Form No. 3362-144 Rev A Greensmaster® Flex 21 Walk-Behind Mower Model No. 04022 (Traction Unit)—Serial No. 290000001 and Up Model No. 04202 (Cutting Unit)—Serial No. 290000001 and Up Model No. 04208 (Cutting Unit)—Serial No. 290000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
Traction unit: 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. Model No. Serial No. This spark ignition system complies with Canadian ICES-002. Introduction Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely.
Contents Adjusting the Rear Roller .................................... 29 Adjusting the Bedknife to the Reel ...................... 30 Adjusting the Height of Cut ................................ 30 Setting the Machine to Match Turf Conditions ..................................................... 32 Servicing the Bedbar........................................... 33 Adjusting the Cut-Off Bar .................................. 34 Backlapping the Reel .......................................... 34 Storage....
Safety – Refuel outdoors only and do not smoke while refuelling. This machine meets or exceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-2004 specifications in effect at the time of production when the Operator Presence Kit, Part No. 105-5333 is installed. – 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.
Maintenance and Storage • When using any attachments, never direct discharge of material toward bystanders nor allow anyone near the machine while in operation. • Never operate the machine with damaged guards, shields, or without safety protective devices in place. Be sure all interlocks are attached, adjusted properly, and functioning properly. • Do not change the engine governor settings or overspeed the engine. Operating the engine at excessive speed may increase the hazard of personal injury.
• Know how to stop the engine quickly. • Do not operate the machine while wearing tennis shoes or sneakers. • Wearing safety shoes and long pants is advisable and required by some local ordinances and insurance regulations. • Handle gasoline carefully. Wipe up any spills. • Check the safety interlock switches daily for proper operation. If a switch should fail, replace the switch before operating the machine. • Always stand behind the handle when starting and operating the machine.
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 lost. 115-1613 1. Warning—read the Operator’s Manual. 2. Warning—remove the spark plug wire before performing any maintenance on the machine. 3. Thrown object hazard—keep bystanders a safe distance from the machine. 4. Cutting, dismemberment hazard of hand or foot—stay away from moving parts. 93-6085 1. Fast 2.
104-2617 104-2618 1. Parking brake 2. Disengage 1. Traction drive 2. Reel drive 3. Neutral 3. Engage 4. Forward 5. Lever engaged 6. Lever disengaged 93-8064 105-2411 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. 1. Transmission oil 115-1614 1. Warning—read the Operator’s Manual. 3. Thrown object hazard—keep bystanders a safe distance from the machine. 4.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 Description Use Qty. Handle 1 Install the handle. No parts required – Adjust the handle. Transport wheels (Optional Transport Wheel Kit, Model 04123) 2 Install the transport wheels. No parts required – Check the engine oil and transmission fluid levels Grass basket 1 Install the grass basket.
4. Secure the handle to the bolt and pivot pin with the flange lock nut (Figure 5). 1 5. Locate cable tie loosely securing throttle cable to wire harness. Position cable tie approximately one inch behind transmission and tighten cable tie. Installing the Handle Parts needed for this procedure: 1 2 Handle Adjusting the Handle Procedure 1. Remove the flange lock nut from the bolt and pivot pin on each side of the mower (Figure 4). No Parts Required Procedure 1.
3 Installing the Transport Wheels Parts needed for this procedure: 2 Transport wheels (Optional Transport Wheel Kit, Model 04123) Procedure 1. Push kick stand down with foot and pull up on handle support until kick stand has rotated forward, over center (Figure 7). Figure 8 1. Locking clip 3. Rotate wheel back and forth until it slides completely onto axle and locking clip is secured in groove on axle shaft. 4. Repeat procedure on opposite side of machine. 5. Inflate the tires to 12-15 psi. 6.
Product Overview 5 Installing the Grass Basket Parts needed for this procedure: 1 Grass basket Procedure Grasp basket by top lip and slide basket frame into the receivers (Figure 9). Figure 10 1. 2. 3. 4. Handle Control panel Engine Transport wheels 5. Cutting unit 6. Grass basket 7. Fuel tank Controls 1 Figure 9 1. Grass basket 2 2. Basket receivers 4 5 3 G009976 Figure 11 1. Throttle control 2. Traction & reel drive engagement lever 3. Service/parking brake 4. On/off switch 5.
Traction and Reel Drive Engagement Lever Fuel Shut-Off Valve The fuel shut-off valve (Figure 12) is located on left front of engine. Valve has two positions: Closed and Open. Move lever to closed position (lever horizontal) when storing or transporting machine. Open valve (lever vertical) before starting engine. The traction and reel drive engagement lever (Figure 11) is located on front right side of control panel. Traction lever has two positions: Neutral and Forward.
Specifications Operation Width 35-1/2 inches (90.1 cm) Height 41–1/4 inches (104.8 cm) Length with basket 61–1/2 inches (156.2 cm) Note: Determine the left and right sides of the machine from the normal operating position. Weight with full fluids and basket 267 lb (121 kg) Think Safety First Dry weight with basket 256 lb (116 kg) Please carefully read all of the safety instructions and decals in the safety section. Knowing this information could help you or bystanders avoid injury.
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. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills. • Do not fill the fuel tank completely full. Add gasoline to the fuel tank until the level is 1 inch (25 mm) below the bottom of the filler neck. This empty space in the tank allows gasoline to expand. Figure 15 1. Fuel tank cap 2.
Transport Operation 2. Place traction lever into Engage position and engine controls in starting position. 3. Attempt to start engine. Engine should not start. If engine starts, the interlock switch needs service. Correct problem before operating. Refer to Servicing Interlock Switch. 4. With the engine running (low idle) and the brake ON, try to engage the traction lever. The engine should kill. If the engine does not kill, the interlock switch needs service. Correct problem before operating.
Method of Mowing The greens should be mowed in a straight back and forth direction across the green. Avoid circular mowing or turning the mower on greens areas since scuffing may occur. Turning the mower should be done off the green by raising the cutting reel (pushing the handle down) and turning on the traction drum. Mowing should be done at a normal walking pace. Fast speeds saves very little time and will result in an inferior mowing job.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Change the engine oil. After the first 25 hours • Clean the fuel filter. • Change the transmission fluid. Before each use or daily • Check the engine oil level. Every 25 hours • Clean the air cleaner (more often in dirty or dusty conditions). Every 50 hours • Change the engine oil.
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 Engine Oil The crankcase must be filled with 20 fluid ounces of proper viscosity oil before staring. The engine uses any high-quality oil having the American Petroleum Institute - APl - “service classification" SF, SG, SH or SJ. Oil viscosity - weight - must be selected according to ambient temperature. Figure 19 illustrates the temperature/viscosity recommendations. Figure 20 1. Oil level gauge 2. Drain plug 2. Remove oil level gauge by rotating it counterclockwise. 3.
3. Push down on handle to tip mower and engine backward, allowing all oil to run into drain pan. 4. Install drain plug and refill crankcase with the specified oil; refer to Checking the Oil Level. C. Saturate element with clean engine oil. Squeeze element to remove excess oil and to distribute oil thoroughly. An oil damp element is desirable. 4. Check condition of paper element. Clean by gently tapping the filter or replace as required. Servicing the Air Cleaner 5.
Fuel System Maintenance Electrical System Maintenance Cleaning the Fuel Filter Servicing the Interlock Switch Service Interval: After the first 25 hours Use the following procedure if the switch needs adjustment or replacement. Every 50 hours 1. Make sure the engine is off and traction lever is Disengaged. 1. Close fuel shut off valve and unscrew bowl from filter body (Figure 26). 2. Engage traction lever until it contacts neutral stop (Figure 27). Figure 26 1. Shut-off valve 2.
Drive System Maintenance When the transmission is warm, the transmission fluid is hot and under pressure. Allow the transmission to cool before servicing. Use caution when removing the check, fill or drain plugs from the transmission. Checking the Transmission Fluid Level Service Interval: Every 50 hours 1. Place a drain pan at the rear of the machine. The transmission is filled at the factory with approximately 94 fluid ounces of Mobil Dexron lll automatic transmission fluid. 2.
Brake Maintenance Belt Maintenance Adjusting the Service/Parking Brake Checking and Adjusting the Belts If service/park brake slips when operated, an adjustment is required. Service Interval: Every 100 hours Make sure belts are properly tensioned to assure proper operation of the machine and unnecessary wear. 1. Move service/parking brake lever to Off position. 2. To increase cable tension, loosen front cable jam nut and tighten back cable jam nut (Figure 29) until a force of 11–14 lb.
Reel Drive Belt (Transmission coupler) 3. To adjust belt tension: A. Loosen the bearing housing mounting nuts (Figure 32). 1. Remove the belt cover mounting fasteners and belt cover to expose belt (Figure 34). Figure 32 1. Reel drive belt 2. Bearing housing mounting nuts Figure 34 1. Belt cover 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 33) 2.
Figure 36 1. Reel drive belt 2. Bearing housing mounting nuts Figure 38 1. Traction drive belt cover 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 37). 2. Check tension by depressing belt (Figure 39) at mid span of pulleys with 4 ± 1 lb of force. Belt should deflect 3/16 to 5/16 inch (4.8 to 7.9 mm). If the deflection is incorrect, proceed to next step. Figure 37 1. Bearing housing 2. 3/8" Torque wrench here C.
Controls System Maintenance Adjusting the Traction Control If traction control does not engage or it slips during operation, an adjustment is required. 1. Move traction control to Disengaged position. 2. To increase cable tension, loosen front cable jam nut and tighten back cable jam nut (Figure 42) until a force of 12-16 lb. is required to engage traction control. Measure the force at the control knob. Figure 40 1. Tang washer 2. Idler bracket bolt B.
Cutting Unit Maintenance Separating the Cutting Unit from the Traction Unit 1. Place the mower on its drums on a level surface. 2. Lower kick stand. Insert a 1/4" dia. pin or equivalent into frame hole above kick stand mounting bolt (Figure 44). Figure 43 1. Reel control cable 3. Tighten front cable jam nut. 4. Check control operation. Figure 44 3. Kick stand 1. 1/4" Pin 2. Handle 3. Remove grass basket. 4. Remove (2) bolts securing cutting unit pivot arms to traction unit frame tube (Figure 45).
Figure 48 1. Spacer 2. Sideplate mounting flange Figure 46 3. Roller bracket 1. Transmission coupling • Position the spacer below the sideplate mounting flange when height of cut settings range from 1/8" to 1" (Figure 49). 7. Reverse procedure to install cutting unit. Note: When tightening the pivot arm mounting fasteners, use an adjustable end wrench to hold the pivot arm parallel to the side plate (Figure 47). Figure 49 1. Sideplate mounting flange 2. Spacer 3. Roller bracket 2.
at a time, until paper is pinched lightly, when inserted from the front, parallel to the bedknife. A slight drag will be noted as the paper is pulled. Figure 50 1. Sideplate mounting bolts Figure 52 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 screws are not resting on work surface. Note: Each time adjusting screw is rotated one click clockwise, the bedknife moves .0007 inch closer to reel.
Figure 55 4. Rotate adjusting screw until roller contacts front of gauge bar. Adjust both ends of roller until entire roller is parallel to the bedknife. Figure 53 1. Rear roller bracket 2. Height-of-cut arm 3. Locknut 4. Adjusting screw Important: When set properly, the rear and front rollers will contact the gauge bar and the screw will be snug against the bedknife. This ensures that the height-of-cut is identical at both ends of the bedknife. 2.
Setting the Machine to Match Turf Conditions Use the following table to set the machine to match turf conditions. Flex Greensmower Cutting Unit Set-up Matrix Bedbars: Standard and Optional Part Number Description Mower Aggressiveness 106-2468-01 Standard Flex 21 Less 99-3794-03 Aggressive Flex 21 More Mower Height of Cut Range Comments Standard Bedknives: Standard and Optional Part Number Description 93-4262 Microcut Flex 21 0.062 - 0.125 inches 93-4263 Tournament Flex 21 0.125 -0.
Figure 56 1. Reel drive belt 2. Drive pulley 3. Driven pulley Servicing the Bedbar Removing the Bedbar 1. Turn the bedbar adjuster screw, counterclockwise, to back the bedknife away from reel (Figure 57). Figure 58 1. Bedbar bolt 4. Remove each bedbar bolt allowing bedbar to be pulled downward and removed from machine. Account for 2 nylon and 2 stamped steel washers on each end of bedbar (Figure 59). Figure 57 1. Bedbar adjusting screw 2. Spring tension nut 3. Bedbar 2. Nut 4. Jam nut 5.
Assembling the Bedbar Backlapping the Reel 1. Install bedbar, positioning mounting ears between washer and bedbar adjuster. 1. Remove plug from the reel drive cover on the left side of reel assembly (Figure 61) 2. Secure bedbar to each side plate with bedbar bolts (jam nuts on bolts) and 8 washers. A nylon washer is to be positioned on each side of side plate boss. Place a steel washer outside each of the nylon washers. Torque bolts to 240-320 in.-lb. 3.
Storage 1. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine’s cylinder head fins and blower housing. Important: You can wash the machine with mild detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the shift lever plate, and engine. 2. For long-term storage (more than 90 days) add stabilizer/conditioner additive to fuel in the tank. A.
Toro General Commercial Products 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).
