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2840
Installation Instructions
12 pgs1.18 Mb0
Parts Catalogue
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Toro 2840 Installation Instructions

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Page 1
LightKit
Z580SeriesMowers
ModelNo.02840
Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
FormNo.3368-211RevB
InstallationInstructions
1
2
3
Rearlightbracket2 Washer(5/16inch) Nut(M8) Bolt(M8x75) Washer(M8) Bolt(M5x16) Washer(M5) Nut(M5) Rearlamp2 Reector Lefthandheadlamp Righthandheadlamp1 Frontlightbracket2 Bolt(M8x20) Washer(M8) Nut(M8) Horn1 Blankswitch2 Switchpanel Combinationswitchassembly Adaptorswitchmount1 Hazardswitch1 Lightingswitch1 Hazardswitchlens1 Lightingswitchlens1 Grommet Cabletie Bolt(M5) Washer(M5) Nut(M5) Screw Crimpterminal—Piggyback Crimpterminal—Malebullet Crimpterminal—Femalebullet
Qty.
Use
4 4 4 4 4 8 4
2 1
1 2 1
1 1
2 1 1 1 1 1 1 1 1
MountthelampstotheROPS.
Mounttheheadlampsandhorn
Installthefrontswitches.
©2011—TheT oro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
Registeratwww.Toro.com.
OriginalInstructions(EN)
PrintedintheUK.
AllRightsReserved
Page 2
G015994
580mm
Numberplatelampassembly1 Bolt(M5x16) Washer(1/4x3/4inch) Nut(M5)
4
Lampplatebracket1 Bolt(M6x16) Washer(M6x12) Nut(M6) 30ampfuse
CAUTION
Ifyouleavethekeyintheignitionswitch,someone couldaccidentallystarttheengineandseriously injureyouorotherbystanders.
Parkthemachineonalevelsurface,applythe parkingbreak,removethekeyfromtheignition, anddisconnectthebatteryterminals.
Note:Referencesinthismanualtorightandleftare determinedfromstandardoperatingposition.
Qty.
Use
2 4 4
Routethewiringharness. 2 4 2 1
1
MountingtheLampstothe ROPS
Partsneededforthisprocedure:
2Rearlightbracket
4
Washer(5/16inch)
4
Nut(M8)
4
Bolt(M8x75)
4
Washer(M8)
4
Bolt(M5x16)
8
Washer(M5)
4
Nut(M5)
2Rearlamp
2
Reector
Procedure
Figure1
2.Lifttheenginecover.
3.Alignthebottomofthebracketalongthemarkon theROPS.SecurethebrackettotheROPSusing2 bolts(M8x75),2washers(M8),2washers(5/16 inch),and2nuts(M8)(Figure2).
1.Measure580mm(23inches)fromthegroundtothe ROPSandmarkboththeleftandrighthandside (Figure1).
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G016005
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Figure2
G016006
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2
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4
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1.Washers(M8)5.Reector
2.Bolts(M8x75)6.Nuts(M5)10.ROPS
3.Bolts(M5x16)7.Washers(5/16 inch)
4.Washers(M5)8.Nuts(M8)
9.Bracket
4.Mountthereectortothebracketusing2bolts(M5 x16),4washers(M5),and2nuts(M5)(Figure2).
5.Mounttherearlamptothebracketusing2starx washersand2nutsincludedwiththelampassembly
Figure3).
(
Figure3
1.Rearlamp
2.Nut(includedwithrear lamp)
3.Starxwasher(included withrearlamp)
4.ROPS
5.Bracket
6.Repeatsteps2-5fortheoppositeside.
2
MountingtheHeadLampsand Horn
Partsneededforthisprocedure:
1
Lefthandheadlamp
1Righthandheadlamp
2Frontlightbracket
1
Bolt(M8x20)
2
Washer(M8)
1
Nut(M8)
1Horn
Procedure
1.Locatethetwoboltsalongtheleftsiderailand removethe2boltsand2nuts(Figure4).
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G015996
Figure4
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G016007
G015997
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1
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G016008
Leftsiderail
1.Removethesenutsandbolts.
2.Mountafrontlightbrackettotheleftsiderailusing theremovednutsandbolts(Figure5).
Figure6
Rightsiderail
1.Removethesenutsandbolts.
5.Mountthehorntotheleftsidebracketasshownin Figure7.Secureitwithabolt(M8x20),2washers (M8),andanut(M8).
Figure5
1.Bolt(existing)4.Siderail
2.Springwasher(included withheadlamp)
3.Nut(includedwithhead lamp)
3.Fixthelefthandheadlamptothefrontlightbracket usingaspringwasherandanutprovidedwiththe lamp(
4.Repeatsteps1-3fortherighthandside(Figure6).
Figure5).
5.Nut(existing)
6.Frontlightbracket
Figure7
Leftsidehornmount
1.Bolt(M8x20)5.Leftsiderail
2.Washer(M8)6.Nut(M8)
3.Leftheadlamp7.Washer(M8)
4.Horn8.Bracket
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G015998
1
Note:Allburrsmustberemovedfromtheedgesto
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4
2
1
G016009
avoiddamagetothewires.
3
InstallingtheSwitches
Partsneededforthisprocedure:
2Blankswitch
1
Switchpanel
1
Combinationswitchassembly
1Adaptorswitchmount
1Hazardswitch
1Lightingswitch
1Hazardswitchlens
1Lightingswitchlens
2
Grommet
1
Cabletie
1
Bolt(M5)
1
Washer(M5)
1
Nut(M5)
1
Screw
1
Crimpterminal—Piggyback
1
Crimpterminal—Malebullet
1
Crimpterminal—Femalebullet
2.Connectthecombinationswitchassemblytothe adaptorswitchmountandsecureitwithascrew
Figure9).
(
Figure9
Procedure
1.Cut40mm(1-1/2inch)offtherightmotioncontrol Figure8).Useatwopartepoxyresintoglue
lever( theadaptorswitchmountintothemotioncontrol lever(Figure8).
1.Motioncontrollever
2.Adaptorswitchmount
3.Screw(includedwith switchassembly)
4.Combinationswitch assembly
3.Pushthehazardswitch,lightingswitch,and2blank switchesintotheswitchpanelasshown(Figure10).
Figure8
1.40mm
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4
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2
1
G016010
Figure10
G015999
G016000
3
4
!
1
2
G015942
1.Lightingswitch lens
2.Hazardswitch lens
3.Blankswitches5.Hazardswitch
4.Switchpanel
6.Lightingswitch
4.Installthehazardswitchlensandthelightingswitch lens.
5.Fitthegrommetstotherearheadlampwiresby feedingtheconnectorsthroughthegrommethole oneatatime(
Figure11).
Figure12
1.Switches
2.Flashingrelaybase
3.Flasherrelay
4.Cabletie
7.Removethe4screwsonthecontrolpanel (Figure13).
Figure13
1.Ignitionswitch
2.Screw
8.Iftheignitionswitchhas6terminals(Figure14), proceedtostep9.Iftheignitionswitchhas5 terminals(Figure15),proceedtostep10.
1.Grommets
Figure11
6.Plugthewiringharnessintotheswitches.Securethe ashingrelaybasewithabolt(M5),washer(M5), andnut(M5).Cabletietheharnessasshown,and plugintheasherrelay(Figure12).
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1
2
3
G015940
Figure14
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2
3
4
5
G016442
G016001
1.Existingconnector3.Piggybackterminal
2.Redwire
Figure15
1.Thickpinkwire4.Malebullet
2.Thinpinkwire5.Redwire
3.Femalebulletconnector
Figure16
1.Screws
9.Crimpapiggybackconnectortotheredwireonthe lightingharness.removethesingleconnectorfrom theignitionswitch.Connectthepiggybacktothis position,thenreconnecttheremovedconnectorto thepiggyback(
Figure14).
10.Cutthethinpinkwirehalfwayup,striptheinsulation, andconnectittothebluefemalebulletcrimp terminal.Thencrimpthemalebullettotheredwire onthelightingharnessandconnectittotheignition switchinthepositionindicatedbyFigure15.
11.Retthecontrolpanel,thenttheswitchpanelto therightsideofthecontrolpanelusing2existing screws(
Figure16).
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G016012
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6
RoutingtheWiringHarness
Partsneededforthisprocedure:
1Numberplatelampassembly
2
Bolt(M5x16)
4
Washer(1/4x3/4inch)
4
Nut(M5)
1Lampplatebracket
2
Bolt(M6x16)
4
Washer(M6x12)
2
Nut(M6)
1
30ampfuse
Procedure
1.Connectthe4wayand3wayconnectorstothe combinationswitchassemblyandtheremaining connectortotherighthandfrontheadlamp.Route theharnesstotheleftalongthefrontrailand connectthelefthandfrontheadlamp(
2.Routetheharnessalongtheleftsiderailtoconnect thelefthandfrontheadlampandhorn.Connect thetwosmallconnectorstothehornandthelarge connectortothefrontheadlamp(Figure18).
3.Routetheharnesstotherearofthemachineto connecttherearheadlampsandnumberplatelamp. Feedthewirethroughtheleftrearbrackethole. Bendtherearheadlampplatetabtoaangleof90 degreeupwards,thenconnectthewires.Repeatthe sameprocessfortherightrearheadlamp(
Figure18).
Figure18).
Figure17
Z593only
1.Nuts(M5)4.Washer(M6x12)
2.Washer(1/4x3/4inch)5.Nuts(M6)
3.Bolts(M6x16)
6.Bracket
5.Z597only–Replacetheyellow20ampfusewith ablue30ampfuse.
6.Cabletietheharnesstotheframe,ensuringthatitis keptawayfromanyheatormovingparts(
Figure18).
7.Connecttheredandblackwireringterminalstothe battery(Figure18).
8.Replaceandsecureallcovers.
4.Z597–Feedthewirethroughtherearpanel(center slot)andthenumberplatelampgrommet.Connect theconnectorstotheplate.Securetherearlamp backingtotherearpanelwithabolt(M5x16), 2washers(1/4x3/4inch),and2nuts(M5) (Figure18).
Z593–Feedthewirethroughtherearpanel(center slot)andthenumberplatelampgrommet.Connect theconnectorstotheplate.Mountthenumberplate lamptothelampplatebracketusing2nuts(M5)and 2washers(1/4x3/4inch).Mounttheassemblyto therearpanelusing2bolts(M6x16),4washers(M6 x12),and2nuts(M6)(Figure17).
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G01601 1
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1.ForZ597only
Figure18
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Operation
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2
G016073
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G016074
SwitchFunctions
•Hazardwarningswitch—Operatesthehazard warninglights,andwillworkwhethertheignition isswitchedonoroff(Figure19).
–Pressthesideoftherockerswitchwiththe
hazardwarningsymboltoturnonthehazard warninglights.
–Presstheothersideoftherockerswitchtoturn
offthehazardwarninglights.
Figure20
1.Headlampanddipped beamswitch
2.Directionindicatorswitch
•Headlampanddippedbeamheadlampswitch— Operatestheheadlampsonlywhentheignitionis switchedon(Figure20).
–Pushthesliderforwardtoturnonthehead
lamp.
Figure19
1.Masterlightswitch2.Hazardwarningswitch
–Pushthesliderbackwardtoturnonthedipped
beamheadlamp.
•Hornswitch—Operatesthehornonlywhenthe
•Masterlightswitch—Operatesthefront,rear,and headlamps.Onlyworksiftheignitionisswitched on(Figure19).
ignitionisswitchedon.
–Pushthebuttontosoundthehorn.
–Releasethebuttontostopthehorn.
–Pressthesideoftherockerswitchwiththe
masterlightsymboltoturnonthelights.
–Presstheothersideoftherockerswitchtoturn
offthelights.
•Directionindicatorswitch—Operatestheright­andleft-handdirectionindicatorlights.Onlywork iftheignitionisswitchedon(
Figure20).
–Presstheleft-handsideoftheswitchtoggleto
turnontheleft-handdirectionindicatorlights.
–Presstheright-handsideoftheswitchtoggle
tothecentral(off)positiontoturnoffthe left-handdirectionindicatorlights.
–Presstheright-handsideoftheswitchtoggleto
turnontheright-handdirectionindicatorlights.
–Presstheleft-handsideoftheswitchtoggle
tothecentral(off)positiontoturnoffthe right-handdirectionindicatorlights.
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Maintenance
MaintenanceTips
•Checkthatalllightsareworkingonaregularbasis.
•Cleanalllensesregularlywithanonpetroleum-based cleaner.
•Ensurethatthedrainslotsarekeptclearofdebris.
•Ifthemowerisgoingtobestoredoutdoors,verify thatthelensissecuredproperlytopreventwater fromenteringthelights.
Headlights—replacingabulb:
1.Removethelenscover.
2.Replacethebulb.
3.Replacethelenscover.
4.Adjustthelightstoensuretheycomplywithlocal roadlegislation.
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TheToroTotalCoverageGuarantee
ALimitedWarranty
ConditionsandProductsCovered
TheT oro toanagreementbetweenthem,jointlywarrantyourToroCommercial product(“Product”)tobefreefromdefectsinmaterialsorworkmanship fortwoyearsor1500operationalhours*,whicheveroccursrst.This warrantyisapplicabletoallproductswiththeexceptionofAerators (refertoseparatewarrantystatementsfortheseproducts).Wherea warrantableconditionexists,wewillrepairtheProductatnocosttoyou includingdiagnostics,labor ,parts,andtransportation.Thiswarranty beginsonthedatetheProductisdeliveredtotheoriginalretailpurchaser. *Productequippedwithanhourmeter.
®
Companyanditsafliate,T oroWarrantyCompany ,pursuant
InstructionsforObtainingWarrantyService
YouareresponsiblefornotifyingtheCommercialProductsDistributoror AuthorizedCommercialProductsDealerfromwhomyoupurchasedthe Productassoonasyoubelieveawarrantableconditionexists.Ifyouneed helplocatingaCommercialProductsDistributororAuthorizedDealer ,or ifyouhavequestionsregardingyourwarrantyrightsorresponsibilities, youmaycontactusat:
CommercialProductsServiceDepartment themanufacturerWarrantyCompany
811 1LyndaleAvenueSouth Bloomington,MN55420-1 196 E-mail:commercial.warranty@toro.com
OwnerResponsibilities
AstheProductowner ,youareresponsibleforrequiredmaintenance andadjustmentsstatedinyourOperator’sManual.Failuretoperform requiredmaintenanceandadjustmentscanbegroundsfordisallowinga warrantyclaim.
ItemsandConditionsNotCovered
Notallproductfailuresormalfunctionsthatoccurduringthewarranty periodaredefectsinmaterialsorworkmanship.Thiswarrantydoesnot coverthefollowing:
•Productfailureswhichresultfromtheuseofnon-T ororeplacement
parts,orfrominstallationanduseofadd-on,ormodiednon-T oro brandedaccessoriesandproducts.Aseparatewarrantymaybe providedbythemanufactureroftheseitems.
•Productfailureswhichresultfromfailuretoperformrecommended
maintenanceand/oradjustments.Failuretoproperlymaintainyour ToroproductpertheRecommendedMaintenancelistedinthe Operator’sManualcanresultinclaimsforwarrantybeingdenied.
•ProductfailureswhichresultfromoperatingtheProductinan
abusive,negligentorrecklessmanner.
•Partssubjecttoconsumptionthroughuseunlessfoundtobe
defective.Examplesofpartswhichareconsumed,orusedup,during normalProductoperationinclude,butarenotlimitedto,brakes padsandlinings,clutchlinings,blades,reels,bedknives,tines, sparkplugs,castorwheels,tires,lters,belts,andcertainsprayer componentssuchasdiaphragms,nozzles,andcheckvalves,etc.
•Failurescausedbyoutsideinuence.Itemsconsideredtobeoutside
inuenceinclude,butarenotlimitedto,weather,storagepractices, contamination,useofunapprovedcoolants,lubricants,additives, fertilizers,water,orchemicals,etc.
•Normalnoise,vibration,wearandtear,anddeterioration.
•Normal“wearandtear”includes,butisnotlimitedto,damageto
seatsduetowearorabrasion,wornpaintedsurfaces,scratched decalsorwindows,etc.
Parts
Partsscheduledforreplacementasrequiredmaintenancearewarranted fortheperiodoftimeuptothescheduledreplacementtimeforthatpart. Partsreplacedunderthiswarrantyarecoveredforthedurationofthe originalproductwarrantyandbecomethepropertyofT oro.Torowill makethenaldecisionwhethertorepairanyexistingpartorassemblyor replaceit.T oromayuseremanufacturedpartsforwarrantyrepairs.
NoteRegardingDeepCycleBatteryWarranty:
Deepcyclebatterieshaveaspeciedtotalnumberofkilowatt-hoursthey candeliverduringtheirlifetime.Operating,recharging,andmaintenance techniquescanextendorreducetotalbatterylife.Asthebatteriesinthis productareconsumed,theamountofusefulworkbetweencharging intervalswillslowlydecreaseuntilthebatteryiscompletelywornout. Replacementofwornoutbatteries,duetonormalconsumption,isthe responsibilityoftheproductowner.Batteryreplacementmayberequired duringthenormalproductwarrantyperiodatowner’sexpense.
MaintenanceisatOwner’sExpense
Enginetune-up,lubricationcleaningandpolishing,replacementof ItemsandConditionsNotCoveredlters,coolant,andcompleting RecommendedMaintenancearesomeofthenormalservicesT oro productsrequirethatareattheowner’sexpense.
GeneralConditions
RepairbyanAuthorizedT oroDistributororDealerisyoursoleremedy underthiswarranty .
NeitherTheToroCompanynorToroWarrantyCompanyisliablefor indirect,incidentalorconsequentialdamagesinconnectionwiththe useoftheToroProductscoveredbythiswarranty,includingany costorexpenseofprovidingsubstituteequipmentorserviceduring reasonableperiodsofmalfunctionornon-usependingcompletion ofrepairsunderthiswarranty.ExceptfortheEmissionswarranty referencedbelow,ifapplicable,thereisnootherexpresswarranty.
Allimpliedwarrantiesofmerchantabilityandtnessforusearelimitedto thedurationofthisexpresswarranty.Somestatesdonotallowexclusions ofincidentalorconsequentialdamages,orlimitationsonhowlongan impliedwarrantylasts,sotheaboveexclusionsandlimitationsmaynot applytoyou.
Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveother rightswhichvaryfromstatetostate.
CountriesOtherthantheUnitedStatesorCanada
CustomersshouldcontacttheirthemanufacturerDistributor(Dealer)toobtainguaranteepoliciesforyourcountry,province,orstate.Ifforanyreason youaredissatisedwithyourDistributor’sserviceorhavedifcultyobtainingguaranteeinformation,contactthethemanufacturerimporter.Ifallother remediesfail,youmaycontactusatthemanufacturerWarrantyCompany.
374-0277RevA
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