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

Cabletie3

Assemblethelightbartothemachine.

4Nopartsrequired–AssembletheLEDlightstothelightbar.

5Cabletie3Installthewireharnesstothemachine.

62-positionrockerswitch1Installthelightswitch(machinemodels

04042,04043,04046,and04047).

7Nopartsrequired–Finishthelightkitinstallation.

8111LyndaleAvenueSouth

Bloomington,MN55420

Registeratwww.Toro.com.OriginalInstructions(EN)

PrintedintheUSA

AllRightsReserved*3399-947*C

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

Figure2

1.P04T-handleconnector

(batteryadapter-wire

harness)

2.P04connector

(battery-wireharness)

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).

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.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).

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

Important:Ensurethewireharnesshasa

generousloopofwireinsidetheshield.When

adjustingthealignmentofthelights,theoperator

mustnotbeabletopullthewireharnesstightand

strainthe2-socketconnector.

6.Assembletheshieldandmountbrackettotheframeof

theLEDlightwiththecarriageboltandnut(Figure8).

7.Torquethenutto429to519N∙cm(38to46in-lb).

8.Repeatsteps3through7totheotherLEDlightand

shield.

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.

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.

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.

InstallingtheLightSwitch

eFlex1800and2100SeriesMachines

Partsneededforthisprocedure:

12-positionrockerswitch

Procedure

1.Removetheplugfromtheopeningattheleftfaceof

thecontrolpanel(Figure13).

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).

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).

Notes:

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