Form No. 3368-218 Rev A Light Kit Groundsmaster 7200 Series Mowers Model No. 02841—Serial No. 311000001 and Up Installation Instructions Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 6 © 2011—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Description Qty. Use No parts required – Prepare to install the kit.
Procedure 7 8 9 Description Use Qty. Left-hand indicator headlamp Right-hand indicator headlamp 1 1 No parts required – Install the lights, horn, and combination switch. No parts required – Finish the installation. No parts required – Set the headlights. 1 Preparing to Install the Kit No Parts Required Procedure Important: You will need to install the Auxiliary Power Unit (model 30382) on your machine to complete this kit. 1. Move the machine to level ground and set the parking brake. 2.
Figure 3 1. UNC bolts Figure 2 1. Control panel top 2. Master lights switch Note: Save the bolts for future use. 3. Hazard warning switch 4. Knockout plugs 2. Loosen the 2 retaining bolts on the diesel tank (Figure 4 and Figure 5) just enough to slide the front light brackets between the platform and the tank (Figure 6 and Figure 7). 3. Insert the master lights switch and the hazard warning switch as shown in Figure 2. Note: Position the lens on the switches away from the operator.
Figure 5 Figure 7 Left-Hand Side 1. Retaining bolt 1. Drill 5 mm hole here 2. Slide the board into position 3. UNC bolt 3. Secure the brackets in place with the 2 UNC bolts previously removed. 4. Drill a 5 mm hole in each of the boards in the position shown in Figure 6 and Figure 7. 5. Secure the front light brackets in place with 2 self-tapping bolts (M6) provided in the kit. Note: Apply a dab of grease to the bolt thread to make assembly easier. Figure 6 Right-Hand Side 1.
4 Assembling and Installing the Tail Board Parts needed for this procedure: Figure 8 1. 2. 3. 4. 5. Headlamp Hex-head bolt (M8-20) Washer (M8) Front light board Washer (part of headlamp) 6. 7. 8. 9. Nut (part of headlamp) Horn Washer (M8) Locknut (M8) 8. Secure the right-hand headlamp to the right-hand light bracket.
5. Use a drill to enlarge 2 existing holes in the rear cross member (located behind the seat) to 8.5 mm diameter (Figure 11). Figure 11 1. Seat Figure 9 1. 2. 3. 4. 5. Rear speed decal bracket License plate bracket Light bracket brace Right light bracket Left light bracket 6. 7. 8. 9. Locknut (M8) Washer (M8) Hex-head bolt (M8-25) Main light bracket 6. Secure the lighting board to the rear cross member with 2 bolts (M8), 4 washers (M8), 2 nylon spacers, and 2 locknuts (M8) (Figure 10). 2.
5 Installing the Combination Switch Assembly Parts needed for this procedure: 1 Combination assembly switch 1 Adapter switch mount Procedure Figure 13 1. To install the adaptor switch mount, cut 40 mm off the right-hand motion control lever (Figure 12). 1. Combination switch assembly 2. bolts (2) Note: Use a 2-part epoxy resin to glue the adaptor into the lever tube. G015998 1 Figure 12 1. Cut 40 mm off here 2.
6 Installing the Wiring Harness Parts needed for this procedure: 1 Wiring harness 1 Hex-head bolt (M8) 1 Locknut (M5) 2 Washer (M5) 1 Hex-head bolt (M5) 2 Washer (M4) 1 Locknut (M4) 1 Hex-head bolt (M4-12) 10 Short cable tie 10 Long cable tie 1 20-amp fuse 1 Left-hand indicator headlamp 1 Right-hand indicator headlamp Figure 14 1. Combination assembly switch 2. Left-hand indicator headlamp 3. Horn 4. Right-hand indicator headlamp 5. Left-hand rear lamp 6. License plate lamp 7.
5. Insert the flasher relay. 6. Plug the twin pink wire (male-blade terminal) into the pink wire of the main wire harness (female receptacle) (switched positive) as shown in Figure 15. 7. Plug the red wire (male-blade terminal) into the red wire of the main wire harness (female receptacle) (switched positive); refer to Figure 15. 8. Replace the 10-amp fuse with the 20-amp fuse from the kit (Figure 15). 9.
3. Connect the red/white wire to the 5W side of the side tail light bulb (Figure 18). Connecting to the Right-hand Headlight 1. Route the last branch of the wire harness with connectors to the combination switch assembly and the right-hand lamp and indicator (Figure 12) through the right-hand chassis at the rear wheel toward the headlight (Figure 16). 4. Place the lamp assembly inside the rubber housing (ensure that the indicator bulb is on the outside), and press the lens into place.
Operation 9 Operating the Switches Setting the Headlights • The hazard warning switch operates the hazard warning lights and will work whether the ignition is switched to ON or OFF (Figure 20). No Parts Required 1 Procedure To comply with the road vehicle lighting regulations, adjust the front dipped beam headlights so that the horizontal part of the cutoff of the beam is inclined downward 1.3% (0.75 degree).
Maintenance • Keep the lenses clean by wiping them with a damp cloth. Do not use solvent-based cleaners. • Replace all light bulbs as needed. Use replacement bulbs that have the proper voltage and wattage rating; refer to the old bulb for details. Figure 21 1. Headlamp and dipped beam switch 2. Horn button 3. Direction indicator switch – Press the left-hand side of the switch toggle to turn on the left-hand direction indicator lights.
