Form No. 3367-381 Rev B Greensmaster® Flex 18 or Flex 21 Walk-Behind Mower Model No. 04019—Serial No. 311000001 and Up Model No. 04024—Serial No. 311000001 and Up Model No. 04025—Serial No. 311000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, 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. 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. Important: This engine is not equipped with a spark arrester muffler.
Contents Adjusting the Belts ............................................. 28 Controls System Maintenance................................. 31 Adjusting the Traction Control ........................... 31 Adjusting the Reel Control.................................. 31 Storage....................................................................... 32 Introduction................................................................. 2 Safety .........................................................................
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.
• • • • • • • • • • Keep all parts in good working condition and all hardware and hydraulic fittings tightened. Replace all worn or damaged parts and decals. • If the fuel tank has to be drained, do this outdoors. • Be careful during adjustment of the machine to prevent entrapment of the fingers between moving blades and fixed parts of the machine. • Disengage drives, disengage the cutting unit, set parking brake, stop engine and disconnect spark plug wire.
• To start and stop the engine: – Open fuel shut-off valve. – Verify that the traction and reel drive control levers on handle are in Neutral position. – Move the on/off switch, located on the control panel, to ON position, set choke to full choke position (cold start) and throttle to half throttle. – Pull starter cord to start engine. – Move throttle to Slow and on/off switch to Off position to stop engine. • To transport mower from one area to another: – Install transport wheels. – Disengage reel drive.
Sound Pressure Level-Flex 21 Vibration Level-Flex 21 This unit has a sound pressure level at the operator’s ear of 92 dBA, which includes an Uncertainty Value (K) of 1 dBA. Hand-Arm Measured vibration level for right hand = 2.36 m/s2 Measured vibration level for left hand = 2.47 m/s2 Sound pressure level was determined according to the procedures outlined in EN 836. Uncertainty Value (K) = 0.5 m/s2 Measured values were determined according to the procedures outlined in EN 836.
105-2411 1. Transmission oil 93-9886 1. Use unleaded gasoline. 104-2617 1. Traction drive 2. Reel drive 3. Neutral 4. Forward 5. Lever engaged 6. Lever disengaged 104-2618 1. Parking brake 2. Disengage 3. Engage 115-1614 1. Warning—read the Operator’s Manual. 3. Thrown object hazard—keep bystanders a safe distance from the machine. 4. Warning—stay away from moving parts; keep all guards in place. 2. Warning—do not operate the machine unless you are trained.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 6 7 Description Qty. Use Bolt, M10 x 25mm 2 Install the cutting unit to the traction unit Handle 1 Install the handle. Kickstand assembly Spring Small spacer Large spacer Large bolt (M8–1.25 x 100) Small bolt (M8–1.25 x 030) Locknut (M8 x 1.25) Washer (M8) 1 1 1 1 1 1 2 2 Install the kickstand for Flex 18 Mowers Only. No parts required – Adjust the handle.
Note: Determine the left and right sides of the machine from the normal operating position. 1 Installing the Cutting Unit to the Traction Unit Parts needed for this procedure: 2 Figure 4 Bolt, M10 x 25mm 1. Transmission coupling 1. Place the mower on its drums on a level surface. 4. Rotate the traction unit frame (Figure 5) forward until it engages the cutting unit pivot arms. 5. Secure the traction unit frame to the cutting unit pivot arms with (2) M10 x 25mm bolts (Figure 5) 2. Lower kick stand.
Figure 8 1. Left handle end 2. Support arm Figure 6 3. Squeeze the handle ends inward and install them on the step of the pivot pin (Figure 8). 4. Secure the handle to the bolt and pivot pin with the flange lock nut (Figure 8). 2 5. Locate cable tie loosely securing throttle cable to wire harness. Position cable tie approximately one inch behind transmission and tighten cable tie.
frame with the bolt and washer, the small spacer, and locknut (M8–1.25) (Figure 9). Ensure the bolt is installed from the inside of the frame as shown in Figure 9. 3. Install a washer (M8) onto the large bolt (M8–1.25 x 100). 4. Install the spacer into the spring and install the large bolt (M8–1.25 x 100) into the spacer. Important: When installing the spring, place one end of the spring under the rear frame (Figure 9). Figure 10 1. Spring 2. Spring end under the frame 5.
5 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 12). Figure 13 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.
7 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 14). Figure 14 1. Grass basket 2.
Traction and Reel Drive Engagement Lever Product Overview The traction and reel drive engagement lever (Figure 16) is located on front right side of control panel. Traction lever has two positions: Neutral and Forward. Pushing lever forward engages traction drive. The reel drive lever has two positions: Engage and Disengage. Move top of lever to the left to engage reel or back to neutral to disengage reel.
Fuel Shut-Off Valve Kickstand The fuel shut-off valve (Figure 17) is located on left front of engine. Valve has two positions: Closed and Open. Move lever to closed position when storing or transporting machine. Open valve before starting engine. The kickstand (Figure 19) is mounted to rear of machine and is used to raise rear of machine for installation or removal of transport wheels. Recoil Starter Pull recoil starter handle (Figure 18) to start engine. 1 Figure 19 1.
Operation DANGER 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. Note: Determine the left and right sides of the machine from the normal operating position. Think Safety First • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills. Please carefully read all of the safety instructions and decals in the safety section.
Checking the Interlock Switch Operation 5. If the engine does not shut off, the interlock switch needs service. Correct the problem before operating. 6. Carefully lift up on handle to release kick stand. CAUTION If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. • Do not tamper with the interlock switches. • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine.
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. If optional transport wheels are not going to be installed, proceed to step 4. 1. Push kick stand down with foot and pull up on handle support until kick stand has rotated forward, over center.
Figure 23 1. Traction drive -neutral 2. Traction drive neutral & reel drive off 3. Traction drive-engaged (transport) 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 23). After Mowing 1. Drive off green, move reel drive and traction control levers to Disengage and stop the engine. 2.
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 approximately 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 24 illustrates the temperature/viscosity recommendations. Figure 25 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. Servicing the Air Cleaner Service Interval: Every 25 hours Every 100 hours 1. Make sure wire is off spark plug. Figure 28 2. Remove wing nuts securing air cleaner cover to air cleaner and remove cover. Clean cover thoroughly (Figure 27). 1. Foam element 2. Paper element 4.
Fuel System Maintenance electrodes because engine damaged could result from grit entering the cylinder. 3. Set air gap at 0.028-0.032 inch (Figure 30). Install correctly gapped spark plug and tighten firmly to 17 ft.-lb (23 N-m). Cleaning the Fuel Filter Service Interval: After the first 25 hours Every 50 hours 1. Close fuel shut off valve and unscrew bowl from filter body (Figure 31). Figure 30 Figure 31 1. Shut-off valve 2. Bowl 2. Clean bowl and filter in clean gasoline and install.
Electrical System Maintenance Drive System Maintenance Servicing the Interlock Switch Checking the Transmission Fluid Level Use the following procedure if the switch needs adjustment or replacement. Service Interval: Every 50 hours 1. Make sure the engine is off and traction lever is Disengaged. The transmission is filled at the factory with approximately 94 fluid ounces of Mobil Dexron lll automatic transmission fluid. 2. Engage traction lever until it contacts neutral stop (Figure 32).
Brake Maintenance Changing the Transmission Fluid Adjusting the Service/Parking Brake Service Interval: After the first 25 hours Every 800 hours (Or 2 years, whichever occurs first) Note: The service/parking brake is a holding brake not a stopping brake. It is designed to hold the machine on a 17 degree slope without moving. Important: Use only Mobil Dexron lll or equivalent transmission fluids. Other fluids could cause system damage.
Belt Maintenance Adjusting the Belts Make sure belts are properly tensioned to assure proper operation of the machine and unnecessary wear. Check belts frequently. Reel Drive Belt (Reel) 1. Remove the belt cover mounting fasteners and belt cover to expose belt (Figure 36). 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. (4-4.5 N-m) of torque to set belt tension (Figure 39) Figure 36 1. Belt cover 2.
Reel Drive Belt (Transmission coupler) 1. Remove the belt cover mounting fasteners and belt cover to expose belt (Figure 40). Figure 42 1. Reel drive belt Figure 40 2. Bearing housing mounting nuts B. Using a 3/8 inch drive torque wrench, rotate the bearing housing with 35-40 in.-lb. (4-4.5 N-m) of torque to set belt tension (Figure 43). 1. Belt cover 2. Check tension by depressing belt (Figure 41) 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).
Traction Drive Belt 1. Remove belt cover mounting fasteners and belt cover to expose belt (Figure 44). Figure 46 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 47). 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-tension the belt. Figure 44 1. Traction drive belt cover 2.
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. Figure 49 2. To increase cable tension, loosen front cable jam nut and tighten back cable jam nut (Figure 48) until a force of 10-13 lbs. (4.5-5.8 kg) is required to engage traction control. 1. Reel control cable 3. Tighten front cable jam nut. 4. Check control operation.
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.
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The Toro Total Coverage Guarantee A 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).
