Toro 4043, 4042 User Manual

PART NO. 12189SL

Service Manual

(Models 04043 and 04042)

Greensmaster

Preface

The purpose of this publication is to providetheservice technician with information for troubleshooting, testing and repairing assemblies and components on the Greensmaster eFlex 1800 (Model 04043) and eFlex 2100 (Model 04042).

REFER TO THE OPERATOR’SMANUALFOROPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.Spaceisprovided inChapter 2of this booktoinserttheOperator’sManualandPartsCatalogs for your machine. Replacement Operator’s Manuals and Parts Catalogs are available on the internet at www.toro.com

TheToroCompanyreserves therighttochange product specifications or this publication without notice.

eFlex 1800/2100

This safety symbol means DANGER, WARNING or CAUTION, PERSONAL SAFETY INSTRUCTION. 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 givegeneral information aboutthe

correct operation, maintenance, service, testing or repair of the machine.

IMPORTANT: The IMPORTANT notice will give important in structions which must be followed to prevent damage to systems or components on the machine.

E The Toro Company -- 2012

This page is intentionally blank.

Greensmaster eFlex 1800/2100

Chapter 1 -- Safety

General Safety Instructions 1 -- 2..................

Safety and Instruction Decals 1 -- 4................

Chapter 2 -- Product Records and Maintenance

Product Records 2 -- 1...........................

Maintenance 2 -- 1...............................

Equivalents and Conversions 2 -- 2................

Torque Specifications 2 -- 3.......................

Chapter 3 -- Traction and Reel Drive System

Specifications 3 -- 2..............................

General Information 3 -- 3........................

Special Tools 3 -- 6..............................

Adjustments 3 -- 8...............................

Service and Repairs 3 -- 11.......................

Chapter 4 -- Electrical System

General Information 4 -- 2........................

Electrical System Operation 4 -- 4.................

Lithium Battery Pack Charger Operation 4 -- 6......

Special Tools 4 -- 10.............................

Troubleshooting 4 -- 12...........................

InfoCenter Display 4 -- 16.........................

Adjustments 4 -- 22..............................

Component Testing 4 -- 26........................

Service and Repairs 4 -- 44.......................

Chapter 5 -- Chassis a nd Controls

Specifications 5 -- 2..............................

General Information 5 -- 3........................

Service and Repairs 5 -- 4........................

Chapter 6 -- Cutting Unit

Specifications 6 -- 3..............................

General Information 6 -- 4........................

Special Tools 6 -- 6..............................

Factors That Affect Quality Of Cut 6 -- 8............

Adjustments 6 -- 10..............................

Service and Repairs 6 -- 11.......................

Chapter 7 -- Groomer

Specifications 7 -- 2..............................

General Information 7 -- 3........................

Troubleshooting 7 -- 4............................

Adjustments 7 -- 6...............................

Service and Repairs 7 -- 7........................

Chapter 8 -- Foldout Drawings

Electrical Schematic 8 -- 3........................

Wire Harness Drawings 8 -- 4.....................

SafetyProduct Records

and Maintenance

Drive System

Traction and Reel

System

Electrical

Controls

Chassis andCutting Unit

Greensmaster eFlex 1800/2100

GroomerFoldout

Drawings

This page is intentionally blank.

Greensmaster eFlex 1800/2100

GENERAL SAFETY INSTRUCTIONS 2............

Before Operating 2............................

While Operating 3............................

Maintenance and Service 3....................

Battery Pack Connection 4.....................

SAFETY AND INSTRUCTION DECALS 4..........

Chapter 1

Safety

Greensmaster eFlex 1800/2100 Page 1 -- 1 Safety

General Safety Instructions

Greensmaster eFlex 1800 and eFlex 2100 machines havebeen tested andcertified byTORO forcompliance with existing safety standards and specifications. Although hazardcontrol and accidentprevention are partially dependent upon the design and configuration of themachine, thesefactorsarealso dependentuponthe awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine. Improper use or maintenanceof themachine canresult ininjury ordeath. To reduce the potential for injury or death, comply with the following safety instructions.

WARNING

Toreduce thepotentialfor injury ordeath,comply with the following safety instructions.

Before Operating

WARNING

The eFlex battery pack contains high voltage which could burn or electrocute you.

 Never attempt to open the battery pack.  Do not place anything in the connector on

the battery pack other than the wire harness connector that came with the product.

 Use extreme care when handling a battery

pack with a cracked case.

 Only use the charger designed for the

battery pack.

1. Operatethemachineonlyafter reviewingandunderstandingthe contentsofthe Operator’sManual andOperator Training DVD.A replacement Operator’sManual is available on the internet at www.toro.com

2. Never allowchildrento operatethe machineor allow adults to operate it without proper instructions.

3. Become familiar with the controls and know how to stop the machine and electric motor quickly.

4. Keep all shields, safety devices and decals in place. Ifashield, safetydeviceor decalismalfunctioning,illegibleordamaged,repairorreplace it beforeoperating the machine.

5. Always wear substantial shoes. Do not operate machine whilewearing sandals, tennis shoes or sneakers. Donotwear loosefittingclothingwhich couldgetcaught in moving parts and cause personal injury.

6. Wearing safety glasses, safety shoes, long pants, ear protection and a hard hat is advisable and required by some local safety and insurance regulations.

7. Ensure work area is clear of objects which might be picked up and thrown by the cutting reel.

8. Keep everyone, especially children and pets, away from the areas of operation.

9. The safety interlock switches are for the operator’s protection;donotdisconnectthem. Check theoperation oftheswitchesdailyto assuretheinterlocksystemis operating. If a switch isdefective, replace itbefore operating the machine. See Component Testing in Chapter 4

-- Electrical System.

Greensmaster eFlex 1800/2100Page 1 -- 2Safety

While Operating

1. Always stand behind the handle when starting and operating the machine.

2. To begin machine operation: A. Make sure that themachine wire harness iscon-

nected to the battery pack B. Verify that the control lever on handle is in NEU-

TRAL position for both traction and reel drives. C. Move key switch to START position until the I nfo

Center display lights up, then release switch to the RUN position.

3. Before leaving t he operator’s positionof the mower: A. Stop the machine on level ground. B. Disengage both the traction and reel drives with

the control lever and set the parking brake. C. Move key switch to OFF position and wait for all

machine motion to stop.

4. Beforeemptyingbasketof clippings,disengage traction and reel drives, set the parking brake, move key switchtoOFFpositionand wait forelectricmotortostop. Waitfor allmachinemotiontostop beforeremovingbasket.

5. If thecutting unitstrikes asolid objector vibratesabnormally, stop machine operation immediately. Disengage the traction/mow lever, turn key switch to OFF position, wait for all machine motion to stop. Then, disconnect battery pack (see Battery Pack Connection in thissection)and inspect cuttingunitfordamage. Adamaged reel or bedknife must be repaired or replaced before operation is commenced.

6. Whenever machine is left unattended, be sure electricmotor is stopped,cuttingunit reelisnot spinningand key switch is in the OFF position. Remove key from switch.

Safety

Maintenance and Service

1. TheTraction Unit andCutting UnitOperator’s Manu-

alsprovide information regardingtheoperation,general maintenance and maintenance intervals for your Greensmaster machine. Refer to these publications for additional information when servicing the machine.

2. Before servicing or making adjustments to the ma-

chine, set the parking brake, move key switch to OFF positionandwaitforall machinemotiontostop.Remove key from the ignition switch. Disconnect battery pack (seeBattery PackConnection inthis section)to prevent unintentional machine operation.

3. To make sure entire machine is in good condition,

keepallnuts, bolts, screwsandbeltsproperly tightened.

4. To reduce potential fire hazard, keep the battery

pack, electrical connectors, cutting unit and drive components free of debris.

5. Wear heavy gloves and use caution when checking

or servicing the cutting unit.

6. Ifthe electricmotormust berunningtoperformmain-

tenanceormakeanadjustment,keephands,feet,clothing and all parts of the body away from the cutting unit and all moving parts. Keep bystanders away.

7. Before installing,removing or workingon the cutting unit,disconnectthebatterypack(seeBatteryPackConnectionin thissection)to preventunintentionalmachine operation.

8. Do not open or alter the battery pack in any way. Openingthebatterypack may exposeyoutodangerous electrical voltage. The warranty will be voided if you attempttoopen the batterypack.Withtheexception ofthe battery pack fuse, fuse cover and labels, there are no consumer serviceable parts on or in the battery pack.

9. If there ever is a need to ship the battery pack from your eFlexmachine, you will needspecial packaging to comply with shipping regulations. Refer to the Operator’s Manual for additional battery shipping information.

10.If major repairs are ever needed or assistance is required, contact your Authorized TORO Distributor.

11.At the 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 accessories. Replacement parts and accessories made by othermanufacturers may result innon-conformance with safety standards and the warranty may be voided.

Greensmaster eFlex 1800/2100 Page 1 -- 3 Safety

Battery Pack Connection

CAUTION

Before servicing the machine, disconnect the the machine fromthe battery pack. This will prevent unexpected machine operation.

To prevent unexpected machine operation during service, disconnect the machine from the battery pack as thefirst stepinany repair(Fig.1). Oncethe battery pack hasbeendisconnected,the electrical systemonthemachinecanbesafelyworked on.Takecare during repairs, however, to not allow tools or vehicle components to complete the battery circuit that was opened with the cable removal.

Connect the machine wire harness to the battery pack as the last step in any repair.

WARNING

The eFlex battery pack contains high voltage which could burn or electrocute you.

 Never attempt to open the battery pack.  Do not place anything in the connector on

the battery pack other than the wire harness connector that came with the product.

 Use extreme care when handling a battery

pack with a cracked case.

 Only use the charger designed for the

battery pack.

1. Battery pack

2. Battery connector

Figure 1

3. Machine connector

Safety and Instruction Decals

Safety decals and instructions are easily visible to the operatorand are locatednear any areaof potentialdanger. Replace any decal that is damaged or lost. Decal part numbersare listed in yourParts Catalog. Orderreplacementdecals fromyour AuthorizedTORODistributor.

Greensmaster eFlex 1800/2100Page 1 -- 4Safety

Product Records and Maintenance

PRODUCT RECORDS 1.........................

MAINTENANCE 1..............................

EQUIVALENTS AND CONVERSIONS 2...........

Decimal and Millimeter Equivalents 2............

U.S. to Metric Conversions 2...................

TORQUE SPECIFICATIONS 3...................

Fastener Identification 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 6..................

Conversion Factors 6.........................

Product Records

Chapter 2

Product Records

and Maintenance

Insert Operator’s Manual and Parts Catalog for your Greensmaster eFlex 1800 or eFlex 2100 at the end of this section. Additionally, if any optional equipment or accessorieshave beeninstalled toyour machine,insert the Installation Instructions, Operator’s Manuals and PartsCatalogs forthose options at the endof thischapter.

Maintenance

Maintenanceproceduresand recommendedserviceintervals for the Greensmaster eFlex 1800 and eFlex 2100arecoveredintheOperator’sManual.Refertothat publicationwhen p erforming regularequipmentmaintenance.

Greensmaster eFlex 1800/2100 Page 2 -- 1 Product Records and Maintenance

Equivalents and Conversions

0.09375

Greensmaster eFlex 1800/2100Page 2 -- 2Product Records and Maintenance

Torque Specifications

Recommended fastener torque values are listed in the following tables. For criticalapplications, asdetermined byToro,eitherthe recommendedtorqueora torquethat is uniqueto the application isclearly identified andspecified in this Service Manual.

These Torque Specifications for the installation and tightening of fasteners shall applyto all fastenerswhich do nothave aspecific requirementidentified inthis Service Manual. The following factors shall be considered when applying torque: cleanliness of the fastener, use of a thread sealant (e.g. Loctite), degree of lubrication on the fastener, presence of a prevailing torquefeature (e.g. Nylock nut), hardness of the surface underneath thefastener’shead orsimilarconditionwhich affectsthe installation.

Fastener Identification

Asnotedin the followingtables,torquevaluesshould b e 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 engagement, etc.

The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut) and mating part, then back off fastener 1/4 of a turn. Measurethe torquerequired to tightenthe fasteneruntil thelinesmatchup.

Product Records

and Maintenance

Grade1 Grade5 Grade8

Inch Series Bolts and Screws

Class 8.8 Class 10.9

Metric Bolts and Screws

Greensmaster eFlex 1800/2100 Page 2 -- 3 Product Records and Maintenance

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series Fasteners)

Grade 1, 5 &

Thread Size

#6--32UNC

#6--40UNF 17 + 2 192 + 23 25 + 3 282 + 34

#8--32UNC

#8--36UNF 31 + 4 350 + 45 43 + 5 486 + 56

#10--24UNC

#10--32UNF 48 + 5 542 + 56 68 + 7 768 + 79

1/4 -- 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1130+ 113 140 + 15 1582 + 169

1/4 -- 28 UNF 53 + 7 65 + 10 734 + 113 115 + 12 1299 + 136 160 + 17 1808 + 192

5/16 -- 18 UNC 115 + 15 105 + 15 1186 + 169 200 + 25 2 260+ 282 300 + 30 3390 + 339

5/16 -- 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2542 + 282 325 + 33 3672 + 373

3/8 -- 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 5 58 + 7

8withThin

Height Nuts

in--lb in--lb N--cm in--lb N--cm in--lb N--cm

10 + 2 13 + 2 147 + 23

13 + 2 25 + 5 282 + 30

18 + 2 30 + 5 339 + 56

ft--lb ft--lb N--m ft--lb N--m ft--lb N--m

SAE Grade 1 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

SAE Grade 5 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

15 + 2 169 + 23 23 + 3 262 + 34

29 + 3 328 + 34 41 + 5 463 + 56

42 + 5 475 + 56 60 + 6 678 + 68

SAE Grade 8 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 5 or Stronger Nuts)

3/8 -- 24 UNF 17 + 2 18+ 2 24 + 3 35 + 4 47 + 5 50 + 6 68 + 8

7/16 -- 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9

7/16 -- 20 UNF 29 + 3 29 + 3 39 + 4 55 + 6 75 + 8 77 + 8 104 + 11

1/2 -- 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 11 142 + 15

1/2 -- 20 UNF 32 + 4 53 + 7 72 + 9 85 + 9 115 + 12 120 + 12 163 + 16

5/8 -- 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 21 285 + 28

5/8 -- 18 UNF 75 + 10 95+ 15 129 + 20 170 + 18 230 + 24 240 + 24 325 + 33

3/4 -- 10 UNC 93 + 12 140 + 20 190 + 27 265 + 27 359+ 37 375+ 38 508+ 52

3/4 -- 16 UNF 115 + 15 165 + 25 224 + 34 300 + 30 407+ 41 420 + 43 569 + 58

7/8 -- 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81

7/8 -- 14 UNF 155 + 25 260 + 30 353 + 41 475 + 48 644 + 65 667 + 66 904 + 89

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: The nominal torque values listed above for Grade 5 and8 fasteners are based on 75% of the minimum proof load specifiedin SAEJ429. The tolerance is approximately +

10% of the nominal torque value. Thin

height nuts include jam nuts.

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 eFlex 1800/2100Page 2 -- 4Product Records and Maintenance

Standard To rque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)

Class 8.8 Bolts, Screws and Studs with

Thread Size

M5 X 0.8 57 + 6in--lb 644 + 68 N--cm 78 + 8in--lb 881 + 90 N--cm

M6 X 1.0 96 + 10 in--lb 1085 + 113 N- -cm 133 + 14 in--lb 1503 + 158 N--cm M8 X 1.25 19 + 2ft--lb 26 + 3N--m 28 + 3ft--lb 38 + 4N--m M10 X 1.5 38 + 4ft--lb 52 + 5N--m 54 + 6ft--lb 73 + 8N--m

M12 X 1.75 66 + 7ft--lb 90 + 10 N--m 93+ 10 ft--lb 126 + 14 N--m

M16 X 2.0 166+ 17 ft--lb 225 + 23 N--m 229 + 23 ft--lb 310 + 31 N--m M20 X 2.5 325 + 33 ft--lb 440 + 45 N-- m 450 + 46 ft--lb 610 + 62 N--m

Regular Height Nuts

(Class 8 or Stronger Nuts)

NOTE: The nominal torque values listed above are

based on 75% of the minimum proof load specified in SAEJ1199.The toleranceisapproximately+ nominal torque value.

Class 10.9 Bolts, Screws and Studs with

Regular Height Nuts

(Class 10 or Stronger Nuts)

10%ofthe

Product Records

and Maintenance

Greensmaster eFlex 1800/2100 Page 2 -- 5 Product Records and Maintenance

Other Torque Specifications

SAE Grade 8 Steel Set Screws

Recommended Torque

Thread Size

Square Head Hex Socket

1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb

5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb

3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3ft--lb 1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb

Thread Cutting Screws

(Zinc Plated Steel)

Type 1, Type 23 or Type F

Thread Size Baseline Torque*

No. 6 -- 32 UNC 20 + 5in--lb

Wheel Bolts and Lug Nuts

Thread Size

7/16 -- 20 UNF

Grade 5

1/2 -- 20 UNF

Grade 5

M12 X 1.25

Class 8.8

M12 X 1.5

Class 8.8

** For steel wheels and non--lubricated fasteners.

Thread Cutting Screws

(Zinc Plated Steel)

Thread

Size

No. 6 18 20 20 + 5in--lb

Threads per Inch Type A Type B

Recommended Torque**

65 + 10 ft--lb 88 + 14 N--m

80 + 10 ft--lb 108 + 14 N--m

Baseline Torque*

No. 8 -- 32 UNC 30 + 5in--lb

No. 10 -- 24 UNC 38 + 7in--lb

1/4 -- 20 UNC 85 + 15 in--lb

5/16 -- 18 UNC 110 + 20 in--lb

3/8 -- 16 UNC 200 + 100 in--lb

Conversion Factors

in--lb X 11.2985 = N--cm N--cm X 0.08851 = in--lb

ft--lb X 1.3558 = N--m N--m X 0.7376 = ft--lb

No. 8 15 18 30 + 5in--lb No. 10 12 16 38 + 7in--lb No. 12 11 14 85 + 15 in--lb

*Holesize, materialstrength, materialthickness &finish must be considered when determining specific torque values. All torque values are based on non--lubricated fasteners.

Greensmaster eFlex 1800/2100Page 2 -- 6Product Records and Maintenance

Traction and Reel Drive System

SPECIFICATIONS 2............................

GENERAL INFORMATION 3.....................

Operator’s Manuals 3.........................

Battery Pack Connection 3.....................

Disengaging Drum Drive From Transmission 4...

Transmission Belt Tensioner 5..................

SPECIAL TOOLS 6.............................

ADJUSTMENTS 8..............................

Cutting Unit Clip Adjustment 8..................

Reel Clutch Adjustment 9......................

SERVICE AND REPAIRS 11......................

Reel Drive Belt 11.............................

Reel Drive Assembly 12.......................

Reel Drive Bearing Housing 14.................

Drum Drive Belt 16............................

Drum Drive Idler Assembly 18..................

Traction Drums 20............................

Differential Assembly 24.......................

Differential Assembly Service 26................

Transmission Drive Belt 28.....................

Transmission Idler System 30..................

Transmission Reel Drive System 32.............

Removing Seized Reel Clutch Shaft From

Transmission 35............................

Transmission Drive System 36..................

Transmission Drum Drive System 38............

Transmission 40..............................

Chapter 3

Drive System

Traction and Reel

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 1

Specifications

Item Description

Transmission Permanent Magnet DC Motor Directly Coupled to

Traction Drive Transmission to Traction Drive uses Multi--Ribbed Poly--V Belt

Differential Spur Gear Planetary Differential

Traction Brake Band Style (at differential shaft drive)

Traction Drum Dual Cast Aluminum, 7.5 inch (19 cm) Diameter

Cutting Reel Drive Transmission Reel Clutch Shaft to Telescoping Drive Shaft

Final Reel Drive has Three (3) Pulleys with Positive Drive Belt

First Stage of a Multi--Ribbed Poly--V Belt Drive

Belt Tension Maintained by Spring Loaded Idler Pulley

Two Beam Style Couplers Used in Reel Drive System

Pulley Configuration Allows Six (6) Clip Adjustments

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 2

General Information

Operator’s Manuals

The Traction Unit and Cutting Unit Operator’s Manuals provide information regarding the operation, general maintenance and maintenance intervals for your Greensmaster machine. Refer to these Operator’s Manuals for additional information when servicing the machine.

Battery Pack Connection

CAUTION

Before servicing the machine, disconnect the the machine from the battery pack. This will prevent unexpected machine operation.

To prevent unexpected machine operation during service, disconnect the machine from the battery pack as thefirst step inany repair (Fig.1). Once thebatterypack hasbeendisconnected,the electrical systemonthemachinecanbesafelyworked on.Takecare duringrepairs, however, to not allow tools or vehicle components to complete the battery circuit that was opened with the cable removal.

Connect the machine wire harness to the battery pack as the last step in any repair.

WARNING

The eFlex battery pack contains high voltage which could burn or electrocute you.

 Never attempt to open the battery pack.  Do not place anything in t he connector on

the battery pack other than the wire

harness connector that came with the

product.

 Use extreme care when handling a battery

pack with a cracked case.

 Only use the charger designed for the

battery pack.

1. Battery pack

2. Battery connector

Drive System

Traction and Reel

Figure 1

3. Machine connector

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 3

Disengaging Drum Drive From Transmission

The tractiondrum is driven bya multi--ribbed belt thatis tensionedwith aspring loaded idlerassembly.To disengage the traction drum drive from the transmission, follow the following procedure:

1. Parkmachineonlevelsurface.Turnkeyswitchtothe OFF position and remove key from the switch. Disconnect the battery pack (see Battery Pack Connection in this section).

2. Locate the traction engage/disengage lever next to the RH drive housing drum (Fig. 2).

CAUTION

Becarefulwhen rotating thetractionengage/disengagelever.The lever isspring loaded andmay cause personal injury. Push lever from the front when removing belt tension to prevent unexpected movement of the lever.

3. Rotate traction engage/disengage lever toward the rear of the machine to the disengaged position to remove tension from the drum drive belt.

4. To engage the drum drive, rotate traction engage/ disengage leverto the engaged position by rotatingthe lever toward the front of the machine.

Figure 2

1. Traction lever (engaged) 2. RH handle clamp

5. Connectthebatterypack (seeBattery PackConnection in this section).

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 4

Transmission Belt Tensioner

The transmission pulleys are driven by a multi--ribbed belt that is tensioned with a spring loaded idler assembly.Ifthe transmission belttensionneedstobe engaged or disengaged, follow the following procedure:

1. Parkmachineonlevelsurface.Turnkeyswitchtothe OFF position and remove key from the switch. Disconnect the battery pack (see Battery Pack Connection in this section).

2. Locate the transmissionengage/disengage shaft on the inside of the transmission next to the battery pack (Fig. 3).

CAUTION

Be careful when rotating the transmission engage/disengage lever. The lever is spring loaded and may cause personal injury.

3. To disengage the spring loaded idler from thetransmission drive belt, use a 3/8” wrench to rotate the engage/disengage shaft 1/4 turn clockwise.

4. To engage the idler into the transmission drive belt, use a3/8” wrenchto rotate theengage/disengage shaft 1/4 turn counter--clockwise. The transmission belt is properlytensionedwhenthealignmentmarksontheengage/disengage shaft and the transmission cover are aligned (Fig. 4).

5. Connectthebatterypack (seeBattery PackConnection in this section).

Figure 3

1. Transmission

2. Engage/disengage shaft

Figure 4

1. Engage/disengage shaft

2. Alignment mark

3. Battery pack

3. Cover alignment mark

Drive System

Traction and Reel

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 5

Special Tools

Modified Socket for Reel Clutch Bearing Collar

The modified socket is used to remove and install the reel clutch bearing collar when servicing the transmission reel clutch shaft (Fig. 5). Refer to Transmission ReelDrive Systeminthe ServiceandRepairs sectionof this chapter for complete information on servicing the reel clutch shaft assembly.

Socket Modification

1. Make sure that socket (9/16” or 15mm) to be modified fits over the reel clutch shaft bearing collar.

2. Drill a hole or grind slots in socket walls to allow a 5/32” pin to extend through socket. A modified socket with ground slots is shown in Figure 6.

Modified Socket Use ( Fig. 7) IMPORTANT: To prevent damage, avoid using ex-

cessive clamping pressure on the reel clutch shaft assembly.

1. Bearing collar

2. Reel clutch shaft

123

Figure 5

3. Hub flat location

1. Use flats on reel drive hub to carefully secure reel clutchshaft assemblyin avise. Usea visewith softjaws to prevent damage to clutch shaft assembly components.

2. Slide modified socket over bearing collar.

3. Align modified socket so that 5/32” pin can be inserted through socket and hole in bearing collar.

4. Use modifiedsocket andsocket wrenchto loosenor tighten bearing collar.

1. Modified socket

2. Reel clutch shaft assy

Figure 6

Figure 7

3. Pin

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 6

Spline Insert Tool

Usesplineinserttooltoremoveorinstalldrivesplineinto transmission driven pulley. Referto Transmission Drive System inthe Service andRepairs section ofthis chapter for complete information on servicing the transmission drive system.

Toro Part Number: TOR4112

Figure 8

Drive System

Traction and Reel

1. Motor adapter

2. Transmission housing

3. Splined coupler

Figure 9

4. Drive spline

5. Driven pulley

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 7

Adjustments

Cutting Unit Clip Adjustment

Cuttingunitclipadjustment on theeFlex1800and eFlex 2100 can bechanged by installing the cutting unit drive pulleysto the appropriatelocations onthe reel driveassembly.Clip frequencypulley locationsfor 11 bladeand 14 blade cutting units are shown in Figure 11 below.

To adjust clip frequency, follow the following s teps:

1. Parkmachineonlevelsurface.Turnkeyswitchtothe OFF position and remove key from the switch. Disconnect the battery pack (see Battery Pack Connection in the General Information section of this chapter).

2. Removereeldrive coverandreel drivebeltfromside ofcuttingunit (seeReelDriveBelt intheServiceand Repairs section of this chapter).

3. Loosen two(2)set screwsfrom drivepulleys thatare to be removed. Slide pulleys from shafts.

4. Apply antiseize lubricant to top of woodruff keys.Arrange pulleys on reel drive assembly as needed for desired clip frequency (Fig. 11).

5. Secure all pulleys with two (2) set screws. To rque screws from 60 to 65 in--lb (6.8 to 7.3 N--m).

1. Reel drive cover

2. Reel drive belt

3. Pulley

Antiseize Lubricant

Figure 10

60 to 65 in--lb

(6.8 to 7.3 N--m)

4. Set screw

5. Woodruff key

6. Install reel drive belt and reel drive cover to cutting unit(see Reel DriveBeltin theServiceand Repairssection of this chapter).

7. Connectthebatterypack (seeBattery PackConnection in the General Information section of this chapter).

POSITIONBLADES

A11 14 B C

0.147 0.115

0.153 0.120

0.160 0.126

CLIP

0.174 0.137

0.182 0.143

0.190 0.149

22 22

24 25 24 25

24 25 25 24

22 25 22 24

25 22 24 22

SET SCREW

60 -- 65 IN LBS

22 TOOTH PULLEY IS ALUMINUM COLOR 24 TOOTH PULLEY IS BLACK COLOR 25 TOOTH PULLEY IS RED COLOR

Figure 11

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 8

Reel Clutch Adjustment

To adjust the reel clutch, follow the following steps:

2. Remove rubber plugfrom front oftransmission toallow viewing of reel drive clutch components (Fig. 12).

3. Releaseclutch cablespringtension byremovingreel clutch cable from casting slot of transmission:

A. Loosen upper jam nut that secures reel cable to casting slot of transmission.

B. Lift cable free from casting slot of transmission.

4. Loosen jam nut that secures set screw position in reel clutch lever (Fig. 12).

5. Apply light upward pressure against the reel clutch lever.

6. Backoutsetscrew inreel clutchlever untilreelclutch hubcauses thetips ofthe reeldrive hubteeth tocontact the mating reel clutch pulley.

7. While maintaining light pressure on reel clutchlever, rotate set screw clockwise until a gap of 0.040” to

0.060”(1.0to1.5mm)isattainedbetweenthereeldrive hub and reel clutch hub.

8. Tighten jam nut to secure adjustment. Make sure that set screw does not rotate while tightening jam nut.

9. Install rubber plug into front of transmission.

10.Install reel cable to casting slot of transmission and confirmthatcablespring lengthis properlyset(seeReel Clutch Cable Replacement in Chapter 5 -- Chassis and Controls).

0.040” to 0.060” (1.0 to 1.5 mm)

1. Reel drive hub tooth

2. Reel drive hub

3. Reel clutch hub

4. Reel clutch lever

Drive System

Traction and Reel

Light Upward

Pressure

Figure 12

5. Set screw

6. Jam nut

7. Gap location

11.Connect thebattery pack(seeBatteryPackConnection in the General Information section of this chapter).

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 9

1. Reel clutch lever

2. Reel clutch hub

Figure 13

3. Reel drive hub

4. Reel clutch pulley

This page is intentionally blank.

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 10

Service and Repairs

Reel Drive Belt

EFlex machinesuse apositive drive belton the leftside of the machine to operate the cutting unit.

Removal

2. Remove reel drive cover to expose reel drive belt (Fig. 14).

3. Loosen the bearing housing mounting nut (Fig. 15).

4. Using a 5/8” (16mm) wrench, rotate the bearing housing to release tension on reel drive belt (Fig. 15).

5. Remove reel drive belt from the pulleys.

Figure 14

1. Reel drive cover 2. Flange head screw

Drive System

Traction and Reel

Installation

1. Makesurethat thebattery packisdisconnected(see Battery Pack Connection in the General Information section of this chapter).

2. Using a 5/8” (16mm) wrench, rotate and hold the bearing housingto allow reel drive belt installation (Fig.

15).

3. Place a new drive belt onto the pulleys.

4. Release bearing housing to apply tension to reel drivebelt. Makesure thatbearing housing rotatesfreely which will allow accurate belt tension.

5. Rotate reel drive at least one (1) full turn to ensure that drive belt is properly tensioned.

6. Tighten the bearing housing mounting nut (Fig. 15).

7. Install reel drive cover to machine and secure with flange head screw (Fig. 14).

8. Connectthebatterypack (seeBattery PackConnection in the General Information section of this chapter).

1. Reel drive belt

2. Bearing housing nut

Figure 15

3. Compression spring

4. Bearing housing

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 11

Reel Drive Assembly

Antiseize Lubricant

Antiseize

Lubricant

60 to 65 in--lb

(6.8 to 7.3 N--m)

RIGHT

FRONT

Antiseize Lubricant

Figure 16

1. Reel drive housing

2. O--ring

3. Carriage screw

4. Washer head screw

5. Flange head screw (2 used)

6. Hex nut (2 used)

7. Reel drive shaft

8. Reel pulley (22 tooth) (aluminum)

9. O--ring

10. Reel idler shaft

11. Reel pulley (24 tooth) (black)

12. Bearing housing assembly

13. Cover plug

14. Reel pulley (25 tooth) (red)

15. Belt

16. Compression spring

17. Hardened washer

18. Hex nut

19. Reel drive cover

NOTE: Cutting unit clip adjustment on the eFlex 1800

and eFlex 2100 is adjusted by installing the cutting unit drivepulleys(items8,11and14)tothe appropriate locations on the reel drive assembly (see Cutting Unit Clip Adjustment in the Adjustments section of this chapter).

20. Shoulder bolt

21. Spring pin

22. Woodruff key (3 used)

23. Set screw (2 used per pulley)

24. Ball bearing (2 used)

25. Spacer

26. Push nut

27. Cutting unit

28. Flange head screw

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 12

Reel Drive Assembly Removal (Fig. 16)

2. Slide the telescoping coupler off the cutting unit hex shaft (Fig. 17).

3. Removereeldrive belt (seeReelDriveBeltReplacement in this section).

4. Loosen two (2) set screws (item 23) that secure reel pulley (item 8) to reel drive shaft (item 7). Slide pulley from drive shaft. Locateand retrieve woodruff key (item

22) from shaft.

5. Remove washer head screw (item 4) that secures reel drive housing to cutting unit side plate.

NOTE: Hex nuts (item6) haveadhesive appliedduring cutting unit production. The nuts should remain in cutting unit side plate during reel drive housing removal.

6. Remove two (2) flange headscrews (item5) thatsecure reel drive housing to cutting unit side plate.

3. Position reel drive assembly to cutting unit. Make sure that spring pin (item 21) and compression spring (item16) arepositionedbetween reeldrive housingand bearing housing assembly.

4. Secure reeldrive assembly with two (2)flange head screws (item 5) and washer head screw (item 4).

5. Install woodruff key(item 22) to reel driveshaft (item

7). Apply antiseize lubricant to top of key.

6. Slide reel pulley (item 8) onto reel drive shaft until it contacts shoulder on shaft. Secure reel pulley with two (2) set screws (item 23). Torque set screws from 60 to 65 in--lb (6.8 to 7.3 N--m).

7. Install reel drive belt (see Reel Drive Belt Replacement in this section). Make sure that reel drive cover is securedtohousingafterbeltinstallation.

8. Slide the telescoping coupler onto the cutting unit hex shaft (Fig. 17).

9. Connectthebatterypack (seeBatteryPackConnection in the General Information section of this chapter).

Drive System

Traction and Reel

7. Remove reel drive assembly from cutting unit.

8. Remove components from reel drive housing as necessary using Figure 16 as a guide.

A. If idlershaft bearings(item24) are toberemoved, use press to remove bearings and bearing spacer from shaft. Discard bearings after removal.

NOTE: See Reel Drive Bearing Housing in this section for disassembly and assembly information of bearing housing assembly (item 12).

NOTE: Reel pulleys (items 8,11and 14) can beidentified by color and number of teeth. Pulley location can vary based on desired cutting unit clip frequency (see Cutting UnitClip Adjustment inthe Adjustments section of this chapter).

Reel Drive Assembly Installation (Fig. 16)

1. Install allremoved components to reeldrive housing using Figure 16 as a guide.

A. If bearings (item 24) were removed from idler shaft, use press to install bearings and bearing spacer onto shaft.

Figure 17

1. Telescoping coupler 2. Cutting unit hex shaft

2. Apply light coating of grease on reel drive housing O--rings (items 2 and 9).

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 13

Reel Drive Bearing Housing

1. Retaining ring

2. Reel input shaft

3. Bearing (2 used)

4. Bearing spacer

5. Wave washer

Figure 18

6. Flocked bearing shield

7. Wave spring

8. Flat washer

9. Retaining ring

10. Bearing housing

11. Spring pin (2 used)

12. Flex coupling

13. Reel hex shaft

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 14

Disassembly (Fig. 18)

Assembly (Fig. 18)

2. Remove reel drive bearing housing from reel drive housing (see Reel Drive Assembly in this section).

3. Removeretainingring(item 1)from bearinghousing.

4. Slide reel input shaft assembly from bearing housing. Remove wave washer (item 5) from bearing housing.

IMPORTANT: When removing flexcoupler (item 12) from reel input shaft (item 2), do not mar outer surface of coupler (e.g. grasping with pliers or mounting in vise) as coupler may be damaged and fail prematurely.

5. Supportflex coupler(item12) to preventitfrombeing damaged during spring pin removal. Push spring pin fromflex couplerandreel inputshaft.Slide couplerfrom shaft and discard spring pin.

6. Remove retaining r ing (item 9) from shaft. Then remove flat washer (item 8), wave spring (item 7) and flocked bearing shield (item 6) from shaft. Note orientation of flocked shield for assembly purposes.

7. Press bearingsand bearingspacerfromshaft ifnecessary. Discard bearings if removed.

8. Clean all bearing housing components.

1. Ifbearingswereremovedfromreelinputshaft, install new bearings onto shaft. Press first bearing fully onto shaft. Position spacer on shaft and then press second bearing onto shaft.

2. Install flocked bearing shield (item 6), wave spring (item 7) and then flat washer (item 8) onto reel input shaft. Secure components to shaft with retaining ring (item 9). It may be necessary to drive the retaining ring onto theinput shaft with atubular tool and mallet.Make sure that retaining ring is fully seated into shaft groove after installation.

3. Place wave washer (item 5) into bearing housing.

4. Fillcavitybetween bearingswithMobilHighTemperature XHP--222 grease (or equivalent).

5. Installreel inputshaftassembly into bearinghousing andsecurewithretainingring(item1).

IMPORTANT: When installing flex coupler (item 12) onto reel input shaft (item 2), do not mar outer surface of coupler (e.g. grasping with pliers or mount ing in vise) as coupler may be damaged and fail prematurely.

6. Slide flex coupler onto reel input shaft, supportcoupler to prevent it from being damaged during spring pin installation. Installnew spring pin into coupler to secure it to shaft.

7. Install reel drive bearing housing to reel drive housing (see Reel Drive Assembly in this section).

Drive System

Traction and Reel

8. Connectthebatterypack (seeBatteryPackConnection in the General Information section of this chapter).

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 15

Drum Drive Belt

See text for

tightening procedure

15 to 17 ft--lb

(21to23N--m)

Figure 19

1. Drum drive cover

2. Washer head screw (7 used)

3. Gasket

4. Wave washer

5. Gear assembly

6. Retaining ring

7. Brake band

8. Brake mount pin

9. Extension spring

10. Drum drive belt

11. Brake clevis pin

12. Drum drive housing

The drum drive system on eFlex 1800 and eFlex 2100 machines uses a multi--ribbed poly--V drive belt on the right side of the traction drum.

Removal (Fig. 19)

2. Remove transport wheelsif attached (see Transport Wheelsin the Serviceand Repairs s ection of Chapter6

-- Chassis and Controls).

13. Retaining ring

14. Idler pulley assembly

15. Shoulder screw

16. Idler arm assembly

17. Washer head screw (4 used)

18. Drive pulley (from transmission)

3. Rotatetractionengage/disengagelever tothedisengaged position to remove tension from the drum drive belt(Fig. 20) (seeDisengagingDrum DriveFromTransmission inthe General Information sectionof this chapter).

4. Remove seven (7) washer head screws that secure the drum drive cover.Removecover to exposethe traction drive belt.

5. Remove and discard gasket (item 3) from between cover and housing.

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 16

6. Remove retaining ring (item 6) that secures brake band to brake clevis pin. Slide brake band from brake clevis and brake mount pins and remove band from drum drive housing.

7. Carefully remove one end of extension spring (item

9) from anchor point and rotate spring away from drive belt.

8. Pivot the idler pulley away from the drum drive belt to loosen belt tension (Fig. 21).

9. Remove drum drive belt from drive pulley and then from differential pulley.

Installation (Fig. 19)

1. Makesurethat thebattery packisdisconnected(see Battery Pack Connection in the General Information section of this chapter).

2. Placedrumdrivebeltontodifferentialpulleyandthen fit beltto drive pulley. Make sure thatbelt is onrear side of idler pulley.

3. Carefully install removed end of extension spring (item 9) to anchor point.

4. Install brake band over brake surface of differential pulley. Slide ends of brake band onto brake clevis and brakemountpins. Secure brakebandtobrake clevispin with retaining ring (item 6).

Figure 20

1. Traction lever (engaged) 2. RH handle clamp

Drive System

Traction and Reel

5. Make surethat wave washer (item 4) is pressed into bore of drum drive cover.

6. Position new gasket (item 3) to housing surface.

7. Slide drum drive cover onto drum drive assembly.

8. Install seven(7) washer head screws to securecover to housing. Tighten screws as follows:

A. F irst, using an alternating crossing pattern, torque all screws from 15 to 40 in--lb (1.7 to 4.5 N--m).

B. Again using an alternating crossing pattern, torque all screws from 85 to 95 in--lb (9.6 to 10.7 N--m).

9. Rotate traction engage/disengage lever to the engaged position to tension the drum drive b elt (Fig. 20).

10.Install transport wheels if they were attached (see Transport Wheels in the Service and Repairs section of Chapter 6 -- Chassis and Controls).

11.Connect thebattery pack(seeBatteryPackConnection in the General Information section of this chapter).

1. Traction drive belt

2. Drive pulley

3. Idler pulley

Figure 21

4. Differential pulley

5. Brake band

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 17

Drum Drive Idler Assembly

See text for

tightening procedure

15 to 17 ft--lb

(21to23N--m)

Figure 22

1. Drum drive cover

2. Washer head screw (7 used)

3. Gasket

4. Wave washer

5. Gear assembly

6. Retaining ring

7. Brake band

8. Brake mount pin

9. Extension spring

10. Drum drive belt

11. Brake clevis pin

12. Drum drive housing

Removal

2. Remove transport wheelsif attached (see Transport Wheelsin the Serviceand Repairs s ection of Chapter6

-- Chassis and Controls).

3. Rotatetractionengage/disengageleverto the disengaged position to remove tension from the drum drive belt (see Disengaging Drum Drive From Transmission in the General Information section of this chapter).

13. Retaining ring

14. Idler pulley assembly

15. Shoulder screw

16. Idler arm assembly

17. Washer head screw (4 used)

18. Drive pulley (from transmission)

4. Remove seven (7) washer head screws that secure thedrumdrive cover.Removecover toexposethe drum drive system.

5. Remove and discard gasket (item 3) from between cover and housing.

6. Carefully remove the end of the extension spring (item9)fromidlerarm.

7. Remove shoulder screw (item 15) that secures the idler arm assembly to the drum drive housing. Remove idler arm assembly from housing.

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 18

8. Disassemble idler arm assembly as needed (Fig.

23). Replaceworn or damaged bearings and bushings. A. Remove flange bushings from idler bracket. B. Remove retaining ring from idler bracket. Slide

idler pulley from bracket shaft. Press ball bearings from idler pulley.

Installation

1. If idler arm assembly was disassembled (Fig. 23): A. Press new flange bushings into idler bracket. B. Pressnewballbearingsfully intoidler pulleymak-

ingsure toapply pressuretoouter bearingrace only. Slide pulley assembly onto idlerbracket and secure with retaining ring.

2. Position idler arm assembly to drum drive housing

andsecurewith shoulderscrew (item15).Torqueshoulderscrewfrom15to17ft--lb(21to23 N--m).Checkthat idler arm assembly can pivot freely after tightening shoulder screw.

3. Carefully secure the end of the extension spring

(item 9) to idler arm.

4. Make surethat wave washer (item 4) is pressed into

bore of drum drive cover.

5. Position new gasket (item 3) to housing surface.

6. Slide drum drive cover onto drum drive assembly.

Figure 23

1. Flange bushing (2 used)

2. Idler bracket

3. Ball bearing (2 used)

4. Idler pulley

5. Retaining ring

Drive System

Traction and Reel

7. Install seven(7) washer head screws to securecov-

er to housing. Tighten screws as follows:

A. F irst, using an alternating crossing pattern, torque all screws from 15 to 40 in--lb (1.7 to 4.5 N--m).

B. Again using an alternating crossing pattern, torque all screws from 85 to 95 in--lb (9.6 to 10.7 N--m).

8. Rotate traction engage/disengage lever to the en-

gagedpositiontotensionthedrumdrive belt(see Disengaging Drum Drive From Transmission in the General Information section of this chapter).

9. Install transport wheels if they were attached (see

Transport Wheels in the Service and Repairs section of Chapter 6 -- Chassis and Controls).

10.Connectthe batterypack(seeBatteryPackConnec-

tion in the General Information section of this chapter).

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 19

Traction Drums

Antiseize

Lubricant

RIGHT

FRONT

140 to 160 ft--lb

(190 to 216 N--m)

75 to 90 ft--lb

(102 to 122 N--m)

70 to 80 ft--lb

(95 to 108 N--m)

Figure 24

1. Drum drive housing

2. Straight bushing

3. Flange bushing (4 used)

4. Brake lever

5. Traction lever

6. Square key (2 used)

7. Drum shaft

8. Long spur gear

9. Differential assembly

10. RH traction drum

11. Jam nut

12. Grease seal

13. LH traction drum

14. Ball bearing (2 used)

15. Bearing nut

16. LH hex shaft

17. Straight bushing (2 used)

18. Dowel pin (2 used)

19. Cap screw

20. Flat washer

Traction Drum Removal (Fig. 24)

2. If installed, remove transport wheels (see Transport Wheelsin the Serviceand Repairs s ection of Chapter6

-- Chassis and Controls).

21. Traction engage lever

22. Retaining ring (2 used)

23. Brake lever

24. Retaining ring

25. LH side plate

26. Washer head screw

27. Lock collar

28. Pin

29. Thrust washer

30. O--ring

3. Remove handle assembly from machine (see Handle Assembly in the Service and Repairs section of Chapter 6 -- Chassis and Controls).

4. Supportbothsidesof machine framewithjackstands or suitable blocking to prevent the machine from moving.

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 20

5. Separate LHside plate (item25) from machine(Fig.

25):

A. Remove flange nut, hardened washer and carriagescrew(items3,4and6inFig.25)thatsecure LH side plate to rear frame.

B. Remove three (3) flange screws and hardened washers (items 8 and 4 in Fig. 25) that secure LH side plate to frame.

C. Slide LH side plate from supporting bearing and remove from machine.

6. Insertbar stockorother suitable toolthroughspokes

of LH traction drum to keep drum from turning.

7. WhileretainingLHdrum,loosenandremovebearing

nut (item 15) from traction drum assembly. The ball bearing(item14)ispressedontothebearingnutsoitwill be removed with the nut.

8. SlideLH tractiondrum(item 13)fromdrum shaft.Lo-

cate and retrieve square key from shaft.

9. If necessary, carefullyremove grease seal (item 12)

from LH traction drum taking care to not damage bore of drum. Discard removed seal.

1. Kickstand

2. Rear frame

3. Flange nut

4. Hardened washer

5. Frame

6. Carriage screw

Figure 25

7. LH side plate

8. Flange screw (3 used)

9. Counterweight

10. Offset handle clamp

11. Handle clamp

Drive System

Traction and Reel

10.If necessary, removeLH hex shaft (item 16) and ball

bearing (item 14) from bearing nut. 1 1.Insertbar stockor othersuitabletool throughspokes

of RH traction drum to keep drum from turning.

12.Remove O--ring (item 30),pin (item 28)and lock col-

lar (item 27) from drum shaft.

13.While retaining remainingdrum, loosen andremove

jam nut (item 11) from long spur gear.

14.Remove RH traction drum (item 10) from machine.

Locate and retrieve square key from spur gear. NOTE: If removal of the drum shaft (item 7), long spur

gear (item 8) or differential assembly (Item 9) is necessary, see Differential Assembly in this section.

Traction Drum Installation (Fig. 24)

1. Make sure that drum shaft (item 7), long spur gear

(item 8) and differential assembly (Item 9) are installed to drum drive housing (refer to Differential Assembly in

4. Align slot in RH traction drum (item 10) with key on long spur gear and slide traction drum onto gear.

this section).

5. Insert barstock orother suitabletool throughspokes

2. Install LH hex shaft (item 16) and ball bearing (item

of RH traction drum to keep drum from turning.

14)to bearingnut (item 15) if they were removed. Press

bearing fullyonto bearing nut.Torque hexshaft from 70 to 80 ft--lb (95 to 108 N--m).

6. Install jam nut (item 11) onto threads of long spur gear to secure RH traction drum. Torque jam nut from 140 to 160 ft--lb (190 to 216 N--m).

3. Place square key (item 6) into slot of long spurgear

(item 8). Apply antiseize lubricant to top surface of key. Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 21

0.470” to 0.530”

(12.0 to 13.4 mm)

Figure 26

1. LH traction drum 2. Grease seal

7. Slide lock collar (item 27) onto drum shaft. Align holesin collarand shaftand theninstallpin (item28).Fit O--ring (item 30) to slot in collar.

13.Secure LH side plate(item 25) to machine (Fig.25): A. Slide LH side plate onto supporting bearing.

8. If grease seal (item 12) was removed from LH traction drum, installnew grease seal into drum. Makesure that seal lip is orientated toward center of drum. Press sealinto drumbore sothat sealis recessedfrom 0.470” to0.530”(12.0to13.4mm)fromedgeofdrum(Fig.26).

9. Placesquare key(item 6) intoslot ofdrum shaft.Apply antiseize lubricant to top surface of key.

10.Align slot in LH traction drum (item 13) with key on drum shaft and carefully slide traction drum onto shaft taking care to not damage grease seal in drum.

11.Insert barstock orothersuitable t ool throughspokes of LH traction drum to keep drum from turning.

12.Make sure thatball bearing (item14)is pressedonto the bearing nut (item 15). While retaining LH drum, secure drum to traction drum assembly with bearing nut (item 15). Torque bearing nut from 75 to 90 ft--lb (102 to 122 N--m).

B. Secure LH side plate to frame with three (3) flange screws and hardened washers.

C. Secure LH side plate to rear frame with carriage screw, hardened washer and flange nut.

14.Install handle assemblyto machine (see Handle As-

sembly in the Service and Repairs sectionof Chapter 6

-- ChassisandControls).Makesure thatallcableadjust-

ments are correct.

15.Install transport wheels if necessary (see Transport

Wheels in the Serviceand Repairs sectionof Chapter6

-- Chassis and Controls).

16.Connectthe battery pack(seeBatteryPackConnec-

tion in the General Information section of this chapter).

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 22

This page is intentionally blank.

Drive System

Traction and Reel

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 23

Differential Assembly

Antiseize

Lubricant

RIGHT

FRONT

140 to 160 ft--lb

(190 to 216 N--m)

75 to 90 ft--lb

(102 to 122 N--m)

70 to 80 ft--lb

(95 to 108 N--m)

Loctite #242

Figure 27

1. Drum drive housing

2. Straight bushing

3. Flange bushing (4 used)

4. Brake lever

5. Traction lever

6. Square key (2 used)

7. Drum shaft

8. Long spur gear

9. Differential assembly

10. RH traction drum

11. Jam nut

12. Grease seal

13. LH traction drum

14. Ball bearing (2 used)

15. Bearing nut

16. LH hex shaft (LH threads)

17. Straight bushing (2 used)

18. Dowel pin (2 used)

19. Cap screw

20. Flat washer

21. Traction engage lever

Disassembly (Fig. 27)

22. Retaining ring (2 used)

23. Brake lever

24. Retaining ring

25. LH side plate

26. Washer head screw

27. Lock collar

28. Pin

29. Thrust washer

30. O--ring

31. Spur gear assembly

2. Remove traction drums from machine (see Traction

Drums in this section).

3. Slide spurgear assembly from differentialassembly

in drum drive housing (Fig. 28).

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 24

4. If necessary,disassemble spur gear assembly (Fig.

29). A. The hex shaft has left hand threads. The shaft

also has thread locking compound on threads. B. Press ball bearing and flange bushing from spur

gear as needed.

IMPORTANT: As drum shaft(item 7)and differential assembly (item 9) are removed, make sure to retrieve and note location of thrust washer (item 29) for assembly purposes.

4. Place thrust washer (item 29) onto drum shaft (item

7). Insert drum shaft into differential assembly. Make surethatdrumshaftproperlyengagesdifferentialgears.

5. Install traction drums to machine (see Traction Drums in this section).

6. Installdrum drive beltfrom machine(seeDrumDrive Belt in this section).

7. Connectthebatterypack (seeBatteryPackConnection in the General Information section of this chapter).

5. Pushdrum shaft(item 7)out ofdifferential assembly.

Makesuretolocateand retrievethrustwasher(item29).

6. Slide differentialassembly from long spurgear (item

8) and drum drive housing (item 1).

NOTE: For differentialserviceprocedure, seeDifferential Assembly Service in this section.

7. If necessary, slide longspur gear (item 8) from drum

drive housing. Straight bushings (item 17) in long spur gear should be inspected for wear or damage and replaced if needed.

8. Ballbearing (item14) thatsupports longspur gearis

pressed into drum drive housing. Make sure that bearing is in good condition and is pressed fully to shoulder of housing.

Assembly (Fig. 27)

1. If long spur gear (item 8) was removed from drum

drive housing,slide gear into ballbearing in drivehousing.

2. If spur gear assembly (Fig. 29) was taken apart, as-

semble as necessary:

Drive System

Traction and Reel

Figure 28

1. Drum drive housing 2. Spur gear assembly

70 to 80 ft--lb

(95 to 108 N--m)

A. Press new ball bearing fully onto spur gear if removed.

B. Press new flange bushing into spur gear if removed.

C. If the hex shaft was removed from the spur gear, apply Loctite #242 (or equivalent) to threads of hex shaft. Install hex shaft (left hand threads) into spur gearandtorquefrom 70to80 ft--lb (95to108N--m).

3. Make sure that differential housing cavity is packed

20% to 30% full of high temperature Mobil XHP--222 grease (or equivalent). Slide differential assembly into drum drive housing (item 1) and onto long spur gear (item8). Makesure thatspur gearproperlyengages differential gears.

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 25

1. Spur gear

2. Ball bearing

Figure 29

3. Hex shaft (LH threads)

4. Flange bushing

Differential Assembly Service

99 to 121 in--lb

(11.2 to 13.6 N--m)

Figure 30

1. Housing

2. Cover

3. Ball bearing (2 used)

4. Pin (6 used)

5. Dual spur gear (6 used)

6. Spacer (9 used)

Disassembly (Fig. 30)

1. Remove differential assembly from machine (see Differential Assembly in this section).

2. Remove six(6) socket headscrews that securecovertohousing.Notealignmentof indexmarks onhousing and cover for assembly purposes (Fig. 31).

3. Placedifferential assemblyonworkbenchso thatthe differential is resting onthe cover withhousing orientated up.

7. Spur gear (3 used)

8. Socket head screw (6 used)

6. Slide each pin with gears and spacers from cover. Notelocation of gearsandspacers oneachof thesix(6) pins.

7. If necessary, remove ball bearings from cover and housing. There are two (2) holes in thecover and housing that allow use of a pin punch to remove bearings. Discard removed bearings.

Inspection (Fig. 30)

1. Clean all differential components.

4. Lift housing from differentialassembly leaving internalcomponents positionedon cover.Forassemblypurposes, note that index mark on housing is aligned with a pin that has one (1) gear (Fig. 32).

5. Note locations of projections on inside of cover for assemblypurposes. Theprojections needto be aligned with the pins that have one (1) gear (Fig. 33).

2. Inspect all differential gears carefully looking for chipped teeth, wear or other damage. Because gear tooth damage is rarely isolated to one gear, replace gears as a complete set if internal damage is found.

3. Inspect gear pins (item 4) for scoring or wear.

4. Replace all worn or damaged differential assembly components.

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 26

Assembly (Fig. 30)

1. If ball bearing was removed from either cover or

housing,press newballbearing intobearing bore.Make sure that bearing is fully pressed to shoulder of bore.

2. Place cover (with bearing installed) on workbench.

3. Slide each pin with gears and spacers into cover.

Makesurethatprojectionsoninsideofcover are aligned with the pins that have one (1) gear (Fig. 33).

4. Positionhousingontoassembly makingsure thatpin

with one (1) gear is positioned next to index mark on housing (Fig. 32). Also, align index marks on housing and cover during assembly (Fig. 31).

5. After housing is installed, use one of the spur gears

(see Differential Assembly in this section) to rotate differential gears making sure that they rotate freely without binding. If binding is noted, identify and correct cause before securing the cover.

6. Secure cover to housing with six (6) socket head

screws. Torque screws from 99 to 121 in--lb (11.2 to

13.6 N--m).

7. Pack differential housing cavity 20% to 30% full of

high temperature Mobil XHP --222 grease (or equivalent).

Figure 31

1. Cover index mark 2. Housing index mark

Drive System

Traction and Reel

8. Install differential assembly to machine (see Differ-

ential Assembly in this section).

1. Housing index mark

2. Pin with 2 gears

Figure 32

3. Pin with 1 gear

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 27

1. Projection on cover

2. Pin with 2 gears

Figure 33

3. Pin with 1 gear

Transmission Drive Belt

See text for

tightening

procedure

RIGHT

FRONT

1. Transmission assembly

2. Transmission belt

3. Gasket

4. Wave washer (2 used)

5. Transmission cover

6. Washer head screw (7 used)

Transmission removal from the machine is not necessary to service the transmission drive belt. The transmission drive belt can be replaced by removing the battery packfrom the frame, removing thetransmission cover and then removing the drive belt.

Drive Belt Removal (Fig. 34)

2. Remove battery pack from machine (see Battery Pack in the Service and Repairs section of Chapter 4 -Electrical System).

Figure 34

7. Drive shaft wire

8. Telescoping coupler

IMPORTANT: During disassembly, make sure that tension is released from transmission belt before removing transmission cover.

4. Remove tensionon transmission beltby rotatingthe engage/disengage shaft clockwise (see Transmission BeltTensioner inthe GeneralInformation sectionof this chapter).

5. Remove seven (7) washer head screws that secure transmission cover to transmission. Carefully remove cover from transmission. Remove and discard gasket (item 3).

6. Make sure that wave washers (item 4) remain in bearing bores of transmission cover.

3. Usetips ofneedle nosepliersto spreadends ofdrive shaft wire (item 7) in telescoping coupler (item 8). With wireendsspread, slidecouplerfrom t ransmission shaft.

7. Note transmission belt routing for assembly purposes (Fig. 35).

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 28

8. Remove transmission belt from drive and idler pul-

leys in transmission.

9. Check conditionof all pulleys and idlercomponents.

10.Clean inside of transmission before installing new

belt.

Drive Belt Installation (Fig. 34) IMPORTANT: During assembly, make sure that

transmissioncover isinstalled withfasteners properly torqued before applying tension to transmission belt.

1. Install new transmission belt onto pulleys in trans-

mission. Make sure that belt is correctly routed around drive and idler pulleys (Fig. 35).

2. Make sure that wave washers (item 4) are pressed

into bearing bores of transmission cover. Also, make surethat two(2)dowel pinsarepressed intoboresinthe transmission housing.

3. Positionnew gasketto transmissionassembly.Align

gasket to two (2) dowel pins in transmission housing.

4. Installtransmissioncover.If n ecessary,usea rubber

mallet at dowel locations(Fig. 36)to seatcover totransmission.

5. Install seven(7) washer head screws to securecov-

er to transmission. Tighten screws as follows:

Figure 35

1. Engage/disengage shaft

2. Drive pulley

3. Reel clutch pulley

Drive System

Traction and Reel

4. Idler pulley

5. Drum drive pulley

6. Idler pulley

A. F irst, using an alternating crossing pattern, torque all screws from 15 to 40 in--lb (1.7 to 4.5 N--m).

B. Again using an alternating crossing pattern, torque all screws from 85 to 95 in--lb (9.6 to 10.7 N--m).

6. Applytension totransmission beltby rotating theen-

gage/disengage shaft counter--clockwise ( see Transmission Belt Tensioner in the General Information section of this chapter).

7. Slide telescoping coupleronto transmission shaft so

thatdrive shaftwire engages hexshaft ontransmission. Make sure that telescopingcoupler isproperly attached to cutting unit hex shaft.

8. Install battery pack to machine (see Battery Pack in

theServiceand RepairssectionofChapter 4-- Electrical System).

9. Connectthebatterypack (seeBattery PackConnec-

tion in the General Information section of this chapter).

Figure 36

1. Transmission cover 2. Dowel location

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 29

Transmission Idler System

15 to 17 ft--lb

(21 to 23 N--m)

RIGHT

FRONT

1. Transmission cover

2. Engage/disengage shaft

3. Transmission belt

4. Extension spring

5. Main drive idler

6. Driven pulley (drum drive)

7. Flange bushing (4 used)

8. Cap screw (2 used)

9. Idler pulley bushing (2 used)

10. Ball bearing (6 used)

Transmission removal from the machine is not necessaryto servicethe transmissionidler system.Transmissionidlercomponentscanbe accessed byremovingthe battery packfrom the frame, removing thetransmission cover and then removing the drive belt.

Figure 37

11. Idler pulley (2 used)

12. Idler pulley

13. Shoulder screw

14. Retaining ring

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 30

Disassembly (Fig. 37)

1. Parkmachineonlevelsurface.Turnkeyswitchtothe

OFF position and remove key from the switch. Disconnect the battery pack (see Battery Pack Connection in the General Information section of this chapter).

2. Remove transmission drive belt (see Transmission

Drive Belt in this section).

3. Disassemble idler system as required using Figure

37as a guide.Discardball bearingsif theyare removed from idler pulleys.

4. Checkbushings (items7 and9) forwear or damage.

Replace bushings if necessary. Bushings for engage/ disengage shaft (item 2) are pressed into the transmission housing and cover.

Assembly (Fig. 37)

1. Assemble idler system as required using Figure 37

as a guide. Ball bearings that support idler pulleys are pressed into the pulleys.

A. If bearings were removed from idler pulleys, press new bearings fully to shoulder of idlerpulleys.

B. If extension spring (item 4) was removed, make sure that ends of spring are orientated as shown in Fig. 38.

C. If main drive idler (item 5) was removed, secure idler to transmission housing with shoulder screw (item13). Torque shoulderscrew from 15 to17 ft--lb (21to23N--m).

D. After securing idler components to transmission housing, make sure that all idler pulleys rotate smoothly.

Figure 38

1. Engage/disengage shaft

2. Main drive idler

3. Extensionspring

Drive System

Traction and Reel

4. Idler pulley

5. Transmission belt

2. Install transmission drive belt and all machine com-

ponents removed for idler system service (see Transmission Drive Belt in this section).

3. Connectthebatterypack (seeBattery PackConnec-

tion in the General Information section of this chapter).

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 31

Transmission Reel Drive System

RIGHT

FRONT

Indicator

Mark

Loctite #242

23 to 27 ft--lb

(32to36N--m)

Loctite #242

1. Transmission housing

2. Flex coupler

3. Hex shaft

4. Spring pin (2 used)

5. Retaining ring

6. Plug

7. Retaining ring (reel clutch cable)

8. Flange bushing (2 used)

9. Flange bushing (2 used)

10. Reel clutch lever

11. Reel brake ring

12. Ball bearing

13. Retaining ring

14. Reel brake disc

15. Clutch pivot pin (2 used)

16. Reel clutch fork

17. Reel clutch hub

18. Reel drive hub

19. Clutch shaft

Transmission removal from the machine is not necessary to service the transmission reel drive system. Transmission reel drive components can be accessed by removing the battery pack from the frame, removing thetransmissioncover andthenremoving the drivebelt.

Reel Clutch Shaft Removal (Fig. 39)

2. Disconnect reel clutch cable fromtransmission (see Reel ClutchCable Replacement in the Service and Repairs section of Chapter 6 -- Chassis and Controls).

Figure 39

20. Spacer

21. Ball bearing (2 used)

22. Reel clutch pulley

23. Bearing collar

24. Flocked bearing shield

25. Wave spring

26. Flat washer

27. Retaining ring

28. Ball bearing

3. Remove transmission drive belt (see Transmission Drive Belt in this section).

4. Remove retaining ring (item 5) that secures reel clutchlever (item10) in transmissionhousing. Slide reel clutch lever from housing. Note missing tooth in spline areaof leverwhich isused foralignment withreel clutch fork (item 16).

5. Pull reel clutch shaft assembly from transmission housing. NOTE: If ball bearing (item 28) on reel clutch shaft assembly is seized in housing, refer to Removing SeizedReelClutchShaftFromTransmissioninthissection for removal procedure.

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 32

6. Inspect flangebushings andreel brake ringfor wear

or damage (Fig. 40). Replace bushings and brake ring if necessary.

Reel Clutch Shaft Disassembly (Fig. 39) NOTE: The following procedure covers complete dis-

assembly of reel clutch shaft assembly. Depending on service needs of machine, it may not be necessary to perform every step of this procedure.

IMPORTANT: When removing flex coupler (item 2) from clutch shaft, do not mar outer surface of coupler (e.g. grasping with pliers or mounting in vise) as coupler may be damaged and fail prematurely.

1. Support flex coupler (item 2)to prevent it from being

damaged during spring pin removal. Push spring pin fromflex coupler andbearingcollar (item23).Slide couplerwith hexshaft (item3) fromcollar.Discard removed spring pin.

2. Press ball bearing (item 28) from end of reel clutch

shaft. Discard removed bearing.

3. Carefully remove retaining ring (item 13) that se-

cures reel brake disc (item 14) to reel drive hub (item

18).Takecareto notdamagebrakedisc frictionmaterial

when removing retaining ring.

1. Transmission housing

2. Flange bushing

Figure 40

3. Flange bushing

4. Reel brake ring

Drive System

Traction and Reel

21345678

4. Removereel brakedisc(item 14)from reeldrivehub

noting orientation of disc for assembly purposes. Friction material sideof disc needs to be positionedtoward the reel brake ring (item 11) which is pressed into the transmission housing.

5. Slide reel clutch hub (item 17) and reel clutch fork

(item 16) assembly from reel drive hub (item 18). Note correctorientationofindicatormarkonforkforassembly purposes.If necessary, removepivot pins(item 15)and separate fork from hub.

6. Use modifiedsocket (see SpecialToolsin this chap-

ter)to remove bearing collar assemblyfrom clutchshaft (Fig. 41).

IMPORTANT: To prevent damage, avoid using excessive clamping pressure on the reel clutch shaft assembly.

A. Use flatson reeldrivehub tocarefully securereel clutch shaft assembly in a vise. Use a vise with soft jaws to prevent damage to clutch shaft assembly components.

B. Slide modified socket over bearing collar. Align modified socket so that 5/32” pin can be inserted through socket and hole in bearing collar.

Figure 41

1. Retaining ring

2. Flat washer

3. Wave spring

4. Flocked bearing seal

5. Ball bearing

6. Bearing collar

7. Reel clutch shaft

8. Hub flat location

7. Remove retaining ring (item 27), flat washer (item

26), wave spring (item 25) and flocked bearing shield (item24) frombearing collar.Note orientationof flocked shield for assembly purposes.

8. Press bearing (item 12) from bearing collar.Discard removed bearing.

9. Slide reel clutch pulley assembly and reel drive hub from clutch shaft.

10.If necessary, remove ball bearings and spacer from pulley. Discard removed bearings.

Reel Clutch Shaft Assembly (Fig. 39)

1. Ifball bearingswere removedfrom reelclutch pulley, press newinner bearing fullyto bottom ofbore in pulley. Installspacer into pulleyandthen pressnewouter bearing into pulley until it contacts spacer.

C. Use modified socket and socket wrench to remove bearing collar assembly from clutch shaft.

2. If bearing was removed from bearing collar, press new bearing fully onto collar.

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 33

3. Slide reel clutch pulley assembly and reel drive hub onto clutch shaft.

10.Press new ball bearing (item 28) fully to shoulder of reel clutch shaft.

4. Use modifiedsocket (see SpecialToolsin this chapter) to install bearing collar assembly onto clutch shaft (Fig. 41).

IMPORTANT: To prevent damage, avoid using excessive clamping pressure on the reel clutch shaft assembly.

A. Use flatsonreel drivehubto carefullysecurereel clutch shaft assembly in a vise. Use a vise with soft jaws to prevent damage to clutch shaft assembly components.

B. Use modified socket, 5/32” p in and socket wrench to install bearing collar assembly to clutch shaft.Torque bearingcollar from 23to27ft--lb (32 to 36 N--m).

5. Install flocked bearing shield (item 24) (flocked side orientated toward bearing location), wave spring (item

25), flat washer (item 26) and retaining r ing (item 27) onto bearing collar.

6. If reel clutch fork (item 16) was separated from reel clutch hub (item 17), clutch pivot pins (item 15) should eitherbe replaced(newpins havepatchlock onthreads) or have Loctite #242 (or equivalent) applied to threads beforeinstallation. Secure forkto clutch hubwith two(2) pivot pins.

7. Slide reel clutch hub (item 17) and reel clutch fork (item 16) assembly onto reel drive hub (item 18). Make sure thatindicator mark onfork is toward therear of the transmission.

8. Install reel brake disc (item 14) onto reel drive hub. Friction material side of disc needs to be positioned toward the reel brake ring (item 11)which is pressed into the transmission housing.

IMPORTANT: When installing flex coupler (item 2) onto shaft, do not mar outersurface of coupler (e.g. grasping with pliers or mounting i n vise) ascoupler may be damaged and fail prematurely.

11.Slide flex coupler onto bearing collar (item 23), sup port coupler to prevent it from being damaged during springpin installation. Installnew springpin into coupler to secure coupler to collar.

Reel Clutch Shaft Installation (Fig. 39)

1. Before inserting reel clutch assembly into transmission housing, thoroughlyclean reel brake ring (item 11) that is pressed into housing.

2. Slide reel clutch shaft assembly into transmission housing.

3. Align missingtooth in spline area of reel clutch lever (item 10) with reel clutch fork (item 16). Insert lever through housing and fork. Secure lever with retaining ring (item 5).

4. Install transmission drive belt and all machine components removed for reel drive system service (see Transmission Drive Belt in this section).

5. Check r eel clutch adjustment (see Reel Clutch Adjustmentin theAdjustmentssectionof thischapter).Adjust as needed.

6. Connect reel clutch cable to transmission (see Reel Clutch Cable Replacement in the Service and Repairs sectionofChapter6-- ChassisandControls).Makesure that clutch cable is properly adjusted.

7. Connectthebatterypack (see BatteryPack Connection in the General Information section of this chapter).

9. Carefully secure reel brake disc (item 14) to reel drive hub (item 18) with retaining ring (item 13). Take care to not damage brake disc friction material when installing retaining ring.

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 34

Removing Seized Reel Clutch Shaft From Transmission

If reel clutch shaft assembly cannot be easily removed from transmission housing due to bearing seizure, the following procedure can be followed toremove the reel clutch shaft assembly.

1. Make sure that transmission drive belt and reel

clutch lever are removed from housing (see Transmission Drive Belt and TransmissionReel Drive System in this section).

2. Carefully drill two (2) No. 7 (0.201” diameter) holes

in the transmission housing using the dimples in the housing ascenters for theholes (Fig. 43).Holes should be drilled completely through the housing allowing external access to the ball bearing on the reel shaft.

3. Use a 3/16” punch through the drilled holes to care-

fully drive the bearing and reel clutch shaft from the transmission housing.

IMPORTANT: Ball bearing will be damaged during this procedure. Remove ball bearing from reel clutch shaft and discard bearing after shaft has been removed from ho using (see Transmission ReelDriveSystemin thissectionforbearingremoval information).

4. Clean and inspect bearing bore in housing. If dam-

ageis severein housing,replace transmissionhousing.

5. Use a 1/4”--20 UNC tap to install threads in the two

(2) holes drilled in the transmission housing.

6. Install two (2) 1/4”--20 cap screws with flat washers

into tapped holes in the transmission housing. Cap screwsno longerthan 3/8”in length should beused. After screw installation, make sure that the ends of the screws DO NOT extend into the ball bearing bore in the housing.

Figure 42

1. Reel clutch shaft

2. Ball bearing

3. Housing bearing bore

Figure 43

1. Transmission housing 2. Housing dimple

Drive System

Traction and Reel

7. Service the reel clutch shaft assembly as needed

(see Transmission Reel Drive System in this section). Make sure that new ball bearing is installed on reel clutch shaft.

8. Install reel clutch shaft assembly into transmission

housing andassemble transmission(see Transmission Reel Drive System in this section).

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 35

Transmission Drive System

See text for

tightening procedure

RIGHT

FRONT

21 to 25 ft--lb

(29to33N--m)

Loctite #242

1. Motor adapter

2. Washer head screw (4 used)

3. Wave washer

4. Ball bearing

5. Retaining ring

6. Splined coupler

7. Drive spline

8. Driven pulley

9. Ball bearing

10. Flocked bearing shield

11. Wave spring

12. Flat washer

Transmission removal from the machine is not necessary to service the transmission drive system shown in Figure 44. Transmission drive components can be accessedbyremoving thebatterypackfrom theframe,removing the electric motor from the transmission, removingthetransmission coverand thenremovingthe drive belt.

Disassembly (Fig. 44)

Figure 44

13. Retaining ring

14. Set screw

15. Electric motor assembly

16. Transmission housing

17. Flange head screw (2 used)

18. O--ring

2. Remove electric motor from machine (see Electric Motor in the Service and Repairs section of Chapter 4

-- Electrical System).

3. Remove transmission drive belt (see Transmission Drive Belt in this section). Make sure that wave washer (item 3) remains in bearing bore of transmission cover.

4. Slide driven pulley assembly ( including bearings) from motor adapter.

5. If necessary, remove four (4) washer head screws (item 2) that secure motoradapter (item 1) to transmission housing and remove adapter from housing.

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 36

6. As necessary, remove components from driven

pulley (item 8):

D. Install set screw (item 14) into end of pulley and tighten against drive spline.

A. Remove retainingring(item13), flat washer(item

12),wavespring (item11)and flocked bearingshield (item 10) from driven pulley. Note orientation of flocked shield for assembly purposes.

B. Press bearings (items 4 and 9) from pulley. Discard removed bearings.

C. Remove retaining ring (item 5) and slide splined coupler (item 6) from pulley. Clean splined coupler and inspect coupler for wear or damage.

D. Inspectthedrivespline (item7)thatis attachedto drivenpulley.Drive splineshould befree ofbending, distortion or other damage.

7. Ifdrivespline(item7)needstobe removed fromdriv-

en pulley, use the following procedure:

IMPORTANT: Avoid using excessive clamping pressure on the driven pulley flats to prevent damage to pulley.

A. Use flats on driven pulley to carefully secure pulleyinavise.Useavisewithsoftjawstoprevent pulley damage.

E. Secure coupler (item 6) in driven pulley with retaining ring (item 5).

2. Install all removed components onto driven pulley (item 8).

A. If bearings (items 4 and 9) were removed from driven pulley, press new bearings onto pulley.

B. As required, install flocked bearing shield (item

10)(flockedsideorientatedtowardbearinglocation), wave spring (item 11) and flat washer (item 12) onto drivenpulley.Securecomponentswith retainingring (item 13).

3. If motor adapter (item 1) was removed from transmissionhousing,secureadapter tohousingwith four(4) washerheadscrews (item2).Tightenscrewsasfollows:

A. First, using an alternating crossing pattern, torque all screws from 15 to 40 in--lb (1.7 to 4.5 N--m).

B. Again using an alternating crossing pattern, torque all screws from 85 to 95 in--lb (9.6 to 10.7 N--m).

Drive System

Traction and Reel

B. Remove set screw (item 14) from end of pulley. C. Slide coupler (item 6) onto drive spline and use

splineinserttool(seeSpecialToolsinthis chapter)to remove drive spline from driven pulley.

Assembly (Fig. 44)

1. If drive spline (item 7) was removed from driven

pulley, secure drive spline to pulley:

IMPORTANT: Avoid using excessive clamping pressure on the driven pulley flats to prevent damage to pulley.

A. Use flats on driven pulley to carefully secure pulleyinavise.Useavisewithsoftjawstoprevent pulley damage.

B. Drive spline should either bereplaced (newdrive spline has patchlock on threads) or have Loctite #242(or equivalent)appliedto threadsbeforeinstallation.

C. Slide coupler (item 6) onto drive spline and use splineinserttool(seeSpecialToolsinthis chapter)to secure drive spline into driven pulley.

4. Slide driven pulley assembly (including bearings) into motor adapter.

5. Install transmission drive belt and all machine components removed for reel drive system service (see Transmission Drive Belt in this section).

6. Fill internal spline area of splined coupler (item 6) withhigh temperatureMobilXHP--222 grease(orequivalent).

7. Install electric motor to transmission (see Electric Motor in the Service and Repairs section of Chapter 4

-- Electrical System).

8. Connectthebatterypack (seeBatteryPackConnection in the General Information section of this chapter).

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 37

Transmission Drum Drive System

Antiseize

Lubricant

RIGHT

FRONT

See text for

tightening procedure

1. Transmission housing

2. Extension housing

3. Ball bearing (2 used)

4. Driven pulley (traction drum drive)

5. Hardened washer (2 used)

6. Driven pulley

7. Spacer

8. Wave washer

9. Woodruff key

Transmission removal from the machine is not necessary to service the transmission drum drive system shown in Figure 45. Transmission drum drive components can be accessed by removing the battery pack from the frame, removing the transmission cover and then removing the drive belt.

Disassembly (Fig. 45)

2. Remove transmission drive belt (see Transmission Drive Belt in this section).

Figure 45

10. Washer head screw (4 used)

11. Flange nut

12. Flange head screw (2 used)

13. Cap screw

3. Remove flange head screw (item 12) and hardened washer (item 5) that secure driven pulley (item 6) to shaft.Slide pulleyfrom shaft.Locate andretrieve woodruff key (item 9).

4. Remove drum drive belt from machine (see Drum Drive Belt in this section).

5. Slide traction drum drive driven pulley (item 4) from extension housing.

6. If necessary, remove ball bearings (item 3), spacer (item7) andwave washer(item 8)from extensionhousing.

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 38

7. If it is necessary to remove extension housing (item

2):

3. Slide shaft of traction drum drive driven pulley (item

4) through extension housing bearings and spacer.

A. Loosen fasteners (items 12, 11 and 13) that secure transmission housing to machine frame.

B. Remove four(4)washer head screwsthatsecure extension housing to transmission housing.

C. Removefour (4) washerheadscrewsthat secure extension housing to RH drum drive housing (Fig.

46). D. Carefullyshift positionof transmissionhousingto

allow removal of the extension housing.

Assembly (Fig. 45)

1. If extension housing was removed: A. Position the extension housing between trans-

mission housing and RH drum drive housing. B. Align extension housing with RH drum drive

housing. Install four (4) washer head screws finger tight to hold extension housing in position.

C. Position transmission housing to the extension housing. Install four (4) washer head screws finger tight to hold extension housing in position.

4. Apply antiseize lubricant to pulley surface of drum drive driven pulley (item 4).

5. Install woodruffkey (item 9) in shaft and slide driven pulley (item 6) onto shaft. Secure pulley (item 6) with hardened washer (item 5) and flange head screw (item

12).

6. Install drum drive belt to machine (see Drum Drive Belt in this section).

7. Install transmission drive belt and all machine components removed for drum drive system service (see Transmission Drive Belt in this section).

8. Connectthebatterypack (seeBatteryPackConnection in the General Information section of this chapter).

Drive System

Traction and Reel

D. Secure extension housing to transmission housing and RH drum drive housing with washer head screws.First, t orque allwasherhead screwsfrom15 to40in-- lb (1.7to 4.5N--m).Then,usinganalternating crossingpattern, torque allscrews from 85to 95 in--lb (9.6 to 10.7 N-- m).

E. Secure transmission housing to machine frame by tightening fasteners (items 12, 11 and 13). If fasteners were removed, make sure that washer (item

5) is below frame tube.

2. Ifremoved, slidewave washer(item 8),spacer (item

7) and ball bearings (item 3) into extension housing.

Figure 46

1. RH drum drive housing

2. Extension housing assy

3. Screw (4 used)

See text for

4. Idler arm assembly

5. Idler pulley assembly

tightening procedure

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 39

T ransmission

See text for

tightening procedure

1. Transmission assembly

2. Flange head screw

3. O--ring

4. Flange head screw (2 used)

5. Electric motor assembly

6. Drum drive belt

7. Brake band

8. Washer head screw (11 used)

9. Drum drive cover

10. Gasket

11. Retaining ring

12. Extension spring

Transmission removal from the machine is not necessary in order to service internal transmission components. Transmission components can be accessed by removingthe batterypack fromthe frame,removing the transmissioncover and then removing thetransmission drive belt. If transmission removal is desired, proceed with the following steps. Once the transmission has beenremovedfromthemachine,serviceproceduresfor internal transmission components are described earlier in this section.

21 to 25 ft--lb

(29to33N--m)

RIGHT

FRONT

Figure 47

13. Cap screw

14. Hardened washer

15. RH drum drive housing

16. Flange head screw

17. Extension housing

Transmission Removal

2. Disconnect reel clutchcable from transmission (see Reel ClutchCable Replacement in theService and Repairs section of Chapter 6 -- Chassis and Controls).

3. Slide the telescoping coupleroff the cutting unit hex shaft (Fig. 48).

Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 40

4. Remove RH drum drive cover and drive belt from

machine (see Drum Drive Belt in this section).

4. Once all fasteners have been installed, fully tighten fasteners in the following order:

5. Remove electric motor from machine (see Electric

Motor in the Service and Repairs section of Chapter 4

-- Electrical System).

6. Remove battery pack from machine (see Battery

Pack in the Service and Repairs section of Chapter 4 -Electrical System).

7. Remove four (4) washer head screws (item 8) that

secure extension housing (item 17) to RH drum housing.

8. Support transmission to prevent it from falling.

9. Remove fasteners that secure transmission to ma-

chine frame.

A. F lange head screw (item 2) that secures front of transmission to frame.

B. Cap screw (item 13), hardenedwasher (item 14) and flange head screw (item 16) that secure rear of transmission to frame.

10.Carefully move transmission assembly toward left

side of machine until extension housing is clear of RH drum housing. Lift transmission from machine.

11.To disassemble transmission, refer to Transmission

Drive Belt, Transmission Idler System, Transmission Reel Drive System, Transmission Drive System and Transmission Drum Drive System in this section.

A. Four (4) washer head screws (item 8). First, torque all screws from 15 to 40 in--lb (1.7 to 4.5 N--m). Then, using an alternating crossing pattern, torquescrewsfrom85 to95in--lb(9.6 to 10.7N--m).

B. Cap screw (item 13) and flange head nut (item

16) that secure rear of transmission to frame. C. Flange head screw (item 2) that secures front of

transmission to frame.

5. Install battery pack to machine (see Battery Pack in theServiceandRepairssectionofChapter 4--Electrical System).

6. Install electric motor to transmission (see Electric Motor in the Service and Repairs section of Chapter 4

-- Electrical System).

7. Install drum drive belt and RH drum drive cover to machine (see Drum Drive Belt in this section).

8. Slide the telescoping coupler onto the cutting unit hex shaft (Fig. 48).

9. Connect reel clutch cable to transmission (see Reel Clutch Cable Replacement in the Service and Repairs section of Chapter 6 -- Chassis and Controls).

10.Connectthe batterypack (seeBatteryPackConnection in the General Information section of this chapter).

Drive System

Traction and Reel

Transmission Installation

1. Makesure thatall internaltransmission components

arecorrectly installed beforetransmission is installedto machine frame.

2. Carefully install transmission assembly toward right

side of machine so that extension housing is inserted into RH drum housing.

3. Align transmission mounting holes with frame and

RH drumhousing. Install andfinger tighten fastenersto secure transmission to machine.

A. Four (4)washer headscrews(item 8)thatsecure extension housing (item 17) to RH drum housing.

B. Cap screw (item 13), hardenedwasher (item 14) and flange head screw (item 16) that secure rear of transmission to frame. Make sure that washer (item

14) is below frame tube. C. Flange head screw (item 2) that secures front of

transmission to frame.

Figure 48

1. Telescoping coupler 2. Cutting unit hex shaft

Greensmaster eFlex 1800/2100 Traction and Reel Drive SystemPage 3 -- 41

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Greensmaster eFlex 1800/2100Traction and Reel Drive System Page 3 -- 42

Chapter 4

Electrical System

GENERAL INFORMATION 2.....................

Operator’s Manuals 2.........................

Electrical Drawings 2..........................

Toro Electronic Controller (TEC) 2..............

CAN--bus Communications 3...................

Lithium Battery Pack Connection 3..............

ELECTRICAL SYSTEM OPERATION 4............

LITHIUM BATTERYPACK CHARGER

OPERATION 6................................

Startup 7....................................

Ramp Up 7..................................

Charging 7...................................

Cell Balance 8................................

Standby 8...................................

Hibernate 9..................................

Charger Fault Codes 9........................

SPECIAL TOOLS 10............................

TROUBLESHOOTING 12........................

InfoCenter Does Not Start Up 12................

Traction Circuit Is Inoperative 13................

Cutting Reel Circuit Is Inoperative 13............

Machine Is Inoperative and InfoCenter Power

Light Indicates That a Fault Has Occurred 14...

EZ Turn System is Not Working 14..............

Machine Operates But InfoCenter Display is

Not Working 14.............................

INFOCENTER DISPLAY 16......................

Main Information Screen 16....................

Operator Advisories 17........................

Main Menu Screen 18.........................

Faults Screen 18.............................

Service Screen 19............................

Diagnostics Screen 20.........................

About Screen 21..............................

Settings Screen 21............................

ADJUSTMENTS 22.............................

Parking Brake Latch Switch 22.................

Traction Switch 23............................

Reel Engage Switch 24........................

COMPONENT TESTING 26......................

Fuse Block 27................................

Lithium Battery Pack Fuse 28..................

Key Switch 29................................

Parking Brake Latch Switch 30.................

Traction Switch 32............................

Reel Engage Switch 34........................

EZ Turn Switch 36............................

EZ Turn Sensor 37............................

Speed Control Potentiometer 38................

Main Contactor 40............................

Toro Electronic Controller 42...................

CAN--bus Termination Resistor 43..............

SERVICE AND REPAIRS 44.

Electric Motor 44..............................

Electric Motor Service 46......................

Lithium Battery Pack 48.......................

Lithium Battery Pack Charger 51................

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

System

Electrical

Greensmaster eFlex 1800/2100 Page 4 -- 1 Electrical System

General Information

The Greensmaster eFlex uses a 53 volt DC (nominal) electrical system that is an isolated circuit. The vehicle frame is not used for any ground connections.

Operator’s Manuals

TheTractionUnitandLithiumBatteryPack ChargerOperator’s Manuals provide information regarding the operation, general maintenance and maintenance intervals for your Greensmaster machine and charger. Refer to these Operator ’s Manuals for additional information when servicing the machine.

Electrical Drawings

The electricalschematic and wire harness drawingsfor Greensmaster eFlex 1800 and 2100 machines are located in Chapter 8 -- Foldout Drawings.

Toro Electronic Controller (TEC)

After performing any repair on machine electrical components,makesure thatwiringis routedandsecured so as to prevent abrasion or contact with moving machine parts.

Greensmaster eFlex 1800 and 2100 machines use a Toro Electronic Controller (TEC) to manage machine electrical functions. The controller is microprocessor controlledthat senses thecondition of various switches (inputs) anddirects electrical powerto control appropriate machine functions (outputs) based on the inputs. The status of inputs to the controller as well as outputs fromthe controllercanbe monitored withthe InfoCenter displayontheconsole.Ifaproblemexiststhatcouldprevent normal operation, the InfoCenter display will display an operator advisory or fault code to assist in identifying the problem. The TEC controller is attached tothemachineunderthepowercentercoverlocatedbehind the battery pack.

1. TEC controller

2. Battery pack

Figure 1

3. TEC harness connector

Greensmaster eFlex 1800/2100Page 4 -- 2Electrical System

CAN--bus Communications

The TEC controller communicates with other electrical components(lithium batterypack,electric motorandInfoCenter display) on a CAN--bus communication system. The CAN--bus system reduces the number of electricalcomponentsand connections usedonthemachineandallowsthe numberofwiresinthe wireharness to be reduced.

CAN identifies the Controller Area Network that is used on the Greensmaster. Two (2) twisted wires form the bus. These wires provide the data p athways between machine components. The engineering term for these two (2) wires are CAN--high and CAN--low.At the ends of thetwisted pair ofbus wires are120 ohm termination resistors.

Lithium Battery Pack Connection

CAUTION

Before servicing the machine, disconnect the the machine from the lithium battery pack. This will prevent unexpected machine operation.

Each of the components t hat is controlled by the CAN-buslinkonlyneedsfour(4)wirestooperateandcommunicate to the system: CAN--high, CAN--low, B+ (power) and ground.

IMPORTANT: The termination r esistors at the ends of the bus wires are required for proper electrical system operation.

System

Electrical

To prevent unexpected machine operation during service, disconnect the machine from the lithium battery packas thefirst stepinany repair(Fig.2). Oncethe battery pack has been disconnected, the electrical system onthe machinecan besafelyworked on.Takecare duringrepairs,however,tonotallowtoolsorvehiclecomponents to complete the battery circuit that was opened with the cable removal.

Connect the machine wire harness to the battery pack as the last step in any repair.

WARNING

The eFlex lithium battery pack contains high voltage which could burn or electrocute you.

 Never attempt to open the battery pack.  Do not place anything in t he connector on

the battery pack other than the wire

harness connector that came with the

product.

 Use extreme care when handling a battery

pack with a cracked case.

 Only use the charger designed for the

battery pack.

1. Lithium battery pack

2. Battery connector

Figure 2

3. Machine connector

Greensmaster eFlex 1800/2100 Page 4 -- 3 Electrical System

Electrical System Operation

Greensmaster eFlex machines utilize a 53 VDC (nominal)lithium ionbatterypack tosupplyelectrical powerto the Toro electronic controller (TEC), an electric motor and a main contactor. Circuitprotection for this 53 VDC (nominal) system includes two (2) fuses that reside in the wireharness fuse block and a single fuse inthe battery pack.

The battery pack allows a single component to be attached to the machine as the electrical power supply. This pack provides a nominal 53 volt (42V to 64V @ 100% state of charge), 35 Amp --hour supply and includes an integrated battery management system. The batterymanagement system usesCAN communication with the TEC controller and battery charger.

AToroElectronic Controller (TEC)is usedon eFlex machines to manage machine electrical functions. The controller is microprocessor controlled that senses the conditionofvariousswitches(inputs)and directselectricalpower to controlappropriatemachine functions(outputs) based on the inputs.

The electricmotor used onthe eFlex isa 48 VDC,1200 watt, brushless,permanent magnetDC motor.The motorhas its ownintegralcontroller andhelicalgear reduction. The machine TEC controller provides motor direction withcommunication via the CAN--bus system. Themotorprovidespower for thetraction drum andcutting unit when engaged by the operator.

Themaincontactorexistsintheelectricalsystem toconnectthebattery packtotheelectricmotor.TheTEC controller determines when the main contactor should be engaged.

Control for the components in the electrical system is handled by integral controllers in the battery pack and electric motor along with direction from the machine TEC controller via the CAN--bus system.

TheInfoCenterDisplay provides information forthe machineoperatorduringmachineoperation,provideselectrical system diagnostic a ssistance for technicians and allows inputs for adjustable machine settings. The status of TEC controller inputs and outputs can be monitored with the InfoCenter display.

The 53 VDC (nominal) system is an isolated system so thevehicleframe isnotusedforany groundconnections on the eFlexmachine. A set of connectors are included onthemachinewhichcanbeusedtodisconnectthemachine wireharness from the batterypack to preventunexpected machine operation when performing service.

Battery Charging

The eFlex lithium ion battery pack requires regular charging that is provided by the lithium battery pack charger(includedwith themachine).The outputvoltage andcurrentof thechargerare controlled withCAN communication with the battery management system. Battery storage wake--up, maintenance features and long term storage discharge function are provided by the charger to improveoverall battery life. It is strongly recommendedthat thechargerbe connectedto thebattery pack whenever the machine is not in use.

Start Process

When the key switch is rotated to the START position, the machine electrical system goes through a wake--up process. The contactor in the battery pack should click as it is energized followed by the main contactor being energized (audible click). Both the TEC controller and the electric motor controller will be initialized. Once the InfoCenter Display comes on--line, the key switch can bereleased totheRUN positionandthe machinewillbe ready for operation.

Run Process

Pushing the traction engagement lever forward is used to close the traction switch. This closed switch is used as an input by the TEC controller which communicates to the electric motor to engage. Motor rotation speed andthustraction speedisdeterminedby thespeedcontrolsetting thatis adjustedby the operator.Actualmotor speedis monitoredby theTEC andmotor controllers so that as traction load changes (e.g. moving up or down an incline) the motor can compensate as needed.

Engaging the cutting reel with the engagement lever closes both the traction and reel engage switches. The electric motor will be engaged with control of motor speed handled by theTEC and motor controllers based on operator speed setting and load on the machine.

The EZ turn feature of an eFlex machine is available when the the cutting reel is engaged and the EZ turn switch on the console is in the ON position. When turningthemachinewithEZturnengaged,theground speed will be reduced as the cutting unit is raised from theground.Speed willincreaseasthe cuttingunitis lowered back to the turf after turning has been completed. The EZ turn featureis not activewhen themachine is in transport position.

NOTE: Information about individual electrical components in the electrical system is includedin the Component Testing section of this chapter.

Greensmaster eFlex 1800/2100Page 4 -- 4Electrical System

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System

Electrical

Greensmaster eFlex 1800/2100 Page 4 -- 5 Electrical System

Lithium Battery Pack Charger Operation

The lithium battery pack charger (Fig. 3) is used to charge the nominal 53 volt (42V to 64V @ 100% state of charge) 35Ah Lithium battery pack that is used to power the eFlex. The charger communicates via CAN with the battery management system (BMS) located within the lithium battery pack. The charger shall respond to the CAN messaging issued by the BMS which will communicate, among other things, the immediate voltageand currentneeds ofthebatterypack. Thecharger is intended to be used indoors only and can be left connected to the target battery pack indefinitely.

Power input to the charger is provided by an AC power supply cord. Power supply for the charger can be either 110/120 VAC or 220/240 VAC. The output cord from chargerto batterypack includesa positivecable,a negativecable, a wake up wireand CAN--bus cables.Make sure thatthe correct powersupply and outputcords are used for the lithium battery pack charger.

Thecharger isequipped withthree (3)LED’s toindicate the charger is ON, the battery is CHARGING and the battery is READY (fully charged). Additionally, the LCD messagedisplay on thecharger canbe usedto monitor the charging process.

1. Power supply cord

2. Output cord

3. Fuse tray

4. Input power socket

5. Power switch

Figure 3

CHARGING

READY

6. LCD message display

7. On LED

8. Charging LED

9. Ready LED

NOTE: Refer toyour eFlexOperator’sManualandLith-

ium Battery Pack Charger Operator’s Manual for additional information about the eFlex battery charger.

NOTE: It is strongly recommended that the chargerbe connectedto thebattery pack,plugged intoa wall outlet and turned ON whenever the machine is not in use.

The batterypack charging operation is fully automated. Whenregular chargingoccurs toready thebattery pack for in season mowing, battery charging states include startup, ramp up, charging, cell balance and standby. When the battery pack is in storage, the charger also provides a hibernate state. The LCD message display on the front ofthe charger will identify the present state of the charger.

Thechargerwillautomaticallyshutdown(exitanyactive state and return to the startup state) if the output cord from the charger to the batterypack is un--plugged or if the AC power to the charger is interrupted (e.g. circuit breaker tripped).

The charger states are described on the following pages.

Greensmaster eFlex 1800/2100Page 4 -- 6Electrical System

Startup

Whenthe batterychargerpowerswitch isinitially turned on,the chargermakessurethat thechargerbus voltage isat zero volts.If necessary,the chargerdischarges the busas astepin thestartup process. Thisis typicalinthe event that the charger power is cycled OFF and then back ON.

STARTUP MESSAGE SCREENS

TORO Li+ CHARGER

Discharge Caps, Wait

XX.XV XX.X% X.XA

Once the bus voltage is correct for startup, the charger will wake the battery pack. Thebattery pack runs some internal diagnostics, and if all is OK, the battery main contactorcloses. The chargerwill thensend asignal on the CAN--bus to stay connected to the battery pack. If batterypackinternaldiagnosticsdeterminethatall isnot OK, the battery pack will send a fault message.

During startup, the battery voltage, state of charge (as percent of fully charged) and amperage will be displayed in the LCD message display.

Ramp Up

Once the battery pack contactor is closed, the charger detects the voltage level of the battery pack. The chargerbusisthenpre--chargedtomatchthebatteryvoltage tobe surethatthere isnot a voltagedifferentialbetween the charger and battery pack.

During rampup, the batteryvoltage, state ofcharge (as percentof fullycharged) andcharging amperage willbe displayed in the LCD message display.

1. Bus discharge

2. Battery pack wake

RAMP UP MESSAGE SCREEN

TORO Li+ CHARGER

Startup

WakeAsserted

XX.XV XX.X% X.XA

TORO Li+ CHARGER

Battery Accepted

XX.XV XX.X% X.XA

Figure 4

3. Battery connected

TORO Li+ CHARGER

State 2, Ramp Up

XX.XV XX.X% X.XA

Figure 5

System

Electrical

Charging

Thelithiumbatterypackwillcommunicateto the charger thepropervoltageandcurrentlevelsrequiredforbattery charging. The charger will make its output at the given voltagelevel andset the currentlimit asindicated bythe pack.

Duringcharging, thebatteryvoltage, stateof charge(as percentof fullycharged) andcharging amperage willbe displayed in the LCD message display.

Greensmaster eFlex 1800/2100 Page 4 -- 7 Electrical System

CHARGING MESSAGE SCREEN

TORO Li+ CHARGER

State 3, CHARGING

XX.XV XX.X% X.XA

Figure 6

Cell Balance

Once the pack has charged to 100% state of charge (SOC), the battery pack will determine if cell balancing is needed. If necessary, it will equalize the individual cellsinthebatterypack.Thechargerwillcease to output current and voltage, and will presenta high impedance connection at the high voltage terminal of the battery. If cell balancing is not needed, the charger will progress to the standby mode.

CELL BALANCE MESSAGE SCREEN

TORO Li+ CHARGER

State 4, Cell Balance

Ok To Use Battery

XX.XV XX.X% X.XA

Once the battery pack accomplishes cell balancing to the required level, it will send a CAN message to the charger to commence charging again (at the voltage and current limits indicated via CAN). The pack and chargerwill gothrough thiscycle 2to 3times untileither the battery pack is satisfied with the results of the cell equalization or 18 hours has passed. At this point in time, the pack will change to ”Charge Done” state, and the charger shall respond by shutting down the battery pack. If the pack fails to terminate the balancing or charging within 19 hours from start of charge, the charger shall terminatethe charge. In either case, the charger shall shutthe pack down and switch to theStandby state.

During cell balancing, the battery voltage, state of charge (as percent of fully charged) and amperage will be displayed in the LCD message display.

Standby

The charger stays in standby mode from completion of charge until 24 hours from start of charge has passed. While in standby, the charger LCD message display is heldin thebrightlylit mode.Oncethe 24timeperiod has elapsed, the charger will go into it’s lowest power consumption mode of Hibernate.

During standby, the battery state of charge (as percent of fully charged) will be displayed in the LCD message display.Typically,SOC fora fullycharged batterywill be from 98% to 100%.

ST ANDBY MESSAGE SCREEN

Figure 7

TORO Li+ CHARGER

State 5, STANDBY

BATTERY READY

SOC: XX.X%

Figure 8

Greensmaster eFlex 1800/2100Page 4 -- 8Electrical System

Hibernate

The hibernate state of the charger isa very low AC current drawcharger mode. This state starts automatically 24 hours after the start of the latest charge operation. While inhibernate, the onlything the chargeris doing is monitoringtime,anddisplayingthe statusofthecharger with theLCD message display ata dimmed brightness. 216 hours (nine days) after hibernate begins, the charger will power back up and wake up the battery pack. There are 2 sub--states within hibernate, assuming hibernate has not been interrupted, that prepare and maintain the battery pack during long term storage.

Upon waking up from hibernate mode, the pack and charger will establish CAN communications to determine system status. If all is OK, the charger will initiate a discharge of the battery pack. The goal of this discharge is to reduce the pack SOC from 100% to 40% within30 days.This dischargeis donebecausethe lithium battery pack capacity can be permanently reduced if stored at too high of SOC for too long. When the battery pack reaches 40% SOC, it will indicate thatthe discharge is completed by changing it’s state to ”STORAGE”. The charger will then go back into hibernate mode.

To return the battery packto 100% state of charge after hibernation, disconnect battery charger from battery and connect battery to eFlex machine. Turn key switch to START and allow full start up process of machine. Then,turn switchtoOFF andallowfull shutdownof machine.Finally,reconnectbatterypack tocharger toallow battery pack to receive full charge.

HIBERNATE MESSAGE

TORO Li+ CHARGER

State 6, HIBERNATE

SCREENS

WAKE after HIBERNATE

XX.XV XX.X% X.XA

Figure 9

1. During hibernate mode 2. Wake from hibernate

System

Electrical

Every ten (10) days thereafter, the charger will power back up and monitor the battery pack’s status. If the pack reaches too low of SOC (30%)the pack will berechargedto40%SOC.

Charger Fault Codes

During thebattery pack charging operation, thecharger mayidentifyaproblem witheitherthechargeror thebattery pack. If a fault is determined, the fault will be displayed in the charger LCD message display. The LCD message will identify either a charger or pack fault, a faultidentificationcodeandafaultcodedescription(Fig.

10). Shouldthere be chargingoperation issues dueto afault

with the charger or battery pack, a first step to remedy the issue would be to turn the battery charger power switch to OFF, disconnect charger output cordfrom the battery pack, disconnect charger power cord from the outlet and wait for a minute to allow complete charger and battery shutdown. Then, correctlyconnect the battery pack charger and restart the charging operation to seeif operationhas returnedto normal.Some faultswill be reset during the restart and will then allow normal charger operation. If a fault continues to occur, make sure to record the fault information and contact your Toro Distributor for assistance.

FAULT MESSAGE SCREENS

TORO Li+ CHARGER

STANDARD MODE

CHARGER FAULT 10

OUTOFRANGELOGV

TORO Li+ CHARGER

STANDARD MODE

PACK FAULT 21

OVER TEMP FLT

Figure 10

1. Charger fault display 2. Battery fault display

Greensmaster eFlex 1800/2100 Page 4 -- 9 Electrical System

Special Tools

Order special tools from your Toro Distributor. Some tools may also be available from a local supplier.

Multimeter

The multimeter can test electrical components and circuits for current, resistance or voltage.

NOTE: Toro recommends the use of a DIGITAL Volt-Ohm--Amp multimeter when testing electrical circuits. Thehighimpedance(internalresistance)ofadigitalmeter in the voltage mode will make sure that excess current is not allowed through the meter. This excess current can cause damage to circuits not designed to carry it.

Figure 11

Skin--Over Grease

Specialnon--conductive greasewhich formsa lightprotective skin to help waterproof electrical switches and contacts.

Toro Part Number: TOR50547

Dielectric Gel

Dielectric gel should be used to prevent corrosion of connectionterminals.To ensure completecoatingof terminals, liberally apply gel to both component and wire harness connector, plug connector to component, unplug connector, reapply gel to bothsurfaces and reconnect harness connector to component. Connectors should be thoroughly packed with gel for effective results.

Figure 12

Toro Part Number: 107--0342

Figure 13

Greensmaster eFlex 1800/2100Page 4 -- 10Electrical System

Electric Motor Rotor Tool Set

Therotor toolset forthe electricmotor isrequired to remove and install the rotor from the motor housing. The tool set includes base plate, threaded shaft and handle (Fig. 14).

Toro Part Number: TOR6028 NOTE: For electric motor service procedures, see

Electric Motor Service in the Service and Repairs section of this chapter.

Rotor Removal

1. Remove gearbox cover and output gear from motor assembly(see ElectricMotorServicein theServiceand Repairs section of this chapter).

2. Remove screws that secure motor cover. Do not remove cover from motor assembly.

1. Base plate

2. Threaded shaft

Figure 14

3. Handle

3. Securetool setbase plateto motor housingwith four (4) of the cover screws.

4. Install threaded shaft into base plate.

IMPORTANT: The rotor magnets are very powerful andcan cause theroto r toshiftpositionvery rapidly duringremoval.Becautious during rotorremovalto prevent component damage or personal injury.

5. Turnthreaded shaft withhandle to remove rotor and motor cover from motor housing. Support rotor to prevent it from falling from housing during removal.

6. Leave threaded shaft installed in same position in base plate for rotor installation purposes.

Rotor Installation

1. Securetool setbase plateto motor housingwith four (4) of the cover screws.

2. Make sure that threaded shaft is installed into base plate so that the end of the threadedshaft prevents the rotor body from entering the motor housing.

1. Screw (6 used)

2. Motor cover

3. O--ring

4. O--ring

5. Wavewasher

Figure 15

6. Bearing

7. Rotor

8. Bearing

9. O--ring

10. Housing assembly

System

Electrical

IMPORTANT: The rotor magnets are very powerful andcan cause theroto r toshiftpositionvery rapidly during installation. Be cautious during rotor installationtoprevent component damageorpersonalinjury.

3. While guidingrotor into motorhousing, slowly rotate threadedshafttoallowtherotortobedrawnintothe housing. Once rotor is fully installed into housing, remove tool set from motor housing.

Greensmaster eFlex 1800/2100 Page 4 -- 11 Electrical System

Troubleshooting

CAUTION

The interlock switches must not be by--passed, they must be connected forproper electricaltroubleshooting and safety.

Remove all jewelry, especially rings and watches, before doing any electrical testing or troubleshooting.

Foreffective troubleshootingand repairs,there mustbe a goodunderstanding ofthe electricalcircuits and components used on this machine (see Wiring Schematic and Wire Harness Drawing sections of this chapter).

NOTE: Check InfoCenter display for possible operator advisoriesor faultswheneverdiagnosingmachine electrical problems.

InfoCenter Does Not Start Up

Possible Causes Correction

Key switch was not rotated to the START position.

The lithium battery pack is disconnected from the machine wire harness.

The lithium battery pack is discharged. MachineF1--1(30amp)orF1--2(3amp)fuseisfaulty. The lithium battery pack fuse is faulty.

Turn key switch to START and wait for InfoCenter to start.

Connect the battery pack to the machine wire harness.

Charge the battery pack. Check fuses and replace if faulty. Check battery pack fuse and replace fuse if faulty.

Theignitionswitchisfaulty.

The main contactor is faulty.

Wire harness connections or wires are loose or damaged.

The lithium battery pack is faulty (battery charger should be used to identify a battery pack fault).

TEC controller is faulty.

Check ignition switch and circuit wires. Repair as necessary.

Check main contactor and circuit wires. Repair as necessary.

Check electrical connections. Repair wire harness as necessary.

Replace the battery pack.

Replace TEC controller.

Greensmaster eFlex 1800/2100Page 4 -- 12Electrical System

Traction Circuit Is Inoperative

NOTE: The parking brakelatch has tobe released, the

operator presence control has to be engaged and the speed control has to be above the zero speed position before the traction circuit will operate.

Possible Causes

Traction switch is not adjusted c orrectly or is faulty.

Speed control potentiometer is faulty.

Parking brake latch switch is not adjusted correctly or is faulty.

Wire harness connections or wires are loose or damaged.

A problem exists with the traction or reel drive system. Electric motor is faulty (NOTE: Fault should be

displayed on InfoCenter if electric motor is faulty).

Correction

Use InfoCenter Diagnostics screen to check traction switch operation. Adjust or replace traction switch if necessary.

Use InfoCenter Diagnostics screen to check speed control potentiometer operation. Check and repair speed control potentiometer and circuit wires if necessary.

Use InfoCenter Diagnostics screen to check parking brake latch switch operation. Adjust or replace parking brake latch switch if necessary.

Check electrical connections. Repair wire harness as necessary.

Refer to Chapter 3 -- Traction and Reel Drive System. Use InfoCenter Faults and Diagnostics screens to

check reel circuit operation. Check electric motor and circuit wires. Repair as necessary.

System

Electrical

Cutting Reel Circuit Is Inoperative

Possible Causes Correction

Reel engage switch is not adjusted or is faulty.

Wire harness connections or wires are loose or damaged.

Electric motor is faulty (NOTE: Fault should be displayed on InfoCenter if electric motor is faulty).

Use InfoCenter Diagnostics screen to check reel engage switch operation. Adjust or replace reel engage switch if necessary.

Check electrical connections. Repair wiring as needed.

Check electric motor and circuit wires. Repair as necessary.

Greensmaster eFlex 1800/2100 Page 4 -- 13 Electrical System

Machine Is Inoperative and InfoCenter Power Light Indicates That a Fault Has Occurred

Possible Causes Correction

System fault has been detected by controller.

An electrical fault occurred that can be reset by the controller.

EZ Turn System is Not Working

NOTE: TheEZturnswitchhastobeON,themowcir-

cuit has to be engagedand the cutting unit needs to be raised before the EZ turn system will operate.

Possible Causes

EZ turn circuit wire harness connections or wires are loose or damaged.

EZ turn switch on control panel is faulty.

EZ turn sensor on the cutting unit roll frame is not adjusted correctly or is faulty.

Cutting unit pitch arms are binding on side plate bushings.

Use Faults Screen information in the InfoCenter section of this chapter to help identify source of problem.

Attempt to restart the machine to see if machine operation has returned to normal. If fault still remains, use Faults Screen information in the InfoCenter section of this chapter to help identify source of problem.

Correction

Check electrical connections. Repair wiring as needed.

Use InfoCenter Diagnostics screen to check EZ turn switch operation. Replace EZ turn switch if necessary.

Use InfoCenter Diagnostics screen to check EZ turn sensor operation. Adjust or replace EZ turn sensor if necessary (see Operator’s Manual for EZ turn sensor adjustment).

Clean pitch arms and bushings.

MachineOperatesButInfoCenter Display is Not Working

Possible Causes Correction

Wire harness connections or wires to InfoCenter Display are loose or damaged.

The InfoCenter Display is faulty.

Check electrical connections. Repair wiring as needed.

Replace InfoCenter Display.

Greensmaster eFlex 1800/2100Page 4 -- 14Electrical System

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Electrical

Greensmaster eFlex 1800/2100 Page 4 -- 15 Electrical System

InfoCenter Display

The Greensmaster eFlex InfoCenter Display is a LCD device that is located on the handle console. The InfoCenter provides information for the machine operator during machine operation, provides electrical system diagnostic assistance for technicians and allows inputs for adjustable machine settings.

Main Information Screen

The InfoCentermain informationscreen (Fig. 16) is displayed when the key switch is in either the RUN or START position. When the key switch is initially turned tothe STARTposition, thepower lighton thescreen will illuminate. During normal machine operation, this screen displays the battery charge indicator and the speed control setting.

Ifanelectricalmachinefaultoccurs,theInfoCenterpower light will blink to notify the operator and a descriptive message will be displayed. Also, the fault log indicator on the InfoCenter screen will be displayed to notify the operator that recent machine faults have occurred. AccessingthefaultlogisdescribedbelowinFaultsScreen.

Powerfor the InfoCenterisavailablewhen energizedby the TEC controller (key switch is in the START or RUN position).ACAN--bussystem involvingthe TECcontroller,the electricmotor controller,the lithium batterypack and the InfoCenter is used to provide necessary machine communication for InfoCenter operation.

The mainmenu and additional informationscreens can be accessed from the InfoCenter main information screenby pressingand releasingthe menu/back button (left button) on the display. Once to the Main Menu screen (Fig. 17), navigation to the menu items can occur. Information on the main menu and menu item screens is included below.

1. Power light

2. Battery indicator

3. Fault log indicator

4. Speed control setting

Main Menu

Faults

Service Diagnostics

1. Main menu

2. Menu items

3. Move to menu items

Figure 16

5. Menu/back button

6. Down button

7. Right button

Figure 17

4. Choose menu item

5. Back button

Greensmaster eFlex 1800/2100Page 4 -- 16Electrical System

Operator Advisories

Operator advisories are automatically displayed by the InfoCenter whena machine function requires additional action (Fig. 18). An advisory will not be logged into the fault log.

InfoCenter advisories include the following: System Shutdown (#201): This advisory notifies the

operatorthatthemachineisshuttingdown.Becausethe shutdownprocess takessome time,this advisoryis displayedso thatanoperator isaware oftheshutdown and machine operationis not available.The shutdown advisorywill bedisplayed afterthe keyswitch is turnedOFF.

Low Battery Shutdown (#202): If the battery state of charge is too low for continued machine operation, the low battery shutdown advisory will notify the operator that the machine will automatically shutdown. Battery charging is necessary before returning the machine to normal operation.

EnergySavingModeActive (#203): If thebatterystate of charge is too low for normal machine operation, the energy saving mode activeadvisory will notifythe operatorthatthemachineis operatingwith reducedfunctionality (cutting unit disengaged and reduced traction speed). Battery charging is necessary before returning the machine to normal operation.

Energy Saving Mode Warning (#204): If the battery state ofcharge is toolow for normal machineoperation, the energysaving mode warningadvisory will notify the operator that the machine will start operating with reduced functionality (cutting unit disengaged and reduced traction speed) in approximately 30 seconds. Battery charging is necessary before returning the machine to normal operation.

Motor Current Limit (#207): This advisory notifies the operator that the electric motor is already running at maximumcurrentand cannotdeliverany additionalper formance.For example,the motor current limit advisory would be displayed if the speed control was increased whenthe motor wasalreadyproviding maximumperformance.

Brake On (#209): The brake on advisory will notify the operator that the parking brake latch is engaged when attempting to engage the traction drive system.

High Power Consumption Run Time Reduced (#210): The high power consumption identifies that

electric motor draw is excessive and willreduce the run time of the machine. Excessive cutting unit bedknife contact or accessory use may generate this advisory.

Motor Disabled (#212): The motor disabled advisory willidentify that electricmotor operationwasstopped by the controller. A fault should have been generated that will provide additional information as to cause of the issue.

Disengage Traction (#213): This advisory notifies the operatorthat the tractionlever isengaged andneeds to bereleasedbeforeoperationcan becontinued.Thedisengagetractionadvisorywillbedisplayedif the machine is turned on with the traction lever already engaged.

Advisory #209

Brake On

System

Electrical

BatteryCurrentLimit(#205):This advisory notifiesthe

operator that the electric motor drive current has been loweredby thelithium batterypack controller. The operatormay noticelower machineperformance. For example, the Battery Current Limit advisory would be displayed if the battery pack temperature is excessive.

UseHandbrake (#206): Thisadvisorynotifies theoper-

1. Advisory identification 2. Advisory name

Figure 18

ator thatthe electric motorregenerative brakingcurrent has been lowered by the lithium battery pack controller which will affect the motor braking system. In this instance, the operator may have to use the handbrake to slow the machine. The Use Handbrake advisory wouldbedisplayed,forexample,ifthemowerwitha fully charged battery was going down a long hill during operation.

Greensmaster eFlex 1800/2100 Page 4 -- 17 Electrical System

Main Menu Screen

The main menu screen can be accessed from the InfoCentermain information screenby pressingand releasing the menu/back button ( left button) on the display. Once to the main menu screen ( Fig. 19), navigation to thefive (5)different menuitems canoccur.Pressingthe movetomenu itembutton(centerbutton) allowsadifferent menu item to be highlighted. Selection of the highlighted item is completed by pressing the choose item button (right button).

The main menu items include faults, service, diagnostics, about and settings. These menu items are described below.

To return to the main information screen from the main menu screen, press the back button (left button).

Faults Screen

Main Menu

Faults

Service Diagnostics

1. Main menu

2. Menu items

3. Move to menu items

Figure 19

4. Choose menu item

5. Back button

The faults screen (Fig. 20) will list all machine electrical faults that have occurred since the faults were last cleared fromthe InfoCenter.The faults will beidentified by a number and when the fault occurred. Faults that might occuron the eFlexmachine are listed in the chart on the next page.

The InfoCenterfault log canbe cleared byselecting the clearsystem faultsmenu item.The clearedfaultswill be removed from the InfoCenter but will be retained in the TEC controller memory.

If a fault occurs during machine use, there may be a change in machine functionalitydue tothe fault. Should there be machine operationissues due to a fault, a first step to remedy the issue would be to move the traction leverto the NEUTRAL position, turnthe keyswitch OFF and allow all machine functions to stop. Then, attempt to restart the machine to see if operation has returned to normal. Some faults will be reset during the restart and will then allow normal function. If a fault continues tooccur,furthersystemevaluationand possiblecomponent repair or replacement will be necessary.

To return to the main menu screen from the faults screen, press the back button (left button).

Faults

#11 Clear System Faults

1. Fault menu

2. Fault items

3. Move to menu items

-- 3 2 . 6 A g o

Figure 20

4. Choose menu item

5. Back button

Greensmaster eFlex 1800/2100Page 4 -- 18Electrical System

Fault Identification

#1 Internal TEC controller fault #2 12V DC supply fault #3 5V DC supply fault #4 Lithium battery pack bus fault #5 CAN--bus communication fault #6 Motorovercurrentfault #7 Motor over temperature fault #8 Motor overspeed fault

#9 Internal electric motor fault #10 Electricmotor stalledduringoperation #11 Software incompatible #12 Key switch stuck in ON position #13 Internal lithium battery pack fault

Service Screen

Fault Description

The servicescreen (Fig. 21) contains machineinformation including runtime (hours that key switch has been intheONposition),mowtime(hoursthatcuttingreelhas been engaged), poweruse (power deliveryby batteryin watts),battery charge(percent ofbatterycapacity), battery current (amps delivered by battery), battery volts (batterypotentialinvolts)andenergy(totalenergydelivered bybattery over itsentire life inwatt--hours). Values listed for service menu items cannot be changed.

To return to the main menu screen from the service screen, press the back button (left button).

Service

Runtime:

Mow Time: Power Use:

1. Service menu

2. Service items

3. Move to menu items

Figure 21

4. Choose menu item

5. Back button

132.4 Hours

83.8 Hours 29 Watts

System

Electrical

Greensmaster eFlex 1800/2100 Page 4 -- 19 Electrical System

Diagnostics Screen

The diagnostics screen (Fig. 22)lists the various states of machine electrical components. The diagnostics screen should be used to check operation of machine switches and controls.

IMPORTANT: When using the diagnostics screen, make sureto have machine on kickstand to prevent unexpected machine movement as switches and controls are moved.

NOTE: Some of the component states may have de-

scription available when using the diagnostics screen. If an arrow icon is shown on the screen, pressing the choose menu item button will display the description if available.

The diagnostics screen includes the following: D Key On identifies that the key switch is in the RUN

position. D Key Start indicates that the key switch is in the

STARTposition ornot.NOTE:Thekeystart positioncan be verified in the diagnostics screen by rotating the switch to the START position. The motor will re--initialize.

electric motor speed. Rotating the speed wheel should change the setting. Voltage for throttle settings should rangefrom0.35to 4.80 VDCdepending onspeed wheel location.

D Target RPM lists the desired electric motor RPM based on the speed control setting.Rotating the speed wheel should change the setting.

D Motor RPMidentifiesthe actualelectric motor RPM. ThemotorRPM shouldbe veryclosetothe TargetRPM.

D 12V Supplyindicates thesupplied voltageavailable forthe12 VDCcircuits(InfoCenter,EZ turnsensor).The 12V Supplyshould typically be slightlyhigher than 12.0 VDC.

D 5V Supply indicates the supplied voltage available for the 5 VDC circuit (speed control). The 5V Supply should typically be slightly higher than 5.0 VDC.

D CAN bus identifies whether the machine commu- nication bus status is normal or not.

To return to the mainmenu screen from thediagnostics screen, press the back button (left button).

D PBrake Latch identifies that the parkingbrake latch is engaged or not.

D EZ Turn indicates whether the EZ turn operation is ONor OFF.NOTE: TheEZ turnswitch andEZ turnsensor are in series so both switch and sensor have to be ON (switchON with the cuttingunit raised for a turn) for the diagnosticsscreen to identifythe EZTurn operation as beingON. If either theswitch is OFF or the sensor is OFF (cutting unit lowered to the ground), the EZ Turn operation will be OFF.

D Traction identifies that the tractionlever is engaged or not engaged.

D Reel Enableindicateswhether thecuttingreel isen- gaged or not engaged.

D Throttle identifies the throttle control setting (in volts) that is used by the TEC controller to determine

Diagnostics

Key On:

Key Start: PBrake Latch:

1. Diagnostics menu

2. Diagnostics items

3. Move to menu items

ON OFF ON

Figure 22

4. Choose menu item

5. Back button

Greensmaster eFlex 1800/2100Page 4 -- 20Electrical System

About Screen

Theabout screen(Fig.23) identifiesthemachinemodel number,serialnumberandTECcontrollersoftwarerevision.

To return to the main menu screen from the about screen, press the back button (left button).

About

Model:

SN: S/W Rev:

04042

312000101

Settings Screen

The settings screen (Fig. 24) identifies the InfoCenter language and units (English or Metric). The settings screen also allows the operator to customize the backlight (brightness)and contrast settingsfor the InfoCenter display.

If eitherthe backlightor contrast itemsare selected,the center button (--) or right button (+) can be used to change the display settings.

To return to the main menu screen from the settings screen, press the back button (left button).

1. About menu

2. About items

3. Move to menu items

Settings

Language:

Units: LCD Backlight:

Figure 23

4. Choose menu item

5. Back button

English English

40%

+/--

System

Electrical

Figure 24

1. Settings menu

2. Settings items

3. Move to menu items

4. Change menu item

5. Back button

Greensmaster eFlex 1800/2100 Page 4 -- 21 Electrical System

Adjustments

Parking Brake Latch Switch

The parking brake latch switch is a normally open proximityswitch.Theswitchisattachedtothehandleassembly switch mount bracket (Fig. 25).

When theparking brake latch isnot applied, the latchis positionednear thetargetend oftheparking brakelatch switch so the switch is closed. The parking brake latch ismoved awayfrom theswitch whenthe latchis applied causing the switch to be in its normally open state.

ParkingBrakeLatchSwitchAdjustment

1. Park machineon level surface and place traction lever in the NEUTRAL position. Turn key switch to the OFF position and remove key from the switch.

2. Disconnect the battery pack (see Lithium Battery Pack Connection in the General Information section of this chapter).

3. Remove console cover from handle to allowaccess to parking brake latch switch (Fig. 26).

4. Raise the parking brake lever and e ngage the parking brake latch.

Figure 25

1. Service brake lever

2. Park brake latch switch

3. Parking brake latch

5. With the parking brake latch engaged, there should befrom 0.000” to0.090” (0.0to 2.2mm) clearance between the latchand the parking brakelatch switch (Fig.

25).

6. If clearance is incorrect, loosen brake latch switch mounting fasteners, adjust clearance and tighten fasteners.Recheck clearancebetweenlever andswitchafter tighteningfasteners. The parkingbrake latch should rotate freely past the switch.

7. When brake latch switch adjustment is completed, install console cover to handle.

8. Connect the battery pack (see Lithium Battery Pack Connection in the General Information section of this chapter).

RIGHT FRONT

Figure 26

1. Park brake latch switch

2. Switch panel

3. Lower handle

4. Screw (2 used)

5. Lock nut (2 used)

6. Console cover

7. Screw (4 used)

Greensmaster eFlex 1800/2100Page 4 -- 22Electrical System

Traction Switch

The traction switch isa normally open proximity switch. The switch is attached to the handle assembly switch mount bracket (Fig. 27).

Whenthetractionengagementleveris notengaged,the head of the cap screwin the traction lever is positioned away from the target end of the traction switch so the switch is in its normal open state. The head of the cap screwin thetractionengagementlever ismovedtoward the switch target when the traction lever is engaged causing the switch to close.

Traction Switch Adjustment

1. Park machineon level surface andplace traction lever in the NEUTRAL position. Turn key switch to the OFF position and remove key from the switch.

2. Disconnect the battery pack (see Lithium Battery Pack Connection in the General Information section of this chapter).

3. Remove console cover from handle to allow access to traction switch (Fig. 28).

1. Engagement lever

2. Traction switch

Figure 27

3. Cap screw head

System

Electrical

4. Move the traction engagement lever forward to the engaged position.

5. With the traction engagement lever in the engaged position, there should be from 0.030” to 0.120” (0.8 to

3.0 mm) clearance between the head of the cap screw in the traction lever and the traction switch (Fig. 27).

NOTE: With traction lever pushed fully forward against its rotation stop, the head of the cap screw should not deflect the traction switch more than 0.030” (0.8 mm). The traction lever will rotate back slightly once latched. At that point, the required clearance (0.030” to 0.120”) should be maintained.

6. If clearance is incorrect, loosen traction switch mounting fasteners, adjust clearance and tighten fasteners. Recheck clearance between screw head and switch after tightening fasteners. The screw head must not contact the switch.

7. When traction switch adjustment is completed, install console cover to handle.

8. Connect the battery pack (see Lithium Battery Pack Connection in the General Information section of this chapter).

RIGHT FRONT

Figure 28

1. Traction switch

2. Engagement lever assy

3. Lower handle

4. Screw (2 used)

5. Lock nut (2 used)

6. Console cover

7. Screw (4 used)

8. Switch mount bracket

Greensmaster eFlex 1800/2100 Page 4 -- 23 Electrical System

Reel Engage Switch

The reel engage switch is a normally open proximity switch. The switch is attached to the handle assembly switch mount bracket (Fig. 29).

Whenthe cuttingreelis notengaged, the tabon thecutting reel engagement lever is positionedaway from the target end of the reel engage switch so the switch remainsopen. Thetab ontheengagement leveris moved nexttotheswitch whenthecuttingreelisengaged causing the switch to close.

Reel Engage Switch Adjustment

1. Park machineon level surface and place traction lever in the NEUTRAL position. Turn key switch to the OFF position and remove key from the switch.

2. Disconnect the battery pack (see Lithium Battery Pack Connection in the General Information section of this chapter).

3. Remove console cover from handle to allowaccess to reel engage switch (Fig. 30).

1. Engagement lever

2. Reel engage switch

Figure 29

3. Lever tab

4. Move the engagement lever forward to the cutting reel engagement position.

5. With the engagement lever in the cutting reel drive engagement position, there should be from 0.030” to

0.090” (0.8 to 2.2 mm) clearance between the tab on the cutting reel engagement lever and the reel engage switch (Fig. 29).

6. If clearance is incorrect, loosen reel engage switch mounting fasteners, adjust clearance and tighten fasteners. Recheck clearance between lever tab and switch after tightening fasteners. The tab on the cutting reel engagement lever must not contact the switch.

7. When reel engage switch adjustment is completed, install console cover to handle.

8. Connect the battery pack (see Lithium Battery Pack Connection in the General Information section of this chapter).

RIGHT FRONT

Figure 30

1. Reel engage switch

2. Engagement lever assy

3. Lower handle

4. Screw (2 used)

5. Lock nut (2 used)

6. Console cover

7. Screw (4 used)

8. Switch mount bracket

Greensmaster eFlex 1800/2100Page 4 -- 24Electrical System

This page is intentionally blank.

System

Electrical

Greensmaster eFlex 1800/2100 Page 4 -- 25 Electrical System

Component Testing

Whenever possible,check component circuit operation withthe InfoCenterDisplayon theconsole.With thekey switchin theRUN position,use theInfoCenter Diagnostics menu to make sure that the component state changesas the componentis toggled.This quick check identifiesthatthecomponentandcircuitwiringareworking as designed. If the InfoCenter o peration suggests thata componentcircuitis notfunctioningcorrectly,proceed to the appropriate component testing procedure found in this section. If the test procedure identifies no problem with the component, carefully inspect the wire harness and connectors for problems.

The Greensmaster eFlex uses a 53 volt DC (nominal) electrical system that is an isolated circuit. The vehicle frame is not used for any ground connections.

For accurate resistance and/or continuity checks, electricallydisconnect the component being testedfrom the circuit(e.g.unplug the ON/OFFswitchconnectorbefore doing a continuity check on switch). Individual components shouldbe electrically isolated (e.g. disconnectall leads or remove from circuit) from the circuit when tested.

CAUTION

When testing a machine electrical component for continuity with a multimeter (ohms setting), makesurethatcomponentisdisconnectedfrom machine wire harness to prevent current flow through the component.

CAUTION

Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the lithium batterypack toopen thebattery circuitbeforeworking on the electrical system.

Greensmaster eFlex 1800/2100Page 4 -- 26Electrical System

Fuse Block

The fuse block on Greensmaster eFlex machines is attached to the machine under the power center cover (Fig. 31).

Fuse Access

1. Park machineon level surface andplace traction lever in the NEUTRAL position. Turn key switch to the OFF position and remove key from the switch. Disconnect the battery pack (see Lithium Battery Pack Connection in the General Information section of this chapter).

2. Remove two (2) screws that secure rear of power center cover to machine (Fig. 31). Then, loosen upper two (2) screws on cover. Remove cover from machine.

Fuse Identification and Function

UseFigure32to identify eachindividualfuseanditscorrect amperage. Fuses for Greensmaster eFlex machines have the following function:

Fuse F1--1 (30 Amp): Protects main power supply circuits.

FuseF1--2(3Amp):Protects logicpowersupplycircuits.

Fuse F1--3 (3 Amp): Protects optional LED work light circuit.

Fuse F1--4: This fuse block position is open.

Fuse Testing

1. Power center cover

2. Rear screw (2 used)

Figure 31

3. Upper screw (2 used)

System

Electrical

1. Access the fuse block as described above.

2. Carefullyremovefusefromthe fuseblockfortesting. Figure 32

3. Fuseshouldhave continuitybetweenfuseterminals.

1. Fuse F1--1 (30 amp)

2. Fuse F1--2 (3 amp)

3. Fuse F3--1 (3 amp)

4. Fuse F4--1 (open)

IMPORTANT: The eFlex uses special fuses that are rated for 80 volts. If fuse replacement is necessary, make sure to use fuses as identified in your eFlex Parts Catalog. DO NOT use regular automotive fuses in your eFlex.

4. Carefully install functional fuse into fuse holder.

5. Afterfuse serviceis completed,securepower center

cover to machine with four (4) screws.

6. Connect the battery pack (see Lithium Battery Pack

Connection in the General Information section of this chapter).

Greensmaster eFlex 1800/2100 Page 4 -- 27 Electrical System

Lithium Battery Pack Fuse

The lithium battery pack that provides electrical power for eFlex machines includes a fuse for battery circuit protection. Removal of the fuse cover on the bottom of thebatterypack isrequiredtoaccess thefuseinthebattery pack (Fig. 33).

IMPORTANT: Do not open the l ithium battery pack. With the exception of the battery pack fuse, fuse cover and labels, there are no consumer serviceable parts on or in the battery pack. If you open the battery pack, you will void thewarranty.The battery pack is protected by tamper--alerting devices.

Fuse Access

1. Park machineon level surface and place traction lever in the NEUTRAL position. Turn key switch to the OFF position and remove key from the switch. Disconnect the battery pack (see Lithium Battery Pack Connection in the General Information section of this chapter).

2. Raise and support battery pack to allow access to fuse cover (see LithiumBattery Pack inthe Service and Repairs section of this chapter).

3. Remove eight (8) screws and lock washers that secure fuse cover to bottom of battery pack (Fig. 34). Remove cover.

4. After fuse service is completed:

4. Carefully install functional fuse into fuse holder.

5. Install fuse cover and connect battery pack as described above.

Figure 33

1. Lithium battery pack

2. Fuse cover

3. Screw (8 used)

A. Secure fuse cover to bottom of battery pack with eight (8) screws and lock washers (Fig. 34). Torque screws 3in--lb(0.34N--m).

B. Lower and secure batte ry pack to machine (see LithiumBattery Packinthe ServiceandRepairs section of this chapter).

C. Connect the battery pack (see Lithium Battery Pack Connectionin the General Information section of this chapter).

Fuse Testing

1. Access the battery pack fuse as described above.

2. Carefully remove fuse from the battery pack fuse holder for testing.

3. Fuseshouldhave continuitybetween fuseterminals.

IMPORTANT: The fuse used in the lithium battery packis averyfast acting58volt fuse.If battery pack fuse replacement is necessary, make sure to use fuse as identified in your eFlex Parts Catalog.

1. Screw (8 used)

2. Lock washer (8 used)

3. Cover

3in--lb

(0.34 N--m)

Figure 34

4. Lithium battery pack

5. Fuse

Greensmaster eFlex 1800/2100Page 4 -- 28Electrical System

Key Switch

The key switch allows machine operation to be turned on andoff. The key switch has three (3) positions:OFF, RUNand START.This switchis oneofseveral inputsfor the TEC controller and is located on the console on the handle (Fig. 35).

Check key switch operation with the InfoCenter on the console.With thekey switchin the RUNposition, theInfoCenter should allow the information screen to be displayed. With the InfoCenter in the Diagnostics menu, choose Key Start and make sure that the switch state changes as the key switch is moved to START and is then released. If the InfoCenter operation suggests a faulty key switch, proceed to key switch testing below.

NOTE: If the eFlex machine is sitting idle for five (5) minuteswith the keyswitchin theRUNposition, themachine will shut off.

RIGHT

NOTE: A faulty key switch may cause a #12fault to be generated and displayed on the InfoCenter.Refer to InfoCenterDisplayinthischapterfor informationonfaults.

Key Switch Testing

1. Park machineon level surface andplace traction le-

ver in the NEUTRAL position. Turn key switch to the OFF position and remove key from the switch. Disconnect the battery pack (see Lithium Battery Pack Connection in the General Information section of this chapter).

2. Remove console cover from handle to allow access

to key switch (Fig. 35).

3. Disconnect wire harness electrical connector from

the key switch.

4. With the use of a multimeter (ohms setting), the

switch functions may be tested to determine whether continuityexists betweenthe various terminals for each switch position. The switch terminals are marked as shown in Figure 36. The circuitry of the on/off switch is shown in the chart in Figure 37. Verify continuity between switch terminals.

5. Replace key switch if necessary.

6. When switch testing is complete, connect wire har-

ness electrical connector to the key switch. Install console cover to handle.

FRONT

Figure 35

1. Key switch

2. Switch panel

3. Lower handle

RUN

OFF

START

FRONT VIEW

Figure 36

SWITCH

POSITION

OFF NONE

RUN B+C+F, D+E

STAR T A+B+C

Figure 37

4. Console cover

5. Screw (4 used)

REAR VIEW

CIRCUITS

System

Electrical

7. Connect the battery pack (see Lithium Battery Pack

Connection in the General Information section of this chapter).

Greensmaster eFlex 1800/2100 Page 4 -- 29 Electrical System

Parking Brake Latch Switch

RIGHT

FRONT

Figure 38

1. Parking brake latch switch

2. Switch panel

3. Lower handle

4. Washer head screw (2 used)

5. Lock nut (2 used)

The parking brake latch switch is a normally open proximity switch. This switch is one of several inputs for the TEC controller. Theswitch is attached to the handle assembly switch mount bracket (Fig. 39).

When the parking brake latch is released, the latch is positionednear thetargetend oftheparking brakelatch switch so the switch is closed. The parking brake latch is moved away from the switch when the latch is engaged causing the switch to be in its normally open state.

6. Console cover

7. Washer head screw (4 used)

Check Parking Brake Latch Switch Operation

Check parking brake latch switch operation with the InfoCenteron theconsole.With thekeyswitch inthe RUN position and the InfoCenter in the Diagnostics menu, choose P Brake Latch and make sure that the switch statechangesastheparkingbrakelatchis engagedand released. Further parking brake latch switch testing is necessaryonlyifthe switchstatedoesnotchange when using the InfoCenter.

Greensmaster eFlex 1800/2100Page 4 -- 30Electrical System

ParkingBrakeLatchSwitchTesting

1. Park machineon level surface andplace traction le-

2. Remove console cover from handle to allow access

toparkingbrakelatchswitch(Fig.38).

3. Disconnect parking brake latch switch connector

from the machine wire harness.

4. Check the continuity of the parking brake latch

switchbyconnectingamultimeter(ohmssetting) across the switch connector terminals.

5. With the parking brake released, there should be

continuity (zero ohms) across the switch terminals.

6. Verify that the switch opens (infinite ohms) as the

parking brake latch is engaged.

Figure 39

1. Service brake lever

2. Park brake latch switch

3. Parking brake latch

7. Replace parking brake latch switch if necessary.

ParkingBrakeLatchSwitchRemoval/Installation

1. Disconnectparkingbrakelatchswitchfromthema-

chinewireharness.

2. Remove washer head screws and lock nuts that

mount switch to switch panel on handle (Fig. 38). Remove switch from machine.

NOTE: For proper parking brake latch switch operation, thescrews and lock nutsused to securethe switch are stainless steel. If these fasteners are replaced, make sure to use correct fasteners.

3. Position switch to switch panel and secure with

screws and lock nuts (Fig. 38).

4. Adjust brake latch switch (see Parking Brake Latch

Switch in the Adjustments section of this chapter).

5. Connect switch to machine wire harness. Secure

console cover to handle.

6. Connect the battery pack (see Lithium Battery Pack

Connection in the General Information section of this chapter).

System

Electrical

Greensmaster eFlex 1800/2100 Page 4 -- 31 Electrical System

Traction Switch

RIGHT

FRONT

Figure 40

1. Traction switch

2. Engagement lever assembly

3. Lower handle

4. Washer head screw (2 used)

5. Lock nut (2 used)

6. Consolecover

The tractionswitch is a normally open proximityswitch. This switch isone of several inputs for the TEC controller.Theswitchisattachedtothehandleassemblyswitch mount bracket (Fig. 41).

Whenthetractionengagementleverisnot engaged,the head of the cap screwin the traction lever is positioned away from the target end of the traction switch so the switch is in its normal open state. The head of the cap screwin thetractionengagement leverismovedtoward the switch target when the traction lever is engaged causing the switch to close.

7. Washer head screw (4 used)

8. Switch mount bracket

CheckTractionSwitchOperation

Check traction switch operation with the InfoCenter on theconsole.With the keyswitchin the RUNpositionand the InfoCenter in the Diagnostics menu, choose Tractionand make surethat theswitch statechanges asthe traction lever is applied and released. Further traction switch testing is necessary only if the switch state does not change when using the InfoCenter.

Greensmaster eFlex 1800/2100Page 4 -- 32Electrical System

Traction Switch Testing

1. Park machineon level surface andplace traction le-

2. Remove console cover from handle to allow access

to traction switch (Fig. 40). Disconnect traction switch connector from the machine wire harness.

3. Check the continuity of the traction switch by con-

necting a multimeter (ohms setting) across the switch connector terminals.

4. With the traction lever in the NEUTRAL position,

there should not becontinuity (infiniteohms) across the switch terminals.

5. Verifythat theswitch closes(zero ohms)as thetrac-

tion lever is engaged.

6. Replace traction switch if necessary.

Traction Switch Removal/Installation

1. Engagement lever

2. Traction switch

Figure 41

3. Cap screw head

System

Electrical

1. Disconnect traction switch from the machine wire

harness.

2. Remove screws and lock nuts that mount switch to

switch mount bracket on handle (Fig. 40). Remove switch from machine.

NOTE: For propertraction switchoperation,the screws and lock nuts used to secure the interlock switch are stainless steel. If these fasteners are replaced, make sure to use correct fasteners.

3. Position traction switch toswitch bracketand secure

with screws and lock nuts (Fig. 40).

4. Adjust tractionswitch (seeTractionSwitch inthe Ad-

justments section of this chapter). Make sure that lock nuts are securely tightened after adjustment.

5. Connect switch to machine wire harness. Secure

console cover to handle.

6. Connect the battery pack (see Lithium Battery Pack

Connection in the General Information section of this chapter).

Greensmaster eFlex 1800/2100 Page 4 -- 33 Electrical System

Reel Engage Switch

RIGHT

FRONT

Figure 42

1. Reel engage switch

2. Engagement lever assembly

3. Lower handle

4. Washer head screw (2 used)

5. Lock nut (2 used)

6. Consolecover

The reel engage switch is a normally open proximity switch. This switch is one of several inputs for the TEC controller. The switch is attached to the handle assembly switch mount bracket (Fig. 43).

Whenthe cuttingreelis notengaged, the tabon thecutting reel engagement lever is positionedaway from the target end of the reel engage switch so the switch remains open. The tab on the reel lever is moved next to the switchwhen the cutting reel isengaged causing the switch to close.

7. Washer head screw (4 used)

8. Switch mount bracket

CheckTractionSwitchOperation

Reel engage switch operation can be checked with the InfoCenter on the console. With the key switch in the RUN position and the InfoCenter in the Diagnostics menu, choose Reel Enable and make sure that the switch statechanges as thecutting reelis engaged and released.Further reelengageswitch testingisnecessary only if the switch state does not change when using the InfoCenter.

Greensmaster eFlex 1800/2100Page 4 -- 34Electrical System

Reel Engage Switch Testing

1. Park machineon level surface andplace traction le-

2. Remove console cover from handle to allow access

to reel engage switch(Fig. 42). Disconnect reel engage switch connector from the machine wire harness.

3. Check the continuity of the reel engage switch by

connecting a multimeter (ohms setting) across the switch connector terminals.

4. With the cuttingreel drivenot engaged,there should

notbe continuity(infinite ohms)across theswitch terminals.

5. Verifythat the switch closes (zero ohms) as the cut-

ting reel drive is engaged.

6. Replace switch if necessary.

Reel Engage Switch Removal/Installation

1. Engagement lever

2. Reel engage switch

Figure 43

3. Reel lever tab

System

Electrical

1. Disconnect reel engage switch from the machine

wire harness.

2. Remove screws and lock nuts that mount switch to

switch panel on handle (Fig. 42). Remove switch from machine.

NOTE: For proper reel engage switch operation, the screws and lock nuts used to secure the reel engage switch are stainless steel. If these fasteners are replaced, make sure to use correct fasteners.

3. Position switch to switch panel and secure with

screws and lock nuts (Fig. 42).

4. Connect the battery pack (see Lithium Battery Pack

Connection in the General Information section of this chapter).

Greensmaster eFlex 1800/2100 Page 4 -- 35 Electrical System

EZ Turn Switch

TheEZturnswitchallowstheEZturnfeaturetobe turnedon andoff.This switch isone of severalinputsfor theTECcontroller.TheEZturnswitchislocatedonthe control panel (Fig. 44).

NOTE: TheEZturnfunctionisonlyactivewhenthemachine is being operated with the cutting unit engaged. Also,the EZturnswitch andEZturn sensorarein series sobothswitch andsensorhaveto be ONforthe EZ Turn function being ON. If either the switch or the sensor is OFF,theEZTurnfunctionwillbeOFF.

RIGHT FRONT

EZ turn switch operation can be checked with the InfoCenter on the console. With the key switch in the RUN position and the InfoCenter in the Diagnostics menu, choose EZ Turn and make sure that the switch state changesas the switchis toggledbetween ONand OFF. Further EZ turn switch testing is necessary only if the switch state does notchange when using the InfoCenter.

Switch Testing

1. Park machineon level surface and place traction lever in the NEUTRAL position. Turn key switch to the OFF position and remove key from the switch. Disconnect the battery pack (see Lithium Battery Pack Connection in the General Information section of this chapter).

2. Remove console cover from handle to allowaccess to EZ turn switch (Fig. 44). Disconnect EZ turn switch connector from the machine wire harness.

3. The EZ turn switch terminals are marked as shown in Figure 45. The circuitry of the switch is shown in Figure 46. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity existsbetween the variousterminals foreach switch position. Verify continuity between switch terminals.

4. Replace EZ turn switch if necessary.

5. Connect switch to machine wire harness. Secure console cover to handle.

Figure 44

1. EZ turn switch

2. Switch panel

3. Lower handle

4. Console cover

5. Screw (4 used)

1243

Figure 45

SWITCH

POSITION

NORMAL

CIRCUITS

OFF 1+2 4+5

ON 2+3 5+6

Figure 46

OTHER

CIRCUITS

6. Connect the battery pack (see Lithium Battery Pack Connection in the General Information section of this chapter).

Greensmaster eFlex 1800/2100Page 4 -- 36Electrical System

EZ Turn Sensor

The EZturn sensor isa normally openproximity sensor that mounts toa bracket mounted to the cutting unit roll frame(Fig.47). Thesensing platefor thesensor isa targetplateattached to thetopof thecuttingunitassembly. TheTECcontroller monitors theoperationoftheEZ turn sensor.

Whenthe traction unitis supportedon thetraction drum withthecuttingunit supportedby bothfrontandrearrollerson levelground, thetarget endof theEZ turnsensor is positioned away from the target plate on the cutting unitso the sensor is open.The EZturn sensoris moved toward the cutting unit target platewhen the cutting unit is raised for turning, causing the sensor to close.

NOTE: The EZ turn sensor LED should be illuminated whenever the machine is operational (key switch in the RUN position) and the cutting unit is raised.

NOTE: TheEZturnfunctionisonlyactivewhenthemachine is being operated with the cutting unit engaged. Also,the EZturnswitch andEZturn sensorarein series sobothswitch a nd sensorhavetobe ONfortheEZ Turn function to be ON. If either the switch or the sensor is OFF, the EZ Turn function will be OFF.

C. TurnkeyswitchtotheSTARTpositiontowakeup the machine and then turn key switch to the RUN position.

D. Connect multimeter common ( --) test probe to harness connector terminal C (black wire) and secondtest probetoharness connectorterminalA (pink wire) (Fig. 48). Verify with the multimeter that harness connector has 12 VDC circuit voltage present.

E. If sensor connector has circuit voltage present and sensor LED did not function, replace EZ turn sensor. Adjust sensor after installation (refer to Operator’s Manual).

5. After EZturn sensortesting iscomplete, plugsensor connector into machine wire harness.

6. Connect the battery pack (see LithiumBattery Pack Connection in the General Information section of this chapter).

System

Electrical

NOTE: Information on EZturn sensor adjustmentis included in the eFlex Operator’s Manual.

Sensor Testing

1. Park machineon level surface andplace traction le-

ver in the NEUTRAL position.

2. Turnkeyswitchtothe STARTposition towake upthe

machine and then turn key switch to the RUN position.

3. Check LED on cable end of EZ turn sensor:

A. Thesensor LEDshouldnot beilluminatedwhen the cutting unit is being supported by both front and rear rollers on level ground.

B. Thesensor LED shouldbe illuminatedwhen the cutting unit is raised (handle pushed down).

4. If the EZ turn sensor LED did not function correctly:

A. Make sure that EZ turn sensor is properly adjusted (see Operator’s Manual). If necessary, adjust sensor and return to step 4 above.

B. Make surekeyswitchisOFFand then disconnect the EZ turn sensor connector fromthe machine wire harness.

Figure 47

1. EZ turn sensor

2. Target plate

3. Cutting unit roll frame

4. Sensor LED location

5. 1.5” block under roller

WIRE HARNESS CONNECTOR FOR SENSOR

PINK wire atA ORANGE wire at B BLACK wire at C

Figure 48

Greensmaster eFlex 1800/2100 Page 4 -- 37 Electrical System

Speed Control Potentiometer

RIGHT

FRONT

Figure 49

1. Potentiometer

2. Cap screw (2 used)

3. Spacer (2 used)

4. Speed wheel

5. Seal

6. Throttle bracket

7. Spacer (2 used)

8. Clutch disc

The speed control potentiometer controls the e lectric motor speed which determines traction and cutting reel speed. The TEC controller uses the potentiometer settingasaninputtodeterminethenecessarysignaloutput for themotor controller for correctelectric motor speed. The speed control potentiometer is attached to the speed control assembly on the handle (Fig. 49).

9. Spring

10. Lock nut (2 used)

11. Console cover

12. Washer head screw (4 used)

Speed Control Potentiometer Operation

Speed controlpotentiometer operation can bechecked withtheInfoCenter.Withthe keyswitchin theRUNpositionandtheInfoCenter intheDiagnosticsmenu,choose Throttle and make sure that the displayed voltage changes as the speed wheel is rotated. Further potentiometer testing is necessary only if the displayed voltage does not change when using the InfoCenter.

Greensmaster eFlex 1800/2100Page 4 -- 38Electrical System

Testing

1. Park machineon level surface andplace traction le-

2. Remove console cover from handle to allow access

to speed control potentiometer.

3. Disconnect machine wire harness connector from

the potentiometer. Remove potentiometer from machine using Figure 49 as a guide.

NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a smallresistance value (usually

0.5 ohms or less). This resistance is due to the internal

resistanceof themeter andtest leads.Subtract thisvaluefrom from themeasured valueof thecomponent you are testing.

4. Using a multimeter, measure resistances between

potentiometer terminals as follows (Fig. 50):

A. Verify thatresistance between terminals B andC is approximately 5000 ohms. Record measured resistance.

B. Measure resistance between terminals A and C and then measure resistance between terminals A andB. Recordtheseresistances. Thetotal ofthe two measured resistances should be approximately 5000 ohms.

C. Rotate thereel speed potentiometer to othersettings and repeat step B above. The total of the two resistances should consistently be approximately 5000 ohms.

1. Terminal A

2. Terminal B

Figure 50

3. Terminal C

System

Electrical

D. If measured resistances are incorrect, replace speed control potentiometer.

5. After testing is completed, secure potentiometer to

machine using Figure 49 as a guide. Secure wire harness connectorto potentiometer.Secure console cover to handle.

6. Connect the battery pack (see Lithium Battery Pack

Connection in the General Information section of this chapter).

Greensmaster eFlex 1800/2100 Page 4 -- 39 Electrical System

Main Contactor

Greensmaster eFlex machines use the main contactor to connect the lithium battery pack and the electric motor. The contactor is energized by the TEC controller. Thecontactorisattachedto themachine underthe power center cover ( Fig. 51).

NOTE: When the key switch is turned to the START position,thecontactor insidethebattery packwillbe energizedfollowedshortly bythe maincontactorbeing energized. There should be an audible click as each of these contactors are energized.

NOTE: A faulty main contactormay cause a #4 faultto be generatedand displayed on the InfoCenter.Refer to InfoCenter Display in this chapter for information on faults.

Main Contactor Testing

1. Park machineon level surface and place traction lever in the NEUTRAL position. Turn key switch to the OFF position and remove key from the switch. Disconnect the battery pack (see Lithium Battery Pack Connection in the General Information section of this chapter).

2. Remove two (2) screws that secure rear of power center cover to machine (Fig. 51). Then, loosen upper two (2) screws on cover. Carefully remove cover from machine.

3. Make sure that battery pack is disconnected. Use a multimeter to measure resistance across the contactor postsasfollows(Fig.52):

1. Power center cover

2. Screw (4 used)

3. Rear base

4. Contactor

5. Flange nut (2 used)

Figure 51

6. Flat washer (2 used)

7. Lock nut (2 used)

8. Flat washer (2 used)

9. Lock nut (2 used)

A. Resistanceacross themain contactposts should be infinite ohms.

B. Resistance across the coil posts should be approximately 195 ohms.

4. The machine wire harness connector for work lights canbeusedtoaccessagroundconnectionformain contactor voltage testing:

A. Locate thewire harnessconnectorfor worklights located on left side of upper handle. The connector willbe identifiedwith a tagand willhave apink and a black wire attached to the connector.

B. Remove plug or work light harness connector (if machine is equipped with optional work lights) from machine wire harness work light connector.

C. The machine wire harness work light connector leadingtotheharnessblackwirewillbe used forcontactor voltage testing.

WIRING

DIAGRAM

Figure 52

1. Main contact post 2. Coil post

Greensmaster eFlex 1800/2100Page 4 -- 40Electrical System

5. Use a multimeter to measure voltage across the

main contactor posts as follows:

A. Position rubber boots away from main contactor posts to allow access to posts with multimeter probes (Fig. 53).

B. Connect m ultimeter common (--) test probe to ground connector in work light connector (step 4 above).

C. Make sure that traction lever is in the NEUTRAL position.Temporarilyconnect battery pack(seeLithium Battery Pack Connection in the General Information section of this chapter).

D. TurnkeyswitchtotheSTARTpositiontowakeup the machine and then turn key switch to the RUN position. The main contactor should click as it is energized.

E. Using the second multimeter test probe, verify thatall four (4)posts onmain contactor havesystem voltage (42V to 64V @ 100% state of charge) present (Fig. 53). If one (1) or more posts DO NOT have system voltage present, the contactor is faulty. I f none of the posts have voltage present, make sure that common(--) test probeis still connectedto work light connector and if so, look for electrical issues at other machine components as the contactor is not being energized correctly.

1. Main contactor

2. Rubberboot

Figure 53

3. Main contact post

4. Coil post

System

Electrical

F. TurnkeyswitchtotheOFFposition.Themain contactor should click as it is de--energized.

G. Disconnect the batterypack (see LithiumBattery Pack Connection in the General Information section of this chapter).

6. If testing determines that main contactor is faulty,

make sure that battery pack is disconnected and then replace main contactor.

7. When main contactor testing is complete, install

power center cover to machine (Fig. 51).

8. Connect the battery pack (see Lithium Battery Pack

Connection in the General Information section of this chapter).

Greensmaster eFlex 1800/2100 Page 4 -- 41 Electrical System

Toro Electronic Controller

Greensmaster eFlex machines use a Toro Electronic Controller (TEC) to monitor the condition of various switches(inputs) andthendirect electricalpower output toallow certainmachinefunctions. Thecontrollerisalso connected to the CAN--bus system for communications with the electric motor andbattery controllers. TheTEC controller is attached to the machine under the power center cover (Fig. 54).

Inputs from the key switch, parking brake latch switch, traction switch, reel engage switch, EZ turn switch, EZ turn sensor, speed control potentiometer and lithium batterypack statusareall monitoredbythe TECcontroller.

TEC controller current output to the electric motor precharge circuit, main contactor, 12 VDC outputs (InfoCenterdisplay,EZ turnsensor andoptional hourmeter) and 5 VDC output (speed control potentiometer) are controlled based on the inputs received by the controller.

The diagram in Figure 55 depicts the connection terminalfunctionsof theTECcontroller.Two(2)wire harness connectorsattach to thecontroller with e ach of theconnectors including twelve (12) pins. The connector pins are listed in the diagram.

The InfoCenter display should be used for checking inputs andoutputs of thecontroller usedon your Greensmaster (see InfoCenter Display section in thischapter). TheInfoCenterdisplay canalsobeusedtoidentifyfaults and operator advisories that indicate operation issues with the machine.

Because of the solid statecircuitry builtinto the controller, there is no method to test it directly. The controller may be damaged if an attempt ismade to test it with an electrical test device, such as a digital multimeter.

Figure 54

1. TEC controller 2. Lithium battery pack

IGNITION

SWITCH

INPUTS

OUTPUTS

DIGITAL INPUTS

(OPEN/

CLOSED)

IGNITION

SWITCH

INPUT

ANALOG

INPUT

(VARIABLE)

CAN BUS

GROUND

Figure 55

Greensmaster eFlex 1800/2100Page 4 -- 42Electrical System

CAN--bus Termination Resistor

Systemcommunication betweenelectrical components on Greensmaster eFlex machines is accomplished on a CAN--bus communication system. Two (2) specially designed, twisted cables form the bus for the networks used on the eFlex. These wires provide the data pathways betweenmachine components.At the ends of the twistedpairofbuscablesare120ohm terminationresistors.

The resistors plug intothe wire harness in the following areas:

Termination

Resistor

A. On themainwireharnessnearthe InfoCenter under the handle console cover.

B. On the battery wire harness near the lithium battery pack connection.

NOTE: Refer to theElectricalSchematic and WireHarnessDrawingsinChapter8 -- FoldoutDrawingsforadditional information on termination resistor locations and wire connections.

IMPORTANT: The termination resistors at the ends of the bus cables are required for proper electrical system operation.

Resistor Test

The termination resistors (Fig. 56) can be individually tested using a digital multimeter (ohms setting). There should be 120 ohms resistance between terminals A and B. Terminal C is not used on Greensmaster eFlex machines.

Figure 56

System

Electrical

Greensmaster eFlex 1800/2100 Page 4 -- 43 Electrical System

Service and Repairs

Electric Motor

21 to 25 ft--lb

(29to33N--m)

Figure 57

1. Electric motor assembly

2. Flange head screw (2 used)

3. O--ring

4. Transmission housing

5. Rear frame

NOTE: A faulty electric motor assembly may cause a

#5, #6, #7,#8 or #9 fault to begenerated and displayed onthe InfoCenterdisplay.Refer toInfoCenter Displayin this chapter for information on faults.

6. LH side plate

7. Frame

FRONT

RIGHT

Greensmaster eFlex 1800/2100Page 4 -- 44Electrical System

Toro 4043, 4042 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Table Of Contents

Table of Contents

General Safety Instructions

Before Operating

While Operating

Maintenance and Service

Battery Pack Connection

Safety and Instruction Decals

Table of Contents

Product Records

Maintenance

Equivalents and Conversions

Torque Specifications

Fastener Identification

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series Fasteners)

Standard To rque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)

Other Torque Specifications

Conversion Factors

Table of Contents

Specifications

General Information

Operator’s Manuals

Battery Pack Connection

Disengaging Drum Drive From Transmission

Transmission Belt Tensioner

Special Tools

Adjustments

Cutting Unit Clip Adjustment

Reel Clutch Adjustment

Service and Repairs

Reel Drive Belt

Reel Drive Assembly

Reel Drive Bearing Housing

Drum Drive Belt

Drum Drive Idler Assembly

Traction Drums

Differential Assembly

Differential Assembly Service

Transmission Drive Belt

Transmission Idler System

Transmission Reel Drive System

Removing Seized Reel Clutch Shaft From Transmission

Transmission Drive System

Transmission Drum Drive System

T ransmission

Table of Contents

General Information

Operator’s Manuals

Electrical Drawings

Toro Electronic Controller (TEC)

Lithium Battery Pack Connection

Electrical System Operation

Lithium Battery Pack Charger Operation

Startup

Ramp Up

Charging

Cell Balance

Standby

Hibernate

Charger Fault Codes

Special Tools

Troubleshooting

InfoCenter Does Not Start Up

Traction Circuit Is Inoperative

Cutting Reel Circuit Is Inoperative

Machine Is Inoperative and InfoCenter Power Light Indicates That a Fault Has Occurred

EZ Turn System is Not Working

MachineOperatesButInfoCenter Display is Not Working

InfoCenter Display

Main Information Screen

Operator Advisories

Main Menu Screen

Faults Screen

Service Screen

Diagnostics Screen