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Form No. 3359-189 Rev A
Greensmaster
®
Flex 18 or Flex 21
Walk-Behind Mower
Model No. 04030 (Traction Unit)—Serial No. 280000001
and Up
Model No. 04206 (Cutting Unit)—Serial No. 280000001
and Up
Model No. 04031 (Traction Unit)—Serial No. 280000001
and Up
Model No. 04202 (Cutting Unit)—Serial No. 280000001
and Up
Register at www.Toro.com.
Original Instructions (EN)
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Table of Contents
Related Manuals for Toro 04030
Summary of Contents for Toro 04030
- Page 1 Form No. 3359-189 Rev A Greensmaster ® Flex 18 or Flex 21 Walk-Behind Mower Model No. 04030 (Traction Unit)—Serial No. 280000001 and Up Model No. 04206 (Cutting Unit)—Serial No. 280000001 and Up Model No. 04031 (Traction Unit)—Serial No. 280000001 and Up Model No.
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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
Unit..............31 Safe Operating Practices ........4 Adjusting the Rear Roller ........31 Toro Mower Safety ..........5 Adjusting the Bedknife to the Reel ...... 32 Sound Pressure for a Flex 18......... 6 Adjusting the Height of Cut ........ 33 Sound Power for a Flex 18 ........ -
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
• Slow down and use caution when making turns The following list contains safety information specific and crossing roads and sidewalks. Stop reels if not to Toro products or other safety information that you mowing. must know that is not included in the CEN, ISO, or •... -
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: Sound Power For A Flex 21
Sound Power for a Flex 21 Vibration for a Flex 21 This unit has a guaranteed sound power level of 98 dBA, This unit does not exceed a hand/arm vibration level of based on measurements of identical machines per ISO 2.50 m/s , based on measurements of identical machines 11094. - Page 8 93-8064 1. Warning—read the instructions before servicing or performing maintenance. 2. Cutting hazard of hand or foot—stop the engine and wait for moving parts to stop. 93-9886 1. Use unleaded gasoline. 104-2617 1. Traction drive 4. Forward 2. Reel drive 5.
- Page 9 115-1614 1. Warning—read the Operator’s Manual. 3. Thrown object hazard—keep bystanders a safe distance from the machine. 2. Warning—do not operate the machine unless you are trained. 4. Warning—stay away from moving parts; keep all guards in place.
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Page 10: Setup
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Qty. Handle Install the handle. Kickstand assembly Spring Small spacer Large spacer Install the kickstand for Flex 18 Mowers Only. Large bolt (M8–1.25 x 100) Small bolt (M8–1.25 x 030) Locknut (M8 x 1.25) Washer (M8) -
Page 11: Installing The Handle
4. Secure the handle to the bolt and pivot pin with the flange lock nut (Figure 5). 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 8 1. Ring pins Figure 6 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 8). 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 in Engine Maintenance , page 22. 2. Check the transmission fluid level, refer to Checking Figure 9 the Transmission Fluid Level in Drive System 1. -
Page 14: Product Overview
Traction and Reel Drive Engagement Product Overview Lever The traction and reel drive engagement lever (Figure 13) 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
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. Figure 16 1. Kick stand... -
Page 16: Operation
Operation Note: Determine the left and right sides of the In certain conditions, gasoline is extremely machine from the normal operating position. flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. Think Safety First •... -
Page 17: Checking The Interlock Switch Operation
Checking the Interlock Switch 1. Make sure traction and reel drive levers are in Disengaged position. Operation Note: Engine will not start if traction lever is in the engaged position. 2. Open the fuel shut-off valve on the engine. If safety interlock switches are disconnected 3. -
Page 18: Preparing To Mow
Preparing to Mow 1. Return traction control lever to Disengage, throttle to Slow and stop engine. 2. Push kick stand down with foot and pull up on handle support until kick stand has rotated forward, over center. 3. Remove transport wheels. 4. - Page 19 Figure 20 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 20).
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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 27). 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 Checking the Transmission Servicing the Interlock Switch 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: Brake Maintenance
Brake Maintenance 1. Place a drain pan at the rear of the machine. 2. Remove the drain plug from the rear of the transmission (Figure 31). Adjusting the Service/Parking Brake If service/park brake slips when operated, an adjustment is required. 1. -
Page 27: Belt Maintenance
Belt Maintenance 3. To adjust belt tension: A. Loosen the bearing housing mounting nuts (Figure 35). 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. - Page 28 Reel Drive Belt (Transmission coupler) 1. Remove the belt cover mounting fasteners and belt cover to expose belt (Figure 37). Figure 39 1. Reel drive belt 2. Bearing housing mounting nuts Figure 37 B. Using a 3/8 inch drive torque wrench, rotate the bearing housing with 35-40 in.-lb.
- Page 29 Figure 41 Figure 43 1. Traction drive belt cover 1. Tang washer 2. Idler bracket bolt 2. Check tension by depressing belt (Figure 42) at mid B. Using a 3/8 inch drive torque wrench, rotate the span of pulleys with 4 ± 1 lb of force. Belt should idler bracket with 35-40 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 46 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 47). -
Page 32: Adjusting The Bedknife To The Reel
Figure 51 1. Spacer 3. Roller bracket 2. Sideplate mounting flange Figure 53 • Position the spacer below the sideplate mounting 1. Sideplate mounting bolts flange when height of cut settings range from 1/8" to 1" (Figure 52). 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 57 Adjusting the Height of Cut 3. -
Page 34: Adjusting The Cut-Off Bar
Figure 58 Figure 59 1. Cut-off bar 4. Rotate adjusting screw until roller contacts front of gauge bar. Adjust both ends of roller until entire 2. Insert .060 inch feeler gauge between top of reel and roller is parallel to the bedknife. bar and tighten screws. -
Page 35: Setting The Machine To Match Turf Conditions
Setting the Machine to Match Turf Conditions 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 Aggressive... -
Page 36: Servicing The Bedbar
Use the following table and Figure 60 to set the rate of clip. Clip (Refer to Figure 60 for pulley locations.) Drive pulley number of teeth Driven pulley number of teeth 11 Blade Clip 8 Blade Clip .14 inches (standard) .19 inches .16 inches .24 inches... -
Page 37: Backlapping The Reel
1. Reel drive cover plug 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 Sharpening Reel and Rotary Mowers Manual, Form No. 80-300 PT. -
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 If for any reason you are dissatisfied with your Distributor’s service or have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.