Toro 04295 User manual

FormNo.3401-934RevA
LEDLightandWirelessHourMeterHarnessKit
2012andAfterGreensmaster®800,1000,1600,Flex™1800,or
2100SeriesMower
ModelNo.04295
InstallationInstructions
ContactyourAuthorizedToroDistributorformoreinformation.
ThisproductcomplieswithallrelevantEuropeandirectives;fordetails,pleaseseetheseparateproductspecicDeclarationof
Conformity(DOC)sheet.
WARNING
CALIFORNIA
Proposition65Warning
ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato
causecancer,birthdefects,orreproductiveharm.
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachine.
2Nopartsrequired–Removethecontrol-panelcover(1800
or2100seriesmachines).
Flangeheadscrew2
Voltageregulator1
Mountingbracket1
3Wireharness1
Assemblethevoltageregulator.
4Cabletie2Routethewireharness.
5Rockerswitch1Connectthewireharness.
6Nopartsrequired–FinishtheLEDlightandwirelesshour
meterharnesskitinstallation.
7Nopartsrequired–InstallthewireharnesstotheLEDlight
kitand/orwirelesshourmeterkit.
©2015—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3401-934*A

1
PreparingtheMachine
NoPartsRequired
Preparingan800,1000,or1600Series
Machine
1.Ensurethereel-driveleverisintheREEL-DRIVEOFF
position;refertotheOperator’sManual.
2.Movethemachinetoalevelsurfaceandsetthe
traction-drivelevertotheTRACTION-DRIVENEUTRAL
position;refertotheOperator’sManual
3.SetthethrottlecontroltotheSLOWpositionandset
theOn-OffswitchtotheOFFposition;refertothe
Operator’sManual.
4.Settheparkingbrake;refertotheOperator’sManual.
5.Disconnectthespark-plugwirefromtheterminalof
thesparkplug(Figure1).
Figure1
1.Spark-plugwire
Preparingan1800or2100Series
Machine
1.Ensurethetractionandreeldriveengagementleveris
intheREEL-DRIVEOFFposition;refertotheOperator’s
Manual.
2.Movethemachinetoalevelsurfaceandsetthe
tractionandreeldriveengagementlevertothe
TRACTION-DRIVENEUTRALposition;refertothe
Operator’sManual.
3.SetthethrottlecontroltotheSLOWpositionandset
theOn-OffswitchtotheOFFposition;refertothe
Operator’sManual.
4.Settheparkingbrake;refertotheOperator’sManual.
5.Disconnectthespark-plugwirefromtheterminalof
thesparkplug(Figure2).
Figure2
1.Spark-plugwire
2

2
RemovingtheControl-Panel
Cover(1800or2100Series
Machines)
NoPartsRequired
Procedure
1.Removethe4ange-headscrews(1/4x1/2inch)that
securethecontrol-panelcovertothesupportbracket
ofthehandlebar(Figure3).
Figure3
1.Control-panelcover3.Supportbracket(handle
bar)
2.Flange-headscrew(1/4x
1/2inch)
2.Movethecontrol-panelcoverupandforwardfromthe
controlpanel,andremovethecoverfromthemachine
(Figure3).
Note:Retaintheange-headscrewsandcontrol-panel
coverforassemblyin6FinishingtheLEDLightand
WirelessHourMeterHarnessKitInstallation(page
10).
3
AssemblingtheVoltage
Regulator
Partsneededforthisprocedure:
2Flangeheadscrew
1Voltageregulator
1Mountingbracket
1Wireharness
AssemblingtheVoltageRegulator,
MountingBracket,andWireHarness
1.Alignthegroundterminalandtheslotsinthevoltage
regulatortotheholesinthemountingbracket(Figure
4).
Figure4
1.Flangeheadscrew3.Voltageregulator
2.Groundterminal4.Mountingbracket
2.Assembletheterminalandregulatortothebracket
with2angeheadscrews(Figure4).
3.Torquetheangeheadscrewsto283to395N∙cm(25
to35in-lb).
4.Connectthe3-pinconnectorofthewireharnesswith
the3-socketconnectorofthevoltageregulator(Figure
5).
Note:Ensurethattheconnectorsarefullyseatedand
thelatchoftheconnectorssnaptogethersecurely.
3

Figure5
1.3-pinconnector(wire
harness)
2.3-socketconnector
(voltageregulator)
AssemblingtheVoltageRegulatorand
MountingBrackettotheMachine
1.Preparethemachineforinstallationofthevoltage
regulatorandmountingbracketbyperformingthe
following:
•800,1000,or1600seriesmachine
A.Atthebackoftheengine,removethecabletie
thatsecuresthewireharnessfortheinterlock
moduletothewire-harnessbracket(Aof
Figure7).
Figure6
Figure7
1.Cabletie(r-treeanchor)4.Stud(fueltank)
2.Wire-harnessbracket5.Flange-headbolt(10-24x
3/8inch)
3.Nut6.Interlockmodule
B.Removethe2nutsthatsecurethewire-harness
brackettotheengine(AofFigure7)
C.Removetheange-headbolt10-24x3/8
inchthatsecurestheinterlockmoduletothe
wire-harnessbracket(Figure7).
Note:Younolongerneedthewire-harness
bracket.
•1800or2100seriesmachine—Atthebackofthe
engine,removethe2nutsthatsecurethetankto
theengine(Figure9).
Figure8
1.Fueltank3.Stud(fueltank)
2.Nut
4

2.Alignthegroundterminalofthewireharnesswiththe
leftholeshortangeofthemountingbracketforthe
voltageregulatorasshowninFigure9.
Figure9
1.Groundterminal(wire
harness)
3.Nut
2.Stud(fueltank)4.Mountingbracket(voltage
regulator)
3.Aligntheholesintheshortangeofthemounting
bracketforthevoltageregulatorwiththerearstuds
ofthefueltank(Figure9).
4.Assemblethemountingbracketandgroundterminal
totheenginewiththe2nutsthatyouremovedinstep
1(Figure9).
5.Torquethenutsto9.7to12.0N∙m(86to106in-lb).
4
RoutingtheWireHarness
Partsneededforthisprocedure:
2Cabletie
Procedure
1.Routethewireharnessfromthemountingbracketto
thelefthandlebar(Figure10andFigure11).
Figure10
800,1000,or1600SeriesMachine
1.Console3.Cableties
2.Wireharness4.Lefthandlebartube
5

Figure11
1800or2100SeriesMachines
1.Lefthandlebar3.Wireharness
2.Supportbracket(handle
bar)
4.Cableties
2.Routethewireharnessalongthelefthandlebarand
acrossthesupportbracketofthehandlebars(Figure
11).
3.Securethewireharnesswith2cabletiesasshownin
Figure10andFigure11.
5
ConnectingtheWireHarness
Partsneededforthisprocedure:
1Rockerswitch
ConnectingtheWireHarnesstothe
Engine
1.Locatetheengine-alternatorharnessattherearsideof
theenginecase(Figure12).
Note:Theengine-alternatorharnesshas2wireswith
singlesocketconnectors.
Figure12
1.Bulletconnectors(wire
harness)
2.Socketconnectors
(engine-alternator
harness)
2.Connectthe2bulletconnectorsofthewireharness
tothe2socketconnectorsoftheengine-alternator
harness(Figure12).
6

IdentifyingtheElectricalConnectors
•Usethe3-socketconnectorwheninstallingtheoptional
Wireless-HourMeterKit(Figure13andFigure14).
•Usethe2-socketconnectorlightharnessinterconnect
wheninstallingtheoptionalLEDLightKit(Figure13
andFigure14)
Figure13
800,1000,or1600SeriesMachine
1.2-socketconnector
(LED-lightharness
interconnect—usewith
theoptionalLEDLightKit)
3.10-socketconnector(light
switch)
2.3-socketconnector(hour
meter—usewiththe
optionalWirelessHour
MeterKit)
Figure14
1800or2100SeriesMachines
1.10-socketconnector(light
switch)
3.2-socketconnector
(LED-lightharness
interconnect—usewith
theoptionalLEDLightKit)
2.3-socketconnector(hour
meter—usewiththe
optionalWirelessHour
MeterKit)
7

InstallingtheLightSwitch(800,1000,
1600SeriesMachines)
1.Removetheknock-outplugatthetopleftareaforthe
console(AFigure15).
Figure15
1.Knock-outplug(console)3.10-socketconnector(wire
harness—LightKitand
HourMeterWireHarness
Kit)
2.2-positionrockerswitch
2.Pullupthe10-socketconnectorofthewireharness
fromthelightkitandhourmeterwireharnesskit
throughtheopeninginthecontrolpanel(Figure15).
3.Connectthe10-pinconnectorofthe2-positionrocker
switchintothe10-socketconnectorofthelightkitand
hourmeterkit(Figure15).
Note:Ensurethattheconnectorsarefullyseatedand
thelatchoftheconnectorssnaptogethersecurely.
4.Aligntheswitchsothatthenotchinthebodyofthe
switchistowardtheleftsideofthecontrolpanel
(Figure16).
Figure16
1.Opening(controlpanel)3.Notch(body—rocker
switch)
2.2-positionrockerswitch4.Leftsideofthecontrol
panel
5.Inserttheswitchintotheopeninginthecontrolpanel
untiltheswitchsnapssecurelyintothepanel(Figure
16).
8

InstallingtheLightSwitch(1800or
2100SeriesMachines)
1.Removetheplugfromtheopeningattheleftfaceof
thecontrolpanel(Figure17).
Figure17
1.Plug3.2-positionrockerswitch
2.Opening(controlpanel)4.10-socketconnector(wire
harness—LightKitand
HourMeterWireHarness
Kit)
2.Pullupthe10-socketconnectorofthewireharness
fromthelightkitandhourmeterwireharnesskit
throughtheopeninginthecontrolpanel(Figure17).
3.Connectthe10-pinconnectorofthe2-positionrocker
switchintothe10-socketconnectorofthelightkitand
hourmeterkit(Figure17).
Note:Ensurethattheconnectorsarefullyseatedand
thelatchoftheconnectorssnaptogethersecurely.
4.Aligntheswitchsothatthenotchinthebodyofthe
switchistowardthefrontofthecontrolpanel(Figure
18).
Figure18
1.Opening(controlpanel)3.Notch(body—rocker
switch)
2.2-positionrockerswitch4.Frontofthecontrolpanel
5.Inserttheswitchintotheopeninginthecontrolpanel
untiltheswitchsnapssecurelyintothepanel(Figure
18).
9

6
FinishingtheLEDLightand
WirelessHourMeterHarness
KitInstallation
NoPartsRequired
InstallingtheControl-PanelCover
(1800or2100SeriesMachines)
1.Alignthekey-holeslotinthecontrol-panelcoverover
thetractionandreeldriveengagementlever(Figure19).
Figure19
1.Tractionandreeldrive
engagementlever
3.Flange-headscrews(1/4
x1/2inch)
2.Key-holeslot
(control-panelcover)
4.Supportbracket(handle
bar)
2.Aligntheholesinthesideofthecontrol-panelcover
withtheholesinthesupportbracketforthehandle
bars(Figure19).
3.Installthecontrol-panelcovertothesupportbracket
withthe4ange-headscrews(1/4x1/2inch)thatyou
removedinstep1of2RemovingtheControl-Panel
Cover(1800or2100SeriesMachines)(page3).
4.Torquetheange-headscrewsto5.2to6.8N∙m(46
to60in-lb).
ConnectingtheSpark-PlugWire
Connectthespark-plugwiretotheterminalofthesparkplug
asshowninFigure2of1PreparingtheMachine(page2).
7
InstallingtheWireHarness
totheLEDLightKitand/or
WirelessHourMeterKit
NoPartsRequired
Procedure
•RefertotheinstallationinstructionsinyourLEDLight
KittoinstallthewireharnessfortheLEDlighttothe
wireharnessoftheLEDLightandWirelessHourMeter
HarnessKit.
•RefertotheinstallationinstructionsinthemyTurf™
WirelessHourmeterSystemreferenceguidetoinstallthe
hourmetertothewireharness.
10