Form No. 3440-885 Rev A Road Light Kit LT2240 Compact Triple 4-Wheel Drive Turf Mower, LT3340 Triple Reel Mower, or LT-F3000 Triple Flail Mower Model No. 02850—Serial No. 400000000 and Up Installation Instructions This product complies with all relevant European directives; for details, please see the Declaration of Incorporation (DOI) at the back of this publication. Important: The wiring system for this machine is designed for use with LED lights only. Use Toro-supplied lights only.
Installation Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Qty. Use 1 No parts required – Prepare the machine. 2 Right, rear light assembly Left, rear light assembly Bolt (16 x 110 mm) Flange nut (16 mm) 1 1 2 2 Install the ROPS components. 3 Adhesive reflector 2 Apply the adhesive reflectors.
Procedure Description Use Qty. 14 No parts required – Connect the battery. 15 Hydraulic test equipment 260 to 325 bar (3771 to 4714 psi) with a quick-disconnect fitting (facility-provided) . Prepare to test hydraulic pressure. 16 Hydraulic test equipment 260 to 325 bar (3771 to 4714 psi) with a Quick-Connect Fitting (machines without the optional differential-lock kit) or a Minimess™ fitting (machines with the optional differential-lock kit)—facility provided .
Opening the Hood Models 31654 Unlatch and open the hood. Disconnecting the Battery 1. Loosen the forward nut of the negative battery-cable terminal (Figure 4). g290372 Figure 2 Removing the Storage Compartment Models 31657 and 31659 1. At the left side of the operator’s platform, open the door of the storage compartment (Figure 3). g344733 Figure 4 1. Nut (negative battery-cable terminal) 2. 2. Negative battery post Lift the negative battery cable from the battery post (Figure 4).
2 Installing the ROPS Components Parts needed for this procedure: 1 Right, rear light assembly 1 Left, rear light assembly 2 Bolt (16 x 110 mm) 2 Flange nut (16 mm) g344222 Procedure 1. Figure 6 Right side shown Remove the pivot bolt (16 x 100 mm) and flange nut (16 mm) from the right side of the roll bar (Figure 5). 1. New bolt (16 x 110 mm) 2. Right, rear light assembly Discard the pivot bolt (16 x 100 mm) and flange nut (16 mm). 3. g344223 Figure 5 1. Pivot bolt (16 x 100 mm) 2. 3.
3 Applying the Adhesive Reflectors Parts needed for this procedure: 2 Adhesive reflector Procedure Apply the 2 adhesive reflectors to the rear of the engine cover (Figure 7 or Figure 8).
4 Installing the Switches Parts needed for this procedure: 1 Headlight switch 1 Turn signal switch 1 Hazard switch For Model 31654 1. Remove the plugs shown in from the control arm (Figure 9 and Figure 10). Discard the plugs. g344364 Figure 10 2. Remove the instrument panel and switch plate from the control arm (Figure 11 and Figure 12). Retain the fasteners for later installation. g344366 Figure 9 g344365 Figure 11 1. Button-head screw (4 x 16 mm) 7 2.
g344362 Figure 14 g344367 Figure 12 1. Button-head screw (8 x 20 mm) 3. 1. Headlight switch 2. Switch plate 5. Pull through the terminal blocks with the following labels: • HEADLIGHT SWITCH • TURN SIGNAL SWITCH • HAZARD SWITCH 4. 2. Hazard switch Connect the 3 switches to the corresponding terminal blocks (Figure 13 and Figure 14). g344363 Figure 13 1. Turn signal switch 8 Install the previously removed instrument panel and switch plate from the control arm (Figure 11 and Figure 12).
For Models 31657 and 31659 1. Remove the control-arm cover from the control arm to help access the terminal blocks (Figure 15). g344286 Figure 17 3. Pull through the terminal blocks with the following labels: • HEADLIGHT SWITCH g344284 • TURN SIGNAL SWITCH Figure 15 1. Phillips-head screw • HAZARD SWITCH 2. Control-arm cover 4. 2. Remove the plugs shown in from the control arm (Figure 16 and Figure 17). Connect the 3 switches to the corresponding terminal blocks (Figure 18 and Figure 19).
g344282 Figure 19 1. Hazard switch 2. Turn signal switch 5 g344461 Figure 20 Assembling the Front Light Bar Assembly 1. New hex-head bolt (12 x 80 mm) 4. Previously removed lock washer (12 mm) 2. Right light assembly 5. Previously removed locknut (12 mm) 3. Front light bar assembly Parts needed for this procedure: 1 Front light bar assembly 1 Right light assembly 1 Left light assembly 2 Hex-head bolt (12 x 80 mm) 3. Procedure 1. Remove the fasteners from the right light assembly.
6 Installing the Light Bar Mounting Brackets Parts needed for this procedure: 2 Light bar mount 4 Flange nut (8 mm) 4 Flange-head bolt (8 x 30 mm) 4 Washer (8 mm) Identifying the Mounting Bracket Hole Positions g344485 Figure 22 1. Model 31654 2. Model 31657 3. Model 31659 Note: You can also refer to the decal on the light bar (Figure 23) for information about the mounting bracket hole positions.
Assembling the Mounting Brackets to the Light Bar 1. Align the holes in the mounting bracket with the holes in the arm of the light bar (Figure 24) that you identified in Identifying the Mounting Bracket Hole Positions (page 11). Note: Ensure that the tab of the mounting bracket is aligned away from the light assembly. g345100 Figure 24 1. Flange locknut (8 mm) 4. Bolt (8 x 65 mm) 2. Tab (mounting bracket) 5. Light bar arm 3. Washer (8 mm) 2.
7 Installing the Light Bar Parts needed for this procedure: 1 Decal g344557 Figure 27 Model 31657 Procedure 1. Align the holes in the light bar mounting brackets with the holes in the latch plate and pivot-arm plate (Figure 25, Figure 26, or Figure 27). 2. Loosely assemble the mounting bracket to the latch plate (Figure 28) with a flange-head capscrew (6 x 25 mm) and flange locknut (6 mm). 3.
8 Installing the Brake-Pressure Transducer g344293 Parts needed for this procedure: 1 Pressure transducer 1 Fitting (3/4 x 7/16 inch) 1 Adapter fitting (1/4 x 7/16 inch) 1 Seal (1/4 inch)—For Machines with the Differential Lock Kit installed only For Model 31654 1. At the right side of the traction pump, remove the plug from the T-fitting at port B of the traction pump (Figure 29). g344289 Figure 29 1. T-fitting (traction pump port B) 3. Adapter fitting (1/4 x 7/16 inch) 2. Plug 14 2.
g344293 Figure 32 8. g344291 Figure 30 1. Adapter fitting (1/4 x 7/16 inch) Remove the cap from the brake pressure sensor connector (Figure 33). 2. Brake-pressure transducer 5. Torque the brake-pressure transducer to 27 N∙m (20 ft-lb). 6. Remove the cable tie that secures the 3-pin connector of the machine wire harness labeled BRAKE PRESSURE SENSOR to the hose adjacent to the forward traction manifold (Figure 31). g344325 Figure 33 g344439 Figure 31 3. Brake pressure sensor 1. Cap 2.
For Models 31657 and 31659 1. At the right side of the traction pump, remove the plug from port MB of the pump (Figure 34). g344080 Figure 35 g343559 1. Reducer fitting (3/4 x 7/16 inch) 4. 5. 2. Brake-pressure transducer Torque the transducer to 27 N∙m (20 ft-lb). Remove the cable tie that secures the 3-pin connector of the machine wire harness labeled BRAKE PRESSURE SENSOR to the hose adjacent to the forward traction manifold (Figure 36). g344440 Figure 36 1.
g343559 g344072 Figure 39 1. 3-pin connector (labeled g344073 BRAKE PRESSURE SENSOR—machine Figure 38 1. 3-pin connector—machine wire harness (labeled BRAKE PRESSURE SENSOR) wire harness) 3. Brake-pressure transducer 2. 2. Cap 8. 2. Brake-pressure transducer Remove the brake-pressure transducer from the reducer fitting (Figure 40). Note: Retain the pressure transducer for later installation.
g344907 Figure 41 1. Port-MB (traction pump) 3. Straight fitting (3/8 x 3/4 inch) 2. Reducer fitting (3/4 x 7/16 inch) 4. Install the straight fitting (3/8 x 3/4 inch) into port-MB of the traction pump (Figure 41). 5. Torque the straight fitting to 163 N∙m (120 ft-lb).
2. 9 Secure the number plate to the number-plate bracket using 2 flange-head bolts (6 x 20 mm) and 2 flange nuts (6 mm) as shown in Figure 43. Assembling the Number Plate Parts needed for this procedure: 1 Number plate 1 Number-plate bracket 1 Number-plate light 2 Phillips-head screw (#6 x 1 inch) 2 Locknut (#6) 2 Flange-head bolt (6 x 20 mm) 2 Flange nut (6 mm) g344532 Figure 43 Procedure 1.
4. 10 Drill 1 hole (5 mm) to the left of the number light (Figure 45). Installing the Number and Light Parts needed for this procedure: 2 Flange-head bolt (6 x 20 mm) 4 Washer 2 Flange nut (6 mm) Procedure 1. Place the assembled number plate onto the plastic bulkhead and push the number plate as far forward as possible. 2. Center the assembled number plate on the plastic bulkhead. 3.
11 Routing the Wire Harness Parts needed for this procedure: 1 Light kit wire harness 6 Adhesive clamp 2 Tube insert 8 Cable tie Placing the Wire Harness Overview Refer to Figure 47 for an overview of where the wire harness routes on the machine. g344560 Figure 46 1. Assembled number plate 3. Washers 2. Flange-head bolt (6 x 20 mm) 4. Flange nut (6 mm) 6. Route the wiring from the number light through the 5 mm hole.
Routing and Connecting the Wire Harness to the Front Light Bar Assembly 1. Route the wire harness through the opening in the front arm pivot-plate mount and then through the latch plate (Figure 48). 2. Secure the harness to the front arm pivot-plate mount using 2 adhesive clamps (Figure 48). g344617 Figure 50 6. Connect the wire-harness connectors to the right and left light assemblies (Figure 51). g345099 Figure 48 3.
Routing and Connecting the Wire Harness at the Rear of the Machine 1. Remove the plastic bulkhead to access the electrical connector with the number plate assembly attached. 2. Connect the black wire on the number light to the number 2 on the deutsch connector (Figure 53). 3. Connect the white wire on the number light to the number 1 on the deutsch connector (Figure 53). 4. Connect the number-light breakout to the main wire harness near the plastic bulkhead.
g028923 Figure 57 1. Fuse (10 A) g344628 2. Fuse (15 A) Figure 56 2. 8. Secure the harness using the cable ties. At the back of the electrical-mount panel, plug the flasher relay into an open relay socket (Figure 58). 12 Installing the Fuses and Flasher Relay For Model 31654 Parts needed for this procedure: 1 Fuse (10 A) 1 Fuse (15 A) 1 Flasher relay g295696 Figure 58 1. Relay socket Procedure 1. Install the fuse (10 A) and fuse (15 A) beneath the horn as shown in Figure 57. 24 2.
13 Installing the Fuses and Flasher Relay For Models 31657 and 31659 Parts needed for this procedure: g345585 2 Mini fuse (7.5 A) 1 Flasher relay Figure 60 1. Flasher relay Procedure 1. Remove the fuse-block cover located next to the battery (Figure 59). 5. Plug in the connector and secure it using a cable tie. 6. Install the control-arm cover (Figure 61). g328464 Figure 59 1. Fuse block 2. Fuse-block cover g344284 Figure 61 2. Install the 2 mini fuses (7.
Closing the Hood 14 Models 31654 Close and latch the hood. Connecting the Battery Installing the Storage Compartment No Parts Required Models 31657 and 31659 Connecting the Battery 1. 1. Align the holes on the bottom of the storage compartment with the holes in the chassis brackets. 2. Assemble the storage compartment to the machine with the 3 knobs and 3 washers (Figure 63). Assemble the terminal of the negative battery cable (Figure 62) onto the negative battery post. g344733 Figure 62 1.
15 Preparing to Test the Hydraulic Pressure Model 31654 Parts needed for this procedure: . Hydraulic test equipment 260 to 325 bar (3771 to 4714 psi) with a quick-disconnect fitting (facility-provided) g344291 Figure 65 1. Adapter fitting (T-fitting—traction pump port-B) Installing the Quick-Connect Fitting 1. 3. At the right side of the traction pump, remove the 3-pin connector labeled BRAKE PRESSURE SENSOR from the brake-pressure transducer (Figure 64). 2.
16 Preparing to Test the Hydraulic Pressure Models 31657 and 31659 Parts needed for this procedure: g344403 Figure 67 . 6. Connect the battery, lower the hood, and perform the hydraulic-pressure test; refer to Connecting the Battery (page 26), Closing the Hood (page 26), and 17 Testing the Hydraulic Pressure (page 31). Installing the Quick-Connect Fitting Preparing the Traction Pump 1.
Compartment (page 26), and 17 Testing the Hydraulic Pressure (page 31). Preparing the Traction Pump Machines without the Optional Differential-Lock Kit 1. At the right side of the traction pump, assemble the test equipment onto the quick-connect fitting (Figure 73). g344080 Figure 70 1. Reducer fitting (3/4 x 7/16 inch) 3. 2. Brake-pressure transducer Assemble the quick-connect fitting (Figure 71) into the reducer fitting. g343559 g344071 Figure 71 1. Reducer fitting (3/4 x 7/16 inch) g344077 2.
Preparing the Forward Traction Manifold 5. Machines with the Optional Differential-Lock Kit 1. Unlatch and raise the operator’s platform; refer to the Operator’s Manual. 2. At the front traction manifold, remove the dust cap from the Minimess fitting in port-TPB (Figure 74). g344122 Figure 74 1. Dust cap 3. 2. Minimess fitting (port-TPB—front traction manifold) Assemble the test equipment onto the Minimess fitting (Figure 75).
Hydraulic-Pressure Table 17 Testing the Hydraulic Pressure Model Normal Pressure Range 31654 300 to 325 bar (4351 to 4713 psi) 31657 and 31659 260 to 280 bar (3771 to 4061 psi) Important: If the hydraulic pressure measurements are lower than or higher than the normal pressure range, contact Toro customer care. No Parts Required Procedure 1. 9. Start the engine and move the machine to a level, open area. Important: The area to the rear and around the machine must be clear. 2.
18 Finishing the Hydraulic Test Model 31654 No Parts Required g344321 Installing the Brake-Pressure Transducer 1. Figure 77 1. Adapter fitting Disconnect the test equipment from the quick-connect fitting (Figure 76). 3. 2. Quick-connect fitting Assemble the brake-pressure transducer into the adapter fitting (Figure 78). g344293 g344291 Figure 78 1. Adapter fitting (1/4 x 7/16 inch) g344346 Figure 76 2. Remove the quick-connect fitting from the adapter fitting (Figure 77).
g344324 Figure 79 1. Brake-pressure transducer g344317 Figure 81 2. 3-pin connector (labeled BRAKE PRESSURE SENSOR) 19 Installing the Dust Cap Machines without the Optional Road Light Kit 1. Finishing the Hydraulic Test Disconnect the test equipment from the quick-connect fitting (Figure 80). Models 31657 and 31659 No Parts Required Installing the Brake-Pressure Transducer g344293 Machines with the Optional Road Light Kit—and without the Optional Differential-Lock Kit 1. g344319 Figure 80 2.
g343559 g344080 Figure 84 1. Reducer fitting (3/4 x 7/16 inch) 4. Torque the transducer to 27 N∙m (20 ft-lb). 5. Plug the 3-pin connector of the machine wire harness labeled BRAKE PRESSURE SENSOR into the connector of the pressure transducer (Figure 85). g344106 Figure 82 2. 2. Brake-pressure transducer Remove the quick-connect fitting from the reducer fitting (Figure 83). Note: Retain the quick-connect fitting. g344072 Figure 85 1. 3-pin connector (labeled BRAKE PRESSURE SENSOR) g344071 2.
g343559 g344124 Figure 88 3. Install the dust cap over the Minimess fitting in port-TPB (Figure 89). g344105 Figure 86 2. Assemble the dust cap over the quick-connect fitting (Figure 87). g344122 Figure 89 1. Dust cap g344079 Figure 87 4. Installing the Dust Cap Machines with the Optional Differential-Lock Kit 1. Raise the operator’s platform; refer to the Operator’s Manual. 2. Remove the test equipment from port-TPB of the front traction manifold (Figure 88). 35 2.
20 Calibrating the Brake-Pressure Transducer No Parts Required Model 31654 1. Open the hood. 2. Locate and plug the diagnostic cable into the CAN DIAGNOSTIC PORT (2-pin connector) located near the main contoller (left side of the engine). Contact your authorize Toro distributor for a cable. 3. Plug the cable into the computer. 4. Open the DANFOSS PLUS 1 program. Contact your authorize Toro distributor for access to this program. 5.
g345520 Figure 91 37
Models 31657 and 31659 1. Remove the control-arm cover from the control arm to help access the terminal blocks (Figure 92). g344284 Figure 92 1. Phillips-head screw 2. 2. Control-arm cover Locate and plug the diagnostic cable into the CAN DIAGNOSTIC PORT. Contact your authorize Toro distributor for a cable. 3. Plug the cable into the computer. 4. Open the Toro Diag progam at ToroConnect. 5. Select T:Primary located on the left side of the screen (Figure 93). 6.
g345518 Figure 93 39
21 Completing the Installation No Parts Required Lowering the Operator’s Platform WARNING g290369 Figure 95 Operating the machine with the platform unlatched may cause you to lose control of the machine, resulting in serious injury to you and bystanders. 1. Platform-latch handle 3. Never operate the machine without first checking that the operator platform latching mechanism is fully engaged and in good working order. 1. 2.
Brake Lights Operation The brake lights automatically turn on when the machine is decelerating (when the control pedal is returning to neutral, when travelling in a forward direction only). Position the marker lights (front and rear). Press the top of the switch—the switch will illuminate and the red (rear) and white (front) marker lights will turn on. Adjusting the Headlights Maintenance Adjust the headlights so that the horizontal part of the cut-off of the beam is tilted downward at 2.0%. 1.
Declaration of Incorporation The Toro Company, 8111 Lyndale Ave. South, Bloomington, MN, USA declares that the following unit(s) conform(s) to the directives listed, when installed in accordance with the accompanying instructions onto certain Toro models as indicated on the relevant Declarations of Conformity. Model No. 02850 Serial No.
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The Toro Warranty Two-Year or 1,500 Hours Limited Warranty Parts Conditions and Products Covered The Toro Company warrants your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for 2 years or 1,500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
