Form No. 3363-412 Rev B Greensmaster® Flex 18 or Flex 21 Walk-Behind Mower Model No. 04202 (Cutting Unit)—Serial No. 310000001 and Up Model No. 04206 (Cutting Unit)—Serial No. 310000001 and Up Model No. 04207 (Cutting Unit)—Serial No. 310000001 and Up Model No. 04208 (Cutting Unit)—Serial No. 310000001 and Up Model No. 04019 (Traction Unit)—Serial No. 310000001 and Up Model No. 04024 (Traction Unit)—Serial No. 310000001 and Up Model No. 04025 (Traction Unit)—Serial No.
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.
Servicing the Air Cleaner .................................... 23 Replacing the Spark Plug .................................... 23 Fuel System Maintenance ....................................... 24 Cleaning the Fuel Filter....................................... 24 Electrical System Maintenance................................ 25 Servicing the Interlock Switch ............................ 25 Drive System Maintenance ..................................... 25 Checking the Transmission Fluid Level ...............
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.
93-8064 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. 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 105-2411 1. Transmission oil 115-1614 1. Warning—read the Operator’s Manual. 3. Thrown object hazard—keep bystanders a safe distance from the machine.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 6 7 Description Use Qty. Bolt, M10 x 25mm 2 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.
4. Rotate the traction unit frame (Figure 6)forward until it engages the cutting unit pivot arms. 1 5. Secure the traction unit frame to the cutting unit pivot arms with (2) M10 x 25mm bolts (Figure 6) Installing the Cutting Unit to the Traction Unit Parts needed for this procedure: 2 Bolt, M10 x 25mm 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 4). Figure 6 1.
4. Secure the handle to the bolt and pivot pin with the flange lock nut (Figure 9). 2 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 3 Handle Installing the Kickstand for Flex 18 Mowers Only Procedure 1. Remove the flange lock nut from the bolt and pivot pin on each side of the mower (Figure 8).
Figure 12 1. Ring pins Figure 10 1. Left handle end 5. Large bolt (M8–1.25 x 100) 6. Spring 7. Large spacer 8. Ssmall bolt (M8–1.25 x 030) 2. Locknut (M8–1.25) 3. Small spacer 4. Washer (M8) 2. While supporting handle, remove ring pins from each side and raise or lower handle to desired operating position (Figure 12). 3. Reinstall ring pins and hair pin cotters. 5 6.
6 Checking Fluid Levels No Parts Required Procedure 1. Check the engine oil level, refer to Checking the Engine Oil Level. 2. Check the transmission fluid level, refer to Checking the Transmission Fluid Level. Figure 13 1. Kick stand 7 2. Press wheel locking clip toward the center of wheel and slide wheel onto hex shaft (Figure 14). 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 15).
Traction and Reel Drive Engagement Lever Product Overview The traction and reel drive engagement lever (Figure 17) 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 18) 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 20) 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 19) to start engine. 1 Figure 20 1.
Operation 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 4. Move traction lever into Engage position, engine must shut off. 5. If the engine does not shut off, the interlock switch needs service. Correct the problem before operating. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. 6. Carefully lift up on handle to release kick stand. Starting and Stopping the Engine • Do not tamper with the interlock switches.
Transport Operation Method of Mowing Note: Do not run the mower engine while transporting it in a transport trailer because damage can occur to the mower. 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.
Figure 24 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 24). 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 25 illustrates the temperature/viscosity recommendations. Figure 26 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 29 2. Remove wing nuts securing air cleaner cover to air cleaner and remove cover. Clean cover thoroughly (Figure 28). 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 31). Install correctly gapped spark plug and tighten firmly to 17 ft.-lb. 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 32). Figure 31 Figure 32 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 33).
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) If service/park brake slips when operated, an adjustment is required. Important: Use only Mobil Dexron lll or equivalent transmission fluids. Other fluids could cause system damage. 1. Move service/parking brake lever to Off position. 2.
Belt Maintenance 3. To adjust belt tension: A. Loosen the bearing housing mounting nuts (Figure 39). 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 37). Figure 39 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.
Reel Drive Belt (Transmission coupler) 1. Remove the belt cover mounting fasteners and belt cover to expose belt (Figure 41). Figure 43 1. Reel drive belt Figure 41 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 44). 1. Belt cover 2. Check tension by depressing belt (Figure 42) 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).
Figure 45 Figure 47 1. Traction drive belt cover 1. Tang washer 2. Check tension by depressing belt (Figure 46) 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. 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 48).
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 50 2. To increase cable tension, loosen front cable jam nut and tighten back cable jam nut (Figure 49) until a force of 10-13 lbs. is required to engage traction control. 1. Reel control cable 3. Tighten front cable jam nut. 4. Check control operation. Measure the force at the control knob.
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 51). Figure 53 1. Transmission coupling 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 54). Figure 51 3. Kick stand 1.
Figure 55 1. Spacer 2. Sideplate mounting flange 3. Roller bracket Figure 57 • Position the spacer below the sideplate mounting flange when height of cut settings range from 1/8" to 1" (Figure 56). 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 screws are not resting on work surface.
from the front, parallel to the bedknife. A slight drag will be noted as the paper is pulled. Figure 59 Figure 60 1. Rear roller bracket 2. Height-of-cut arm Note: Each time adjusting screw is rotated one click clockwise, the bedknife moves .0007 inch closer to reel. Do not overtighten the adjusting screws. 3. Locknut 4. Adjusting screw 2. Loosen nut on gauge bar (Figure 61) and set adjusting screw to desired height-of-cut. Distance between bottom of screw head and face of bar is height-of-cut. 5.
Figure 62 5. Tighten nuts to secure adjustment. Do not overtighten nut. Tighten enough to remove play from washer. Note: Use the following chart to determine which bedknife is best 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 63) to cutting unit. Figure 63 1. Cut-off bar 2. Insert .060 inch feeler gauge between top of reel and bar and tighten screws.
Setting the Machine to Match Turf Conditions Note: Use the following table to set the machine to match turf conditions.
Note: Use the following table and Figure 64 to set the rate of clip. Clip (Refer to Figure 64 for pulley locations.) Drive pulley number of teeth Driven 14 Blade pulley Clip number of inch (mm) teeth 11 Blade Clip inch (mm) 8 Blade Clip inch (mm) 27 (standard) 22 (standard) 0.112 (2.9) 0.143 (3.6) 0.197 (5.0) 22 22 0.138 (3.5) 0.176 (4.5) 0.241 (6.1) 22 27 0.172 (4.4) 0.219 (5.6) 0.301 (7.7) Figure 65 The reel is shipped with one 27 tooth and one 22 tooth pulley. To get a .
Figure 68 Figure 67 1. Bedbar bolt 2. Steel washer 1. Reel drive cover plug 3. Nut 4. Nylon washer 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. Assembling the Bedbar 1. Install bedbar, positioning mounting ears between washer and bedbar adjuster. 2. Secure bedbar to each side plate with bedbar bolts (jam nuts on bolts) and 8 washers.
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.
Notes: 39
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).
