Form No. 3357-158 Rev C Greensmaster® Flex 18 or Flex 21 Walk-Behind Mower Model No. 04018 (Traction Unit)—Serial No. 260003001 and Up Model No. 04206 (Cutting Unit)—Serial No. 260000001 and Up Model No. 04022 (Traction Unit)—Serial No. 260003001 and Up Model No. 04202 (Cutting Unit)—Serial No. 260000001 and Up G000507 Register at www.Toro.com.
Warning Model No. 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. Serial No. This spark ignition system complies with Canadian ICES-002. Introduction Figure 2 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. 1.
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.
• Wearing safety shoes and long pants is advisable and required by some local ordinances and insurance regulations. • Handle gasoline carefully. Wipe up any spills. • Check the safety interlock switches daily for proper operation. If a switch should fail, replace the switch before operating the machine. After every two years, replace all interlock switches in the safety system, regardless if they are working properly or not. • Always stand behind the handle when starting and operating the machine.
Sound Pressure for a Flex 21 Vibration for a Flex 21 This unit has a maximum sound pressure level at the operator’s ear of 85 dBA, based on measurements of identical machines per EN 11094 and EN 836. This unit does not exceed a hand/arm vibration level of 2.50 m/s2, based on measurements of identical machines per EN 1033. Sound Power for a Flex 21 Safety and Instructional Decals This unit has a guaranteed sound power level of 98 dBA, based on measurements of identical machines per EN 11094.
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.
104-2621 1. Read the Operator’s Manual.
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).
3 Adjusting the Handle No Parts Required Procedure 1. Remove hairpin cotters from ring pins on each side of mower (Figure 8). Figure 6 1. Left handle end 2. Locknut (M8–1.25) 3. Small spacer 4. Washer (M8) 5. Large bolt (M8–1.25 x 100) 6. Spring 7. Large spacer 8. Ssmall bolt (M8–1.25 x 030) 6. Place a nut runner over the end of the spring pointing towards the rear and move the end of the spring over and under the kickstand spacer (Figure 7). Figure 8 1. Ring pins 2.
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).
Product Overview throttle linkage to carburetor. Engine speed can be varied from 2400 RPM to 3600 RPM. Traction and Reel Drive Engagement Lever 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.
or transporting machine. Open valve before starting engine. Recoil Starter Pull recoil starter handle (Figure 15) to start engine. Figure 16 1. Kick stand Specifications Flex 21 Figure 15 1. Recoil starter 2. On/off switch 3. Hour meter On/Off Switch The on/off switch (Figure 15) is located on rear of engine. Move switch to On position to start engine and Off to stop engine. Hour Meter 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.
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 Please carefully read all of the safety instructions and decals in the safety section. Knowing this information could help you or bystanders avoid injury.
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.
Starting the Engine Preparing to Mow Note: Make sure spark plug wire is installed on spark plug. 1. Make sure traction and reel drive levers are in Disengaged position. 1. Return traction control lever to Disengage, throttle to Slow and stop engine. 2. 3. 4. 5. 6. 2. Push kick stand down with foot and pull up on handle support until kick stand has rotated forward, over center. Note: Engine will not start if traction lever is in the engaged position. Open the fuel shut-off valve on the engine.
Figure 19 1. Alignment stripes Control Operation To operate the controls while mowing: 1. Start the engine, set the throttle at reduced speed, push down on handle to raise cutting unit, move traction lever to Engaged position and transport mower onto collar of green (Figure 20). Figure 20 1. Traction drive -neutral 2. Traction drive neutral & reel drive off 2. Move traction lever to Disengaged position and Engage reel drive lever (Figure 20). 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 21 illustrates the temperature/viscosity recommendations. −20 ° C −10 ° C 0 ° C 10 ° C 20 ° C 30 ° C 40 ° C SAE 40 Figure 22 SAE 30 1.
4. When servicing foam element, check condition of paper element. Clean or replace every 100 hours or as required. 5. Install foam element, paper element, and air cleaner cover. Important: Do not operate the engine without the air cleaner element because extreme engine wear and damage will likely result. Replacing the Spark Plug Service Interval: Every 100 hours Use an NGK BPR 5ES spark plug or equivalent. Correct air gap is 0.028-0.032 inch. 1. Pull molded wire off spark plug (Figure 25). Figure 23 1.
Fuel System Maintenance Electrical System Maintenance Cleaning the Fuel Filter Servicing the Interlock Switch Service Interval: After the first 25 hours Service Interval: Every 1,500 hours Every 50 hours Use the following procedure if the switch needs adjustment or replacement. 1. Close fuel shut off valve and unscrew bowl from filter body (Figure 27). 1. Make sure the engine is off and traction lever is Disengaged. 2. Engage traction lever until it contacts neutral stop (Figure 28). Figure 27 1.
Drive System Maintenance Checking the Transmission Fluid Level Service Interval: Every 50 hours The transmission is filled at the factory with approximately 94 fluid ounces of Mobil Dexron lll automatic transmission fluid. Note: The seals used in the transmission are internally lubricated with grease. During initial operation of mower, slight weeping of grease from these seals will occur. Wipe off excess grease. Important: Use only Mobil Dexron lll or equivalent transmission fluids.
Brake Maintenance Changing the Transmission Fluid Adjusting the Service/Parking Brake Service Interval: After the first 25 hours Every 1,500 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 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 32). Figure 34 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. of torque to set belt tension (Figure 35) Figure 32 1. Belt cover 2.
Figure 38 Figure 36 1. Reel drive belt 1. Belt cover 2. Check tension by depressing belt (Figure 37) 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. 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 39). Figure 39 1. Bearing housing Figure 37 2. 3/8" Torque wrench here C.
Figure 40 Figure 42 1. Tang washer 1. Traction drive belt cover 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 43). 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. 2. Check tension by depressing belt (Figure 41) at mid span of pulleys with 4 ± 1 lb of force.
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 45 2. To increase cable tension, loosen front cable jam nut and tighten back cable jam nut (Figure 44) 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 46). Figure 48 1. Transmission coupling 7. Reverse procedure to install cutting unit. Note: When tightening the pivot arm mounting fasteners, use an adjustable (crescent) wrench to hold the pivot arm parallel to the side plate (Figure 49). Figure 46 3. Kick stand 1.
Figure 50 1. Spacer 2. Sideplate mounting flange 3. Roller bracket Figure 52 • Position the spacer below the sideplate mounting flange when height of cut settings range from 1/8" to 1" (Figure 51). 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 54 Figure 55 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 56) 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 57 Figure 58 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 59 to set the rate of clip. Clip (Refer to Figure 59 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 59).
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.
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.
