Toro Greensmaster Flex 1800 Service Manual
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Toro Greensmaster Flex 1800 Service Manual

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Form No. 12188SL Rev. D
Greensmaster
®
Flex 1800/1820/2100/2120
(Models 04040, 04041, 04044 and 04045)
Original Instructions (EN)

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Summary of Contents for Toro Greensmaster Flex 1800

  • Page 1 Form No. 12188SL Rev. D Greensmaster ® Flex 1800/1820/2100/2120 (Models 04040, 04041, 04044 and 04045) Original Instructions (EN)
  • Page 2 THE TORO COMPANY 2020 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be...
  • Page 3 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.com...
  • Page 4 NOTES...
  • Page 5 IMPORTANT: The IMPORTANT notice will give im- The Toro Company reserves the right to change product portant instructions which must be followed to pre- specifications or this publication without notice. vent damage to systems or components on the machine.
  • Page 6 This page is intentionally blank. Greensmaster Flex 1800/1820/2100/2120...
  • Page 7 ......5 - 10 Component Testing ......5 - 11 Greensmaster Flex 1800/1820/2100/2120...
  • Page 8 This page is intentionally blank. Greensmaster Flex 1800/1820/2100/2120...

  • Page 9: Table Of Contents

    ....SAFETY AND INSTRUCTION DECALS ..Greensmaster Flex 1800/1820/2100/2120 Page 1 − 1 Safety...

  • Page 10: Safety Instructions

    Safety Instructions Greensmaster Flex machines have been tested and certified by TORO for compliance with existing safety WARNING standards and specifications. Although hazard control and accident prevention are partially dependent upon To reduce the potential for injury or death, com- the design and configuration of the machine, these fac- ply with the following safety instructions.

  • Page 11: While Operating

    4. To reduce potential fire hazard, keep the engine area machine, use genuine Toro replacement parts and ac- free of excessive grease, grass, leaves and accumula- cessories. Replacement parts and accessories made tion of dirt.

  • Page 12: Safety And Instruction Decals

    Replace any decal that is damaged or lost. Decal part numbers are listed in your Parts Catalog. Order re- placement decals from your Authorized TORO Distribu- tor. Safety Page 1 − 4...
  • Page 13 Maintenance Maintenance procedures and recommended service in- tervals for the Greensmaster Flex machines are cov- ered in the Operator’s Manual. Refer to that publication when performing regular equipment maintenance. Greensmaster Flex 1800/1820/2100/2120 Page 2 − 1 Product Records and Maintenance...
  • Page 14 Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 − 2 Greensmaster Flex 1800/1820/2100/2120...
  • Page 15 For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
  • Page 16 NOTE: Reduce torque values listed in the table above by 25% for lubricated fasteners. Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite. Product Records and Maintenance Page 2 − 4 Greensmaster Flex 1800/1820/2100/2120...
  • Page 17 NOTE: Reduce torque values listed in the table above by 25% for lubricated fasteners. Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite. Greensmaster Flex 1800/1820/2100/2120 Page 2 − 5 Product Records and Maintenance...
  • Page 18 All torque values are based on non−lubricated fasteners. 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 Product Records and Maintenance Page 2 − 6 Greensmaster Flex 1800/1820/2100/2120...
  • Page 19 ........Engine Coupler Sleeve ..... SUBARU SERVICE MANUAL Greensmaster Flex 1800/1820/2100/2120 Page 3 − 1 Engine...
  • Page 20 This page is intentionally blank. Engine Page 3 − 2 Greensmaster Flex 1800/1820/2100/2120...

  • Page 21: Specifications

    Ignition System Electronic flywheel magneto Spark Plug NGK BR−6HS Spark Plug Gap 0.024” to 0.028” (0.6 to 0.7 mm) Lighting Coil 12 V AC / 15 Watt Dry Weight 34.2 lbs (15.5 kg) Greensmaster Flex 1800/1820/2100/2120 Page 3 − 3 Engine...

  • Page 22: General Information

    Greensmaster Flex mowers are supplied through your commonly available in many service shops. Several local Toro distributor. Be prepared to provide your dis- special tools are described in the Subaru Service Manu- tributor with the Toro model and serial number.

  • Page 23: Adjustments

    Modification to this cap will void the engine warranty and likely will make the engine non−compliant with emission certification of the engine. Greensmaster Flex 1800/1820/2100/2120 Page 3 − 5 Engine...

  • Page 24: Service And Repairs

    4. Make sure blower housing and/or engine cylinder shroud are installed to the engine if removed. 5. Attach spark plug wire to spark plug. Figure 3 1. Blower housing 2. Rewind starter Engine Page 3 − 6 Greensmaster Flex 1800/1820/2100/2120...

  • Page 25: Spark Plug

    5. Install correctly gapped spark plug into cylinder head and torque plug 17 ft−lb (23 N−m). 6. Connect spark plug wire to spark plug. Ignition Components Engine ignition component information is included in the Subaru Service Manual. Greensmaster Flex 1800/1820/2100/2120 Page 3 − 7 Engine...

  • Page 26: Engine

    Slide cable from governor lever. 2. If engine is to be disassembled, it may be easier to C. Position throttle cable away from engine. drain oil from engine before removing engine from trac- tion unit. Engine Page 3 − 8 Greensmaster Flex 1800/1820/2100/2120...
  • Page 27 (item 14). Torque set screws 65 in−lb (7.3 spark plug wire is not connected to engine spark plug. N−m). 2. Make sure that all parts removed from the engine during maintenance or rebuilding are properly installed to the engine. Greensmaster Flex 1800/1820/2100/2120 Page 3 − 9 Engine...
  • Page 28 G. Position front of engine base to align engine and transmission couplers. Fully tighten flange head screw (item 9) to secure front of engine base. H. Fully tighten fasteners at rear of engine base. Engine Page 3 − 10 Greensmaster Flex 1800/1820/2100/2120...

  • Page 29: Engine Coupler Sleeve

    0.250” (6.4 mm) before coupler replace- 2. Key 5. Coupler sleeve 3. Engine coupler ment is necessary. If a coupler sleeve has torn or missing cogs, the coupler should be replaced. Figure 9 Figure 10 Greensmaster Flex 1800/1820/2100/2120 Page 3 − 11 Engine...
  • Page 30 This page is intentionally blank. Engine Page 3 − 12 Greensmaster Flex 1800/1820/2100/2120...
  • Page 31 Transmission ......Greensmaster Flex 1800/1820/2100/2120 Page 4 − 1 Traction and Reel Drive System...

  • Page 32: Specifications

    Transmission Reel Clutch Shaft to Telescoping Drive Shaft Two Beam Style Couplers Used in Reel Drive System Final Reel Drive has Three (3) Pulleys with Positive Drive Belt Pulley Configuration Allows Six (6) Clip Adjustments Traction and Reel Drive System Page 4 - 2 Greensmaster Flex 1800/1820/2100/2120...

  • Page 33: General Information

    4. To engage the drum drive, rotate traction engage/ disengage lever to the engaged position by rotating the lever toward the front of the machine. 5. Connect spark plug wire to spark plug. Greensmaster Flex 1800/1820/2100/2120 Page 4 − 3 Traction and Reel Drive System...

  • Page 34: Transmission Belt Tensioner

    (Fig. 3). 5. Connect spark plug wire to spark plug. Figure 3 1. Engage/disengage shaft 3. Cover alignment mark 2. Alignment mark Traction and Reel Drive System Page 4 − 4 Greensmaster Flex 1800/1820/2100/2120...

  • Page 35: Special Tools

    4. Use modified socket and socket wrench to loosen or tighten bearing collar. Figure 6 1. Modified socket 3. Pin 2. Reel clutch shaft assy Greensmaster Flex 1800/1820/2100/2120 Page 4 − 5 Traction and Reel Drive System...

  • Page 36: Adjustments

    22 TOOTH PULLEY IS ALUMINUM COLOR 0.160 0.126 24 TOOTH PULLEY IS BLACK COLOR 0.174 0.137 25 TOOTH PULLEY IS RED COLOR 0.182 0.143 0.190 0.149 Figure 8 Traction and Reel Drive System Page 4 − 6 Greensmaster Flex 1800/1820/2100/2120...

  • Page 37: Reel Clutch Adjustment

    Clutch Cable Replacement in Chapter 5 − Chassis and Controls). Figure 10 1. Reel clutch lever 3. Reel drive hub 2. Reel clutch hub 4. Reel clutch pulley Greensmaster Flex 1800/1820/2100/2120 Page 4 − 7 Traction and Reel Drive System...

  • Page 38: Transmission Clutch Adjustment (1800/2100)

    Figure 11 0.025” to 0.045” (0.7 to 1.1 mm) Figure 12 1. Hub 4. Thrust friction assy 2. Fixed housing 5. Mounting plate 3. Rotating housing 6. Shim locations Traction and Reel Drive System Page 4 − 8 Greensmaster Flex 1800/1820/2100/2120...

  • Page 39: Transmission Clutch Adjustment (1820/2120)

    4. Make sure that clutch has proper level of multi−pur- center should be 2.5” (63.5 mm) when the clutch lever pose ATF before returning the machine to operation is disengaged. (see the machine Operator’s Manual). Greensmaster Flex 1800/1820/2100/2120 Page 4 − 9 Traction and Reel Drive System...
  • Page 40 This page is intentionally blank Traction and Reel Drive System Page 4 − 10 Greensmaster Flex 1800/1820/2100/2120...

  • Page 41: Service And Repairs

    Figure 15 flange head screw (Fig. 14). 1. Reel drive belt 3. Compression spring 2. Bearing housing nut 4. Bearing housing 8. Connect spark plug wire to spark plug. Greensmaster Flex 1800/1820/2100/2120 Page 4 − 11 Traction and Reel Drive System...

  • Page 42: Reel Drive Assembly

    (items 8, 11 and 14) to the appropriate locations on the reel drive assembly (see Cutting Unit Clip Adjust- ment in the Adjustments section of this chapter). Traction and Reel Drive System Page 4 − 12 Greensmaster Flex 1800/1820/2100/2120...
  • Page 43 A. If bearings (item 24) were removed from idler shaft, use press to install bearings and bearing spacer onto shaft. 2. Apply light coating of grease on reel drive housing O−rings (items 2 and 9). Greensmaster Flex 1800/1820/2100/2120 Page 4 − 13 Traction and Reel Drive System...

  • Page 44: Reel Drive Bearing Housing

    11. Spring pin (2 used) 3. Bearing (2 used) 8. Flat washer 12. Flex coupling 4. Bearing spacer 9. Retaining ring 13. Reel hex shaft 5. Wave washer Traction and Reel Drive System Page 4 − 14 Greensmaster Flex 1800/1820/2100/2120...
  • Page 45 8. Clean all bearing housing components. 7. Install reel drive bearing housing to reel drive hous- ing (see Reel Drive Assembly in this section). 8. Connect spark plug wire to spark plug. Greensmaster Flex 1800/1820/2100/2120 Page 4 − 15 Traction and Reel Drive System...

  • Page 46: Drum Drive Belt

    2. Remove transport wheels if attached (see Transport 5. Remove and discard gasket (item 3) from between Wheels in the Service and Repairs section of Chapter 6 cover and housing. − Chassis and Controls). Traction and Reel Drive System Page 4 − 16 Greensmaster Flex 1800/1820/2100/2120...
  • Page 47 10.Install transport wheels if they were attached (see Transport Wheels in the Service and Repairs section of Chapter 6 − Chassis and Controls). 11. Connect spark plug wire to spark plug. Greensmaster Flex 1800/1820/2100/2120 Page 4 − 17 Traction and Reel Drive System...

  • Page 48: Drum Drive Idler Assembly

    Remove belt (see Disengaging Drum Drive From Transmission idler arm assembly from housing. in the General Information section of this chapter). Traction and Reel Drive System Page 4 − 18 Greensmaster Flex 1800/1820/2100/2120...
  • Page 49 9. Install transport wheels if they were attached (see Transport Wheels in the Service and Repairs section of Chapter 6 − Chassis and Controls). 10.Connect spark plug wire to spark plug. Greensmaster Flex 1800/1820/2100/2120 Page 4 − 19 Traction and Reel Drive System...

  • Page 50: Traction Drums

    2. If installed, remove transport wheels (see Transport ing. Wheels in the Service and Repairs section of Chapter 6 − Chassis and Controls). Traction and Reel Drive System Page 4 − 20 Greensmaster Flex 1800/1820/2100/2120...
  • Page 51 140 to 160 ft−lb (190 to 216 N−m). 3. Place square key (item 6) into slot of long spur gear (item 8). Apply antiseize lubricant to top surface of key. Greensmaster Flex 1800/1820/2100/2120 Page 4 − 21 Traction and Reel Drive System...
  • Page 52 (item 15). While retaining LH drum, se- cure drum to traction drum assembly with bearing nut (item 15). Torque bearing nut from 75 to 90 ft−lb (102 to 122 N−m). Traction and Reel Drive System Page 4 − 22 Greensmaster Flex 1800/1820/2100/2120...
  • Page 53 This page is intentionally blank. Greensmaster Flex 1800/1820/2100/2120 Page 4 − 23 Traction and Reel Drive System...

  • Page 54: Differential Assembly

    1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the engine spark 3. Slide spur gear assembly from differential assembly plug. in drum drive housing (Fig. 28). Traction and Reel Drive System Page 4 − 24 Greensmaster Flex 1800/1820/2100/2120...
  • Page 55 (or equivalent). Slide differential assembly into drum drive housing (item 1) and onto long spur gear (item 8). Make sure that spur gear properly engages dif- ferential gears. Greensmaster Flex 1800/1820/2100/2120 Page 4 − 25 Traction and Reel Drive System...

  • Page 56: Differential Assembly Service

    The projections need to be aligned 4. Replace all worn or damaged differential assembly with the gear pins that have one (1) gear (Fig. 32). components. Traction and Reel Drive System Page 4 − 26 Greensmaster Flex 1800/1820/2100/2120...
  • Page 57 3. Gear pin with 1 gear 2. Gear pin with 2 gears Figure 33 1. Housing index mark 3. Gear pin with 1 gear 2. Gear pin with 2 gears Greensmaster Flex 1800/1820/2100/2120 Page 4 − 27 Traction and Reel Drive System...

  • Page 58: Transmission Drive Belt

    (item 7) in telescoping coupler (item 8). With transmission cover to transmission. Carefully remove wire ends spread, slide coupler from transmission shaft. cover from transmission. Remove and discard gasket (item 3). Traction and Reel Drive System Page 4 − 28 Greensmaster Flex 1800/1820/2100/2120...
  • Page 59 Secure coupler with two (2) set screws (item 12). Torque set screws from 60 to 65 in−lb (6.8 to 7.3 N−m). Greensmaster Flex 1800/1820/2100/2120 Page 4 − 29 Traction and Reel Drive System...

  • Page 60: Transmission Idler System

    Transmis- sion idler components can be accessed by removing the engine from the frame, removing the transmission cover and then removing the drive belt. Traction and Reel Drive System Page 4 − 30 Greensmaster Flex 1800/1820/2100/2120...
  • Page 61 2. Install transmission drive belt and all machine com- ponents removed for idler system service (see Trans- mission Drive Belt in this section). Greensmaster Flex 1800/1820/2100/2120 Page 4 − 31 Traction and Reel Drive System...

  • Page 62: Transmission Reel Drive System

    Reel Clutch Cable Replacement in the Service and Re- Seized Reel Clutch Shaft From Transmission in this sec- pairs section of Chapter 6 − Chassis and Controls). tion for removal procedure. Traction and Reel Drive System Page 4 − 32 Greensmaster Flex 1800/1820/2100/2120...
  • Page 63 2. If bearing was removed from bearing collar, press C. Use modified socket and socket wrench to re- new bearing fully onto collar. move bearing collar assembly from clutch shaft. Greensmaster Flex 1800/1820/2100/2120 Page 4 − 33 Traction and Reel Drive System...
  • Page 64 (item 11) which is pressed into Clutch Cable Replacement in the Service and Repairs the transmission housing. section of Chapter 6 − Chassis and Controls). Make sure that clutch cable is properly adjusted. Traction and Reel Drive System Page 4 − 34 Greensmaster Flex 1800/1820/2100/2120...

  • Page 65: Removing Seized Reel Clutch Shaft From Transmission

    Make sure that new ball bearing is installed on reel clutch shaft. 8. Install reel clutch shaft assembly into transmission housing and assemble transmission (see Transmission Reel Drive System in this section). Greensmaster Flex 1800/1820/2100/2120 Page 4 − 35 Traction and Reel Drive System...

  • Page 66: Transmission Clutch System (1800/2100)

    6. Remove entire clutch assembly (including items 1, 5, is OFF. 6 and 8) from transmission housing. 2. Remove transmission drive belt (see Transmission Drive Belt in this section). Traction and Reel Drive System Page 4 − 36 Greensmaster Flex 1800/1820/2100/2120...
  • Page 67 40 in−lb (1.7 to 4.5 N−m). Then, torque all screws from 95 to 105 in−lb (10.7 to 11.8 N−m). Figure 46 1. Clevis 3. Bellcrank rod 2. Jam nut (2 used) 4. Balljoint Greensmaster Flex 1800/1820/2100/2120 Page 4 − 37 Traction and Reel Drive System...

  • Page 68: Clutch Assembly Service (1800/2100)

    1. Before disassembling clutch, measure rotation angle of clutch lever (Fig. 48). If lever can be rotated more than 22 , the clutch assembly is worn and clutch replacement is necessary. Figure 48 Traction and Reel Drive System Page 4 − 38 Greensmaster Flex 1800/1820/2100/2120...
  • Page 69 10), rotating housing (item 13), hub (item 14), drive in- (see Transmission Clutch Adjustment − 1800/2100 in serts (item 16) or fixed housing (item 17) is worn or dam- this Chapter). aged, replace clutch assembly. Greensmaster Flex 1800/1820/2100/2120 Page 4 − 39 Traction and Reel Drive System...

  • Page 70: Transmission Clutch System (1820/2120)

    Transmission components (including the clutch assembly) can be accessed by removing the engine from the frame, removing the transmission cover and then removing the transmission drive belt. Traction and Reel Drive System Page 4 − 40 Greensmaster Flex 1800/1820/2100/2120...
  • Page 71 B. Fluid level should be within 0.06 inch (1.5 mm) from the bottom of the clutch housing check hole plug. Greensmaster Flex 1800/1820/2100/2120 Page 4 - 41 Traction and Reel Drive System...

  • Page 72: Clutch Assembly Service (1820/2120)

    (item 12). Remove spring anchor 1. Remove clutch assembly from transmission housing and jam nut from actuator pin. (see Transmission Clutch System in this section). 2. Drain lubricant from transmission. Traction and Reel Drive System Page 4 - 42 Greensmaster Flex 1800/1820/2100/2120...
  • Page 73 6. Make sure that O- ring is placed on actuator plug (item 15). Carefully install plug to actuator pin and clutch housing taking care to not damage oil seal in plug during assembly. Greensmaster Flex 1800/1820/2100/2120 Page 4 - 43 Traction and Reel Drive System...

  • Page 74: Clutch Shaft Service (1820/2120)

    Use a vise with soft jaws to prevent 4. Slide clutch cam (item 24) with bearing from end of damage to clutch shaft. clutch shaft. Traction and Reel Drive System Page 4 − 44 Greensmaster Flex 1800/1820/2100/2120...
  • Page 75 A. Remove retaining ring (item 10) from clutch shaft. B. Use press to remove bearing from clutch shaft. Discard removed bearing. C. Remove bearing spacer (item 14) from clutch shaft. Greensmaster Flex 1800/1820/2100/2120 Page 4 − 45 Traction and Reel Drive System...
  • Page 76 Figure 54 1. Clutch actuator ramp 2. Clutch cam ramp IMPORTANT: The flocked seal should be installed so the flocked side of the seal is toward the bearing location. Traction and Reel Drive System Page 4 − 46 Greensmaster Flex 1800/1820/2100/2120...
  • Page 77 This page is intentionally blank Greensmaster Flex 1800/1820/2100/2120 Page 4 − 47 Traction and Reel Drive System...

  • Page 78: Transmission Drum Drive System

    6. If necessary, remove ball bearings (item 3), spacer 2. Remove transmission drive belt (see Transmission (item 7) and wave washer (item 8) from extension hous- Drive Belt in this section). ing. Traction and Reel Drive System Page 4 − 48 Greensmaster Flex 1800/1820/2100/2120...
  • Page 79 5) is below frame tube. 3. Screw (4 used) 2. If removed, slide wave washer (item 8), spacer (item 7) and ball bearings (item 3) into extension housing. Greensmaster Flex 1800/1820/2100/2120 Page 4 − 49 Traction and Reel Drive System...

  • Page 80: Transmission

    5. Remove RH drum drive cover and belt from machine 1. Park machine on a level surface. Make sure engine (see Drum Drive Belt in this section). is OFF. Traction and Reel Drive System Page 4 − 50 Greensmaster Flex 1800/1820/2100/2120...
  • Page 81 (item 12) that secure rear of transmis- sion to frame. Make sure that washer (item 9) is be- low frame tube. C. Flange head screw (item 2) that secures front of transmission to frame. Greensmaster Flex 1800/1820/2100/2120 Page 4 − 51 Traction and Reel Drive System...
  • Page 82 This page is intentionally blank. Traction and Reel Drive System Page 4 − 52 Greensmaster Flex 1800/1820/2100/2120...
  • Page 83 Lighting Coil ....... Greensmaster Flex 1800/1820/2100/2120 Page 5 - 1...
  • Page 84 This page is intentionally blank. Electrical System Page 5 − 2 Greensmaster Flex 1800/1820/2100/2120...

  • Page 85: General Information

    The Traction Unit Operator’s Manual provide informa- tion regarding the operation, general maintenance and maintenance intervals for your Greensmaster machine. Refer to this Operator’s Manual for additional informa- tion when servicing the machine. Greensmaster Flex 1800/1820/2100/2120 Page 5 − 3 Electrical System...

  • Page 86: Wiring Schematics

    (machine serial numbers below 400000000) ON\OFF SWITCH is open in the ON position TRACTION SWITCH is closed when traction lever is in neutral PARKING BRAKE LATCH SWITCH is closed when parking brake latch is engaged Electrical System Page 5 - 4 Greensmaster Flex 1800/1820/2100/2120...
  • Page 87 (machine serial numbers above 400000000) ON\OFF SWITCH is open in the ON position TRACTION SWITCH is closed when traction lever is in neutral PARKING BRAKE LATCH SWITCH is closed when parking brake latch is engaged Greensmaster Flex 1800/1820/2100/2120 Page 5 - 5 Electrical System...

  • Page 88: Wire Harnesses

    Drawing No. 120- 6304 Rev C INTERLOCK MODULE ENGINE VIOLET MAGNETO PARKING BRAKE WHITE ORANGE TRACTION LATCH SWITCH SWITCH YELLOW YELLOW HOUR VIOLET METER ON/OFF ENGINE SWITCH GROUND Wire Harness Diagram (machine serial numbers below 400000000) Electrical System Page 5 - 6 Greensmaster Flex 1800/1820/2100/2120...
  • Page 89 Drawing No. 122- 0965 Rev C Wire Harness Drawing (machine serial numbers above 400000000) Drawing No. 122- 0965 Rev C Wire Harness Diagram (machine serial numbers above 400000000) Greensmaster Flex 1800/1820/2100/2120 Page 5 - 7 Electrical System...

  • Page 90: Special Tools

    Multimeter The multimeter can test electrical components and cir- cuits for current, resistance or voltage. NOTE: Toro recommends the use of a DIGITAL Volt- Ohm- Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
  • Page 91 For testing electronic ignitions. Saves time because you will know if the ignition is causing the problem on a non- starting engine. The tester determines if ignition spark is present. Toro Part Number: TOR4036 Figure 4 Greensmaster Flex 1800/1820/2100/2120 Page 5 - 9...

  • Page 92: Troubleshooting

    Traction switch is not adjusted or is Adjust or replace traction switch. faulty. An engine problem exists that Repair engine. causes the engine to stop. Interlock module is faulty. Replace interlock module. Electrical System Page 5 - 10 Greensmaster Flex 1800/1820/2100/2120...

  • Page 93: Component Testing

    4. Pull the engine starter rope and observe the spark tester. Visible and audible sparks should be produced if the ignition system is operating properly. Greensmaster Flex 1800/1820/2100/2120 Page 5 - 11 Electrical System...

  • Page 94: On/Off Switch

    7. Install console cover to handle. BACK OF SWITCH Figure 6 NOTE: On/Off switch terminals 3, 4, 5 and 6 are not used on Greensmaster Flex machines. Electrical System Page 5 - 12 Greensmaster Flex 1800/1820/2100/2120...

  • Page 95: Optional Light Switch

    7. Install console cover to handle. BACK OF SWITCH Figure 8 NOTE: Optional light switch terminals 1, 4, 5 and 6 are not used on Greensmaster Flex machines. Greensmaster Flex 1800/1820/2100/2120 Page 5 - 13 Electrical System...

  • Page 96: Parking Brake Latch Switch

    2. Switch panel 6. Console cover 3. Lower handle 7. Screw (4 used) 3. Position switch to switch panel and secure with 4. Screw (2 used) screws and lock nuts (Fig. 10). Electrical System Page 5 - 14 Greensmaster Flex 1800/1820/2100/2120...

  • Page 97: Traction Switch

    3. Position traction switch to switch bracket and secure 2. Traction lever assembly 6. Console cover with screws and lock nuts (Fig. 12). 3. Lower handle 7. Screw (4 used) 4. Screw (2 used) 8. Switch mount bracket Greensmaster Flex 1800/1820/2100/2120 Page 5 - 15 Electrical System...

  • Page 98: Interlock Module

    NOTE: If lights are desired on the Flex machine, use equipped with a lighting coil to provide electrical current the recommended Toro LED light kit that is available for an optional LED light kit. The coil is located under the from your Toro Distributor.
  • Page 99 ....... . . Transport Wheels (Optional) ....Greensmaster Flex 1800/1820/2100/2120 Page 6 − 1 Chassis and Controls...

  • Page 100: Specifications

    Specifications Item Description Transport Wheel (Optional) Tire Pressure 12 to 15 PSI (83 to 103 kPa) Chassis and Controls Page 6 − 2 Greensmaster Flex 1800/1820/2100/2120...

  • Page 101: General Information

    Operator’s Manual The Operator’s Manual provides information regarding the operation, adjustment procedures and general maintenance for your Greensmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine. Greensmaster Flex 1800/1820/2100/2120 Page 6 − 3 Chassis and Controls...

  • Page 102: Service And Repairs

    (Fig. 2). On Flex 1800/1820 machines, the offset handle 4. Disconnect throttle cable from engine (see Throttle clamps are mounted on the inside of the side plates (Fig. Cable Replacement in this section). Chassis and Controls Page 6 − 4 Greensmaster Flex 1800/1820/2100/2120...
  • Page 103 9. Hair pin 3. Carriage screw 10. Side plate (LH shown) 4. Carriage screw 11. Flange nut 5. Shoulder bolt 12. Flange nut 6. Bushing 13. Handle clamp 7. Rubber bumper Greensmaster Flex 1800/1820/2100/2120 Page 6 − 5 Chassis and Controls...

  • Page 104: Throttle Cable Replacement

    5. Throttle control 2. Flat washer 6. Throttle mount D. Tighten screw on cable clamp to secure the 3. Retaining ring 7. Mount cable guide 4. Throttle cable throttle cable. Chassis and Controls Page 6 − 6 Greensmaster Flex 1800/1820/2100/2120...

  • Page 105: Brake Cable Replacement

    2. Brake cable 9. Screw (4 used) 3. Bushing (2 used) 10. Spacer 4. Flange nut 11. Washer 5. Spring 12. Screw 6. Parking brake latch 13. Handle assembly 7. Lock nut Greensmaster Flex 1800/1820/2100/2120 Page 6 − 7 Chassis and Controls...

  • Page 106: Traction Clutch Cable Replacement

    B. Remove flange nut that secures cable eyelet to lever assembly for assembly purposes. transmission bellcrank lever and slide cable eyelet from lever. 5. Remove traction clutch cable from machine. Chassis and Controls Page 6 − 8 Greensmaster Flex 1800/1820/2100/2120...
  • Page 107 Figure 10 1. Shift handle 5. Upper cable jam nut 2. Traction clutch cable 6. Lower cable jam nut 3. Reel clutch cable 7. Shift mount bracket 4. Traction cable spring Greensmaster Flex 1800/1820/2100/2120 Page 6 − 9 Chassis and Controls...

  • Page 108: Reel Clutch Cable Replacement

    C. Remove cable tie that secures reel drive cable to 5. Remove reel clutch cable from machine. transmission bracket. Chassis and Controls Page 6 − 10 Greensmaster Flex 1800/1820/2100/2120...
  • Page 109 D. While holding the bottom jam nut in place, tighten top cable jam nut. 4. Install console cover to handle assembly. Greensmaster Flex 1800/1820/2100/2120 Page 6 − 11 Chassis and Controls...

  • Page 110: Traction And Reel Drive Engagement Lever Assembly

    17. Reel shift lever 27. Roll pin 8. Spring collar 18. Reel cam lever 28. Retaining ring (3 used) 9. Spacer 19. Ball bearing 29. Extension spring 10. Spring lever 20. Cap screw Chassis and Controls Page 6 − 12 Greensmaster Flex 1800/1820/2100/2120...
  • Page 111 2. Shift arm link 4. Shift link tab shifter bracket, shift mount and switch mount bracket) to handle. Secure assembly in place with four (4) flange head screws and flange nuts. Greensmaster Flex 1800/1820/2100/2120 Page 6 − 13 Chassis and Controls...
  • Page 112 System). Adjust switch if necessary. 8. Install console cover to handle. Figure 17 1. Transport lever 4. Shifter bracket 2. Reel shaft lever 5. Screw and nut 3. Clearance location Chassis and Controls Page 6 − 14 Greensmaster Flex 1800/1820/2100/2120...
  • Page 113 This page is intentionally blank. Greensmaster Flex 1800/1820/2100/2120 Page 6 − 15 Chassis and Controls...

  • Page 114: Kickstand

    NOTE: The offset handle clamps on Flex 2100/2120 machines are mounted on the outside of the side plates. On Flex 1800/1820 machines, the offset handle clamps are mounted on the inside of the side plates. Chassis and Controls Page 6 − 16 Greensmaster Flex 1800/1820/2100/2120...
  • Page 115 5. Pivot kickstand up and hold against the frame stops. Use a nutdriver or small diameter pipe over the end of the torsion spring. Push the spring end down and out to install spring (Fig. 19). Greensmaster Flex 1800/1820/2100/2120 Page 6 − 17 Chassis and Controls...

  • Page 116: Transport Wheels (Optional)

    7. Torsion spring 11. Inner tube 3. Shallow rim 8. Shoulder screw (2 used) 12. Hub bushing 4. Tire 9. Cap screw (4 used) 13. Flange nut (4 used) 5. Hub Chassis and Controls Page 6 − 18 Greensmaster Flex 1800/1820/2100/2120...
  • Page 117 2. Support the machine on the kick stand. 3. Slide transport wheel completely onto the wheel hex shaft until the wheel retaining lever is secured into the groove on the wheel hex shaft. Greensmaster Flex 1800/1820/2100/2120 Page 6 − 19 Chassis and Controls...
  • Page 118 This page is intentionally blank. Chassis and Controls Page 6 − 20 Greensmaster Flex 1800/1820/2100/2120...
  • Page 119 If an older production Flex cutting unit (serial number be- low 312000000) has been installed on a newer Flex 21 traction unit, use information from the appropriate Flex 21 service manual when servicing that cutting unit. Greensmaster Flex 1800/1820/2100/2120 Page 7 − 1 Cutting Unit...

  • Page 120: Specifications

    ROLLERS: The rear roller is a 2.000” (5.1 cm) diameter aluminum full roller. The front roller is a 2.500” (6.3 cm) diameter roller that is chosen from a variety of configura- tions (narrow spaced Weihle front roller is shown). Cutting Unit Page 7 − 2 Greensmaster Flex 1800/1820/2100/2120...

  • Page 121: General Information

    Figure 1 Lock nut 2. Support Greensmaster Flex 1800/1820/2100/2120 Page 7 − 3 Cutting Unit...

  • Page 122: Separating Cutting Unit From Traction Unit

    Figure 3 1. Telescoping coupler 2. Cutting unit hex shaft Figure 4 1. Cutting unit pitch arm 3. Flange head screw 2. Traction unit roll frame Cutting Unit Page 7 − 4 Greensmaster Flex 1800/1820/2100/2120...

  • Page 123: Special Tools

    Special Tools Some special tools may have been supplied with your mower or are available as TORO parts. Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Gauge Bar Assembly Toro Part Number: 13−8199 Used to verify height−of−cut.
  • Page 124 This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the Turf Evaluator (Toro part no. 97931SL).
  • Page 125 Because the top grind angle on bedknives is critical for edge retention, and therefore after− cut appearance, Toro has develop these service tools for accurately measuring the top grind angle on all bedknives. Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar.

  • Page 126: Factors That Can Affect Quality Of Cut

    Make sure bedbar pivot bolts are securely seated (see Bedbar in Service and Repairs section of this chapter). Number of reel blades. Use correct number of blades for clip frequency and optimum height−of−cut range. Cutting Unit Page 7 − 8 Greensmaster Flex 1800/1820/2100/2120...
  • Page 127 The traction drive belt may be loose or worn. Check the condition of the traction belt. Replace traction drive belt if necessary. Groomer reel operation. See Troubleshooting section of Chapter 8 − Groomer. Greensmaster Flex 1800/1820/2100/2120 Page 7 − 9 Cutting Unit...

  • Page 128: Adjustments

    210 to 240 in−lb (24 to 27 N−m). 6. After tightening the side plate, recheck the rear roller. If necessary, loosen and adjust second side plate. 7. After leveling rear roller, complete cutting unit set−up and adjustment sequence. Cutting Unit Page 7 − 10 Greensmaster Flex 1800/1820/2100/2120...

  • Page 129: Service And Repairs

    4. Remove plug from the reel drive cover on the left side of the reel assembly (Fig. 16). 5. Insert a 1/2” socket onto hex of reel drive shaft. 6. Backlap according to procedure in Toro General Ser- vice Training Book, Reel Mower Basics (part no. 09168SL).

  • Page 130: Bedbar Assembly

    (item 17) and four (4) plastic washers the rear of the cutting unit (see Supporting Cutting Unit (item 16) from the cutting unit side plates. when Servicing in the General Information section of this chapter). Cutting Unit Page 7 − 12 Greensmaster Flex 1800/1820/2100/2120...
  • Page 131 5. Position bedbar into cutting unit. Make sure that the 4. Plastic washer 8. Lock nut top of each bedbar arm is between washer (item 11) and adjuster screw flange (item 4). Greensmaster Flex 1800/1820/2100/2120 Page 7 − 13 Cutting Unit...

  • Page 132: Bedknife Replacement And Grinding

    28 N−m). # TOR510880 7. After installing bedknife to bedbar, grind bedknife. 1st − 10 in−lb (1 N−m) 12 14 2nd − 200 to 250 in−lb (23 to 28 N−m) Figure 21 Cutting Unit Page 7 − 14 Greensmaster Flex 1800/1820/2100/2120...
  • Page 133 1. Use Toro General Service Training Book, Reel Mow- er Basics (part no. 09168SL) and grinder manufactur- er’s instructions for bedknife grinding information. 2. After bedknife grinding is complete, install bedbar to cutting unit (see Bedbar Installation in this section).

  • Page 134: Bedbar Adjuster Service

    NOTE: Bedbar adjuster shaft (item 4) has left−hand on bushing to slot in frame and install bushings. threads. 3. Unscrew bedbar adjuster shaft (item 4) from the bed- bar adjuster screw. Cutting Unit Page 7 − 16 Greensmaster Flex 1800/1820/2100/2120...
  • Page 135 1/2 turn. 1. Crossmember 3. Cap screw 2. Detent 7. Adjust cutting unit (see Cutting Unit Operator’s Manual). Greensmaster Flex 1800/1820/2100/2120 Page 7 − 17 Cutting Unit...

  • Page 136: Reel Assembly

    1800/1820 cutting units, square nuts are used instead bly Service in this section for information on servicing of flange nuts. Cutting unit service procedures are the the cutting reel assembly. same on both models. Cutting Unit Page 7 - 18 Greensmaster Flex 1800/1820/2100/2120...
  • Page 137 Figure 30 1. Bearing lock screw 3. Support plate, weld side 2. Reel shaft 4. Pry bar Greensmaster Flex 1800/1820/2100/2120 Page 7 - 19 Cutting Unit...
  • Page 138 The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move (Fig. 31). Cutting Unit Page 7 - 20 Greensmaster Flex 1800/1820/2100/2120...
  • Page 139 1” hex portion of the shaft to tighten the reel drive shaft from 90 to 110 ft- lb (123 to 149 N- m). 10.Adjust cutting unit (see Cutting Unit Operator’s Manual). Greensmaster Flex 1800/1820/2100/2120 Page 7 - 21 Cutting Unit...

  • Page 140: Reel Assembly Service

    (123 to 149 N−m) (Left Hand Threads) Figure 30 1. Cutting reel 3. Bearing (2 used) 5. Bearing lock screw (RH threads) 2. Flocked seal (2 used) 4. Reel drive shaft (LH threads) Cutting Unit Page 7 − 22 Greensmaster Flex 1800/1820/2100/2120...
  • Page 141 2. Press flocked seals onto reel shaft with flocked side orientated toward bearing location. Seal should be per- pendicular to reel shaft after installation. Greensmaster Flex 1800/1820/2100/2120 Page 7 − 23 Cutting Unit...

  • Page 142: Preparing Reel For Grinding

    1. Follow reel grinder manufacturer’s instructions to Blade Land Width Range 0.030 to 0.050 in (0.8 to 1.2 mm) grind cutting reel to Toro specifications (see Reel Grind- ing Specifications chart to the right). Additional reel Service Limit - 0.010 in (0.25 mm)

  • Page 143: Front Roller

    5. Center front roller to the cutting reel and secure to HOC arms with cap screws (item 1). 6. Adjust cutting unit (see Cutting Unit Operator’s Manual). 7. Install cutting unit to machine. Greensmaster Flex 1800/1820/2100/2120 Page 7 − 25 Cutting Unit...

  • Page 144: Rear Roller

    Install two (2) carriage screws and flange nuts to retain bracket in position. Do not fully tight- en flange nuts. Cutting Unit Page 7 − 26 Greensmaster Flex 1800/1820/2100/2120...
  • Page 145 This page is intentionally blank. Greensmaster Flex 1800/1820/2100/2120 Page 7 − 27 Cutting Unit...

  • Page 146: Roller Service

    This will preserve the patch lock feature in the new lock nuts. Use the new nuts only after new bearings and Figure 38 seals have been installed. 1. Bearing lock nut 3. Bearing 2. Black assembly washer Cutting Unit Page 7 − 28 Greensmaster Flex 1800/1820/2100/2120...
  • Page 147 2. Yellow assembly washer 4. Seal nut(s). 12.Install bearing lock nut with V−ring onto each end of the roller shaft. Torque lock nuts from 25 to 30 ft−lb (34 to 41 N−m). Greensmaster Flex 1800/1820/2100/2120 Page 7 − 29 Cutting Unit...
  • Page 148 This page is intentionally blank Cutting Unit Page 7 − 30 Greensmaster Flex 1800/1820/2100/2120...
  • Page 149 Groomer Brush ......Greensmaster Flex 1800/1820/2100/2120 Page 8 − 1 Belt Driven Groomer (Optional)

  • Page 150: Specifications

    The groomer drive assembly is attached to inch (0.8 to 15.7 mm) at mowing HOC range of 0.060 to the right side of the cutting unit. 0.750 inch (1.5 to 19.1 mm). Belt Driven Groomer (Optional) Page 8 − 2 Greensmaster Flex 1800/1820/2100/2120...

  • Page 151: General Information

    Greensmaster Flex ma- chine. Refer to this publication for additional information when servicing the groomer assembly. Greensmaster Flex 1800/1820/2100/2120 Page 8 − 3 Belt Driven Groomer (Optional)

  • Page 152: Troubleshooting

    5. The height−of−cut. 11. Stress periods for turf (e.g. high temperatures, high humidity, unusually high traffic). 6. The grooming depth. 7. The type of grass on the green. Belt Driven Groomer (Optional) Page 8 − 4 Greensmaster Flex 1800/1820/2100/2120...

  • Page 153: Grooming Reel Mechanical Problems

    Grooming depth is not equal on Adjust depth if necessary. Check both ends of grooming reel. and adjust cutting unit set up (level bedknife to reel, level rear roller to reel, set height−of−cut, etc.). Greensmaster Flex 1800/1820/2100/2120 Page 8 − 5 Belt Driven Groomer (Optional)

  • Page 154: Adjustments

    5. Repeat step 4 on the opposite end of the groomer. Then, recheck setting on the first side of groomer. Height setting on both ends of groomer should be identi- cal. Belt Driven Groomer (Optional) Page 8 − 6 Greensmaster Flex 1800/1820/2100/2120...

  • Page 155: Service And Repairs

    5. Secure belt cover to machine with three (3) lock nuts (Fig. 2). Figure 3 1. Drive pulley 4. Driven pulley 2. Idler pulley 5. Groomer drive belt 3. Idler pulley nut Greensmaster Flex 1800/1820/2100/2120 Page 8 − 7 Belt Driven Groomer (Optional)

  • Page 156: Groomer Cover (Counter Rotating Groomer Drive)

    Figure 5 1. Groomer cover 6. Plunger detent 2. Plug 7. Cap screw 3. Shaft 8. Retaining ring 4. O−ring 9. Set screw 5. Thrust washer 10. Handle Belt Driven Groomer (Optional) Page 8 − 8 Greensmaster Flex 1800/1820/2100/2120...
  • Page 157 (142 grams) of Mobil XHP221 grease (or equivalent). C. Install new gasket and then groomer cover as- sembly to RH drive plate. Secure cover with five (5) flange head screws. Greensmaster Flex 1800/1820/2100/2120 Page 8 − 9 Belt Driven Groomer (Optional)

  • Page 158: Grooming Reel (Forward Rotating Groomer Drive)

    Engage parking brake. groomer arm lift rod to RH drive plate assembly (Fig. 8). 2. Remove the cutting unit from the machine and place cutting unit on a flat work area. Belt Driven Groomer (Optional) Page 8 − 10 Greensmaster Flex 1800/1820/2100/2120...
  • Page 159 5. Position groomer shim (item 8) to RH drive plate as- with lock nut (item 1). Torque lock nut from 17 to 21 ft−lb sembly. (24 to 28 N−m). Greensmaster Flex 1800/1820/2100/2120 Page 8 − 11 Belt Driven Groomer (Optional)
  • Page 160 (item 16) and HOC nut (item 21). 14.Secure RH groomer arm assembly to RH drive plate with spring washer (item 12) and lock nut (item 13). Belt Driven Groomer (Optional) Page 8 − 12 Greensmaster Flex 1800/1820/2100/2120...
  • Page 161 This page is intentionally blank. Greensmaster Flex 1800/1820/2100/2120 Page 8 − 13 Belt Driven Groomer (Optional)

  • Page 162: Grooming Reel (Counter Rotating Groomer Drive)

    7. Loosen cap screws (item 7) that secure front roller 3. Make sure that handle on groomer cover is rotated shaft to groomer arms. toward front of machine so that groomer drive is en- gaged. Belt Driven Groomer (Optional) Page 8 − 14 Greensmaster Flex 1800/1820/2100/2120...
  • Page 163 1. Roller cap screw 4. Spring washer 2. Grooming reel assembly 5. Groomer arm lift rod side plate. 3. Lock nut Greensmaster Flex 1800/1820/2100/2120 Page 8 − 15 Belt Driven Groomer (Optional)
  • Page 164 NOTE: After greasing groomer bearings, operate groomer for 30 seconds, stop machine and wipe excess 9. Install extension spring to RH drive plate assembly grease from groomer shaft and seals. (Fig. 11). Belt Driven Groomer (Optional) Page 8 − 16 Greensmaster Flex 1800/1820/2100/2120...

  • Page 165: Grooming Reel Service

    5. Install grooming reel back onto cutting unit (see CENTER BLADES ON SHAFT Grooming Reel Installation in this section). Figure 17 1. Lock nut 2. Grooming shaft Greensmaster Flex 1800/1820/2100/2120 Page 8 − 17 Belt Driven Groomer (Optional)

  • Page 166: Grooming Reel Bearing Replacement

    Seal lips (toward center of cutting unit) Figure 20 1. RH drive plate assy 3. Seal (2 used) 2. Bearing (2 used) Belt Driven Groomer (Optional) Page 8 − 18 Greensmaster Flex 1800/1820/2100/2120...
  • Page 167 1. Outer bearing 5. Seal lip 2. Drive plate shoulder 6. Support plate bearing 3. Inner bearing 7. Drive plate (RH side) 4. Inner race 8. Support plate (LH side) Greensmaster Flex 1800/1820/2100/2120 Page 8 − 19 Belt Driven Groomer (Optional)

  • Page 168: Idler Assembly (Forward Rotating Groomer Drive)

    5. RH drive plate 9. Bearing (2 used) 2. Spacer 6. O−ring 10. Retaining ring 3. Idler bracket 7. Retaining ring 11. Idler pulley 4. Spacer 8. Grease fitting 12. Lock nut Belt Driven Groomer (Optional) Page 8 − 20 Greensmaster Flex 1800/1820/2100/2120...
  • Page 169 2. Install drive pulley, drive belt and belt cover to right side of mower (see Grooming Reel Installation in this section). 3. Check and adjust grooming reel height and mower height−of−cut settings. Greensmaster Flex 1800/1820/2100/2120 Page 8 − 21 Belt Driven Groomer (Optional)

  • Page 170: Idler Assembly (Counter Rotating Groomer Drive)

    4. Remove RH drive plate assembly from right side of torqued. Do not install idler gears, extension spring or cutting unit (see Grooming Reel (Counter Rotating groomer cover assembly to drive plate assembly. Groomer Drive) in this section). Belt Driven Groomer (Optional) Page 8 − 22 Greensmaster Flex 1800/1820/2100/2120...
  • Page 171 5. Plate bearing location 3. Adjustment cam 120 in−lb (13.5 N−m) Figure 29 1. RH drive plate assy 3. 43T idler gear/bearing 2. Flange nut 4. 47T idler gear/bearing Greensmaster Flex 1800/1820/2100/2120 Page 8 − 23 Belt Driven Groomer (Optional)

  • Page 172: Lift Arm Assembly

    15. Groomer plate (LH shown) 4. E−ring 10. Spring washer 16. Lock nut 5. Groomer lift rod 11. Cap screw 17. Spring washer 6. Lock screw 12. Bushing 18. Bushing Belt Driven Groomer (Optional) Page 8 − 24 Greensmaster Flex 1800/1820/2100/2120...
  • Page 173 Figure 30 are the same on both sides of cutting unit. NOTE: Grooved pin (item 3) is used to retain lock screw (item 6) to lift arm assembly. Greensmaster Flex 1800/1820/2100/2120 Page 8 − 25 Belt Driven Groomer (Optional)

  • Page 174: Groomer Brush

    Make sure that the J−bolts are installed with the threaded portion on the outside of the brush (Fig. 32). 1. J−bolt 2. Lock nut Torque lock nuts from 20 to 25 in−lb (2.3 to 2.8 N−m). Belt Driven Groomer (Optional) Page 8 − 26 Greensmaster Flex 1800/1820/2100/2120...
  • Page 175 The Gear Box Assembly ........................9–9 Idler Assembly ..........................9–16 Groomer Reel ..........................9–19 Servicing the Groomer Reel ......................9–21 Height Adjuster Assembly ........................ 9–23 Servicing the Grooming Brush (Optional)..................9–25 Greensmaster Flex 1800/1820/2100/2120 Page 9–1 Universal Groomer (Optional) 12188SL Rev D...

  • Page 176: Specifications

    Allows grooming reel to be raised above the height/depth adjustment for no grooming reel action while mowing. The groomer drive assembly is attached to the Groomer drive right side of the cutting unit. Universal Groomer (Optional): Specifications Page 9–2 Greensmaster Flex 1800/1820/2100/2120 12188SL Rev D...

  • Page 177: General Information

    Greensmaster eFlex machine. Refer to this publication for additional information when servicing the groomer assembly. Greensmaster Flex 1800/1820/2100/2120 Page 9–3 Universal Groomer (Optional): General Information 12188SL Rev D...

  • Page 178: Troubleshooting

    9. The overall turf management program—irrigation, fertilizing, weed control, coring, over-seeding, sand dressing, disease control, and pest control. 10. Stress periods for turf—high temperatures, high humidity, and unusually high traffic. Universal Groomer (Optional): Troubleshooting Page 9–4 Greensmaster Flex 1800/1820/2100/2120 12188SL Rev D...

  • Page 179: Groomer Reel Mechanical Problems

    Check and adjust the cutting reel. unit set up (level bed knife to reel, level rear roller to reel, set the height-of-cut, etc.). Greensmaster Flex 1800/1820/2100/2120 Page 9–5 Universal Groomer (Optional): Troubleshooting 12188SL Rev D...

  • Page 180: Special Tools

    Special tools for servicing Toro Commercial Products are available from your Toro Distributor. Some of these tools may have been supplied with your machine, are available as Toro parts, or may also be available from a local tool supplier. Reel Thread Repair Taps 15/16–16 Right-Hand Thread –...
  • Page 181 Syringe – 50cc (2 ounce) Toro Part No. 137-0872 Aids in accurately filling the optional Universal Groomer gear box with oil. Greensmaster Flex 1800/1820/2100/2120 Page 9–7 Universal Groomer (Optional): Special Tools 12188SL Rev D...

  • Page 182: Service And Repairs

    Note: The Groomer Operator’s Manual provides information regarding the installation, set-up, operation, and maintenance of the universal groomer on your machine. Refer to these instructions for additional information when servicing the groomer. Universal Groomer (Optional): Service and Repairs Page 9–8 Greensmaster Flex 1800/1820/2100/2120 12188SL Rev D...

  • Page 183: The Gear Box Assembly

    (page 9–19). 3. Remove the drive shield. 4. Install a 5/16–18 X 5/8 inch square head set screw (Toro p/n 1-803022) in the end of the drive shaft and tighten to 13 N·m (120 in-lb); refer to Figure 5. Remove the cotter pin and clevis pin from the height adjustment rod at the front of the groomer gear box.
  • Page 184 Universal Groomer (Optional): Service and Repairs Page 9–10 Greensmaster Flex 1800/1820/2100/2120 12188SL Rev D...
  • Page 185 F. Slide the groomer housing assembly from the drive shaft. G. Tip up the cutting unit to access the bottom of the reel to remove the drive shaft assembly. Greensmaster Flex 1800/1820/2100/2120 Page 9–11 Universal Groomer (Optional): Service and Repairs...
  • Page 186 12. Clean the threads in the end of the reel shaft. A right-hand thread and left-hand thread tap is available to clean or repair the threads if necessary; refer to Reel Thread Repair Taps (page 9–6). Universal Groomer (Optional): Service and Repairs Page 9–12 Greensmaster Flex 1800/1820/2100/2120 12188SL Rev D...
  • Page 187 Thrust washer Locknut O-ring Driver gear O-ring Bearing (2 each) Dowel pin (2 each) Oil seal Drain/fill plug (4 each) Driven shaft Straight bushing (2 each) Shield Greensmaster Flex 1800/1820/2100/2120 Page 9–13 Universal Groomer (Optional): Service and Repairs 12188SL Rev D...
  • Page 188 The gear box oil capacity is 50 ml (1.7 fluid ounces). 15. Operate the groomer gear box by hand to check for proper operation prior to installation. Universal Groomer (Optional): Service and Repairs Page 9–14 Greensmaster Flex 1800/1820/2100/2120 12188SL Rev D...
  • Page 189 6. Remove the square head set screw from the end of the drive shaft. 7. Install the clevis pin and a new cotter pin to secure the height adjustment rod to the front of the groomer gear box. Greensmaster Flex 1800/1820/2100/2120 Page 9–15 Universal Groomer (Optional): Service and Repairs...

  • Page 190: Idler Assembly

    4. Remove the cotter pin and clevis pin from the height adjustment rod at the front of the idler arm and remove the idler assembly from the cutting unit. Discard the cotter pin. Universal Groomer (Optional): Service and Repairs Page 9–16 Greensmaster Flex 1800/1820/2100/2120 12188SL Rev D...
  • Page 191 4. Install reel drive assembly, reel pulley, reel drive belt and then reel drive cover to left side of cutting unit (see Reel Drive Assembly in the Service and Repairs section of Chapter 4 - Traction and Reel Drive System). Greensmaster Flex 1800/1820/2100/2120 Page 9–17 Universal Groomer (Optional): Service and Repairs...

  • Page 192: Groomer Reel

    2. Position the groomer reel between the groomer output and stub shafts. Universal Groomer (Optional): Service and Repairs Page 9–18 Greensmaster Flex 1800/1820/2100/2120 12188SL Rev D...
  • Page 193 5 to 7 N∙m (45 to 60 in-lb). 4. Check the groomer reel height and mower height-of-cut settings. Adjust as necessary. Greensmaster Flex 1800/1820/2100/2120 Page 9–19 Universal Groomer (Optional): Service and Repairs 12188SL Rev D...

  • Page 194: Servicing The Groomer Reel

    Figure 11 Groomer reel shaft Spacer (39 each) Groomer blade (40 each) Locknut (2 each) 3. Remove the locknut from either end of the shaft (Figure 11). Universal Groomer (Optional): Service and Repairs Page 9–20 Greensmaster Flex 1800/1820/2100/2120 12188SL Rev D...
  • Page 195 5. Install the O-ring on the non-drive end of the groomer shaft. 6. Install the groomer reel back onto the cutting unit; refer to Installing the Groomer Reel (page 9–18). Greensmaster Flex 1800/1820/2100/2120 Page 9–21 Universal Groomer (Optional): Service and Repairs 12188SL Rev D...

  • Page 196: Height Adjuster Assembly

    5. Disassemble the height adjuster assembly (Figure 12). 6. Clean all the components and inspect for wear or damage. Replace all the components that are worn or damaged. Universal Groomer (Optional): Service and Repairs Page 9–22 Greensmaster Flex 1800/1820/2100/2120 12188SL Rev D...
  • Page 197 7. Adjust the flange nuts (item 8 in Figure 12) on the groomer height adjustment rods until the springs are compressed to 16 mm (0.625 inch). Greensmaster Flex 1800/1820/2100/2120 Page 9–23 Universal Groomer (Optional): Service and Repairs 12188SL Rev D...

  • Page 198: Servicing The Grooming Brush (Optional)

    When assembling the spiral brush to the shaft, ensure that the J-bolts are installed with the threaded portion on the outside of the brush and tighten the locknuts to 2.3 to 2.8 N∙m (20 to 25 in-lb). Universal Groomer (Optional): Service and Repairs Page 9–24 Greensmaster Flex 1800/1820/2100/2120 12188SL Rev D...

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