Toro Greensmaster Flex 21 Bedienungsanleitung

PART NO. 01089SL (Rev. C)

Service Manual

GreensmasterFlex 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 21.

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 – 2001, 2002, 2004, 2006

Greensmaster Flex 21

This page is intentionally blank.

Rev. B

Greensmaster Flex 21

Table Of Contents

Chapter 1 – Safety

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

Safety and Instruction Decals 1 – 3. . . . . . . . . . . . . . . .

Chapter 2 – Product Records and Manuals

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

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

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

Chapter 3 – Engine

Introduction 3 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Adjustments 3 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 3 – 7. . . . . . . . . . . . . . . . . . . . . . . .

Kawasaki FE120 Service Manual

Chapter 4 – Traction and Reel Drive System

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

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

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

Service and Repairs 4 – 9. . . . . . . . . . . . . . . . . . . . . . . .

Chapter 5 – Electrical System

Wiring Schematics 5 – 2. . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools 5 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Chapter 6 – Chassis and Controls

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

Adjustments 6 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Chapter 7 – Cutting Unit

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

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

Special Tools 7 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 7 – 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 7 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 7 – 14. . . . . . . . . . . . . . . . . . . . . . .

Chapter 8 – Groomer (Model 04201)

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

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

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

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

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

Chapter 9 – Groomer (Model 04204)

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

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

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

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

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

SafetyProduct Records

and Manuals

Engine

Traction and Reel

Drive System

Electrical

System

Chassis andCutting Unit

Controls

Groomer

(Model 0 201)

Groomer

(Model 0 20 )

Greensmaster Flex 21

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Greensmaster Flex 21 Page 1 – 1 Safety

Chapter 1

Safety

Table of Contents

SAFETY INSTRUCTIONS 1. . . . . . . . . . . . . . . . . . . . . .

Before Operating 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

While Operating 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance and Service 2. . . . . . . . . . . . . . . . . . . .

SAFETY AND INSTRUCTION DECALS 3. . . . . . . . . .

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 reading and under-

standing the contents of this manual. A replacement

manual is available on the internet at www.toro.com or

by sending 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 engine quickly.

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

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

legible, 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

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 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.

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 a switch should malfunction, replace the

switch before operating machine. (After every two

years, replace the interlock switch in the safety system,

whether it is working properly or not.)

Safety

Greensmaster Flex 21

Page 1 – 2

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 and stop the engine:

A. Open fuel shut-off valve.

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.

E. Move throttle to SLOW and on/off switch to OFF

position to stop engine.

4. To transport mower from one area to another:

A. Install transport wheels.

B. Disengage reel drive.

C. Start engine.

D. Press down on handle to raise front of mower and

engage traction drive.

5. Before beginning mowing operation:

A. Disengage traction drive.

B. Stop engine.

C. Remove transport wheels.

D. Start engine.

E. Engage reel drive.

6. Before emptying basket of clippings, disengage trac-

tion drive, reduce engine speed and move on/off switch

to OFF position to stop engine.

7. 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.

8. 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.

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

gine is stopped and cutting unit reel is not spinning.

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

an extended period of time.

Maintenance and Service

1. Before servicing or making adjustments to the ma-

chine, stop the engine and pull the high tension lead off

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

quired, contact an Authorized TORO Distributor.

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

free of excessive grease, grass, leaves and accumula-

tion of dirt.

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

nance adjustment, keep hands, feet, clothing, and any

parts of the body away from the cutting unit and any

moving parts. Keep everyone away.

6. Do not overspeed the engine by changing governor

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

sure safety and accuracy, have an Authorized TORO

Distributor check maximum engine speed with a

tachometer.

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

oil to the crankcase.

8. Engine must be shut off before checking or adding

fluid to the transmission.

9. To be sure of optimum performance and safety, al-

ways purchase genuine TORO replacement parts and

accessories. Replacement parts and accessories made

by other manufacturers could be dangerous. Such use

could void the product warranty of The Toro Company.

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

Greensmaster Flex 21

Page 1 – 4

Safety

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Greensmaster Flex 21 Page 2 – 1 Product Records and Manuals

Chapter 2

Product Records and Manuals

Table of Contents

PRODUCT RECORDS 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) 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 Manuals and Parts Catalogs for your

Greensmaster Flex 21 at the end of this section.

Product Records

and Manuals

Greensmaster Flex 21

Page 2 – 2

Product Records and Manuals

Equivalents and Conversions

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