Toro Greensmaster Flex21 04021 User manual

Form No. 3352-305
Greensmaster® Flex21Walk-Behind MowerModel No. 04021 (Traction Unit) —Serial No. 250000001and Up
Model No. 04200 (Cutting Unit) —Serial No. 250000001 andUp
Register your product at www.Toro.com Original Instructions (EN)

Warning
CALIFORNIA
Pr oposition 65 W ar ning
T he engine exhaust fr om this pr oduct contains
chemicals kno wn to the State of Calif or nia to
cause cancer , bir th defects, or other r epr oducti v e
har m.
T his spark ignition system complies with Canadian
ICES-002
Contents
Introduction ......................................................... 2
Safety .................................................................. 4
Safe Operating Practices ........................... 4
T oro Mo w er Safety .................................. 5
Sound Pressure Lev el ............................... 6
Sound P o w er Lev el .................................. 6
Vibration Lev el ....................................... 6
Safety and Instr uctional Decals . . . . . . . . . . . . . . . . . 7
Setup ................................................................... 9
1 Installing the Handle ............................. 9
2 Adjusting the Handle ........................... 10
3 Installing the T ranspor t W heels . . . . . . . . . . . . . 10
4 Chec king Fluid Lev els ......................... 11
5 Installing the Grass Bask et . . . . . . . . . . . . . . . . . . . 11
6 R eading the Man uals and Viewing the
Video .................................... 11
Product Ov er view ............................................... 13
Controls .............................................. 13
Specifications ....................................... 14
Operation .......................................................... 15
T hink Safety First .................................. 15
Chec king the Engine Oil Lev el . . . . . . . . . . . . . . . . 15
Filling the Fuel T ank .............................. 15
Chec king the Interloc k Switc h
Operation .............................. 16
Star ting and Stopping the Engine . . . . . . . . . . . . . 16
T ranspor t Operation ............................. 16
Pre paring to Mo w ................................. 17
Mo wing Operation ................................ 17
Maintenance ....................................................... 19
R ecommended Maintenance
Sc hedule(s) ................................... 19
Daily Maintenance Chec klist . . . . . . . . . . . . . . . . . . . 20
Engine Maintenance .................................... 21
Engine Oil ........................................... 21
Ser vicing the Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . 21
R e placing the Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . 22
Fuel System Maintenance .............................. 23
Cleaning the Fuel Filter .......................... 23
Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . . 23
Ser vicing the Interloc k Switc h . . . . . . . . . . . . . . . . 23
Dri v e System Maintenance ............................ 23
Chec king the T ransmission Fluid
Lev el ..................................... 23
Changing the T ransmission Fluid . . . . . . . . . . . . . 24
Brak e Maintenance ...................................... 24
Adjusting the Ser vice/P arking
Brak e .................................... 24
Belt Maintenance ......................................... 24
Adjusting the Belts ................................ 24
Controls System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 27
Adjusting the T raction Control . . . . . . . . . . . . . . . . 27
Adjusting the R eel Control . . . . . . . . . . . . . . . . . . . . . 28
Cutting Unit Maintenance .............................. 28
Se parating the Cutting Unit from the
T raction Unit ......................... 28
Lev eling the R ear R oller to the
R eel ...................................... 29
Adjusting the Bedknife to the R eel . . . . . . . . . . . 29
Adjusting the Height of Cut . . . . . . . . . . . . . . . . . . . . 30
Adjusting the Cut-Off Bar . . . . . . . . . . . . . . . . . . . . . . 31
Ser vicing the Bedbar .............................. 31
Bac klapping the R eel ............................. 32
Storag e .............................................................. 33
Introduction
R ead this infor mation carefully to lear n ho w to operate
and maintain y our product properly and to a v oid injur y
and product damag e . Y ou are responsible for operating
the product properly and safely .
Y ou ma y contact T oro directly at www .T oro .com for
product and accessor y infor mation, help finding a
dealer , or to register y our product.
W henev er y ou need ser vice , g en uine T oro par ts , or
additional infor mation, contact an A uthorized Ser vice
Dealer or T oro Customer Ser vice and ha v e the model
and serial n umbers of y our product ready . Figure 1
and Figure 2 identify the location of the model and
serial n umbers on the product. W rite the n umbers in
the space pro vided.
© 2004—The Toro® Company8111 Lyndale Avenue SouthBloomington, MN 55420
2
Contact us at www.Toro.com.
Printed in the USA.All Rights Reserved

Figure 1
1. Location of the model and serial numbers-Traction unit
T raction unit:
Model No.
Serial No.
Figure 2
1. Location of the model and serial numbers-Cutting Unit
Cutting unit:
Model No.
Serial No.
T his man ual identifies potential hazards and has
safety messag es identified b y the safety aler t symbol
( Figure 3 ), whic h signals a hazard that ma y cause
serious injur y or death if y ou do not follo w the
recommended precautions .
Figure 3
1. Safety alert symbol.
T his man ual uses tw o other w ords to highlight
infor mation. Impor tant calls attention to special
mec hanical infor mation and Note emphasizes g eneral
infor mation w or th y of special attention.
3

Safety
T his mac hine meets or ex ceeds 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, P ar t No .
105-5333 is installed.
Improper use or maintenance b y the operator or o wner
can result in injur y . T o reduce the potential for injur y ,
comply with these safety instr uctions and alw a ys pa y
attention to the safety aler t symbol, whic h means
CA UTION , W ARNING , or D ANGER-“personal
safety instr uction." F ailure to comply with the
instr uction ma y result in personal injur y or death.
Safe Operating PracticesT he follo wing instr uctions are from the CEN standard
EN 836:1997, ISO standard 5395:1990, and ANSI
B71.4-1999.
Training
•R ead the Operator’ s Man ual and other training
material carefully . Be familiar with the controls ,
safety signs , and the proper use of the equipment.
•Nev er allo w c hildren or people unfamiliar with
these instr uctions to use or ser vice the mo w er .
Local regulations ma y restrict the ag e of the
operator .
•Nev er mo w while people , especially c hildren, or
pets are nearb y .
•K ee p in mind that the operator or user is
responsible for accidents or hazards occur ring to
other people or their proper ty .
•T he o wner/user can prev ent and is responsible for
accidents or injuries occur ring to himself or herself ,
other people , or proper ty .
Preparation
•W hile mo wing, alw a ys w ear substantial footw ear ,
long trousers , hard hat, safety glasses , and ear
protection. Long hair , loose clothing, or jew elr y
ma y g et tangled in mo ving par ts . Do not operate
the equipment when barefoot or w earing open
sandals .
•T horoughly inspect the area where the equipment
is to be used and remo v e all objects whic h ma y be
thro wn b y the mac hine .
•W ar ning-Fuel is highly flammable . T ak e the
follo wing precautions:
– Store fuel in containers specifically designed
for this pur pose .
– R efuel outdoors only and do not smok e while
refuelling .
– Add fuel before star ting the engine . Nev er
remo v e the cap of the fuel tank or add fuel
while the engine is r unning or when the engine
is hot.
– If fuel is spilled, do not attempt to star t the
engine but mo v e the mac hine a w a y from the
area of spillag e and a v oid creating any source
of ignition until fuel v apors ha v e dissipated.
– R e place all fuel tanks and container caps
securely .
•R e place faulty silencers .
•Ev aluate the ter rain to deter mine what accessories
and attac hments are needed to properly and
safely perfor m the job . Only use accessories and
attac hments appro v ed b y the man ufacturer .
•Chec k that operator’ s presence controls , safety
switc hes and shields are attac hed and functioning
properly . Do not operate unless they are
functioning properly .
Operation
•Do not operate the engine in a confined space
where dang erous carbon mono xide fumes can
collect.
•Mo w only in da ylight or in g ood ar tificial light.
•Before attempting to star t the engine , diseng ag e all
blade attac hment clutc hes , shift into neutral, and
eng ag e the parking brak e .
•Do not use on slopes of more than 15°.
•R emember there is no suc h thing as a safe slope .
T ra v el on g rass slopes requires par ticular care . T o
guard ag ainst o v er tur ning:
– do not stop or star t suddenly when g oing up
or do wnhill;
– eng ag e clutc h slo wly , alw a ys k ee p mac hine in
g ear , especially when tra v elling do wnhill;
– mac hine speeds should be k e pt lo w on slopes
and during tight tur ns;
– sta y aler t for humps and hollo ws and other
hidden hazards;
– nev er mo w across the face of the slope , unless
the mo w er is designed for this pur pose .
•Sta y aler t for holes in the ter rain and other hidden
hazards .
•W atc h out for traffic when crossing or near
roadw a ys .
•Stop the blades rotating before crossing surfaces
other than g rass .
4

•W hen using any attac hments , nev er direct disc harg e
of material to w ard b ystanders nor allo w any one
near the mac hine while in operation.
•Nev er operate the mac hine with damag ed guards ,
shields , or without safety protecti v e devices in
place . Be sure all interloc ks are attac hed, adjusted
properly , and functioning properly .
•Do not c hang e the engine g o v er nor settings or
o v erspeed the engine . Operating the engine at
ex cessi v e speed ma y increase the hazard of personal
injur y .
•Before lea ving the operator’ s position:
– stop on lev el g round;
– diseng ag e the po w er tak e-off and lo w er the
attac hments;
– c hang e into neutral and set the parking brak e;
– stop the engine .
•Diseng ag e dri v e to attac hments when transpor ting
or not in use .
•Stop the engine and diseng ag e dri v e to attac hment
– before refuelling;
– before remo ving the g rass catc her/catc hers;
– before making height adjustment unless
adjustment can be made from the operator’ s
position.
– before clearing bloc kag es;
– before c hec king, cleaning or w orking on the
mo w er;
– after striking a foreign object or if an abnor mal
vibration occurs . Inspect the mo w er for
damag e and mak e re pairs before restar ting and
operating the equipment.
•R educe the throttle setting before stopping engine
and, if the engine is pro vided with a fuel shut-off
v alv e , tur n the v alv e off at the conclusion of
mo wing .
•K ee p hands and feet a w a y from the cutting unit.
•Slo w do wn and use caution when making tur ns
and crossing roads and sidew alks . Stop reels if not
mo wing .
•Do not operate the mo w er under the influence of
alcohol or dr ugs
•Use care when loading or unloading the mac hine
into a trailer or tr uc k
•Use care when approac hing blind cor ners , shr ubs ,
trees , or other objects that ma y obscure vision.
Maintenance and Storage
•K ee p all n uts , bolts and screws tight to be sure the
equipment is in safe w orking condition.
•Nev er store the equipment with fuel in the tank
inside a building where fumes ma y reac h an open
flame or spark.
•Allo w the engine to cool before storing in any
enclosure .
•T o reduce the fire hazard, k ee p the engine , silencer ,
batter y compar tment and fuel storag e area free of
g rass , lea v es , or ex cessi v e g rease .
•Chec k the g rass catc her frequently for w ear or
deterioration.
•K ee p all par ts in g ood w orking condition and all
hardw are and h y draulic fittings tightened. R e place
all w or n or damag ed par ts and decals .
•If the fuel tank has to be drained, do this outdoors .
•Be careful during adjustment of the mac hine to
prev ent entrapment of the fing ers betw een mo ving
blades and fix ed par ts of the mac hine .
•Diseng ag e dri v es , diseng ag e the cutting unit, set
parking brak e , stop engine and disconnect spark
plug wire . W ait for all mo v ement to stop before
adjusting, cleaning or re pairing .
•Clean g rass and debris from cutting unit, dri v es ,
m ufflers , and engine to help prev ent fires . Clean up
oil or fuel spillag e .
•Carefully release pressure from components with
stored energ y .
•Disconnect batter y and remo v e spark plug wire
before making any re pairs . Disconnect the neg ati v e
ter minal first and the positi v e last. R econnect
positi v e first and neg ati v e last.
•Use care when c hec king the reel. W ear glo v es and
use caution when ser vicing them.
•K ee p hands and feet a w a y from mo ving par ts . If
possible , do not mak e adjustments with the engine
r unning .
Toro Mower Safety
T he follo wing list contains safety infor mation specific
to T oro products or other safety infor mation that y ou
m ust kno w that is not included in the CEN , ISO , or
ANSI standard.
T his product is capable of amputating hands and
feet and thro wing objects . Alw a ys follo w all safety
instr uctions to a v oid serious injur y or death.
Use of this product for pur poses other than its intended
use could pro v e dang erous to user and b ystanders .
•Kno w ho w to stop the engine quic kly .
•Do not operate the mac hine while w earing tennis
shoes or sneak ers .
5

•W earing safety shoes and long pants is advisable
and required b y some local ordinances and
insurance regulations .
•Handle g asoline carefully . Wipe up any spills .
•Chec k the safety interloc k switc hes daily for proper
operation. If a switc h should fail, re place the switc h
before operating the mac hine . After ev er y tw o
years , re place all interloc k switc hes in the safety
system, reg ardless if they are w orking properly or
not.
•Alw a ys stand behind the handle when star ting and
operating the mac hine .
•T o star t and stop the engine:
– Open fuel shut-off v alv e .
– V erify that the traction and reel dri v e control
lev ers on handle are in Neutral position.
– Mo v e on/off switc h to ON position, set c hok e
to full c hok e position (cold star t) and throttle
to half throttle .
– Pull star ter cord to star t engine .
– Mo v e throttle to Slo w and on/off switc h to
Off position to stop engine .
•T o transpor t mo w er from one area to another :
– Install transpor t wheels .
– Diseng ag e reel dri v e .
– Star t engine .
– Press do wn on handle to raise front of mo w er
and eng ag e traction dri v e .
•Before beginning mo wing operation:
– Diseng ag e traction dri v e .
– Stop engine .
– R emo v e transpor t wheels .
– Star t engine
– Eng ag e reel dri v e .
•Using the mac hine demands attention. T o prev ent
loss of control:
– Do not dri v e close to sand traps , ditc hes ,
creeks , or other hazards .
– R educe speed when making shar p tur ns . A v oid
sudden stops and star ts .
– W hen near or crossing roads , alw a ys yield the
right-of-w a y .
– Apply the ser vice brak es when g oing do wnhill
to k ee p forw ard speed slo w and to maintain
control of the mac hine .
•T he g rass bask et m ust be in place during operation
of the reels or thatc hers for maxim um safety . Shut
the engine off before emptying the bask ets .
•Do not touc h the engine , m uffler , or exhaust pipe
while the engine is r unning or soon after it has
stopped because these areas could be hot enough
to cause bur ns .
•Sta y clear of the rotating screen at the side of the
engine to prev ent direct contact with y our body
or clothing .
•W hen a person or pet appears unexpectedly in
or near the mo wing area, stop mo wing . Careless
operation, combined with ter rain angles , ricoc hets ,
or improperly positioned guards can lead to thro wn
object injuries . Do not resume mo wing until the
area is cleared.
Maintenance and Storage
•Chec k all fuel lines for tightness and w ear on a
regular basis . Tighten or re pair them as needed.
•If the engine m ust be r unning to perfor m a
maintenance adjustment, k ee p hands , feet, clothing,
and any par ts of the body a w a y from the cutting
unit, attac hments , and any mo ving par ts , especially
the screen at the side of the engine . K ee p ev er y one
a w a y .
•T o ensure safety and accuracy , ha v e an A uthorized
T oro Distributor c hec k the maxim um engine speed
with a tac hometer . Maxim um g o v er ned engine
speed should be 3600 RPM.
•If major re pairs are ev er needed or if assistance is
desired, contact an A uthorized T oro Distributor .
•Use only T oro-appro v ed attac hments and
re placement par ts . T he w ar ranty ma y be v oided if
used with unappro v ed attac hments .
Sound Pressure Level
T his unit has an equi v alent contin uous A-w eighted
sound pressure at the operator ear of: 84 dB(A), based
on measurements of identical mac hines per procedures
outlined in Directi v e 98/37/EC and amendments .
Sound Power Level
T his unit has a guaranteed sound po w er lev el of:
95 dB A/1 pW , based on measurements of identical
mac hines per Directi v e 2000/14/EC and amendments .
Vibration Level
T his unit has a hand-ar m vibration lev el of 4.50 m/s
2
,
based on measurements of identical mac hines per ISO
5349 procedures .
6

Safety and Instructional Decals
Safety decals and instr uctions are easily visible to the operator and are located near any area of
potential dang er . R e place any decal that is damag ed or lost.
93-7348
1. Warning—read the Operator’s Manual .2. Fire hazard—no re, open ames, or smoking; when addingfuel to the tank, leave space between the fuel and the top ofthe tank.3. Thrown object hazard—keep bystanders a safe distance fromthe machine.
4. Cutting hazard of hand or foot—stay away from movingparts
93-9356
1. Entanglement hazard—stay away from moving parts.
105-5309
1. Hot surface/burn hazard—keep a safe distance from the hotsurface.
93-6085
1. Fast
3. Slow2. Continuous variable setting
93-9886
1. Use unleaded gasoline.
7

104-2618
1. Parking brake
3. Engage2. Disengage
93-8064
1. Warning—read the instructions before servicing orperforming maintenance.2. Cutting hazard of hand or foot—stop the engine and waitfor moving parts to stop.
104-2617
1. Traction drive 4. Forward2. Reel drive 5. Lever engaged3. Neutral 6. Lever disengaged
105-2411
1. Transmission oil
104-2621
1. Read the Operator’s Manual .
8

Setup
Loose Parts
Use the chart below to verify that all parts have been shipped.
Step
Description
Qty.
Use
1
Handle
1
Install the handle.
2
No parts required
–
Adjust the handle.
3
Transport wheels (Optional TransportWheel Kit, Model 04123)
2
Install the transport wheels.
4
No parts required
–
Check the engine oil and transmissionuid levels
5
Grass basket
1
Install the grass basket.
Operator’s Manual
1
Engine Operator’s Manual
1
Parts Catalog
1
Operator Video
16
Certicate of compliance
1
Read the manuals and watch the videobefore operating the machine.
Note: Deter mine the left and right sides of the
mac hine from the nor mal operating position.
Step
1
Installing the Handle
Parts needed for this step:
1
Handle
Procedure
1. R emo v e the flang e loc k n ut from the capscrew and
pi v ot pin on eac h side of the mo w er ( Figure 4 ).
Figure 4
1. Flange lock nut
2. Pivot pin
2. Inser t the handle ends through the slots in the
handle suppor t ar ms ( Figure 5 ).
9

Figure 5
1. Left handle end
3. Pivot pin2. Support arm
4. Locknut
3. Squeeze the handle ends inw ard and install them
on the ste p of the pi v ot pin ( Figure 5 ).
4. Secure the handle to the capscrew and pi v ot pin
with the flang e loc k n ut ( Figure 5 ).
5. Locate cable tie loosely securing throttle cable to
wire har ness . P osition cable tie appro ximately one
inc h behind transmission and tighten cable tie .
Step
2
Adjusting the Handle
No Parts Required
Procedure
1. R emo v e hair pin cotters from ring pins on eac h side
of mo w er ( Figure 6 ).
Figure 6
1. Ring pins
2. W hile suppor ting handle , remo v e ring pins from
eac h side and raise or lo w er handle to desired
operating position ( Figure 6 ).
3. R einstall ring pins and hair pin cotters .
Step
3
Installing the TransportWheels
Parts needed for this step:
2
Transport wheels (Optional Transport WheelKit, Model 04123)
Procedure
1. Push kic k stand do wn with foot and pull up on
handle suppor t until kic k stand has rotated forw ard,
o v er center ( Figure 7 ).
10