Toro 4021 User manual

Operator’s Manual
Domestic English (EN)
Form No. 3327–369 Rev. A
GreensmasterFlex 21
Greensmaster Walk-Behind Mower
Model No. 04021—210000001 and Up (Traction Unit)
Model No. 04200—210000001 and Up (Cutting Unit)

2
All Rights Reserved
Printed in the USA
2000 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other reproductive
harm.
Warning
This spark ignition system complies with Canadian
ICES-002.
Ce système d’allumage par étincelle de véhicule est
conforme à la norme NMB-002 du Canada.
Contents
Page
Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 4. . . . . . . . . . . . . . . . . . .
Toro Mower Safety 6. . . . . . . . . . . . . . . . . . . . . . .
Sound Pressure Level 7. . . . . . . . . . . . . . . . . . . . . .
Sound Power Level 7. . . . . . . . . . . . . . . . . . . . . . .
Vibration Level 7. . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 7. . . . . . . . . . . . . . .
Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 9. . . . . . . . . . . . . . . . . . . .
Dimensions 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Equipment 10. . . . . . . . . . . . . . . . . . . . . . .
Setup 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts Chart 11. . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Handle 11. . . . . . . . . . . . . . . . . . . . . .
Adjusting the Handle 12. . . . . . . . . . . . . . . . . . . . . .
Installing the Transport Wheels 12. . . . . . . . . . . . . .
Before Operating 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adding Engine Oil 13. . . . . . . . . . . . . . . . . . . . . . . .
Filling the Fuel Tank 13. . . . . . . . . . . . . . . . . . . . . .
Checking the Transmission Fluid 14. . . . . . . . . . . .
Separating Cutting Unit from Traction Unit 14. . . .
Leveling the Rear Roller to the Reel 15. . . . . . . . . .
Adjusting the Bedknife to the Reel 16. . . . . . . . . . .
Adjusting the Height of Cut 16. . . . . . . . . . . . . . . . .
Adjusting the Cut-Off Bar 17. . . . . . . . . . . . . . . . . .
Installing the Grass Basket 17. . . . . . . . . . . . . . . . .
Checking the Interlock Switch Operation 18. . . . . .
Page
Operation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Think Safety First 18. . . . . . . . . . . . . . . . . . . . . . . .
Controls 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping 19. . . . . . . . . . . . . . . . . . . . . .
Transport Operation 20. . . . . . . . . . . . . . . . . . . . . . .
Preparing to Mow 20. . . . . . . . . . . . . . . . . . . . . . . . .
Mowing Operation 20. . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 22. . . . . . . .
Daily Maintenance Checklist 23. . . . . . . . . . . . . . . .
Engine Oil 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing the Air Cleaner 24. . . . . . . . . . . . . . . . . .
Replacing the Spark Plug 25. . . . . . . . . . . . . . . . . . .
Cleaning the Fuel Filter 25. . . . . . . . . . . . . . . . . . . .
Changing the Transmission Fluid 25. . . . . . . . . . . .
Adjusting the Belts 26. . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Traction Control 29. . . . . . . . . . . . . .
Adjusting the Service/Parking Brake 29. . . . . . . . . .
Adjusting the Reel Control 29. . . . . . . . . . . . . . . . .
Servicing the Interlock Switch 30. . . . . . . . . . . . . . .
Servicing the Bedbar 30. . . . . . . . . . . . . . . . . . . . . .
Backlapping the Reel 31. . . . . . . . . . . . . . . . . . . . . .
The Toro General Commercial Products Warranty 32. .

3
Introduction
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready. Figures 1 & 2
illustrate the location of the model and serial numbers on
the product.
1
Figure 1
1. Locationof the model and serial numbers–Traction unit
1
Figure 2
1. Locationof the model and serial numbers–Cutting unit
Write the product model and serial numbers in the space
below:
Traction unit
Model No.
Serial No.
Cutting unit
Model No.
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard.
However, regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or
moderate injury if you do not follow the recommended
precautions.
This manual uses two other words to highlight
information. Important calls attention to special
mechanical information and Note: emphasizes general
information worthy of special attention.

4
Safety
This machine meets or exceeds CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI
B71.4-1999 specifications in effect at the time of
production when the Operator Presence Kit, Part No.
105–5333 is installed.
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert symbol, which means
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
Safe Operating Practices
The following instructions are from the CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI
B71.4-1999.
Training
•Read the Operator’s Manual and other training
material carefully. Be familiar with the controls, safety
signs, and the proper use of the equipment.
•Never allow children or people unfamiliar with these
instructions to use or service the mower. Local
regulations may restrict the age of the operator.
•Never mow while people, especially children, or pets
are nearby.
•Keep in mind that the operator or user is responsible
for accidents or hazards occurring to other people or
their property.
•The owner/user can prevent and is responsible for
accidents or injuries occurring to himself or herself,
other people, or property.
Preparation
•While mowing, always wear substantial footwear, long
trousers, hard hat, safety glasses, and ear protection.
Long hair, loose clothing, or jewelry may get tangled
in moving parts. 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 engine. Never remove
the cap of the fuel tank or add fuel while the
engine is running or when the engine is hot.
– If fuel is spilled, do not attempt to start the engine
but move the machine away from the area of
spillage and avoid creating any source of ignition
until fuel vapors have dissipated.
– Replace all fuel tanks and container caps securely.
•Replace faulty silencers.
•Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Only use accessories and attachments
approved by the manufacturer.
•Check that operator’s presence controls, safety
switches and shields are attached and functioning
properly. Do not operate unless they are functioning
properly.
Operation
•Do not operate the engine in a confined space where
dangerous carbon monoxide fumes can collect.
•Mow only in daylight or in good artificial light.
•Before attempting to start the engine, disengage all
blade attachment clutches, shift into neutral, and
engage the parking brake.
•Do not use on slopes of more than
–5°when mowing on side hills;
–10° when mowing uphill;
–15°when mowing downhill.
•Remember there is no such thing as a safe slope.
Travel on grass slopes requires particular care. To
guard against overturning:
– do not stop or start suddenly when going up or
downhill;
– engage clutch slowly, always keep machine in gear,
especially when travelling downhill;
– machine speeds should be kept low on slopes and
during tight turns;
– stay alert for humps and hollows and other hidden
hazards;
– never mow across the face of the slope, unless the
mower is designed for this purpose.
•Stay alert for holes in the terrain and other hidden
hazards.

5
•Watch out for traffic when crossing or near roadways.
•Stop the blades rotating before crossing surfaces other
than grass.
•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.
•Before leaving the operator’s position:
– stop on level ground;
– disengage the power take-off and lower the
attachments;
– change into neutral and set the parking brake;
– stop the engine.
•Disengage drive to attachments when transporting or
not in use.
•Stop the engine and disengage drive to attachment
– before refuelling;
– before removing the grass catcher/catchers;
– before making height adjustment unless adjustment
can be made from the operator’s position.
– before clearing blockages;
– before checking, cleaning or working on the
mower;
– after striking a foreign object or if an abnormal
vibration occurs. Inspect the mower for damage
and make repairs before restarting and operating
the equipment.
•Reduce the throttle setting during engine run-out and,
if the engine is provided with a shut-off valve, turn the
fuel 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 influence of
alcohol or drugs
•Use care when loading or unloading the machine into a
trailer or truck
•Use care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.
Maintenance and Storage
•Keep all nuts, bolts and screws tight to be sure the
equipment is in safe working condition.
•Never store the equipment with fuel in the tank inside
a building where fumes may reach an open flame or
spark.
•Allow the engine to cool before storing in any
enclosure.
•To reduce the fire hazard, keep the engine, silencer,
battery compartment and fuel storage area free of
grass, leaves, or excessive grease.
•Check the grass catcher frequently for wear or
deterioration.
•Keep all parts in good working condition and all
hardware and hydraulic fittings tightened. Replace all
worn or damaged parts and decals.
•If the fuel tank has to be drained, do this outdoors.
•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.
•Carefully release pressure from components with
stored energy.
•Disconnect battery and remove spark plug wire before
making any repairs. Disconnect the negative terminal
first and the positive last. Reconnect positive first and
negative last.
•Use care when checking the reel. Wear gloves and use
caution when servicing them.
•Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.

6
Toro Mower Safety
The following list contains safety information specific to
Toro products or other safety information that you must
know that is not included in the CEN, ISO, or ANSI
standard.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
Use of this product for purposes other than its intended
use could prove dangerous to user and bystanders.
•Know how to stop the engine quickly.
•Do not operate the machine while wearing tennis shoes
or sneakers.
•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.
•To start and stop the engine:
A. Open fuel shut-off valve.
B. Verify that the traction and reel drive control levers
on handle are in Neutral position.
C. Move on/off switch to ON position, set choke to
full choke position (cold start) and throttle to half
throttle.
D. Pull starter cord to start engine.
E. Move throttle to Slow and on/off switch to Off
position to stop engine.
•To transport mower from one area to another:
F. Install transport wheels.
G. Disengage reel drive.
H. Start engine.
I. Press down on handle to raise front of mower and
engage traction drive.
•Before beginning mowing operation:
J. Disengage traction drive.
K. Stop engine.
L. Remove transport wheels.
M. Start engine
N. Engage reel drive.
•Using the machine demands attention. To prevent loss
of control:
– Do not drive close to sand traps, ditches, creeks, or
other hazards.
– Reduce speed when making sharp turns. Avoid
sudden stops and starts.
– When near or crossing roads, always yield the
right-of-way.
– Apply the service brakes when going downhill to
keep forward speed slow and to maintain control of
the machine.
•The grass basket must be in place during operation of
the reels or thatchers for maximum safety. Shut the
engine off before emptying the baskets.
•Do not touch the engine, muffler, or exhaust pipe
while the engine is running or soon after it has stopped
because these areas could be hot enough to cause
burns.
•Stay clear of the rotating screen at the side of the
engine to prevent direct contact with your body or
clothing.
•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.
Maintenance and Storage
•Check all fuel lines for tightness and wear on a regular
basis. Tighten or repair them as needed.
•If the engine must be running to perform a
maintenance adjustment, keep hands, feet, clothing,
and any parts of the body away from the cutting unit,
attachments, and any moving parts, especially the
screen at the side of the engine. Keep everyone away.
•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.
•If major repairs are ever needed or if assistance is
desired, contact an Authorized Toro Distributor.
•Use only Toro-approved attachments and replacement
parts. The warranty may be voided if used with
unapproved attachments.

7
Sound Pressure Level
This unit has an equivalent continuous A-weighted sound
pressure at the operator ear of: 84 dB(A), based on
measurements of identical machines per procedures
outlined in Directive 98/37/EC and amendments.
Sound Power Level
This unit has a guaranteed sound power level of:
95 dBA/1 pW, based on measurements of identical
machines per Directive 2000/14/EC and amendments.
Vibration Level
This unit has a hand–arm vibration level of 4.50 m/s2,
based on measurements of identical machines per ISO
5349 procedures.
Safety and Instruction 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.
Part No. 93-7348
1. Danger—readthe operator’s manual.
2. Fire or open flame—sparks, flame, and smoking prohibited. Fill
the fuel tank no higher than to the bottom of the filler neck.
3. Thrown object hazard—keep bystanders away.
4. Cutting hazard to fingers, hands, and feet—do not open or
remove safety shields while engine is running.
Part No. 93-9356
1. Entanglementhazard—stay away from moving parts.
Part No. 105–5309
1. Hot surface hazard—stay away.
Part No. 93-6085
1. Fast
2. Variablespeed 3. Slow
Part No. 93-9886
1. Use unleaded fuel only.

8
Part No. 104-2618
1. Parking brake
2. Parking
brake–disengaged
3. Parking brake–engaged
Part No. 104-2617
1. Traction drive
2. Reel drive
3. Neutral
4. Forward
5. Lever–engaged
6. Lever–disengaged
Part No. 104–2621
1. Read operator’s manual
Part No. 93-8064
1. Danger—readthe
operator’s manual before
performing maintenance.
2. Cutting hazard to hands,
fingers, and feet—stop the
engine before going near
rotating reels.
Part No. 105–2411
1. Transmissionoil

9
Specifications
General Specifications
Engine Kawasaki, 4-cycle, 3.7 (2.7 kw) air cooled OHV engine, 3600 RPM, 7.57 cu in. (124 cc) displacement, cast iron cylinder sleeve; electronic ignition with integral
lighting coil; maximum noise suppression muffler; 83 dB(A) at operator’s ear
Fuel capacity 2.64 qt. (2.5 l); regular grade unleaded gasoline
Traction/implement drive
Integral gearbox assembly directly mounted to the engine. The traction drive
consists of a constant mesh planetary gear reduction incorporating a wet bath
band-type clutch and brake driving a Peerless differential assembly integrated into
the gearbox assembly. The implement drive is a constant mesh gear driven
countershaft with integral cone wet clutch.
Ground speed Mowing speed: 1.3 to 3.5 MPH (2.1 to 5.6 km/h)
Transport speed: 5.3 MPH (8.5 km/h) maximum
Traction drum Dual cast aluminum, 7.5 in. (19 cm) diameter tapered on outer 1/3 of length
Controls Engine mounted on/off switch, recoil starter, and choke; handle mounted throttle lever, dual function traction/reel control lever, service/parking brake lever; safety
devices include neutral interlock system, service/parking brake, enclosed
Handle Loop style; 1 in. (2.5 cm) diameter with easy pull pin height adjustment, operator
selected
Optional Transport tires Two quick detachable pneumatic tires; 3.00/3.25 x 6, 3.25 in. (8.25 cm) tread width;
15 psi (1.03 bars) tire pressure
Reel construction 5 in. (12.7 cm) diameter, 11 high strength, low allow steel blades, through
hardened, impact resistant
Suspension Semi-floating cutting unit separable from drive unit pivoting around reel centerline
(pitch axis) and pivoting around bedknife centerline side to side (roll axis)
Width of cut 21 in. (53.3 cm)
Height of cut 1/16 to 19/64 in. (1.5 to 7.5 mm) with Micro–Cut bedknife
Clip frequency 11 blade (standard): .16 in. (4.1 mm)
11 blade w/clip kit: .14 or .21 in. (3.5 or 6.4 mm)
Bedknife/bedbar Dual screw adjustment to reel; bedknife is high carbon through-hardened steel;
micro–cut bedknife standard
Grass basket Molded polyethylene with integrated graphics highlighting overlap guidelines;
vented for high efficiency collection
Rollers
Front roller: aluminum Wiehle, 2.5 in. (6.35 cm) diameter, .20 spacing, with sealed
bearings and multi-lip seals standard
Rear roller: aluminum full roller, 2 in. (5.1 cm) diameter with sealed bearings and
multi-lip seals standard
Dry weight 250 lb. (114 kg) with aluminum Wiehle roller, kickstand and grass basket; without
transport tires and groomer

10
Dimensions
Width 35–1/4”
Height 40”
Length 54”
Optional Equipment
Transport Wheel Kit Model No. 04122
Light Kit Model No. 04058
Grooming Reel Kit Model No. 04201
11 Blade Cutting Unit Model No. 04200
Wiehle Roller (.92 spacing) Part No. 99-6215
Tournament Bedknife Part No. 93-4263
1/8 in. Bedknife Part No. 93-4264
Clip Kit Part No. 105–5325
Hour Meter Kit Part No. 105–5350
Spark Arrester Kit Part No. 98-3426
High Altitude Jet
(for altitudes of 3000 to 6000 ft.) Part No. 98-8735
High Altitude Jet
(for altitudes above 6000 ft.) Part No. 98-8736
Extended Micro–cut Part No. 104–7720
Operator Presence Kit Part No. 105–5333
8 Blade Reel Assembly Part No. 105–2400
Full Roller Part No. 104–9796

11
Setup
Note: Determine the left and right sides of the machine from the normal operating position.
Loose Parts Chart
Note: Use this chart as a checklist to ensure all parts necessary for assembly have been shipped. If any of these parts are
missing, total setup cannot be completed.
Description Qty. Use
Grass basket 1Install on the machine.
Operator’s manual 1Read before operating the machine.
Engine operator’s manual 1Read before operating the machine.
Parts catalog 1
Operator video 1 View before operating the machine
Certificate of compliance 1
Registration cards 2Fill out and return to Toro.
Installing the Handle
1. Remove the flange lock nut from the capscrew and
pivot pin on each side of the mower (Fig. 3).
1
2
Figure 3
1. Flangelock nut 2. Pivot pin
2. Insert the handle ends through the slots in the handle
support arms (Fig. 4).
3. Squeeze the handle ends inward and install them on
the step of the pivot pin (Fig. 4).
1
3
4
2
Figure 4
1. Left handle end
2. Support arm 3. Pivot pin 4. Locknut
4. Secure the handle to the capscrew and pivot pin with
the flange lock nut (Fig. 4).
5. Locate cable tie loosely securing throttle cable to wire
harness. Position cable tie approximately one inch
behind transmission and tighten cable tie.

12
Adjusting the Handle
1. Remove hairpin cotters from ring pins on each side of
mower (Fig. 5).
1
Figure 5
1. Ring pins
2. While supporting handle, remove ring pins from each
side and raise or lower handle to desired operating
position (Fig. 5).
3. Reinstall ring pins and hair pin cotters.
Installing the Transport Wheels
1. Push kick stand down with foot and pull up on handle
to support mower on kick stand.
2. Apply Anti–Seize lubricant to the exposed ends of
axles and slide wheel onto axle (Fig. 6).
1
Figure 6
1. Left axle shaft
3. Pivot wheel locking clip away from center of wheel
allowing wheel to slide farther onto axle (Fig. 7).
4. Rotate wheel back and forth until it slides completely
onto axle and locking clip is secured in groove on axle
shaft.
1
Figure 7
1. Locking clip
5. Repeat procedure on opposite side of machine.
6. Tires to be inflated to 12–15 psi.

13
Before Operating
Adding Engine Oil
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. Temperature/viscosity
recommendations are:
SAE 5W20
–4°F14°F32°F50°F68°F86°F104°F
SAE 10W30/ SAE 10W–40
SAE 30
SAE 40
–20°C –10°C0°C10°C20°C30°C40°C
Note: Using multi-grade oils (5W-20, 10W-30, and
10W-40) will increase oil consumption. Check the oil
level more frequently when using them.
1. Position mower so the engine is level and clean around
oil level gauge (Fig. 8).
1
Figure 8
1. Oil level gauge
2. Remove gauge by rotating counterclockwise.
3. Wipe gauge clean and insert it into filler port. Then
remove and check level of oil. Do not screw into port.
If level is low, add only enough oil to raise level to
bottom of filler opening. Recheck level of oil. Do not
overfill.
Note: The Toro Company recommends that the oil level
be checked each time mower is used or after every 5
operating hours. Initially, change oil after the first 20
hours of operation; thereafter, change oil after every 50
hours of operation. More frequent oil changes are required
in dusty or dirty conditions.
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.
1
2
Figure 9
1. Fuel tank cap 2. Fuel gauge
Gasoline is harmful or fatal if swallowed.
Long-term exposure to vapors can cause serious
injury and illness.
•Avoid prolonged breathing of vapors.
•Keep face away from nozzle and gas tank or
conditioner opening.
•Keep gas away from eyes and skin.
Warning

14
Danger
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.
•Fill the fuel tank outdoors, in an open area,
when the engine is cold. Wipe up any gasoline
that spills.
•Do not fill the fuel tank completely full. Add
gasoline to the fuel tank until the level is 1/4 to
1/2 in. (6 to 13 mm) below the bottom of the
filler neck. This empty space in the tank allows
gasoline to expand.
•Never smoke when handling gasoline, and stay
away from an open flame or where gasoline
fumes may be ignited by a spark.
•Store gasoline in an approved container and
keep it out of the reach of children. Never buy
more than a 30-day supply of gasoline.
•Always place gasoline containers on the ground
away from your vehicle before filling.
•Do not fill gasoline containers inside a vehicle
or on a truck or trailer bed because interior
carpets or plastic truck bed liners may insulate
the container and slow the loss of any static
charge.
•When practical, remove gas–powered
equipment from the truck or trailer and refuel
the equipment with its wheels on the ground.
•If this is not possible, then refuel 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
(Fig. 9). Using unleaded gasoline, fill fuel tank no
higher than to bottom of filter screen. Do not overfill.
2. Install fuel tank cap and wipe up any spilled gasoline.
Checking the Transmission
Fluid
The transmission is filled at the factory with
approximately 94 fluid ounces of Dexron lll automatic
transmission fluid. Check fluid level before the engine is
first started and every 50 hours thereafter.
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 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 (Fig. 10). 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 fill hole.
1
2
Figure 10
1. Check/fillplug 2. Drain plug
3. Install the plug.
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
(Fig. 11).
1
2
Figure 11
1. Kick stand 2. 1/4” Pin
3. Remove grass basket.
4. Remove (2) capscrews securing cutting unit pivot arms
to traction unit frame tube (Fig. 12).

15
1
1
2
3
3
Figure 12
1. Cuttingunit pivot arms
2. Traction unit frame tube 3. Capscrews
5. Rotate pivot arms forward (Fig. 12) and rest traction
unit on restrained kickstand.
6. Pull cutting unit forward about 2 in. (51 mm) and then
to the right to disengage the transmission coupling
(Fig. 12).
1
Figure 13
1. Transmissioncoupling 2.
7. Reverse procedure to install cutting unit.
Leveling the Rear Roller to the
Reel
1. Position cutting unit on a flat, level surface preferably
a precision ground surface plate.
2. Place a 1/4 in. (6.4 mm) or thicker plate under the reel
blades and against front edge of bedknife.
Note: Be sure the plate covers the full length of the reel
blades and three blades contact.
3. Firmly press down on cutting unit and maintain
pressure on rear roller. Try inserting a piece of paper
under each end of the roller. If the gap is greater than
the piece of paper, on either end, an adjustment may
be required, proceed to step 4.
4. Loosen locknuts securing right rear roller bracket to
cutting unit sideplate (Fig. 14).
1
2
Figure 14
1. Right rear roller bracket 2. Locknuts
5. While holding reel securely on plate and maintaining
pressure on rear roller, rotate lower right roller
mounting bolt (Fig. 15). This mounting bolt has an
offset, which when rotated, acts as an eccentric (cam)
to raise or lower the roller. There is an I.D. dot which
denotes the offset of the bolt. Dot indicates in which
direction right end of roller moves when bolt is turned
and should always be in the rear half of the arc as
shown in figure 15.
1
Figure 15
1. Eccentric bolt
Note: If additional adjustment is required, replace the
screw on the left-hand bracket with another eccentric bolt,
Part No. 105–3833. Ensure both rear roller brackets are in
the same hole.
6. To verify if roller is level, try inserting a piece of
paper under each end of roller.

16
7. When roller is level, tighten nuts securely.
Adjusting the Bedknife to the
Reel
Bedknife to reel adjustment is accomplished by loosening
or tightening bedbar adjusting screws, located on top of
mower.
1. Position machine on a flat, level work surface. Make
sure reel contact is removed by turning bedbar
adjusting screws counterclockwise (Fig. 16).
1
Figure 16
1. Bedbaradjusting screw
2. Tilt mower on back to expose bedknife and reel.
3. At one end of reel, insert a long strip of newspaper
between reel and bedknife (Fig. 17). While slowly
rotating reel forward, turn bedbar adjusting screw
clockwise (on same end of reel, one click at a time,
until paper is pinched lightly, when inserted from the
front, parallel to the bedknife. A slight drag will be
noted as the paper is pulled (Fig. 16).
Figure 17
Note: Each time adjusting screw is rotated one click
clockwise, bedknife moves .0007 in. closer to reel. Do not
overtighten the adjusting screws.
4. Check for light contact at other end of reel using paper
and adjust as required.
5. After adjustment 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
(Fig. 17). 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 for precision cutting
(see Toro reel sharpening manual).
Adjusting the Height of Cut
1. Adjust rear roller brackets (Fig. 18) to upper or lower
position depending on desired height of cut range.
•The upper position (factory setting) is used when
height of cut settings range from 1/16 to 5/32”.
•The lower position is used when height of cut settings
range from 1/8” to 19/64”.
2. Verify that rear roller is level and that bedknife to reel
contact is correct. Tip mower on back to expose front
and rear rollers and bedknife.
3. Loosen locknuts securing height-of-cut arms to
cutting unit side plates (Fig. 18).
2
3
4
1
Figure 18
1. Rear roller bracket
2. Height-of-cut arm 3. Locknut 4. Adjusting screw

17
4. Loosen nut on gauge bar (Fig. 19) and set adjusting
screw to desired height-of-cut. Distance between
bottom of screw head and face of bar is height-of-cut.
1
2
3
Figure 19
1. Gaugebar
2. Height adjusting screw 3. Nut
5. Hook screw head on cutting edge of bedknife and rest
rear end of bar on rear roller (Fig. 20).
Figure 20
6. Rotate adjusting screw until roller contacts front of
gauge bar. Adjust both ends of roller until entire roller
is parallel to the bedknife.
Important When set properly, the rear and front
rollers will contact the gauge bar and the screw will be
snug against the bedknife. This ensures that the
height-of-cut is identical at both ends of the bedknife.
7. Tighten nuts to secure adjustment.
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 (Fig. 21) to cutting
unit.
1
Figure 21
1. Cut-off bar
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.
Note: The bar is adjustable to compensate for changes in
turf conditions. The bar should be adjusted closer to reel
when turf is extremely dry. By contrast, adjust bar further
away from reel when turf conditions are wet. The bar
should be parallel to reel to ensure optimum performance
and should be adjusted whenever reel is sharpened on a
reel grinder.
Installing the Grass Basket
Grasp basket by top lip and slide basket frame into the
receivers (Fig. 22).
1
2
Figure 22
1. Grass basket 2. Basket receivers

18
Checking the Interlock Switch
Operation
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.
•Replace switches every two years regardless of
whether they are operating properly or not.
Caution
1. Push kick stand down with foot and pull up on handle
to support mower on kick stand.
2. Place traction lever into Engage position and engine
controls in starting position.
3. Attempt to start engine. Engine should not start. If
engine starts, the interlock switch needs service.
Correct problem before operating. Refer to Servicing
Interlock Switch, page 30.
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.
Controls
Throttle Control
The throttle control (Fig. 23) is located on rear right side
of control panel. Lever connects to and operates throttle
linkage to carburetor. Engine speed can be varied from
2400 RPM to 3600 RPM.
2
3
1
Figure 23
1. Throttlecontrol
2. Traction & reel drive
engagement lever
3. Service/parking brake
Traction and Reel Drive Engagement
Lever
The traction and reel drive engagement lever (Fig. 23) 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.
Service/Parking Brake
The service/parking brake (Fig. 23) is located on left front
side of control panel. Use brake to slow or stop machine.
The brake can also be used as a parking brake. Pulling the
lever back over center will set the parking brake. Brake
must be released before traction drive is engaged.
Operator Presence Control
The optional operator presence control must be engaged
before engaging the traction lever or the engine will stop.
Choke Lever
The choke lever (Fig. 24) is located on left front of
engine. Lever has two positions: Run and Choke. Move
lever to Choke position when starting a cold engine. After
engine starts move lever to Run position.

19
1
2
Figure 24
1. Choke lever 2. Fuel shut-off valve
Fuel Shut-Off Valve
The fuel shut-off valve (Fig. 24) 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.
Recoil Starter
Pull recoil starter handle (Fig. 25) to start engine.
2
1
Figure 25
1. Recoil starter 2. On/off switch
On/Off Switch
The on/off switch (Fig. 25) is located on rear of engine.
Move switch to On position to start engine and Off to stop
engine.
Kickstand
The kickstand (Fig. 26) is mounted to rear of machine and
is used to raise rear of machine for installation or removal
of transport wheels.
1
Figure 26
1. Kick stand
Starting and Stopping
Note: Make sure spark plug wire is installed on spark
plug.
1. Make sure traction and reel drive levers are in
Disengaged position.
Note: Engine will not start if traction lever is in the
engaged position.
2. Open fuel shut-off valve on engine (Fig. 24).
3. Move on/off switch (Fig. 25 ) to On position.
4. Move throttle control (Fig. 23) to Fast position.
5. Move choke lever (Fig. 24) to half-open position when
starting a cold engine. Choke may not be required
when starting a warm engine.
6. Pull recoil starter handle out until positive engagement
results, then pull vigorously to start engine. Open
choke as engine warms up.
Important Do not pull recoil rope to its limit or let go
of starter handle when rope is pulled out because rope
may break or recoil assembly may be damaged.
7. To stop engine during operation, move traction and
reel drive controls to Disengaged position, throttle
control to Slow and on/off switch to Off.
8. Pull spark plug wire off spark plug to prevent the
possibility of accidental starting before storing
machine.
9. Close fuel shut-off valve before storing or transporting
mower in a vehicle.

20
Transport Operation
1. Push kickstand down with foot and pull up on handle
to raise rear of mower and install transport wheels.
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
speed and transport mower to desired destination.
Preparing to Mow
1. Return traction control lever to Disengage, throttle to
Slow and stop engine.
2. Push kickstand down with foot and pull up on handle
to raise wheels off the ground.
3. Remove transport wheels.
4. Release kickstand.
Mowing Operation
Proper use of the machine provides the smoothest turf
cutting available.
Important Grass clippings act as a lubricant when
mowing. Excessive operation of the cutting unit with the
absence of grass clippings can damage the cutting unit.
Prior to Mowing
Be sure the mower is carefully adjusted and is set evenly
on both sides of the reel. Improper mower adjustment is
magnified in the appearance of the clipped turf. Remove
all foreign objects from turf prior to mowing. Make sure
everyone, especially children and pets, are clear of the
work area.
Method of Mowing
The greens should be mowed in a straight back and forth
direction across the green. Avoid circular mowing or
turning the mower on greens areas since scuffing may
occur. Turning the mower should be done off the green by
raising the cutting reel (pushing the handle down) and
turning on the traction drum. Mowing should be 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
(Fig. 27).
1
Figure 27
1. Alignmentstripes
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 (Fig. 28).
2. Move traction lever to Disengaged position and
Engage reel drive lever (Fig. 28).