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Greensmaster Flex 21

Page 6 – 1

Chassis and Controls

Chapter 6

Chassis and Controls

Table of Contents

SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handle Height Adjustment

. . . . . . . . . . . . . . . . . . . .

SERVICE AND REPAIRS

. . . . . . . . . . . . . . . . . . . . . .

Handle Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking Brake Cable Replacement

. . . . . . . . . . . .

Traction Cable Replacement

. . . . . . . . . . . . . . . . . .

Reel Control Cable Replacement

. . . . . . . . . . . . . .

Throttle Cable Replacement

. . . . . . . . . . . . . . . . . .

Wheels

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Kickstand

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chassis and

Controls

Summary of Contents for Greensmaster Flex 21

Page 1: ...complete Model and Serial Number to The Toro Company Attn Technical Publications 8111 Lyndale Avenue South Minneapolis MN 55420 1196 The Toro Company reserves the right to change product specification...

Page 2: ...Greensmaster Flex 21 This page is intentionally blank...

Page 3: ...5 2 Special Tools 5 4 Troubleshooting 5 5 Component Testing 5 6 Service and Repairs 5 8 Chapter 6 Chassis and Controls Specifications 6 2 Adjustments 6 3 Service and Repairs 6 4 Chapter 7 Cutting Unit...

Page 4: ...Greensmaster Flex 21 This page is intentionally blank...

Page 5: ...now how to stop the engine quickly 4 Keep all shields safety devices and decals in place If a shield safety device or decal is malfunctioning il legible or damaged repair or replace it before operatin...

Page 6: ...damaged reel or bedknife must be repaired or replaced before opera tion is commenced 9 Whenever machine is left unattended be sure en gine is stopped and cutting unit reel is not spinning Close fuel s...

Page 7: ...ty decals and instructions are easily visible to the operator and are located near any area of potential dan ger Replace any decal that is damaged or lost Part numbers are listed in your Parts Catalog...

Page 8: ...Greensmaster Flex 21 Page 1 4 Safety This page is intentionally blank...

Page 9: ...ric Conversions 2 TORQUE SPECIFICATIONS 3 Fastener Identification 3 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 4 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric...

Page 10: ...Greensmaster Flex 21 Page 2 2 Product Records and Manuals Equivalents and Conversions...

Page 11: ...vailing torque feature hardness of the surface underneath the fastener s head or similar condition which affects the installation As noted in the following tables torque values should be reduced by 25...

Page 12: ...2 22 3 30 3 41 4 43 4 58 5 3 8 24 UNF 17 2 18 2 24 3 35 3 47 4 50 4 68 5 7 16 14 UNC 27 3 27 3 37 4 50 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 5 75 7 77 7 104 9 1 2 13 UNC 30 3 48 7 65 9 75 8 1...

Page 13: ...b 90 10 N m 92 9 ft lb 125 12 N m M16 X 2 0 166 15 ft lb 225 20 N m 229 22 ft lb 310 30 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 37 ft lb 610 50 N m NOTE Reduce torque values listed in the table abov...

Page 14: ...lb Wheel Bolts and Lug Nuts Thread Size Recommended Torque 7 16 20 UNF Grade 5 65 10 ft lb 88 14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1 5 Cl...

Page 15: ...ONS 3 GENERAL INFORMATION 4 Filling the Fuel Tank 4 Fuel Shut off Valve 5 ADJUSTMENTS 6 Throttle Cable Adjustment 6 SERVICE AND REPAIRS 7 Engine Oil 7 Air Cleaner 8 Fuel Filter 9 Spark Plug 9 Ignition...

Page 16: ...ervice shops Special tools are described in the Kawasaki FE120 Service Manual that is included at the end of this Chapter The use of some specialized test equipment is explained However the cost of th...

Page 17: ...Mechanical flyweight Idle Speed no load 2400 100 RPM High Idle no load 3600 100 RPM Direction of rotation Counter clockwise facing PTO shaft Fuel Unleaded automotive grade gasoline Fuel Tank Capacity...

Page 18: ...iner and slow the loss of any static charge When practical remove gas powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then re...

Page 19: ...ve is located on the left rewind start er side of the engine It has two positions CLOSED and OPEN Position valve to the closed position when stor ing or transporting the machine Rotate valve to the op...

Page 20: ...or lever 4 Make sure throttle lever is in the FAST position and the governor lever is against the high speed idle screw 5 Tighten throttle cable screw securing the throttle cable to the governor lever...

Page 21: ...he oil level so that it is between the marks on the gauge DO NOT OVERFILL Use any high quality detergent oil having the American Petroleum Institute API Service Classification SC SD SE SF SG or SH 5 R...

Page 22: ...nd warm water Squeeze it to remove dirt Do not twist element because foam may tear B DRY by wrapping the element in a clean rag Squeeze rag and foam element to dry element C SATURATE element with clea...

Page 23: ...Spark Plug Use a NGK BPR 5ES spark plug or equivalent Remove plug after every 100 operating hours and check its condition 1 Make sure engine is OFF Pull high tension lead off the spark plug 2 Clean ar...

Page 24: ...bore Excessive oil entering the combustion chamber past worn valve guides valve stems rings piston and or cylinder bore Replace spark plug Has gray or light tan deposits on the firing tip Light gray o...

Page 25: ...on lead from the spark plug IMPORTANT Never clean engine with pressurized water Water could enter and contaminate the fuel system 2 Clean cooling fins on cylinder and cylinder head Re move engine shro...

Page 26: ...3 Interlock module 14 Module bracket 15 Cap screw 16 Set screw 17 Cap screw 18 Lock washer 19 Washer 20 Flat washer 21 Lock nut 22 Cap screw 23 Isolator mount 24 Flange nut 25 Damper assembly 26 Muffl...

Page 27: ...wires from wiring harness C Disconnect ground wire from engine by removing cap screw and lock washer 6 Remove engine from the engine base Fig 16 A Remove four flange nuts that secure gearbox as sembly...

Page 28: ...nstall four flange nuts that secure gearbox as sembly to setscrews on engine crankcase cover flange F Install four cap screws and flat washers through the engine and engine base Put flange nut on each...

Page 29: ...on Coupler Drive Belt Adjustment 8 SERVICE AND REPAIRS 9 Reel Drive and Transmission Coupler Belt Replacement 9 Reel Drive Assembly 10 Reel Drive and Transmission Coupler Bearing Housing 11 Traction D...

Page 30: ...e drive belts Gearbox Fluid Dexron III Automatic Transmission Fluid or equivalent Gearbox Fluid Capacity 2 9 qt 2 78 l Differential Integral in gearbox assembly Brake Band drum in gearbox Traction Dru...

Page 31: ...pecified Other fluid types can cause gearbox damage or per formance problems 3 If fluid level is low add enough of the proper fluid type Dexron III Automatic Transmission Fluid or equivalent until flu...

Page 32: ...over adjust or brake band may drag 4 Tighten front brake cable jam nut 5 Check parking brake control operation Figure 2 1 Parking brake cable 2 Front cable jam nut 3 Back cable jam nut 2 3 1 Traction...

Page 33: ...l Cable Adjustment 3 The reel control cable force should increase the trac tion control force by 7 to 10 lb 32 to 45 N The force should be measured at the control knob For example if the traction cont...

Page 34: ...late loosen cap screw that secures the idler bracket to the side plate Fig 7 B With a 3 8 inch drive torque wrench pivot the idler pulley against the backside of the belt from 35 to 40 in lb 40 to 46...

Page 35: ...ion If deflection is incorrect proceed to next step 3 To adjust reel drive belt tension A Loosen the two bearing housing mounting nuts Fig 9 B With a 3 8 in drive torque wrench pivot the bear ing hous...

Page 36: ...is incorrect proceed to next step 3 To adjust drive belt tension A Loosen the two bearing housing mounting nuts Fig 12 B With a 3 8 in drive torque wrench pivot the bear ing housing from 35 to 40 in...

Page 37: ...rive belt right side Fig 14 or left side Fig 15 3 Loosen the two bearing housing mounting nuts 4 Pivot bearing housing to loosen belt tension Re move drive belt from the two pulleys Installation 1 Par...

Page 38: ...ex tube 24 Drive shaft plate assembly 25 Gearbox shaft 26 Reel drive plate assembly 27 Reel drive cover 28 Lock nut 29 Spacer 30 Spacer 31 Lock washer 32 Cap screw 33 Plug 34 Retaining ring if equippe...

Page 39: ...way from the frame Bearing Housing Disassembly NOTE Do not mar outer surface of flex coupler e g grasping with pliers or mounting in vise as coupler may be damaged and fail prematurely 1 Push spring p...

Page 40: ...ize lubricant to the bore of the pulley and install pulley onto shaft A Left side pulley uses a pulley washer B Right side pulley should be installed with the flange outward 6 Secure the pulley to the...

Page 41: ...Greensmaster Flex 21 Traction and Reel Drive System Rev C Page 4 13 This page is intentionally blank Traction and Reel Drive System...

Page 42: ...nge nut 25 Pulley washer 26 Pulley 22 tooth 27 Pulley sleeve 28 Retaining ring early models 29 Woodruff key 30 Carriage screw 31 Flat washer 32 Cap screw 33 Flange nut 34 LH traction cover 35 LH hex s...

Page 43: ...belt 4 Loosen idler bracket cap screw on back of side plate Fig 23 Pivot the idler pulley away from the drive belt to loosen belt tension Fig 22 5 Remove traction drive belt from both pulleys Install...

Page 44: ...ark mower on a level surface Make sure engine is OFF Remove high tension lead from the spark plug 2 If idler pulley or bearings were removed A Press bearings into pulley sleeve making sure to apply pr...

Page 45: ...Greensmaster Flex 21 Traction and Reel Drive System Rev C Page 4 17 This page is intentionally blank Traction and Reel Drive System...

Page 46: ...talled remove transport wheels see Wheels in the Service and Repairs section of Chapter 6 Chassis and Controls 3 Remove belt cover and traction drive belt from each side of mower see Traction Drive Be...

Page 47: ...ad from the spark plug 2 Pivot mower back and position drum assembly un der the mower Pivot mower back down 3 Position drum spacers on sides of drum NOTE The left side hex shaft and drum assembly have...

Page 48: ...own in the Figure 27 are from the right side of the machine Traction Drum Removal Fig 27 1 Park mower on a level surface Make sure engine is OFF Remove high tension lead from the spark plug 2 If insta...

Page 49: ...ls with grease Fill cavity in hub between bearings and seal positions with grease C Press seals into hub so the seals are flush with the hub surface Lightly grease lip of both seals D Lightly grease t...

Page 50: ...achine frame Tighten the bear ing set screw to secure the bearings to the drum shafts Torque set screws from 40 to 50 in lb 4 5 to 5 7 N m NOTE The left side drum pulley has left hand threads Fig 29 8...

Page 51: ...earbox fluid to drain completely When drained install drain plug Torque drain plug from 85 to 105 in lb 97 to 124 kg cm 6 Make sure that mower is on its traction drum on a lev el surface IMPORTANT Use...

Page 52: ...rom gearbox assembly see Change Gear box Fluid in this section 3 Remove traction control and reel control cables from gearbox see Control Cable Replacement in the Service and Repairs section of Chapte...

Page 53: ...xle from frame to complete gearbox removal 11 Slide locking collars from axle shafts 12 Remove and discard flange gasket from between engine and gearbox Gearbox Installation 1 Park traction unit on a...

Page 54: ...Install woodruff keys and place traction drive pulleys onto gearbox axles Fig 32 Secure pulleys to axles with pulley washers and flange nuts Torque flange nuts from 40 to 50 ft lb 54 to 68 N m 10 Ins...

Page 55: ...Greensmaster Flex 21 Traction and Reel Drive System Rev C Page 4 27 This page is intentionally blank Traction and Reel Drive System...

Page 56: ...s section of Chapter 6 Chassis and Controls 5 Remove traction drive belt covers and belts from both sides of mower see Traction Drive Belt Replace ment in this section 6 Remove flange nut that secures...

Page 57: ...e extended race bearings and bearing flan gettes to frame with carriage bolts flat washers and flange nuts 8 Check bearing alignment by rotating the long differ ential drive shaft Shaft should rotate...

Page 58: ...n shaft SN below 230000001 55 Ball bearing 56 Retaining ring 57 Differential assembly traction drive 58 Gasket 59 Gearbox cover 60 Keyed bushing 61 E ring 62 Gearbox lever 63 Socket head screw 64 Sock...

Page 59: ...ully remove traction shaft from the gearbox tak ing care not to distort traction band Fig 43 Note If gearbox is still attached to engine traction lever on en gine side of gearbox will have to be loose...

Page 60: ...the gear box base and cover 3 If clutch shaft was disassembled use Figure 45 as a guide to install components to clutch shaft Rotate clutch fork to allow clutch shaft assembly to be posi tioned into g...

Page 61: ...over Torque gearbox fasteners from 120 to 140 in lb 137 to 159 kg cm in the sequence shown in Figure 48 13 Place traction drive lever onto gearbox shaft noting location of alignment splines on shaft a...

Page 62: ...ial gears carefully looking for chipped teeth wear or other damage Because gear tooth damage is rarely isolated to one gear the four bev el gears are only available as a complete set 3 Scoring or wear...

Page 63: ...odels Without Operator Presence 2 Later Models With Operator Presence 3 SPECIAL TOOLS 4 TROUBLESHOOTING 5 Starting Problems 5 COMPONENT TESTING 6 Ignition System Operation 6 Ignition Coil 6 Interlock...

Page 64: ...INTERLOCK MODULE ON OFF SWITCH IGNITION COIL BLACK BLACK Kawasaki FE120 Engine ON OFF SWITCH is open in the ON position INTERLOCK SWITCH is closed when traction lever is in NEUTRAL HIGH TENSION LEAD...

Page 65: ...ine ON OFF SWITCH is open in the ON position INTERLOCK SWITCH is closed when traction lever is in NEUTRAL HIGH TENSION LEAD FLYWHEEL RED CONNECTOR LIGHTING COIL YELLOW YELLOW ORANGE HOUR METER OPTIONA...

Page 66: ...its The high impedance internal resistance of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits...

Page 67: ...trical problems related to the ignition system Some ignition system testing is covered in this chapter Starting Problems Problem Possible Causes Correction Engine will not start ON OFF switch is in th...

Page 68: ...to maintain normal starting speeds 1 With engine not running remove high tension lead from the spark plug and connect it to the spark tester Fig 4 2 Connect spring clip of tester to a good ground on...

Page 69: ...tch to wiring harness 3 With engine ON OFF switch in the ON position at tempt to start the engine If the engine does not start check the interlock module using the following steps 4 Disconnect red wir...

Page 70: ...k gap The traction lever must not contact the switch 6 Engage traction lever and verify that the switch opens no continuity Removal 1 Disconnect switch from the wires leading from the In terlock modul...

Page 71: ...the handle the switch closes allowing the engine to run Using a multimeter this switch can be tested as follows 1 With the bail released away from the handle there should be no continuity between the...

Page 72: ...Greensmaster Flex 21 Page 5 10 Electrical System This page is intentionally blank...

Page 73: ...able of Contents SPECIFICATIONS 2 ADJUSTMENTS 3 Handle Height Adjustment 3 SERVICE AND REPAIRS 4 Handle Assembly 4 Parking Brake Cable Replacement 6 Traction Cable Replacement 7 Reel Control Cable Rep...

Page 74: ...Greensmaster Flex 21 Page 6 2 Chassis and Controls Specifications Item Description Tire Pressure 12 to 15 PSI 0 83 to 1 04 bar...

Page 75: ...the engine OFF 2 Remove hairpin cotters from the ring pins on each side of the mower handle 3 Support handle and remove ring pins from each side of the mower handle Raise or lower handle to the de si...

Page 76: ...r 22 Control bracket 23 Reel lever pin 24 Friction washer 25 Dowel pin 26 Throttle cable 27 Cap screw 28 Cap screw 29 Throttle lever 30 Compression spring 31 Lock nut 32 Brake cable spacer 33 Cable ti...

Page 77: ...screw on each end of the handle Fig 4 5 Remove handle from frame Handle Installation 1 Slide handle ends through the holes in the handle arms with grommets Install handle to the frame using cap screw...

Page 78: ...the bracket 6 Remove brake cable from the mower Installation 1 Secure brake cable eyelet to the brake lever on the mower handle with flange head screw spacer and lock nut Fig 6 2 Position cable to th...

Page 79: ...ever assembly 5 Remove traction cable from the mower Installation 1 Secure traction cable spring to the traction lever as sembly Fig 8 A Install cable spring to pin on traction lever assem bly and sec...

Page 80: ...el control lever 5 Remove reel control cable from the mower Installation 1 Secure reel control cable to the reel control lever Fig 10 A Hook cable spring to reel control lever B Secure the cable housi...

Page 81: ...trol brack et B Unhook cable end from throttle lever 6 Remove throttle cable from the mower Installation 1 Connect throttle cable to the throttle lever Snap throttle cable housing to the control brack...

Page 82: ...heel hex shaft Installation 1 Make sure mower is parked on a level surface and the engine is OFF 2 Push kickstand down with one foot while pulling up on the handle This will support the mower on the k...

Page 83: ...e four cap screws and flange nuts from the deep rim and shallow rim Remove shallow rim from the deep rim 3 Remove bolt from the hub Remove bolt spring and locking clip from the hub Reassembly 1 Reinst...

Page 84: ...orsion spring Push the torsion spring down and in to release spring tension Fig 18 4 Remove flange nuts cap screws flat washers spacers and torsion spring from the kickstand and frame Note long spacer...

Page 85: ...ity of Cut 7 ADJUSTMENTS 9 Bedknife to Reel Adjustment 9 Leveling Rear Roller 10 Rear Roller Height Adjustment 11 Height of Cut Adjustment 12 Cut off Bar Adjustment 13 SERVICE AND REPAIRS 14 Backlappi...

Page 86: ...1 carbon steel blades optional 8 blades welded to 5 stamped steel spiders HEIGHT OF CUT RANGE 1 16 to 19 64 inch 1 6 to 7 5 mm WIDTH OF CUT 21 inches 53 3 cm CLIP 0 16 inch 0 41 cm BEDKNIFE AND BEDBAR...

Page 87: ...Flex 21 Page 7 3 Cutting Unit Rev C General Information Grass Basket Installation 1 Grasp basket by top lip and slide the basket frame into the receivers Figure 1 1 1 Grass basket 2 Basket receivers 2...

Page 88: ...t traction unit on restrained kickstand 6 Pull cutting unit forward about 2 inches 51 mm and then to the right to disengage the transmission coupler Fig 4 7 Reverse procedure to install cutting unit t...

Page 89: ...s at a safe distance from the rotating reel Figure 6 Bedknife Screw Tool TOR510880 This screwdriver type bit is made to fit Toro bedknife at taching screws Use this bit with a 3 8 drive torque wrench...

Page 90: ...a threaded roller shaft NOTE TOR4105 is an alternative to using washers and spacers listed above Figure 9 Sleeve Driver TOR4107 Used to drive the wear sleeve into position on the cutting reel shaft F...

Page 91: ...t has rounded cutting edges or rifling grooved or wavy appearance cannot be corrected by tightening the bedknife to reel contact Grind reel to remove taper and or rifling Grind bedknife to sharpen and...

Page 92: ...etermined by the height of cut See Rear Roller Height Adjustment in Adjustments section Roller condition Make sure rollers rotate freely Repair bearings as necessary See Roller Bearing Replacement in...

Page 93: ...to the bedknife insert a long strip of newspaper between the reel and bed knife B While slowly rotating the reel forward turn bed bar adjusting screw clockwise one click at a time until the paper is p...

Page 94: ...l securely on surface plate and maintaining pressure on the rear roller rotate lower right roller mounting bolt This bolt has an offset which when rotated acts as an eccentric to raise or lower the ro...

Page 95: ...lower position should be used for height of cut range 125 to 296 inch 3 2 to 7 5 mm 1 Remove rear roller see Roller Removal 2 Loosen locknuts that secure roller brackets to mower side plates 3 Move e...

Page 96: ...bottom of screw head and face of bar is height of cut Fig 18 Tighten nut on gauge bar 6 Hook adjusting screw head on the cutting edge of the bedknife Rest the rear end of the bar on the rear roller Fi...

Page 97: ...allel to the reel to as sure optimum performance and should be adjusted whenever the reel is sharpened 1 Park mower on a level surface Make sure engine is OFF Remove high tension lead from the spark p...

Page 98: ...ersonal injury Stay away from the reel when backlapping Never use a short handled paint brush for applying lapping compound Part No TOR299100 backlapping brush assembly complete or individual componen...

Page 99: ...bedbar adjusting screw Fig 22 3 Apply anti seize lubricant to threads and shank of bedbar bolts 4 Secure bedbar to each side plate with bedbar bolts jam nuts threaded onto bolts and 8 washers Fig 23 A...

Page 100: ...here can be variations in the mounting surface of the bedbar a new bedknife will not be perfectly flat after it is installed Because of this it is necessary to backlap or grind a new bedknife after in...

Page 101: ...Greensmaster Flex 21 Page 7 17 Cutting Unit Rev C This page is intentionally blank Cutting Unit...

Page 102: ...e nut 3 Flat washer 4 Carriage screw 5 Shoulder bolt 6 Rear roller bracket 7 Cap screw 8 Height of cut screw 9 Flange nut 10 Height of cut washer 11 Height of cut arm 12 Front roller assembly 13 Eccen...

Page 103: ...ler bracket Roller Installation 1 To install front roller insert one end of roller into height of cut arm Push roller far enough to allow other end of shaft to be positioned in other height of cut arm...

Page 104: ...eal out of roller assembly Discard removed seals NOTE Seals will be destroyed when servicing the roll ers Do not re use seals that have been removed Bearing Removal NOTE It is recommended to replace b...

Page 105: ...led Fig 31 3 After seal installation rotate the roller several times to allow the seal to seat 4 After seating the seals measure the rolling resist ance using one of the following procedures A Wrap a...

Page 106: ...eplace lock nut if any damage is found 4 Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until seal and bearing are removed from roller cavity Remove second seal a...

Page 107: ...seal onto each end of the roller shaft Tighten nuts until they bottom against bearings Fig 37 Remove nuts from roller shaft 8 Position an assembly spacer and yellow assembly washer see Special Tools o...

Page 108: ...0 15 2 3 4 5 6 7 4 8 9 10 11 12 13 14 15 40 18 17 16 29 27 26 27 20 17 28 Anti seize lubricant FRONT RIGHT 160 to 175 in lb 182 to 200 kg cm 1 19 31 32 33 34 35 Threadlocking Compound 36 38 39 30 37 A...

Page 109: ...ve these items from the reel if equipped 12 Cutting unit side plates and shield frame can be sep arated by removing two flange head screws per side Installation Fig 39 1 Place cutting unit on a flat l...

Page 110: ...side plate F Remove reel bearing lock nut pulley spacer pulley and flange nut from reel 7 Apply anti seize lubricant to internal threads of reel bearing lock nut Block reel with a piece of wood to pr...

Page 111: ...Greensmaster Flex 21 Page 7 27 Cutting Unit Rev C This page is intentionally blank Cutting Unit...

Page 112: ...side 13 Wave washer 14 Nylon bushing 15 Bushing 16 Cutting reel Figure 44 4 10 5 13 14 15 12 10 6 2 2 3 4 5 6 7 8 3 9 1 11 FRONT RIGHT 16 NOTE Cutting units with serial numbers below 240001001 were p...

Page 113: ...ke seals during installa tion as seal damage could occur 2 To assemble right side bearing housing A The right side bearing housing should have outer retaining ring installed prior to bearing installat...

Page 114: ...Nylon bushing 14 Bushing 15 Cutting reel 16 Wear sleeve 17 V Ring seal Figure 45 FRONT RIGHT 1 2 3 4 5 6 7 10 2 8 3 9 11 4 5 13 14 12 4 4 9 15 16 17 17 16 NOTE Cutting units with serial numbers above...

Page 115: ...grease NOTE Bearing housings originally equipped with can nister seals cutting units with serial numbers below 240001000 are deeper than bearing housings used on later production machines Inner seal...

Page 116: ...at the reel blades Remove small amounts of material with each pass of the grinder 4 Grind cutting reel refer to TORO Sharpening Reel and Rotary Mowers Manual Form No 80 300 PT 5 After completing grind...

Page 117: ...ATION 3 Transport Mode 3 TROUBLESHOOTING 4 Factors Affecting Grooming 4 Groomer Reel Mechanical Problems 5 ADJUSTMENTS 6 Height Depth of Grooming Adjustment 6 SERVICE AND REPAIRS 7 Drive Belt Replacem...

Page 118: ...ng is also adjustable to 1 4 and 3 4 inch 6 4 and 19 1 mm spacing by varying the number of blades and spacers GROOMING PENETRATION Maximum of 0 125 inch 3 2 mm HEIGHT ADJUSTMENT KNOB Allows a 0 003 in...

Page 119: ...l is not rotat ing IMPORTANT When transporting the mower make sure the cutting unit is disengaged and the groomer reel is raised to its transport position 1 To raise the groomer reel to the transport...

Page 120: ...Use the groomer carefully READ AND UNDERSTAND THE OPERA TION INSTRUCTIONS BEFORE OPERATING OR TESTING GROOMER PERFORMANCE Variables That Affect the Use and Performance of Grooming Reels 1 The growing...

Page 121: ...nd replace faulty bear ing s Replace spring If the belt slips it probably is worn and must be replaced Repair or replace belt if necessary A broken or worn belt could be the result of improper belt ro...

Page 122: ...e quick up levers on both sides of the mower to lower the groomer reel to the grooming position Fig 3 NOTE Improper or over aggressive use of the groom er reel i e too deep or too frequent grooming ma...

Page 123: ...t idler pulley by placing a 10mm wrench on pulley nut and rotating clockwise to relax belt tension Slip groomer drive belt off pulleys Release idler Fig 5 4 Install new drive belt to drive pulley idle...

Page 124: ...to reverse the shaft replace individual blades or replace the entire shaft The shaft can be reversed so that the sharpest edge of the blades are forward Removal 1 Park mower on a level surface Make s...

Page 125: ...er shaft into RH side plate bearing and then position side plate to cutting unit frame Secure with two tapered nuts Fig 9 Tighten nuts from 30 to 35 ft lb 41 to 47 N m NOTE The drive pulley has left h...

Page 126: ...shaft Then place first blade against spacers Fig 12 2 Rotate location mark on each installed blade one flat of the shaft either in a clockwise or counterclockwise direction The direction of location m...

Page 127: ...ring Note Seals are a two piece design Seals should be installed so the lip side of the seal assembly is facing out see inset in Figure 14 4 Reinstall LH groomer side plate to mower A Position LH groo...

Page 128: ...belt tension Removal 1 Remove groomer belt cover drive belt and drive pulley from right side of mower see Groomer Reel Re moval in this section 2 Using Figures 16 and 17 as guides remove idler bracke...

Page 129: ...ze lubricant Disassembly 1 Remove adjuster arm from cutting unit see Groomer Reel Removal in this section 2 Disassemble adjuster arm using Figure 18 as a guide Note Right and left side adjuster arms a...

Page 130: ...1 Inner oil seal Figure 19 16 21 18 23 24 25 22 21 31 15 2 3 4 5 6 7 4 8 9 10 11 12 13 14 15 31 18 17 16 29 27 26 27 20 17 28 Anti seize lubricant FRONT RIGHT 160 to 175 in lb 182 to 200 kg cm 1 19 Th...

Page 131: ...itch arms and bushings in frame to accept bearing housings The reel shaft end with keyway should be on the left side of the frame 4 Attach both bearing housings assemblies through the frame onto the r...

Page 132: ...Greensmaster Flex 21 Groomer Model 04201 Rev B Page 8 16 This page is intentionally blank...

Page 133: ...e 3 TROUBLESHOOTING 4 Factors Affecting Grooming 4 Groomer Reel Mechanical Problems 5 ADJUSTMENTS 6 Height Depth of Groomer Adjustment 6 SERVICE AND REPAIRS 7 Groomer Belt Replacement 7 Groomer Reel 8...

Page 134: ...19 1 mm spacing by varying the number of blades and spacers GROOMER PENETRATION From 410 inch 10 4 mm above ground level to 0 125 inch 3 2 mm below ground level at mowing HOC range of 062 to 296 inch...

Page 135: ...transport position To place the groomer reel in the raised transport posi tion remove the lock screw and rotate the lift arm to raise the groomer reel Install the lock screw to retain the groomer reel...

Page 136: ...Use the groomer carefully READ AND UNDERSTAND THE OPERA TION INSTRUCTIONS BEFORE OPERATING OR TESTING GROOMER PERFORMANCE Variables That Affect the Use and Performance of Grooming Reels 1 The growing...

Page 137: ...replace faulty bear ing s Replace spring If the belt slips it probably is worn and must be replaced Repair or replace belt if necessary A broken or worn belt could be the result of improper belt routi...

Page 138: ...ments section of Chapter 7 Cutting Unit 3 Position the groomer reel to the lowered grooming position Fig 3 NOTE Improper or over aggressive use of the groom er reel i e too deep or too frequent groomi...

Page 139: ...idler pulley by placing a 10mm wrench on pulley nut and rotating clockwise to relax belt tension Slip groomer drive belt off pulleys Fig 5 Release idler 4 Install new drive belt to drive pulley idler...

Page 140: ...place individual blades or replace the shaft The shaft can be reversed so that the sharpest edge of the groomer blades are forward Removal 1 Park mower on a level surface Make sure engine is OFF Remov...

Page 141: ...H side plate bearings taking care not to damage seal in side plate Thread flange nut onto the shaft threads but do not tighten 4 Carefully place RH side plate onto groomer shaft tak ing care not to da...

Page 142: ...de plate Fig 7 12 Center front roller and tighten cap screws to secure roller Figs 7 and 8 13 Reinstall groomer drive belt and belt cover to right side of mower see Groomer Belt Replacement in this se...

Page 143: ...te location mark on each installed blade one flat of the shaft either in a clockwise or counterclockwise direction The direction of location mark rotation must remain constant on the shaft 3 For 1 2 i...

Page 144: ...in this sec tion 2 Remove LH groomer side plate A Take reel drive assembly from left side of cutting unit see Cutting Reel Removal in the Service and Repairs section of Chapter 7 Cutting Unit B Remov...

Page 145: ...plate to mower making sure that groomer arm lift rod is positioned through bushing in side plate B Place spring washer and lock nut on lift rod threads Fig 14 Tighten lock nut C Install reel drive as...

Page 146: ...ng to maintain proper belt tension Removal 1 Remove groomer belt cover drive belt and drive pulley from right side of mower see Groomer Reel Re moval in this section 2 Using Figures 15 and 16 as guide...

Page 147: ...utting unit see Groom er Reel Removal in this section 2 Disassemble groomer arm using Figure 17 as a guide NOTE Right and left side HOC groomer arms and lift arm assemblies are different other compone...

Page 148: ...8 16 21 18 23 24 25 22 21 31 15 2 3 4 5 6 7 4 8 9 10 11 12 13 14 15 31 18 17 16 29 27 26 27 20 17 28 Anti seize lubricant FRONT RIGHT 160 to 175 in lb 182 to 200 kg cm 1 19 Threadlocking Compound 30 1...

Page 149: ...oduction reels install wear sleeve and v ring seal to reel Fig 20 CAUTION Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when handling the cu...

Page 150: ...er brush uses the same procedure as removal and installation of the groomer reel see Groomer Reel in this section To remove the groomer brush from the shaft remove the lock nut and J bolt from both en...

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