Toro 04022 Greensmaster Flex 21, Operator'S Manual

Page 1: ... No 04018 Traction Unit Serial No 270000001 and Up Model No 04206 Cutting Unit Serial No 270000001 and Up Model No 04022 Traction Unit Serial No 260000001 and Up Model No 04202 Cutting Unit Serial No 260000001 and Up Register your product at www Toro com Original Instructions EN ...

Page 2: ... Figure 1 and Figure 2 identify the location of the model and serial numbers on the product Write the numbers in the space provided Figure 1 1 Location of the model and serial numbers Traction unit Traction unit Model No Serial No Figure 2 1 Location of the model and serial numbers Cutting Unit Cutting unit Model No Serial No This manual identifies potential hazards and has safety messages identifie...

Page 3: ...ng Operation 20 Maintenance 22 Recommended Maintenance Schedule s 22 Daily Maintenance Checklist 23 Engine Maintenance 24 Engine Oil 24 Servicing the Air Cleaner 24 Replacing the Spark Plug 25 Fuel System Maintenance 26 Cleaning the Fuel Filter 26 Electrical System Maintenance 26 Servicing the Interlock Switch 26 Drive System Maintenance 27 Checking the Transmission Fluid Level 27 Changing the Tra...

Page 4: ... Do not operate the equipment when barefoot or wearing open sandals Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine Warning Fuel is highly flammable Take the following precautions Store fuel in containers specifically designed for this purpose Refuel outdoors only and do not smoke while refuelling Add fuel before starting the en...

Page 5: ... repairs before restarting and operating the equipment Reduce the throttle setting before stopping engine and if the engine is provided with a fuel shut off valve turn the valve off at the conclusion of mowing Keep hands and feet away from the cutting unit Slow down and use caution when making turns and crossing roads and sidewalks Stop reels if not mowing Do not operate the mower under the influen...

Page 6: ...nd reel drive control levers on handle are in Neutral position Move on off switch 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 Start engine Press down on handle ...

Page 7: ...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 Sound Power for a Flex 18 This unit has a guaranteed sound power level of 96 dBA based on measurements of identical machines per EN 11094 Vibration for a Flex 18 This unit does not exceed a hand arm vibration level of 2 50 m s2 based on measurements of identical machin...

Page 8: ...open ames or smoking when adding fuel to the tank leave space between the fuel and the top of the tank 3 Thrown object hazard keep bystanders a safe distance from the machine 4 Cutting hazard of hand or foot stay away from moving parts 93 9356 1 Entanglement hazard stay away from moving parts 105 5309 1 Hot surface burn hazard keep a safe distance from the hot surface 93 6085 1 Fast 3 Slow 2 Conti...

Page 9: ...before servicing or performing maintenance 2 Cutting hazard of hand or foot stop the engine and wait for moving parts to stop 104 2617 1 Traction drive 4 Forward 2 Reel drive 5 Lever engaged 3 Neutral 6 Lever disengaged 105 2411 1 Transmission oil 104 2621 1 Read the Operator s Manual 9 ...

Page 10: ... No parts required Check the engine oil and transmission uid levels 6 Grass basket 1 Install the grass basket Operator s Manual 1 Engine Operator s Manual 1 Parts Catalog 1 Operator Video 1 7 Certi cate of compliance 1 Read the manuals and watch the video before operating the machine Note Determine the left and right sides of the machine from the normal operating position Step 1 Installing the Han...

Page 11: ... right side of the kickstand to the frame with the bolt and washer the small spacer and locknut M8 1 25 Figure 6 Ensure the bolt is installed from the inside of the frame as shown in Figure 6 3 Install a washer M8 onto the large bolt M8 1 25 x 100 4 Install the spacer into the spring and install the large bolt M8 1 25 x 100 into the spacer Important When installing the spring place one end of the ...

Page 12: ... from each side and raise or lower handle to desired operating position Figure 8 3 Reinstall ring pins and hair pin cotters Step 4 Installing the Transport Wheels Parts needed for this step 2 Transport wheels Optional Transport Wheel Kit Model 04123 Procedure 1 Push kick stand down with foot and pull up on handle support until kick stand has rotated forward over center Figure 9 Figure 9 1 Kick sta...

Page 13: ... Step 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 24 2 Check the transmission fluid level refer to Checking the Transmission Fluid Level in Drive System Maintenance page 27 Step 6 Installing the Grass Basket Parts needed for this step 1 Grass basket Procedure Grasp basket by top lip and slide bask...

Page 14: ...he Video Parts needed for this step 1 Operator s Manual 1 Engine Operator s Manual 1 Parts Catalog 1 Operator Video 1 Certi cate of compliance Procedure 1 Read the manuals 2 View the Operator video 3 Store the documentation in a safe place 14 ...

Page 15: ...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 Service Parking Brake The service parking brake Figure 13 is located on left front side of control panel Pulling the lever back over center will set the parking brake Brake must be released before traction drive i...

Page 16: ...tart engine Figure 15 1 Recoil starter 3 Hour meter 2 On off switch 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 The hour meter Figure 15 located on rear of engine indicates the total hours of machine operation Kickstand The kickstand Figure 16 is mounted to rear of machine and is used to raise r...

Page 17: ...coil maximum noise suppression muf er 85 dB A at operator s ear Fuel capacity 2 64 qt 2 5 l regular grade unleaded gasoline 2 64 qt 2 5 l regular grade unleaded gasoline Ground speed Mowing speed 1 3 to 3 3 MPH 2 1 to 5 3 km h Transport speed 4 9 MPH 7 9 km h maximum Mowing speed 1 3 to 3 3 MPH 2 1 to 5 3 km h Transport speed 4 9 MPH 7 9 km h maximum Width of cut 21 inches 53 3 cm 18 inches 45 7 c...

Page 18: ... Checking the Engine Oil Level in Engine Maintenance page 24 Filling the Fuel Tank Important Never use methanol gasoline containing methanol gasohol containing more than 10 ethanol gasoline additives premium gasoline or white gas because the fuel system could be damaged Do not mix oil with gasoline Figure 17 1 Fuel tank cap 2 Fuel gauge Gasoline is harmful or fatal if swallowed Long term exposure ...

Page 19: ...el such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete 1 Clean around fuel tank cap and remove cap from tank Figure 17 Using unleaded gasoline fill fuel tank no higher than to bottom o...

Page 20: ...port until kick stand has rotated forward over center 2 To release kickstand pull up on handle and lower rear of mower onto transport wheels 3 Ensure traction and reel drive controls are in Disengage position and start engine 4 Set throttle control to Slow tip front of machine up gradually engage traction drive and slowly increase engine speed 5 Adjust throttle to operate mower at desired ground s...

Page 21: ...ove traction lever to Disengaged position and Engage reel drive lever Figure 20 Figure 20 1 Traction drive neutral 3 Traction drive engaged transport 2 Traction drive neutral reel drive off 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 f...

Page 22: ...vel Every 25 hours Clean the air cleaner more often in dirty or dusty conditions Every 50 hours Change the engine oil Clean the fuel lter Check the transmission uid level Every 100 hours Clean or replace the paper air lter element more often in dirty or dusty conditions Check the spark plug Every 200 hours Decarbon the engine Every 1 500 hours Replace the interlock switch Change the transmission u...

Page 23: ...king brake operation Check that pivot joints operate freely Check the fuel level Check the engine oil level Check the air lter Clean the engine cooling ns Check for unusual engine noises Check for unusual operating noises Check the reel to bedknife adjustment Check the height of cut adjustment Touch up damaged paint Notation for Areas of Concern Inspection performed by Item Date Information 23 ...

Page 24: ...ne is level and clean around oil level gauge Figure 22 Figure 22 1 Oil level gauge 2 Drain plug 2 Remove oil level gauge by rotating it counterclockwise 3 Wipe oil level gauge clean and insert it into filler port Do not screw into port Then remove and check level of oil If level is low add only enough oil to raise level to bottom of filler opening Recheck level of oil Do not overfill 4 Reinstall oil ...

Page 25: ...nt with clean engine oil Squeeze element to remove excess oil and to distribute oil thoroughly An oil damp element is desirable Figure 24 1 Foam element 2 Paper element 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 e...

Page 26: ...uel Filter Initially clean fuel filter after the first 25 hours of operation thereafter clean after every 50 hours operation 1 Close fuel shut off valve and unscrew bowl from filter body Figure 27 Figure 27 1 Shut off valve 2 Bowl 2 Clean bowl and filter in clean gasoline and install Electrical System Maintenance Servicing the Interlock Switch Use the following procedure if the switch needs adjustment...

Page 27: ...excess grease Important Use only Mobil Dexron lll or equivalent transmission fluids Other fluids could cause system damage 1 Place the mower on its drums on a level surface 2 Remove the check fill plug from the right hand side of the transmission Figure 29 The oil level should come to the bottom of the fill hole If it does not add enough of the proper oil type until the level reaches the bottom of the...

Page 28: ... 31 until a force of 6 9 lb is required to engage brake Force to be measured at lever knob Do not over adjust or brake band may drag Figure 31 1 Traction cable 2 Service parking brake cable 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 mou...

Page 29: ...ousing mounting nuts Figure 34 Do not over tension belt D Install belt cover Reel Drive Belt Transmission coupler 1 Remove the belt cover mounting fasteners and belt cover to expose belt Figure 36 Figure 36 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 1 4 inch 6 mm If the deflection is incorrect proceed to next step Figure ...

Page 30: ...gure 38 Do not over tension belt D Install belt cover Traction Drive Belt 1 Remove belt cover mounting fasteners and belt cover to expose belt Figure 40 Figure 40 1 Traction drive belt cover 2 Check tension by depressing belt Figure 41 at mid span of pulleys with 4 1 lb of force Belt should deflect 1 4 inch 6 mm If the deflection is incorrect proceed to next step Figure 41 1 Traction drive belt 3 To...

Page 31: ...o 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 Measure the force at the control knob Figure 44 1 Traction cable 2 Service parking brake cable 3 Tighten front cable jam nut 4 Check control operation Adjusting the Reel Control If reel control does not engage or it slips during operation an ...

Page 32: ...frame tube Figure 47 Figure 47 1 Cutting unit pivot arms 3 Bolts 2 Traction unit frame tube 5 Rotate pivot arms forward Figure 47 and rest traction unit on restrained kickstand 6 Pull cutting unit forward about 2 inch 51 mm and then to the right to disengage the transmission coupling Figure 48 Figure 48 1 Transmission coupling 7 Reverse procedure to install cutting unit Adjusting the Rear Roller 1...

Page 33: ...mower to expose front and rear rollers and bedknife Note The position of the rear roller to the reel is controlled by the machining tolerances of the assembled components and paralleling is not required A limited amount of adjustment is possible by setting the cutting unit on a surface plate and loosening the sideplate mounting bolts Figure 51 Adjust and re tighten bolts Figure 51 1 Sideplate moun...

Page 34: ...justment is accomplished check to see if reel can pinch paper when inserted from the front and cut paper when inserted at a right angle to the bedknife Figure 53 It should be possible to cut paper with minimum contact between the bedknife and the reel blades Should excessive reel drag be evident it will be either necessary to backlap or regrind the cutting unit to achieve the sharp edges needed fo...

Page 35: ...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 57 to cutting unit Figure 57 1 Cut off bar 2 Insert 060 inch feeler gauge between top of reel and bar and tighten screws Ensure bar and ree...

Page 36: ...s Aggressive 98 7261 Microcut Flex 18 0 062 0 125 inches Standard 98 7260 Tournament Flex 18 0 125 0 25 inches 110 2300 Extended Microcut Flex 18 0 062 0 125 inches Less Aggressive 110 2301 Low Cut Flex 18 0 25 inches and up Rollers Standard and Optional Part Number Description Mower Diameter Material Comments 107 9037 Narrow Wiehle Flex 21 2 5 inches Aluminum Standard Front 107 9038 Wide Wiehle F...

Page 37: ...he gearbox pulleys Figure 58 1 Reel drive belt 3 Driven pulley 2 Drive pulley Servicing the Bedbar Removing the Bedbar 1 Turn the bedbar adjuster screw counterclockwise to back the bedknife away from reel Figure 59 Figure 59 1 Bedbar adjusting screw 4 Jam nut 2 Spring tension nut 5 Bedbar bolt 3 Bedbar 2 Back out the spring tension nut until the washer is no longer tensioned against the bedbar Fig...

Page 38: ...justing the Bedknife to the Reel Backlapping the Reel 1 Remove plug from the reel drive cover on the left side of reel assembly Figure 62 Figure 62 1 Reel drive cover plug 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 Contact with the reel or other moving parts can res...

Page 39: ...gine to distribute conditioned fuel through the fuel system 5 minutes B Either stop engine allow it to cool and drain the fuel tank or operate the engine until it stops C Restart the engine and run it until it stops Repeat on Choke until the engine will not restart D Dispose of fuel properly Recycle as per local codes Note Do not store stabilizer conditioned gasoline over 90 days 3 Check and tight...

Page 40: ...e not limited to weather storage practices contamination use of unapproved coolants lubricants additives or chemicals etc Normal wear and tear items Normal wear and tear includes but is not limited to damage to seats due to wear or abrasion worn painted surfaces scratched decals or windows etc Parts Parts scheduled for replacement as required maintenance are warranted for the period of time up to ...