Toro 04018 Greensmaster Flex 18, Operator'S Manual

Page 1: ...del No 04018 Traction Unit Serial No 260003001 and Up Model No 04206 Cutting Unit Serial No 260000001 and Up Model No 04022 Traction Unit Serial No 260003001 and Up Model No 04202 Cutting Unit Serial No 260000001 and Up G000507 Register at www Toro com Original Instructions EN ...

Page 2: ...and serial numbers of your product ready Figure 1 and Figure 2 identify the location of the model and serial numbers on the product Write the numbers in the space provided Figure 1 1 Location of the model and serial numbers Traction unit Traction unit Model No Serial No Figure 2 1 Location of the model and serial numbers Cutting Unit Cutting unit Model No Serial No This manual identifies potential...

Page 3: ...on 18 Preparing to Mow 18 Mowing Operation 18 Maintenance 20 Recommended Maintenance Schedule s 20 Daily Maintenance Checklist 21 Engine Maintenance 22 Engine Oil 22 Servicing the Air Cleaner 22 Replacing the Spark Plug 23 Fuel System Maintenance 24 Cleaning the Fuel Filter 24 Electrical System Maintenance 24 Servicing the Interlock Switch 24 Drive System Maintenance 25 Checking the Transmission F...

Page 4: ...uel is highly flammable Take the following precautions Store fuel in containers specifically designed for this purpose Refuel outdoors only and do not smoke while refuelling Add fuel before starting the engine Never remove the cap of the fuel tank or add fuel while the engine is running or when the engine is hot If fuel is spilled do not attempt to start the engine but move the machine away from t...

Page 5: ...afe working condition Never store the equipment with fuel in the tank inside a building where fumes may reach an open flame or spark Allow the engine to cool before storing in any enclosure To reduce the fire hazard keep the engine silencer battery compartment and fuel storage area free of grass leaves or excessive grease Check the grass catcher frequently for wear or deterioration Keep all parts ...

Page 6: ...mum safety Shut the engine off before emptying the baskets Do not touch the engine muffler or exhaust pipe while the engine is running or soon after it has stopped because these areas could be hot enough to cause burns Stay clear of the rotating screen at the side of the engine to prevent direct contact with your body or clothing When a person or pet appears unexpectedly in or near the mowing area...

Page 7: ...nstructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger Replace any decal that is damaged or lost 93 7348 1 Warning read the Operator s Manual 2 Fire hazard no fire open flames or smoking when adding fuel to the tank leave space between the fuel and the top of the tank 3 Thrown object hazard keep bystanders a safe dist...

Page 8: ...64 1 Warning read the instructions before servicing or performing maintenance 2 Cutting hazard of hand or foot stop the engine and wait for moving parts to stop 104 2617 1 Traction drive 4 Forward 2 Reel drive 5 Lever engaged 3 Neutral 6 Lever disengaged 105 2411 1 Transmission oil 8 ...

Page 9: ...104 2621 1 Read the Operator s Manual 9 ...

Page 10: ...o parts required Adjust the handle 4 Transport wheels Optional Transport Wheel Kit Model 04123 2 Install the transport wheels 5 No parts required Check the engine oil and transmission fluid levels 6 Grass basket 1 Install the grass basket Media and Additional Parts Description Qty Use Operator s Manual 1 Engine Operator s Manual 1 Parts Catalog 1 Operator Training Material 1 Certificate of Complia...

Page 11: ...ure 1 Kickstand assembly 1 Spring 1 Small spacer 1 Large spacer 1 Large bolt M8 1 25 x 100 1 Small bolt M8 1 25 x 030 2 Locknut M8 x 1 25 2 Washer M8 Procedure 1 Position the kickstand between the tabs on the rear of the frame 2 Install a washer M8 onto the small bolt M8 1 25 x 030 Install the right side of the kickstand to the frame with the bolt and washer the small spacer and locknut M8 1 25 Fi...

Page 12: ... the kickstand spacer 3 Adjusting the Handle No Parts Required Procedure 1 Remove hairpin cotters from ring pins on each side of mower Figure 8 Figure 8 1 Ring pins 2 While supporting handle remove ring pins from each side and raise or lower handle to desired operating position Figure 8 3 Reinstall ring pins and hair pin cotters 4 Installing the Transport Wheels Parts needed for this procedure 2 T...

Page 13: ...i 6 Carefully lift up on handle support to release kick stand 5 Checking Fluid Levels No Parts Required Procedure 1 Check the engine oil level refer to Checking the Engine Oil Level in Engine Maintenance page 22 2 Check the transmission fluid level refer to Checking the Transmission Fluid Level in Drive System Maintenance page 25 6 Installing the Grass Basket Parts needed for this procedure 1 Gras...

Page 14: ...gage and Disengage Move top of lever to the left to engage reel or back to neutral to disengage reel Service Parking Brake The service parking brake Figure 13 is located on left front side of control panel Pulling the lever back over center will set the parking brake Brake must be released before traction drive is engaged Operator Presence Control The optional operator presence control must be eng...

Page 15: ... 61 1 2 inches 156 2 cm 61 inches 155 cm Weight with full fluids and basket 267lb 121 kg 261lb 118 kg Dry weight with basket 256lb 116 kg 250lb 113 kg Engine Kawasaki 4 cycle 3 7 2 7 kw air cooled OHV engine 3600 RPM 7 57 cu inch 124 cc displacement cast iron cylinder sleeve electronic ignition with integral lighting coil maximum noise suppression muffler 85 dB A at operator s ear Kawasaki 4 cycle...

Page 16: ...read all of the safety instructions and decals in the safety section Knowing this information could help you or bystanders avoid injury Checking the Engine Oil Level Check the engine oil level before each use or every 8 operating hours refer to Checking the Engine Oil Level in Engine Maintenance page 22 Filling the Fuel Tank Important Never use methanol gasoline containing methanol gasohol contain...

Page 17: ...her than from a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete 1 Clean around fuel tank cap and remove cap from tank Figure 17 Using unleaded gasoline fill fuel tank no higher than to bottom of filter screen Do not overfill 2 Install fuel tank cap and wipe up ...

Page 18: ...eel drive controls are in Disengage position and start engine 4 Set throttle control to Slow tip front of machine up gradually engage traction drive and slowly increase engine speed 5 Adjust throttle to operate mower at desired ground speed and transport mower to desired destination Preparing to Mow 1 Return traction control lever to Disengage throttle to Slow and stop engine 2 Push kick stand dow...

Page 19: ...Traction drive neutral 3 Traction drive engaged transport 2 Traction drive neutral reel drive off 4 Traction drive reel drive engaged 3 Move traction lever to Engaged position increase throttle speed until the mower is traveling at the desired ground speed drive the mower out onto the green area lower the front of the mower down and commence operation Figure 20 After Mowing 1 Drive off green move ...

Page 20: ...ery 25 hours Clean the air cleaner more often in dirty or dusty conditions Every 50 hours Change the engine oil Clean the fuel filter Check the transmission fluid level Every 100 hours Clean or replace the paper air filter element more often in dirty or dusty conditions Check the spark plug Every 200 hours Decarbon the engine Every 1 500 hours Replace the interlock switch Change the transmission f...

Page 21: ...ng 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 Touch up damaged paint Notation for Areas of Concern Inspection performed by Item Date Information 21 ...

Page 22: ...1 Oil level gauge 2 Drain plug 2 Remove oil level gauge by rotating it counterclockwise 3 Wipe oil level gauge clean and insert it into filler port Do not screw into port Then remove and check level of oil If level is low add only enough oil to raise level to bottom of filler opening Recheck level of oil Do not overfill 4 Reinstall oil level gauge and wipe up any spilled oil Changing the Engine Oi...

Page 23: ...r replace every 100 hours or as required 5 Install foam element paper element and air cleaner cover Important Do not operate the engine without the air cleaner element because extreme engine wear and damage will likely result Replacing the Spark Plug Service Interval Every 100 hours Use an NGK BPR 5ES spark plug or equivalent Correct air gap is 0 028 0 032 inch 1 Pull molded wire off spark plug Fi...

Page 24: ...adjustment or replacement 1 Make sure the engine is off and traction lever is Disengaged 2 Engage traction lever until it contacts neutral stop Figure 28 Figure 28 1 Traction lever 3 Interlock switch 2 Neutral stop 4 032 Gap 3 Loosen interlock switch mounting fasteners Figure 28 4 Place a 032 thick shim between the traction lever and the interlock switch Figure 28 5 Tighten interlock switch mounti...

Page 25: ...ight weeping of grease from these seals will occur Wipe off excess grease Important Use only Mobil Dexron lll or equivalent transmission fluids Other fluids could cause system damage 1 Place the mower on its drums on a level surface 2 Remove the check fill plug from the right hand side of the transmission Figure 29 The oil level should come to the bottom of the fill hole If it does not add enough ...

Page 26: ...all the drain plug 5 Place the mower on its drums on a level surface 6 Fill the transmission with approximately 94 fluid ounces of the proper type of transmission fluid until the level reaches the bottom of the check fill hole refer to Checking the Transmission Fluid 7 Install the check fill plug Brake Maintenance Adjusting the Service Parking Brake If service park brake slips when operated an adj...

Page 27: ...ct proceed to next step Figure 33 1 Reel drive belt 3 Driven pulley 2 Drive pulley 3 To adjust belt tension A Loosen the bearing housing mounting nuts Figure 34 Figure 34 1 Reel drive belt 2 Bearing housing mounting nuts B Using a 3 8 inch drive torque wrench rotate the bearing housing with 35 40 in lb of torque to set belt tension Figure 35 Figure 35 1 Bearing housing 2 3 8 Torque wrench here C W...

Page 28: ...ounting nuts Figure 38 Figure 38 1 Reel drive belt 2 Bearing housing mounting nuts B Using a 3 8 inch drive torque wrench rotate the bearing housing with 35 40 in lb of torque to set belt tension Figure 39 Figure 39 1 Bearing housing 2 3 8 Torque wrench here C While holding the torque wrench setting tighten the bearing housing mounting nuts Figure 38 Do not over tension belt D Install belt cover T...

Page 29: ...loosen the bolt securing the idler bracket to the side plate Figure 42 Figure 42 1 Tang washer 2 Idler bracket bolt B Using a 3 8 inch drive torque wrench rotate the idler bracket with 35 40 in lb of torque to set the belt tension Figure 43 While holding the torque wrench setting tighten the idler bracket mounting bolt The tang washer is installed to prevent the belt from slipping Do not over tens...

Page 30: ...nt cable jam nut 4 Check control operation Adjusting the Reel Control If reel control does not engage or it slips during operation an adjustment is required 1 Make sure traction control is properly adjusted refer to Adjusting the Traction Control 2 To increase cable tension loosen front cable jam nut and tighten back cable jam nut Figure 45 located on top of gear box until the reel cable force add...

Page 31: ...gure 47 and rest traction unit on restrained kickstand 6 Pull cutting unit forward about 2 inch 51 mm and then to the right to disengage the transmission coupling Figure 48 Figure 48 1 Transmission coupling 7 Reverse procedure to install cutting unit Note When tightening the pivot arm mounting fasteners use an adjustable crescent wrench to hold the pivot arm parallel to the side plate Figure 49 Fi...

Page 32: ...ts and paralleling is not required A limited amount of adjustment is possible by setting the cutting unit on a surface plate and loosening the sideplate mounting bolts Figure 52 Adjust and re tighten bolts Figure 52 1 Sideplate mounting bolts Important Whenever the cutting unit has to be tipped to expose bedknife reel prop up rear of cutting unit to make sure nuts on back end of bedbar adjusting s...

Page 33: ... reel blades Should excessive reel drag be evident it will be either necessary to backlap or regrind the cutting unit to achieve the sharp edges needed for precision cutting see Toro reel sharpening manual Adjusting the Height of Cut For heights of cut greater than 500 the high height of cut kit must be installed 1 Loosen locknuts securing height of cut arms to cutting unit side plates Figure 55 F...

Page 34: ...t suited for the desired height of cut Adjusting the Cut Off Bar Adjust cut off bar to assure clippings are cleanly discharged from the reel area 1 Loosen screws securing top bar Figure 58 to cutting unit Figure 58 1 Cut off bar 2 Insert 060 inch feeler gauge between top of reel and bar and tighten screws Ensure bar and reel are equal distance apart across complete reel Note The bar is adjustable ...

Page 35: ...125 inches Standard 98 7260 Tournament Flex 18 0 125 0 25 inches 110 2300 Extended Microcut Flex 18 0 062 0 125 inches Less Aggressive 110 2301 Low Cut Flex 18 0 25 inches and up Rollers Standard and Optional Part Number Description Mower Diameter Material Comments 107 9037 Narrow Wiehle Flex 21 2 5 inches Aluminum Standard Front 107 9038 Wide Wiehle Flex 21 2 5 inches Aluminum More Penetration 10...

Page 36: ...rvicing the Bedbar Removing the Bedbar 1 Turn the bedbar adjuster screw counterclockwise to back the bedknife away from reel Figure 60 Figure 60 1 Bedbar adjusting screw 4 Jam nut 2 Spring tension nut 5 Bedbar bolt 3 Bedbar 2 Back out the spring tension nut until the washer is no longer tensioned against the bedbar Figure 61 3 On each side of the machine loosen the jam nut securing the bedbar bolt...

Page 37: ... drive cover on the left side of reel assembly Figure 63 Figure 63 1 Reel drive cover plug 2 Insert a 18 mm socket onto hex flange nut on left end of reel shaft 3 Backlap according to the procedure in the Toro Sharpening Reel and Rotary Mowers Manual Form No 80 300 PT Contact with the reel or other moving parts can result in personal injury Stay away from the reel while backlapping Never use a sho...

Page 38: ...gine to distribute conditioned fuel through the fuel system 5 minutes B Either stop engine allow it to cool and drain the fuel tank or operate the engine until it stops C Restart the engine and run it until it stops Repeat on Choke until the engine will not restart D Dispose of fuel properly Recycle as per local codes Note Do not store stabilizer conditioned gasoline over 90 days 3 Check and tight...

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Page 40: ...t limited to weather storage practices contamination use of unapproved coolants lubricants additives or chemicals etc Normal wear and tear items Normal wear and tear includes but is not limited to damage to seats due to wear or abrasion worn painted surfaces scratched decals or windows etc Parts Parts scheduled for replacement as required maintenance are warranted for the period of time up to the ...