Toro Greensmaster Flex 1800 User manual

FormNo.3399-947RevC
LEDLightKit
Greensmaster®Flex™1800/2100SeriesandeFlex®1800/2100
SeriesMower
ModelNo.04293
InstallationInstructions
WARNING
CALIFORNIA
Proposition65Warning
ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato
causecancer,birthdefects,orreproductiveharm.
Important:IfyouareinstallingtheLEDLightKitonGreensmasterModels04040,04041,04044,and04045,ensure
thatyouhaveinstalledtheLEDLightandWirelessHourMeterHarnessKitfor2012andAfter(Model04295)
beforeyouinstalltheLEDlightkit.
Note:Determinetheleft,right,front,andbacksidesofthemachinefromthenormaloperatingposition.
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachine.
2Nopartsrequired–Removethecontrol-panelcover.
Leftlight-barstrap1
Flange-headbolt(5/16x1-1/4inches)4
Flangelocknuts(5/16inch)6
Flange-headbolt(5/16x1inch)2
Washer(5/16inch)2
Rightlight-barstrap1
3
Cabletie3
Assemblethelightbartothemachine.
4Nopartsrequired–AssembletheLEDlightstothelightbar.
5Cabletie3Installthewireharnesstothemachine.
62-positionrockerswitch1Installthelightswitch(machinemodels
04042,04043,04046,and04047).
7Nopartsrequired–Finishthelightkitinstallation.
©2016—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3399-947*C

1
PreparingtheMachine
NoPartsRequired
DisconnectingtheSpark-PlugWire
Flex1800and2100SeriesMachines
1.Ensurethetractionandreeldriveengagementleveris
intheREEL-DRIVEOFFposition;refertotheOperator’s
Manual.
2.Movethemachinetoalevelsurfaceandsetthe
tractionandreeldriveengagementlevertothe
TRACTION-DRIVENEUTRALposition;refertothe
Operator’sManual.
3.SetthethrottlecontroltotheSLOWpositionandrotate
theOn-OffswitchtotheOFFposition;refertothe
Operator’sManual.
4.Removethespark-plugwirefromtheterminalofthe
sparkplug(Figure1).
Figure1
1.Spark-plugwire
DisconnectingtheBattery
eFlex1800and2100SeriesMachines
1.Ensurethetractionandreeldriveengagementleveris
intheREEL-DRIVEOFFposition.
2.Movethemachinetoalevelsurfaceandsetthe
tractionandreeldriveengagementlevertothe
TRACTION-DRIVENEUTRALposition.
3.RotatethekeyswitchtotheOFFposition.
4.Wait10to15minutesforthemotorcapacitorsto
discharge.
5.DisconnecttheT-handleconnectorofthebattery
adapterwireharnessfromtheP04connectorofthe
battery-wireharness(Figure2).
G017237
12
Figure2
1.P04T-handleconnector
(batteryadapter-wire
harness)
2.P04connector
(battery-wireharness)
2

2
RemovingtheControl-Panel
Cover
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.Movethecontrolpanelcoverupandforwardfromthe
controlpanel,andremovethecoverfromthemachine
(Figure3).
Note:Retaintheange-headscrewsandcontrol-panel
coverforassemblyinInstallingtheControl-Panel
Cover(page9).
3
AssemblingtheLightBarto
theMachine
Partsneededforthisprocedure:
1Leftlight-barstrap
4Flange-headbolt(5/16x1-1/4inches)
6Flangelocknuts(5/16inch)
2Flange-headbolt(5/16x1inch)
2Washer(5/16inch)
1Rightlight-barstrap
3Cabletie
InstallingtheLightBarStrapstothe
Machine
1.Alignthe2holesintheleftlight-barstrapwiththe2
holes9.5mm(3/8inch)intheleftsideplate(Figure4).
Figure4
Enginemodelshown;theelectricalmodelsaresimilar.
1.Frontofthemachine4.Hole(leftsideplate)
2.Flange-headbolt(3/8x
1-1/4inches)
5.Flangelocknut(3/8inch)
3.Leftlight-barstrap
2.Assembletheleftlight-barstraptotheleftsideplate
(Figure4)withthe2ange-headbolts(3/8x1-1/4
inches)and2angelocknuts(3/8inch).
3

3.Alignthe2holesintherightlight-barstrapwiththe2
holes9.5mm(3/8inch)holesintherightsideplate
(Figure5).
Figure5
Enginemodelshown;theelectricalmodelsaresimilar.
1.Frontofthemachine4.Rightlight-barstrap
2.Flangelocknut(3/8inch)5.Flange-headbolt(3/8x
1-1/4inches)
3.Hole(rightsideplate)
4.Assembletherightlight-barstraptotherightsideplate
(Figure5)withthe2ange-headbolts(3/8x1-1/4
inches)and2angelocknuts(3/8inch).
5.Torquetheange-headboltsandangenutsto37to
45N∙m(27to33ft-lb).
AssemblingtheLight-BarStraps
1.Aligntheholesinthelight-barstrapsasfollows:
•FlexandeFlex1800seriesmachines—alignthe
2holesfurthestfromthestraightendsoftheleft
light-barstrapandtherightlight-barstrap(Aof
Figure6).
•FlexandeFlex2100seriesmachines—align
the2holesclosesttothestraightendsoftheleft
light-barstrapandtherightlight-barstrap(Bof
Figure6).
Figure6
1.Flange-headbolt(5/16x
1inch)
5.Rightlight-barstrap
2.Holealignment(Flex
andeFlex1800series
machines)
6.Washer(5/16inch)
3.Leftlight-barstrap7.Holealignment(Flex
andeFlex2100series
machines)
4.Flangelocknut(5/16inch)
2.Assemblethelight-barstrapswiththe2ange-head
bolts(5/16x1inch),2washers(5/16inch),and2
angelocknut(5/16inch).
3.Torquethenutsandboltsto1,978to2,542N∙cm(175
to225in-lb).
4

4
AssemblingtheLEDLightsto
theLightBar
NoPartsRequired
AssemblingtheWireHarnesstothe
LEDLightFixtures
1.Connectthe2-pinoftheLEDlightintothe2-socket
connectoroftheLEDlightharness(Figure7).
Note:Ensurethattheconnectorsarefullyseatedand
thelatchoftheconnectorssnaptogethersecurely.
Figure7
1.2-socketconnector(LED
lightharness)
3.2-socketconnector
2.LEDlight4.2-pinconnector(LEDlight)
2.Repeatstep1fortheotherLEDlightandtheother
2-socketconnectoroftheharness(Figure7).
3.Ifassembled,removethelongcarriageboltandnut
thatsecurethemountbrackettotheframeoftheLED
light(Figure8).
Figure8
1.LEDlightharness5.Carriagebolt(short)
2.Carriagebolt(long)6.Mountbracket(LEDlight)
3.Frame(LEDlight)7.Nut
4.Shield
4.Ensurethattheshortcarriageboltisassembled
throughtheholeinthebottomofthemounting
bracketasshowninFigure8.
5.Aligntheholesintheshieldandmountbrackettothe
holesintheframeoftheLEDlightasshowninFigure
8.
Important:Ensurethewireharnesshasa
generousloopofwireinsidetheshield.When
adjustingthealignmentofthelights,theoperator
mustnotbeabletopullthewireharnesstightand
strainthe2-socketconnector.
6.Assembletheshieldandmountbrackettotheframeof
theLEDlightwiththecarriageboltandnut(Figure8).
7.Torquethenutto429to519N∙cm(38to46in-lb).
8.Repeatsteps3through7totheotherLEDlightand
shield.
5

AssemblingtheLEDLightFixturesto
theLight-BarStraps
1.Alignthelightxtureswiththelensesofthelights
towardthefrontofthemachine(Figure9).
Figure9
1.Hole(light-barstrap)5.Cableties
2.Carriagebolt(short)6.Nut
3.Leftlight-barstrap7.Frontofthemachine
4.Harness
2.Aligntheharnessalongtheleftlight-barstrapasshown
inFigure9.
3.Aligntheshortcarriageboltthatyouassembledtothe
mountbracketfortheLEDlightwiththeholeinthe
light-barstrap(Figure9).
4.AssembletheLEDlightandshortcarriagebolttothe
light-barstrapwithanut(Figure9).
5.Repeatsteps3and4fortheotherLEDlight.
6.Torquethenutto1,878to2,542N∙cm(175to225
in-lb)
7.Securethewireharnesstothelight-barstrapswith
cabletiesasshowninFigure9.
Note:Beforetighteningthecableties,makesurethe
LEDlightsarealignedslightlydownwardfromthe
expectednalposition.Thiscanpreventdamaging
theharnessconnectorsifthelightsarerotateddown
bytheoperator.
Note:Ifyouhaveexcesslengthofwireharness
betweentheLEDlights,bundlethewireharnessand
secureitatthecentercabletie.
5
InstallingtheWireHarnessto
theMachine
Partsneededforthisprocedure:
3Cabletie
RoutingtheWireHarness
1.RoutethewiringharnessfortheLEDlightkitdown
theleftlight-barstrapandacrosstothelefthandle-bar
tube(Figure10).
Figure10
1.Cableties
2.Routethewireharnessupthelefthandle-bartubeto
thecontrolpanel(Figure10).
3.Securethewireharnesstotheleftlight-barstrapand
handle-bartubewith3cabletiesasshowninFigure10.
Important:Ifthehandleisnotfullyextended
out,makesurethereissufcientslackinthe
wireharness—approximately76mm(3inches)
betweenthelowestcabletieonthehandleandthe
light-barstrap.
6

ConnectingtheWireHarnesstothe
WireHarnessoftheLEDLightand
WirelessHourMeterHarnessKit
Flex1800and2100SeriesMachines
Note:The2-positionrockerswitchwitha10-pinconnector
isinstalledintheLEDlightandwirelesshourmeterharness
kit.
1.Alignthe2socketconnectorofthewireharnessfor
theLEDlightandwirelesshourmeterharnesskitwith
the2pinconnectorofthewiringharnessoftheLED
lightkit(Figure11).
Figure11
1.2-positionrockerswitch—
10-pinconnector(installed
intheLEDlightand
wirelesshourmeter
harnesskit)
3.2-socketconnector(wire
harness—LEDlightand
wirelesshourmeter
harnesskit)
2.2-pinconnector(wire
harness—LEDlightkit)
2.Connectthe2socketconnectorofthelight-kitharness
tothe2pinconnectoroftheLEDlightandwireless
hourmeterharness(Figure11).
Note:Ensurethattheconnectorsarefullyseatedand
thelatchoftheconnectorssnaptogethersecurely.
ConnectingtheWireHarnesstothe
WireHarnessoftheMachine
eFlex1800and2100SeriesMachines
1.Alignthe2-socketconnectofthewireharnessfor
themachinewiththe2-pinconnectorofthelight-kit
harness(Figure12).
Figure12
1.Plug3.2-socketconnect(wire
harnessofthemachine)
2.2-pinconnector(light-kit
harness)
2.Connectthe2-socketconnectofthewireharnessfor
themachinewiththe2-pinconnectorofthelight-kit
harness(Figure12).
Note:Ensurethattheconnectorsarefullyseatedand
thelatchoftheconnectorssnaptogethersecurely.
6
InstallingtheLightSwitch
eFlex1800and2100SeriesMachines
Partsneededforthisprocedure:
12-positionrockerswitch
Procedure
1.Removetheplugfromtheopeningattheleftfaceof
thecontrolpanel(Figure13).
7

Figure13
1.Plug3.2-positionrockerswitch
2.Opening(controlpanel)4.10-socketconnector
(wireharness—LEDlight
andwirelesshourmeter
harnesskit)
2.Pullupthe8-socketconnectorofthewireharnessfor
themachinethroughtheopeninginthecontrolpanel
(Figure13).
3.Connectthe8-pinconnectorofthe2-positionrocker
switchintothe8-socketconnectorofthewireharness
forthemachine(Figure13).
Note:Ensurethattheconnectorsarefullyseatedand
thelatchoftheconnectorssnaptogethersecurely.
4.Aligntheswitchsothatthenotchinthebodyofthe
switchistowardthebackofthecontrolpanel(Figure
14).
Figure14
1.Opening(controlpanel)3.Notch(body—rocker
switch)
2.Rockerswitch4.Backofthecontrolpanel
5.Inserttheswitchintotheopeninginthecontrolpanel
untiltheswitchsnapssecurelyintothepanel(Figure
14).
8

7
FinishingtheLightKit
Installation
NoPartsRequired
InstallingtheControl-PanelCover
1.Alignthekeyholeslotinthecontrol-panelcoverover
thetractionandreeldrivehandle(Figure15).
Figure15
1.Tractionandreeldrive
handle
3.Flange-headscrew(1/4x
1/2inch)
2.Keyholeslot(control-panel
cover)
4.Supportbracket(handle
bar)
2.Aligntheholesinthecontrol-panelcovertotheholes
inthesupportbracketofthehandlebar(Figure15).
3.Assemblethecovertothebracket(Figure15)withthe
4ange-headscrew(1/4x1/2inch)thatyouremoved
instep1of(page).
4.Tightenthescrewsbyhand.
ConnectingtheSpark-PlugWire
Flex1800and2100SeriesMachines
Connectthespark-plugwiretotheterminalofthespark
plug;refertoFigure1ofDisconnectingtheSpark-PlugWire
(page2).
ConnectingtheBattery
eFlex1800and2100SeriesMachines
ConnecttheT-handleconnectorofthebatteryadapter-wire
harnesstotheP04connectorofthebattery-wireharness;
refertoFigure2ofDisconnectingtheBattery(page2).
9

Notes:
10