FormNo.3368-211RevB
LightKit
Z580SeriesMowers
ModelNo.02840
InstallationInstructions
Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescription
Qty.
Use
Rearlightbracket2
Washer(5/16inch)
4
Nut(M8)
4
Bolt(M8x75)
4
Washer(M8)
4
Bolt(M5x16)
4
Washer(M5)
8
Nut(M5)
4
Rearlamp2
1
Reector
2
MountthelampstotheROPS.
Lefthandheadlamp
1
Righthandheadlamp1
Frontlightbracket2
Bolt(M8x20)
1
Washer(M8)
2
Nut(M8)
1
2
Horn1
Mounttheheadlampsandhorn
Blankswitch2
Switchpanel
1
Combinationswitchassembly
1
Adaptorswitchmount1
Hazardswitch1
Lightingswitch1
Hazardswitchlens1
Lightingswitchlens1
Grommet
2
Cabletie
1
Bolt(M5)
1
Washer(M5)
1
Nut(M5)
1
Screw
1
Crimpterminal—Piggyback
1
Crimpterminal—Malebullet
1
3
Crimpterminal—Femalebullet
1
Installthefrontswitches.
©2011—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.
OriginalInstructions(EN)
PrintedintheUK.
AllRightsReserved
ProcedureDescription
Qty.
Use
Numberplatelampassembly1
Bolt(M5x16)
2
Washer(1/4x3/4inch)
4
Nut(M5)
4
Lampplatebracket1
Bolt(M6x16)
2
Washer(M6x12)
4
Nut(M6)
2
4
30ampfuse
1
Routethewiringharness.
CAUTION
Ifyouleavethekeyintheignitionswitch,someone
couldaccidentallystarttheengineandseriously
injureyouorotherbystanders.
Parkthemachineonalevelsurface,applythe
parkingbreak,removethekeyfromtheignition,
anddisconnectthebatteryterminals.
Note:Referencesinthismanualtorightandleftare
determinedfromstandardoperatingposition.
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
Reector
Procedure
1.Measure580mm(23inches)fromthegroundtothe
ROPSandmarkboththeleftandrighthandside
(Figure1).
G015994
580mm
Figure1
2.Lifttheenginecover.
3.Alignthebottomofthebracketalongthemarkon
theROPS.SecurethebrackettotheROPSusing2
bolts(M8x75),2washers(M8),2washers(5/16
inch),and2nuts(M8)(Figure2).
2
G016005
1
2
3
4
5
4
6
7
8
9
10
Figure2
1.Washers(M8)5.Reector
9.Bracket
2.Bolts(M8x75)6.Nuts(M5)10.ROPS
3.Bolts(M5x16)7.Washers(5/16
inch)
4.Washers(M5)8.Nuts(M8)
4.Mountthereectortothebracketusing2bolts(M5
x16),4washers(M5),and2nuts(M5)(Figure2).
5.Mounttherearlamptothebracketusing2starx
washersand2nutsincludedwiththelampassembly
(
Figure3).
G016006
1
2
3
4
5
Figure3
1.Rearlamp
4.ROPS
2.Nut(includedwithrear
lamp)
5.Bracket
3.Starxwasher(included
withrearlamp)
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).
3
G015996
Figure4
Leftsiderail
1.Removethesenutsandbolts.
2.Mountafrontlightbrackettotheleftsiderailusing
theremovednutsandbolts(Figure5).
1
2
3
4
5
6
7
G016007
Figure5
1.Bolt(existing)4.Siderail
2.Springwasher(included
withheadlamp)
5.Nut(existing)
3.Nut(includedwithhead
lamp)
6.Frontlightbracket
3.Fixthelefthandheadlamptothefrontlightbracket
usingaspringwasherandanutprovidedwiththe
lamp(
Figure5).
4.Repeatsteps1-3fortherighthandside(Figure6).
G015997
Figure6
Rightsiderail
1.Removethesenutsandbolts.
5.Mountthehorntotheleftsidebracketasshownin
Figure7.Secureitwithabolt(M8x20),2washers
(M8),andanut(M8).
3
4
5
6
2
1
7
8
G016008
Figure7
Leftsidehornmount
1.Bolt(M8x20)5.Leftsiderail
2.Washer(M8)6.Nut(M8)
3.Leftheadlamp7.Washer(M8)
4.Horn8.Bracket
4
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
Procedure
1.Cut40mm(1-1/2inch)offtherightmotioncontrol
lever(
Figure8).Useatwopartepoxyresintoglue
theadaptorswitchmountintothemotioncontrol
lever(Figure8).
G015998
1
Figure8
1.40mm
Note:Allburrsmustberemovedfromtheedgesto
avoiddamagetothewires.
2.Connectthecombinationswitchassemblytothe
adaptorswitchmountandsecureitwithascrew
(
Figure9).
3
4
2
1
G016009
Figure9
1.Motioncontrollever
3.Screw(includedwith
switchassembly)
2.Adaptorswitchmount
4.Combinationswitch
assembly
3.Pushthehazardswitch,lightingswitch,and2blank
switchesintotheswitchpanelasshown(Figure10).
5
3
4
5
6
2
1
G016010
Figure10
1.Lightingswitch
lens
3.Blankswitches5.Hazardswitch
2.Hazardswitch
lens
4.Switchpanel
6.Lightingswitch
4.Installthehazardswitchlensandthelightingswitch
lens.
5.Fitthegrommetstotherearheadlampwiresby
feedingtheconnectorsthroughthegrommethole
oneatatime(
Figure11).
G015999
Figure11
1.Grommets
6.Plugthewiringharnessintotheswitches.Securethe
ashingrelaybasewithabolt(M5),washer(M5),
andnut(M5).Cabletietheharnessasshown,and
plugintheasherrelay(Figure12).
G016000
3
4
Figure12
1.Switches
3.Flasherrelay
2.Flashingrelaybase
4.Cabletie
7.Removethe4screwsonthecontrolpanel
(Figure13).
!
1
2
G015942
Figure13
1.Ignitionswitch
2.Screw
8.Iftheignitionswitchhas6terminals(Figure14),
proceedtostep9.Iftheignitionswitchhas5
terminals(Figure15),proceedtostep10.
6
1
2
3
G015940
Figure14
1.Existingconnector3.Piggybackterminal
2.Redwire
1
2
3
4
5
G016442
Figure15
1.Thickpinkwire4.Malebullet
2.Thinpinkwire5.Redwire
3.Femalebulletconnector
9.Crimpapiggybackconnectortotheredwireonthe
lightingharness.removethesingleconnectorfrom
theignitionswitch.Connectthepiggybacktothis
position,thenreconnecttheremovedconnectorto
thepiggyback(
Figure14).
10.Cutthethinpinkwirehalfwayup,striptheinsulation,
andconnectittothebluefemalebulletcrimp
terminal.Thencrimpthemalebullettotheredwire
onthelightingharnessandconnectittotheignition
switchinthepositionindicatedbyFigure15.
11.Retthecontrolpanel,thenttheswitchpanelto
therightsideofthecontrolpanelusing2existing
screws(
Figure16).
G016001
Figure16
1.Screws
7
4
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(
Figure18).
2.Routetheharnessalongtheleftsiderailtoconnect
thelefthandfrontheadlampandhorn.Connect
thetwosmallconnectorstothehornandthelarge
connectortothefrontheadlamp(Figure18).
3.Routetheharnesstotherearofthemachineto
connecttherearheadlampsandnumberplatelamp.
Feedthewirethroughtheleftrearbrackethole.
Bendtherearheadlampplatetabtoaangleof90
degreeupwards,thenconnectthewires.Repeatthe
sameprocessfortherightrearheadlamp(
Figure18).
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).
G016012
1
2
3
4
5
6
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.
8
G01601 1
1
Figure18
1.ForZ597only
9
Operation
SwitchFunctions
•Hazardwarningswitch—Operatesthehazard
warninglights,andwillworkwhethertheignition
isswitchedonoroff(Figure19).
–Pressthesideoftherockerswitchwiththe
hazardwarningsymboltoturnonthehazard
warninglights.
–Presstheothersideoftherockerswitchtoturn
offthehazardwarninglights.
1
2
G016073
Figure19
1.Masterlightswitch2.Hazardwarningswitch
•Masterlightswitch—Operatesthefront,rear,and
headlamps.Onlyworksiftheignitionisswitched
on(Figure19).
–Pressthesideoftherockerswitchwiththe
masterlightsymboltoturnonthelights.
–Presstheothersideoftherockerswitchtoturn
offthelights.
•Directionindicatorswitch—Operatestheright-
andleft-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.
1
2
G016074
Figure20
1.Headlampanddipped
beamswitch
2.Directionindicatorswitch
•Headlampanddippedbeamheadlampswitch—
Operatestheheadlampsonlywhentheignitionis
switchedon(Figure20).
–Pushthesliderforwardtoturnonthehead
lamp.
–Pushthesliderbackwardtoturnonthedipped
beamheadlamp.
•Hornswitch—Operatesthehornonlywhenthe
ignitionisswitchedon.
–Pushthebuttontosoundthehorn.
–Releasethebuttontostopthehorn.
10
Maintenance
MaintenanceTips
•Checkthatalllightsareworkingonaregularbasis.
•Cleanalllensesregularlywithanonpetroleum-based
cleaner.
•Ensurethatthedrainslotsarekeptclearofdebris.
•Ifthemowerisgoingtobestoredoutdoors,verify
thatthelensissecuredproperlytopreventwater
fromenteringthelights.
Headlights—replacingabulb:
1.Removethelenscover.
2.Replacethebulb.
3.Replacethelenscover.
4.Adjustthelightstoensuretheycomplywithlocal
roadlegislation.
11
TheToroTotalCoverageGuarantee
ALimitedWarranty
ConditionsandProductsCovered
TheToro
®
Companyanditsafliate,T oroWarrantyCompany,pursuant
toanagreementbetweenthem,jointlywarrantyourToroCommercial
product(“Product”)tobefreefromdefectsinmaterialsorworkmanship
fortwoyearsor1500operationalhours*,whicheveroccursrst.This
warrantyisapplicabletoallproductswiththeexceptionofAerators
(refertoseparatewarrantystatementsfortheseproducts).Wherea
warrantableconditionexists,wewillrepairtheProductatnocosttoyou
includingdiagnostics,labor,parts,andtransportation.Thiswarranty
beginsonthedatetheProductisdeliveredtotheoriginalretailpurchaser.
*Productequippedwithanhourmeter.
InstructionsforObtainingWarrantyService
YouareresponsiblefornotifyingtheCommercialProductsDistributoror
AuthorizedCommercialProductsDealerfromwhomyoupurchasedthe
Productassoonasyoubelieveawarrantableconditionexists.Ifyouneed
helplocatingaCommercialProductsDistributororAuthorizedDealer,or
ifyouhavequestionsregardingyourwarrantyrightsorresponsibilities,
youmaycontactusat:
CommercialProductsServiceDepartment
themanufacturerWarrantyCompany
8111LyndaleAvenueSouth
Bloomington,MN55420-1196
E-mail:[email protected]
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’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.
•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
originalproductwarrantyandbecomethepropertyofToro.Torowill
makethenaldecisionwhethertorepairanyexistingpartorassemblyor
replaceit.Toromayuseremanufacturedpartsforwarrantyrepairs.
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
RepairbyanAuthorizedToroDistributororDealerisyoursoleremedy
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
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