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GreensmasterR Flex 18/21

1. y 7 RIGHT HAND THREADS 5 ANTISIEZE LUBRICANT Figure 16 RH drum shaft RH drum pulley RH wheel shaft UNE Mobil High Temp XHP 222 Grease A 4 LH drum shaft 5 LH drum pulley 6 LH wheel shaft 1 Mobil High Temp XHP 222 Grease Figure 17 1 Ball bearing 2 Seal 3 Seal ride spacer 4 Drum spindle 5 Drum hub 6 Locknut Traction and Reel Drive System oa LU cc g i oC S 2 E o Le e Drive System Traction Drum Assembly Fig 15 1 Assemble hub spindle assembly Fig 17 A Press one bearing into drum hub by applying pressure to outer bearing race Install bearing spacer into drum hub and fill cavity between spacer and drum hub with Mobil High Temperature XHP 222 grease or equivalent Press second bearing into drum hub by applying pressure to outer bearing race Make sure that spacer is centered in hub B Pack rear cavity of oil seals with Mobil High Tem perature XHP 222 grease or equivalent Fill hub cavity between bearings and seal positions with Mo bil High Temperature XHP 222 grease or equiva lent C Press seals into hub so the seals are flush with the hub surface Lightly grease lip of both seals D Lightly grease the drum spindle and slide spindle into the hub Slide seal ride spacer onto spindle an
2. Greensmaster Flex 18 21 Page 4 3 Traction and Reel Drive System This page is intentionally blank Traction and Reel Drive System Page4 4 Greensmaster Flex 18 21 Service and Repairs Reel Drive and Transmission Coupler Drive Belt Replacement Fig 1 and 2 Flex 18 and Flex 21 machines use two identical positive drive belts to operate the cutting unit Replacement of these belts requires the same procedure Removal 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the engine spark plug 2 Remove belt cover to expose appropriate drive belt right side Fig 1 or left side Fig 2 3 Loosen the two 2 bearing housing mounting nuts 4 Pivot bearing housing to loosen belt tension Re move drive belt from the two pulleys Installation 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the spark plug 2 Place a new drive belt onto the two pulleys 3 Adjust drive belt tension see Operator s Manual 4 Install belt cover to machine and secure with flange nut Torque flange nut 100 in Ib 11 3 N m 5 Connect spark plug wire to spark plug Greensmaster Flex 18 21 Page4 5 b d Figure 1 1 RH reel drive belt 3 Gearbox assembly 2 Bearing housing nuts Figure 2 3 LH cutting reel sideplate 1 LH reel drive belt 2 Bearing housing nuts Traction and Reel Drive System Q cc p i oC S 2 9 g
3. 7 Lighting Coll 4 i nenbieeeeR pe 7 SERVICE AND REPAIRS sosca 8 Interlock Switch nsus sasaaa 8 Operator Presence Switch Optional 9 oO o 0 oo 2 o lu Greensmaster Flex 18 21 Page 5 1 Electrical System Wiring Schematic HIGH TENSION LEAD RED INTERLOCK MODULE BLACK a IGNITION COIL E N p j BLACK GREEN ORANGE ENGINE MAGNETO FLYWHEEL Key V ON OFF SWITCH CONNECTOR LIGHTING COIL OPERATOR PRESENCE SWITCH OPTIONAL YELLOW YELLOW aX CONNECTOR c INTERLOCK SWITCH HOURMETER Kawasaki FE 120 Engine ONYOFF SWITCH is open in the ON position INTERLOCK SWITCH is closed when traction lever is in NEUTRAL OPERATOR PRESENCE SWITCH is closed when bail is against handle Electrical System Page 5 2 Greensmaster Flex 18 21 S pecial Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PROD UCTS 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 of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it S
4. Drive System Reel Drive Assembly 40 to 50 ft Ib 54 to 68 N m 35 17 100 in Ib 11 3 N m 40 to 50 ft Ib 54 to 68 N m ER uc d 40 to 50 ft Ib 54 to 68 N m Antiseize Lubricant 40 to 50 ft Ib M 54 to 68 N m 11 3 N m Figure 3 1 Hex shaft 12 Flange nut 2 used per housing 23 Hex tube 2 Flex coupling 13 Flat washer 2 used per housing 24 Drive shaft plate assembly 3 Spring pin 14 Woodruff key 25 Gearbox shaft 4 Shaft 15 Pulley 22 tooth 26 Reel drive plate assembly 5 Oil seal 16 Belt 27 Reel drive cover 6 Retaining ring 17 Flange nut 28 Plug 7 Bearing 18 Pulley washer 29 Spacer 8 Spacer 19 Belt cover assembly 30 Spacer 9 Carriage screw 2 used per housing 20 Cap screw 2 used 31 Lock washer 10 Bearing housing 21 Spacer 2 used 32 Cap screw 11 Spacer 22 Lock nut 2 used 33 Pulley 27 tooth NOTE On early production Flex 18 cutting units the 22 unit and has a pulley washer on the outside These ma tooth pulley attached to the cutting reel left side of cut chines do not use a pulley washer item 18 on the 27 ting unit is mounted with the flange toward the cutting tooth pulley item 33 Traction and Reel Drive System Page4 6 Greensmaster Flex 18 21 Reel Drive and Transmission Coupler Bearing Housing Fig 3 Service ofthe reel drive bearing housings on either side of the machine requires similar procedures Removal 1 Park machine on a level s
5. Greensmaster Flex 18 21 Page4 1 Traction and Reel Drive System Specifications Item Description Traction Drive Integral Gearbox Assembly Attached Directly to Engine Differential to Traction Drive has 8 mm Pitch Positive Drive Belts Gearbox F luid Dexron Ill Automatic Transmission Fluid or equivalent Gearbox Fluid Capacity 2 9 U S qt 2 81 Differential Integral in Gearbox Assembly Parking Brake Band Drum in gearbox Traction Drum Dual Cast Aluminum 7 5 inch 19 1 cm Diameter Cutting Reel Drive Gear Driven Countershaft in gearbox with Cone Wet Clutch Flexible Coupler Shaft Used in Reel Drive S ystem Gearbox to Reel Drive has 8 mm Pitch Positive Drive Belts Traction and Reel Drive System Page 4 2 Greensmaster Flex 18 21 General Information Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your Greensmaster machine Refer to the Operator s Manual for additional information when ser vicing the machine Gearbox Seals The Greensmaster Flex 18 and Flex 21 use cannister seals in the gearbox This type of seal is internally lubri cated and like other seals could normally have a light lubricant film evident at the seal lips Cannister seals will also cause a slightly higher amount of drag than other seal types Drive System ao Q cS i S 2 o
6. D D o 7 Attach spark plug wire to engine spark plug Greensmaster Flex 18 21 Page7 9 Cutting Unit Bedbar 190 to 240 in Ib 21 5 to 27 1 N m S id Antiseize Lubricant UL MS 120 A A 6 i 8 9 J Pd J lt Antiseize Lubricant 200 to 250 in Ib 22 6 to 28 2 N m Figure 14 1 Grass shield 7 Flange nut 2 used 13 Rubber bushing 2 used 2 Washer head screw 3 used 8 Flat washer 4 used 14 Nylon bushing 2 used 3 Bedbar 9 Plastic washer 4 used 15 Weight 4 Bedknife 10 Cutoff bar 16 Cap screw 2 used 5 Screw 11 Screw 4 used 17 Flat washer 4 used 6 Bedbar bolt 2 used 12 Cap screw 2 used 18 Lock nut 4 used Removal Fig 14 1 Position machine on a flat level work surface Make sure engine is OFF Remove spark plug wire from the engine spark plug 2 On both sides of cutting unit loosen bedbar adjuster screw by turning screw counterclockwise Fig 15 3 Back offthe spring tension lock nut until the washer is no longer tensioned against the bedbar Fig 15 4 Loosen flange nuts securing the bedbar pivot bolts on both sides ofthe cutting unit Remove both pivot bolts with flange nut nylon washer and metal washer Figs 15 and 16 Locate and retrieve second nylon and metal washers from between bedbar and cutting unit side plate Cutting Unit Page 7 10 Contact with the reel bedknife or other cutting unit parts can result in persona
7. E Wipe up any spilled gasoline F Fuel may leak from filler neck when mower is tilted for servicing if tank is over filled 10 Check the safety interlock switch daily for proper op eration see Component Testing in Chapter 5 Electri cal System If safety switch should malfunction replace the switch before operating machine After every two years replace the safety interlock switch whether it is working properly or not Greensmaster Flex 18 21 While Operating 1 Do notrun the engine in a confined area without ade 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 that the 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 Before servicing or making adjustments to the ma chine stop the engine and wait for all machine move mentto stop Remove the spark plug wire from the spark plug to prevent accidental starting of the engine 2 To ma
8. 2006 This page is intentionally blank Greensmaster Flex 18 21 Table Of Contents Chapter 1 Safety Safety Instructions 0 000 e eae 1 2 Safety and Instruction Decals 1 4 Chapter 2 Product Records and Maintenance Product Records scis seco eter 2 1 Maintenance ccc ccc n 2 1 Equivalents and Conversions 2 2 Torque Specifications cece eee ees 2 3 Chapter 3 Engine Specifications css kee chee DD heed 3 2 Introduction heehee ee ie 3 3 General Information 0000 008 3 3 Adjustments 2 206 ne Se eed n PE Ren 3 4 Service and Repairs 0 ccc eee 3 5 KAWASAKI FE120 SERVICE MANUAL Chapter 4 Traction and Reel Drive System Specifications 0 a 4 2 General Information 0 000 0008 4 3 Service and Repairs 0 000 e eee 4 5 Chapter 5 Electrical System Wiring Schematic 00 0c ee eee 5 2 Special 00S 4 sce erential oes 5 3 Troubleshooting ssssssesssseeeeeeee 5 5 Component Testing 0 00sec eee 5 6 Service and Repairs 0 cece eee 5 8 Greensmaster Flex 18 21 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 Se
9. 0 83 to 1 04 bar Chassis and Controls Page 6 2 Greensmaster Flex 18 21 General Information Operator s Manual The Operator s Manual provides information regarding the operation adjustment procedures and general maintenance for your Greensmaster machine R efer to the Operator s Manual for additional information when servicing the machine cs 5 2 22 Qe 2 So rz Greensmaster Flex 18 21 Page 6 3 Chassis and Controls Service and Repairs Handle Assembly Handle Brake lever Brake bracket assembly Console assembly Detent ball Retaining ring Retaining ring Interlock switch proximity Handle rod 10 Traction cable 11 Lock washer 2 used 12 Pin 13 Handle hub mount 9 00 SS OEE UD ES 14 Traction reel drive knob black 15 Socket head screw Chassis and Controls 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 OC Figure 1 Roll pin Traction control lever Bushing 4 used Reel lever Reel clutch cable Wiper Control bracket Reel lever pin Friction washer 2 used Dowel pin Throttle cable Cap screw Cap screw 3 used Throttle lever Support rod Page 6 4 Lock nut 4 used Spacer 3 used Retaining ring 3 used Brake cable Lock nut Brake knob red Flange head screw Lock nut 2 used Cap screw 4 used Cap screw Detent spring Washer head screw 5 used Cable tie 4 used Fla
10. 5 Normal operation Identify and replace faulty bear ing s Replace spring If the groomer 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 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 mower with the engine running Always stop the engine and remove the high tension lead from the spark plug before working on the mower Height Depth of Groomer Adjustment NOTE Grooming is performed above the soil level When adjusting groomer height depth grooming blades should never penetrate the soil 1 Position mower on a flat level working surface Make sure engine is OFF Remove high tension lead from the engine spark plug 2 Make sure rollers are clean and cutting reel is setto the desired height of cut see Adjustments section of Chapter 7 Cutting Unit 3 Position the grooming reel to the lowered grooming position Fig 3 NOTE Improper or over aggressive use of the 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 4 On one end
11. E Install cap screw and lock washer F Tighten fasteners to secure reel drive plate to cut ting unit G Carefully install spacer item 12 into grease seal in LH side plate taking care not to damage seal Cutting Unit Page 7 22 11 Apply antiseize lubricantto end of reel shaft Position woodruff key drive pulley and washer if equipped on reel shaft Block reel with a piece of wood to prevent it from turning Install flange nut that secures pulley to reel shaft Torque flange nut from 40 to 50 ft Ib 54 to 68 N m 12 Secure grass shield to side plates with removed fas teners 13 Check for free movement of reel assembly by rotat ing pulley If binding is noted identify and correct prob lem before continuing 14 Install reel drive belt adjust belt tension and install belt cover see Reel Drive Belt and Transmission Cou pler Drive Belt Replacement in Service and R epairs sec tion of Chapter 4 Traction and Reel Drive S ystem 15 If cutting unit is equipped with a groomer install grooming reel see Grooming Reel in the Service and Repairs section of Chapter 8 Groomer 16 Install front and rear rollers see Roller Installation in this section 17 Install bedbar to the cutting unit see Bedbar Installa tion in this section 18 Complete cutting unit set up and adjustment se quence NOTE The parallel position of the rear roller to the cut ting reel is controlled by the precision machined compo n
12. Insertthrottle cable into the nut B Tighten throttle cable screw to hold cable in the nut Do not fully tighten screw C Position three 3 washers and cable clamp to frame Secure with cap screw and flange nut in the Adjustments section of Chapter 3 Engine Figure 12 1 Handle 4 Control bracket 6 Secure throttle cable with cable tie Attach spark plug 2 Throttle cable 5 Console 5 Adjustthrottle cable see Throttle Cable Adjustment 3 Throttle lever 6 Screw 4 used wire to spark plug Greensmaster Flex 18 21 Page 6 9 Chassis and Controls Transport Wheels Optional Loctite 242 Figure 13 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 Cap screw 4 used 13 Flange nut 4 used 5 Hub Chassis and Controls Page 6 10 Greensmaster Flex 18 21 Wheel Removal Fig 14 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 13 1 Remove three 3 cap screws and lock washers from the shallow rim and hub Remove hub from deep rim 2 Inspect hub bushing item 12 If worn or damaged replace bushing Figure 14 1 Wheel retaining I 2 Wheel hex shaft 3 Remove four
13. PWNE Greensmaster Flex 18 21 Throttle Cable Replacement Removal 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the spark plug 2 Remove cable tie that secures throttle cable 3 Remove throttle cable from the engine governor link age as follows Fig 10 A Unscrew throttle cable screw enough to release the throttle cable from the nut in the governor lever B Remove cap screw and flange nut that secure cable clamp to traction unit frame Fig 11 Locate and retrieve three 3 washers from under clamp Figure 10 p 1 Governor lever 3 Throttle cable screw C Pull throttle cable clear of the nut in the governor 2 Throttle cable 4 Throttle cable nut lever 4 Remove four 4 screws securing the console to the handle and move console forward and away from the handle 5 Remove throttle cable from the throttle lever assem bly Fig 12 A Unsnap the cable housing from the control brack et B Unhook cable end from throttle lever 6 Remove throttle cable from the machine Installation Figure 11 1 Throttle cable 2 Cable clamp 1 Connect throttle cable to the throttle lever Snap throttle cable housing to the control bracket Fig 12 cs amp 2 2 N o6 wo co 57 2 Position console to handle and secure console with four 4 screws 3 Route throttle cable to the governor lever 4 Install cable to the governor lever as follows Fig 10 A
14. Rotate pitch arms forward and rest traction unit on locked kickstand 6 Pull cutting unit forward about 2 inches 51 mm and then to the rightto disengage the transmission coupler Fig 3 7 Slide cutting unit away from machine 8 Reverse procedure to install cutting unit to traction unit 9 Attach spark plug wire to engine spark plug Figure 1 1 Kickstand 2 1 4inch pin Figure 2 1 Cutting unit pitch arm 3 Cap screw flat washer 2 Traction unit front frame z 2 D E 5 o Figure 3 1 Coupler hex tube 2 Coupler hex shaft Greensmaster Flex 18 21 Page7 3 Cutting Unit Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PROD UCTS Gauge Bar Assembly Toro Part Number 13 8199 Used to verify height of cut Backlapping Brush Assembly Toro Part Number TOR299100 Used to apply lapping compound to cutting units while keeping the operator s hands ata safe distance from the rotating reel Bedknife Screw Tool Toro Part Number TOR510880 This screwdriver type bit is 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 DO NOT use an air or manual impact wrench with this tool Roller Bearing Installation Tools Washers and spacer used to install bearings and seals into front and rear rollers Seal installation washer black 107 8133 Seal installation s
15. The left side drum pulley has left hand threads Fig 16 8 Apply antiseize lubricant to the external threads of the drum shafts Secure both drum pulleys item 19 to the drum shafts NOTE The rightside wheel shaft has left hand threads Fig 16 9 Apply Loctite 242 or equivalent to the threads of the transport wheel shafts item 17 Install wheel shafts into drum drive shafts Torque wheel shafts from 45 to 55 ft Ib 61 to 75 N m 10 Install traction belts and adjust belt tension see Traction Drive Belt Replacement in this section 11 Install traction drive belt cover and secure with flange nut Torque flange nut 100 in Ib 11 3 N m 12 Install transport wheels if they were attached see Transport Wheels in the Service and Repairs section of Chapter 6 Chassis and Controls 13 Connect spark plug wire to spark plug Greensmaster Flex 18 21 Greensmaster Flex 18 21 This page is intentionally blank Page 4 15 Traction and Reel Drive System Drive System ao Q g S 2 E h Le Gearbox Figure 18 1 Gearbox assembly 2 Flange gasket 3 Engine gear 4 Engine adapter Engine Cap screw ONO Gearbox Removal 1 Park mower on a level surface Make sure engine is OFF Remove spark plug wire from the spark plug 2 Drain oil from gearbox assembly 3 Remove traction control and reel control cables from gearbox 4 If installed remove transport wheels see
16. 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 6 Greensmaster Flex 18 21 Rear roller level Reel and rear roller should be parallel for proper cutting performance see Leveling Rear Roller in Adjustments 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 belts may be loose or worn Check the condition of the traction belts Adjust or replace traction drive belts as necessary Groomer reel operation See Troubleshooting section of Chapter 8 Groomer Greensmaster Flex 18 21 Page7 7 Cutting Unit Adjustments Never work on the cutting unit with the engine Contact with the reel bedknife or other cutting running Always stop the e
17. 2 GENERAL INFORMATION 000 000 eee 3 Operator s Manual 0 000 eee 3 Separating Cutting Unit From Traction Unit 3 SPEGIAL TOOES cer RP DDR ERR 4 FACTORS THAT CAN AFFECT QUALITY OF CUT 6 ADJUSTMENTS cece eee eee ees 8 Leveling Rear Roller 0 0 0 cece eee eee 8 SERVICE AND REPAIRS e cece eens 9 Backlapping 2E a n peda nema ERS 9 BOO DETRAS c 10 Bedknife Service cece cece ees 12 Bedbar Adjuster Service suse 14 RO ll rs a ER Roe e ee a eec ds 16 Roller Service essen 18 Cutting Reel ceste ec rx nnn 20 Cutting Reel Service sssesssiiuusese 23 Side Plate Service 0 cece eee 24 Preparing Reel for Grinding 26 Greensmaster Flex 18 21 Page7 1 Cutting Unit Specifications REEL CONSTRUCTION 5 inch 12 7 cm diameter 11 carbon steel blades welded to 5 stamped steel spi ders High strength low alloy steel blades are thru hard ened and impact resistant An optional 8 blade cutting reel is available FRAME CONSTRUCTION Precision machined die cast aluminum 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 two lock nuts Standard bench height of cut range is 1 16 to 19 64 inch 1 6 to 7 5 mm depending on type of bedknife installed Effective HOC may vary depending on turf conditions type of be
18. 4 Bedknife 12 Cap screw 2 used 20 V ring 5 Screw 11used 13 Rubber bushing 2 used 21 Wear sleeve 6 Bedbar bolt 2 used 14 Flange bushing 2 used 22 Cutting reel 7 Flange nut 2 used 15 Weight 23 LH pitch arm 8 Flat washer 4 used 16 Cap screw 2 used 24 Bearing lock nut Cutting Reel Removal Fig 29 1 Remove cutting unit from machine see Separating Cutting Unit from Traction Unit in this chapter Place cutting unit on a flat level surface or on a stable work bench Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when handling the cutting reel 2 Remove bedbar from the cutting unit see Bedbar Removal in this section 3 If cutting unit is equipped with a groomer remove grooming reel see Grooming Reel in the Service and Repairs section of Chapter 8 Groomer Cutting Unit Page 7 20 4 Remove belt cover and reel drive belt from the left side of the cutting unit NOTE On early production Flex 18 cutting units the 22 tooth pulley attached to the cutting reel left side of cut ting unit is mounted with the flange toward the cutting unit and has a pulley washer on the outside 5 Block reel with a piece of wood to prevent reel from turning Remove flange nut that secures drive pulley to reel shaft Fig 31 Remove pulley washer if equipped and pulley from the shaft Remove woodruff key and seal spacer from reel shaft 6 Rem
19. 6 to 6 3 mm Place roller shim below side plate flange when HOC is from 1 8 to 1 3 2 to 25 4 mm B Install roller spacer and shaft retainer onto rear roller shaft on the opposite side of the cutting unit Install two 2 socket head screws roller shim and flange nuts but do not tighten fully Fig 22 flange nuts socket head screws roller shim roller 3 Center installed roller evenly between the sides of spacer and shaft retainer that secure rear roller Note the cutting unit Secure roller in place by tightening the location of roller shim for assembly purposes fasteners C Remove rear roller from retainer that remains se 4 If front roller was removed check height of cut and cured to cutting unit side plate adjust as necessary 5 Attach spark plug wire to engine spark plug Greensmaster Flex 18 21 Page 7 17 Cutting Unit Roller Service 25 to 30 ft Ib 34 to 41 N m NS d 7 25 to 30 ft Ib 34 to 41 N m Figure 23 1 Wiehle roller 2 Smooth roller 3 Roller shaft 4 Ball bearing 5 Seal NOTE Several different rollers are available for the Flex 18 and Flex 21 cutting unit Roller service proce dures are identical for all types of rollers Disassembly Fig 23 1 To hold roller shaft for bearing lock nut removal install a 3 6 24 UNF 2B screw into threaded end of roller shaft and secure in place with jam nut 2 While retaining shaft loosen and remove bearing lock nut from each
20. 7 Capscrew 8 Ring pin 9 Hairpin cotter Chassis and Controls k 5 2 22 a o6 czo 57 Parking Brake Cable Replacement Removal 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the engine spark plug 2 Disengage parking brake to release tension on the brake cable Remove cable ties that secure cable 3 Remove parking brake cable from the gearbox as follows Fig 4 A Loosen front cable jam nut and lift cable free from casting slot on gearbox B Loosen lock nut that secures gearbox brake lever to splined gearbox shaft Slide lever toward engine to allow room for cable eyelet removal C Remove retaining ring from the gearbox brake le ver D Remove brake cable eyelet from brake lever 4 Remove flange head screw spacer and lock nut that secures brake cable eyelet to brake lever on machine handle Fig 5 5 Remove retaining ring securing the brake cable to the brake bracket Fig 5 Remove 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 head screw spacer and lock nut Fig 5 2 Position cable to the brake bracket and install retain ing ring Fig 5 3 Route brake cable to the gearbox assembly Install brake cable to the gearbox and gearbox brake lever as follows Fig 4 A Position brake lever on splined gearbox shaft to allo
21. 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 6 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 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 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 6 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 16 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 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 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 M
22. Flex 18 21 Page 8 15 Groomer Groomer Arm Assembly Antiseize Lubricant c Antiseize 4 amp Lubricant Antiseize Lubricant Figure 17 1 HOC groomer arm LH shown 6 Lockscrew 11 Cap screw 2 Flange nut 7 Bushing 12 Bushing 3 Grooved pin 8 Liftarm assembly LH shown 13 Wave washer 4 E ring 9 Detent spring 14 Groomer adjuster 5 Groomer lift rod 10 Spring washer Groomer Page 8 16 Greensmaster Flex 18 21 Disassembly Fig 17 1 Remove groomer arm from cutting unit F ig 18 A Loosen cap screw that secures front roller to groomer arm B Remove lock nut and spring washer that secure groomer lift rod to cutting unit side plate C Remove lock nut and HOC washer that secure groomer arm to cutting unit side plate D Slide groomer arm from front roller and cutting unit 2 Disassemble groomer arm using Figure 17 as a guide NOTE Right and left side HOC groomer arms and lift arm assemblies are different other components shown in Figure 17 are the same on both sides of machine NOTE Grooved pin item 3 is used to retain lock screw item 6 to lift arm assembly Assembly Fig 17 1 Apply antiseize lubricant to threads of groomer lift rod item 5 and lift arm assembly item 8 Assemble groomer arm using Figure 17 as a guide 2 Install groomer arm onto cutting unit Fig 18 A Slide groomer arm onto front roller shaft and to cutting unit B Secure groomer arm to cutting u
23. Greensmaster Flex 18 21 Greensmaster Flex 18 21 This page is intentionally blank Page4 9 Traction and Reel Drive System Drive System ao Q g S 2 E h Le Traction Drive Belt Replacement The traction drive system on Flex 18 and Flex 21 ma chines uses a positive drive belt on both sides of the traction drum Belt replacement on either side requires the same procedure Removal 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 Remove flange nut that secures the belt cover F ig 9 Remove belt cover to expose the traction drive belt 4 Loosen cap screw that secures idler bracket to frame Fig 10 Pivot the idler pulley away from the drive belt to loosen belt tension Fig 11 5 Remove traction drive belt from both pulleys Installation 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the spark plug 2 Place traction drive belt onto both pulleys 3 Adjust traction drive belt tension see Operator s Manual 4 Install traction drive belt cover and secure with flange nut Torque flange nut 100 in Ib 11 3 N m 5 Replace transport wheels if they were attached see Transport Wheels in the Service and Repairs section of Chapter 6 Chassis
24. Install woodruff keys and place traction drive pulleys onto gearbox axles with the flange inward F ig 19 Secure pulleys to axles with flange nuts Torque flange nuts from 40 to 50 ft Ib 54 to 68 N m 11 Install traction drive belts properly tension belts and install belt covers see Traction Drive Belt Replacement in this section Greensmaster Flex 18 21 Page 4 17 40 to 50 in Ib A 4 5 to 5 7 N m Antiseize Lubricant 40 to 50 ft Ib 54 to 68 N m Figure 19 1 Flange nut 6 Carriage bolt 2 used 2 Pulley 7 Woodruff key 3 Bearing flangette 8 Gearbox axle 4 Setscrew 9 Flat washer 2 used 5 Extended race bearing 10 Flange nut 2 used Figure 20 2 Flange nut 4 used 1 Gearbox 12 Refill gearbox with proper amount of fluid 13 Install traction control and reel control cables to gear box 14 Adjust control cables traction reel and parking brake as needed 15 Install transport wheels if they were attached see Transport Wheels in the Service and Repairs section of Chapter 6 Chassis and Controls 16 Connect spark plug wire to spark plug Traction and Reel Drive System 3 cs i oc c S E Drive System Gearbox Service 240 in Ib 27 N m 120 to 140 in Ib 13 6 to 15 8 N m M 85 to 105 in Ib 124 amp 9 6to 11 8 N m Q9 MOogRUNH M oH E I IEBIBIIBIE B da Owo o0UnRUNH BO NN Ne NNN uU Gearbox base Ball bearing Caged nee
25. OPERATING OR TESTING GROOMER PERFORMANCE Variables That Affect the Use and Performance of Grooming Reels l The growing season and weather conditions 2 General turf conditions 3 The frequency of grooming cutting number of cut tings per week and how many passes per cutting 4 The blade spacing on the grooming reel 5 The height of cut 6 The grooming depth 7 The type of grass on the green 8 The amount of time that a 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 irrigation fertilizing weed control coring overseeding disease control sand dressing and pest control 11 Stress periods for turf high temperatures high hu midity unusually high traffic Groomer Page 8 4 Greensmaster Flex 18 21 Grooming Reel Mechanical Problems The grooming reel rotates when itis The grooming reel should rotate in the raised transport position No rotation of the grooming reel The turf is damaged or has uneven grooming Greensmaster Flex 18 21 whenever the cutting reel is en gaged Seized grooming reel or idler bear ing s in groomer side plate s Broken or damaged idler spring The groomer belt is worn broken or damaged The grooming reel blades are bent damaged or missing The grooming reel shaft is bentor damaged Grooming depth is not equal on both ends of grooming reel Page 8
26. Transport Wheels in the Service and Repairs section of Chapter 6 Chassis and Controls 5 Remove traction drive belt covers and belts from both sides of mower see Traction Drive Belt Replace ment in this section 6 Remove flange nutthat secures traction drive pulley Fig 19 on both sides of mower Remove pulley and woodruff key from both sides Traction and Reel Drive System Set screw 4 used Lock washer Page 4 16 9 Washer 10 Flange nut 4 used 11 Key 7 Loosen set screws that secure extended race bear ings to gearbox axles Fig 19 8 Remove carriage bolts flange nuts and flat washers that retain bearing flangettes to frame Fig 19 Slide flangettes and bearings toward gearbox 9 Loosen and remove four 4 flange nuts that secure gearbox to engine Fig 20 10 Move gearbox away from the engine to allow remov al of parking brake lever with cable attached from brake shaft of gearbox Loosen lock nut that is used to secure brake lever to the brake shaft Remove lever with cable attached Note that lever and shaft splines identify correct lever location on shaft Greensmaster Flex 18 21 11 Slide gearbox assembly to the right side of mower away from the engine This should allow the left gearbox axle to clear the frame and the gearbox to separate from the engine gear Rotate and pivot gearbox assembly and then slide right side axle from frame to complete gearbox removal 12 Slide bearings
27. and bearing flangettes from gearbox axle shafts 13 Remove and discard flange gasket from between engine and gearbox Gearbox Installation 1 Park traction unit on a level surface Make sure en gine is OFF Remove spark plug wire from the spark plug 2 Place new flange gasket on four 4 set screws installed in engine mounting flange 3 Slide bearings and bearing flangettes onto gearbox axles Make sure that extended race of bearings is posi tioned toward ends of axles 4 Insert gearbox short axle through frame on right side of mower By rotating the gearbox position left axle into frame and input flange of gearbox to engine 5 Install parking brake lever with cable attached to brake shaft of gearbox noting location of alignment splines on shaft and lever 6 Rotate engine crankshaft slowly with recoil starter to align crankshaft gear with gearbox input gear Align gearbox flange onto set screws Install and tighten four 4 flange nuts to secure gearbox to engine Fig 20 7 Secure extended race bearings and bearing flan gettes to frame with carriage bolts flat washers and flange nuts 8 Check bearing alignment by rotating the long gear box axle shaft Shaft should rotate easily if alignment is correct 9 Tighten the bearing set screws to secure the bear ings to the gearbox axles Torque set screws from 40 to 50 in Ib 4 5 to 5 7 N m 10 Apply antiseize lubricant to bores of traction drive pulleys
28. cm ft lb X 1 3558 N m Product Records and Maintenance Page2 6 Wheel Bolts and Lug Nuts Thread Size Recommended Torque 88 14 N m 7 16 20 UNF 65 10 ftlb Grade 5 1 2 20 UNF 80 10 ftlb f 108 14 N m Grade 5 M12X 1 25 80 10ft lIb f 108 14N m Class 8 8 M12 X 1 5 80 10ft lIb f 108 14 N m Class 8 8 For steel wheels and non lubricated fasteners Thread Cutting Screws Zinc Plated Steel Thread Threads per Inch 20 18 16 14 Baseline Torque Lu e o Du m 85 15 in Ib Hole size material strength material thickness amp finish must be considered when determining specific torque values All torque values are based on non lubricated fasteners 18 20 ta eee S ee N cm X 0 08851 z in Ib N m X 0 7376 ft Ib Greensmaster Flex 18 21 Chapter 3 TORO Engine Table of Contents SPECIFICATIONS oi eR remm mnes 2 INTRODUCTION cece ccc n eee 3 GENERAL INFORMATION cece eee 3 Operator s Manual 0000 eee 3 ADJ U STMENTS iei ub e ee ees 4 Throttle Cable Adjustment 4 SERVICE AND REPAIRS sssssss 5 Cooling System ssssssssssseeeeeee 5 Ignition Components 0 00 cece ee eee 5 S Park Plugi ocn Geum dee Gee e cea ee 6 nce 8 KAWASAKI FE120 SERVICE MANUAL Greensmaster Flex 18 21 Page3 1 Engine Specifications Item Description Make Designation Kawasaki 4
29. end of roller shaft 3 Remove v ring from each end of roller 4 Carefully inspect seating surface and threads of bearing lock nuts Replace lock nut if any damage is found 5 Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until seal and bearing are removed from roller cavity in the opposite end of the roller Remove second seal and bearing from roller cav ity by tapping on other end of shaft 6 Clean bearing cavity in roller and remove any corro sion with crocus cloth 7 Discard removed bearings and seals Assembly Fig 23 1 Place roller shaft into clean roller Cutting Unit Page 7 18 6 V ring 7 Bearing lock nut Figure 24 1 Roller 4 V ring 2 Ball bearing 5 Bearing lock nut 3 Seal 6 Roller shaft Figure 25 3 Bearing 1 Bearing lock nut 2 Black assembly washer Greensmaster Flex 18 21 2 If tool TOR4105 is not available install seals and E Install tool with seal installed onto each end of bearings with installation washers and spacers see the roller shaft Tighten each tool until the tool shoul Special Tools as follows der bottoms out against the roller housing Remove tools from roller shaft NOTE If bearing lock nuts are being replaced use original lock nuts for assembly purposes if possible 4 Lubricate lips of ins
30. machine on a level surface Make sure the en gine is OFF 2 Pivot kickstand up and hold against the 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 Push the torsion spring down and in to release spring tension Fig 17 4 Remove flange nuts cap screws flat washers spacers and torsion spring from the kickstand and frame Note that long spacer and torsion spring is on the left side of the machine and short spacer is on the right 5 Remove kickstand from the frame Chassis and Controls Page 6 12 9 Cap screw 10 Support bushing 11 Cap screw 12 Frame assembly Installation Fig 16 1 Make sure machine is parked on a level surface and the engine is OFF 2 Position kickstand inside the machine frame Insert cap screws through the washers kickstand spacers and frame Fig 16 3 Secure cap screws with flange nuts Tighten fasten ers 4 Pivotkickstand up and hold against the frame stops Use a nutdriver or small diameter pipe over the end of the torsion spring Push the spring end down and out to install spring Fig 17 Figure 17 3 Torsion spring end 1 Kickstand 2 Torsion spring Greensmaster Flex 18 21 Chapter 7 Cutting Unit TORO Table of Contents SPECIFICATIONS 4 eR eR meten
31. verify that the switch opens no continuity Removal 1 Disconnect switch from the wires leading from the In terlock module 2 Remove fasteners and spacers that mount switch to control bracket on handle Fig 7 Remove switch from bracket Installation 1 Position switch to control bracket with fasteners and spacers Fig 7 2 Adjust interlock switch see Adjustment above as necessary Make sure that lock nuts are securely tight ened after adjustment 3 Connect switch to wires from the interlock module Figure 6 1 Traction lever 3 Interlock switch 2 Neutral stop 4 Clearance PWN Electrical System Page5 8 Figure 7 Interlock switch 5 Spacer 2 used Control bracket 6 Lock nut 2 used Handle 7 Console Cap screw 2 used Greensmaster Flex 18 21 Operator Presence Switch Optional The optional Operator Presence Kit for the Flex 18 and Flex 21 uses a switch mounted on the equipment handle that is operated by a bail When the operator holds the bail against the handle the switch closes allowing the engine to run The common terminal and normally open terminal of the switch are used for the operator presence system on the Flex 18 and Flex 21 Fig 8 The normally closed termi nal is not used Testing Using a multimeter the operator presence switch can be tested as follows 1 With the bail released away from the handle there should be no continuity between the two terminals u
32. 1 is OFF Remove spark plug wire from the engine spark plug 2 To remove front roller assembly A Loosen cap screw that secures front roller shaft to height of cut arm on both sides of the mower B On one side of cutting unit remove lock nut and height of cut washer that secure height of cut arm to side plate C If equipped with groomer remove lock nut and 2 spring washer that secures groomer side plate to height of cut arm loosened in step B D Slide height of cut arm from end of front roller shaft E Remove front roller from height of cut arm that remains secured to cutting unit side plate 3 To remove rear roller assembly A On one side of the cutting unit loosen two 2 flange nuts that secure rear roller B On other side of cutting unit remove two 2 ller Installation Fig 22 To install front roller A Insert one end of front roller into height of cut arm that is secured to cutting unit side plate B Slide second height of cut arm onto front roller shaft Secure height of cut arm to side plate with height of cut washer and lock nut C If equipped with groomer secure groomer side plate to height of cut arm with lock nut and spring washer To install rear roller A Place rear roller shaft between roller spacer and shaft retainer that are still attached to the cutting unit side plate NOTE Place roller shim above side plate flange when HOC is from 1 16 to 1 4 1
33. 4 Driven bevel gear 8 Roll pin The differential assembly is an integral component of the gearbox assembly Service ofthe differential assem bly requires removal and disassembly of the gearbox Disassembly Fig 31 1 Remove gearbox from mower see Gearbox Remov al and disassemble gearbox see Gearbox Disassem bly to remove differential assembly 2 Support differential assembly and drive out roll pin that locates gear shaft Discard roll pin 3 Remove gear shaft two 2 thrust washers and two 2 driven bevel gears 4 Remove retaining ring from each axle Discard re taining rings 5 Pull each axle free from drive bevel gear washer and input gear housing Note that axle washers are different from washers used on gear shaft Traction and Reel Drive System Page 4 22 9 Input gear housing 10 Gear shaft 11 Bushing Inspection Fig 31 1 Clean all differential components 2 Inspect all differential bevel gears carefully looking for chipped teeth wear or other damage Because gear tooth damage is rarely isolated to one gear replace bev el gears as a complete set 3 Inspect axle shafts and gear shaft for scoring or wear 4 Inspect gear teeth axle bearing areas and gear shaft bores of the input gear housing Replace bushings if damaged 5 Replace all worn or damaged differential assembly components Greensmaster Flex 18 21 Assembly Fig 31 1 Insert RH short axle into input gear hou
34. 4 cap screws and flange nuts from the eer reta ina over SATIS TR deep rim and shallow rim Remove shallow rim from the deep rim 4 Separate tire tube and deep rim 5 If necessary remove shoulder screws torsion spring and retaining lever from the hub Wheel Assembly Fig 13 1 If shoulder screws were removed from hub apply Loctite 242 or equivalent to threads of shoulder screws Secure torsion spring and retaining lever to the hub with shoulder screws 2 Assemble tire tube and deep rim Figure 15 3 Install shallow rim into the tire Align and secure shal 1 Wheel hex shaft low rim to the deep rim with four 4 cap screws and flange nuts Tighten fasteners cs S2 2 N o6 o 57 4 Install hub into deep rim Secure hub to deep rim with three 3 cap screws and lock washers Tighten fasten ers Wheel Installation Fig 14 1 Make sure machine is parked on a level surface and the engine is OFF 2 Supportthe machine on the kick stand 3 Apply antiseize lubricant to the exposed end of the wheel hex shaft Fig 15 4 Slide transport wheel completely onto the wheel hex shaft until the wheel retaining lever is secured into the groove on the wheel hex shaft Greensmaster Flex 18 21 Page 6 11 Chassis and Controls Kickstand Figure 16 1 Kickstand 5 Torsion spring 2 Cap screw 6 Cap screw 3 Flatwasher 7 Spacer 4 Long spacer 8 Flange nut Removal Fig 16 1 Park
35. 8 19 20 21 22 23 Loctite 242 24 4 amp 7to10in Ib N m 0 8 to 1 1 Figure 5 Interlock module 24 Module bracket 25 Throttle cable screw 26 Set screw 4 used 27 Cap screw 28 Lock washer 2 used 29 Flat washer 30 Flat washer 31 Lock nut 32 Cap screw 33 Isolator mount 2 used 34 Page3 8 Jam nut 2 used Tab washer 2 used Hourmeter Lock washer 2 used Muffler guard Cap screw 4 used Muffler guard bracket 2 used Square key Washer head screw 4 used Flat washer 4 used Hourmeter mounting clip Greensmaster Flex 18 21 Engine Removal Fig 5 1 Make sure machine is parked on a level surface with the engine OFF Remove spark plug wire from the spark plug to prevent the engine from starting Close fuel shut off valve 2 If engine is to be disassembled it may be easier to drain oil from engine before removing engine from trac tion unit 3 4 7 Drain oil from gearbox Remove throttle cable from engine A Remove cap screw and flange nut that secure cable clamp to traction unit frame Fig 6 Locate and retrieve three 3 washers from under clamp B Loosen screw that secures throttle cable to throttle cable nut enough to slide the cable out of the nut Fig 7 C Position throttle cable away from engine Disconnect electrical connections from engine Fig A Unplug wire harness connector from interlock modul
36. Relief Angle Fontana Figure 19 Oo Oo o o Oo O O Oo Oo o Oo Standard Bedknife 4 1 69 42 9 mm Front Face Extended Bedknife x 1 88 47 8 mm Figure 20 Greensmaster Flex 18 21 This page is intentionally blank Greensmaster Flex 18 21 Page 7 13 Cutting Unit Bedbar Adjuster Service NICK V Antiseize 3 Lubricant Figure 21 1 Adjuster shaft 6 Adjuster screw 10 Washer 2 Flange bushing 7 Detent 11 Spring 3 Cutting unit frame 8 Lock washer 12 Lock nut 4 Wave washer 9 Cap screw 13 Cutting unit side plate LH shown 5 Retaining ring Removal Fig 21 1 Position machine on a flat level work surface Make sure engine is OFF Remove spark plug wire from the engine spark plug 2 Remove bedbar see Bedbar Removal in this sec tion 3 Remove lock nut item 12 spring item 11 and washer item 10 from adjuster screw NOTE The adjuster shaft item 1 has left hand threads 4 Unscrew adjuster screw item 6 from the adjuster shaft item 1 5 Remove retaining ring item 5 and wave washer item 4 from adjuster shaft and remove adjuster shaft from cutting unit frame 6 Inspect flange bushings item 2 and remove from cutting unit frame if necessary 7 If the detent item 7 is damaged remove it from the cutting unit frame by removing the cap screw item 9 and lock washer item 8 Cutting Unit Page 7 14 Installation Fig 21 1 Ifthe det
37. Special Tools on each end of roller shaft Fig 28 Thread nut onto each end of shaft G Tighten each nut until the yellow assembly wash C FESS ers bottom out against the roller housing Remove O EN AAA nuts assembly washers and assembly spacers from roller shaft ew WivZ Lh fl PA Esai 3 If tool TOR4105 see Special Tools is available install seals and bearings with tool TOR4105 as follows Figure 27 A Position a new bearing and tool TOR4105 onto t Bearing lock nut 2 Seal each end of the roller shaft B Tighten tools until the bearings are fully seated into each end of the roller Remove tool from each end of the roller IMPORTANT Failure to grease tool shoulder be fore seal installation may result in seal damage C Apply a coating of grease to tool shoulder to pre vent seal damage during seal installation Figure 28 1 Bearing lock nut 3 Assembly spacer D Carefully install seal onto each ofthe tools Pack 2 Yellow a sembly washer cd oen the back of the seal 75 to 90 full with 2 grease Fig 26 Greensmaster Flex 18 21 Page 7 19 Cutting Unit Cutting Reel 190 to 240 in Ib 21 5 to 27 1 N m Antiseize Lubricant Antiseize Lubricant Antiseize Lubricant Figure 29 1 Grass shield 9 Plastic washer 4 used 17 Flat washer 4 used 2 Washer head screw 3 used 10 Cutoff bar 18 Lock nut 4 used 3 Bedbar 11 Screw 4 used 19 RH pitch arm
38. TORO 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 18 Model 04018 and Flex 21 Model 04022 REFER TO THE OPERATOR S MANUAL FOR OPER ATING MAINTENANCE AND ADJUSTMENT INSTRUCTIONS Space is provided in Chapter 2 of this book to insert the Operator s Manual and Parts Catalogs for your machine Replacement Operator s Manuals and Parts Catalogs are available on the internet at www toro com or by sending complete Model and Serial Number to The Toro Company Attn Technical Publications 8111 Lyndale Avenue South Minneapolis MN 55420 1196 The Toro Company reserves the right to change product specifications or this publication without notice PART NO 06149SL Service Manual Models 04018 04019 04030 04022 04024 04025 04031 Greensmaster Flex 18 21 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 portant instructions which must be followed to pre vent damage to systems or components on the machine O The Toro Company
39. ack off lock nut 1 2 turn Fig 15 9 Adjust bedbar see Bedknife to Reel Adjustment in this section 10 After adjustments are complete attach spark plug wire to engine spark plug Greensmaster Flex 18 21 Page 7 11 wie TODE Figure 15 Bedbar 4 Flange nut Bedbar adjuster screw 5 Bedbar bolt Spring tension lock nut 6 Washer Side plate Rubber bushing Nylon bushing Nylon washer 5 Metal washer 6 Bedbar 7 Bedbar pivot bolt 8 Flange nut 2 D E 5 Cutting Unit Bedknife Service Bedknife Removal 1 Remove bedbar from cutting unit frame see Bedbar Removal in this section 2 Remove screws that fasten bedknife to bedbar using a socket wrench and bedknife screw tool see Special Tools Discard screws Remove bedknife from bedbar Fig 17 Bedknife Installation 1 Use a scraper to remove all rust scale and corrosion from bedbar surface before installing new bedknife Also make sure bedbar threads are clean If necessary use 5 16 18UNC 24A tap to chase threads in bedbar 2 Use new screws to secure bedknife to bedbar Apply antiseize lubricant to the screws before installing Take care to keep antiseize lubricant from taper on screw heads IMPORTANT Do notuse an impact wrench to tight en screws into the bedbar 3 Install all screws but do not tighten fully Then using a torque wrench and bedknife screw tool torq
40. adjust er spring is fully compressed then loosen lock nut 1 2 turn 9 Complete cutting unit set up and adjustment se quence Figure 12 1 Grass shield 4 Lock nut 2 used 2 Cap screw 2 used 5 Shoulder bolt 4 used 3 Flat washer 2 used 6 Square nut 4 used Cutting Unit Page 7 8 Greensmaster Flex 18 21 Service and Repairs Backlapping 1 Park cutting unit on a level surface Make sure en gine is OFF Remove spark plug wire from the engine spark plug 2 Make sure reel drive lever is DISENGAGED 3 Remove plug from the reel drive cover on the left side of the reel assembly Fig 13 4 Inserta 18 mm socket onto hex flange nut on left side of reel shaft Contact with the reel or other moving parts can Figure 13 result in personal injury 1 Cover plug Stay away from the reel when backlapping 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 5 Backlap according to procedure in TORO Sharpen ing Reel and Rotary Mowers Manual Form No 80300 SL NOTE For a better cutting edge run a file across the front face of the bedknife when the lapping operation is completed This will remove any burrs or rough edges that may have built up on the cutting edge 6 Install reel drive cover plug when backlapping opera tion is completed Fig 13
41. aft Make sure that wear Sleeve is flush to 0 015 flush to 0 4 mm pastthe bear ing shoulder 5 Slide the v ring seal onto the reel shaft with the thick shoulder of the v ring seal facing inward WEAR SLEEVE TO BE FLUSH TO 0 015 0 4 MM PAST BEARING SHOULDER 1 Reel shaft 2 Wear sleeve Greensmaster Flex 18 21 Page 7 23 Figure 33 3 V ring seal Cutting Unit Side Plate Service 210 to 240 in Ib 23 7 to 27 1 N m Figure 34 1 Crossmember 10 Adjuster screw 2 used 18 Ball bearing 2 used 2 Adjuster shaft 2 used 11 Washer 2 used 19 RH side plate 3 Thrust washer 12 Compression spring 2 used 20 Wave washer 4 Flange bushing 4 used 13 Lock nut 2 used 21 Nylon bushing 2 used 5 Cap screw 2 used 14 LH side plate 22 Rubber bushing 2 used 6 Lock washer 2 used 15 Shoulder bolt 4 used 23 Pitch bushing 2 used 7 Detent 2 used 16 Oil seal 4 used 24 Retaining ring 2 used 8 Wave washer 2 used 17 O ring 25 Square nut 4 used 9 Retaining ring 2 used Disassembly Fig 34 1 Remove side plate s from cutting unit see Cutting Reel Removal in this section 2 Remove inner and outer grease seals item 16 from side plate 3 On RH side plate remove outer retaining ring item 24 that secures the bearing in the side plate 4 Remove bearing item 18 from side plate Inspect bearing to insure that it spins freely and has minimal ax ial play The bearing b
42. alls must be free of deformation and scoring Replace the bearing if necessary 5 On LH side plate remove o ring item 17 from the groove in the side plate bore Discard o ring Cutting Unit Page 7 24 6 On RH side plate remove wave washer item 20 and thrust washer item 3 from side plate Inner retain ing ring can remain in the side plate 7 Remove all grease from the side plate bore Thor oughly clean side plate Inspect side plate and replace if wear or damage is found 8 Inspect pitch bushing for wear or damage If neces sary remove bushing from side plate and press new bushing fully onto side plate 9 Inspect nylon bushings item 21 and rubber bush ings item 22 in side plates Remove and replace bush ings if necessary Greensmaster Flex 18 21 Assembly Fig 34 1 On RH side plate if inner retaining ring item 24 was removed install inner retaining ring Insert thrust wash er item 3 and then wave washer item 20 into the side plate 2 On LH side plate insert o ring item 17 into groove in side plate Make sure that o ring is not twisted and is seated in side plate groove Apply a light coating of grease onto the o ring and side plate bore 3 Pack bearing item 18 with Mobil High Temperature XHP 222 grease or equivalent P ress bearing into the side plate 4 On RH side plate install outer retaining ring item 24 into side plate groove 5 Pack the inner cavity of seals i
43. and Controls 6 Connect spark plug wire to spark plug Figure 9 1 Traction belt cover 2 Flange nut 1 Side plate 2 Idler bracket cap screw Figure 11 1 Idler pulley 4 Drum pulley 2 Idler bracket 5 Gearbox axle pulley 3 Traction drive belt Traction and Reel Drive System Page 4 10 Greensmaster Flex 18 21 Traction Drive Idler Pulley and Bearings Removal 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 Remove traction drive belt cover 4 Remove cap screw and tab washer that secures the idler bracket to the side plate of the mower Fig 14 5 Remove cap screw and shoulder nut on which the idler assembly pivots Figs 13 and 14 Remove idler assembly Figure 12 1l Gearbox axle shaft 7 Traction drive pulley E 2 Frame 8 Traction driven pulley L 6 If idler pulley sleeve or bearings require replace 3 Idler bracket 8 Shoulder nut tE ment 4 Bearing 10 Cap screw Tp 5 Pulley sleeve 11 Cap screw a A Pull bearings and pulley sleeve from idler 6 Traction drive belt 12 Tab washer Se 84 B Press bearings from pulley sleeve Installation 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the spark plug 2 If idler pulley sleeve or be
44. arings were removed A Press bearings into pulley sleeve making sure to apply pressure to outer bearing race only B Install pulley assembly onto idler shaft pressing on inner bearing race 3 Position idler assembly using cap screw and shoul der nut Figs 13 and 14 Tighten shoulder nut Check Figure 13 that idler assembly can pivot freely after tightening 1 Idler pulley 3 Shoulder nut shoulder nut 2 Idler bracket 4 Install cap screw and tab washer that positions the idler bracket to the side plate of the mower Fig 14 Make sure that washer tab is in slot and orientated down 5 Adjusttraction belt tension see Operator s Manual 6 Install traction drive belt cover and secure with flange nut Torque flange nut 100 in Ib 11 3 N m 7 Replace transport wheels if they were attached see Transport Wheels in the Service and Repairs section of I Chapter 6 Chassis and Controls Figure 14 1 Side plate 3 Idler pivot cap screw 8 Connect spark plug wire to spark plug 2 Idler bracket cap screw Greensmaster Flex 18 21 Page 4 11 Traction and Reel Drive System Traction Drum Assembly 40 to 50 ft Ib 40 to 50 in Ib rii 54 to 68 N m 4 5 to 5 7 N m Antiseize Lubricant 45 to 55 ft Ib 61 to 75 N m 65 to 75 ft Ib 88 to 102 N m NS Antiseize Lubricant S 100 in Ib 11 3 N m Figure 15 1 Traction drum RH shown 13 Shoulder nut 2 used 25 Bearing flangette 4 used 2 Ball b
45. arks are produced the igni tion system is operating properly NOTE Ifa sheared flywheel key exists the spark tester may indicate an operating ignition system but ignition timing will be incorrect 6 If visible and audible sparks are not produced the ignition system is not operating properly A Check wires and connectors of the ON OFF switch and ignition coil for grounding or damaged in sulation B If wires and connectors are good test the ON OFF switch and ignition coil individually see Kawa saki FE120 Service Manual at the end of Chapter 3 Engine C If the ON OFF switch and ignition coil test proper ly see Interlock Module and S witch in this section for further testing sulation breakdown under high running voltages See Kawasaki FE 120 Service Manual at the end of Chap ter 3 Engine for ignition component testing informa tion Greensmaster Flex 18 21 Interlock Module and Switch The interlock module prevents the engine from starting unless the interlock switch is closed traction lever in NEUTRAL After a safe start the engine will continue to run with the interlock switch open traction lever FOR WARD or closed If the engine will not start perform the following tests to determine if the interlock module or interlock switch is at fault 1 Check that there is a good ground between the inter lock module green wire and the engine Fig 5 Check all other electrical connections and the inter
46. as disassembled use Figure 26 as a guide to install components to clutch shaft Install clutch shaft assembly into gearbox base and rotate clutch fork to plunger hub Place thrust washer on cover end of shaft 4 Attach link to fork shaft and bellcrank Secure with two 2 retaining rings 5 Lubricate long differential axle shaft and carefully slide differential assembly into bushing and seal in base 6 If planetary assembly was disassembled use Figure 25 as a guide to install components to planetary assem bly If input gear was removed install with shallow web casting toward sun gear Traction and Reel Drive System Page 4 20 7 Install planetary assembly with brake band installed into gearbox engaging gears of differential assembly Note On Flex 21 if gearbox is still attached to engine parking brake lever on engine side of gearbox with cable should be installed onto brake shaft as plan etary assembly is installed into gearbox Shallow web casting V2 Brake Band Location Traction Band Location Figure 25 1 Sun gear 7 Woodruff key 2 Input gear 8 Planet gear 3 used 3 Carrier assembly 9 Thrust washer 4 Ring gear 10 Wave washer 5 Traction drum 11 Thrust washer 6 E ring 12 E ring Figure 26 1 Clutch shaft 6 Thrust bearing 2 Clutch gear bearing 7 Thrust washer 3 Cone clutch hub 8 Plunger hub bearing 4 Retaining ring 9 Snap ring 5 Thrust washer sm ID 10 Square k
47. both carriage screws through the bearing housing and plate Install washers and flange nuts on carriage screws Do not fully tighten flange nuts at this time 4 Position spacer onto shaft Place woodruff key into shaft keyslot 5 Apply antiseize lubricantto the bore of the pulley and install pulley onto shaft A Leftside pulley uses a pulley washer B Right side pulley should be installed with the flange outward NOTE Do not grasp hex shaft when tightening flange nut that secures pulley as flex coupler may be damaged and fail prematurely 6 Secure the pulley to the shaft with flange nut Torque 7 Install reel drive belt to the reel drive assembly and adjust belt see Reel Drive and Transmission Coupler Drive Belt Replacement in this section Make sure that bearing housing flange nuts are securely tightened after drive belt adjustment 8 Install reel drive belt cover and secure with flange nut Torque flange nut 100 in Ib 11 3 N m 9 Attach cutting unitto the traction unit see Separating Cutting Unit F rom Traction Unit in the General Informa tion section of Chapter 7 Cutting Unit 10 Connect spark plug wire to spark plug Figure 7 1 Bearing housing LH 2 Carriage screw Mobil High Temp XHP 222 Grease Mobil High Temp XHP 222 Grease flange nut from 40 to 50 ft Ib 54 to 68 N m Figure 8 1 Shaft 3 Seal 2 Bearing Traction and Reel Drive System Page4 8
48. 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 or similar condition which affects the installation Fastener Identification 2 i Grade 1 Grade 5 Inch Series Bolts and Screws Greensmaster Flex 18 21 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 5 cS S Class 8 8 Class 10 9 Metric Bolts and Screws Product Records and Maintenance N cs o o Q E o 3 gei P a and Maintenance Standard 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 ul ul WwW W
49. ctions NOTE After greasing groomer bearings operate groomer for 30 seconds stop machine and wipe excess grease from groomer shaft and seals 5 Check and adjust grooming reel height and mower height of cut settings Greensmaster Flex 18 21 Page 8 13 Groomer Idler Assembly Figure 15 1 Lock nut 6 Seal 10 Pivot hub 2 Flat washer 7 Bearing 11 Bushing 3 Retaining ring 8 Grease fitting 12 Idler bracket 4 Idler bearing 9 RH side plate 13 Retaining ring 5 Idler pulley The right side plate assembly of the groomer drive kit in corporates the idler system for tensioning the groomer drive belt The idler system uses a spring to maintain proper belt tension Removal 1 Remove groomer belt cover drive belt and drive pulley from right side of mower see Grooming Reel Re moval in this section 2 Using Figures 15 and 16 as guides remove idler bracket idler pulley and or idler bearings for service as needed Installation 1 Assemble components using Figures 15 and 16 as guides NOTE When properly installed the idler pulley should move freely 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 Figure 16 1 RH side plate 3 Idler bracket 2 Drive pulley 4 Idler pulley w bearings Groomer Page 8 14 Greensmaster Flex 18 21 This page is intentionally blank Greensmaster
50. cures the traction cable housing to the control bracket B Remove retaining ring that secures cable spring to pin on traction lever assembly C Remove cable from traction lever assembly 5 Remove traction cable from the machine Installation 1 Secure traction cable spring to the traction lever as k 52 22 a o6 o 57 Figure 7 sembly Fig 7 y g 1 Control bracket 5 Cable housing i 2 Traction lever assembly 6 Retaining ring A Install cable spring to pin on traction lever assem 3 Traction cable spring J Control knob bly and secure with retaining ring 4 Retaining ring B Secure the cable housing to the control bracket with retaining ring 2 Route traction cable to the gearbox Install cable to the gearbox as follows Fig 6 A Secure cable eyelet to gearbox traction lever with retaining ring B Position traction cable to the casting slot of gear box with a washer and jam nut on each side of the slot 3 Adjust traction cable see Operator s Manual 4 Install cable ties to secure traction cable Attach spark plug wire to spark plug Greensmaster Flex 18 21 Page 6 7 Chassis and Controls Reel Control Cable Replacement Removal 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the engine spark plug 2 Assure reel drive lever is in the DISENGAGED posi tion Remove cable ties that secure reel control cable 3 Remove reel cont
51. d insert spacer into oil seal Secure drum spindle to prevent it from turning and then secure spindle to the hub with lock nut 2 Position traction drums to hub spindle assembly Se cure each traction drum to hub spindle with four 4 cap screws and lock washers Torque cap screws 100 in Ib 11 3 N m Traction Drum Installation Fig 15 1 Position machine on a level surface Make sure en gine is OFF Remove spark plug wire from the spark plug 2 If removed loosely install bearings item 11 and bearing flangettes item 10 to machine frame Make sure that extended race of bearings is positioned to the outside of the frame 3 Pivot mower back and position traction drum assem bly under the mower Lower mower onto traction drum Traction and Reel Drive System Page 4 14 4 Position drum spacers to sides of drum 5 Insert bar stock or other suitable tool through spokes of drum to keep drum from turning NOTE The left side drum shaft has left hand threads Fig 16 6 Apply antiseize lubricant to drum shaft item 8 threads and install shafts through bearings spacers and into drum After both shafts are installed torque drum shafts from 65 to 75 ft Ib 88 to 102 N m 7 Tighten the fasteners that secure the bearing flan gettes item 10 to the machine frame Tighten the bear ing set screw item 25 to secure each bearing to the drum shaft Torque set screws from 40 to 50 in Ib 4 5 to 5 7 N m NOTE
52. d lock washer C Connect wire harness to interlock module 6 Connect throttle cable to engine A Position throttle cable to engine B Slide throttle cable through throttle cable nut Fig 7 C Position three 3 washers and cable clamp to frame Fig 6 Secure with cap screw and flange nut D Adjust throttle cable See Throttle Cable Adjust ment in the Adjustment section of this chapter Make sure that throttle cable screw is tightened after cable adjustment 7 Fill gearbox to proper fluid level 8 Check and adjust engine oil level as needed 9 Attach spark plug wire to the spark plug Open fuel shut off valve Greensmaster Flex 18 21 Chapter 4 TORO Traction and Reel Drive System Table of Contents SPECIFICATIONS eso ree rette a 2 GENERAL INFORMATION 000 00a ee 3 Operator s Manual 000 eee eee 3 Gearbox Seals cece eee 3 SERVICE AND REPAIRS cece ee eeee 5 Reel Drive and Transmission Coupler Drive BeltReplacement 04 5 Reel Drive Assembly 0 000 e eee eee 6 Reel Drive and Transmission Coupler Bearing Housing 0 c cece eee eee 7 Traction Drive BeltReplacement 10 gE Traction Drive Idler Pulley and Bearings 11 E 2 Traction Drum Assembly 4 12 a Gearbox Cusco core sect ez aeris 16 2s Gearbox SerV Ce u un 18 sa Differential Service 0 ccc e cece eee 23 um
53. d setting B High idle speed should be 3500 to 3700 RPM Adjust high idle speed screw in or out to attain the correct high idle speed setting WNP Engine Page 3 4 Throttle cable screw Throttle cable Governor lever Figure 1 4 Low idle speed screw 5 High idle speed screw Greensmaster Flex 18 21 Service and Repairs Cooling System IMPORTANT The engine that powers the Flex 18 and Flex 21 is air cooled Operating the engine with dirty or plugged cooling fins or a plugged or dirty b lower 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 dirt and debris Fig 3 Re move housing if necessary IMPORTANT Never operate engine without the blower housing installed Overheating 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 Ignition Components Engine ignition component information is included in Chapter 5 Electrical System Figure 2 1 Engine cylinder shroud Figure 3 1 Blower housing 2 Rewind sta
54. dge shafts from base Locate thrust washer that fits on cover end of clutch shaft Fig 23 Remove and discard gasket 7 Carefully remove traction shaft from the gearbox tak Figure 23 i j j j 1 Traction shaft with band 4 Reel drive clutch shaft ing care to not distort traction band Fig 24 Note On 2 planetary assembly boc aie UR Flex 21 if gearbox is still attached to engine traction le 3 Differential assembly ver on engine side of gearbox must be loosened and re moved as traction shaft is removed from gearbox 8 Slide differential assembly from gearbox Fig 24 9 Pull planetary assembly with parking brake band and shaft from gearbox Fig 24 Note Remove park ing brake lever if still attached to brake shaft 10 Use Figure 25 as a guide to remove components from planetary assembly If input gear is removed note orientation on shaft 11 Remove retaining rings that secure link to clutch bell crank and clutch fork shaft Fig 24 Remove link 12 Rotate clutch fork shaft to allow removal of reel drive clutch shaft assembly from gearbox base Fig 24 Use Figure 24 Figure 26 as a guide to remove components from clutch shaft 1 Traction shaft with band 4 Reel drive clutch shaft 2 Planetary assembly 5 Clutch thrust washer 3 Differential assembly 6 Clutch fork Greensmaster Flex 18 21 Page 4 19 Traction and Reel Drive System 13 Gearbox seals can be removed as f
55. dknife rollers and attachments installed CLIP 0 14 inch 3 56 mm with 11 blade reel 0 19 inch 4 83 mm with optional 8 blade reel Cutting Unit Page 7 2 BEDKNIFE AND BEDBAR Single edged high carbon steel bedknife hardened to RC 48 54 A cast iron bed bar is fastened to the cutting unit GRASS SHIELD Non adjustable shield with adjusta ble cut off bar to improve grass discharge from reel in dry conditions COUNTERBALANCE WEIGHT A cast iron weight mounted on right end of cutting unit balances the cutting unit APPROXIMATE WEIGHT Flex 18 with11 Blade Reel Flex 21 with 11 Blade Reel 81 Ib 36 7 kg 89 Ib 40 4 kg Greensmaster Flex 18 21 General Information Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for the cutting unit on your Greensmaster ma chine Refer to this publication for additional information when servicing the cutting unit 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 kickstand Insert a 1 4 diameter pin or equiv alent into frame hole above kickstand mounting bolt to lock kickstand in place Fig 1 3 Remove grass basket if installed 4 Remove two 2 cap screws and flat washers secur ing cutting unit pitch arms to traction unit front frame Fig 2 5
56. dle bearing Bushing Bushing Bushing Bushing Keyed flanged bushing Oil seal Oil seal Dowel pin 2 used Drain plug Snap ring Clutch fork Fork shaft Thrust washer Bellcrank Link Retaining ring Clutch shaft reel drive Retaining ring Thrust washer Thrust bearing Thrust washer Clutch gear Figure 21 Needle bearing Square key 2 used Cone assembly Lock nut 2 used Plunger hub Cap screw 2 used Thrust washer Flat washer 4 used Sun gear Woodruff key Input gear Carrier bushing Planet gear carrier Flanged bushing Needle bearing Planet gear 3 used Roller bearing 3 used Ring gear Clevis pin 2 used Brake band Brake shaft Clevis pin 2 used Hollow hex plug Thrust washer NOTE On Flex 21 machines itis possible to separate the gearbox cover from the base while the gearbox is still installed on the traction unit The traction band plane tary assembly and reel drive clutch shaft assembly can be removed from the gearbox in this manner Service to the differential bushings and bearings requires removal of the gearbox from the traction unit Traction and Reel Drive System Page 4 18 Traction drum assembly Thrust washer Cap screw Traction band assembly Traction shaft Ball bearing Retaining ring 4 used Differential assembly traction drive Gasket Gearbox c
57. e B Disconnect engine stop switch and armature wires from wire harness connectors C Disconnect wire harness ground wire from en gine by removing cap screw and lock washer Remove engine from the engine base Fig 6 A Remove four 4 flange nuts that secure gearbox assembly to set screws on engine crankcase cover B Support gearbox between mower frame and gearbox flange C Remove four 4 cap screws flat washers and flange nuts that secure engine to engine base of trac tion unit D Carefully slide engine away from gearbox as sembly to allow engine gear to clear gearbox Re move and discard flange gasket item 2 E Remove the engine from the traction unit If necessary remove cap screw lock washer and flat washer that secure engine gear to crankshaft Slide gear from crankshaft Remove square key from engine crankshaft keyway Greensmaster Flex 18 21 Figure 6 1 Gearbox flange nuts 3 Throttle cable clamp 2 Engine mounting screws fn ee Figure 7 1 Governor lever 3 Throttle cable screw 2 Throttle cable 4 Throttle cable nut Figure 8 1 Wire harness 4 Armature wire 2 Interlock module 5 Cap screw lock washer 3 Stop switch wire Page3 9 Engine Engine Installation Fig 5 l 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 maintenanc
58. e Service and Repairs section of Chapter 7 Cutting Unit B Remove lock nut and spring washer that secure AALA LH groomer am lift rod to LH groomer side plate Fig Figure 14 14 Remove LH groomer side plate from mower 1 LH groomer side plate 3 LH groomer arm 2 Lock nut spring washer 3 Replace bearings in both side plate assemblies F ig 13 A Remove seals from groomer side plates Discard seals B Push bearings out of housing Discard bearings Bearing Installation Fig 13 1 Install new bearings in both side plate assemblies Fig 13 A Slide new bearings into side plates Position race extensions toward center of housing B Install new seals into side plates Note Seals should be installed so the lip side of the seal will face the center of the cutting reel When bearings are greased grease will purge from inner seals 2 Install LH groomer side plate to mower A Position LH groomer side plate to mower making sure that groomer arm lift rod is positioned through bushing in side plate B Place spring washer and lock nut on lift rod threads Fig 14 Tighten lock nut C Install reel drive assembly to left side of cutting unit see Cutting Reel Installation in the Service and Repairs section of Chapter 7 Cutting Unit 3 Install grooming reel and RH groomer side plate see Grooming Reel Installation in this section 4 Lubricate groomer bearings see Groomer Reel Kit Installation Instru
59. e coupler and discard spring pin 2 Remove seal and then retaining ring from housing 3 Pull shaft with bearings and spacer from housing 4 Press bearings and spacer from shaft Bearing Housing Assembly 1 Press first bearing fully onto shaft Position spacer and press second bearing onto the shaft 2 Fill cavity between bearings with Mobil High Temper Figure 6 ature XHP 222 grease or equivalent Fig 8 1 Bearing housing RH 3 Flex coupler 2 Carriage screw 4 Hex shaft Greensmaster Flex 18 21 Page 4 7 Traction and Reel Drive System 3 Apply grease to the bore of the bearing housing Install shaft with bearings and spacer into housing and secure with retaining ring 4 Fill small cavity between outer bearing and seal loca tion in bearing housing approximately half full of Mobil High Temperature XHP 222 grease or equivalent Fig 8 5 Pack rear cavity of oil seal with Mobil High Tempera ture XHP 222 grease or equivalent F ig 8 Install oil seal into housing NOTE When installing flex coupler 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 6 Slide coupler onto shaft and secure with new spring pin Installation 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the spark plug 2 Position bearing housing with shaft and coupler to the plate assembly 3 Place
60. e or rebuilding are properly installed to the engine 3 If engine gear was removed from crankshaft posi tion square key in crankshaft keyway Slide gear onto crankshaft Secure gear to crankshaft with cap screw lock washer and flat washer 4 Install engine to engine base Fig 5 and 6 A Make sure that four 4 set screws are secure in engine crankcase cover If set screws were removed from engine cover apply Loctite 242 or equivalent to set screw threads install into engine cover and tighten securely B Install new flange gasket item 2 to set screws on crankcase cover C Position engine on the engine base with the drive gear towards the gearbox assembly D Slide engine toward gearbox while guiding drive gear into gearbox input area Crankshaft may have to be turned to mesh engine gear teeth with gearbox input gears E Install and finger tighten four 4 flange nuts that secure gearbox assembly to set screws on engine crankcase cover F Install four 4 cap screws with flat washers through the engine and engine base Put flange nut on each cap screw and hand tighten G Fully tighten flange nuts that secure gearbox as sembly to engine and then tighten flange nuts that secure engine to engine base Engine Page 3 10 5 Connect electrical connections to engine Fig 8 A Connect wire harness connectors to engine stop switch and armature wires B Secure ground wire to engine with cap screw an
61. earing 4 used 14 Drum shaft spacer 2 used 26 Traction drive pulley 2 used 3 Drum hub 15 Flat washer 4 used 27 Pulley sleeve 2 used 4 Bearing 2 used 16 Traction belt 2 used 28 Seal 2 used 5 Drum spindle 17 Transport wheel shaft RH shown 29 Tab washer 2 used 6 Seal ride spacer 18 Woodruff key 2 used 30 Cap screw 2 used 7 Lock nut 19 Traction pulley RH shown 31 Lock washer 8 used 8 Drum shaft RH shown 20 Cover seal 32 Carriage screw 10 used 9 Bearing spacer 21 Belt cover RH shown 33 Flange nut 12 used 10 Flange 4 used 22 Cap screw 8 used 34 Gearbox assembly 11 Extended race bearing 4 used 23 Cap screw 2 used 35 Set screw 4 used 12 Drum drive idler 2 used 24 Flange nut 2 used NOTE Components shown in the Figure 15 are from the right side of the machine Traction and Reel Drive System Page 4 12 Greensmaster Flex 18 21 Traction Drum Removal Fig 15 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the engine spark plug 2 If installed remove transport wheels see Transport Wheels in the Service and Repairs section of Chapter 6 Chassis and Controls 3 Remove belt cover and traction drive belt from each side of mower see Traction Drive Belt Replacement in this section 4 Loosen setscrews item 25 that secure bearings to drum shafts 5 Insert bar stock or other suitable tool through spokes of drum to keep dru
62. ed it must be connected for proper electrical troubleshooting and safety NOTE See the Kawasaki FE120 Service Manual at the end of Chapter 3 Engine for additional engine igni tion system troubleshooting information Engine will not start ON OFF switch is in the OFF Turn switch to ON or replace switch position or is grounded Ignition spark plug wire is not connected to spark plug Electrical wires are loose or damaged Interlock switch is not adjusted or is faulty Interlock module is faulty Engine will start but will not continue to run damaged Interlock module is faulty Greensmaster Flex 18 21 Electrical wires are loose or Page 5 5 Connect spark plug wire to spark plug Check electrical connections Repair wiring Adjust or replace interlock switch Replace interlock module Check electrical connections Repair wiring Replace interlock module Electrical System n 5 T 2 TT 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 Individual components should be electrically isolated e g disconnect all leads or re move from circuit from the circuit when tested When testing electrical continuity with a multimeter ohms setting make sure that engine is not running to prevent current flow th
63. eee 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 5 Other Torque Specifications 000 eee 6 Conversion Factors cece cece eee 6 Product Records Insert Operator s Manual and Parts Catalog for your Greensmaster Flex 18 or Flex 21 at the end of this sec tion Additionally if any optional equipment or accesso ries 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 18 and Flex 21 are covered in the Operator s Manual Refer to that publica tion when performing regular equipment maintenance Greensmaster Flex 18 21 Page 2 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 03125 0 794 17 32 0 53125 13 494 3 64 0 046875 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 3 175 5
64. ent item 7 was removed secure detent to the cutting unit frame with cap screw and lock washer 2 If flange bushings item 2 were removed align key on bushing to slot in frame and install bushings 3 Apply antiseize lubricant on internal threads of ad juster shaft item 1 and slide into flange bushings in cut ting unit frame 4 Install wave washer item 4 and retaining ring item 5 to secure adjuster shaft to cutting unit frame 5 Thread adjuster screw item 6 into adjuster shaft 6 Install washer item 10 spring item 11 and lock nut item 12 onto adjuster screw 7 Install bedbar see Bedbar Installation in this sec tion 8 Adjust cutting unit Greensmaster Flex 18 21 This page is intentionally blank Greensmaster Flex 18 21 Page 7 15 Cutting Unit Rollers Antiseize Lubricant Figure 22 1 Rear roller 7 Lock nut 2 used 13 Front roller 2 Roller shim 2 used 8 Height of cut washer 2 used 14 Bearing lock 2 used per roller 3 Flange nut 4 used 9 Height of cut arm 2 used 15 V ring 2 used per roller 4 Shaftretainer 2 used 10 Roller spacer 2 used 16 Seal 2 used per roller 5 Socket head screw 4 used 11 Plow bolt 2 used 17 Bearing 2 used per roller 6 Height of cut screw 2 used 12 Cap screw 2 used 18 Roller shaft Cutting Unit Page 7 16 Greensmaster Flex 18 21 Roller Removal Fig 22 Ro 1 Park machine on a level surface Make sure engine
65. ents of the assembled cutting unit If necessary a limited amount of adjustment is possible to parallel the rear roller to the cutting reel see Leveling Rear Roller in the Adjustment section of this chapter 19 Install cutting unit to the traction unit see Separating Cutting Unit from Traction Unit in this chapter Greensmaster Flex 18 21 Cutting Reel Service Fig 33 NOTE Install new reel components on each end ofthe reel shaft that mates with newly serviced side plate com ponents 1 Remove the v ring seal from the reel shaft 2 Using a flat blade screw driver or similar tool careful ly remove wear sleeve from the reel shaft taking care to not damage the reel shaft surface Discard wear sleeve after removal 3 Inspectthe reel shaft as follows Reel should be re placed if damage or wear is determined A Check the reel shaft for bending and distortion by placing the shaft ends in V blocks B Check the reel blades for bending or cracking C Check the threads on the ends of the reel shaft for wear or damage Also inspect woodruff keyslot for damage D Check the service limit of the reel diameter see Preparing Reel for Grinding in this section IMPORTANT During installation do not nick or scratch the wear sleeve surface as grease seal fail ure could result 4 Apply grease to reel shaftto ease wear sleeve instal lation Using tool TOR4105 see Special Tools press the wear sleeve onto the reel sh
66. er Adjustment 6 SERVICE AND REPAIRS sosca 7 Groomer Drive Belt Replacement 7 Grooming Reel cc cece cece eens 8 Grooming Reel Service ccc cece ees 11 Groomer Reel Bearing Replacement 12 Idler Assembly 000 000 c cece eee 14 Groomer Arm Assembly 000008 16 Grooming Brush cce cece cece eens 18 Greensmaster Flex 18 21 Page 8 1 Groomer Specifications MOUNTING The groomer drive kit is mounted to the mower reel bearing housings and frame REEL CONSTRUCTION 2 375 inch 6 cm diameter 35 steel blades with 1 2 inch 12 7 mm blade spacing Spacing is also adjustable to 1 4 and 3 4 inch 6 4 and 19 1 mm spacing by varying the number of blades and spacers GROOMER PENETRATION From 410 inch 10 4 mm above ground level to 0 125 inch 3 2 mm below ground level at mowing HOC range of 062 to 296 inch 1 6 to 7 5 mm Groomer Page 8 2 HEIGHT ADJ USTMENT KNOB Allows a 0 003 inch 0 08 mm increment of height adjustment for each click of the adjuster QUICK UP DOWN FEATURE Allows grooming reel to be raised above the height depth adjustment for no grooming while cutting WIDTH OF GROOMER Flex 18 16 inches 40 6 cm Flex 21 19 inches 48 3 cm Greensmaster Flex 18 21 General Information Transport Mode IMPORTANT Before changing groomer position make certain that the reel drive lever is in the disen gaged position a
67. er onto gearbox shaft noting location of alignment splines on shaft and lever Mount traction lever with cable boss outward Fig 30 Secure lever with cap screw and lock nut Parking brake lever installation should be done with cable attached to lever as gearbox is being installed on machine 15 Check gearbox operation A Engage and disengage clutch brake band and traction band Check for smooth engagement B Turn one differential axle shaft and check that other shaft rotates in opposite direction C If smooth operation is not detected correct prob lem before completing assembly 16 Install reel drive assembly to the gearbox Fig 22 A Apply antiseize lubricant to the bore of the reel drive pulley Place woodruff key in gearbox shaft and slide pulley and pulley washer onto shaft Thread flange nut onto shaft B Position reel drive belt over pulleys and properly tension belt see Transmission Coupler Drive Belt Adjustment in this section C Tighten flange nut to secure pulley Greensmaster Flex 18 21 Page 4 21 Figure 28 1 Traction shaft 2 Traction band Figure 30 3 Cable mounting boss 1 Traction drive lever 2 Parking brake lever Traction and Reel Drive System Traction and Reel Drive System Differential Service Figure 31 1 RH short axle 5 Drive bevel gear 2 LH long axle 6 Washer 3 Retaining ring 7 Washer
68. ermined 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 18 21 26 3N m 38 4 ft lb 52 5N m 54 6 ft lb 73 8N m 66 7 ft Ib 90 10 N m 93 10 ft lb 126 14 N m 166 17 ft Ib 225 23 N m 229 23 ft lb 310 31 N m 325 33 ft Ib 440 45 N m 450 46 ft Ib 610 62 N m Page2 5 28 3 ft lb 38 4 N m NOTE The nominal torque values listed above are based on 7596 of the minimum proof load specified in SAE J 1199 The tolerance is approximately 1096 of the nominal torque value Product Records and Maintenance Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size 140 20 in Ib 73 12 in Ib 1 4 20 UNC 5 16 18 UNC 215 35 in Ib 145 20 in Ib 3 8 16 UNC 35 10 ft lb 1 2 13 UNC 75 15 ft lb 50 10 ft lb 18 3 ft lb Thread Cutting Screws Zinc Plated Steel Type 1 Type 23 or Type F Thread Size Baseline Torque No 6 32 UNC 20 5 in Ib No 8 32UNC 30 5 in Ib 1 4 20 UNC 85 15 in Ib 5 16 18 UNC 110 20 in Ib 3 8 16 UNC 200 100 in Ib No 10 24 UNC 38 7 in Ib Conversion Factors in Ib X 11 2985 2 N
69. esult in personal injury Use heavy gloves when handling the cutting reel IMPORTANT When installing cutting reel take care to not nick or scratch the wear sleeve surfaces as grease seal failure could result 6 Carefully insert cutting reel into LH side plate grease seals and bearing taking care to not damage wear seal or grease seals The reel shaft end with keyway should be on the left side of the frame 7 Carefully slide RH side plate and pitch arm onto reel shaft taking care to not damage wear seal or grease seals Secure RH side plate to crossmember with two 2 shoulder bolts and square nuts Fig 32 Torque shoulder bolts from 210 to 240 in Ib 23 7 to 27 1 N m NOTE The reel bearing lock nut has left hand threads 8 Apply antiseize lubricant to internal threads of reel bearing lock nut Block reel with a piece of wood to pre vent it from turning Install and tighten the reel bearing lock nutto the reel shaft 9 Install reel weighton right side of cutting unit with two 2 cap screws and flat washers 10 Install reel drive plate to cutting unit Fig 31 A Position spacer item 5 to LH side plate B If cutting unit is equipped with a groomer install LH groomer side plate see Groomer Reel Bearing Replacement in the Service and Repairs section of Chapter 8 Groomer C Position two 2 spacers item 4 and reel drive plate to LH side plate D Install two 2 cap screws flat washers and lock nuts
70. ey 2 used SEAL REMOVAL TOOL 188 dia 2 L 5 dia Tap 1 4 20 UNC 2 Figure 27 Greensmaster Flex 18 21 8 If traction band is replaced the new band will have an ink mark on the upper end of the band Fig 28 9 Carefully fit traction shaft with band to the planetary assembly and gearbox base taking care not to distort traction band Traction band should easily slide over traction drum during installation If traction band is im properly placed on the traction shaft or if the band is dis torted it will not fit easily on the drum Check that planetary assembly is free to rotate with band installed Note OnFlex 21 if gearbox is still attached to engine traction lever on engine side of gearbox should be instal led onto traction shaft is shaft is installed into gearbox 10 Rotate differential shaft to verify that all gears and shafts are meshed properly 11 Use dowel pins to position gasket to gearbox base 12 Lubricate short differential axle shaft Position gear box cover to shafts and fit cover to the gearbox base 13 Position drive shaft plate to gearbox with three fas teners two socket head screws shorter and one cap screw with lock washer Install four socket head screws longer and washers in remaining holes in gearbox cov er Torque gearbox fasteners from 120 to 140 in Ib 13 6 to 15 8 N m in the sequence shown in Figure 29 14 Place traction drive lev
71. ight 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 B co o w pan I I I I M o ul Ui 100 10 1130 113 140 15 1582 169 1299 136 160 17 1808 192 2260 282 300 30 3390 339 2542 282 325 33 3672 373 115 12 200 25 225 25 68 7 75 8 102 11 105 11 583 61 600 60 813 81 644 65 667 66 904 89 NOTE The nominal torque values listed above for Grade 5 and 8 fasteners are based on 7596 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 142 15 85 9 150 15 170 18 265 27 300 30 430 45 475 48 Greensmaster Flex 18 21 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Regular Height Nuts 57 6 in Ib M5 X 0 8 96 10 in Ib Class 8 8 Bolts Screws and Studs with Class 8 or Stronger Nuts 644 68 N cm 78 8 in Ib 881 90 N cm 1085 113 N cm Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 133 14 in Ib 1503 158 N cm M6X 1 0 M8 X 1 25 19 2 ft lb NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be det
72. iles 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 18 21 Torque Specifications Recommended fastener torque values are listed in the following tables For critical applications as determined by Toro either the recommended torque or a torque that is unique to the application is clearly identified and spe cified in this Service Manual These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Ser vice Manual The following factors shall be considered when applying torque
73. ke sure entire machine is in good condition keep all nuts bolts screws and belts properly tightened 3 To reduce potential fire hazard keep the engine area free of excessive grease grass leaves and accumula tion of dirt 4 Wear heavy gloves and use caution when checking or servicing the cutting unit 5 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 18 21 Pagel 3 5 Before emptying basket of clippings disengage trac tion and reel drives reduce engine speed and move on off switch to OFF position to stop engine 6 Do not touch engine muffler or exhaust pipe while engine is running or soon after it has stopped because these areas are hot enough to cause burns 7 Ifthe cutting unit strikes a solid object or vibrates ab normally stop immediately turn engine off wait for all motion to stop and inspect for damage A damaged reel or bedknife must be repaired or replaced before opera tion 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 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 or in a vehicle 6 Do notoverspeed the engine by changing governor se
74. kin Over Grease Toro Part Number 505 165 Special non conductive grease which forms a light pro tective skin to help waterproof electrical switches and contacts Dielectric Gel Toro Part Number 107 0342 Dielectric gel should be used to prevent corrosion of connection terminals To ensure complete coating of ter 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 Greensmaster Flex 18 21 Page 5 3 Some tools may also be available from a local supplier Figure 1 Figure 2 Figure 3 Electrical System Electrical System Spark Tester Toro Part Number TOR4036 For testing electronic ignitions Saves time because you will know if the ignition is causing the problem on a non starting engine The tester determines if ignition spark is present Figure 4 Electrical System Page 5 4 Greensmaster Flex 18 21 Troubleshooting Remove all jewelry especially rings and watches before doing any electrical testing or troubleshooting For effective troubleshooting and repairs there must be a good understanding of the electrical circuits and com ponents used on this machine see Wiring Schematic section of this chapter Starting Problems The interlock switch must not be by pass
75. l injury Use heavy gloves when handling the cutting reel or bedknife 5 Remove bedbar from the cutting unit by pulling downward 6 Inspect nylon bushings and rubber bushings in cut ting unit side plates Remove and replace bushings if necessary Greensmaster Flex 18 21 Installation Fig 14 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the spark plug 2 Install bedbar from bottom of cutting unit frame mak ing sure that bedbar mounting ears are positioned be tween washer and bedbar adjuster screw Fig 15 3 Thread flange nuts fully onto bedbar pivot bolts with flange away from head of pivot bolt Apply antiseize lu bricant to threads and shank of pivot bolts 4 Slide metal washer and then nylon washer onto each bedbar pivot bolt The metal washer must contact the flange nut 5 Position metal washer and nylon washer between bedbar and cutting unit side plate The nylon washer should be placed next to the side plate 6 Slide each bedbar pivot bolt assembly through side plate and washers and then thread into bedbar After both bedbar bolts have been installed torque bedbar pivot bolts from 190 to 240 in Ib 21 5 to 27 1 N m 7 Tighten flange nuts until all end play is removed from outside washers Do not overtighten flange nuts After tightening flange nuts inner washers still might rotate 8 Tighten spring tension lock nut to fully compress spring and then b
76. late 13 Inspect seals bushings and bearings in side plates for wear or damage Replace components as needed Installation 1 Park mower on a level surface Make sure engine is OFF Remove high tension lead from the spark plug 2 Apply a light coating of grease to seal lips in RH and LH side plates Make sure that seals bushings and bearing are properly positioned in side plates Figure 8 3 Carefully place grooming reel assembly into the LH 1 Roller retaining cap screw side plate bearings taking care to not damage seal in 2 Cap plug side plate Thread flange nut onto the shaft threads but do not fully tighten 4 Carefully place RH side plate onto grooming shaft taking care not to damage seals in side plate Position side plate to the cutting unit Secure side plate with two 2 shoulder nuts item 13 NOTE The drive pulley has left handed threads To prevent cutting reel from turning when installing drive pulley block reel with piece of wood 5 Apply a light coating of grease to drive pulley hub tak ing care to not get grease on belt surface Install and tighten drive pulley onto the reel shaft Figure 9 6 Align splines of driven pulley to grooming shaft and 1 RH side plate 3 Driven pulley install pulley onto the shaft Thread flange nut onto the 2 Driv pulley shaft threads but do not fully tighten Greensmaster Flex 18 21 Page 8 9 Groomer NOTE To prevent grooming shaft from turning when in
77. lock module for damage Repair or replace any damaged wiring or components 2 Check the adjustment and continuity of the interlock switch located on equipment handle A Disconnect interlock switch wire connector from wiring harness B Place traction lever in the FORWARD position The switch should be open no continuity C Place traction lever in the NEUTRAL position The switch should be closed continuity D Adjust interlock switch until it opens and closes properly when the traction lever is in the FORWARD and NEUTRAL positions See Interlock S witch in the Service and Repairs section of this Chapter E Connect interlock switch to wiring harness 3 With engine ON OFF switch in the ON position at tempt to start the engine If the engine does not start check the interlock module using the following steps A Disconnect red wire male connector where it connects to the black wire leading to the ignition coil Fig 5 B Attempt to start the engine The engine should start Lighting Coil The engine on the Greensmaster Flex 18 and Flex 21 is equipped with a lighting coil to provide electrical current for an optional lighting kit The coil is located under the engine flywheel and uses permanent magnets on the flywheel to operate See the Kawasaki FE 120 Service Manual atthe end of Chapter 3 Engine for lighting coil testing information Greensmaster Flex 18 21 Page 5 7 C Ground the red wire male con
78. m from turning NOTE The right side transport wheel shaft has left hand threads Fig 16 6 Loosen and remove both transport wheel shafts item 17 NOTE The left side drum pulley has left hand threads Fig 16 7 Loosen and remove both drum pulleys item 19 NOTE The left side drum shaft has left hand threads Fig 16 8 Unscrew both drum shafts item 8 from traction drum assembly 9 Locate and remove drum spacer item 41 from each side of traction drum assembly 10 Remove traction drum assembly from the mower 11 If necessary remove bearing flangettes item 10 and bearings item 11 from machine frame Traction Drum Disassembly Fig 15 1 Remove four 4 cap screws item 22 and lock wash ers item 34 that secure each traction drum to drum hub spindle assembly Separate traction drums from hub spindle assembly 2 Retain drum spindle item 5 to prevent it from turn ing and remove lock nut item 7 Carefully slide drum spindle from the drum hub assembly 3 Remove seal ride spacer item 6 seals item 28 bearings item 4 and bearing spacer item 9 from drum hub Greensmaster Flex 18 21 Page 4 13 RIGHT 2 HAND s LOCTITE 2242 i ANTISIE ZE LUBRICANT Lu LEFT HAND THREADS LOCTITE 242 LEFT HAND THREADS
79. n Technical Publications 8111 Lyndale Avenue South Minneapolis Minnesota 55420 1196 2 Never allow children to operate the machine or allow 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 all shields safety devices and decals in place If a shield safety device or decal is malfunctioning illeg ible or damaged repair or replace it before operating the machine 5 Always wear substantial shoes Do not operate ma chine while wearing sandals tennis shoes or sneakers Do not wear loose fitting clothing which could get caught in moving parts and cause personal injury 6 Wearing safety glasses safety shoes long pants ear protection and a helmet is advisable and required by some local safety and insurance regulations Safety Page 1 2 To reduce the potential for injury or death comply with the following safety instructions 7 Ensure work area is clear of objects which might be picked up and thrown by the cutting reel 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 Do notremove 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
80. nd that the cutting reel is not rotat ing IMPORTANT When transporting the mower make sure the cutting unit is disengaged and the groom ing reel is raised to its transport position To place the grooming reel in the raised transport posi tion remove the lock screw and rotate the lift arm to raise the grooming reel Install the lock screw to retain the grooming reel in the transport position Fig 1 To place the grooming reel in the lowered grooming position remove the lock screw and rotate the lift arm to lower the grooming reel Install the lock screw to retain the grooming reel in the grooming position Fig 2 Greensmaster Flex 18 21 Page 8 3 Figure 1 1 Liftarm 2 Lock screw transport Figure 2 2 Lock screw grooming 1 Liftarm Groomer Troubleshooting Factors Affecting Grooming Performance There are a number of factors that can affect the 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 It is 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 OPERA TION INSTRUCTIONS BEFORE
81. nector to the en gine block and attempt to start the engine The en gine should not start D Connect the red wire to the black wire 4 Disconnect interlock switch on handle from wiring harness Position engine ON OFF switch to ON A Attempt to start the engine The engine should not start B J umper across the wire harness connector termi nals and attempt to start the engine The engine should start C Remove jumper and connect interlock switch to wiring harness 5 Replace interlock module if it fails either of the tests in step 3 or 4 Figure 5 4 Armature wire 5 Ground connection 6 Wires to interlock switch Wire harness Interlock module Stop switch wire WNE Electrical System n 5 T 2 TT Service and Repairs NOTE See the Kawasaki FE120 Service Manual at the end of Chapter 3 Engine for additional repair in formation Interlock Switch Adjustment 1 Make sure the engine is OFF and the traction lever is in the NEUTRAL position 2 Loosen interlock switch mounting fasteners 3 Hold traction lever against the neutral stop Fig 6 4 Position switch to allow from 0 032 to 0 062 0 81 to 1 58 mm clearance between the traction lever and the interlock switch Fig 6 5 Tighten interlock switch mounting fasteners Re check clearance between lever and switch after tighten ing fasteners The traction lever must not contact the switch 6 Engage traction lever and
82. nge bushing Bronze bushing 2 used Greensmaster Flex 18 21 Handle Removal 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the engine spark plug 2 Note location of cable ties used to secure control cables Remove cable ties 3 Disconnect A Reel control and traction cables from gearbox see Cable Replacement in this section B Parking brake cable from brake bracket assem bly see Cable Replacement in this section C Throttle cable from engine see Throttle Cable Replacement in this section D Interlock switch wire connection 4 Loosen and remove flange nut from cap screw on each end of the handle Fig 3 5 Remove handle from frame Handle Installation 1 Slide handle ends through the holes in the handle arms with grommets Install handle to the frame using cap screw pivot pin and flange nut on each side 2 Attach and adjust A Reel control traction and parking brake cables see Cable Replacement in this section B Throttle cable see Throttle Cable Replacement in this section C Interlock switch wire connection 3 Secure cables to handle with cable ties 4 Attach spark plug wire to spark plug wr Greensmaster Flex 18 21 Page 6 5 Ur i ui E Figure 2 Handle end 4 Ring pin Handle arm w grommet 5 Capscrew Hairpin cotter 6 Pivotpin Handle Handle arm Handle grommet Handle support spacer Pivot pin 6 Flange nut
83. ngine and remove the unit parts can result in personal injury Use spark plug wire from the spark plug first ben ae when handling the cutting reel or edknife 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 amount of side plate adjust ment is possible to make sure that the cutting unit is properly aligned 1 Place the assembled cutting unit on a surface plate 2 On both sides of cutting unit loosen bedbar adjuster screw by turning screw counterclockwise Fig 11 3 Back off the spring tension lock nuts until the washer is no longer tensioned against the bedbar Fig 11 4 Loosen but do not remove two 2 cap screws and a lock nuts that secure the grass shield to the side plates Figure 11 Fig 12 1 Bedbar 3 Spring tension lock nut d 2 Bedbar adjuster screw 5 Loosen but do not remove four 4 shoulder bolts that secure the side plates to the crossmember Fig 12 210 to 240 in Ib 23 7 to 27 1 N m 6 Adjustthe position of the side plates to parallel the rear roller and cutting reel Then tighten the four 4 shoulder bolts to a torque from 210 to 240 in Ib 23 7 to 27 1 N m 7 Tighten the cap screws and lock nuts that secure the grass shield to the cutting unit side plates 8 Tighten each spring tension lock nut until the
84. nit side plate with HOC washer and lock nut C Secure groomer lift rod to cutting unit side plate with spring washer and lock nut D Make sure that front roller is centered to cutting unit Secure front roller to groomer arm with cap screw 3 Check height of cut and adjust as needed Figure 18 1 HOC screw 5 Locknut 2 Groomer sideplate 6 HOC washer 3 Spring washer 7 Groomer arm 4 Lock nut 8 Plow bolt Figure 19 1 LH groomer side plate 3 LH groomer arm 2 Lock nut spring washer Greensmaster Flex 18 21 Page 8 17 Groomer Grooming Brush Figure 20 1 Grooming brush shaft 3 J bolt 2 Locknut The grooming brush attaches to the groomer drive in place of the grooming reel Removal and installation of the grooming brush use the same procedure as removal and installation of the grooming reel see Grooming Reel in this section To remove the grooming brush from the shaft remove the lock nut and J bolt from both ends of the brush While retaining the shaft rotate the brush and slide from the shaft When assembling the brush to the shaft se cure the assembly with J bolts and lock nuts Make sure that the J bolts are installed with the threaded portion Figure 21 on the outside of the brush Fig 21 Torque lock nuts 1 J bolt 2 Locknut from 20 to 25 in Ib 2 3 to 2 8 N m Groomer Page 8 18 Greensmaster Flex 18 21
85. nut item 7 and spring washer item 6 that secure RH groomer arm lift rod to RH side plate F ig 7 Groomer Page8 8 5 Remove lock nut item 29 HOC washer item 28 and plow bolt item 27 that secure RH groomer arm as sembly to RH side plate Do not change height of cut screw adjustment Remove RH groomer arm assembly 6 Pull frontroller assembly out of LH groomer arm and remove from mower NOTE To prevent grooming shaft from turning when removing driven pulley use wrench on shaft flats to hold shaft 7 Remove the flange nut that secures driven pulley item 15 to grooming shaft Remove driven pulley from shaft Greensmaster Flex 18 21 prevent cutting reel from turning when removing drive NOTE The drive pulley has left handed threads To E pulley block reel with piece of wood E 8 Use a 3 8 drive socket wrench to remove drive pulley item 17 from the cutting reel shaft 9 Remove two 2 shoulder nuts item 13 that secure the groomer RH side plate to the cutting unit side plate Remove the groomer RH side plate 10 Remove the cap plug from LH side plate Fig 8 NOTE To prevent the grooming shaft from turning when removing flange nut use wrench on shaft flats to hold shaft E f Figure 7 11 Remove the flange nut that secures the grooming 1 Cap screw 3 Grooming shaft shaftto the LH side plate 2 Frontroller shaft 4 Locknut spring washer 12 Pull the grooming reel from the LH side p
86. nut torque should be from 17 to 21 ft Ib 23 to 28 N m 15 Apply Loctite 242 or equivalent to threads of cap plug item 21 Install cap plug into LH side plate and torque from 60 to 80 ft Ib 82 to 108 N m Fig 8 16 Install groomer belt cover to cutting unit 17 Lubricate groomer bearings 18 Attach spark plug wire to engine spark plug NOTE After greasing groomer bearings operate groomer for 30 seconds stop machine and wipe excess grease from grooming shaft and seals Greensmaster Flex 18 21 Grooming Reel Service Inspect grooming reel blades frequently for damage and wear Straighten bent blades with a pliers Replace blades that are worn or damaged Fig 12 Blades that are rounded to the midpoint of the blade tip must be re placed Carbide tipped grooming blades Fig 11 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 12 should be replaced if worn or damaged Blades that are rounded to the midpoint of the blade tip can be reversed on the grooming shaft to extend the life of the blade Disassembly Fig 10 1 Remove grooming reel from cutting unit see Groom ing Reel Removal in this section 2 Remove lock nut from either end of the shaft 3 Remove spacers and grooming blades as neces sary Assembly Fig 10 1 Start by placing two 2 space
87. of the grooming reel measure the dis tance from the lowest tip of the grooming blade to the working surface Lift and turn height adjustment knob to raise or lower the blade tip Fig 3 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 Height setting on both ends of groomer should be identi cal 6 Attach spark plug wire to engine spark plug Figure 3 3 Height adjustment knob 1 Liftarm 2 Lock screw grooming Groomer Page8 6 Greensmaster Flex 18 21 Service and Repairs Groomer Drive Belt Replacement 1 Park mower on a level surface Make sure engine is OFF Remove high tension lead from the engine spark plug 2 Remove two 2 lock nuts that secure groomer belt cover to cutting unit then remove cover Fig 4 3 Pivot idler pulley by placing a 10mm wrench on pulley nut and rotating clockwise to relax belt tension Slip groomer drive belt off pulleys Fig 5 Release idler IMPORTANT When installing groomer drive belt make sure that belt is centered on the pulleys and in the grooves 4 Install new groomer drive belt to drive pulley idler pulley and driven pulley observing correct belt routing Fig 5 Make sure that groomer belt is centered in pul leys 5 Rotate drive pulley a few revolutions to make sure that drive belt remains centered in
88. ollows A Using a 1 4 thick 3 X 3 square piece of steel make a seal removal tool as shown in Fig 27 B If seal is secured with retaining ring remove re taining ring Slide seal removal tool over shaft C Using the tool as a template locate mark and drill two 7 64 109 diameter holes in outer face of seal D Screw two No 8 164 diameter by 3 4 long self tapping screws into outer face of seal E Install two 1 4 20 by 1 long cap screws into tapped holes in seal removal tool and alternately tighten cap screws to pull seal out of gearbox Dis card removed seals NOTE Gearbox seals will be damaged when removed Do not re use seals that have been removed 14 Carefully inspect all internal gears shafts washers bushings and bearings Replace all worn or damaged components Assembly Fig 21 1 Replace all removed oil seals bushings and bear ings in the gearbox cover and base Note The oil seal for the reel drive clutch shaft is a red orange color to dif ferentiate it from other similarly sized seals in the gear box Oil seals should be installed flush or slightly recessed in seal bore If seal is secured with retaining ring install retaining ring If clutch shaft caged needle bearing in gearbox base is replaced item 3 closed end of bearing should be flush with outside of base after installation 2 Thoroughly apply grease to seal lips in both the gear box base and cover 3 If clutch shaft w
89. on 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 G rind bedknife to 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
90. ove reel drive plate from cutting unit Fig 31 A Remove fasteners that secure reel drive plate to cutting unit side plate B Pull drive plate assembly from cutting unit Greensmaster Flex 18 21 C If cutting unitis equipped with a groomer remove LH groomer side plate see Groomer Reel Bearing Replacement in the Service and Repairs section of Chapter 8 Groomer D Locate and retrieve three 3 spacers items 4 and 5 from between reel drive plate and side plate 7 Remove front and rear rollers from cutting unit see Roller Removal in this section 8 Support reel weight on right side of the cutting unit to prevent it from falling Remove two 2 cap screws and flat washers that secure weight Remove reel weight from cutting unit NOTE The reel bearing lock nuthas left hand threads Figure 30 1 Capscrew w lock washer 3 LH cutting reel sideplate 9 Block reel with a piece of wood to prevent reel from 2 Cap screw w flat washer turning Remove reel bearing lock nut from right side of peek 40 to 50 ft Ib 10 Remove cap screw flat washer and lock nut that se 9419 68 Nom cures grass shield to RH side plate IMPORTANT Support reel to prevent it from falling as side plate is removed 11 Remove two 2 shoulder bolts and square nuts that secure RH side plate to crossmember Fig 32 Slide RH side plate and pitch arm from reel shaft Antiseize 4 Lubricant 12 Slide cutting reel from the LH side plate and cu
91. over Keyed bushing E ring Traction drive lever Socket head screw 2 used Socket head screw 4 used Drive shaft plate assembly Internal lock washer Oil seal red orange color O ring Dowel pin Wave washer Hub Retaining ring Parking brake lever Greensmaster Flex 18 21 Disassembly Fig 21 1 Clean outside of the gearbox assembly 2 Remove reel drive assembly from gearbox F ig 22 A Loosen flange nut that secures reel drive pulley to gearbox clutch shaft B Remove reel drive belt C Remove flange nut and pulley washer from gear box clutch shaft and slide pulley from shaft Take woodruff key from shaft D Pull drive shaft plate from gearbox after removing Figure 22 1 Drive shaft plate 4 Flange nut three 3 feras eu p head screws and one a Socket hesd erew a PE A OERE cap screw with lock washer 3 Cap screw w lock washer 3 Remove all burrs from axle and clutch shafts 4 Loosen lock nutthatis used to secure traction lever to the traction shaft Remove lever Note that lever and shaft splines identify correct lever location on shaft 5 Remove four 4 remaining socket head screws and flat washers that secure gearbox cover to base Drive System e LU cc s S a4 9 g NOTE Gearbox cover removal will be easier by lightly lubricating external extensions of axles and shafts 6 Pull gearbox cover from gearbox base taking care not to dislo
92. pacer 107 3505 Bearing installation washer yellow 104 6126 Cutting Unit Page7 4 Some tools may have been supplied with your mower or are available as TORO parts Some tools may also be available from a local supplier Figure 4 Figure 5 Figure 6 4 Seal Installation Spacer Bearing Installation Washer Seal Installation Washer Figure 7 Greensmaster Flex 18 21 Bearing and Seal Installer Toro Part Number TOR4105 Used to install bearings and seals into front and rear roll ers NOTE TOR4105 is an alternative to using washers and spacers listed above Figure 8 Sleeve Driver Toro Part Number TOR4107 Used to drive the wear sleeve into position on the cutting reel shaft Figure 9 Sleeve Driver and Bearing and Seal Installer Set Toro Part Number TOR4108 Set includes both TOR4105 and TOR4107 in a plastic storage case with foam inserts Figure 10 Greensmaster Flex 18 21 Page7 5 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 secti
93. peration general maintenance and maintenance intervals for your Greensmaster machine Refer to the Operator s Manual for additional information when ser vicing the machine Greensmaster Flex 18 21 Page 3 3 use of some specialized test equipment is explained However the cost of the test equipment and the special ized nature of some repairs may dictate that the work be done at an engine repair facility Service and repair parts for Kawasaki engines are sup plied through your local Toro distributor Be prepared to provide your distributor with the Toro model and serial number Engine Adjustments Throttle Cable Adjustment If a new throttle cable must be installed or the cable is out of adjustment adjust the cable as follows 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the spark plug 2 Move throttle control lever on the handle to the FAST position 3 Loosen throttle cable screw that secures the throttle cable to the governor lever 4 Make sure throttle lever is in the FAST position and the governor lever is against the high idle speed screw 5 Tighten throttle cable screw to secure the throttle cable to the governor lever 6 After cable adjustment connect spark plug wire to spark plug start engine and check engine speed with a tachometer A Low idle speed should be 2300 to 2500 RPM Ad just low idle speed screw in or outto attain the correct low idle spee
94. pulleys during opera tion 6 Position belt coverto cutting unit and secure with two 2 lock nuts 7 Attach spark plug wire to engine spark plug Figure 4 1 Groomer belt cover 2 Lock nut Figure 5 1 Drive pulley 4 Driven pulley 2 Idler pulley 5 Groomer drive belt 3 Idler pulley nut Greensmaster Flex 18 21 Page 8 7 Groomer Grooming Reel 17 to 21 ft Ib 23 to 28 N m NS A Loctite 242 60 to 80 ft Ib 82 to 108 N m 17 to 21 ft Ib 23 to 28 N m Figure 6 1 LH groomer arm 11 Cap screw 2 used 20 Lock nut 2 used 2 RH groomer arm 12 Decal 21 Cap plug 3 Non drive side plate 13 Shoulder nut 2 used 22 Grease fitting 4 Drive side plate 14 Lock nut 2 used 23 Cap screw 2 used 5 Bushing 2 used 15 Driven pulley 24 Groomer shim 6 Spring washer 2 used 16 Flange nut 2 used 25 Extension spring 7 Locknut 2 used 17 Drive pulley 26 Oil seal 8 Grooming shaft assembly 18 Groomer belt 27 Plow bolt 2 used 9 Extended race bearing 2 used 19 Groomer belt cover 28 HOC washer 2 used 10 Front roller Removal 1 Park mower on a level surface Make sure engine is OFF Remove high tension lead from the engine spark plug 2 Remove groomer belt cover and groomer belt from right side of mower see Groomer Drive Belt Replace ment in this section 3 Loosen cap screws that secure front roller shaft to RH and LH groomer arms Figs 7 and 8 4 Remove lock
95. rol cable from the gearbox as fol lows Fig 8 A Loosen front cable jam nutand lift cable free from casting slot of gearbox B Remove retaining ring that secures cable eyelet to reel control bellcrank C Remove reel drive cable from gearbox 4 Remove reel control cable from the reel control lever as follows Fig 9 A Remove retaining ring that secures the cable housing to the control bracket B Unhook reel control cable spring from reel control lever 5 Remove reel control cable from the machine Installation 1 Secure reel control cable to the reel control lever Fig 9 A Hook cable spring to reel control lever B Secure the cable housing to the control bracket with retaining ring 2 Route reel control cable to the gearbox Install cable to the gearbox as follows Fig 8 A Secure cable eyelet to the reel control bellcrank with retaining ring B Position reel cable to the casting slot on gearbox with a washer and jam nut on each side of the slot 3 Adjust reel control cable see Operator s Manual 4 Secure reel control cable with cable ties 5 Attach spark plug wire to spark plug Chassis and Controls Page6 8 Figure 8 1 Reel control cable 4 Reel control bellcrank 2 Cable jam nuts 5 Retaining ring 3 Cable eyelet Figure 9 5 Retaining ring 6 Traction lever assembly 7 Control knob Control bracket Reel control lever Reel control cable spring Cable housing
96. rough the component components for Ignition System Operation The engine on Flex 18 and Flex 21 machines has a mag neto ignition system consisting of an ignition coil spark plug and permanent flywheel magnets A flywheel key maintains proper ignition timing Testing the Ignition System NOTE Do notremove 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 4 Pull the engine starter rope and observe the spark tester Visible and audible sparks should be produced Ignition Coil A commercial coil tester can be used to testthe ignition coil The coil can be tested for a badly shorted or broken winding with a digital multimeter However a multimeter can not detect layer shorts and shorts resulting from in Electrical System Page5 6 NOTE See the Kawasaki FE120 Service Manual at the end of Chapter 3 Engine for more component test ing information 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 5 If visible and audible sp
97. round to the desired cylinder shape NOTE When grinding the cutting reel be careful to not overheat the reel blades Remove small amounts of ma terial with each pass of the grinder 4 Grind cutting reel referto TORO Sharpening Reel and Rotary Mowers Manual Form No 80 300 PT 5 After completing grinding process A If equipped install grooming reel see Grooming Reel in the Service and Repairs Section of Chapter 8 Groomer B Install front roller see Roller Installation in this section C Install bedbar assembly see Bedbar Installation in this section D Complete mower set up and adjustment se quence Reel Grinding Specifications Nominal Reel Diameter 5 in 127 mm Service Limit Reel Diameter 4 5 in 114 mm Blade Relief Angle 309 Relief Angle Range 20 to 40 Blade Land Width 0 040 in 1 0 mm Blade Land Width Range 0 030 to 0 060 in 0 8 to 1 5 mm Max Reel Taper 0 040 in 1 0 mm BLADE RELIEF ANGLE REEL DIAMETER TAPER D D Figure 36 Cutting Unit Page 7 26 Greensmaster Flex 18 21 Chapter 8 TORO Groomer Table of Contents SPECIFICATIONS arderi ee eR emen 2 GENERAL INFORMATION 000 000 eee 3 Transport Mode ccc ccc c cece eee eens 3 TROUBLESHOOTING 0c eee ee eee 4 Factors Affecting Grooming Performance 4 Grooming Reel Mechanical Problems 5 ADJUSTMENTS Tanna cece eee 6 Height Depth of Groom
98. rs against a lock nut installed on one end of grooming shaft Then place first blade against spacers 2 For 1 2 inch 12 7 mm spacing make sure there are two 2 spacers between blades 3 When all blades have been installed place final two 2 spacers on shaft and then thread lock nut onto the shaft 4 Position lock nuts to allow blades and spacers to be centered on the shaft Torque lock nuts from 200 to 250 in Ib 22 6 to 28 3 N m so spacers are not free to ro tate 5 Install grooming reel back on cutting unit see Grooming Reel Installation in this section Greensmaster Flex 18 21 Page 8 11 ae 1 Grooming blade 2 Sharp edge CENTER BLADES ON SHAFT 200 to 250 in Ib 22 6 to 28 3 N m Figure 10 1 Lock nut 3 Spacers 2 Shaft 4 Grooming blade IO Figure 11 1 Grooming blade 2 Carbide tip OE ROTATION NU Figure 12 3 Dull rounded edge Groomer Groomer Reel Bearing Replacement Seal lip Figure 13 1 RH groomer side plate 4 Grease fitting 6 Side plate bushing 2 Oil seal 5 Bushing 7 LH groomer side plate 3 Bearing w extended inner race Groomer Page 8 12 Greensmaster Flex 18 21 Bearing Removal Fig 13 1 Remove front roller RH groomer side plate and grooming reel see Grooming Reel Removal in this sec tion 2 Remove LH groomer side plate A Take reel drive assembly from left side of cutting unit see Cutting Reel Removal in th
99. rter Greensmaster Flex 18 21 Page 3 5 Engine Spark Plug Use a NGK BPR 5ES spark plug or equivalent 1 Make sure engine is OFF Carefully pull spark plug L wire off the spark plug 0 028 to 0 032 0 7 to 0 8 mm 2 Clean around spark plug and remove plug from the cylinder head NOTE The condition of the spark plug can give an ac curate picture of the overall condition of the engine Use B5 X29 9600000 00 the chart on the following page as a guide to determine au MED possible problems with the engine 3 Inspectthe spark plug Figure 4 IMPORTANT Replace a cracked fouled or dirty spark plug Do not sand blast scrape or clean spark plug electrodes because engine damage could re sult from grit entering cylinder 4 Set electrode gap from 0 028 to 0 032 0 7 to 0 8 mm Install correctly gapped spark plug into cylinder head and torque plug to 17 ft lb 23 N m Connect spark plug wire to spark plug Engine Page3 6 Greensmaster Flex 18 21 NORMAL Has gray or light tan deposits on the firing tip LEAD FOULED Has dark black gray tan or yellow deposits May have a fused glazed coating on the in sulator tip Caused by highly leaded gasoline Replace spark plug GAP BRIDGED Gap between electrodes is closed by de posit build up May be caused by carbon or oil fouling Replace spark plug Greensmaster Flex 18 21 OVER HEATING Light gray or white insulator with small gray bro
100. rvice and Repairs Chapter 8 Groomer Specifications General Information Troubleshooting Adjustments Service and Repairs Product Records and Maintenance 7 LU cc cS S S 2 o Electrical Chassis and System Drive System Controls This page is intentionally blank Greensmaster Flex 18 21 Chapter 1 S afety TORO Table of Contents SAFETY INSTRUCTIONS cece eee ee 2 Before Operating s u auaa 2 While Operating 0 cc cece 3 Maintenance and Service 000 eens 3 SAFETY AND INSTRUCTION DECALS 4 Greensmaster Flex 18 21 Pagel 1 Safety Safety Instructions Although hazard control and accident prevention par tially are dependent upon the design and configuration of the machine these factors are also dependent upon the awareness concern and proper training of the per sonnel involved in the operation transport mainte nance and storage of the machine Improper use or maintenance of the machine can result in injury or death To reduce the potential for injury or death comply with the following safety instructions Before Operating 1 Operate the machine only after reviewing and under standing the contents of the Operator s Manual and Op erator Training DVD A replacement Operator s Manual is available on the internet at www toro com or by send ing the complete model and serial number to The Toro Company Att
101. sed on the Operator Presence Kit switch Fig 8 2 With the bail held against the handle there should be continuity between the same two terminals Adjustment 1 Mount operator presence switch to allow switch plunger to be depressed 0 080 2 0 mm when operator presence bail is engaged 2 Switch plunger should be fully extended when oper ator presence bail is released 1 Plunger 2 Common Greensmaster Flex 18 21 Page 5 9 Figure 8 3 Normally open 4 Normally closed Electrical System T 5 E 2 TT ao N LE 7 This page is intentionally blank Electrical System Page 5 10 Greensmaster Flex 18 21 Chapter 6 TORO Chassis and Controls Table of Contents SPECIFICATIONS 2 RR em n memes 2 GENERAL INFORMATION cece eae 3 Operator s Manual 00000 eee eee 3 SERVICE AND REPAIRS ccc eee eee 4 Handle Assembly 0 00000 cece eee eee 4 Parking Brake Cable Replacement 6 Traction Control Cable Replacement 7 Reel Control Cable Replacement 8 Throttle Cable Replacement 9 Transport Wheels Optional 10 KiCkStarid zin bis beet esed ed durs tears 12 cs 5 2 22 Qe Zo So o Greensmaster Flex 18 21 Page 6 1 Chassis and Controls Specifications Item Description Transport Wheel Optional Tire Pressure 12 to 15 PSI
102. sing on the gear side Install washer drive bevel gear and new re taining ring on short axle Install LH long axle into re maining side of input gear housing using the same procedure 2 Through the open sides of the input gear housing align two driven bevel gears and rotate axle to move them into their correct position Greensmaster Flex 18 21 Page 4 23 3 Place a washer between input gear housing and each driven bevel gear Install gear shaft with grooved end located at roll pin hole 4 Check gear and shaft alignment by rotating one axle The other axle should turn in the opposite direction with out any binding Once free axle movement is checked install new roll pin to secure gear shaft 5 Install differential assembly in gearbox and as semble gearbox see Gearbox Assembly Install gear box to traction unit see Gearbox Installation Traction and Reel Drive System Drive System e E 3 c 2 9 This page is intentionally blank Traction and Reel Drive System Page 4 24 Greensmaster Flex 18 21 Chapter 5 TORO Electrical System Table of Contents WIRING SCHEMATIC 2 c cee eee eee 2 SPECIAL TOOLS x waives e cR ERR d 3 TROUBLESHOOTING cc cece eee eee 5 Starting Problems 60 cece e eee 5 COMPONENT TESTING oos 6 Ignition System Operation 00 6 Ignition Coll eonun eke eee es 6 Interlock Module and Switch
103. stalling flange nuts use wrench on shaft flats to hold shaft 7 Secure grooming reel by tightening flange nuts on both ends of grooming shaft Torque flange nuts from 17 to 21 ft Ib 23 to 28 N m 8 Insert front roller into LH groomer arm 9 Position RH groomer arm to front roller groomer RH side plate and mower frame Secure groomer arm to mower with carriage bolt washer and flange nut 10 Install spring washer and lock nut to secure RH groomer arm lift rod to RH groomer side plate Fig 7 11 Center front roller and tighten cap screws to secure roller Figs 7 and 8 IMPORTANT When installing groomer drive belt make sure that belt is centered on the pulleys and in the grooves 12 Install groomer drive belt to right side of mower see Groomer Drive Belt Replacement in this section Do not install belt cover atthis time 13 Check grooming reel height and mower height of cut settings Adjust as needed Groomer Page 8 10 Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when rotating the cutting reel 14 After groomer height has been adjusted rotate cut ting reel by hand to make sure that the grooming shaft is seated in the bearings and rotates without binding Also make sure that the groomer drive belt is tracking straight in the pulleys After rotating the reel re check the torque on the flange nuts on both ends of grooming shaft Flange
104. stroke OHV single cylinder air cooled gasoline engine FE120D Bore x Stroke 2 36 x 1 73 60 mm x 44 mm Total Displacement 7 6 in 124 cc Compression Ratio 8 4 1 Carburetor Float feed fixed main jet Governor Mechanical flyweight Low Idle Speed no load 2400 100 RPM High Idle Speed no load 3600 100 RPM Direction of rotation Counter clockwise facing PTO shaft Fuel Unleaded automotive grade gasoline Fuel Tank Capacity 2 6 U S qt 2 5 I Engine Oil See Operator s Manual Lubrication S ystem Splash type Oil Capacity 0 63 U S qt 0 6 Air Cleaner Dual element Ignition System Transistorized flywheel magneto with ignition advance Spark Plug NGK BPR 5ES Spark Plug Gap 0 028 to 0 032 0 7 to 0 8 mm Dry Weight 32 4 lbs 14 7 kg Engine Page 3 2 Greensmaster Flex 18 21 Introduction This Chapter gives information about specifications maintenance troubleshooting testing and repair of the gasoline engine used in the Greensmaster Flex 18 and Flex 21 mowers Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the Kawasaki FE120D Service Manual that is included at the end of this Chapter The General Information Operator s Manual The Operator s Manual provides information regarding the o
105. talled seals with 2 grease This will preserve the patch lock feature in the new lock nuts Use the new nuts only after new bearings 5 Inserta v ring seal onto each bearing lock nut with and seals have been installed the thick shoulder of the v ring seal toward the lock nut Fig 24 A Position a new bearing black assembly washer see Special Tools and original lock nut onto each NOTE If original bearing lock nut s are being used end of the roller shaft Fig 25 apply Loctite 242 or equivalent to threads of lock nut s B Tighten nuts until the bearings are seated into each end of the roller Remove nut and black assem 6 Install bearing lock nut with v ring onto each end of bly washer from each end of the roller the roller shaft Torque lock nuts from 25 to 30 ft Ib 34 to 41 N m IMPORTANT Failure to grease bearing lock nut before seal installation may cause seal damage C Apply a coating of grease to bearing lock nut shoulder surface to prevent seal damage during seal installation Fig 26 D Carefully install seals onto bearing lock nuts Pack the back of the seal 75 to 90 full with 2 grease Fig 26 E Install a nut with seal onto each end of the roller shaft Tighten nuts until they bottom against bearings Fig 27 Remove nuts from roller shaft Figure 26 1 Bearing lock nut 3 Grease nut surface 2 Seal 4 Pack with grease F Position an assembly spacer and yellow assem bly washer see
106. tem 16 with Mobil High Temperature XHP 222 grease or equivalent Also fill side plate cavity between installed bearing and both seal locations 7596 to 9596 full with Mobil High Tem perature XHP 222 grease or equivalent Fig 35 6 Press grease packed inner and outer seals into the side plate until seals are flush with the surface ofthe side plate bore Seal lips of both inner and outer seals should be toward the bearing 7 Install side plate s to cutting unit see Cutting R eel Installation in this section FILL 75 TO 95 WITH MOBIL HIGH TEMP XHP 222 GREASE FILL 75 TO 95 WITH MOBIL HIGH TEMP XHP 222 GREASE GREASE SEAL TO BE FLUSH GREASE SEAL TO BE FLUSH PACK WITH RH SIDE PLATE MOBIL HIGH TEMP SHOWN i XHP 222 GREASE Figure 35 Greensmaster Flex 18 21 Page 7 25 Cutting Unit Preparing Reel for Grinding NOTE Check to make sure the reel bearings are in good condition before grinding a reel 1 Remove bedbar assembly see Bedbar Removal in this section 2 Remove front roller see Roller Removal in this sec tion 3 Remove grooming reel if installed see Grooming Reel in the Service and Repairs Section of Chapter 8 Groomer NOTE Some grinding machines may require that the cutting reel be removed from the mower NOTE The cutting unit must be aligned so the grinding wheel will travel parallel to the reel shaft This will result in the reel being g
107. tting unit 13 If necessary remove LH side plate and pitch arm Piguet i 1 Flange nut 7 Cap screw from crossmember and grass shield 2 Drive pulley 22 tooth 8 Reel drive plate xTM 3 Lock nut 2 used 9 Woodruff key 14 Refer to Cutting Reel Service in this section for infor 4 Spacer 2 used 10 Cap screw 2 used mation on reel inspection and wear sleeve and v ring 5 Spacer 11 Flat washer 2 used 6 Lock washer 12 Seal spacer seal service Cutting Reel Installation Fig 29 210 to 240 in Ib 1 Use a flat level surface or a stable work bench to 23 7 to 27 1 N m install cutting reel Cutting Unit 2 If separated attach LH side plate to crossmember with two 2 shoulder bolts and square nuts Fig 32 Torque shoulder bolts from 210 to 240 in Ib 23 7 to 27 1 N m Make sure that LH pitch arm is installed on bushing on side plate 3 Apply antiseize lubricant to bearing journals of cut ting reel 4 Make sure that wear sleeve and v ring seal are prop Figure 32 erly installed on both ends of reel shaft see Cutting Reel X gure T x f q rossmember side pla Service in this section 2 Shoulder bolt 4 used 6 Nylon bushing ob 3 RH side plate 7 Rubber bushing 5 Apply grease to lips of grease seals in side plates to 4 Square nut 4 used ease reel installation Greensmaster Flex 18 21 Page 7 21 Cutting Unit Contact with the reel bedknife or other cutting unit parts can r
108. ttings Maximum engine speed is 3600 RPM To en sure safety and accuracy check maximum engine speed with a tachometer 7 Engine must be shut off before checking oil or adding oil to the engine crankcase or transmission 8 If major repairs are ever needed or assistance is re quired contact an Authorized TORO Distributor 9 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 near any area of potential dan ger Replace any decal that is damaged or lost Decal part numbers are listed in your Parts Catalog Order re placement decals from your Authorized TORO Distribu tor Safety Pagel 4 Greensmaster Flex 18 21 Chapter 2 TORO ProductRecords and Maintenance no oO D3 O Table of Contents E ce PRODUCT RECORDS oorr 1 EE MAINTENANCE ssseee In 1 g EQUIVALENTS AND CONVERSIONS 2 Decimal and Millimeter Equivalents 2 U S to Metric Conversions usse 2 TORQUE SPECIFICATIONS sss 3 Fastener Identification ccc cece
109. ue screws from 200 to 250 in Ib 22 6 to 28 2 N m Use a torqu ing pattern working from the center toward each end of the bedknife Fig 18 4 Grind bedknife after installation onto bedbar Bedknife Grinding Since there can be variations in the mounting surface of the bedbar a new bedknife will not be perfectly flat after it is installed It is therefore necessary to grind a new bedknife after installing itto the bedbar Follow the exist ing bedknife angle and grind only enough to make sure the top surface is true Fig 19 The bedbar needs to be removed from mower for proper bedknife grinding NOTE When grinding bedknife be careful to not over heat the bedknife Remove small amounts of material with each pass of the grinder Also clean and dress grinding stone often during the grinding process l For bedknife grinding information refer to TORO Sharpening Reel and Rotary Mowers Manual Form No 80 300 PT Bedknife Grinding Specifications Standard bedknife relief angle 3 see Fig 20 Extended bedknife relief angle 7 see Fig 20 1 Front Angle Range 3 to 179 Cutting Unit Page 7 12 2 After bedknife grinding is complete install bedbar to the mower see Bedbar Installation in this section 200 to 250 in Ib n 57 Antiseize 22 6 to 28 2 N m yA Lubricant D Figure 17 1 Screw 3 Bedbar 2 Bedknife IUE TR ERES 1 9 7 5 3 12 4 6 8 10 Figure 18 Top Face Remove Burr
110. urface Make sure engine is OFF Remove spark plug wire from the spark plug 2 Remove the cutting unit from the traction unit see Separating Cutting Unit F rom Traction Unit in the Gener al Information section of Chapter 7 Cutting Unit 3 Remove belt cover and reel drive belt from the side of the mower that requires service see Reel Drive and Transmission Coupler Drive Belt Replacement in this section f f Figure 4 NOTE Do notgrasp hex shaft Fig 6 when loosening 1 LH reel drive belt 3 Pulley 27 tooth flange nut that secures pulley as flex coupler may be 2 Flange nut washer 4 Pulley flange nut damaged and fail prematurely 4 Remove flange nut that secures pulley to the shaft Fig 4 and 5 Slide pulley and pulley washer if equipped from the shaft Remove woodruff key and spacer ao Q e cs S 2 E Drive System 5 Remove flange nuts and washers from carriage screws that secure bearing housing to plate assembly 6 Slide bearing housing with shaft and coupler away from the frame Bearing Housing Disassembly NOTE When removing flex coupler from shaft do not mar outer surface of coupler e g grasping with pliers or mounting in vise as coupler may be damaged and fail Figure 5 prematurely 1 RH reel drive belt 3 Pulley 22 tooth 2 Flange nut washer 4 Pulley flange nut 1 Push spring pin from flex coupler and shaft to allow coupler to be removed from shaft Remov
111. w A A UJ N me m ul e ul e co N e Co N ul fie fit fie fie J fa fie o ul gt W ul ul A w N N 6 32 UNC 147 23 6 40 UNF 8 32 UNC 282 56 8 36 UNF 10 24 UNC 339 56 10 32 UNF 1 4 20 UNC 599 79 1 4 28 UNF 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 16 2 3 8 24 UNF 7 16 14 UNC 27 3 7 16 20 UNF 29 3 1 2 13 UNC 30 3 1 2 20 UNF 32 4 5 8 11 UNC 88 12 119 16 5 8 18 UNF 75 10 95 15 129 20 3 4 10 UNC 93 112 140 20 190 27 3 4 16 UNF 115 15 165 25 224 34 7 8 9 UNC 140 20 225 25 305 34 zx we we zouper hcm ue m 3B 16unc see 1 2 eam e o meun me ares meaw e m hace e war heu e mer M o w w N N N a M gt N I I I I I I Ke wo gt gt w w 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 as 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 He
112. w room for cable eyelet installation B Install cable eyelet to the brake lever and secure with retaining ring C Slide brake lever toward gearbox and secure with lock nut D Attach brake cable to the casting slot on gearbox with a washer and jam nut on each side of the slot Chassis and Controls Page 6 6 4 Adjust brake cable see Operator s Manual 5 Secure brake cable with cable ties 6 Attach spark plug wire to spark plug Figure 4 1 Brake cable 4 Gearbox brake lever 2 Cable eyelet 5 Retaining ring 3 Cable jam nuts 1 Handle 5 Lock nut 2 Brake cable 6 Retaining ring 3 Flange head screw 7 Brake lever 4 Spacer 8 Brake bracket Greensmaster Flex 18 21 Traction Control Cable Replacement Removal 1 Park machine on a level surface Make sure engine is OFF Remove spark plug wire from the engine spark plug 2 Move traction lever to the DISENGAGED position Remove cable ties that secure traction cable 3 Remove traction cable from the gearbox as follows Fig 6 A Loosen front cable jam nut and lift traction cable free from casting slot of gearbox 1 Traction cable 4 Gearbox traction lever B Remove retaining ring that secures cable eyelet 2 Cable jam nuts 5 Retaining ring 3 Cable eyelet to gearbox traction lever C Remove traction cable from gearbox 4 Remove traction cable from the traction lever as sembly as follows Fig 7 A Remove retaining ring that se
113. wn or black spots Electrode has a bluish burnt appearance May be caused by engine overheating loose spark plug wrong fuel type plug heat range too hot or incorrect ignition timing Replace spark plug CARBON FOULED Black dry fluffy carbon deposits are found on insulator tip electrodes and exposed shell surfaces Weak ignition plug heat range too cold fuel mixture too rich or excessive idling may be the cause Replace spark plug OIL FOULED Wet black deposits can be found on elec trodes insulator and in the bore Excessive oil entering the combustion chamber past worn valve guides valve stems rings piston and or cylinder bore Replace spark plug Page3 7 FUSED SPOT DEPOSIT Has spotty or melted deposits resembling blisters or bubbles Replace spark plug WORN Has severely eroded or worn electrodes Caused by normal wear Replace spark plug PRE IGNITION Electrodes are melted and the insulator may be blistered Metallic deposits on the insulator indicate engine damage Engine overheating burnt valves plug heat range too hot incorrect ignition timing or wrong type of fuel are causes Replace spark plug Engine Engine Gearbox assembly Flange gasket Engine gear Engine adapter Engine Flat washer 4 used Flange nut 8 used Cap screw 4 used Hourmeter bracket 10 Damper 11 Cap screw 3 used 12 Wire harness OPNPIRWNH Engine 13 14 15 16 17 1

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