Toro Greensmaster Flex 1800 User manual

Form No. 12188SL Rev. D
Greensmaster®
Flex 1800/1820/2100/2120
(Models 04040, 04041, 04044and 04045)
Original Instructions (EN)

© THE TORO COMPANY 2020
This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No
intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be
reproduced by a third party without the express written consent of The Toro Company (and/or the appropriate affiliated company).
Revision History
Revision Date Description
-- 2012 Initial Issue.
A 02/2018 Added revision history.
B 04/2018 Added 1820/2120 models, revised bedknife installation procedure,
added Universal Groomer chapter.
C 06/2018 Added 1820/2120 wet clutch fluid specifications
D 04/2020 Added new schematic, wire harness, optional light switch

Reader Comments
The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality
and usefulness of its publications. To do this effectively, we encourage user feedback.
Please comment on the completeness, accuracy, organization, usability, and readability of this manual
by an e-mail to [email protected]
or Mail to:
Technical Publication Manager, Commercial
The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Phone: [phone]

NOTES _

(Models 04040, 04041, 04044 and 04045)
PART NO. 12188SL Rev. D
Service Manual
GreensmasterRFlex 1800/1820/2100/2120
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing
and repairing assemblies and components on the
Greensmaster Flex 1800 (Model 04041), Flex 1820
(Model 04045), Flex 2100 (Model 04040) and Flex 2120
(Model 04044).
REFER TO THE OPERATOR’S MANUAL FOR OPER-
ATING, MAINTENANCE AND ADJUSTMENT
INSTRUCTIONS. Space is provided in Chapter 2 of this
book to insert the Operator’s Manual and Parts Catalogs
for your machine. Replacement Operator’s Manuals
and Parts Catalogs are available on the internet at
www.toro.com
The Toro Company reserves the right to change product
specifications or this publication without notice.
This safety symbol means DANGER, WARNING
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: ANOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
EThe Toro Company - 2012, 2018, 2020

Greensmaster Flex 1800/1820/2100/2120
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Greensmaster Flex 1800/1820/2100/2120
Table Of Contents
Chapter 1 - Safety
Safety Instructions 1 - 2..........................
Safety and Instruction Decals 1 - 4................
Chapter 2 - Product Records and Maintenance
Product Records 2 - 1...........................
Maintenance 2 - 1...............................
Equivalents and Conversions 2 - 2................
Torque Specifications 2 - 3.......................
Chapter 3 - Engine
Specifications 3 - 3..............................
General Information 3 - 4........................
Adjustments 3 - 5...............................
Service and Repairs 3 - 6........................
SUBARU SERVICE MANUAL
Chapter 4 - Traction and Reel Drive System
Specifications 4 - 2..............................
General Information 4 - 3........................
Special Tools 4 - 5..............................
Adjustments 4 - 6...............................
Service and Repairs 4 - 11.......................
Chapter 5 - Electrical System
General Information 5 - 3........................
Wiring Schematics 5 - 4.........................
Wire Harnesses 5 - 6............................
Special Tools 5 - 8..............................
Troubleshooting 5 - 10...........................
Component Testing 5 - 11........................
Chapter 6 - Chassis and Controls
Specifications 6 - 2..............................
General Information 6 - 3........................
Service and Repairs 6 - 4........................
Chapter 7 - Cutting Unit
Specifications 7 - 2..............................
General Information 7 - 3........................
Special Tools 7 - 5..............................
Factors That Affect Quality Of Cut 7 - 8............
Adjustments 7 - 10..............................
Service and Repairs 7 - 11.......................
Chapter 8 - Belt Driven Groomer (Optional)
Specifications 8 - 2..............................
General Information 8 - 3........................
Troubleshooting 8 - 4............................
Adjustments 8 - 6...............................
Service and Repairs 8 - 7........................
Chapter 9 - Universal Groomer (Optional)
Specifications 9 - 2..............................
General Information 9 - 3........................
Troubleshooting 9 - 4............................
Service and Repairs 9 - 6........................
SafetyProduct Records
and Maintenance
Engine
Traction and Reel
Drive System
Electrical
System
Chassis andCutting Unit
Controls
Groomer
Groomer
Universal

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Greensmaster Flex 1800/1820/2100/2120 Page 1 −1 Safety
Chapter 1
Safety
Table of Contents
SAFETY INSTRUCTIONS 2......................
Before Operating 2............................
While Operating 3............................
Maintenance and Service 3....................
SAFETY AND INSTRUCTION DECALS 4..........
Safety

Greensmaster Flex 1800/1820/2100/2120Page 1 −2Safety
Safety Instructions
Greensmaster Flex machines have been tested and
certified by TORO for compliance with existing safety
standards and specifications. Although hazard control
and accident prevention are partially dependent upon
the design and configuration of the machine, these fac-
tors are also dependent upon the awareness, concern
and proper training of the personnel involved in the op-
eration, transport, maintenance and storage of the ma-
chine. Improper use or maintenance of the machine can
result in injury or death. To reduce the potential for injury
or death, comply with the following safety instructions.
WARNING
To reduce the potential for injury or death, com-
ply with the following safety instructions.
Before Operating
1. Operate the machine only after reviewing and under-
standing the contents of the Operator’s Manual and Op-
erator Training DVD. A replacement Operator’s Manual
is available on the internet at www.toro.com
2. Never allow children to operate the machine or allow
adults to operate it without proper instructions.
3. Become familiar with the controls and know how to
stop the machine and engine quickly.
4. Keep all shields, safety devices and decals in place.
If a shield, safety device or decal is malfunctioning, illeg-
ible or damaged, repair or replace it before operating the
machine.
5. Always wear substantial shoes. Do not operate ma-
chine while wearing sandals, tennis shoes or sneakers.
Do not wear loose fitting clothing which could get caught
in moving parts and cause personal injury.
6. Wearing safety glasses, safety shoes, long pants,
ear protection and a hard hat is advisable and required
by some local safety and insurance regulations.
7. Ensure work area is clear of objects which might be
picked up and thrown by the cutting reel.
8. Keep everyone, especially children and pets, away
from the areas of operation.
9. Since gasoline is highly flammable; handle it careful-
ly.
A. Use an approved gasoline container.
B. Do not remove cap from fuel tank when engine is
hot or running.
C. Do not smoke while handling gasoline.
D. Fill fuel tank outdoors and no higher than to the
bottom of filter screen. Do not overfill fuel tank.
E. Wipe up any spilled gasoline.
F. Fuel may leak from filler neck when mower is
tilted for servicing if tank is over filled.
10.The safety interlock switches are for the operator’s
protection; do not disconnect them. Check the operation
of the switches daily to assure the interlock system is op-
erating. If a switch is defective, replace it before operat-
ing the machine. See Component Testing in Chapter 5
−Electrical System.

Greensmaster Flex 1800/1820/2100/2120 Page 1 −3 Safety
While Operating
1. Do not run the engine in a confined area without ade-
quate ventilation. Exhaust fumes are hazardous and
could be deadly.
2. Always stand behind the handle when starting and
operating the machine.
3. To start the engine:
A. Open fuel shut-off valve. Make sure spark plug
wire is connected to spark plug.
B. Verify that the control lever on handle is in NEU-
TRAL position for both traction and reel drives.
C. Move on/off switch to ON position, set choke to
full choke position (cold start) and throttle to half
throttle.
D. Pull starter cord to start engine.
4. To stop the engine:
A. Disengage reel and traction drives and reduce
engine speed to SLOW.
B. Move on/off switch to OFF position to stop en-
gine.
5. Before emptying basket of clippings, disengage trac-
tion and reel drives, reduce engine speed and move on/
off switch to OFF position to stop engine. Wait for all
machine motion to stop before removing basket.
6. Do not touch engine, muffler or exhaust pipe while
engine is running or soon after it has stopped because
these areas are hot enough to cause burns.
7. If the cutting unit strikes a solid object or vibrates ab-
normally, stop machine operation immediately, turn en-
gine off, wait for all machine motion to stop and inspect
for damage. A damaged reel or bedknife must be re-
paired or replaced before operation is commenced.
8. Whenever machine is left unattended, be sure en-
gine is stopped and cutting unit reel is not spinning.
9. Close fuel shut-off valve if machine is not to be used
for an extended period of time. Also, close fuel shut-off
valve if machine is to be transported on a trailer or in a
vehicle.
Maintenance and Service
1. The Traction Unit and Cutting Unit Operator’s Manu-
als provide information regarding the operation, general
maintenance and maintenance intervals for your
Greensmaster machine. Refer to these publications for
additional information when servicing the machine.
2. Before servicing or making adjustments to the ma-
chine, stop the engine and wait for all machine motion
to stop. Remove the spark plug wire from the spark plug
to prevent accidental starting of the engine.
3. To make sure entire machine is in good condition,
keep all nuts, bolts, screws and belts properly tightened.
4. To reduce potential fire hazard, keep the engine area
free of excessive grease, grass, leaves and accumula-
tion of dirt.
5. Wear heavy gloves and use caution when checking
or servicing the cutting unit.
6. If the engine must be running to perform mainte-
nance or make an adjustment, keep hands, feet, cloth-
ing and all parts of the body away from the cutting unit
and all moving parts. Keep bystanders away.
7. Do not overspeed the engine by changing governor
settings. Recommended engine high idle speed is from
3190 to 3340 RPM. To ensure safety and accuracy,
check engine speed with a tachometer.
8. Engine must be shut off and cooled down before
checking oil or adding oil to the engine crankcase.
9. If major repairs are ever needed or assistance is re-
quired, contact your Authorized TORO Distributor.
10.At the time of manufacture, the machine conformed
to all applicable safety standards. To assure optimum
performance and continued safety certification of the
machine, use genuine Toro replacement parts and ac-
cessories. Replacement parts and accessories made
by other manufacturers may result in non-conformance
with the safety standards and the warranty may be
voided.
Safety

Greensmaster Flex 1800/1820/2100/2120Page 1 −4Safety
Safety and Instruction Decals
Safety decals and instructions are easily visible to the
operator and are located near any area of potential dan-
ger. Replace any decal that is damaged or lost. Decal
part numbers are listed in your Parts Catalog. Order re-
placement decals from your Authorized TORO Distribu-
tor.

Greensmaster Flex 1800/1820/2100/2120 Page 2 −1 Product Records and Maintenance
Chapter 2
Product Records and Maintenance
Table of Contents
PRODUCT RECORDS 1.........................
MAINTENANCE 1..............................
EQUIVALENTS AND CONVERSIONS 2...........
Decimal and Millimeter Equivalents 2............
U.S. to Metric Conversions 2...................
TORQUE SPECIFICATIONS 3...................
Fastener Identification 3.......................
Standard Torque for Dry, Zinc Plated, and Steel
Fasteners (Inch Series Fasteners) 4...........
Standard Torque for Dry, Zinc Plated, and Steel
Fasteners (Metric Fasteners) 5...............
Other Torque Specifications 6..................
Conversion Factors 6.........................
Product Records
Insert Operator’s Manual and Parts Catalog for your
Greensmaster Flex machine at the end of this section.
Additionally, if any optional equipment or accessories
have been installed to your machine, insert the Installa-
tion Instructions, Operator’s Manuals and Parts Cata-
logs for those options at the end of this chapter.
Maintenance
Maintenance procedures and recommended service in-
tervals for the Greensmaster Flex machines are cov-
ered in the Operator’s Manual. Refer to that publication
when performing regular equipment maintenance.
Product Records
and Maintenance

0.09375
Greensmaster Flex 1800/1820/2100/2120Page 2 −2Product Records and Maintenance
Equivalents and Conversions

Greensmaster Flex 1800/1820/2100/2120 Page 2 −3 Product Records and Maintenance
Torque Specifications
Recommended fastener torque values are listed in the
following tables. For critical applications, as determined
by Toro, either the recommended torque or a torque that
is unique to the application is clearly identified and spe-
cified in this Service Manual.
These Torque Specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in this Ser-
vice Manual. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (e.g. Loctite), degree of lubrication
on the fastener, presence of a prevailing torque feature
(e.g. Nylock nut), hardness of the surface underneath
the fastener’s head or similar condition which affects the
installation.
As noted in the following tables, torque values should be
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread en-
gagement, etc.
The standard method of verifying torque shall be per-
formed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
Fastener Identification
Grade 1 Grade 5 Grade 8
Inch Series Bolts and Screws
Class 8.8 Class 10.9
Metric Bolts and Screws
Product Records
and Maintenance

Greensmaster Flex 1800/1820/2100/2120Page 2 −4Product Records and Maintenance
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series Fasteners)
Thread Size
Grade 1, 5 &
8 with Thin
Height Nuts
SAE Grade 1 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
in−lb in−lb N−cm in−lb N−cm in−lb N−cm
# 6 −32 UNC
10 + 2 13 + 2 147 + 23
15 + 2 169 + 23 23 + 3 262 + 34
# 6 −40 UNF 17 + 2 192 + 23 25 + 3 282 + 34
# 8 −32 UNC
13 + 2 25 + 5 282 + 30
29 + 3 328 + 34 41 + 5 463 + 56
# 8 −36 UNF 31 + 4 350 + 45 43 + 5 486 + 56
# 10 −24 UNC
18 + 2 30 + 5 339 + 56
42 + 5 475 + 56 60 + 6 678 + 68
# 10 −32 UNF 48 + 5 542 + 56 68 + 7 768 + 79
1/4 −20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1130 + 113 140 + 15 1582 + 169
1/4 −28 UNF 53 + 7 65 + 10 734 + 113 115 + 12 1299 + 136 160 + 17 1808 + 192
5/16 −18 UNC 115 + 15 105 + 15 1186 + 169 200 + 25 2260 + 282 300 + 30 3390 + 339
5/16 −24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2542 + 282 325 + 33 3672 + 373
ft−lb ft−lb N−mft−lb N−mft−lb N−m
3/8 −16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 5 58 + 7
3/8 −24 UNF 17 + 2 18 + 2 24 + 3 35 + 4 47 + 5 50 + 6 68 + 8
7/16 −14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9
7/16 −20 UNF 29 + 3 29 + 3 39 + 4 55 + 6 75 + 8 77 + 8 104 + 11
1/2 −13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 11 142 + 15
1/2 −20 UNF 32 + 4 53 + 7 72 + 9 85 + 9 115 + 12 120 + 12 163 + 16
5/8 −11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 21 285 + 28
5/8 −18 UNF 75 + 10 95 + 15 129 + 20 170 + 18 230 + 24 240 + 24 325 + 33
3/4 −10 UNC 93 + 12 140 + 20 190 + 27 265 + 27 359 + 37 375 + 38 508 + 52
3/4 −16 UNF 115 + 15 165 + 25 224 + 34 300 + 30 407 + 41 420 + 43 569 + 58
7/8 −9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81
7/8 −14 UNF 155 + 25 260 + 30 353 + 41 475 + 48 644 + 65 667 + 66 904 + 89
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
engine oil or thread sealant such as Loctite.
NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the mini-
mum proof load specified in SAE J429. The tolerance is
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.

Greensmaster Flex 1800/1820/2100/2120 Page 2 −5 Product Records and Maintenance
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)
Thread Size
Class 8.8 Bolts, Screws and Studs with
Regular Height Nuts
(Class 8 or Stronger Nuts)
Class 10.9 Bolts, Screws and Studs with
Regular Height Nuts
(Class 10 or Stronger Nuts)
M5 X 0.8 57 + 6 in−lb 644 + 68 N−cm 78 + 8 in−lb 881 + 90 N−cm
M6 X 1.0 96 + 10 in−lb 1085 + 113 N−cm 133 + 14 in−lb 1503 + 158 N−cm
M8 X 1.25 19 + 2 ft−lb 26 + 3 N−m28 + 3 ft−lb 38 + 4 N−m
M10 X 1.5 38 + 4 ft−lb 52 + 5 N−m54 + 6 ft−lb 73 + 8 N−m
M12 X 1.75 66 + 7 ft−lb 90 + 10 N−m 93 +10 ft−lb 126 +14 N−m
M16 X 2.0 166 +17 ft−lb 225 + 23 N−m229 + 23 ft−lb 310 + 31 N−m
M20 X 2.5 325 + 33 ft−lb 440 + 45 N−m450 + 46 ft−lb 610 + 62 N−m
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
engine oil or thread sealant such as Loctite.
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately + 10% of the
nominal torque value.
Product Records
and Maintenance

Greensmaster Flex 1800/1820/2100/2120Page 2 −6Product Records and Maintenance
Other Torque Specifications
SAE Grade 8 Steel Set Screws
Thread Size
Recommended Torque
Square Head Hex Socket
1/4 −20 UNC 140 + 20 in−lb 73 + 12 in−lb
5/16 −18 UNC 215 + 35 in−lb 145 + 20 in−lb
3/8 −16 UNC 35 + 10 ft−lb 18 + 3 ft−lb
1/2 −13 UNC 75 + 15 ft−lb 50 + 10 ft−lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Size Baseline Torque*
No. 6 −32 UNC 20 + 5 in−lb
No. 8 −32 UNC 30 + 5 in−lb
No. 10 −24 UNC 38 + 7 in−lb
1/4 −20 UNC 85 + 15 in−lb
5/16 −18 UNC 110 + 20 in−lb
3/8 −16 UNC 200 + 100 in−lb
Wheel Bolts and Lug Nuts
Thread Size Recommended Torque**
7/16 −20 UNF
Grade 5
65 + 10 ft−lb 88 + 14 N−m
1/2 −20 UNF
Grade 5
80 + 10 ft−lb 108 + 14 N−m
M12 X 1.25
Class 8.8
80 + 10 ft−lb 108 + 14 N−m
M12 X 1.5
Class 8.8
80 + 10 ft−lb 108 + 14 N−m
** For steel wheels and non−lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
Threads per Inch
Baseline Torque*
Type A Type B
No. 6 18 20 20 + 5 in−lb
No. 8 15 18 30 + 5 in−lb
No. 10 12 16 38 + 7 in−lb
No. 12 11 14 85 + 15 in−lb
* Hole size, material strength, material thickness & finish
must be considered when determining specific torque
values. All torque values are based on non−lubricated
fasteners.
Conversion Factors
in−lb X 11.2985 = N−cm N−cm X 0.08851 = in−lb
ft−lb X 1.3558 = N−mN−m X 0.7376 = ft−lb

Greensmaster Flex 1800/1820/2100/2120 Page 3 −1 Engine
Chapter 3
Engine
Table of Contents
SPECIFICATIONS 3............................
GENERAL INFORMATION 4.....................
Operator’s Manual 4..........................
Fuel Evaporative Control System 4..............
ADJUSTMENTS 5..............................
Throttle Cable Adjustment 5....................
SERVICE AND REPAIRS 6......................
Cooling System 6.............................
Spark Plug 7.................................
Ignition Components 7........................
Engine 8.....................................
Engine Coupler Sleeve 11.....................
SUBARU SERVICE MANUAL
Engine

Greensmaster Flex 1800/1820/2100/2120Page 3 −2Engine
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