Toro 02917 User manual

FormNo.3412-264RevA
RoadLightswithBrakeLightsKit
Groundsmaster®3400TractionUnit
ModelNo.02917—SerialNo.400000000andUp
InstallationInstructions
Thiskitisdesignedtoprovideafullsetofroadlightswithmountingbracketsandoperationswitches.
Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachine.
Left,rearlightbracket1
Right,rearlightbracket1
Bolt(M16x110mm)2
Nut(M16)2
2
Fuse(15A)2
Installtherearlights.
Dowtyseal(1/4inch)1
Pressureswitchadapter1
Pressureswitch1
3Pressureswitchcable1
Installthepressureswitch.
Numberplatebracket1
2-waytabhousingconnector1
Flasherrelay1
4Standardshorterrelay1
Installthenumberplatebracket.
Centerheadlightmount1
Rightheadlightmount1
Leftheadlightmount1
Bolt(M6x20mm)8
Locknut(M6)8
Bolt(M10x25mm)4
Locknut(M10)4
Washer(3/8inch)8
Mountingbracket2
5
4-waytabhousingconnector2
Installthefrontlights.
Instrumentpanelconnectorlead1
Hazardwarningswitch1
Lightsswitch1
Indicatorswitch1
Hornbutton1
Horndecal1
6
Cabletie24
Installthecontrolpanelswitches.
©2016—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.OriginalInstructions(EN)
PrintedintheUK
AllRightsReserved*3412-264*A

ProcedureDescriptionQty.Use
7Reector2Installthereectors.
8Seriallabel1Installtheseriallabel.
MediaandAdditionalParts
DescriptionQty.Use
InstallationInstructions1Readbeforeinstallingandoperatingkit
PartsCatalog1Usetoreferencepartnumbers
1
PreparingtheMachine
NoPartsRequired
Procedure
1.Parkthemachineonalevelsurface,lowerthecutting
unit,engagetheparkingbrake,shutofftheengine,and
removethekeyfromtheignitionswitch.
2.Disconnectthenegative(–)batterycablefromthe
battery.
WARNING
Gasesthatemitfromthebatteryareexplosive.
Keepopenamesandelectricalsparkaway
fromthebattery.Whenworkingwiththe
battery,wearsafetygogglesandrubbergloves.
Donotsmoke.
2
InstallingtheRearLights
Partsneededforthisprocedure:
1Left,rearlightbracket
1Right,rearlightbracket
2Bolt(M16x110mm)
2Nut(M16)
2Fuse(15A)
Procedure
Note:Ifyouarettingtherearlightstoamachinewith
aserialnumberof316999999andlower,therearlight
mountingbracketsneedtobereplacedwiththebracketsthat
aresuppliedaslooseparts.
Therearlightsattachtotheoutsideoftherollbarpostson
theleftandrightsidesofthemachine.Thelightswillbe
insertedintotheexistingboltholesintherollbar.
1.Opentheenginecover.
2.Lifttheoperatorplatform.
3.Removethebulkheadbehindtheoperator’sseatby
unscrewingthe4bolts(Figure1).
Note:Removingthebulkheadenablesaccesstothe
mainwiringloom.
2

g018276
1
2
g018276
Figure1
1.Bulkhead2.Bolt(4)
4.Ensurethattherollbarpivotboltsandclampboltsare
inplaceandaretight,andorthesecuringpinsarein
placetoretainthetophoop.
5.Removetherollbarpivotboltontheleftsideofthe
machine.
6.Aligntheindicatedholeintheleftrearlightbracket
withtheholeintherollbarandinsertthenewbolt
(M16x110mm),usingtheexistingwashers(Figure
2orFigure3).
g197780
Figure2
Machinewithserialnumbers316999999andlower
1.Bolt(M16x110mm)4.Leftrearlightbracket
2.Existingwashers5.Rollbar
3.Orangeindicatorsideup6.Nut(M16)
g196536
Figure3
Machinewithserialnumbers400000000to999999999
1.Bolt(M16x110mm)4.Rollbar
2.Orangeindicatorsideup5.Existingwasher
3.Leftrearlightbracket6.Nut(M16)
3

7.Installthenewnut(M16)ontotheboltandtorqueit
to15N∙m(11ft-lb).
Note:Donotovertightenitasthiswillmaketheroll
bardifculttofold.
8.Removetherollbarpivotboltontherightsideofthe
mower.
9.Aligntheindicatedholeintherightrearlightbracket
withtheholeintherollbarandinsertthenewbolt
(M16x110mm),usingtheexistingwashers(Figure
4orFigure5).
g197781
Figure4
Machinewithserialnumbers316999999andlower
1.Nut(M16)4.Rightrearlightbracket
2.Existingwashers5.Orangeindicatorsideup
3.Rollbar6.Bolt(M16x110mm)
g196537
Figure5
Machinewithserialnumbers400000000to999999999
1.Nut(M16)4.Bolt(M16x110mm)
2.Existingwasher5.Rightrearlightbracket
3.Rollbar6.Orangeindicatorsideup
10.Installthenewnut(M16)ontotheboltandtorqueit
to15N∙m(11ft-lb).
Note:Donotovertightenthenut,asthismakesthe
rollbardifculttofold.
Note:Ifthereisalreadyabeaconkitttedtotheright
orleftside,usetheexistingboltandthenewnylocnuts
(M16)providedwiththiskit.
11.Feedallelectricalcablesdownthefrontoftherollbar
frameandontotheelectricalmountpanel.
12.Connectthecablestothemainwiringharnessofthe
machinewhichislocatedontheelectricalbulkhead
(Figure6),asfollows:
A.Connectthe4-pin,left,rear,light-assembly,wiring
connectortothecorresponding4-pinelectrical
connectorontheleftsideofthemainwiring
harness.
B.Connectthe4-pin,right,rear,light-assembly,
wiringconnectortothecorresponding4-pin
electricalconnectorontherightsideofthemain
wiringharness.
Note:The2-pinelectricalconnectorsontheleft
andrightrear-lightassemblyisrequiredforthe
number-platelight.Only1ofthe2-pinelectrical
connectorsisused.
4

g018243
1
23
g018243
Figure6
1.4-pin,left,rear,
light-assemblyconnector
onthemainwiringharness
3.4-pin,left,rear,
light-assemblyconnector
onthemainwiringharness
2.3-pin,
electrical-pressure-switch,
cableconnectoronthe
mainwiringharness
13.Install2fuses(15A)intothefuseblock.Usetherst
andthirdreceptaclesfromtheleftendofthefuse
block(Figure7).
g018244
1
g018244
Figure7
1.Fuse—15amp(2)
3
InstallingthePressureSwitch
Partsneededforthisprocedure:
1Dowtyseal(1/4inch)
1Pressureswitchadapter
1Pressureswitch
1Pressureswitchcable
Procedure
Thepressureswitchcontrolsthebrakelights.Theswitchis
screwedintothemaintransmissionline.
1.Locatethe3hoseconnectionsontherightsideofthe
transmissionpump.Thelowerfrontconnectiontothe
pumphasateettingwithablankingcap.
2.Removethisblankingcapfromtheteetting.
3.Screwthepressureswitchadapterintotheteetting
usingadowtyseal(1/4inch)asshowninFigure8.
5

g018247
123
g018247
Figure8
1.Dowtyseal(1/4inch)3.Pressureswitch
2.Pressure-switchadapter
4.Screwthepressureswitchintothisadapter(Figure8).
Torquetheswitchto34N∙m(25ft-lb).
5.Workingontheelectricalbulkhead,plugthe3-pin
connectoroftheelectricalpressureswitchcabletothe
correspondingconnectorlocatedonthemainwiring
harnessofthemachine(Figure6andFigure9).
g028149
Figure9
Connectorsasviewedfromthecableentryside
1.Green/Yellow5.Blue
2.Yellow6.Pressureswitchconnector
(mainwiringharness)
3.Black7.Pressureswitchcable
connector
4.Brown
6.Runtheelectricalpressureswitchcablefromthe
electricalbulkhead,downtherightrollbarpost,and
forwardalongthechassisrailtothepressureswitch.
7.Plugtheconnectorintothepressureswitchandsecure
it.
4
InstallingtheNumberPlate
Bracket
Partsneededforthisprocedure:
1Numberplatebracket
12-waytabhousingconnector
1Flasherrelay
1Standardshorterrelay
Procedure
Thenumberplatewithlightattachestothebulkhead.
1.Inthecenteroftheplasticbulkheadcover,
approximately40mm(1-1/2inches)fromthefront,
drillan8mmdiameterhole(Figure10).
g018245
1
2
g018245
Figure10
1.Drillahole(8mm)here.2.Numberplatebracket
WARNING
Usingadrillwithoutpropereyeprotection
mayallowdebristoentertheeye,causing
injury.
Whendrillingorcarryingoutotheroperation,
alwaysweareyeprotection.
2.Feedthenumberplatecablethroughthehole(8mm)
intheplasticbulkheadcover.Installthenumberplate
bracketandthebulkheadwiththebulkheadfasteners
previouslyremoved.
6

3.Pushthe2-waytabhousingconnectorontothe
terminalsofthenumberplatecable(Figure11).
g028150
Figure11
1.Redwire3.2-waytabhousing
connector
2.Blackwire
4.Connectthenumber-plate-lightwiringtoeitherthe
leftorrightrear-light-assembly-wiring,2-pinelectrical
connector.
5.Plugtheasherrelayintotheleftvacant-relaysocket
andthestandardshorterrelayintotherightvacant-relay
socket(Figure12).
g018246
1
2
g018246
Figure12
1.Flasherrelay2.Standardshorterrelay
5
InstallingtheFrontLights
Partsneededforthisprocedure:
1Centerheadlightmount
1Rightheadlightmount
1Leftheadlightmount
8Bolt(M6x20mm)
8Locknut(M6)
4Bolt(M10x25mm)
4Locknut(M10)
8Washer(3/8inch)
2Mountingbracket
24-waytabhousingconnector
Procedure
Thefrontlightassembliesattachtothecenterheadlight
mount,whichattachestothemachineusingtwomounting
brackets(Figure13):
1.Installthe2mountingbracketstothefrontofthe
machineusing2bolts(M10x25mm),4washers(3/8
inch),and2locknuts(M10)asshowninFigure13.
2.Installthecenterheadlightmounttothemounting
bracketsusing2bolts(M10x25mm),4washers(3/8
inch),and2locknuts(M10)asshowninFigure13.
3.Applyanti-seizegreasetofullycoattheinsidewallof
thetubeendsandallthesurfacesofthespringsand
tube-endproles(Figure13).
4.Whileholdingtherightheadlightmount,threadthe
wiringcabledownthroughtheendtubesandoutfrom
theheadlightmountcutout(Figure13).
5.Securetherightheadlightmounttothecenterheadlight
mountusingthe4bolts(M6x20mm)and4locknuts
(M6)asshowninFigure13.
7

g018249
9
7
4
8
5
6
1
2
3
4
56
7
8
8
8
10
10
11
g018249
Figure13
1.Centerheadlightmount7.Nylocnut(M10)
2.Rightheadlightmount8.Washer(3/8inch)
3.Leftheadlightmount9.Mountingbracket
4.Screw(M6x20mm)10.Applyanti-seizehere
5.Nylocnut(M6)11.Headlightmountcutout
6.Screw(M10x25mm)
6.Installthe4waytab-housingconnectorontothe
wiringcablebypushingthepinsintothebackof
theconnector.(Figure14).Identifyandmarkthis
connectoras“R”tohelpwithcableidenticationwhen
makingtheconnectionstothemachinemainwiring
harness.
g028151
Figure14
Connectorasviewedfromthecableentryside
1.Blue4.Black
2.Green5.4-waytabhousing
connector
3.Red/White
7.Repeatsteps4through6,markingtheconnectorwith
an“L”instep6.
8.Passthecablesdownthroughthecutoutforthetowing
pointandthoughtheholesinthefrontchassistothe
cuttingunitmanifoldlocatedundertheoperator’s
platform.
9.Locatethetwo4-pinconnectorsonthemainwiring
harnesslocatedneartothecuttermanifold.
10.Connecttheconnectoronthemachinewiringharness
withthegreen/whitewiretotheidentiedleftlight
assemblyconnector.(Figure15).
g028152
Figure15
1.Blue4.Black
2.Green/white5.Green
3.Red/white6.4-waytab-housing
connector
11.Connecttheconnectoronthemachinewiringharness
withthegreen/redwiretotheidentiedrightlight
assemblyconnector(Figure16).
g028152
Figure16
1.Blue4.Black
2.Green/red5.Green
3.Red/white6.4-waytab-housing
connector
8

6
InstallingtheControlPanel
Switches
Partsneededforthisprocedure:
1Instrumentpanelconnectorlead
1Hazardwarningswitch
1Lightsswitch
1Indicatorswitch
1Hornbutton
1Horndecal
24Cabletie
Procedure
1.Removethe6screwssecuringthecontrolpaneltothe
controlpod.
2.Carefullyliftoffthepanel.
Note:Ensurethattheconnectorstotheexisting
switchesarenotdisturbed.
3.Installtheinstrumentpanelconnectorleadintothe
controlarm.
4.Feedtheconnectorleadinstrumentpanelupthrough
theopeninginthebottomofthecontrolpodsothat
theendwiththe3connectorsareinsidethecontrol
pod,andtheendwiththesinglelargeconnectorisfed
downthecontrolarm.
5.RemovetheswitchblankpanelsFigure17.
Note:Thepanelsarelocatedjustabovethekeyswitch
ontherearfaceofthecontrolpod.
g018292
12
g018292
Figure17
1.Switchblank—lightswitch2.Switchblank—hazard
switch
6.Passthehazardandlightswitchconnectorsthrough
theswitchhole.
Note:Thehazardandlightconnectorsareonthe
shorterleads;thehazardconnectorisredandthelight
connectorisblack.Theindicatorconnectorisblack
andonthelongerlead.
7.Connectthelightandhazardswitchestothecorrect
connectorandpushtheswitchintothehole(Figure
18).
g018253
12
g018253
Figure18
1.Lightswitch2.Hazardswitch
9

8.Onthecontrolpanel,removetheroundplug(horn
button)andtherectangularplug(indicatorswitch)
showninFigure19.
G018336
12
g018336
Figure19
1.Roundplug—hornbutton2.Rectangular
plug—indicatorswitch
9.Installthehorndecal;lineitupwiththeedgesofthe
roundandrectangularholes(Figure20).
G018335
1
2
3
g018335
Figure20
1.Hornbutton3.Directionindicatorswitch
2.Horndecal
10.Installthehornbuttonandthedirectionindicator
switchontothecontrolpanel(Figure20).Installthe
directionindicatorswitchwiththegreen/redwires
totheleftandthegreen/whitewirestotheright,as
showninFigure21.
1
2
G018338
g018338
Figure21
1.Green/Red2.Green/White
11.Connectthedirectionindicatorswitchtotheconnector
leadinstrumentpanel.
Note:Theindicatorconnectorisblackandonthe
longerlead.
12.Connectthepinkwireandtheblack/purplewireto
thehornbutton.
Note:Thepinkwireandtheblack/purplewireare
locatedinthecontrolpanel.
13.Workingundertheoperatorplatform,connectthe
connectorleadinstrumentpaneltothemulti-pin
connectoronthemachine’smainelectrical-wiring
harness.
Note:Themulti-pinconnectorislocatedinthe
chassisrailtotherightofthetransmissionpump.
14.Attachcabletiestoallcablesforthefrontlights,rear
lights,andthepressureswitch.
Important:Ensurethatthecabletiesproperly
securethecables.Thetieswillpreventthecables
frombecomingtrappedorchafed.
15.Connectthenegativebatterycable.
16.Testtheswitchesonthecontrolpaneltoensurethat
theyareoperatingcorrectly.
17.Retthecontrolpaneltoensurethatnoconnectors
havebecomedetachedandthatnocablesarenipped.
18.Lowerandlatchtheenginecoverandoperator’s
platform.
10