Form No. 3385-895 Rev A Greensmaster® Flex™ 1800 and 2100 Traction Unit Model No. 04040—Serial No. 314004001 and Up Model No. 04041—Serial No. 314004001 and Up g018274 Register at www.Toro.com.
This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet. your product ready. Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided. WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm.
Contents Storage ........................................................................34 Introduction .................................................................. 2 Safety ........................................................................... 4 Safe Operating Practices........................................... 4 Toro Mower Safety .................................................. 5 Sound Power Level .................................................. 6 Sound Pressure Level...................
Safety This machine meets or exceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-2012 specifications in effect at the time of production. • • Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER-“personal safety instruction.
• Use care when checking the reel. Wear gloves and use – after striking a foreign object or if an abnormal vibration occurs. Inspect the mower for damage and make repairs before restarting and operating the equipment. • caution when servicing them. Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.
Sound Pressure Level guards can lead to thrown object injuries. Do not resume mowing until the area is cleared. • Model 04040: Maintenance and Storage This unit has a sound pressure level at the operator’s ear of 84 dBA, which includes an Uncertainty Value (K) of 1 dBA. • Check all fuel lines for tightness and wear on a regular • • • • basis. Tighten or repair them as needed.
120–2769 1. Toxic gas inhalation hazard—do not operate indoors. 115-7051 1. Fast 2. Continuous variable setting 3. Slow 2. Explosion hazard—stop the engine and keep away from open flames when refueling. 3. Warning—stop the engine and turn off the fuel before leaving the machine. 4. Warning—disconnect the spark plug wire and read the instruction before servicing or performing maintenance. 5. Hot surface/burn hazard—do not touch hot surfaces. 6.
115-7274 1. Lights (optional) 3. Engine—start 2. Hour meter 4.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 Description Qty. Use Bolt, 3/8 x 3/4 inch 2 Install the cutting unit to the traction unit Handle retainer Hair pin cotter 2 2 Install the handle retainers Transport wheels (Optional Transport Wheel Kit, Model 04123) 2 Install the transport wheels. No parts required – Check the engine oil level Grass basket 1 Install the grass basket.
Note: Determine the left and right sides of the machine from the normal operating position. 1 Installing the Cutting Unit to the Traction Unit Parts needed for this procedure: 2 Figure 4 Bolt, 3/8 x 3/4 inch 1. Transmission coupling Procedure 4. Maneuver the traction unit frame (Figure 5) forward until it engages the cutting unit pivot arms. 1. Place the mower on its drums on a level surface. 3 2.
2 3 Installing the Handle Retainers Installing the Transport Wheels Parts needed for this procedure: 2 Handle retainer 2 Hair pin cotter Parts needed for this procedure: 2 Procedure Transport wheels (Optional Transport Wheel Kit, Model 04123) Procedure 1. While supporting the handle, remove the cable ties securing the handle clamps to the side plates (Figure 6). 1.
3. Rotate the wheel back and forth until it slides completely onto the axle and the locking clip is secured in the groove on the axle shaft. 2. Guide the basket lip between the cutting unit side plates and over the front roller (Figure 9). 3. Install the basket hooks over the frame loop (Figure 9). 4. Repeat the procedure on the opposite side of the machine. Important: If you ever drop the basket, examine the pitch arm contact points near the lower lip of the basket for damage (Figure 10).
Throttle Control Product Overview The throttle control (Figure 12 and Figure 13) is located on the right rear side of the control panel. Rotate the throttle to regulate the engine speed. The lever connects to and operates the throttle linkage to the carburetor. The engine speed can be varied from 1565 ±100 rpm to 3265 ±75 rpm. 3 2 4 5 6 1 1 7 g018266 9 2 8 Figure 11 1. Traction and reel drive engagement lever 6. Fuel tank 2. Operator presence control 7. Grass basket 3. Handle 8.
Figure 15 1. Parking brake latch 2. Service brake Parking Brake Latch Figure 14 1. Neutral 3. Traction drive-engaged (transport) 2. Traction drive neutral and reel drive off 4. Traction drive and reel drive engaged The parking brake latch (Figure 15) is used in conjunction with the service brake. With the service brake engaged, rotate the parking brake latch toward the brake handle and release the service brake onto the latch to hold the service brake in place. Pull the brake lever to release it.
Recoil Starter Pull the recoil starter handle (Figure 18) to start the engine. g018267 Figure 16 1. Choke lever in choke position g018268 Figure 18 1. Recoil starter Fuel Shut-off Valve The fuel shut-off valve (Figure 17) is located on the engine. The valve has two positions: Closed and Open. Move the lever to the closed position when storing or transporting machine. Open the valve before starting the engine. The fuel cup is located below the shut-off valve.
1 2 3 G018142 Figure 21 1. Kickstand—storage position 2. Locking pin g018793 Figure 19 1. Lower center machine handle 2. Kickstand loop Figure 20 1. Kickstand 2. Kickstand loop • To prevent the unit from tipping backwards when removing the reel, lower the kickstand and push in the locking pin to lock it in the service position (Figure 21). 16 3.
Specifications Operation 1800 Traction Unit Width 82.5 cm (32-1/2 inches) Height 104.8 cm (41–1/4 inches) Length with basket 152.4 cm (60 inches) Net Weight (with 11 blade cutting unit and grass basket installed) 117 kg (258 lb) Note: Determine the left and right sides of the machine from the normal operating position. Think Safety First Please carefully read all of the safety instructions and decals in the safety section. Knowing this information could help you or bystanders avoid injury.
DANGER WARNING In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills. • Keep face away from nozzle and gas tank or conditioner bottle opening.
Starting and Stopping the Engine Note: For illustrations and descriptions of the controls referenced in this section, refer to the Controls section in Operation. Starting the Engine Note: Make sure the spark plug wire is installed on the spark plug. 1. Make sure the traction and reel drive levers are in the Disengaged position. Note: The engine will not start if the traction lever is in the engaged position. Figure 23 1. Handle clamp 2. Move the on/off switch to the On position. 3. Carriage bolts 3.
4. Ensure the traction and reel drive controls are in Disengage position and start engine. 5. Set the throttle control to Slow, tip the front of the machine up, gradually engage the traction drive and slowly increase the engine speed. 6. Adjust the throttle to operate the mower at the desired ground speed and transport the mower to the desired destination. Preparing to Mow 1. Return the traction control lever to the Disengage, throttle to Slow and stop the engine. Figure 25 2.
Checking the Operation of the Interlock Switches Service Interval: Before each use or daily CAUTION If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. • Do not tamper with the interlock switches. • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine. Using the Operator Presence Control (OPC) Interlock Switch 1.
Releasing the Transmission 5. With the OPC depressed and the shift lever moved to the left, engage the traction and reel drive, release the OPC (Figure 27). The traction lever should disengage. If the traction lever does not disengage, the interlock system needs service. Correct the problem before operating. Refer to Servicing the Traction Interlock Switch (page 30), Adjusting the Traction Control (page 33), or Adjusting the Reel Control (page 34).
Setting the Machine to Match Turf Conditions Use the following table to set the machine to match turf conditions.
121-4681 Narrow Wiehle—Long 6.4 cm (2.5 inches)/Aluminum More edge support; 1.7 inches (4.3 cm) longer 120-9605 Rear Roller 5.1 cm (2.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Important: When using the unit in conjunction with the Trans Pro 80, always use the stops on the trailer when servicing the machine. Over tipping can result in fuel spillage. The stop on the Rail Ramp Kit requires a broom handle or similar item to be inserted through the holes behind the wheels.
Daily Maintenance Checklist Important: Duplicate this page for routine use. Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri. Check the safety interlock operation. Check the parking brake operation. Check that pivot joints operate freely. Check the fuel level. Check the engine oil level. Check the air filter. Clean the engine cooling fins. Check for unusual engine noises. Check for unusual operating noises. Check the reel-to-bedknife adjustment. Check the height-of-cut adjustment.
Engine Maintenance Servicing the Engine Oil The crankcase must be filled with approximately 20 fluid ounces (0.6 l) of the proper viscosity oil before staring. The engine uses any high-quality oil having the American Petroleum Institute - APl - “service classification" SE or higher. Oil viscosity - weight - must be selected according to ambient temperature. Figure 29 illustrates the temperature/viscosity recommendations. 1 2 g018270 Figure 30 2. Drain plug 1. Oil level gauge 3.
6. Dispose of the used oil properly. Recycle as per local codes. Servicing the Air Cleaner Service Interval: Every 50 hours 1. Make sure the wire is off the spark plug. 2. Remove the wing nut securing the air cleaner cover to the air cleaner and remove the cover. Clean the cover thoroughly (Figure 32 and Figure 33). 1 Figure 33 g018271 Figure 32 1. Air cleaner cover 3. If the foam element is dirty, remove it from the paper element (Figure 33). Clean it thoroughly. C. 4. Foam element 5.
Servicing the Spark Plug Fuel System Maintenance Service Interval: Every 100 hours Use an NGK BR 6HS spark plug or equivalent. The correct air gap is 0.6 to 0.7 mm (0.024 to 0.028 inch). Cleaning the Fuel Cup and Screen 1. Pull the molded wire off the spark plug (Figure 34). Service Interval: After the first 20 hours Every 100 hours/Monthly (whichever comes first) 1. Close the fuel shut off valve and unscrew the fuel cup from the filter body (Figure 36).
Electrical System Maintenance 6. Install the fuel tank cap to the fuel tank. Replacing the Fuel Line Service Interval: Every 1,000 hours Servicing the Traction Interlock Switch Replace the fuel line after every 1000 hours. If fuel leaks from the line, replace it immediately. Use the following procedure if the switch needs adjustment or replacement. 1. Make sure the engine is off. 2. Remove the control panel. 3. Engage the traction lever. Figure 38 1. Traction lever 2. Interlock switch 4.
Brake Maintenance Servicing the Brake Interlock Switch 2. Remove the control panel. Adjusting the Service/Parking Brake 3. Engage the service brake lever and engage the parking brake latch. If the service/parking brake slips when operated, an adjustment to the cable is required. 1. Make sure the engine is off. 4. Loosen the interlock switch mounting fasteners (Figure 39). 1. Move the service/parking brake lever to the Off position. 2. Remove the control panel. 3.
Belt Maintenance D. Make sure the compression spring is applying the proper tension on the belt. E. Tighten the bearing housing mounting nut. Inspecting the Reel Drive Belt F. Install the belt cover. Service Interval: Every 1,000 hours Make sure the reel drive belt is properly tensioned to assure proper operation of the machine and unnecessary wear. Check belt frequently. Transmission Cover Access Hole 1.
Controls System Maintenance Adjusting the Traction Control If the traction control does not engage or it slips during operation, an adjustment is required. 1. Move the traction control to the Disengaged position. 2. Check to see if there is any slack in the traction control cable at the extension spring (Figure 45). If slack exists, adjust the jam nuts at the bulkhead (Figure 46) to remove the slack from the cable without extending the spring. Figure 46 1. Clevis pin & cotter pin 3. Jam nuts 2.
Adjusting the Reel Control Storage If reel control does not properly engage, an adjustment is required. 1. Remove any grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. Clean the dirt and chaff from the outside of the engine's cylinder head fins and the blower housing. 1. Make sure the reel control is disengaged. 2. At the transmission bulkhead, adjust the reel control cable (Figure 47), to attain a spring length of 70.6 to 72.4 mm (2.78 to 2.
Notes: 35
The Toro Total Coverage Guarantee A Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
