Form No. 3359-189 Rev A Greensmaster® Flex 18 or Flex 21 Walk-Behind Mower Model No. 04030 (Traction Unit)—Serial No. 280000001 and Up Model No. 04206 (Cutting Unit)—Serial No. 280000001 and Up Model No. 04031 (Traction Unit)—Serial No. 280000001 and Up Model No. 04202 (Cutting Unit)—Serial No. 280000001 and Up Register at 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 Traction Control ........................... 30 Adjusting the Reel Control.................................. 30 Cutting Unit Maintenance....................................... 31 Separating the Cutting Unit from the Traction Unit................................................................ 31 Adjusting the Rear Roller .................................... 31 Adjusting the Bedknife to the Reel ...................... 32 Adjusting the Height of Cut ................................
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.
• 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.
stopped because these areas could be hot enough to cause burns. • Wearing safety shoes and long pants is advisable and required by some local ordinances and insurance regulations. • When a person or pet appears unexpectedly in or near the mowing area, stop mowing. Careless operation, combined with terrain angles, ricochets, or improperly positioned guards can lead to thrown object injuries. Do not resume mowing until the area is cleared. • Handle gasoline carefully. Wipe up any spills.
Sound Power for a Flex 21 Vibration for a Flex 21 This unit has a guaranteed sound power level of 98 dBA, based on measurements of identical machines per ISO 11094. This unit does not exceed a hand/arm vibration level of 2.50 m/s2, based on measurements of identical machines per EN 1033. 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. 115-1615 1.
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.
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 Description Use Qty. 1 Handle 1 Install the handle. 2 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. Transport wheels (Optional Transport Wheel Kit, Model 04123) 2 Install the transport wheels.
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 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 4).
Figure 8 1. Ring pins Figure 6 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 8). 3. Reinstall ring pins and hair pin cotters. 4 6.
5 Checking Fluid Levels No Parts Required Procedure 1. Check the engine oil level, refer to Checking the Engine Oil Level in Engine Maintenance , page 22. 2. Check the transmission fluid level, refer to Checking the Transmission Fluid Level in Drive System Maintenance , page 25. Figure 9 1. Kick stand 2. Press wheel locking clip toward the center of wheel and slide wheel onto hex shaft (Figure 10).
Traction and Reel Drive Engagement Lever Product Overview The traction and reel drive engagement lever (Figure 13) 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.
Specifications Open. Move lever to closed position when storing or transporting machine. Open valve before starting engine. Flex 21 Recoil Starter Width 35-1/2 inches (90.1 32 inches (81.3 cm) cm) Height 41–1/4 inches (104.8 cm) 41–1/2 inches (105.4 cm) Length with basket 61–1/2 inches (156.2 cm) 61 inches (155 cm) Weight with full fluids and basket 267lb (121 kg) 261lb (118 kg) Dry weight with basket 256lb (116 kg) 250lb (113 kg) Engine Kawasaki, 4-cycle, 3.7 (2.
Operation Note: Determine the left and right sides of the machine from the normal operating position. 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. 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 1. Make sure traction and reel drive levers are in Disengaged position. 2. 3. 4. 5. 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. 6. 1.
Preparing to Mow 1. Return traction control lever to Disengage, throttle to Slow and stop engine. 2. Push kick stand down with foot and pull up on handle support until kick stand has rotated forward, over center. 3. Remove transport wheels. 4. Release kickstand. Mowing Operation Figure 19 Proper use of the machine provides the smoothest turf cutting available. 1. Alignment stripes Important: Grass clippings act as a lubricant when mowing.
Figure 20 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 20). 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 21 illustrates the temperature/viscosity recommendations. Figure 22 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 25 2. Remove wing nuts securing air cleaner cover to air cleaner and remove cover. Clean cover thoroughly (Figure 24). 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 27). 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 28). Figure 27 Figure 28 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 29).
Brake Maintenance 1. Place a drain pan at the rear of the machine. 2. Remove the drain plug from the rear of the transmission (Figure 31). Adjusting the Service/Parking Brake If service/park brake slips when operated, an adjustment is required. 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 32) until a force of 11–14 lb. is required to engage brake. Force to be measured at lever knob.
Belt Maintenance 3. To adjust belt tension: A. Loosen the bearing housing mounting nuts (Figure 35). 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 33). Figure 35 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 37). Figure 39 1. Reel drive belt Figure 37 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 40). 1. Belt cover 2. Check tension by depressing belt (Figure 38) 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 41 Figure 43 1. Traction drive belt cover 1. Tang washer 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). 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 44).
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 46 2. To increase cable tension, loosen front cable jam nut and tighten back cable jam nut (Figure 45) until a force of 12-16 lb. 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 47). Figure 49 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 50). Figure 47 3. Kick stand 1.
Figure 51 1. Spacer 2. Sideplate mounting flange 3. Roller bracket Figure 53 • Position the spacer below the sideplate mounting flange when height of cut settings range from 1/8" to 1" (Figure 52). 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 55 Figure 56 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 57) 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 58 Figure 59 1. Cut-off bar 4. Rotate adjusting screw until roller contacts front of gauge bar. Adjust both ends of roller until entire roller is parallel to the bedknife. 2. Insert .060 inch feeler gauge between top of reel and bar and tighten screws. Ensure bar and reel are equal distance apart across complete reel. Important: When set properly, the rear and front rollers will contact the gauge bar and the screw will be snug against the bedknife.
Setting the Machine to Match Turf Conditions Use the following table to set the machine to match turf conditions.
Use the following table and Figure 60 to set the rate of clip. Clip (Refer to Figure 60 for pulley locations.) Drive pulley number of teeth Driven pulley number of teeth 11 Blade Clip 8 Blade Clip 27 22 .14 inches (standard) .19 inches 22 22 .16 inches .24 inches 22 27 .21 inches .29 inches The reel is shipped with one 27 tooth and one 22 tooth pulley. To get a .16 inch clip, you must purchase a 22 tooth pulley. The clip can only be changed on the reel drive (Figure 60).
Note: For a better cutting edge, run a file across the front face of the bedknife when the lapping operation is completed. This will remove any burrs or rough edges that may have built up on the cutting edge. 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.
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The 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.
