Toro 04861 Service Manual Download Page 1

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Form No. 20248SL Rev C

Greensmaster

eFlex 1021

(Model 04861)

Summary of Contents for 04861

Page 1: ...Form No 20248SL Rev C Greensmaster eFlex 1021 Model 04861...

Page 2: ...021 Initial issue B 01 2022 Cutting unit drive spline information C 07 2022 Updated the reel drive handle bedknife groomer drive gearbox idler plate groomer reel height adjuster chapters Revision Hist...

Page 3: ...Revision History continued Revision Date Description Greensmaster eFlex 1021 Page 3 Revision History 20248SL Rev C...

Page 4: ...y we encourage user feedback Please comment on the completeness accuracy organization usability and readability of this manual by an e mail to servicemanuals toro com or Mail to Technical Publication...

Page 5: ...NOTES Greensmaster eFlex 1021 Page 5 NOTES 20248SL Rev C...

Page 6: ...NOTES Page 6 Greensmaster eFlex 1021 20248SL Rev C...

Page 7: ...cation without notice DANGER This safety symbol means danger When you see this symbol carefully read the instructions that follow Failure to obey the instructions could kill or cause serious permanent...

Page 8: ...g340146 Figure 1 Preface Page 8 Greensmaster eFlex 1021 20248SL Rev C...

Page 9: ...uence component orientation that may not be obvious Critical Torque This icon is used to highlight an assembly torque requirement that is different than what is recommended in the Standard Torque Tabl...

Page 10: ...3 Chapter 4 Traction and Reel Drive Systems 4 1 General Information 4 2 Adjustments 4 3 Service and Repairs 4 5 Chapter 5 Electrical System 5 1 General Information 5 2 Electrical System Operation 5 4...

Page 11: ...Chapter 1 Safety Table of Contents Safety Instructions 1 2 Safety and Instructional Decals 1 5 Greensmaster eFlex 1021 Page 1 1 Safety 20248SL Rev C...

Page 12: ...e the unit is running or shortly after it has been running Allow the engine muffler and other components to cool before working near them Avoid fires and explosions Use extreme care in handling fuel F...

Page 13: ...y approved procedure Avoid unsafe machine operation Always test the safety interlock system after adjusting or repairing the machine Refer to the Chapter 5 Electrical System page 5 1 in this manual fo...

Page 14: ...fire extinguishers are for ordinary combustible materials such as paper wood cardboard and most plastics The numerical rating on these types of extinguishers indicates the amount of water it holds an...

Page 15: ...it and cutting units of your Groundsmaster If any decal becomes illegible or damaged install a new decal Decal part numbers are listed in your Parts Catalog Order replacement decals from Authorized To...

Page 16: ...Safety Safety and Instructional Decals Page 1 6 Greensmaster eFlex 1021 20248SL Rev C...

Page 17: ...cations 2 5 Calculating the Torque Values When Using a Drive Adapter Wrench 2 6 Identifying the Fastener 2 7 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 2 8 Standard Torque for...

Page 18: ...Specifications Overall Dimensions g340580 Figure 2 Specifications and Maintenance Specifications Page 2 2 Greensmaster eFlex 1021 20248SL Rev C...

Page 19: ...m 0 062 to 0 500 inch depending on type of bedknife installed Effective HOC may vary depending on turf conditions type of bedknife rollers attachments installed and rear drum position Bedknife and bed...

Page 20: ...30 to 0 620 inch Height of groom range 0 381 to 19 1 mm 0 015 to 0 750 inch Width of groomer 54 6 cm 21 5 inch Height adjustment knob Allows a 0 08 mm 0 003 inch increment of height adjustment for eac...

Page 21: ...ue feature e g nylock nut hardness of the surface underneath the head of the fastener or similar condition which affects the installation As noted in the following tables the torque values should be r...

Page 22: ...que When using a torque wrench with a drive adapter wrench the calculated torque will be lower than the listed torque recommendation Example The measured effective length of the torque wrench distance...

Page 23: ...d into the fastener and pre applied dry thread locking compound Keep in mind a fastener with a locking feature usually means there will be friction during initial installation and during removal Toro...

Page 24: ...50 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 6 75 8 77 8 104 11 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 11 142 15 1 2 20 UNF 32 4 53 7 72 9 85 9 115 12 120 12 163 16 5 8 11 UNC 65 10 88 12 119...

Page 25: ...M20 X 2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610 62 N m Note Reduce the torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated wit...

Page 26: ...b 88 14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1 5 Class 8 8 80 10 ft lb 108 14 N m For steel wheels and non lubricated fasteners Thread Cuttin...

Page 27: ...tener installation Most thread locking compounds allow the fastener to be removed with standard tools once cured High strength thread locking compounds may require applying heat to the fastener and th...

Page 28: ...ue and previously used gaskets or gasket compounds SILICONE SEALANT Designed for a broad variety of sealing and bonding requirements silicone sealants are usually room temperature vulcanizing RTV whic...

Page 29: ...revent corrosion of unsealed connection terminals To ensure complete coating of the terminals liberally apply the gel to the component and wire harness connector plug the connector into the component...

Page 30: ...Brush Assembly K Line Part No 29 9100 For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel Components for the brush assembly are also available in...

Page 31: ...sary to grind the bedknife after installing it to the bedbar 1 Place the angle indicator on the bottom side of the bedknife with the digital display facing you as shown 2 Press the Alt Zero button on...

Page 32: ...tting reel and other spherical components Tape calibration is in fixed inch readings no adjustments Roller Rebuilding Tools The following combination of washers and spacers can be used to install bear...

Page 33: ...ther This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the Turf Evaluator Toro part no 97931SL available from your local authorized Toro Distributor Drive Sha...

Page 34: ...and install the rotor from the electric motor housing The tool includes the puller hub threaded shaft handle and four screws Lithium Ion Battery Service Wire Harness Toro Part No 122 1947 Use to ident...

Page 35: ...nd Solving Problems 3 2 Operator Advisories 3 3 Machine Faults 3 5 Battery Charger Error and Fault Codes 3 8 Electrical System Problems 3 9 Aftercut Appearance 3 11 Factors Affecting Grooming 3 12 Gro...

Page 36: ...the problem 3 Assess Performance Ensure that you have all the necessary tools for testing Test all potential causes of the failure Reevaluate and create a new hypothesis if necessary 4 Repair Return...

Page 37: ...d functionality cutting unit disengaged and reduced traction speed Battery charging is necessary before returning the machine to normal operation 204 Energy Saving Mode Warning If the battery state of...

Page 38: ...y engaged 214 Battery Temperature Too Low This advisory notifies that the battery operating temperature is too low and the controller was denied the motor operation 215 Battery Temperature Too High Th...

Page 39: ...hine functions to stop Then attempt to restart the machine to see if operation has returned to normal Some faults will be reset during the restart and will then allow normal function If a fault contin...

Page 40: ...ect of this fault is that the motor output torque will be limited This will result in reduced reel speed and potential stall 1 Let machine cool Note that this fault is not produced by a bad sensor 2 O...

Page 41: ...shutdown the contactor opens and the bus discharges before shutting the machine down This discharge failed to go below the threshold in the required amount of time Most likely cause is a shorted conta...

Page 42: ...clean and secure Code E 0 2 3 High AC voltage error greater than 270 VAC Connect the charger to an AC power source that provides stable AC power between 85 270 VAC at 45 65 Hz Code E 0 2 4 Charger fa...

Page 43: ...s damaged Check the key switch and circuit wires Repair as necessary The main contactor is damaged Check the main contactor and circuit wires Repair as necessary The wire harness connections or wires...

Page 44: ...e machine operation has returned to normal If the fault remains active use the Faults screen information in the InfoCenter section of this chapter to help identify source of problem Machine Operates B...

Page 45: ...dknife to reel contact Grind the reel to remove taper and or rifling Grind the bedknife to sharpen and or remove rifling A new bedknife must be ground or backlapped after installation to the bedbar Re...

Page 46: ...lso affect grooming performance Variables that Affect the Use and Performance of Grooming Reels 1 The growing season and weather conditions 2 General turf conditions 3 The frequency of grooming cuttin...

Page 47: ...set up information The grooming reel blades are bent damaged or missing Repair or replace blades if necessary The grooming reel shaft is bent or damaged Replace grooming reel shaft The turf is damaged...

Page 48: ...Troubleshooting Grooming Reel Mechanical Problems Page 3 14 Greensmaster eFlex 1021 20248SL Rev C...

Page 49: ...ssion 4 2 Adjustments 4 3 Adjusting the Reel Drive Belt 4 3 Service and Repairs 4 5 Reel Drive Belt 4 5 Reel Drive Assembly 4 7 Drum Drive Gear Box Assembly 4 12 Drum Assembly 4 18 Transmission Gear B...

Page 50: ...surface release the clutch bail engage the service and parking brake rotate the key switch to OFF and remove the key refer to the Operator s Manual 2 Disconnect the battery pack refer to Disconnectin...

Page 51: ...tor s Manual 2 Disconnect the battery pack refer to Disconnecting and Connecting the Lithium Battery Pack page 5 3 3 Remove the 4 socket head screws 7 that secure the reel drive cover 6 to the reel dr...

Page 52: ...elt tension refer to step 4 g391185 Figure 13 1 Upper idler arm socket head screw 2 Beam style torque wrench C Ensure that the reel drive gasket 5 is in position and assemble the reel drive cover 6 to...

Page 53: ...e cutting unit drive lever is in the DISENGAGE position park the machine on a level surface release the clutch bail engage the service and parking brake rotate the key switch to OFF and remove the key...

Page 54: ...3 2 Place the new drive belt 2 over the pulleys 3 Adjust the reel belt tension refer to Adjusting the Reel Drive Belt page 4 3 4 Align the reel drive gasket 5 to the reel drive housing 1 and install...

Page 55: ...Lock nut 18 Nut 29 Idler bushing 8 Reel pulley 22 tooth 19 Nut 30 Socket head screw 9 Reel pulley spacer 2 each 20 O ring 31 Reel belt 10 Bolt 21 V ring seal 32 Socket head screw 4 each 11 Bearing sh...

Page 56: ...er arm 28 11 Remove the socket head screw 30 that secures the idler arm 28 to the reel drive housing 25 12 If necessary remove the idler bushing 29 from the idler arm 28 13 Remove the retaining ring 4...

Page 57: ...aining rings 3 and 4 from the reel drive housing 6 21 Use a press to remove the 4 ball bearings 2 and 5 from the reel drive housing 6 Discard the ball bearings after removal Greensmaster eFlex 1021 Pa...

Page 58: ...the new O ring 20 and install onto the pivot sleeve 10 Pack the internal splines of the reel shaft driven 22 with grease Slide the reel shaft driven 22 into the reel drive housing 25 11 Slide the spa...

Page 59: ...2 23 Install the reel drive belt refer to Installing the Reel Drive Belt page 4 6 24 Adjust the reel drive belt refer to Adjusting the Reel Drive Belt page 4 3 25 Install the cutting unit onto the ma...

Page 60: ...is procedure 1 Ensure that the cutting unit drive lever is in the DISENGAGE position park the machine on a level surface release the clutch bail engage the service and parking brake rotate the key swi...

Page 61: ...transmission gear box assembly 1 8 If necessary remove the RH hexagonal shaft 4 from the RH drum drive gear box assembly 5 9 Remove the truss screw 12 nut 9 and washer 11 that secures the 2 splined co...

Page 62: ...32 O ring 9 Wire spring 21 Spur gear 33 Dowel pin 2 each 10 Oil seal 22 Socket head screw 34 Bearing spacer 11 Spur gear 23 Ball bearing 2 each 12 Nut 24 Wave washer Note Refer to Figure 19 during thi...

Page 63: ...bearings after removal 8 Remove the nut 17 and bearing pin 31 that secures the spur gear 20 to the drum drive housing 25 9 Remove the spur gear 20 and bearing spacer 34 from the drum drive housing 25...

Page 64: ...gs 6 bearing spacer 7 spring washer 9 and drum drive shaft 5 to the drum drive housing 25 Note The outer diameter and inner diameter of the ball bearings 6 must be slip fit 6 Install the V ring seal 4...

Page 65: ...he hexagonal shaft to 54 to 67 7 N m 40 to 50 ft lb 2 Apply a light coat of grease and install the O ring 29 to the drum drive housing 25 3 If removed slide the drive tube item 6 in Figure 18 onto the...

Page 66: ...DISENGAGE position park the machine on a level surface release the clutch bail engage the service and parking brake rotate the key switch to OFF and remove the key refer to the Operator s Manual 2 Di...

Page 67: ...spindle 5 2 Remove the 4 bolts 2 and lock washers 3 that secures the drum hub plate 4 to the drum hub 10 3 Remove the shoulder bolts 11 that secures the drum hub plate 4 to the traction drum 1 4 Remo...

Page 68: ...le 5 can move axially relative to the drum hub 1 Note The lock nut 3 turns hard on the drum spindle 5 when tightened Ensure that all rotation has stopped when tightening A good solid sound indicates t...

Page 69: ...Disconnecting and Connecting the Lithium Battery Pack page 5 3 3 Position the LH and RH drum drive gear box assembly item 5 in Figure 21 and traction drum 2 onto the frame assembly 7 4 Secure the LH a...

Page 70: ...t 2 each 13 Coupler shaft 22 Electric motor 5 Drive shaft 14 Compression Spring 23 O ring 6 Frame assembly 15 Collar lock 24 Reel drive coupling 7 Slide adaptor 16 Hex tube 25 Drive tube 8 Jam nut 17...

Page 71: ...ler shaft 13 and disconnect the cutting unit from the transmission gear box assembly 7 Remove the nuts 4 washers 3 and truss screws 1 that secures the splined couplers 2 to the drive shaft 5 Remove th...

Page 72: ...RB plug 18 O ring seal 28 E ring 9 Detent spring 19 Traction selector shaft 29 Adapter vent 10 Detent ball 20 Groomer pin 30 Breather vent Note Refer to Figure 25 during this procedure 1 Remove the ho...

Page 73: ...ke plate retainer 25 Bolt 8 Bolt 2 each 17 Retaining ring 9 Differential shaft 2 each 18 Brake band 4 Remove the neutral spur gear assembly item 5 in Figure 26 and wave washer 3 from the transmission...

Page 74: ...housing assembly 23 Remove the retainer plate 15 from the transmission housing assembly 23 12 Slide and remove the brake lever assembly 19 from the transmission housing assembly 23 Remove the flat wir...

Page 75: ...ar 14 Slider spur gear 14 Slide and remove the reel clutch actuator item 16 in Figure 27 from the transmission housing assembly 20 If necessary remove the reel clutch shoe 15 from the reel clutch actu...

Page 76: ...the 2 ball bearings 6 from the spur gear 17 Discard the ball bearings 6 22 Remove the thin lock nut 18 that secures the input shaft 19 to the transmission housing assembly 20 Slide and remove the inp...

Page 77: ...igure 25 and slide onto the groove of the traction selector shaft 19 10 Insert the straight bushings item 4 in Figure 25 into the transmission housing 26 Press the straight bushings into the transmiss...

Page 78: ...pin through brake band into the transmission housing assembly item 23 in Figure 26 place the flat wire spring 22 and brake plate retainer 16 onto the transmission housing assembly 27 Place the retaine...

Page 79: ...ng 44 If removed insert the 2 dowel pins item 17 in Figure 25 into the transmission housing assembly 26 45 Install the new transmission gasket item 22 in Figure 25 and transmission cover assembly 23 o...

Page 80: ...th jam nut 8 onto the transmission gear box assembly 10 4 Install the splined couplers 2 to the drive shaft 5 and secure with truss screws 1 washers 3 and nuts 4 Torque tighten the truss screws to 10...

Page 81: ...mbly 23 Transmission housing assembly 6 Neutral slider shaft 15 Retainer plate pin 24 Cable brake lever 7 Square key 2 each 16 Brake plate retainer 25 Bolt 8 Bolt 2 each 17 Retaining ring 9 Differenti...

Page 82: ...usings 1 apart 3 Use a press to remove the 6 differential pins 2 and 6 differential spur gears 3 from the differential housings 1 Inspecting the Differential Assembly 1 Clean all the differential asse...

Page 83: ...Insert the differential spur gears 3 to the differential pins 2 by pointing the gears shoulder up 6 Fill the differential housing assembly 1 with 0 08 lb 1 25 oz of grease 7 Attach the 2 differential...

Page 84: ...Traction and Reel Drive Systems Service and Repairs Page 4 36 Greensmaster eFlex 1021 20248SL Rev C...

Page 85: ...enter Display 5 10 Adjustments 5 20 Traction Bail Proximity Sensor 5 20 Testing the Electrical Components 5 21 Fuses 5 22 CAN bus 5 24 Toro Electronic Controller TEC 5 26 Lithium Ion Battery Controlle...

Page 86: ...Operator s Manual The Traction Unit Operator s Manual and Lithium Battery Pack Charger Operator s Manual provide information regarding the operation general maintenance and maintenance intervals for...

Page 87: ...r that came with the product Only use the charger designed for the battery WARNING Always disconnect the batteries at the battery disconnect provided when servicing products with lithium ion batteries...

Page 88: ...ides electrical system diagnostic assistance for the technicians and allows inputs for the adjustable machine settings The status of TEC inputs and outputs can be monitored with the InfoCenter display...

Page 89: ...engage The motor rotation speed and traction speed is determined by the throttle potentiometer setting that is adjusted by the operator The TEC and motor controller monitor the motor speed so that as...

Page 90: ...hat is controlled by the CAN bus link only needs four 4 wires to operate and communicate to the system CAN High CAN Low power and ground The key switch needs to be in the ON position for the component...

Page 91: ...nsole If a problem exists that could prevent normal operation the InfoCenter display will display an operator advisory or fault code to assist in identifying the problem The TEC is attached to the bat...

Page 92: ...urely connected before machine operation can occur 2 Protects the battery from operating discharging and charging outside their safe operating voltage amperage and temperature ranges 3 Operates an int...

Page 93: ...u will void the warranty The controller case is protected by tamper alerting devices Opening the controller case may result in personal injury and property damage Note If the Lithium Ion Battery Contr...

Page 94: ...for the InfoCenter is available when energized by the TEC the key switch is in the ON position A CAN bus system involving the TEC electric motor controller and lithium ion battery pack provides neces...

Page 95: ...KEY SWITCHED ON AFTER 5 SECONDS MAIN INFORMATION SCREEN g339628 Figure 36 Greensmaster eFlex 1021 Page 5 11 Electrical System Electrical System Operation 20248SL Rev C...

Page 96: ...enter splash screen appears Figure 37 The splash screen provides the hour meter information After the splash screen has been displayed for 5 seconds the main information screen will appear on the Info...

Page 97: ...nfoCenter screen will be displayed to notify the operator that recent machine faults have occurred Accessing the fault log is described below in the Faults Screen page 5 15 Main Menu Service Diagnosti...

Page 98: ...igure 41 1 Main menu 4 Menu back button 2 Left right button 5 Menu items 3 Down button The main menu screen can be accessed from the InfoCenter main information screen by pressing and releasing the me...

Page 99: ...in the Machine Faults page 3 5 The InfoCenter fault log can be cleared by selecting the clear system faults menu item The cleared faults will be removed from the InfoCenter but will be retained in the...

Page 100: ...ry current amps delivered by battery Battery volts battery potential in volts Total usage total usage of the battery over its entire life in Amp hours Capacity total capacity of the battery in Amp hou...

Page 101: ...e key switch is in the RUN position Key Start indicates that the key switch is in the START position or not Note The key start position can be verified in the diagnostics screen by rotating the switch...

Page 102: ...the operator to customize the backlight brightness and contrast settings for the InfoCenter display Units Use the left right button as indicated by the at the bottom of the screen to select between me...

Page 103: ...3 Menu back button The about screen Figure 46 identifies the machine model number serial number and TEC software revision To return to the main menu screen from the about screen press the menu back bu...

Page 104: ...at secures the control cover to the handle assembly Remove the control cover from the machine 4 Get access to the proximity sensor Pull up and release the traction bail 5 When the bail is open adjust...

Page 105: ...cuit The machine frame is not used for any ground connections For accurate resistance and or continuity checks electrically disconnect the component being tested from the circuit e g unplug the key sw...

Page 106: ...ing the Lithium Battery Pack page 5 3 3 Remove the 4 bolts that secures the battery cover to the battery mount refer to Figure 48 Remove the battery cover from the battery mount Fuse Identification an...

Page 107: ...d for 80 V If the fuse replacement is necessary ensure to use the fuses as identified in your eFlex Parts Catalog Do not use regular automotive fuses in your eFlex machine 4 Carefully install the func...

Page 108: ...gh CAN Low power and ground The key switch needs to be in the ON position for the components on the network to be activated Two specially designed twisted wires form the CAN bus These wires provide th...

Page 109: ...hms indicates the CAN bus terminator resistor is not connected or damaged 4 Refer to CAN bus Terminator Resistor page 5 38 and or see electrical schematic and wire harness drawing in Appendix A page A...

Page 110: ...he battery mount inside the battery cover refer to Figure 52 IMPORTANT Before performing any welding on the machine do the following to prevent damaging the electrical system of the machine Disconnect...

Page 111: ...d outputs of the controller used on your Greensmaster refer to InfoCenter Display page 5 10 The InfoCenter display can also be used to identify faults and operator advisories that indicate operation i...

Page 112: ...uses the sub net to verify the presence and condition of the battery before allowing battery power to the machine The BMS is also connected to the CAN bus which allows it to forward battery informatio...

Page 113: ...rness connector pin 6 and the BMS B terminal 3 An audible Click should come from the BMS shortly after the key switch is set to the ON position The Click sound indicates the contactor inside the BMS h...

Page 114: ...the machine on a level surface release the clutch bail engage the service and parking brake rotate the key switch to OFF and remove the key refer to the Operator s Manual 2 Disconnect the battery pac...

Page 115: ...the key switch in the ON position the machine will shut off Note A damaged key switch may cause a 12 fault to be generated and displayed on the InfoCenter Refer to the Faults Screen page 5 15 for inf...

Page 116: ...ge 5 32 Check the continuity between the switch terminals Circuit Logic Table Switch Position Circuits OFF None ON B C F D E START A B C 6 Replace the key switch if necessary 7 After you complete the...

Page 117: ...8 Link shaft 18 Proximity sensor 28 Lock 9 Washer 19 Screw 2 each 29 Lock nut 2 each 10 Clevis pin 20 Screw 2 each The throttle and clutch bail potentiometers controls the electric motor speed which...

Page 118: ...remove the potentiometer from the machine Figure 60 Note Before taking the small resistance readings with a digital multimeter short the multimeter test leads together The meter displays a small resi...

Page 119: ...the potentiometers a minimum voltage reading of 0 5V for proper function is required This can be read in the InfoCenter The adjustment is completed by rotating the potentiometers in the mounting slot...

Page 120: ...A damaged main contactor may cause a 16 fault to be generated and displayed on the InfoCenter Refer to the Faults Screen page 5 15 for information on faults Testing the Main Contactor 1 Ensure that th...

Page 121: ...and test leads Subtract this value from the measured value for the tested component 5 Measure the resistance across the contactor coil terminals Resistance of the coil should be approximately 195 ohm...

Page 122: ...inator resistor Figure 64 can be tested using a digital multimeter ohms setting Locate the CAN bus terminator resistor and remove the cable tie that secures the resistor to the wire harness Unplug the...

Page 123: ...necting the Lithium Battery Pack page 5 3 3 Remove the four bolts that secures the battery cover to the battery mount Remove the battery cover from the machine 4 Disconnect the machine wire harness co...

Page 124: ...and break continuity between terminals 30 and 87 as voltage is applied and removed from terminal 85 8 Replace the relay as necessary 9 If the relay tests correctly and a circuit problem still exists...

Page 125: ...age 5 15 for information on faults Removing the Electric Motor 1 Ensure that the cutting unit drive lever is in the DISENGAGE position park the machine on a level surface release the clutch bail engag...

Page 126: ...losed cell foam seal 6 onto the electric motor shaft 2 Apply a coat of anti seize to the key 7 and install the key onto the motor shaft 3 Position the electric motor to the transmission align the moto...

Page 127: ...refer to Special Tools page 2 13 Note When servicing the electric motor use a clean workspace with a non metal surface The motor rotor includes very powerful magnets that can cause the rotor to move...

Page 128: ...event it from falling during removal 7 Remove the motor cover and wave washer from the rotor assembly 8 Remove and discard the O rings from the motor cover 9 Remove and discard the O ring from the mot...

Page 129: ...magnets are very powerful and can cause the rotor to shift position very rapidly during installation Be cautious during rotor installation to prevent component damage or personal injury 7 While suppo...

Page 130: ...r BMS CAUTION To prevent accidentally shorting disconnected battery cables across other components or tools insulate the battery cable terminals with 76 mm 3 inch lengths of 1 2 inch internal diameter...

Page 131: ...Battery Pack page 5 3 3 Remove the four bolts that secures the battery cover to the battery mount Remove the battery cover from the machine g338794 Figure 72 1 Lithium Ion battery controller 5 B termi...

Page 132: ...personal injury and property damage 9 Install the lithium ion battery controller in reverse order Install the controller with the positive terminals upward refer to Figure 70 and Figure 72 10 Tighten...

Page 133: ...nicipality or recycling facility Caring for the Lithium Ion Battery When mowing use the InfoCenter to monitor the state of charge of the lithium ion battery pack Consistently operating the machine wit...

Page 134: ...arger is disconnected and reconnected Shipping and Transporting the Lithium Ion Battery The US Department of Transportation and international transportation authorities require that lithium ion batter...

Page 135: ...the battery pack whenever the machine is not in use Refer to the Operator s Manual for battery charging and battery charger operation information Refer to Battery Charger Error and Fault Codes for bat...

Page 136: ...e CAUTION To prevent accidentally shorting disconnected battery cables across other components or tools insulate the battery cable terminals with 76 mm 3 inch lengths of 1 2 inch internal diameter rub...

Page 137: ...er to Disconnecting and Connecting the Lithium Battery Pack page 5 3 3 Remove the four bolts that secures the battery cover to the battery mount Remove the battery cover from the machine 4 Label and d...

Page 138: ...sitive terminal towards the front side and the negative terminal towards rear side of the machine 2 After installing the battery into the battery mount secure the battery with four bolts washers and n...

Page 139: ...3 Service and Repairs 6 4 Replacing the Brake Cable 6 4 Replacing the Reel Cable 6 7 Cutting Unit Drive Lever Assembly 6 10 Brake Latch Shaft 6 12 Handle Assembly 6 14 Kickstand 6 21 Transport Wheels...

Page 140: ...egarding the operation adjustment procedures and general maintenance for your Greensmaster machine Refer to the Operator s Manual for additional information when servicing the machine Controls Wheels...

Page 141: ...o OFF and remove the key refer to the Operator s Manual 2 Disconnect the battery pack refer to Disconnecting and Connecting the Lithium Battery Pack page 5 3 3 To remove slack from the reel cable perf...

Page 142: ...r to Figure 78 during this procedure 1 Ensure that the cutting unit drive lever is in the DISENGAGE position park the machine on a level surface release the clutch bail rotate the key switch to OFF an...

Page 143: ...spring 7 from the spring anchor on the brake lever assembly 3 Note the orientation of the brake cable spring hook on the brake lever assembly for assembly purpose 6 Remove the brake cable 9 from the m...

Page 144: ...e cable lever assembly Adjust the cable jam nuts to remove the slack in the brake cable 4 Check the brake cable adjustment refer to Operator s Manual 5 Install the lower cover and control cover to the...

Page 145: ...Refer to Figure 80 during this procedure 1 Ensure that the cutting unit drive lever is in the DISENGAGE position park the machine on a level surface release the clutch bail engage the service and park...

Page 146: ...3 from the clevis connector 10 on the reel lever assembly 5 Note the orientation of cable spring hook on the shaft assembly for assembly purposes 6 Remove the reel cable 1 from the machine Installing...

Page 147: ...le lever assembly Adjust the cable jam nuts to remove the slack in the clutch cable 4 Check and adjust the reel cable refer to Adjusting the Reel Cable page 6 3 5 Install the lower cover and control c...

Page 148: ...pring 2 each 16 Split bushing 25 Upper receiver weldment 8 Control cover 17 Socket cap 26 Flange nut 9 Bolt and washer assembly 8 each 18 Cotter pin clip 27 Reel lever assembly Disassembling the Cutti...

Page 149: ...haft 15 If necessary remove the split bushing 16 and 12 from the main control shaft Assembling the Cutting Unit Drive Lever Assembly 1 If removed apply a coat of grease in inner diameter of split bush...

Page 150: ...hine on a level surface release the clutch bail engage the service and parking brake rotate the key switch to OFF and remove the key refer to the Operator s Manual 2 Disconnect the battery pack refer...

Page 151: ...tch shaft 9 2 Slide and position the brake latch shaft 9 into the upper receiver weldment 12 3 Slide and position the brake lock lever 4 onto the brake latch shaft 9 Secure the brake lock lever with t...

Page 152: ...nge bushing 2 each 17 Brake cable 29 Bolt 6 Brake lever 18 Cotter pin 30 Bolt 7 Flange nut 4 each 19 Lower handle assembly 31 Flange bushing 2 each 8 Upper receiver weldment 20 Flange nut 32 Bolt 9 Nu...

Page 153: ...nut 24 Screw 2 each 5 Key switch 15 Lock 25 Potentiometer sensor 6 Bail catch fork 16 Potentiometer sensor 26 Control bail lever 7 Clip pin 2 each 17 Mount 27 Throttle cable 8 Link shaft 18 Proximity...

Page 154: ...utting Unit Drive Lever Assembly page 6 10 12 Remove the brake latch shaft refer to Disassembling the Brake Latch Shaft page 6 12 13 Remove the flange nut 7 and bolt 21 which function as a throttle ar...

Page 155: ...ach 2 Bolt 2 each 8 Flange nut 4 each 14 Torques head screw 2 each 3 Flange bushing 4 each 9 Nut 2 each 15 Right bail bracket 4 Clutch bail assembly 10 Upper receiver weldment 16 Handle 5 Clutch bail...

Page 156: ...igure 86 and 2 bolts 11 that secure the handle mount 7 to the upper receiver weldment 15 Remove the handle mount from the upper receiver weldment g391562 Figure 87 1 Lower handle assembly 4 Washer 2 B...

Page 157: ...n 14 bearing washer 15 and cotter pin 18 10 If removed install the lift assist handle 27 to the upper receiver weldment 8 and secure with the bolts 11 and 16 11 Slide the upper receiver weldment item...

Page 158: ...ail Proximity Sensor page 5 20 28 Reposition the wire harness to the bottom control cover 26 in Figure 84 Install the cover to the upper receiver weldment 8 with the 2 screw and washer assemblies 25 2...

Page 159: ...TION 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 1 Ensure that the cutting unit drive lever...

Page 160: ...spring retainer 13 by removing the nut 4 washer 12 and bolt 11 9 If necessary remove the spacers 8 from the kickstand 14 Installing the Kickstand g337280 Figure 89 1 Kickstand raised 3 Kickstand lowe...

Page 161: ...each Removing the Transport Wheel 1 Ensure that the cutting unit drive lever is in the DISENGAGE position park the machine on a level surface release the clutch bail engage the service and parking br...

Page 162: ...bly of the wheel 2 Remove the 3 bolts and 3 lock washers from the shallow rim and hub Remove the hub from the deep rim 3 Inspect the hub bushing Replace the bushing if worn or damaged 4 Remove the 4 b...

Page 163: ...lange nuts Tighten the fasteners 4 Install the hub into the deep rim Secure the hub to the deep rim with the 3 bolts and 3 lock washers Tighten the fasteners 5 Inflate the tire to 83 to 103 kPa 12 to...

Page 164: ...kstand 3 Remove the wheel clip and remove the rail kit wheel from the wheel hex shaft on each side 4 If necessary install the transport wheels refer to Installing the Transport Wheel page 6 25 Install...

Page 165: ...e key switch to OFF and remove the key refer to the Operator s Manual 2 Disconnect the battery pack refer to Disconnecting and Connecting the Lithium Battery Pack page 5 3 3 Remove the cutting unit fr...

Page 166: ...bly using the Figure 95 as a guide Assembly of the Flex Frame Assembly Assemble the flex frame assembly using the Figure 95 as a guide Installing the Flex Frame Assembly 1 Position the flex frame asse...

Page 167: ...he Cutting Unit when Servicing 7 2 Adjustments 7 3 DPA Cutting Unit Characteristics 7 3 Leveling the Rear Roller 7 4 Service and Repairs 7 6 Bedbar Assembly 7 6 Servicing the Bedbar Adjuster 7 10 Bedk...

Page 168: ...ation and maintenance information Refer to the Cutting Unit Operator s Manual and the kit Installation Instructions for additional information when servicing the cutting units Supporting the Cutting U...

Page 169: ...ble with this design gives the necessary control to provide a continual self sharpening action This feature maintains sharp cutting edges assures good quality of cut and greatly reduces the need for r...

Page 170: ...rear roller is parallel to the cutting reel by trying to fit a 0 13 mm 0 005 in shim between the rear roller and the bench plate at each end of rear roller Rotate the roller and recheck the clearance...

Page 171: ...g the rear roller parallel to the reel Tighten the shoulder bolts from 24 to 27 N m 210 to 240 in lb 6 Recheck the clearance between the rear roller and the bench plate If necessary loosen and adjust...

Page 172: ...her 2 each 9 Washer 2 each 2 Keyed flanged bushing 4 each 6 Retaining ring 2 each 10 Compression spring 3 Detent 2 each 7 Bedbar adjuster screw 2 each 11 Nut 2 each 4 Bolt 2 each 8 Bedbar assembly 12...

Page 173: ...ylon bushing 8 Lock nut 4 Plastic washer 2 each 9 Bed knife 5 Metal washer 10 Screw 13 each 4 Loosen the lock nuts item 8 in Figure 100 on each bedbar bolt 7 5 Remove the two bedbar bolts item 7 in Fi...

Page 174: ...or other cutting unit parts can result in personal injury Use heavy gloves when handling the bedbar Note If a new bedknife is attached to the bedbar there may be interference between the bedknife and...

Page 175: ...bearing alignment When the lock nut is correctly tightened the inside washers may be loose 8 Tighten both lock nuts item 8 in Figure 101 until outside metal washers do not have any end play but it can...

Page 176: ...refer to Removing the Bedbar page 7 7 2 Remove the lock nut 11 compression spring 10 and washer 9 from the bedbar adjuster screw 7 Note The bedbar adjuster shaft 1 has left hand threads 3 Unscrew the...

Page 177: ...her 5 and a retaining ring 6 Note The bedbar adjuster shaft 1 has left hand threads 4 Apply anti seize lubricant to the threads of the bedbar adjuster screw 7 that fit into adjuster shaft 1 the left h...

Page 178: ...fe 1 Use a scraper to remove all rust scale and corrosion from the bedbar surface under the bedknife Lightly oil the bedbar surface before installing the bedknife 2 Make sure that screw threads in bed...

Page 179: ...tighten the 2 outer screws to 1 N m 10 in lb 6 Working from the center of the bedknife toward each end tighten screws from 23 to 28 N m 200 to 250 in lb 7 After installing the bedknife to bedbar grin...

Page 180: ...Operating the cutting unit with the bedknife below the service limit may result in poor after cut appearance and reduce the structural integrity of the bedknife g227152 Figure 106 1 Service limit reel...

Page 181: ...grinder manufacturer s instructions for bedknife grinding information 2 After grinding the bedknife install the bedbar assembly in the cutting unit refer to Installing the Bedbar page 7 8 Note Always...

Page 182: ...e grinder 5 If you have a precision flat granite surface plate check the bedbar bedknife refer to Checking the Bedknife on a Granite Surface Plate page 7 17 6 Install the bedbar bedknife assembly to t...

Page 183: ...108 1 Shim 002 inch to test for gaps 3 Granite surface plate 2 Inspect the surface between the bedknife and granite for light 2 If there is a gap that the shim fits through or light shows between the...

Page 184: ...ut 7 Bushing 14 Grass shield 21 RH side plate This section provides the procedure for removing and installing the reel assembly reel reel bearing bearing lock screw reel nut and seals from the cutting...

Page 185: ...CAUTION Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when removing the cutting reel IMPORTANT If the reel bearings or seals are being repl...

Page 186: ...nt Roller page 7 27 10 Remove the rear roller refer to Removing the Rear Roller page 7 28 11 Support the cutting reel to prevent it from shifting or falling and remove the 2 socket head screws 3 that...

Page 187: ...xial play 3 Inspect the reel as follows A Place the reel shaft ends in V blocks and check the reel shaft for distortion B Check the threads in the ends of the reel shaft C Check the reel blades for be...

Page 188: ...spline adapter threads and the internal threads of the LH reel nut Replace the spline adapter or LH reel nut if necessary IMPORTANT Use high strength thread locking compound Loctite 271 or equivalent...

Page 189: ...arefully slide the cutting reel assembly into the right side plate Make sure that the reel bearing is fully seated in the RH side plate and that the reel nut on the left exposed end of the cutting ree...

Page 190: ...ANT The reel nut on the left end of the cutting reel has left hand threads The reel nut on the right end of the cutting reel has right hand threads C Rest the handle of the pry bar against the front r...

Page 191: ...D Adjust the optional groomer reel if equipped refer to the universal groomer Installation Instructions Preparing the Reel for Grinding Reel Grinding Specifications Reel Diameter New D 128 5 mm 5 06...

Page 192: ...found on the Service Reference Set available from your Authorized Toro Distributor Relief grind the reel blades to the minimum blade land width if the reel blade land width exceeds the service limit S...

Page 193: ...unit if necessary Installing the Front Roller Note Refer to Figure 115 during this procedure 1 Place the cutting unit on a level work surface Use an appropriate support to raise the front of the cutti...

Page 194: ...Kit there will be additional roller shims installed between the rear roller and the cutting unit side plate 3 Remove one of the rear roller retainer assemblies 4 Slide the rear roller assembly from t...

Page 195: ...ionary while removing the bearing lock nut 1 install a 3 8 24 UNF 2B screw with a jam nut into the threaded end of the roller shaft 5 and tighten the jam nut against the roller shaft Remove the bearin...

Page 196: ...cutting unit on a level work surface Use an appropriate support to raise the front of the cutting unit off the work surface 2 Inspect the condition of both height of cut screws 9 and replace them if n...

Page 197: ...te with a plow bolt 2 height of cut washer and lock nut 6 Center the front roller 3 in the cutting unit and tighten the pinch bolts 8 that secure the front roller shaft to the height of cut arms 7 Ins...

Page 198: ...DPA Cutting Units Service and Repairs Page 7 32 Greensmaster eFlex 1021 20248SL Rev C...

Page 199: ...llation Instructions 8 2 Service and Repairs 8 3 Groomer Drive Gearbox 8 4 Idler Plate 8 16 Groomer Reel 8 19 The Height Adjuster Assembly 8 22 The Height Adjuster Assembly 8 26 The Grooming Brush Opt...

Page 200: ...e set up operation general maintenance procedures and maintenance intervals for the groomer assembly on your Greensmaster machine Refer to the Installation Instructions for additional information when...

Page 201: ...each 2 Idler assembly 4 Groomer reel CAUTION Never work on the groomer with the machine running Always stop the machine and wait for all machine movement to stop before working on the groomer Greensm...

Page 202: ...cover lip 4 Single lug groomer gearbox The groomer gearbox assembly is located on the opposite side of the cutting unit from the reel drive Removing the Gearbox Assembly Refer to Figure 121 and Figure...

Page 203: ...lip of the groomer drive gearbox cover Figure 121 6 Tip up the cutting unit to access the bottom of the reel to remove the drive shaft assembly 7 Insert a long handled pry bar 3 8 x 12 inch with screw...

Page 204: ...head set screw Toro Part No 1 803022 into the end of the drive shaft for the groomer drive gearbox and tighten the set screw to 13 N m 120 in lb refer to Figure 122 IMPORTANT The square head set screw...

Page 205: ...e cutting unit use a right hand thread turn the drive shaft counterclockwise to remove the gearbox 11 Use a heavy wall 6 point socket and breaker bar at the outboard end of the groomer gearbox drive s...

Page 206: ...d drain the oil C Remove the 4 socket head screws that secure the gearbox cover to the gearbox housing and cover Remove and discard the cover gasket D Remove the thrust washer sun gear and ring gear f...

Page 207: ...cause a high blade J Move the pry bar against the weld side of the reel support plate closest to the groomer gearbox and lift the pry bar so that it contacts the front roller K Use the drive shaft re...

Page 208: ...Knob single lug gearbox 27 Single lug gearbox cover 38 Lock nut 6 Gearbox housing 17 Retaining ring 28 2 lug groomer gearbox cover 39 Driver gear 7 Dowel pin 2 each 18 Thrust washer 29 Gasket 40 Beari...

Page 209: ...r 15 minutes before continuing this procedure 7 Carefully clean all the gasket material from the gearbox housing and cover 8 Inspect the V ring seals bearings gears and bushings in the gearbox assembl...

Page 210: ...ated between the 4 socket head screws Torque the plugs to 4 to 5 N m 32 to 42 in lb 17 Add 50 ml 1 7 fluid ounces 80W 90 gear oil into the gearbox through the hole in the face of the cover 18 Install...

Page 211: ...ug groomer gearbox 9 Threads reel shaft 5 2 lug groomer gearbox Refer to Figure 127 for this procedure 1 Install a 5 16 18 X 5 8 inch square head set screw Toro Part No 1 803022 into the end of the dr...

Page 212: ...f the pry bar against the front roller 6 Position the groomer drive gearbox assembly against the cutting unit and rotate the drive shaft assembly clockwise until it is seated against the reel shaft IM...

Page 213: ...ulder screw B Align the hardened washer between the eye bolt and the gearbox cover lug C Assemble the eye bolt and hardened washer to the gearbox lug with the shoulder screw Torque the shoulder screw...

Page 214: ...groomer gearbox Note Early universal groomers used 2 non adjustable compression springs on eye bolts for the 2 lug gearbox and idler plate The single lug gearbox and idler plate assemblies are the cu...

Page 215: ...he retaining ring C Assemble the 2 bearing shields to the idler plate with flocked side of shield toward the bearing D Check the idler plate orientation left side of the cutting unit and insert the st...

Page 216: ...roomer gearbox 4 Cotter pin 2 Eye bolt 5 Spring pin idler plate cross drilled with a 2 lug groomer gearbox 3 Shoulder screw 6 Adjuster pin 3 Install the reel drive refer to Installing the Reel Drive A...

Page 217: ...or other cutting unit parts can result in personal injury Use heavy gloves when handling the groomer reel 1 Carefully remove the 4 jam nuts 4 bolts and 4 shaft clamps that secure the groomer reel to...

Page 218: ...the blades from the groomer shaft If necessary remove second lock nut from the shaft 4 Inspect and replace worn or damaged components 5 Assemble the groomer reel as follows Note New lock nuts have an...

Page 219: ...he groomer blades should be centered on the shaft 6 Install the groomer reel back onto the cutting unit refer to Installing the Groomer Reel page 8 21 Installing the Groomer Reel 1 Position the groome...

Page 220: ...uick up handle 18 Eye bolt 8 Groomer height of cut arm 19 Shoulder screw 9 Height of cut washer 20 Hardened washer 10 Lock nut 21 Single lug groomer gearbox 11 Bumper Note Early universal groomers use...

Page 221: ...justers 2 Assemble the height of cut bolts to the height of cut arms 3 If both the height of cut arms are removed align 1 height of cut arm and height of cut bolt to the cutting unit side plate 4 Loos...

Page 222: ...th with optional washers 19 mm 0 75 inch 2 Original spring length distance between top and bottom washers 4 Belleville washer 15 Subtract the desired 75 inch or 19 mm spring length from the current sp...

Page 223: ...ted in step 15 18 Apply medium strength thread locking compound to the threads of the shoulder screws 19 Align the hardened washers between the eye bolts to the groomer gearbox and idler arm lugs and...

Page 224: ...outer 21 Cotter pin 4 Screw 10 Lock nut 16 Washer 20 6 x 10 3 mm 0 813 x 0 406 inch 5 Detent spring 11 Bumper 17 Serrated flange nut 6 Quick up cover 12 Lock screw 18 Eye bolt Note Early universal gr...

Page 225: ...per threads of the eye bolts and lower threads of the height of cut bolts 2 Assemble an eye bolt to each of the height of cut arms with a serrated flange nut washer 20 6 x 10 3 mm 0 813 x 0 406 inch i...

Page 226: ...e groomer reel height refer to Universal Groomer Drive Kit Installation Instructions 15 Ensure that both groomer quick up handles are in the OPERATING position g396899 Figure 138 1 Transport position...

Page 227: ...roomer Reel page 8 19 The grooming brush element or shaft can be serviced separately To remove the spiral grooming brush from the shaft remove the lock nut and J bolt from both ends of the brush assem...

Page 228: ...Universal Groomer Optional Service and Repairs Page 8 30 Greensmaster eFlex 1021 20248SL Rev C...

Page 229: ...Foldout Drawings Table of Contents Electrical Drawing Designations A 2 Electrical Schematic A 3 Wire Harness Drawing A 4 Wire Harness Drawing A 5 Greensmaster eFlex 1021 Page A 1 Foldout Drawings 202...

Page 230: ...include a line with an alternate color These wires are identified with the wire color and line color with either a or _ separating the color abbreviations listed above e g R BK is a red wire with a bl...

Page 231: ...Greensmaster eFlex 1021 Drawing 122 1647 Rev A Sheet 1 of 1 20248SL Rev C Page A 3 Electrical Schematic g349607...

Page 232: ...Page A 4 20248SL Rev C Greensmaster eFlex 1021 Drawing 122 1734 Rev D Sheet 1 of 2 Wire Harness Drawing CV g349608...

Page 233: ...Greensmaster eFlex 1021 Drawing 122 1734 Rev D Sheet 2 of 2 20248SL Rev C Page A 5 Wire Harness Drawing g349609...

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