Form No. 3361-484 Rev B Greensmaster® Flex 18 or Flex 21 Walk-Behind Mower Model No. 04019 (Traction Unit)—Serial No. 290000001 and Up Model No. 04206 (Cutting Unit)—Serial No. 290000001 and Up Model No. 04207 (Cutting Unit)—Serial No. 290000001 and Up Model No. 04024 (Traction Unit)—Serial No. 290000001 and Up Model No. 04202 (Cutting Unit)—Serial No. 290000001 and Up Model No. 04025 (Traction Unit)—Serial No. 290000001 and Up Model No. 04208 (Cutting Unit)—Serial No.
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 Belts ............................................. 27 Controls System Maintenance................................. 30 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 ................................
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.
• • • • • • • • • 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. Wait for all movement to stop before adjusting, cleaning or repairing. • Clean grass and debris from cutting unit, drives, mufflers, and engine to help prevent fires. Clean up oil or fuel spillage.
– 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. and any parts of the body away from the cutting unit, attachments and any moving parts. Keep everyone away. – Pull starter cord to start engine. • To ensure safety and accuracy, have an Authorized Toro Distributor check the maximum engine speed with a tachometer. Maximum governed engine speed should be 3600 RPM.
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 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.
Figure 18 1. Choke lever 2. Fuel shut-off valve Figure 20 1. Kick stand Fuel Shut-Off Valve 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. Specifications 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.
Height of cut Clip frequency 1/16 to 19/64 inches (1.5 to 7.5 mm) with Micro-Cut bedknife 1/16 to 19/64 inches (1.5 to 7.5 mm) with Micro-Cut bedknife 11 blade (standard): .14 in. 11 blade (standard): .14 inch Operation Note: Determine the left and right sides of the machine from the normal operating position. Think Safety First Attachments/Accessories Please carefully read all of the safety instructions and decals in the safety section.
Checking the Interlock Switch 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. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills. • Do not tamper with the interlock switches.
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. 2. Install the transport wheels. 3. To release kickstand, pull up on handle and lower rear of mower onto transport wheels. 4. Ensure traction and reel drive controls are in Disengage position and start engine. 5.
done at a normal walking pace. Fast speeds saves very little time and will result in an inferior mowing job. To assist in maintaining a straight line across the green and to keep the machine an equal distance from the edge of the previous cut, use the alignment stripes on the basket (Figure 23). Figure 23 1. Alignment stripes Figure 24 1. Traction drive -neutral Control Operation 2. Traction drive neutral & reel drive off 3. Traction drive-engaged (transport) 4.
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 Service Interval: Every 100 hours 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.
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 9 ± 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 75–85 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 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 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 1. Gauge bar 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) * An additional 22 tooth pulley is required for this clip setting.
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).
