Toro Greensmaster Flex 18 04018 Bedienungsanleitung

(Models 04018, 04019, 04030, 04022, 04024, 04025, 04031)

PART NO. 06149SL

Service Manual

GreensmasterFlex 18/21

Preface

The purpose of this publication is to provide the service

technician with information for troubleshooting, testing

and repairing assemblies and components on the

Greensmaster Flex 18 (Model 04018) and Flex 21

(Model 04022).

REFER TO THE OPERATOR’S MANUAL FOR OPER-

ATING, MAINTENANCE AND ADJUSTMENT

INSTRUCTIONS. Space is provided in Chapter 2 of this

book to insert the Operator’s Manual and Parts Catalogs

for your machine. Replacement Operator’s Manuals

and Parts Catalogs are available on the internet at

www.toro.com or by sending complete Model and Serial

Number to:

The Toro Company

Attn. Technical Publications

8111 Lyndale Avenue South

Minneapolis, MN 55420–1196

The Toro Company reserves the right to change product

specifications or this publication without notice.

This safety symbol means DANGER, WARNING

or CAUTION, PERSONAL SAFETY INSTRUC-

TION. When you see this symbol, carefully read

the instructions that follow. Failure to obey the

instructions may result in personal injury.

NOTE: A NOTE will give general information about the

correct operation, maintenance, service, testing or re-

pair of the machine.

IMPORTANT: The IMPORTANT notice will give im-

portant instructions which must be followed to pre-

vent damage to systems or components on the

machine.

The Toro Company – 2006

Greensmaster Flex 18/21

This page is intentionally blank.

Greensmaster Flex 18/21

Table Of Contents

Chapter 1 – Safety

Safety Instructions 1 – 2. . . . . . . . . . . . . . . . . . . . . . . . . .

Safety and Instruction Decals 1 – 4. . . . . . . . . . . . . . . .

Chapter 2 – Product Records and Maintenance

Product Records 2 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 2 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equivalents and Conversions 2 – 2. . . . . . . . . . . . . . . .

Torque Specifications 2 – 3. . . . . . . . . . . . . . . . . . . . . . .

Chapter 3 – Engine

Specifications 3 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 3 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information 3 – 3. . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 3 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 3 – 5. . . . . . . . . . . . . . . . . . . . . . . .

KAWASAKI FE120 SERVICE MANUAL

Chapter 4 – Traction and Reel Drive System

Specifications 4 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information 4 – 3. . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 4 – 5. . . . . . . . . . . . . . . . . . . . . . . .

Chapter 5 – Electrical System

Wiring Schematic 5 – 2. . . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools 5 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 5 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Testing 5 – 6. . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 5 – 8. . . . . . . . . . . . . . . . . . . . . . . .

Chapter 6 – Chassis and Controls

Specifications 6 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information 6 – 3. . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 6 – 4. . . . . . . . . . . . . . . . . . . . . . . .

Chapter 7 – Cutting Unit

Specifications 7 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information 7 – 3. . . . . . . . . . . . . . . . . . . . . . . .

Special Tools 7 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Factors That Affect Quality Of Cut 7 – 6. . . . . . . . . . . .

Adjustments 7 – 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 7 – 9. . . . . . . . . . . . . . . . . . . . . . . .

Chapter 8 – Groomer

Specifications 8 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information 8 – 3. . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 8 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 8 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 8 – 7. . . . . . . . . . . . . . . . . . . . . . . .

SafetyProduct Records

and Maintenance

Engine

Traction and Reel

Drive System

Electrical

System

Chassis andCutting Unit

Controls

Groomer

Greensmaster Flex 18/21

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Greensmaster Flex 18/21 Page 1 – 1 Safety

Chapter 1

Safety

Table of Contents

SAFETY INSTRUCTIONS 2. . . . . . . . . . . . . . . . . . . . . .

Before Operating 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

While Operating 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance and Service 3. . . . . . . . . . . . . . . . . . . .

SAFETY AND INSTRUCTION DECALS 4. . . . . . . . . .

Safety

Greensmaster Flex 18/21Page 1 – 2Safety

Safety Instructions

Although hazard control and accident prevention par-

tially are dependent upon the design and configuration

of the machine, these factors are also dependent upon

the awareness, concern and proper training of the per-

sonnel involved in the operation, transport, mainte-

nance and storage of the machine. Improper use or

maintenance of the machine can result in injury or

death. To reduce the potential for injury or death, comply

with the following safety instructions.

To reduce the potential for injury or death,

comply with the following safety instructions.

WARNING

Before Operating

1. Operate the machine only after reviewing and under-

standing the contents of the Operator’s Manual and Op-

erator Training DVD. A replacement Operator’s Manual

is available on the internet at www.toro.com or by send-

ing the complete model and serial number to:

The Toro Company

Attn. Technical Publications

8111 Lyndale Avenue South

Minneapolis, Minnesota 55420–1196

2. Never allow children to operate the machine or allow

adults to operate it without proper instructions.

3. Become familiar with the controls and know how to

stop the machine and engine quickly.

4. Keep all shields, safety devices and decals in place.

If a shield, safety device or decal is malfunctioning, illeg-

ible or damaged, repair or replace it before operating the

machine.

5. Always wear substantial shoes. Do not operate ma-

chine while wearing sandals, tennis shoes or sneakers.

Do not wear loose fitting clothing which could get caught

in moving parts and cause personal injury.

6. Wearing safety glasses, safety shoes, long pants,

ear protection and a helmet is advisable and required by

some local safety and insurance regulations.

7. Ensure work area is clear of objects which might be

picked up and thrown by the cutting reel.

8. Keep everyone, especially children and pets away

from the areas of operation.

9. Since gasoline is highly flammable; handle it careful-

ly.

A. Use an approved gasoline container.

B. Do not remove cap from fuel tank when engine is

hot or running.

C. Do not smoke while handling gasoline.

D. Fill fuel tank outdoors and no higher than to the

bottom of filter screen. Do not overfill fuel tank.

E. Wipe up any spilled gasoline.

F. Fuel may leak from filler neck when mower is

tilted for servicing if tank is over filled.

10.Check the safety interlock switch daily for proper op-

eration; see Component Testing in Chapter 5 – Electri-

cal System. If safety switch should malfunction, replace

the switch before operating machine. After every two

years, replace the safety interlock switch, whether it is

working properly or not.

Greensmaster Flex 18/21 Page 1 – 3 Safety

While Operating

1. Do not run the engine in a confined area without ade-

quate ventilation. Exhaust fumes are hazardous and

could be deadly.

2. Always stand behind the handle when starting and

operating the machine.

3. To start the engine:

A. Open fuel shut-off valve. Make sure spark plug

wire is connected to spark plug.

B. Verify that the control lever on handle is in NEU-

TRAL position for both traction and reel drives.

C. Move on/off switch to ON position, set choke to

full choke position (cold start) and throttle to half

throttle.

D. Pull starter cord to start engine.

4. To stop the engine:

A. Disengage reel and traction drives and reduce

engine speed to SLOW.

B. Move on/off switch to OFF position to stop en-

gine.

5. Before emptying basket of clippings, disengage trac-

tion and reel drives, reduce engine speed and move on/

off switch to OFF position to stop engine.

6. Do not touch engine, muffler or exhaust pipe while

engine is running or soon after it has stopped because

these areas are hot enough to cause burns.

7. If the cutting unit strikes a solid object or vibrates ab-

normally, stop immediately, turn engine off, wait for all

motion to stop and inspect for damage. A damaged reel

or bedknife must be repaired or replaced before opera-

tion is commenced.

8. Whenever machine is left unattended, be sure en-

gine is stopped and cutting unit reel is not spinning.

9. Close fuel shut-off valve if machine is not to be used

for an extended period of time. Also, close fuel shut-off

valve if machine is to be transported on a trailer or in a

vehicle.

Maintenance and Service

1. Before servicing or making adjustments to the ma-

chine, stop the engine and wait for all machine move-

ment to stop. Remove the spark plug wire from the spark

plug to prevent accidental starting of the engine.

2. To make sure entire machine is in good condition,

keep all nuts, bolts, screws and belts properly tightened.

3. To reduce potential fire hazard, keep the engine area

free of excessive grease, grass, leaves and accumula-

tion of dirt.

4. Wear heavy gloves and use caution when checking

or servicing the cutting unit.

5. If the engine must be running to perform mainte-

nance or make an adjustment, keep hands, feet, cloth-

ing and all parts of the body away from the cutting unit

and all moving parts. Keep bystanders away.

6. Do not overspeed the engine by changing governor

settings. Maximum engine speed is 3600 RPM. To en-

sure safety and accuracy, check maximum engine

speed with a tachometer.

7. Engine must be shut off before checking oil or adding

oil to the engine crankcase or transmission.

8. If major repairs are ever needed or assistance is re-

quired, contact an Authorized TORO Distributor.

9. At the time of manufacture, the machine conformed

to all applicable safety standards. To assure optimum

performance and continued safety certification of the

machine, use genuine Toro replacement parts and ac-

cessories. Replacement parts and accessories made

by other manufacturers may result in non-conformance

with the safety standards and the warranty may be

voided.

Safety

Greensmaster Flex 18/21Page 1 – 4Safety

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. Decal

part numbers are listed in your Parts Catalog. Order re-

placement decals from your Authorized TORO Distribu-

tor.

Greensmaster Flex 18/21 Page 2 – 1 Product Records and Maintenance

Chapter 2

Product Records and Maintenance

Table of Contents

PRODUCT RECORDS 1. . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EQUIVALENTS AND CONVERSIONS 2. . . . . . . . . . .

Decimal and Millimeter Equivalents 2. . . . . . . . . . . .

U.S. to Metric Conversions 2. . . . . . . . . . . . . . . . . . .

TORQUE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . .

Fastener Identification 3. . . . . . . . . . . . . . . . . . . . . . .

Standard Torque for Dry, Zinc Plated, and Steel

Fasteners (Inch Series Fasteners) 4. . . . . . . . . . .

Standard Torque for Dry, Zinc Plated, and Steel

Fasteners (Metric Fasteners) 5. . . . . . . . . . . . . . .

Other Torque Specifications 6. . . . . . . . . . . . . . . . . .

Conversion Factors 6. . . . . . . . . . . . . . . . . . . . . . . . .

Product Records

Insert Operator’s Manual and Parts Catalog for your

Greensmaster Flex 18 or Flex 21 at the end of this sec-

tion. Additionally, if any optional equipment or accesso-

ries have been installed to your machine, insert the

Installation Instructions, Operator’s Manuals and Parts

Catalogs for those options at the end of this chapter.

Maintenance

Maintenance procedures and recommended service in-

tervals for the Greensmaster Flex 18 and Flex 21 are

covered in the Operator’s Manual. Refer to that publica-

tion when performing regular equipment maintenance.

Product Records

and Maintenance

0.09375

Greensmaster Flex 18/21Page 2 – 2Product Records and Maintenance

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