Road Light Kit

1. Park the machine on a level surface.

2. Lower the cutting units.

3. Engage the parking brake.

4. Shut off the engine and remove the key.

5. Wait for all moving parts to stop.

6. Allow the engine to cool completely.

1. Move the platform-latch handle (Figure 1) toward the front of the machine until the latch hooks clear the locking bar.

   

   Figure 1

   1. Platform-latch handle

2. Raise the platform (Figure 2).

   Note: The gas lift cylinder assists lifting the platform.

   

   Figure 2

1. At the left side of the operator’s platform, open the door of the storage compartment (Figure 3).

   

   Figure 3

   1. Washer
   2. Knob
   3. Storage compartment

2. Remove the 3 knobs and 3 washers that secure the storage compartment to the machine, and remove the compartment (Figure 3).

Unlatch and open the hood.

1. Loosen the forward nut of the negative battery-cable terminal (Figure 4).

   

   Figure 4

   1. Nut (negative battery-cable terminal)
   2. Negative battery post

2. Lift the negative battery cable from the battery post (Figure 4).

   Note: Position the negative-battery cable where it cannot contact the negative battery post.

1. Remove the plugs shown from the control arm (Figure 9 and Figure 10).

   Discard the plugs.

   

   Figure 9

   

   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.

   

   Figure 11

   1. Button-head screw (4 x 16 mm)
   2. Instrument panel
   

   Figure 12

   1. Button-head screw (8 x 20 mm)
   2. Switch plate

3. Pull through the control-arm harness connectors with the following labels:

   • LIGHTS

   • INDICATORS

   • HAZARDS

4. Connect the 3 switches to the corresponding harness connectors (Figure 13 and Figure 14).

   

   Figure 13

   1. Turn signal switch
   

   Figure 14

   1. Headlight switch
   2. Hazard switch

5. Install the previously removed instrument panel and switch plate from the control arm (Figure 11 and Figure 12).

1. Remove the 2 Phillips-head screws (1/4 x 1 inch) that secure the control-arm cover to the control arm, and remove the cover (Figure 15).

   

   Figure 15

   1. Phillips-head screw (1/4 x 1 inch)
   2. Control-arm cover

2. Remove the Phillips-head screw (#10 x 3-1/2 inches), locknut (#10), and 5 flange-head screws (#10 x 3/8 inch) that secure the right control-arm panel to the control arm (Figure 14).

   

   Figure 16

   1. Locknut (#10)
   2. Phillips-head screw (#10 x 3-1/2 inches)
   3. Flange-head screw (#10 x 3/8 inch)
   4. Right control-arm panel

3. Remove the plugs shown in (Figure 17 and Figure 18) from the control arm.

   Discard the plugs.

   

   Figure 17

   1. Plugs
   

   Figure 18

   1. Plug

4. Pull harness connectors with the following labels through the control arm:

5. Connect the 3 switches to the corresponding harness connectors (Figure 19 and Figure 20).

   

   Figure 19

   1. Turn signal switch
   2. Hazard switch
   

   Figure 20

   1. 8-pin connector (labeled —machine wire harness)
   2. Headlight switch

6. Assemble the right control-arm panel to the control arm (Figure 21) with the Phillips-head screw (#10 x 3-1/2 inches), locknut (#10), and 5 flange-head screws (#10 x 3/8 inch).

   

   Figure 21

   1. Locknut (#10)
   2. Phillips-head screw (#10 x 3-1/2 inches)
   3. Flange-head screw (#10 x 3/8 inch)
   4. Right control-arm panel

Figure 23

Holes (light bar arm)

Use the illustration in Figure 24 to identify the mounting bracket hole positions on the arm of the light bar for your machine.

Figure 24

1. Model 31654
2. Model 31657
3. Model 31659

Note: You can also refer to the decal on the light bar (Figure 25) for information about the mounting bracket hole positions.

Figure 25

1. Align the holes in the mounting bracket with the holes in the arm of the light bar (Figure 26) that you identified in Identifying the Mounting Bracket Hole Positions.

   Note: Ensure that the tab of the mounting bracket is aligned away from the light assembly.

   

   Figure 26

   1. Flange locknut (8 mm)
   2. Tab (mounting bracket)
   3. Washer (8 mm)
   4. Bolt (8 x 65 mm)
   5. Light bar arm

2. Loosely assemble the mounting bracket to the light bar arm (Figure 26) with the 2 bolts (8 x 65 mm), 2 washers (8 mm), and 2 flange locknuts (8 mm).

3. Repeat steps 1 and 2 at the other arm of the light bar.

1. At the right side of the traction pump, remove the plug from the T-fitting at port B of the traction pump (Figure 31).

   

   Figure 31

   1. T-fitting (traction pump port B)
   2. Plug
   3. Adapter fitting (1/4 x 7/16 inch)

2. Assemble the adapter fitting (1/4 x 7/16 inch) into the T-fitting (Figure 31).

3. Torque the assemble the adapter to 34 to 41 N∙m (25 to 30 ft-lb).

4. Assemble the brake-pressure transducer into the adapter fitting (Figure 32).

   

   Figure 32

   1. Adapter fitting (1/4 x 7/16 inch)
   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 33).

   

   Figure 33

   1. 3-pin connector (labeled BRAKE PRESSURE SENSOR—machine wire harness)

7. Route the 3-pin connector and wires toward the right side of the traction pump.

   

   Figure 34

8. Remove the cap from the brake pressure sensor connector (Figure 35).

   

   Figure 35

   1. Cap
   2. 3-pin connector (labeled BRAKE PRESSURE SENSOR—machine wire harness)
   3. Brake pressure sensor

9. Plug the brake pressure sensor connector into the brake-pressure transducer (Figure 35).

1. At the right side of the traction pump, remove the plug from port MB of the pump (Figure 36).

   Note: Machines that have 4WD in reverse installed, replace the test port in port MB in the traction pump with the brake pressure transducer supplied in this kit.

   

   Figure 36

   1. Port-MB (traction pump)
   2. Plug
   3. Reducer fitting (3/4 x 7/16 inch)

2. Assemble the reducer fitting into port MB of the pump (Figure 36).

3. Torque the reducer fitting to 81 N∙m (60 ft-lb).

4. Assemble the brake-pressure transducer (Figure 37) into the reducer fitting (3/4 x 7/16 inch).

   

   Figure 37

   1. Reducer fitting (3/4 x 7/16 inch)
   2. Brake-pressure transducer

5. Torque the 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 38).

   

   Figure 38

   1. 3-pin connector (labeled BRAKE PRESSURE SENSOR—machine wire harness)

7. Route the 3-pin connector and wires toward the right side of the traction pump (Figure 39).

   

   Figure 39

8. Remove the cap from the 3-pin connector of the machine wire harness labeled BRAKE PRESSURE SENSOR (Figure 40).

   

   Figure 40

   1. 3-pin connector—machine wire harness (labeled BRAKE PRESSURE SENSOR)
   2. Cap
   3. Brake-pressure transducer

9. Plug the 3-pin connector labeled BRAKE PRESSURE SENSOR into the connector of the pressure transducer (Figure 40).

1. Route the 3-pin connector labeled and wiring toward front-traction manifold (Figure 41).

   

   Figure 41

   1. Front-traction manifold
   2. 3-pin connector (labeled )
   3. Front of the machine

2. Remove the hex-socket plug from port-PS of the front traction manifold (Figure 42).

   

   Figure 42

   1. Port-PS (front traction manifold)
   2. Hex-socket plug

3. Assemble the adapter fitting (1/4 x 7/16 inch) into port- of the front traction manifold (Figure 43) with a seal (1/4 inch).

   

   Figure 43

   1. Adapter fitting (1/4 x 7/16 inch)
   2. Seal (1/4 inch)
   3. Port- (front traction manifold)
   4. Brake-pressure transducer

4. Torque the adapter fitting to 34 to 41 N∙m (25 to 30 ft-lb).

5. Assemble the brake-pressure transducer into the adapter fitting (Figure 43).

6. Torque the transducer to 27 N∙m (20 ft-lb).

7. Plug the 3-pin connector labeled into the brake-pressure transducer (Figure 44).

   

   Figure 44

   1. Brake-pressure transducer
   2. 3-pin connector (labeled —machine wire harness)

Remove 4 bolts, 4 lock washers, and 4 washers that secure the bulkhead (Figure 47) to the electrical panel, and remove the bulkhead.

Note: Retain the bulkhead, bolts, lock washers, and washers.

Figure 47

1. Bolts
2. Lock washer
3. Washer
4. Bulkhead

1. Place the assembled number-plate bracket onto the bulkhead and align the bracket as far forward as possible.

2. Center the assembled number plate on the bulkhead.

3. Using the bracket as the template, drill 2 holes (7 mm) through the bulkhead (Figure 48).

   

   Figure 48

   1. Drill 2 holes (7 mm) in the bulkhead.

4. Drill a hole (6.5 mm) through the bulkhead to the left of the number-plate light (Figure 49).

   

   Figure 49

   1. Drill a hole (6.5 mm)—bulkhead.

5. Loosely assemble number-plate bracket to the bulkhead using 2 flange-head bolts (6 x 20 mm), 3 washers (1/4 x 3/4 inch) , and a flange locknut (6 mm) as shown in Figure 50.

   You will install the locknut to the machine left flange-head bolt in Securing the Plate-Light Harness to the Bulkhead.

   

   Figure 50

   1. Flange-head bolt (6 x 20 mm)
   2. Washers
   3. Flange locknut (6 mm)
   4. Machine right—bulkhead

6. Route the harness of the number-plate light (Figure 51) through the hole (6.5 mm) that you drilled in step 4.

   Note: You will install the 2-pin connector and wedge lock in Assembling the Plate-Light Connector.

   

   Figure 51

   1. Harness (number-plate light)
   2. Hole (6.5 mm—bulkhead)

1. At the bulkhead, insert the terminal of the white light wire into the pin 1 position of the 2-pin connector (Figure 52).

   

   Figure 52

   1. Pin 1 position (2-pin connector)
   2. White wire (number plate-light harness)
   3. Black wire (number plate-light harness)
   4. Pin 2 position (2-pin connector)
   5. Wedge lock

2. Insert the terminal of the black light wire into the pin 2 position of the 2-pin connector (Figure 52).

3. Insert the wedge lock into the 2-pin connector.

1. Assemble a cushioned support clamp onto the harness of the number-plate light (Figure 53).

   

   Figure 53

   1. Flange locknut (6 mm)
   2. Cushioned support clamp
   3. Flange-head bolt (6 x 20 mm)
   4. Harness (number-plate light)

2. Assemble the cushioned support clamp and a flange nut (6 mm) onto the machine left flange-head bolt (Figure 53).

3. Tighten the 2 flange-head bolts and 2 flange locknuts that secure the number-plate bracket and clamp to the bulkhead.

Refer to Figure 54 for an overview of where the wire harness routes on the machine.

Figure 54

1. Locate the 6-pin connector labeled and 6-pin connector labeled of the kit harness connectors (Figure 55).

   

   Figure 55

   1. 6-pin connector (headlight—kit harness connector)
   2. Swivel-interface shell
   3. 90° backshell

2. Separate the 90° backshell from the swivel-interface shell (Figure 55).

3. Separate the swivel-interface shell from the 6-pin connector (Figure 55).

4. Repeat steps 2 and 3 of the other headlight connector.

1. Route the wire harness segment labeled through the left opening in the front arm pivot-plate mount and then through the latch plate (Figure 56).

   

   Figure 56

2. Route the wire harness segment labeled through the right opening in the front arm pivot-plate mount and then through the latch plate (Figure 56).

3. Secure the harness to the front arm pivot-plate mount using 2 adhesive clamps (Figure 56).

4. Route the wire harness through the inside of the left and right side of the front light bar assembly (Figure 57).

5. Secure the wire harness at the front using 4 adhesive clamps (Figure 57).

   

   Figure 57

6. Route the wire harness through the hole in the front channel by pushing the harness through until you can see the harness from the side of the light bar assembly (Figure 58).

   

   Figure 58

1. Assemble the swivel-interface shell to the 6-pin connector (Figure 59).

   

   Figure 59

   1. 6-pin connector (headlight—kit harness connector)
   2. Swivel-interface shell
   3. 90° backshell

2. Assemble the 90° backshell to the swivel-interface shell (Figure 59).

   Note: Ensure that the conduit is secure to the 90° backshell.

3. Repeat steps 1 and 2 of the other headlight connector.

4. Connect the wire-harness connectors to the right and left light assemblies (Figure 60).

   

   Figure 60

5. Install the 2 tube insert into the sides of the front light bar assembly (Figure 61).

   

   Figure 61

6. Secure the wire harness using cable ties.

1. At the lower ROPS-cross tube (Figure 62), remove the cap from the 6-pin connector of the machine wire harness labeled (Figure 63).

   

   Figure 62

   

   Figure 63

   1. Cap
   2. 6-pin connector (labeled —machine wire harness)
   3. 6-pin connector (labeled—light kit wire harness)

2. Plug the 6-pin connector of the light kit wire harness labeled into the 6-pin connector of the machine wire harness labeled (Figure 63).

At the back of the electrical panel, route the kit wire harness along machine wire harness at the bottom of the panel (Figure 64).

Figure 64

1. At the back of the electrical panel, remove the upper right locknut and washer that secure the controller to the panel (Figure 65).

   

   Figure 65

   1. Controller
   2. Bolt (6 x 65 mm)
   3. Washer
   4. Locknut (6 mm)

2. Assemble a cushioned support clamp onto the branch of the kit harness labeled as shown in Figure 66.

   

   Figure 66

   1. Kit harness branch (labeled )
   2. Bolt (6 x 65 mm)
   3. Cushioned support clamp
   4. Washer
   5. Locknut (6 mm)

3. Assemble the clamp onto the bolt, and secure the clamp and controller to the electrical pane with the washer and locknut (Figure 66).

4. Align the bulkhead to the electrical panel.

5. Plug the connector of the number plate-light harness into the connector of the kit harness labeled (Figure 67).

   

   Figure 67

   1. 2-pin connector (number plate-light harness)
   2. 2-pin connector (kit harness—labeled )

1. At the back of the electrical panel, remove the upper right flange locknut that secures the controller to the panel (Figure 68).

   

   Figure 68

   1. Flange-head bolt (6 x 30 mm)—upper right
   2. Flange locknut (6 mm)

2. Assemble a cushioned support clamp onto the branch of the kit harness labeled as shown in Figure 69.

   

   Figure 69

   1. Kit harness branch (labeled )
   2. Flange-head bolt (6 x 30 mm)—upper right
   3. Cushioned support clamp
   4. Flange locknut (6 mm)

3. Assemble the clamp onto the flange-head bolt, and secure the clamp and controller to the electrical panel with the flange locknut (Figure 69).

4. Align the bulkhead to the electrical panel.

5. Plug the connector of the number plate-light harness into the connector of the kit harness labeled (Figure 70).

   

   Figure 70

   1. 2-pin connector (number plate-light harness)
   2. 2-pin connector (kit harness—labeled )

1. Identify the connectors from the light kit harness labeled and , and along the connectors across the lower, back half of the electrical panel (Figure 71).

   

   Figure 71

2. Connect to the and connectors to the left rear and right rear light assemblies (Figure 71).

Secure the harness to the machine (Figure 72 or Figure 73) with the 8 cable ties.

Figure 72

Model 31654

Figure 73

Models 31657 and 31659

Assemble the bulkhead to the electrical panel (Figure 74) with the 4 bolts, 4 lock washers, and 4 washers that you removed in Removing the Bulkhead.

Figure 74

1. Bolts
2. Lock washer
3. Washer
4. Bulkhead

1. Assemble the terminal of the negative battery cable (Figure 80) onto the negative battery post.

   

   Figure 80

   1. Nut (negative battery-cable terminal)
   2. Negative battery post

2. Tighten the forward nut and T-bolt (Figure 80) of the negative battery cable terminal.

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 81).

   

   Figure 81

   1. Washer
   2. Knob
   3. Storage compartment

3. Close the storage-compartment door.

1. Lower the platform carefully (Figure 82).

   Note: The gas lift cylinder helps support the platform.

   

   Figure 82

2. As the platform nears the fully lowered position, move the platform-latch handle (Figure 83) toward the front of the machine.

   Note: This ensures that the latch hooks clear the locking bar.

   

   Figure 83

   1. Platform-latch handle
   2. Locking bar

3. Fully lower the platform and move the platform-latch handle toward the rear of the machine until the latch hooks fully engage the locking bar (Figure 84).

   

   Figure 84

   1. Platform-latch handle

1. Model 31654: Close the hood.

2. Start the engine and run it to warm the coolant to 70 to 75°C (160 to 170 °F).

3. Raise the cutting units and release the parking brake.

4. Slowly drive the machine forward.

   Note: The brake lights should shut off immediately.If the brake lights remain illuminated or remain illuminated too long when you press the pedal forward, calibrate the brake-pressure transducer.

   • Model 31654: Refer to Preparing for Calibration and Calibrating the Brake-Pressure Transducer.

   • Models 31657 and 31659: Refer to Preparing for Calibration and Calibrating the Brake-Pressure Transducer.

5. Release the traction pedal.

   Note: The brake lights should illuminate immediately.If the brake lights do not illuminate or do not illuminate quickly when you release the forward pedal, calibrate the brake-pressure transducer.

   • Model 31654: Refer to Preparing for Calibration and Calibrating the Brake-Pressure Transducer.

   • Models 31657 and 31659: Refer to Preparing for Calibration and Calibrating the Brake-Pressure Transducer.

6. Lower the cutting units, engage the parking brake, shut off the engine and remove the key, and wait for all moving parts to stop.

1. Open the hood.

2. At the left side of the engine, near the main controller (Figure 85), remove the cap from the 2-pin connector of the machine harness.

   

   Figure 85

3. Plug the diagnostic cable into the connector.

   Contact your authorized Toro distributor for a cable.

4. Plug the cable into the computer.

1. Open the program.

   Contact your authorized Toro distributor for access to this program.

2. Select Brake Light Parameters from the menu (Figure 86).

   

   Figure 86

3. Adjust the brake-light pressure (Figure 86) as follows:

   • If the brake lights do not illuminate or do not illuminate quickly when you release the forward pedal, reduce the pressure (kPa).

   • If the brake lights remain illuminated or remain illuminated too long when you release the forward pedal, increase the pressure (kPa).

4. Test the brake light; refer to Testing the Brake Lights.

1. Inside the control arm, remove the cap from the 3-pin connector of the control-arm harness labeled (Figure 87).

   

   Figure 87

   1. Cap
   2. 3-pin connector (labeled —control-arm harness)

2. Plug the diagnostic cable into the connector.

   Contact your authorized Toro distributor for a cable.

3. Plug the cable into the computer.

4. Ensure that the parking brake is engaged, and start the engine.

1. Open the Toro Diag program at ToroConnect.

2. Select T:Primary located on the left side of the screen (Figure 88).

   

   Figure 88

3. Select the Config tab at the top of the screen (Figure 88).

4. Select Max Brake Pressure (psi) inside the Config menu and set the default as standard (Figure 88).

5. Adjust the brake-light pressure as follows:

   Important: When increasing or decreasing the pressure (psi), do so in 1 to 5 increments.

   • If the brake lights do not illuminate or do not illuminate quickly when you release the forward pedal, reduce the pressure (psi).

   • If the brake lights remain illuminated or remain illuminated too long when you release the forward pedal, increase the pressure (psi).

6. Test the brake light; refer to Testing the Brake Lights.

1. Shut off the engine, remove the key, and wait for all moving parts to stop.

2. Disconnect the diagnostic cable from the connector.

3. Assemble the cap onto the connector labeled .

Close and latch the hood.

Install the control-arm cover (Figure 89) with the 2 Phillips-head screws (1/4 x 1 inch) that you removed in Installing the Transducer.

Figure 89

1. Phillips-head screw (1/4 x 1 inch)
2. Control-arm cover

The lights controls are marked with the symbols shown in Figure 90.

Figure 90

1. Hazard warning
2. Direction indicators
3. Lights—On/Off

The headlights and taillights operate as the position marker lights.

• To illuminate the marker lights when the engine is shut off, press the top of the light switch.

• To illuminate the headlights and marker lights, run the engine or rotate the ignition switch to the RUN position, and press the top of the light switch.

• To shut off the lights, press the bottom of the light switch.

Press the top of the hazard light switch to flash all indicator lamps simultaneously.

Note: You do not need to have the ignition switch in the RUN position to operate the hazard lights.

Run the machine with the ignition switch rotated to the RUN position, and press the relevant side of the direction-indicator switch to flash the 2 indicator lamps at that side of the machine.

The brake lights automatically illuminate when the machine decelerates (when the control pedal returns to the NEUTRAL position—only while driving forward).