringcableconnectorontothe
wiringcablebypushingthepinsintotheconnector.
(Figure12).Identifyandmarkthisconnectoras
R.H.tohelpwithcableidenticationwhenmaking
theconnectionstothemachinemainwiringloom.
6

g018250
2
1
4
3
5
Figure12
1.Blue4.Black
2.Green5.PM4connector
3.Red/White
8.RepeattheaboveprocedurefortheL.H.light
assembly.IdentifyandmarkthisconnectorasL.H.
tohelpwithcableidenticationwhenmakingthe
connectionstothemachinemainwiringloom.
9.Thecablescannowbeconnectedtothemainwiring
loomofthemachine.Passthecablesdownthrough
thecutoutforthetowingpointandthoughtheholes
inthefrontchassistothecuttingunitmanifold
locatedundertheoperatorsplatform.
10.Locatethetwo4-pinconnectorsonthemainwiring
loomlocatedneartothecuttermanifold.
11.Removetheblankingcapsfromthelighting
connectorsonthemainwiringloom.
12.Connecttheconnectoronthemachinewiringloom
withGREEN/WHITEwiretotheidentiedL/H
lightassemblyconnector.(Figure13).
g018251
1
2
3
4
5
6
1
4
3
Figure13
1.Blue4.Black
2.Green/White5.Green
3.Red/White6.PM4connector
13.Securetheconnector,onthemachinewiringloom
withtheGREEN/REDwire,totheidentiedR/H
lightassemblyconnector(Figure14).
g018252
1
2
3
4
5
6
1
4
3
Figure14
1.Blue4.Black
2.Green/Red5.Green
3.Red/White6.PM4connector
7

6
InstallingtheControlPanel
Switches
Partsneededforthisprocedure:
1Instrumentpanelconnectorlead
1Switch,hazardwarning
1Switch,lights
1Switch,indicator
1Button,horn
1Decal,horn
10Cabletie
14Cabletie
Procedure
1.Removethesixscrewssecuringthecontrolpanel
tothecontrolpod.
2.Carefullyliftoffthepanelensuringthatthe
connectorstotheexistingswitchesarenotdisturbed.
3.Installtheinstrumentpanelconnectorleadintothe
controlarm.
4.Feedtheconnectorleadinstrumentpanelupthrough
theopeninginthebottomofthecontrolpod,so
thattheendwiththethreeconnectorsareinside
thecontrolpodandtheendwiththesinglelarge
connectorisfeeddownthecontrolarm.
5.Intherearfaceofthecontrolpod,justabovethe
keyswitch,areswitchblankpanels.
6.Removethetwoswitchblankpanelsandpassthe
connectorsandwiresforthehazardandlightswitch
thoughtheswitchhole(Figure15).TheHazard
andLightsconnectorsareontheshorterleads,the
hazardconnectorisredandthelightconnectoris
black.Theindicatorconnectorisblackandonthe
longerlead.
g018292
12
Figure15
1.Switchblank–lightswitch2.Switchblank–hazard
switch
7.Connectthelightandhazardswitchtothecorrect
connectorandpushtheswitchintothehole
(Figure16).
g018253
12
Figure16
1.Lightswitch2.Hazardswitch
8.Onthecontrolpanel,removetheroundblanking
plugandtherectangularblankingplugnexttoit
(Figure17).
8

G018336
12
Figure17
1.Roundblankingplug–horn
button
2.Rectangularblanking
plug-indicatorswitch
9.Installthehorndecallininguptheedgesofthe
roundandrectangularholes(Figure18).
G018335
1
2
3
Figure18
1.Hornbutton3.Directionindicatorswitch
2.Horndecal
10.Installthehornbuttonandthedirectionindicator
switchintothecontrolpanel(Figure18).Installthe
directionindicatorswitchwiththeGreen/Redwires
totheleftandtheGreen/Whitewirestotheright,as
showninFigure19.
1
2
G018338
Figure19
1.Green/Red2.Green/White
11.Connectthedirectionindicatorswitchtothe
connectorleadinstrumentpanel.Theindicator
connectorisblackandonthelongerlead.
12.Inthecontrolpaneltherewillbeapinkand
black/purplewirefortheHornbutton.Connectthe
pinkandblackwirestothehornswitch.
13.Workingundertheoperatorplatform,connectthe
connectorleadinstrumentpaneltothemultipin
connectoronthemachinemainelectricalwiring
loom.Thisislocatedinthechassisrailtotheright
ofthetransmissionpump.
14.Cabletieallcablesforthefrontlights,rearlightsand
thepressureswitchsothattheyaresecureandto
preventthemfrombecomingtrappedorchafed.
15.Reconnectthenegativebatterycable.
16.Testtheswitchesonthecontrolpaneltoensurethat
theyareoperatingcorrectly.
17.Retthecontrolpanelensuringthatnoconnectors
havebecomedetachedandthatnocablesarenipped.
18.Lowerandlatchtheenginecoverandoperators
platform.
9

7
InstallingtheReectors
Partsneededforthisprocedure:
2Reector
Procedure
Afxareectortoeachsideoftheenginecover.
Ensurethattheoutsideedgeofeachreectorisadhered
100mm(4inches)fromeachedgeoftheenginecover
(Figure20).Makesurethesurfaceiscleanbefore
mountingthereectors.
g018255
1
2
Figure20
1.100mm(4inches)2.Reector
8
InstallingtheSerialLabel
Partsneededforthisprocedure:
1Seriallabel
Procedure
Afxtheseriallabeladjacenttothemachineseriallabel.
Makesurethesurfaceiscleanbeforemountingtheserial
label.
10