Form No. 3422-731 Rev B Greensmaster® Flex™1820 and 2120 Traction Unit Model No. 04044—Serial No. 403070001 and Up Model No. 04045—Serial No. 403070001 and Up Register at www.Toro.com.
on safe operating practices, including safety tips and training materials, go to www.Toro.com. This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet. Whenever you need service, genuine Toro parts, or additional information, contact an authorized Toro distributor and have the model and serial numbers of your product ready. The model and serial numbers are located on a plate on the rear frame.
Contents Servicing the Traction-Interlock Switch ...................................................................... 31 Servicing the Brake-Interlock Switch................. 32 Brake Maintenance ............................................. 32 Adjusting the Service/Parking Brake................. 32 Belt Maintenance ................................................ 33 Inspecting the Reel-Drive Belt........................... 33 Visually Inspecting the Reel Clutch ...................
Safety • Do not operate the machine without all guards This machine has been designed in accordance with EN ISO 5395:2013 and ANSI B71.4-2017 and meets these standards when you add the Operator Presence Kit and required decals. • • General Safety • This product is capable of amputating hands and feet and of throwing objects. Always follow all safety instructions to avoid serious personal injury. and other safety protective devices in place and working on the machine.
decal120-9571 120-9571 1. Lower the lever to disengage the traction. decal131-3111 131-3111 1. Fast 2. Slow decal120-9598 120-9598 1. Brake 4. Parking brake 2. Release handle to disengage the brake. 5. Rotate the latch to lock the parking brake; compress the handle to release the latch. decal133-8062 133-8062 3. Compress the handle to engage the brake. decal130-8322 130-8322 1. Use only gasoline that contains 10% ethanol by volume (E10) or less. 3.
decal115-7274 115-7274 1. Lights (optional) 3. Engine—start 2. Hour meter 4. Engine—shut off decal133-2335 133-2335 1. Warning—read the Operator’s Manual; do not operate the machine unless you are trained. 2. Warning—wear hearing protection. 3. Thrown object hazard—keep bystanders a safe distance away from the machine. 4. Warning—stay away from moving parts; keep all guards and shields in place. 6 5. Do not tow the machine.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 6 7 8 Description Use Qty. No parts required – Prepare the traction unit (optional). Bolt (3/8 x 3/4 inch) 2 Install the cutting unit to the traction unit. Handle retainer Hairpin cotter 2 2 Install the handle retainers. Transport wheels—Transport Wheel Kit (Model No. 04123 [Optional]) 2 Install the transport wheels. No parts required – Check the engine-oil level.
1 2 Preparing the Traction Unit Installing the Cutting Unit to the Traction Unit Optional—Cutting Unit Models 04251, 02452, 04253, or 04254 Parts needed for this procedure: 2 No Parts Required Bolt (3/8 x 3/4 inch) Procedure Procedure If you are installing cutting unit Models 04251, 02452, 04253, or 04254 on this traction unit, complete the following steps: Note: To install the weight rod onto your machine, refer to the installation instructions in your cutting unit Operator’s Manual. 1.
3 Installing the Handle Retainers Parts needed for this procedure: g000483 2 Handle retainer 2 Hairpin cotter Figure 6 1. Transmission coupling 4. Procedure 1. Maneuver the machine frame forward until it engages the cutting unit pivot arms Figure 7. While supporting the handle, remove the cable ties that secure the handle clamps to the side plates (Figure 8). g032418 Figure 7 1. Telescoping coupler 3. Bolt 2. Cutting-unit hex shaft 5. 6. 7.
4 Installing the Transport Wheels Optional Parts needed for this procedure: 2 Transport wheels—Transport Wheel Kit (Model No. 04123 [Optional]) Procedure 1. g017591 Use your foot to push the center of the kickstand down and pull up on the lower handle support until the kickstand has rotated forward and over center (Figure 9). Figure 10 1. Locking clip g016833 3. Rotate the wheel back and forth until it fits onto the axle and the locking clip is secured in the groove on the axle shaft. 4.
6 Installing the Production-Year Decal CE Machines Only Parts needed for this procedure: g032407 1 Production-year decal Figure 12 1. Basket hooks Procedure 3. If you use this machine in a country that complies to CE standards, apply the production-year decal near the serial plate; refer to Figure 11. Install the basket hooks over the frame loop (Figure 12). Important: If you ever drop the basket, examine the pitch-arm contact points near the lower lip of the basket for damage (Figure 13).
Product Overview 8 Breaking in the Machine No Parts Required Procedure Only 8 hours of mowing operation is required for the break-in period. The first several hours of operation are critical to future dependability of the machine. You must monitor the machine performance closely so that minor difficulties, which could lead to major problems, are noted and can be corrected.
Throttle Control The throttle control (Figure 15 and Figure 16) is located on the right, rear side of the control panel. Rotate the throttle to regulate the engine speed. g027738 Figure 16 1. Full speed g000494 Figure 17 2. Slow speed Traction and Reel-Drive Engagement Lever 1. NEUTRAL 3. Traction—FORWARD (transport) 2. Traction—NEUTRAL and reel drive—DISENGAGE 4. Traction—FORWARD and reel drive—ENGAGE To operate the reel, the lever has 2 positions: ENGAGE and DISENGAGE.
Service Brake Choke Lever The service brake (Figure 18) is located on the left front side of the handle. Pulling back the lever applies the service brake. The choke lever (Figure 19) is located on the left front of the engine. The lever has 2 positions: RUN and CHOKE. Move the lever to the CHOKE position when starting a cold engine. After the engine starts, move the lever to the RUN position. You must disengage the brake before you engage the traction drive.
Recoil-Starter Handle Pull the recoil-starter handle (Figure 21) to start the engine. g018268 Figure 21 1. Recoil-starter handle g018793 Figure 22 Kickstand 1. Lower-center handle 2. Kickstand loop The kickstand (Figure 23) is mounted to the rear of the machine. Use the kickstand when you install or remove the transport wheels or the cutting unit.
Specifications 1820 Traction Unit Width 82.5 cm (32-1/2 inches) Height 104.8 cm (41-1/4 inches) Length with basket Net Weight (with 11-blade cutting unit and grass basket installed) 46 cm (18 inches) Height of cut 1.5 to 7.5 mm (1/16 to 19/64 inch) with Micro-Cut bedknife Figure 24 1. Kickstand—STORAGE position 3. Kickstand—SERVICE position 117 kg (258 lb) Width of cut Clip frequency g018142 152.4 cm (60 inches) Adjustable (refer to your cutting unit Operator’s Manual) 2120 Traction Unit 2.
Performing Daily Maintenance Operation Before Operation Perform the daily maintenance procedures; refer to Daily Maintenance Checklist (page 27). Note: Determine the left and right sides of the machine from the normal operating position. Checking the Engine-Oil Level Before Operation Safety Check the engine-oil level before each use or every 8 operating hours, refer to Checking the Engine-Oil Level (page 28). General Safety • Never allow children or untrained people to operate or service the machine.
Filling the Fuel Tank WARNING Fuel is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. • Never fill the fuel tank inside an enclosed trailer. • Do not fill the fuel tank completely full.
Setting the Machine to Match Turf Conditions Use the following table to set the machine to match turf conditions.
Adjusting the Handle Height Note: The machine is shipped with the handle adjusted to the lowest position. The machine is normally operated with the handle telescoped out to its maximum height. 1. Loosen the 3 carriage bolts and nuts securing each side of the handle in the handle clamps (Figure 26). g017005 Figure 27 1. Hairpin cotter 3. Carriage bolts 2. Nut 2. Pull up on the handle slowly and evenly on each side until it is in the desired operating position. 3.
Checking the Operation of the Interlock Switches lever does not disengage, the interlock system needs service. Correct the problem before operating the machine; refer to Servicing the Traction-Interlock Switch (page 31). Service Interval: Before each use or daily 5. With the OPC pressed and the shift lever moved to the left, engage the traction and reel drive and release the OPC (Figure 29). The traction lever should disengage.
Important: Do not run the engine while transporting it on a trailer because damage can occur to the machine. OPC, and engage the traction lever (Figure 29). The engine should labor to overcome the brake but should not shut off. If the engine shuts off immediately, the interlock switch needs service. Correct the problem before operating the machine; refer to Servicing the Brake-Interlock Switch (page 32). 4. 5.
• Do not touch the engine, muffler, or exhaust pipe • • • • • • hazards. Tall grass can hide obstructions. Uneven terrain could overturn the machine. – Be aware that operating the machine on wet grass, across slopes, or downhill may cause the machine to lose traction. Loss of traction may result in sliding and a loss of braking and steering. – Use extreme caution when operating the machine near dropoffs, ditches, embankments, water hazards, or other hazards.
Releasing the Transmission • Avoid circular mowing or turning the machine on the greens areas to prevent scuffing. If the machine becomes disabled with the motor brake on, you can disengage the drum from the transmission to allow the machine to be maneuvered. 1. On the right rear corner of the machine, locate the traction engage/disengage lever next to the drive housing drum (Figure 30).
After Operation After Operation Safety General Safety • Reduce the throttle setting before shutting off the engine and, if the engine has a fuel-shutoff valve, turn off the valve after mowing. • Clean grass and debris from the machine to help prevent fires. Clean up oil or fuel spills. Transporting the Machine After mowing, transport the machine away from the job site; refer to Transporting the Machine Using Transport Wheels (page 22) or Transporting the Machine Using a Trailer (page 22).
Maintenance WARNING Failing to properly maintain the machine could result in premature failure of machine systems, causing possible harm to you or bystanders. Keep the machine well maintained and in good working order as indicated in these instructions. Note: Determine the left and right sides of the machine from the normal operating position. Important: Do not tip the machine at an angle greater than 25°.
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.
Pre-Maintenance Procedures Engine Maintenance Pre-Maintenance Safety • Fuel is flammable and explosive, and can cause • Disengage the drives and the cutting unit, • Check all fuel lines for tightness and wear Engine Safety personal injury. engage the parking brake, shut off the engine, and disconnect the spark-plug wire. Wait for all movement to stop before adjusting, cleaning, or repairing the machine. regularly. Tighten or repair them as needed. • Tipping the machine may cause the fuel to leak.
2. Position the machine so that the engine is level, and clean the area around the oil-level gauge (Figure 34). 2. At the rear of the machine, place a drain pan under the drain plug (Figure 34). Loosen the drain plug. 3. Push down on the handle to tip the machine and engine backward, allowing all the oil to run into the drain pan. Important: Do not tip the machine at an angle greater than 25°.
C. dry it, but do not twist it, as the foam may tear. Servicing the Spark Plug Saturate the element with clean engine oil. Squeeze the element to remove the excess oil and to distribute the oil. Service Interval: Every 100 hours Use an NGK BR6HS spark plug or equivalent. The correct air gap is 0.6 to 0.7 mm (0.024 to 0.028 inch). Note: A foam element that is damp with oil is desirable. 1. Pull the molded wire off the spark plug (Figure 38). g016986 Figure 38 1. Spark-plug wire 2.
Fuel System Maintenance Electrical System Maintenance Cleaning the Fuel-Tank Screen Servicing the Traction-Interlock Switch Service Interval: After the first 20 hours Use the following procedure if the traction-interlock switch needs adjustment or replacement. Every 100 hours/Monthly (whichever comes first) 1. Unscrew and remove the fuel-tank cap from the fuel tank (Figure 40). 1. Ensure that the engine is off. 2. Remove the control panel. 3. Engage the traction lever. g016857 Figure 40 1.
Brake Maintenance Servicing the Brake-Interlock Switch 1. Ensure that the engine is off. 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, adjust the cable as follows: 4. Loosen and remove the interlock-switch mounting fasteners (Figure 42). 1. Move the service/parking brake lever to the OFF position. 2. Remove the control panel. 3.
Belt Maintenance C. Clean any debris from inside the belt compartment and from around the compression spring (Figure 45). Inspecting the Reel-Drive Belt D. Ensure that the compression spring is applying the proper tension on the belt. E. Tighten the bearing housing mounting nut. Service Interval: Every 1,000 hours F. Install the belt cover. 1. Shut off the engine and remove the key. 2. Loosen the flange bolt that secures the belt cover and remove the belt cover to expose the belt (Figure 44).
Engaging/Disengaging the Transmission-Belt Tensioner Controls System Maintenance Adjusting the Traction Control The transmission belt is tensioned by a spring-loaded idler pulley. If you must engage or disengage the belt tension, use a 3/8-inch wrench to rotate the engage/disengage shaft (Figure 46) to the desired position. Rotating the shaft 1/4-turn (90°) clockwise disengages the idler from the belt (Figure 47).
E. Move the traction control to the ENGAGED position. F. Measure the distance from the pin on either end of the traction-control spring (Figure 48); repeat steps A through F until it is within 7.3 to 7.6 cm (2-7/8 to 3 inches). Adjusting the Reel Control If the reel control does not properly engage, an adjustment is necessary. 1. Ensure that the reel control is disengaged. 2. At the transmission bulkhead, adjust the reel-control cable (Figure 49) to attain a spring length of 70.6 to 72.4 mm (2.
Storage Storage Safety • Never store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or on other appliances. • Allow the engine to cool before storing the machine in any enclosure. Storing the Machine 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 cylinder-head fins and the blower housing.
Notes:
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Toro General Commercial Product Warranty A Two-Year 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).
