Toro Greensmaster eFlex 1021 Service Manual
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Toro Greensmaster eFlex 1021 Service Manual

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© 2021—The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
Greensmaster
(Model 04861)
Form No. 20248SL Rev A
®
eFlex 1021
Contact us at www.Toro.com.
Original Instructions (EN)
All Rights Reserved

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  • Page 1 Form No. 20248SL Rev A Greensmaster ® eFlex 1021 (Model 04861) © 2021—The Toro® Company Original Instructions (EN) 8111 Lyndale Avenue South Contact us at www.Toro.com. Bloomington, MN 55420 All Rights Reserved...
  • Page 2 Revision History Revision Date Description Initial issue. 05/2021 Revision History Page 2 Greensmaster ® eFlex 1021 20248SL Rev A...
  • 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 servicemanuals@toro.com...
  • Page 4 NOTES NOTES Page 4 Greensmaster ® eFlex 1021 20248SL Rev A...
  • Page 5 Service Manual for reference. Additional copies of the Operator’s Manuals, Installation Instructions and Parts Catalogs are available at www.toro.com. The Toro Company reserves the right to change the product specifications or this publication without notice. DANGER This safety symbol means danger.
  • Page 6 g340146 Figure 1 Preface Page 6 Greensmaster ® eFlex 1021 20248SL Rev A...
  • Page 7 Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S. components) that may have been removed.

  • Page 8: Table Of Contents

    Table of Contents Preface ........................ 5 Chapter 1: Safety .................... 1–1 Safety Instructions ..................1–2 Safety and Instructional Decals ..............1–5 Chapter 2: Specifications and Maintenance ............ 2–1 Specifications ....................2–2 Torque Specifications ................... 2–5 Shop Supplies .................... 2–11 Special Tools ....................2–13 Chapter 3: Troubleshooting ................
  • Page 9 Chapter 1 Safety Table of Contents Safety Instructions ..........................1–2 Safety and Instructional Decals ......................1–5 Greensmaster ® eFlex 1021 Page 1–1 Safety 20248SL Rev A...

  • Page 10: Safety Instructions

    Safety Instructions The Greensmaster eFlex 1021 machine is tested and certified by Toro for compliance with existing safety standards and specifications. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, these factors are also dependent on the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
  • Page 11 – Use only Toro-specified lithium-ion battery packs designed for your machine. Do not mix battery of any brand or type in Toro products. – Use only the Toro-specified lithium-ion charger designed to charge your machine. Do not attempt to use any other battery charger.
  • Page 12 – Do not work under a suspended load. – Ensure chock blocks are used on equipment that can move. – Use lifts or jacks and jack stands that are rated to support the total weight of the machine and any attachments. –...

  • Page 13: Safety And Instructional Decals

    Numerous safety and instruction decals are affixed to the traction unit and cutting units of your Groundsmaster. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog. Order replacement decals from Authorized Toro Distributor. Greensmaster ®...
  • Page 14 Safety: Safety and Instructional Decals Page 1–6 Greensmaster ® eFlex 1021 20248SL Rev A...
  • Page 15 Chapter 2 Specifications and Maintenance Table of Contents Specifications ............................2–2 Overall Dimensions..........................2–2 Traction and Reel Drive Systems ....................... 2–3 Controls, Wheels and Accessories ....................2–3 DPA Cutting Units ..........................2–3 Universal Groomer..........................2–4 Torque Specifications ........................... 2–5 Calculating the Torque Values When Using a Drive-Adapter Wrench ..........2–6 Identifying the Fastener........................

  • Page 16: Specifications

    Specifications Overall Dimensions g340580 Figure 2 Specifications and Maintenance: Specifications Page 2–2 Greensmaster ® eFlex 1021 20248SL Rev A...

  • Page 17: Traction And Reel Drive Systems

    35 kg (77 lbs) 14 blade 35 kg (77 lbs) 36.3 kg (80 lbs) Options: Refer to the Cutting Unit Parts Catalog or contact your local Authorized Toro Distributor for available cutting unit options. Greensmaster ® eFlex 1021 Page 2–3...

  • Page 18: Universal Groomer

    Universal Groomer Item Description Grooming reel diameter 6 cm (2.375 inch) Groomer mounting The drive assembly for the grooming reel is located on the opposite side of the cutting unit from the belt drive. Groomer height setting Mowing: 0.8 to 15.7 mm (0.030 to 0.620 inch). HOC range: 1.5 to 19.1 mm (0.060 to 0.750 inch).

  • Page 19: Torque Specifications

    Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual.

  • Page 20: Calculating The Torque Values When Using A Drive-Adapter Wrench

    Calculating the Torque Values When Using a Drive-Adapter Wrench g205924 Figure 3 Torque Conversion Factor = A / B Torque wrench A (effective length of torque wrench) Drive-adapter wrench (crowsfoot) B (effective length of torque wrench and drive-adapter wrench) Using a drive-adapter wrench (e.g., crowfoot wrench) in any position other than 90°...

  • Page 21: Identifying The Fastener

    Toro recommends replacing fasteners with a locking feature once they have been removed because the effectiveness of the locking feature diminishes with each reuse. If it is necessary to reuse a fastener with a locking feature; apply a thread locking compound (Loctite for example) to the fastener during installation.

  • Page 22: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch Series)

    Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, and 8 with Studs, and Sems with Studs, and Sems with Studs, and Sems with Thin Height Regular Height Nuts...

  • Page 23: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Metric Fasteners)

    Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Class 10.9 Bolts, Screws, and Thread Size Studs with Regular Height Nuts Studs with Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8 57 ±...

  • Page 24: Other Torque Specifications

    Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 3/8 - 16 UNC 35 ±...

  • Page 25: Shop Supplies

    Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply.
  • Page 26 GASKET COMPOUND Used to create a seal between mating parts. Gasket compounds may be used with or without the presence of a pre-formed gasket. Gasket compounds may be solvent or silicone based, and cure when exposed to air or designed to cure in an air-less environment (anaerobic). Most gasket compounds are designed to be applied to clean surfaces free of oil, chemical residue and previously used gaskets or gasket compounds.

  • Page 27: Special Tools

    This excess current can damage the circuits that are not designed to carry it. Dielectric Gel Toro Part No. 107-0342 Use the dielectric gel to prevent corrosion of unsealed connection terminals. To ensure complete coating of the...
  • Page 28 Cutting Performance Paper Toro Part No. 125–5610 (300 strips) Cutting performance paper is used to test the cutting reel performance after adjusting the reel to bedknife clearance. Backlapping Brush Assembly K Line Part No.
  • Page 29 Reel Thread Repair Taps 15/16–16 Right-Hand Thread – Toro Part No. 137–0926 15/16–16 Left-Hand Thread – Toro Part No. 137–0927 Use to clean or repair the internal threads of cutting unit reels. Angle Indicator and Magnetic Mount Angle Indicator: Toro Part No. 131-6828 Magnetic Mount: Toro Part No.
  • Page 30 Bedknife Screw Tool K-Line Part No. TOR510880A This screwdriver-type bit is made to fit Toro bedknife attaching screws. Use this bit with a torque wrench to secure the bedknife to the bedbar. IMPORTANT Important: To prevent damage to the bedbar, DO NOT use an air or manual impact wrench with this tool.
  • Page 31 This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the Turf Evaluator (Toro part no. 97931SL) available from your local authorized Toro Distributor.
  • Page 32 Lithium-Ion Battery Shipping Kit Toro Part No. 137–9650 Use the original packaging or the battery shipping kit and a certified carrier to ship one of the lithium-ion batteries. The kit includes the appropriate carton, packing, labels, and instructions necessary to confirm to current lithium-ion battery shipping regulations in the USA.
  • Page 33 Chapter 3 Troubleshooting Table of Contents GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems ......3–2 Gather Information ..........................3–2 Evaluate Potential Causes ......................... 3–2 Assess Performance.......................... 3–2 Repair ..............................3–2 Solution Confirmation......................... 3–2 Operator Advisories..........................3–3 Machine Faults ............................

  • Page 34: Gears - The Systematic Approach To Defining, Diagnosing And Solving Problems

    GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems Gather Information • Information reported by the customer • Information observed by you • Establish the what, where and when of the issue Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis •...

  • Page 35: Operator Advisories

    Operator Advisories g339631 Figure 9 Advisory name Advisory identification Operator advisories are automatically displayed by the InfoCenter when a machine function requires additional action (Figure 9). An advisory will not be logged into the fault log. The InfoCenter advisories include the following: #201 (System Shutdown): This advisory notifies the operator that the machine is shutting down.
  • Page 36 #212 (Motor Disabled): The motor disabled advisory will identify that electric motor operation was stopped by the controller. A fault should have been generated that will provide additional information as to cause of the issue. #213 (Disengage Traction): This advisory notifies the operator that the bail lever is engaged and needs to be released before operation can be continued.

  • Page 37: Machine Faults

    Machine Faults Faults --32.6 Ago Clear System Faults g339627 Figure 10 Left/right button Fault items Down button Fault menu Menu/back button The faults screen (Figure 10) will list all the machine electrical faults that have occurred since the faults were last cleared from the InfoCenter. The faults will be identified by a number and when the fault occurred.
  • Page 38 Motor will likely need replacing if the fault continues. Software One of the devices in the Use Toro DIAG to reprogram the Incompatible system has software that is machine. incompatible. Key Stuck Master The battery has detected Verify the battery is charged.
  • Page 39 Fault Table (continued) Fault Fault Title Additional Controller Fault Condition/Circuit Service Actions Number Affected Description Notes Software Master The software has detected Try rebooting machine, Error an issue with reading the disconnect and reconnect the battery, look for short circuits throttle sensor.

  • Page 40: Battery Charger Error And Fault Codes

    Ensure that the battery is in good condition. Code E-0-0-4 Lithium-ion battery controller (BMS) or Contact an Authorized Toro Distributor battery fault detected for assistance. Code E-0-0-7 Battery amp hour limit exceeded Check all battery cable connections for corrosion or damage.

  • Page 41: Electrical System Problems

    Electrical System Problems CAUTION Remove all the jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. For the effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components that are used on this machine;...
  • Page 42 Machine is Inoperative and InfoCenter Power Light Indicates That a Fault Has Occurred Possible Causes Correction System fault has been detected by controller. Use the Faults screen information in the InfoCenter section of this chapter to help identify source of problem. An electrical fault occurred that can be reset Attempt to restart the machine to see if the by the controller.

  • Page 43: Aftercut Appearance

    Note: For additional information regarding cutting unit troubleshooting, a number of Reel Mower and Aftercut Appearance General Training Books can be found on the Service Reference Set available from your Authorized Toro Distributor. Factors That Can Affect Quality of Cut...

  • Page 44: Factors Affecting Grooming

    Factors Affecting Grooming There are a number of factors that can affect the performance of grooming. These factors vary for different golf courses and from green to green. It is important to inspect the turf frequently and vary the grooming practice with turf needs.

  • Page 45: Grooming Reel Mechanical Problems

    Grooming Reel Mechanical Problems Problem Possible Causes Correction Groomer not engaged. Groomer drive gears are worn Inspect groomer drive or damaged. assembly and replace damaged drive components. The turf is damaged or has The groomer is set too Refer to groomer Installation uneven grooming.
  • Page 46 Troubleshooting: Battery Charger Error and Fault Codes Page 3–14 Greensmaster ® eFlex 1021 20248SL Rev A...
  • Page 47 Chapter 4 Traction and Reel Drive Systems Table of Contents General Information ..........................4–2 Disengaging The Drum Drive From Transmission................4–2 Adjustments ............................4–3 Adjusting the Reel Drive Belt......................4–3 Service and Repairs ..........................4–5 Reel Drive Belt ........................... 4–5 Reel Drive Assembly..........................

  • Page 48: General Information

    General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine. Disengaging The Drum Drive From Transmission g335307 Figure 11 Transmission gear box assembly Traction engage/disengage lever The traction drum is driven by series of spur gears inside the transmission gear box assembly.

  • Page 49: Adjustments

    Adjustments g312311 Figure 12 Reel drive box assembly Carriage bolt Socket head screw (4 each) Reel belt Bolt Gasket Idler arm Reel drive cover Adjusting the Reel Drive Belt 1. Park the machine on a level surface. Disconnect the battery pack; refer to Connecting the Lithium Battery Pack (page 5–3).
  • Page 50 Adjusting the Reel Drive Belt (continued) 4. Adjust belt (2) tension as follows: A. Loosen the bolt (4) and rotate the idler arm (3) to release the tension on the reel drive belt (2). B. Pivot the idler arm (3) clockwise against the backside of the belt and apply a torque 3.9 to 4.5 N∙m (35 to 40 in-lb) to internal hex socket on the idler arm (3) and tighten the nut of carriage bolt (4).

  • Page 51: Service And Repairs

    Service and Repairs Reel Drive Belt g312311 Figure 13 Reel drive box assembly Carriage bolt Socket head screw (4 each) Reel belt Bolt Gasket Idler arm Reel drive cover The greensmaster machines use a positive drive belt on the right side of the machine to operate the cutting unit.
  • Page 52 Removing the Reel Drive Belt (continued) 5. Remove the reel drive belt (2) from the pulleys. Installing the Reel Drive Belt 1. Ensure that the carriage bolt (4) is loose enough to move the idler arm (3) freely. 2. Place the new drive belt (2) onto the pulleys. 3.

  • Page 53: Reel Drive Assembly

    Reel Drive Assembly g312399 Figure 14 Expansion plug Hipro key Reel drive cover Reel shaft-driver Washer Reel drive gasket Helical coupling Reel drive housing Retaining ring Spring pin (2 each) Socket head screw (2 each) Ball bearing (2 each) Coupler shaft Reel pulley - 24 tooth Carriage bolt Snap ring...
  • Page 54 Removing the Reel Drive Assembly (continued) 3. Remove the reel drive belt; refer to Removing the Reel Drive Belt (page 4–5). 4. Remove and discard the reel drive gasket (3) from the housing (25). 5. If necessary remove the expansion plug (1) from the reel drive cover (2). 6.
  • Page 55 Installing the Reel Drive Assembly Note: Refer to Figure 14 during the procedure. 1. Use a press to install the 4 ball bearings (items 2 and 5 in Figure 15) into the reel drive housing (6). 2. Secure the ball bearings with 2 retaining rings (item 3 and 4 in Figure into the reel drive housing (6).
  • Page 56 Installing the Reel Drive Assembly (continued) 21. Install the reel drive housing (25) onto the cutting deck and secure with the bolt (10), 2 socket head screws (26) and nuts (19). 22. If removed, install the expansion plug (1) into the reel drive cover (2). 23.

  • Page 57: Drum Drive Gear Box Assembly

    Drum Drive Gear Box Assembly g335443 Figure 17 Transmission gear box assembly Drive tube Splined coupler Traction drum Frame assembly Truss screw Shoulder bolt (3 each) Shoulder bolt LH hex shaft RH hex shaft Drum drive gear box assembly Washer Removing the Drum Drive Gear Box Assembly Note: Refer to Figure 17...
  • Page 58 Removing the Drum Drive Gear Box Assembly (continued) 4. Remove the shoulder bolt (8) that secures the RH drum drive gear box assembly (5) to the frame assembly (7). 5. Remove the 3 shoulder bolts (3) that secures the RH drum drive gear box assembly (5) to the traction drum (2).
  • Page 59 Disassembly of Drum Drive Gear Box Assembly g258844 Figure 18 Oil seal Drum drive housing Washer Drum drive cover Retaining ring Outer drum hub Socket head screw (5 each) Oil seal V-ring seal Plug (2 each) Retaining ring Drum drive shaft Flange nut O-ring Ball bearing (2 each)
  • Page 60 Disassembly of Drum Drive Gear Box Assembly (continued) 5. Remove the nut (12) that secures the spur gear (11) to the drum drive shaft (5). Slide and remove the spur gear (11) from the drum drive shaft (5). Locate and retrieve the key (30) from the drum drive shaft (5). 6.
  • Page 61 Assembly of Drum Drive Gear Box Assembly g263151 Figure 19 1. Install the ball bearings (23), wave washer (24) and spur gear (21) to the drum drive housing (25). Note: The outer diameter and inner diameter of the ball bearings (23) must be slip fit.
  • Page 62 Assembly of Drum Drive Gear Box Assembly (continued) 12. Install the drum drive cover (14) to the drum drive housing (25) and secure with 5 socket head screws (15). Torque tighten the socket head screws to 1.7 to 4.5 N∙m (15 to 40 in-lb). Use an alternation pattern and torque tighten the socket head screws to 9.6 to 10.7 N∙m (85 to 95 in-lb).

  • Page 63: Drum Assembly

    Drum Assembly g335443 Figure 20 Transmission gear box assembly Drive tube Splined coupler Traction drum Frame assembly Truss screw Shoulder bolt (3 each) Shoulder bolt LH hex shaft RH hex shaft Drum drive gear box assembly Washer Removing the Drum Assembly Note: Refer to Figure 20 during this procedure.
  • Page 64 Disassembly of Drum Drive Assembly g258879 Figure 21 Traction drum (2 each) Drum spindle Spacer Bolt (8 each) Seal (2 each) Drum hub Lock washer (8 each) Ball bearing (2 each) Shoulder bolt (6 each) Drum hub plate (2 each) Spacer Lock nut Note: Refer to...
  • Page 65 Assembly of Drum Drive Assembly g258942 Figure 22 Drum hub Spacer Ball bearing (2 each) Spacer Drum spindle Lock nut Seal (2 each) Note: The seal side of each bearing (item 7 in Figure 22) should face inside of the drum hub; refer to Figure 1.
  • Page 66 Installing the Drum Drive Assembly 1. Park the machine on a level surface. Disconnect the battery pack; refer to Connecting the Lithium Battery Pack (page 5–3). 2. Position the LH and RH drum drive gear box assembly (item 5 in Figure and traction drum (2) onto the frame assembly (7).

  • Page 67: Transmission Gear Box Assembly

    Transmission Gear Box Assembly g335652 Figure 23 Truss screw (2 each) Transmission gear box assembly Socket head screw (3 each) Splined coupler (4 each) Helical coupling V-ring seal Washer (2 each) Spring pin (2 each) Lock nut (2 each) Coupler shaft Electric motor Drive shaft Compression Spring...
  • Page 68 Removing the Transmission Gear Box Assembly Note: Refer to Figure 23 during this procedure. 1. Park the machine on a level surface. Disconnect the battery pack; refer to Connecting the Lithium Battery Pack (page 5–3). 2. Disconnect the brake cable; refer to Removing the Brake Cable (page 6–4).
  • Page 69 Disassembling the Transmission Gear Box Assembly g339791 Figure 24 Retaining ring Grease seal Brake mount pin Spacer bushing Ball bearing (2 each) Transmission gasket O-ring Spacer Transmission cover Straight bushing (2 each) Oil seal (2 each) Socket head screw (12 each) Retaining ring (2 each) Oil seal Ball bearing (2 each)
  • Page 70 Disassembling the Transmission Gear Box Assembly (continued) 3. Remove the oil seal (6), retaining ring (5) from the transmission cover (23). Use a press to remove the ball bearing (25) from the transmission cover (23). Discard the oil seals and ball bearing. g339790 Figure 25 External retaining ring...
  • Page 71 Disassembling the Transmission Gear Box Assembly (continued) 9. If necessary, disassemble the differential assembly (14); refer to Disassembly of Differential Assembly (page 4–33). 10. Remove the bolt (25) that secures the cable brake lever (24) onto the brake lever (19). Slide and remove the cable brake lever (24) and external retaining ring (1) from the brake lever (19).
  • Page 72 Disassembling the Transmission Gear Box Assembly (continued) g339789 Figure 26 Short bearing pin Flange nut (2 each) Reel clutch shoe O-ring Wave spring Reel clutch actuator Long bearing pin Ball bearing (2 each) Spur gear Thin lock nut Bearing spacer (2 each) Retaining ring (2 each) Retaining ring (4 each) Reel drive shaft...
  • Page 73 Disassembling the Transmission Gear Box Assembly (continued) C. Slide and remove the slider spur gear (14) from the reel drive shaft (12). D. Remove the two key squares (13) from the reel drive shaft (12). 16. Remove the nut (8) and long bearing pin (3) that secures the spur gear assembly (7) to the transmission housing assembly (20).
  • Page 74 Assembling the Transmission Gear Box Assembly 1. Use a press to install the spacer (item 13 in Figure 24) and new ball bearings (12 and 25) into the transmission housing (26). 2. Install the retaining ring (item 5 in Figure 24) into the transmission housing (26).
  • Page 75 Assembling the Transmission Gear Box Assembly (continued) 19. Apply a coat of grease to the O-ring (item 2 in Figure 26) and slide the O-ring onto the long bearing pin (3). Install the spur gear assembly (7) and bearing spacer (4) onto the transmission housing assembly (20) and secure with the long bearing pin (3) and nut (8).
  • Page 76 Assembling the Transmission Gear Box Assembly (continued) 37. Insert the wave washer (item 3 in Figure 25) and neutral spur gear assembly (5) into the transmission housing assembly (23). Make sure that the traction selector shaft (item 19 in Figure 24) is engaged in shift selection neutral spur gear (item 5 in Figure...
  • Page 77 Installing the Transmission Gear Box Assembly Note: Refer to Figure 23 during this procedure. Install the electric motor (22) and motor adaptor (18) onto the transmission gear box assembly (6) and secure with the two socket head screws (19). 2. Position the transmission gear box assembly (10) onto the frame assembly and secure with 2 bolts (9) and a socket head screw (19).

  • Page 78: Differential Assembly

    Differential Assembly g339790 Figure 27 External retaining ring O-ring (2 each) Brake lever Pipe plug Retaining ring (2 each) O-ring Wave washer Flange bearing (2 each) Brake clevis pin Ball bearing (2 each) Ball bearing (2 each) Flat wire spring Neutral spur gear Differential assembly Transmission housing assembly...
  • Page 79 Disassembly of Differential Assembly g259978 Figure 28 Differential housing (2 each) Differential spur gear (6 each) Socket head screw (6 each) Differential pin (6 each) Differential gear 1. Remove the 6 socket head screws (item 5 in Figure 28) that secures the differential housing assembly (1) to the differential gear (4).
  • Page 80 Assembly of Differential Assembly 1. Place the differential housings (1) on the work bench. 2. Insert the 3 differential pins (2) in each differential housing. g260016 Figure 29 Differential spur gears with shoulder up Press flush 3. The differential pins (2) must be inserted in alternate holes of the differential housing (1) and ensure that the differential pins (2) are flush to the surface of the differential housing;...

  • Page 81: Chapter 5: Electrical System

    Electrical System Operation ........................5–4 Battery Charging ..........................5–4 Start Process ............................. 5–4 Run Process ............................5–5 CAN-bus Communications......................... 5–6 Toro Electronic Controller (TEC) ......................5–7 Lithium-Ion Battery Controller (BMS) ....................5–8 InfoCenter Display ........................... 5–10 Adjustments............................5–20 Traction Bail Proximity Sensor ......................5–20 Testing the Electrical Components.......................

  • Page 82: General Information

    General Information The Greensmaster eFlex 1021 machine uses a 48 VDC electrical system that is an isolated circuit. The machine frame is not used for any ground connections. After performing any repair on the machine electrical components, ensure that the wiring is routed and secured so as to prevent abrasion or contact with moving machine parts.

  • Page 83: Connecting The Lithium Battery Pack

    Connecting the Lithium Battery Pack WARNING Battery terminals, battery cables, or metal tools could short against metal components causing sparks. Sparks can cause the battery damage and high heat, resulting in personal injury. • When removing or installing the battery, do not allow the battery terminals or battery cables to touch any metal parts of the machine.

  • Page 84: Electrical System Operation

    The battery management system uses CAN communication with the TEC and battery charger. A Toro Electronic Controller (TEC) is used on the eFlex machines to manage the machine electrical functions. The controller is microprocessor controlled that senses the condition of various switches (inputs) and directs electrical power to control appropriate machine functions (outputs) based on the inputs.

  • Page 85: Run Process

    Run Process The traction bail lever controls the traction speed potentiometer. This traction speed potentiometer is used as an input by the TEC which communicates to the electric motor to engage. The motor rotation speed and traction speed is determined by the throttle potentiometer setting that is adjusted by the operator.

  • Page 86: Can-Bus Communications

    The Toro DIAG electronic control diagnostics service system is available to Authorized Toro Distributors to support machine fault diagnosis and maintenance services of the machine electrical control devices. The Toro DIAG connector is located inside the upper cover assembly; refer to...

  • Page 87: Toro Electronic Controller (Tec)

    Figure 32 Samsung SDI controller Lithium battery pack The Greensmaster machine use a Toro Electronic Controller (TEC) to manage the machine electrical functions. The controller is a microprocessor controlled device that senses the condition of various switches (inputs) and directs electrical power to control the appropriate machine functions (outputs) based on the inputs.

  • Page 88: Lithium-Ion Battery Controller (Bms)

    Lithium-Ion Battery Controller (BMS) g338267 Figure 33 Lithium-ion battery controller The machine uses a Lithium-ion battery controller or Battery Management System (BMS) to manage the lithium-ion battery. The lithium-ion battery communicate with the BMS through a sub-net via the battery interface harness. The battery interface harness includes a 4-pin connector at the battery and a 9-pin connector at the BMS.
  • Page 89 Opening the controller case may result in personal injury and property damage. Note: If the Lithium-Ion Battery Controller is replaced for any reason, the machine software must be updated; contact an Authorized Toro Distributor for assistance. Greensmaster ®...

  • Page 90: Infocenter Display

    Note: Icons that are used on the InfoCenter display are identified in the Traction Unit Operator’s Manual. Note: If the InfoCenter display is replaced for any reason, the machine software must be updated; contact an Authorized Toro Distributor for assistance. Electrical System: Electrical System Operation Page 5–10 Greensmaster ®...
  • Page 91 AFTER SECONDS MAIN INFORMATION SCREEN g339628 Figure 35 Greensmaster ® eFlex 1021 Page 5–11 Electrical System: Electrical System Operation 20248SL Rev A...
  • Page 92 Splash Screen g339634 Figure 36 Fault indicator Down button Hour meter Menu/back button Left/right button When the key switch is initially turned to the RUN or START position, the fault indicator illuminates for a few seconds to verify indicator operation and the InfoCenter splash screen appears (Figure 36).
  • Page 93 Main Information Screen (continued) The InfoCenter main information screen (Figure 37) is displayed after the initial splash screen has been displayed for 5 seconds. The main information screen is the default screen as it will be displayed during normal machine operation. The main information screen provides the following information to the operator: •...
  • Page 94 Operator Advisories g339631 Figure 39 Advisory name Advisory identification Operator advisories are automatically displayed by the InfoCenter when a machine function requires additional action (Figure 39). An advisory will not be logged into the fault log. (Refer to Operator Advisories (page 3–3)).
  • Page 95 Main Menu Screen (continued) • Settings • About Press the down button (as indicated by the at the bottom of the screen) to highlight the desired menu screen, then press the left/right button (as indicated by the at the bottom of the screen) to enter the highlighted menu screen. To return to the main information screen from the main menu screen, press the menu/back button (as indicated by the at the bottom of the screen).
  • Page 96 Service Screen Hours: 132.4 Hours Power Use: 29 Watts Battery Charge g339632 Figure 42 Left/right button Service items Down button Service menu Menu/back button The service screen (Figure 42) contains the following machine information: • Hours (hours that the key switch has been in the ON position) •...
  • Page 97 Diagnostics Screen agnostics art: Traction: g339626 Figure 43 Left/right button Diagnostics items Down button Diagnostics menu Menu/back button The diagnostics screen (Figure 43) lists the various states of the machine electrical components. The diagnostics screen should be used to check the operation of the machine switches and controls.
  • Page 98 Diagnostics Screen (continued) • 5V Supply indicates the supplied voltage available for the 5 VDC circuit. The 5V Supply should typically be slightly higher than 5.0 VDC. • CAN identifies whether the machine communication bus status is normal or not. •...
  • Page 99 About Screen About 04861 400000000 g339625 Figure 45 Left/right button About items Down button About menu Menu/back button The about screen (Figure 45) identifies the machine model number, serial number, and TEC software revision. To return to the main menu screen from the about screen, press the menu/back button (as indicated by the at the bottom of the screen).

  • Page 100: Adjustments

    Adjustments Traction Bail Proximity Sensor g349622 Figure 46 Jam nuts Clutch bail link Proximity sensor Adjusting the Traction Bail Proximity Sensor 1. Park the machine on a level surface. Ensure that the key switch is in OFF position and the traction control is in NEUTRAL. 2.

  • Page 101: Testing The Electrical Components

    Testing the Electrical Components Whenever possible, check the component circuit operation with the InfoCenter display on the console. With the key switch in the RUN position, use the InfoCenter diagnostics menu to ensure that the component state changes as the component is toggled. This quick check identifies that the component and circuit wiring are working as designed.

  • Page 102: Fuses

    Fuses g338648 Figure 47 Battery cover Washer head bolt (4 each) A group of fuses are used to protect the 12 VDC and 48 VDC systems and are located under the battery cover. Accessing the Fuse 1. Park the machine on a level surface and make sure that the clutch bail in the NEUTRAL position.
  • Page 103 Testing the Fuse 1. Access the fuse block as described above. 2. Carefully remove the fuse from the fuse block for testing. 3. The fuse should have continuity between the fuse terminals. IMPORTANT The eFlex machine uses special fuses that are rated for 80 V. If the fuse replacement is necessary, ensure to use the fuses as identified in your eFlex Parts Catalog.

  • Page 104: Can Bus

    2. Disconnect the battery pack; refer to Connecting the Lithium Battery Pack (page 5–3). 3. The Toro DIAG connector is located inside the upper cover assembly; refer Figure Electrical System: Testing the Electrical Components Page 5–24 Greensmaster ®...
  • Page 105 4. Refer to CAN-bus Terminator Resistor (page 5–39) and/or see electrical schematic and wire harness drawing in Appendix A (page A–1). If necessary, contact an Authorized Toro Distributor for assistance. Greensmaster ® eFlex 1021 Page 5–25 Electrical System: Testing the Electrical Components...

  • Page 106: Toro Electronic Controller (Tec)

    Figure 51 Samsung SDI controller Lithium battery pack The Greensmaster machine use a Toro Electronic Controller (TEC) to manage the machine electrical functions. The controller is a microprocessor controlled device that senses the condition of various switches (inputs) and directs electrical power to control the appropriate machine functions (outputs) based on the inputs.
  • Page 107 Toro Electronic Controller (TEC) (continued) g338695 Figure 52 The diagram in Figure 52 depicts the connection terminal functions of the TEC. Two wire harness connectors attach to the controller with each of the connectors including 12 pins. The connector pins are listed in the diagram.

  • Page 108: Lithium-Ion Battery Controller (Bms)

    The BMS is attached to the battery mount inside the battery cover. Note: If the Lithium–Ion Battery Controller is replaced for any reason, the machine software must be updated; contact an Authorized Toro Distributor for assistance. Testing the Lithium-Ion Battery Controller...
  • Page 109 Testing the Lithium-Ion Battery Controller (continued) g338794 Figure 55 Lithium-Ion battery controller B- terminal Positive (+) terminal Negative (–) terminal B+ terminal COM terminal M-S terminal Although there is no method to test the solid state circuitry built into the controller directly, some aspects of the lithium-ion battery controller operation can be tested as follows;...

  • Page 110: Electric Motor

    Note: If the electric motor is replaced for any reason, the machine software must be updated; contact an Authorized Toro Distributor for assistance. Testing the Electric Motor 1. Park the machine on a level surface and make sure that the clutch bail in the NEUTRAL position.

  • Page 111: Key Switch

    Key Switch g338795 Figure 57 Screw (4 each) InfoCenter mount InfoCenter display Key switch Handle The key switch allows the machine operation to be turned on and off. The key switch has 3 positions: OFF, RUN, and START. This switch is 1 of the several inputs for the TEC and is located on the InfoCenter mount (Figure 57).
  • Page 112 Testing the Key Switch (continued) g190999 Figure 58 5. With the use of a multimeter (ohms setting), test the switch functions to determine if continuity exists between the various terminals for each switch position. The switch terminals are marked as shown in Figure 58.

  • Page 113: Throttle Potentiometer And Clutch Bail Potentiometer

    Throttle Potentiometer and Clutch Bail Potentiometer g337125 Figure 59 Screw (4 each) Spacer (2 each) Extension spring InfoCenter display Control bail lever Spring tab Clevis pin Spacer (2 each) InfoCenter mount Lock nut Screw (2 each) Key switch Lock Throttle potentiometer sensor Bail catch fork Clutch bail potentiometer sensor Control bail lever...
  • Page 114 Checking the Operation of Throttle and Clutch Bail Potentiometers Check the operation of throttle and clutch bail potentiometers with the InfoCenter. With the key switch in the RUN position and the InfoCenter in the diagnostics menu, choose the Throttle and ensure that the displayed voltage changes as the speed wheel is rotated.
  • Page 115 Testing the Throttle and Clutch Bail Potentiometers (continued) 6. After you complete the testing, secure the potentiometers to the machine (Figure 59). Secure the wire harness connector to the potentiometer. Secure the handle cover to the handle. Note: When re-installing the potentiometers, a minimum voltage reading of 0.5V for proper function is required.

  • Page 116: Main Contactor

    Main Contactor g339029 Figure 61 Contactor Bolt (2 each) The Greensmaster eFlex machines use the main contactor to connect the lithium battery pack and the electric motor. The contactor is energized by the TEC. The contactor is attached to the battery mount under the battery cover; refer Figure Note: When the key switch is turned to the START position, the contactor inside the battery pack will be energized followed shortly by the main contactor...
  • Page 117 Testing the Main Contactor (continued) g202780 Figure 62 Main contact post Coil post 4. Ensure that the battery pack is disconnected. Use a multimeter to measure the resistance across the contactor posts as follows (Figure 62). A. Resistance across the main contact posts should be infinite ohms. B.
  • Page 118 Testing the Main Contactor (continued) g339028 Figure 63 Main contactor Coil post Main contact post 6. Use a multimeter to measure the voltage across the main contactor posts as follows: A. Position the rubber boots away from the main contactor posts to get access to the posts with multimeter probes (Figure 63).

  • Page 119: Can-Bus Terminator Resistor

    6. If the resistor test correctly and a circuit problem still exists, check the CAN-bus; refer to Testing the CAN bus (page 5–24), wire harness drawings Appendix A (page A–1) for additional information, or contact an Authorized Toro Distributor for assistance. Greensmaster ® eFlex 1021 Page 5–39 Electrical System: Testing the Electrical Components...

  • Page 120: Relay

    Relay g339075 Figure 65 Relay Washer Bolt The relay used on the eFlex machine is 4 terminal 48 V relay and located inside the battery cover and next to TEC controller; refer to Figure Testing the Relay 1. Park the machine on a level surface and make sure that the clutch bail in the NEUTRAL position.
  • Page 121 Testing the Relay (continued) 5. Using a multimeter (ohms setting), measure the coil resistance between terminals 85 and 86. The resistance should be from 990 to 1210 ohms. 6. Verify infinite resistance (no continuity) exists between terminals 30 and 87. 7.

  • Page 122: Service And Repairs

    Service and Repairs Electric Motor g339147 Figure 67 Frame assembly Motor adaptor Transmission gear box assembly Socket head screw (3 each) Electric motor Socket head screw (4 each) Closed cell foam seal Note: A damaged electric motor assembly may cause a #7, #8, #9, or #10 fault to be generated and displayed on the InfoCenter display.
  • Page 123 Removing the Electric Motor (continued) 5. Remove the 4 socket-head screws (item 3 in Figure 67) that secure the electric motor to the motor adaptor (4). 6. Carefully slide the electric motor from the transmission, and remove the motor from the machine. 7.

  • Page 124: Servicing The Electric Motor

    Servicing the Electric Motor g293229 Figure 68 Cap screw (6 each) Bearing Motor cover O-ring O-ring Housing assembly Wave washer Lip seal Bearing O-ring Rotor Note: If the motor housing, controller, or cable damage occurs, the electric motor replacement is necessary. These components are not available separately. Note: If problems with electric motor exist, an advisory or fault may be identified on the InfoCenter display.
  • Page 125 Motor rotor tool shaft Motor rotor tool base plate 4. Secure the base plate of the motor rotor tool (Toro part number 139-8420) to the housing with four M6 – 1.0 X 50 cap screws. 5. Install the rotor tool shaft into the base plate and turn it in against the rotor shaft.
  • Page 126 Assembling the Electric Motor (continued) 4. Lubricate new O-rings with dielectric lubricant and install the O-rings into the grooves in the motor cover. Place the wave washer in the cover bearing bore and fit the rotor assembly into the cover. 5.

  • Page 127: Lithium-Ion Battery Controller (Bms)

    Lithium-Ion Battery Controller (BMS) g349591 Figure 70 Bolt (4 each) Positive (+) battery cables Washer (4 each) Negative (-) battery cables Lithium-ion battery controller Nut (4 each) Removing and Installing Lithium-Ion Battery Controller (BMS) CAUTION To prevent accidentally shorting disconnected battery cables across other components or tools, insulate the battery cable terminals with 76 mm (3 inch) lengths of 1/2 inch internal diameter rubber hose immediately after disconnecting the cables.
  • Page 128 Removing and Installing Lithium-Ion Battery Controller (BMS) (continued) CAUTION Do not open the lithium-Ion battery controller. There are no serviceable parts on or in the lithium-ion battery controller case. If you open the controller case, you will void the warranty. The controller case is protected by tamper-alerting devices.
  • Page 129 10. Tighten the power supply and battery cable fasteners from 9 to 10 N·m (80 to 90 in-lb), then apply battery terminal protector Toro Part No. 107-0392 or a light layer of grease to the battery terminals and cable connectors to reduce corrosion.

  • Page 130: Lithium-Ion Battery Pack

    Use only Toro-specified lithium-ion battery packs designed for your machine. Do not mix batteries of any brand or type in Toro products. Failure to do so may result in personal injury and property damage.
  • Page 131 Storing the Lithium-Ion Battery Do not store the machine in a location where the temperature will drop below -25°C (-13°F) or rise above 45°C (113°F). Because storage temperature will affect the life of the battery pack, avoid storing the machine in temperatures outside of this range.
  • Page 132 Charging the Lithium-Ion Batteries WARNING When charging lithium-ion battery: • Use only the Toro-specified lithium-ion charger designed to charge your machine. Do not attempt to use any other battery charger. • Do not over-charge or over-discharge lithium-ion battery. Failure to follow these recommendations may result in personal injury and property damage.
  • Page 133 Removing the Lithium-Ion Battery (continued) WARNING When removing or installing the battery: • Do not allow the battery terminals or battery cables to touch any metal parts of the machine. • Do not allow metal tools to short between the battery terminals or battery cables and metal parts of the machine.
  • Page 134 Removing the Lithium-Ion Battery (continued) g339409 Figure 74 Negative (-) terminal Washer Lithium-ion battery Lock washer Positive (+) terminal 1. Park the machine on a level surface and make sure that the clutch bail in the NEUTRAL position. Turn the key switch to the OFF position and remove the key from the key switch.
  • Page 135 5. Tighten the battery cable fasteners (item 6 in Figure 74) from 8.4 to 9.6 N·m (75 to 85 in-lb), then apply battery terminal protector Toro Part No. 107-0392 or a light layer of grease to the battery terminals and cable connectors to reduce corrosion.
  • Page 136 Electrical System: Service and Repairs Page 5–56 Greensmaster ® eFlex 1021 20248SL Rev A...
  • Page 137 Chapter 6 Controls, Wheels and Accessories Table of Contents General Information ..........................6–2 Operator’s Manual ..........................6–2 Adjustments ............................6–3 Adjusting the Reel Cable........................6–3 Service and Repairs ..........................6–4 Replacing the Brake Cable ........................ 6–4 Replacing the Reel Cable ........................6–7 Cutting Unit Drive Lever Assembly.....................

  • Page 138: General Information

    General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, adjustment procedures, and general maintenance for your Greensmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine. Controls, Wheels and Accessories : General Information Page 6–2 Greensmaster ®...

  • Page 139: Adjustments

    Adjustments Adjusting the Reel Cable g336875 Figure 76 Retaining ring Jam nut Reel selector knob Reel cable g349621 Figure 77 Rear jam nut Reel cable Front jam nut 1. Park the machine on a level surface. Ensure that the key switch is in OFF position and the traction control is in NEUTRAL and parking brake is released.

  • Page 140: Service And Repairs

    Service and Repairs Replacing the Brake Cable g336874 Figure 78 Shoulder screw Upper receiver weldment Brake cable spring Flange bushing (2 each) Flange nut Jam nut Lever Handle assembly Brake cable Removing the Brake Cable Note: Refer to Figure 78 during this procedure.
  • Page 141 Removing the Brake Cable (continued) g336873 Figure 79 Retaining ring Brake lever Brake cable Cable eyelet Jam nut 3. Remove the brake cable (item 5 in Figure 79) from the brake lever shaft on the transmission gear box assembly as follows: A.
  • Page 142 Installing the Brake Cable (continued) side of the slot. Adjust and tighten the jam nuts so that equal amount of cable threads are visible above and below jam nuts. 3. Make final adjustment of the brake cable at the brake cable lever assembly. Adjust the cable jam nuts to remove the slack in the brake cable.

  • Page 143: Replacing The Reel Cable

    Replacing the Reel Cable g336876 Figure 80 Reel cable V-ring seal Clevis pin Jam nut Reel lever assembly Upper receiver weldment Cable spring Cotter pin clip Retaining ring Knob Split bushing Reel lever handle rod Clevis connector Removing the Reel Cable Note: Refer to Figure 80 during this procedure.
  • Page 144 Removing the Reel Cable (continued) 3. Remove the reel cable (item 4 in Figure 81) from the reel selector assembly (2) as follows: A. Loosen the front cable jam nut (3) and lift the reel cable (4) from the casting slot of the base. B.

  • Page 145: Cutting Unit Drive Lever Assembly

    Cutting Unit Drive Lever Assembly g336962 Figure 82 V-ring seal Lower handle cover Clevis connector Reel lever handle rod Reel cable Clevis pin (4 each) Knob Split bushing Extension spring Retaining ring Cotter pin clip Shoulder screw Control shaft clamp (2 each) Link assembly Reel lock lever assembly Socket head screw (4 each)
  • Page 146 Disassembling the Cutting Unit Drive Lever Assembly (continued) 3. Remove the bolts and washers (item 9 in Figure 82) that secures the control covers (item 8 and 10) to the upper receiver weldment (25) and handle assembly. 4. Remove the reel lever handle rod (2) from the reel lever assembly (27). 5.

  • Page 147: Brake Latch Shaft

    Brake Latch Shaft g336961 Figure 83 Shoulder bolt Roll pin Brake latch shaft Bolt Torsion spring Flange bushing (2 each) Lever Flange nut Flange bushing (2 each) Brake lock lever Flange nut Upper receiver weldment Disassembling the Brake Latch Shaft Note: Refer to Figure 83 during this procedure.
  • Page 148 Assembling the Brake Latch Shaft 1. Slide and position the torsion spring (10) onto the brake latch shaft (9). 2. Slide and position the brake latch shaft (9) into the upper receiver weldment (12). 3. Slide and position the brake lock lever (4) onto the brake latch shaft (9). Secure the brake lock lever with the roll pin (5).

  • Page 149: Handle Assembly

    Handle Assembly g337124 Figure 84 Throttle arm Flange nut Screw and washer assembly (2 each) Washer Clevis pin Bottom control cover Handle Bearing spacer Lift assist handle Shoulder screw Bolt Jam nut Flange bushing (2 each) Brake cable Bolt Lever Cotter pin Bolt Lower handle assembly...
  • Page 150 g337125 Figure 85 Screw (4 each) Spacer (2 each) Extension spring InfoCenter display Control bail lever Spring tab Clevis pin Spacer (2 each) InfoCenter mount Lock nut Screw (2 each) Key switch Lock Potentiometer sensor Bail catch fork Potentiometer sensor Control bail lever Clip pin (2 each) Mount...
  • Page 151 Disassembling the Handle Assembly Note: Refer to Figure 84 Figure 85 during this procedure. 1. Park the machine on a level surface. Ensure that the key switch is in OFF position and the traction control is in NEUTRAL. 2. Disconnect the battery pack; refer to Connecting the Lithium Battery Pack (page 5–3).
  • Page 152 Disassembling the Handle Assembly (continued) 25. Remove the handle adjuster assembly from the upper receiver weldment and separate handle torsion spring (23) and spring spacer (24) from the handle adjuster assembly (22). g337168 Figure 86 LH bail bracket Handle mount Spacer (2 each) Bolt (2 each) Flange nut (4 each)
  • Page 153 Disassembling the Handle Assembly (continued) 29. Remove the flange nut (8) and bolt (2) that secure the clutch bail assembly (4) to the handle mount (7). Remove the clutch bail assembly from the handle mount. Remove the compression spring (6), 2 flange bushings (3) and spacer tube (13) from the handle mount.
  • Page 154 Assembling the Handle Assembly (continued) 5. Position the compression spring (6), spacer tube (13) and 2 bushings (3) into the handle mount (7). Install the clutch bail assembly (4) to the handle mount (7) and secure with the bolt (2) and flange nut (8). 6.
  • Page 155 Assembling the Handle Assembly (continued) 28. Install the lower handle cover to the handle assembly and secure with the 4 bolts. 29. Install the control cover to the handle assembly and secure with the 4 bolts. 30. Connect the battery pack; refer to Connecting the Lithium Battery Pack (page 5–3).

  • Page 156: Kickstand

    Kickstand g337281 Figure 88 Lower handle assembly Dowel pin (4 each) Nut (2 each) LH torsion spring Frame assembly Kickstand Spring mount pin Spacer (2 each) Kickstand lock pin Bolt Bolt (2 each) Compression spring Bolt (2 each) E-ring Flat washer (2 each) Plain washer (2 each) Lock nut Spring retainer (2 each)
  • Page 157 Removing the Kickstand (continued) 1. Park the machine on a level surface. Ensure that the key switch is in OFF position and the traction control is in NEUTRAL. 2. Disconnect the battery pack; refer to Connecting the Lithium Battery Pack (page 5–3).

  • Page 158: Transport Wheels (Optional)

    Transport Wheels (Optional) g200275 Figure 90 Bolt (3 each) Deep rim Hub bushing Flange nut (4 each) Bolt (4 each) Shallow rim Torsion spring Lock washer (3 each) Tire Wheel retaining lever Inner tube Shoulder screw (2 each) Removing the Transport Wheel 1.
  • Page 159 Removing the Transport Wheel (continued) g200276 Figure 91 Wheel retaining lever 3. Pivot the wheel retaining lever away from the center of the wheel. Slide the transport wheel off the wheel hex shaft. Disassembling the Transport Wheel g261682 Figure 92 Wheel hex shaft 1.
  • Page 160 Assembling the Transport Wheel 1. If the shoulder screws were removed from the hub, apply Loctite #242 (or equivalent) to the threads of the shoulder screws. Secure the torsion spring and retaining lever to the hub with the shoulder screws. 2.

  • Page 161: Rail Kit Wheels (Optional)

    Rail Kit Wheels (Optional) g261683 Figure 93 Wheel hex shaft Rail kit wheel Wheel clip Removing the Rail Kit Wheel 1. Park the machine on a level surface. Ensure that the key switch is in OFF position and the traction control is in NEUTRAL. 2.

  • Page 162: Flex Frame Assembly

    Flex Frame Assembly g337283 Figure 94 Machine assembly Socket head screws (4 each) Flex frame assembly Removing the Flex Frame Assembly 1. Park the machine on a level surface. Ensure that the key switch is in OFF position and the traction control is in NEUTRAL. 2.
  • Page 163 Disassembly of the Flex Frame Assembly g337282 Figure 95 Pivot pin latch (2 each) Carriage bolt (3 each) Carriage bolt (4 each) E-ring (2 each) LH hub end RH hub end Lever (2 each) Roll frame assembly Frame link Pivot pin (2 each) Flange nut (8 each) Flange nut (3 each) Spring (2 each)
  • Page 164 Controls, Wheels and Accessories : Service and Repairs Page 6–28 Greensmaster ® eFlex 1021 20248SL Rev A...
  • Page 165 Chapter 7 DPA Cutting Units Table of Contents General Information ..........................7–2 Cutting Unit Operator's Manual ......................7–2 Supporting the Cutting Unit when Servicing ..................7–2 Adjustments ............................7–3 DPA Cutting Unit Characteristics......................7–3 Service and Repairs ..........................7–4 Bedbar Assembly..........................7–4 Servicing the Bedbar Adjuster......................

  • Page 166: General Information

    General Information Cutting Unit Operator's Manual The Cutting Unit Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for the cutting units on your machine. Additionally, if optional kits have been installed on the cutting units (e.g. groomer), the Installation Instructions for the kit includes set-up, operation and maintenance information.

  • Page 167: Adjustments

    Adjustments DPA Cutting Unit Characteristics CAUTION Never install or work on or near a cutting unit or cutting unit suspension with the machine running. Always stop the machine and remove the key before working on or near a cutting unit. Note: When adjusting reel to bedknife or grinding/backlapping, cutting unit assembly must be attached to traction unit or frame fixture.

  • Page 168: Service And Repairs

    Service and Repairs Bedbar Assembly g312976 Figure 97 Bedbar adjuster shaft (2 each) Wave washer (2 each) Washer (2 each) Keyed flanged bushing (4 each) Retaining ring (2 each) Compression spring Detent (2 each) Bedbar adjuster screw (2 each) Nut (2 each) Bolt (2 each) Bedbar assembly Side plate...
  • Page 169 Removing the Bedbar Note: Refer to Figure 97 during this procedure. 1. Remove the cutting unit from the machine and place the cutting unit on a flat work surface; refer to Operator’s Manual. 2. Loosen the nuts (11) on the end of each bedbar adjuster assembly (1) until the washers (9) are loose.
  • Page 170 Installing the Bedbar g226763 Figure 99 Metal washer Side plate Rubber bushing Bedbar Nylon bushing Bedbar pivot bolt Plastic washer (2 each) Lock nut 1. If rubber bushing (item 2 in Figure 99) was removed from either side plate, apply grease to outside surface of new bushing and install into side plate (1).
  • Page 171 Installing the Bedbar (continued) 7. Install the bedbar bolt assemblies (item 7 in Figure 99). Make sure that the washers are not caught on the threads of the pivot bolts. Torque tighten each bedbar bolt (7) from 22 to 27 N∙m (190 to 240 in-lb). IMPORTANT Do not over tighten the lock nuts as this can distort the side plates and affect reel bearing alignment.

  • Page 172: Servicing The Bedbar Adjuster

    Servicing the Bedbar Adjuster Removing the Bedbar Adjuster g312976 Figure 100 Bedbar adjuster shaft (2 each) Wave washer (2 each) Washer (2 each) Keyed flanged bushing (4 each) Retaining ring (2 each) Compression spring Detent (2 each) Bedbar adjuster screw (2 each) Nut (2 each) Bedbar assembly Bolt (2 each)
  • Page 173 Installing the Bedbar Adjuster 1. If previously removed, secure the detent (3) to the side plate (12) with the bolt (4). 2. If previously removed, align the key on the flange bushings (2) to the slots in the cutting unit side plate (12) and install. 3.

  • Page 174: Bedknife

    Bedknife Removing the Bedknife g227001 Figure 101 Bedknife screw (13 used) Bedbar Bedknife Remove the bedbar from the cutting unit; refer to Removing the Bedbar (page 7–5). Remove screws from bedbar using a socket wrench and bedknife screw tool; refer to Special Tools (page 2–13).
  • Page 175 Installing the Bedknife (continued) IMPORTANT Do not use an impact wrench to tighten screws into the bedbar. 3. Use new screws to secure bedknife to bedbar. Apply anti-seize lubricant to the threads of new screws. Do not apply anti-seize lubricant to the taper of the screw heads.
  • Page 176 Grinding the Bedknife Bedknife Grinding Specifications Standard Bedknife Relief Angle 3° minimum Fairway Bedknife Relief Angle 3° minimum Extended Bedknife Relief Angle 7° minimum Front Angle Range 13° to 17° g207289 Figure 103 Top angle Front surface Top surface Front angle Remove burr 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 177 Angle Indicator and Magnetic Mount (page 2–15). 1. Use Toro General Service Training Book, Reel Mower Basics (part no. 09168SL) and grinder manufacturer's instructions for bedknife grinding information. After grinding the bedknife, install the bedbar assembly in the cutting unit;...

  • Page 178: Reel Assembly

    Reel Assembly g313076 Figure 105 Drive spline Bolt Reel assembly Reel nut - LH Cutoff bar Flange shoulder bolt Strip seal RH side plate LH side plate Crossmember Bearing lock screw Grass shield Gasket Mount pin Bolt Reel weight Bushing Flat wire spring Bolt Pitch arm...
  • Page 179 Removing the Reel Assembly (continued) 2. Disconnect the battery pack; refer to Connecting the Lithium Battery Pack (page 5–3). CAUTION Contact with the reel, bedknife or other cutting unit parts can result in personal injury. Use heavy gloves when removing the cutting reel. 3.
  • Page 180 Removing the Reel Assembly (continued) IMPORTANT To avoid grinding the reel, do not contact the cutting edge of any blade with the pry bar as this may damage the cutting edge and/or cause a high blade. C. Move the pry bar against the weld side of the reel support plate closest to the bearing lock screw.
  • Page 181 Inspecting the Reel Assembly g287676 Figure 107 Cutting reel Reel nut (black – left hand thread) Flocked seal (2 each) Groove indication left hand threads Bearing (2 each) Left-most reel spider reel nut (right hand thread) Bearing shoulder Remove the reel nuts from the cutting reel. Slide the bearings and seals from the reel shaft.
  • Page 182 Inspecting the Reel Assembly (continued) Note: The reel nut on the left end of the cutting reel has a black finish and has left-hand threads. The left end of the cutting reel shaft is identified with a groove cut just inside of the left-most reel spider. Tighten the reel nuts to the specified torque once the cutting reel is installed in the cutting unit.

  • Page 183: Chapter 8: Universal Groomer (Optional) (Page

    Installing the Reel Assembly (continued) IMPORTANT To avoid grinding the reel, do not contact the cutting edge of any blade with the pry bar as this may damage the cutting edge and/or cause a high blade. B. Move the pry bar against the weld side of the reel support plate closest to the bearing lock screw.
  • Page 184 7–20). Additional reel grinding information can be found in the Cutting Unit Operator’s Manual. An additional resource is the Toro Basics Series Training Book, Reel Mower Basics (part no. 09168SL) found on the Service Reference Set available from your Authorized Toro Distributor.
  • Page 185 Preparing the Reel for Grinding (continued) Note: Always adjust the cutting unit after grinding the reel and/or bedknife; refer to the Cutting Unit Operator’s Manual. To extend the cutting unit performance by allowing the reel and the bedknife to hold their edge longer, an additional adjustment may be required after the first few minutes of operation as the reel and bedknife conform to each other.

  • Page 186: Roller Assemblies

    Roller Assemblies Removing the Front Roller g313144 Figure 110 Plow bolt (2 each) Lock nut (2 each) Front roller assembly Pinch bolt (2 each) Height-of-cut arm (2 each) Height-of-cut screw (2 each) Note: Refer to Figure 110 during this procedure. 1.
  • Page 187 Installing the Front Roller (continued) 6. Center the front roller in the cutting unit and tighten the pinch bolts that secure the front roller shaft to the height-of-cut arms. 7. Adjust the cutting unit height-of-cut; refer to the Cutting Unit Operator’s Manual.
  • Page 188 Installing the Rear Roller (continued) 5. Center the rear roller in the cutting unit and tighten the flange nuts at each of the retainer assemblies. 6. Adjust the rear roller height; refer to the Cutting Unit Operator’s Manual. Disassembling the Roller g313345 Figure 112 Bearing lock nut (2 each)
  • Page 189 Assembling the Roller g261670 Figure 113 Roller Bearing lock nut Ball bearing Roller shaft Seal g261681 Figure 114 Bearing Bearing lock nut Seal Note: The rear roller is a low drag roller. 1. Press the bearing into the roller (support both inner and outer raceways). 2.
  • Page 190 Installing the Front Roller (continued) 4. Slide the front roller shaft (3) into the height-of-cut arm (5) attached to the cutting unit (10). 5. Slide the remaining height-of-cut arm (5) onto the other end of roller shaft. Secure the remaining height-of-cut arm to the side plate with a plow bolt (2), height-of-cut washer and lock nut.
  • Page 191 Chapter 8 Universal Groomer (Optional) Table of Contents General Information ..........................8–2 Installation Instructions ........................8–2 Grooming Performance........................8–2 Service and Repairs ..........................8–3 The Gear Box Assembly ........................8–4 Idler Assembly ..........................8–13 Groomer Reel ..........................8–15 The Height Adjuster Assembly ......................8–18 The Grooming Brush (Optional) .......................

  • Page 192: General Information

    General Information Installation Instructions The Installation Instructions for the groomer provides information regarding the set-up, operation, general maintenance procedures, and maintenance intervals for the groomer assembly on your Greensmaster machine. Refer to the Installation Instructions for additional information when servicing the groomer assembly.

  • Page 193: Service And Repairs

    Service and Repairs g251028 Figure 115 Gear box assembly Height adjuster assembly (2 each) Idler assembly Groomer reel CAUTION Never work on the groomer with the machine running. Always stop the machine and wait for all machine movement to stop before working on the groomer.

  • Page 194: The Gear Box Assembly

    The Gear Box Assembly g285625 Figure 116 Gear box assembly Cotter pin Input shaft Drive shield Clevis pin The groomer gear box assembly is located on the opposite side of the cutting unit from the reel drive. Removing the Gear Box Assembly Refer to Figure 116 for this procedure.
  • Page 195 Weld side of reel support plate Groomer gear box assembly Pry bar 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 117.
  • Page 196 Removing the Gear Box Assembly (continued) IMPORTANT You must use a 6-point socket with a heavy wall to remove the gear box from the reel. Do not use an impact wrench. Groomer gear boxes installed on the right side of the cutting unit use a standard right hand thread;...
  • Page 197 Removing the Gear Box Assembly (continued) 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. g285909 Figure 119 Damaged input shaft assembly Weld side of reel support plate Drive shaft removal tool Pry bar...
  • Page 198 Removing the Gear Box Assembly (continued) 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 Special Tools (page 2–13). Universal Groomer (Optional): Service and Repairs Page 8–8 Greensmaster...
  • Page 199 Servicing the Gear Box g285711 Figure 120 Drive adapter – silver Thrust washer Ring gear Input shaft O-ring Flange bushing O-ring (3 each) O-ring Sun gear V-ring Bearing Dowel pin (2 each) Oil seal Drain/fill plug (4 each) Planet gear (3 each) Groomer housing Straight bushing (2 each) Flange bushing (3 each)
  • Page 200 Servicing the Gear Box (continued) 3. Slide the sun gear, ring gear, and planet gears from the pins on the gear box housing. 4. Continue to disassemble the gear box as necessary. 5. If the drive adapter requires replacement, apply medium strength thread locking compound (Loctite 243 or equivalent) to the internal threads of the drive shaft and the larger threads of the drive adapter (reel end).
  • Page 201 Installing the Gear Box Assembly Refer to Figure 116 for this procedure. 1. Apply medium strength thread locking compound (Loctite 243 or equivalent) to the threads in the reel and allow the thread locking compound to cure for 15 minutes before continuing this procedure. 2.
  • Page 202 Installing the Gear Box Assembly (continued) 8. Apply a retaining compound (Loctite 609 or equivalent) to the lip of the drive housing and install the drive shield. 9. Install the groomer reel assembly; refer to Installing the Groomer Reel (page 8–17).

  • Page 203: Idler Assembly

    Idler Assembly g285713 Figure 122 Socket-head screw (2 each) Lock nut (2 each) Flange nut Bolt Shield Clevis pin Motor adapter Stub shaft Cotter pin Bushing Flocked seal (2 each) Collar Idler arm Bearing O-ring Retaining ring Note: The groomer idler assembly is located on the opposite side of the groomer gearbox assembly.
  • Page 204 Installing the Idler Assembly (continued) C. Install the bearing shields with flocked side of shield toward the bearing. D. Check the idler arm orientation (left or right cutting unit) and insert the stub shaft (item 9 in Figure 122) through shields and bearing. Use the through hole in the shaft to prevent shaft from rotating, tighten the flange nut to 37 to 45 N∙m (27 to 33 ft-lb).

  • Page 205: Groomer Reel

    Groomer Reel g313422 Figure 123 Shaft clamp (4 each) Bolt (4 each) Jam nut (4 each) Groomer reel Remove the groomer reel to replace individual groomer blades or replace the shaft. The groomer reel can be reversed to provide additional blade life. Removing the Groomer Reel CAUTION Contact with the reel or other cutting unit parts can result in personal...
  • Page 206 Servicing the Groomer Reel g282211 Figure 124 Groomer reel shaft Spacer (50 each) Groomer blade (51 each) Locknut (2 each) Inspect the groomer reel blades frequently for any damage and wear. Straighten the bent blades. Either replace the worn blades or reverse the individual blades to put the sharpest blade edge forward: refer to Figure 124.
  • Page 207 Servicing the Groomer Reel (continued) D. When all the blades have been installed, install the second lock nut onto the shaft. Center the blades and spacers on the shaft by adjusting the lock nuts. E. Use the through holes in shaft to prevent the shaft from rotating and tighten the second lock nut to 42 to 48 N∙m (375 to 425 in-lb).

  • Page 208: The Height Adjuster Assembly

    The Height Adjuster Assembly g251107 Figure 125 Height adjuster knob Washer (2 each) Quick up lever Carriage bolt Compression spring Quick up cover Height-of-cut bracket Flange nut Detent spring Flange nut Height adjustment rod Button-head screw Height adjustment bolt Groomer hose Groomer pin Note: Early universal groomers used 2 compression springs on non-adjustable height adjustment rods.
  • Page 209 Assembling the Height Adjuster 1. Apply anti-seize lubricant to the upper threads of the adjustment rod and lower threads of the height adjusters. Assemble the height adjuster assembly. 2. If both the height adjusters are removed, fit 1 height adjuster assembly to the cutting unit side plate and secure it with the carriage bolt and flange nut.

  • Page 210: The Grooming Brush (Optional)

    The Grooming Brush (Optional) g285731 Figure 127 Spiral brush Lock nut (2 each) Brush shaft Grooming brush J-bolt (2 each) Roll pin (2 each) The optional grooming brush attaches to the groomer in place of the groomer reel. The grooming brush is removed and installed from the groomer in the same manner as the groomer reel;...
  • Page 211 Appendix A Foldout Drawings Table of Contents Electrical Drawing Designations......................A–2 Electrical Schematic...........................A–3 Wire Harness Drawing ........................A–4 Wire Harness Drawing ........................A–5 Greensmaster ® eFlex 1021 Page A–1 Foldout Drawings 20248SL Rev A...

  • Page 212: Electrical Drawing Designations

    Y or YE YELLOW Numerous harness wires used on the Toro machines include a line with an alternate color. These wires are identified with the wire color and line color with either a / or _ separating the color abbreviations listed above (e.g., R/BK is a red wire with a black line, OR_BK is an orange wire with a black line).

  • Page 213: Electrical Schematic

    Electrical Schematic g349607 Greensmaster eFlex 1021, Drawing 122-1647 Rev A, Sheet 1 of 1 20248SL Rev A Page A–3...

  • Page 214: Wire Harness Drawing

    Wire Harness Drawing g349608 Page A–4 20248SL Rev A Greensmaster eFlex 1021, Drawing 122-1734 Rev D, Sheet 1 of 2...
  • Page 215 Wire Harness Drawing g349609 Greensmaster eFlex 1021, Drawing 122-1734 Rev D, Sheet 2 of 2 20248SL Rev A Page A–5...

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