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Toro
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04202
Toro 04202 Service Manual
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Greensmaster Flex 21
Page 1 – 3
Safety
Safety and Instruction Decals
Safety decals and instructions are easily visible to the
operator
and are located near any area of potential dan-
ger
. Replace any decal that is damaged or lost. Part
numbers
are listed in your Parts Catalog. Order replace-
ment decals from your Authorized TORO Distributor
.
Safety
6
8
Table of Contents
Chapter 3 Engine
15
Table of Contents
15
Introduction
16
Specifications
17
General Information
18
Filling the Fuel Tank
18
Fuel Shut-Off Valve
19
Adjustments
20
Throttle Cable Adjustment
20
Engine Oil
21
Service and Repairs
21
Air Cleaner
22
Fuel Filter
23
Spark Plug
23
Cooling System
25
Ignition Components
25
Engine Removal and Installation
26
Chapter 4 Traction and Reel Drive System
29
Specifications
30
General Information
31
Check Gearbox Fluid
31
Gearbox Seals
31
Adjustments
32
Parking Brake Cable Adjustment
32
Traction Control Cable Adjustment
32
Reel Control Cable Adjustment
33
Traction Drive Belt Adjustment
34
Reel Drive Belt Adjustment
35
Transmission Coupler Drive Belt Adjustment
36
Service and Repairs
37
Reel Drive and Transmission Coupler Belt Replacement
37
Reel Drive Assembly
38
Reel Drive and Transmission Coupler Bearing Housing
39
Traction Drive Assembly
42
Traction Drive Belt Replacement
43
Traction Drive Idler Pulley and Bearings
44
Traction Drum Assembly (Serial Number below 240001001)
46
Traction Drum Assembly (Serial Number above 240001000)
48
Change Gearbox Fluid
51
Gearbox (Serial Number below 240001001)
52
Gearbox (Serial Number above 240001000)
56
Gearbox Assembly
58
Differential Assembly
62
Chapter 5 Electrical System
63
Wiring Schematics
64
Early Models (Without Operator Presence)
64
Later Models (with Operator Presence)
65
Special Tools
66
Troubleshooting
67
Starting Problems
67
Component Testing
68
Ignition Coil
68
Ignition System Operation
68
Interlock Module and Switch
69
Lighting Coil
69
Interlock Switch
70
Service and Repairs
70
Chapter 6 Chassis and Controls
73
Specifications
74
Adjustments
75
Handle Height Adjustment
75
Service and Repairs
76
Handle Assembly
76
Parking Brake Cable Replacement
78
Traction Cable Replacement
79
Reel Control Cable Replacement
80
Throttle Cable Replacement
81
Kickstand
82
Wheels
82
Chapter 7 Cutting Unit
85
Specifications
86
General Information
87
Grass Basket Installation
87
Separating Cutting Unit from Traction Unit
88
Cutting Reel and Roller Seals
88
Special Tools
89
Troubleshooting
91
Factors that Can Affect Quality of Cut
91
Adjustments
93
Bedknife to Reel Adjustment
93
Leveling Rear Roller
94
Rear Roller Height Adjustment
95
Height-Of-Cut Adjustment
96
Cut-Off Bar Adjustment
97
Backlapping
98
Service and Repairs
98
Bedbar
99
Bedknife Service
100
Rollers
102
Roller Service (Roller Shaft with Circlip)
104
Roller Service (Threaded Roller Shaft)
106
Cutting Reel
108
Cutting Reel Bearing Service (Cannister Style Seals)
112
Cutting Reel Bearing Service (V-Ring Style Seals)
114
Preparing Reel for Grinding
116
Chapter 8 Groomer (Model 04201)
117
Specifications
118
General Information
119
Transport Mode
119
Troubleshooting
120
Factors Affecting Grooming
120
Groomer Reel Mechanical Problems
121
Drive Belt Replacement
123
Service and Repairs
123
Groomer Reel
124
Groomer Reel Bearing Replacement
127
Idler Assembly
128
Adjuster Arm Assembly
129
Cutting Reel
130
Chapter 9 Groomer (Model 04204)
133
Specifications
134
General Information
135
Transport Mode
135
Troubleshooting
136
Factors Affecting Grooming
136
Groomer Reel Mechanical Problems
137
Height/Depth of Groomer Adjustment
138
Groomer Belt Replacement
139
Service and Repairs
139
Groomer Reel
140
Groomer Reel Service
143
Groomer Reel Bearing Replacement
144
Idler Assembly
146
Groomer Arm Assembly
147
Cutting Reel
148
Groomer Brush
150
Other manuals for Toro 04202
Operator's Manual
40 pages
Installation Instructions
24 pages
4
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Toro 04202 Specifications
General
Brand
Toro
Model
04202
Category
Lawn Mower
Language
English
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