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Toro 04022 Operator's Manual

Walk-behind mower
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Form No. 3362-144 Rev A
Greensmaster
®
Flex 21
Walk-Behind Mower
Model No. 04022 (Traction Unit)—Serial No. 290000001
and Up
Model No. 04202 (Cutting 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 1 Up Model No. 04202 (Cutting 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)

  • 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

    Setting the Machine to Match Turf Safety ................4 Conditions ............. 32 Safe Operating Practices ........4 Servicing the Bedbar........... 33 Toro Mower Safety ..........5 Adjusting the Cut-Off Bar ........34 Sound Pressure............. 6 Backlapping the Reel .......... 34 Sound Power ............6 Storage...............

  • 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 mowing. The following list contains safety information specific 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

    ON position, set choke to full choke position (cold start) and throttle to half throttle. • To ensure safety and accuracy, have an Authorized Toro Distributor check the maximum engine speed – Pull starter cord to start engine. with a tachometer. Maximum governed engine speed –...

  • 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.

  • Page 9: Setup

    Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Qty. Handle Install the handle. – No parts required Adjust the handle. Transport wheels (Optional Transport Install the transport wheels. Wheel Kit, Model 04123) Check the engine oil and transmission –...

  • Page 10: 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 Adjusting the Handle...

  • Page 11: 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 7). Figure 8 1.

  • Page 12: Installing The Grass Basket

    Product Overview 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 9). Figure 10 1. Handle 5. Cutting unit 2. Control panel 6. Grass basket 3.
  • Page 13 Traction and Reel Drive Engagement Fuel Shut-Off Valve Lever The fuel shut-off valve (Figure 12) is located on left The traction and reel drive engagement lever (Figure 11) front of engine. Valve has two positions: Closed and is located on front right side of control panel. Traction Open.

  • Page 14: Specifications

    Contact your • Keep face away from nozzle and gas tank or Authorized Service Dealer or Distributor or go to conditioner opening. www.Toro.com for a list of all approved attachments • Keep gas away from eyes and skin. and accessories.

  • Page 15: 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. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills.

  • Page 16: Starting And Stopping The Engine

    Transport Operation 2. Place traction lever into Engage position and engine controls in starting position. Note: Do not run the mower engine while transporting 3. Attempt to start engine. Engine should not start. it in a transport trailer because damage can occur to If engine starts, the interlock switch needs service.
  • Page 17 Method of Mowing The greens should be mowed in a straight back and forth direction across the green. Avoid circular mowing or turning the mower on greens areas since scuffing may occur. Turning the mower should be done off the green by raising the cutting reel (pushing the handle down) and turning on the traction drum.

  • Page 18: 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 19: 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 20: Engine Maintenance

    Engine Maintenance Engine Oil The crankcase must be filled with 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 21: Servicing The Air Cleaner

    3. Push down on handle to tip mower and engine C. Saturate element with clean engine oil. Squeeze backward, allowing all oil to run into drain pan. element to remove excess oil and to distribute oil thoroughly. An oil damp element is desirable. 4.

  • Page 22: Fuel System Maintenance

    Fuel System Electrical System Maintenance Maintenance Cleaning the Fuel Filter Servicing the Interlock Switch Service Interval: After the first 25 hours Use the following procedure if the switch needs adjustment or replacement. Every 50 hours 1. Make sure the engine is off and traction lever is 1.

  • Page 23: Drive System Maintenance

    Drive System Maintenance When the transmission is warm, the transmission fluid is hot and under pressure. Allow the transmission to cool before servicing. Checking the Transmission Use caution when removing the check, fill or Fluid Level drain plugs from the transmission. Service Interval: Every 50 hours 1.

  • Page 24: Brake Maintenance

    Brake Maintenance Belt Maintenance Adjusting the Service/Parking Checking and Adjusting the Brake Belts If service/park brake slips when operated, an adjustment Service Interval: Every 100 hours is required. Make sure belts are properly tensioned to assure proper 1. Move service/parking brake lever to Off position. operation of the machine and unnecessary wear.
  • Page 25 Reel Drive Belt (Transmission coupler) 3. To adjust belt tension: A. Loosen the bearing housing mounting nuts 1. Remove the belt cover mounting fasteners and belt (Figure 32). cover to expose belt (Figure 34). Figure 32 1. Reel drive belt 2.
  • Page 26 Figure 36 1. Reel drive belt 2. Bearing housing mounting Figure 38 nuts 1. Traction drive belt cover B. Using a 3/8 inch drive torque wrench, rotate the 2. Check tension by depressing belt (Figure 39) at mid bearing housing with 35-40 in.-lb. of torque to span of pulleys with 4 ±...

  • Page 27: 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. 2. To increase cable tension, loosen front cable jam nut and tighten back cable jam nut (Figure 42) until a force of 12-16 lb.

  • Page 28: 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 43 (Figure 44).

  • Page 29: Adjusting The Rear Roller

    Figure 48 1. Spacer 3. Roller bracket 2. Sideplate mounting flange Figure 46 1. Transmission coupling • Position the spacer below the sideplate mounting flange when height of cut settings range from 7. Reverse procedure to install cutting unit. 1/8" to 1" (Figure 49). Note: When tightening the pivot arm mounting fasteners, use an adjustable end wrench to hold the pivot arm parallel to the side plate (Figure 47).

  • Page 30: Adjusting The Bedknife To The Reel

    (Figure 51). unit to achieve the sharp edges needed for precision cutting (see Toro reel sharpening manual). Adjusting the Height of Cut For heights of cut greater than .500", the high height of cut kit must be installed.
  • Page 31 Figure 55 4. Rotate adjusting screw until roller contacts front of gauge bar. Adjust both ends of roller until entire Figure 53 roller is parallel to the bedknife. 1. Rear roller bracket 3. Locknut Important: When set properly, the rear and 2.

  • Page 32: 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 33: Servicing The Bedbar

    Figure 56 1. Reel drive belt 3. Driven pulley 2. Drive pulley Servicing the Bedbar Removing the Bedbar 1. Turn the bedbar adjuster screw, counterclockwise, to back the bedknife away from reel (Figure 57). Figure 58 1. Bedbar bolt 2. Nut 4.

  • Page 34: Adjusting The Cut-Off Bar

    Adjusting the Cut-Off Bar end of reel shaft. Adjust cut-off bar to assure clippings are cleanly 3. Backlap according to the procedure in the Toro discharged from the reel area: Sharpening Reel and Rotary Mowers Manual, Form No. 80-300 PT.

  • Page 35: 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 36 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...

This manual is also suitable for:

Greensmaster flex 210420204208

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