Page 1
LightKit
Z580SeriesMowers
ModelNo.02840
Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
FormNo.3368-211RevB
InstallationInstructions
Procedure
1
2
3
Rearlightbracket
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
Procedure
Numberplatelampassembly
4
Lampplatebracket
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:
2
4
Washer(5/16inch)
4
Nut(M8)
4
Bolt(M8x75)
4
Washer(M8)
4
Bolt(M5x16)
8
Washer(M5)
4
Nut(M5)
2
2
Reector
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).
2
Page 3
G016005 
1 
2 
3 
4 
5 
4 
6 
7 
8 
9 
10 
Figure2
1.Washers(M8)
2.Bolts(M8x75)6.Nuts(M5)
3.Bolts(M5x16)7.Washers(5/16 
inch)
4.Washers(M5)
9.Bracket
4.Mountthereectortothebracketusing2bolts(M5 
x16),4washers(M5),and2nuts(M5)(Figure2).
5.Mounttherearlamptothebracketusing2starx 
washersand2nutsincludedwiththelampassembly
Figure3).
(
Figure3
1.Rearlamp
2.Nut(includedwithrear 
lamp)
3.Starxwasher(included 
withrearlamp)
4.ROPS
5.Bracket
6.Repeatsteps2-5fortheoppositeside.
2
MountingtheHeadLampsand 
Horn
Partsneededforthisprocedure:
1
Lefthandheadlamp
1
2
1
Bolt(M8x20)
2
Washer(M8)
1
Nut(M8)
1
Procedure
1.Locatethetwoboltsalongtheleftsiderailand 
removethe2boltsand2nuts(Figure4).
3
Page 4
Figure4
Leftsiderail
1.Removethesenutsandbolts.
2.Mountafrontlightbrackettotheleftsiderailusing 
theremovednutsandbolts(Figure5).
Figure6
Rightsiderail
1.Removethesenutsandbolts.
5.Mountthehorntotheleftsidebracketasshownin 
Figure7.Secureitwithabolt(M8x20),2washers 
(M8),andanut(M8).
Figure5
1.Bolt(existing)
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)
2.Washer(M8)
3.Leftheadlamp
4.Horn
4
Page 5
Note:Allburrsmustberemovedfromtheedgesto 
avoiddamagetothewires.
3
InstallingtheSwitches
Partsneededforthisprocedure:
2
1
Switchpanel
1
Combinationswitchassembly
1
1
1
1
1
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
5
Page 6
Figure10
1.Lightingswitch 
lens
2.Hazardswitch 
lens
3.Blankswitches
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 
plugintheasherrelay(Figure12).
6
Page 7
Figure14
1.Existingconnector
2.Redwire
Figure15
1.Thickpinkwire
2.Thinpinkwire
3.Femalebulletconnector
Figure16
1.Screws
9.Crimpapiggybackconnectortotheredwireonthe 
lightingharness.removethesingleconnectorfrom 
theignitionswitch.Connectthepiggybacktothis 
position,thenreconnecttheremovedconnectorto 
thepiggyback(
Figure14).
10.Cutthethinpinkwirehalfwayup,striptheinsulation, 
andconnectittothebluefemalebulletcrimp 
terminal.Thencrimpthemalebullettotheredwire 
onthelightingharnessandconnectittotheignition 
switchinthepositionindicatedbyFigure15.
11.Retthecontrolpanel,thenttheswitchpanelto 
therightsideofthecontrolpanelusing2existing 
screws(
Figure16).
7
Page 8
4
RoutingtheWiringHarness
Partsneededforthisprocedure:
1
2
Bolt(M5x16)
4
Washer(1/4x3/4inch)
4
Nut(M5)
1
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)
2.Washer(1/4x3/4inch)
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).
8
Page 9
1.ForZ597only
Figure18
9
Page 10
Operation
SwitchFunctions
•
–Pressthesideoftherockerswitchwiththe
hazardwarningsymboltoturnonthehazard 
warninglights.
–Presstheothersideoftherockerswitchtoturn
offthehazardwarninglights.
Figure20
1.Headlampanddipped 
beamswitch
2.Directionindicatorswitch
•
–Pushthesliderforwardtoturnonthehead
lamp.
Figure19
1.Masterlightswitch
–Pushthesliderbackwardtoturnonthedipped
beamheadlamp.
•
•
ignitionisswitchedon.
–Pushthebuttontosoundthehorn.
–Releasethebuttontostopthehorn.
–Pressthesideoftherockerswitchwiththe
masterlightsymboltoturnonthelights.
–Presstheothersideoftherockerswitchtoturn
offthelights.
•
Figure20).
–Presstheleft-handsideoftheswitchtoggleto
turnontheleft-handdirectionindicatorlights.
–Presstheright-handsideoftheswitchtoggle
tothecentral(off)positiontoturnoffthe 
left-handdirectionindicatorlights.
–Presstheright-handsideoftheswitchtoggleto
turnontheright-handdirectionindicatorlights.
–Presstheleft-handsideoftheswitchtoggle
tothecentral(off)positiontoturnoffthe 
right-handdirectionindicatorlights.
10
Page 11
Maintenance
MaintenanceTips
•
•
•
•
Headlights—replacingabulb:
1.Removethelenscover.
2.Replacethebulb.
3.Replacethelenscover.
4.Adjustthelightstoensuretheycomplywithlocal 
roadlegislation.
11
Page 12
TheToroTotalCoverageGuarantee
ALimitedWarranty
ConditionsandProductsCovered
TheT oro 
toanagreementbetweenthem,jointlywarrantyourToroCommercial 
product(“Product”)tobefreefromdefectsinmaterialsorworkmanship 
fortwoyearsor1500operationalhours*,whicheveroccursrst.This 
warrantyisapplicabletoallproductswiththeexceptionofAerators 
(refertoseparatewarrantystatementsfortheseproducts).Wherea 
warrantableconditionexists,wewillrepairtheProductatnocosttoyou 
includingdiagnostics,labor ,parts,andtransportation.Thiswarranty 
beginsonthedatetheProductisdeliveredtotheoriginalretailpurchaser. 
*Productequippedwithanhourmeter.
®
Companyanditsafliate,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,ormodiednon-T oro 
brandedaccessoriesandproducts.Aseparatewarrantymaybe 
providedbythemanufactureroftheseitems.
•Productfailureswhichresultfromfailuretoperformrecommended 
maintenanceand/oradjustments.Failuretoproperlymaintainyour 
ToroproductpertheRecommendedMaintenancelistedinthe 
Operator’sManual canresultinclaimsforwarrantybeingdenied.
•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.
•Failurescausedbyoutsideinuence.Itemsconsideredtobeoutside 
inuenceinclude,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 
makethenaldecisionwhethertorepairanyexistingpartorassemblyor 
replaceit.T oromayuseremanufacturedpartsforwarrantyrepairs.
NoteRegardingDeepCycleBatteryWarranty:
Deepcyclebatterieshaveaspeciedtotalnumberofkilowatt-hoursthey 
candeliverduringtheirlifetime.Operating,recharging,andmaintenance 
techniquescanextendorreducetotalbatterylife.Asthebatteriesinthis 
productareconsumed,theamountofusefulworkbetweencharging 
intervalswillslowlydecreaseuntilthebatteryiscompletelywornout. 
Replacementofwornoutbatteries,duetonormalconsumption,isthe 
responsibilityoftheproductowner.Batteryreplacementmayberequired 
duringthenormalproductwarrantyperiodatowner’sexpense.
MaintenanceisatOwner’sExpense
Enginetune-up,lubricationcleaningandpolishing,replacementof 
ItemsandConditionsNotCoveredlters,coolant,andcompleting 
RecommendedMaintenancearesomeofthenormalservicesT oro 
productsrequirethatareattheowner’sexpense.
GeneralConditions
RepairbyanAuthorizedT oroDistributororDealerisyoursoleremedy 
underthiswarranty .
NeitherTheToroCompanynorToroWarrantyCompanyisliablefor 
indirect,incidentalorconsequentialdamagesinconnectionwiththe 
useoftheToroProductscoveredbythiswarranty,includingany 
costorexpenseofprovidingsubstituteequipmentorserviceduring 
reasonableperiodsofmalfunctionornon-usependingcompletion 
ofrepairsunderthiswarranty.ExceptfortheEmissionswarranty 
referencedbelow,ifapplicable,thereisnootherexpresswarranty.
Allimpliedwarrantiesofmerchantabilityandtnessforusearelimitedto 
thedurationofthisexpresswarranty.Somestatesdonotallowexclusions 
ofincidentalorconsequentialdamages,orlimitationsonhowlongan 
impliedwarrantylasts,sotheaboveexclusionsandlimitationsmaynot 
applytoyou.
Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveother 
rightswhichvaryfromstatetostate.
CountriesOtherthantheUnitedStatesorCanada
CustomersshouldcontacttheirthemanufacturerDistributor(Dealer)toobtainguaranteepoliciesforyourcountry,province,orstate.Ifforanyreason 
youaredissatisedwithyourDistributor’sserviceorhavedifcultyobtainingguaranteeinformation,contactthethemanufacturerimporter.Ifallother 
remediesfail,youmaycontactusatthemanufacturerWarrantyCompany.
374-0277RevA