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Greensmaster Flex 1800/2100

1. Figure 7 1 Service brake lever 3 Parking brake latch 2 Park brake latch switch Figure 8 Park brake latch switch Switch panel Lower handle Screw 2 used 5 Lock nut 2 used 6 Console cover 7 Screw 4 used AUNDH Electrical System o 0 w 7A oo S o lu Traction Switch Switch Adjustment 1 Make sure the engine is OFF and the traction lever is in the NEUTRAL position 2 Remove console cover from handle to allow access to traction switch Fig 10 3 Move the traction lever forward to engage the trac tion drive 4 With the traction drive engaged there should be from 0 030 to 0 090 0 8 to 2 3 mm clearance between the head of the cap screw in the traction lever and the traction switch Fig 9 5 If clearance is incorrect loosen traction switch mounting fasteners adjust clearance and tighten fas teners Recheck clearance between cap screw head and switch after tightening fasteners The cap screw in the traction lever must not contact the switch Switch Testing 1 Make sure the engine is OFF and the traction lever is inthe NEUTRAL position Disconnect traction switch connector from the machine wire harness 2 Check the continuity of the traction switch by con necting a multimeter ohms setting across the connec tor terminals 3 With the traction lever in the NEUTRAL position there should be continuity zero ohms across the sw
2. 11 Traction S Witch acte ede eas 12 Interlock Module 2 cece eee ee 13 LiGhtnG Cll 2 2 elu yates tad aad eae 13 o oO t2 oo S o Ww Greensmaster Flex 1800 2100 Page5 1 Electrical System This page is intentionally blank Electrical System Page 5 2 Greensmaster Flex 1800 2100 General Information Operator s Manual The Traction Unit Operator s Manual provide informa tion regarding the operation general maintenance and maintenance intervals for your Greensmaster machine Refer to this Operator s Manual for additional informa tion when servicing the machine o oO t2 oo S o Ww Greensmaster Flex 1800 2100 Page 5 3 Electrical System Wiring Schematic HIGH TENSION LEAD INTERLOCK MODULE R IGNITION COIL VIOLET BLACK ORANGE ENGINE MAGNETO FLYWHEEL VIOLET YELLOW VIOLET YELLOW 9 PARKING BRAKE LATCH SWITCH LIGHTING COIL CONNECTOR ON OFF CONNECTOR SWITCH IN OFF TRACTION SWITCH Subaru Engine ON OFF SWITCH is open in the ON position TRACTION SWITCH is closed when traction lever is in neutral PARKING BRAKE LATCH SWITCH is closed when parking brake latch is engaged Electrical System Page 5 4 Greensmaster Flex 1800 2100 Wire Harness Drawings P06 PARKING BRAKE
3. ccc cece I 1 E E EQUIVALENTS AND CONVERSIONS 2 Decimal and Millimeter Equivalents 2 U S to Metric Conversions issus 2 TORQUE SPECIFICATIONS 0 caus 3 Fastener Identification cc cece e eee es 3 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Fasteners 4 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners 0005 5 Other Torque Specifications sssss 6 Conversion Factors ccc cece cece eee 6 Product Records Insert Operator s Manual and Parts Catalog for your Greensmaster F lex 1800 or Flex 2100 at the end of this section Additionally ifany optional equipmentor acces sories have been installed to your machine insert the Installation Instructions Operator s Manuals and Parts Catalogs for those options at the end of this chapter Maintenance Maintenance procedures and recommended service in tervals for the Greensmaster Flex 1800 and Flex 2100 are covered in the Operator s Manual R efer to that pub lication when performing regular equipment mainte nance Greensmaster Flex 1800 2100 Page2 1 Product Records and Maintenance Decimal and Millimeter Equivalents Equivalents and Conversions Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 08125 0 794 17 32 0 53125 13 494 3 64 0 046875
4. 1 191 35 64 0 546875 13 891 1 16 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 09375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 8 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 82 0 21875 5 556 283 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 82 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 16 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7 6 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906
5. C Connect wire harness ground wire to engine by installing LH rear cap screw item 7 in Fig 5 flat washer item 11 in Fig 5 and flange nut item 8 in Fig 5 Apply skin over grease see S pecial Tools in Chapter 5 Electrical System to prevent corrosion D If machine is equipped with optional lighting kit connect wire harness connectors to engine alterna tor wires 7 Connect throttle cable to engine Fig 6 A Slide throttle cable end into governor lever B Place throttle cable under cable clamp and se cure with screw C Adjustthrottle cable See Throttle Cable Adjust ment in the Adjustment section of this chapter Make sure thatallfasteners are tightened after cable adjustment 8 Check and adjust engine oil level as needed 9 Attach spark plug wire to the spark plug Open fuel shut off valve on fuel tank 10 Start engine and allow it to warm to operating tem perature Check high and low idle speeds and adjust if necessary Page 3 10 Greensmaster Flex 1800 2100 Engine Coupler Sleeve The coupler sleeve used on Greensmaster Flex 1800 and 2100 allows a positive coupling between the engine andtransmission while also providing vibration damping and quiet operation The outer surface of the coupler Sleeve includes a series of curved lines thatcan be used to gauge the condition of the internal coupler cogs that are used to connect the engine and transmission cou plers When the coupler sleeve is new
6. Installation Fig 10 1 Apply a light coating of grease to ends of grooming reel shaft and also to seal lips in RH drive plate and LH support plate Make sure thatall bearings bushings and seals are properly installed 2 Make sure that O ring item 11 is installed on grooming reel shaft Apply light coating of grease to O ring 3 Carefully place grooming reel assembly into the LH support plate taking care to not damage seal in support plate or O ring on shaft 4 Apply light coating of grease to O ring on RH drive Figure 13 plate assembly pivot hub and pilot bore of cutting unit 1 Roller cap screw 4 Spring washer side plate 5 eae reel assembly 5 Groomer arm lift rod d Locknut Greensmaster Flex 1800 2100 Page 8 15 Groomer 5 Carefully slide RH drive plate onto grooming reel shaft taking care to not damage seals in drive plate Position drive plate to the support plate on the cutting unit frame and secure with four 4 button head screws item 30 Make sure that drive plate rotates freely after installation 6 Install driven gear item 14 onto grooming reel shaft A Apply light coating of grease to hub on driven gear item 14 B Carefully slide driven gearonto the grooming reel shaft taking care to not damage seal in drive plate NOTE To prevent grooming reel shaftfrom turning when installing driven gear use wrench on shaftflats to hold shaft C Secure gear to shaft with lock nut item 15 To
7. 10 The safety interlock switches are for the operator s protection do notdisconnectthem Check the operation of the switches daily to assure the interlock system is op erating If a switch is defective replace it before operat ing the machine See Component Testing in Chapter 5 Electrical System Greensmaster Flex 1800 2100 While Operating 1 Donotrun the engine in a confined area withoutade quate ventilation Exhaust fumes are hazardous and could be deadly 2 Always stand behind the handle when starting and operating the machine 3 To start the engine A Open fuel shut off valve Make sure spark plug wire is connected to spark plug B Verify thatthe control lever on handle is in NEU TRAL position for both traction and reel drives C Move on off switch to ON position set choke to full choke position cold start and throttle to half throttle D Pull starter cord to start engine 4 To stop the engine A Disengage reel and traction drives and reduce engine speed to SLOW B Move on off switch to OFF position to stop en gine Maintenance and Service 1 The Traction Unitand Cutting Unit Operator s Manu als provide information regarding the operation general maintenance and maintenance intervals for your Greensmaster machine Refer to these publications for additional information when servicing the machine 2 Before servicing or making adjustments to the ma chine stop the engine and wait for
8. Figure 19 4 Spring washer 5 Groomer arm lift rod 1 Roller cap screw 2 Grooming reel assembly 3 Locknut FORWARD ROTATING GROOMER Seal lips toward center of cutting unit Figure 20 1 RH drive plate assy 3 Seal 2 used 2 Bearing 2 used Greensmaster Flex 1800 2100 2 Install LH support plate to left side of cutting unit COUNTER ROTATING GROOMER A Apply antiseize lubricant to threads of LH groom er arm lift rod B Position LH support plate to cutting unit making sure that LH groomer arm lift rod is positioned through bushing in support plate C Place spring washer and lock nut on lift rod threads Fig 19 Tighten lock nut D Install reel drive assembly reel pulley reel drive Seal lips belt and then reel drive cover to left side of cutting NS toward center of unit see Reel Drive Assembly in the Service and Re cutting unit pairs section of Chapter 4 Traction and Reel Drive System Figure 21 RH drive plate assy 3 Seal 2 used Bearing 2 used Ne 3 Install grooming reel front roller and RH drive plate to right side of cutting unit see Grooming R eel Forward Rotating or Counter R otating in this section 4 Check and adjust grooming reel height and mower height of cut settings i toward center of 5 Install cutting unit to the machine cutting unit 6 Lubricate groomer bearings NOTE After greasing groomer bearings operate groomer for 30 seconds s
9. Toro Part Number TOR510880 This screwdriver type bitis made to fit Toro bedknife at taching screws Use this bit with a 3 8 drive torque wrench to secure the bedknife to the bedbar F DO NOT use an air or manual impact wrench with this tool 3 Figure 7 Cutting Unit Page7 6 Greensmaster Flex 1800 2100 Roller Bearing Installation Tools Washers and spacer used to install bearings and seals into front and rear rollers Fig 8 Seal installation washer 107 8133 Seal installation spacer 107 3505 Bearing installation washer 104 6126 As an alternative to using washers and spacers listed Seal Installation Seal Installation Bearing Installation above a special tool setis available thatcan be used for Washer Spacer hr roller bearing and seal installation Fig 9 black yellow Figure 8 Toro Part Number TOR4105 Figure 9 Diameter Circumference Measuring Tape Toro Part Number TOR 6023 Spring steel measuring tape for accurately measuring the circumference and outside diameter of cutting reel and other spherical components Tape calibration is in fixed inch readings no adjustments Figure 10 Turf E valuator Tool Toro Model Number 04399 Cutting Unit Many turf discrepancies are subtle and require closer examination In these instances the Turf Evaluator grass viewing tool is helpful It can assistturf managers and service technicians in determining causes for poor reel mower performance and i
10. Washer head screw Detent ball Detent spring Shift arm link Shoulder screw 2 used Shifter link Bumper 2 used Spring collar Spacer Spring lever Chassis and Controls Figure 14 Shift handle Extension spring Latch pin Bushing 10 used Shifter latch Transport lever Reel shift lever Reel cam lever Ball bearing Cap screw Page 6 12 Note orientation of spring hook Screw Flat washer Flat washer Shoulder screw Lock nut 2 used Lock nut Roll pin Retaining ring 3 used Extension spring Greensmaster Flex 1800 2100 Disassembly Note orientation 1 Make sure the engine is OFF and the traction lever of spring hooks is in the NEUTRAL position 2 Remove console cover from handle to allow access to lever assembly Fig 15 3 Disconnect reel clutch and traction clutch cables from lever assembly see Cable Replacement in this section Position ends of cables away from lever as sembly 4 Disconnect wire harness connector from traction switch Fig 15 5 Disconnect spring item 11 in Figure 15 that con nects operator presence control with traction lever as sembly 6 Remove four 4 flange head screws and flange nuts thatsecure lever assembly and brackets to handle Re move assembly including leverassembly shifter brack et shift mount and switch mount bracket from handle 7 Remove two 2 flange head screws and flange nuts
11. location 2 Press flocked seals onto reel shaft with flocked side orientated toward bearing location Seal should be per pendicular to reel shaft after installation Greensmaster Flex 1800 2100 Page 7 27 3 Slide bearings fully onto reel shaft Bearings should bottom on reel shaft shoulder IMPORTANT When installing reel drive shaft item 4 use appropriate wrench or socket on 1 hex sur face of shaft Do not use 1 2 extension on end of reel drive shaft when loosening or tightening drive shaft The 1 2 hex is intended for backlapping only 4 Install bearing lock screw item 5 and reel drive shaft item 4 into reel shaft to secure bearings Reel drive shaft has LH threads and should be installed in end of reelshaftidentified with a groove thatis justinside of reel spider Fig 37 NOTE Installation torque for bearing lock screw and reel drive shaftis from 90 to 110 ft Ib 123 to 149 N m Itis easiestto torque these items after the cutting reel is installed in the cutting unit frame see Reel Assembly Removal and Installation in this section Figure 37 3 RHthreads 1 LH threads 2 Groove Cutting Unit Preparing Reel for Grinding NOTE Before grinding a cutting reel make sure thatall cutting unitcomponents are in good condition Depend ing on type of grinder used faulty cutting unit compo nents can affect grinding results NOTE When grinding be careful to not overheat the cutting reel bla
12. side of the cutting unit crossmember Fig 23 Cutting unit service procedures are the same on both models Removal Fig 22 1 Remove lock nut item 3 compression spring item 2 and washer item 11 from bedbar adjuster screw 2 Remove bedbar see Bedbar Removal in this sec tion NOTE Bedbar adjuster shaft item 4 has left hand threads 3 Unscrew bedbaradjustershaft item 4 from the bed bar adjuster screw Cutting Unit Flange bushing Page 7 16 9 Retaining ring 10 Bedbar adjuster screw 11 Washer 4 Remove retaining ring item 9 and wave washer item 8 from bedbar adjuster shaftand remove adjuster shaft from cutting unit frame 5 Inspect flange bushings item 5 in cutting unit side plate and remove if necessary 6 If detent item 7 is damaged remove itfrom cutting unit side plate by removing the cap screw item 6 Installation Fig 22 1 Ifdetent item 7 was removed secure detentto cut ting unit side plate with cap screw 2 If flange bushings item 5 were removed align key on bushing to slot in frame and install bushings Greensmaster Flex 1800 2100 3 Slide bedbar adjuster shaft item 4 into flange bush ings in cutting unitside plate Secure adjuster shaft with wave washer item 8 and retaining ring item 9 NOTE Bedbar adjuster shaft item 4 has left hand threads 4 Applyantiseize lubricantto threads of bedbaradjust er screw that fit into adjuster shaft Threa
13. the center line on the outer surface ofthe sleeve is basically straight while the lines above and below are curved in different directions Fig 9 As the coupler wears with normal machine use the curved lines may visually straighten indicated that the coupler has distorted When removed from the ma chine the innercogs ofa used coupler may exhibitsome offsetas shown in Figure 10 This type ofoffset will gen erally not impact normal machine operation The cog Offset can be 0 250 6 4 mm before coupler replace ment is necessary Ifa coupler sleeve has torn or missing cogs the coupler should be replaced Figure 8 1 Engine 4 Setscrew 2 used 2 Key 5 Coupler sleeve 3 Engine coupler Figure 9 Figure 10 Greensmaster Flex 1800 2100 Page 3 11 Engine This page is intentionally blank Engine Page 3 12 Greensmaster Flex 1800 2100 Chapter 4 TORO Traction and Reel Drive System Table of Contents SPECIFICATIONS o nere ener ues 2 GENERAL INFORMATION 000 cee ee 3 Operator s Manuals cece eee neces 3 Disengaging Drum Drive From Transmission 3 Transmission Belt Tensioner 4 SPECIAL TOOLS oeiee e err edna Aes 5 Modified Socket for Reel Clutch Bearing Collar 5 ADJUSTMENTS 4 0 5 60 0 n Re xen ehe 6 Cutting Unit Clip Adjustment 0 6 Reel Clutch Adjustment sssssssssss 7 SERVICE AND REPAIRS 0 0 cece eee 9 eE Reel
14. the shaft secure the assembly with J bolts and lock nuts Make sure that the J bolts are installed with the Figure 32 threaded portion on the outside of the brush Fig 32 1 J bolt 2 Lock nut Torque lock nuts from 20 to 25 in Ib 2 3 to 2 8 N m Groomer Page 8 26 Greensmaster Flex 1800 2100
15. 10 Traction and Reel Drive Engagement Lever Assembly career tenter ry ER 12 Kickstand 4 zik b ace ak NER 16 Transport Wheels Optional 18 cs amp 2 22 Qe Zo So 2 Greensmaster Flex 1800 2100 Page6 1 Chassis and Controls Specifications Item Description Transport Wheel Optional Tire Pressure 12 to 15 PSI 83 to 103 kPa Chassis and Controls Page 6 2 Greensmaster Flex 1800 2100 General Information Operator s Manual The Operator s Manual provides information regarding the operation adjustment procedures and general maintenance for your Greensmaster machine Refer to the Operator s Manual for additional information when servicing the machine cs amp 2 22 Qe o9 So ro Greensmaster Flex 1800 2100 Page 6 3 Chassis and Controls Service and Repairs Handle Assembly 8 Throttle assembly 9 Console cover 10 Washer head screw 4 used Figure 1 1 Brake lever 5 Traction clutch cable 2 Brake cable 6 Reel clutch cable 3 Throttle cable 7 Traction and reel drive lever 4 Handle Handle Removal Fig 1 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the engine spark plug 2 Remove console cover from handle assembly 3 Disconnect reel clutch traction clutch and brake cables from transmission see Cable Replacement in this section 4 Disconnect throttle ca
16. 2 used 27 Lock collar 7 Drum shaft 18 Dowel pin 2 used 28 Pin 8 Long spur gear 19 Cap screw 29 Thrust washer 9 Differential assembly 20 Flat washer 30 O ring 10 RH traction drum 21 Traction engage lever 31 Spur gear assembly 11 Jam nut Disassembly Fig 24 2 Remove traction drums from machine see Traction Drums in this section 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the engine spark 3 Slide spur gear assembly from differential assembly plug in drum drive housing F ig 25 Traction and Reel Drive System Page 4 22 Greensmaster Flex 1800 2100 4 If necessary disassemble spur gear assembly Fig 26 A The hex shaft has left hand threads The shaft also has thread locking compound on threads B Press ball bearing and flange bushing from spur gear as needed IMPORTANT As drum shaft item 7 and differential assembly item 9 are removed make sure to re trieve and note location of thrust washer item 29 for assembly purposes 5 Push drum shaft item 7 outof differential assembly Make sure to locate and retrieve thrust washer item 29 6 Slide differential assembly from long spur gear item 8 and drum drive housing item 1 NOTE Fordifferential service procedure see Differen tial Assembly Service in this section 7 Ifnecessary slide long spur gear item 8 from drum drive housing Straight bushings item 17 in long spur gear should be in
17. 5 in both HOC arms If necessary apply antiseize lubricant to threads ofnew HOC screw Thread new HOC screw into HOC arm NOTE When assembling HOC arms to side plates make sure thatring on HOC screw fits into the notch on the side plate 3 If both HOC arms were removed from cutting unit side plate position one ofthe arms to side plate Secure arm to side plate with plow bolt item 4 HOC washer item 6 and HOC nut item 7 Tab on HOC washer should be positioned into HOC arm slot and orientated down toward the roller 4 Slide frontrollershaftinto arm attached to the cutting unit Slide second HOC arm onto the other end of roller shaft Secure second arm to cutting unit side plate with plow bolt item 4 HOC washer item 6 and HOC nut item 7 5 Center front roller to the cutting reel and secure to HOC arms with cap screws item 1 6 Adjust cutting unit see Cutting Unit Operator s Manual 7 Install cutting unitto machine Cutting Unit Page 7 18 Antiseize Lubricant Figure 24 1 Cap screw 5 HOC screw 2 HOC arm 6 HOC washer 3 Frontroller assembly 7 HOC nut 4 Plow bolt Figure 25 3 HOC screw 4 HOC washer amp nut 1 Frontroller assembly 2 HOC arm Greensmaster Flex 1800 2100 Rear Roller Removal Fig 26 1 Park machine on a level surface Make sure the en gine is OFF and the traction lever is in NEUTRAL 2 Remove the cutting unitfrom the machine and place on a leve
18. 9 Remove HOC nut item 2 HOC washer item 9 and plow bolt item 35 thatsecure RH groomerarm assem bly to RH drive plate assembly Do not change height of cut screw adjustment Remove RH groomer arm assembly from cutting unit 10 R emove front roller from cutting unit NOTE To prevent grooming reel shaft from turning when removing driven gear item 14 use wrench on shaft flats to hold shaft Figure 11 11 Remove the lock nut item 15 that secures driven is Extensionspring 3 47T idler gear gear item 14 to grooming reel shaft Remove driven 2 43T idler gear 4 Groomer drive gear gear from shaft NOTE To prevent cutting reel from turning when re moving groomer drive gear item 17 use a 1 2 socket on hex of reel drive shaftthatis used forbacklapping the cutting reel 12 Loosen and remove groomer drive gear item 17 from the cutting reel shaft 13 Remove four 4 button head screws item 30 that secure the RH drive plate assembly item 12 to the sup port plate on the cutting unit frame Remove the RH drive plate assembly from grooming shaft and cutting unit 14 Carefully pull the grooming reel from the LH support 120 in Ib plate 13 5 N m 15 Inspect seals bushings and bearings in RH drive i RH Figure e m band plate LH support plate and groomer arms for wear or 2 AST qear enring A Bande damage Also inspect gears and idler components for wear or damage Replace components as needed
19. Connect spark plug wire to spark plug BT ET 11 77 BLADES POSITION LE 60 65 IN LBS y 22 TOOTH PULLEY IS ALUMINUM COLOR 24 TOOTH PULLEY IS BLACK COLOR 25 TOOTH PULLEY IS RED COLOR Figure 8 Traction and Reel Drive System Page4 6 Greensmaster Flex 1800 2100 Reel Clutch Adjustment To adjustthe reel clutch follow the following steps 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the engine spark plug 2 Remove rubber plug from front of transmission to al low viewing of reel drive clutch components F ig 9 3 Releaseclutch cable spring tension by removing reel clutch cable from casting slot of transmission A Loosen upper jam nut that secures reel cable to casting slot of transmission B Lift cable free from casting slot of transmission 4 Loosen jam nut that secures set screw position in reel clutch lever Fig 9 5 Apply light upward pressure againstthe reel clutch lever 6 Backoutsetscrew in reelclutch lever until reel clutch hub causes the tips ofthe reel drive hub teeth to contact the mating reel clutch pulley 7 While maintaining light pressure on reel clutch lever rotate setscrew clockwise until a gap of 0 040 to 0 060 1 0 to 1 5 mm is attained between the reel drive hub and reel clutch hub 8 Tighten jam nut to secure adjustment Make sure that set screw does notrotate while tightening jam nut 9 Install rubber plug into front of tr
20. Instruction Decals 1 4 Chapter 2 Product Records and Maintenance ProductRecords 222 ssec metera ARR Res 2 1 Mainteriance isle cba a ERRARE 2 1 Equivalents and Conversions 2 2 Torque Specifications cece cece eee 2 3 Chapter 3 Engine Specifications cis wie ee Sede YS 3 3 General Information 0000 0s 3 4 Adjustments eet x et Re m siot 3 5 Service and Repairs u a 3 6 SUBARU SERVICE MANUAL Chapter 4 Traction and Reel Drive System Specifications cocco sre e a AEE 4 2 General Information 000 0s 4 3 Special TOS 2 seg daa etna ERR ERR ERES 4 5 Adjustments cete mete eee 4 6 Service and Repairs 0 0c eee 4 9 Chapter 5 Electrical System General Information 00008 5 3 Wiring Schematic n aaua 5 4 Wire Harness Drawings sssaaa 5 5 Special Tools i bet Rr RR ems 5 6 Troubleshooting 00 cece 5 8 Component Testing 0 eee eee 5 9 Greensmaster Flex 1800 2100 Chapter 6 Chassis and Controls Specifications General Information Service and Repairs Chapter 7 Cutting Unit Specifications General Information Special Tools Factors That Affect Quality Of Cut Adjustments Service and Repairs Chapter 8 Groomer Specifications General Information Troubleshooting Adjustments Service and Re
21. OFF Remove spark plug wire from the engine spark plug 4 Supportboth sides of machine frame with jackstands or suitable blocking to prevent the machine from mov 2 Ifinstalled remove transport wheels see Transport ing Wheels in the Service and Repairs section of Chapter 6 Chassis and Controls Traction and Reel Drive System Page 4 18 Greensmaster Flex 1800 2100 5 Separate LH side plate item 25 from machine F ig 22 A Remove flange nut hardened washer and car riage screw items 3 4 and 6 inFig 22 that secure LH side plate to rear frame B Remove three 3 flange screws and hardened washers items 8 and 4 in Fig 22 that secure LH side plate to frame C Slide LH side plate from supporting bearing and remove from machine 6 Insertbar stock or other suitable tool through spokes of LH traction drum to keep drum from turning 7 While retaining LH drum loosen and remove bearing nut item 15 from traction drum assembly The ball bearing item 14 is pressed onto the bearing nutso it will be removed with the nut 8 Slide LH traction drum item 13 from drum shaft Lo cate and retrieve square key from shaft 9 f necessary carefully remove grease seal item 12 from LH traction drum taking care to not damage bore of drum Discard removed seal 10 If necessary remove LH hex shaft item 16 and ball bearing item 14 from bearing nut 11 Insertbar stock or other suitable tool through spokes of RH
22. Reel Drive System Final Reel Drive has Three 3 Pulleys with Positive Drive Belt Pulley Configuration Allows Six 6 Clip Adjustments Traction and Reel Drive System Page 4 2 Greensmaster Flex 1800 2100 General Information Operator s Manuals The Traction Unit and Cutting Unit Operator s Manuals provide information regarding the operation general maintenance and maintenance intervals for your Greensmaster machine Refer to these Operator s Manuals for additional information when servicing the machine Disengaging Drum Drive From Transmission The traction drum is driven by a multi ribbed belt that is tensioned with a spring loaded idler assembly To disen gage the traction drum drive from the transmission fol low the following procedure 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the engine spark plug Drive System 2 Locate the traction engage disengage lever next to the RH drive housing drum Fig 1 a s s S z iS i 5 A Be careful when rotating the traction engage dis engage lever The leveris spring loaded and may cause personal injury Push lever from the front when removing belt tension to prevent unex pected movement of the lever 3 Rotate traction engage disengage lever toward the rear of the machine to the disengaged position to re Figure 1 move tension from the drum drive b
23. System Page 4 30 3 Remove transmission drive belt see Transmission Drive Belt in this section 4 Remove retaining ring item 5 that secures reel clutch lever item 10 in transmission housing Slide reel clutch lever from housing Note missing tooth in spline area of lever which is used for alignment with reel clutch fork item 16 5 Pull reel clutch shaft assembly from transmission housing NOTE If ball bearing item 28 on reel clutch shaft assembly is seized in housing refer to Removing SeizedReelClutch ShaftFrom Transmission in this sec tion for removal procedure Greensmaster Flex 1800 2100 6 Inspectflange bushings and reel brake ring for wear or damage Fig 37 Replace bushings and brake ring if necessary Reel Clutch Shaft Disassembly Fig 36 NOTE The following procedure covers complete dis assembly of reel clutch shaft assembly Depending on service needs of machine it may not be necessary to perform every step of this procedure IMPORTANT When removing flex coupler item 2 from clutch shaft do not mar outer surface of cou pler e g grasping with pliers or mounting in vise as coupler may be damaged and fail prematurely 1 Support flex coupler item 2 to preventit from being damaged during spring pin removal Push spring pin from flex coupler and bearing collar item 23 Slide cou pler with hex shaft item 3 from collar Discard removed spring pin 2 Press ball bearing item 28 fr
24. all machine motion to stop Remove the spark plug wire from the spark plug to prevent accidental starting of the engine 3 To make sure entire machine is in good condition keep all nuts bolts screws and belts properly tightened 4 To reduce potential fire hazard keep the engine area free of excessive grease grass leaves and accumula tion of dirt 5 Wear heavy gloves and use caution when checking or servicing the cutting unit 6 If the engine must be running to perform mainte nance or make an adjustment keep hands feet cloth ing and all parts of the body away from the cutting unit and all moving parts Keep bystanders away Greensmaster Flex 1800 2100 Page 1 3 5 Before emptying basketof clippings disengage trac tion and reel drives reduce engine speed and move on off switch to OFF position to stop engine Wait for all machine motion to stop before removing basket 6 Do not touch engine muffler or exhaust pipe while engine is running or soon after ithas stopped because these areas are hot enough to cause burns 7 Ifthe cutting unitstrikes a solid objector vibrates ab normally stop machine operation immediately turn en gine off wait for all machine motion to stop and inspect for damage A damaged reel or bedknife must be re paired or replaced before operation is commenced 8 Whenever machine is left unattended be sure en gine is stopped and cutting unit reel is not spinning 9 Close fuel shut
25. compression spring item 3 is fitted to LH side plate 4 Place flat wire spring into bearing bore of LH side plate Carefully slide the cutting reel assembly with flocked seals reel bearings bearing lockscrew and reel drive shaft into the LH side plate Make sure thatbear ing is fully seated into side plate 5 Carefully slide the RH side plate with pitch arm item 7 and compression spring item 3 onto the cutting reel assembly frontroller and rear roller Make sure thatside plate is fully seated onto bearing on reel shaft 6 Install shoulder bolts item 4 and flange nuts item 5 to secure the RH side plates to the crossmember Torque the shoulder bolts from 210 to 240 in Ib 24 to 27 N m Cutting Unit Page 7 24 IMPORTANT If reel drive shaft item 4 in Fig 35 is to be tightened use appropriate wrench or socket on 1 hex surface of shaft Do not use 1 2 hex on end of reel drive shaft when loosening or tightening drive shaft The 1 2 hex is intended for backlapping only 7 If bearing lock nut RH threads and reel drive shaft LH threads were loosened during cutting reel service put a block of wood between the cutting reel blades to prevent the reel from rotating Torque bearing lock nut RH threads and reel drive shaft LH threads from 90 to 110 ft Ib 123 to 149 N m Fig 35 8 Secure the bedbar assembly to RH side plate see Bedbar Installation in this section Make sure that plas tic and steel
26. engine is OFF Remove spark plug wire from the spark plug 2 Using a 5 8 16mm wrench rotate and hold the bearing housing to allow reel drive belt installation F ig 12 3 Place a new drive belt onto the pulleys 4 Release bearing housing to apply tension to reel drive belt Make sure thatbearing housing rotates freely which will allow accurate belt tension 5 Rotate reel drive at least one 1 full turn to ensure that drive belt is properly tensioned 6 Tighten the bearing housing mounting nut Fig 12 7 Install reel drive cover to machine and secure with flange head screw Fig 11 8 Connect spark plug wire to spark plug Greensmaster Flex 1800 2100 Page 4 9 Figure 11 1 Reel drive cover 2 Flange head screw Figure 12 3 Compression spring 4 Bearing housing 1 Reel drive belt 2 Bearing housing nut Traction and Reel Drive System s s S z Q o Drive System Reel Drive Assembly Antiseize Lubricant Antiseize Lubricant Figure 13 1 Reel drive housing 11 Reel pulley 24 tooth black 2 O ring 12 Bearing housing assembly 3 Carriage screw 13 Cover plug 4 Washer head screw 14 Reel pulley 25 tooth red 5 Flange head screw 2 used 15 Belt 6 Hex nut 2 used 16 Compression spring 7 Reel drive shaft 17 Hardened washer 8 Reel pulley 22 tooth aluminum 18 Hex nut 9 O ring 19 Reel drive cover 10 Reel idler shaft NOTE Cu
27. from engine Fig 6 A Loosenscrew thatsecures cable clamp to engine bracket Remove cable from clamp B Loosen screw that secures throttle cable to gov ernor lever Slide cable from governor lever C Position throttle cable away from engine Greensmaster Flex 1800 2100 4 Disconnect electrical connections from engine Fig 7 A Unplug wire harness connector from engine ar mature wire B Disconnect wire harness ground wire from en gine by removing LH rearcap screw item 7 inFig 5 flatwasher item 11 in Fig 5 and flange nut item 8 in Fig 5 C If machine is equipped with optional lighting kit disconnect wire harness connectors from engine al ternator wires 5 Remove engine base assembly with engine at E S tached from machine Figure 6 1 Throttle cable 3 Governor lever screw A Remove two 2 cap screws item 13 hardened 2 Cable clamp washers item 6 and flange nuts item 8 thatsecure rear of engine base to rear frame B Support front of engine base to prevent it from moving C Remove flange head screw item 9 and hard ened washer item 10 that secure engine base to frame D Carefully move engine and engine base assem bly away from transmission so that engine coupler item 3 slides out of coupler sleeve item 4 Once engine coupler is removed from sleeve remove en gine base assembly from machine 6 If necessary remove engine from engine base Figure 7
28. head area around spark plug and re move plug from the cylinder head 3 Inspectthe spark plug ME ESPERE IMPORTANT Replace a cracked fouled or dirty ER RED RD spark plug Do notsand blast scrape orclean spark O ae lee E plug electrodes because engine damage could re sult from grit entering cylinder Figure 4 4 Setspark plug electrode gap from 0 024 to 0 028 0 6 to 0 7 mm 5 Install correctly gapped spark plug into cylinder head and torque plug 17 ft Ib 23 N m 6 Connect spark plug wire to spark plug Ignition Components Engine ignition componentinformation is included in the Subaru Service Manual Greensmaster Flex 1800 2100 Page 3 7 Engine Engine A f SE PES r N we A Figure 5 Engine 6 Hardened washer 2 used 7 Cap screw 4 used 8 Flange nut 6 used 9 Flange head screw 10 Hardened washer Square key Engine coupler Coupler sleeve Engine base SURUNH Engine Removal Fig 5 1 Parkmachine ona levelsurface with the engine OFF Remove spark plug wire from the spark plug to prevent the engine from starting Close fuel shut offvalve on en gine 2 If engine is to be disassembled it may be easier to drain oil from engine before removing engine from trac tion unit Engine Page3 8 Antiseize Lubricant 11 Flat washer 4 used 12 Wire harness 13 Cap screw 2 used 14 Set screw 2 used 15 Transmission assembly Remove throttle cable
29. in this Service Manual These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do nothave a specific requirement identified in this S er vice Manual The following factors shall be considered when applying torque cleanliness of the fastener use of a thread sealant e g Loctite degree of lubrication on the fastener presence of a prevailing torque feature e g Nylock nut hardness of the surface underneath the fastener s head orsimilar condition which affects the installation Fastener Identification o Grade 1 Grade 5 Inch Series Bolts and Screws Greensmaster Flex 1800 2100 Page 2 3 As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be determined based on the aluminum or brass material strength fastener size length of thread en gagement etc The standard method of verifying torque shall be per formed by marking a line on the fastener head or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Class 8 8 Class 10 9 Metric Bolts and Screws Product Records and Maintenance Product Records o i i S E i S
30. install cable to transmission Fig 9 Figure 9 A Secur letto transmissiontraction lever ecure cable eyele omana miSSIONTACION fe vis 1 Traction clutch cable 4 Flange nut with flange nut 2 Transmission 5 Bellcrank lever 3 Traction cable bracket B Position traction cable to the casting slotoftrans mission with a jam nut flat washer and lock washer on each side ofthe slot Adjustand tighten jam nuts so that equal amount of cable threads are visible above and below jam nuts 3 Make final traction clutch cable adjustment at trac tion lever assembly Adjust cable jam nuts to remove slack in cable without rotating the transmission bell crank lever more than 3 approximately 0 060 1 5 mm at slot 4 Install console cover to handle assembly cs amp 2 22 Qe o0 So 2 Figure 10 1l Shifthandle 5 Upper cable jam nut 2 Traction clutch cable 6 Lower cable jam nut 3 Reel clutch cable 7 Shift mount bracket 4 Traction cable spring Greensmaster Flex 1800 2100 Page6 9 Chassis and Controls Reel Clutch Cable Replacement Note orientation of spring hook Figure 11 1 Brake cable 5 Reel clutch cable 9 Traction switch 2 Brake lever 6 Console cover 10 Traction clutch cable 3 Leverassembly 7 Washer head screw 4 used 11 Shifter bracket 4 Shift mount 8 Lower handle Removal 3 Remove console cover from handle assembly to al low access to upper end of reel clutch cable 1 Park machine on
31. items 12 11 and 13 that se cure transmission housing to machine frame B Remove four 4 washer head screws thatsecure extension housing to transmission housing and RH drum drive housing C Remove four 4 washer head screws thatsecure extension housing to RH drum drive housing Fig 48 D Carefully shift position of transmission housing to allow removal of the extension housing Assembly Fig 47 1 If extension housing was removed A Position the extension housing between trans mission housing and RH drum drive housing B Align extension housing with RH drum drive housing Install four 4 washer head screws finger tight to hold extension housing in position C Position transmission housing to the extension housing Install four 4 washer head screws finger tight to hold extension housing in position D Secure extension housing to transmission hous ing and RH drum drive housing with washer head screws First torque all washerhead screws from 15 to 40in Ib 1 7 to 4 5 N m Then using an alternat ing crossing pattern torque all screws from 85 to 95 in Ib 9 6 to 10 7 N m E Secure transmission housing to machine frame by tightening fasteners items 12 11 and 13 If fas teners were removed make sure that washer item 5 is below frame tube 2 If removed slide wave washer item 8 spacer item 7 and ball bearings item 3 into extension housing Greensmaster Flex 1800 2100 Page 4 39 3
32. of the cover G Apply Loctite 242 or equivalent to threads of setscrew Install setscrew into end of shaftto secure handle in place 2 Install groomer cover assembly to RH drive plate as sembly Fig 4 Figure 6 A Make sure that handle on groomer cover is ro 1 Shaft 3 Plunger detent tated toward the front of the machine 2 Cam point B Fill groomer cover with approximately five 5 ounces 142 grams of Mobil XHP221 grease or equivalent C Install new gasket and then groomer cover as sembly to RH drive plate Secure cover with five 5 flange head screws Greensmaster Flex 1800 2100 Page 8 9 Groomer Grooming Reel Forward Rotating Groomer Drive 100 ft Ib 135 N m Antiseize Lubricant 17 to 21 ft Ib 24 to 28 N m Figure 7 1 Locknut 4 used 10 Cap screw 2 used 19 Driven pulley 2 Drive cover 11 Bushing 2 used 20 HOC screw 2 used 3 Groomer drive belt 12 Spring washer 2 used 21 HOC nut 2 used 4 Drive pulley 13 Lock nut 2 used 22 Plow bolt 2 used 5 Shoulder bolt 2 used 14 LH support plate assembly 23 Grooming reel assembly 6 Spring 15 LH groomer arm assembly 24 Front roller assembly 7 RHdrive plate assembly 16 HOC washer 2 used 25 RH cutting unit sideplate 8 Groomer shim 17 Rear roller height shim 26 LH cutting unit sideplate 9 RH groomer arm assembly 18 Socket head screw 4 used 27 O ring Remove the grooming reel to replace individual blades to r
33. plate using Figure 26 as a guide Make sure that retaining ring item 7 is fully seated in groove of reel hub after assembly NOTE When properly installed the idler bracket item 4 should pivot freely on reel hub 2 Install RH drive plate assembly to rightside of cutting unit see Grooming Reel Counter Rotating Groomer Drive in this section Make sure that 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 Greensmaster Flex 1800 2100 3 Check adjustment of adjustment cam Fig 28 A Rotate idlerbracketso the bracketstop is against the adjustment cam B While holding bracketstop againstthe cam mea sure the distance between the idler gear bearing sur faces on the idler bracket and the drive plate This distance should be 1 484 37 7 mm C If distance is incorrect loosen flange nut that se cures adjustment cam to drive plate Rotate the ad justment cam until distance is correct Then tighten flange nutto secure adjustment Make sure that dis tance is still correct after tightening the nut 4 Install idler gears to drive plate assembly Fig 29 Torque flange nuts that secure idler gears 120 in Ib Figure 27 13 5 N m 1 Groomercoverassembly 3 Gasket 2 Screw 5 used 4 Handle 5 Install extension spring to idler bracket and adjust ment cam 6 Fillgroomercoverwith approximatel
34. reel clutch shaft IMPORTANT When installing flex coupler item 2 onto shaft do not mar outer surface of coupler e g grasping with pliers or mounting in vise as coupler may be damaged and fail prematurely 11 Slide flex coupler onto bearing collar item 23 sup port coupler to prevent it from being damaged during spring pin installation Install new spring pin into coupler to secure coupler to collar Reel Clutch Shaft Installation Fig 36 1 Before inserting reel clutch assembly into transmis sion housing thoroughly clean reel brake ring item 11 that is pressed into housing 2 Slide reel clutch shaft assembly into transmission housing 3 Align missing tooth in spline area of reel clutch lever item 10 with reel clutch fork item 16 Insert lever through housing and fork Secure lever with retaining ring item 5 4 Install transmission drive belt and all machine com ponents removed for reel drive system service see Transmission Drive Belt in this section 5 Check reel clutch adjustment see Reel Clutch Ad justmentin the Adjustments section ofthis chapter Ad just as needed 6 Connectreel clutch cable to transmission see Reel Clutch Cable Replacement in the Service and Repairs section of Chapter6 Chassis and Controls Make sure that clutch cable is properly adjusted Greensmaster Flex 1800 2100 Removing Seized Reel Clutch Shaft From Transmission If reel clutch shaft assembly cannot be easil
35. removed bearing 6 Remove oil seal item 9 from thrust friction assem bly Note orientation of oil seal for assembly purposes Discard removed oil seal 7 Press fixed housing item 17 assembly from hub Remove retaining ring and then remove ball bearing from housing Discard removed bearing 8 Inspect clutch components for wear or damage If mounting plate item 5 thrust friction assembly item 10 rotating housing item 13 hub item 14 drive in serts item 16 orfixed housing item 17 is worn ordam aged replace clutch assembly Clutch Assembly Fig 44 1 Press new ball bearing into fixed housing item 17 and secure with retaining ring Then press fixed hous ing item 17 assembly onto hub and secure with retain ing ring item 1 2 Install new oil seal item 9 into thrustfriction assem bly 3 Press new ball bearing into rotating housing item 13 and secure with retaining ring Then press rotating housing assembly onto thrust friction assembly item 10 4 Apply coating of high temperature Mobil XHP 222 grease or equivalent to spline area of hub item 14 5 Install airgap cover item 15 and then thrust friction assembly item 10 with rotating housing item 13 at tached onto hub Take care to not damage oil seal dur ing assembly 6 Slide shim item 6 wave spring item 8 spring cup item 7 and second shim item 6 onto hub Secure as sembly with retaining ring item 1 7 Ins
36. system but ignition timing will be incorrect 5 If visible and audible sparks are not produced a problem exists either with engine ignition components or with machine components To identify whether the problem exists with the engine or the machine discon nect the wire harness connector violet wire from the engine primary wire and repeat step 4 above A If visible and audible sparks are not produced with the engine primary wire disconnected the en gine ignition system is not operating properly Refer tothe Subaru Service Manualforengine information B If visible and audible sparks are produced with the engine primary wire disconnected machine components e g on off switch parking brake latch switch traction switch interlock module machine wire harness are damaged or faulty Refer to ma chine component testing information in this section Electrical System o oO 1 7A oo S o UI On Off Switch The on off switch is located on the console on the han dle This rocker switch allows the engine to be turned on and off Testing 1 Make sure the engine is OFF and the traction lever is in the NEUTRAL position 2 Remove console cover from handle to allow access to on off switch Fig 5 3 Disconnect wire harness electrical connector from the on off switch 4 With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the vario
37. tips in the same direction 2 For1 2inch 1 3 cm blade spacing make sure there are two 2 blade spacers between blades Fig 14 3 When all blades have been installed place second thick spacer on shaft and then thread second lock nut onto the shaft 4 Position lock nuts to allow blades and spacers to be centered on the shaft Fig 17 Torque lock nuts from 200 to 250in Ib 23 to 28 N m so Spacers are notfree to rotate 5 Install grooming reel back onto cutting unit see Grooming Reel Installation in this section Greensmaster Flex 1800 2100 Page 8 17 UJ N Ey Figure 16 3 Dull rounded edge 1 Grooming blade 2 Sharp edge 200 to 250 in Ib 23 to 28 N m E ooh 5 y Figure 14 Grooming reel shaft 4 Thick spacer 2 used Groomer blade 5 Locknut 2 used Blade spacer 6 O ring ROTATION Figure 15 Grooming blade 2 Carbide tip 3 Q CENTER BLADES ON SHAFT 9 Figure 17 1 Lock nut 2 Grooming shaft Groomer Grooming Reel Bearing Replacement Bearing Removal 1 Position machine on a clean and level surface with engine stopped Engage parking brake 2 Remove the cutting unitfrom the machine and place cutting unit on a flat work area 3 To remove groomer RH drive plate assembly from right side of cutting unit remove front roller grooming reel and then drive plate assembly see Grooming R eel Forward Rotating or Counter Rotating in this section 4 To remove
38. transmission removal is desired proceed with the fol lowing steps Once the transmission has been removed from the machine service procedures for internal com ponents are described earlier in this section Transmission Removal 1 Park machine on a level surface Make sure engine is OFF Traction and Reel Drive System Page 4 40 2 Disconnectreel clutch cable from transmission see Reel Clutch Cable R eplacement in the Service and Re pairs section of Chapter 6 Chassis and Controls 3 Disconnect traction clutch cable from transmission see Traction Clutch Cable Replacementin the Service and Repairs section of Chapter 6 Chassis and Con trols 4 Slide the telescoping coupler off the cutting unit hex shaft Fig 50 5 Remove RH drum drive cover and belt from machine see Drum Drive Belt in this section Greensmaster Flex 1800 2100 6 Remove engine from machine see Engine Removal in the Service and Repairs section of Chapter 3 En gine 7 Remove four 4 washer head screws item 7 that secure extension housing item 13 to RH drum hous ing 8 Supporttransmission to prevent it from falling 9 Remove fasteners that secure transmission to ma chine frame A Flange head screw item 2 that secures front of transmission to frame B Cap screw item 10 hardened washer item 9 and flange nut item 12 thatsecure rearoftransmis sion to frame 10 Carefully move transmission assembly toward le
39. two lock nuts Standard bench height of cut range is 0 062 to 0 500 inch 1 6 to 12 7 mm depending on type of bed knife installed An optional High Heightof CutKitis avail able for higher HOC adjustments Effective HOC may vary depending on turf conditions type of bedknife roll ers and attachments installed CLIP Clip frequency is adjusted by moving the pulleys onthe cutting unitreel drive housing 6 clip adjustments are possible based on pulley configuration ROLLERS The rear roller is a 2 000 5 1 cm diameter aluminum full roller The front roller is a 2 500 6 3 cm diameter roller thatis chosen from a variety of configura tions narrow spaced Weihle front roller is shown Greensmaster Flex 1800 2100 Page 7 3 ha bd ba tad bel Tha ht j POPPER ERE LOL LL EIL IM MM BEDKNIFE AND BEDBAR Single edged Edgemax bedknife solid tool steel construction used with 11 and 14 blade cutting unit A castiron bedbar is fastened to the cutting unit Other optional bedknives and a less aggressive bedbar are available GRASS SHIELD Non adjustable shield with adjusta ble cut off bar to improve grass discharge from reel in wet conditions COUNTERBALANCE WEIGHT A cast iron weight mounted on rightend of cutting unitbalances the cutting unit APPROXIMATE WEIGHT Flex 1800 with11 Blade Reel 68 Ib 30 8 kg Flex 1800 with14 Blade Reel 71 Ib 32 2 kg Flex 2100 with 11 Blade Reel 71 Ib 32 2 kg Flex 2100 with 14 Blad
40. washers are properly positioned 9 Secure front and rear rollers to RH side plate see Front Roller Installation and Rear Roller Installation in this section 10 Adjust cutting unit see Cutting Unit Operator s Manual NOTE The parallel position of the rear roller to the cut ting reel is controlled by the precision machined cross member and side plates of the cutting unit If necessary the cutting unit side plates can be loosened and a slight adjustment can be made to parallel the rear roller with the cutting reel see Leveling Rear Roller in the Set Up and Adjustments section of this Chapter 11 Install reel pulley belt and reel drive cover to reel drive assembly Refer to Reel Drive Assembly in the Service and Repairs section of Chapter 4 Traction and Reel Drive System for procedure to install and adjust these components 12 Install cutting unit to the machine Greensmaster Flex 1800 2100 This page is intentionally blank Greensmaster Flex 1800 2100 Page 7 25 Cutting Unit Cutting Reel Assembly Service 90 to 110 ft Ib 123 to 149 N m Right Hand Threads N 90 to 110 ft Ib 123 to 149 N m 4 Left Hand Threads Figure 36 1 Cutting reel 3 Bearing 2 used 5 Bearing lock screw RH threads 2 Flocked seal 2 used 4 Reel drive shaft LH threads Cutting Unit Page 7 26 Greensmaster Flex 1800 2100 Disassembly of Cutting Reel Fig 36 IMPORTANT When removing reel drive shaft
41. with spring washer item 12 and lock nut item 13 Groomer Page 8 12 15 Center front roller to cutting unit and tighten cap screws item 10 to secure roller 16 Install groomer drive belt item 3 and groomer drive cover item 2 to RH drive plate see Groomer Belt Re placement in this section 17 Check grooming reel height and mower height of cut settings Adjust as needed 18 Install cutting unitto the machine 19 Lubricate groomer bearings see Groomer Installa tion Instructions NOTE After greasing groomer bearings operate groomerfor 30 seconds stop machine and wipe excess grease from groomer shaft and seals Greensmaster Flex 1800 2100 This page is intentionally blank Greensmaster Flex 1800 2100 Page 8 13 Groomer Grooming Reel Counter Rotating Groomer Drive 120 in Ib 13 5 N m 125 ft Ib 170 N m Antiseize Lubricant LN 17 to 21 ft Ib 120 in Ib 24 to 28 N m 13 5 N m Figure 10 1 RH groomer arm assembly 13 Shoulder bolt 2 used 25 Extension spring 2 HOC nut 2 used 14 Driven gear 30T 26 Inner spring 2 used 3 Bushing 2 used 15 Lock nut 27 Outer spring 2 used 4 Spring washer 2 used 16 Front roller 28 LH support plate assembly 5 Lock nut 2 used 17 Groomer drive gear 45T 29 Support plate 6 LH groomer arm assembly 18 Bearing 2 used 30 Button head screw 4 used 7 Cap screw 2 used 19 RH cutting unit side plate 31 Roller shim 8 Grooming r
42. 0 ft lb 18 3 ft lb 108 14 N m Class 8 8 M12 X 1 5 80 10 ft lb f 108 14 N m Class 8 8 For steel wheels and non lubricated fasteners Thread Cutting Screws Thread Cutting Screws Zinc Plated Steel Zinc Plated Steel T T 1 16 14 E No 6 32 UNC 20 5 in Ib 20 5i No 8 32 UNC 30 5 in Ib EO 30 5 in Ib um Las oer No 10 24 UNC 38 7 in Ib 1 4 20 UNC 85 15 in Ib 5 16 18 UNC 110 20 in Ib Hole size materialstrength materialthickness amp finish must be considered when determining specific torque 3 8 16 UNC 200 100 in Ib values All torque values are based on non lubricated 8 5 85 15 in Ib fasteners Conversion Factors in Ib X 11 2985 2 N cm N cm X 0 08851 in Ib ft lb X 1 3558 N m N m X 0 7376 ft Ib Product Records and Maintenance Page2 6 Greensmaster Flex 1800 2100 Chapter 3 TORO Engine Table of Contents SPECIFICATIONS c edhe bl eee whe 3 GENERAL INFORMATION cece eee 4 Operator s Manual 00 c cece 4 Fuel Evaporative Control System 4 ADJUSTMENTS tmr baa ohne named 5 Throttle Cable Adjustment 4 5 SERVICE AND REPAIRS cece eee nee 6 Cooling System rriari Tetida e ea Eaa 6 SparkPlug us iir vie eb ere eee 7 Ignition Components 0 0c eee 7 Engine ced ead nian Veda Madea 8 Engine Coupler Sleeve 00008 11 SUBARU SERVICE MANUAL Greensmaster Flex 1800 2100 Page
43. 005 0 13 mm shim at each end of rear roller If the shim will pass under the roller at one end butnotthe other a frame adjustment should be made 4 Loosen but do not remove the two 2 shoulder bolts thatsecure the side plate to the frame opposite the side thatis not level Fig 12 5 Adjust the position of the side plate to parallel the rear roller and cutting reel Then tighten the shoulder bolts to a torque from 210 to 240 in Ib 24 to 27 N m 6 Aftertightening the side plate recheckthe rearroller If necessary loosen and adjust second side plate 7 After leveling rear roller complete cutting unitset up and adjustment sequence 210 to 240 in Ib 24 to 27 N m Figure 12 1 Side plate RH shown 2 Shoulder bolt Cutting Unit Page 7 10 Greensmaster Flex 1800 2100 Service and Repairs Backlapping TO AVOID PERSONAL INJ URY OR DEATH e Never place hands or feet in the reel area while backlapping Stay away from the reel when backlapping e Donotattemptto restartreel by hand orfoot e Donotadjust cutting reel while backlapping e Never use a short handled paint brush for applying lapping compound Part Number TOR299100 backlapping brush assembly see Special Tools is available from your local Authorized Toro Distributor NOTE Additional instructions and procedures on backlapping are available in the Toro General Service Training Book Reel Mower Basics part no 09168SL 1 Park machine on a
44. 1 Armature wire 3 Alternator wires 2 Harness ground wire A Remove cap screws item 7 flat washers item 11 and flange nuts item 8 thatsecure engine to en gine base 3 If engine coupler item 3 was removed from engine B Remove engine from engine base output shaft install coupler 7 If necessary remove two 2 set screws item 14 that secure engine coupler item 3 to engine output shaft Slide coupler from shaft Remove square key item 2 from engine output shaft keyway A Position square key in outputshaftkeyway Apply antiseize lubricantto top surface of key B Slide coupler onto output shaft until it contacts Engine Installation Fig 5 shoulder on shaft C Secure coupler to output shaft with two 2 set screws item 14 Torque set screws 65 in Ib 7 3 N m 1 Position machine on a level surface Make sure that spark plug wire is not connected to engine spark plug 2 Make sure that all parts removed from the engine during maintenance or rebuilding are properly installed to the engine Greensmaster Flex 1800 2100 Page3 9 Engine 4 5 Install engine to engine base if itwas removed A Position engine on the engine base NOTE When installing engine to engine base do notinstall fastener in LH rear engine mounting hole Ground wire connection is made at this location when engine base is attached to machine frame Fig 7 B Install and tighten three 3 cap screws item 7 flatwashers ite
45. 10 7 N m 8 Rotate traction engage disengage lever to the en gaged position to tension the drum drive belt see Disen gaging Drum Drive From Transmission in the General Information section of this chapter 9 Install transport wheels if they were attached see Transport Wheels in the Service and Repairs section of Chapter 6 Chassis and Controls 10 Connect spark plug wire to spark plug Greensmaster Flex 1800 2100 Page 4 17 Traction and Reel Drive System Traction Drums Antiseize Lubricant 9 N PW 140 to 160 ft Ib M 190 to 216 N m i 15 75 to 90 ft Ib 102 to 122 N m P d 70 to 80 ft Ib n il 95 to 108 N m Figure 21 1 Drum drive housing 11 J am nut 21 Traction engage lever 2 Straight bushing 12 Grease seal 22 Retaining ring 2 used 3 Flange bushing 4 used 13 LH traction drum 23 Brake lever 4 Brake lever 14 Ball bearing 2 used 24 Retaining ring 5 Traction lever 15 Bearing nut 25 LH side plate 6 Square key 2 used 16 LH hex shaft 26 Washer head screw 7 Drum shaft 17 Straight bushing 2 used 27 Lock collar 8 Long spur gear 18 Dowel pin 2 used 28 Pin 9 Differential assembly 19 Cap screw 29 Thrust washer 10 RH traction drum 20 Flat washer 30 O ring Traction Drum Removal Fig 21 3 Remove handle assembly from machine see Han dle Assembly in the Service and Repairs section of 1 Park machine on a level surface Make sure engine Chapter 6 Chassis and Controls is
46. 2 Throttle cable clamp Figure 5 1 Pin 5 Throttle control 2 Flat washer 6 Throttle mount 3 Retaining ring 7 Mount cable guide 4 Throttle cable Greensmaster Flex 1800 2100 Brake Cable Replacement Removal 1 Park machine on a level surface Make sure the en gine is OFF the traction lever is in NEUTRAL and park ing brake is released 2 Remove brake cable from the brake lever shaft on the drum drive housing Fig 6 A Loosen front cable jam nut that secures cable to casting slot on drum drive housing Separate cable from slot B Remove retaining ring that secures cable eyelet to the brake shaft on drum drive housing C Remove brake cable eyelet from brake lever shaft 3 Remove console cover from handle assembly to al low access to upper end of brake cable 4 Remove flange nutthat secures brake cable eyelet to brake lever on machine handle Fig 7 5 Loosen lower brake cable jam nutand lift cable free from brake cable bracketon lower handle assembly R e move cable from the bracket 6 Remove brake cable from the machine Installation 1 Secure brake cable eyelet to the brake lever on the machine handle with flange nut Fig 7 2 Attach brake cable to brake cable bracketon handle assembly with a washerand jam nuton each side ofthe bracket Adjust jam nuts so that equal amount of cable threads are visible above and below jam nuts Leave jam nuts snug until final cable adjustment 3 Rout
47. 3 1 Engine This page is intentionally blank Engine Page 3 2 Greensmaster Flex 1800 2100 Specifications Item Description Make Designation Subaru 4 stroke OHC single cylinder air cooled gasoline engine with gear reduction Bore x Stroke 2 28 in x 1 89 in 58 mm x 48 mm Total Displacement 7 69 in 126 cc Carburetor Float feed fixed main jet Governor Mechanical flyweight Low Idle Speed no load 1465 to 1665 RPM High Idle Speed no load 3190 to 3340 RPM Direction of rotation Clockwise facing PTO shaft Fuel Unleaded automotive grade gasoline Fuel Tank Capacity 2 85 U S qt 2 7 Engine Oil See Operator s Manual Lubrication System Splash type Oil Capacity 0 63 U S qt 0 6 I Air Cleaner Dual element Ignition S ystem Electronic flywheel magneto Spark Plug NGK BR 6HS Spark Plug Gap 0 024 to 0 028 0 6 to 0 7 mm Lighting Coil 12V AC 15 Watt Dry Weight 34 2 Ibs 15 5 kg Greensmaster Flex 1800 2100 Page 3 3 Engine General Information This Chapter gives information about specifications maintenance troubleshooting testing and repair of the Subaru gasoline engine used on the GreensmasterFlex 1800 and Flex 2100 mowers Most repairs and adjustments require tools which are commonly available in many service shops Several special tools ar
48. 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 000 25 400 1 mm 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Maintenance Page 2 2 Greensmaster Flex 1800 2100 Torque Specifications Recommended fastener torque values are listed in the following tables F or critical applications as determined by Toro eitherthe recommended torque ora torque that is unique to the application is clearly identified and spe cified
49. 7 1 Transmission housing 3 Flange bushing 2 Flange bushing 4 Reel brake ring Figure 38 1 Retaining ring 5 Ball bearing 2 Flat washer 6 Bearing collar 3 Wave spring 7 Reel clutch shaft 4 Flocked bearing seal 8 Hub flat location 7 Remove retaining ring item 27 flat washer item 26 wave spring item 25 and flocked bearing shield item 24 from bearing collar Note orientation of flocked shield for assembly purposes 8 Press bearing item 12 from bearing collar Discard removed bearing 9 Slide reel clutch pulley assembly and reel drive hub from clutch shaft 10 If necessary remove ball bearings and spacer from pulley Discard removed bearings Reel Clutch Shaft Assembly Fig 36 1 Ifball bearings were removed from reel clutch pulley press new inner bearing fully to bottom of bore in pulley Install spacerinto pulley and then press new outer bear ing into pulley until it contacts spacer 2 If bearing was removed from bearing collar press new bearing fully onto collar Traction and Reel Drive System Traction and Reel Drive System 3 Slide reel clutch pulley assembly and reel drive hub onto clutch shaft 4 Use modified socket see Special Tools in this chap ter to install bearing collar assembly onto clutch shaft Fig 38 IMPORTANT To prevent damage avoid using ex cessive clamping pressure on the reel clutch shaft assembly A Useflats onreeldrive hub to carefull
50. Drive Belt nunn sisse 9 EE Reel Drive Assembly sssssseese 10 So Reel Drive Bearing Housing 12 Q E Drum Drive Belt s ec reete eere 14 so Drum Drive Idler Assembly 05 16 Traction Dr ms sese eee es 18 Differential Assembly 0005 22 Differential Assembly Service 24 Transmission Drive Belt 005 26 Transmission Idler System sse 28 Transmission Reel Drive System 30 Removing Seized Reel Clutch Shaft From Transmission seansa darani ee 33 Transmission Clutch System 4 34 Cl tch Service s 204 oe s x RR RR CR 36 Transmission Drum Drive System 38 Transmission c eR perd RS 40 Greensmaster Flex 1800 2100 Page4 1 Traction and Reel Drive System Specifications Item Description Transmission Engine Powered Ramp Engagement Style Friction Clutch Transmission Drive uses Multi Ribbed Poly V Belt Belt Tension Maintained by S pring Loaded Idler Pulley Traction Drive Transmission to Traction Drive uses Multi Ribbed Poly V Belt Belt Tension Maintained by Spring Loaded Idler Pulley Differential Spur Gear Planetary Differential Parking Brake Band Style at differential shaft drive Traction Drum Dual Cast Aluminum 7 5 inch 19 cm Diameter Cutting Reel Drive Transmission Reel Clutch Shaft to Telescoping Drive Shaft Two Beam Style Couplers Used in
51. Drum Drive System Antiseize Lubricant See text for tightening procedure Figure 47 1 Transmission housing 6 Driven pulley 2 Extension housing 7 Spacer 3 Ball bearing 2 used 8 Wave washer 4 Driven pulley traction drum drive 9 Woodruff key 5 Hardened washer 2 used Transmission removal from the machine is not neces sary to service the transmission drum drive system shown in Figure 47 Transmission drum drive compo nents can be accessed by removing the engine from the frame removing the transmission cover and then re moving the drive belt Disassembly Fig 47 1 Park machine on a level surface Make sure engine is OFF 2 Remove transmission drive belt see Transmission Drive Belt in this section Traction and Reel Drive System Page 4 38 10 Washer head screw 4 used 11 Flange nut 12 Flange head screw 2 used 13 Cap screw 3 Remove flange head screw item 12 and hardened washer item 5 that secure driven pulley item 6 to shaft Slide pulley from shaft Locate and retrieve wood ruff key item 9 4 Remove drum drive belt from machine see Drum Drive Belt in this section 5 Slide traction drum drive driven pulley item 4 from extension housing 6 If necessary remove ball bearings item 3 spacer item 7 and wave washer item 8 from extension hous ing Greensmaster Flex 1800 2100 7 Ifitis necessary to remove extension housing item 2 A Loosen fasteners
52. Ib 102 to 122 N m Traction and Reel Drive System Page 4 20 13 Secure LH side plate item 25 to machine Fig 22 A Slide LH side plate onto supporting bearing B Secure LH side plate to frame with three 3 flange screws and hardened washers C Secure LH side plate to rear frame with carriage screw hardened washer and flange nut 14 Install handle assembly to machine see Handle As sembly in the Service and R epairs section of Chapter 6 Chassis and Controls Make surethatall cable adjust ments are correct 15 Install transport wheels if necessary see Transport Wheels in the Service and R epairs section of Chapter 6 Chassis and Controls 16 Connect spark plug wire to spark plug Greensmaster Flex 1800 2100 Drive System a s s S S Q 1 o A This page is intentionally blank Greensmaster Flex 1800 2100 Page 4 21 Traction and Reel Drive System Differential Assembly Antiseize Lubricant 140 to 160 ft Ib 190 to 216 N m Med 15 75 to 90 ft Ib 102 to 122 N m p d 70 to 80 ft Ib 95 to 108 N m Figure 24 1 Drum drive housing 12 Grease seal 22 Retaining ring 2 used 2 Straight bushing 13 LH traction drum 23 Brake lever 3 Flange bushing 4 used 14 Ball bearing 2 used 24 Retaining ring 4 Brake lever 15 Bearing nut 25 LH side plate 5 Traction lever 16 LH hex shaft LH threads 26 Washer head screw 6 Square key 2 used 17 Straight bushing
53. LATCH SWITCH J03 HOUR INTER OCK P05 METER INTERE ON OFF SWITCH ET i P02 TRACTION SWITCH Wire Harness Drawing INTERLOCK MODULE PO C Dt E B gt Ez o 0 2 oo S o lw VIOLET Em ENGINE VIOLET MAGNETO TRACTION po WHITE PARKING BRAK amp SWITCH m YELLOW LATCH SWITCH VIOLET VIOLET BLACK C ON OFF ENGINE 1 1 saecu GROUND Wire Harness Diagram Greensmaster Flex 1800 2100 Page 5 5 Electrical System S pecial Tools Order special tools from your Toro Distributor Some tools may also be available from a local supplier Multimeter The multimeter can test electrical components and cir cuits for current resistance or voltage NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance ofa 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 not designed to carry it Skin Over Grease Special non conductive grease which forms a light pro tective skin to help waterproof electrical switches and contacts Toro Part Number TOR50547 Dielectric Gel Dielectric gel should be used to prevent corrosion of connection terminals To ensure complete c
54. LH support plate assembly from left side of cutting unit Fig 18 A Remove reel drive cover drive belt reel pulley and then reel drive assembly from cutting unit see ReelDrive Assembly in the Service and Repairs sec tion of Chapter 4 Traction and Reel Drive System B Remove lock nut and spring washer that secure LH groomer arm lift rod to LH support plate Fig 19 Remove support plate from cutting unit 5 Remove grooming reel seals and bearings from RH drive plate and LH support plate assemblies Figs 20 21 and 22 Discard all removed seals and bearings Bearing Installation 1 Install new grooming reel bearings and seals into RH drive plate and LH support plate assemblies F ig 23 IMPORTANT Bearings should be installed with ex tended inner races toward center of housing Also apply pressure equally to inner and outer bearing races when installing bearings A Press new outer bearing fully to shoulder of RH drive plate bore Then install new inner bearing until inner race contacts outer bearing race B Press new bearing into LH support plate until itis flush with shoulder of bearing bore C Install new seals into groomerside plates NOTE Seals should be installed so the lip side of the seal will face the center ofthe cutting reel When bearings are greased grease will purge from inner seals Groomer Page 8 18 Figure 18 1l Cutting unit 2 Reel drive assembly 3 LH support plate
55. PART NO 12188SL Service Manual TORO Models 04041 and 04040 Greensmaster Flex 1800 2100 Preface The purpose of this publication is to provide the service technician with information for troubleshooting testing and repairing assemblies and components on the Greensmaster Flex 1800 Model 04041 and Flex 2100 Model 04040 REFER TO THE OPERATOR S MANUAL FOR OPER ATING MAINTENANCE AND ADJUSTMENT INSTRUCTIONS Space is provided in Chapter 2 of this book to insertthe Operator s Manualand Parts Catalogs for your machine Replacement Operator s Manuals and Parts Catalogs are available on the internet at www toro com The Toro Company reserves the rightto change product specifications or this publication without notice This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE A NOTE will give general information about the correct operation maintenance service testing or re pair of the machine IMPORTANT The IMPORTANT notice will give im portantinstructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 2012 This page is intentionally blank Greensmaster Flex 1800 2100 Table Of Contents Chapter 1 Safety Safety Instructions 0c eee eee 1 2 Safety and
56. Slide shaft of traction drum drive driven pulley item 4 through extension housing bearings and spacer 4 Apply antiseize lubricant to pulley surface of drum drive driven pulley item 4 5 Install woodruff key item 9 in shaftand slide driven pulley item 6 onto shaft Secure pulley item 6 with hardened washer item 5 and flange head screw item 12 6 Install drum drive belt to machine see Drum Drive Belt in this section 7 Install transmission drive belt and all machine com ponents removed for drum drive system service see Transmission Drive Belt in this section See text for tightening procedure Figure 48 RH drum drive housing 4 Idler arm assembly Extension housing assy 5 Screw 4 used Idler pulley assembly Ne Traction and Reel Drive System s s S S 2 1 5 Drive System Transmission See text for tightening procedure Washer head screw 11 used 10 Cap screw 11 RH drum drive housing 12 Flange nut 13 Extension housing Figure 49 1 Transmission assembly 6 Drum drive cover 2 Flange head screw 7 3 Drum drive belt 8 Retaining ring 4 Extension spring 9 Hardened washer 5 Brake band Transmission removal from the machine is not neces sary in order to service internal transmission compo nents Transmission components can be accessed by removing the engine from the frame removing the transmission cover and then removing the drive belt If
57. Tighten nuts until they bottom againstbearings F ig 31 Remove nuts from roller shaft 8 Position an assembly spacer and yellow assembly washer see Special Tools on each end of roller shaft Fig 32 Thread nut onto each end of shaft 9 Tighten each nut until the yellow assembly washers bottom out against the roller housing Remove nuts as sembly washers and assembly spacers from roller shaft 10 Lubricate lips of installed seals with 2 grease 11 Carefully slide a dry V ring onto each bearing lock nut The V rings should be installed without any lubrica tion NOTE If original bearing lock nut s are being used apply Loctite 242 or equivalent to threads of lock nut s 12 Install bearing lock nut with V ring onto each end of the roller shaft Torque lock nuts from 25 to 30 ft Ib 34 to 41 N m Figure 30 3 Grease nutsurface 4 Pack with grease 1 Bearing lock nut 2 Seal LI ESRD BR CARY ZZL LLA SANZ a LUE Figure 31 1 Bearing lock nut 2 Seal AY TIPP NH ESI Figure 32 3 Assembly spacer 1l Bearing lock nut 2 Yellow assembly washer Greensmaster Flex 1800 2100 Page 7 21 4 Seal Cutting Unit Cutting Reel Assembly Removal and Installation 210 to 240 in Ib 24 to 27 N m Flex 2100 Shown 210 to 240 in Ib 24 to 27 N m Figure 33 1 Crossmember 6 Cutting reel assembly 11 Hex nut 2 LH side plate 7 RH pitch arm 12 O ring 3 Co
58. a level surface Make sure the en gine is OFF and the traction lever is in NEUTRAL 4 Remove reel clutch cable from traction lever as sembly Fig 13 2 Remove reel clutch cable from transmission Fig 12 A Loosen lower cable jam nut that secures reel clutch cable to shift mount bracket on handle Slide A Loosen frontcable jam nutand lift cable free from cable from bracket casting slot of transmission B Remove cable spring from spring anchoron lever B Remove retaining ring that secures cable eyelet assembly Note orientation of cable spring hook on to reel clutch lever and slide cable eyeletfrom lever lever assembly for assembly purposes C Remove cable tie thatsecures reel drive cable to 5 Remove reel clutch cable from machine transmission bracket Chassis and Controls Page 6 10 Greensmaster Flex 1800 2100 Installation 1 Secure reel clutch cable to traction lever assembly 2 780 to 2 850 70 6 to 72 4 mm Fig 13 A Install cable spring to spring anchor on lever as sembly Orientate cable spring hook end toward front of machine B Slide the cable housing into the shift mount bracket slot Make sure that a jam nut flat washer and lock washer are on both sides of bracket Adjust jam nuts so that equal amount of cable threads are visible above and below jam nuts Leave jam nuts snug until final cable adjustment 2 Route reel clutch cable to transmission and install cable Fig 12 Figur
59. ange head screws and flange nuts Greensmaster Flex 1800 2100 Page 6 13 Chassis and Controls 4 Connectspring item 11 in Figure 15 between trac tion lever assembly and operator presence control 5 Connect wire harness connector to traction switch Fig 15 6 Connectreel clutch and traction clutch cables to le ver assembly see Cable Replacement in this section Check cable operation and adjust as necessary 7 Check adjustment of traction switch see Traction Switch in the Adjustments section of Chapter5 Electri cal System Adjust switch if necessary 8 Install console cover to handle Figure 17 1 Transport lever 4 Shifter bracket 2 Reel shaft lever 5 Screw and nut 3 Clearance location Chassis and Controls Page 6 14 Greensmaster Flex 1800 2100 This page is intentionally blank cs amp 2 22 Qe Zo So 2 Greensmaster Flex 1800 2100 Page 6 15 Chassis and Controls Kickstand Figure 18 1 Kickstand 5 Frame 9 Spacer 2 Flange nut 6 Rearframe 10 Retaining ring 3 Spacer 7 Service position locking pin 11 LH side plate 4 Cap screw 8 Compression spring 12 Torsion spring NOTE The offset handle clamps on Flex 2100 ma chines are mounted on the outside ofthe side plates On Flex 1800 machines the offset handle clamps are mounted on the inside ofthe side plates The illustration in Figure 18 shows the Flex 2100 Chassis and Controls Page 6 16 Greensmaster Flex 1800 2100 Re
60. ansmission 10 Install reel cable to casting slot of transmission and confirm that cable spring length is properly set see Reel Clutch Cable Replacementin Chapter 5 Chassis and Controls Greensmaster Flex 1800 2100 0 040 to 0 060 Light Upward 1 0 to 1 5 mm Pressure Figure 9 Reel drive hub tooth Reel drive hub Reel clutch hub 4 Reelclutch lever 5 Setscrew 6 Jam nut UJ N HI Page4 7 Figure 10 3 Reel drive hub 4 Reelclutch pulley 1 Reel clutch lever 2 Reel clutch hub Traction and Reel Drive System s s S S e 5 A Drive System This page is intentionally blank Traction and Reel Drive System Page4 8 Greensmaster Flex 1800 2100 Service and Repairs Reel Drive Belt Flex 1800 and Flex 2100 machines use a positive drive belton the leftside ofthe machine to operate the cutting unit Removal 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the engine spark plug 2 Remove reel drive cover to expose reel drive belt Fig 11 3 Loosen the bearing housing mounting nut Fig 12 4 Using a 5 8 16mm wrench rotate the bearing housing to release tension on reel drive belt Fig 12 5 Remove reel drive belt from the pulleys Installation 1 Park machine on a level surface Make sure
61. ar Re moval in this section NOTE Flex 1800 cutting units use 11 screws to secure bedknife to bedbar Flex 2100 cutting units use 13 screws to secure bedknife to bedbar 2 Remove screws from bedbar using a socket wrench and bedknife screw tool see S pecial Tools in this chap ter Discard screws 3 Remove bedknife from the bedbar Bedknife Installation Fig 18 1 Use scraper to remove all rust scale and corrosion from bedbar surface and lightly oil bedbar surface be fore installing bedknife Cutting Unit Page 7 14 3 Bedknife 2 Make sure that screw threads in bedbar 5 16 18UNC 2A are clean If necessary use tap to clean threads 3 Apply antiseize lubricant to the threads of new screws Take care to keep antiseize lubricantfrom taper on screw heads IMPORTANT Do notuse an impact wrench to tight en screws into the bedbar 4 Usenew screws to secure bedknife to bedbar Install all screws but do nottighten fully Then using a torque wrench and bedknife screw tool see Special Tools in this chapter torque screws from 200 to 250 in Ib 23 to 28 N m Use a torquing pattern working from the center toward each end of the bedknife Fig 19 5 After installing bedknife to bedbar grind bedknife Greensmaster Flex 1800 2100 Bedknife Grinding Since there can be variations in the mounting surface of the bedbar a new bedknife will notbe perfectly flat after itis installed to the bedbar Because oft
62. asket 4 If necessary remove shaft from groomer cover Fig A Loosensetscrew item 9 on top of shaftand slide handle from shaft B Remove retaining ring item 8 and thrust washer item 5 from shaft C Remove plunger detent item 6 from groomer cover D Slide shaft out of groomer cover Remove and discard O ring item 4 from shaft 5 Remove grease from inside groomer cover and RH drive plate on cutting unit Thoroughly clean and inspect all groomer drive components Figure 4 1 Groomercoverassembly 3 Gasket 2 Groomer Page 8 8 UC EU NE Screw 5 used Groomer cover Plug Shaft O ring Thrust washer 4 Handle Antiseize Lubricant Figure 5 6 Plunger detent 7 Capscrew 8 Retaining ring 9 Setscrew 10 Handle Greensmaster Flex 1800 2100 Installation Flush to 0 020 1 If removed install shaft into groomer cover Fig 5 Flush to 0 5 mm A Install new O ring into groove of shaft B Apply antiseize lubricant to shaft surface that is below the retaining ring groove C Slide shaft up through bore of cover and secure 3 with thrust washer and retaining ring D Position shaftin coversothatcam pointofshaftis located away from the gasket surface Fig 6 E Install plunger detent into groomer cover so that end of plunger if from flush to 0 020 0 5 mm ex tending from cover surface Fig 6 F Slide handle into shaft so that it extends toward the front
63. ble from engine see Throttle Cable Replacement in this section Chassis and Controls Page 6 4 5 Disconnectwire harness connections from electrical components on handle Position wire harness away from handle 6 Note height adjustment of handle for assembly pur poses 7 Supporthandle assembly to prevent it from moving NOTE The offset handle clamps on Flex 2100 ma chines are mounted on the outside of the side plates Fig 2 On Flex 1800 machines the offset handle clamps are mounted on the inside of the side plates Fig 3 Greensmaster Flex 1800 2100 8 Remove handle clamps from handle assembly F ig 2 or 3 A Remove carriage screws and flange nuts thatse cure handle clamps to offset handle clamps B Remove flange nuts that secure shoulder bolts at bottom of handle clamps C Remove inner handle clamps Leave shoulder bolts and outer handle clamps in place on handle 9 Remove the handle assembly from the machine 10 If rubber bumpers item 7 in Fig 2 or 3 need to be replaced cut bumpers to remove from handle clamps Apply soapy water to inside of new bumpers to ease installation onto clamps Handle Installation Fig 1 1 Position handle assembly to outer handle clamps on machine 2 Fitinner handle clamps to the handle assembly and secure with removed fasteners Fig 2 or 3 Adjust han dle height before fully tightening the fasteners NOTE The handle is traditionally operated with
64. bly into transmission housing Secure clutch housing to transmission housing with four 4 washerhead screws item 15 Tighten screws as fol lows A First torque all four 4 screws from 15 to 40 in Ib 1 7 to 4 5 N m B Then torque all screws from 85 to 95 in Ib 9 6 to 10 7 N m 7 Secure bellcrank rod item 19 to clutch lever with cap screw item 23 and flange nut item 14 8 Install transmission drive belt and all machine com ponents removed for clutch system disassembly see Transmission Drive Belt in this section 9 Verify that traction clutch cable is properly adjusted see Traction Clutch Cable Replacementin the Service and Repairs section of Chapter 6 Chassis and Con trols Figure 42 1 Clutch housing 2 Clutch lever 3 Bellcrank rod assembly 4 Bellcrank lever KE 8 150 to 8 210 207 0 to 208 5 mm Figure 43 3 Bellcrank rod 4 Balljoint 1 Clevis 2 Jam nut 2 used Traction and Reel Drive System r s s S z iS o A Drive System Clutch Service Figure 44 1 Retaining ring 3 used 7 Spring cup 13 Rotating housing 2 Retaining ring 8 Wave spring 14 Hub 3 Shim 6 used 9 Oil seal 15 Airgap cover 4 Ball bearing 2 used 10 Thrust friction assembly 16 Fixed drive insert 6 used 5 Mounting plate 11 Retainin
65. d bedbar ad juster screw item 10 into adjuster shaft 5 Install bedbar see Bedbar Installation in this sec tion 6 Install washer item 11 spring item 2 and lock nut item 3 onto adjuster screw Tighten the lock nut on each bedbar adjuster assembly until the compression spring is fully compressed then loosen lock nut 1 2 turn 7 Adjust cutting unit see Cutting Unit Operator s Manual Flex 1800 Shown 1 Crossmember 2 Detent Greensmaster Flex 1800 2100 Page 7 17 Figure 23 3 Capscrew Cutting Unit Front Roller Removal Fig 24 1 Park machine on a level surface Make sure the en gine is OFF and the traction lever is in NEUTRAL 2 Remove the cutting unitfrom the machine and place on a level working surface Use appropriate support to raise front roller from work surface 3 Loosen cap screw item 1 thatsecures the frontroll er Shaft to each front height of cut arm 4 Onone ofthe height of cut arms remove HOC nut item 7 HOC washer item 6 and plow bolt item 4 that secure HOC arm to the cutting unit side plate Remove the HOC arm from the cutting unit 5 Slide the front roller assembly from the remaining HOC arm on the cutting unit 6 If necessary remove the second HOC arm from the cutting unit Installation Fig 24 1 Place cutting uniton a level working surface and use appropriate support to support front of cutting unit 2 Inspect condition of HOC screws item
66. d or dirty blower housing will result in engine overheating and damage 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the spark plug IMPORTANT Never clean engine with pressurized water Water could enter and contaminate the fuel system 2 Clean cooling fins on cylinder and cylinder head Re move engine cylinder shroud from engine for more thor ough cleaning Fig 2 3 Clean blower housing of dirtand debris Fig 3 Re move housing if necessary IMPORTANT Never operate engine with the cylin der shroud and blower housing removed Overheat ing and engine damage will result 4 Make sure blower housing and or engine cylinder shroud are installed to the engine if removed 5 Attach spark plug wire to spark plug 72773 E DETEETI E 81 0 3 EDELELUIE Figure 2 1l Engine cylinder shroud 2 Cooling fins 1 Blower housing Engine Page3 6 NS 0 d 1 O S VA iN UT Ec aS gt Q Figure 3 2 Rewind starter Greensmaster Flex 1800 2100 Spark Plug Use a NGK BR 6HS spark plug or equivalent 1 Make sure engine is OFF Carefully remove spark Ds plug wire from the spark plug 0 024 to 0 028 0 6 to 0 7 mm 2 Clean cylinder
67. dentify and correct cause before securing the cover 6 Secure cover to housing with six 6 socket head screws Torque screws from 99 to 121 in Ib 11 2 to 13 6 N m 7 Pack differential housing cavity 2096 to 3096 full of high temperature Mobil XHP 222 grease or equiva lent 8 Install differential assembly to machine see Differ ential Assembly in this section Greensmaster Flex 1800 2100 Page 4 25 Figure 28 1 Cover index mark 2 Housing index mark 4 NIA j uu Ss SIA Figure 29 1 Projection on cover 2 Gear pin with 2 gears 3 Gear pin with 1 gear Figure 30 1 Housing index mark 2 Gear pin with 2 gears 3 Gear pin with 1 gear Traction and Reel Drive System Traction and Reel Drive System Transmission Drive Belt Antiseize Lubricant See text for tightening procedure 60 to 65 in Ib 6 8 to 7 3 N m Figure 31 Transmission assembly Transmission belt Gasket Wave washer Transmission cover Key gU RUNH o o9 Transmission removal from the machine is not neces sary to service the transmission drive belt The trans mission drive belt can be replaced by removing the engine fromthe frame removing the transmission cover and then removing the drive belt Drive Belt Removal Fig 31 1 Park machine on a level surface Make sure engine is OFF 2 Remove engine from machine see Engine Removal in the Service and Repairs section of Cha
68. des Remove small amounts of material with each pass of the grinder 1 Follow reel grinder manufacturer s instructions to grind cutting reel to Toro specifications see Reel Grind ing Specifications chart to the right Additional reel grinding information can be found in the Toro General Service Training Book Reel Mower Basics part no 09168SL 2 After completing the reel grinding process adjust cutting unit see Cutting Unit Operator s Manual Reel Diameter Blade Land Width T LE Reel Grinding Specifications Reel Diameter New 5 060 in 128 5 mm Service Limit Reel Reel Shaft Diameter OD 1 375 in 34 9 mm Service Limit 0 010 in 0 25 mm Reel Diameter Taper Rotation Reel Diameter Taper D1 D2 Figure 38 Cutting Unit Page 7 28 Greensmaster Flex 1800 2100 Chapter 8 TORO Groomer Table of Contents SPECIFICATIONS is ec bees eee Res 2 GENERAL INFORMATION 00c ce eeeee 3 Installation Instructions ccc eee eee 3 TROUBLESHOOTING ccc cece cece eee 4 Factors Affecting Grooming 000 4 Grooming Reel Mechanical Problems 5 ADJUSTMENTS ccc ccc ccc eect teens 6 Height Depth of Groomer Adjustment 6 SERVICE AND REPAIRS 0ceeeeeeeees 7 Groomer Belt Replacement Forward Rotating Groomer Drive ccc ccc cece ee eee 7 Groomer Cover Counter Rotating Groomer Drive cives bt Pad a ee OCA 8 Groomi
69. djusting groomer height depth groomer blades FORWARD ROTATING GROOMER SHOWN should never penetrate the soil 1 Position machine on a clean and level surface with engine stopped Engage parking brake 2 Make sure rollers are clean and cutting reel is setto the desired height of cut see Cutting Unit Operator s Manual for cutting unit adjustment procedures 3 Position the grooming reel to the lowered grooming position Fig 1 NOTE Improperorover aggressive use ofthe groom ing reel i e too deep or too frequent grooming may cause unnecessary stress on the turf leading to severe greens damage Use the groomer cautiously Figure 1 1 Height adjustment knob 2 Lockscrew 4 On one end of the grooming reel measure the dis did tance from the lowest tip of the groomer blade to the working surface Liftand turn height adjustment knob to raise or lower the blade tip Fig 1 Each notch on the adjustment knob changes the groomer height approxi mately 0 003 inch 0 08 mm 5 Repeat step 4 on the opposite end of the groomer Then recheck setting on the first side of groomer Heightsetting on both ends of groomer should be identi cal Groomer Page8 6 Greensmaster Flex 1800 2100 Service and Repairs Groomer Belt Replacement Forward Rotating Groomer Drive 1 Position machine on a clean and level surface with engine stopped Engage parking brake 2 Remove three 3 lock nuts that secure groomer drive cover t
70. ds with Class 8 or Stronger Nuts 644 68 N cm 1085 113 N cm Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 78 8 in Ib 881 90 N cm 133 14 in Ib 1503 158 N cm M6 X 1 0 M8 X 1 25 19 2 ft lb M10 X 1 5 38 4 ft lb M12X 1 75 66 7 ft lb M16 X 2 0 166 17 ft lb M20 X 2 5 325 33 ft lb NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material strength length of thread engagement etc NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite Greensmaster Flex 1800 2100 26 3N m 52 5N m 90 10 N m 225 23 N m 440 45 N m Page 2 5 28 3 ft lb 38 4 N m NOTE The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J 1199 The tolerance is approximately 10 ofthe nominal torque value Product Records and Maintenance Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size square Head HexSocket 7o 20unr 65210m 8214n Grade 5 1 2 20UNF 80 10 ft lb 108 14 N m 5 16 18 UNC 215 435in lb 145 20 in Ib Grade 5 3 8 16 UNC 35 1
71. e fer to the Subaru Service Manual Ignition System Operation The engine on Greensmaster Flex 1800 and Flex 2100 machines has a magneto ignition system consisting of an ignition coil a spark plug and permanent flywheel magnets A flywheel key maintains proper ignition tim ing Testing the Ignition System NOTE Donotremove spark plug from the engine when testing the ignition system The spark plug is necessary to maintain normal starting speeds 1 With engine not running remove spark plug wire from the spark plug and connect it to the spark tester see Special Tools in this chapter 2 Connect spring clip of tester to a good unpainted ground on the engine block 3 Make sure ON OFF switch is in the ON position Also make sure that the traction lever is in the NEU TRAL position 4 Pull the engine starter rope and observe the spark tester Visible and audible sparks should be produced if the ignition system is operating properly Greensmaster Flex 1800 2100 Page 5 9 When testing electrical components for continuity with a multimeter ohms setting make sure that engine is not running to prevent current flow through the component The ignition system produces a dangerously high voltage Do not touch the spark plug ignition coil or spark plug lead when the engine is running you can receive a severe electrical shock NOTE Ifa shearedflywheelkey exists the spark tester may indicate an operating ignition
72. e 12 A 1 Transmission 4 Retaining ring A Secure cable eyelet to transmission reel clutch 2 Reelclutch cable 5 Cable spring 3 Reel clutch lever 6 Rubber plug lever with retaining ring B Position reel cable to the casting slotoftransmis sion with a jam nut flat washer and lock washer on each side of the slot C Adjust and tighten jam nuts to compress cable spring to a length of 2 780 to 2 850 70 6 to 72 4 mm D Remove rubber plug at front of transmission to view reel clutch Make sure that reel clutch teeth dis engage when the clutch is released Also verify that clutch teeth do not bottom out when clutch is en gaged E Secure reel drive cable to transmission bracket with cable tie 3 Make finalreelclutch cable adjustmentattraction le ver assembly Fig 13 cs amp 2 22 Qe o0 So 2 A Loosen both top and bottom cable jam nuts at shift mount bracket Figure 13 1 Shift handle 5 Upper cable jam nut B Pull down lightly on outer sheath of clutch cable Peace ae ir CE LE bral ia hey 4 Reel cable spring C Rotate bottom cable jam nutup on cable threads until the bottom lock washer just contacts the shift mount bracket D While holding the bottom jam nutin place tighten top cable jam nut 4 Install console cover to handle assembly Greensmaster Flex 1800 2100 Page 6 11 Chassis and Controls Traction and Reel Drive Engagement Lever Assembly 0 Note orientation of spring hook
73. e Reel 74 Ib 33 5 kg NOTE weights listed do not include front roller or groomer Cutting Unit gt D Z o General Information Operator s Manual The Cutting Unit Operator s Manual provides informa tion regarding the operation general maintenance and maintenance intervals for the cutting unit on your Greensmaster machine Additionally if optional kits have been installed on the cutting unit e g grooming reel the installation instructions forthe kitincludes set up and operation information Refer to those publica tions for additional information when servicing the cutting unit Supporting Cutting Unit when Servicing Whenever the cutting unithas to be tipped to expose the bedknife or cutting reel support the rear of the cutting unitto make sure the lock nuts on the back of the bedbar adjuster screws are not resting on the work surface SOAM e Figure 1 1 Lock nut 2 Support Cutting Unit Page 7 4 Greensmaster Flex 1800 2100 Separating Cutting Unit from Traction Unit 1 Position mower on a flat level work surface Make sure engine is OFF Remove spark plug wire from the engine spark plug 2 Lower the kickstand and push in the locking pin to lock the kickstand in the service position Fig 2 Allow the kickstand and machine to rest against the locking pin 3 Remove grass basket from cutting unit if installed 4 Slide the telescoping coupler offthe cutting unithex sha
74. e brake cable to the drum drive housing and se cure brake cable to the brake lever shaft on the drum drive housing Fig 6 A Install cable eyeletto the brake lever and secure with retaining ring B Attach brake cable to the casting slot on drum drive housing with a washer and jam nuton each side of the slot Adjust jam nuts so that equal amount of cable threads are visible above and below jam nuts Greensmaster Flex 1800 2100 Page 6 7 4 Adjustcable jam nuts atbrake cable bracketon han dle assembly so that it requires 35 pounds 156 N ap plied to the brake lever to release the parking brake latch After final cable adjustment make sure that brake does not drag 5 Install console cover to handle assembly 1 Brake cable 2 Cable eyelet Figure 6 3 Cable jam nut location 4 Retaining ring 10 5 to 12 5 in Ib 1 2 to 1 4 N m Figure 7 1 Brake lever 8 Brake lever keeper 2 Brake cable 9 Screw 4 used 3 Bushing 2 used 10 Spacer 4 Flange nut 11 Washer 5 Spring 12 Screw 6 Parking brake latch 13 Handle assembly 7 Locknut Chassis and Controls Chassis and Controls Traction Clutch Cable Replacement Note orientation of spring hook 9 Traction switch 10 Traction clutch cable Washer head screw 4 used 11 Shifter bracket Figure 8 1 Brake cable 5 Reel clutch cable 2 Brake lever 6 Console cover 3 Leverassembly 7 4 Shift mount 8 Lower handle Removal 1 Park mac
75. e cutting unit side plates Greensmaster Flex 1800 2100 Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when handling the bedbar 7 Remove bedbar assembly from cutting unit 8 Inspect nylon bushings item 15 and rubber bush ings item 14 in side plates for wear or damage Re move bushings and replace if necessary Bedbar Installation Fig 16 1 If rubber bushing was removed from either cutting unit side plate apply grease to outside surface of new bushing and install into side plate The bushing should be installed flush with the inside of the side plate Fig 17 2 If removed install the nylon bushings item 15 with flange facing outward Apply antiseize lubricantto inside of flange bushing 3 Apply antiseize lubricant to the bedbar threads and the shoulder area of each bedbar pivot bolt Fig 17 IMPORTANT When installing washers items 16 and 17 make sure that plastic washers are posi tioned on either side of the cutting unit sideplate Fig 17 4 Slide one 1 metal washer item 17 and thenone 1 plastic washer item 16 onto each bedbar pivot bolt Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when handling the bedbar 5 Position bedbar into cutting unit Make sure that the top of each bedbar arm is between washer item 11 and adjuster screw flange item 4 Green
76. e described in the Subaru Service Manu al The use of some specialized test equipment is ex Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your Greensmaster machine R efer to the Operator s Manual for additional information when ser vicing the machine Fuel Evaporative Control System To meet worldwide emission requirements the engine thatpowers your Flex moweris equipped with a fuel cap that has an integrated carbon canister This fuel cap captures fuel vapors from the fuel tank prior to venting to atmosphere Engine Page3 4 plained However the costofthe testequipmentand the specialized nature of some repairs may dictate thatthe work be done atan engine repair facility Service and repair parts for the Subaru engine used on Greensmaster Flex mowers are supplied through your local Toro distributor Be prepared to provide your dis tributor with the Toro model and serial number To prevent saturating the carbon cannister in the fuel cap itis importantto make sure thatthe fuel tank is not overfilled The recommended level for a full fuel tank is flush with the top of the plastic fill screen in the tank Do not overfill the tank when refueling Greensmaster Flex 1800 2100 Adjustments Throttle Cable Adjustment If a new throttle cable must be installed or the cable is out of adjustment adjustthe cable as follows 1 Park mach
77. e plate 7 Remove reel drive assembly from cutting unit 8 Remove components from reel drive housing as necessary using Figure 13 as a guide A Ifidlershaftbearings item 24 are to be removed use press to remove bearings and bearing spacer from shaft Discard bearings after removal NOTE See Reel Drive Bearing Housing in this section for disassembly and assembly information of bearing housing assembly item 12 NOTE Reel pulleys items 8 11 and 14 can be identi fied by color and number of teeth Pulley location can vary based on desired cutting unit clip frequency see Cutting UnitClip Adjustmentin the Adjustments section of this chapter Reel Drive Assembly Installation Fig 13 1 Install all removed components to reel drive housing using Figure 13 as a guide A If bearings item 24 were removed from idler shaft use press to install bearings and bearing spacer onto shaft 2 Apply light coating of grease on reel drive housing O rings items 2 and 9 Greensmaster Flex 1800 2100 Page 4 11 3 Position reel drive assembly to cutting unit Make sure that spring pin item 21 and compression spring item 16 are positioned between reel drive housing and bearing housing assembly 4 Secure reel drive assembly with two 2 flange head screws item 5 and washer head screw item 4 5 Install woodruff key item 22 to reel drive shaft item 7 Apply antiseize lubricantto top of key 6 Slide reel pul
78. eel assembly 20 Gasket 32 Socket head screw 4 used 9 HOC washer 2 used 21 Flange head screw 5 used 33 43T idler gear 10 HOC screw 2 used 22 Groomer cover assembly 34 LH cutting unit side plate 11 O ring 23 47T idler gear 35 Plow bolt 2 used 12 RH drive plate assembly 24 Flange nut 2 used 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 Removal Fig 10 1 Position machine on a clean and level surface with engine stopped Engage parking brake 2 Remove the cutting unitfrom the machine and place cutting unit on a flat work area 3 Make sure that handle on groomer cover is rotated toward front of machine so that groomer drive is en gaged Groomer Page 8 14 4 Remove groomer cover assembly item 22 and gas ket item 20 from machine see Groomer Cover Count er Rotating Groomer Drive in this section Discard gasket 5 Carefully remove extension spring from anchor points on RH drive plate Fig 11 6 Remove the two 2 idler gears 43T and 47T from the RH drive plate assembly Fig 12 The bearings are pressed into the gears 7 Loosen cap screws item 7 that secure front roller shaftto groomer arms Greensmaster Flex 1800 2100 8 Remove lock nutand spring washer that secure RH groomerarm liftrod to RH drive plate assembly F ig 13
79. efore reinstalling new belt Drive Belt Installation Fig 31 IMPORTANT During assembly make sure that transmission coveris installed with fasteners prop erly torqued before applying tension to transmis sion belt 1 Install new transmission belt onto pulleys in trans mission Make sure that belt is correctly routed around drive and idler pulleys Fig 32 2 Make sure that wave washer item 4 is pressed into bearing bores of transmission cover Also make sure that two 2 dowel pins are pressed into bores in the transmission housing 3 Position new gasketto transmission assembly Align gasket to two 2 dowel pins in transmission housing 4 Installtransmission cover If necessary use a rubber mallet at dowel locations Fig 33 to seat cover to trans mission 5 Install seven 7 washer head screws to secure cov er to transmission Tighten screws as follows A First using an alternating crossing pattern torque all screws from 15 to 40 in Ib 1 7 to 4 5 N m B Again using an alternating crossing pattern torque all screws from 85 to 95 in Ib 9 6 to 10 7 N m 6 Apply tension to transmission belt by rotating the en gage disengage shaft counter clockwise see Trans mission Belt Tensioner in the General Information section of this chapter 7 Install key item 6 to transmission shaft Apply anti seize lubricant to top of key 8 Slide coupler item 11 onto transmission shaft until itis flush wit
80. elt T i 1 Engaged position 2 Disengaged position 4 To engage the drum drive rotate traction engage disengage lever to the engaged position by rotating the lever toward the front of the machine 5 Connect spark plug wire to spark plug Greensmaster Flex 1800 2100 Page4 3 Traction and Reel Drive System Transmission Belt Tensioner The transmission pulleys are driven by a multi ribbed belt that is tensioned with a spring loaded idler assem bly Ifthe transmission belttension needs to be engaged or disengaged follow the following procedure 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the engine spark plug 2 Locate the transmission engage disengage shaft next to the engine Fig 2 A CAUTION Be careful when rotating the transmission en gage disengage lever The leveris spring loaded and may cause personal injury 3 To disengage the spring loaded idler from the trans mission drive belt use a 3 8 wrench to rotate the en gage disengage shaft 1 4 turn clockwise 4 To engage the idler into the transmission drive belt use a 3 8 wrench to rotate the engage disengage shaft 1 4 turn counter clockwise The transmission belt is properly tensioned when the alignment marks on the en gage disengage shaft and the transmission cover are aligned Fig 3 5 Connect spark plug wire to spark plug Figure 2 Transmission 3 Engine Engage disengage s
81. ely from side to side on the idler bracket pin 2 Install drive pulley drive belt and belt cover to right side of mower see Grooming Reel Installation in this section 3 Check and adjust grooming reel height and mower height of cut settings Figure 25 1l Drive pulley 2 Idler pulley assembly 3 Driven pulley Greensmaster Flex 1800 2100 Page 8 21 4 RH drive plate assy 5 Groomer drive belt Groomer Idler Assembly Counter Rotating Groomer Drive Figure 26 1 RH drive plate 5 Spacer 9 Flange nut 2 Adjustment cam 6 Reel hub 10 Extension spring 3 Spacer 7 Retaining ring 11 Grease fitting 4 Idler bracket 8 O ring 12 Grease seal The groomer RH drive plate assembly incorporates the idler system for engaging the groomer gear drive Disassembly Fig 26 1 Position machine on a clean and level surface with engine stopped Engage parking brake 2 Make sure that handle on groomer cover is rotated toward front of machine so that groomer drive is en gaged 3 Remove groomer cover assembly and gasket from machine see Groomer Cover Counter Rotating Groomer Drive in this section 4 Remove RH drive plate assembly from right side of cutting unit see Grooming Reel Counter Rotating Groomer Drive in this section Groomer Page 8 22 5 Using Figure 26 as a guide remove idler compo nents from RH drive plate as needed Assembly Fig 26 1 Assemble idler components to RH drive
82. emove inner ball bearing item 7 from clutch shaft Discard bearing Assembly Fig 41 1 If bellcrank rod item 19 was disassembled thread rod into clevis until the end ofthe rod is flush with the in side of the clevis Then install balljoint so the centers are from 8 150 to 8 210 207 0 to 208 5 mm as shown in Figure 43 Also make sure that sides of clevis and balljointare parallelto preventbinding during operation 2 Ifdrive pulley item 8 was removed from clutch shaft install components on shaft A If inner ball bearing item 7 was removed from clutch shaft press new bearing onto shaft B Slide drive pulley item 8 onto bearing on clutch shaft C Press new outer ball bearing item 9 onto clutch shaft D Install flocked bearing shield item 10 wave spring item 11 and flat washer item 12 onto clutch shaft Secure with retaining ring item 13 3 Align clutch to clutch shaft and slide clutch onto clutch shaft Secure clutch to shaft with flange head screw item 2 and washer item 4 4 Secure drive pulley to clutch with three 3 washer head screws First torque all three 3 screws from 15 to 40 in Ib 1 7 to 4 5 N m Then torque all screws from 95 to 105 in Ib 10 7 to 11 8 N m Greensmaster Flex 1800 2100 Page 4 35 5 Position clutch housing to clutch and secure with three 3 flange head screws item 2 Make sure that grommet item 3 is secure on housing 6 Install clutch assem
83. eplace worn groomer components to reverse the blades on the shaft if not equipped with carbide blades or to replace the grooming shaft Removal Fig 7 1 Position machine on a clean and level surface with engine stopped Engage parking brake 2 Remove the cutting unitfrom the machine and place cutting unit on a flat work area Groomer Page 8 10 3 Remove groomer drive cover item 2 and groomer drive belt item 3 from groomer drive see Groomer Belt Replacement in this section 4 Loosen cap screws item 10 thatsecure front roller shaft to groomer arms 5 Remove lock nut and spring washer that secure RH groomer arm liftrod to RH drive plate assembly Fig 8 Greensmaster Flex 1800 2100 6 Remove HOC nut item 21 HOC washer item 16 and plow bolt item 22 thatsecure RH groomer arm as sembly to RH support plate assembly Do not change height of cut screw adjustment Remove RH groomer arm assembly from cutting unit 7 Remove front roller assembly from cutting unit NOTE To prevent grooming reel shaft from turning when removing driven pulley item 19 use wrench on shaft flats to hold shaft 8 Remove the lock nut item 1 that secures driven pulley item 19 to grooming reel shaft Remove driven pulley from shaft NOTE To prevent cutting reel from turning when re moving drive pulley item 4 use a 1 2 socketon hex of reel drive shaft that is used for backlapping the cutting reel 9 Loosen a
84. ernor lever C Separate throttle cable from engine 3 Remove console cover from handle assembly to al low access to upper end of throttle cable 4 Remove throttle cable from the throttle control as sembly Fig 5 A Remove retaining ring and flat washer that se cure throttle cable end to pin on throttle control Slide cable end from throttle control B Remove the cable housing from the throttle mount 5 Remove throttle cable from the machine Installation 1 Connect throttle cable to throttle control assembly Fig 5 A Secure throttle cable end to pin on throttle control with flat washer and retaining ring B Secure cable housing to throttle mount 2 Route throttle cable to the engine Make sure that cable is routed on rightside of throttle mountcable guide item 7 in Fig 5 3 Install cable to the engine governor linkage as fol lows Fig 4 A Slide throttle cable end into governor lever B Place throttle cable under cable clamp C Make sure throttle control is in the FAST position and the governor lever is against the high speed screw on governor linkage D Tighten screw on cable clamp to secure the throttle cable Chassis and Controls Page 6 6 4 Check throttle cable adjustment see Throttle Cable Adjustment in the Adjustments section of Chapter 3 Engine 5 Install console cover to handle assembly Figure 4 3 Governor lever 4 High speed screw 1 Throttle cable
85. ever and switch af ter tightening fasteners The parking brake latch must not contact the switch Switch Testing 1 Make sure the engine is OFF and the traction lever is inthe NEUTRAL position Disconnect parking brake latch switch connector from the machine wire harness 2 Check the continuity of the brake latch switch by con necting a multimeter ohms setting across the connec tor terminals 3 With the parking brake latch released there should be no continuity infinite ohms across the switch termi nals 4 Verify that the switch closes zero ohms as the ser vice brake lever and parking brake latch are engaged 5 Replace switch if necessary Switch Removal Installation 1 Disconnect parking brake latch switch from the ma chine wire harness 2 Remove screws and lock nuts that mount switch to switch panel on handle Fig 8 Remove switch from machine NOTE For proper parking brake latch switch opera tion the screws and lock nuts used to secure the brake latch switch are stainless steel Ifthese fasteners are re placed make sure to use correct fasteners 3 Position switch to switch panel and secure with screws and lock nuts Fig 8 Greensmaster Flex 1800 2100 Page 5 11 4 Adjust brake latch switch as necessary see Switch Adjustment above 5 Connect switch to machine wire harness Secure console cover to handle EC NA IZ Q AW SS Yu NE
86. f gears and spacers on each ofthe six 6 gear pins 7 If necessary remove ball bearings from cover and housing There are two 2 holes in the cover and hous ing that allow use of a pin punch to remove bearings Discard removed bearings Inspection Fig 27 1 Clean all differential components 2 Inspect all differential gears carefully looking for chipped teeth wear or other damage Because gear tooth damage is rarely isolated to one gear replace gears as a complete set 3 Inspect gear pins item 4 for scoring or wear 4 Replace all worn or damaged differential assembly components Greensmaster Flex 1800 2100 Assembly Fig 27 1 If ball bearing was removed from either cover or housing press new ball bearing into bearing bore Make sure that bearing is fully pressed to shoulder of bore 2 Place cover with bearing installed on workbench 3 Slide each gear pin with gears and spacers into cov er Make sure that projections on inside of cover are aligned with the pins that have one 1 gear Fig 29 4 Position housing onto assembly making sure that gear pin with one 1 gear is positioned next to index mark on housing Fig 30 Also align index marks on housing and cover during assembly Fig 28 5 After housing is installed use one of the spur gears see Differential Assembly in this section to rotate dif ferential gears making sure thatthey rotate freely with out binding If binding is noted i
87. flange bushings from idler bracket Dis card removed bushings B Remove retaining ring from idler bracket Slide idler pulley from bracket shaft Press ball bearings from idler pulley Discard removed bearings Installation 1 Ifidler arm assembly was disassembled A Press new flange bushings into idler bracket B Press new ball bearings fully into idler pulley mak ing sure to apply pressure to outer bearing race only Figure 20 Slide pulley assembly onto idler bracket and secure range PIRE 2 used T darin Se er bracke B etaining ring with retaining ring 3 Ball bearing 2 used 2 Position idler arm assembly to drum drive housing and secure with shoulder screw item 15 Torque shoul derscrew from 15 to 17 ft Ib 21 to 23 N m Check that idler arm assembly can pivot freely after tightening shoulder screw Ez c E o2 eo SF So 22 p sa b 3 Carefully secure the end of the extension spring item 9 to idler arm 4 Make sure that wave washer item 4 is pressed into bore of drum drive cover 5 Position new gasket item 3 to housing surface 6 Slide drum drive cover onto drum drive assembly 7 Install seven 7 washer head screws to secure cov er to housing Tighten screws as follows A First using an alternating crossing pattern torque all screws from 15 to 40 in Ib 1 7 to 4 5 N m B Again using an alternating crossing pattern torque all screws from 85 to 95 in Ib 9 6 to
88. ft Fig 3 5 Loosen two 2 flange head screws that secure cut ting unit pitch arms to traction unit roll frame Fig 4 It is not necessary to completely remove the screws 6 Rotate pitch arms forward and rest traction unit against the kickstand 7 Roll cutting unit away from machine 8 Reverse procedure to install cutting unit to traction unit 9 After cutting unit is installed to traction unit attach spark plug wire to engine spark plug sx TI nues RENT M i A c E TAS Figure 2 1 Kickstand 2 Locking pin D 2 Figure 3 1l Telescoping coupler 2 Cutting unit hex shaft Figure 4 1 Cutting unit pitch arm 3 Flange head screw 2 Traction unit roll frame Greensmaster Flex 1800 2100 Page7 5 Cutting Unit Special Tools Some special tools may have been supplied with your mower or are available as TORO parts Order special tools from your Toro Distributor Some tools may also be available from a local supplier Gauge Bar Assembly Toro Part Number 13 8199 Used to verify height of cut i Figure 5 Backlapping Brush Assembly Toro Part Number TOR299100 Used to apply lapping compound to cutting unit while keeping the operator s hands ata safe distance from the rotating reel Components for the brush assembly are available indi vidually as follows Figure 6 Brush 36 4310 Handle 29 9080 Handle cap 2410 18 Bedknife Screw Tool
89. ft side of machine until extension housing is clear of RH drum housing Lift transmission from machine 11 To disassemble transmission refer to Transmission Drive Belt Transmission Idler System Transmission Reel Drive System Transmission Clutch System and Transmission Drum Drive System in this section Transmission Installation 1 Make sure thatalltransmission components are cor rectly installed before transmission is installed to ma chine frame 2 Carefully install transmission assembly toward right side of machine so that extension housing is inserted into RH drum housing 3 Align transmission mounting holes with frame and RH drum housing Install and finger tighten fasteners to secure transmission to machine A Four 4 washerhead screws item 7 thatsecure extension housing item 13 to RH drum housing B Cap screw item 10 hardened washer item 9 and flange nut item 12 thatsecure rear of transmis sion to frame Make sure that washer item 9 is be low frame tube C Flange head screw item 2 that secures front of transmission to frame Greensmaster Flex 1800 2100 Page 4 41 4 Once all fasteners have been installed fully tighten fasteners in the following order A Four 4 washer head screws item 7 First torque all screws from 15 to 40 in Ib 1 7 to 4 5 N m Then using an alternating crossing pattern torque screws from 85 to 95 in Ib 9 6 to 10 7 N m B Cap screw item 10 and fla
90. g ring 17 Fixed housing 6 Shim 2 used 12 Ball bearing 18 Retaining ring NOTE Mounting plate item 5 thrustfriction assembly item 10 rotating housing item 13 hub item 14 drive inserts item 16 and fixed housing item 17 are not available separately If any of these clutch components are worn or damaged replace complete clutch assem bly Clutch Inspection l Before disassembling clutch measure rotation angle of clutch lever Fig 45 If lever can be rotated more than 22 the clutch assembly is worn and clutch replacement is necessary Traction and Reel Drive System Page 4 36 Clutch Disassembly Fig 44 NOTE Ball bearings items 4 and 12 are a pressed fit on both races A press is required to disassemble clutch 1 Remove both retaining rings item 1 from ends of hub item 14 2 Press mounting plate item 5 assembly from hub Remove retaining ring and then remove shims item 3 and ball bearing from mounting plate Note location of shims for assembly purposes Discard removed bear ing Greensmaster Flex 1800 2100 3 Remove retaining ring item 1 two 2 shims item 6 spring cup item 7 and wave spring item 8 from hub 4 Slide thrustfriction assembly item 10 with rotating housing item 13 attached from hub Remove airgap cover item 15 5 Press rotating housing assembly from thrust friction assembly Remove retaining ring and ball bearing from rotating housing Discard
91. g unit 4 Disassemble lift arm using Figure 30 as a guide NOTE Right and left side HOC groomer arms item 1 and liftarm assemblies item 8 are different other com ponents shown in Figure 30 are the same on both sides of cutting unit NOTE Grooved pin item 3 is used to retain lock screw item 6 to lift arm assembly Greensmaster Flex 1800 2100 Page 8 25 Assembly Fig 30 1 Assemble lift arm using Figure 30 as a guide 2 Apply antiseize lubricant to threads of groomer lift rod item 5 and lift arm assembly stud item 8 3 Installliftarm onto cutting unit Secure with flange nut item 2 and lock nut item 16 with spring washer item 17 4 Secure groomer in raised or lowered position with lock screw item 6 5 Check and adjust grooming reel height and mower height of cut settings Groomer Groomer Brush 20 to 25 in Ib 2 3 to 2 8 N m 20 to 25 in Ib 2 3 to 2 8 N m Figure 31 1 Groomer brush shaft 3 J bolt 5 O ring 2 Locknut 4 Groomer brush The groomer brush attaches to the groomer drive in place of the grooming reel Removal and installation of the groomerbrush uses the same procedure as removal and installation of the grooming reel see Grooming Reel Forward Rotating or CounterR otating in this sec tion To remove the groomer brush from the shaft remove the lock nutand J boltfrom both ends of the brush and slide the brush from the shaft When assembling the brush to
92. gn slot in RH traction drum item 10 with key on long spur gear and slide traction drum onto gear 5 Insertbarstock orother suitable tool through spokes of RH traction drum to keep drum from turning 6 Install jam nut item 11 onto threads of long spur gear to secure RH traction drum Torque jam nut from 140 to 160 ft Ib 190 to 216 N m Traction and Reel Drive System r s s S S 2 1 o _ LT Drive System 7 Slide lock collar item 27 onto drum shaft Align holes in collarand shaftand then install pin item 28 F it O ring item 30 to slot in collar 8 If grease seal item 12 was removed from LH trac tion drum install new grease seal into drum Make sure that seal lip is orientated toward center of drum Press seal into drum bore so thatseal is recessed from 0 470 to 0 530 12 0 to 13 4 mm from edge of drum Fig 23 9 Place square key item 6 into slotof drum shaft Ap ply antiseize lubricant to top surface of key 10 Align slot in LH traction drum item 13 with key on drum shaft and carefully slide traction drum onto shaft taking care to not damage grease seal in drum 11 Insertbar stock or other suitable tool through spokes of LH traction drum to keep drum from turning 12 Make sure thatball bearing item 14 is pressed onto the bearing nut item 15 While retaining LH drum se cure drum to traction drum assembly with bearing nut item 15 Torque bearing nut from 75 to 90 ft
93. gure 14 1 Cover plug Top Face Remove Burr pd Relief Angle Front Face FrontAngle Figure 15 Cutting Unit Bedbar Assembly Flex 2100 Shown 200 to 250 in Ib 23 to 28 N m 190 to 240 in Ib 22 to 27 N m Antiseize Lubricant Figure 16 1 Bedbar 7 Detent 2 used 13 Lock nut 2 used 2 Bedknife 8 Wave washer 2 used 14 Rubber bushing 2 used 3 Screw 13 used 9 Retaining ring 2 used 15 Nylon bushing 2 used 4 Bedbar adjuster screw 2 used 10 Lock nut 2 used 16 Plastic washer 4 used 5 Bedbar adjuster shaft 2 used 11 Washer 2 used 17 Metal washer 4 used 6 Cap screw 2 used 12 Compression spring 2 used 18 Bedbar pivot bolt 2 used Bedbar Removal Fig 16 1 Park machine on a level surface Make sure the en gine is OFF and the traction lever is in NEUTRAL 2 Remove the cutting unitfrom the machine and place cutting unit on a flat work area 3 Tip the cutting unitto expose the bedknife Support the rear of the cutting unit see Supporting Cutting Unit when Servicing in the General Information section of this chapter Cutting Unit Page 7 12 4 Loosen the lock nuts item 13 on the end of each bedbar adjuster assembly until washer item 11 is loose 5 Loosen the lock nuts item 10 on each bedbar pivot bolt item 18 6 Remove two 2 bedbar pivot bolts item 18 four 4 metal washers item 17 and four 4 plastic washers item 16 from th
94. h the end ofthe shaft Secure coupler with two 2 setscrews item 12 Torque setscrews from 60 to 65 in Ib 6 8 to 7 3 N m Greensmaster Flex 1800 2100 Page 4 27 9 Secure coupler guard item 10 to transmission 10 Slide telescoping coupler onto transmission shaftso that drive shaft wire engages hex shafton transmission Make sure thattelescoping coupler is properly attached to cutting unit hex shaft 11 Install engine to machine see Engine Installation in the Service and Repairs section of Chapter 3 Engine Figure 32 1 Engage disengage shaft 4 Idler pulley 2 Drive pulley 5 Drum drive pulley 3 Reel clutch pulley 6 Idler pulley ZA I Jl eZ ZF I HH M Figure 33 1 Transmission cover 2 Dowel location Traction and Reel Drive System E o 3 c 2 Drive System Transmission Idler S ystem 15 to 17 ft lb 21 to 23 N m Figure 34 1 Transmission cover 6 Driven pulley drum drive 11 Idler pulley 2 used 2 Engage disengage shaft 7 Flange bushing 4 used 12 Idler pulley 3 Transmission belt 8 Cap screw 2 used 13 Shoulder screw 4 Extension spring 9 Idler pulley bushing 2 used 14 Retaining ring 5 Main drive idler 10 Ball bearing 6 used Transmission removal from the machine is not neces saryto service the transmission idler system Transmis sion idler components can be accessed by removing the engine fromthe frame removing the transm
95. haft 4 Cutting unit drive Ne me n Figure 3 Engage disengage shaft 3 Cover alignment mark Alignment mark 1 2 Traction and Reel Drive System Page4 4 Greensmaster Flex 1800 2100 S pecial Tools Modified Socket for Reel Clutch Bearing Collar The modified socket is used to remove and install the reel clutch bearing collar when servicing the transmis sion reel clutch shaft Fig 4 Refer to Transmission Reel Drive System in the Service and Repairs section of this chapter for complete information on servicing the reel clutch shaft assembly Socket Modification 1 Make sure that socket 9 16 or 15mm to be modi fied fits over the reel clutch shaft bearing collar Figure 4 2 Drill a hole or grind slots in socket walls to allow a 1 Bearing collar 3 Hub flat location 5 32 pin to extend through socket A modified socket 2 Reel clutch shaft with ground slots is shown in Figure 5 Modified Socket Use Fig 6 IMPORTANT Avoid using excessive clamping pressure on the reel clutch shaft assembly to pre vent damage Traction and Reel Drive System 1 Use flats on reel drive hub to carefully secure reel clutch shaftassembly in a vise Use a vise with softjaws to prevent damage to clutch shaft assembly compo nents 2 Slide modified socket over bearing collar 3 Align modified socket so that 5 32 pin can be in serted through socket and hole in bearing collar 4 Use modified socketand
96. hen remove cover Fig 2 3 Pivot idler pulley by placing a 12mm wrench on pulley nutand rotating idler bracketto relax belttension Slip groomer drive belt off pulleys Fig 3 Carefully re lease idler bracket IMPORTANT Make sure that the drive belt is cen tered on the pulleys and correctly aligned with pulley grooves after installation 4 Install new drive beltto drive pulley idler pulley and Figure 2 driven pulley observing correct belt routing Fig 3 dy Groomer drive cover 2y Locknut Sused 5 Secure beltcoverto machine with three 3 lock nuts Fig 2 Figure 3 1 Drive pulley 4 Driven pulley 2 Idler pulley 5 Groomer drive belt 3 Idler pulley nut Greensmaster Flex 1800 2100 Page 8 7 Groomer Groomer Cover Counter Rotating Groomer Drive OnFlex machines with the counterrotating groomer the groomer cover includes a handle which engages and disengages the groomer drive When the handle is ro tated toward the front of the machine the groomer is en gaged Removal 1 Position machine on a clean and level surface with engine stopped Engage parking brake 2 Make sure that handle on groomer cover is rotated toward front of machine so that groomer drive is en gaged 3 Remove groomer cover assembly from machine Fig 4 A Remove five 5 flange head screws that secure groomer cover assembly to RH drive plate B Remove groomer cover assembly and gasket from machine Discard g
97. hine on a level surface Make sure the en gine is OFF and the traction lever is in NEUTRAL 2 Remove traction clutch cable from the transmission Fig 9 A Loosen front cable jam nutthatsecures cable to traction cable bracket on transmission Lift cable from bracket B Remove flange nut that secures cable eyelet to transmission bellcrank lever and slide cable eyelet from lever 3 Remove console cover from handle assembly to al low access to upper end of traction clutch cable 4 Remove traction clutch cable from the traction lever assembly Fig 10 A Loosen lower cable jam nut that secures traction clutch cable to shift mount bracket on handle Slide cable from bracket B Remove cable spring from spring anchor on lever assembly Note orientation of cable spring hook on lever assembly for assembly purposes 5 Remove traction clutch cable from machine Chassis and Controls Page 6 8 Greensmaster Flex 1800 2100 Installation 1 Secure traction clutch cable to the traction lever as sembly Fig 10 A Install cable spring to spring anchor on lever as sembly B Slide the cable housing into the shift mount bracket slot Make sure that a jam nut flat washer and lock washer are on both sides of bracket Adjust jam nuts so that equal amount of cable threads are visible above and below jam nuts Leave jam nuts snug until final cable adjustment 2 Route traction clutch cable to the transmission and
98. his itis neces sary to grind a new bedknife after installing itto the bed bar Follow the existing angle that was ground into the bedknife and grind only enough to make sure the top surface ofthe bedknife is true and perfectly flat F ig 20 NOTE When grinding the bedknife be careful to not overheatthe bedknife Remove small amounts of mate rial with each pass ofthe grinder Also clean and dress grinding stone often during the grinding process 1 UseToro GeneralService Training Book Reel Mow er Basics part no 09168SL and grinder manufactur er s instructions for bedknife grinding information 2 After bedknife grinding is complete install bedbar to cutting unit see Bedbar Installation in this section Greensmaster Flex 1800 2100 Page 7 15 O 8 GG GG GG 8 8 8 l 13 11 9 7 5 3 1 2 4 6 8 10 12 Figure 19 Remove Burr Relief Angle Face FrontAngle Figure 20 piae e a gg TS O 8 8 G G O G O G G 8 OG gg TS Bedknife 1 689 i umb o EA umb o EA Bedknife 1 876 47 7 i Figure 21 Cutting Unit Bedbar Adjuster Service Flex 2100 Shown Antiseize Lubricant Figure 22 1 Bedbarassembly 2 Compression spring 3 Lock nut 4 Bedbar adjuster shaft Cap screw Detent Wave washer o xo NOTE The detent item 7 used on Flex 2100 is toward the center of the cutting unitas shown in Figure 22 On Flex 1800 cutting units the detentis mounted on the out
99. ine on Greensmaster F lex 1800 and Flex 2100 machines is equipped with a lighting coil to provide elec trical current for an optional LED light kit The coil is lo cated under the engine flywheel and uses permanent magnets on the flywheelto operate The lighting coil has a 12VAC outputthatis rated at15 watts See the Subaru Service Manual for additional lighting coil information Greensmaster Flex 1800 2100 Page 5 13 Figure 11 3 Park brake latch switch 1 Interlock module 2 Traction switch NOTE If lights are desired on the Flex 1800 or 2100 use the recommended Toro LED lightkitthatis available from your Toro Distributor Incandescent or halogen lights will notoperate with the engine lighting coil that is on these machines NOTE f lighting coil output is to be measured with a multimeter a load has to be applied to the circuit Electrical System o 0 1 oo 2B lu This page is intentionally blank Electrical System Page 5 14 Greensmaster Flex 1800 2100 Chapter 6 TORO Chassis and Controls Table of Contents SPECIFICATIONS mom eR eem eme 2 GENERAL INFORMATION aasa 3 Operator s Manual 00 c eee 3 SERVICE AND REPAIRS sese 4 Handle Assembly osusu a 4 Throttle Cable Replacement 6 Brake Cable Replacement 000ees 7 Traction Clutch Cable Replacement 8 Reel Clutch Cable Replacement
100. ine on a level surface Make sure engine is OFF Remove spark plug wire from the spark plug 2 Move throttle control on the machine handle to the FAST position 3 Loosen throttle cable screw thatsecures the throttle cable to the governor lever 4 Make sure throttle controlis inthe FAST position and the governor lever is against the high speed screw 5 Tighten screw to secure the throttle cable to the gov ernor lever 6 After cable adjustment connect spark plug wire to spark plug startengine and allow itto warm to operating temperature Check engine speed with a tachometer A Low idle speed should be 1465 to 1665 RPM Ad justlow idle screw on carburetor to attain the correct low idle speed setting B High idle speed should be 3190 to 3340 RPM Adjustthrottle cable position on engine to attain the correct high idle speed setting IMPORTANT The engine governor control is equipped with a tamper resistant cap to preventad justment of high idle speed Modification to this cap will void the engine warranty and likely will make the engine non compliant with emission certification of the engine 1l Throttle cable 2 Throttle cable clamp Greensmaster Flex 1800 2100 Page3 5 Figure 1 3 Governor lever Engine Service and Repairs Cooling System IMPORTANT The engine that powers the Green smaster Flex 1800 and Flex 2100 is air cooled Op erating the engine with dirty or plugged cooling fins or a plugge
101. ing brake latch is not applied The module also allows the engine to run if the parking brake latch is applied and traction is not engaged The interlock module controls grounding of the engine ignition system When the engine starter rope is pulled the engine magneto will begin to create current The in terlock module uses that current through the traction and parking brake latch switches to determine the state of the switches If switch state is correct the interlock module opens the magneto to ground circuit so the en gine can startand run Once running the interlock mod ule allows the engine to continue to operate unless the parking brake latch is applied and traction is engaged If the engine will not start perform the following tests to determine if the interlock module is at fault 1 Check operation of the engine ignition system see Ignition System Operation in this section 2 Check the operation of both the parking brake latch and traction switches see Parking Brake Latch S witch and Traction S witch in this section Adjust or replace switch if necessary 3 Check wire harness for damage see Wiring Sche matic and Wire Harness Drawings in this chapter Re pairorreplace any damaged wire harness components 4 If the engine ignition system parking brake latch switch traction switch and wire harness all prove to be operating correctly and engine does not start replace interlock module Lighting Coil The eng
102. ission cover and then removing the drive belt Traction and Reel Drive System Page 4 28 Greensmaster Flex 1800 2100 Disassembly Fig 34 1 Park machine on a level surface Make sure engine is OFF 2 Remove transmission drive belt see Transmission Drive Belt in this section 3 Disassemble idler system as required using Figure 34 as a guide Discard ball bearings ifthey are removed from idler pulleys 4 Check bushings items 7 and 9 for wearordamage Replace bushings if necessary Bushings for engage disengage shaft item 2 are pressed into the transmis sion housing and cover Assembly Fig 34 1 Assemble idler system as required using Figure 34 as a guide Ball bearings that support idler pulleys are Figure 35 pressed into the pulleys 1 Engage disengage shaft 4 Idler pulley 2 Main drive idler 5 Transmission belt A If bearings were removed from idler pulleys 3 Extension spring press new bearings fully to shoulder of idler pulleys Drive System B If extension spring item 4 was removed make sure that ends of spring are orientated as shown in Fig 35 cc s S S 2 o A C If main drive idler item 5 was removed secure idler to transmission housing with shoulder screw item 13 Torque shoulder screw from 15 to 17 ft Ib 21 to 23 N m D After securing idler components to transmission housing make sure that all idler pulleys rotate smoothly 2 Insta
103. itch terminals 4 Verify that the switch opens infinite ohms as the traction lever is engaged 5 Replace switch if necessary Switch Removal Installation 1 Disconnect traction switch from the machine wire harness 2 Remove screws and lock nuts that mount switch to switch mount bracket on handle Fig 10 Remove switch from machine NOTE Forpropertraction switch operation the screws and lock nuts used to secure the interlock switch are stainless steel If these fasteners are replaced make sure to use correct fasteners 4 Adjusttraction switch as necessary see Switch Ad justment above Make sure that switch fasteners are securely tightened after adjustment 5 Connect switch to machine wire harness Secure console cover to handle PRAD m Figure 9 1 Traction lever 3 Cap screw head 2 Traction switch Figure 10 E 1 Traction switch 5 Lock nut 2 used 3 Position traction switch to switch bracketand secure 2 Traction lever assembly 6 Console cover with screws and lock nuts Fig 10 3 Lower handle 7 Screw 4 used 4 Screw 2 used 8 Switch mount bracket Electrical System Page 5 12 Greensmaster Flex 1800 2100 Interlock Module The interlock module prevents the engine from starting unless the traction leveris disengaged Once the engine is running the engine will continue to run with the trac tion lever engaged or disengaged as long as the park
104. item 4 use appropriate wrench or socket on 1 hex sur face of shaft Do not use 1 2 extension on end of reel drive shaft when loosening or tightening drive shaft The 1 2 hex is intended for backlapping only 1 Remove bearing lock screw item 5 and reel drive shaft item 4 from cutting reel Reel drive shaft has LH threads and is in end of reel shaftidentified with a groove that is just inside of reel spider Fig 37 2 Slide bearings from reel shaft 3 Note orientation of flocked seals for assembly pur poses Remove seals from reel shaft Inspection of Cutting Reel Fig 36 1 Inspect reel bearings to insure that they spin freely and have minimal axial play 2 Inspectthe reelshaftas follows If reel damage is de tected replace cutting reel A Checkthe reel shaftfor bending and distortion by placing the shaft ends in V blocks B Check the reel blades for bending or cracking C Check the service limit of the reel diameter see Preparing a Reel for Grinding in this section D Check threads in ends of reel shaft 3 Checkthe woodruffkey slotand hex drive on the reel drive shaft item 4 for excessive wear or distortion Re place drive shaft if damage is evident Assembly of Cutting Reel Fig 36 1 If bearings and or flocked seals were removed from reel shaft discard removed components and replace IMPORTANT The flocked seal should be installed so the flocked side of the seal is toward the bearing
105. l working surface Place support blocks under bedbar to raise rear roller from work surface 3 Loosen two 2 flange nuts thatsecure the rear roller shaftto each rear roller bracket 4 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 rear roller bracket and cutting unit side plate A Note quantity and location of roller shims for as sembly purposes B Remove flange nuts and sockethead screws that secure rearroller bracketand roller shims to the cut ting unit side plate C Remove the roller bracket and roller shims from the rear roller and cutting unit 5 Slide the rear roller assembly from the remaining rear roller bracket on the cutting unit 6 If necessary remove the second rear roller bracket and roller shims from the cutting unit Installation Fig 26 1 Place cutting unit on a level working surface NOTE Refer to Cutting Unit Operator s Manual for number of roller shims required for various height of cut settings 2 Ifbothrearrollerbrackets were removed from cutting unitside plate position brackets and roller shims to one of the side plates Install two 2 carriage screws and flange nuts to retain bracketin position Do notfully tight en flange nuts Greensmaster Flex 1800 2100 Page 7 19 Figure 26 1 Rear roller assembly 2 Roller height spacer 3 Socket head screw 4 Fla
106. level surface Make sure the en gine is OFF and the traction lever is in NEUTRAL 2 The backlapping operation can be done with the cut ting unit either removed or attached to the traction unit A If cutting unitis attached to the traction unit slide the telescoping coupler off the cutting unit hex shaft before backlapping Also remove spark plug wire from the engine spark plug and make sure reel drive lever is DISENGAGED 3 Make initial reel to bedknife adjustments appropriate for backlapping on cutting unit 4 Remove plug fromthe reel drive coveronthe leftside of the reel assembly Fig 14 5 Inserta 1 2 socket onto hex of reel drive shaft 6 Backlap according to procedure in Toro GeneralSer vice Training Book Reel Mower Basics part no 09168SL 7 When the backlapping operation is completed and cutting reel is stopped run a file across the front face of the bedknife Fig 15 This will remove any burrs or rough edges that may have built up on the cutting edge Greensmaster Flex 1800 2100 Page 7 11 8 Install reel drive cover plug when backlapping opera tion is completed Fig 14 9 Adjustcutting unit reel to bedknife as needed 10 If cutting unitis attached to the traction unit slide the telescoping coupler onto the cutting unit hex shaft At tach spark plug wire to the engine spark plug DAL X ESN NA MN p GX Figure 13 2 Cutting unit hex shaft 1 Telescoping coupler Fi
107. ley item 8 onto reel drive shaftuntil it contacts shoulder on shaft Secure reel pulley with two 2 set screws item 23 Torque setscrews from 60 to 65 in Ib 6 8 to 7 3 N m 7 Install reel drive belt see Reel Drive Belt Replace mentin this section Make sure that reel drive cover is secured to housing after belt installation 8 Slide the telescoping coupler onto the cutting unit hex shaft Fig 14 9 Connect spark plug wire to spark plug Figure 14 2 Cutting unit hex shaft 1 Telescoping coupler Traction and Reel Drive System Traction and Reel Drive System Reel Drive Bearing Housing Figure 15 1 Retaining ring 6 Flocked bearing shield 10 Bearing housing 2 Reel input shaft 7 Wave spring 11 Spring pin 2 used 3 Bearing 2 used 8 Flat washer 12 Flex coupling 4 Bearing spacer 9 Retaining ring 13 Reel hex shaft 5 Wave washer Traction and Reel Drive System Page 4 12 Greensmaster Flex 1800 2100 Disassembly Fig 15 1 Park mower on a level surface Make sure engine is OFF Remove spark plug wire from the engine spark plug 2 Remove reel drive bearing housing from reel drive housing see Reel Drive Assembly in this section 3 Removeretaining ring item 1 from bearing housing 4 Slide reel input shaft assembly from bearing hous ing Remove wave washer item 5 from bearing hous ing IMPORTANT When removing flex coupler item 12 from reel input shaft item 2 do not ma
108. ll transmission drive belt and all machine com ponents removed for idler system service see Trans mission Drive Belt in this section Greensmaster Flex 1800 2100 Page 4 29 Traction and Reel Drive System Transmission Reel Drive System Loctite 242 Indicator x Mark 23 23 to 27 ft Ib sid 32 to 36 N m Figure 36 1 Transmission housing 11 Reel brake ring 20 Spacer 2 Flex coupler 12 Ball bearing 21 Ball bearing 2 used 3 Hex shaft 13 Retaining ring 22 Reel clutch pulley 4 Spring pin 2 used 14 Reel brake disc 23 Bearing collar 5 Retaining ring 15 Clutch pivot pin 2 used 24 Flocked bearing shield 6 Plug 16 Reel clutch fork 25 Wave spring 7 Retaining ring reel clutch cable 17 Reel clutch hub 26 Flat washer 8 Flange bushing 2 used 18 Reel drive hub 27 Retaining ring 9 Flange bushing 2 used 19 Clutch shaft 28 Ball bearing 10 Reel clutch lever Transmission removal from the machine is not neces sary to service the transmission reel drive system Transmission reel drive components can be accessed by removing the battery pack from the frame removing the transmission coverand then removing the drive belt Reel Clutch Shaft Removal Fig 36 1 Park machine on a level surface Make sure engine is OFF 2 Disconnectreel clutch cable from transmission see Reel Clutch Cable Replacementin the Service and Re pairs section of Chapter 6 Chassis and Controls Traction and Reel Drive
109. ly 1 Place roller shaft into roller NOTE If bearing lock nuts are being replaced use original lock nuts for assembly purposes if possible This will preserve the patch lock feature in the new lock nuts Use the new nuts only after new bearings and seals have been installed 6 V ring 7 Bearing lock nut Figure 28 1 Roller 4 V ring 2 Ball bearing 5 Bearing lock nut 3 Seal 6 Roller shaft Figure 29 1 Bearing lock nut 3 Bearing 2 Black assembly washer Cutting Unit Page 7 20 Greensmaster Flex 1800 2100 NOTE Special tool TOR4105 see Special Tools can be used instead of washers and spacer when installing bearings and seals in roller 2 Position a new bearing black assembly washer see Special Tools and original lock nut onto each end ofthe roller shaft Fig 29 3 Tighten nuts until the bearings are seated into each end of the roller 4 Remove nutand black assembly washer from each end of the roller IMPORTANT Failure to grease bearing lock nut be fore seal installation may result in seal damage 5 Apply a coating of grease to the nut surface to pre vent seal damage during seal installation Fig 30 6 Carefully install seals onto bearing lock nuts Pack the back of the seal 75 to 90 full with 2 grease Fig 30 7 Installa nutwith seal onto each end ofthe rollershaft
110. ly place RH drive plate onto groomer shaft taking care not to damage Seals in drive plate Position drive plate to the cutting unit frame and secure with two 2 shoulder bolts item 5 Make sure thatRH drive plate rotates freely after installation 7 Apply light coating of grease to hub on driven pulley item 19 taking care to notgetgrease on belt surface of pulley Slide driven pulley onto the grooming reel shaft taking care to not damage seal in RH drive plate NOTE To prevent grooming reel shaft from turning when securing driven pulley use wrench on shaft flats to hold shaft 8 Secure driven pulley item 19 to grooming reel shaft with lock nut item 1 Torque lock nutfrom 17 to 21 ft Ib 24 to 28 N m Groomer NOTE To preventcutting reel from turning when instal ling drive pulley use a 1 2 socket on hex of reel drive shaft that is used for backlapping the cutting reel 9 Secure drive pulley item 4 to cutting reel shaft Torque pulley to 100 ft Ib 135 N m 10 Insert front roller into LH groomer arm assembly 11 Make sure that bushing item 11 is installed in RH drive plate assembly 12 Apply antiseize lubricant to threads of RH groomer arm lift rod 13 Position RH groomer arm assembly to front roller groomer RH drive plate and cutting unit frame Secure groomerarm to cutting unitwith plow bolt item 22 HOC washer item 16 and HOC nut item 21 14 Secure RH groomerarm assembly to RH drive plate
111. m 11 and flange nuts item 8 to se cure engine to engine base Do notinstall fastener in LH rear engine mounting hole C Fully tighten flange nuts thatsecure engine to en gine base Install engine base assembly with engine attached to machine Engine A Make sure that coupler sleeve item 4 is placed on transmission input shaft coupler B Position engine base assembly to machine C Carefully slide engine base assembly toward transmission allowing engine coupler to be inserted into coupler sleeve on transmission Engine output shaft may have to be turned to align engine coupler with coupler sleeve D Supportengine base assembly to allow fasteners to be installed E Install and finger tighten two 2 cap screws item 13 hardened washers item 6 and flange nuts item 8 that secure rear of engine base to rear frame F Align frame hole with front mounting boss of en gine base Install and finger tighten flange head screw item 9 and hardened washer item 10 that secure engine base to frame G Position front of engine base to align engine and transmission couplers Fully tighten flange head screw item 9 to secure front of engine base H Fully tighten fasteners at rear of engine base 6 Connect electrical connections to engine Fig 7 A Apply dielectric gel see Special Tools in Chapter 5 Electrical System to wire harness connectors B Connectwire harness connectorto engine arma ture wire
112. ments section of this chapter Roller condition Make sure rollers rotate freely Repair roller bearings if necessary see Roller Service in Service and Repairs section of this chapter Traction speed Check maximum governed engine speed Adjust engine to specifications if necessary see Adjustments section in Chapter 3 Engine The traction drive belt may be loose or worn Check the condition of the traction belt Replace traction drive belt if necessary Groomer reel operation See Troubleshooting section of Chapter 8 Groomer Greensmaster Flex 1800 2100 Page7 9 Cutting Unit Adjustments Ay caution Never work on the cutting unit with the engine running Always stop the engine and remove the spark plug wire from the spark plug first Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when handling the cutting reel or bedknife Leveling Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment parallel If the side plates are disassembled or as the cutting reel wears a limited amountof side plate adjust ment is possible to make sure that the cutting unit is properly aligned 1 Place the assembled cutting uniton a surface plate 2 Make sure that bedknife is properly adjusted to cut ting reel 3 Using the surface plate check if rear rolleris level to cutting reel by using a 0
113. moval Fig 18 1 Park machine on a level surface Make sure the en gine is OFF 2 Pivotkickstand up and hold againstthe frame stops Be careful when removing or applying tension from or to the torsion spring of the kickstand The spring is under heavy load and may cause personal injury 3 Use a nutdriver or small diameter pipe over the end of the torsion spring P ush the torsion spring down and into release spring tension F ig 19 Slide torsion spring from pin on rear frame 4 Remove cap screw spacer and flange nut that se cure left side of kickstand to rear frame 5 Remove kickstand from the machine 6 Ifnecessary disassemble and remove service posi tion locking pin assembly items 7 8 9 and 10 from rear frame Installation Fig 18 1 Make sure machine is parked on a level surface and the engine is OFF 2 If service position locking pin assembly items 7 8 9 and 10 was removed from rear frame install removed locking pin components 3 Position kickstand inside the machine frame Insert cap screw item 4 through the rear frame kickstand and spacer Thread flange nut on cap screw and tighten to secure kickstand 4 Slide torsion spring onto pin on rearframe P lace end of spring in slotted hole in bottom of rear frame 5 Pivotkickstand up and hold againstthe frame stops Use a nutdriver or small diameter pipe over the end of the torsion spring Push the spring end down and outto install spri
114. mower height of cut settings Adjust as needed 18 Install cutting unit to the machine 19 Lubricate groomer bearings see Groomer Installa tion Instructions NOTE After greasing groomer bearings operate groomerfor 30 seconds stop machine and wipe excess grease from groomer shaft and seals Greensmaster Flex 1800 2100 Grooming Reel Service Inspectgrooming reel blades frequently for damage and wear Straighten bent blades with a pliers Replace blades that are worn or damaged Carbide tipped grooming blades Fig 15 should be re placed if the carbide tip is worn loose or missing Also if the blade is eroded around the carbide insert the blade should be replaced Grooming blades without a carbide tip Fig 16 should be replaced if worn or damaged Blades without a car bide tip that are rounded to the midpoint of the blade tip can be reversed on the grooming shaftto extend the life of the blade Disassembly Fig 14 1 Remove grooming reel from cutting unit see G room ing Reel Removal in this section 2 Remove lock nut from either end of the shaft Fig 14 3 Remove spacers and blades from groomer shaft as necessary Assembly Fig 14 l Start by placing thick spacer against the lock nut installed on one end of groomer shaft Then place first blade against installed spacer Fig 14 IMPORTANT If groomer is equipped with blades with carbide tips make sure that blades are installed with the
115. mpression spring 2 used 8 Flange head screw 2 used 13 Grass shield 4 Shoulder bolt 2 used per side plate 9 RH side plate 14 Flat wire spring 5 Flange nut 2 used per side plate 10 Weight 15 LH pitch arm NOTE This section provides the procedure for remov NOTE Flex 2100 cutting units use shoulder bolts item ing and installing the cutting reel assembly cutting reel 4 and flange nuts item 5 to secure the side plates to flocked seals reel bearings bearing lock screw and reel the crossmember as shown in Figure 33 On Flex 1800 nut from the cutting unit R efer to Cutting Reel Assem cutting units square nuts are used instead of flange bly Service in this section for information on servicing nuts Cutting unit service procedures are the same on the cutting reel assembly both models Cutting Unit Page 7 22 Greensmaster Flex 1800 2100 Cutting Reel Assembly Removal Fig 33 NOTE Removal of the cutting reel can be completed by removing the RH side plate from the cutting unit crossmember The LH side plate including the reel drive assembly does not have to be removed from the crossmember when using the following procedure Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when removing the cutting reel 1 Park machine on a level surface Make sure the en gine is OFF and the traction lever is in NEUTRAL 2 Remove the cutting unitfrom the machine and place cu
116. n comparing the effective height of cut of one mowed surface to another This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the Turf Evaluator Toro part no 97931SL Figure 11 Greensmaster Flex 1800 2100 Page 7 7 Cutting Unit Factors That Can Affect Quality of Cut There are a number of factors that can contribute to un satisfactory quality of cut some of which may be turf conditions Turf conditions such as excessive thatch sponginess or attempting to cut off too much grass height may not always be overcome by adjusting the cutting unit It is important to remember that the lower the height of cut the more critical these factors are See Cutting Unit Operator s Manual and the Adjust ments section and Service and Repairs section of this chapter for detailed adjustment and repair information Governed engine speed Reel bearing condition Reel and bedknife sharpness Bedknife to reel adjustment Height of cut Check maximum governed engine speed Adjust engine to specifications if necessary see Adjustments section in Chapter 3 Engine Check and replace reel bearings if necessary see Cutting Reel in the Service and Repairs section of this chapter A reel and or bedknife that 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 t
117. n the OFF position Ignition spark plug wire is not connected to spark plug Traction lever is not in the NEUTRAL position An engine problem exists that prevents the engine from running ON OFF switch is faulty Electrical wires are loose or damaged Traction switch is not adjusted or is faulty Interlock module is faulty Parking brake latch is engaged Electrical wires are loose or damaged Traction switch is not adjusted or is faulty An engine problem exists that causes the engine to stop Interlock module is faulty Page5 8 Turn switch to ON Connect spark plug wire to spark plug Place traction lever in the NEUTRAL position Repair engine Replace ON OFF switch Check electrical connections Repair wiring as needed Adjust or replace traction switch Replace interlock module Disengage parking brake latch Check electrical connections Repair wiring as needed Adjust or replace traction switch Repair engine Replace interlock module Greensmaster Flex 1800 2100 Component Testing For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit e g unplug the ON OFF switch connector before doing a continuity check on switch Individual compo nents should be electrically isolated e g disconnect all leads or remove from circuit from the circuit when tested NOTE For engine component testing information r
118. nd remove drive pulley item 4 from the cutting reel shaft 10 Remove two 2 shoulder bolts item 5 that secure the RH drive plate assembly item 7 to the cutting unit frame Remove the groomer drive plate assembly from grooming shaft and cutting unit Locate and retrieve groomer shim item 8 11 Carefully pull the grooming reel from the LH support plate assembly 12 Inspect seals bushings and bearings in RH drive plate LH support plate and groomer arms for wear or damage Replace components as needed Installation Fig 7 1 Apply a light coating of grease to ends of grooming shaft and also to seal lips in drive side and support plates Make sure thatall bearings bushings and seals are properly installed 2 Make sure that O ring item 27 is installed on grooming shaft Apply light coating of grease to O ring 3 Carefully place grooming reel assembly into the LH support plate taking care to not damage seal in support plate or O ring on shaft 4 Apply light coating of grease to O ring on RH drive plate assembly pivot hub and pilot bore of cutting unit side plate 5 Position groomer shim item 8 to RH drive plate as sembly Greensmaster Flex 1800 2100 Page 8 11 Figure 8 1 Roller cap screw 2 Grooming reel assembly 3 Locknut 4 Spring washer 5 Groomer arm lift rod Figure 9 4 RH drive plate assy 5 Groomer drive belt 1 Drive pulley 2 Idler pulley 3 Driven pulley 6 Careful
119. ne orallow adults to operate it without proper instructions 3 Become familiar with the controls and know how to stop the machine and engine quickly 4 Keep allshields safety devices and decals in place Ifa shield safety device or decalis malfunctioning illeg ible or damaged repairorreplace itbefore operating the machine 5 Always wear substantial shoes Do notoperate ma chine while wearing sandals tennis shoes or sneakers Do notwearloose fitting clothing which could getcaught in moving parts and cause personal injury 6 Wearing safety glasses safety shoes long pants ear protection and a hard hat is advisable and required by some local safety and insurance regulations 7 Ensure work area is clear of objects which might be picked up and thrown by the cutting reel Safety Pagel 2 A WARNING To reduce the potential for injury or death com ply with the following safety instructions 8 Keep everyone especially children and pets away from the areas of operation 9 Since gasoline is highly flammable handle it careful ly A Use an approved gasoline container B Donotremove cap from fuel tank when engine is hot or running C Do not smoke while handling gasoline D Fill fuel tank outdoors and no higher than to the bottom of filter screen Do not overfill fuel tank E Wipe up any spilled gasoline F Fuel may leak from filler neck when mower is tilted for servicing if tank is over filled
120. ng Fig 19 Greensmaster Flex 1800 2100 Page 6 17 RT A E Donny Figure 19 3 Rear frame 4 Service locking pin 1 Kickstand 2 Torsion spring Chassis and Controls cs amp 2 22 Qe Zo So 2 Transport Wheels Optional Figure 20 1 Cap screw 3 used 6 Wheel retaining lever 10 Deep rim 2 Lock washer 3 used 7 Torsion spring 11 Inner tube 3 Shallow rim 8 Shoulder screw 2 used 12 Hub bushing 4 Tire 9 Capscrew 4 used 13 Flange nut 4 used 5 Hub Chassis and Controls Page 6 18 Greensmaster Flex 1800 2100 Wheel Removal Fig 21 1 Park machine on a level surface Make sure the en gine is OFF 2 Supportthe machine on the kickstand 3 Pivot wheel retaining lever away from the center of the wheel Slide transport wheel off the wheel hex shaft Wheel Disassembly Fig 20 1 Make sure thattire is fully deflated before disassem bly of wheel 2 Removethree 3 cap screws and lock washers from the shallow rim and hub Remove hub from deep rim 3 Inspecthub bushing item 12 If worn or damaged replace bushing 4 Remove four 4 cap screws and flange nuts from the deep rim and shallow rim R emove shallow rim from the deep rim 5 Separate tire tube and deep rim 6 Ifnecessary remove shoulderscrews torsion spring and retaining lever from the hub Wheel Assembly Fig 20 1 If shoulder screws were removed from hub apply L
121. ng R eel Forward Rotating Groomer Drug costante utis beats ty end adatti ds 10 Grooming R eel Counter Rotating Groomer Dre Mtt ode ed do ee Cad Ee 14 Grooming Reel Service sunaus 17 Grooming Reel Bearing Replacement 18 Idler Assembly Forward Rotating Groomer DM Pm ETE 20 Idler Assembly Counter Rotating Groomer Dire due td Neto trt cele sepe 22 Lift Arm Assembly 0 00 cece eee 24 Groomer BruSh sss 26 Greensmaster Flex 1800 2100 Page 8 1 Groomer Specifications MOUNTING The groomer is mounted to the cutting unit side plates GROOMING REEL CONSTRUCTION 2 375 inch 6 cm diameter 41 steel blades with 1 2 inch blade spac ing Blade spacing can be adjusted to 1 4 inch or 3 4 inch by altering the number and position of blade spacers on the groomer Grooming reel is available with either steel or carbide tipped blades The groomer brush can be installed in place of grooming reel GROOMER HEIGHT SETTING From 0 030 to 0 620 inch 0 8 to 15 7 mm atmowing HOC range of 0 060 to 0 750 inch 1 5 to 19 1 mm Groomer Page 8 2 WIDTH OF GROOMER 19 380 inches 50 3 cm HEIGHT ADJ USTMENT KNOB Allows a 0 003 inch 0 08 mm incrementof heightadjustmentfor each click of the adjuster UP DOWN FEATURE Allows grooming reel to be raised above the height depth adjustmentfor no groom ing reel action while mowing GROOMER DRIVE Both forward rotating and counter rotating groomer drive sys
122. nge nut 5 Roller shim 6 Shaftretainer 3 Slide rear roller shaft into the rear roller bracket at tached to the cutting unit Slide second rear roller brack etonto the other end of roller shaft Secure second roller bracketand shims to cutting unit side plate with two 2 carriage screws and flange nuts Do not fully tighten flange nuts 4 Center rear roller to the cutting reel and secure in place by tightening four 4 flange nuts 5 Adjust cutting unit see Cutting Unit Operator s Manual 6 Install cutting unit to machine Cutting Unit Roller Service 25 to 30 ft Ib 34 to 41 N m 6 Q 7 25 to 30 ft lb 34 to 41 N m Figure 27 1 Weihle roller 4 Ball bearing 2 Smooth roller 5 Seal 3 Roller shaft Disassembly 1 To hold roller shaft for bearing lock nut removal installa 3 8 24 UNF 2B screw into threaded end of roller shaftand secure screw in place with jam nut While re taining shaft remove bearing lock nutfrom each end of roller shaft 2 Remove V ring from each end of roller 3 Carefully inspect seating surface and threads of bearing lock nuts Replace 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 sealand bearing from roller cavity by tapping on shaft 5 Clean bearing cavity in roller and remove any rust with crocus cloth Assemb
123. nge nut item 12 that secure rear of transmission to frame C Flange head screw item 2 that secures front of transmission to frame 5 Install engine to machine see Engine Installation in the Service and Repairs section of Chapter 3 Engine 6 Install drum drive belt and RH drum drive cover to machine see Drum Drive Belt in this section 7 Slide the telescoping coupler onto the cutting unit hex shaft Fig 50 8 Connect traction clutch and reel clutch cables to transmission see Traction Clutch Cable Replacement and Reel Clutch Cable Replacementin the Service and Repairs section of Chapter 6 Chassis and Controls Ny RAS Ge ANS EN oo S Figure 50 1l Telescoping coupler 2 Cutting unit hex shaft Traction and Reel Drive System 9 cc s S S Q 1 5 _ Drive System This page is intentionally blank Traction and Reel Drive System Page 4 42 Greensmaster Flex 1800 2100 Chapter 5 TORO Electrical System Table of Contents GENERAL INFORMATION 00000ee 3 Operator s Manual lauu 3 WIRING SCHEMATIC 0 cece eee eee eee 4 WIRE HARNESS DRAWINGS ssss 5 SPECIAL TOOLS 1 eGo neve es 6 TROUBLESHOOTING 0 cece ee eee 8 Starting Problems 000s c eee e eee 8 COMPONENT TESTING 0 000 cece eee 9 Ignition System Operation 0000 9 On OTf S witch ec me 10 Parking Brake Latch Switch
124. o sharpen and or remove rifling The most common cause of rifling is bedknife to reel contact that is too tight A new bedknife must be ground or backlapped after installation to the bedbar Check bedknife to reel contact daily The bedknife must have light contact across the entire reel No contact 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 see Backlapping in the Service and Repairs section of this chapter Excessively dull cutting edges must be corrected by grinding the reel and bedknife see Preparing Reel for Grinding in the Service and Repairs section of this chapter Effective or actual height of cut depends on the mower weight and turf conditions Effective height of cut will be different than the bench set height of cut Proper bedknife for height of cut If the bedknife is too thick for effective height of cut poor quality of cut will result Number of reel blades Stability of bedbar Cutting Unit Make sure bedbar pivot bolts are securely seated see Bedbar in Service and Repairs section of this chapter Use correct number of blades for clip frequency and optimum height of cut range Page7 8 Greensmaster Flex 1800 2100 Rear roller level Reel and rear roller should be parallel for proper cutting performance see Leveling Rear Roller in Adjust
125. oating ofter minals liberally apply gel to both component and wire harness connector plug connector to component un plug connector reapply gel to both surfaces and recon nect harness connector to component Connectors should be thoroughly packed with gel for effective re sults Toro Part Number 107 0342 Electrical System Page5 6 Figure 1 Figure 2 Figure 3 Greensmaster Flex 1800 2100 Spark Tester Fortesting electronic ignitions Saves time because you will know ifthe ignition is causing the problem on a non starting engine The tester determines if ignition spark is present Toro Part Number TOR4036 Greensmaster Flex 1800 2100 Page 5 7 Figure 4 Electrical System e ot 0 gt oo 25 Ww Troubleshooting Remove all jewelry especially rings and watches before doing any electrical testing or troubleshooting Foreffective troubleshooting and repairs there mustbe a good understanding ofthe electrical circuits and com ponents used on this machine see Wiring Schematic The interlock switches must not be by passed they mustbe connected for proper electrical troubleshooting and safety NOTE For engine component testing information re fer to the Subaru Service Manual and Wire Harness Drawing sections of this chapter Starting Problems Engine will not start Engine will start but will not continue to run Electrical System ON OFF switch is i
126. octite 242 or equivalent to threads of shoulder screws Secure torsion spring and retaining leverto the hub with shoulder screws 2 Assemble tire tube and deep rim 3 Install shallow rim into the tire Align and secure shal low rim to the deep rim with four 4 cap screws and flange nuts Tighten fasteners 4 Install hub into deep rim Secure hub to deep rim with three 3 cap screws and lock washers Tighten fasten ers 5 Inflate tire from 12 to 15 PSI 83 to 103 kPa Wheel Installation Fig 21 1 Make sure machine is parked on a level surface and the engine is OFF 2 Supportthe machine on the kick stand 3 Slide transport wheel completely onto the wheel hex shaft until the wheel retaining lever is secured into the groove on the wheel hex shaft Figure 21 1 Wheel retaining lever 2 Wheel hex shaft Figure 22 1 Wheel hex shaft Greensmaster Flex 1800 2100 Page 6 19 Chassis and Controls cs amp 2 2 Qe Zo So 2 This page is intentionally blank Chassis and Controls Page 6 20 Greensmaster Flex 1800 2100 Chapter 7 Cutting Unit Table of Contents SPECIFICATIONS cc cece cece nn 3 GENERAL INFORMATION 0 00eaes 4 Operator s Manual soaua 4 Supporting Cutting Unit when Servicing 4 Separating Cutting Unit from Traction Unit 5 SPECIAL LO OES z zm ipei bere e 6 FACTORS THAT CAN AFFECT QUALITY OF CUT 8 ADJUSTMENTS sseee RH 10 Leveling Rear Rolle
127. off valve if machine is not to be used for an extended period of time Also close fuel shut off valve if machine is to be transported on a trailer orina vehicle 7 Do not overspeed the engine by changing governor settings Recommended engine high idle speed is from 3190 to 3340 RPM To ensure safety and accuracy check engine speed with a tachometer 8 Engine must be shut off and cooled down before checking oil or adding oil to the engine crankcase 9 If majorrepairs are ever needed or assistance is re quired contact your Authorized TORO Distributor 10 Atthe time of manufacture the machine conformed to all applicable safety standards To assure optimum performance and continued safety certification of the machine use genuine Toro replacement parts and ac cessories Replacement parts and accessories made by other manufacturers may result in non conformance with the safety standards and the warranty may be voided Safety S afety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located nearany area of potential dan ger Replace any decal that is damaged or lost Decal part numbers are listed in your P arts Catalog Order re placementdecals from your Authorized TORO Distribu tor Safety Pagel 4 Greensmaster Flex 1800 2100 Chapter 2 TORO Product Records and Maintenance N oD D Oo Table of Contents E c PRODUCT RECORDS er such eS 1 EE MAINTENANCE
128. om end of reel clutch shaft Discard removed bearing 3 Carefully remove retaining ring item 13 that se cures reel brake disc item 14 to reel drive hub item 18 Take care to notdamage brake disc friction material when removing retaining ring 4 Remove reel brake disc item 14 from reel drive hub noting orientation of disc for assembly purposes Fric tion material side of disc needs to be positioned toward the reel brake ring item 11 which is pressed into the transmission housing 5 Slide reel clutch hub item 17 and reel clutch fork item 16 assembly from reel drive hub item 18 Note correctorientation of indicator mark on fork forassembly purposes If necessary remove pivot pins item 15 and separate fork from hub 6 Use modified socket see S pecial Tools in this chap ter to remove bearing collar assembly from clutch shaft Fig 38 IMPORTANT To prevent damage avoid using ex cessive clamping pressure on the reel clutch shaft assembly A Use flats on reel drive hub to carefully secure reel clutch shaft assembly in a vise Use a vise with soft jaws to prevent damage to clutch shaft assembly components B Slide modified socket over bearing collar Align modified socket so that 5 32 pin can be inserted through socket and hole in bearing collar C Use modified socket and socket wrench to re move bearing collar assembly from clutch shaft Greensmaster Flex 1800 2100 Page 4 31 Figure 3
129. om the engine spark plug 2 Remove transport wheels if attached see Transport Wheels in the Service and Repairs section of Chapter 6 Chassis and Controls Traction and Reel Drive System Page 4 14 3 Rotate traction engage disengage lever to the disen gaged position to remove tension from the drum drive belt Fig 17 see Disengaging Drum Drive F rom Trans mission in the General Information section ofthis chap ter 4 Remove seven 7 washer head screws that secure the drum drive cover Remove coverto expose the trac tion drive belt 5 Remove and discard gasket item 3 from between cover and housing Greensmaster Flex 1800 2100 6 Remove retaining ring item 6 that secures brake band to brake clevis pin Slide brake band from brake clevis and brake mount pins and remove band from drum drive housing 7 Carefully remove one end of extension spring item 9 from anchor point and rotate spring away from drive belt 8 Pivotthe idler pulley away from the drum drive belt to loosen belt tension Fig 18 9 Remove drum drive belt from both pulleys Installation Fig 16 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the spark plug 2 Placedrumdrive beltonto differential pulley and then fit beltto drive pulley Make sure that belt is on rear side of idler pulley Fig 18 3 Carefully install removed end of exten
130. omer is set too aggressive ly The grooming reel blades are bent damaged or missing The grooming reel shaft is bent or damaged Grooming depth is not equal on both ends of grooming reel Page 8 5 Normal operation Identify and replace faulty bear ing s Replace idler 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 routing or seized bearings in groomer assem bly Handle needs to be rotated toward the front of the machine to engage the groomer drive Identify and replace faulty bear ing s Replace idler spring Inspect groomer drive assembly and replace damaged drive compo nents Refer to groomer Installation In structions for groomer set up infor mation Repair or replace blades if neces sary Replace grooming reel shaft Adjust depth if necessary Check and adjust cutting unit set up level bedknife to reel level rear roller to reel set height of cut etc Groomer Adjustments Never work on the cutting unit with the engine running Always stop the engine and remove spark plug wire from the engine spark plug before working on the cutting unit NOTE See the Groomer Installation Instructions for adjustment procedures for the groomer on your Greensmaster Height Depth of Groomer Adjustment NOTE Grooming is performed above the soil level When a
131. pairs Product Records and Maintenance Drive System cc s S S iS 5 _ Electrical System Chassis and Controls This page is intentionally blank Greensmaster Flex 1800 2100 Chapter 1 S afety TORO Table of Contents SAFETY INSTRUCTIONS cc cece eee 2 Before Operating 0 cece eee eee 2 While Operating 00 eee 3 Maintenance and Service sss 3 SAFETY AND INSTRUCTION DECALS 4 Greensmaster Flex 1800 2100 Pagel 1 Safety Safety Instructions Greensmaster Flex 1800 and Flex 2100 machines have been tested and certified by TORO for compliance with existing safety standards and specifications Although hazard control and accident prevention are partially de pendent upon the design and configuration of the ma chine these factors are also dependent upon the awareness concern and proper training of the person nel involved in the operation transport maintenance and storage of the machine Improper use or mainte nance ofthe machine can resultin injury or death To re duce the potential for injury or death comply with the following safety instructions Before Operating 1 Operate the machine only afterreviewing and under standing the contents ofthe Operator s Manualand Op erator Training DVD A replacement O perator s Manual is available on the internet at www toro com 2 Neverallow children to operate the machi
132. pter 3 En gine 3 Usetips of needle nose pliers to spread ends of drive shaft wire item 7 in telescoping coupler item 8 With wire ends spread slide couplerfrom transmission shaft Traction and Reel Drive System Drive shaft wire Telescoping coupler Washer head screw 2 used Page 4 26 10 Coupler guard 11 Coupler 12 Set screw 2 used 13 Washer head screw 7 used 4 Remove coupler guard item 10 from transmission 5 Loosen two 2 setscrews item 12 thatsecure cou pler item 11 to transmission shaft Slide coupler from transmission shaft Locate and retrieve key item 6 IMPORTANT During disassembly make sure that tension is released from transmission belt before removing transmission cover 6 Remove tension on transmission belt by rotating the engage disengage shaft clockwise see Transmission Belt Tensioner in the General Information section of this chapter 7 Remove seven 7 washer head screws that secure transmission cover to transmission Carefully remove cover from transmission Remove and discard gasket item 3 Greensmaster Flex 1800 2100 8 Make sure that wave washer item 4 is pressed into reel drive shaft bore of transmission cover 9 Note transmission belt routing for assembly pur poses Fig 32 10 Remove transmission belt from drive and idler pul leys in transmission 11 Check condition of all pulleys and idler components 12 Clean inside of transmission b
133. r 0c eee eae 10 SERVICE AND REPAIRS cceceeeeeeeee 11 Backlapping iure cem ht hace te eh ade 11 Bedbar Assembly 0 cece eee eee 12 Bedknife Service cc cece eee ees 14 Bedbar Adjuster Service cece cece aee 16 FONUROMEr sari agin Wa eek a ate tenes 18 Rear Roller ccc cece cece eee eas 19 Roller Service sess 20 Cutting Reel Assembly Removal and Installation reete exer Rn eae ees 22 Cutting Reel Assembly Service 26 Preparing Reel for Grinding 28 NOTE This chapter includes service information for Flex 1800 and 2100 cutting units with serial number above 312000000 If an older production Flex 21 cutting unit serial number below 312000000 has been in stalled on a Flex 2100 traction unit use information from the appropriate Flex 21 service manual when servicing that cutting unit Greensmaster Flex 1800 2100 Page7 1 Cutting Unit This page is intentionally blank Cutting Unit Page 7 2 Greensmaster Flex 1800 2100 Specifications REEL CONSTRUCTION 5 inch 12 7 cm diameter 11 or 14 carbon steel blades welded to 5 stamped steel spiders High strength low alloy steel blades are thru hardened and impact resistant FRAME CONSTRUCTION Precision machined die castaluminum cross member with two bolt on die cast aluminum side plates HEIGHT OF CUT Cutting height is adjusted on the front roller by two vertical screws and held by
134. r outer sur face of coupler e g grasping with pliers or mount ing in vise as coupler may be damaged and fail prematurely 5 Supportflex coupler item 12 to preventitfrom being damaged during spring pin removal Push spring pin from flex coupler and reel inputshaft Slide coupler from shaft and discard spring pin 6 Remove retaining ring item 9 from shaft Then re move flat washer item 8 wave spring item 7 and flocked bearing shield item 6 from shaft Note orienta tion of flocked shield for assembly purposes 7 Press bearings and bearing spacer from shaftif nec essary Discard bearings if removed 8 Clean all bearing housing components Greensmaster Flex 1800 2100 Page 4 13 Assembly Fig 15 1 Ifbearings were removed from reel inputshaft install new bearings onto shaft Press first bearing fully onto shaft Position spacer on shaft and then press second bearing onto shaft 2 Install flocked bearing shield item 6 wave spring item 7 and then flat washer item 8 onto reel input shaft Secure components to shaft with retaining ring item 9 It may be necessary to drive the retaining ring onto the input shaft with a tubular tool and mallet Make sure that retaining ring is fully seated into shaft groove after installation 3 Place wave washer item 5 into bearing housing 4 Fill cavity between bearings with Mobil High Temper ature XHP 222 grease or equivalent 5 Install reel inputshaf
135. r 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 Groomer Page 8 4 8 The amount of time thata grooming reel has been in use on a particular turf area 9 The amount of traffic on the turf 10 The overall turf management program e g irriga tion fertilizing weed control coring overseeding dis ease control sand dressing and pest control 11 Stress periods for turf e g high temperatures high humidity unusually high traffic Greensmaster Flex 1800 2100 Grooming Reel Mechanical Problems The grooming reel rotates when itis The grooming reel should rotate in the raised transport position for ward rotating groomer drive No rotation of the grooming reel forward rotating groomer drive No rotation of the grooming reel counter rotating groomer drive The turf is damaged or has uneven grooming Greensmaster Flex 1800 2100 whenever the cutting reel is en gaged Seized grooming reel or idler bear ing s in groomer side plate s Broken or damaged drive belt idler spring The groomer drive belt is worn bro ken or damaged Handle on groomer cover is rotated rearward so that groomer drive is disengaged Seized grooming reel or idler bear ing s in groomer side plate s Broken or damaged drive idler spring Groomer drive gears are worn or damaged The gro
136. re in the housing 7 Service the reel clutch shaft assembly as needed see Transmission Reel Drive System in this section Make sure that new ball bearing is installed on reel clutch shaft 8 Install reel clutch shaft assembly into transmission housing and assemble transmission see Transmission Reel Drive System in this section Greensmaster Flex 1800 2100 Page 4 33 Figure 39 1 Reel clutch shaft 3 Housing bearing bore 2 Ball bearing Figure 40 1 Transmission housing 2 Housing dimple Traction and Reel Drive System o cc s c c 2 c k Drive System Transmission Clutch System 15 to 17 ft lb 21 to 23 N m See text for tightening procedure N See text for tightening procedure Figure 41 1 Clutch housing 10 Flocked bearing shield 18 Bellcrank lever 2 Flange head screw 5 used 11 Wave spring 19 Bellcrank rod assembly 3 Grommet 12 Flat washer 20 Clevis pin 4 Hardened washer 13 Retaining ring 21 Cotter pin 5 Clutch assembly 14 Flange nut 22 Flange nut 6 Clutch shaft 15 Washer head screw 7 used 23 Cap screw 7 Ball bearing 16 Cable bracket 24 Shoulder screw 8 Drive pulley 17 Flange bushing 2 used 25 Traction clutch cable 9 Ball bearing Transmission removal from the machine is not neces sary to service the transmission clutch system Trans mission clutch components can be accessed by removing the engine from the frame removing the tran
137. rk plug wire to spark plug Figure 25 1 Drum drive housing 2 Spur gear assembly 70 to 80 ft Ib 95 to 108 N m Figure 26 1 Spurgear 2 Ball bearing 3 Hexshaft LH threads 4 Flange bushing Traction and Reel Drive System cc s S z iS o A Drive System Differential Assembly Service 99 to 121 in Ib 11 2 to 13 6 N m Figure 27 1 Housing 4 Gear pin 6 used 2 Cover 5 Dual spur gear 6 used 3 Ball bearing 2 used Disassembly Fig 27 1 Remove differential assembly from machine see Differential Assembly in this section 2 Remove six 6 sockethead screws thatsecure cov erto housing Note alignmentofindex marks on housing and cover for assembly purposes Fig 28 3 Place differential assembly on workbench so thatthe differential is resting on the cover with housing orientat ed up 4 Lifthousing from differential assembly leaving inter nal components positioned on cover Forassembly pur poses note that index mark on housing is aligned with a gear pin that has one 1 gear Fig 30 5 Note locations of projections on inside of cover for assembly purposes The projections need to be aligned with the gear pins that have one 1 gear Fig 29 Traction and Reel Drive System 6 Spacer 9 used Page 4 24 7 Spur gear 3 used 8 Socket head screw 6 used 6 Slide each gearpin with gears and spacers from cov er Note location o
138. rque lock nutfrom 17 to 21 ft Ib 24 to 28 N m NOTE To preventcutting reel from turning when instal ling groomer drive gear item 17 use a 1 2 socket on hex of reel drive shaft that is used for backlapping the cutting reel 7 Secure groomer drive gear item 17 to cutting reel shaft Torque gear to 125 ft Ib 170 N m 8 Install the two 2 idler gears 43T and 47T to RH drive plate assembly Fig 12 Secure gears with flange nuts and torque flange nuts 120 in Ib 13 5 N m 9 Install extension spring to RH drive plate assembly Fig 11 Groomer Page 8 16 10 Insert front roller into LH groomer arm assembly 11 Make sure that bushing item 3 is installed in RH drive plate assembly 12 Apply antiseize lubricant to threads of RH groomer arm lift rod 13 Position RH groomer arm assembly to front roller RH drive plate and cutting unit frame Secure groomer arm to cutting unitwith plow bolt item 35 HOC washer item 9 and HOC nut item 2 14 Secure RH groomerarm assembly to drive plate with spring washer item 4 and lock nut item 5 15 Center front roller to cutting unit and tighten cap screws item 7 to secure roller 16 F ill groomer cover with approximately five 5 ounces 142 grams of Mobil XHP221 grease or equivalent Install new gasket and then groomer cover assembly to RH drive plate see Groomer Cover Counter R otating Groomer Drive in this section 17 Check grooming reel height and
139. s threads coated with a lubricant such as engine oil or thread sealant such as Loctite Product Records and Maintenance Page 2 4 SAE Grade 8 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J 995 Grade 5 or Stronger Nuts SAE Grade 5 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J 995 Grade 2 or Stronger Nuts 169 23 262 34 192 23 282 34 328 34 463 56 350 45 486 56 475 56 678 68 542 56 768 79 o o B A co o w Der I I I I M o Ui Ui 100 10 1130 113 140 15 160 17 300 30 325 33 1582 169 115 12 1299 136 1808 192 200 25 2260 282 3390 339 225 25 2542 282 3672 373 95 9 104 11 5 6 7 102 11 142 15 600 60 667 66 NOTE The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75 of the mini mum proof load specified in SAE J 429 The tolerance is approximately 10 of the nominal torque value Thin height nuts include jam nuts 77 8 115 12 163 16 150 15 203 20 285 28 170 18 230 24 325 33 265 27 359 37 508 52 300 30 407 41 569 58 430 45 583 61 813 81 c ul oco oco oco N N co A A ul co N n i fie Jit oco N ul A2 475 48 644 65 904 89 Greensmaster Flex 1800 2100 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Regular Height Nuts Thread Size M5 X 0 8 57 6 in Ib 96 10 in Ib Class 8 8 Bolts Screws and Stu
140. sion spring item 9 to anchor point Figure 17 4 Install brake band over brake surface of differential Li Engaged position ay Disengaged positon pulley Slide ends of brake band onto brake clevis and brake mountpins Secure brake band to brake clevis pin with retaining ring item 6 s s S S Q o A Drive System 5 Make sure that wave washer item 4 is pressed into bore of drum drive cover 6 Position new gasket item 3 to housing surface 7 Slide drum drive cover onto drum drive assembly 8 Install seven 7 washer head screws to secure cov er to housing Tighten screws as follows A First using an alternating crossing pattern torque all screws from 15 to 40 in Ib 1 7 to 4 5 N m Figure 18 B Again using an alternating crossing pattern 1 Traction drive belt 4 Differential pulley torque all screws from 85 to 95 in Ib 9 6 to 10 7 2 Drive pulley 5 Brake band N m 3 Idler pulley 9 Rotate traction engage disengage lever to the en gaged position to tension the drum drive belt Fig 17 10 Install transport wheels if they were attached see Transport Wheels in the Service and Repairs section of Chapter 6 Chassis and Controls 11 Connect spark plug wire to spark plug Greensmaster Flex 1800 2100 Page 4 15 Traction and Reel Drive System Drum Drive Idler Assembly See text for tightening procedure DEA 15 to 17 ft lb 21 to 23 N m Fig
141. smaster Flex 1800 2100 Page 7 13 6 Position one 1 metal washer item 17 and one 1 plastic washer item 16 between bedbar and each cut ting unitside plate Fig 17 7 Install the bedbar pivot bolt assemblies Make sure thatplastic washers are notcaughton the threads ofthe pivot bolts Torque each bedbar pivot bolt from 190 to 240 in Ib 22 to 27 N m 8 Tighten both lock nuts item 10 until outside wash ers do nothave any endplay but still can be rotated Do notover tighten the lock nuts as this can distortthe side plates and affectreel bearing adjustment When the lock nutis correctly tightened there may be a gap atthe in side washers 9 Tighten the lock nut item 13 on each bedbar adjust er assembly until the adjuster spring is fully com pressed then loosen lock nut 1 2 turn 10 Adjust cutting unit see Cutting Unit Operator s Manual 11 Install cutting unitto machine N Antiseize Lubricant Figure 17 1 Cutting unit sideplate 5 Metal washer 2 Rubber bushing 6 Bedbar 3 Nylon bushing 7 Bedbar pivot bolt 4 Plastic washer 8 Lock nut Cutting Unit Bedknife Service Antiseize Lubricant 200 to 250 in Ib Flex 2100 Shown Lightly Oil Bedbar Surface 23 to 28 N m 1 Figure 18 1 Screw 2 Bedbar Bedknife Removal Fig 18 1 Remove bedbar from cutting unit see Bedb
142. smission cover and then removing the drive belt Disassembly Fig 41 1 Park machine on a level surface Make sure engine is OFF 2 Remove transmission drive belt see Transmission Drive Belt in this section Traction and Reel Drive System Page 4 34 3 Remove flange nut item 14 and cap screw item 23 thatsecure bellcrank rod assembly item 19 to clutch le ver Separate rod from clutch lever 4 Support clutch housing to prevent it from falling 5 Remove four 4 washer head screws item 15 that secure clutch housing to transmission housing 6 Removeentire clutch assembly including items 1 5 6 and 8 from transmission housing Greensmaster Flex 1800 2100 7 Remove three 3 flange head screws item 2 that secure clutch housing to clutch assembly Remove clutch housing from clutch 8 Remove flange head screw item 2 and washer item 4 that secure clutch to clutch shaft 9 Remove three 3 washer head screws that secure drive pulley to clutch Slide clutch from clutch shaft 10 If necessary remove drive pulley item 8 from clutch shaft A Remove retaining ring item 13 flat washer item 12 wave spring item 11 and flocked bearing shield item 10 from clutch shaft Note orientation of flocked shield for assembly purposes B Use bearing puller to remove outer ball bearing item 9 from clutch shaft Discard bearing C Slide drive pulley item 8 from clutch shaft D If necessary r
143. socket wrench to loosen or tighten bearing collar Figure 6 1 Modified socket 3 Pin 2 Reel clutch shaft assy Greensmaster Flex 1800 2100 Page4 5 Traction and Reel Drive System Adjustments Cutting Unit Clip Adjustment Cutting unit clip adjustment on the Flex 1800 and Flex 2100 can be changed by installing the cutting unit drive 60 to 65 in Ib pulleys to the appropriate locations on the reel drive as Antiseize 6 8 to 7 3 N m sembly Clip frequency pulley locations for 11 blade and Lubricant 14 blade cutting units are shown in Figure 8 below To adjust clip frequency follow the following steps 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the engine spark plug 2 Removereeldrive coverand reel drive beltfrom side of cutting unit see Reel Drive Beltin the Service and Re pairs section of this chapter 3 Loosen two 2 setscrews from drive pulleys thatare to be removed Slide pulleys from shafts 4 Apply antiseize lubricantto top of woodruff keys Ar range pulleys on reel drive assembly as needed for de Figure 7 sired clip frequency Fig 8 1 Reel drive cover 4 Setscrew 2 Reel drive belt 5 Woodruff key 5 Secure all pulleys with two 2 set screws Torque 3 Pulley screws from 60 to 65 in Ib 6 8 to 7 3 N m 6 Install reel drive belt and reel drive cover to cutting unit see Reel Drive Beltin the Service and Repairs sec tion of this chapter 7
144. spected for wear or damage and re placed if needed 8 Ballbearing item 14 thatsupports long spur gearis pressed into drum drive housing Make sure that bear ing is in good condition and is pressed fully to shoulder of housing Assembly Fig 24 1 If long spur gear item 8 was removed from drum drive housing slide gear into ball bearing in drive hous ing 2 If spur gear assembly Fig 26 was taken apart as semble as necessary A Press new ball bearing fully onto spur gear if re moved B Press new flange bushing into spur gear if re moved C Ifthe hex shaft was removed from the spur gear apply Loctite 242 or equivalent to threads of hex shaft Install hex shaft left hand threads into spur gear and torque from 70to 80 ft Ib 95 to 108 N m 3 Make sure that differential housing cavity is packed 2096 to 3096 full of high temperature Mobil XHP 222 grease or equivalent Slide differential assembly into drum drive housing item 1 and onto long spur gear item 8 Make sure thatspur gear properly engages dif ferential gears Greensmaster Flex 1800 2100 Page 4 23 4 Place thrust washer item 29 onto drum shaft item 7 Insert drum shaft into differential assembly Make sure thatdrum shaftproperly engages differential gears 5 Install traction drums to machine see Traction Drums in this section 6 Install drum drive beltfrom machine see Drum Drive Belt in this section 7 Connect spa
145. ssmember Remove pitch arm item 7 and compression spring item 3 from RH side plate Greensmaster Flex 1800 2100 Page 7 23 9 Carefully slide the cutting reel assembly with flocked seals reel bearings bearing lock screw and reel drive shaft from the LH side plate Locate and remove flat wire spring item 14 Figure 34 1 Reel drive cover 3 Reel pulley 2 Belt 90 to 110 ft Ib 5 7 123to 149 N m Right Hand Threads 90 to 110 ft Ib 123 to 149 N m Left Hand Threads Use this 1 hex surface when removing or installing reel drive shaft d Figure 35 4 Reel drive shaft 5 Bearing lock screw 6 Reel groove location 1 Cutting reel 2 Flocked seal 2 used 3 Bearing 2 used Cutting Unit Cutting Reel Assembly Installation Fig 33 1 Thoroughly clean side plates and other cutting unit components Inspect side plates and pitch arms for wear or damage and replace components if needed 2 Make sure thatflocked seals reel bearings bearing lock screw and reel drive shaft are properly positioned on cutting reel see Reel Assembly Service in this sec tion Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when installing the cutting reel 3 Position the cutting uniton a flatwork area The roll ers bedbar and cutting unit crossmember should be at tached to LH side plate Make sure that pitch arm item 15 and
146. tall shims item 3 and new ball bearing into mounting plate item 5 P osition shims in same location as noted during disassembly Secure assembly with re taining ring 8 Press mounting plate item 5 assembly onto hub and secure with retaining ring item 1 Greensmaster Flex 1800 2100 Page 4 37 9 After clutch assembly measure clearance between thrust friction assembly and mounting plate Fig 46 Clearance should be from 0 025 to 0 045 0 7 to 1 1 mm If necessary remove mounting plate item 5 in Fig 46 assembly and change shim locations item 6 in Fig 46 to adjust clearance Moving shims from outside the bearing to inside the bearing decreases clearance Moving shims from inside the bearing to outside the bearing increases clearance 10 New Clutch Assembly 22 Worn Clutch Assembly iu NN A Figure 45 0 025 to 0 045 0 7 to 1 1 mm 4 1 5 Figure 46 1 Hub 2 Fixed housing 3 Rotating housing 4 Thrustfriction assy 5 Mounting plate 6 Shim locations Traction and Reel Drive System cc s S S iS i o A Drive System Transmission
147. tandard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Fasteners Grade1 5 amp 8 with Thin Height Nuts SAE Grade 1 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J 995 Grade 2 or Stronger Nuts Thread Size co Ui uw w B B w N m m oi Ui a1 eo a1 eo N pen M Ui I I I I I I I I I I I wo co o Ui gt uw Ui gt w N N 6 32 UNC 147 23 6 40 UNF 8 32 UNC 282 30 8 36 UNF 10 24 UNC 339 56 10 32 UNF 1 4 20 UNC 48 7 599 79 1 4 28 UNF 5347 734 113 5 16 18 UNC 115 15 105 15 1186 169 5 16 24 UNF 138 17 128 17 1446 192 3 8 16 UNC 3 8 24 UNF 7 16 14UNC 27 3 7 16 20 UNF 29 3 1 2 13 UNC 30 3 1 2 20 UNF 32 4 5 8 11 UNC 119 16 5 8 18 UNF 75 10 129 20 3 4 10 UNC 93 12 140 20 190 27 3 4 16 UNF 115 15 165 25 224 34 7 8 9 UNC 140 20 225 25 305 34 cea au mer bud scc 3 aw M o w w N N N a o M gt N I I I I I I wo wo gt gt w w 13 2 65 10 88 12 95 15 7 8 14 UNF 155 25 260 30 353 41 NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material strength length of thread engagement etc NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined a
148. tassembly into bearing housing and secure with retaining ring item 1 IMPORTANT When installing flex coupler item 12 onto reel input shaft item 2 do not mar outer sur face of coupler e g grasping with pliers or mount ing in vise as coupler may be damaged and fail prematurely 6 Slide flex coupler onto reel inputshaft support cou pler to preventit from being damaged during spring pin installation Install new spring pin into couplerto secure it to shaft 7 Install reel drive bearing housing to reel drive hous ing see Reel Drive Assembly in this section 8 Connect spark plug wire to spark plug Traction and Reel Drive System r a s S S Q 5 Drive System Drum Drive Belt See text for tightening procedure DEA 15 to 17 ft lb 21 to 23 N m Figure 16 1 Drum drive cover 7 Brake band 13 Retaining ring 2 Washer head screw 7 used 8 Brake mount pin 14 Idler pulley assembly 3 Gasket 9 Extension spring 15 Shoulder screw 4 Wave washer 10 Drum drive belt 16 Idler arm assembly 5 Gear assembly 11 Brake clevis pin 17 Washer head screw 4 used 6 Retaining ring 12 Drum drive housing 18 Drive pulley from transmission The drum drive system on Flex 1800 and Flex 2100 ma chines uses a multi ribbed poly V drive belton the right side of the traction drum Removal Fig 16 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire fr
149. tems are availableforthe Flex 1800 and 2100 The groomer drive assembly is at tached to the right side of the cutting unit Greensmaster Flex 1800 2100 General Information Installation Instructions The Installation Instructions for the groomer provide in formation regarding the operation general mainte nance procedures and maintenance intervals for the groomer assembly on your Greensmaster Flex ma chine R eferto this publication for additional information when servicing the groomer assembly Greensmaster Flex 1800 2100 Page 8 3 Groomer Troubleshooting Factors Affecting Grooming There are a number of factors thatcan affectthe perfor mance of grooming These factors vary for different golf courses and from green to green It is important to in spect the turf frequently and vary the grooming practice with turf needs Itis important to remember that factors affecting quality of cut also affect grooming performance IMPORTANT Improper or overaggressive use of the grooming reel such as too deep or frequent grooming may cause unnecessary stress on the turf leading to severe turf damage Use the groomer carefully READ AND UNDERSTAND THE INSTAL LATION INSTRUCTIONS BEFORE OPERATING OR TESTING GROOMER 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 cut tings pe
150. that secure switch mount bracket and shift mount to shifter bracket Separate brackets to allow disassembly of lever assembly Figure 15 1 Traction switch 7 Screw 4 used 8 Dis ble bl 2 Traction lever assembly 8 Switch mount bracket assemble lever assembly as necessary using 3 Lower handle 9 Shifter bracket Figures 14 and 15 as guides Note orientation of end 4 Flange screw 4 used 10 Shift mount hooks on all springs for assembly purposes 5 Flange nut 4 used 11 Spring 6 Console cover Assembly 1 Assemble lever assembly using Figures 14 and 15 as guides A Ifshiftarm link item 4 in Figure 14 was removed from transport lever make sure thattab on shift arm link is positioned toward solid end of latch pin Fig 16 Chassis and Controls NOTE One of the mounting holes in both the switch mount bracket and shift mount is elongated to allow for adjustment of clearance between transport lever item 16 in Figure 14 and reel shift lever item 17 in Figure 14 2 Secure switch mountbracketand shiftmountto shift er bracket with two 2 flange head screws and flange nuts Before fully tightening fasteners position legs of shifter bracket to allow 0 040 1 0 mm clearance be tween transport lever and reel shift lever Fig 17 Figure 16 3 Position lever assembly including lever assembly 2 e Ar shifter bracket shiftmountand switch mount bracket to handle Secure assembly in place with four 4 fl
151. the handle adjusted to the maximum height 3 Attach reel clutch traction clutch and brake cables to transmission see Cable Replacement in this section Check cable operation and adjust if necessary 4 Attach throttle cable to engine see Throttle Cable Replacement in this section Check cable operation and adjust if necessary 5 Attach wire harness connections to electrical com ponents on handle 6 Secure console cover to handle assembly 7 Attach spark plug wire to spark plug Greensmaster Flex 1800 2100 SLO OUR WN MOOR WN Page 6 5 Flex 2100 Figure 2 Handle 8 Handle retainer Offset handle clamp 9 Hair pin Carriage screw 10 Side plate LH shown Carriage screw 11 Flange nut Shoulder bolt 12 Flange nut Bushing 13 Handle clamp Rubber bumper Flex 1800 Chassis and Figure 3 Handle 8 Handle retainer Offset handle clamp 9 Hair pin Carriage screw 10 Side plate LH shown Carriage screw 11 Flange nut Shoulder bolt 12 Flange nut Bushing 13 Handle clamp Rubber bumper Chassis and Controls Controls Throttle Cable Replacement Removal 1 Park machine on a level surface Make sure the en gine is OFF and the traction lever is in NEUTRAL 2 Removethrottle cable from the engine governor link age Fig 4 A Loosen screw thatsecures cable clamp to engine bracket Remove cable from clamp B Loosen screw that secures throttle cable to gov ernor lever Slide cable from gov
152. top machine and wipe any ex cess grease from groomer shaft and seals Figure 22 1 LH support plate 3 Seal 2 Bearing 4 Plug Figure 23 1 Outer bearing 5 Seal lip 2 Drive plate shoulder 6 Support plate bearing 3 Inner bearing 7 Drive plate RH side 4 Inner race 8 Support plate LH side Greensmaster Flex 1800 2100 Page 8 19 Groomer Idler Assembly Forward Rotating Groomer Drive Figure 24 1 Pivothub 5 RH drive plate 9 Bearing 2 used 2 Spacer 6 O ring 10 Retaining ring 3 Idler bracket 7 Retaining ring 11 Idler pulley 4 Spacer 8 Grease fitting 12 Lock nut Groomer Page 8 20 Greensmaster Flex 1800 2100 The groomer RH drive plate assembly incorporates the idler system for tensioning the groomer drive belt The idler system uses a spring to maintain proper belt ten sion Removal 1 Position machine on a clean and level surface with engine stopped Engage parking brake 2 Remove groomer belt cover drive belt and drive pulley from groomer drive side of mower see Grooming Reel Removal in this section 3 Using Figures 24 and 25 as guides remove idler bracket idler pulley and or idler bearings as needed Installation 1 Assemble components using Figures 24 and 25 as guides NOTE When properly installed the idler pulley should move fre
153. traction drum to keep drum from turning 12 Remove O ring item 30 pin item 28 and lock col lar item 27 from drum shaft 13 While retaining remaining drum loosen and remove jam nut item 11 from long spur gear 14 Remove RH traction drum item 10 from machine Locate and retrieve square key from spur gear NOTE If removal of the drum shaft item 7 long spur gear item 8 or differential assembly Item 9 is neces sary see Differential Assembly in this section Traction Drum Installation Fig 21 1 Make sure that drum shaft item 7 long spur gear item 8 and differential assembly Item 9 are installed to drum drive housing refer to Differential Assembly in this section 2 Install LH hex shaft item 16 and ball bearing item 14 to bearing nut item 15 ifthey were removed Press bearing fully onto bearing nut Torque hex shaft from 70 to 80 ft Ib 95 to 108 N m 3 Place square key item 6 into slot of long spur gear item 8 Apply antiseize lubricant to top surface of key Greensmaster Flex 1800 2100 Page 4 19 Figure 22 1 Kickstand 7 LH side plate 2 Rear frame 8 Flange screw 3 used 3 Flange nut 9 Counterweight 4 Hardened washer 10 Offset handle clamp 5 Frame 11 Handle clamp 6 Carriage screw 0 470 to 0 530 12 0 to 13 4 mm Figure 23 1 LH traction drum 2 Grease seal 4 Ali
154. tting unit clip adjustment on the Flex 1800 and Flex 2100 is adjusted by installing the cutting unit drive pulleys items 8 11 and 14 to the appropriate loca tions on the reel drive assembly see Cutting Unit Clip Adjustment in the Adjustments section of this chapter Traction and Reel Drive System Page 4 10 Antiseize Lubricant 60 to 65 in Ib 6 8 to 7 3 N m 20 Shoulder bolt 21 Spring pin 22 Woodruff key 3 used 23 Setscrew 2 used per pulley 24 Ball bearing 2 used 25 Spacer 26 Push nut 27 Cutting unit 28 Flange head screw Greensmaster Flex 1800 2100 Reel Drive Assembly Removal Fig 13 1 Park mower on a level surface Make sure engine is OFF Remove spark plug wire from the engine spark plug 2 Slide the telescoping coupler off the cutting unit hex shaft Fig 14 3 Remove reel drive belt see R eel Drive BeltReplace ment in this section 4 Loosen two 2 setscrews item 23 thatsecure reel pulley item 8 to reel drive shaft item 7 Slide pulley from drive shaft Locate and retrieve woodruff key item 22 from shaft 5 Remove washer head screw item 4 that secures reel drive housing to cutting unit side plate NOTE Hex nuts item 6 have adhesive applied during cutting unit production The nuts should remain in cut ting unit side plate during reel drive housing removal 6 Remove two 2 flange head screws item 5 that se cure reel drive housing to cutting unit sid
155. tting unit on a flat work area 3 Remove reel drive cover and belt from reel drive as sembly Then remove reel pulley from reel drive shaft Referto Reel Drive Assembly inthe Service and Repairs section of Chapter 4 Traction and Reel Drive System for procedure to remove these components IMPORTANT If reel drive shaft item 4 in Fig 35 is to be loosened use appropriate wrench or socket on 1 hex surface of shaft Do notuse 1 2 extension on end of reel drive shaft when loosening ortighten ing drive shaft The 1 2 hex is intended for backlap ping only 4 If bearings or seals are to be removed from cutting reel puta block of wood between the cutting reel blades to prevent the reel from rotating Loosen bearing lock screw RH threads and reel drive shaft LH threads to allow easier removal after reel assembly is removed from cutting unit Fig 35 5 Remove the bedbar pivot boltand washers from the RH side plate Note location of plastic and steel washers for assembly purposes see Bedbar Removal in this section 6 Loosen fasteners thatsecure frontand rear rollers to RH side plate see FrontRoller Removal and Rear R oll er Removal in this section 7 Support cutting reel to prevent it from shifting or fal ling 8 Remove shoulder bolts item 4 and flange nuts item 5 thatsecure the RH side plate to the cutting unitcross member Remove the RH side plate from the reel shaft rollers bedbar and cutting unit cro
156. ure 19 1 Drum drive cover 7 Brake band 13 Retaining ring 2 Washer head screw 7 used 8 Brake mount pin 14 Idler pulley assembly 3 Gasket 9 Extension spring 15 Shoulder screw 4 Wave washer 10 Drum drive belt 16 Idler arm assembly 5 Gear assembly 11 Brake clevis pin 17 Washer head screw 4 used 6 Retaining ring 12 Drum drive housing 18 Drive pulley from transmission Removal 4 Remove seven 7 washer head screws that secure 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the engine spark plug 2 Remove transport wheels if attached see Transport Wheels in the Service and Repairs section of Chapter 6 Chassis and Controls 3 Rotatetraction engage disengage leverto the disen gaged position to remove tension from the drum drive belt see Disengaging Drum Drive From Transmission in the General Information section of this chapter Traction and Reel Drive System Page 4 16 the drum drive cover Remove coverto expose the drum drive system 5 Remove and discard gasket item 3 from between cover and housing 6 Carefully remove the end of the extension spring item 9 from idler arm 7 Remove shoulder screw item 15 that secures the idler arm assembly to the drum drive housing Remove idler arm assembly from housing Greensmaster Flex 1800 2100 8 Disassemble idler arm assembly as needed Fig 20 Replace worn or damaged bearings and bushings A Remove
157. us terminals for each switch position The switch terminals are marked as shown in Figure 6 The circuitry of the on off switch is shown in the chart below Verify continuity between switch terminals SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS Figure 5 1 On Off switch 4 Console cover OFF 2 1 5 4 Z Switchpand escrow used ONS 5e se Be spo ee 5 Replace switch if necessary 6 When switch testing is complete connect wire har ness electrical connector to the on off switch 7 Install console cover to handle BACK OF SWITCH Figure 6 NOTE On Off switch terminals 3 4 5 and 6 are not used on Greensmaster Flex 1800 and Flex 2100 ma chines Electrical System Page 5 10 Greensmaster Flex 1800 2100 Parking Brake Latch Switch Switch Adjustment 1 Make sure the engine is OFF and the traction lever is in the NEUTRAL position 2 Remove console cover from handle to allow access to parking brake latch switch Fig 8 3 Engage the parking brake lever and engage the parking brake latch 4 With the parking brake latch applied there should be from 0 030 to 0 090 0 8 to 2 3 mm clearance between the parking brake latch and the parking brake latch switch Fig 7 5 If clearance is incorrect loosen brake latch switch mounting fasteners adjust clearance and tighten fas teners Recheck clearance between l
158. y five 5 ounces 142 grams of Mobil XHP 221 grease or equivalent Install new gasket and then groomer cover assembly to RH drive plate see Groomer Cover Counter Rotating Groomer Drive in this section 7 Check and adjust grooming reel height and mower height of cut settings Figure 28 1 Idler bracket 4 Idler bearing location 2 Idler bracket stop 5 Plate bearing location 3 Adjustment cam 2 __ 120in Ib 13 5 N m Figure 29 1 RH drive plate assy 3 43T idler gear bearing 2 Flange nut 4 47T idler gear bearing Greensmaster Flex 1800 2100 Page 8 23 Groomer Lift Arm Assembly EN Antiseize m d Lubricant c Antiseize 77 A Lubricant Antiseize Be Lubricant Figure 30 1 HOC groomer arm LH shown 7 Bushing 13 Wave washer 2 Flange nut 8 Liftarm assembly LH shown 14 Groomer adjuster 3 Grooved pin 9 Detent spring 15 Groomer plate LH shown 4 E ring 10 Spring washer 16 Lock nut 5 Groomer lift rod 11 Cap screw 17 Spring washer 6 Lock screw 12 Bushing 18 Bushing Groomer Page 8 24 Greensmaster Flex 1800 2100 Disassembly Fig 30 1 Position machine on a clean and level surface with engine stopped Engage parking brake 2 Remove flange nut item 2 that secures lift arm to HOC groomer arm Remove lock nut item 16 and spring washer item 17 that secure lift arm to groomer plate Loosen lock screw item 6 completely 3 Remove lift arm from cuttin
159. y removed from transmission housing due to bearing seizure the following procedure can be followed to remove the reel clutch shaft assembly 1 Make sure that transmission drive belt and reel clutch lever are removed from housing see Transmis sion Drive Beltand Transmission Reel Drive System in this section 2 Carefully drill two 2 No 7 0 201 diameter holes in the transmission housing using the dimples in the housing as centers for the holes Fig 40 Holes should be drilled completely through the housing allowing ex ternal access to the ball bearing on the reel shaft 3 Use a 3 16 punch through the drilled holes to care fully drive the bearing and reel clutch shaft from the transmission housing IMPORTANT Ball bearing will be damaged during this procedure Remove ball bearing from reel clutch shaft and discard bearing after shaft has been removed from housing see Transmission Reel Drive System in this section for bearing remov al information 4 Clean and inspect bearing bore in housing If dam age is severe in housing replace transmission housing 5 Usea 1 4 20 UNC tap to install threads in the two 2 holes drilled in the transmission housing 6 Install two 2 1 4 20 cap screws with flat washers into tapped holes in the transmission housing Cap screws no longer than 3 8 in length should be used Af ter screw installation make sure that the ends of the screws DO NOT extend into the ball bearing bo
160. y secure reel clutch shaft assembly in a vise Use a vise with soft jaws to prevent damage to clutch shaft assembly components B Use modified socket 5 32 pin and socket wrench to install bearing collar assembly to clutch shaft Torque bearing collarfrom 23 to 27 ft Ib 32 to 36 N m 5 Install flocked bearing shield item 24 flocked side orientated toward bearing location wave spring item 25 flat washer item 26 and retaining ring item 27 onto bearing collar 6 If reel clutch fork item 16 was separated from reel clutch hub item 17 clutch pivot pins item 15 should either be replaced new pins have patchlock on threads or have Loctite 242 or equivalent applied to threads before installation Secure fork to clutch hub with two 2 pivot pins 7 Slide reel clutch hub item 17 and reel clutch fork item 16 assembly onto reel drive hub item 18 Make sure that indicator mark on fork is toward the rear of the transmission 8 Install reel brake disc item 14 onto reel drive hub Friction material side of disc needs to be positioned to ward the reel brake ring item 11 which is pressed into the transmission housing Traction and Reel Drive System Page 4 32 9 Carefully secure reel brake disc item 14 to reel drive hub item 18 with retaining ring item 13 Take care to not damage brake disc friction material when installing retaining ring 10 Press new ball bearing item 28 fully to shoulder of

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