Toro Greensmaster Flex 18 04018 Service Manual
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Toro Greensmaster Flex 18 04018 Service Manual

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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
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.
(Models 04018, 04019, 04030, 04022, 04024, 04025, 04031)
Greensmaster
AND
ADJUSTMENT
E The Toro Company – 2006
R
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.
PART NO. 06149SL

Service Manual

Flex 18/21

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Summary of Contents for Toro Greensmaster Flex 18 04018

  • Page 1: Service Manual

    Attn. Technical Publications vent damage to systems or components on the 8111 Lyndale Avenue South machine. Minneapolis, MN 55420–1196 The Toro Company reserves the right to change product specifications or this publication without notice. E The Toro Company – 2006...
  • Page 2 This page is intentionally blank. Greensmaster Flex 18/21...

  • Page 3: Table Of Contents

    Table Of Contents Chapter 1 – Safety Chapter 6 – Chassis and Controls Safety Instructions ......1 –...

  • Page 4: Greensmaster Flex

    This page is intentionally blank. Greensmaster Flex 18/21...

  • Page 5: Safety Instructions

    Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS ..... . Before Operating ......While Operating .

  • Page 6: Safety Instructions

    Training DVD. A replacement Operator’s Manual 8. Keep everyone, especially children and pets away is available on the internet at www.toro.com or by send- from the areas of operation. ing the complete model and serial number to: 9.

  • Page 7: While Operating

    To assure optimum or servicing the cutting unit. performance and continued safety certification of the machine, use genuine Toro replacement parts and ac- 5. If the engine must be running to perform mainte- cessories. Replacement parts and accessories made...

  • Page 8: Safety And Instruction Decals

    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 Page 1 – 4...

  • Page 9: Product Records

    Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......MAINTENANCE ......EQUIVALENTS AND CONVERSIONS .

  • Page 10: Equivalents And Conversions

    Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 – 2 Greensmaster Flex 18/21...

  • Page 11: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
  • Page 12 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series Fasteners) Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
  • Page 13 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws and Studs with Class 10.9 Bolts, Screws and Studs with Thread Size Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...

  • Page 14: Fasteners (Inch Series Fasteners)

    Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Thread Size Square Head Hex Socket 7/16 – 20 UNF 65 + 10 ft–lb 88 + 14 N–m Grade 5 1/4 –...
  • Page 15 Chapter 3 Engine Table of Contents SPECIFICATIONS ......INTRODUCTION ......GENERAL INFORMATION .

  • Page 16: Specifications

    Specifications Item Description Make / Designation Kawasaki, 4–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)

  • Page 17: Introduction

    Service and repair parts for Kawasaki engines are sup- commonly available in many service shops. Special plied through your local Toro distributor. Be prepared to tools are described in the Kawasaki FE120D Service provide your distributor with the Toro model and serial Manual that is included at the end of this Chapter.

  • Page 18: Adjustments

    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.

  • Page 19: Service And Repairs

    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.

  • Page 20: Spark Plug

    Spark Plug Use a NGK BPR 5ES spark plug or equivalent. 1. Make sure engine is OFF. Carefully pull spark plug 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.
  • Page 21 NORMAL OVER HEATING FUSED SPOT DEPOSIT Has gray or light tan deposits on the firing Light gray or white insulator with small gray Has spotty or melted deposits resembling tip. brown or black spots. Electrode has a bluish blisters or bubbles. burnt appearance.

  • Page 22: Engine

    Engine Loctite #242 11 18 RIGHT FRONT 7 to 10 in–lb (0.8 to 1.1 N–m) Figure 5 1. Gearbox assembly 13. Interlock module 24. Jam nut (2 used) 2. Flange gasket 14. Module bracket 25. Tab washer (2 used) 3. Engine gear 15.
  • Page 23 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.
  • Page 24 Engine Installation (Fig. 5) 5. Connect electrical connections to engine (Fig. 8): 1. Position machine on a level surface. Make sure that A. Connect wire harness connectors to engine stop spark plug wire is not connected to engine spark plug. switch and armature wires.
  • Page 25 Chapter 4 Traction and Reel Drive System Table of Contents SPECIFICATIONS ......GENERAL INFORMATION .

  • Page 26: Specifications

    Specifications Item Description Traction Drive Integral Gearbox Assembly Attached Directly to Engine Differential to Traction Drive has 8 mm Pitch Positive Drive Belts Gearbox Fluid Dexron III Automatic Transmission Fluid (or equivalent) Gearbox Fluid Capacity 2.9 U.S. qt (2.8 l) Differential Integral in Gearbox Assembly Parking Brake...

  • Page 27: General Information

    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.
  • Page 28 This page is intentionally blank. Traction and Reel Drive System Page 4 – 4 Greensmaster Flex 18/21...

  • Page 29: Service And Repairs

    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.

  • Page 30: Reel Drive Assembly

    Reel Drive Assembly 40 to 50 ft–lb Antiseize Lubricant (54 to 68 N–m) RIGHT FRONT 100 in–lb (11.3 N–m) 40 to 50 ft–lb (54 to 68 N–m) Antiseize Lubricant Antiseize Lubricant 40 to 50 ft–lb (54 to 68 N–m) Antiseize Lubricant 100 in–lb 40 to 50 ft–lb...

  • Page 31: Reel Drive And Transmission Coupler Bearing Housing

    Reel Drive and Transmission Coupler Bearing Housing (Fig. 3) Service of the reel drive bearing housings on either side of the machine requires similar procedures. Removal 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the spark plug. 2.

  • Page 32: Adjustments

    3. Apply grease to the bore of the bearing housing. 7. Install reel drive belt to the reel drive assembly and Install shaft with bearings and spacer into housing and adjust belt (see Reel Drive and Transmission Coupler secure with retaining ring. Drive Belt Replacement in this section).
  • Page 33 This page is intentionally blank. Greensmaster Flex 18/21 Page 4 – 9 Traction and Reel Drive System...

  • Page 34: Traction Drive Belt Replacement

    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.

  • Page 35: Traction Drive Idler Pulley And Bearings

    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 –...

  • Page 36: Traction Drum Assembly

    Traction Drum Assembly 40 to 50 in–lb 100 in–lb 40 to 50 ft–lb (11.3 N–m) (4.5 to 5.7 N–m) (54 to 68 N–m) Antiseize Lubricant 45 to 55 ft–lb (61 to 75 N–m) Loctite #242 65 to 75 ft–lb (88 to 102 N–m) Antiseize Lubricant RIGHT...
  • Page 37 Traction Drum Removal (Fig. 15) LOCTITE #242 RIGHT HAND 1. Park machine on a level surface. Make sure engine THREADS is OFF. Remove spark plug wire from the engine spark plug. 2. If installed, remove transport wheels (see Transport LEFT Wheels in the Service and Repairs section of Chapter 6 HAND –...
  • Page 38 Traction Drum Assembly (Fig. 15) 4. Position drum spacers to sides of drum. 1. Assemble hub/spindle assembly (Fig. 17): 5. Insert bar stock or other suitable tool through spokes of drum to keep drum from turning. A. Press one bearing into drum hub by applying pressure to outer bearing race.
  • Page 39 This page is intentionally blank. Greensmaster Flex 18/21 Page 4 – 15 Traction and Reel Drive System...

  • Page 40: Gearbox

    Gearbox RIGHT FRONT Figure 18 1. Gearbox assembly 5. Engine 9. Washer 2. Flange gasket 6. Set screw (4 used) 10. Flange nut (4 used) 3. Engine gear 7. Cap screw 11. Key 4. Engine adapter 8. Lock washer Gearbox Removal 7.
  • Page 41 11. Slide gearbox assembly to the right side of mower, 40 to 50 in–lb away from the engine. This should allow the left gearbox Antiseize Lubricant (4.5 to 5.7 N–m) axle to clear the frame and the gearbox to separate from the engine gear.

  • Page 42: Gearbox Service

    Gearbox Service 240 in–lb (27 N–m) RIGHT FRONT 26 13 32 23 25 26 120 to 140 in–lb 23 32 (13.6 to 15.8 N–m) 21 22 85 to 105 in–lb (9.6 to 11.8 N–m) Figure 21 1. Gearbox base 26. Needle bearing 50.
  • Page 43 Disassembly (Fig. 21) 1. Clean outside of the gearbox assembly. 2. Remove reel drive assembly from gearbox (Fig. 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.
  • Page 44 13.Gearbox seals can be removed as follows: 7. Install planetary assembly (with brake band installed) into gearbox, engaging gears of differential A. Using a 1/4” thick, 3” X 3” square piece of steel, assembly. Note: On Flex 21, if gearbox is still attached make a seal removal tool as shown in Fig.
  • Page 45 8. If traction band is replaced, the new band will have an ink mark on the upper end of the band (Fig. 28). MARK LOCATION 9. Carefully fit traction shaft with band to the planetary assembly and gearbox base taking care not to distort traction band.

  • Page 46: Differential Service

    Differential Service RIGHT FRONT Figure 31 1. RH (short) axle 5. Drive bevel gear 9. Input gear/housing 2. LH (long) axle 6. Washer 10. Gear shaft 3. Retaining ring 7. Washer 11. Bushing 4. Driven bevel gear 8. Roll pin The differential assembly is an integral component of Inspection (Fig.
  • Page 47 Assembly (Fig. 31) 3. Place a washer between input gear/housing and each driven bevel gear. Install gear shaft with grooved 1. Insert RH (short) axle into input gear/housing on the end located at roll pin hole. gear side. Install washer, drive bevel gear and new re- taining ring on short axle.
  • Page 48 This page is intentionally blank. Traction and Reel Drive System Page 4 – 24 Greensmaster Flex 18/21...

  • Page 49: Special Tools

    Chapter 5 Electrical System Table of Contents WIRING SCHEMATIC ......SPECIAL TOOLS ......TROUBLESHOOTING .

  • Page 50: Wiring Schematic

    Wiring Schematic HIGH TENSION LEAD INTERLOCK MODULE BLACK IGNITION COIL ENGINE MAGNETO (FLYWHEEL) LIGHTING COIL OPERATOR PRESENCE SWITCH (OPTIONAL) CONNECTOR HOURMETER INTERLOCK SWITCH Kawasaki FE120 Engine ON\OFF 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 –...

  • Page 51: Special Tools

    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.
  • Page 52 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 –...

  • Page 53: Troubleshooting

    Troubleshooting The interlock switch must not be by–passed, it must be connected for proper electrical troubleshooting and CAUTION safety. Remove all jewelry, especially rings and NOTE: See the Kawasaki FE120 Service Manual at watches, before doing any electrical testing or the end of Chapter 3 –...

  • Page 54: Component Testing

    Component Testing For accurate resistance and/or continuity checks, elec- NOTE: See the Kawasaki FE120 Service Manual at trically disconnect the component being tested from the the end of Chapter 3 – Engine for more component test- circuit (e.g. unplug the ON/OFF switch connector before ing information.

  • Page 55: Interlock Module And Switch

    Interlock Module and Switch The interlock module prevents the engine from starting C. Ground the red wire (male connector) to the en- unless the interlock switch is closed (traction lever in gine block and attempt to start the engine. The en- NEUTRAL).

  • Page 56: Service And Repairs

    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.

  • Page 57: Operator Presence Switch (Optional)

    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.
  • Page 58 This page is intentionally blank. Electrical System Page 5 – 10 Greensmaster Flex 18/21...
  • Page 59 Chapter 6 Chassis and Controls Table of Contents SPECIFICATIONS ......GENERAL INFORMATION ..... Operator’s Manual .

  • Page 60: Specifications

    Specifications Item Description Transport Wheel (Optional) Tire Pressure 12 to 15 PSI (0.83 to 1.04 bar) Chassis and Controls Page 6 – 2 Greensmaster Flex 18/21...

  • Page 61: General Information

    General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, adjustment procedures and general maintenance for your Greensmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine. Greensmaster Flex 18/21 Page 6 – 3 Chassis and Controls...

  • Page 62: Service And Repairs

    Service and Repairs Handle Assembly 37 32 RIGHT FRONT Figure 1 1. Handle 16. Roll pin 31. Lock nut (4 used) 2. Brake lever 17. Traction control lever 32. Spacer (3 used) 3. Brake bracket assembly 18. Bushing (4 used) 33.
  • Page 63 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).

  • Page 64: Parking Brake Cable Replacement

    Parking Brake Cable Replacement Removal 4. Adjust brake cable (see Operator’s Manual). 1. Park machine on a level surface. Make sure engine 5. Secure brake cable with cable ties. is OFF. Remove spark plug wire from the engine spark 6. Attach spark plug wire to spark plug. plug.

  • Page 65: Traction Control Cable Replacement

    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.

  • Page 66: Reel Control Cable Replacement

    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.

  • Page 67: Throttle Cable Replacement

    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.

  • Page 68: Transport Wheels (Optional)

    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.
  • Page 69 Wheel Removal (Fig. 14) 1. Park machine on a level surface. Make sure the en- gine is OFF. 2. Support the 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.

  • Page 70: Kickstand

    Kickstand RIGHT FRONT Figure 16 1. Kickstand 5. Torsion spring 9. Cap screw 2. Cap screw 6. Cap screw 10. Support bushing 3. Flat washer 7. Spacer 11. Cap screw 4. Long spacer 8. Flange nut 12. Frame assembly Removal (Fig. 16) Installation (Fig.
  • Page 71 Chapter 7 Cutting Unit Table of Contents SPECIFICATIONS ......GENERAL INFORMATION ..... Operator’s Manual .

  • Page 72: Specifications

    Specifications REEL CONSTRUCTION: 5–inch (12.7 cm) diameter, BEDKNIFE AND BEDBAR: Single edged high carbon 11 carbon steel blades welded to 5 stamped steel spi- steel bedknife, hardened to RC 48-54. A cast iron bed- ders. High strength low alloy steel blades are thru hard- bar is fastened to the cutting unit.

  • Page 73: General Information

    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.

  • Page 74: Special Tools

    Order special tools from the TORO SPECIAL TOOLS Some tools may have been supplied with your mower or AND APPLICATIONS GUIDE (COMMERCIAL PROD- are available as TORO parts. Some tools may also be UCTS). available from a local supplier. Gauge Bar Assembly Toro Part Number: 13–8199...
  • Page 75 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.

  • Page 76: Factors That Can Affect Quality Of Cut

    Factors That Can Affect Quality of Cut There are a number of factors that can contribute to un- cutting unit. It is important to remember that the lower satisfactory quality of cut, some of which may be turf the height–of–cut, the more critical these factors are. conditions.
  • Page 77 Factor Possible Problem/Correction 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).

  • Page 78: Adjustments

    Adjustments DANGER CAUTION Contact with the reel, bedknife or other cutting Never work on the cutting unit with the engine unit parts can result in personal injury. Use running. Always stop the engine and remove the heavy gloves when handling the cutting reel or spark plug wire from the spark plug first.

  • Page 79: Service And Repairs

    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.

  • Page 80: Bedbar

    Bedbar 190 to 240 in–lb (21.5 to 27.1 N–m) Antiseize Lubricant Antiseize Lubricant 200 to 250 in–lb (22.6 to 28.2 N–m) RIGHT FRONT Figure 14 1. Grass shield 7. Flange nut (2 used) 13. Rubber bushing (2 used) 2. Washer head screw (3 used) 8.
  • Page 81 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.

  • Page 82: Bedknife Service

    Also, clean and dress grinding stone often during the grinding process. Standard Bedknife 1. For bedknife grinding information, refer to TORO 1.69” (42.9 mm) Sharpening Reel and Rotary Mowers Manual, Form No. 80-300 PT.
  • Page 83 This page is intentionally blank. Greensmaster Flex 18/21 Page 7 – 13 Cutting Unit...

  • Page 84: Bedbar Adjuster Service

    Bedbar Adjuster Service Antiseize 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.
  • Page 85 This page is intentionally blank. Greensmaster Flex 18/21 Page 7 – 15 Cutting Unit...

  • Page 86: Rollers

    Rollers Antiseize Lubricant RIGHT FRONT 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.
  • Page 87 Roller Removal (Fig. 22) Roller Installation (Fig. 22) 1. Park machine on a level surface. Make sure engine 1. To install front roller: is OFF. Remove spark plug wire from the engine spark A. Insert one end of front roller into height–of–cut plug.

  • Page 88: Roller Service

    Roller Service 25 to 30 ft–lb (34 to 41 N–m) 25 to 30 ft–lb (34 to 41 N–m) Figure 23 1. Wiehle roller 4. Ball bearing 6. V–ring 2. Smooth roller 5. Seal 7. Bearing lock nut 3. Roller shaft NOTE: Several different rollers are available for the Flex 18 and Flex 21 cutting unit.
  • Page 89 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.

  • Page 90: Cutting Reel

    Cutting Reel 190 to 240 in–lb (21.5 to 27.1 N–m) Antiseize Lubricant Antiseize Lubricant RIGHT FRONT 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.
  • Page 91 C. If cutting unit is 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.
  • Page 92 11. Apply antiseize lubricant to end of reel shaft. Position DANGER 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 Contact with the reel, bedknife or other cutting shaft.

  • Page 93: Cutting Reel Service

    Cutting Reel Service (Fig. 33) NOTE: Install new reel components on each end of the reel shaft that mates with newly serviced side plate com- ponents. WEAR SLEEVE TO BE FLUSH TO 0.015” (0.4 MM) PAST 1. Remove the v–ring seal from the reel shaft. BEARING SHOULDER 2.

  • Page 94: Side Plate Service

    Side Plate Service 210 to 240 in–lb (23.7 to 27.1 N–m) FRONT RIGHT 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.
  • Page 95 Assembly (Fig. 34) FILL 75% TO 95% WITH 1. On RH side plate, if inner retaining ring (item 24) was MOBIL HIGH TEMP XHP–222 GREASE removed, install inner retaining ring. Insert thrust wash- er (item 3) and then wave washer (item 20) into the side FILL 75% TO 95% WITH plate.

  • Page 96: Preparing Reel For Grinding

    Blade Land Width Range 0.030 to 0.060 in (0.8 to 1.5 mm) 4. Grind cutting reel (refer to TORO Sharpening Reel Max. Reel Taper 0.040 in (1.0 mm) and Rotary Mowers Manual, Form No. 80-300 PT).
  • Page 97 Chapter 8 Groomer Table of Contents SPECIFICATIONS ......GENERAL INFORMATION ..... Transport Mode .

  • Page 98: Specifications

    Specifications MOUNTING: The groomer drive kit is mounted to the HEIGHT ADJUSTMENT KNOB: Allows a 0.003 inch mower reel bearing housings and frame. (0.08 mm) increment of height adjustment for each click of the adjuster. REEL CONSTRUCTION: 2.375 inch (6 cm) diameter, 35 steel blades with 1/2 inch (12.7 mm) blade spacing.

  • Page 99: General Information

    General Information Transport Mode IMPORTANT: Before changing groomer position, make certain that the reel drive lever is in the disen- gaged position and 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.

  • Page 100: Troubleshooting

    Troubleshooting Factors Affecting Grooming Performance There are a number of factors that can affect the perfor- IMPORTANT: Improper or overaggressive use of mance of grooming. These factors vary for different golf the grooming reel, such as too deep or frequent courses and from green to green.

  • Page 101: Grooming Reel Mechanical Problems

    Grooming Reel Mechanical Problems Problem Possible Causes Correction The grooming reel rotates when it is The grooming reel should rotate Normal operation. in the raised, transport position. whenever the cutting reel is en- gaged. No rotation of the grooming reel. Seized grooming reel or idler bear- Identify and replace faulty bear- ing(s) in groomer side plate(s).

  • Page 102: Adjustments

    Adjustments CAUTION 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.

  • Page 103: Service And Repairs

    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.

  • Page 104: Grooming Reel

    Grooming Reel Loctite #242 60 to 80 ft–lb (82 to 108 N–m) 17 to 21 ft–lb (23 to 28 N–m) 17 to 21 ft–lb (23 to 28 N–m) RIGHT FRONT Figure 6 1. LH groomer arm 11. Cap screw (2 used) 20.
  • Page 105 NOTE: The drive pulley has left handed threads. To prevent cutting reel from turning when removing drive pulley, block reel with piece of wood. 8. Use a 3/8” drive socket wrench to remove drive pulley (item 17) from the cutting reel shaft. 9.
  • Page 106 NOTE: To prevent grooming shaft from turning when DANGER installing flange nuts, use wrench on shaft flats to hold shaft. Contact with the reel, bedknife or other cutting 7. Secure grooming reel by tightening flange nuts on unit parts can result in personal injury. Use both ends of grooming shaft.

  • Page 107: Grooming Reel Service

    Grooming Reel Service Inspect grooming reel blades frequently for damage and wear. Straighten bent blades with a pliers. Replace CENTER BLADES ON SHAFT blades that are worn or damaged (Fig. 12). Blades that are rounded to the midpoint of the blade tip must be re- placed.

  • Page 108: Groomer Reel Bearing Replacement

    Groomer Reel Bearing Replacement Seal lip Seal lip 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 –...
  • Page 109 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 the Service and Repairs section of Chapter 7 –...

  • Page 110: Idler Assembly

    Idler Assembly Seal lip Seal lip 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.
  • Page 111 This page is intentionally blank. Greensmaster Flex 18/21 Page 8 – 15 Groomer...

  • Page 112: Groomer Arm Assembly

    Groomer Arm Assembly Antiseize Lubricant Antiseize Lubricant Antiseize Lubricant Figure 17 1. HOC groomer arm (LH shown) 6. Lock screw 11. Cap screw 2. Flange nut 7. Bushing 12. Bushing 3. Grooved pin 8. Lift arm assembly (LH shown) 13. Wave washer 4.
  • Page 113 Disassembly (Fig. 17) 1. Remove groomer arm from cutting unit (Fig. 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.

  • Page 114: Grooming Brush

    Grooming Brush 20 to 25 in–lb (2.3 to 2.8 N–m) 20 to 25 in–lb (2.3 to 2.8 N–m) Figure 20 1. Grooming brush shaft 3. J–bolt 4. Grooming brush 2. Lock nut The grooming brush attaches to the groomer drive in place of the grooming reel.

This manual is also suitable for:

Greensmaster flex 18 04030Greensmaster flex 18 04022Greensmaster flex 18 04024Greensmaster flex 18 04019Greensmaster flex 21 04025Greensmaster flex 21 04031 ... Show all

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