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Form No. 3361-484 Rev B
Greensmaster
®
Flex 18 or Flex 21
Walk-Behind Mower
Model No. 04019 (Traction Unit)—Serial No. 290000001
and Up
Model No. 04206 (Cutting Unit)—Serial No. 290000001
and Up
Model No. 04207 (Cutting Unit)—Serial No. 290000001
and Up
Model No. 04024 (Traction Unit)—Serial No. 290000001
and Up
Model No. 04202 (Cutting Unit)—Serial No. 290000001
and Up
Model No. 04025 (Traction Unit)—Serial No. 290000001
and Up
Model No. 04208 (Cutting Unit)—Serial No. 290000001
and Up
To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
Original Instructions (EN)
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Table of Contents
Related Manuals for Toro 04019
Summary of Contents for Toro 04019
- Page 1 Up Model No. 04025 (Traction Unit)—Serial No. 290000001 and Up Model No. 04208 (Cutting Unit)—Serial No. 290000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com. Original Instructions (EN)
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Page 2: Introduction
Whenever you need service, genuine Toro parts, or Model No. additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model Serial No. and serial numbers of your product ready. Figure 1 and Figure 2 identify the location of the model and serial This manual identifies potential hazards and has numbers on the product. -
Page 3: Table Of Contents
Safety ................4 Cutting Unit Maintenance........31 Safe Operating Practices ........4 Separating the Cutting Unit from the Traction Toro Mower Safety ..........5 Unit..............31 Sound Pressure for a Flex 18......... 6 Adjusting the Rear Roller ........31 Sound Power for a Flex 18 ........6 Adjusting the Bedknife to the Reel ...... -
Page 4: Safety
Safety – Refuel outdoors only and do not smoke while refuelling. This machine meets or exceeds CEN standard – Add fuel before starting the engine. Never EN 836:1997, ISO standard 5395:1990, and ANSI remove the cap of the fuel tank or add fuel while B71.4-2004 specifications in effect at the time of the engine is running or when the engine is hot. -
Page 5: Toro Mower Safety
Stop reels if not The following list contains safety information specific mowing. to Toro products or other safety information that you • Do not operate the mower under the influence of must know that is not included in the CEN, ISO, or alcohol or drugs ANSI standard. -
Page 6: Sound Pressure For A Flex 18
– Pull starter cord to start engine. • To ensure safety and accuracy, have an Authorized Toro Distributor check the maximum engine speed – Move throttle to Slow and on/off switch to Off with a tachometer. Maximum governed engine speed position to stop engine. -
Page 7: Safety And Instructional Decals
Safety and Instructional 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. 115-1613 1. Warning—read the 3. Thrown object Operator’s Manual. hazard—keep bystanders a safe distance from the 93-6085... - Page 8 104-2617 104-2618 1. Traction drive 4. Forward 1. Parking brake 3. Engage 2. Reel drive 5. Lever engaged 2. Disengage 3. Neutral 6. Lever disengaged 93-8064 105-2411 1. Warning—read the instructions before servicing or performing maintenance. 1. Transmission oil 2. Cutting hazard of hand or foot—stop the engine and wait for moving parts to stop.
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Page 9: Setup
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Qty. Bolt, M10 x 25mm Handle Install the handle. Kickstand assembly Spring Small spacer Large spacer Install the kickstand for Flex 18 Mowers Only. -
Page 10: Installing The Cutting Unit To The Traction Unit
4. Rotate the traction unit frame (Figure 6)forward until it engages the cutting unit pivot arms. 5. Secure the traction unit frame to the cutting unit pivot arms with (2) M10 x 25mm bolts (Figure 6) Installing the Cutting Unit to the Traction Unit Parts needed for this procedure: Bolt, M10 x 25mm... -
Page 11: Installing The Kickstand For Flex 18 Mowers Only
4. Secure the handle to the bolt and pivot pin with the flange lock nut (Figure 9). 5. Locate cable tie loosely securing throttle cable to wire harness. Position cable tie approximately one Installing the Handle inch behind transmission and tighten cable tie. Parts needed for this procedure: Handle Installing the Kickstand for... -
Page 12: Adjusting The Handle
Figure 12 1. Ring pins Figure 10 1. Left handle end 5. Large bolt (M8–1.25 x 2. While supporting handle, remove ring pins from 100) each side and raise or lower handle to desired 2. Locknut (M8–1.25) 6. Spring operating position (Figure 12). 7. -
Page 13: Checking Fluid Levels
Checking Fluid Levels No Parts Required Procedure 1. Check the engine oil level, refer to Checking the Engine Oil Level. 2. Check the transmission fluid level, refer to Checking Figure 13 the Transmission Fluid Level. 1. Kick stand 2. Press wheel locking clip toward the center of wheel and slide wheel onto hex shaft (Figure 14). -
Page 14: Product Overview
Traction and Reel Drive Engagement Product Overview Lever The traction and reel drive engagement lever (Figure 17) 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. -
Page 15: Specifications
Figure 18 1. Choke lever 2. Fuel shut-off valve Figure 20 1. Kick stand Fuel Shut-Off Valve The fuel shut-off valve (Figure 18) is located on left front of engine. Valve has two positions: Closed and Specifications Open. Move lever to closed position when storing or transporting machine. -
Page 16: Attachments/Accessories
Contact your Checking the Engine Oil Level Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments Check the engine oil level before each use or every 8 and accessories. -
Page 17: Checking The Interlock Switch Operation
Checking the Interlock Switch Operation 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. If safety interlock switches are disconnected • Fill the fuel tank outdoors, in an open area, or damaged the machine could operate when the engine is cold. -
Page 18: Starting And Stopping The Engine
4. Move traction lever into Engage position, engine If optional transport wheels are not going to be must shut off. installed, proceed to step 4. 5. If the engine does not shut off, the interlock 1. Push kick stand down with foot and pull up on switch needs service. - Page 19 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 (Figure 23).
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Page 20: Maintenance
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Maintenance Procedure Interval • Change the engine oil. After the first 8 hours • Clean the fuel filter. After the first 25 hours •... -
Page 21: Daily Maintenance Checklist
Daily Maintenance Checklist Important: Duplicate this page for routine use. Maintenance For the week of: Check Item Mon. Tues. Wed. Thurs. Fri. Sat. Sun. Check the safety interlock operation. Check the parking brake operation. Check that pivot joints operate freely. Check the fuel level. -
Page 22: Engine Maintenance
Engine Maintenance Engine Oil The 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. -
Page 23: Servicing The Air Cleaner
3. Push down on handle to tip mower and engine backward, allowing all oil to run into drain pan. 4. Install drain plug and refill crankcase with the specified oil; refer to Checking the Oil Level. Servicing the Air Cleaner Service Interval: Every 25 hours Every 100 hours 1. -
Page 24: Fuel System Maintenance
Fuel System electrodes because engine damaged could result from grit entering the cylinder. Maintenance 3. Set air gap at 0.028-0.032 inch (Figure 31). Install correctly gapped spark plug and tighten firmly to 17 ft.-lb. Cleaning the Fuel Filter Service Interval: After the first 25 hours Every 50 hours 1. -
Page 25: Electrical System Maintenance
Electrical System Drive System Maintenance Maintenance Servicing the Interlock Switch Checking the Transmission Fluid Level Use the following procedure if the switch needs adjustment or replacement. Service Interval: Every 50 hours 1. Make sure the engine is off and traction lever is The transmission is filled at the factory with Disengaged. -
Page 26: Changing The Transmission Fluid
Changing the Transmission Brake Maintenance Fluid Adjusting the Service/Parking Service Interval: After the first 25 hours Brake Every 800 hours (Or 2 years, whichever occurs first) If service/park brake slips when operated, an adjustment is required. Important: Use only Mobil Dexron lll or equivalent transmission fluids. -
Page 27: Belt Maintenance
Belt Maintenance 3. To adjust belt tension: A. Loosen the bearing housing mounting nuts (Figure 39). Adjusting the Belts Service Interval: Every 100 hours Make sure belts are properly tensioned to assure proper operation of the machine and unnecessary wear. Check belts frequently. - Page 28 Reel Drive Belt (Transmission coupler) 1. Remove the belt cover mounting fasteners and belt cover to expose belt (Figure 41). Figure 43 1. Reel drive belt 2. Bearing housing mounting nuts Figure 41 B. Using a 3/8 inch drive torque wrench, rotate the bearing housing with 35-40 in.-lb.
- Page 29 Figure 45 Figure 47 1. Traction drive belt cover 1. Tang washer 2. Idler bracket bolt 2. Check tension by depressing belt (Figure 46) at mid B. Using a 3/8 inch drive torque wrench, rotate the span of pulleys with 9 ± 1 lb of force. Belt should idler bracket with 75–85 in.-lb.
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Page 30: Controls System Maintenance
Controls System Maintenance Adjusting the Traction Control If traction control does not engage or it slips during operation, an adjustment is required. 1. Move traction control to Disengaged position. Figure 50 2. To increase cable tension, loosen front cable jam 1. -
Page 31: Cutting Unit Maintenance
Cutting Unit Maintenance 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 (Figure 51). -
Page 32: Adjusting The Bedknife To The Reel
Figure 55 1. Spacer 3. Roller bracket 2. Sideplate mounting flange Figure 57 • Position the spacer below the sideplate mounting 1. Sideplate mounting bolts flange when height of cut settings range from 1/8" to 1" (Figure 56). Important: Whenever the cutting unit has to be tipped to expose bedknife/reel, prop up rear of cutting unit to make sure nuts on back end of bedbar adjusting screws are not resting on... -
Page 33: Adjusting The Height Of Cut
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). Figure 61 Adjusting the Height of Cut 3. -
Page 34: Adjusting The Cut-Off Bar
Figure 62 1. Gauge bar 5. Tighten nuts to secure adjustment. Do not overtighten nut. Tighten enough to remove play from washer. Note: Use the following chart to determine which bedknife is best suited for the desired height of cut. Adjusting the Cut-Off Bar Adjust cut-off bar to assure clippings are cleanly discharged from the reel area:... -
Page 35: Setting The Machine To Match Turf Conditions
Setting the Machine to Match Turf Conditions Note: Use the following table to set the machine to match turf conditions. Flex Greensmower Cutting Unit Set-up Matrix Bedbars: Standard and Optional Part Number Description Mower Aggressiveness Comments 106-2468-01 Standard Flex 21 Less Standard 99-3794-03... -
Page 36: Servicing The Bedbar
0.138 (3.5) 0.176 (4.5) 0.241 (6.1) 0.172 (4.4) 0.219 (5.6) 0.301 (7.7) * An additional 22 tooth pulley is required for this clip setting. Figure 65 Contact your local Authorized Toro Distributor for assistance. 1. Bedbar adjusting screw 4. Jam nut 2. Spring tension nut 5. -
Page 37: Backlapping The Reel
4. Nylon washer 2. Insert a 18 mm socket onto hex flange nut on left end of reel shaft. 3. Backlap according to the procedure in the Toro Assembling the Bedbar Sharpening Reel and Rotary Mowers Manual, Form 1. Install bedbar, positioning mounting ears between No. -
Page 38: Storage
Storage 1. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine’s cylinder head fins and blower housing. Important: You can wash the machine with mild detergent and water. - Page 39 Notes:...
- Page 40 Countries Other than the United States or Canada Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfi ed with your Distributor’s service or have diffi...