Toro Greensmaster eFlex 1800 Page 197 Service Manual Download

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Replacing the Brake Cable

g198894

Figure 135

Bail lever cover

Brake latch

17.

Spacer

Lift bail assembly

10.

Extension spring

18.

Screw (4 each)

Shoulder screw

11.

Bushing (2 each)

19.

Lower handle

Flat washer

12.

Brake lever

20.

Console cover

Locknut

13.

Brake cable

21.

Washer-head screw (4 each)

Upper handle

14.

Flange nut

22.

Reel clutch cable

Brake lever keeper

15.

Button-head screw

23.

Traction lever assembly

Locknut

16.

Washer

Removing the Brake Cable

1. Park the machine on a level surface, turn the key switch to the O

position,

and remove the key from the key switch. Disconnect the battery pack; refer
to

Connecting the Lithium Battery Pack (page 6–3)

2. Remove the brake cable from the brake lever shaft on the drum drive housing

(

Figure 136

) as follows:

A. Loosen the front cable jam nut that secures the cable to the casting slot

on the drum drive housing. Separate the cable from the slot.

Greensmaster

eFlex 1800, 2100 and 2120

Page 6–7

Chassis and Controls: Service and Repairs

12189SL Rev E

Summary of Contents for Greensmaster eFlex 1800

Page 1: ...l No 312000001 and Up Model 04043 Serial No 312000001 and Up Model 04046 Serial No 400000000 and Up Model 04049 Serial No 400000000 and Up 2018 The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 Original Instructions EN Contact us at www Toro com All Rights Reserved ...

Page 2: ...sue B 2017 Added eFlex 2120 C 01 2018 Added Revision History D 04 2018 Updated Cutting Unit chapter E 03 2019 Added Model 04049 and updated models 04042 04043 and 04046 fitted with 04069 Revision History Page 2 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 3: ...ncourage 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 Manager Commercial The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 1196 Phone 1 952 887 8495 Greensmaster eFlex 1800 2100 and 2120 Page 3 Reader Comments 12189SL Rev E ...

Page 4: ...NOTES NOTES Page 4 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 5: ...nge the product specifications or this publication 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 injury or disability WARNING This safety symbol means warning When you see this symbol carefully read the instructions that follow Failure to obey the inst...

Page 6: ...equence 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 Tables refer to Torque Specifications page 2 7 Fluid Specifications This icon is used to highlight fluid specifications and capacities that are less common and may not appear on the machine service deca...

Page 7: ...d 04046 5 10 Special Tools 5 16 InfoCenter Display 5 19 Adjustments 5 33 Testing the Electrical Components 5 39 Service and Repairs 5 69 Chapter 6 Chassis and Controls 6 1 General Information 6 2 Service and Repairs 6 4 Chapter 7 Cutting Unit 7 1 General Information 7 2 Adjustments 7 6 Service and Repairs 7 8 Chapter 8 Belt Driven Groomer 8 1 General Information 8 2 Adjustments 8 4 Service and Rep...

Page 8: ...0 2100 and 2120 for Models 04042 04043 04046 and 04049 fitted with 04069 A 10 Wire Harness Li Battery 1800 2100 and 2120 for Model 04042 04043 and 04046 A 11 Wire Harness Li Diagnostic 1800 2100 and 2120 for Model 04042 04043 and 04046 A 12 Wire Harness Li Adapater 1800 2100 and 2120 for Model 04042 04043 and 04046 A 13 Preface Page 8 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 9: ...uctions 1 2 Before Operating the Machine 1 3 While Operating the Machine 1 4 Maintenance and Service 1 5 Connecting the Lithium Battery Pack 1 6 Safety and Instructional Decals 1 7 Greensmaster eFlex 1800 2100 and 2120 Page 1 1 Safety 12189SL Rev E ...

Page 10: ...f the machine The improper use or maintenance of the machine can result in injury or death WARNING To reduce the potential of injury or death comply with the following safety instructions WARNING The eFlex lithium battery pack contains high voltage which could burn or electrocute you Do not attempt to open the battery pack Do not place anything in the connector of the battery pack other than the w...

Page 11: ...te the machine while wearing sandals tennis shoes or sneakers Do not wear loose fitting clothing which could get caught in moving parts and cause personal injury Wearing safety glasses safety shoes long pants ear protection and a hard hat is advisable and required by some local safety and insurance regulations Ensure that the work area is clear of objects which might be picked up and thrown by the...

Page 12: ...asket of clippings disengage the traction and reel drives set the parking brake turn the key switch to the OFF position and wait for the electric motor to stop Wait for all the machine movement to stop before removing the basket 5 If the cutting unit strikes a solid object or vibrates abnormally stop the machine operation immediately Disengage the traction mow lever turn the key switch to the OFF ...

Page 13: ...f the body away from the cutting unit and all moving parts Keep bystanders away Before installing removing or working on the cutting unit disconnect the battery pack refer to Connecting the Lithium Battery Pack page 1 6 to prevent unintentional machine operation Do not open or change the battery pack in any way Opening the battery pack may expose you to dangerous electrical voltage The warranty wi...

Page 14: ...will prevent unexpected machine operation g202195 Figure 2 eFlex 2120 Model 04046 shown 1 Machine connector 2 Battery pack 3 Battery connector To prevent unexpected machine operation during service disconnect the machine from the battery pack as the first step in any repair Figure 2 Once the battery pack has been disconnected the electrical system on the machine can be safely worked on During repa...

Page 15: ...re located near any area of potential danger Replace any decal that is damaged or lost The decal part numbers are listed in your Parts Catalog Order replacement decals from your Authorized Toro Distributor Greensmaster eFlex 1800 2100 and 2120 Page 1 7 Safety Safety and Instructional Decals 12189SL Rev E ...

Page 16: ...Safety Safety and Instructional Decals Page 1 8 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 17: ...5 Universal Groomer Optional 2 6 Torque Specifications 2 7 Identifying the Fastener 2 8 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 2 9 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners 2 10 Other Torque Specifications 2 11 Conversion Factors 2 11 Shop Supplies 2 12 Special Tools 2 14 Greensmaster eFlex 1800 2100 and 2120 Page 2 1 Specifications and M...

Page 18: ...Specifications Overall Dimensions g272543 Figure 3 Specifications and Maintenance Specifications Page 2 2 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 19: ...with positive drive belt Pulley configuration allows 6 clip adjustments Electrical System Item Description Power Lithium Ion battery pack nominal 53 V 35 Ah 42 to 64 V 1 68 kWh with integrated battery management system utilizing CAN communication with the TEC and charger Single battery affixed to unit and charged onboard Electric motor Brushless permanent magnet DC motor nominal 1 2 kW 20 A contin...

Page 20: ...ncy is adjusted by moving the pulleys on the cutting unit reel drive housing 6 clip adjustments are possible based on pulley configuration Rollers The rear roller is a 5 1 cm 2 inches diameter aluminum full roller The front roller is a 6 3 cm 2 5 inches diameter roller that is chosen from a variety of configurations narrow spaced Wiehle front roller is shown in Figure 4 Bedknife and bedbar Single ...

Page 21: ... 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 8 to 15 7 mm 0 030 to 0 620 inch at mowing HOC range of 1 5 to 19 1 mm 0 060 to 0 750 inch Width of groomer 49 2 cm 19 380 inches Height adjustment knob Allows a 0 08 mm 0 003 inch increment of height adjustment for each cl...

Page 22: ...de plates Groomer height setting Mowing 0 8 to 15 7 mm 0 030 to 0 620 inch HOC range 1 5 to 19 1 mm 0 060 to 0 750 inch Width of groomer 54 6 cm 21 5 inches Height adjustment knob Allows a 0 003 inch 0 08 mm increment of height adjustment for each click of the adjuster Quick up feature Allows grooming reel to be raised above the height depth adjustment for no grooming reel action while mowing Groo...

Page 23: ...ture 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 reduced by 25 for the lubricated fasteners to achieve the similar stress as a dry fastener The torque values must be reduced when the fastener is threaded into the aluminum or brass The specific torque value...

Page 24: ... 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 recommends replacing fasteners with a locking feature once they have been removed because the effectiveness of the locking feature diminishes with each reuse If it is necessary to reuse a fastener with a lo...

Page 25: ...8 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 16 150 15 203 20 210 21 285 28 5 8 18 UNF 75 10 95 15 129 20 170 18 230 24 240 24 325 33 3 4 10 UNC 93 12 140 20 190 27 265 27 359 37 375 38 508 52 3 4 16 UNF 115 15 165 25 224 34 300 30 407 41 420 43 569 5...

Page 26: ...2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610 62 N m Note The torque values must be reduced when installing the fasteners into threaded aluminum or brass The specified torque value should be determined based on the aluminum or base material strength fastener size length of thread engagement etc Note The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J1...

Page 27: ...4 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 Cutting Screws Zinc Plated Steel Threads per Inch Thread Size Type A Type B Baseline Torque No 6 18 20 20 5 in lb No 8 15 18 30 5 in lb No 10 12 16 38 7 in lb No 12 11 14 85 15 in lb The hole size material streng...

Page 28: ... a shop supply may appear in figures that support a procedure Always refer to the written procedure for specific information regarding the type and the application of a shop supply IMPORTANT Always follow manufacturers instructions when using or storing shop supplies Specifications and Maintenance Shop Supplies Page 2 12 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 29: ...ousings or onto shafts When cured bearing and sleeve retaining compound fills the gap between mating parts with a hard resin that increases load distribution and protects against corrosion Adhesive Used to secure a variety of components immediately prior to assembly May be recommended for installing new components or when reusing a component that had a pre applied adhesive such as hood seals mould...

Page 30: ... of 14 gauge wire a 20 amp in line fuse two 2 alligator clips and necessary connectors Connecting the wire to switch terminals 1 and 2 will allow the momentary switch contacts to be used for the remote starter switch Note For information on using the remote starter switch to prime the hydraulic pumps Remote Starter Switch purchased Remote Starter Switch fabricated Multimeter Obtain this tool local...

Page 31: ... terminals liberally apply the gel to the component and wire harness connector plug the connector into the component unplug the connector apply the gel to both surfaces again and connect the harness connector to the component again The connectors must be fully packed with gel for effective results Note Do not use the dielectric gel on the sealed connection terminals as the gel can unseat the conne...

Page 32: ...rance Reel Drive Shaft Toro Part No TOR4112 Use the drive shaft for rotating the reel during cutting unit adjustment or any time the hydraulic reel motor is removed Backlapping Brush Assembly Toro 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 individually Brush 36 4310 H...

Page 33: ...e 3 Bedbar 2 Angle Indicator 3 Remove the angle indicator and place the magnetic mount on the edge of the bedknife so the face of the magnet is flat against the top angle of the bedknife 4 Place the angle indicator on the mount with the digital display facing you as shown The angle displayed on the indicator is the current bedknife top angle g223326 Figure 9 1 Angle indicator surface 4 Bedbar 2 Ma...

Page 34: ...ng the washers and spacer listed above this special tool set can be used to install bearings and seals into the front and rear rollers Turf Evaluator Tool Toro Part No 04399 Many turf discrepancies are subtle and require closer examination In these instances the Turf Evaluator grass viewing tool is helpful It can assist turf managers and service technicians in determining causes for poor reel mowe...

Page 35: ...lution Confirmation 3 2 Electrical System Troubleshooting 3 3 Factors That Can Affect Quality of Cut 3 6 Factors Affecting Grooming 3 7 Grooming Reel Mechanical Problems 3 8 The information In this chapter is intended to help troubleshoot machine operation issues Keep in mind there can be more than one cause for a machine malfunction Greensmaster eFlex 1800 2100 and 2120 Page 3 1 Troubleshooting 1...

Page 36: ...ypothesis Narrow down the focus of the problem Assess Performance Ensure you have all the necessary tools for testing Test all potential causes of the failure Reevaluate and create a new hypothesis if necessary Repair Return the unit to service by repairing rebuilding or replacing Solution Confirmation Did the issue go away Was the root cause of the issue correctly repaired Are there any other new...

Page 37: ...ey are damaged The lithium battery pack fuse is damaged Check the battery pack fuse and replace the fuse if damaged The key switch is 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 are loose or damaged Check the electrical connections Repair the wir...

Page 38: ...the wiring as necessary The electric motor is damaged Note Fault should be displayed on the InfoCenter if the electric motor is damaged Check the electric motor and circuit wires Repair as necessary Machine is Inoperative and InfoCenter Power Light Indicates That a Fault Has Occurred Possible Causes Correction System fault has been detected by controller Use the Faults screen information in the In...

Page 39: ...anual for EZ turn sensor adjustment The cutting unit pitch arms are binding on the side plate bushings Clean the pitch arms and bushings Machine Operates But InfoCenter Display is Not Working Possible Causes Correction The wire harness connections or wires to the InfoCenter display are loose or damaged Check the electrical connections Repair the wiring as necessary The InfoCenter display is damage...

Page 40: ...ntact will dull the cutting edges Excessive contact accelerates wear of both edges Quality of cut is adversely affected by both conditions Slightly dull cutting edges may be corrected by backlapping refer to Backlapping page 7 8 Excessively dull cutting edges must be corrected by grinding the reel and bedknife refer to Preparing the Reel for Grinding page 7 34 4 Height of cut Effective or actual h...

Page 41: ...y of cut also 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 cutting number of cuttings per week and how many passes per cutting 4 The blade spacing on the grooming reel 5 The height of cut 6 The grooming depth 7 The type of grass on the green 8 The amount ...

Page 42: ...sengaged Handle needs to be rotated toward the front of the machine to engage the groomer drive Seized grooming reel or idler bearing s in groomer side plate s Identify and replace damaged bearing s Broken or damaged drive idler spring Replace idler spring No rotation of the grooming reel counter rotating groomer drive Groomer drive gears are worn or damaged Inspect groomer drive assembly and repl...

Page 43: ...4 12 Service and Repairs 4 14 Reel Drive Belt 4 14 Reel Drive Assembly 4 16 Reel Drive Bearing Housing 4 19 Drum Drive Belt 4 21 Drum Drive Idler Assembly 4 24 Traction Drums 4 27 Differential Assembly 4 31 Servicing the Differential Assembly 4 34 Transmission Drive Belt 4 38 Transmission Idler System 4 41 Transmission Reel Drive System 4 43 Removing the Reel Clutch Shaft seized bearing condition ...

Page 44: ... the operation general maintenance and maintenance intervals for your machine Refer to the Operator s Manual for additional information when servicing the machine Traction and Reel Drive System General Information Page 4 2 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 45: ...unexpected machine operation g202195 Figure 10 eFlex 2120 Model 04046 shown 1 Machine connector 2 Battery pack 3 Battery connector To prevent unexpected machine operation during service disconnect the machine from the battery pack as the first step in any repair Figure 10 Once the battery pack has been disconnected the electrical system on the machine can be safely worked on During repairs ensure ...

Page 46: ...to the right drive housing drum Figure 11 CAUTION Be careful when rotating the traction engage disengage lever The lever is spring loaded and may cause personal injury Push the lever from the front when removing belt tension to prevent unexpected movement of the lever 3 Rotate the traction engage disengage lever toward the rear of the machine to the disengaged position to remove tension from the d...

Page 47: ... the key from the key switch Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 4 3 g203656 Figure 12 eFlex 2120 Model 04046 shown 1 Transmission 2 Engage disengage shaft 3 Battery pack g205908 Figure 13 1 Alignment mark 2 Engage disengage shaft 3 Cover alignment mark 2 Locate the transmission engage disengage shaft on the inside of the transmission next to the battery p...

Page 48: ... 1 4 turn clockwise 4 To engage the idler into the transmission drive belt use a 3 8 inch wrench to rotate the engage disengage shaft 1 4 turn counterclockwise The transmission belt is properly tensioned when the alignment marks on the engage disengage shaft and the transmission cover are aligned Figure 13 5 Connect the battery pack refer to Connecting the Lithium Battery Pack page 4 3 Traction an...

Page 49: ... Drive System page 4 43 for complete information on servicing the reel clutch shaft assembly Socket Modification 1 Ensure that the socket 15 mm or 9 16 inch to be modified fits over the reel clutch shaft bearing collar g203658 Figure 15 2 Drill a hole or grind slots in the socket walls to allow a 5 32 inch pin to extend through the socket A modified socket with ground slots is shown in Figure 15 G...

Page 50: ...sembly in a vise Use a vise with soft jaws to prevent damage to the clutch shaft assembly components Figure 16 2 Slide the modified socket over the bearing collar 3 Align the modified socket so that the 5 32 inch pin can be inserted through the socket and hole in the bearing collar 4 Use the modified socket and socket wrench to loosen or tighten the bearing collar Traction and Reel Drive System Sp...

Page 51: ...ne Toro Part No TOR4112 Use a spline insert tool to remove or install the drive spline into the transmission driven pulley Refer to Transmission Drive System page 4 50 for complete information on servicing the transmission drive system Greensmaster eFlex 1800 2100 and 2120 Page 4 9 Traction and Reel Drive System Special Tools 12189SL Rev E ...

Page 52: ...surface turn the key switch to the OFF position and remove the key from the key switch Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 4 3 2 Remove the reel drive cover and reel drive belt from side of the cutting unit refer to Reel Drive Belt page 4 14 g203640 Figure 19 1 Set screw 2 each 4 Reel drive belt 2 Pulley 5 Woodruff key 3 Reel drive cover 3 Loosen the 2 set...

Page 53: ...drive assembly as necessary for desired clip frequency Figure 20 5 Secure all the pulleys with the 2 set screws torque the screws to 8 3 to 8 9 N m 74 to 79 in lb 6 Install the reel drive belt and reel drive cover to the cutting unit refer to Reel Drive Belt page 4 14 7 Connect the battery pack refer to Connecting the Lithium Battery Pack page 4 3 Greensmaster eFlex 1800 2100 and 2120 Page 4 11 Tr...

Page 54: ...ug from the front of the transmission to view the reel drive clutch components Figure 21 3 Release the clutch cable spring tension by removing the reel clutch cable from the casting slot of the transmission as follows A Loosen the upper jam nut that secures the reel cable to the casting slot of the transmission B Lift the cable free from the casting slot of the transmission 4 Loosen the jam nut th...

Page 55: ...mm 0 040 to 0 060 inch is attained between the reel drive hub and the reel clutch hub 8 Tighten the jam nut to secure the adjustment Ensure that the set screw does not rotate while tightening the jam nut 9 Install the rubber plug into the front of the transmission 10 Install the reel cable to the casting slot of the transmission and confirm that the cable spring length is properly set refer to Rep...

Page 56: ...Pack page 4 3 g203646 Figure 23 1 Reel drive cover 2 Flange head screw 2 Remove the reel drive cover to expose the reel drive belt Figure 23 g203647 Figure 24 1 Compression spring 3 Bearing housing nut 2 Bearing housing 4 Reel drive belt 3 Loosen the bearing housing mounting nut Figure 24 4 Use a 16 mm 5 8 inch wrench rotate the bearing housing to release tension on the reel drive belt Figure 24 5...

Page 57: ... reel drive belt Ensure that the bearing housing rotates freely which allows accurate belt tension 5 Rotate the reel drive at least 1 full turn to ensure that the drive belt is properly tensioned 6 Tighten the bearing housing mounting nut Figure 24 7 Install the reel drive cover to the machine and secure the cover with the flange head screw Figure 23 8 Connect the battery pack refer to Connecting ...

Page 58: ... Belt 27 Compression spring 8 Ball bearing 2 each 18 Reel pulley 22 tooth aluminum 28 Carriage screw 9 Washer head screw 19 Reel pulley 24 tooth black 10 Reel idler shaft 20 Flange head screw 2 each Note The cutting unit clip adjustment on the eFlex 1800 2100 and 2120 is adjusted by installing the cutting unit drive pulleys items 12 18 and 19 in Figure 25 to the appropriate locations on the reel d...

Page 59: ...uring cutting unit production The nuts must remain in cutting unit side plate during the reel drive housing removal 6 Remove the 2 flange head screws item 20 in Figure 25 that secure the reel drive housing to the cutting unit side plate 7 Remove the reel drive assembly from the cutting unit 8 Remove the components from the reel drive housing as necessary Figure 25 9 If the idler shaft ball bearing...

Page 60: ...lange head screws item 20 in Figure 25 and washer head screw 5 Install the woodruff key to the reel driveshaft item 21 in Figure 25 Apply anti seize lubricant at the top of the key 6 Slide the reel pulley item 18 in Figure 25 onto the reel driveshaft until it contacts the shoulder on the shaft Secure the reel pulley with the 2 set screws torque the set screws to 8 3 to 8 9 N m 74 to 79 in lb 7 Ins...

Page 61: ...rn the key switch to the OFF position and remove the key from the key switch Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 4 3 2 Remove the reel drive bearing housing from the reel drive housing refer to Reel Drive Assembly page 4 16 3 Remove the retaining ring item 10 in Figure 27 from the bearing housing 4 Slide the reel input shaft assembly from the bearing housi...

Page 62: ...ave spring and flat washer onto the reel input shaft Secure the components to the shaft with the retaining ring item 14 in Figure 27 If necessary drive the retaining ring onto the input shaft with a tubular tool and mallet Ensure that the retaining ring is fully seated into the shaft groove after installation 3 Place the wave washer item 7 in Figure 27 into the bearing housing 4 Fill the cavity be...

Page 63: ...Flex 1800 2100 and 2120 machines uses a multi ribbed poly V drive belt on the right side of the traction drum Removing the Drum Drive Belt 1 Park the machine on a level surface turn the key switch to the OFF position and remove the key from the key switch Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 4 3 2 If installed remove the transport wheels refer to Transport ...

Page 64: ...1 Traction drive belt 3 Idler pulley 5 Brake band 2 Drive pulley 4 Differential pulley 9 Pivot the idler pulley away from the drum drive belt to loosen the belt tension Figure 29 10 Remove the drum drive belt from the drive pulley and then from the differential pulley Installing the Drum Drive Belt 1 Ensure that the battery pack is disconnected refer to Connecting the Lithium Battery Pack page 4 3...

Page 65: ... 40 in lb B Again use an alternating crossing pattern torque all the screws to 9 6 to 10 7 N m 85 to 95 in lb g203650 Figure 30 1 Traction lever engaged 2 Right handle clamp 9 Rotate the traction engage disengage lever to the engaged position to tension the drum drive belt Figure 30 10 Install the rail kit wheels if they were attached refer to Rail Kit Wheels Optional page 6 24 11 Install the tran...

Page 66: ...achine on a level surface turn the key switch to the OFF position and remove the key from the key switch Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 4 3 2 If installed remove the transport wheels refer to Transport Wheels Optional page 6 21 3 If installed remove the rail kit wheels refer to Rail Kit Wheels Optional page 6 24 4 Rotate the traction engage disengage ...

Page 67: ...er pulley from the bracket shaft Press the ball bearings from the idler pulley Installing the Drum Drive Idler Assembly 1 If the idler arm assembly was disassembled Figure 32 do the following steps A Press new flange bushings into the idler bracket B Press new ball bearings fully into the idler pulley and ensure to apply pressure to the outer bearing race only Slide the pulley assembly onto the id...

Page 68: ...to 10 7 N m 85 to 95 in lb 8 Rotate the traction engage disengage lever to the engaged position to tension the drum drive belt refer to Disengaging the Drum Drive from the Transmission page 4 4 9 Install the rail kit wheels if they were attached refer to Rail Kit Wheels Optional page 6 24 10 Install the transport wheels if they were attached refer to Transport Wheels Optional page 6 21 11 Connect ...

Page 69: ...eft traction drum 8 Brake lever 18 Retaining ring 28 Grease seal 9 Dowel pin 2 each 19 Ball bearing 2 each 29 Jam nut 10 Drum drive housing 20 O ring 30 Right traction drum Removing the Traction Drum 1 Park the machine on a level surface turn the key switch to the OFF position and remove the key from the key switch Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 4 3 2...

Page 70: ...ove the 3 flange head screws and 3 hardened washers items 5 and 6 in Figure 34 that secure the left side plate to the frame C Slide the left side plate from supporting bearing and remove from the machine 7 Insert a bar stock or other suitable tool through the spokes of the left traction drum to keep the drum from turning 8 While retaining the left drum loosen and remove the bearing nut item 26 in ...

Page 71: ...fer to Differential Assembly page 4 31 2 Install the left hex shaft item 25 in Figure 33 and ball bearing to the bearing nut if they were removed Press the bearing fully onto the bearing nut Torque the hex shaft to 95 to 108 N m 70 to 80 ft lb 3 Place the square key item 3 in Figure 33 into the slot of the long spur gear Apply anti seize lubricant to the top surface of the key 4 Align the slot in ...

Page 72: ...ball bearing item 19 in Figure 33 is pressed onto the bearing nut While retaining the left drum secure the drum to the traction drum assembly with a bearing nut Torque the bearing nut to 102 to 122 N m 75 to 90 ft lb 13 Secure the left side plate to the machine Figure 34 as follows A Slide the left side plate onto the supporting bearing B Secure the left side plate to the frame with the 3 flange h...

Page 73: ... 5 Straight bushing 2 each 16 Washer head screw 27 Left traction drum 6 Traction lever 17 Brake lever 28 Grease seal 7 Flange bushing 4 each 18 Retaining ring 29 Jam nut 8 Brake lever 19 Ball bearing 2 each 30 Right traction drum 9 Dowel pin 2 each 20 O ring 31 Spur gear assembly 10 Drum drive housing 21 Lock collar 11 Straight bushing 22 Pin Greensmaster eFlex 1800 2100 and 2120 Page 4 31 Tractio...

Page 74: ... 2 Drum drive housing 3 Slide the spur gear assembly from the differential assembly in the drum drive housing Figure 37 g203655 Figure 38 1 Flange bushing 3 Ball bearing 2 Spur gear 4 Hex shaft left hand threads 4 If necessary disassemble the spur gear assembly Figure 38 A The hex shaft has left hand threads The shaft also has thread locking compound on threads B Press the ball bearing and flange ...

Page 75: ...e housing 2 If the spur gear assembly was disassembled assemble as necessary Figure 38 A Press a new ball bearing fully onto the spur gear if removed B Press a new flange bushing into the spur gear if removed C If the hex shaft was removed from the spur gear apply Loctite 242 or equivalent to the threads of the hex shaft Install the hex shaft left hand threads into the spur gear torque the hex sha...

Page 76: ...9 1 Ball bearing 2 each 4 Spacer 9 each 7 Spur gear 3 each 2 Socket head screw 6 each 5 Pin 6 each 8 Cover 3 Dual spur gear 6 each 6 Housing Traction and Reel Drive System Service and Repairs Page 4 34 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 77: ...ted up g204324 Figure 41 1 Housing index mark 2 Pin with 2 gears 3 Pin with 1 gear 4 Lift the housing from the differential assembly leaving the internal components positioned on the cover For assembly purposes note that the index mark on the housing is aligned with a pin that has 1 gear Figure 41 5 For assembly purposes note the locations of the projections on the inside of the cover The projecti...

Page 78: ...he cover with the bearing installed on the workbench g204325 Figure 42 1 Projection on cover 2 Pin with 2 gears 3 Pin with 1 gear 3 Slide each pin with gears and spacers into the cover Ensure that the projections on inside of the cover are aligned with the pins that have 1 gear Figure 42 4 Position the housing onto the assembly and ensure that the pin with 1 gear is positioned next to the index ma...

Page 79: ...al Assembly continued 8 Install the differential assembly to the machine refer to Differential Assembly page 4 31 Greensmaster eFlex 1800 2100 and 2120 Page 4 37 Traction and Reel Drive System Service and Repairs 12189SL Rev E ...

Page 80: ... each 6 Driveshaft wire The transmission removal from the machine is not necessary to service the transmission drive belt The transmission drive belt can be replaced by removing the battery pack from the frame removing the transmission cover and removing the drive belt Traction and Reel Drive System Service and Repairs Page 4 38 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 81: ...to remove tension on the transmission belt refer to Transmission Belt Tensioner page 4 5 5 Remove the 7 washer head screws item 3 in Figure 43 that secure the transmission cover to the transmission Carefully remove the cover from the transmission Remove and discard the gasket 6 Ensure that the wave washers item 2 in Figure 43 remain in the bearing bores of the transmission cover g204326 Figure 44 ...

Page 82: ...ocations Figure 45 to seat cover to the transmission 5 Install the 7 washer head screws to secure the cover to the transmission Tighten the screws as follows A First use an alternating crossing pattern torque all the screws to 1 7 to 4 5 N m 15 to 40 in lb B Again use an alternating crossing pattern torque all the screws to 9 6 to 10 7 N m 85 to 95 in lb 6 Rotate the engage disengage shaft counter...

Page 83: ...e 9 Transmission cover 14 Extension spring 5 Ball bearing 6 each 10 Idler pulley 2 each The transmission removal from the machine is not necessary to service the transmission idler system The transmission idler components can be accessed by removing the battery pack from the frame removing the transmission cover and removing the drive belt Greensmaster eFlex 1800 2100 and 2120 Page 4 41 Traction a...

Page 84: ...d into the pulleys A If the bearings were removed from the idler pulleys press new bearings fully to the shoulder of the idler pulleys g205732 Figure 47 1 Engage disengage shaft 4 Main drive idler 2 Idler pulley 5 Extension spring 3 Transmission belt B If the extension spring was removed ensure that the ends of the spring are orientated as shown in Figure 47 C If the main drive idler item 13 in Fi...

Page 85: ...0 Flex coupler 20 Reel clutch hub The transmission removal from the machine is not necessary to service the transmission reel drive system The transmission reel drive components can be accessed by removing the battery pack from the frame removing the transmission cover and removing the drive belt Removing the Reel Clutch Shaft bearing not seized 1 Park the machine on a level surface turn the key s...

Page 86: ...Flange bushing 6 Inspect the flange bushings and reel brake ring for wear or damage Figure 49 Replace the bushings and brake ring if necessary Disassembling the Reel Clutch Shaft Note The following procedure covers complete disassembly of the reel clutch shaft assembly Depending on service needs of the machine it may not be necessary to perform every step of this procedure IMPORTANT When removing ...

Page 87: ...ing 3 Bearing collar 6 Wave spring 6 Use a modified socket refer to Special Tools page 4 7 to remove the bearing collar assembly from the clutch shaft Figure 50 IMPORTANT To prevent damage avoid using excessive clamping pressure on the reel clutch shaft assembly A Use the flats on the reel drive hub to carefully secure the reel clutch shaft assembly in a vise Use a vise with soft jaws to prevent d...

Page 88: ...tch shaft Torque the bearing collar to 32 to 36 N m 23 to 27 ft lb 5 Install the flocked bearing shield item 14 in Figure 48 flocked side orientated toward bearing location wave spring flat washer and retaining ring onto the bearing collar 6 If the reel clutch fork item 3 in Figure 48 was separated from the reel clutch hub the clutch pivot pins must be replaced new pins have patch lock on threads ...

Page 89: ...housing 2 Slide the reel clutch shaft assembly into the transmission housing 3 Align the missing tooth in spline area of the reel clutch lever item 27 in Figure 48 with the reel clutch fork Insert the lever through the housing and fork Secure the lever with the retaining ring 4 Install the transmission drive belt and all the machine components removed for the reel drive system service refer to Tra...

Page 90: ...o Transmission Drive Belt page 4 38 g205736 Figure 52 1 Transmission housing 2 Housing dimple 2 Carefully drill 2 No 7 0 201 inch diameter holes in the transmission housing using the dimples in the housing as centers for the holes Figure 52 The holes should be drilled completely through the housing allowing external access to the ball bearing on the reel shaft 3 Use a 3 16 inch punch through the d...

Page 91: ...ransmission housing 6 Install the 2 1 4 inch 20 bolts with flat washers into the tapped holes in the transmission housing The bolts not longer than 3 8 inch in length should be used After you install the bolts ensure that the ends of the bolts do not extend into the ball bearing bore in the housing 7 Service the reel clutch shaft assembly as necessary refer to Transmission Reel Drive System page 4...

Page 92: ...e battery pack from the frame removing the electric motor from the transmission removing the transmission cover and removing the drive belt Disassembling the Transmission Drive System 1 Park the machine on a level surface turn the key switch to the OFF position and remove the key from the key switch Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 4 3 2 Remove the elec...

Page 93: ...oid using excessive clamping pressure on the driven pulley flats to prevent damage to pulley A Use the flats on the driven pulley to carefully secure the pulley in a vise Use a vise with soft jaws to prevent pulley damage B Remove the set screw item 8 in Figure 53 from the end of the pulley C Slide the splined coupler onto the drive spline and use a spline insert tool refer to Spline Insert Tool p...

Page 94: ...from the transmission housing secure the adapter to the housing with the 4 washer head screws Tighten the screws as follows A First use an alternating crossing pattern torque all the screws to 1 7 to 4 5 N m 15 to 40 in lb B Again use an alternating crossing pattern torque all the screws to 9 6 to 10 7 N m 85 to 95 in lb 4 Slide the driven pulley assembly including bearings into the motor adapter ...

Page 95: ...assembling the Transmission Drum Drive System 1 Park the machine on a level surface turn the key switch to the OFF position and remove the key from the key switch Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 4 3 2 Remove the transmission drive belt refer to Transmission Drive Belt page 4 38 3 Remove the flange head screw item 10 in Figure 54 and hardened washer tha...

Page 96: ...sing to allow removal of the extension housing Assembling the Transmission Drum Drive System 1 If the extension housing was removed do as follows A Position the extension housing between the transmission housing and the right drum drive housing B Align the extension housing with the right drum drive housing Install the 4 washer head screws finger tight to hold the extension housing in position C P...

Page 97: ... spacer 4 Apply the anti seize lubricant to the pulley surface of the drum drive driven pulley 5 Install the woodruff key in the shaft and slide the driven pulley item 8 in Figure 54 onto the shaft Secure the pulley with the hardened washer and flange head screw 6 Install the drum drive belt to the machine refer to Drum Drive Belt page 4 21 7 Install the transmission drive belt and all the machine...

Page 98: ... from the machine is not necessary in order to service the internal transmission components The transmission components can be accessed by removing the battery pack from the frame removing the transmission cover removing the transmission drive belt If the transmission removal is necessary proceed with the following steps Once the transmission has been removed from the machine service procedures fo...

Page 99: ...asher head screws item 8 in Figure 56 that secure the extension housing to the right drum housing 8 Support the transmission to prevent it from falling 9 Remove the fasteners that secure the transmission to the machine frame A The flange head screw item 2 in Figure 56 that secures front of the transmission to the frame B The bolt item 13 in Figure 56 hardened washer and flange head screw that secu...

Page 100: ...ave been installed fully tighten the fasteners in the following order A The 4 washer head screws First torque all the screws to 1 7 to 4 5 N m 15 to 40 in lb Then use an alternating crossing pattern torque the screws to 9 6 to 10 7 N m 85 to 95 in lb B The bolt and flange head screw that secure the rear of the transmission to the frame C The flange head screw that secures the front of the transmis...

Page 101: ...n Menu Screen 5 25 Faults Screen 5 26 Service Screen 5 28 Diagnostics Screen 5 29 Settings Screen 5 31 About Screen 5 32 Adjustments 5 33 Parking Brake Latch Switch 5 33 Traction Switch 5 35 Reel Engage Switch 5 37 Testing the Electrical Components 5 39 Fuse Block 5 40 Lithium Battery Pack Fuse For Models 04042 04043 and 04046 5 43 Toro Electronic Controller 5 45 Key Switch 5 47 Parking Brake Latc...

Page 102: ...80 Samsung Battery Controller for Models 04042 04043 04046 and 04049 fitted with 04069 5 84 Lithium Battery Pack Charger for Models 04042 04043 and 04046 5 88 Lithium Battery Pack Charger for Models 04042 04043 04046 and 04049 fitted with 04069 5 90 Electrical System Service and Repairs Page 5 2 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 103: ...s Manuals 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 your Greensmaster machine and charger Refer to these Operator s Manuals for additional information when servicing the machine Electrical Schematics and Diagrams Refer to the Electrical Schematics and Wire Harn...

Page 104: ...itches inputs and directs electrical power to control the appropriate machine functions outputs based on the inputs The status of inputs to the controller as well as outputs from the controller can be monitored with the InfoCenter display on the console If a problem exists that could prevent normal operation the InfoCenter display will display an operator advisory or fault code to assist in identi...

Page 105: ...Figure 59 IMPORTANT Before performing any welding on the machine do the following to prevent damaging the electrical system of the machine Disconnect the machine connector from the lithium battery pack Disconnect the wire harness connectors from the Toro Electronic Controller Greensmaster eFlex 1800 2100 and 2120 Page 5 5 Electrical System General Information 12189SL Rev E ...

Page 106: ...ster The 2 twisted wires form the bus These wires provide the data pathways between the machine components The engineering term for these 2 wires are CAN High and CAN Low At the ends of the twisted pair of bus wires are the 120 ohm terminator resistors The CAN bus link controls each of the components that requires only 4 wires to operate and communicate to the system CAN High CAN Low B power and g...

Page 107: ...event unexpected machine operation g202195 Figure 60 eFlex 2120 Model 04046 shown 1 Machine connector 2 Battery pack 3 Battery connector To prevent unexpected machine operation during service disconnect the machine from the battery pack as the first step in any repair Figure 60 Once the battery pack has been disconnected the electrical system on the machine can be safely worked on During repairs e...

Page 108: ...nd electric motor along with direction from the machine TEC via the CAN bus system The InfoCenter display provides information to the operator during the operation of the machine provides 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 The 53 VDC nomin...

Page 109: ...ng the cutting unit with the engagement lever closes both the traction and reel engage switches The electric motor will be engaged with control of motor speed handled by the TEC and motor controller based on the operator speed setting and load on the machine The EZ turn feature of an eFlex machine is available when the cutting unit is engaged and the EZ turn switch on the console is in the ON posi...

Page 110: ...battery pack charger The charger is equipped with 3 LED s to indicate the charger is ON the battery is CHARGING and the battery is READY fully charged Additionally the LCD message display on the charger can be used to monitor the charging process Note Refer to your Traction Unit Operator s Manual and Lithium Battery Pack Charger Operator s Manual for additional information about the eFlex battery ...

Page 111: ...oltage is correct for start up the charger will wake the battery pack The battery pack runs some internal diagnostics and if all is OK the battery main contactor closes The charger will then send a signal on the CAN bus to stay connected to the battery pack If the battery pack internal diagnostics determine that all is not OK the battery pack will send a fault message During start up the battery v...

Page 112: ...l be displayed in the LCD message display Charging g202199 Figure 64 Charging Message Screen The lithium battery pack communicates to the charger the proper voltage and current levels required for battery charging The charger make its output at the given voltage level and set the current limit as indicated by the pack During charging the battery voltage state of charge as percent of fully charged ...

Page 113: ...r will respond by shutting down the battery pack If the pack fails to terminate the balancing or charging within 19 hours from start of charge the charger will terminate the charge In either case the charger will shut the pack down and switch to the Standby state During cell balancing the battery voltage state of charge as percent of fully charged and amperage will be displayed in the LCD message ...

Page 114: ... reduce the pack SOC from 100 to 40 within 30 days This discharge is done because the lithium battery pack capacity can be permanently reduced if stored at too high of SOC for too long When the battery pack reaches 40 SOC it will indicate that the discharge is completed by changing its state to Storage The charger will then go back into hibernate mode Every 10 days thereafter the charger will powe...

Page 115: ...remedy the issue would be to turn the battery charger power switch to the OFF position disconnect the charger output cord from the battery pack disconnect the charger power cord from the outlet and wait for a minute to allow complete charger and battery shutdown Then correctly connect the battery pack charger and restart the charging operation to see if operation has returned to normal Some faults...

Page 116: ... electric motor is required to remove and install the rotor from the motor housing The tool set includes base plate threaded shaft and handle Figure 69 Note For the electric motor service procedures refer to Servicing the Electric Motor page 5 71 Removing the Rotor 1 Remove the gearbox cover and output gear from the motor assembly refer to Servicing the Electric Motor page 5 71 Electrical System S...

Page 117: ...the threaded shaft with handle to remove the rotor and motor cover from the motor housing Support the rotor to prevent it from falling from the housing during removal 6 Leave the threaded shaft installed in same position in the base plate for rotor installation purposes Installing the Rotor 1 Secure the tool set base plate to the motor housing with the 4 cover screws 2 Ensure that the threaded sha...

Page 118: ... housing slowly rotate the threaded shaft to allow the rotor to be drawn into the housing Once the rotor is fully installed into housing remove the tool set from the motor housing Electrical System Special Tools Page 5 18 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 119: ...ians and allows inputs for the adjustable machine settings Power for the InfoCenter is available when energized by the TEC the key switch is in the START or RUN position A CAN bus system involving the TEC electric motor controller lithium battery pack and InfoCenter provide necessary machine communication for the InfoCenter operation Note Icons that are used on the InfoCenter display are identifie...

Page 120: ...g202945 Figure 72 Electrical System InfoCenter Display Page 5 20 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 121: ... indicator illuminates for a few seconds to verify indicator operation and the InfoCenter splash screen appears Figure 73 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 InfoCenter screen Greensmaster eFlex 1800 2100 and 2120 Page 5 21 Electrical System InfoCenter Display 12189SL Rev E ...

Page 122: ...following information to the operator Battery charge indicator Speed control setting If an electrical machine fault occurs the InfoCenter fault indicator will blink to notify the operator and a descriptive message will be displayed Also the fault log indicator on the InfoCenter screen will be displayed to notify the operator that recent machine faults have occurred Accessing the fault log is descr...

Page 123: ...advisory will be displayed after the key switch is turned OFF Low Battery Shutdown 202 If the battery state of charge is too low for continued machine operation the low battery shutdown advisory will notify the operator that the machine will automatically shutdown Battery charging is necessary before returning the machine to normal operation Energy Saving Mode Active 203 If the battery state of ch...

Page 124: ...ower Consumption Run Time Reduced 210 The high power consumption identifies that electric motor draw is excessive and will reduce the run time of the machine Excessive cutting unit bedknife contact or accessory use may generate this advisory Motor Disabled 212 The motor disabled advisory will identify that electric motor operation was stopped by the controller A fault should have been generated th...

Page 125: ...an occur The main menu screen provides access to the following menu screens Faults Service Diagnostics Settings About Press the down button as indicated by the at the bottom of the screen to highlight the desired menu screen then press the left right button as indicated by the at the bottom of the screen to enter the highlighted menu screen To return to the main information screen from the main me...

Page 126: ...p to remedy the issue would be to move the traction lever to the NEUTRAL position turn the key switch to the OFF position and allow all the machine 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 continues to occur further system evaluation and possible compo...

Page 127: ...compatible 12 Key switch stuck in the ON position 13 Internal lithium battery pack fault 15 Software fault 16 Contactor fault 17 Throttle sensor fault For Models 04042 and 04043 only For Models 04042 04043 04046 and 04049 fitted with 04069 only Greensmaster eFlex 1800 2100 and 2120 Page 5 27 Electrical System InfoCenter Display 12189SL Rev E ...

Page 128: ...r delivery by battery in watts Battery charge percent of battery capacity Battery current amps delivered by battery Battery volts battery potential in volts Energy total energy delivered by battery over its entire life in watt hours Values listed for service menu items cannot be changed To return to the main menu screen from the service screen press the menu back button as indicated by the at the ...

Page 129: ...y On identifies that the 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 to the START position The motor will re initialize PBrake Latch identifies that the parking brake latch is engaged or not EZ Turn indicates whether the EZ turn operation is ON ...

Page 130: ...M The motor RPM should be very close to the Target RPM 12V Supply indicates the supplied voltage available for the 12 VDC circuits InfoCenter EZ turn sensor The 12V Supply should typically be slightly higher than 12 0 VDC 5V Supply indicates the supplied voltage available for the 5 VDC circuit speed control The 5V Supply should typically be slightly higher than 5 0 VDC CAN bus identifies whether t...

Page 131: ...elect from numerous language options Allow the desired selection to remain in view for 5 seconds Backlight Press the left right button as indicated by the at the bottom of the screen then use the down button to decrease or the left right button to increase the InfoCenter display brightness as indicated by the and the at the bottom of the screen Contrast Press the left right button as indicated by ...

Page 132: ...out screen Figure 82 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 button as indicated by the at the bottom of the screen Electrical System InfoCenter Display Page 5 32 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 133: ...ttached to the handle assembly switch panel Figure 83 When the parking brake latch is not applied the latch is positioned near the target end of the parking brake latch switch so that the switch is closed The parking brake latch is moved away from the switch when the latch is applied causing the switch to be in its normally open state Greensmaster eFlex 1800 2100 and 2120 Page 5 33 Electrical Syst...

Page 134: ... 4 Raise the parking brake lever and engage the parking brake latch 5 With the parking brake latch engaged there should be 0 0 to 2 2 mm 0 000 to 0 090 inch clearance between the latch and the parking brake latch switch Figure 83 6 If the clearance is incorrect loosen the brake latch switch mounting fasteners adjust the clearance and tighten the fasteners Check the clearance between the lever and ...

Page 135: ...en the traction engagement lever is not engaged the head of the bolt in the traction lever is positioned away from the target end of the traction switch so that the switch is in its normal open state The head of the bolt in the traction engagement lever is moved toward the switch target when the traction lever is engaged causing the switch to close Greensmaster eFlex 1800 2100 and 2120 Page 5 35 E...

Page 136: ... mm 0 030 to 0 120 inch clearance between the head of the bolt in the traction lever and the traction switch Figure 85 Note With the traction lever pushed fully forward against its rotation stop the head of the bolt should not deflect the traction switch more than 0 8 mm 0 030 inch The traction lever will rotate back slightly once latched At that point the required clearance 0 030 to 0 120 inch sh...

Page 137: ... switch mount bracket Figure 87 When the cutting unit is not engaged the tab on the cutting unit engagement lever is positioned away from the target end of the reel engage switch so that the switch remains open The tab on the engagement lever is moved next to the switch when the cutting unit is engaged causing the switch to close Greensmaster eFlex 1800 2100 and 2120 Page 5 37 Electrical System Ad...

Page 138: ...d to the cutting unit engagement position 5 With the engagement lever in the cutting unit drive engagement position there should be 0 8 to 2 2 mm 0 030 to 0 090 inch clearance between the tab on the cutting unit engagement lever and the reel engage switch Figure 87 6 If the clearance is incorrect loosen the reel engage switch mounting fasteners adjust the clearance and tighten the fasteners Check ...

Page 139: ...uit 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 switch connector before doing a continuity check on switch Individual components should be electrically isolated e g disconnect all the leads or remove the leads from the circuit from the circuit when te...

Page 140: ...h to the OFF position and remove the key from the key switch 2 Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 5 7 3 For Models 04042 04043 and 04046 Remove the 2 screws that secure the rear of the power center cover to the machine Figure 89 Then loosen the upper 2 screws on the cover and remove the cover from the machine g269778 Figure 90 eFlex 2120 Model 04049 shown...

Page 141: ...1 Fuse F1 1 30 A 3 Fuse F1 3 3 A 2 Fuse F1 2 3 A 4 Fuse F1 4 open g269792 Figure 92 eFlex 2120 Model 04049 shown 1 Fuse F1 1 30 A 3 Fuse F1 3 3 A 2 Fuse F1 2 3 A 4 Fuse F1 4 open Refer to Figure 91 or Figure 92 to identify each individual fuse and its correct amperage The fuses for the Greensmaster eFlex machines have the following functions Fuse F1 1 30 A Protects main power supply circuits Green...

Page 142: ...NT The eFlex machine uses special fuses that are rated 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 functional fuse into the fuse holder 5 After you complete the fuse service secure the power center cover to the machine with the 4 screws 6 Connect the...

Page 143: ... pack 4 Lock washer 8 each 2 Fuse 5 Screw 8 each 3 Fuse cover The lithium battery pack that provides electrical power for the eFlex machines includes a fuse for battery circuit protection Removal of the fuse cover on the bottom of the battery pack is required to access the fuse in the battery pack Figure 93 Greensmaster eFlex 1800 2100 and 2120 Page 5 43 Electrical System Testing the Electrical Co...

Page 144: ...r 5 After you complete the fuse service A Secure the fuse cover to the bottom of the battery pack with the 8 screws and 8 lock washers Figure 94 torque the screws to 0 34 N m 3 in lb B Lower and secure the battery pack to the machine refer to Lithium Battery Pack for Models 04042 04043 and 04046 page 5 74 C Connect the battery pack refer to Connecting the Lithium Battery Pack page 5 7 Testing the ...

Page 145: ...hen direct electrical power output to allow certain machine functions The controller is also connected to the CAN bus system for communications with the electric motor and battery controllers The TEC is attached to the machine under the power center cover behind the lithium battery pack Figure 95 for models 04042 04043 and 04046 The TEC is attached to the mount bracket inside the battery cover Fig...

Page 146: ...l functions of the TEC Two wire harness connectors attach to the controller with each of the connectors including 12 pins The connector pins are listed in the diagram The InfoCenter display should be used for checking inputs and outputs of the controller used on your Greensmaster refer to InfoCenter Display page 5 19 The InfoCenter display can also be used to identify faults and operator advisorie...

Page 147: ...tion suggests a damaged key switch proceed to the key switch testing below Note If the eFlex machine is sitting idle for 5 minutes with the key switch in the RUN 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 26 for information on faults Testing the Key Switch 1 Park the machine on ...

Page 148: ...Table page 5 48 Check the continuity between the switch terminals Circuit Logic Table Switch Position Circuits OFF None RUN B C F D E START A B C 6 Replace the key switch if necessary 7 After you complete the testing connect the wire harness electrical connector to the key switch 8 Install the console cover to the handle Figure 98 9 Connect the battery pack refer to Connecting the Lithium Battery ...

Page 149: ...ing brake latch switch 4 Washer head screw 4 each 7 Switch panel 2 Washer head screw 2 each 5 Console cover 3 Locknut 2 each 6 Lower handle Greensmaster eFlex 1800 2100 and 2120 Page 5 49 Electrical System Testing the Electrical Components 12189SL Rev E ...

Page 150: ...arking brake latch is engaged and released Further parking brake latch switch testing is necessary only if the switch state does not change when using the InfoCenter Testing the Parking Brake Latch Switch 1 Park the machine on a level surface and place the traction lever in the NEUTRAL position Turn the key switch to the OFF position and remove the key from the key switch 2 Disconnect the battery ...

Page 151: ...ake latch switch the screws and locknuts used to secure the switch are stainless steel If these fasteners are replaced ensure to use correct fasteners 3 Position the switch to the switch panel and secure with the 2 washer head screws and 2 locknuts Figure 100 4 Adjust the parking brake latch switch refer to Parking Brake Latch Switch page 5 33 5 Connect the switch to the machine wire harness Secur...

Page 152: ...ch 2 Lower handle 5 Washer head screw 2 each 8 Switch mount bracket 3 Console cover 6 Traction switch g202427 Figure 103 1 Traction switch 3 Bolt head 2 Switch mount bracket 4 Engagement lever Electrical System Testing the Electrical Components Page 5 52 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 153: ...le to get access to the traction switch Figure 102 4 Disconnect the traction switch connector from the machine wire harness 5 Connect a multimeter ohms setting across the switch connector terminals to check the continuity of the traction switch 6 With the traction lever in the NEUTRAL position there should not be continuity infinite ohms across the switch terminals 7 Check that the switch closes z...

Page 154: ...cket 2 Lower handle 5 Washer head screw 2 each 8 Locknut 2 each 3 Console cover 6 Reel engage switch g202429 Figure 105 1 Switch mount bracket 3 Reel lever tab 2 Reel engage switch 4 Engagement lever Electrical System Testing the Electrical Components Page 5 54 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 155: ...ge 5 7 3 Remove the console cover from the handle to get access to the reel engage switch Figure 104 4 Disconnect the reel engage switch connector from the machine wire harness 5 Connect a multimeter ohms setting across the switch connector terminals to check the continuity of the reel engage switch 6 With the cutting unit drive not engaged there should not be continuity infinite ohms across the s...

Page 156: ...itch with the InfoCenter on the console With the key switch in the RUN position and the InfoCenter in the diagnostics menu choose the EZ Turn and ensure that the switch state changes as the switch is toggled between ON and OFF Further EZ turn switch testing is necessary only if the switch state does not change when using the InfoCenter Testing the EZ Turn Switch 1 Park the machine on a level surfa...

Page 157: ...e various terminals for each switch position Check the continuity between the switch terminals Circuit Logic Table Switch Position Normal Circuits Other Circuits OFF 1 2 4 5 ON 2 3 5 6 6 Replace the EZ turn switch if necessary 7 Connect the switch to the machine wire harness Secure the console cover to the handle 8 Connect the battery pack refer to Connecting the Lithium Battery Pack page 5 7 Gree...

Page 158: ...e machine is operational the key switch in the RUN position and the cutting unit is raised Note The EZ Turn function is only active when the machine is being operated with the cutting unit engaged Also the EZ turn switch and EZ turn sensor are in series so both switch and sensor have to be ON for the EZ Turn function to be ON If either the switch or the sensor is OFF the EZ Turn function will be O...

Page 159: ... the multimeter common test probe to the harness connector terminal C black wire and second test probe to the harness connector terminal A pink wire Figure 109 Check with the multimeter that the harness connector has 12 VDC circuit voltage present E If the sensor connector has circuit voltage present and sensor LED did not function replace the EZ turn sensor Adjust the sensor after installation re...

Page 160: ... assembly on the handle Figure 110 Checking the Operation of Speed Control Potentiometer Check the operation of speed control potentiometer with the InfoCenter With the key switch in the RUN position and the InfoCenter in the diagnostics menu choose the Throttle and ensure that the displayed voltage changes as the speed wheel is rotated Further potentiometer testing is necessary only if the displa...

Page 161: ...nces between the potentiometer terminals as follows Figure 111 A Check that the resistance between the terminals B and C is approximately 5 000 ohms Record the measured resistance B Measure the resistance between the terminals A and C and then measure the resistance between the terminals A and B Record these resistances The total of the 2 measured resistances should be approximately 5 000 ohms C R...

Page 162: ...h 5 Contactor 2 Battery 6 Nut 2 each 3 Mount bracket 7 TEC 4 Controller The Greensmaster eFlex machines use the main contactor to connect the lithium battery pack and the electric motor The contactor is energized by the TEC For Models 04042 04043 and 04046 The contactor is attached to the machine under the power center cover Figure 112 for Models 04042 04043 04046 Electrical System Testing the Ele...

Page 163: ...page 5 7 3 For Models 04042 04043 and 04046 Remove the 2 screws that secure the rear of the power center cover to the machine Figure 112 Then loosen the upper 2 screws on the cover Carefully remove the cover from the machine For Models 04042 04043 04046 and 04049 fitted with 04069 Remove the 8 bolts that secures the battery cover to the mount bracket refer to Figure 90 Remove the battery cover fro...

Page 164: ... connector step 5 C Ensure that the traction lever is in the NEUTRAL position Temporarily connect the battery pack refer to Connecting the Lithium Battery Pack page 5 7 D Turn the key switch to the START position to wake up the machine and then turn the key switch to the RUN position The main contactor should click as it is energized E Use the second multimeter test probe check that all 4 posts on...

Page 165: ...ntactor testing install the power center cover to the machine Figure 112 for models 04042 04043 and 04046 and install the battery cover and secure with 8 bolts for Models 04042 04043 04046 and 04049 fitted with 04069 9 Connect the battery pack refer to Connecting the Lithium Battery Pack page 5 7 Greensmaster eFlex 1800 2100 and 2120 Page 5 65 Electrical System Testing the Electrical Components 12...

Page 166: ...s and wire connections IMPORTANT The terminator resistors at the ends of the bus cables are required for proper electrical system operation Testing the CAN bus Terminator Resistor 1 The CAN bus terminator resistor Figure 116 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 167: ...to the OFF position and remove the key from the key switch 2 Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 5 7 3 Remove the 8 bolts that secures the battery cover to the mount bracket refer to Figure 90 Remove the battery cover from the mount bracket 4 Note the position of the connectors and wire harness on the relay for the assembly purposes Disconnect the machine ...

Page 168: ...rminal 86 and apply 48 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87a as 48 VDC is applied and removed from terminal 85 8 Replace the relay if necessary 9 If the relay test correctly and a circuit problem still exists check the wire harness refer to A Electrical Schematic 1800 2100 and 2120 for Models 04042 04043 04046 and 04049 fitted with 04069 page A ...

Page 169: ...26 for information on faults Removing the Electric Motor 1 Park the machine on a level surface and place the traction lever in the NEUTRAL position Turn the key switch to the OFF position and remove the key from the key switch 2 Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 5 7 3 Disconnect the electric motor connections from the machine wire harness 4 Support the e...

Page 170: ...of the electric motor 2 Apply grease to the splines of the motor shaft 3 Position the electric motor to the transmission align the splines of the motor shaft to the transmission coupler and insert the motor shaft into the coupler Slide the motor fully to the transmission surface 4 Secure the electric motor to the transmission with the 2 flange head screws torque the screws to 29 to 33 N m 21 to 25...

Page 171: ...exist an advisory or fault may be identified on the InfoCenter display Refer to the InfoCenter Display page 5 19 for information on advisories and faults Disassembling the Electric Motor 1 Remove the 6 torx head screws that secure the gearbox cover item 2 in Figure 119 to the front of the motor housing 2 Carefully slide the gearbox cover from the front of the motor 3 Remove and discard the O rings...

Page 172: ...ct grease in the output gear area of the motor housing If grease is clean and not contaminated it can remain in the housing If grease is contaminated clean the grease from the housing and replace with 15 ml of NLGI grade 00 grease during motor assembly 12 Inspect the motor components for wear or damage Replace the components or complete electric motor assembly if necessary Assembling the Electric ...

Page 173: ... front of the housing Ensure that the output gear teeth mesh with the rotor gear g202786 Figure 120 1 Gearbox cover 3 Shaft seal 2 Output gear 11 Install the shaft seal item 1 in Figure 119 into the gearbox cover Press the shaft seal into the front cover until it is flush with the cover surface The shaft seal should have the seal lip toward the inside of the motor Figure 120 12 Lubricate new O rin...

Page 174: ...l and Lithium Battery Pack Charger Operator s Manual for additional information about lithium battery pack service and handling Removing the Lithium Battery Pack 1 Park the machine on a level surface and place the traction lever in the NEUTRAL position Turn the key switch to the OFF position and remove the key from the key switch g202788 Figure 121 1 Battery wire harness 6 pin 2 Main wire harness ...

Page 175: ...sher 6 each 4 Battery base 9 Foam strip 5 Flange head screw 2 each 3 Remove the tall nut item 3 in Figure 122 that secures the rear of the battery base to the frame 4 Loosen but do not remove the 2 flange head screws item 5 in Figure 122 and 2 flange nuts to allow the battery base to pivot Greensmaster eFlex 1800 2100 and 2120 Page 5 75 Electrical System Service and Repairs 12189SL Rev E ...

Page 176: ...he raised position g202790 Figure 124 eFlex 2120 Model 04046 shown 1 Wire harness connector 2 Rotating locking collar 3 Battery receptacle 6 Rotate the wire harness connector locking collar counterclockwise and disconnect the connector from the battery pack Figure 124 CAUTION The weight of the battery pack is 24 5 kg 54 lb Support the battery pack to prevent it from falling and causing personal in...

Page 177: ...e harness connector with the slots in the battery pack receptacle and press the wire harness connector into the battery pack receptacle B Rotate the locking collar on the harness connector clockwise until it engages with the battery pack receptacle and begins to pull in toward the battery Continue rotating the collar approximately 120 1 3 of a turn until it fully seats IMPORTANT When pivoting batt...

Page 178: ...ct the battery pack to the battery charger when the machine is not in use Keep the battery pack cover clean A dirty cover will increase the heat in the battery pack and will reduce the energy capacity and life of the battery pack The eFlex lithium battery pack includes a fuse for battery circuit protection For information on servicing the battery pack fuse refer to Lithium Battery Pack Fuse For Mo...

Page 179: ...d on the machine as battery powered equipment with some regulatory requirements Contact the US Department of Transportation or the appropriate government body in your country for detailed regulations on transportation of your eFlex or eFlex battery The Toro Battery Shipping Kit includes instructions that detail information on shipping the lithium battery pack Refer to the Operator s Manual for par...

Page 180: ...ion about Samsung lithium battery pack service and handling Removing the Samsung Lithium Battery Pack 1 Park the machine on a level surface and place the traction lever in the NEUTRAL position Turn the key switch to the OFF position and remove the key from the key switch 2 Disconnect the battery pack refer to Service Procedure Icons page 6 Remove the 8 bolts that secures the battery cover to the m...

Page 181: ...ck If you open the battery pack you will void the warranty The battery pack is protected by tamper alerting devices Installing the Samsung Lithium Battery Pack 1 Ensure that the battery pack is clean and free from dirt 2 Carefully position the battery pack onto the mount bracket The battery connectors should be towards the mount bracket 3 Secure the battery pack to the mount bracket with the 4 bol...

Page 182: ...ery pack when you are finished mowing for the day to ensure that the battery is fully charged for the next mowing Lithium ion batteries do not have a charge memory issue and do not need to be fully discharged before charging them Ensure that the battery pack is charged with the Toro lithium battery pack charger that is specially designed for the eFlex battery pack For best battery life connect the...

Page 183: ...gulatory requirements Contact US Department of Transportation or the appropriate government body in your country for detailed regulations on transportation of your eFlex or eFlex battery The Toro Battery Shipping Kit includes instructions that detail information on shipping the lithium battery pack Refer to the Operator s Manual for part number information These instructions are also available for...

Page 184: ...Samsung Battery Controller for Models 04042 04043 04046 and 04049 fitted with 04069 g270331 Figure 127 Electrical System Service and Repairs Page 5 84 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 185: ...ry Pack Charger Operator s Manual for additional information about Samsung lithium battery pack service and handling Removing the Samsung Battery Controller 1 Park the machine on a level surface and place the traction lever in the NEUTRAL position Turn the key switch to the OFF position and remove the key from the key switch 2 Disconnect the battery pack refer to Service Procedure Icons page 6 Rem...

Page 186: ...onsumer serviceable parts on or in the battery controller If you open the battery controller you will void the warranty The controller is protected by tamper alerting devices Installing the Samsung Battery Controller g270648 Figure 128 1 Negative Power out to machine 4 COM port From battery 2 Negative Power in from battery 5 Positive Power in from battery 3 COM port To machine 6 Positive Power out...

Page 187: ... the mount bracket and secure with the 4 bolts washers and nuts 11 If removed install the TEC controller to the mount bracket as below A Install the TEC controller to the mount bracket and secure with 2 bolts and flange nuts refer to Figure 127 B Connect the connectors to the TEC controller 12 If removed install the relay to the mount bracket as below A Install the relay to the mount bracket and s...

Page 188: ...Pack Charger Operator s Manual and Lithium Battery Pack Charger Operation for Models 04042 04043 and 04046 page 5 10 in this chapter for additional information about the eFlex battery charger Note Ensure that the charger is connected to the battery pack plugged into a wall outlet and turned ON whenever the machine is not in use The LED s and LCD message display on the charger should identify charg...

Page 189: ...y shutdown Then correctly connect the battery pack charger and restart the charging operation to see if operation has returned to normal Some faults will be reset during the restart and will then allow normal charger operation If a fault continues to occur ensure to record the fault information from the charger LCD display and contact your Toro Distributor for assistance With the exception of the ...

Page 190: ...ne improperly Do not allow untrained people to operate this equipment Thoroughly review the safety instructions before you operate this equipment Do not attempt to open the battery pack charger Do not place anything in the connector of the battery pack charger other than the power supply cord that came with the product Refer to Lithium Battery Charger Operator s Manual for additional information a...

Page 191: ...ice and Repairs 6 4 Handle Assembly 6 4 Replacing the Brake Cable 6 7 Replacing the Reel Clutch Cable 6 10 Traction and Reel Drive Engagement Lever Assembly 6 14 Kickstand 6 18 Transport Wheels Optional 6 21 Rail Kit Wheels Optional 6 24 Greensmaster eFlex 1800 2100 and 2120 Page 6 1 Chassis and Controls 12189SL Rev E ...

Page 192: ...operation adjustment procedures and general maintenance for your Greensmaster eFlex machine Refer to the Operator s Manual for additional information when servicing the machine Chassis and Controls General Information Page 6 2 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 193: ...prevent unexpected machine operation g202195 Figure 132 eFlex 2120 Model 04046 shown 1 Machine connector 2 Battery pack 3 Battery connector To prevent unexpected machine operation during service disconnect the machine from the battery pack as the first step in any repair Figure 132 Once the battery pack has been disconnected the electrical system on the machine can be safely worked on During repai...

Page 194: ... Remove the console cover from the handle assembly Figure 133 3 Disconnect the reel clutch and brake cables from the transmission refer to Replacing the Brake Cable page 6 7 and Replacing the Reel Clutch Cable page 6 10 4 For assembly purposes label all the wire harness connections Disconnect the wire harness connections from the electrical components on the handle Position the wire harness away f...

Page 195: ...iage screws and flange nuts that secure the handle clamps to the offset handle clamps B Remove the flange nuts that secure the shoulder bolts at the bottom of the handle clamps C Remove the inner handle clamps Leave the shoulder bolts and outer handle clamps in place on the handle 8 Remove the handle assembly from the machine Installing the Handle Assembly 1 Position the handle assembly to the out...

Page 196: ... 6 10 Check the operation of the cables and adjust if necessary 4 Connect the wire harness connections to the electrical components on the handle 5 Secure the console cover to the handle assembly Figure 133 6 Connect the battery pack refer to Connecting the Lithium Battery Pack page 6 3 Chassis and Controls Service and Repairs Page 6 6 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 197: ...on lever assembly 8 Locknut 16 Washer Removing the Brake Cable 1 Park the machine on a level surface turn the key switch to the OFF position and remove the key from the key switch Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 6 3 2 Remove the brake cable from the brake lever shaft on the drum drive housing Figure 136 as follows A Loosen the front cable jam nut that ...

Page 198: ...t Adjust the jam nuts so that equal amount of cable threads are visible above and below the jam nuts Leave the jam nuts snug until final cable adjustment g198895 Figure 136 1 Retaining ring 3 Cable jam nut location 2 Cable eyelet 4 Brake cable 3 Route the brake cable to the drum drive housing and secure the brake cable to the brake lever shaft on the drum drive housing Figure 136 as follows A Inst...

Page 199: ...g the Brake Cable continued 6 Connect the battery pack refer to Connecting the Lithium Battery Pack page 6 3 Greensmaster eFlex 1800 2100 and 2120 Page 6 9 Chassis and Controls Service and Repairs 12189SL Rev E ...

Page 200: ...cket 9 Reel clutch cable 2 Brake cable 6 Lower handle 10 Traction lever assembly 3 Washer head screw 4 each 7 Traction switch 11 Shifter bracket 4 Console cover 8 Reel engage switch Chassis and Controls Service and Repairs Page 6 10 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 201: ...tch cable from the transmission Figure 138 as follows A Loosen the front cable jam nut and lift the cable free from the casting slot of the transmission B Remove the retaining ring that secures the cable eyelet to the reel clutch lever and slide the cable eyelet from the lever C Remove the cable tie that secures the reel drive cable to the transmission bracket 3 Remove the console cover from the h...

Page 202: ...te the cable spring hook end toward front of the machine B Slide the cable housing into the shift mount bracket slot Ensure that a jam nut flat washer and lock washer are on both sides of the bracket Adjust the jam nuts so that equal amount of cable threads are visible above and below the jam nuts Leave the jam nuts snug until final cable adjustment 2 Route the reel clutch cable to the transmissio...

Page 203: ...le jam nuts at the shift mount bracket B Pull down lightly on outer sheath of the clutch cable C Rotate the bottom cable jam nut up on the cable threads until the bottom lock washer just contacts the shift mount bracket D While holding the bottom jam nut in place tighten the top cable jam nut 4 Install the console cover to the handle assembly 5 Connect the battery pack refer to Connecting the Lith...

Page 204: ...4 Bumper 2 each 14 Reel shift lever 24 Latch pin 5 Extension spring 15 Spring collar 25 Roll pin 6 Retaining ring 3 each 16 Extension spring 26 Shifter latch 7 Spring lever 17 Washer head screw 27 Spacer 8 Shifter link 18 Ball bearing 28 Transport lever 9 Locknut 19 Shoulder screw 29 Screw 10 Detent ball 20 Locknut 2 each Chassis and Controls Service and Repairs Page 6 14 Greensmaster eFlex 1800 2...

Page 205: ... of the cable away from the traction lever assembly 4 Disconnect the wire harness connectors from the traction and reel engage switches Figure 141 5 Disconnect the spring item 4 in Figure 141 that connects operator presence control with the traction lever assembly 6 Remove the 4 flange head screws item 5 in Figure 141 and 4 flange nuts that secure the traction lever assembly and brackets to the ha...

Page 206: ...nd of the latch pin Figure 142 Note One of the mounting holes in both the switch mount bracket and shift mount is elongated to allow for adjustment of clearance between the transport lever item 28 in Figure 140 and the reel shift lever item 14 in Figure 140 3 Secure the switch mount bracket and shift mount to the shifter bracket with the 2 flange head screws item 13 in Figure 141 and 2 flange nuts...

Page 207: ...e harness connectors to the traction and reel engage switches Figure 141 7 Connect the reel clutch cable to the traction lever assembly refer to Replacing the Reel Clutch Cable page 6 10 Check the operation of the cable and adjust as necessary 8 Check the adjustment of the traction and reel engage switches refer to Traction Switch page 5 35 and Reel Engage Switch page 5 37 Adjust the switches if n...

Page 208: ...chines the offset handle clamps are mounted on the inside of the side plates The illustration in Figure 144 shows the eFlex 2100 2120 Removing the Kickstand 1 Park the machine on a level surface turn the key switch to the OFF position and remove the key from the key switch Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 6 3 2 Pivot the kickstand up and hold against th...

Page 209: ...3 4 5 and 6 in Figure 144 from the rear frame Installing the Kickstand 1 Ensure that the machine is parked on a level surface and key is removed from the key switch 2 If the service position locking pin assembly items 3 4 5 and 6 in Figure 144 was removed from the rear frame install removed locking pin components 3 Position the kickstand inside the machine frame Insert the bolt item 7 in Figure 14...

Page 210: ...ng the Kickstand continued 6 Connect the battery pack refer to Connecting the Lithium Battery Pack page 6 3 Chassis and Controls Service and Repairs Page 6 20 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 211: ...ub bushing 2 Flange nut 4 each 7 Hub 12 Bolt 4 each 3 Shallow rim 8 Torsion spring 13 Lock washer 3 each 4 Tire 9 Wheel retaining lever 5 Inner tube 10 Shoulder screw 2 each Greensmaster eFlex 1800 2100 and 2120 Page 6 21 Chassis and Controls Service and Repairs 12189SL Rev E ...

Page 212: ...ssembling the Transport Wheel 1 Ensure that the tire is fully deflated before disassembly of wheel 2 Remove the 3 bolts item 1 in Figure 146 and 3 lock washers from the shallow rim and hub and remove the hub from the deep rim 3 Inspect the hub bushing item 11 in Figure 146 Replace the bushing if worn or damaged 4 Remove the 4 bolts item 12 in Figure 146 and 4 flange nuts from the deep rim and shal...

Page 213: ...im with the 4 bolts item 12 in Figure 146 and 4 flange nuts Tighten the fasteners 4 Install the hub into the deep rim Secure the hub to the deep rim with the 3 bolts item 1 in Figure 146 and 3 lock washers Tighten the fasteners 5 Inflate the tire to 83 to 103 kPa 12 to 15 psi Installing the Transport Wheel 1 Ensure that the machine is parked on a level surface and the key is removed from the key s...

Page 214: ...ls Optional page 6 21 Installing the Rail Kit Wheel 1 Ensure that the machine is parked on a level surface and the key is removed from the key switch 2 Support the machine on the kickstand 3 If installed remove the transport wheels refer to Transport Wheels Optional page 6 21 Note The eFlex 1800 2100 and 2120 series requires a different wheel offset than all other Toro Greensmowers Ensure to read ...

Page 215: ...Traction Unit 7 4 Adjustments 7 6 Leveling the Rear Roller 7 7 Service and Repairs 7 8 Backlapping 7 8 Bedbar Assembly 7 10 Servicing the Bedknife 7 13 Servicing the Bedbar Adjuster 7 16 Front Roller 7 18 Rear Roller 7 20 Servicing the Roller 7 22 Cutting Unit Assembly 7 26 Servicing the Cutting Unit Assembly 7 31 Preparing the Reel for Grinding 7 34 Greensmaster eFlex 1800 2100 and 2120 Page 7 1 ...

Page 216: ...ns for the kit includes set up and operation information Refer to those publications for additional information when servicing the cutting unit Supporting the Cutting Unit when Servicing g207100 Figure 150 1 Locknut 2 Support Whenever the cutting unit has to be tipped to expose the bedknife or cutting unit support the rear of the cutting unit to ensure that the locknuts on the back of the bedbar a...

Page 217: ...prevent unexpected machine operation g202195 Figure 151 eFlex 2120 Model 04046 shown 1 Machine connector 2 Battery pack 3 Battery connector To prevent unexpected machine operation during service disconnect the machine from the battery pack as the first step in any repair Figure 151 Once the battery pack has been disconnected the electrical system on the machine can be safely worked on During repai...

Page 218: ... pack refer to Connecting the Lithium Battery Pack page 7 3 3 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 Figure 152 4 Remove the grass basket from the cutting unit if installed g203645 Figure 153 1 Telescoping coupler 2 Cutting unit hex shaft 5 Slide the telescoping coupler off the cu...

Page 219: ...y to completely remove the screws Figure 154 7 Rotate the pitch arms forward and rest traction unit against the kickstand 8 Roll the cutting unit away from the machine 9 Reverse the procedure to install the cutting unit to the traction unit 10 After the cutting unit is installed to the traction unit connect the battery pack refer to Connecting the Lithium Battery Pack page 7 3 Greensmaster eFlex 1...

Page 220: ...ery pack from the wire harness This will prevent unexpected machine operation DANGER Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when handling the cutting unit or bedknife Cutting Unit Adjustments Page 7 6 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 221: ...utting unit by using a 0 13 mm 0 005 inch shim at each end of the rear roller If the shim will pass under the roller at one end but not the other a frame adjustment should be made 4 Loosen but do not remove the 2 shoulder bolts that secure the side plate to the frame opposite the side that is not level Figure 155 5 Adjust the position of the side plate to parallel the rear roller and cutting unit ...

Page 222: ...ro Part No 09168SL 1 Park the machine on a level surface turn the key switch to the OFF position and remove the key from the key switch Ensure that the traction lever is in the NEUTRAL position 2 Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 7 3 g206880 Figure 156 1 Telescoping coupler 2 Cutting unit hex shaft 3 The backlapping operation can be done with the cutting...

Page 223: ... of the bedknife Figure 158 This will remove any burrs or rough edges that may have built up on the cutting edge 9 Install the reel drive cover plug when backlapping operation is completed Figure 157 IMPORTANT When adjusting the bedknife to cutting unit ensure that the contact is as light as possible to lengthen the amount of work the machine will perform on each charge 10 Adjust the cutting unit ...

Page 224: ... 2 each 6 Metal washer 4 each 12 Bedbar adjuster screw 2 each 18 Rubber bushing 2 each Removing the Bedbar 1 Park the machine on a level surface turn the key switch to the OFF position and remove the key from the switch Ensure that the traction lever is in the NEUTRAL position 2 Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 7 3 3 Remove the cutting unit from the mac...

Page 225: ...necessary Installing the Bedbar 1 If the rubber bushing was removed from either cutting unit side plate apply grease to the outside surface of new bushing and install into the side plate The bushing should flush with the inside of the side plate 2 If removed install the nylon bushings item 15 in Figure 159 with flange facing outward Apply anti seize lubricant to the inside of flange bushing 3 Appl...

Page 226: ...rs do not have any endplay but still can be rotated Do not overtighten the locknuts as this can distort the side plates and affect the reel bearing adjustment When the locknut is correctly tightened there may be a gap at the inside washers 9 Tighten the locknut item 9 in Figure 159 on each bedbar adjuster assembly until the adjuster spring is fully compressed then loosen the locknut 1 2 turn IMPOR...

Page 227: ...bedbar with a socket wrench and a bedknife screw tool refer to Bedknife Screw Tool page 2 17 Discard the screws Remove the bedknife from the bedbar 3 Refer to Grinding the Bedknife page 7 14 for additional information Installing the Bedknife 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 bedknif...

Page 228: ...bedknife Grinding the Bedknife Bedknife Grinding Specifications Standard Bedknife Relief Angle 3 minimum Fairway Bedknife Relief Angle 3 minimum Extended Bedknife Relief Angle 7 minimum Front Angle Range 13 to 17 g207289 Figure 163 1 Top angle 4 Front surface 2 Top surface 5 Front angle 3 Remove burr Since there can be variations in the mounting surface of the bedbar it is necessary to grind the b...

Page 229: ...bedknife edge while grinding Because the top grind angle on bedknives is critical for edge retention and therefore after cut appearance Toro has developed special service tools for accurately measuring the top grind angle on all bedknives refer to Angle Indicator and Magnetic Mount page 2 17 1 Use Toro General Service Training Book Reel Mower Basics part no 09168SL and grinder manufacturer s instr...

Page 230: ...Wave washer 2 Bolt 6 Washer 10 Flange bushing 3 Bedbar assembly 7 Bedbar adjuster screw 11 Bedbar adjuster shaft 4 Locknut 8 Retaining ring g206885 Figure 166 eFlex 1800 2120 1 Crossmember 2 Bolt 3 Detent Cutting Unit Service and Repairs Page 7 16 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 231: ...edbar Adjuster 1 If the detent item 1 in Figure 165 was removed secure the detent to the cutting unit side plate with the bolt 2 If the flange bushings item 10 in Figure 165 were removed align the key on the bushing to the slot in the frame and install the bushings in the cutting unit side plates 3 Slide the bedbar adjuster shaft item 11 in Figure 165 into the flange bushings in the cutting unit s...

Page 232: ...OC washer and nut 2 HOC screw 4 HOC arm 1 Park the machine on a level surface turn the key switch to the OFF position and remove the key from the key switch Ensure that the traction lever is in the NEUTRAL position 2 Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 7 3 Cutting Unit Service and Repairs Page 7 18 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 233: ... screw Thread the new HOC screw into the HOC arm Note When assembling HOC arms to the side plates ensure that the ring on HOC screw fits into the notch on the side plate 3 If both the HOC arms were removed from the cutting unit side plate position one of the arms to the side plate Secure the arm to the side plate with the plow bolt item 2 in Figure 167 HOC washer and HOC nut The tab on the HOC was...

Page 234: ...e rear roller shaft to each rear roller bracket 5 On one of the rear roller brackets Note On cutting units equipped with optional high height of cut kit there will be additional roller shims installed between the rear roller bracket and the cutting unit side plate A For assembly purposes note the quantity and location of the roller shims B Remove the flange nuts and socket head screws that secure ...

Page 235: ...roller bracket attached to the cutting unit Slide the second rear roller bracket onto the other end of the roller shaft Secure the second roller bracket and shims to cutting unit side plate with the 2 carriage screws and 2 flange nuts Do not fully tighten the flange nuts 4 Center the rear roller to the cutting unit and secure in place by tightening the 4 flange nuts 5 Adjust the cutting unit refer...

Page 236: ...er shaft 2 Remove the V ring item 2 in Figure 170 from each end of the roller 3 Carefully inspect the seating surface and threads of the bearing locknuts item 1 in Figure 170 Replace the locknut if there is any damage 4 Loosely secure the roller assembly in a bench vise and lightly tap one end of the roller shaft until the seal and bearing are removed from the roller cavity Remove the second seal ...

Page 237: ...ding Tools page 2 18 can be used instead of washers and spacer when installing the bearings and seals in roller g206891 Figure 172 1 Bearing 2 Black assembly washer 3 Bearing locknut 2 Position a new bearing black assembly washer refer to Roller Rebuilding Tools page 2 18 and original locknut onto each end of the roller shaft Figure 172 3 Tighten the nuts until the bearings are seated into each en...

Page 238: ...173 6 Carefully install the seals onto the bearing locknuts Pack the back of the seal 75 to 90 full with 2 grease Figure 173 g206893 Figure 174 1 Seal 2 Bearing locknut 7 Install a nut with seal onto each end of the roller shaft Tighten the nuts until they bottom against bearings Figure 174 Remove the nuts from the roller shaft Cutting Unit Service and Repairs Page 7 24 Greensmaster eFlex 1800 210...

Page 239: ...housing Remove the nuts assembly washers and assembly spacers from the roller shaft 10 Lubricate the lips of installed seals with 2 grease 11 Carefully slide a dry V ring onto each bearing locknut The V rings should be installed without any lubrication Note If original bearing locknut s are being used apply Loctite 242 or equivalent to the threads of the locknut s 12 Install the bearing locknut wi...

Page 240: ...re for removing and installing the cutting unit assembly cutting unit flocked seals reel bearings bearing lock screw and reel nut from the cutting unit refer to Servicing the Cutting Unit Assembly page 7 31 for information on servicing the cutting unit assembly Note EFlex 2100 2120 cutting units use shoulder bolts and flange nuts to secure the side plates to the crossmember as shown in Figure 176 ...

Page 241: ...attery pack refer to Connecting the Lithium Battery Pack page 7 3 3 Remove the cutting unit from the machine and place the cutting unit on a flat work area g207105 Figure 177 1 Reel pulley 2 Belt 3 Reel drive cover 4 Remove the reel drive cover and belt from the reel drive assembly and remove the reel pulley from the reel driveshaft refer to Chapter 4 Traction and Reel Drive System page 4 1 for pr...

Page 242: ...r to Removing the Bedbar page 7 10 7 Loosen the fasteners that secure the front and rear rollers to the right side plate refer to Removing the Front Roller page 7 18 and Removing the Rear Roller page 7 20 8 Support the cutting unit to prevent it from shifting or falling 9 Remove the shoulder bolts item 8 in Figure 176 and flange nuts that secure the right side plate to the cutting unit crossmember...

Page 243: ... roller and rear roller Ensure that the side plate is fully seated onto bearing on the reel shaft 6 Install the shoulder bolts item 8 in Figure 176 and flange nuts to secure the right side plate to the crossmember torque the shoulder bolts to 24 to 27 N m 210 to 240 in lb IMPORTANT If the reel driveshaft item 5 in Figure 178 is to be tightened use appropriate wrench or socket on 1 inch hex surface...

Page 244: ... with the cutting unit refer to Leveling the Rear Roller page 7 7 11 Install the reel pulley belt and reel drive cover to the reel drive assembly refer to Chapter 4 Traction and Reel Drive System page 4 1 for procedure to install and adjust these components 12 Install the cutting unit to the machine 13 After all necessary adjustments have been made connect the battery pack refer to Connecting the ...

Page 245: ... the Cutting Unit IMPORTANT When removing the reel driveshaft item 5 in Figure 179 use appropriate wrench or socket on 1 inch hex surface of shaft Do not use 1 2 inch extension on the end of the reel driveshaft when loosening or tightening the driveshaft The 1 2 inch hex is intended for backlapping only Greensmaster eFlex 1800 2100 and 2120 Page 7 31 Cutting Unit Service and Repairs 12189SL Rev E ...

Page 246: ...e shaft ends in V blocks B Check the reel blades for bending or cracking C Check the service limit of the reel diameter refer to Preparing the Reel for Grinding page 7 34 D Check the threads in the ends of the reel shaft 3 Check the woodruff key slot and hex drive on the reel driveshaft item 5 in Figure 179 for excessive wear or distortion Replace the driveshaft if there is any damage Assembling t...

Page 247: ...ft into the reel shaft to secure the bearings The reel driveshaft has left hand threads and should be installed in the end of the reel shaft identified with a groove that is just inside of reel spider Note Installation torque for bearing lock screw and reel driveshaft is 123 to 149 N m 90 to 110 ft lb It is easiest to torque these items after the cutting unit is installed in the cutting unit frame...

Page 248: ...ng unit to Toro specifications refer to the Reel Grinding Specifications Table page 7 34 Additional reel grinding information can be found in the Toro General Service Training Book Reel Mower Basics Toro Part No 09168SL 2 After completing the reel grinding process adjust the cutting unit refer to the Cutting Unit Operator s Manual Reel Grinding Specifications Table Reel diameter new 128 5 mm 5 060...

Page 249: ...ing Groomer Drive 8 6 Groomer Cover Counter Rotating Groomer Drive 8 7 Grooming Reel Forward Rotating Groomer Drive 8 10 Grooming Reel Counter Rotating Groomer Drive 8 14 Servicing the Grooming Reel 8 18 Replacing the Grooming Reel Bearing 8 20 Idler Assembly Forward Rotating Groomer Drive 8 24 Idler Assembly Counter Rotating Groomer Drive 8 26 Lift Arm Assembly 8 29 Groomer Brush 8 31 Greensmaste...

Page 250: ...g 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 Belt Driven Groomer General Information Page 8 2 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 251: ...ent unexpected machine operation g202195 Figure 182 eFlex 2120 Model 04046 shown 1 Machine connector 2 Battery pack 3 Battery connector To prevent unexpected machine operation during service disconnect the machine from the battery pack as the first step in any repair Figure 182 Once the battery pack has been disconnected the electrical system on the machine can be safely worked on During repairs e...

Page 252: ...esired height of cut refer to Cutting Unit Operator s Manual for cutting unit adjustment procedures g228141 Figure 183 Forward Rotating Groomer 1 Height adjustment knob 2 Lock screw 4 Position the grooming reel to the lowered grooming position Figure 183 Note Improper or over aggressive use of the grooming reel i e too deep or too frequent grooming may cause unnecessary stress on the turf leading ...

Page 253: ...he Groomer continued 7 After groomer adjustment is completed connect the battery pack refer to Connecting the Lithium Battery Pack page 8 3 Greensmaster eFlex 1800 2100 and 2120 Page 8 5 Belt Driven Groomer Adjustments 12189SL Rev E ...

Page 254: ...e 184 g228143 Figure 185 1 Drive pulley 3 Idler pulley nut 5 Groomer drive belt 2 Idler pulley 4 Driven pulley 4 Pivot idler pulley by placing a 12 mm wrench on pulley nut and rotating idler bracket to relax belt tension Slip groomer drive belt off pulleys Figure 185 Carefully release idler bracket 5 Install new drive belt to drive pulley idler pulley and driven pulley observing correct belt routi...

Page 255: ...roomer drive is engaged g228144 Figure 186 1 Groomer cover assembly 3 Gasket 2 Flange head screw 5 each 4 Handle 4 Remove groomer cover assembly from machine Figure 186 A Remove 5 flange head screws that secure groomer cover assembly to right drive plate B Remove groomer cover assembly and gasket from machine Discard gasket 5 If necessary remove shaft from groomer cover Figure 187 A Loosen set scr...

Page 256: ...etent 10 Handle 3 Shaft 7 Bolt 4 O ring 8 Retaining ring 1 If removed install shaft into groomer cover Figure 187 A Install new O ring into groove of shaft B Apply anti seize lubricant to shaft surface that is below the retaining ring groove Belt Driven Groomer Service and Repairs Page 8 8 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 257: ... extends toward the front of the cover F Apply Loctite 242 or equivalent to threads of set screw Install set screw into end of shaft to secure handle in place 2 Install groomer cover assembly to right drive plate assembly Figure 186 A Ensure that the handle on groomer cover is rotated toward the front of the machine B Fill groomer cover with approximately 142 g 5 fl oz of Mobil XHP221 grease or eq...

Page 258: ...r shim 17 Right cutting unit side plate 9 Right groomer arm assembly 18 Left cutting unit side plate Remove the grooming reel to replace individual blades to replace worn groomer components to reverse the blades on the shaft if not equipped with carbide blades or to replace the grooming shaft Removing the Grooming Reel Forward Rotating Groomer Drive 1 Park machine on level surface Turn key switch ...

Page 259: ...t 2 Idler pulley 4 Right drive plate assembly 6 Remove locknut item 13 in Figure 189 and spring washer that secure right groomer arm lift rod to drive plate assembly Figure 190 7 Remove HOC nut item 21 in Figure 189 HOC washer and plow bolt that secure right groomer arm assembly to drive plate assembly Do not change height of cut screw adjustment Remove right groomer arm assembly from cutting unit...

Page 260: ...late 5 Position groomer shim item 8 in Figure 189 to right drive plate assembly 6 Carefully place right drive plate assembly onto groomer shaft taking care to not damage seals in drive plate Position drive plate to the cutting unit frame and secure with 2 shoulder bolts item 5 in Figure 189 Ensure that the right drive plate rotates freely after installation 7 Apply light coating of grease to hub o...

Page 261: ...eplacing the Groomer Belt Forward Rotating Groomer Drive page 8 6 17 Check grooming reel height and mower height of cut settings Adjust as necessary 18 Install cutting unit to the machine 19 Lubricate groomer bearings refer to Installation Instructions page 8 2 20 Connect the battery pack refer to Connecting the Lithium Battery Pack page 8 3 Note After greasing groomer bearings operate groomer for...

Page 262: ... 4 each 9 HOC washer 2 each 20 Gasket 31 Plow bolt 2 each 10 HOC screw 2 each 21 Flange head screw 5 each 32 Left cutting unit side plate 11 O ring 22 Groomer cover assembly 33 43T idler gear Remove the grooming reel to replace individual blades to replace worn groomer components to reverse the blades on the shaft if not equipped with carbide blades or to replace the grooming shaft Removing the Gr...

Page 263: ...7 Discard gasket g228291 Figure 193 1 Extension spring 3 47T idler gear 2 43T idler gear 4 Groomer drive gear 6 Carefully remove extension spring from anchor points on right drive plate Figure 193 g228292 Figure 194 1 Right drive plate assembly 3 43T gear bearing 2 Flange nut 4 47T gear bearing 7 Remove the 2 idler gears 43T and 47T from the right drive plate assembly Figure 194 The bearings are p...

Page 264: ...remove groomer drive gear item 17 inFigure 192 from the cutting unit shaft 14 Remove 4 button head screws item 30 in Figure 192 that secure the right drive plate assembly to the support plate on the cutting unit frame Remove the right drive plate assembly from grooming shaft and cutting unit 15 Carefully pull the grooming reel from the left support plate 16 Inspect seals bushings and bearings in r...

Page 265: ...re 194 Secure gears with flange nuts and torque flange nuts 13 5 N m 120 in lb 9 Install extension spring to right drive plate assembly Figure 193 10 Insert front roller into left groomer arm assembly 11 Ensure that the bushing item 3 in Figure 192 is installed in right drive plate assembly 12 Apply anti seize lubricant to threads of right groomer arm lift rod 13 Position right groomer arm assembl...

Page 266: ...ade should be replaced g228296 Figure 197 1 Grooming blade 3 Dull rounded edge 2 Sharp edge 4 Rotation Grooming blades without a carbide tip Figure 197 should be replaced if worn or damaged Blades without a carbide tip that are rounded to the midpoint of the blade tip can be reversed on the grooming shaft to extend the life of the blade Disassembling the Grooming Reel g228294 Figure 198 1 Grooming...

Page 267: ...ure 198 IMPORTANT If groomer is equipped with blades with carbide tips ensure that the blades are installed with the tips in the same correct direction 2 For 1 3 cm 1 2 inch blade spacing ensure there are 2 blade spacers between blades Figure 198 3 When all blades have been installed place second thick spacer on shaft and then thread second locknut onto the shaft g228297 Figure 199 1 Locknut 2 Cen...

Page 268: ...r to Grooming Reel Forward Rotating Groomer Drive page 8 10 or Grooming Reel Counter Rotating Groomer Drive page 8 14 g228298 Figure 200 1 Cutting unit 2 Reel drive assembly 3 Left support plate 5 To remove support plate assembly from left side of cutting unit Figure 200 A Remove reel drive cover drive belt reel pulley and then reel drive assembly from cutting unit refer to Reel Drive Assembly pag...

Page 269: ...ter of cutting unit g228301 Figure 203 Counter rotating groomer 1 Right drive plate assembly 3 Seal 2 each 2 Bearing 2 each 4 Seal lips toward center of cutting unit g228302 Figure 204 1 Left support plate 4 Plug 2 Bearing 5 Seal lips toward center of cutting unit 3 Seal Greensmaster eFlex 1800 2100 and 2120 Page 8 21 Belt Driven Groomer Service and Repairs 12189SL Rev E ...

Page 270: ... bore Then install new inner bearing until inner race contacts outer bearing race B Press new bearing into left support plate until it is flush with shoulder of bearing bore C Install new seals into groomer side plates Note Seals should be installed so that the lip side of the seal will face the center of the cutting unit When bearings are greased grease will purge from inner seals 2 Install left ...

Page 271: ...4 Check and adjust grooming reel height and mower height of cut settings 5 Install cutting unit to the machine 6 Lubricate groomer bearings 7 Connect the battery pack refer to Connecting the Lithium Battery Pack page 8 3 Note After greasing groomer bearings operate groomer for 30 seconds stop machine and wipe any excess grease from groomer shaft and seals Greensmaster eFlex 1800 2100 and 2120 Page...

Page 272: ...itch to the OFF position and remove key from the switch Ensure that the traction lever is in the NEUTRAL position Engage parking brake 2 Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 8 3 3 If idler pulley item 10 in Figure 206 needs to be serviced remove locknut and slide pulley with bearings from idler bracket Remove retaining ring and bearings from idler pulley 4 ...

Page 273: ...e When properly installed the idler bracket item 4 in Figure 206 should pivot freely on pivot hub Also the idler pulley should move freely from side to side on the idler bracket pin 2 Install right drive plate assembly to right side of cutting unit refer to Grooming Reel Forward Rotating Groomer Drive page 8 10 3 Check and adjust grooming reel height and mower height of cut settings 4 When all adj...

Page 274: ...Retaining ring 11 Grease fitting 4 Idler bracket 8 O ring 12 Grease seal g228307 Figure 209 1 Groomer cover assembly 3 Gasket 2 Flange head screw 5 each 4 Handle The groomer right drive plate assembly incorporates the idler system for engaging the groomer gear drive Belt Driven Groomer Service and Repairs Page 8 26 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 275: ...ly installed the idler bracket item 4 in Figure 208 should pivot freely on reel hub 2 Install right drive plate assembly to right side of cutting unit refer to Grooming Reel Counter Rotating Groomer Drive page 8 14 Ensure that the groomer drive gear and grooming reel driven gear are properly torqued Do not install idler gears extension spring or groomer cover assembly to drive plate assembly g2283...

Page 276: ...ket and adjustment cam 6 Fill groomer cover with approximately 142 g 5 fl oz of Mobil XHP221 grease or equivalent Install new gasket and then groomer cover assembly to right drive plate refer to Groomer Cover Counter Rotating Groomer Drive page 8 7 7 Check and adjust grooming reel height and mower height of cut settings 8 When all adjustments have been completed connect the battery pack refer to C...

Page 277: ...Engage parking brake 2 Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 8 3 3 Remove flange nut item 2 in Figure 212 that secures lift arm to HOC groomer arm Remove locknut and spring washer that secure lift arm to side plate Loosen lock screw completely 4 Remove lift arm from cutting unit 5 Disassemble lift arm Figure 212 Note Right and left side HOC groomer arms and ...

Page 278: ... item 2 in Figure 212 and locknut with spring washer 4 Secure groomer in raised or lowered position with lock screw item 6 in Figure 212 5 Check and adjust grooming reel height and mower height of cut settings 6 When all adjustments have been completed connect the battery pack refer to Connecting the Lithium Battery Pack page 8 3 Belt Driven Groomer Service and Repairs Page 8 30 Greensmaster eFlex...

Page 279: ...rooming Reel Counter Rotating Groomer Drive page 8 14 g228312 Figure 214 1 J bolt 2 Locknut To remove the groomer brush from the shaft remove the locknut and J bolt from both ends of the brush and slide the brush from the shaft When assembling the brush to the shaft secure the assembly with J bolts and locknuts Ensure that the J bolts are installed with the threaded portion on the outside of the b...

Page 280: ...Belt Driven Groomer Service and Repairs Page 8 32 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 281: ...necting the Lithium Battery Pack 9 3 Service and Repairs 9 4 Gear Box Assembly 9 5 Idler Assembly 9 10 Groomer Reel 9 12 Servicing the Groomer Reel 9 14 Height Adjuster Assembly 9 16 Servicing the Grooming Brush Optional 9 18 Greensmaster eFlex 1800 2100 and 2120 Page 9 1 Universal Groomer Optional 12189SL Rev E ...

Page 282: ...e 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 Universal Groomer Optional General Information Page 9 2 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 283: ... unexpected machine operation g202195 Figure 215 eFlex 2120 Model 04046 shown 1 Machine connector 2 Battery pack 3 Battery connector To prevent unexpected machine operation during service disconnect the machine from the battery pack as the first step in any repair Figure 215 Once the battery pack has been disconnected the electrical system on the machine can be safely worked on During repairs ensu...

Page 284: ...he 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 Refer to these instructions for additional information when servicing the groomer Universal Groomer Optional Service and Repairs Page 9 4 Greens...

Page 285: ...nd remove the key from the key switch 2 Remove the groomer reel assembly refer to Removing the Groomer Reel page 9 12 CAUTION Contact with the reel or other cutting unit parts can result in personal injury Use heavy gloves when handling the cutting unit 3 Safely prevent the reel from rotating by blocking the cutting unit with a piece of wood near one of the reel spiders IMPORTANT The groomer gear ...

Page 286: ... from the reel B Remove the cotter pin item 3 in Figure 217 and clevis pin from the height adjustment rod at the front of the groomer gear box Discard the cotter pin C Continue to unscrew the input shaft and remove the gear box from the cutting unit Universal Groomer Optional Service and Repairs Page 9 6 Greensmaster eFlex 1800 2100 and 2120 12189SL Rev E ...

Page 287: ...etent ball 9 Bearing 24 Oil seal 39 O ring 10 O ring 3 each 25 Ball bearing 2 each 40 Left drive clutch decal 11 Flange bushing 26 Flange bushing 3 each 41 Clutch knob 12 Gasket 27 Planet gear 3 each 42 Right drive clutch decal 13 Driver gear 28 Driven gear 43 Gear box assembly 14 Retaining ring 29 Locknut 15 Bearing 2 each 30 Ring gear 1 Remove the drain fill plug item 6 in Figure 218 and drain t...

Page 288: ...nput shaft during adapter installation as input shaft damage may occur 1 If the sun gear ring gear or the gear box housing bearings are replaced press the bearings all the way to shoulder in part 2 If the flange bushings are replaced ensure that the flange bushing is fully seated against the part 3 Ensure that all the retaining rings and O rings are fully seated in the ring groove 4 Lubricate the ...

Page 289: ...hand thread Turn the input shaft clockwise to install the gear box 3 Install the gear box to the cutting unit as follows A Apply medium strength threadlocker to the input shaft threads and turn the input shaft clockwise until it is seated against the reel B Install a new cotter pin and clevis pin and secure the height adjustment rod to the front of the groomer gear box C Tighten the input shaft to...

Page 290: ...h 2 Remove the electric motor from the cutting unit refer to Electric Motor page 5 69 3 Remove the groomer reel assembly refer to Removing the Groomer Reel page 9 12 4 Remove the cotter pin and clevis pin from the height adjustment rod at the front of the idler arm Discard the cotter pin 5 Remove the 2 socket head screws item 5 in Figure 219 that secure the adaptor to the cutting unit and remove t...

Page 291: ...ugh shields and bearing Use the through hole in the shaft to prevent shaft from rotating tighten the flange nut to 37 to 45 N m 27 to 33 ft lb E If the collar was removed from the idler arm install the collar and tighten to 33 to 41 N m 24 to 30 ft lb 2 Apply anti seize lubricant to the outside diameter of the adaptor Figure 220 Position the idler arm over the adaptor 3 Apply Loctite to the 2 sock...

Page 292: ...nit from the machine refer to the Traction Unit Operator s Manual CAUTION Contact with the reel or other cutting unit parts can result in personal injury Use heavy gloves when handling the groomer reel 2 Carefully remove the 4 jam nuts item 2 in Figure 221 4 bolts and 4 shaft clamps that secure the groomer reel to the output and stub shafts 3 Lift the groomer reel from the cutting unit 4 Inspect t...

Page 293: ...tion the groomer reel between the groomer output and stub shafts 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 Greensmaster eFlex 1800 2100 and 2120 Page 9 13 Universal Groomer Optional Service and Repairs 12189SL Rev E ...

Page 294: ...d or replaced for best groomer performance Disassembling 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 2 Remove the groomer reel from the cutting unit refer to Removing the Groomer Reel page 9 12 g229841 Figure 223 1 Groomer reel shaft 3 Spacer 39 each 2 Groomer blade 40...

Page 295: ...ately install 11 6 mm 0 46 inch spacers and blades ensure that all the blades are separated by a spacer 3 When all the blades have been installed install the second locknut onto the shaft Center the blades on shaft by adjusting locknuts 4 Use the through holes in shaft to prevent the shaft from rotating tighten the second locknut to 42 to 48 N m 31 to 35 ft lb After tightening the locknut spacers ...

Page 296: ...ns and clevis pins that secure the height adjustment rods to the groomer gear box and idler arm Discard the cotter pins 3 Loosen the 2 height adjustment bolts item 15 in Figure 224 and 2 locknuts 4 Remove the flange nut item 4 in Figure 224 and carriage bolt that secure the height adjuster assembly to the cutting unit side plate and remove the front roller and height adjuster from the cutting unit...

Page 297: ...ight adjustment bolt and 1 washer is above slot in side plate and 1 washer and locknut is below slot in side plate 4 Install new cotter pins and clevis pins and secure the height adjustment rods to the groomer gear box and idler arm 5 Adjust the cutting unit height of cut refer to Cutting Unit Operators Manual 6 Check the groomer reel height and adjust as necessary g207293 Figure 225 1 Height adju...

Page 298: ...er Reel page 9 12 The grooming brush element or shaft can be serviced separately Figure 226 To remove the spiral grooming brush from the shaft remove the locknut and J bolt from both ends of the brush assembly and slide the brush from the shaft When assembling the spiral brush to the shaft ensure that the J bolts are installed with the threaded portion on the outside of the brush and tighten the l...

Page 299: ... Main 2120 for Model 04046 A 7 Wire Harness Diagram Main 2120 for Model 04046 A 8 Wire Harness Drawing Main 1800 2100 and 2120 for Models 04042 04043 04046 and 04049 fitted with 04069 A 9 Wire Harness Drawing Main 1800 2100 and 2120 for Models 04042 04043 04046 and 04049 fitted with 04069 A 10 Wire Harness Li Battery 1800 2100 and 2120 for Model 04042 04043 and 04046 A 11 Wire Harness Li Diagnosti...

Page 300: ...e 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 black line OR_BK is an orange wire with a black line Wire Size The individual wires of the electrical harness diagrams in this chapter identify both the wire color and the wire size Examples 16 BK 16 AWG Amer...

Page 301: ...eensmaster eFlex 1800 2100 and 2120 Models 04043 04042 and 04046 Drawing 3387 793 Rev B Sheet 1 of 1 12189SL Rev E Page A 3 Electrical Schematic 1800 2100 and 2120 for Models 04042 04043 and 04046 g207429 ...

Page 302: ...ensmaster eFlex 1800 2100 and 2120 Models 04042 04043 04046 and 04049 fitted with 04069 Drawing 122 1241 Rev A Sheet 1 of 1 Electrical Schematic 1800 2100 and 2120 for Models 04042 04043 04046 and 04049 fitted with 04069 g271033 ...

Page 303: ...Greensmaster eFlex 1800 2100 Models 04043 04042 Drawing 117 4708 Rev B Sheet 1 of 2 12189SL Rev E Page A 5 Wire Harness Drawing Main 1800 2100 for Models 04042 and 04043 g207442 ...

Page 304: ...Page A 6 12189SL Rev E Greensmaster eFlex 1800 2100 Models 04043 04042 Drawing 117 4708 Rev B Sheet 2 of 2 Wire Harness Diagram Main 1800 2100 for Models 04042 and 04043 g207444 ...

Page 305: ...Greensmaster eFlex 2120 Model 04046 Drawing 122 0967 Rev B Sheet 1 of 2 12189SL Rev E Page A 7 Wire Harness Drawing Main 2120 for Model 04046 g207443 ...

Page 306: ...Page A 8 12189SL Rev E Greensmaster eFlex 2120 Model 04046 Drawing 122 0967 Rev B Sheet 2 of 2 Wire Harness Diagram Main 2120 for Model 04046 g207445 ...

Page 307: ...and 2120 Models 04042 04043 04046 and 04049 fitted with 04069 Drawing 122 1242 Rev A Sheet 1 of 2 12189SL Rev E Page A 9 Wire Harness Drawing Main 1800 2100 and 2120 for Models 04042 04043 04046 and 04049 fitted with 04069 g271034 ...

Page 308: ...smaster eFlex 1800 2100 and 2120 Models 04042 04043 04046 and 04049 fitted with 04069 Drawing 122 1242 Rev A Sheet 1 of 2 Wire Harness Drawing Main 1800 2100 and 2120 for Models 04042 04043 04046 and 04049 fitted with 04069 g271035 ...

Page 309: ...nsmaster eFlex 1800 2100 and 2120 Models 04043 04042 and 04046 Drawing 119 1349 Rev J Sheet 1 of 1 12189SL Rev E Page A 11 Wire Harness Li Battery 1800 2100 and 2120 for Model 04042 04043 and 04046 g207431 ...

Page 310: ...A 12 12189SL Rev E Greensmaster eFlex 1800 2100 and 2120 Models 04043 04042 and 04046 Drawing 120 6339 Rev A Sheet 1 of 1 Wire Harness Li Diagnostic 1800 2100 and 2120 for Model 04042 04043 and 04046 g207435 ...

Page 311: ...nsmaster eFlex 1800 2100 and 2120 Models 04043 04042 and 04046 Drawing 117 4749 Rev E Sheet 1 of 1 12189SL Rev E Page A 13 Wire Harness Li Adapater 1800 2100 and 2120 for Model 04042 04043 and 04046 g207439 ...

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