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

+ 158 hidden pages

Toro 4043, 4042 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