Installation Instructions

ManualsBrandsToro ManualsWalk-Behind MowersClutch Reel Kit, Greensmaster Flex/eFlex 1800 or 2100 Series Traction Unit

FormNo.3432-681RevB

ClutchReelKit

Greensmaster

Flex

™

/eFlex

1800or2100SeriesTractionUnit

ModelNo.139-5626

InstallationInstructions

Installation

PreparingtheMachine

NoPartsRequired

Procedure

1.Parkthemachineonalevelsurface.

2.Engagetheparkingbrake.

3.Shutoffthemachineandremovethekey(if

equipped).

4.Disconnectthebatterypack(ifequipped).

5.Formachinesequippedwithanengine:

Removethespark-plugwirefromthesparkplug.

RemovingtheEngine(If

Equipped)

NoPartsRequired

RemovingtheThrottleCable

1.Loosenthescrewthatsecuresthecableclamp

totheenginebracket.Removethecablefrom

theclamp.

2.Loosenthescrewthatsecuresthethrottlecable

tothegovernorlever.Slidethecablefromthe

governorlever.

3.Positionthethrottlecableawayfromtheengine.

DisconnectingtheElectrical

Connections

1.Unplugthewireharnessconnectorfromthe

enginearmaturewire.

2.Disconnectthewireharnessgroundwirefrom

enginebyremovingtheleftrearcapscrew,at

washer,andangenut.

3.Ifthemachineisequippedwiththeoptional

lightingkit,disconnectthewireharness

connectorsfromtheenginealternatorwires.

RemovingtheEngineBase

Assembly

1.Removethe2capscrews,hardenedwashers,

andangenutsthatsecuretherearofengine

basetotherearframe.

2.Supportthefrontoftheenginebasetopreventit

frommoving.

3.Removetheangeheadscrewandhardened

washerthatsecuretheenginebasetotheframe.

4.Carefullymovetheengineassemblyawayfrom

transmission,removetheenginecouplerfrom

thesleeve,andremovetheengineassembly.

8111LyndaleAvenueSouth

Bloomington,MN55420

Registeratwww.Toro.com.

OriginalInstructions(EN)

PrintedintheUSA

AllRightsReserved

*3432-681*B

Summary of content (12 pages)

PAGE 1
Form No. 3432-681 Rev B Clutch Reel Kit Greensmaster® Flex™/eFlex® 1800 or 2100 Series Traction Unit Model No. 139-5626 Installation Instructions 2 Installation 1 Preparing the Machine Removing the Engine (If Equipped) No Parts Required No Parts Required Removing the Throttle Cable Procedure 1. Park the machine on a level surface. 2. Engage the parking brake. 3. Shut off the machine and remove the key (if equipped). 4. Disconnect the battery pack (if equipped). 5.
PAGE 2
4. 3 Loosen the 2 flange-head bolts that secure cutting unit pitch arms to the traction unit roll frame. Note: It is not necessary to completely remove Removing the Cutting Unit from the Traction Unit the bolts. No Parts Required Procedure 1. Lower the kickstand and push in the locking pin to lock the kickstand in the service position. Allow the kickstand and machine to rest against the locking pin. g207107 Figure 3 1. Cutting unit pitch arm 3. Traction unit frame 2.
PAGE 3
the cable spring hook on the lever assembly for assembly purposes. 4 4. Removing the Reel Clutch Cable 5 Disengaging the Transmission Belt Tensioner No Parts Required Removing the Reel Clutch Cable from the Transmission 1. Remove the reel clutch cable from the machine. Loosen the front cable jam nut and lift the cable free from the casting slot of the transmission.
PAGE 4
6 Removing the Transmission Belt No Parts Required Procedure 1. Support the flex coupler to prevent it from being damaged during the spring pin removal. Note: Do not damage the outer surface of the coupler (e.g. grasping with pliers or mounting in vise) as the coupler may become damaged and fail prematurely. 2. Push the spring pin from the flex coupler and bearing collar (Figure 6). 3. Slide the coupler with hex shaft from the collar. Discard the removed spring pin. g294284 Figure 6 1. Coupler 4.
PAGE 5
Note: Check the condition of all pulleys and idler components. Clean the inside of the transmission before installing the belt. g294626 Figure 7 1. Transmission assembly 5. Flex-coupler assembly 2. Wave washer 3. Washer-head screw 4. Transmission cover 6. Gasket 7.
PAGE 6
7 Removing the Reel-Clutch-Lever Assembly No Parts Required Procedure 1. Remove the retaining rings that secure the reel clutch lever in the transmission housing (Figure 8). g293391 Figure 9 2. Slide the reel clutch lever from the housing. Note the missing tooth in the spline area of the lever which is used for alignment with the reel clutch fork. 3. Pull the reel clutch shaft assembly from the transmission housing. Note: Inspect the flange bushings and reel brake ring for wear or damage.
PAGE 7
2. Install the new reel clutch fork on the shaft assembly with the existing pivot pins. Note: Ensure that the fork has the set screw hole pointing toward the shaft. g293386 Figure 11 1. Pivot pin 2. Clutch-shaft assembly g293384 Figure 13 5. Remove the reel clutch fork from the shaft assembly. g293389 Figure 12 g293386 Figure 14 6. Inspect and replace any damaged parts on the reel-clutch shaft assembly. 1.
PAGE 8
g294296 Figure 15 g203642 5. Figure 16 Slide reel clutch shaft assembly into transmission housing. 6. Align the missing tooth in the spline area of the reel clutch lever with the reel clutch fork (item 16). Insert the lever through the housing and fork. 7. Install the set screw into the clutch fork, securing it to the shaft. 8. Install the small v-ring seal onto the reel clutch lever shaft with the lip seal facing the transmission housing. Secure the v-ring with the washer and flange bolt. 1. 2.
PAGE 9
10 Installing the Transmission Drive Belt and the Transmission Cover Parts needed for this procedure: 1 Spring pin 1 Gasket g203643 Figure 17 1. Reel clutch lever 2. Reel clutch pulley Procedure 3. Reel clutch hub 4. Reel drive hub Important: Ensure that the transmission cover is installed with the fasteners properly torqued before applying tension to the transmission belt. 1. Install the transmission belt onto the pulleys in the transmission.
PAGE 10
2. Ensure that the 2 dowel pins are pressed into the bores in the transmission housing. 3. Position the new gasket to the transmission assembly. Align the gasket to 2 dowel pins in the transmission housing. 4. Install the transmission cover. If necessary, use a rubber mallet at the dowel locations to seat the cover to the transmission. 12. Install the new spring pin into the coupler to secure the coupler to the collar.
PAGE 11
4. While holding the bottom jam nut in place, tighten the top cable jam nut. 5. Install the console cover to the handle assembly. 12 Installing the Engine No Parts Required Installing the Engine Base Assembly 1. Ensure that the coupler sleeve is placed on the transmission input shaft coupler. 2. Position the engine base assembly to the machine. 3. Carefully slide the engine base assembly toward the transmission allowing the engine coupler to be inserted into the coupler sleeve on the transmission.
PAGE 12
Connecting the Throttle Cable 13 1. Slide the throttle cable end into the governor lever. 2. Place the throttle cable under the cable clamp and secure with the screw. Installing the Cutting Unit 3. Adjust the throttle cable. Ensure that all fasteners are tightened after the cable adjustment. No Parts Required 4. Check and adjust the engine oil level as needed. Procedure 5. Attach the spark plug wire to the spark plug. Open the fuel shut-off valve on the fuel tank.