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Service Manual
Form No. 3367-381 Rev B
Greensmaster
®
Flex 18 or Flex 21
Walk-Behind Mower
Model No. 04019—Serial No. 311000001 and Up
Model No. 04024—Serial No. 311000001 and Up
Model No. 04025—Serial No. 311000001 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 Model No. 04019—Serial No. 311000001 and Up Model No. 04024—Serial No. 311000001 and Up Model No. 04025—Serial No. 311000001 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 additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the product. -
Page 3: Table Of Contents
Adjusting the Reel Control........31 Safety ................4 Storage............... 32 Safe Operating Practices ........4 Toro Mower Safety ..........5 Sound Power Level-Flex 18 ........6 Sound Pressure Level-Flex 18 ....... 6 Vibration Level-Flex 18 ........6 Sound Power Level-Flex 21 ........6 Sound Pressure Level-Flex 21 ....... -
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
The following list contains safety information specific • Lightning can cause severe injury or death. If to Toro products or other safety information that you lightning is seen or thunder is heard in the area, do must know that is not included in the CEN, ISO, or not operate the machine;... -
Page 6: Sound Power Level-Flex 18
• To ensure safety and accuracy, have an Authorized panel, to ON position, set choke to full choke Toro Distributor check the maximum engine speed position (cold start) and throttle to half throttle. with a tachometer. Maximum governed engine speed –... -
Page 7: Sound Pressure Level-Flex 21
Sound Pressure Level-Flex 21 Vibration Level-Flex 21 Hand-Arm This unit has a sound pressure level at the operator’s ear of 92 dBA, which includes an Uncertainty Value (K) Measured vibration level for right hand = 2.36 m/s of 1 dBA. Measured vibration level for left hand = 2.47 m/s Sound pressure level was determined according to the Uncertainty Value (K) = 0.5 m/s... - Page 8 105-2411 1. Transmission oil 93-9886 1. Use unleaded gasoline. 104-2617 1. Traction drive 4. Forward 2. Reel drive 5. Lever engaged 3. Neutral 6. Lever disengaged 104-2618 1. Parking brake 3. Engage 2. Disengage 115-1614 1. Warning—read the Operator’s Manual. 3.
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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 Install the cutting unit to the traction unit 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
Note: Determine the left and right sides of the machine from the normal operating position. Installing the Cutting Unit to the Traction Unit Parts needed for this procedure: Figure 4 Bolt, M10 x 25mm 1. Transmission coupling 1. Place the mower on its drums on a level surface. 4. -
Page 11: Installing The Handle
Figure 8 1. Left handle end 3. Pivot pin 4. Locknut 2. Support arm Figure 6 3. Squeeze the handle ends inward and install them on the step of the pivot pin (Figure 8). 4. Secure the handle to the bolt and pivot pin with the flange lock nut (Figure 8). -
Page 12: Adjusting The Handle
frame with the bolt and washer, the small spacer, and locknut (M8–1.25) (Figure 9). Ensure the bolt is installed from the inside of the frame as shown in Figure 9. 3. Install a washer (M8) onto the large bolt (M8–1.25 x 100). -
Page 13: Installing The Transport Wheels
Installing the Transport Wheels Parts needed for this procedure: Transport wheels (Optional Transport Wheel Kit, Model 04123) Procedure 1. Push kick stand down with foot and pull up on handle support until kick stand has rotated forward, over center (Figure 12). Figure 13 1. -
Page 14: Installing The Grass Basket
Installing the Grass Basket Parts needed for this procedure: Grass basket Procedure Grasp basket by top lip and slide basket frame into the receivers (Figure 14). Figure 14 1. Grass basket 2. Basket receivers... -
Page 15: Product Overview
Traction and Reel Drive Engagement Product Overview Lever The traction and reel drive engagement lever (Figure 16) 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 16: Specifications
A selection of Toro approved attachments and accessories are available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories. -
Page 17: Operation
Operation DANGER In certain conditions, gasoline is extremely Note: Determine the left and right sides of the flammable and highly explosive. A fire or explosion machine from the normal operating position. from gasoline can burn you and others and can damage property. -
Page 18: Checking The Interlock Switch Operation
Checking the Interlock Switch 5. If the engine does not shut off, the interlock switch needs service. Correct the problem before Operation operating. 6. Carefully lift up on handle to release kick stand. CAUTION If safety interlock switches are disconnected or Starting and Stopping the damaged the machine could operate unexpectedly Engine... -
Page 19: Preparing To Mow
If optional transport wheels are not going to be by raising the cutting reel (pushing the handle down) installed, proceed to step 4. and turning on the traction drum. Mowing should be done at a normal walking pace. Fast speeds saves very 1. - Page 20 Figure 23 1. Traction drive -neutral 3. Traction drive-engaged (transport) 2. Traction drive neutral & 4. Traction drive & reel drive reel drive off engaged 3. Move traction lever to Engaged position, increase throttle speed until the mower is traveling at the desired ground speed, drive the mower out onto the green area, lower the front of the mower down and commence operation (Figure 23).
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Page 21: 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 22: 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 23: 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 24: 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 25: 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 30). Install correctly gapped spark plug and tighten firmly to 17 ft.-lb (23 N-m). Cleaning the Fuel Filter Service Interval: After the first 25 hours Every 50 hours 1. -
Page 26: 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 27: 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) Note: The service/parking brake is a holding brake not a stopping brake. It is designed to hold the machine on Important: Use only Mobil Dexron lll or equivalent a 17 degree slope without moving. -
Page 28: Adjusting The Belts
Belt Maintenance Adjusting the Belts Make sure belts are properly tensioned to assure proper operation of the machine and unnecessary wear. Check belts frequently. Reel Drive Belt (Reel) 1. Remove the belt cover mounting fasteners and belt cover to expose belt (Figure 36). Figure 38 1. - Page 29 Reel Drive Belt (Transmission coupler) 1. Remove the belt cover mounting fasteners and belt cover to expose belt (Figure 40). Figure 42 1. Reel drive belt 2. Bearing housing mounting nuts Figure 40 B. Using a 3/8 inch drive torque wrench, rotate the bearing housing with 35-40 in.-lb.
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Page 30: Traction Drive Belt
Traction Drive Belt 1. Remove belt cover mounting fasteners and belt cover to expose belt (Figure 44). Figure 46 1. Tang washer 2. Idler bracket bolt B. Using a 3/8 inch drive torque wrench, rotate the Figure 44 idler bracket with 35-40 in.-lb. of torque to set 1. -
Page 31: 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 49 2. To increase cable tension, loosen front cable jam nut 1. -
Page 32: 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 33 Notes:...
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Page 36: The Toro Total Coverage Guarantee
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 dissatisfied with your Distributor’s service or have difficulty obtaining guarantee information, contact the Toro importer.