Form No. 3435-609 Rev A Greensmaster® Flex™ 2120 Traction Unit Model No. 04053—Serial No. 400000000 and Up Register at www.Toro.com.
Whenever you need service, genuine Toro parts, or additional information, contact an authorized Toro distributor and have the model and serial numbers of your product ready. The model and serial numbers are located on a plate on the rear frame. Write the numbers in the space provided. This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet.
Contents Cleaning the Fuel-Tank Screen......................... 33 Electrical System Maintenance ........................... 34 Servicing the Traction-Interlock Switch ...................................................................... 34 Servicing the Brake-Interlock Switch................. 34 Brake Maintenance ............................................. 35 Adjusting the Service/Parking Brake................. 35 Belt Maintenance ................................................
Safety • Do not operate the machine without all guards This machine has been designed in accordance with EN ISO 5395 and ANSI B71.4-2017 and meets these standards when you add the required decals. • Keep bystanders and children out of the operating and other safety protective devices in place and functioning properly on the machine. area. Never allow children to operate the machine.
decal120-9571 120-9571 1. Lower the lever to disengage the traction. decal131-3111 131-3111 1. Fast 2. Slow decal120-9598 120-9598 1. Brake 4. Parking brake 2. Release handle to disengage the brake. 5. Rotate the latch to lock the parking brake; compress the handle to release the latch. decal133-8062 133-8062 3. Compress the handle to engage the brake. decal130-8322 130-8322 1. Use only gasoline that contains 10% ethanol by volume (E10) or less. 3.
decal115-7274 115-7274 1. Lights (optional) 3. Engine—start 2. Hour meter 4. Engine—shut off decal133-2335 133-2335 1. Warning—read the Operator’s Manual; all operators should be trained before operating the machine. 3. Thrown object hazard—keep bystanders away. 2. Warning—wear hearing protection. 4. Warning—stay away from moving parts; keep all guards and shields in place. 6 5. Do not tow 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 8 Description Use Qty. No parts required – Prepare the traction unit (optional). Bolt (3/8 x 3/4 inch) 2 Install the cutting unit to the traction unit. Handle retainer Hairpin cotter 2 2 Install the handle retainers. Transport wheels—Transport Wheel Kit (Model No. 04123 [Optional]) 2 Install the transport wheels. No parts required – Check the engine-oil level.
1 2 Preparing the Traction Unit Installing the Cutting Unit to the Traction Unit Optional—Cutting Unit Models 04251, 04252, 04253, or 04254 Parts needed for this procedure: 2 No Parts Required Bolt (3/8 x 3/4 inch) Procedure Procedure If you are installing cutting unit Model No. 04251, 04252, 04253, or 04254 on this traction unit, complete the following steps: Note: To install the weight rod onto your machine, refer to the installation instructions in your cutting unit Operator’s Manual. 1.
3 Installing the Handle Retainers Parts needed for this procedure: g000483 2 Handle retainer 2 Hairpin cotter Figure 6 1. Transmission coupling 4. Procedure 1. Maneuver the machine frame forward until it engages the cutting unit pivot arms Figure 7. While supporting the handle, remove the cable ties that secure the handle clamps to the side plates (Figure 8). g032418 Figure 7 1. Telescoping coupler 3. Bolt 2. Cutting-unit hex shaft 5. 6. 7.
4 Installing the Transport Wheels Optional Parts needed for this procedure: 2 Transport wheels—Transport Wheel Kit (Model No. 04123 [Optional]) Procedure 1. g017591 Use your foot to push the center of the kickstand down and pull up on the lower handle support until the kickstand has rotated forward and over center (Figure 9). Figure 10 1. Locking clip g016833 3. Rotate the wheel back and forth until it fits onto the axle and the locking clip is secured in the groove on the axle shaft. 4.
6 Installing the Production-Year Decal CE Machines Only Parts needed for this procedure: g032407 1 Production-year decal Figure 12 1. Basket hooks Procedure 3. If you use this machine in a country that complies to CE standards, apply the production-year decal near the serial plate; refer to Figure 11. Install the basket hooks over the frame loop (Figure 12). Important: If you ever drop the basket, examine the pitch-arm contact points near the lower lip of the basket for damage (Figure 13).
Product Overview 8 Breaking in the Machine No Parts Required Procedure Only 8 hours of mowing operation is required for the break-in period. The first several hours of operation are critical to future dependability of the machine. You must monitor the machine performance closely so that minor difficulties, which could lead to major problems, are noted and can be corrected.
Throttle Control The throttle control (Figure 15 and Figure 16) is located on the right, rear side of the control panel. Rotate the throttle to regulate the engine speed. g027738 Figure 16 1. Full speed g000494 Figure 17 2. Slow speed Traction and Reel-Drive Engagement Lever 1. NEUTRAL 3. Traction—FORWARD (transport) 2. Traction—NEUTRAL and reel drive—DISENGAGE 4. Traction—FORWARD and reel drive—ENGAGE To operate the reel, the lever has 2 positions: ENGAGE and DISENGAGE.
Service Brake Choke Lever The service brake (Figure 18) is located on the left front side of the handle. Pulling back the lever applies the service brake. The choke lever (Figure 19) is located on the left front of the engine. Use the lever to aid in starting a cold engine; refer to Using the Choke Lever (page 22). You must disengage the brake before you engage the traction drive.
Recoil-Starter Handle Pull the recoil-starter handle (Figure 19) to start the engine. Kickstand The kickstand (Figure 21) is mounted to the rear of the machine. Use the kickstand when you install or remove the transport wheels or the cutting unit. • To use the kickstand to install the transport wheels, lower the kickstand to the ground and step down on the loop while pulling up and back on the lower-center handle (Figure 20). g239955 Figure 21 1. Kickstand CAUTION 2.
Specifications Operation 2120 Traction Unit Width 90.1 cm (35-1/2 inches) Height 104.8 cm (41-1/4 inches) Length with basket Net Weight (with 11-blade cutting unit and grass basket installed) Note: Determine the left and right sides of the machine from the normal operating position. 152.4 cm (60 inches) 117.9 kg (260 lb) Width of cut 53.3 cm (21 inches) Height of cut 1.5 to 7.
Filling the Fuel Tank such equipment with a portable container rather than from a fuel-dispenser nozzle. • Keep the nozzle in contact with the rim of the fuel DANGER tank or container operating at all times until fueling is complete. In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel 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 fuel that spills.
WARNING Fuel is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. • Avoid prolonged breathing of vapors. • Keep your face away from the nozzle and fuel tank or conditioner bottle opening. • Avoid contact with skin; wash off spills with soap and water. 1. Clean around the fuel-tank cap and remove the cap from the tank (Figure 23). Fill the fuel tank to the bottom of the fill-neck opening. Important: Do not overfill the tank with fuel. g265976 Figure 23 1.
Setting the Machine to Match Turf Conditions Use the following table to set the machine to match turf conditions.
Adjusting the Handle Height Note: The machine is shipped with the handle adjusted to the lowest position. The machine is normally operated with the handle telescoped out to its maximum height. 1. Loosen the 3 carriage bolts and nuts securing each side of the handle in the handle clamps (Figure 24). g017005 Figure 25 1. Hairpin cotter 3. Carriage bolts 2. Nut 2. Pull up on the handle slowly and evenly on each side until it is in the desired operating position. 3.
Checking the Operation of the Interlock Switches traction lever should disengage. If the traction lever does not disengage, the interlock system needs service. Correct the problem before operating the machine; refer to Servicing the Traction-Interlock Switch (page 34). Service Interval: Before each use or daily CAUTION 5. With the OPC pressed and the shift lever moved to the left, engage the traction and reel drive and release the OPC (Figure 27). The traction lever should disengage.
3. 4. 5. 4. With the engine running, engage the service brake (not the parking-brake latch), press the OPC, and engage the traction lever (Figure 27). The engine should labor to overcome the brake but should not shut off. If the engine shuts off immediately, the interlock switch needs service. Correct the problem before operating the machine; refer to Servicing the Brake-Interlock Switch (page 34). Securely fasten the machine to the trailer.
• Use care when mowing on wet grass. Poor footing • • • • • • • • g273576 Figure 29 1. Fuel-shutoff lever—CLOSED position 2. Fuel-shutoff lever—OPEN position During Operation During Operation Safety • • General Safety • The owner/operator can prevent and is responsible for accidents that may cause personal injury or property damage. • • Wear appropriate clothing, including eye protection; long pants; substantial, slip-resistant footwear; and hearing protection.
Note: The choke may not be required when – Evaluate the site conditions of the day to determine if the slope is safe for machine operation. Use common sense and good judgment when performing this evaluation. Changes in the terrain, such as moisture, can quickly affect the operation of the machine on a slope. Operate across slopes, never up and down. Avoid operation on excessively steep or wet slopes. Poor footing could cause a slip-and-fall accident. Identify hazards at the base of the slope.
3. Important: Push the lever from the front to prevent your hand from being struck by the spring loaded lever. Operating the Machine in Low Light Conditions Move the machine as needed Use the LED Light Kit when you operate the machine in low light conditions; contact your authorized Toro distributor. Important: If possible, do not tow the machine. If it is absolutely necessary, do not tow at any speed greater than 4.8 kph (3 mph); always disengage the transmission from the drum.
4. Move the lever to the traction—FORWARD and reel drive—ENGAGE position (Figure 32), increase the throttle speed until the machine is traveling at the desired ground speed, drive the machine onto the green, lower the cutting unit to the ground, and begin mowing. Operating the Controls after Mowing 1. Drive off the green, move the reel drive and traction control levers to the DISENGAGED position, and shut off the engine. 2.
Maintenance Maintenance Safety • Before you leave the operator’s position, do the following: WARNING – Park the machine on a level surface. Failing to properly maintain the machine could result in premature failure of machine systems, causing possible harm to you or bystanders. – Move the throttle to the low-idle position. – Disengage the cutting unit(s). – Ensure that the traction is in neutral. Keep the machine well maintained and in good working order as indicated in these instructions.
Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 20 hours • Change the engine oil. • Clean the fuel-tank screen. Before each use or daily • Check the operation of the interlock switches. • Check the engine-oil level. • Inspect the air-filter elements. Every 50 hours • Clean the air-filter elements. Every 100 hours • Change the engine oil. • Inspect and adjust the spark plug; replace it if necessary. • Clean the fuel-tank screen.
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.
Pre-Maintenance Procedures Engine Maintenance Preparing the Machine for Maintenance • Do not change the governor speed or overspeed Engine Safety the engine. • Run the engine dry or remove the fuel with a hand pump; never siphon the fuel. If you must drain the fuel tank, do it outdoors. WARNING While you are maintaining or adjusting the machine, someone could start the engine. Accidentally starting the engine could seriously injure you or other bystanders.
Changing the Engine Oil Service Interval: After the first 20 hours/After the first month (whichever comes first) Every 100 hours/Every 6 months (whichever comes first) WARNING Oil may be hot after the engine has been run, and contact with hot oil can cause severe personal injury. Avoid contacting the hot engine oil when you drain it. g266053 Figure 35 1. Dipstick 3. 1. Shut off the engine and wait for all moving parts to stop; refer to Shutting Off the Engine (page 24). 2.
Servicing the Air Cleaner Service Interval: Before each use or daily Every 50 hours/Every 3 months (whichever comes first) Every 300 hours/Yearly (whichever comes first) Important: Do not operate the engine without the air filter assembly; extreme engine damage will occur. 1. Shut off the engine and wait for all moving parts to stop; refer to Shutting Off the Engine (page 24). 2. Remove the wingnut securing the air-cleaner cover (Figure 37). 3. Remove the air-cleaner cover.
Servicing the Spark Plug Fuel System Maintenance Service Interval: Every 100 hours/Every 6 months (whichever comes first) Every 300 hours/Yearly (whichever comes first) Cleaning the Fuel-Tank Screen Use an NGK BPR6ES spark plug or equivalent. 1. Shut off the engine and wait for all moving parts to stop; refer to Shutting Off the Engine (page 24). Service Interval: After the first 20 hours Every 100 hours/Monthly (whichever comes first) 2. Clean around the spark plug. 3.
Servicing the Brake-Interlock Switch Electrical System Maintenance 1. Ensure that the engine is off. Servicing the Traction-Interlock Switch 2. Remove the control panel. 3. Engage the service-brake lever and engage the parking-brake latch. Use the following procedure if the traction-interlock switch needs adjustment or replacement. 4. Loosen and remove the interlock-switch mounting fasteners (Figure 41). 1. Ensure that the engine is off. 2. Remove the control panel. 3.
Brake Maintenance Belt Maintenance Adjusting the Service/Parking Brake Inspecting the Reel-Drive Belt If the service/parking brake slips when operated, adjust the cable as follows: Service Interval: Every 1,000 hours 1. Move the service/parking brake lever to the OFF position. 2. Remove the control panel. 3.
Engaging/Disengaging the Transmission-Belt Tensioner C. Clean any debris from inside the belt compartment and from around the compression spring (Figure 44). D. Ensure that the compression spring is applying the proper tension on the belt. E. Tighten the bearing housing mounting nut. F. Install the belt cover. The transmission belt is tensioned by a spring-loaded idler pulley.
Adjusting the Traction Control Controls System Maintenance If the traction control does not engage or if it slips during operation, an adjustment is necessary. 1. Move the traction control to the ENGAGED position. 2. Measure the distance from the pin on either end of the traction-control spring (Figure 48); if it is not within 7.3 to 7.6 cm (2-7/8 to 3 inches), adjust the clutch according to the steps below.
Adjusting the Reel Control Storage If the reel control does not properly engage, an adjustment is necessary. Storage Safety 1. Ensure that the reel control is disengaged. 2. At the control-handle bulkhead, loosen the reel-control cable until there is slack in the cable (Figure 49). • Shut off the engine, remove the key (if equipped), and wait for all movement to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it.
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