Toro 04063 User manual

FormNo.3415-336RevA
LEDLightKit
SerialNumber400000000andAfterGreensmaster®800,1000,
1600,Flex™1820/2120,andeFlex®1820/2120SeriesMower
ModelNo.04063
ModelNo.04064
InstallationInstructions
WARNING
CALIFORNIA
Proposition65Warning
Thisproductcontainsachemical
orchemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orreproductiveharm.
Usetheappropriatemodelforyourmachineas
follows:
•ModelNo.04063—Greensmaster®800,1000,
and1600seriesmachines
•ModelNo.04064—Greensmaster®Flex
1820/2120oreFlex1820/2120seriesmachines
Note:Determinetheleft,right,front,andbacksides
ofthemachinefromthenormaloperatingposition.
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachine.
2Nopartsrequired–Removethecontrol-panelcover(1820
or2120seriesmachines).
LEDlightassembly2
Lightmount2
Flange-headbolt(3/8inch)4
3Flangenut(3/8inch)2
Assemblethelightmountstothe800,
1000,and1600seriesmachine.
LEDlightassembly2
Lightmount2
Mountplate1
Flange-headbolt(3/8inch)1
Flange-headbolt(5/16x1inch)1
Flange-headbolt(5/16x1-1/2inches)4
Flangelocknut(5/16inch)4
Flangenut(3/8inch)1
Flangenut(5/16inch)1
4
Washer4
Assemblethelightmountstothe1820
or2120seriesmachine.
5Wireharness2Assemblethewireharnessestothe
machine.
62-positionrockerswitch1Installthelightswitch.
7Cabletie10Installthecableties.
8Nopartsrequired–Finishthelightkitinstallation.
©2017—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3415-336*A

1
PreparingtheMachine
NoPartsRequired
DisconnectingtheSpark-Plug
Wire
800,1000,and1600SeriesMachines
1.Ensurethatthereel-driveleverisinthe
DISENGAGEposition;refertotheOperator’s
Manual.
2.Movethemachinetoalevelsurfaceandset
thetraction-drivelevertotheNEUTRALposition;
refertotheOperator’sManual.
3.SetthethrottlecontroltotheSLOWpositionand
pushtheOn-OffswitchtotheOFFposition;refer
totheOperator’sManual.
4.Engagetheservicebrakeandholdinplacewith
theparking-brakeknob;refertotheOperator’s
Manual.
5.Removethespark-plugwirefromtheterminalof
thesparkplug(Figure1).
g032966
Figure1
1.Spark-plugwire
DisconnectingtheSpark-Plug
Wire
Flex1820and2120SeriesMachines
1.Ensurethetractionandreeldriveengagement
leverisintheDISENGAGEposition;refertothe
Operator’sManual.
2.Movethemachinetoalevelsurfaceandset
thetractionandreeldriveengagementleverto
theNEUTRALposition;refertotheOperator’s
Manual.
3.SetthethrottlecontroltotheSLOWpositionand
pushtheOn-OffswitchtotheOFFposition;refer
totheOperator’sManual.
4.Pulltheservicebrakeleverbackandholdin
placewiththeparking-brakelatch;refertothe
Operator’sManual.
5.Removethespark-plugwirefromtheterminalof
thesparkplug(Figure1).
DisconnectingtheBattery
eFlex1820and2120SeriesMachines
1.Ensurethetractionandreeldriveengagement
leverisintheDISENGAGEposition;refertothe
Operator’sManual.
2.Movethemachinetoalevelsurfaceandset
thetractionandreeldriveengagementleverto
theNEUTRALposition;refertotheOperator’s
Manual.
3.RotatethekeyswitchtotheOFFposition;refer
totheOperator’sManual.
4.Pulltheservicebrakeleverbackandholdin
placewiththeparkingbrakelatch;refertothe
Operator’sManual
5.Wait10to15minutesforthemotorcapacitors
todischarge.
6.DisconnecttheT-handleconnectorofthebattery
adapterwireharnessfromtheP04connectorof
thebatterywireharness(Figure2).
g210482
Figure2
1.P04T-handleconnector
(batteryadapterwire
harness)
2.P04connector(battery
wireharness)
2

2
Removingthe
Control-PanelCover
1820or2120SeriesMachines
NoPartsRequired
Procedure
1.Removethe4ange-headscrews(1/4x1/2
inch)thatsecurethecontrol-panelcovertothe
supportbracketofthehandlebar(Figure3).
g032757
Figure3
1.Control-panelcover3.Supportbracket(handle
bar)
2.Flange-headscrew(1/4x
1/2inch)
2.Movethecontrolpanelcoverupandforward
fromthecontrolpanel,andremovethecover
fromthemachine(Figure3).
Note:Retaintheange-headscrewsand
control-panelcoverforassemblyinInstallingthe
Control-PanelCover(page14).
3
AssemblingtheLight
Mountstothe800,1000,
and1600SeriesMachine
Partsneededforthisprocedure:
2LEDlightassembly
2Lightmount
4Flange-headbolt(3/8inch)
2Flangenut(3/8inch)
Procedure
1.Removeanddiscardtheboltfromtheupper
frameofbothsideplatesasshowninFigure4.
g210479
Figure4
1.Bolt
2.Loosentheboltsontherightreeldrivecover,
thenraisethecover(Figure5).
Important:Loosen,butdonotremovethe
bolts.
Note:Raisingthecoverwillallowyoutousea
wrenchtotightentheboltthatisclosesttothe
cover.
3

g207878
Figure5
1.Bolt—loosen
3.Use4ange-headbolts(3/8inch)and2ange
nuts(3/8inch)tosecurethelightmountstoboth
sideplates(Figure6).
Note:Ensuethatthethrottlecableisrouted
behindthelightmount.
g206126
Figure6
1.Flange-headbolt(3/8
inch)
3.Flangenut(3/8inch)
2.Lightmount
4.RemovethenutandthewasherfromeachLED
lightassembly,thenusethenutandthewasher
tosecuretheLEDlightstoeachlightmount
(Figure7).
g200656
Figure7
1.LEDlight3.Washer
2.Lightmount4.Nut
4
AssemblingtheLight
Mountstothe1820or2120
SeriesMachine
Partsneededforthisprocedure:
2LEDlightassembly
2Lightmount
1Mountplate
1Flange-headbolt(3/8inch)
1Flange-headbolt(5/16x1inch)
4Flange-headbolt(5/16x1-1/2inches)
4Flangelocknut(5/16inch)
1Flangenut(3/8inch)
1Flangenut(5/16inch)
4Washer
Procedure
1.Use2ange-headbolts(5/16x1-1/2inches),2
washers,and2angenuts(5/16inch)tosecure
themountplatetotheleftsideplate(Figure8
orFigure9).
4

•Flex/eFlex1820machines:positionthe
mountplatetotheoutsideoftheleftside
plate(Figure8).
•Flex/eFlex2120machines:positionthe
mountplatetotheinsideoftheleftside
plate(Figure9).
g210476
Figure8
Flex/eFlex1820MachineShown
1.Flangelocknut(5/16inch)4.Flange-headbolt(5/16x
1-1/2inches)
2.Mountplate5.Leftsideplate
3.Washer
g200371
Figure9
Flex/eFlex2120MachineShown
1.Flangelocknut(5/16inch)4.Flange-headbolt(5/16x
1-1/2inches)
2.Mountplate5.Leftsideplate
3.Washer
2.Use1ange-headbolt(3/8inch),1ange-head
bolt(5/16x1inch),1angenut(3/8inch),and
1angenut(5/16inch)tosecurealightmount
tothemountplate(Figure10).
5

g206120
Figure10
Flex/eFlex2120MachineShown
1.Lightmount4.Flangenut(5/16inch)
2.Flange-headbolt(5/16x
1inch)
5.Flangenut(3/8inch)
3.Flange-headbolt(3/8
inch)
3.Use2ange-headbolts(5/16x1-1/2inches),2
washers,and2angenuts(5/16inch)tosecure
alightmounttotherightdrivehousing(Figure
11).
g206121
Figure11
1.Flange-headbolt(5/16x
1-1/2inch)
4.Lightmount
2.Washer5.Flangelocknut(5/16inch)
3.Drivehousing
4.RemovethenutandthewasherfromeachLED
lightassembly,thenusethenutandthewasher
tosecuretheLEDlightstoeachlightmount
(Figure12).
g200370
Figure12
1.LEDlight3.Washer
2.Lightmount4.Nut
6

5
AssemblingtheWire
HarnessestotheMachine
Partsneededforthisprocedure:
2Wireharness
AttachingtheWireHarnessesto
theLEDLights
1.Connectthe2-pinconnectoroftheLEDlightinto
the2-socketconnectoroftheLEDlightharness
(Figure13).
Ensurethattheconnectorsarefullyseated
andthelatchoftheconnectorssnaptogether
securely.
g200657
Figure13
1.2-socketconnector(wire
harness)
2.2-pinconnector(LEDlight)
2.Repeatstep1fortheotherwireharnessand
LEDlight.
RoutingtheWireHarness
Routethewireharnessesdowneachlightmountand
upeachhandleasshowninFigure14.
Note:Ensurethatthewireharnessesarerouted
belowthedifferentialaxleshaft(Figure15).
g210745
Figure14
800,1000,and1600SeriesMachineshown
1.Wireharness
g210746
Figure15
800,1000,and1600SeriesMachineshown
1.Wireharness2.Differentialaxleshaft
7

ConnectingtheLEDLightWire
HarnessestotheMachineWire
Harness
800,1000,and1600SeriesMachines
Note:PerformthefollowingstepsfortheLEDlight
wireharnessesonbothsidesofthemachine.
1.Atthebackoftheconsole,removetheplug
fromthe2-socketconnectorofthemachinewire
harness(Figure16).
g206149
Figure16
Leftsideofthemachineshown
1.2-socketconnector(wire
harness—machine)
3.2-pinconnector(wire
harness—LEDlightkit)
2.Plug4.Console
2.Connectthe2-pinconnectoroftheLEDlight
wireharnesstothe2-socketconnectorofthe
machinewireharness(Figure16).
Ensurethattheconnectorsarefullyseated
andthelatchoftheconnectorssnaptogether
securely.
3.Performthepreviousstepsforthewireharness
ontheothersideofthemachine(Figure17).
g210747
Figure17
1.Wireharness—LEDlight
kit
3.Installed2-pinconnector
and2-socketconnector
2.Wireharness—machine
8

ConnectingtheLEDLightWire
HarnessestotheMachineWire
Harness
Flex1820and2120SeriesMachines
Note:PerformthefollowingstepsfortheLEDlight
wireharnessesonbothsidesofthemachine.
1.Atthefrontoftheconsole,removetheplug
fromthe2-socketconnectorofthemachinewire
harness(Figure18).
g210534
Figure18
Leftsideofthemachineshown
1.2-pinconnector(wire
harness—LEDlightkit)
3.2-socketconnector(wire
harness—machine)
2.Plug
2.Connectthe2-pinconnectoroftheLEDlight
wireharnesstothe2-socketconnectorofthe
machinewireharness(Figure18).
Ensurethattheconnectorsarefullyseated
andthelatchoftheconnectorssnaptogether
securely.
3.Performthepreviousstepsforthewireharness
ontheothersideofthemachine(Figure19).
g210792
Figure19
1.Installed2-pinconnector(wireharness—LEDlightkit)
9

ConnectingtheLEDLightWire
HarnessestotheMachineWire
Harness
eFlex1820and2120SeriesMachines
Note:PerformthefollowingstepsfortheLEDlight
wireharnessesonbothsidesofthemachine.
1.Atthefrontoftheconsole,removetheplug
fromthe2-socketconnectorofthemachinewire
harness(Figure20).
g210537
Figure20
Leftsideofthemachineshown
1.2-pinconnector(wire
harness—LEDlightkit)
3.2-socketconnector(wire
harness—machine)
2.Plug
2.Connectthe2-pinconnectoroftheLEDlight
wireharnesstothe2-socketconnectorofthe
machinewireharness(Figure20).
Ensurethattheconnectorsarefullyseated
andthelatchoftheconnectorssnaptogether
securely.
3.Performthepreviousstepsforthewireharness
ontheothersideofthemachine(Figure21).
g210792
Figure21
1.Installed2-pinconnector(wireharness—LEDlightkit)
10

6
InstallingtheLightSwitch
Partsneededforthisprocedure:
12-positionrockerswitch
InstallingtheLightSwitch(800,
1000,and1600SeriesMachines)
1.Ifequipped,removetheplugfromtheopening
attheleftfaceofthecontrolpanel(Figure22).
g207838
Figure22
1.Plug3.2-positionrockerswitch
2.Knock-outplug4.10-socketconnector
2.Createanopeningfortheswitchbyremoving
theknock-outplugifequipped.
3.Pullupthe10-socketconnnectorofthemachine
wireharnessthroughtheopeninginthecontrol
panel(Figure22).
4.Connectthe10-pinconnectorofthe2-position
rockerswitchintothe10-socketconnectorofthe
wireharnessforthemachine(Figure22).
Ensurethattheconnectorsarefullyseated
andthelatchoftheconnectorssnaptogether
securely.
5.Aligntheswitchsothatthenotchintheswitch
bodyistowardtheleftsideofthecontrolpanel
(Figure23).
g032984
Figure23
1.Opening(controlpanel)3.Notch(body—rocker
switch)
2.2-positionrockerswitch4.Leftsideofthecontrol
panel
6.Inserttheswitchintotheopeninginthecontrol
paneluntiltheswitchsnapssecurelyintothe
panel(Figure23).
11

InstallingtheLightSwitch
(eFlex/Flex1820and2120Series
Machines)
1.Removetheplugfromtheopeningattheleft
faceofthecontrolpanel(Figure24orFigure25).
g032849
Figure24
eFlex1820/2120MachineShown
1.Plug3.2-positionrockerswitch
2.Opening(controlpanel)4.8-socketconnector(wire
harness—LEDlightand
wirelesshourmeter
harnesskit)
g208352
Figure25
Flex1820/2120MachineShown
1.Plug3.2-positionrockerswitch
2.Opening(controlpanel)4.8-socketconnector(wire
harness—LEDlightand
wirelesshourmeter
harnesskit)
2.Pullupthe8-socketconnectorofthewire
harnessforthemachinethroughtheopeningin
thecontrolpanel(Figure24orFigure25).
3.Connectthe8-pinconnectorofthe2-position
rockerswitchintothe8-socketconnectorof
thewireharnessforthemachine(Figure24or
Figure25).
Ensurethattheconnectorsarefullyseated
andthelatchoftheconnectorssnaptogether
securely.
4.Aligntheswitchsothatthenotchinthebody
oftheswitchistowardthebackofthecontrol
panel(Figure26).
12

g032853
Figure26
eFlex1820/2120MachineShown
1.Opening(controlpanel)3.Notch(body—rocker
switch)
2.Rockerswitch4.Backofthecontrolpanel
5.Inserttheswitchintotheopeninginthecontrol
paneluntiltheswitchsnapssecurelyintothe
panel(Figure26).
7
InstallingtheCableTies
Partsneededforthisprocedure:
10Cabletie
Procedure
Important:Asyouinstallthecableties,ensure
thatthewireharnesseshaveenoughslackto
preventstresspointsandarefreefromany
movingparts
1.Use8cabletiestosecurethewireharnessesto
themachine(Figure27).
Note:Attach4cabletiestothelightmounts
and4cabletiestothehandle.
g200658
Figure27
800,1000,and1600SeriesMachineshown
1.Cabletie(8)2.Wireharness
2.Usetheremaining2cabletiesasfollows:
•800,1000,and1600Seriesmachines:
SecuretheLEDlightkitwireharnesstothe
harnessofthemachinewithasshownin
Figure28.
Note:Performthisstepforbothsidesofthe
machine.
13

g032885
Figure28
Leftsideofthemachineshown
1.Wireharness(machine)3.Wireharness(LEDlight
kit)
2.Cabletie
•eFlex/Flex1820and2120Series
machines:
Useacabletietobundletheremaining
lengthofthewireharnesstogether(Figure
29).
Note:Performthisstepforbothsidesofthe
machine.
g200973
Figure29
Leftsideofthemachineshown
1.Installed2-pinconnector
(wireharness—LEDlight
kit)
2.Cabletie
8
FinishingtheLightKit
Installation
NoPartsRequired
InstallingtheControl-PanelCover
1820or2120SeriesMachines
1.Alignthekeyholeslotinthecontrol-panelcover
overthetractionandreeldrivehandle(Figure
30).
g032818
Figure30
1.Tractionandreeldrive
handle
3.Flange-headscrew(1/4x
1/2inch)
2.Keyholeslot(control-panel
cover)
4.Supportbracket(handle
bar)
2.Aligntheholesinthecontrol-panelcovertothe
holesinthesupportbracketofthehandlebar
(Figure30).
3.Assemblethecovertothebracket(Figure
30)withthe4ange-headscrews(1/4x1/2
inch)thatyouremovedin2Removingthe
Control-PanelCover(page3).
14

ConnectingtheSpark-PlugWire
800,1000,1600,andFlex1820and2120
SeriesMachines
Connectthespark-plugwiretotheterminalofthe
sparkplug;refertoFigure1ofDisconnectingthe
Spark-PlugWire(page2).
ConnectingtheBattery
eFlex1820and2120SeriesMachines
ConnecttheT-handleconnectorofthebattery
adapter-wireharnesstotheP04connectorof
thebatterywireharness;refertoFigure2of
DisconnectingtheBattery(page2).
Operation
OperatingtheLightSwitch
PresstherockerswitchtoturntheLEDlightstothe
ONorOFFposition;refertoFigure31.
g211057
Figure31
1.ONposition3.LEDlightswitch
2.OFFposition
UsingtheLEDLightKitwiththe
WirelessHourMeterKit
IftheLEDlightkitisusedwiththewirelesshourmeter
kit,refertothewirelesshourmeterkit.
Note:TheuseoftheLEDlightkitwiththewireless
hourmeterkitmaycausetheLEDlightstoicker
slightlyatlowidle.
15