Toro 4042 manual

(Models 04043 and 04042) P ART NO. 12189 SL Service Manual Greensmaster R eFlex 1800/2100 Preface The purpo se of this publicat ion is to provide the service technician with information for troubleshooting, testing and repairing assemblie s and components on the Greensmaster eFlex 1800 (Model 04 043) and eFlex 2100 (Model 04042). REFER TO THE OPERA[...]

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Greensmaster eFlex 1800 /2100 T able Of Contents Chapter 1 - - Safety General Saf ety Instru ctions 1 - - 2 .................. Safety and Instruction Deca ls 1 - - 4 ................ Chapter 2 - - Product Records and Maintenance Product Records 2 - - 1 ........................... Maintenance 2 - - 1 ............................ ... Equivalents and [...]

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Greensmaster eFlex 1800 /2100 Page 1 - - 1 Safet y Chapter 1 Safety T able of Contents GENERAL SAFETY INSTRUCTIONS 2 ............ Before Oper ating 2 ............................ While Operating 3 ............................ Maintenance and Service 3 .................... Battery Pack Connection 4 ..................... SAFETY AND INSTRUCTION DECALS[...]

Greensmaster eFlex 1800/2100 Page 1 - - 2 Safety General Safety Instructions Greensmaster eFlex 180 0 and eFlex 2100 mac hines have been tested an d certified by TORO for com pliance with existing safety standards and specifications. Al- though hazard co ntrol and accident prevention are par- tially dependent up on the design and configura tion of [...]

Greensmaster eFlex 1800 /2100 Page 1 - - 3 Safet y While Operating 1. Always stand behind th e handle when starting and operating the machi ne. 2. T o begin machine op eration: A. Make sure that the machine wire harnes s is con- nected to the battery pack B. V erify that the control lever on handle is in NEU- TRAL position for both traction and ree[...]

Greensmaster eFlex 1800/2100 Page 1 - - 4 Safety Battery Pack Connection CAUTION Before servicing the machine, disconne ct the the machine from the battery pack. This will pre- vent unexpected machine ope ration. T o prevent unexpected machine operat ion during ser- vice, disconnect the machine from the battery pack as the first step in any repair [...]

Greensmaster eFlex 1800 /2100 Page 2 - - 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance T able of Contents PRODUCT RECORDS 1 ......................... MAINTENANCE 1 ..... ......................... EQUIV ALENTS AND CONVERSIONS 2 ........... Decimal and Millimeter Equivalents 2 ...... ...... U.S. to Metric Conversions 2 .[...]

0.09375 Greensmaster eFlex 1800/2100 Page 2 - - 2 Product Records a nd Maintenance Equivalents and Conversions[...]

Greensmaster eFlex 1800 /2100 Page 2 - - 3 Product Records and Maintenance T orque Specifications Recommended fastener torque values are listed in the following tables. For critical applica tions, as determined by T oro, either the recommended torque or a torque that is unique to the application is clearly iden tified and spe- cified in this Servic[...]

Greensmaster eFlex 1800/2100 Page 2 - - 4 Product Records a nd Maintenance Standard T orque for Dry , Zinc Plated and St eel Fasteners (Inch Series Fasteners) Thread Size Grade 1, 5 & 8w i t hT h i n Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Hei ght Nuts (SAE J995 G rade 2 or Stro nger Nuts) SAE Grade 5 Bol ts, Scr ew[...]

Greensmaster eFlex 1800 /2100 Page 2 - - 5 Product Records and Maintenance Standard T orque for Dry , Zinc Plated and Steel Fasteners (M etric Fasteners) Thre ad Size Class 8 .8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8[...]

Greensmaster eFlex 1800/2100 Page 2 - - 6 Product Records a nd Maintenance Other T orque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended T orque 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 + 3f t - - l b 1/2 -[...]

Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Pa ge 3 - - 1 Chapter 3 T raction and Reel Drive System T able of Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TION 3 ..................... Operator ’s Ma nuals 3 ......................... Battery Pack Connection 3 ..................... Disengaging Dru m Dr[...]

Greensmaster eFlex 1800/2100 T raction and Reel Drive System Page 3 - - 2 Specifications Item Description T ransmission Permanent Magne t DC Motor Directly Coupled to First Stage of a Multi- - Ribbed Poly - -V Belt Drive Belt T ension Maintained by Spring Loaded Idler Pulley T raction Drive T r ansmission to T raction D rive uses Multi - - Ribbed P[...]

Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Pa ge 3 - - 3 General Information Operator ’ s Manuals The T raction Unit and Cutting Unit Operator ’s Manuals provid e informa tion regardin g the operat ion, gener al maintenance and mai ntenance intervals for your Greensm aster machine. Refer to the se Operator ’s Manuals for [...]

Greensmaster eFlex 1800/2100 T raction and Reel Drive System Page 3 - - 4 Disengaging Dr um Drive From T ransmission The traction drum is driven by a multi - - ribbed belt that is tensioned with a spring loade d idler assembly . T o disen- gage the traction drum drive from the transmission, fol- low the following procedur e: 1. Park machine on leve[...]

Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Pa ge 3 - - 5 T ransmission Belt T ensioner The tra nsmission pulleys a re driven b y a multi - - ribbed belt that is tensioned with a spring loaded idler assem- bly . If the transmission belt tension needs to be engaged or disengaged, follow t he following procedu re: 1 . P a r km a c[...]

Greensmaster eFlex 1800/2100 T raction and Reel Drive System Page 3 - - 6 Special T ools Modified Socket for Reel Clutch Bear ing Collar The modified socket is u sed to remove and inst all the reel clutch beari ng collar when servicing the tran smis- sion reel clutch shaft (Fig. 5). Refer to T ransmission Reel Drive System in the Service and Repair[...]

Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Pa ge 3 - - 7 Spline Insert T ool Use spline insert tool to remove or install drive spline into transmission driven pulley . Refer to Transmission Drive System in the Service and Repai rs section of this chap- ter for complete informatio n on servicing the transmis- sion drive system. [...]

Greensmaster eFlex 1800/2100 T raction and Reel Drive System Page 3 - - 8 Adjustments Cutting Unit Clip Adjustment Cutting unit clip adjustment on the eFlex 1800 and eFlex 2100 can be changed by installi ng the cutting unit drive pulleys to the appropriate loca tions on the reel drive as- sembly . Clip frequency pulley locations for 1 1 blade and 1[...]

Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Pa ge 3 - - 9 Reel Clutch Adjustment T o adjust the reel clu tch, follow the followi ng steps: 1 . P a r km a c h i n eo nl e v e ls u r f a c e .T u r nk e ys w i t c ht ot h e OFF position and remove key from the swit ch. Discon- nect the battery pack (see Batte ry Pack Connection in[...]

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Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Page 3 - - 1 1 Service and Repairs Reel Drive Belt EFlex machines use a positive drive belt on the left side of the machine to operate the cu tting unit. Removal 1 . P a r km a c h i n eo nl e v e ls u r f a c e .T u r nk e ys w i t c ht ot h e OFF position and remove key from the swit[...]

Greensmaster eFlex 1800/2100 T raction and Reel Drive System Page 3 - - 12 Reel Drive Assembly 1. Reel drive housing 2. O - - rin g 3. Carriage screw 4. W asher 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 - - rin g 10. Reel idler shaft 1 1. Reel pulley (24 tooth) (black)[...]

Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Page 3 - - 13 Reel Drive Assembly Removal (Fig. 16) 1 . P a r km a c h i n eo nl e v e ls u r f a c e .T u r nk e ys w i t c ht ot h e OFF position and remove key from the swit ch. Discon- nect the battery pack (see Batte ry Pack Connection in the General Information se ction of this c[...]

Greensmaster eFlex 1800/2100 T raction and Reel Drive System Page 3 - - 14 Reel Drive B earing Housing Figure 18 2 3 6 8 9 10 11 13 1 5 7 12 4 1. Retaining ring 2. Reel input shaft 3. Bearin g (2 used ) 4. Bearin g space r 5. W ave washer 6. Flocked bearing shield 7. W ave spring 8. Flat washer 9. Retaining ring 10. Bearing housing 1 1. Spring pin [...]

Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Page 3 - - 15 Disassembly (Fig. 18 ) 1 . P a r km a c h i n eo nl e v e ls u r f a c e .T u r nk e ys w i t c ht ot h e OFF position and remove key from the swit ch. Discon- nect the battery pack (see Batte ry Pack Connection in the General Information se ction of this chapter). 2. Rem[...]

Greensmaster eFlex 1800/2100 T raction and Reel Drive System Page 3 - - 16 Drum Drive Belt 1. D rum drive c over 2. W asher head screw (7 used) 3. Gasket 4. W ave washer 5. Gear as sembly 6. Retaining ring 7. Brake band 8. Brake mount pin 9. E xtension spring 10. Drum drive belt 1 1. Brake clev is pin 12. Drum drive housing 13. Retaining ring 14. I[...]

Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Page 3 - - 17 6. Remove retaining ring (item 6) that secures brake band to brake clevis pin. Slide brake b and from brake clevis and brake mount p ins and remove band from drum drive housing. 7. Carefully remove one e n d of extension spring (item 9) from anchor point and rotate spring[...]

Greensmaster eFlex 1800/2100 T raction and Reel Drive System Page 3 - - 18 Drum Drive Idler As sembly 1. D rum drive c over 2. W asher head screw (7 used) 3. Gasket 4. W ave washer 5. Gear as sembly 6. Retaining ring 7. Brake band 8. Brake mount pin 9. E xtension spring 10. Drum drive belt 1 1. Brake clev is pin 12. Drum drive housing 13. Retaining[...]

Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Page 3 - - 19 8. Disassemble idler arm assembly as needed (Fig. 23). Replace wo r n or damaged bea rings and bushings. A. Remove flange bushings from id ler bracket. B. Remove retaining ring f rom idler bra cket. Slide idler pulley from bracket s haft. Press ball bearings from idler pu[...]

Greensmaster eFlex 1800/2100 T raction and Reel Drive System Page 3 - - 20 T raction Drum s 1. Drum drive housing 2. Straight bushing 3. Flange bushing (4 used) 4. Brake lev er 5. T raction lever 6. Square key (2 used) 7. Drum shaft 8. Long spur gear 9. Differential assembly 10. RH traction drum 1 1. Jam nut 12. Grease seal 13. LH traction drum 14.[...]

Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Page 3 - - 21 5. Separate LH side plate (item 25) from machine (Fig. 25): A. Remove flange nut, har dened washer and car- r i a g es c r e w( i t e m s3 ,4a n d6i nF i g .2 5 )t h a ts e c u r e LH side plate to rear frame. B. Remove thre e (3) flange screws an d hardened washers (item[...]

Greensmaster eFlex 1800/2100 T raction and Reel Drive System Page 3 - - 22 7. Slide lock colla r (item 27) onto drum shaf t. Align holes in collar and shaft and t hen install pin (item 28). Fit O - - ring (item 30) to slot in collar . 8. If grease se al (item 12) wa s removed fr om LH trac - tion drum , install new gre ase seal into dru m. Ma ke su[...]

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Greensmaster eFlex 1800/2100 T raction and Reel Drive System Page 3 - - 24 Differentia l Assembly 1. Drum drive housing 2. Straight bushing 3. Flange bushing (4 used) 4. Brake lev er 5. T raction lever 6. Square key (2 used) 7. Drum shaft 8. Long spur gear 9. Differential assembly 10. RH traction drum 11 . J a m n u t 12. Grease seal 13. LH tractio[...]

Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Page 3 - - 25 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 fla nge bushing from spur gear as needed. IMPORT ANT : As drum shaft (item 7) and different[...]

Greensmaster eFlex 1800/2100 T raction and Reel Drive System Page 3 - - 26 Differential Assembly Ser vice 1. Housing 2. Cover 3. Ball bearing (2 used) 4. Pin (6 use d) 5. Dual spu r gear (6 use d) 6. Spacer (9 u sed) 7. Spur gear (3 used) 8. Socket head s crew (6 used) Figure 30 2 3 6 8 1 5 7 4 4 6 5 6 3 99 to 121 in - - lb (1 1.2 to 13.6 N - - m) [...]

Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Page 3 - - 27 Assembly (Fig. 30) 1. If ball bearin g was removed from either cover or housing, p ress new ball bearing in to bearing bore. Make sure that bearing is fully pressed to shoulder of bore. 2. Place cover (with bear ing installed) on workbench. 3. Slide each pin with gears an[...]

Greensmaster eFlex 1800/2100 T raction and Reel Drive System Page 3 - - 28 T ransmission Drive Belt Figure 34 1. T ransmission assembly 2. T ransmission belt 3. Gasket 4. W ave washer (2 used) 5. T ransmission cover 6. W asher head screw (7 used) 7. Drive sha ft wire 8. T elescoping coupler FRONT RIGHT 2 3 6 8 1 5 7 4 See text for tightening proced[...]

Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Page 3 - - 29 8. Remove transmissi on belt from drive and idler pul- leys in transmission. 9. Check condition of all pulleys and id ler components. 10. Clean inside of transmission before installing new belt. Drive Belt Installation (Fig. 34) IMPORT ANT : During assembly , make sure th[...]

Greensmaster eFlex 1800/2100 T raction and Reel Drive System Page 3 - - 30 T ransmission Id ler System Figure 37 1. T rans missio n cover 2. Engage/disengage shaft 3. T ransmission belt 4. E xtension 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 be[...]

Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Page 3 - - 31 Disassembly (Fig. 37) 1 . P a r km a c h i n eo nl e v e ls u r f a c e .T u r nk e ys w i t c ht ot h e OFF position and remove key from the swit ch. Discon- nect the battery pack (see Batte ry Pack Connection in the General Information se ction of this chapter). 2. Remo[...]

Greensmaster eFlex 1800/2100 T raction and Reel Drive System Page 3 - - 32 T ransmission Reel Drive System Figure 39 1. T ransmission housing 2. Flex coupler 3. Hex shaf t 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 1 1. Reel brake[...]

Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Page 3 - - 33 6. Inspect flan ge bushings and reel bra ke ring for wear or damage (Fig. 40). R eplace bushings an d brake ring if necessary . Reel Clutch Shaft Disassem bly (Fig. 39) NOTE: The following procedure covers co mplete dis- assembly of reel clutch shaft assembly . Depending [...]

Greensmaster eFlex 1800/2100 T raction and Reel Drive System Page 3 - - 34 3. Slide reel clutch pulley assembly and reel drive hub onto clutch shaft. 4. Use modified socket (see Special T ools in this chap- ter) to install bearing colla r assembly onto clutch shaft (Fig. 41). IMPORT ANT : T o prevent damage, avoid using ex - cessive clamping pre ss[...]

Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Page 3 - - 35 Removing Seized Reel Clutc h Shaft From T ransmission If reel clutch shaft assembly cannot be easily removed from transmission housing due to bearing seizure, the following procedure can be fo llowed to remove the reel clutch shaf t assembly . 1. Make sure that transmissi[...]

Greensmaster eFlex 1800/2100 T raction and Reel Drive System Page 3 - - 36 T ransmission Drive System Figure 44 1. Motor adapter 2. W asher head scre w (4 u sed) 3. W ave washer 4. Ball be aring 5. Retaining ring 6. Splined coupler 7. Drive spline 8. Driven pulley 9. Ball bearing 10. Flocked bearing shield 1 1. W ave spring 12. Flat washer 13. Reta[...]

Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Page 3 - - 37 6. As necessary , remove components from driven pulley (item 8): A. Remove retaining ring (item 13), flat washer (item 12), wave spring (item 1 1) and flocked bearing shield (item 10) from driven pu lley . Note orientation of flocked shield fo r assembly purpos es. B. Pre[...]

Greensmaster eFlex 1800/2100 T raction and Reel Drive System Page 3 - - 38 T ransmission Drum Drive System Figure 45 1. T ransmission housing 2. Exte nsion housing 3. Ball bearing (2 used) 4. Driven p ulley ( tract ion dr um driv e) 5. Hardened washer (2 used) 6. Driven pulley 7. Spacer 8. W ave washer 9. W o odruff key 10. Washer head screw (4 use[...]

Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Page 3 - - 39 7. If it is necessary to remove extension housing (item 2): A. Loosen fasteners (items 12, 1 1 and 13) that se- cure transm ission housing to m achine frame . B. Remove four (4) washer head screws that secure extension housing to transmission housing. C. Remove four (4) w[...]

Greensmaster eFlex 1800/2100 T raction and Reel Drive System Page 3 - - 40 T ransmission Figure 47 1. T ransmission assembly 2. Flange head scre w 3. O - - rin g 4. Flange head screw (2 used) 5. Electric motor assembly 6. Drum drive belt 7. Brake band 8. W asher head screw ( 1 1 used) 9. Drum drive cover 10. Gasket 1 1. Retaining ring 12. Extension[...]

Greensmaster eFlex 1800 /2100 T raction and Re el Drive S ystem Page 3 - - 41 4. Remove RH drum drive cover and d rive belt from machine (see Drum Drive Belt in this section). 5. Remove electric motor from machine (see Electric Motor in the Service and Repairs section of Chapter 4 - - Elec trical System ). 6. Remove battery pack from machine (see B[...]

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Greensmaster eFlex 1800 /2100 Page 4 - - 1 Electric al Sy stem Chapter 4 Electrical System T able of Contents GENERAL INFORMA TION 2 ..................... Operator ’s Ma nuals 2 ......................... Electrical Drawings 2 .................... ...... T oro Electronic Cont roller (TEC) 2 .............. CAN - - b us Communications 3 ............[...]

Greensmaster eFlex 1800/2100 Page 4 - - 2 Electrical S ystem General Information The Greensmaster eFlex uses a 53 volt D C (nominal) electrical system that is an isolated circuit. The vehicle frame is not used for any ground connections. After performing any repair on machine electrical com - ponents, make sure that wiring is routed and secured so [...]

Greensmaster eFlex 1800 /2100 Page 4 - - 3 Electric al Sy stem CAN - - bus Communications The TEC controller communicates w ith other electrical components (lithium battery pack, electric motor and In- foCenter display) on a CAN - - bus communication sys- tem. The CAN - - bus system reduces the number of electrical components and connections used o[...]

Greensmaster eFlex 1800/2100 Page 4 - - 4 Electrical S ystem Electrical System Operation Greensmaster eFlex machines utilize a 53 VDC (nomi- nal) lithium ion battery pack to supply electrica l power to the T oro electronic controlle r (TEC), an electric motor and a main contactor . Circuit protection for this 53 VDC (nominal) system includes two (2[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 5 Electric al Sy stem This page is intentionally blank. Electrical System[...]

Greensmaster eFlex 1800/2100 Page 4 - - 6 Electrical S ystem Lithium Battery Pack Charger Oper ation 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. Th e charger communica tes via CA N with the battery managem ent system (B[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 7 Electric al Sy stem Startup When the battery charger power switch is initially turned on, the charger makes sure that the charger bus voltage is at zero volts. If necessary , the charger discharges the bus as a step in the startup process. This is typical in the event that the charger power is cycled OFF a[...]

Greensmaster eFlex 1800/2100 Page 4 - - 8 Electrical S ystem Cell Balance Once the pack has char ged to 100% state of char ge (SOC), the battery pa ck will determine if cell balancing is needed. I f necessary , it will equalize the individ ual cells in the battery pack. The charger will cease to output current and voltage, and will pre sent a high [...]

Greensmaster eFlex 1800 /2100 Page 4 - - 9 Electric al Sy stem Hibernate The hibernate state of the charger is a very low AC cur- rent draw charger mode. This state starts automati cally 24 hours after the start of the latest charge operation. While in hibernate, the only thing the charger is doing is monitoring time, and displaying the status of t[...]

Greensmaster eFlex 1800/2100 Page 4 - - 10 Electrical Syst em Special T ools Order special tools from your T oro Distributor . Some tools may also be available from a local supplier . Multimet er The multimeter can test ele ctrical components and cir- cuits for current, re sistance or voltage. NOTE: T oro recommen ds the use of a DIGIT AL V olt - -[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 1 1 Electri cal System Electric Motor Rotor T ool Set The rotor tool set for the electric motor is requi red to re- move and install the rotor from the motor housing. The tool set incl udes base plate, thre aded shaft and handle (Fig. 14). T oro Part Number: TOR602 8 NOTE: For electric motor se rv ice proced[...]

Greensmaster eFlex 1800/2100 Page 4 - - 12 Electrical Syst em T roubleshooting CAUTION Remove all jewelry , especially rings and watches, before doing any electrical testing or troubleshooting. For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and com- ponents used o n this machine (s ee Wiring[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 13 Electri cal System T raction Circuit Is Inoperativ e NOTE: The parking brake latch has to be released, the operator presence c ontrol has to be en gaged and the speed control has to be above the zero speed position before the traction circuit w ill operate. Possible Causes Correctio n T raction switch is [...]

Greensmaster eFlex 1800/2100 Page 4 - - 14 Electrical Syst em Machine Is Inoperative a nd InfoCenter Power Light Indicates That a Fault Has Occ urred Possible Causes Correction System fault has been de tected by controller . An electric al fault occur red that can be r eset by the controller . Use Faults Screen information i n the InfoCenter sectio[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 15 Electri cal System This page is intentionally blank. Electrical System[...]

Greensmaster eFlex 1800/2100 Page 4 - - 16 Electrical Syst em InfoCenter Display The Greensmaster eFlex InfoCe nter Display is a LCD device that is loc ated on the han dle console. The In fo- Center provides information f or the machine operator during machine operation, p rovides elec trical system diagnostic assistance for technicians an d allows[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 17 Electri cal System Operator Advisories Operator advisories are automatically displayed by the InfoCenter wh en a machine funct ion requires addition al action (Fig. 18). An advisory will not be logg ed into the fault log. InfoCenter a dvisories inclu de the following : System Shutdown (#201): This advisor[...]

Greensmaster eFlex 1800/2100 Page 4 - - 18 Electrical Syst em Main Menu Screen The main menu screen can be accessed from the Info- Center main informat ion screen by pressing and releas- ing the menu/back b utton (left button) on the display . Once to the main menu s creen (Fig. 19), navig ation to the five (5) dif ferent menu items can occur . Pre[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 19 Electri cal System Fault Identification Fault Description #1 Internal TEC c ontroller fault #2 12V DC suppl y fault #3 5V DC supply fault #4 Lithium battery pack bus fault #5 CAN - - bus communication fault #6 M o t o ro v e rc u r r e n tf a u l t #7 Motor over temper ature fault #8 Motor overspeed fault[...]

Greensmaster eFlex 1800/2100 Page 4 - - 20 Electrical Syst em Diagnos tics Scr een The diagnostics scr een (Fig. 22) list s the various st ates of machine electrical com ponents. The diagnostics screen should be used to check operation of machi ne switches and controls. IMPORT ANT : When using the diagnostics screen, make sure to have ma chine on k[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 21 Electri cal System About Screen The about screen (Fig. 23) identifies the machine model number , serial numbe r and TEC controller software revi- sion. T o return to the main menu screen from the about screen, press the bac k button (left button). Figure 23 About Model: SN: S/W Rev: 04042 312000101 A 1 5 [...]

Greensmaster eFlex 1800/2100 Page 4 - - 22 Electrical Syst em Adjustments Parking Brake Latch Switch The parking br ake latch switch is a nor mally open pr ox- i m i t ys w i t c h .T h es w i t c hi sa t t a c h e dt ot h eh a n d l ea s - sembly switch mount bracket (Fig. 25). When the parking brake latch is not applied, the l atch is positioned [...]

Greensmaster eFlex 1800 /2100 Page 4 - - 23 Electri cal System Tr a c t i o n S w i t c h The traction switch is a normally open proximity switch. The switch is attac hed to the handle a ssembly switch mount bracket (Fig. 27). When the traction engagement lever is not engaged, the head of the cap screw in the traction l ever is positione d away fro[...]

Greensmaster eFlex 1800/2100 Page 4 - - 24 Electrical Syst em Reel Engage S witch The reel engage switch is a normally open proximity switch. The switch is attached to the handle assembly switch mount bracke t (Fig. 29). When the cutting reel is not engaged, the tab on the cut- ting reel engagement lever is positioned away from the target end of th[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 25 Electri cal System This page is intentionally blank. Electrical System[...]

Greensmaster eFlex 1800/2100 Page 4 - - 26 Electrical Syst em Component T esting Whenever possi ble, check component circuit operation with the InfoCenter Display on the console. With the key switch in the RUN position, use the Info Center Diagnos- tics menu to make sure that the component state changes as the compon ent is toggled. Th is quick che[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 27 Electri cal System Fuse Block The fuse block on Gree nsmaster eFlex machines is at- tached to the machine u nder the power center cover (Fig. 31). Fuse Acce ss 1. Park machine on level surface and place traction le- ver in the NEUTRAL position. T urn key switch to the OFF position and remove key from the [...]

Greensmaster eFlex 1800/2100 Page 4 - - 28 Electrical Syst em Lithium Battery Pack Fuse The lithium battery pack that provides el e ctrical power for eFlex machine s includes a fuse for bat tery circuit protection. Removal of the fu se cover on th e bottom of the battery pack is required to access the fuse in the bat- tery pack (Fig. 33). IMPORT AN[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 29 Electri cal System Key Switch The key switch allows mach ine operation to be turned on and off. The key switch has three (3) positio ns: OFF , RUN and ST ART . This switch is one of several inputs for the TEC controller and is locate d on the console on the handle (Fig. 35). Check key switch operation wit[...]

Greensmaster eFlex 1800/2100 Page 4 - - 30 Electrical Syst em Parking Brake Latch Switch 1. Parking b rake latch switch 2. Switch panel 3. Lower handle 4. W asher head scre w (2 u sed) 5. Lock nut (2 used) 6. Console cover 7. W asher head screw (4 used) Figure 38 FRONT RIGHT 5 3 1 2 6 4 7 The parking br ake latch switch is a nor mally open pr ox- i[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 31 Electri cal System P a r k i n gB r a k eL a t c hS w i t c hT e s t i n g 1. Park machine on level surface and place traction le- ver in the NEUTRAL position. T urn key switch to the OFF position and remove key from the swit ch. Discon- nect the battery pack (see Lithium Ba ttery Pack Con- nection in the[...]

Greensmaster eFlex 1800/2100 Page 4 - - 32 Electrical Syst em T raction Switch 1. T rac tion swi tch 2. Engagement lever assembly 3. Lower handle 4. W asher head scre w (2 u sed) 5. Lock nut (2 used) 6. C onsol e cover 7. W asher head screw (4 used) 8. Switch mount bracket Figure 40 FRONT RIGHT 5 3 1 2 6 4 7 8 The traction switch is a normally open[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 33 Electri cal System T raction Switch T esting 1. Park machine on level surface and place traction le- ver in the NEUTRAL position. T urn key switch to the OFF position and remove key from the swit ch. Discon- nect the battery pack (see Lithium Ba ttery Pack Con- nection in the General Information se ction [...]

Greensmaster eFlex 1800/2100 Page 4 - - 34 Electrical Syst em Reel Engage S witch 1. Reel engage switch 2. Engagement lever assembly 3. Lower handle 4. W asher head scre w (2 u sed) 5. Lock nut (2 used) 6. C onsol e cover 7. W asher head screw (4 used) 8. Switch mount bracket Figure 42 FRONT RIGHT 5 3 1 2 6 4 7 8 The reel engage switch is a normall[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 35 Electri cal System Reel Engage Switch T esting 1. Park machine on level surface and place traction le- ver in the NEUTRAL position. T urn key switch to the OFF position and remove key from the swit ch. Discon- nect the battery pack (see Lithium Ba ttery Pack Con- nection in the General Information se ctio[...]

Greensmaster eFlex 1800/2100 Page 4 - - 36 Electrical Syst em EZ T u rn Switch T h eE Zt u r ns w i t c ha l l o w st h eE Zt u r nf e a t u r et ob e turned on and off. This switch is one of several inputs for t h eT E Cc o n t r o l l e r .T h eE Zt u r ns w i t c hi sl o c a t e do nt h e control panel (Fig. 44). NOTE: T h eE Zt u r nf u n c t i[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 37 Electri cal System EZ T urn Sensor The EZ turn sensor is a normally open proximity sensor that mounts to a bracket mounted to the cutting unit roll frame (Fig. 47). The s ensing plate for th e sensor is a tar- get plate attached to the top of the cutting unit assembly . The TEC controller monitors the ope[...]

Greensmaster eFlex 1800/2100 Page 4 - - 38 Electrical Syst em Speed Control Potentiom eter 1. Potentiometer 2. Cap screw (2 used) 3. Spacer (2 use d) 4. Speed wheel 5. Seal 6. Throttle bracket 7. Spacer (2 u sed) 8. Clutch d isc 9. Sprin g 10. Lock nut ( 2 used) 1 1. Console cover 12. Washer head screw (4 used) Figure 49 FRONT RIGHT 6 3 5 4 1 8 9 2[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 39 Electri cal System Te s t i n g 1. Park machine on level surface and place traction le- ver in the NEUTRAL position. T urn key switch to the OFF position and remove key from the swit ch. Discon- nect the battery pack (see Lithium Ba ttery Pack Con- nection in the General Information se ction of this chapt[...]

Greensmaster eFlex 1800/2100 Page 4 - - 40 Electrical Syst em Main Contactor Greensmaster eFlex machines u se the main contactor to connect the lithium batte ry pack and the electric mo- tor . The contactor is energized by the TEC controller . The contactor is attached to the machine under the pow- er center cover (Fig. 51). NOTE: When the key swit[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 41 Electri cal System 5. Use a multimeter to measure voltage across the main contactor posts as follows: A. Position rubb er boots away fr om main contact or posts to allow access to posts with multimeter probes (Fig. 53). B. Connect multimeter common (- - ) test probe to ground connector in work light conne[...]

Greensmaster eFlex 1800/2100 Page 4 - - 42 Electrical Syst em T oro Electronic Controller Greensmaster eFlex machines u se a T oro Electronic Controller (TEC) to monitor the condition of various switches (inputs) and then direct electrical power output to allow certain machine funct ions. The controller is also connected to the CAN - - bus system f[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 43 Electri cal System CAN - - bus T ermination Resistor System communication between electrical components on Greensmaster eFlex machine s is accomplished on a CAN - - bus communication system. T wo (2) specially designed, twisted cables form the bus for the networks used on the eFlex. These wires provide th[...]

Greensmaster eFlex 1800/2100 Page 4 - - 44 Electrical Syst em Service and Repairs Electric Motor 1. Electric motor asse mbly 2. Flange head screw (2 used) 3. O - - ring 4. T ransmission housing 5. Rear frame 6. LH side plate 7. Frame Figure 57 1 2 3 FRONT RIGHT 4 21 to 25 ft - - lb ( 2 9t o3 3N - - m ) 5 6 7 NOTE: A faulty electric motor assembly m[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 45 Electri cal System Removal (Fig. 57) 1. Park machine on level surface and place traction le- ver in the NEUTRAL position. T urn key switch to the OFF position and remove key from the switch. 2. Disconnect the bat tery pack (see Lithium Battery Pack Connection in the General Informa tion section of this ch[...]

Greensmaster eFlex 1800/2100 Page 4 - - 46 Electrical Syst em Electric Motor Service 1. T orx head screw (12 used) 2. Motor cover 3. O - - ring 4. W ave washer (2 used) 5. Bearing (2 used) 6. Rotor 7. Bearin g (2 used ) 8. O - - ring (2 u sed) 9. Housing/ controller/cable assembly 10. O - - r ing 1 1. Output gear 12. Gearbox cover 13. Shaft seal 14[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 47 Electri cal System 8. Remove and discard O- - ring ( item 8) from motor housing. IMPORT ANT : Make sure to not damage the gearbox cover counter bore when removing the shaft se al from the cover . 9. Carefully remove shaft seal from gearbox cover . Dis- card removed seal. 10. If necessary , remove bearings[...]

Greensmaster eFlex 1800/2100 Page 4 - - 48 Electrical Syst em Lithium Battery Pack CAUTION The lithium battery pack contains high voltage which could burn or electrocute you.  Never attempt to open the battery pa ck.  Do not place anything in the connector on the battery pack other than the wir e harness connector that came with the product. [...]

Greensmaster eFlex 1800 /2100 Page 4 - - 49 Electri cal System 8. Remove six (6) cap screws (item 7 in F ig. 60) and flat washers (item 6 in Fig. 60) that secure battery pack to battery base. 9. Carefully remove battery pack from battery base and machine. IMPORT ANT : Do not open the lithium battery pack. With the exception of the batte ry pack fus[...]

Greensmaster eFlex 1800/2100 Page 4 - - 50 Electrical Syst em Lithium Battery Pac k Service IMPORT ANT : Do not open the lithium battery pack. With the exception of the battery pack fuse, fuse cover and labels, ther e are no consumer service- able parts on or in the battery pac k. If you open the battery pack, you will void the warranty . The batte[...]

Greensmaster eFlex 1800 /2100 Page 4 - - 51 Electri cal System Lithium Battery Pack Charger The lithium ba ttery pack cha rger (Fig. 65) is use d to charge the nominal 53 volt (42V to 64V @ 100% sta te of charge), 35Ah lithium ion battery pack that is used to power the eFlex. The ch arger commu nicates via CAN with the battery management system (BM[...]

Greensmaster eFlex 1800/2100 Page 4 - - 52 Electrical Syst em This page is intentionally blank.[...]

Greensmaster eFlex 1800 /2100 Page 5 - - 1 Chassis and Controls Chapter 5 Chassis and Controls T able of Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TION 3 ..................... Operator ’s Ma nual 3 .................... ...... Battery Pack Connection 3 ..................... SERVICE AND REP AIRS 4 .....................[...]

Greensmaster eFlex1800/21 00 Pa ge 5 - - 2 Chassis and Controls Specifications Item Description T ransport Wheel (Optiona l) T ire Pressure 12 to 15 PSI (83 to 10 3 kPa)[...]

Greensmaster eFlex 1800 /2100 Page 5 - - 3 Chassis and Controls General Information Operator ’ s Manual The Operator ’s Manu al provides information regardin g the operatio n, adjustment procedure s and general maintenance for your G reensmaster eFlex machine. Refer to the Operator ’s Manua l for additional inf orma- tion when servicing t he [...]

Greensmaster eFlex1800/21 00 Pa ge 5 - - 4 Chassis and Controls Service and Repairs Handle Assembly Figure 2 1. Brake lever 2. Brake cable 3. Handle 4. Reel clutch cable 5. T raction and reel drive lever 6. Throttle assembly 7. Console cover 8. W asher head screw (4 used) RIGHT 7 8 2 3 6 1 5 4 FRONT Handle Removal (Fig. 2) 1. Park machine on level [...]

Greensmaster eFlex 1800 /2100 Page 5 - - 5 Chassis and Controls 7. Remove handle clamps from han dle assembly (Fig. 3). A. Remove carriage screws and flange nuts that se- cure handle clam ps to offset handle clamps. B. Remove flange nuts that secure shoulder bolts at bottom of handle clamps. C. Remove inner handle clamps. Le ave shoulder bolts and [...]

Greensmaster eFlex1800/21 00 Pa ge 5 - - 6 Chassis and Controls Brake Cable Replacement 1. Brake cable 2. Brake lever 3. Flange nut 4. Bushing (2 used) 5. Brake latch 6. Lock nut 7. Brake lever keeper 8. Screw (4 us ed) 9. Spacer 10. Washer 1 1. Screw 12. Lower handle 13. Extensi on spri ng 14. Conso le cover 15. Washer head screw (4 used) 16. Reel[...]

Greensmaster eFlex 1800 /2100 Page 5 - - 7 Chassis and Controls Removal 1 . P a r km a c h i n eo nl e v e ls u r f a c e .T u r nk e ys w i t c ht ot h e OFF position and remove key from the swit ch. Discon- nect the battery pack (see Batte ry Pack Connection in the Genera l Information sec tion). 2. Remove brake cable from the brake lever shaft o[...]

Greensmaster eFlex1800/21 00 Pa ge 5 - - 8 Chassis and Controls Reel Clutch Cabl e Replacement 1. Brake cable 2. Brake lever 3. Lever as sembly 4. Shift mount 5. Reel clutch cable 6. C onsol e cover 7. W asher head scre w (4 u sed) 8. Lower handle 9. T raction switch 10. Reel enga ge swit ch 1 1. Shifter brac ket Figure 7 1 4 7 8 9 10 2 5 3 6 RIGHT[...]

Greensmaster eFlex 1800 /2100 Page 5 - - 9 Chassis and Controls Installation 1. Secure reel clutch cable to traction lever assembly (Fig. 9): A. Install cable spring to spring a nchor on lever as- sembly . Orientate cable spring hook end toward front of machine. B. Slide the cable housing into the shift mount bracket slot. Make sure that a jam nut [...]

Greensmaster eFlex1800/21 00 Page 5 - - 10 Chassis and Controls T raction and Reel Driv e Engagement Lever Assembly 1. W asher head screw 2. Detent ball 3. Detent spring 4. Shift arm link 5. Shoulder screw (2 used) 6. Shifter link 7. Bumper (2 used) 8. Spring collar 9. Spacer 10. Spring lever 1 1. Shift handle 12. Extensi on spri ng 13. Latch pin 1[...]

Greensmaster eFlex 1800 /2100 Page 5 - - 1 1 Chassis and Contr ols Disassembly 1 . P a r km a c h i n eo nl e v e ls u r f a c e .T u r nk e ys w i t c ht ot h e OFF position and remove key from the swit ch. Discon- nect the battery pack (see Batte ry Pack Connection in the Genera l Information sec tion). 2. Remove console cover from handle to allo[...]

Greensmaster eFlex1800/21 00 Page 5 - - 12 Chassis and Controls 4. Connect spring ( item 1 1 in F igure 1 1) betwe en trac- tion lever assembly and ope rator prese nce control. 5. Connect wire harness connectors to tractio n and reel engage switches (Fig . 1 1). 6. Connect reel clutch cable to lever assembly (see Reel Clutch Cable Replacement in th[...]

Greensmaster eFlex 1800 /2100 Page 5 - - 13 Chassis and Controls This page is intentionally blank. Chassis and Controls[...]

Greensmaster eFlex1800/21 00 Page 5 - - 14 Chassis and Controls Kickstand 1. Kickstand 2. Flange nut 3. Spacer 4. Cap screw 5. Frame 6. Rear frame 7. Service position locking pin 8. Compression spring 9. Spacer 10. Retaining ring 1 1. LH side plate 12. T o rsion s prin g Figure 14 FRONT RIGHT 1 2 3 5 6 8 10 12 11 4 7 9 NOTE: The offset handle clamp[...]

Greensmaster eFlex 1800 /2100 Page 5 - - 15 Chassis and Controls Removal (Fig. 14) 1 . P a r km a c h i n eo nl e v e ls u r f a c e .T u r nk e ys w i t c ht ot h e OFF position and remove key from the swit ch. Discon- nect the battery pack (see Batte ry Pack Connection in the Genera l Information sec tion). 2. Pivot kickstand up and hold against [...]

Greensmaster eFlex1800/21 00 Page 5 - - 16 Chassis and Controls T ransport Wheels (Optional) 1. Cap screw (3 used) 2. Lock washer (3 used) 3. Shallow rim 4. Tire 5. Hub 6. Wheel ret ainin g lever 7. T o rsio n spring 8. Shoulder screw (2 used) 9. Cap scre w (4 used ) 10. Deep rim 1 1. Inner tube 12. Hub bus hing 13. Flange nut (4 used) Figure 16 1 [...]

Greensmaster eFlex 1800 /2100 Page 5 - - 17 Chassis and Controls Wheel Removal (Fig. 17) 1 . P a r km a c h i n eo nl e v e ls u r f a c e .T u r nk e ys w i t c ht ot h e OFF position and remove key from the switch. 2. Support the machin e on the kickstand. 3. Pivot wheel retain ing lever away from the center of the wheel. Slide transport wheel of[...]

Greensmaster eFlex1800/21 00 Page 5 - - 18 Chassis and Controls This page is intentionally blank.[...]

Greensmaster eFlex 1800 /2100 Page 6 - - 1 Cutting Unit Chapter 6 Cutting Unit T able of Contents SPECIFICA TIONS 3 ............................ GENERAL INFORMA TION 4 ..................... Operator ’s Ma nual 4 .................... ...... Supporting Cutting Unit when Se rvicing 4 ........ Battery Pack Connection 4 ..................... Separatin[...]

Greensmaster eFlex 1800/2100 Page 6 - - 2 Cutting Unit This page is intentionally blank.[...]

Greensmaster eFlex 1800 /2100 Page 6 - - 3 Cutting Unit Specifications REEL CONSTRUCTION: 5 - - inch (12.7 cm) d iameter , 1 1 or 14 carbon steel blades welded to 5 stamped steel spiders. High stre ngth low alloy steel bla des are thru hardened and impact resistant. FRAME CONSTRUCTION: Precisio n machined d ie cast aluminum cross member with two bo[...]

Greensmaster eFlex 1800/2100 Page 6 - - 4 Cutting Unit General Information Operator ’ s Manual The Cutting Unit Operator’s Manual provides informa- tion regarding the ope ration, general maintenance and maintenance intervals for the cutting unit on your Greensmaster machine. A dditionally , if optional kits have been installed on the cuttin g u[...]

Greensmaster eFlex 1800 /2100 Page 6 - - 5 Cutting Unit Separating C utting Unit from T raction Unit 1 . P a r km a c h i n eo nl e v e ls u r f a c e .T u r nk e ys w i t c ht ot h e OFF position and remove key from the swit ch. Make sure the traction lever is in the NEUTRAL posi tion. 2. Disconnect the batte ry pack (see Batt ery Pack Con - necti[...]

Greensmaster eFlex 1800/2100 Page 6 - - 6 Cutting Unit Special T ools Some special tools may have be en supplied with your mower or are available as T ORO parts. Order special tools from your T oro Distributor . Some tools may also be available from a local s upplier . Gauge Bar Assembly T oro Part Number: 13 - - 8199 Used to veri fy height - - of [...]

Greensmaster eFlex 1800 /2100 Page 6 - - 7 Cutting Unit Roller Bearing Ins talla tion T ools W ashers and spacer used to install bearings and seals into front and rear rollers (Fig. 9 ). Seal installation washer: 107 - - 8133 Seal installation spacer: 107 - - 3505 Bearing installation washer: 104 - - 6126 As an alternative to using washers and spac[...]

Greensmaster eFlex 1800/2100 Page 6 - - 8 Cutting Unit Factors That Can Affect Quality of Cut There are a number of factors that can contribute to un- satisfactory quality of cut, some of which may be turf conditions. T urf conditions such as exce ssive thatch, “sponginess” or attempting to cut of f too much grass height may not always be overc[...]

Greensmaster eFlex 1800 /2100 Page 6 - - 9 Cutting Unit Factor Possible Problem/Corre ction Roller condition. Make sure rollers rotate freely . Repair roller bearings if necessary (see Roller Serv i c ei nS e r v i c ea n dR e p a i r s section of this chapter). T raction speed. The traction drive belt may be loose or worn. Check the condition of t[...]

Greensmaster eFlex 1800/2100 Page 6 - - 10 Cutting Unit Adjustments CAUTION Before working on the cutting unit, always turn the key switch OFF and disconnect the bat tery pack from the wire harness. This will prevent un- expected machine operation. DANGER Contact with the reel, bedknife or other cutting unit parts can result in personal injury . Us[...]

Greensmaster eFlex 1800 /2100 Page 6 - - 1 1 Cutting Unit Service and Repairs Backlapping DANGER TO A VOID PERSONAL INJURY OR DEA TH: D Never place hands or feet in the reel area while backlapping. Stay away from the re el when backlapping. D Do not attempt to r estart re el by hand or foot. D Do not adjust cutting reel while backlapping. D Never u[...]

Greensmaster eFlex 1800/2100 Page 6 - - 12 Cutting Unit Bedbar Assembly 1. Bedbar 2. Bedknife 3. Screw (13 used) 4. Bedbar adjuster screw (2 used) 5. Bedbar adjuster shaft (2 used) 6. Cap screw (2 used) 7. Detent (2 u sed) 8. W ave washer (2 used) 9. Retaining ring (2 used) 10. Lock nut ( 2 used) 11 . W a s h e r ( 2 u s e d ) 12. Compression sprin[...]

Greensmaster eFlex 1800 /2100 Page 6 - - 13 Cutting Unit 7. Remove two (2) bedbar pivot b olts (item 18), fou r (4) metal washers (item 17) and fo ur (4) plastic w ashers (item 16) from the cutting unit si de plates. CAUTION Contact wit h the reel , bedknif e or othe r cutting unit parts can resu lt in person al injury . Use heavy gloves when handl[...]

Greensmaster eFlex 1800/2100 Page 6 - - 14 Cutting Unit Bedknife Ser vice 1. Screw 2. Bedbar 3. Bedknife Figure 19 200 to 250 in - - lb ( 2 3t o2 8N - - m ) Lightly Oil Bedbar Surface 2 Antiseiz e Lubric ant 1 3 eFlex 2100 Shown Bedknife Removal (Fig. 19) 1. Remove bedb ar from cuttin g unit (see Be dbar Re- moval in this section). NOTE: EFlex 1800[...]

Greensmaster eFlex 1800 /2100 Page 6 - - 15 Cutting Unit Bedknife Grinding Since there can be variations in the mounting surface of the bedbar , a new bedknife will not be perfectl y flat after it is installed to the bedbar . Because of this, it is neces- sary to grind a new bedknife after installing it to the bed- bar . Follow the existing angle t[...]

Greensmaster eFlex 1800/2100 Page 6 - - 16 Cutting Unit Bedbar Adjus ter Service Figure 23 1. Bedbar assembly 2. Compression spring 3. Lock nut 4. Bedbar adjuster shaft 5. Flange bushing 6. Cap scre w 7. Detent 8. W ave washer 9. Retaining ring 10. Bedbar adjus ter screw 1 1. W asher FRONT RIGHT Antiseize Lubricant 2 3 6 8 9 10 11 1 5 7 4 5 eFlex 2[...]

Greensmaster eFlex 1800 /2100 Page 6 - - 17 Cutting Unit 3. Slide adjuster shaft (item 4) into flange bushings i n cutting unit side plate. Secure adjus ter shaft with wave washer (item 8) and retaining ring (item 9). NOTE: Adjuster shaft (item 4) has left - - hand threads. 4. Apply antiseize lubricant to threads of bedbar adjust- er screw (item 10[...]

Greensmaster eFlex 1800/2100 Page 6 - - 18 Cutting Unit Front Roller Removal (Fig. 25) 1. Park machine on level surface. T urn key switch to the OFF position and remove key from the switch. Make sure the traction lever is in the NEUTRAL position. 2. Disconnect the batte ry pack (see Battery Pack Con- nection in the General Information sectio n of t[...]

Greensmaster eFlex 1800 /2100 Page 6 - - 19 Cutting Unit Rear Roller Removal (Fig. 27) 1 . P a r km a c h i n eo nl e v e ls u r f a c e .T u r nk e ys w i t c ht ot h e OFF position and remove key from the swit ch. Make sure the traction lever is in the NEUTRAL posi tion. 2. Disconnect the batte ry pack (see Batt ery Pack Con - nection in the Gene[...]

Greensmaster eFlex 1800/2100 Page 6 - - 20 Cutting Unit Roller Service 1. Wiehle roller 2. Smooth roller 3. Roller shaft 4. Ball bearing 5. Seal 6. V - - ring 7. Bearing lock nut Figure 28 7 6 5 4 2 1 3 4 5 6 7 25 to 30 ft - - lb ( 3 4t o4 1N - - m ) 25 to 30 ft - - lb ( 3 4t o4 1N - - m ) Disassembly 1. T o hold roller shaft for bea ring lock nut [...]

Greensmaster eFlex 1800 /2100 Page 6 - - 21 Cutting Unit NOTE: Special tool T OR4105 (see Special T ools) can be used instead of washers and spacer when installing bearings and seals in ro ller . 2. Position a n ew bearing, black assembly washer (see Special T ools) and original lock nut onto each end of the roller shaft (Fig. 30). 3. T i ghten nut[...]

Greensmaster eFlex 1800/2100 Page 6 - - 22 Cutting Unit Cutting Reel Assembly Removal and Installation 1. Crossmember 2. LH side plate 3. Compression spring (2 used) 4. Shoulder bolt (2 used per side pla te) 5. Flange nut (2 used per side plate) 6. Cutting reel assembly 7. RH pitc h arm 8. Flange head screw (2 used) 9. RH side plate 10. Weight 11 .[...]

Greensmaster eFlex 1800 /2100 Page 6 - - 23 Cutting Unit Cutting Ree l Assembly Removal ( Fig. 34) NOTE: Removal of the cutting reel can be completed by removing the RH side plate from th e cutting unit crossmember . The LH side plate (including the ree l drive assembly) does not have to be removed from the crossmember when using the follo wing pro[...]

Greensmaster eFlex 1800/2100 Page 6 - - 24 Cutting Unit Cutting Reel Assembly Installation (Fig. 34) 1. Thorough ly clean side plates a nd other cut ting unit components. Inspect side plates and pitch arms for wear or damage and replace compo nents if needed. 2. Make sure that flocked seals, reel bearings, b earing lock screw and reel drive shaft a[...]

Greensmaster eFlex 1800 /2100 Page 6 - - 25 Cutting Unit This page is intent ionally blank. Cutting Unit[...]

Greensmaster eFlex 1800/2100 Page 6 - - 26 Cutting Unit Cutting Reel Assembly Service 1. Cutting reel 2. Flocked seal (2 used) 3. Bearin g (2 used ) 4. Reel drive shaft (LH threads) 5. Bearing lock screw (RH threads) Figure 37 9 0 t o 1 1 0 f t- -l b (123 to 149 N - - m) FRONT RIGHT (Right Hand Thr eads) (Left Hand T hreads) 1 2 3 4 5 3 2 9 0 t o 1[...]

Greensmaster eFlex 1800 /2100 Page 6 - - 27 Cutting Unit Disassembly of Cutting Reel (Fig. 37) IMPORT ANT : When removin g reel drive sh aft (item 4), use ap propria te wrench o r socket on 1” h ex sur - face of shaft. Do not use 1 /2” extension on e nd of reel drive shaft when loosening or tightening drive shaft. The 1/2” hex is intended for[...]

Greensmaster eFlex 1800/2100 Page 6 - - 28 Cutting Unit Prepari ng Reel for Grinding NOTE: Before grinding a cutting reel, make sure that all cutting unit compo nents are in good condition . Depend- ing on type of gri nder used, faulty c utting un it compo- nents can affect grinding r esults. NOTE: When grinding, be care ful to not overheat the cut[...]

Greensmaster eFlex 1800 /2100 Groomer Page 7 - - 1 Chapter 7 Groomer T able of Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TION 3 ..................... Installation Instructions 3 ................ ...... Battery Pack Connection 3 ..................... TROUBLESHOOTING 4 ......................... Factors Aff ecting Groomin[...]

Greensmaster eFlex 1800/2100 Groomer Page 7 - - 2 Specifications MOUNTING: The groomer is mounte d to the cutting unit side plates. GROOMING REEL CONSTRUCTION: 2.375 inch (6 cm) diameter , 41 steel blades with 1/2 inch blade spac- ing. Blade spacing can b e adjusted to 1/4 inch or 3/4 inch by altering the n umber and position of blade spa c ers on [...]

Greensmaster eFlex 1800 /2100 Groomer Page 7 - - 3 General Information Installation Instructions The Installation In structions for the groo mer provide in- formation regarding the operation, general main te- nance procedures and mainte nance intervals for the groomer assembly on your Greensmaster eFlex ma- chine. Refer to this publicat ion for add[...]

Greensmaster eFlex 1800/2100 Groomer Page 7 - - 4 T roubleshooting Factors Affecting Grooming There are a number of facto rs that can af fect the perfor- mance of grooming. These f actors vary for dif ferent golf courses and from green to green. It is important to in- spect the turf frequentl y and vary the grooming practice with turf needs. It is [...]

Greensmaster eFlex 1800 /2100 Groomer Page 7 - - 5 Grooming Reel Mechanical Problems Problem Possible Causes Correction The grooming r eel rotates when it is in the raised, transport positio n (for- ward rotati ng groomer drive). T h eg r o o m i n gr e e ls h o u l dr o t a t e whenever the cutting reel is en- gaged. Normal operation. No rotation [...]

Greensmaster eFlex 1800/2100 Groomer Page 7 - - 6 Adjustments CAUTION Before working on the cutting unit, always turn the key switch OFF and disconnect the bat tery pack from the wire harness. This will prevent un- expected machine operation. NOTE: See the Groomer Insta llation Instructions for adjustment proc edures for the groomer on your Greensm[...]

Greensmaster eFlex 1800 /2100 Groomer Page 7 - - 7 Service and Repairs Groomer Belt Replacement (Forward Rotating Groomer Drive) 1 . P a r km a c h i n eo nl e v e ls u r f a c e .T u r nk e ys w i t c ht ot h e OFF position and remove key from the swit ch. Make sure the traction lever is in the NEUTRAL posi tion. 2. Disconnect the batte ry pack (s[...]

Greensmaster eFlex 1800/2100 Groomer Page 7 - - 8 Groomer Cover (C ounter Rotating Groomer Drive) On eFlex machines w ith the counter rotating gro omer , the groomer cover includes a handle which engages and disenga ges the groom er drive. When the handle is rotated toward the front of the machine, the groomer is engaged. Removal 1. Park machine on[...]

Greensmaster eFlex 1800 /2100 Groomer Page 7 - - 9 Installation 1. If removed, install shaft into groomer cover (Fig. 6): A . I n s t a l ln e wO - - r i n gi n t og r o o v eo fs h a f t . B. Apply antiseize lubricant to shaft surface that is below the re taining ring gr oove. C. Slide shaft up through bore of co v er and secure with thrust washer[...]

Greensmaster eFlex 1800/2100 Groomer Page 7 - - 10 Grooming R eel (Forward Rotating G roomer Dr ive) Figure 8 1. Lock nut (4 used) 2. Drive co ver 3. Groomer drive belt 4. Driv e pulley 5. Shoulder bolt (2 used) 6. Sprin g 7. RH drive plate assembly 8. Groome r shim 9. RH groomer arm assembly 10. Cap screw (2 used) 1 1. Bushing (2 used) 12. Spring [...]

Greensmaster eFlex 1800 /2100 Groomer Page 7 - - 1 1 7. Remove HOC nut (item 21), HOC washer (item 16) and plow bolt (ite m 22) that secur e RH groomer ar m as- sembly to drive p late assembly . Do not cha nge height - - of - - cut screw adjustment. Remove RH groomer a rm assembly from cutting unit. 8. Remove front roller asse mbly from cutting uni[...]

Greensmaster eFlex 1800/2100 Groomer Page 7 - - 12 NOTE: T o prevent cutting reel from turning when instal- ling drive p ulley , use a 1/2” socket on hex of reel drive shaft that is used for backlappi ng the cutting reel. 9. Secure drive pulley (item 4) to cutting reel shaft. T orque pulley to 100 ft - - lb (135 N - - m) . 10. Insert front roller[...]

Greensmaster eFlex 1800 /2100 Groomer Page 7 - - 13 This page is intent ionally blank. Groomer[...]

Greensmaster eFlex 1800/2100 Groomer Page 7 - - 14 Grooming R eel (Counter R otating Groomer Drive) Figure 1 1 1. RH groomer arm assembly 2. HOC nut (2 used) 3. Bushin g (2 use d) 4. Spring w asher ( 2 used) 5. Lock nut (2 used) 6. LH groomer arm assembly 7. Cap screw (2 used) 8. Grooming reel assembly 9. HOC washer (2 used) 10. HOC screw (2 used) [...]

Greensmaster eFlex 1800 /2100 Groomer Page 7 - - 15 8. Loosen cap screws (item 7) that secure fron t roller shaft to groomer arms. 9. Remove lock nut and spring washer that secure RH groomer arm lift rod to RH drive plate assembly (F ig. 14). 10. Remove HOC nut (item 2), HOC washer (item 9) and plow bolt (i tem 31) that secu re RH groomer arm assem[...]

Greensmaster eFlex 1800/2100 Groomer Page 7 - - 16 4. Apply light coat ing of grea se to O - - ring on RH drive plate assembly pivot hub an d pilot bore of cutting unit side plate. 5. Carefully slide RH d rive plate onto grooming reel shaft taking care to not da mage seals in drive plate. Position drive plate to the support plate on the cutting uni[...]

Greensmaster eFlex 1800 /2100 Groomer Page 7 - - 17 Grooming Reel Service Inspect gro oming reel blades frequently for damage and wear . Straighten bent blades with a pliers. Replace blades that are worn or damaged. Carbide tipped grooming blades (Fig. 16) should be re- placed if the ca rbide tip is worn, lo ose or missing. Also, if the blade is er[...]

Greensmaster eFlex 1800/2100 Groomer Page 7 - - 18 Grooming R eel Bearing R eplacement Bearing Removal 1. Park machine on level surface. T urn key switch to the OFF position and remove key from the switch. Make sure the traction lever is in the NEUTRAL position. En- gage parking br ake. 2. Disconnect the batte ry pack (see Battery Pack Con- nection[...]

Greensmaster eFlex 1800 /2100 Groomer Page 7 - - 19 2. Install LH support plate to left side of cutting unit: A. Apply antiseize lubric ant to threads of LH groom- er arm lift rod. B. Position suppor t plate to cutting unit making sure that LH groomer arm lift rod is positioned through bushing in support pla te. C. Place spring washer and lock nut [...]

Greensmaster eFlex 1800/2100 Groomer Page 7 - - 20 Idler Assem bly (Forward Rotating Groomer Drive ) Figure 25 1. Pivot hub 2. Spacer 3. Sprin g 4. Idler b racket 5. Spacer 6. RH drive plate 7. O - -ring 8. Retaining ring 9. Grease fitting 10. Idler pulley 1 1. Bearing (2 used) 12. Retaining ring 13. Lock nut 9 10 12 11 5 4 2 1 7 8 6 3 13[...]

Greensmaster eFlex 1800 /2100 Groomer Page 7 - - 21 The groomer RH drive plate assembly incorporates the idler system for tensioni ng the groomer drive be lt. The idler system uses a spring to mai n tain proper belt ten- sion. Removal 1 . P a r km a c h i n eo nl e v e ls u r f a c e .T u r nk e ys w i t c ht ot h e OFF position and remove key from[...]

Greensmaster eFlex 1800/2100 Groomer Page 7 - - 22 Idler Assem bly (Counter Rotating Groomer Drive) Figure 27 1. RH drive pla te 2. Adjustment ca m 3. Spacer 4. Idler b racket 5. Spacer 6. Reel hub 7. Retaining ring 8. O - -ring 9. Flange nut 10. Extension spring 11 . G r e a s e f i t t i n g 12. Grease seal 6 3 5 4 12 9 7 8 10 1 2 11 The groomer [...]

Greensmaster eFlex 1800 /2100 Groomer Page 7 - - 23 3. Check adjustment of adjustment cam (Fig. 29): A. Rotate idler bracket so t he bracket stop is against the adjustment cam. B. While holding bracket stop against the cam, mea- sure the distance between the idler gear bearing sur- faces on the idler bracket and the drive plate . This distance shou[...]

Greensmaster eFlex 1800/2100 Groomer Page 7 - - 24 Lift Arm Assembly Figure 31 1. HOC groomer arm (LH shown) 2. Flange nut 3. Grooved pin 4. E - - ring 5. Groomer lift rod 6. Lock scr ew 7. Bushing 8. Lift arm assembly (LH shown) 9. Detent spring 10. Spring washer 1 1. Cap screw 12. Bushing 13. W ave wash er 14. Groomer adjuster 15. Side plate (LH [...]

Greensmaster eFlex 1800 /2100 Groomer Page 7 - - 25 Disassembly (Fig. 31) 1 . P a r km a c h i n eo nl e v e ls u r f a c e .T u r nk e ys w i t c ht ot h e OFF position and remove key from the swit ch. Make sure the traction lever is in the NEUTRAL position. En- gage parking brake. 2. Disconnect the batte ry pack (see Batt ery Pack Con - nection i[...]

Greensmaster eFlex 1800/2100 Groomer Page 7 - - 26 Groomer Br ush Figure 32 1. Groomer brush shaft 2. Lock nut 3. J - - bolt 4. Groomer brush 5. O - - ring 20 to 25 in - - lb (2.3 to 2.8 N - - m) 20 to 25 in - - lb (2.3 to 2.8 N - - m) 3 1 2 4 2 3 5 The groome r brush atta ches to the gr oomer d rive in place of the grooming reel. Remova l and inst[...]

Greensmaster eFlex 1800 /2100 Page 8 - - 1 Foldout Drawings Chapter 8 Foldout Drawings T able of Contents ELECTRI CAL SCHEMA T IC 3 .................... WIRE HARNESS DRA WINGS Main Wire Harness Drawing 4 ...... ............ Battery Wire Harnes s Drawing 6 ................ Battery Wir e Harness Ada pter Drawing 8 ........ Foldout Drawings[...]

Greensmaster eFlex 1800/2100 Page 8 - - 2 Foldout Drawings This page is intentionally blank.[...]

Page 8 - - 3 Electr ical Schematic Greensmaster eFlex 1800/2100[...]

Page 8 - - 4 Main Wire Har ness Drawing Greensmaster eFlex 1800/2100 EZ TURN SWITCH EZ TURN SENSOR[...]

Page 8 - - 5 Ma in Wire Harn e ss D ia g ram Greensmaster eFlex 1800/2100 BROWN WHITE BLACK RED BLACK BLACK BLACK/ BLUE BLACK BLACK YELLO W PINK ORANGE BLACK WHITE TA N RED/ WHITE WHITE RED/WHI TE BLACK/ WHITE RED/WHI TE BLACK/WHITE BLACK BLACK PINK TA N RED BLACK PINK BLACK/WHITE RED/WHI TE BLUE VIOLET BROWN YELLO W PINK TA N ORANGE WHITE RED/WHI [...]

Page 8 - - 6 Bat t ery W ire Ha rn es s Dra wi n g Greensmaster eFlex 1800/2100[...]

Page 8 - - 7 Bat t ery W ire Ha rn es s Di ag ra m Greensmaster eFlex 1800/2100 RED/WHI TE BLACK/WHITE BLUE RED/WHI TE BLACK/WHITE RED/WHI TE BLACK/WHITE BLUE RED/WHI TE BLACK/WHITE RED BLACK/WHITE BLUE RED/WHI TE BLACK[...]

Page 8 - - 8 Bat t ery W ire Ha rn es s A da p t er Draw in g Greensmaster eFlex 1800/2100 RED BLACK[...]