Toro 04021, 04200, Greensmaster Flex 21 Operator's Manual
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)
Operator ’s Manual
Domestic English (EN)
Warning
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other reproductive
harm.
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
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
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. .
2000 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
All Rights Reserved
Printed in the USA
2
Introduction
Write the product model and serial numbers in the space
below:
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
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.
Figure 1
1. Location o f the model and serial numbers–Traction unit
1
Figure 2
1. Location o f the model and serial numbers–Cutting unit
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.
3
Safety
– Refuel outdoors only and do not smoke while
refuelling.
This machine meets or exceeds CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI
B71.4-1999 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.
– 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;
• Warning—Fuel is highly flammable. Take the
following precautions:
– Store fuel in containers specifically designed for
this purpose.
– 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.
4
• 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.
• 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.
• 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
5
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.
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.
• 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.
• 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.
6
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.
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.
Vibration Level
This unit has a hand–arm vibration level of 4.50 m/s
based on measurements of identical machines per ISO
5349 procedures.
2,
Part No. 93-7348
1. Danger—read the 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. Entanglement hazard—stay away from moving parts.
Part No. 105–5309
1. Hot surface hazard—stay away.
Part No. 93-6085
1. Fast
2. Variable speed
Part No. 93-9886
1. Use unleaded fuel only.
3. Slow
7
Part No. 104-2618
1. Parking brake
2. Parking
brake–disengaged
1. Read operator’s manual
3. Parking brake–engaged
Part No. 104–2621
1. Traction drive
2. Reel drive
3. Neutral
Part No. 104-2617
4. Forward
5. Lever–engaged
6. Lever–disengaged
1. Danger—read the
operator’s manual before
performing maintenance.
Part No. 93-8064
2. Cutting hazard to hands,
fingers, and feet—stop the
engine before going near
rotating reels.
Part No. 105–2411
1. Transmission oil
8
Specifications
General Specifications
Kawasaki, 4-cycle, 3.7 (2.7 kw) air cooled OHV engine, 3600 RPM, 7.57 cu in.
Engine
Fuel capacity 2.64 qt. (2.5 l); regular grade unleaded gasoline
Traction/implement drive
(124 cc) displacement, cast iron cylinder sleeve; electronic ignition with integral
lighting coil; maximum noise suppression muffler; 83 dB(A) at operator ’s ear
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
Traction drum Dual cast aluminum, 7.5 in. (19 cm) diameter tapered on outer 1/3 of length
Controls
Handle
Optional Transport tires
Reel construction
Suspension
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
Bedknife/bedbar
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
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
Loop style; 1 in. (2.5 cm) diameter with easy pull pin height adjustment, operator
selected
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
5 in. (12.7 cm) diameter, 11 high strength, low allow steel blades, through
hardened, impact resistant
Semi-floating cutting unit separable from drive unit pivoting around reel centerline
(pitch axis) and pivoting around bedknife centerline side to side (roll axis)
11 blade (standard): .16 in. (4.1 mm)
11 blade w/clip kit: .14 or .21 in. (3.5 or 6.4 mm)
Dual screw adjustment to reel; bedknife is high carbon through-hardened steel;
micro–cut bedknife standard
Grass basket
Rollers
Dry weight
Molded polyethylene with integrated graphics highlighting overlap guidelines;
vented for high efficiency collection
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
250 lb. (114 kg) with aluminum Wiehle roller, kickstand and grass basket; without
transport tires and groomer
9
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.)
High Altitude Jet
(for altitudes above 6000 ft.)
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
Part No. 98-8735
Part No. 98-8736
10
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