Toro Greensmaster Flex 18 Installation Instructions Manual
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Toro Greensmaster Flex 18 Installation Instructions Manual

Toro Greensmaster Flex 18 Installation Instructions Manual

Engine conversion kit
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Download this manual See also: Operator's Manual
Engine Conversion Kit
Serial Number 280000001 and After Kawasaki-Powered
Walk-Behind Greensmaster
Model No. 138-2137

Introduction

This engine is not equipped with a spark arrester. It is
a violation of California Public Resource Code Section
4442 or 4443 to use or operate the engine on any
forest-covered, brush-covered, or grass-covered land
unless the engine is equipped with a spark arrester,
as defined in Section 4442, maintained in effective
working order or the engine is constructed, equipped,
and maintained for the prevention of fire.
If you require a spark arrester, contact your Authorized
Service Dealer. Genuine Toro spark arresters are
approved by the USDA Forestry Service.
Important:
These installation instructions
contain engine operation and maintenance
information that supersedes the engine operation
and maintenance procedures in your machine
Operator's Manual.
Before operating or maintaining the machine or
engine, always refer to the operating and safety
instructions in your Operator's Manual.
Save these instructions.
Important:
This engine's warranty is provided
by the engine manufacturer. Please refer to the
engine manufacturer's warranty and emissions
system warranty included in the literature packet.
That warranty applies only to the engine. It does
not expand or otherwise alter any express or
implied warranty terms or warranty period that
may apply to the product into which the engine
is installed.
© 2019-The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
Contents
Introduction ............................................................... 1
Safety ....................................................................... 2
Installation ................................................................ 4
Product Overview ................................................... 14
Operation ................................................................ 15
Maintenance ........................................................... 17
Register at www.Toro.com.
®
Flex
™
18 or Flex
WARNING
CALIFORNIA
Proposition 65 Warning
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects,
or other reproductive harm.
Safety and Instructional Decals .......................... 2
1 Installing a Gearbox Vent ................................. 4
2 Removing the Existing Engine ......................... 4
3 Installing the New Engine................................. 7
4 Preparing the New Engine ............................... 8
5 Installing the Controls ...................................... 8
Cable .............................................................11
Controls ........................................................... 14
Fuel Specifications ........................................... 15
Using Stabilizer/Conditioner ............................. 15
Filling the Fuel Tank .......................................... 15
Valve ............................................................. 16
Servicing the Engine Oil.................................... 18
Servicing the Air Cleaner .................................. 19
Servicing the Spark Plug................................... 20
Original Instructions (EN)
All Rights Reserved *3430-379* B
Printed in the USA
Form No. 3430-379 Rev B
™
21 Mowers
Installation Instructions

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Summary of Contents for Toro Greensmaster Flex 18

  • Page 1: Table Of Contents

    Contents If you require a spark arrester, contact your Authorized Service Dealer. Genuine Toro spark arresters are approved by the USDA Forestry Service. Introduction ............... 1 Safety ............... 2...

  • Page 2: Safety

    Safety Safety and Instructional 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 missing. decal93-6085 93-6085 1. Fast 3. Slow 2. Continuous variable setting decal104-2618 104-2618...
  • Page 3 decal115-1614 115-1614 1. Warning—read the Operator's Manual. 3. Thrown object hazard—keep bystanders away. 2. Warning—do not operate the machine unless you are trained. 4. Warning—stay away from moving parts; keep all guards and shields in place. decal138-2138 138-2138 1. Poisonous fumes or 4.

  • Page 4: Installation

    Installation Note: If the machine is equipped with an incandescent light kit, you may need to order a new Removing the Existing kit; contact your authorized Toro distributor for more information. Engine No Parts Required Procedure Installing a Gearbox Vent...
  • Page 5 Remove and discard the console cover (Figure g274782 Figure 5 1. Bolt 6. Retaining ring g029049 2. Reel lever pin 7. Reel lever Figure 3 3. Bushing 8. Traction cable 1. Brake lever grip 3. Traction lever grip 4. Traction lever 9.
  • Page 6 Remove and retain all engine output shaft hardware (Figure Note: You may discard the set screws. g274554 Figure 7 1. Gearbox 4. Washer 7. Gearbox gasket 2. Bolt 5. Engine gear 8. Set screw 3. Lock washer 6. Engine adapter 9.

  • Page 7: Installing The New Engine

    Note: The wire harness bracket is already installed on the engine. Install the gearbox gasket to the set screws on the crankcase cover. Installing the New Engine Position the engine on the engine mount with the shaft facing toward the gearbox assembly. Slide the engine toward the gearbox while Parts needed for this procedure: guiding the drive gear into gearbox input area.

  • Page 8: Preparing The New Engine

    Install the wide clamp and the cable clamp in the new locations on the throttle control with the screw and e-clip (Figure 10). Important: Ensure that the cable clamp is Preparing the New Engine oriented with the wire opening facing toward the wide clamp.

  • Page 9: Installing The Controls

    Installing the Controls Parts needed for this procedure: Traction bracket Throttle lever Spring Procedure g274781 Figure 11 Install the new traction bracket to the handle using the previously removed hardware (Figure 1. Nut 3. Proximity switch (sensor 15). 2. Spacer 4.
  • Page 10 Tighten the nut on the throttle spring until the spring is fully compressed, then back off 1/2 turn (Figure 12). Important: When operating at high idle the throttle lever should not move; if it moves, tighten the nut on the throttle spring slightly. g274739 Figure 12 1.

  • Page 11: Installing The Wire Harness And Throttle Cable

    Installing the Wire Harness and Throttle Cable Parts needed for this procedure: Wire harness Engine switch Cable ties Throttle cable Cable clip Console cover g274609 Figure 14 Procedure 1. Cowling bolt 4. Engine connector Install the wire harness to the interlock connector 2.
  • Page 12 g262107 Figure 15 1. Connect to the throttle lever. 6. Connect to the interlock module. 2. Engine switch 7. Connect to the throttle on the engine. 3. Throttle lever 8. Throttle cable 4. Traction bracket 9. Console cover 5. Wire harness 10.
  • Page 13 Route the cable up the right side of the handle and connect the throttle cable to the traction bracket and lever as shown in Figure Important: Route the cable so that it does not contact any hot or moving parts. g274612 Figure 16 1.

  • Page 14: Lubricating And Adjusting The Machine

    Product Overview Lubricating and Adjusting the Machine No Parts Required Procedure Lubricate the machine according to the instructions in your Operator’s Manual. Fill the gearcase with oil according to the g265059 instructions in your Operator’s Manual. Figure 19 Fill the engine crankcase with oil according to 1.

  • Page 15: Operation

    Filling the Fuel Tank Operation DANGER Fuel Specifications In certain conditions, fuel is extremely Fuel tank capacity: 2.0 L (0.59 US gallons) flammable and highly explosive. A fire or explosion from fuel can burn you and others Recommended fuel: Unleaded gasoline with an and can damage property.

  • Page 16: Opening And Closing The Fuel-Shut-Off Valve

    Opening and Closing the WARNING Fuel-Shut-Off Valve Fuel is harmful or fatal if swallowed. Long-term exposure to vapors can cause Control fuel flow to the engine with the fuel-shut-off serious injury and illness. valve as follows: • Avoid prolonged breathing of vapors. •...

  • Page 17: Maintenance

    Maintenance Important: Refer to your engine owner’s manual for additional maintenance procedures. Recommended Maintenance Schedule(s) Maintenance Service Maintenance Procedure Interval • Change the engine oil. After the first 20 hours • Check the engine-oil level. Before each use or daily •...

  • Page 18: Servicing The Engine Oil

    Servicing the Engine Oil Fill the crankcase with approximately 0.56 L (19 fl oz) of the proper viscosity oil before starting. The engine uses a high-quality oil that has the American Petroleum Institute (API) service classification of SJ or higher. Select the proper oil viscosity (weight) based on the ambient temperature.

  • Page 19: Servicing The Air Cleaner

    Changing the Engine Oil Servicing the Air Cleaner Service Interval: After the first 20 hours Service Interval: Before each use or daily Every 100 hours Every 50 hours Every 300 hours/Yearly (whichever comes first) WARNING Important: Do not operate the engine without Oil may be hot after the engine has been run, the air filter assembly;...

  • Page 20: Servicing The Spark Plug

    Servicing the Spark Plug Clean the paper element by tapping it gently to remove the dirt. Service Interval: Every 100 hours Note: Do not try to brush dirt off the paper Every 300 hours element; brushing forces the dirt into the fibers. Replace the element if tapping it fails to remove Use an NGK BPR6ES spark plug or equivalent.
  • Page 21 Notes:...
  • Page 22 Notes:...
  • Page 23 While the exposure from Toro products may be negligible or well within the “no significant risk” range, out of an abundance of caution, Toro has elected to provide the Prop 65 warnings. Moreover, if Toro does not provide these warnings, it could be sued by the State of California or by private parties seeking to enforce Prop 65 and subject to substantial penalties.

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