Toro 04294 User manual

FormNo.3402-210RevA
LEDLightKit
2012andAfterGreensmaster®800,1000,and1600SeriesMower
ModelNo.04294
InstallationInstructions
WARNING
CALIFORNIA
Proposition65Warning
ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato
causecancer,birthdefects,orreproductiveharm.
Important:EnsurethatyouhaveinstalledtheLightKitandHourMeterWireHarnessKitfor2012andAfter(Model
04295)beforeyouinstalltheLEDlightkit.
Note:Determinetheleft,right,front,andbacksidesofthemachinefromthenormaloperatingposition.
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachine.
Rightlight-barstrap1
Spacer4
Flange-headbolt(3/8x1-1/4inches)4
Leftlight-barstrap1
Flange-headbolt(5/16x1inch)2
Washer(5/16inch)2
Flangelocknut(5/16inch)2
Springpost(1-3/4inches)1
2
Screw(5/16x2-3/4inches)1
Installthelightbartothemachine.
LEDlight2
Harness1
Shield2
3Cabletie7
AssembletheLEDlightstothelightbar.
4Nopartsrequired–Installthewireharnesstothemachine.
5Nopartsrequired–Connectthespark-plugwire.
©2015—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3402-210*A

1
PreparingtheMachine
NoPartsRequired
Procedure
1.Ensurethereeldriveengagementleverisinthe
REEL-DRIVEOFFposition;refertotheOperator’s
Manual.
2.Movethemachinetoalevelsurfaceandsetthetraction
driveengagementlevertotheTRACTION-DRIVE
NEUTRALposition;refertotheOperator’sManual.
3.SetthethrottlecontroltotheSLOWpositionandset
theon-offswitchtotheOFFposition;refertothe
Operator’sManual.
4.Removethespark-plugwirefromtheterminalofthe
sparkplug(Figure1).
Figure1
1.Spark-plugwire
2
InstallingtheLightBartothe
Machine
Partsneededforthisprocedure:
1Rightlight-barstrap
4Spacer
4Flange-headbolt(3/8x1-1/4inches)
1Leftlight-barstrap
2Flange-headbolt(5/16x1inch)
2Washer(5/16inch)
2Flangelocknut(5/16inch)
1Springpost(1-3/4inches)
1Screw(5/16x2-3/4inches)
InstallingtheLightBarStrapstothe
Machine
Note:Haveanotherpersonhelpsupportthehandlebar
whileyouinstallthelightbartothemachine.
1.Withthekickstandup,removethelocknut,washer,
spacer,andscrew(5/16x1inch)securingeachsideof
thekickstandtothesideplates(AofFigure2).
Note:Retainthelocknuts,washers,spacers,and
screws(5/16x1inch)forinstallationinstep13.
2.Removethespringfromthespringpost(1inch)ofthe
kickstand(BofFigure2).
Note:Allowthekickstandtorotatetotheground.
2

Figure2
1.Kickstand5.Sideplate
2.Locknut6.Screw(5/16x1inch)
3.Washer7.Springpost(1inch)
4.Spacer8.Spring
3.Removetheangenut,washer,existingspringpost(1
inch),andscrew(5/16x2inches)fromtherightside
ofthekickstand(AofFigure3).
Note:Discardthescrew(5/16x2inches)andspring
post(1inch).Retaintheangenutandwasherfor
installationinstep5.
4.Installthenewspringpost(1-3/4inches)onthe
kickstandwiththenewscrew(5/16x2-3/4inches);
asshowninBofFigure3.
5.Usetheangenutandwasherthatyouretainedin
step3tosecurethespringposttothekickstand(Bof
Figure3).
Figure3
1.Kickstand5.Existingscrew(5/16x2
inches)
2.Flangenut6.Newspringpost(1-3/4
inches)
3.Washer7.Newscrew(5/16x2-3/4
inches)
4.Existingspringpost(1
inch)
6.Removethe2bolts(3/8x7/8inch)and2lockwashers
(3/8inch)thatsecurethespring-anchorbracketand
right-sideplatetotheouterpadoftherearframeofthe
machine(Figure4).
Note:Discardthebolts;retainthespring,
spring-anchorbracket,and2lockwashersfor
installationinstep7.
Figure4
1.Outerpad(rear
frame—machine)
4.Spring-anchorbracket
2.Right-sideplate5.Lockwasher(3/8inch)
3.Spring6.Bolt(3/8x7/8inch)
3

7.Assemblethespring-anchorbracket,rightlight-bar
strap,2spacers,andright-sideplatetotheouterpadof
therearframe(Figure5)withthe2ange-headbolts
(3/8x1-1/4inches)and2lockwashers(3/8inch)that
youremovedinstep6.
Figure5
1.Spring-anchorbracket5.Rightlight-barstrap
2.Outerpad(rear
frame—machine)
6.Spring
3.Right-sideplate7.Lockwasher(3/8inch)
4.Spacer8.Flange-headbolt(3/8x
1-1/4inches)
8.Removethe2bolts(3/8x7/8inch)and2lockwashers
(3/8inch)thatsecuretheleft-sideplatetotheouter
padoftherearframeofthemachine(Figure6).
Note:Discardthebolts;retainthe2lockwashersfor
installationinstep9.
Figure6
1.Bolt(3/8x7/8inch)3.Right-sideplate
2.Lockwasher(3/8inch)4.Outerpad(rear
frame—machine)
9.Assembletheleftlight-barstrap,2spacers,andleft-side
platetotheouterpadoftherearframe(Figure7)with
the2ange-headbolts(3/8x1-1/4inches)and2lock
washers(3/8inch—removedinstep6).
Figure7
1.Flange-headbolt(3/8x
1-1/4inches)
4.Spacer
2.Lockwasher(3/8inch)5.Left-sideplate
3.Leftlight-barstrap6.Outerpad(rear
frame—machine)
10.Torquethe4ange-headboltsto33to45N∙m(25
to33ft-lb).
4

11.Ensurethatthehookofthespringisinsertedthrough
holeinthespring-anchorbracket.
12.Seatthefreeendofthespringontothespringpostof
thekickstand(AofFigure8).
13.Attachthekickstandtothesideplateswiththe
locknuts,washers,spacers,andscrews(5/16x1inch)
thatyouretainedinstep1(BofFigure8).
Figure8
1.Kickstand5.Washer
2.Newspringpost(1-3/4
inches)
6.Spacer
3.Spring7.Rightsideplate
4.Locknut8.Screw(5/16x1inch)
AssemblingtheLight-BarStraps
1.Aligntheholesinthelightbarstrapsasfollows:
•For800SeriesMachines—alignthe2holesof
theleftlight-barstrapandtherightlight-barstrap
asshowninAofFigure9.
•For1000SeriesMachines—alignthe2holesof
theleftlight-barstrapandtherightlight-barstrap
asshowninBofFigure9.
•For1600SeriesMachines—alignthe2holesof
theleftlight-barstrapandtherightlight-barstrap
asshowninCofFigure9.
Figure9
1.Rightlight-barstrap5.Flangelocknut(5/16inch)
2.Washer(5/16inch)6.Flange-headbolt(5/16x
1inch)
3.Holealignment(800series
machines)
7.Holealignment(1000
seriesmachines)
4.Leftlight-barstrap8.Holealignment(1600
seriesmachines)
2.Assemblethelight-barstrapswiththe2ange-head
bolts(5/16x1inch),2washers(5/16inch),and2
angelocknut(5/16inch).
3.Torquethenutsandboltsto1,978to2,542N∙cm(175
to225in-lb).
5

3
AssemblingtheLEDLightsto
theLightBar
Partsneededforthisprocedure:
2LEDlight
1Harness
2Shield
7Cabletie
AssemblingtheWireHarnesstothe
LEDLightFixtures
1.Connectthe2-pinoftheLEDlightintothe2-socket
connectoroftheLEDlightharness(Figure10).
Note:Ensurethattheconnectorsarefullyseatedand
thelatchoftheconnectorssnaptogethersecurely.
Figure10
1.2-socketconnector(LED
lightharness)
3.2-socketconnector
2.LEDlight4.2-pinconnector(LEDlight)
2.Repeatstep1fortheotherLEDlightandtheother
2-socketconnectoroftheharness(Figure10).
3.Ifassembled,removethelongcarriageboltandnut
thatsecurethemountbrackettotheframeoftheLED
light(Figure11).
Figure11
1.Wireharness(LEDlight
kit)
5.Carriagebolt(short)
2.Carriagebolt(long)6.Mountbracket(LEDlight)
3.Frame(LEDlight)7.Nut
4.Shield
4.Ensurethattheshortcarriageboltisassembled
throughtheholeinthebottomofthemounting
bracketasshowninFigure11.
5.Aligntheholesintheshieldandmountbracketwith
theholesintheframeoftheLEDlightasshownin
Figure11.
Important:Ensurethewireharnesshasa
generousloopofwireinsidetheshield.When
adjustingthealignmentofthelights,youmustnot
beabletopullthewireharnesstightandstrain
the2-socketconnector.
6.Assembletheshieldandmountbrackettotheframe
oftheLEDlightwiththecarriageboltandnut(Figure
11).
7.Torquethenutto429to519N∙cm(38to46in-lb).
8.Repeatsteps3through7totheotherLEDlightand
shield.
6

AssemblingtheLEDLightFixturesto
theLight-BarStraps
1.Alignthelightxtureswiththelensesofthelights
towardthefrontofthemachine(Figure12).
Figure12
1.Hole(light-barstrap)5.Cableties
2.Carriagebolt(short)6.Nut
3.Leftlight-barstrap7.Frontofthemachine
4.Harness
2.Aligntheharnessalongtheleftlight-barstrapasshown
inFigure12.
3.Aligntheshortcarriageboltthatyouassembledtothe
mountbracketfortheLEDlightwiththeholeinthe
light-barstrap(Figure12).
4.AssembletheLEDlightandshortcarriagebolttothe
light-barstrapwithanut(Figure12).
5.Repeatsteps3and4fortheotherLEDlight.
6.Torquethenutto1,878to2,542N∙cm(175to225
in-lb)
7.Securethewireharnesstothelight-barstrapswith
cabletiesasshowninFigure12.
Note:Beforetighteningthecableties,makesurethat
theLEDlightsarealignedslightlydownwardfromthe
expectednalposition.Thiscanpreventdamageto
theharnessconnectorsifyourotatethelightsdown.
Note:Ifyouhaveexcesslengthofwireharness
betweentheLEDlights,bundlethewireharnessand
secureitatthecentercabletie.
4
InstallingtheWireHarnessto
theMachine
NoPartsRequired
Procedure
1.RoutethewireharnessfortheLEDlightkitdownthe
leftlight-barstrapandacrosstothelefthandle-bar
tube(Figure13).
Figure13
1.Cableties
2.Routethewireharnessupthelefthandle-bartubeto
thecontrolpanel(Figure13).
3.Securethewireharnesstotheleftlight-barstrapand
handle-bartubewith3cabletiesasshowninFigure13.
4.Atthebackoftheconsole,connectthe2-pinconnector
ofthewireharnessfortheLEDlightkitintothe
2-socketconnectorofthewireharnessfortheLED
lightandwirelesshourmeterharnesskit(Figure14).
7

Figure14
1.2-socketconnector(wire
harness—LEDlightand
wirelesshourmeter
harnesskit)
3.Console
2.2-pinconnector(wire
harness—LEDlightkit)
5.SecurethewireharnessfortheLEDlightkittothe
harnessofthemachinewithacabletieasshownin
Figure15.
Figure15
1.Wireharness(machine)3.Wireharness(LEDlight
kit)
2.Cabletie
5
ConnectingtheSpark-Plug
Wire
NoPartsRequired
Procedure
Connectthespark-plugwiretotheterminalofthesparkplug;
refertoFigure1of1PreparingtheMachine(page2).
8