Form No. 12188SL Rev.
Revision History Revision Date Description -- 2012 A 02/2018 Added revision history. B 04/2018 Added 1820/2120 models, revised bedknife installation procedure, added Universal Groomer chapter. C 06/2018 Added 1820/2120 wet clutch fluid specifications D 04/2020 Added new schematic, wire harness, optional light switch Initial Issue. © THE TORO COMPANY 2020 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies).
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
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PART NO. 12188SL Rev. D Service Manual (Models 04040, 04041, 04044 and 04045) GreensmasterR Flex 1800/1820/2100/2120 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 1800 (Model 04041), Flex 1820 (Model 04045), Flex 2100 (Model 04040) and Flex 2120 (Model 04044). REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.
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Chapter 6 - Chassis and Controls Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 - 4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4 - 1 1 2 3 3 3 3 3 - 3 4 5 6 Chapter 3 - Engine Specifications . . . . . . . . . . . . . . . . .
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Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
Safety Instructions Greensmaster Flex machines have been tested and certified by TORO for compliance with existing safety standards and specifications. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.
1. Do not run the engine in a confined area without adequate 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 NEUTRAL position for both traction and reel drives. C.
Safety and Instruction 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. Decal part numbers are listed in your Parts Catalog. Order replacement decals from your Authorized TORO Distributor.
Chapter 2 Product Records and Maintenance Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . .
Equivalents and Conversions 0.
Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series Fasteners) Thread Size # 6 − 32 UNC Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in−lb in−lb N−cm 10 + 2 13 + 2 147 + 23 # 6 − 40 UNF # 8 − 32 UNC 13 + 2 25 + 5 282 + 30 # 8 − 36 UNF # 10 − 24 UNC 18 + 2 30 + 5 339 + 56 # 10 − 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in−lb 644 + 68 N−cm 78 + 8 in−lb 881 + 90 N−cm M6 X 1.0 96 + 10 in−lb 1085 + 113 N−cm 133 + 14 in−lb 1503 + 158 N−cm M8 X 1.25 19 + 2 ft−lb 26 + 3 N−m 28 + 3 ft−lb 38 + 4 N−m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Recommended Torque Thread Size Square Head Hex Socket 1/4 − 20 UNC 140 + 20 in−lb 73 + 12 in−lb 5/16 − 18 UNC 215 + 35 in−lb 145 + 20 in−lb 3/8 − 16 UNC 35 + 10 ft−lb 18 + 3 ft−lb 1/2 − 13 UNC 75 + 15 ft−lb 50 + 10 ft−lb Recommended Torque** 7/16 − 20 UNF Grade 5 65 + 10 ft−lb 88 + 14 N−m 1/2 − 20 UNF Grade 5 80 + 10 ft−lb 108 + 14 N−m M12 X 1.25 Class 8.
Chapter 3 Engine Table of Contents Greensmaster Flex 1800/1820/2100/2120 Page 3 − 1 Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel Evaporative Control System . . . . . . . . . . . . . . 4 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Throttle Cable Adjustment . . . . . . . . . . . . . . . . . . . .
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Specifications Item Description Make / Designation Subaru, 4−stroke, OHC single cylinder, air−cooled, gasoline engine with gear reduction Bore x Stroke 2.28 in x 1.89 in (58 mm x 48 mm) 7.69 in3 (126 cc) Total Displacement Carburetor Float feed, fixed main jet Mechanical flyweight Low Idle Speed (no load) 1465 to 1665 RPM High Idle Speed (no load) 3190 to 3340 RPM Direction of rotation Clockwise (facing PTO shaft) Fuel Unleaded, automotive grade gasoline Fuel Tank Capacity 2.85 U.S. qt (2.
General Information This Chapter gives information about specifications, maintenance, troubleshooting, testing and repair of the Subaru gasoline engine used on the Greensmaster Flex 1800/1820/2100 and 2120 mowers. Most repairs and adjustments require tools which are commonly available in many service shops. Several special tools are described in the Subaru Service Manual. The use of some specialized test equipment is ex- plained.
Adjustments Throttle Cable Adjustment If a new throttle cable must be installed or the cable is out of adjustment, adjust the cable as follows: 3 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the spark plug. 2 2. Move throttle control on the machine handle to the FAST position. Engine 3. Loosen throttle cable screw that secures the throttle cable to the governor lever. 4.
Service and Repairs Cooling System IMPORTANT: The engine that powers the machine is air−cooled. Operating the engine with dirty or plugged cooling fins or a plugged or dirty blower housing will result in engine overheating and damage. 2 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the spark plug. IMPORTANT: Never clean engine with pressurized water. Water could enter and contaminate the fuel system. 2. Clean cooling fins on cylinder and cylinder head.
Spark Plug Use a NGK BR−6HS spark plug or equivalent. 1. Make sure engine is OFF. Carefully remove spark plug wire from the spark plug. 0.024” to 0.028“ (0.6 to 0.7 mm) 2. Clean cylinder head area around spark plug and remove plug from the cylinder head. IMPORTANT: Replace a cracked, fouled or dirty spark plug. Do not sand blast, scrape or clean spark plug electrodes because engine damage could result from grit entering cylinder. Engine 3. Inspect the spark plug. Figure 4 4.
Engine Antiseize Lubricant 1 8 65 in−lb (7.3 N−m) 11 8 2 14 4 11 15 12 8 3 7 5 7 10 9 6 FRONT 13 RIGHT Figure 5 1. 2. 3. 4. 5. Engine Square key Engine coupler Coupler sleeve Engine base 6. 7. 8. 9. 10. Hardened washer (2 used) Cap screw (4 used) Flange nut (6 used) Flange head screw Hardened washer Flat washer (4 used) Wire harness Cap screw (2 used) Set screw (2 used) Transmission assembly 3. Remove throttle cable from engine (Fig. 6): Engine Removal (Fig. 5) 1.
4. Disconnect electrical connections from engine (Fig. 7): 3 A. Unplug wire harness connector from engine armature wire. B. Disconnect wire harness ground wire from engine by removing LH rear cap screw (item 7 in Fig. 5), flat washer (item 11 in Fig. 5) and flange nut (item 8 in Fig. 5). 2 C. If machine is equipped with optional lighting kit, disconnect wire harness connectors from engine alternator wires. 5. Remove engine base assembly (with engine attached) from machine: A.
4. Install engine to engine base if it was removed: 6. Connect electrical connections to engine (Fig. 7): A. Position engine on the engine base. NOTE: When installing engine to engine base, do not install fastener in LH rear engine mounting hole. Ground wire connection is made at this location when engine base is attached to machine frame (Fig. 7). B. Install and tighten three (3) cap screws (item 7), flat washers (item 11) and flange nuts (item 8) to secure engine to engine base.
Engine Coupler Sleeve The coupler sleeve used on Greensmaster Flex machines allows a positive coupling between the engine and transmission while also providing vibration damping and quiet operation. The outer surface of the coupler sleeve includes a series of curved lines that can be used to gauge the condition of the internal coupler cogs that are used to connect the engine and transmission couplers. 65 in−lb (7.
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Chapter 4 Traction and Reel Drive System Table of Contents Greensmaster Flex 1800/1820/2100/2120 Page 4 − 1 Traction and Reel Drive System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manuals . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disengaging Drum Drive From Transmission . . . 3 Transmission Belt Tensioner . . . . . . . . . . . . . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . .
Specifications Item Description Transmission Ramp Engagement Style Friction Clutch (1800/2100) Multi- Disk Wet Clutch (1820/2120) Transmission Drive uses Multi- Ribbed Poly- V Belt Belt Tension Maintained by Spring Loaded Idler Pulley Multi- Disk Wet Clutch (1820/2120) Fluid/Capacity Mobil D/M Multi- Purpose Automatic Transmission Fluid or equivalent - 10 oz.
General Information Operator’s Manuals The Traction Unit and Cutting Unit Operator’s Manuals provide information regarding the operation, general maintenance and maintenance intervals for your Greensmaster machine. Refer to these Operator’s Manuals for additional information when servicing the machine. Disengaging Drum Drive From Transmission The traction drum is driven by a multi−ribbed belt that is tensioned with a spring loaded idler assembly.
Transmission Belt Tensioner The transmission pulleys are driven by a multi−ribbed belt that is tensioned with a spring loaded idler assembly. If the transmission belt tension needs to be engaged or disengaged, follow the following procedure: 2 3 1 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 2. Locate the transmission engage/disengage shaft next to the engine (Fig. 2).
Special Tools Modified Socket for Reel Clutch Bearing Collar The modified socket is used to remove and install the reel clutch bearing collar when servicing the transmission reel clutch shaft (Fig. 4). Refer to Transmission Reel Drive System in the Service and Repairs section of this chapter for complete information on servicing the reel clutch shaft assembly. 3 2 1 Socket Modification 1. Make sure that socket (9/16” or 15mm) to be modified fits over the reel clutch shaft bearing collar. 1.
Adjustments Cutting Unit Clip Adjustment Cutting unit clip adjustment on the Flex machines can be changed by installing the cutting unit drive pulleys to the appropriate locations on the reel drive assembly. Clip frequency pulley locations for 11 blade and 14 blade cutting units are shown in Figure 8 below. 60 to 65 in−lb (6.8 to 7.3 N−m) Antiseize Lubricant 4 To adjust clip frequency, follow the following steps: 3 1 1. Park machine on a level surface. Make sure engine is OFF.
Reel Clutch Adjustment To adjust the reel clutch, follow the following steps: 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 6 2. Remove rubber plug from front of transmission to allow viewing of reel drive clutch components (Fig. 9). 5 4 3. Release clutch cable spring tension by removing reel clutch cable from casting slot of transmission: A. Loosen upper jam nut that secures reel cable to casting slot of transmission. 4.
Transmission Clutch Adjustment (1800/2100) 1. Measure rotation angle of clutch lever (Fig. 11). If lever can be rotated more than 22o, the clutch assembly is worn beyond adjustment and clutch replacement is necessary (see Transmission Clutch System − 1800/2100 in this Chapter). ENGAGE o 10 New Clutch Assembly o 22 Worn Clutch Assembly 2. Measure clearance between thrust friction assembly and mounting plate (Fig. 12). Clearance should be from 0.025” to 0.045” (0.7 to 1.1 mm). 3.
Transmission Clutch Adjustment (1820/2120) 3 1 2 2.5” (63.5 mm) 4 2.875” to 3.000” (73 to 76 mm) 6 7 Figure 13 1. Clutch cable 2. Cable bracket 3. Clutch lever 4. Clutch lever pin 5. Extension spring 1. The traction clutch cable must be installed to clutch lever on transmission and lever assembly on handle of machine. 2. Adjust cable nuts at cable bracket on transmission to remove slack in cable without extending the extension spring (up to 0.030” (0.8 mm) slack is permissible).
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Service and Repairs Reel Drive Belt Flex machines use a positive drive belt on the left side of the machine to operate the cutting unit. Removal 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 2. Remove reel drive cover to expose reel drive belt (Fig. 14). 3. Loosen the bearing housing mounting nut (Fig. 15). 1 4. Using a 5/8” (16mm) wrench, rotate the bearing housing to release tension on reel drive belt (Fig. 15). Figure 14 5.
Reel Drive Assembly Antiseize Lubricant 20 12 22 3 Antiseize Lubricant 16 21 60 to 65 in−lb (6.8 to 7.3 N−m) 2 17 18 25 24 4 22 10 27 23 14 26 6 19 9 1 24 23 7 28 22 5 RIGHT FRONT 11 8 Antiseize Lubricant 15 13 Figure 16 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Reel drive housing O−ring Carriage screw Washer head screw Flange head screw (2 used) Hex nut (2 used) Reel drive shaft Reel pulley (22 tooth) (aluminum) O−ring Reel idler shaft 11. 12. 13. 14. 15. 16. 17. 18. 19.
1. Park mower on a level surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 2. Slide the telescoping coupler off the cutting unit hex shaft (Fig. 17). 3. Remove reel drive belt (see Reel Drive Belt Replacement in this section). 4. Loosen two (2) set screws (item 23) that secure reel pulley (item 8) to reel drive shaft (item 7). Slide pulley from drive shaft. Locate and retrieve woodruff key (item 22) from shaft. 3. Position reel drive assembly to cutting unit.
Reel Drive Bearing Housing 11 10 8 6 5 13 3 12 2 1 9 7 4 Figure 18 1. 2. 3. 4. 5. Retaining ring Reel input shaft Bearing (2 used) Bearing spacer Wave washer Traction and Reel Drive System 6. 7. 8. 9. Flocked bearing shield Wave spring Flat washer Retaining ring Page 4 − 14 10. 11. 12. 13.
Disassembly (Fig. 18) Assembly (Fig. 18) 1. Park mower on a level surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 1. If bearings were removed from reel input shaft, install new bearings onto shaft. Press first bearing fully onto shaft. Position spacer on shaft and then press second bearing onto shaft. 3. Remove retaining ring (item 1) from bearing housing. 4. Slide reel input shaft assembly from bearing housing. Remove wave washer (item 5) from bearing housing.
Drum Drive Belt 12 See text for tightening procedure 11 18 17 9 16 6 14 15 13 2 4 10 8 7 5 15 to 17 ft−lb (21 to 23 N−m) 3 1 2 Figure 19 1. 2. 3. 4. 5. 6. Drum drive cover Washer head screw (7 used) Gasket Wave washer Gear assembly Retaining ring 7. 8. 9. 10. 11. 12. Brake band Brake mount pin Extension spring Drum drive belt Brake clevis pin Drum drive housing The drum drive system on Flex machines uses a multi− ribbed poly−V drive belt on the right side of the traction drum. 13. 14. 15. 16.
6. Remove retaining ring (item 6) that secures brake band to brake clevis pin. Slide brake band from brake clevis and brake mount pins and remove band from drum drive housing. 1 7. Carefully remove one end of extension spring (item 9) from anchor point and rotate spring away from drive belt. 8. Pivot the idler pulley away from the drum drive belt to loosen belt tension (Fig. 21). 9. Remove drum drive belt from both pulleys. 2 Installation (Fig. 19) 2.
Drum Drive Idler Assembly 12 See text for tightening procedure 11 18 17 9 16 6 14 15 13 2 4 10 8 7 5 15 to 17 ft−lb (21 to 23 N−m) 3 1 2 Figure 22 1. 2. 3. 4. 5. 6. Drum drive cover Washer head screw (7 used) Gasket Wave washer Gear assembly Retaining ring 7. 8. 9. 10. 11. 12. Brake band Brake mount pin Extension spring Drum drive belt Brake clevis pin Drum drive housing Removal 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 2.
8. Disassemble idler arm assembly as needed (Fig. 23). Replace worn or damaged bearings and bushings. 2 A. Remove flange bushings from idler bracket. Discard removed bushings. 3 B. Remove retaining ring from idler bracket. Slide idler pulley from bracket shaft. Press ball bearings from idler pulley. Discard removed bearings. 5 Installation 1 1. If idler arm assembly was disassembled: A. Press new flange bushings into idler bracket. B.
Traction Drums 9 Antiseize Lubricant 7 6 29 17 5 3 6 4 3 1 18 2 28 3 22 21 20 3 8 17 27 26 22 30 14 10 19 24 23 11 12 13 140 to 160 ft−lb (190 to 216 N−m) 14 RIGHT FRONT 15 75 to 90 ft−lb (102 to 122 N−m) 16 70 to 80 ft−lb (95 to 108 N−m) 25 Figure 24 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Drum drive housing Straight bushing Flange bushing (4 used) Brake lever Traction lever Square key (2 used) Drum shaft Long spur gear Differential assembly RH traction drum 11. 12. 13. 14. 15.
5. Separate LH side plate (item 25) from machine (Fig. 25): 1 A. Remove flange nut, hardened washer and carriage screw (items 3, 4 and 6 in Fig. 25) that secure LH side plate to rear frame. 11 B. Remove three (3) flange screws and hardened washers (items 8 and 4 in Fig. 25) that secure LH side plate to frame. 10 2 C. Slide LH side plate from supporting bearing and remove from machine. 3 4 6. Insert bar stock or other suitable tool through spokes of LH traction drum to keep drum from turning. 6 8.
7. Slide lock collar (item 27) onto drum shaft. Align holes in collar and shaft and then install pin (item 28). Fit O−ring (item 30) to slot in collar. 13.Secure LH side plate (item 25) to machine (Fig. 25): 8. If grease seal (item 12) was removed from LH traction drum, install new grease seal into drum. Make sure that seal lip is orientated toward center of drum. Press seal into drum bore so that seal is recessed from 0.470” to 0.530” (12.0 to 13.4 mm) from edge of drum (Fig. 26). B.
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Differential Assembly 9 Antiseize Lubricant 7 31 6 29 17 5 6 3 4 3 1 18 2 28 3 22 21 20 3 8 17 27 30 10 19 26 22 14 24 23 11 Loctite #242 12 13 140 to 160 ft−lb (190 to 216 N−m) RIGHT FRONT 14 15 75 to 90 ft−lb (102 to 122 N−m) 16 70 to 80 ft−lb (95 to 108 N−m) 25 Figure 27 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
4. If necessary, disassemble spur gear assembly (Fig. 29). A. The hex shaft has left hand threads. The shaft also has thread locking compound on threads. B. Press ball bearing and flange bushing from spur gear as needed. IMPORTANT: As drum shaft (item 7) and differential assembly (item 9) are removed, make sure to retrieve and note location of thrust washer (item 29) for assembly purposes. 4. Place thrust washer (item 29) onto drum shaft (item 7). Insert drum shaft into differential assembly.
Differential Assembly Service 3 1 5 4 6 99 to 121 in−lb (11.2 to 13.6 N−m) 5 6 7 8 4 3 6 2 Figure 30 1. Housing 2. Cover 3. Ball bearing (2 used) 4. Gear pin (6 used) 5. Dual spur gear (6 used) 6. Spacer (9 used) Disassembly (Fig. 30) 1. Remove differential assembly from machine (see Differential Assembly in this section). 2. Remove six (6) socket head screws that secure cover to housing. Note alignment of index marks on housing and cover for assembly purposes (Fig. 31). 7.
Assembly (Fig. 30) 2 1. If ball bearing was removed from either cover or housing, press new ball bearing into bearing bore. Make sure that bearing is fully pressed to shoulder of bore. 1 2. Place cover (with bearing installed) on workbench. 3. Slide each gear pin with gears and spacers into cover. Make sure that projections on inside of cover are aligned with the pins that have one (1) gear (Fig. 32). Figure 31 1. Cover index mark 2. Housing index mark 5.
Transmission Drive Belt See text for tightening procedure 60 to 65 in−lb (6.8 to 7.3 N−m) 13 12 11 1 2 RIGHT FRONT 10 9 3 4 5 6 Antiseize Lubricant 7 8 Figure 34 1. 2. 3. 4. 5. Transmission assembly Transmission belt Gasket Wave washer Transmission cover 6. 7. 8. 9. Key Drive shaft wire Telescoping coupler Washer head screw (2 used) Transmission removal from the machine is not necessary to service the transmission drive belt.
8. Make sure that wave washer (item 4) is pressed into reel drive shaft bore of transmission cover. 9. Note transmission belt routing for assembly purposes (Fig. 35). 10.Remove transmission belt from drive and idler pulleys in transmission. 11. Check condition of all pulleys and idler components. 9. Secure coupler guard (item 10) to transmission. 10.Slide telescoping coupler onto transmission shaft so that drive shaft wire engages hex shaft on transmission.
Transmission Idler System 6 2 7 10 11 10 9 3 8 7 1 4 5 7 13 12 10 14 15 to 17 ft−lb (21 to 23 N−m) RIGHT FRONT Figure 37 1. 2. 3. 4. 5. Transmission cover Engage/disengage shaft Transmission belt Extension spring Main drive idler 6. 7. 8. 9. 10. Driven pulley (drum drive) Flange bushing (4 used) Cap screw (2 used) Idler pulley bushing (2 used) Ball bearing (6 used) 11. 12. 13. 14.
Disassembly (Fig. 37) 4 1. Park machine on a level surface. Make sure engine is OFF. 1 2. Remove transmission drive belt (see Transmission Drive Belt in this section). 3 3. Disassemble idler system as required using Figure 37 as a guide. Discard ball bearings if they are removed from idler pulleys. 4. Check bushings (items 7 and 9) for wear or damage. Replace bushings if necessary. Bushings for engage/ disengage shaft (item 2) are pressed into the transmission housing and cover. 5 4 2 Assembly (Fig.
Transmission Reel Drive System 5 1 8 Indicator Mark 11 16 9 8 10 28 6 7 RIGHT Loctite #242 15 13 14 21 9 15 17 12 18 25 19 27 Loctite #242 22 2 3 20 23 FRONT 23 to 27 ft−lb (32 to 36 N−m) 24 26 4 Figure 39 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Transmission housing Flex coupler Hex shaft Spring pin (2 used) Retaining ring Plug Retaining ring (reel clutch cable) Flange bushing (2 used) Flange bushing (2 used) Reel clutch lever 11. 12. 13. 14. 15. 16. 17. 18. 19.
6. Inspect flange bushings and reel brake ring for wear or damage (Fig. 40). Replace bushings and brake ring if necessary. 1 Reel Clutch Shaft Disassembly (Fig. 39) NOTE: The following procedure covers complete disassembly of reel clutch shaft assembly. Depending on service needs of machine, it may not be necessary to perform every step of this procedure. 3 2 IMPORTANT: When removing flex coupler (item 2) from clutch shaft, do not mar outer surface of coupler (e.g.
3. Slide reel clutch pulley assembly and reel drive hub onto clutch shaft. 4. Use modified socket (see Special Tools in this chapter) to install bearing collar assembly onto clutch shaft (Fig. 41). IMPORTANT: To prevent damage, avoid using excessive clamping pressure on the reel clutch shaft assembly. A. Use flats on reel drive hub to carefully secure reel clutch shaft assembly in a vise. Use a vise with soft jaws to prevent damage to clutch shaft assembly components. B.
Removing Seized Reel Clutch Shaft From Transmission If reel clutch shaft assembly cannot be easily removed from transmission housing due to bearing seizure, the following procedure can be followed to remove the reel clutch shaft assembly. 1 1. Make sure that transmission drive belt and reel clutch lever are removed from housing (see Transmission Drive Belt and Transmission Reel Drive System in this section). 2. Carefully drill two (2) No. 7 (0.
Transmission Clutch System (1800/2100) 2 21 15 to 17 ft−lb (21 to 23 N−m) 1 25 20 18 24 2 4 17 5 19 22 15 16 17 2 3 See text for tightening procedure 14 23 6 9 10 12 7 RIGHT 8 FRONT See text for tightening procedure 15 11 13 Figure 44 1. 2. 3. 4. 5. 6. 7. 8. 9. Clutch housing Flange head screw (5 used) Grommet Hardened washer Clutch assembly Clutch shaft Ball bearing Drive pulley Ball bearing 10. 11. 12. 13. 14. 15. 16. 17.
7. Remove three (3) flange head screws (item 2) that secure clutch housing to clutch assembly. Remove clutch housing from clutch. 5. Position clutch housing to clutch and secure with three (3) flange head screws (item 2). Make sure that grommet (item 3) is secure on housing. 8. Remove flange head screw (item 2) and washer (item 4) that secure clutch to clutch shaft. 6. Install clutch assembly into transmission housing.
Clutch Assembly Service (1800/2100) 1 18 4 16 14 13 12 11 17 15 6 7 1 5 2 1 10 9 8 6 3 4 3 Figure 47 1. 2. 3. 4. 5. 6. Retaining ring (3 used) Retaining ring Shim (6 used) Ball bearing (2 used) Mounting plate Shim (2 used) 7. 8. 9. 10. 11. 12.
Clutch Disassembly (Fig. 47) Clutch Assembly (Fig. 47) NOTE: Ball bearings (items 4 and 12) are a pressed fit on both races. A press is required to disassemble clutch. 1. Press new ball bearing into fixed housing (item 17) and secure with retaining ring. Then, press fixed housing (item 17) assembly onto hub and secure with retaining ring (item 1). 2. Press mounting plate (item 5) assembly from hub. Remove retaining ring and then remove shims (item 3) and ball bearing from mounting plate.
Transmission Clutch System (1820/2120) 15 to 17 ft−lb (21 to 23 N−m) Antiseize Lubricant (top surface of key) 7 16 24 3 4 22 4 13 19 8 12 21 6 9 6 2 20 15 14 17 5 23 10 11 1 See text for tightening procedure 18 FRONT Figure 49 1. 2. 3. 4. 5. 6. 7. 8. Clutch assembly Flange head screw (2 used) Traction cable bracket Flange bushing (2 used) Flange nut (2 used) Belleville washer (2 used) Flange nut Clutch lever 9. 10. 11. 12. 13. 14. 15. 16.
Removal (Fig. 44) Installation (Fig. 44) 1. Park machine on a level surface. Make sure engine is OFF. 1. Position clutch assembly to transmission housing and secure with four (4) washer head screws (item 18). Tighten screws as follows: 3. Remove cotter pin (item 11) and clevis pin (item 10) that secure extension spring to clutch assembly spring anchor. Separate spring from anchor. 4. Support clutch assembly to prevent it from falling. 5.
Clutch Assembly Service (1820/2120) See text for tightening procedure See text for tightening procedure 1 3 18 5 7 19 11 13 15 16 4 17 20 2 12 6 14 8 9 to 11 ft- lb (12 to 14 N- m) 10 9 9 to 11 ft- lb (12 to 14 N- m) Figure 50 1. 2. 3. 4. 5. 6. 7. Washer head screw (8 used) Clutch cover Gasket Oil seal Clutch shaft assembly Socket head screw (3 used) Locator pin 8. 9. 10. 11. 12. 13. 14.
6. Remove locator pin (item 7) from clutch housing. 7. Install new oil seal into clutch cover. Oil seal should be installed to shoulder in cover. Take care during seal installation to prevent damage to seal bore or shoulder in cover. 7. Remove three (3) socket head screws that secure clutch shaft assembly to clutch housing. 8. Place new gasket on clutch housing surface and then carefully install clutch cover. Take care during cover installation that oil seal is not damaged. 8.
Clutch Shaft Service (1820/2120) 2 4 1 6 7 9 11 13 3 14 5 17 8 12 10 15 24 26 16 18 19 20 21 22 23 28 27 25 Figure 52 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Retaining ring Flat washer Wave spring Flocked seal Ball bearing Bearing spacer Ball bearing Clutch pulley Oil seal Retaining ring 11. 12. 13. 14. 15. 16. 17. 18. 19. O−ring Ball bearing Retaining ring Bearing spacer Clutch shaft Compression spring Clutch pack Clutch disc (4 used) Clutch plate (3 used) Clutch Shaft Disassembly (Fig.
5. Carefully release and remove hand clamp from pressure plate (item 20) and clutch pulley housing (item 8) to allow compression spring to extend. 14.If necessary, remove retaining ring (item 26) and then press bearing (item 25) from clutch cam. Discard removed bearing. 6. Remove clutch actuator (item 23), clutch pack (item 17) and pressure plate (item 20) assembly from clutch shaft. 15.If necessary, remove clutch actuator (item 23) and bearing (item 21) from pressure plate (item 20): 8.
Clutch Shaft Assembly (Fig. 52) IMPORTANT: Apply a light coating of multi−purpose ATF to all O−rings and rubber portions of oil seals during assembly of clutch shaft components. 11. Slide flocked seal onto clutch shaft with flocked side orientated toward bearing location. Then, install wave spring (item 3) and flat washer (item 2) onto shaft and secure with retaining ring (item 1). 1. Make sure that all clutch shaft assembly components are cleaned before assembly. 12.
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Transmission Drum Drive System Antiseize Lubricant 4 3 See text for tightening procedure 8 7 1 3 9 10 2 6 11 5 5 RIGHT FRONT 12 12 13 Figure 55 1. 2. 3. 4. 5. Transmission housing Extension housing Ball bearing (2 used) Driven pulley (traction drum drive) Hardened washer (2 used) 6. 7. 8. 9. Driven pulley Spacer Wave washer Woodruff key Transmission removal from the machine is not necessary to service the transmission drum drive system shown in Figure 55.
7. If it is necessary to remove extension housing (item 2): 3. Slide shaft of traction drum drive driven pulley (item 4) through extension housing bearings and spacer. A. Loosen fasteners (items 12, 11 and 13) that secure transmission housing to machine frame. 4. Apply antiseize lubricant to pulley surface of drum drive driven pulley (item 4). B. Remove four (4) washer head screws that secure extension housing to transmission housing and RH drum drive housing. 5.
Transmission 12 13 11 9 10 See text for tightening procedure 7 1 8 2 3 4 FRONT 5 7 6 RIGHT Figure 57 1. 2. 3. 4. 5. Transmission assembly Flange head screw Drum drive belt Extension spring Brake band 6. 7. 8. 9. Drum drive cover Washer head screw (11 used) Retaining ring Hardened washer Transmission removal from the machine is not necessary in order to service internal transmission components.
7. Remove four (4) washer head screws (item 7) that secure extension housing (item 13) to RH drum housing. 8. Support transmission to prevent it from falling. 9. Remove fasteners that secure transmission to machine frame. A. Flange head screw (item 2) that secures front of transmission to frame. B. Cap screw (item 10), hardened washer (item 9) and flange nut (item 12) that secure rear of transmission to frame. 10.
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Chapter 5 Electrical System Table of Contents Electrical System GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 WIRING SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 4 WIRE HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 10 Starting Problems . . . . . .
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General Information Operator’s Manual Electrical System The Traction Unit Operator’s Manual provide information regarding the operation, general maintenance and maintenance intervals for your Greensmaster machine. Refer to this Operator’s Manual for additional information when servicing the machine.
Wiring Schematics HIGH TENSION LEAD INTERLOCK MODULE C D F WHITE YELLOW VIOLET VIOLET YELLOW VIOLET ENGINE MAGNETO (FLYWHEEL) E LIGHTING COIL CONNECTOR B ORANGE A BLACK VIOLET IGNITION COIL PARKING BRAKE LATCH SWITCH 2 1 3 5 4 6 ON/OFF SWITCH (IN OFF) CONNECTOR HOUR METER TRACTION SWITCH Subaru Engine (machine serial numbers below 400000000) ON\OFF SWITCH is open in the ON position TRACTION SWITCH is closed when traction lever is in neutral PARKING BRAKE LATCH SWITCH is closed whe
HIGH TENSION LEAD INTERLOCK MODULE IGNITION COIL F ORANGE E BLACK D WHITE C YELLOW B RED RED ENGINE MAGNETO (FLYWHEEL) YELLOW A LIGHTING COIL PARKING BRAKE LATCH SWITCH ON/OFF SWITCH (IN OFF) 5 4 RED 1 3 6 OPTIONAL LIGHT SWITCH 2 1 3 5 4 TRACTION SWITCH HOUR METER Electrical System BLACK BLUE BLACK RED 2 VIOLET OPTIONAL LIGHT (LH) 6 BLACK OPTIONAL LIGHT (RH) Subaru Engine (machine serial numbers above 400000000) ON\OFF SWITCH is open in the ON position TRACTION SWITCH is
Wire Harnesses Drawing No. 120- 6304 Rev C P05 ON/OFF SWITCH P06 PARKING BRAKE LATCH SWITCH J03 HOUR METER P01 INTERLOCK MODULE J02 ENGINE MAGNETO J01 ENGINE GROUND P02 TRACTION SWITCH Wire Harness Drawing (machine serial numbers below 400000000) Drawing No.
Drawing No. 122- 0965 Rev C Wire Harness Drawing (machine serial numbers above 400000000) Electrical System Drawing No.
Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The multimeter can test electrical components and circuits for current, resistance or voltage. NOTE: Toro recommends the use of a DIGITAL VoltOhm- Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter.
Spark Tester For testing electronic ignitions. Saves time because you will know if the ignition is causing the problem on a nonstarting engine. The tester determines if ignition spark is present.
Troubleshooting The interlock switches must not be by- passed, they must be connected for proper electrical troubleshooting and safety. CAUTION Remove all jewelry, especially rings and watches, before doing any electrical testing or troubleshooting. NOTE: For engine component testing information, refer to the Subaru Service Manual.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ON/OFF switch connector before doing a continuity check on switch). Individual components should be electrically isolated (e.g. disconnect all leads or remove from circuit) from the circuit when tested.
On/Off Switch The on/off switch is located on the console on the handle. This rocker switch allows the engine to be turned on and off. 1 2 Testing 1. Make sure the engine is OFF and the traction lever is in the NEUTRAL position. 3 2. Remove console cover from handle to allow access to on/off switch (Fig. 5). 3. Disconnect wire harness electrical connector from the on/off switch. 4 4.
Optional Light Switch The optional light switch is located on the console on the handle. This rocker switch allows the optional work lights to be turned on and off. 1 2 Testing 1. Make sure the engine is OFF and the traction lever is in the NEUTRAL position. 3 2. Remove console cover from handle to allow access to light switch (Fig. 7). 3. Disconnect wire harness electrical connector from the light switch. 4 4.
Parking Brake Latch Switch Switch Adjustment 1. Make sure the engine is OFF and the traction lever is in the NEUTRAL position. 2. Remove console cover from handle to allow access to parking brake latch switch (Fig. 10). 4. Adjust brake latch switch as necessary (see Switch Adjustment above). 5. Connect switch to machine wire harness. Secure console cover to handle. 1 3. Engage the parking brake lever and engage the parking brake latch. 3 4. With the parking brake latch applied, there should be from 0.
Traction Switch Switch Adjustment 1. Make sure the engine is OFF and the traction lever is in the NEUTRAL position. 2. Remove console cover from handle to allow access to traction switch (Fig. 12). 4. Adjust traction switch as necessary (see Switch Adjustment above). Make sure that switch fasteners are securely tightened after adjustment. 5. Connect switch to machine wire harness. Secure console cover to handle. 3. Move the traction lever forward to engage the traction drive. 1 4.
Interlock Module The interlock module prevents the engine from starting unless the traction lever is disengaged. Once the engine is running, the engine will continue to run with the traction lever engaged or disengaged as long as the parking brake latch is not applied. The module also allows the engine to run if the parking brake latch is applied and traction is not engaged. The interlock module controls grounding of the engine ignition system.
Chapter 6 Chassis and Controls Table of Contents Chassis and Controls SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Throttle Cable Replacement . . . . . . . . . . . . . . . . . . 6 Brake Cable Replacement . .
Specifications Item Description Transport Wheel (Optional) Tire Pressure Chassis and Controls 12 to 15 PSI (83 to 103 kPa) Page 6 − 2 Greensmaster Flex 1800/1820/2100/2120
General Information Operator’s Manual Chassis and Controls The Operator’s Manual provides information regarding the operation, adjustment procedures and general maintenance for your Greensmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Service and Repairs Handle Assembly 8 1 7 2 6 3 9 10 5 4 RIGHT FRONT Figure 1 1. 2. 3. 4. Brake lever Brake cable Throttle cable Handle 5. Traction clutch cable 6. Reel clutch cable 7. Traction and reel drive lever Handle Removal (Fig. 1) 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 2. Remove console cover from handle assembly. 3.
8. Remove handle clamps from handle assembly (Fig. 2 or 3): Flex 2100 1 A. Remove carriage screws and flange nuts that secure handle clamps to offset handle clamps. B. Remove flange nuts that secure shoulder bolts at bottom of handle clamps. 12 C. Remove inner handle clamps. Leave shoulder bolts and outer handle clamps in place on handle. 2 9 11 9. Remove the handle assembly from the machine. 3 13 8 4 6 6 10.If rubber bumpers (item 7 in Fig.
Throttle Cable Replacement Removal 1. Park machine on a level surface. Make sure the engine is OFF and the traction lever is in NEUTRAL. 2. Remove throttle cable from the engine governor linkage (Fig. 4): 4. Check throttle cable adjustment (see Throttle Cable Adjustment in the Adjustments section of Chapter 3 − Engine). 5. Install console cover to handle assembly. 3 A. Loosen screw that secures cable clamp to engine bracket. Remove cable from clamp. B.
Brake Cable Replacement Removal 1. Park machine on a level surface. Make sure the engine is OFF, the traction lever is in NEUTRAL and parking brake is released. 2. Remove brake cable from the brake lever shaft on the drum drive housing (Fig. 6): 4. Adjust cable jam nuts at brake cable bracket on handle assembly so that it requires 35 pounds (156 N) applied to the brake lever to release the parking brake latch. After final cable adjustment, make sure that brake does not drag. 5.
Traction Clutch Cable Replacement Note orientation of spring hook 3 11 8 5 4 10 6 9 2 1 RIGHT FRONT 7 Figure 8 1. 2. 3. 4. Brake cable Brake lever Lever assembly Shift mount 5. 6. 7. 8. Reel clutch cable Console cover Washer head screw (4 used) Lower handle Removal 1. Park machine on a level surface. Make sure the engine is OFF and the traction lever is in NEUTRAL. 2. Remove traction clutch cable from the transmission (Fig. 9): 3.
Installation 1 1. Secure traction clutch cable to the traction lever assembly (Fig. 10): 3 A. Install cable spring to spring anchor on lever assembly. 4 2 5 B. Slide the cable housing into the shift mount bracket slot. Make sure that a jam nut, flat washer and lock washer are on both sides of bracket. Adjust jam nuts so that equal amount of cable threads are visible above and below jam nuts. Leave jam nuts snug until final cable adjustment. 2.
Reel Clutch Cable Replacement Note orientation of spring hook 3 11 8 5 4 10 6 9 2 1 RIGHT FRONT 7 Figure 11 1. 2. 3. 4. Brake cable Brake lever Lever assembly Shift mount 5. 6. 7. 8. Reel clutch cable Console cover Washer head screw (4 used) Lower handle Removal 1. Park machine on a level surface. Make sure the engine is OFF and the traction lever is in NEUTRAL. 2. Remove reel clutch cable from transmission (Fig. 12): A.
Installation 2.780” to 2.850” (70.6 to 72.4 mm) 1. Secure reel clutch cable to traction lever assembly (Fig. 13): 2 1 A. Install cable spring to spring anchor on lever assembly. Orientate cable spring hook end toward front of machine. 5 B. Slide the cable housing into the shift mount bracket slot. Make sure that a jam nut, flat washer and lock washer are on both sides of bracket. Adjust jam nuts so that equal amount of cable threads are visible above and below jam nuts.
Traction and Reel Drive Engagement Lever Assembly Note orientation of spring hook 14 Note orientation of spring hook 18 12 14 7 14 5 11 14 5 23 28 4 15 9 25 24 21 19 16 28 13 1 14 27 29 14 8 14 17 14 10 2 3 26 22 14 7 14 20 6 28 Figure 14 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Washer head screw Detent ball Detent spring Shift arm link Shoulder screw (2 used) Shifter link Bumper (2 used) Spring collar Spacer Spring lever Chassis and Controls 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Disassembly 1. Make sure the engine is OFF and the traction lever is in the NEUTRAL position. Note orientation of spring hooks 2. Remove console cover from handle to allow access to lever assembly (Fig. 15). 2 9 4 11 4 5 3 3. Disconnect reel clutch and traction clutch cables from lever assembly (see Cable Replacement in this section). Position ends of cables away from lever assembly. 4. Disconnect wire harness connector from traction switch (Fig. 15). 10 8 5.
4. Connect spring (item 11 in Figure 15) between traction lever assembly and operator presence control. 3 5. Connect wire harness connector to traction switch (Fig. 15). 6. Connect reel clutch and traction clutch cables to lever assembly (see Cable Replacement in this section). Check cable operation and adjust as necessary. 7. Check adjustment of traction switch (see Traction Switch in the Adjustments section of Chapter 5 − Electrical System). Adjust switch if necessary. 1 2 4 5 5 8.
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Kickstand 1 Flex 2100/2120 Shown 12 2 5 3 7 8 6 RIGHT 9 10 4 11 FRONT Figure 18 1. 2. 3. 4. Kickstand Flange nut Spacer Cap screw 5. 6. 7. 8. Frame Rear frame Service position locking pin Compression spring 9. 10. 11. 12. Spacer Retaining ring LH side plate Torsion spring NOTE: The offset handle clamps on Flex 2100/2120 machines are mounted on the outside of the side plates. On Flex 1800/1820 machines, the offset handle clamps are mounted on the inside of the side plates.
Removal (Fig. 18) 1. Park machine on a level surface. Make sure the engine is OFF. 1 2. Pivot kickstand up and hold against the frame stops. CAUTION Be careful when removing or applying tension from or to the torsion spring of the kickstand. The spring is under heavy load and may cause personal injury. 4 3. Use a nutdriver or small diameter pipe over the end of the torsion spring. Push the torsion spring down and in to release spring tension (Fig. 19). Slide torsion spring from pin on rear frame. 4.
Transport Wheels (Optional) 2 1 13 9 Loctite #242 3 12 8 4 11 10 5 7 6 Figure 20 1. 2. 3. 4. 5. Cap screw (3 used) Lock washer (3 used) Shallow rim Tire Hub Chassis and Controls 6. 7. 8. 9. Wheel retaining lever Torsion spring Shoulder screw (2 used) Cap screw (4 used) Page 6 − 18 10. 11. 12. 13.
Wheel Removal (Fig. 21) 1. Park machine on a level surface. Make sure the engine is OFF. 1 2. Support the machine on the kickstand. 3. Pivot wheel retaining lever away from the center of the wheel. Slide transport wheel off the wheel hex shaft. Wheel Disassembly (Fig. 20) 1. Make sure that tire is fully deflated before disassembly of wheel. 2 2. Remove three (3) cap screws and lock washers from the shallow rim and hub. Remove hub from deep rim. 3. Inspect hub bushing (item 12).
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Chapter 7 Cutting Unit Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Supporting Cutting Unit when Servicing . . . . . . . . 3 Separating Cutting Unit from Traction Unit . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FACTORS THAT CAN AFFECT QUALITY OF CUT . . . . . . . . . . . . . . . . .
Specifications REEL CONSTRUCTION: 5−inch (12.7 cm) diameter, 11 or 14 carbon steel blades welded to 5 stamped steel spiders. High strength low alloy steel blades are thru hardened and impact resistant. FRAME CONSTRUCTION: Precision machined die cast aluminum cross member with two bolt−on die−cast aluminum side plates. HEIGHT−OF−CUT: Cutting height is adjusted on the front roller by two vertical screws and held by two lock nuts. Standard bench height of cut range is 0.062 to 0.500 inch (1.6 to 12.
General Information Operator’s Manual The Cutting Unit Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for the cutting unit on your Greensmaster machine. Additionally, if optional kits have been installed on the cutting unit (e.g. grooming reel), the installation instructions for the kit includes set− up and operation information. Refer to those publications for additional information when servicing the cutting unit.
Separating Cutting Unit from Traction Unit 1. Position mower on a flat, level work surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 1 2. Lower the kickstand and push in the locking pin to lock the kickstand in the service position (Fig. 2). Allow the kickstand and machine to rest against the locking pin. 3. Remove grass basket from cutting unit, if installed. 4. Slide the telescoping coupler off the cutting unit hex shaft (Fig. 3). 5.
Special Tools Some special tools may have been supplied with your mower or are available as TORO parts. Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Gauge Bar Assembly Toro Part Number: 13−8199 Used to verify height−of−cut. Figure 5 Backlapping Brush Assembly Toro Part Number: TOR299100 Used to apply lapping compound to cutting unit while keeping the operator’s hands at a safe distance from the rotating reel.
Roller Bearing Installation Tools Washers and spacer used to install bearings and seals into front and rear rollers (Fig. 8). Seal installation washer: 107−8133 Seal installation spacer: 107−3505 Bearing installation washer: 104−6126 As an alternative to using washers and spacers listed above, a special tool set is available that can be used for roller bearing and seal installation (Fig. 9).
Bedknife Top Angle Indicator and Mount Toro Part Numbers: 131−6828 and 131−6829 Because the top grind angle on bedknives is critical for edge retention, and therefore after− cut appearance, Toro has develop these service tools for accurately measuring the top grind angle on all bedknives. 1 2 3 Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar. 1.
Factors That Can Affect Quality of Cut There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the cutting unit. It is important to remember that the lower the height−of−cut, the more critical these factors are.
Factor Possible Problem/Correction Rear roller level. Reel and rear roller should be parallel for proper cutting performance (see Leveling Rear Roller in Adjustments section of this chapter). Roller condition. Make sure rollers rotate freely. Repair roller bearings if necessary (see Roller Service in Service and Repairs section of this chapter). Traction speed. Check maximum governed engine speed. Adjust engine to specifications if necessary (see Adjustments section in Chapter 3 − Engine).
Adjustments DANGER CAUTION Never work on the cutting unit with the engine running. Always stop the engine and remove the spark plug wire from the spark plug first. Contact with the reel, bedknife or other cutting unit parts can result in personal injury. Use heavy gloves when handling the cutting reel or bedknife. Leveling Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment (parallel).
Service and Repairs Backlapping 9. Adjust cutting unit reel to bedknife as needed. DANGER TO AVOID PERSONAL INJURY OR DEATH: Never place hands or feet in the reel area while backlapping. Stay away from the reel when backlapping. Do not attempt to restart reel by hand or foot. Do not adjust cutting reel while backlapping. 10.If cutting unit is attached to the traction unit, slide the telescoping coupler onto the cutting unit hex shaft. Attach spark plug wire to the engine spark plug.
Bedbar Assembly Flex 2100/2120 Shown 200 to 250 in−lb (23 to 28 N−m) 1 17 16 2 3 190 to 240 in−lb (22 to 27 N−m) 6 13 7 12 11 Antiseize Lubricant 4 9 8 15 RIGHT 14 FRONT 18 16 5 17 10 Figure 18 1. 2. 3. 4. 5. 6. Bedbar Bedknife Screw (13 used) Bedbar adjuster screw (2 used) Bedbar adjuster shaft (2 used) Cap screw (2 used) 7. 8. 9. 10. 11. 12. Detent (2 used) Wave washer (2 used) Retaining ring (2 used) Lock nut (2 used) Washer (2 used) Compression spring (2 used) Bedbar Removal (Fig.
6. Position one (1) metal washer (item 17) and one (1) plastic washer (item 16) between bedbar and each cutting unit side plate (Fig. 19). Contact with the reel, bedknife or other cutting unit parts can result in personal injury. Use heavy gloves when handling the bedbar. 7. Remove bedbar assembly from cutting unit. 8. Inspect nylon bushings (item 15) and rubber bushings (item 14) in side plates for wear or damage. Remove bushings and replace if necessary. Bedbar Installation (Fig. 18) 1.
Bedknife Replacement and Grinding Bedknife Removal Flex 2100/2120 Shown 1. Remove bedbar from cutting unit (see Bedbar Removal in this section). 2 NOTE: Flex 1800/1820 cutting units use 11 screws to secure bedknife to bedbar. Flex 2100/2120 cutting units use 13 screws to secure bedknife to bedbar (Fig. 20). 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special Tools in this chapter). Discard screws. Remove bedknife from the bedbar. 3.
Bedknife Grinding Bedknife Grinding Specifications (see Fig. 23) Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar. Follow the bedknife grinding specifications provided (Fig. 22). Grind only enough so the top surface of the bedknife is true (Fig. 23).
Bedbar Adjuster Service Flex 2100/2120 Shown 1 Antiseize Lubricant 2 6 3 11 7 10 9 8 5 RIGHT FRONT 5 4 Figure 25 1. 2. 3. 4. Bedbar assembly Compression spring Lock nut Bedbar adjuster shaft 5. 6. 7. 8. Flange bushing Cap screw Detent Wave washer 9. Retaining ring 10. Bedbar adjuster screw 11. Washer NOTE: The detent (item 7) used on Flex 2100/2120 is toward the center of the cutting unit as shown in Figure 25.
3. Slide bedbar adjuster shaft (item 4) into flange bushings in cutting unit side plate. Secure adjuster shaft with wave washer (item 8) and retaining ring (item 9). Flex 1800/1820 Shown NOTE: Bedbar adjuster shaft (item 4) has left−hand threads. 4. Apply antiseize lubricant to threads of bedbar adjuster screw that fit into adjuster shaft. Thread bedbar adjuster screw (item 10) into adjuster shaft. 1 5. Install bedbar (see Bedbar Installation in this section). 6.
Reel Assembly 210 to 240 in- lb (24 to 27 N- m) Flex 2100/2120 Shown 8 4 9 13 10 210 to 240 in- lb (24 to 27 N- m) 5 12 1 11 5 5 3 5 2 7 4 6 RIGHT 14 15 FRONT 3 Figure 27 1. 2. 3. 4. 5. Crossmember LH side plate Compression spring (2 used) Shoulder bolt (2 used per side plate) Flange nut (2 used per side plate) 6. 7. 8. 9. 10.
Reel Assembly Removal (Fig. 27) 2 NOTE: Removal of the cutting reel can be completed by removing the RH side plate from the cutting unit crossmember. The LH side plate (including the reel drive assembly) does not have to be removed from the crossmember when using the following procedure. 1 CAUTION 3 Contact with the reel, bedknife or other cutting unit parts can result in personal injury. Use heavy gloves when removing the cutting reel. 1. Park machine on a level surface.
D. Rest the handle of the pry bar against the front roller and loosen the bearing lock screw. IMPORTANT: Do not use 1/2” extension on end of reel drive shaft when loosening or tightening drive shaft. The 1/2” hex is intended for backlapping only. 1 90 to 110 ft- lb (122 to 149 Nm) 2 3 4 E. Position the pry bar in the same manner on the opposite end of the reel and use the appropriate wrench or socket on the 1” hex portion of the shaft to loosen the reel drive shaft. F.
IMPORTANT: To avoid grinding the reel, do not contact the cutting edge of any blade with the pry bar as this may damage the cutting edge and/or cause a high blade. B. Move the pry bar against the weld side of the reel support plate closest to the bearing lock screw. IMPORTANT: The reel drive shaft on the left end of the cutting reel has left- hand threads. The bearing lock screw on the right end of the cutting reel has right- hand threads. C.
Reel Assembly Service 5 3 2 90 to 110 ft−lb (123 to 149 N−m) (Right Hand Threads) 2 3 1 RIGHT 90 to 110 ft−lb (123 to 149 N−m) (Left Hand Threads) FRONT 4 Figure 30 1. Cutting reel 2. Flocked seal (2 used) Cutting Unit 3. Bearing (2 used) 4. Reel drive shaft (LH threads) Page 7 − 22 5.
Disassembly of Cutting Reel (Fig. 30) IMPORTANT: When removing reel drive shaft (item 4), use appropriate wrench or socket on 1” hex surface of shaft. Do not use 1/2” extension on end of reel drive shaft when loosening or tightening drive shaft. The 1/2” hex is intended for backlapping only. 1. Remove bearing lock screw (item 5) and reel drive shaft (item 4) from cutting reel. Reel drive shaft has LH threads and is in end of reel shaft identified with a groove that is just inside of reel spider (Fig. 31).
Preparing Reel for Grinding NOTE: Before grinding a cutting reel, make sure that all cutting unit components are in good condition. Depending on type of grinder used, faulty cutting unit components can affect grinding results. Reel Grinding Specifications NOTE: When grinding, be careful to not overheat the cutting reel blades. Remove small amounts of material with each pass of the grinder. 1.
Front Roller Removal (Fig. 33) 1. Park machine on a level surface. Make sure the engine is OFF and the traction lever is in NEUTRAL. 2. Remove the cutting unit from the machine and place on a level working surface. Use appropriate support to raise front roller from work surface. Antiseize Lubricant 3. Loosen cap screw (item 1) that secures the front roller shaft to each front height−of−cut arm. 4 4.
Rear Roller Removal (Fig. 35) 1. Park machine on a level surface. Make sure the engine is OFF and the traction lever is in NEUTRAL. 4 2. Remove the cutting unit from the machine and place on a level working surface. Place support blocks under bedbar to raise rear roller from work surface. 5 3. Loosen two (2) flange nuts that secure the rear roller shaft to each rear roller bracket. 2 4.
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Roller Service 1 6 5 4 25 to 30 ft−lb (34 to 41 N−m) 2 5 7 4 6 7 25 to 30 ft−lb (34 to 41 N−m) 3 Figure 36 1. Weihle roller 2. Smooth roller 3. Roller shaft 4. Ball bearing 5. Seal 6. V−ring 7. Bearing lock nut Disassembly 1 2 1. To hold roller shaft for bearing lock nut removal, install a 3/8−24 UNF 2B screw into threaded end of roller shaft and secure screw in place with jam nut. While retaining shaft, remove bearing lock nut from each end of roller shaft. 3 4 5 6 2.
NOTE: Special tool TOR4105 (see Special Tools) can be used instead of washers and spacer when installing bearings and seals in roller. 2 3 1 4 2. Position a new bearing, black assembly washer (see Special Tools) and original lock nut onto each end of the roller shaft (Fig. 38). 3. Tighten nuts until the bearings are seated into each end of the roller. 4. Remove nut and black assembly washer from each end of the roller.
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Chapter 8 Belt Driven Groomer (Optional) Table of Contents Groomer SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4 Factors Affecting Grooming . . . . . . . . . . . . . . . . . . . 4 Grooming Reel Mechanical Problems . . . . . . . . . . 5 ADJUSTMENTS . . . . . . . . . . . . . . .
Specifications MOUNTING: The groomer is mounted to the cutting unit side plates. GROOMING REEL CONSTRUCTION: 2.375 inch (6 cm) diameter, 41 steel blades with 1/2 inch blade spacing. Blade spacing can be adjusted to 1/4 inch or 3/4 inch by altering the number and position of blade spacers on the groomer. Grooming reel is available with either steel or carbide tipped blades. The groomer brush can be installed in place of grooming reel. GROOMER HEIGHT SETTING: From 0.030 to 0.620 inch (0.8 to 15.
General Information Installation Instructions Groomer The Installation Instructions for the groomer provide information regarding the operation, general maintenance procedures and maintenance intervals for the groomer assembly on your Greensmaster Flex machine. Refer to this publication for additional information when servicing the groomer assembly.
Troubleshooting Factors Affecting Grooming There are a number of factors that can affect the performance of grooming. These factors vary for different golf courses and from green to green. It is important to inspect the turf frequently and vary the grooming practice with turf needs. It is important to remember that factors affecting quality of cut also affect grooming performance.
Grooming Reel Mechanical Problems Problem Possible Causes Correction The grooming reel rotates when it is The grooming reel should rotate in the raised, transport position (for- whenever the cutting reel is enward rotating groomer drive). gaged. Normal operation. No rotation of the grooming reel (forward rotating groomer drive). Seized grooming reel or idler bearing(s) in groomer side plate(s). Identify and replace faulty bearing(s). Broken or damaged drive belt idler spring. Replace idler spring.
Adjustments CAUTION Never work on the cutting unit with the engine running. Always stop the engine and remove spark plug wire from the engine spark plug. before working on the cutting unit. NOTE: See the Groomer Installation Instructions for adjustment procedures for the groomer on your Greensmaster. Height/Depth of Groomer Adjustment NOTE: Grooming is performed above the soil level. When adjusting groomer height/depth, groomer blades should never penetrate the soil. FORWARD ROTATING GROOMER SHOWN 1.
Service and Repairs Groomer Belt Replacement (Forward Rotating Groomer Drive) 1. Position machine on a clean and level surface with engine stopped. Engage parking brake. 2. Remove three (3) lock nuts that secure groomer drive cover, then remove cover (Fig. 2). 1 3. Pivot idler pulley by placing a 12mm wrench on pulley nut and rotating idler bracket to relax belt tension. Slip groomer drive belt off pulleys (Fig. 3). Carefully release idler bracket.
Groomer Cover (Counter Rotating Groomer Drive) On Flex machines with the counter rotating groomer, the groomer cover includes a handle which engages and disengages the groomer drive. When the handle is rotated toward the front of the machine, the groomer is engaged. 4 2 Removal 1. Position machine on a clean and level surface with engine stopped. Engage parking brake. 2. Make sure that handle on groomer cover is rotated toward front of machine so that groomer drive is engaged. 1 3 3.
Installation Flush to 0.020” (Flush to 0.5 mm) 1. If removed, install shaft into groomer cover (Fig. 5): A. Install new O−ring into groove of shaft. 1 B. Apply antiseize lubricant to shaft surface that is below the retaining ring groove. 3 C. Slide shaft up through bore of cover and secure with thrust washer and retaining ring. D. Position shaft in cover so that cam point of shaft is located away from the gasket surface (Fig. 6). E.
Grooming Reel (Forward Rotating Groomer Drive) 100 ft−lb (135 N−m) 26 25 8 6 17 14 15 22 18 23 4 1 19 7 11 12 27 13 5 1 2 13 3 12 11 Antiseize Lubricant 20 16 21 24 9 RIGHT 17 to 21 ft−lb (24 to 28 N−m) 10 FRONT Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. Lock nut (4 used) Drive cover Groomer drive belt Drive pulley Shoulder bolt (2 used) Spring RH drive plate assembly Groomer shim RH groomer arm assembly 10. 11. 12. 13. 14. 15. 16. 17. 18.
6. Remove HOC nut (item 21), HOC washer (item 16) and plow bolt (item 22) that secure RH groomer arm assembly to RH support plate assembly. Do not change height−of−cut screw adjustment. Remove RH groomer arm assembly from cutting unit. 5 2 7. Remove front roller assembly from cutting unit. NOTE: To prevent grooming reel shaft from turning when removing driven pulley (item 19), use wrench on shaft flats to hold shaft. 8.
NOTE: To prevent cutting reel from turning when installing drive pulley, use a 1/2” socket on hex of reel drive shaft that is used for backlapping the cutting reel. 9. Secure drive pulley (item 4) to cutting reel shaft. Torque pulley to 100 ft−lb (135 N−m). 10.Insert front roller into LH groomer arm assembly. 11. Make sure that bushing (item 11) is installed in RH drive plate assembly. 15.Center front roller to cutting unit and tighten cap screws (item 10) to secure roller. 16.
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Grooming Reel (Counter Rotating Groomer Drive) 10 120 in−lb (13.5 N−m) 125 ft−lb (170 N−m) 31 18 33 24 17 10 21 22 30 27 6 12 7 13 34 11 35 35 20 8 Antiseize Lubricant 19 32 9 18 14 24 1 7 13 4 5 23 15 16 3 2 26 29 25 2 9 28 17 to 21 ft−lb (24 to 28 N−m) 120 in−lb (13.5 N−m) Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
8. Remove lock nut and spring washer that secure RH groomer arm lift rod to RH drive plate assembly (Fig. 13). 2 9. Remove HOC nut (item 2), HOC washer (item 9) and plow bolt (item 35) that secure RH groomer arm assembly to RH drive plate assembly. Do not change height− of−cut screw adjustment. Remove RH groomer arm assembly from cutting unit. 1 3 10.Remove front roller from cutting unit.
5. Carefully slide RH drive plate onto grooming reel shaft taking care to not damage seals in drive plate. Position drive plate to the support plate on the cutting unit frame and secure with four (4) button head screws (item 30). Make sure that drive plate rotates freely after installation. 6. Install driven gear (item 14) onto grooming reel shaft: A. Apply light coating of grease to hub on driven gear (item 14). B.
Grooming Reel Service Inspect grooming reel blades frequently for damage and wear. Straighten bent blades with a pliers. Replace blades that are worn or damaged. 200 to 250 in−lb (23 to 28 N−m) 6 Carbide tipped grooming blades (Fig. 15) should be replaced if the carbide tip is worn, loose or missing. Also, if the blade is eroded around the carbide insert, the blade should be replaced. Grooming blades without a carbide tip (Fig. 16) should be replaced if worn or damaged.
Grooming Reel Bearing Replacement Bearing Removal 1 1. Position machine on a clean and level surface with engine stopped. Engage parking brake. 2 2. Remove the cutting unit from the machine and place cutting unit on a flat work area. 3. To remove groomer RH drive plate assembly from right side of cutting unit, remove front roller, grooming reel and then drive plate assembly (see Grooming Reel (Forward Rotating or Counter Rotating) in this section). 3 4.
2. Install LH support plate to left side of cutting unit: COUNTER ROTATING GROOMER A. Apply antiseize lubricant to threads of LH groomer arm lift rod. 1 3 B. Position LH support plate to cutting unit making sure that LH groomer arm lift rod is positioned through bushing in support plate. 2 C. Place spring washer and lock nut on lift rod threads (Fig. 19). Tighten lock nut. 2 3 D.
Idler Assembly (Forward Rotating Groomer Drive) 7 5 6 4 3 2 1 8 11 9 10 12 Figure 24 1. 2. 3. 4. Pivot hub Spacer Idler bracket Spacer Belt Driven Groomer (Optional) 5. 6. 7. 8. RH drive plate O−ring Retaining ring Grease fitting Page 8 − 20 9. 10. 11. 12.
The groomer RH drive plate assembly incorporates the idler system for tensioning the groomer drive belt. The idler system uses a spring to maintain proper belt tension. 1 5 2 4 Removal 1. Position machine on a clean and level surface with engine stopped. Engage parking brake. 2. Remove groomer belt cover, drive belt and drive pulley from groomer drive side of mower (see Grooming Reel Removal in this section). 3.
Idler Assembly (Counter Rotating Groomer Drive) 9 1 8 12 7 2 10 11 6 3 4 5 Figure 26 1. 2. 3. 4. RH drive plate Adjustment cam Spacer Idler bracket 5. 6. 7. 8. Spacer Reel hub Retaining ring O−ring 9. 10. 11. 12. Flange nut Extension spring Grease fitting Grease seal The groomer RH drive plate assembly incorporates the idler system for engaging the groomer gear drive. 5. Using Figure 26 as a guide, remove idler components from RH drive plate as needed. Disassembly (Fig. 26) Assembly (Fig.
3. Check adjustment of adjustment cam (Fig. 28): 4 A. Rotate idler bracket so the bracket stop is against the adjustment cam. 2 B. While holding bracket stop against the cam, measure the distance between the idler gear bearing surfaces on the idler bracket and the drive plate. This distance should be 1.484” (37.7 mm). C. If distance is incorrect, loosen flange nut that secures adjustment cam to drive plate. Rotate the adjustment cam until distance is correct.
Lift Arm Assembly 1 14 2 13 15 11 7 12 16 10 8 Antiseize Lubricant 9 7 6 3 4 17 Antiseize Lubricant 18 5 Antiseize Lubricant Figure 30 1. 2. 3. 4. 5. 6. HOC groomer arm (LH shown) Flange nut Grooved pin E−ring Groomer lift rod Lock screw Belt Driven Groomer (Optional) 7. 8. 9. 10. 11. 12. Bushing Lift arm assembly (LH shown) Detent spring Spring washer Cap screw Bushing Page 8 − 24 13. 14. 15. 16. 17. 18.
Disassembly (Fig. 30) Assembly (Fig. 30) 1. Position machine on a clean and level surface with engine stopped. Engage parking brake. 1. Assemble lift arm using Figure 30 as a guide. 2. Remove flange nut (item 2) that secures lift arm to HOC groomer arm. Remove lock nut (item 16) and spring washer (item 17) that secure lift arm to groomer plate. Loosen lock screw (item 6) completely. 3. Remove lift arm from cutting unit. 4. Disassemble lift arm using Figure 30 as a guide.
Groomer Brush 3 1 2 5 20 to 25 in−lb (2.3 to 2.8 N−m) 3 20 to 25 in−lb (2.3 to 2.8 N−m) 4 2 Figure 31 1. Groomer brush shaft 2. Lock nut 3. J−bolt 4. Groomer brush 5. O−ring The groomer brush attaches to the groomer drive in place of the grooming reel. Removal and installation of the groomer brush uses the same procedure as removal and installation of the grooming reel (see Grooming Reel (Forward Rotating or Counter Rotating) in this section).
Chapter 9 Universal Groomer (Optional) Table of Contents Specifications ....................................................................................................................................... 9–2 Universal Groomer............................................................................................................................. 9–2 General Information ..............................................................................................................................
Specifications Universal Groomer Item Description Grooming reel diameter 6 cm (2.375 inches) Spring Steel: 40 steel blades with 1/2 inch blade spacing. Carbide: 40 steel blades with 1/2 inch blade spacing. Groomer blade type Thin blade: 81 steel blades with 1/4 inch blade spacing. The groomer brush can be installed in place of grooming reel. Groomer mounting The groomer is mounted to the cutting unit side plates. Groomer height setting Mowing: 0.8 to 15.7 mm (0.030 to 0.620 inch). HOC range: 1.
General Information Installation Instructions The installation instructions for the groomer provide information regarding the operation, general maintenance procedures, and maintenance intervals for the groomer assembly on your Greensmaster eFlex machine. Refer to this publication for additional information when servicing the groomer assembly.
Troubleshooting Factors Affecting Grooming There are a number of factors that can affect the performance of grooming. These factors vary for different golf courses and from green to green. It is important to inspect the turf frequently and vary the grooming practice with turf needs. IMPORTANT Improper or overaggressive use of the groomer (e.g., too deep or too frequent grooming) may cause unnecessary stress on the turf leading to severe turf damage. Use the groomer carefully.
Groomer Reel Mechanical Problems Problem The groomer reel does not rotate. The turf is damaged or has uneven grooming. Greensmaster Flex 1800/1820/2100/2120 12188SL Rev D Possible Causes Correction The groomer drive is in neutral. Engage the groomer drive to forward or reverse. The groomer drive gears are damaged or seized. Repair the groomer drive. The groomer is set too aggressively. Refer to the groomer Installation Instructions for groomer set-up information.
Special Tools Special tools for servicing Toro Commercial Products are available from your Toro Distributor. Some of these tools may have been supplied with your machine, are available as Toro parts, or may also be available from a local tool supplier. Reel Thread Repair Taps 15/16–16 Right-Hand Thread – Toro Part No. 137–0926 15/16–16 Left-Hand Thread – Toro Part No. 137–0927 Use to clean or repair the internal threads of cutting unit reels. Drive Shaft Removal Tool Toro Part No.
Syringe – 50cc (2 ounce) Toro Part No. 137-0872 Aids in accurately filling the optional Universal Groomer gear box with oil.
Service and Repairs g324622 Figure 1 1. Gear box assembly 3. Height adjuster assembly (2 each) 2. Idler assembly 4. Groomer reel CAUTION Do not work on the groomer with the engine running. Always shut off the engine, remove the key from the key switch and wait for all machine movement to stop before working on the groomer. Note: The Groomer Operator’s Manual provides information regarding the installation, set-up, operation, and maintenance of the universal groomer on your machine.
The Gear Box Assembly g323289 Figure 2 1. Gear box assembly 4. Clevis pin 2. Drive shield 5. Input shaft 3. Cotter pin The groomer gear box assembly is located on the right side of the cutting unit. Removing the Gear Box Assembly Refer to Figure 2 for this procedure. 1. Remove the cutting unit from the machine and place it on a level work surface. 2. Remove the groomer reel assembly; refer to Removing the Groomer Reel (page 9–19). 3. Remove the drive shield. 4.
Removing the Gear Box Assembly (continued) g323373 Figure 3 1. 5/16–18 X 5/8 inch square head set screw 4. Reel shaft 2. Input shaft assembly 5. Weld side of reel support plate 3. Groomer gear box assembly 6. Pry bar 7. Insert a long-handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bottom of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move.
Removing the Gear Box Assembly (continued) 9. Rest the handle of the pry bar against the front roller and turn the drive shaft counterclockwise to loosen it from the reel. Continue to unscrew the drive shaft and remove the gear box from the cutting unit. 10. If the hex head on the end of the drive shaft is damaged during removal: A. Remove the drain/fill plug and drain the oil from the gear box. g285845 Figure 4 1. Socket head screw (4 each) 8. Sun gear 2. Gear box cover assembly 9.
Removing the Gear Box Assembly (continued) g323372 Figure 5 1. Damaged input shaft assembly 4. Weld side of reel support plate 2. Drive shaft removal tool 5. Pry bar 3. Reel shaft H. Insert a long-handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bottom of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move.
Servicing the Gear Box g251182 Figure 6 1. Drive adapter – silver 21. Detent ball 2. Input shaft 22. Detent spring 3. O-ring (3 each) 23. Oil seal 4. V-ring 24. Socket-head screw (4 each) 5. 6. Oil seal Groomer housing 25. 26. Groomer cover Cover gasket 7. Ball bearing (2 each) 27. Thrust washer 8. Retaining ring 28. Ball bearing 9. Driven gear 29. Ring gear 10. Actuator shaft 30. Flange bushing 11. Pin 31. Sun gear 12. O-ring 32. Bearing 13. Knob 33.
Servicing the Gear Box (continued) 1. Remove the drain/fill plug and drain the oil from the gear box. 2. Remove the 4 socket-head screws and separate the gear box cover and housing. Remove and discard the cover gasket. 3. Slide the sun gear, ring gear, and planet gears from the pins on the gear box housing. 4. Continue to disassemble the gear box as necessary. 5.
Installing the Gear Box Assembly Refer to Figure 2 for this procedure. 1. Apply medium strength thread locking compound (Loctite 243 or equivalent) to the threads in the reel and allow the thread locking compound to cure for 15 minutes before continuing this procedure. 2. Insert a long-handled pry bar through the front of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move. g323290 Figure 7 1.
Installing the Gear Box Assembly (continued) 8. Apply a retaining compound (Loctite 609 or equivalent) to the lip of the drive housing and install the drive shield. 9. Install the groomer reel assembly; refer to Installing the Groomer Reel (page 9–19). Idler Assembly g251084 Figure 8 1. Flocked bearing shield (2 each) 5. Collar 2. Flange nut 6. Idler arm 3. Clevis pin 7. Stub shaft 4. Cotter pin 8.
Removing the Idler Assembly (continued) 5. Inspect the shields, bearing, and bushing in the idler assembly. Remove and discard the components that are worn or damaged. Installing the Idler Assembly 1. If the shields, bearing, or bushing was removed from the idler arm, install new components as follows: A. Press the bushing into a groomer plate until the bushing is centered in the idler arm bore. B.
Groomer Reel g324623 Figure 9 1. Shaft clamp (4 each) 3. Bolt (4 each) 2. Jam nut (4 each) 4. Groomer reel Remove the groomer reel to replace individual groomer blades or replace the shaft. The groomer reel can be reversed to provide additional blade life. Removing the Groomer Reel 1. Park the machine on a clean and level surface, lower the cutting units completely to the ground, set the parking brake, and remove the key from the key switch.
Installing the Groomer Reel (continued) 3. Secure the groomer reel to the cutting unit with the 4 jam nuts, 4 bolts, and 4 shaft clamps; torque the bolts to 5 to 7 N∙m (45 to 60 in-lb). 4. Check the groomer reel height and mower height-of-cut settings. Adjust as necessary.
Servicing the Groomer Reel g202019 Figure 10 1. Groomer blade 3. Midpoint 2. Sharp edge 4. Dull (rounded) edge Inspect the groomer reel blades frequently for any damage and wear. Straighten the bent blades. Either replace the worn blades or reverse the individual blades to put the sharpest blade edge forward (Figure 10). The blades that are rounded to the midpoint of the blade tip must be reversed or replaced for best groomer performance. Disassembling the Groomer Reel 1.
Disassembling the Groomer Reel (continued) 4. Remove the spacers and blades from the groomer shaft. If necessary, remove second locknut from the shaft. 5. Inspect and replace the components that are worn or damaged. Assembling the Groomer Reel Note: New locknuts have an adhesive patch to prevent the locknut from loosening. If a used locknut is being installed, apply a medium strength threadlocker (Loctite #242 or equivalent) to the threads of the locknut. 1.
Height Adjuster Assembly g324624 Figure 12 1. Height adjuster knob 8. Flange nut 2. Carriage bolt 9. Height adjustment rod 3. Height-of-cut bracket 10. Groomer pin 4. Flange nut 11. Quick up lever 5. Groomer hose 12. Quick up cover 6. Washer (2 each) 13. Detent spring 7. Compression spring 14. Button-head screw Note: Early universal groomers used 2 compression springs on non-adjustable height adjustment rods.
Assembling the Height Adjuster Assembly 1. Apply anti-seize lubricant to the upper threads of the adjustment rod and lower threads of the height adjusters. Assemble the height adjuster assembly (Figure 12). 2. If both the height adjusters are removed, fit 1 height adjuster assembly to the cutting unit side plate and secure it with the carriage bolt and flange nut. Do not tighten the flange nut at this time.
Servicing the Grooming Brush (Optional) g229842 Figure 14 1. Brush element 3. Brush shaft 5. Locknut (2 each) 2. Roll pin (2 each) 4. J-bolt (2 each) 6. Spiral brush The optional grooming brush attaches to the groomer in place of the groomer reel. The grooming brush is removed and installed from the groomer in the same manner as the groomer reel; refer to Groomer Reel (page 9–18). The grooming brush element or shaft can be serviced separately (Figure 14).
