Toro 107-9880 Installation Instructions

Light Kit
For Z400 and Z500 Series Z Master® Mowers
Model No. 107–9880
Installation
Loose Parts
Use the chart below to verify that all parts have been shipped.
Form No. 3354-521 Rev A
Installation Instructions
1 2 3
4
5
6
Template
Diesel adapter wire harness Fuse (20 amp)
Wire harness
Lamp (without a switch) Lamp (with a switch) Front lamp brackets Side lamp bracket Flat washers Rubber grommets Bolt (5/16 x 3/4 inch) Nut (5/16 inch) Curved washer Bolt (3/8 x 3/4 inch) Cable tie Harness clip Bolt (5/16 x 3/4 inch) Nut (5/16 inch) Curved washer Cable tie Harness clip
Description
Qty.
1
1 1
1
2 1 2 1 6 3 2 2 2 1 2 2 5 5 5 2 2
Drill the holes for the front lights.
Install the diesel adapter wire harness (diesel models only).
Install the wire harness.
Assemble the lamps and brackets.
Install the lamps. (Some parts are repeated in Step 6 for the Z500 Series Mowers. You will have extra parts after installing the lamps.)
Install the lamps. (Some parts are repeated in Step 5 for the Z400 Series Mowers. You will have extra parts after installing the lamps.)
Use
7
© 2005—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420
Fuse (20 amp)
1
Register at www.Toro.com. Original Instructions (EN)
Install the Fuse
Printed in the USA. All Rights Reserved
Step
Step
1
Drilling the Holes for the Front Lights (Z500 Series Mowers)
Parts needed for this step:
1
Template
Procedure Note: P erfor m this procedure only if there are
no pre-drilled holes in the footrest for the front lights . If y ou are installing this kit on a Z400 series mo w er , skip this procedure .
1. P osition the template ( Figure 1 ) on either the left or right side of the front of the footrest.
2
Installing the Diesel Adapter Wire Harness
Parts needed for this step:
1
Diesel adapter wire harness
1
Fuse (20 amp)
Procedure Note: T his ste p is only for diesel mac hines
that do not ha v e an open connector on the main wire har ness (Z597 Mo w ers). If y ou ha v e an open connector on the main wire har ness , g o to Installing the Wire Har ness .
1. Install the 20 amp fuse into the fuse connector on the diesel adapter wire har ness .
2. R emo v e the 4 screws ( Figure 2 ) that hold the control panel in place .
Figure 1
1. Template
Note: Ensure that the outer edg e of the template matc hes the outer edg e of the footrest.
2. Mark the position of the holes on the front of the footrest with a metal punc h.
3. Drill 2 holes (3/8 inc h diameter) in the locations that y ou mark ed in ste p 2 .
4. R e peat ste ps 1 through 3 for the other side of the front of the footrest.
Figure 2
1. Control panel screws
3. Lift up the control panel and find the ter minals on the bac k side of the v olt meter ( Figure 3 ) located on the underside of the panel.
2
Figure 3
1. Terminals on the back side of the volt meter
4. Connect the ter minal ends of the diesel adapter wire har ness to the ter minals on the bac k side of the v olt meter .
5. Install the control panel and secure it with the 4 screws that y ou remo v ed in ste p 2 .
6. Connect the diesel adapter wire har ness to the light kit wire har ness .
Figure 4
1. Open connector on the main wire harness
2. Connect the light kit wire har ness connector to a connector on the main wire har ness ( Figure 5 ).
Step
3
Installing the Wire Harness
Parts needed for this step:
1
Wire harness
Procedure Note: If y ou installed a diesel adapter wire
har ness , skip this procedure .
1. Locate the open connector on the main wire har ness ( Figure 4 ).
Figure 5
3. R oute the light kit wire har ness ( Figure 6 ) along the frame .
Figure 6
1. Light kit wire harness
3
Step
4
Assembling the Lamps and Brackets
Parts needed for this step:
2
Lamp (without a switch)
1
Lamp (with a switch)
2
Front lamp brackets
1
Side lamp bracket
6
Flat washers
3
Rubber grommets
Figure 8
Conguration for Z500 Series Mowers
1. Nut
2. Washer 5. Rubber grommet
3. Front lamp bracket
4. Flat washers
Procedure Important: T his pr ocedur e v aries
depending on whether y ou ar e installing this kit on a Z400 or Z500 series mo w er . T he illustrations depict the dif fer ences.
1. R emo v e the n ut and w asher from one of the lamps without a switc h ( Figure 7 for Z400 series mo w ers or Figure 8 for Z500 series mo w ers).
2. Secure the lamp onto one of the front lamp brac k ets as illustrated for y our mo w er in Figure 7 or Figure 8 , using 2 flat w ashers , a r ubber g rommet, and the w asher and n ut y ou remo v ed from the lamp in ste p 1 .
3. R e peat ste ps 1 and 2 for installing the other lamp without a switc h to the other front lamp brac k et.
4. R emo v e the n ut and the w asher from the lamp with a switc h ( Figure 9 for Z400 series mo w ers or Figure 10 for Z500 series mo w ers).
Figure 7
Conguration for Z400 Series Mowers
1. Nut
2. Washer 5. Rubber grommet
3. Front lamp bracket
4. Flat washers
4
Step
5
Installing the Lamps (Z400 Series Mowers)
Parts needed for this step:
2
Bolt (5/16 x 3/4 inch)
2
Nut (5/16 inch)
2
Curved washer
1
Bolt (3/8 x 3/4 inch)
2
Cable tie
2
Harness clip
Figure 9
Conguration for Z400 Series Mowers
1. Nut
2. Washer 5. Rubber grommet
3. Side lamp bracket
Conguration for Z500 Series Mowers
1. Nut
2. Washer 5. Rubber grommet
3. Side lamp bracket
4. Flat washers
Figure 10
4. Flat washers
Procedure Note: If y ou ha v e a Z500 series mo w er , skip this
procedure .
1. Install the 2 front lamps (with brac k ets) onto the front of the footrest with 2 bolts (5/16 x 3/4 inc h), cur v ed w ashers , n uts (5/16 inc h), and har ness clips ( Figure 11 ).
Note: Before installing the n ut on eac h of the bolts , slip the har ness clips onto the light kit wire har ness and install eac h of the clips on a bolt betw een the bac kside of the footrest and the hex n ut ( Figure 11 ).
5. Install the lamp with the switc h onto the side lamp brac k et as illustrated for y our mo w er in Figure 9 or Figure 10 , using 2 flat w ashers , a r ubber g rommet, and the w asher and n ut y ou remo v ed from the lamp in ste p 4 .
Figure 11
5
2. Secure the side lamp and attac hed brac k et to the frame using a bolt (3/8 x 3/4 inc h) ( Figure 12 ).
Figure 12
3. Connect the side light wire connector to the light kit wire har ness connector ( Figure 13 ).
Figure 13
1. Light kit wire harness connector
4. Connect the 2 wire connectors of the front lights to the connectors on the light kit wire har ness ( Figure 13 ).
Figure 14
1. Nut on the lamp bracket
2. Cable tie
6. Set eac h lamp to the desired position and tighten the n ut on the lamp brac k et ( Figure 14 ).
Step
6
Installing the Lamps (Z500 Series Mowers)
Parts needed for this step:
5
Bolt (5/16 x 3/4 inch)
5
Nut (5/16 inch)
5
Curved washer
2
Cable tie
2
Harness clip
5. Secure the light kit wire har ness to the frame with 2 cable ties , one near the left front light and the other to w ard the control panel ( Figure 14 ).
Procedure Note: If y ou ha v e a Z400 series mo w er , skip this
procedure .
1. Install the 2 front lamps (with brac k ets) onto the front of the footrest with the bolts , cur v ed w ashers , and hex n uts pro vided in the kit ( Figure 15 ).
6
Figure 15
Note: Before installing the n ut on eac h of the
lo w er bolts , slip the har ness clips onto the light kit wire har ness and install eac h of the clips on a lo w er bolt betw een the bac kside of the footrest and the hex n ut ( Figure 16 ).
Figure 16
1. Harness clip
2. Secure the side lamp and attac hed brac k et to the frame using a bolt, a cur v ed w asher , and a hex n ut ( Figure 17 ).
Figure 17
3. Connect the side light wire connector to the light kit wire har ness connector ( Figure 18 ).
Figure 18
1. Light kit wire harness connector
4. Connect the 2 wire connectors of the front lights to the connectors on the light kit wire har ness ( Figure 18 ).
5. Secure the light kit wire har ness to the frame with 2 cable ties , one near the left front light ( Figure 19 ) and the other to w ard the control panel.
7
Figure 19
1. Cable tie
6. Set eac h lamp to the desired position and tighten the n ut on the lamp brac k et ( Figure 20 ).
Install the fuse into the fuse bloc k/connector as appropriate for y our mo w er; refer to y our mo w er Operator’ s Manual for more infor mation on installing fuses .
Note: If y ou are installing this kit on a Z500 series mo w er , install the fuse into the accessories fuse bloc k slot (Acc .) or if it is not labeled, the open fuse bloc k slot with the pur ple and white wires .
Figure 20
1. Nut on the lamp bracket
Step
7
Installing the Fuse
Parts needed for this step:
1
Fuse (20 amp)
Procedure Note: Skip this procedure if y ou installed the
fuse already when installing the adaptor on a diesel mo w er .
8
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