Toro 04019, 04024, 04025, Greensmaster Flex 18, Greensmaster Flex 21 Operator's Manual

FormNo.3367-381RevB

Greensmaster

®

Flex18orFlex21

Walk-BehindMower

ModelNo.04019—SerialNo.311000001andUp

ModelNo.04024—SerialNo.311000001andUp

ModelNo.04025—SerialNo.311000001andUp

ToregisteryourproductordownloadanOperator'sManualorPartsCatalogatnocharge,gotowww.T oro.com.OriginalInstructions(EN)

ThisproductcomplieswithallrelevantEuropean
directives,fordetailspleaseseetheseparateproduct
specicDeclarationofConformity(DOC)sheet.

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Important:Thisengineisnotequippedwitha
sparkarrestermufer.ItisaviolationofCalifornia
PublicResourceCodeSection4442touseoroperate
theengineonanyforest-covered,brush-covered,or
grass-coveredland.Otherstatesorfederalareas
mayhavesimilarlaws.

ThissparkignitionsystemcomplieswithCanadian
ICES-002.

Introduction

Thismachineisawalk-behind,reel-bladelawnmower
intendedtobeusedbyprofessional,hiredoperatorsin
commercialapplications.Itisprimarilydesignedfor
cuttinggrassonwell-maintainedlawnsinparks,golf
courses,sportselds,andoncommercialgrounds.Itis
notdesignedforcuttingbrush,mowinggrassandother
growthalongsidehighways,orforagriculturaluses.

Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoidinjury
andproductdamage.Youareresponsibleforoperating
theproductproperlyandsafely.

YoumaycontactTorodirectlyatwww .Toro.comfor
productandaccessoryinformation,helpndinga
dealer,ortoregisteryourproduct.

Figure1

1.Locationofthemodelandserialnumbers-Tractionunit

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure2),whichsignalsahazardthatmaycauseserious
injuryordeathifyoudonotfollowtherecommended
precautions.

Figure2

1.Safetyalertsymbol.

Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizesgeneral
informationworthyofspecialattention.

Wheneveryouneedservice,genuineToroparts,or
additionalinformation,contactanAuthorizedService
DealerorToroCustomerServiceandhavethemodel
andserialnumbersofyourproductready .

Figure1
identiesthelocationofthemodelandserialnumbers
ontheproduct.Writethenumbersinthespace
provided.

©2011—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.Toro.com.

2

PrintedintheUSA.

AllRightsReserved

Contents

Introduction.................................................................2

Safety...........................................................................4

SafeOperatingPractices.......................................4

ToroMowerSafety...............................................5

SoundPowerLevel-Flex18..................................6

SoundPressureLevel-Flex18...............................6

VibrationLevel-Flex18.......................................6

SoundPowerLevel-Flex21..................................6

SoundPressureLevel-Flex21...............................7

VibrationLevel-Flex21........................................7

SafetyandInstructionalDecals.............................7

Setup............................................................................9

1InstallingtheCuttingUnittotheTraction

Unit................................................................10

2InstallingtheHandle........................................11

3InstallingtheKickstandforFlex18Mowers

Only...............................................................11

4AdjustingtheHandle.......................................12

5InstallingtheTransportWheels........................12

6CheckingFluidLevels......................................13

7InstallingtheGrassBasket...............................13

ProductOverview......................................................15

Controls.............................................................15

Specications.....................................................16

Attachments/Accessories...................................16

Operation...................................................................17

ThinkSafetyFirst...............................................17

CheckingtheEngineOilLevel............................17

FillingtheFuelTank...........................................17

CheckingtheInterlockSwitchOperation............18

StartingandStoppingtheEngine........................18

TransportOperation..........................................18

PreparingtoMow...............................................19

MowingOperation.............................................19

Maintenance...............................................................21

RecommendedMaintenanceSchedule(s)................21

DailyMaintenanceChecklist...............................22

EngineMaintenance...............................................23

EngineOil..........................................................23

ServicingtheAirCleaner....................................24

ReplacingtheSparkPlug....................................24

FuelSystemMaintenance.......................................25

CleaningtheFuelFilter.......................................25

ElectricalSystemMaintenance................................26

ServicingtheInterlockSwitch............................26

DriveSystemMaintenance.....................................26

CheckingtheTransmissionFluidLevel...............26

ChangingtheTransmissionFluid........................27

BrakeMaintenance.................................................27

AdjustingtheService/ParkingBrake...................27

BeltMaintenance....................................................28

AdjustingtheBelts.............................................28

ControlsSystemMaintenance.................................31

AdjustingtheTractionControl...........................31

AdjustingtheReelControl..................................31

Storage.......................................................................32

3

Safety

–Refueloutdoorsonlyanddonotsmokewhile

refuelling.

ThismachinemeetsorexceedsCENstandard
EN836:1997,ISOstandard5395:1990,andANSI
B71.4-2004specicationsineffectatthetimeof
productionwhentheOperatorPresenceKit,PartNo.
105-5333isinstalled.

Improperuseormaintenancebytheoperatororowner
canresultininjury.Toreducethepotentialforinjury,
complywiththesesafetyinstructionsandalwayspay
attentiontothesafetyalert
CAUTION,WARNING,orDANGER-“personalsafety
instruction."Failuretocomplywiththeinstructionmay
resultinpersonalinjuryordeath.

symbol,whichmeans

SafeOperatingPractices

ThefollowinginstructionsarefromtheCENstandard
EN836:1997,ISOstandard5395:1990,andANSI
B71.4-2004.

Training

•ReadtheOperator’sManualandothertraining
materialcarefully .Befamiliarwiththecontrols,
safetysigns,andtheproperuseoftheequipment.

•Neverallowchildrenorpeopleunfamiliarwiththese
instructionstouseorservicethemower.Local
regulationsmayrestricttheageoftheoperator.

•Nevermowwhilepeople,especiallychildren,orpets
arenearby .

•Keepinmindthattheoperatororuserisresponsible
foraccidentsorhazardsoccurringtootherpeopleor
theirproperty.

•Theowner/usercanpreventandisresponsiblefor
accidentsorinjuriesoccurringtohimselforherself,
otherpeople,orproperty.

Preparation

•Whilemowing,alwayswearsubstantialfootwear,
longtrousers,hardhat,safetyglasses,andear
protection.Longhair,looseclothing,orjewelrymay
gettangledinmovingparts.Donotoperatethe
equipmentwhenbarefootorwearingopensandals.

•Thoroughlyinspecttheareawheretheequipment
istobeusedandremoveallobjectswhichmaybe
thrownbythemachine.

•Warning-Fuelishighlyammable.Takethe
followingprecautions:

–Addfuelbeforestartingtheengine.Never

removethecapofthefueltankoraddfuelwhile
theengineisrunningorwhentheengineishot.

–Iffuelisspilled,donotattempttostartthe

enginebutmovethemachineawayfromthe
areaofspillageandavoidcreatinganysourceof
ignitionuntilfuelvaporshavedissipated.

–Replaceallfueltanksandcontainercapssecurely.

•Replacefaultysilencers.

•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbythemanufacturer.

•Checkthatoperator’spresencecontrols,safety
switchesandshieldsareattachedandfunctioning
properly.Donotoperateunlesstheyarefunctioning
properly.

Operation

•Donotoperatetheengineinaconnedspacewhere
dangerouscarbonmonoxidefumescancollect.

•Mowonlyindaylightoringoodarticiallight.

•Beforeattemptingtostarttheengine,disengageall
bladeattachmentclutches,shiftintoneutral,and
engagetheparkingbrake.

•Stayalertforholesintheterrainandotherhidden
hazards.

•Watchoutfortrafcwhencrossingornearroadways.

•Stopthebladesrotatingbeforecrossingsurfaces
otherthangrass.

•Whenusinganyattachments,neverdirectdischarge
ofmaterialtowardbystandersnorallowanyonenear
themachinewhileinoperation.

•Neveroperatethemachinewithdamagedguards,
shields,orwithoutsafetyprotectivedevicesinplace.
Besureallinterlocksareattached,adjustedproperly ,
andfunctioningproperly .

•Donotchangetheenginegovernorsettingsor
overspeedtheengine.Operatingtheengineat
excessivespeedmayincreasethehazardofpersonal
injury.

•Beforeleavingtheoperator’sposition:

–stoponlevelground;

–Storefuelincontainersspecicallydesignedfor

thispurpose.

–disengagethepowertake-offandlowerthe

attachments;

4

–changeintoneutralandsettheparkingbrake;

–stoptheengine.

•Disengagedrivetoattachmentswhentransporting
ornotinuse.

•Stoptheengineanddisengagedrivetoattachment

–beforerefuelling;

–beforeremovingthegrasscatcher/catchers;

–beforemakingheightadjustmentunless

adjustmentcanbemadefromtheoperator’s
position.

–beforeclearingblockages;

–beforechecking,cleaningorworkingonthe

mower;

–afterstrikingaforeignobjectorifanabnormal

vibrationoccurs.Inspectthemowerfordamage
andmakerepairsbeforerestartingandoperating
theequipment.

•Reducethethrottlesettingbeforestoppingengine
and,iftheengineisprovidedwithafuelshut-off
valve,turnthevalveoffattheconclusionofmowing.

•Keephandsandfeetawayfromthecuttingunit.

•Slowdownandusecautionwhenmakingturns
andcrossingroadsandsidewalks.Stopreelsifnot
mowing.

•Keepallpartsingoodworkingconditionandall
hardwareandhydraulicttingstightened.Replaceall
wornordamagedpartsanddecals.

•Ifthefueltankhastobedrained,dothisoutdoors.

•Becarefulduringadjustmentofthemachineto
prevententrapmentofthengersbetweenmoving
bladesandxedpartsofthemachine.

•Disengagedrives,disengagethecuttingunit,set
parkingbrake,stopengineanddisconnectsparkplug
wire.Waitforallmovementtostopbeforeadjusting,
cleaningorrepairing.

•Cleangrassanddebrisfromcuttingunit,drives,
mufers,andenginetohelppreventres.Cleanup
oilorfuelspillage.

•Carefullyreleasepressurefromcomponentswith
storedenergy.

•Disconnectbatteryandremovesparkplugwire
beforemakinganyrepairs.Disconnectthenegative
terminalrstandthepositivelast.Reconnect
positiverstandnegativelast.

•Usecarewhencheckingthereel.W earglovesand
usecautionwhenservicingthem.

•Keephandsandfeetawayfrommovingparts.If
possible,donotmakeadjustmentswiththeengine
running.

•Donotoperatethemowerundertheinuenceof
alcoholordrugs

•Lightningcancausesevereinjuryordeath.If
lightningisseenorthunderisheardinthearea,do
notoperatethemachine;seekshelter.

•Usecarewhenloadingorunloadingthemachine
intoatrailerortruck

•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.

MaintenanceandStorage

•Keepallnuts,boltsandscrewstighttobesurethe
equipmentisinsafeworkingcondition.

•Neverstoretheequipmentwithfuelinthetank
insideabuildingwherefumesmayreachanopen
ameorspark.

•Allowtheenginetocoolbeforestoringinany
enclosure.

•Toreducetherehazard,keeptheengine,silencer,
batterycompartmentandfuelstorageareafreeof
grass,leaves,orexcessivegrease.

ToroMowerSafety

Thefollowinglistcontainssafetyinformationspecic
toToroproductsorothersafetyinformationthatyou
mustknowthatisnotincludedintheCEN,ISO ,or
ANSIstandard.

Thisproductiscapableofamputatinghandsand
feetandthrowingobjects.Alwaysfollowallsafety
instructionstoavoidseriousinjuryordeath.

Useofthisproductforpurposesotherthanitsintended
usecouldprovedangeroustouserandbystanders.

•Knowhowtostoptheenginequickly.

•Donotoperatethemachinewhilewearingtennis
shoesorsneakers.

•Wearingsafetyshoesandlongpantsisadvisableand
requiredbysomelocalordinancesandinsurance
regulations.

•Handlegasolinecarefully.Wipeupanyspills.

•Checkthesafetyinterlockswitchesdailyforproper
operation.Ifaswitchshouldfail,replacetheswitch
beforeoperatingthemachine.

•Checkthegrasscatcherfrequentlyforwearor
deterioration.

•Alwaysstandbehindthehandlewhenstartingand
operatingthemachine.

5

•Tostartandstoptheengine:

–Openfuelshut-offvalve.

–Verifythatthetractionandreeldrivecontrol

leversonhandleareinNeutralposition.

–Movetheon/offswitch,locatedonthecontrol

panel,toONposition,setchoketofullchoke
position(coldstart)andthrottletohalfthrottle.

–Pullstartercordtostartengine.

–MovethrottletoSlowandon/offswitchtoOff

positiontostopengine.

•Totransportmowerfromoneareatoanother:

–Installtransportwheels.

–Disengagereeldrive.

–Startengine.

–Pressdownonhandletoraisefrontofmower

andengagetractiondrive.

•Beforebeginningmowingoperation:

–Disengagetractiondrive.

–Stopengine.

–Removetransportwheels.

–Startengine

–Engagereeldrive.

•Usingthemachinedemandsattention.T oprevent
lossofcontrol:

–Donotdriveclosetosandtraps,ditches,creeks,

orotherhazards.

–Reducespeedwhenmakingsharpturns.Avoid

suddenstopsandstarts.

–Whennearorcrossingroads,alwaysyieldthe

right-of-way.

•Thegrassbasketmustbeinplace,duringthe
mowingoperation,formaximumsafety.Shutthe
engineoffbeforeemptyingthebasket.

•Donottouchtheengine,mufer,orexhaustpipe
whiletheengineisrunningorsoonafterithas
stoppedbecausetheseareascouldbehotenough
tocauseburns.

•Whenapersonorpetappearsunexpectedlyin
ornearthemowingarea,stopmowing.Careless
operation,combinedwithterrainangles,ricochets,
orimproperlypositionedguardscanleadtothrown
objectinjuries.Donotresumemowinguntilthe
areaiscleared.

MaintenanceandStorage

•Checkallfuellinesfortightnessandwearona
regularbasis.Tightenorrepairthemasneeded.

•Iftheenginemustberunningtoperforma
maintenanceadjustment,keephands,feet,clothing,
andanypartsofthebodyawayfromthecuttingunit,
attachmentsandanymovingparts.Keepeveryone
away.

•Toensuresafetyandaccuracy,haveanAuthorized
ToroDistributorcheckthemaximumenginespeed
withatachometer.Maximumgovernedenginespeed
shouldbe3600RPM.

•Ifmajorrepairsareeverneededorifassistanceis
desired,contactanAuthorizedToroDistributor.

•UseonlyToro-approvedattachmentsand
replacementparts.Thewarrantymaybevoidedif
usedwithunapprovedattachments.

SoundPowerLevel-Flex18

Thisunithasaguaranteedsoundpowerlevelof96dBA,
whichincludesanUncertaintyValue(K)of1dBA.

Soundpowerlevelwasdeterminedaccordingtothe
proceduresoutlinedinEN11094.

SoundPressureLevel-Flex18

Thisunithasasoundpressurelevelattheoperator’s
earof84dBA,whichincludesanUncertaintyValue(K)
of1dBA.

Soundpressurelevelwasdeterminedaccordingtothe
proceduresoutlinedinEN836.

VibrationLevel-Flex18

Hand-Arm

Measuredvibrationlevelforrighthand=2.36m/s

Measuredvibrationlevelforlefthand=2.47m/s

UncertaintyValue(K)=0.5m/s

Measuredvaluesweredeterminedaccordingtothe
proceduresoutlinedinEN836.

2

2

SoundPowerLevel-Flex21

Thisunithasaguaranteedsoundpowerlevelof97dBA,
whichincludesanUncertaintyValue(K)of1dBA.

Soundpowerlevelwasdeterminedaccordingtothe
proceduresoutlinedinEN11094.

2

6

SoundPressureLevel-Flex21

VibrationLevel-Flex21

Thisunithasasoundpressurelevelattheoperator’s
earof92dBA,whichincludesanUncertaintyValue(K)
of1dBA.

Soundpressurelevelwasdeterminedaccordingtothe
proceduresoutlinedinEN836.

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.

Hand-Arm

Measuredvibrationlevelforrighthand=2.36m/s

Measuredvibrationlevelforlefthand=2.47m/s

UncertaintyValue(K)=0.5m/s

2

Measuredvaluesweredeterminedaccordingtothe
proceduresoutlinedinEN836.

115-1615

1.Warning—donottouchthehotsurface.

2

2

115-1613

1.Warning—readthe

Operator’sManual.

2.Warning—remove
thesparkplugwire
beforeperformingany
maintenanceonthe
machine.

1.Entanglementhazard—stayawayfrommovingparts.

3.Thrownobject
hazard—keepbystanders
asafedistancefromthe
machine.

4.Cutting,dismemberment
hazardofhandor
foot—stayawayfrom
movingparts.

93-9356

1.Fast

2.Continuousvariable
setting

93-6085

3.Slow

1.Engine—stop2.Engine—run

7

112-9408

1.Useunleadedgasoline.

105-2411

1.Transmissionoil

93-9886

104-2617

1.Tractiondrive4.Forward

2.Reeldrive5.Leverengaged

3.Neutral6.Leverdisengaged

104-2618

1.Parkingbrake3.Engage

2.Disengage

115-1614

1.Warning—readtheOperator’sManual.3.Thrownobjecthazard—keepbystandersasafedistancefrom

2.Warning—donotoperatethemachineunlessyouaretrained.

themachine.

4.Warning—stayawayfrommovingparts;keepallguardsin
place.

8

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1
2

3

4

5

6

7

Qty.

Bolt,M10x25mm2Installthecuttingunittothetractionunit

Handle1Installthehandle.

Kickstandassembly1
Spring
Smallspacer
Largespacer1
Largebolt(M8–1.25x100)
Smallbolt(M8–1.25x030)
Locknut(M8x1.25)
Washer(M8)

Nopartsrequired

Transportwheels(OptionalTransport
WheelKit,Model04123)

Nopartsrequired

Grassbasket

1
1

InstallthekickstandforFlex18Mowers

1
1
2
2

–

2Installthetransportwheels.

–

1Installthegrassbasket.

Only.

Adjustthehandle.

Checktheengineoilandtransmission
uidlevels

Use

MediaandAdditionalParts

Description

Operator’sManual
EngineOperator’sManual
PartsCatalog
OperatorTrainingMaterial
CerticateofCompliance

Qty.

Use

1
1
1
1
1

Readorviewbeforeoperatingthemachine

9

Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.

1

InstallingtheCuttingUnitto
theTractionUnit

Partsneededforthisprocedure:

2Bolt,M10x25mm

1.Placethemoweronitsdrumsonalevelsurface.

2.Lowerkickstand.Inserta1/4"dia.pinorequivalent
intoframeholeabovekickstandmountingbolt
(Figure3).

Figure3

1.1/4"Pin

2.Handle

3.Kickstand

Figure4

1.Transmissioncoupling

4.Rotatethetractionunitframe(Figure5)forward
untilitengagesthecuttingunitpivotarms.

5.Securethetractionunitframetothecuttingunit
pivotarmswith(2)M10x25mmbolts(Figure5)

Figure5

1.Cuttingunitpivotarms

2.Tractionunitframe

3.Bolts

3.Pushthecuttingunitunderthetractionunitand
thentothelefttoengagethetransmissioncoupling
(Figure4).

Note:Whentighteningthepivotarmmounting
fasteners,useanadjustableendwrenchtoholdthe
pivotarmparalleltothesideplate(Figure6)

10

1.Lefthandleend

2.Supportarm

Figure8

3.Pivotpin

4.Locknut

Figure6

2

InstallingtheHandle

Partsneededforthisprocedure:

1Handle

Procedure

1.Removetheangelocknutfromtheboltandpivot
pinoneachsideofthemower(

Figure7).

3.Squeezethehandleendsinwardandinstallthemon
thestepofthepivotpin(

4.Securethehandletotheboltandpivotpinwiththe
angelocknut(Figure8).

5.Locatecabletielooselysecuringthrottlecableto
wireharness.Positioncabletieapproximatelyone
inchbehindtransmissionandtightencabletie.

Figure8).

3

InstallingtheKickstandfor
Flex18MowersOnly

Partsneededforthisprocedure:

1Kickstandassembly

1

Spring

1

Smallspacer

1Largespacer

1

Largebolt(M8–1.25x100)

1

Smallbolt(M8–1.25x030)

2

Locknut(M8x1.25)

2

Washer(M8)

Figure7

1.Flangelocknut2.Pivotpin

2.Insertthehandleendsthroughtheslotsinthehandle
supportarms(Figure8).

Procedure

1.Positionthekickstandbetweenthetabsontherear
oftheframe.

2.Installawasher(M8)ontothesmallbolt(M8–1.25
x030).Installtherightsideofthekickstandtothe

11