Toro LT2240 User manual

FormNo.3445-510RevB
RoadLightKit
LT2240Compact,LT34404-WheelDriveTripleReel,orLT-F3000
TripleFlailMower
ModelNo.02850—SerialNo.400000000andUp
InstallationInstructions
ThisproductcomplieswithallrelevantEuropeandirectives;fordetails,pleaseseetheDeclarationof
Incorporation(DOI)atthebackofthispublication.
Important:ThewiringsystemforthismachineisdesignedforusewithLEDlightsonly.Use
Toro-suppliedlightsonly.
Safety
SafetyandInstructional
Decals
Safetydecalsandinstructionsare
easilyvisibletotheoperatorandare
locatednearanyareaofpotential
danger.Replaceanydecalthatis
damagedormissing.
decal134-5457
134-5457
1.Installationlocation
©2021—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.OriginalInstructions(EN)
PrintedintheUK
AllRightsReserved*3445-510*

Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparetoinstalltheroadlightkit.
Right,rearlightassembly1
Left,rearlightassembly1
Bolt(16x110mm)2
2Flangenut(16mm)2
InstalltheROPScomponents.
3Reector2Installthereectors.
Headlightswitch1
Turnsignalswitch1
4Hazardswitch1
Installthelightandhazardswitches.
Frontlightbarassembly1
Rightlightassembly1
Leftlightassembly1
5Hex-headbolt(12x80mm)2
Assemblethefrontlightbarassembly.
Lightbarmount2
Flangenut(8mm)4
Flange-headbolt(8x65mm)4
6Washer(8mm)4
Installthelightbarmountingbrackets.
Flange-headbolt(6x25mm)2
Flangelocknut(6mm)2
Flange-headbolt(8x30mm)4
7Flangelocknut(8mm)4
Installthefrontlightbar.
Pressuretransducer1
Fitting(3/4x7/16inch)1
Adaptertting(1/4x7/16inch)1
8Seal(1/4inch)—ForMachineswiththe
DifferentialLockKitinstalledonly1
Installthebrake-pressuretransducer.
Numberplate1
Number-platebracket1
Number-platelight1
Phillips-headscrew(#6x1inch)2
Locknut(#6)2
Flange-headbolt(6x20mm)2
9
Flangenut(6mm)2
Assemblethenumberplate.
Flange-headbolt(6x20mm)2
Washer(1/4x3/4inch)3
Flangenut(6mm)2
10Cushionedsupportclamp1
Installthenumberplateandlight.
Lightkitwireharness1
Adhesiveclamp6
Tubeinsert2
Cushionedsupportclamp1
11
Cabletie8
Routethewireharness.
2

ProcedureDescriptionQty.Use
Fuse(10A)1
Fuse(15A)1
12Flasherrelay1
Installthefusesandasherrelay(for
Model31654).
Minifuse(7.5A)2
13Flasherrelay1
Installthefuses(forModels31657and
31659).
14Nopartsrequired–Connectthebattery.
15Nopartsrequired–Testandcalibratethebrake-pressure
transducer.
16Nopartsrequired–Completetheinstallation.
1
PreparingtoInstallthe
RoadLightKit
NoPartsRequired
PreparingtheMachine
1.Parkthemachineonalevelsurface.
2.Lowerthecuttingunits.
3.Engagetheparkingbrake.
4.Shutofftheengineandremovethekey.
5.Waitforallmovingpartstostop.
6.Allowtheenginetocoolcompletely.
RaisingtheOperator’sPlatform
1.Movetheplatform-latchhandle(Figure1)
towardthefrontofthemachineuntilthelatch
hooksclearthelockingbar.
g290373
Figure1
1.Platform-latchhandle
2.Raisetheplatform(Figure2).
Note:Thegasliftcylinderassistsliftingthe
platform.
g290372
Figure2
3

RemovingtheStorage
Compartment
Models31657and31659
1.Attheleftsideoftheoperator’splatform,open
thedoorofthestoragecompartment(Figure3).
g328513
Figure3
1.Washer3.Storagecompartment
2.Knob
2.Removethe3knobsand3washersthatsecure
thestoragecompartmenttothemachine,and
removethecompartment(Figure3).
OpeningtheHood
Models31654
Unlatchandopenthehood.
DisconnectingtheBattery
1.Loosentheforwardnutofthenegative
battery-cableterminal(Figure4).
g344733
Figure4
1.Nut(negative
battery-cableterminal)
2.Negativebatterypost
2.Liftthenegativebatterycablefromthebattery
post(Figure4).
Note:Positionthenegative-batterycablewhere
itcannotcontactthenegativebatterypost.
2
InstallingtheROPS
Components
Partsneededforthisprocedure:
1Right,rearlightassembly
1Left,rearlightassembly
2Bolt(16x110mm)
2Flangenut(16mm)
Procedure
1.Removethepivotbolt(16x100mm)andange
nut(16mm)fromtherightsideoftherollbar
(Figure5).
Discardthepivotbolt(16x100mm)andange
nut(16mm).
4

g344223
Figure5
1.Pivotbolt(16x100mm)2.Flangenut(16mm)
2.Securetheright,rearlightassemblytotheroll
barusingthenewbolt(16x110mm)andnew
angenut(16mm)asshowninFigure6.
g344222
Figure6
Rightsideshown
1.Newbolt(16x110mm)3.Newangenut(16mm)
2.Right,rearlightassembly
3.Repeatthisprocedureontheleftsideoftheroll
bar.
3
InstallingtheReectors
Partsneededforthisprocedure:
2Reector
Procedure
Removethebackinglmandmountthe2reectorsto
thebackofthehoodasshowninFigure7orFigure8.
g344248
Figure7
ReectorlocationforModel31654
g344249
Figure8
ReectorlocationforModel31657and31659
5

4
InstallingtheHeadlight,
TurnSignal,andHazard
Switches
Partsneededforthisprocedure:
1Headlightswitch
1Turnsignalswitch
1Hazardswitch
InstallingtheSwitches
Model31654
1.Removetheplugsshownfromthecontrolarm
(Figure9andFigure10).
Discardtheplugs.
g344366
Figure9
g344364
Figure10
2.Removetheinstrumentpanelandswitchplate
fromthecontrolarm(Figure11andFigure12).
Retainthefastenersforlaterinstallation.
g344365
Figure11
1.Button-headscrew(4x16
mm)
2.Instrumentpanel
6

g344367
Figure12
1.Button-headscrew(8x20
mm)
2.Switchplate
3.Pullthroughthecontrol-armharnessconnectors
withthefollowinglabels:
•LIGHTS
•INDICATORS
•HAZARDS
4.Connectthe3switchestothecorresponding
harnessconnectors(Figure13andFigure14).
g344363
Figure13
1.Turnsignalswitch
g344362
Figure14
1.Headlightswitch2.Hazardswitch
5.Installthepreviouslyremovedinstrumentpanel
andswitchplatefromthecontrolarm(Figure
11andFigure12).
InstallingtheSwitches
Models31657and31659
1.Removethe2Phillips-headscrews(1/4x1
inch)thatsecurethecontrol-armcovertothe
controlarm,andremovethecover(Figure15).
g344284
Figure15
1.Phillips-headscrew(1/4x
1inch)
2.Control-armcover
2.RemovethePhillips-headscrew(#10x3-1/2
inches),locknut(#10),and5ange-headscrews
(#10x3/8inch)thatsecuretherightcontrol-arm
paneltothecontrolarm(Figure14).
7

g351205
Figure16
1.Locknut(#10)3.Flange-headscrew(#10x
3/8inch)
2.Phillips-headscrew(#10x
3-1/2inches)
4.Rightcontrol-armpanel
3.Removetheplugsshownin(Figure17and
Figure18)fromthecontrolarm.
Discardtheplugs.
g351226
Figure17
1.Plugs
g351225
Figure18
1.Plug
4.Pullharnessconnectorswiththefollowinglabels
throughthecontrolarm:
•HAZARDSWITCH
•TURNSIGNALSWITCH
•HEADLIGHTSWITCH
5.Connectthe3switchestothecorresponding
harnessconnectors(Figure19andFigure20).
g351223
Figure19
1.Turnsignalswitch2.Hazardswitch
g351224
Figure20
1.8-pinconnector
(labeledHEADLIGHT
SWITCH—machinewire
harness)
2.Headlightswitch
8

6.Assembletherightcontrol-armpaneltothe
controlarm(Figure21)withthePhillips-head
screw(#10x3-1/2inches),locknut(#10),and5
ange-headscrews(#10x3/8inch).
g351204
Figure21
1.Locknut(#10)3.Flange-headscrew(#10x
3/8inch)
2.Phillips-headscrew(#10x
3-1/2inches)
4.Rightcontrol-armpanel
5
AssemblingtheFrontLight
BarAssembly
Partsneededforthisprocedure:
1Frontlightbarassembly
1Rightlightassembly
1Leftlightassembly
2Hex-headbolt(12x80mm)
Procedure
1.Removethefastenersfromtherightlight
assembly.
Retainthelocknut(12mm)andlockwasher(12
mm).Discardthescrew.
2.Securetherightlightassemblytothefrontlight
barassemblyusing1newhex-headbolt(12
x80mm)andthepreviouslyremovedlocknut
(12mm)andlockwasher(12mm)asshownin
Figure22.
Important:Donotovertightenthefasteners,
asyoucoulddamagethelightassembly.
g344461
Figure22
1.Newhex-headbolt(12x
80mm)
4.Previouslyremovedlock
washer(12mm)
2.Rightlightassembly5.Previouslyremoved
locknut(12mm)
3.Frontlightbarassembly
3.Repeatsteps1and2ontheleftside.
9

6
InstallingtheLightBar
MountingBrackets
Partsneededforthisprocedure:
2Lightbarmount
4Flangenut(8mm)
4Flange-headbolt(8x65mm)
4Washer(8mm)
IdentifyingtheMountingBracket
HolePositions
g344484
Figure23
Holes(lightbararm)
UsetheillustrationinFigure24toidentifythe
mountingbracketholepositionsonthearmofthelight
barforyourmachine.
g344485
Figure24
1.Model316543.Model31659
2.Model31657
Note:Youcanalsorefertothedecalonthelightbar
(Figure25)forinformationaboutthemountingbracket
holepositions.
g344605
Figure25
10

AssemblingtheMounting
BracketstotheLightBar
1.Aligntheholesinthemountingbracketwiththe
holesinthearmofthelightbar(Figure26)that
youidentiedinIdentifyingtheMountingBracket
HolePositions(page10).
Note:Ensurethatthetabofthemounting
bracketisalignedawayfromthelightassembly.
g345100
Figure26
1.Flangelocknut(8mm)4.Bolt(8x65mm)
2.Tab(mountingbracket)5.Lightbararm
3.Washer(8mm)
2.Looselyassemblethemountingbrackettothe
lightbararm(Figure26)withthe2bolts(8x65
mm),2washers(8mm),and2angelocknuts
(8mm).
3.Repeatsteps1and2attheotherarmofthe
lightbar.
7
InstallingtheLightBar
Partsneededforthisprocedure:
2Flange-headbolt(6x25mm)
2Flangelocknut(6mm)
4Flange-headbolt(8x30mm)
4Flangelocknut(8mm)
Procedure
1.Aligntheholesinthelightbarmountingbrackets
withtheholesinthelatchplateandpivot-arm
plate(Figure27,Figure28,orFigure29).
g344558
Figure27
Model31659shown;Models31654and31657aresimilar.
1.Flange-headbolt(6x25
mm)
5.Flange-headbolt(8x30
mm)
2.Latchplate6.Pivot-armplate
3.Mountingbracket7.Flangelocknut(8mm)
4.Flangelocknut(6mm)
g344556
Figure28
Model31654
g344557
Figure29
Model31657
11

2.Looselyassemblethemountingbrackettothe
latchplate(Figure30)withaange-headbolt(6
x25mm)andangelocknut(6mm).
3.Looselyassemblethemountingbrackettothe
pivot-armplate(Figure30)withaange-head
bolt(8x30mm)andangelocknut(8mm).
4.Repeatsteps2and3attheothermounting
bracket.
5.Torqueall6mmboltsandlocknuts(Figure30)
to11to13N∙m(97to115in-lb).
g344584
Figure30
1.6mmange-headboltand
locknut
2.8mmange-headbolt
boltsandlocknuts
6.Torqueall8mmboltsandlocknuts(Figure30)
to26to30N∙m(16to22ft-lb).
8
Installingthe
Brake-PressureTransducer
Partsneededforthisprocedure:
1Pressuretransducer
1Fitting(3/4x7/16inch)
1Adaptertting(1/4x7/16inch)
1Seal(1/4inch)—ForMachineswiththeDifferential
LockKitinstalledonly
InstallingtheTransducer
Model31654
1.Attherightsideofthetractionpump,remove
theplugfromtheT-ttingatportBofthetraction
pump(Figure31).
g344293
g344289
Figure31
1.T-tting(tractionpump
portB)
3.Adaptertting(1/4x7/16
inch)
2.Plug
2.Assembletheadaptertting(1/4x7/16inch)
intotheT-tting(Figure31).
3.Torquetheassembletheadapterto34to41
N∙m(25to30ft-lb).
4.Assemblethebrake-pressuretransducerinto
theadaptertting(Figure32).
12

g344291
Figure32
1.Adaptertting(1/4x7/16
inch)
2.Brake-pressure
transducer
5.Torquethebrake-pressuretransducerto27N∙m
(20ft-lb).
6.Removethecabletiethatsecuresthe3-pin
connectorofthemachinewireharnesslabeled
BRAKEPRESSURESENSORtothehoseadjacentto
theforwardtractionmanifold(Figure33).
g344439
Figure33
1.3-pinconnector(labeledBRAKEPRESSURE
SENSOR—machinewireharness)
7.Routethe3-pinconnectorandwirestowardthe
rightsideofthetractionpump.
g344293
Figure34
8.Removethecapfromthebrakepressuresensor
connector(Figure35).
g344325
Figure35
1.Cap3.Brakepressuresensor
2.3-pinconnector(labeled
BRAKEPRESSURE
SENSOR—machinewire
harness)
9.Plugthebrakepressuresensorconnectorinto
thebrake-pressuretransducer(Figure35).
13

InstallingtheTransducer
Models31657and31659withoutthe
DifferentialLockKit
1.Attherightsideofthetractionpump,remove
theplugfromportMBofthepump(Figure36).
g343559
g344078
Figure36
1.Port-MB(tractionpump)3.Reducertting(3/4x7/16
inch)
2.Plug
2.AssemblethereducerttingintoportMBofthe
pump(Figure36).
3.Torquethereducerttingto81N∙m(60ft-lb).
4.Assemblethebrake-pressuretransducer(Figure
37)intothereducertting(3/4x7/16inch).
g344080
Figure37
1.Reducertting(3/4x7/16
inch)
2.Brake-pressure
transducer
5.Torquethetransducerto27N∙m(20ft-lb).
6.Removethecabletiethatsecuresthe3-pin
connectorofthemachinewireharnesslabeled
BRAKEPRESSURESENSORtothehoseadjacentto
theforwardtractionmanifold(Figure38).
g344440
Figure38
1.3-pinconnector(labeledBRAKEPRESSURE
SENSOR—machinewireharness)
7.Routethe3-pinconnectorandwirestowardthe
rightsideofthetractionpump(Figure39).
g343559
Figure39
8.Removethecapfromthe3-pinconnectorofthe
machinewireharnesslabeledBRAKEPRESSURE
SENSOR(Figure40).
14

g344073
Figure40
1.3-pinconnector—machine
wireharness(labeled
BRAKEPRESSURESENSOR)
3.Brake-pressure
transducer
2.Cap
9.Plugthe3-pinconnectorlabeledBRAKE
PRESSURESENSORintotheconnectorofthe
pressuretransducer(Figure40).
InstallingtheBrakePressure
Transducer
MachineswiththeOptionalDifferentialLock
Kit
1.Routethe3-pinconnectorlabeledBRAKE
PRESSURESENSORandwiringtoward
front-tractionmanifold(Figure41).
g344918
Figure41
1.Front-tractionmanifold3.Frontofthemachine
2.3-pinconnector(labeled
BRAKEPRESSURESENSOR)
2.Removethehex-socketplugfromport-PSofthe
fronttractionmanifold(Figure42).
g344933
Figure42
1.Port-PS(fronttraction
manifold)
2.Hex-socketplug
3.Assembletheadaptertting(1/4x7/16inch)
intoport-PSofthefronttractionmanifold(Figure
43)withaseal(1/4inch).
15

g344935
Figure43
1.Adaptertting(1/4x7/16
inch)
3.Port-PS(fronttraction
manifold)
2.Seal(1/4inch)4.Brake-pressure
transducer
4.Torquetheadapterttingto34to41N∙m(25
to30ft-lb).
5.Assemblethebrake-pressuretransducerinto
theadaptertting(Figure43).
6.Torquethetransducerto27N∙m(20ft-lb).
7.Plugthe3-pinconnectorlabeledBRAKE
PRESSURESENSORintothebrake-pressure
transducer(Figure44).
g344934
Figure44
1.Brake-pressure
transducer
2.3-pinconnector(labeled
BRAKEPRESSURE
SENSOR—machinewire
harness)
9
AssemblingtheNumber
Plate
MachineswithouttheOptional
Cab
Partsneededforthisprocedure:
1Numberplate
1Number-platebracket
1Number-platelight
2Phillips-headscrew(#6x1inch)
2Locknut(#6)
2Flange-headbolt(6x20mm)
2Flangenut(6mm)
Procedure
1.Securethenumber-platelighttothe
number-platebracketusingthe2Phillips-head
screws(#6x1inch)and2locknuts(#6)as
showninFigure45.
Retaintheconnectorandwedgelockforlater
installation.
16

g344531
Figure45
1.Locknut(#6)3.Number-platelight
2.Number-platebracket4.Phillips-headscrew(#6x
1inch)
2.Securethenumberplatetothenumber-plate
bracketusing2ange-headbolts(6x20mm)
and2angenuts(6mm)asshowninFigure46.
g344532
Figure46
1.Flangenut(6mm)3.Flange-headbolt(6x20
mm)
2.Number-platebracket4.Numberplate
10
InstallingtheNumber-Plate
BracketandLight
MachineswithouttheOptional
Cab
Partsneededforthisprocedure:
2Flange-headbolt(6x20mm)
3Washer(1/4x3/4inch)
2Flangenut(6mm)
1Cushionedsupportclamp
RemovingtheBulkhead
Remove4bolts,4lockwashers,and4washers
thatsecurethebulkhead(Figure47)totheelectrical
panel,andremovethebulkhead.
Note:Retainthebulkhead,bolts,lockwashers,and
washers.
g346880
Figure47
1.Bolts3.Washer
2.Lockwasher4.Bulkhead
17

AssemblingtheNumberPlateand
Light
1.Placetheassemblednumber-platebracket
ontothebulkheadandalignthebracketasfar
forwardaspossible.
2.Centertheassemblednumberplateonthe
bulkhead.
3.Usingthebracketasthetemplate,drill2holes
(7mm)throughthebulkhead(Figure48).
g347227
Figure48
1.Drill2holes(7mm)inthebulkhead.
4.Drillahole(6.5mm)throughthebulkheadtothe
leftofthenumber-platelight(Figure49).
g347228
Figure49
1.Drillahole(6.5mm)—bulkhead.
5.Looselyassemblenumber-platebrackettothe
bulkheadusing2ange-headbolts(6x20mm),
3washers(1/4x3/4inch),andaangelocknut
(6mm)asshowninFigure50.
Youwillinstallthelocknuttothemachineleft
ange-headboltinSecuringthePlate-Light
HarnesstotheBulkhead(page19).
g349858
Figure50
1.Flange-headbolt(6x20
mm)
3.Flangelocknut(6mm)
2.Washers4.Machineright—bulkhead
6.Routetheharnessofthenumber-platelight
(Figure51)throughthehole(6.5mm)thatyou
drilledinstep4.
Note:Youwillinstallthe2-pinconnector
andwedgelockinAssemblingthePlate-Light
Connector(page19).
g346837
Figure51
1.Harness(number-plate
light)
2.Hole(6.5mm—bulkhead)
18

AssemblingthePlate-Light
Connector
1.Atthebulkhead,inserttheterminalofthewhite
lightwireintothepin1positionofthe2-pin
connector(Figure52).
g351247
Figure52
1.Pin1position(2-pin
connector)
4.Pin2position(2-pin
connector)
2.Whitewire(number
plate-lightharness)
5.Wedgelock
3.Blackwire(number
plate-lightharness)
2.Inserttheterminaloftheblacklightwireintothe
pin2positionofthe2-pinconnector(Figure52).
3.Insertthewedgelockintothe2-pinconnector.
SecuringthePlate-LightHarness
totheBulkhead
1.Assembleacushionedsupportclampontothe
harnessofthenumber-platelight(Figure53).
g349935
Figure53
1.Flangelocknut(6mm)3.Flange-headbolt(6x20
mm)
2.Cushionedsupportclamp4.Harness(number-plate
light)
2.Assemblethecushionedsupportclampand
aangenut(6mm)ontothemachineleft
ange-headbolt(Figure53).
3.Tightenthe2ange-headboltsand2ange
locknutsthatsecurethenumber-platebracket
andclamptothebulkhead.
11
InstallingtheWireHarness
Partsneededforthisprocedure:
1Lightkitwireharness
6Adhesiveclamp
2Tubeinsert
1Cushionedsupportclamp
8Cabletie
PlacingtheWireHarnessOverview
RefertoFigure54foranoverviewofwherethewire
harnessroutesonthemachine.
19

g344563
Figure54
PreparingtheHeadlightWire
HarnessConnectors
1.Locatethe6-pinconnectorlabeledLH
HEADLIGHTand6-pinconnectorlabeledRH
HEADLIGHTofthekitharnessconnectors(Figure
55).
g347279
Figure55
1.6-pinconnector
(headlight—kitharness
connector)
3.90°backshell
2.Swivel-interfaceshell
2.Separatethe90°backshellfromthe
swivel-interfaceshell(Figure55).
3.Separatetheswivel-interfaceshellfromthe
6-pinconnector(Figure55).
4.Repeatsteps2and3oftheotherheadlight
connector.
RoutingandConnectingtheWire
HarnesstotheFrontLightBar
Assembly
1.RoutethewireharnesssegmentlabeledLH
HEADLIGHTthroughtheleftopeninginthefront
armpivot-platemountandthenthroughthe
latchplate(Figure56).
g345099
Figure56
2.RoutethewireharnesssegmentlabeledRH
HEADLIGHTthroughtherightopeninginthefront
armpivot-platemountandthenthroughthe
latchplate(Figure56).
3.Securetheharnesstothefrontarmpivot-plate
mountusing2adhesiveclamps(Figure56).
4.Routethewireharnessthroughtheinsideofthe
leftandrightsideofthefrontlightbarassembly
(Figure57).
5.Securethewireharnessatthefrontusing4
adhesiveclamps(Figure57).
g344582
Figure57
6.Routethewireharnessthroughtheholeinthe
frontchannelbypushingtheharnessthrough
untilyoucanseetheharnessfromthesideof
thelightbarassembly(Figure58).
20