Page 1 Form No. 20248SL Rev C Greensmaster ® eFlex 1021 (Model 04861)
Page 2 Revision History Revision Date Description Initial issue. 05/2021 01/2022 Cutting unit drive spline information 07/2022 Updated the reel drive, handle, bedknife, groomer drive gearbox, idler plate, groomer reel, height adjuster chapters Revision History Page 2 Greensmaster ® eFlex 1021 20248SL Rev C...
Page 3 Revision History (continued) Revision Date Description Greensmaster ® eFlex 1021 Page 3 Revision History 20248SL Rev C...
Page 4 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 5 NOTES Greensmaster ® eFlex 1021 Page 5 NOTES 20248SL Rev C...
Page 6 NOTES Page 6 Greensmaster ® eFlex 1021 20248SL Rev C...
Page 7 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 8 g340146 Figure 1 Preface Page 8 Greensmaster ® eFlex 1021 20248SL Rev C...
Page 9 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 10: Table Of Contents
Table of Contents Preface ........................ 7 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 11 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 C...
Page 12: 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 13 – 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 14 – 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 15: 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 16 Safety: Safety and Instructional Decals Page 1–6 Greensmaster ® eFlex 1021 20248SL Rev C...
Page 17 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 18: Specifications
Specifications Overall Dimensions g340580 Figure 2 Specifications and Maintenance: Specifications Page 2–2 Greensmaster ® eFlex 1021 20248SL Rev C...
Page 19: 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 20: 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 at the right side of the cutting unit. Groomer height setting Height-of-cut range: 0.8 to 15.7 mm (0.030 to 0.620 inch).
Page 21: 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 22: 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 23: 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 24: 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 25: 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 26: 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 27: 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 28 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 29: 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 30 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 31 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 32 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 33 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 34 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 35 Chapter 3 Troubleshooting Table of Contents GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems ......3–2 Operator Advisories..........................3–3 Machine Faults ............................3–5 Battery Charger Error and Fault Codes ....................3–8 Electrical System Problems ........................3–9 Aftercut Appearance..........................3–11 Factors Affecting Grooming .........................
Page 36: Gears - The Systematic Approach To Defining, Diagnosing And Solving Problems
GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems 1. Gather Information • Information reported by the customer • Information observed by you • Establish the “what, where and when” of the issue 2. Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis •...
Page 37: 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 38 #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 39: 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 40 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 machine. is incompatible. Key Stuck Primary The battery has detected Verify the battery is charged.
Page 41 Fault Table (continued) Fault Fault Title Additional Controller Fault Condition/Circuit Service Actions Number Affected Description Notes Software Primary 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 42: 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 43: 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 44 Machine is Inoperative and InfoCenter Power Light Indicates That a Fault Has Occurred Possible Causes Correction The controller has detected a fault. 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 45: Aftercut Appearance
Note: For additional information regarding cutting unit troubleshooting, several 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 Factor...
Page 46: Factors Affecting Grooming
Factors Affecting Grooming There are several 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. IMPORTANT Improper or overaggressive use of the grooming reel, such as too deep or frequent grooming, may cause unnecessary stress on the...
Page 47: 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 48 Troubleshooting: Grooming Reel Mechanical Problems Page 3–14 Greensmaster ® eFlex 1021 20248SL Rev C...
Page 49 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 50: 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 51: Adjustments
Adjustments Adjusting the Reel Drive Belt g312311 Figure 12 Reel drive housing Carriage bolt Socket head screw (4 each) Reel drive belt Bolt Gasket Idler arm Reel drive cover 1. Ensure that the cutting-unit-drive lever is in the D position, park the ISENGAGE machine on a level surface, release the clutch bail, engage the service and parking brake, rotate the key switch to O...
Page 52 Adjusting the Reel Drive Belt (continued) 5. Adjust belt tension as follows: A. Loosen the nut securing carriage bolt (4) and the idler arm (3), and rotate the arm to remove tension from the belt (2). B. Use a beam-style torque wrench to apply 6 to 7 N∙m (55 to 60 in-lb) of force to the upper idler-arm socket-head screw as shown in Figure and tighten the nut to secure the carriage bolt (4) and the idler arm (3).
Page 53: Service And Repairs
Service and Repairs Reel Drive Belt g312311 Figure 14 Reel drive housing Carriage bolt Socket head screw (4 each) Reel drive 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 54 Removing the Reel Drive Belt (continued) 4. Remove and inspect the reel drive gasket (5) from the reel drive housing (1). Replace the reel drive gasket (5) if it is worn or damaged. 5. Loosen the nut securing carriage bolt (4) and the idler arm (3), and rotate the arm to remove tension from the belt (2).
Page 55: Reel Drive Assembly
Reel Drive Assembly g312399 Figure 15 Expansion plug Hipro key Reel drive cover Washer Reel shaft-driver 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 56 Removing the Reel Drive Assembly (continued) parking brake, rotate the key switch to O , and remove the key; refer to the Operator's Manual. 2. Disconnect the battery pack; refer to Disconnecting and Connecting the Lithium Battery Pack (page 5–3). 3.
Page 57 Removing the Reel Drive Assembly (continued) 20. If necessary, remove the retaining rings (3 and 4) from the reel drive housing (6). 21. Use a press to remove the 4 ball bearings (2 and 5) from the reel drive housing (6). Discard the ball bearings after removal. Greensmaster ®...
Page 58 Installing the Reel Drive Assembly Note: Refer to Figure 15 during the procedure. 1. Use a press to install the 4 ball bearings (items 2 and 5 in Figure 16) 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 59 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 60: Drum Drive Gear Box Assembly
Drum Drive Gear Box Assembly g335443 Figure 18 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 18...
Page 61 Removing the Drum Drive Gear Box Assembly (continued) Note: Support the machine on kickstand during this operation. 4. Move the traction engage/disengage lever to the disengage position to remove torque from the drum drive gears. 5. Remove the shoulder bolt (8) that secures the RH drum drive gear box assembly (5) to the frame assembly (7).
Page 62 Disassembly of Drum Drive Gear Box Assembly g258844 Figure 19 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 63 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 64 Assembly of Drum Drive Gear Box Assembly g263151 Figure 20 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 65 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 66: Drum Assembly
Drum Assembly g335443 Figure 21 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 21 during this procedure.
Page 67 Disassembly of Drum Drive Assembly g258879 Figure 22 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 68 Assembly of Drum Drive Assembly g258942 Figure 23 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 23) should face inside of the drum hub; refer to Figure 1.
Page 69 Installing the Drum Drive Assembly 1. Ensure that the cutting-unit-drive lever is in the D position, park the ISENGAGE machine on a level surface, release the clutch bail, engage the service and parking brake, rotate the key switch to O , and remove the key;...
Page 70: Transmission Gear Box Assembly
Transmission Gear Box Assembly g335652 Figure 24 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 71 Removing the Transmission Gear Box Assembly Note: Refer to Figure 24 during this procedure. 1. Ensure that the cutting-unit-drive lever is in the D position, park the ISENGAGE machine on a level surface, release the clutch bail, engage the service and parking brake, rotate the key switch to O , and remove the key;...
Page 72 Disassembling the Transmission Gear Box Assembly g339791 Figure 25 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 73 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 26 External retaining ring...
Page 74 Disassembling the Transmission Gear Box Assembly (continued) 9. If necessary, disassemble the differential assembly (14); refer to Disassembly of Differential Assembly (page 4–34). 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 75 Disassembling the Transmission Gear Box Assembly (continued) g339789 Figure 27 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 76 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 77 Assembling the Transmission Gear Box Assembly 1. Use a press to install the spacer (item 13 in Figure 25) and new ball bearings (12 and 25) into the transmission housing (26). 2. Install the retaining ring (item 5 in Figure 25) into the transmission housing (26).
Page 78 Assembling the Transmission Gear Box Assembly (continued) 19. Apply a coat of grease to the O-ring (item 2 in Figure 27) 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 79 Assembling the Transmission Gear Box Assembly (continued) 37. Insert the wave washer (item 3 in Figure 26) and neutral spur gear assembly (5) into the transmission housing assembly (23). Make sure that the traction selector shaft (item 19 in Figure 25) is engaged in shift selection neutral spur gear (item 5 in Figure...
Page 80 Installing the Transmission Gear Box Assembly Note: Refer to Figure 24 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 81: Differential Assembly
Differential Assembly g339790 Figure 28 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 82 Disassembly of Differential Assembly g259978 Figure 29 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 29) that secures the differential housing assembly (1) to the differential gear (4).
Page 83 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 30 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 84 Traction and Reel Drive Systems: Service and Repairs Page 4–36 Greensmaster ® eFlex 1021 20248SL Rev C...
Page 85 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 86: 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 to prevent abrasion or contact with moving machine parts.
Page 87: Disconnecting And Connecting The Lithium Battery Pack
Disconnecting and 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 88: 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 89: 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. The TEC and motor controller monitor the motor speed so that as traction load changes (e.g., moving up or down an incline) the motor can compensate as necessary.
Page 90: 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 91: Toro Electronic Controller (Tec)
Figure 33 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 92: Lithium-Ion Battery Controller (Bms)
Lithium-Ion Battery Controller (BMS) g338267 Figure 34 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 93 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 94: 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 95 AFTER SECONDS MAIN INFORMATION SCREEN g339628 Figure 36 Greensmaster ® eFlex 1021 Page 5–11 Electrical System: Electrical System Operation 20248SL Rev C...
Page 96 Splash Screen g339634 Figure 37 Fault indicator Down button Hour meter Menu/back button Left/right button When the key switch is initially turned to the ON position, the fault indicator illuminates for a few seconds to verify indicator operation and the InfoCenter splash screen appears (Figure 37).
Page 97 Main Information Screen (continued) The InfoCenter main information screen (Figure 38) 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 98 Operator Advisories g339631 Figure 40 Advisory name Advisory identification Operator advisories are automatically displayed by the InfoCenter when a machine function requires additional action (Figure 40). An advisory will not be logged into the fault log. (Refer to Operator Advisories (page 3–3)).
Page 99 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 100 Service Screen Hours: 132.4 Hours Power Use: 29 Watts Battery Charge g339632 Figure 43 Left/right button Service items Down button Service menu Menu/back button The service screen (Figure 43) contains the following machine information: • Hours (hours that the key switch has been in the ON position) •...
Page 101 Diagnostics Screen agnostics art: Traction: g339626 Figure 44 Left/right button Diagnostics items Down button Diagnostics menu Menu/back button The diagnostics screen (Figure 44) 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 102 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 103 About Screen About 04861 400000000 g339625 Figure 46 Left/right button About items Down button About menu Menu/back button The about screen (Figure 46) 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 104: Adjustments
Adjustments Traction Bail Proximity Sensor g349622 Figure 47 Jam nuts Clutch bail link Proximity sensor Adjusting the Traction Bail Proximity Sensor 1. Ensure that the cutting-unit-drive lever is in the D position, park the ISENGAGE machine on a level surface, release the clutch bail, engage the service and parking brake, rotate the key switch to O , and remove the key;...
Page 105: 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 ON position, use the InfoCenter diagnostics menu to ensure that the component state changes as the component is toggled.
Page 106: Fuses
Fuses g338648 Figure 48 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. Ensure that the cutting-unit-drive lever is in the D position, park the ISENGAGE machine on a level surface, release the clutch bail, engage the service and...
Page 107 Fuse Identification and Function (continued) Fuse F1-4: This fuse block position is open. 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.
Page 108: Can Bus
Operator's Manual. 2. Disconnect the battery pack; refer to Disconnecting and 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 109 4. Refer to CAN-bus Terminator Resistor (page 5–38) 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 110: Toro Electronic Controller (Tec)
Figure 52 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 111 Toro Electronic Controller (TEC) (continued) g338695 Figure 53 The diagram in Figure 53 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 112: 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 113 Testing the Lithium-Ion Battery Controller (continued) g338794 Figure 56 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 114: 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. Ensure that the cutting-unit-drive lever is in the D...
Page 115: Key Switch
Key Switch g338795 Figure 58 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: O and O . This switch is 1 of the several inputs for the TEC and is located on the InfoCenter mount (Figure 58).
Page 116 Testing the Key Switch (continued) g190999 Figure 59 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 59.
Page 117: Throttle Potentiometer And Clutch Bail Potentiometer
Throttle Potentiometer and Clutch Bail Potentiometer g337125 Figure 60 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 118 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 O 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 119 Testing the Throttle and Clutch Bail Potentiometers (continued) 6. After you complete the testing, secure the potentiometers to the machine (Figure 60). 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 120: Main Contactor
Main Contactor g339029 Figure 62 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 O position, the contactor inside...
Page 121 Testing the Main Contactor (continued) g202780 Figure 63 Main contact post Coil post 4. Record the wire connector locations on the contactor being tested for assembly purposes, and disconnect the harness electrical connectors from contactor. Check the contactor and the harness connectors for damage or corrosion and clean or repair as necessary.
Page 122: 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. Electrical System: Testing the Electrical Components Page 5–38 Greensmaster ® eFlex 1021...
Page 123: 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. Ensure that the cutting-unit-drive lever is in the D position, park the ISENGAGE machine on a level surface, release the clutch bail, engage the service and...
Page 124 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 125: 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 126 Removing the Electric Motor (continued) 4. Support the electric motor to prevent it from falling. 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.
Page 127: 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 128 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 129 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 130: 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 131 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 132 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 133: 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 134 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 135 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 136 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 137 Removing the Lithium-Ion Battery (continued) g339409 Figure 74 Negative (-) terminal Washer Lithium-ion battery Lock washer Positive (+) terminal 1. Ensure that the cutting-unit-drive lever is in the D position, park the ISENGAGE machine on a level surface, release the clutch bail, engage the service and parking brake, rotate the key switch to O , and remove the key;...
Page 138 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 139 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 140: 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 141: 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. Ensure that the cutting-unit-drive lever is in the D position, park the ISENGAGE machine on a level surface, release the clutch bail, engage the service and parking brake, rotate the key switch to O...
Page 142: 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 143 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 144 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 145: 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 146 Removing the Reel Cable (continued) g336875 Figure 81 Retaining ring Jam nut Reel selector assembly Reel cable 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.
Page 147 Installing the Reel Cable (continued) B. Position the reel cable (4) to the casting slot of the base with a jam nut (3), flat washer and a lock washer on each side of the slot. 3. Make final adjustment of the reel cable at the reel cable lever assembly. Adjust the cable jam nuts to remove the slack in the clutch cable.
Page 148: 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 149 Disassembling the Cutting Unit Drive Lever Assembly (continued) 2. Disconnect the battery pack; refer to Disconnecting and Connecting the Lithium Battery Pack (page 5–3). 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.
Page 150: Brake Latch Shaft
Brake Latch Shaft g336961 Figure 83 Roll pin Shoulder bolt Brake latch shaft Flange bushing (2 each) Bolt Torsion spring Lever Flange bushing (2 each) Flange nut Brake lock lever Flange nut Upper receiver weldment Disassembling the Brake Latch Shaft Note: Refer to Figure 83 during this procedure.
Page 151 Disassembling the Brake Latch Shaft (continued) 6. Slide and remove the brake latch shaft (9) from the upper receiver weldment (12). 7. Slide and remove the torsion spring (10) from the brake latch shaft (9). Assembling the Brake Latch Shaft 1.
Page 152: 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 Brake lever Cotter pin Bolt Lower handle assembly...
Page 153 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 154 Disassembling the Handle Assembly Note: Refer to Figure Figure Figure Figure 86, and Figure 87 during this procedure. 1. Ensure that the cutting-unit-drive lever is in the D position, park the ISENGAGE machine on a level surface, release the clutch bail, engage the service and parking brake, rotate the key switch to O , and remove the key;...
Page 155 Disassembling the Handle Assembly (continued) 25. If necessary, remove the cotter pin (item 18 in Figure 84), bearing spacer (15) and clevis pin (14) that secure the handle adjuster assembly (22) to the upper receiver weldment (8). 26. Remove the handle adjuster assembly (Item 22 in Figure 84) from the upper receiver weldment and separate handle torsion spring (23) and spring spacer...
Page 156 Disassembling the Handle Assembly (continued) 29. Remove the flange nut (8), and bolt (2) that secure the clutch bail link (5) to the handle mount (7). Remove the 2 flange bushings (3) and spacer tube (13) from the handle mount. 30.
Page 157 Assembling the Handle Assembly (continued) 2. If removed, install the lower handle assembly (1) onto the frame assembly (5) and secure with the 2 bolts (2), anti-rotation washer (3),and washer (4). 3. Lift the lower handle assembly until it contacts the stop, and torque the 2 bolts (Item 2 in Figure 87) to 95 to 101 N·m (70 to 75 ft-lb).
Page 158 Assembling the Handle Assembly (continued) 23. Install the clutch and reel drive lever assembly; refer to Assembling the Cutting Unit Drive Lever Assembly (page 6–11). 24. Install the reel cable; refer to Installing the Reel Cable (page 6–8). 25. Install the brake cable; refer to Installing the Brake Cable (page 6–5).
Page 159: Kickstand
Kickstand g394087 Figure 88 Lower handle assembly Spacer (2 each) LH torsion spring Bolt (2 each) Frame assembly Spring mount pin Nut (3 each) Bolt (2 each) E-ring Plain washer (2 each) Compression spring Spring retainer (2 each) Kickstand lock pin Kickstand Removing the Kickstand CAUTION...
Page 160 Removing the Kickstand (continued) 2. Disconnect the battery pack; refer to Disconnecting and Connecting the Lithium Battery Pack (page 5–3). 3. Pivot the kickstand up and hold against the frame stops. 4. Remove the bolt (item 2 in Figure 88) that secures the spring mount pin (10) and torsion spring (9) to the kickstand (16).
Page 161: 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 162 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 163 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 164: 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. Ensure that the cutting-unit-drive lever is in the D position, park the ISENGAGE machine on a level surface, release the clutch bail, engage the service and parking brake, rotate the key switch to O , and remove the key;...
Page 165: 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. Ensure that the cutting-unit-drive lever is in the D position, park the ISENGAGE machine on a level surface, release the clutch bail, engage the service and parking brake, rotate the key switch to O , and remove the key;...
Page 166 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 167 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 Leveling the Rear Roller........................7–4 Service and Repairs ..........................7–6 Bedbar Assembly..........................
Page 168: 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 169: 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 170: Leveling The Rear Roller
Leveling the Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment (parallel). If the side plates are disassembled a limited amount of side plate adjustment is possible to make sure that the rear roller and cutting reel remain parallel.
Page 171 Leveling the Rear Roller (continued) g381460 Figure 98 Rear roller Side plate Shoulder bolt (2 each) Rear roller adjustment kit (optional) 5. Adjust the position of the side plate so the rear roller contacts the bench plate at both ends, making the rear roller parallel to the reel. Tighten the shoulder bolts from 24 to 27 N∙m (210 to 240 in-lb).
Page 172: Service And Repairs
Service and Repairs Bedbar Assembly g312976 Figure 99 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 173 Removing the Bedbar Note: Refer to Figure 99 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 174 Installing the Bedbar g226763 Figure 101 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 101) was removed from either side plate, apply grease to outside surface of new bushing and install into side plate (1).
Page 175 Installing the Bedbar (continued) 7. Install the bedbar bolt assemblies (item 7 in Figure 101). 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 176: Servicing The Bedbar Adjuster
Servicing the Bedbar Adjuster Removing the Bedbar Adjuster g312976 Figure 102 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 177 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 178: Bedknife
Bedknife Removing the Bedknife g227001 Figure 103 Bedknife screw (13 used) Bedbar Bedknife Remove the bedbar from the cutting unit; refer to Removing the Bedbar (page 7–7). Using a socket wrench and the bedknife screw tool, remove screws that secure the bedknife to the bedbar, and remove the bedknife; refer to Special Tools (page 2–13).
Page 179 Installing the Bedknife (continued) g226894 Figure 104 5. Using a torque wrench and bedknife screw tool, tighten the 2 outer screws to 1 N·m (10 in-lb). 6. Working from the center of the bedknife toward each end, tighten screws from 23 to 28 N·m (200 to 250 in-lb). 7.
Page 180 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° 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 181 Angle Indicator and Magnetic Mount (page 2–15). 1. Use the 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 182 Troubleshooting Bedknife Grinding Perform this troubleshooting procedure is a newly ground bedknife does not cut test paper at the center of the knife. 1. Place a .002 inch shim (Part No. 140-5531) between the outer most left and right magnets and the bedbar-bedknife assembly when placing it in the grinder (Figure 107).
Page 183 Checking the Bedknife on a Granite Surface Plate 1. Place bedbar-bedknife assembly on a precision flat granite surface plate with the cutting-edge down. Look for visible light between the granite and the bedknife, or use a shim to test for .002 inch or greater gaps (Figure 108).
Page 184: Reel Assembly
Reel Assembly g313076 Figure 109 Drive spline Pitch arm Bolt Reel nut - RH Reel nut - LH Flange nut Flat wire spring Gasket Flange shoulder bolt Bolt Sealed bearing Counterweight LH side plate Cutoff bar Seal Bolt Strip seal Reel assembly Mount pin Crossmember...
Page 185 Removing the Reel Assembly (continued) parking brake, rotate the key switch to O , and remove the key; refer to the Operator's Manual. 2. Disconnect the battery pack; refer to Disconnecting and Connecting the Lithium Battery Pack (page 5–3). 3. Remove the cutting unit assembly from the machine; refer to the traction unit Operator’s Manual.
Page 186 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 reel nut being removed.
Page 187 Inspecting the Reel Assembly g399500 Figure 111 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 188 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 189 Inspecting the Reel Assembly (continued) equivalent) to the threads of the spline adapter and the internal threads of the LH reel nut prior to installation. If installing a new spline adapter with factory applied thread locking compound (patch lock): Remove any residual thread locking compound from the internal threads of the LH reel nut.
Page 190 Installing the Reel Assembly (continued) g323557 Figure 113 RH reel nut Support plate, weld side Pry bar Reel shaft A. Insert a long- handled pry bar (3/8 x 12 inch with a screwdriver handle recommended) through the front of the cutting unit. 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;...
Page 191 Installing the Reel Assembly (continued) 13. Use a new gasket and install the counterweight to the right side plate with the fasteners previously removed. 14. If the cutting unit is equipped with an optional groomer, install the groomer gear box; refer to Installing the Gearbox Assembly (page 8–13).
Page 192 7–25). 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 193: Roller Assemblies
Roller Assemblies Removing the Front Roller g313144 Figure 115 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 115 during this procedure. 1.
Page 194 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 195 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 117 Bearing lock nut (2 each)
Page 196 Assembling the Roller g261670 Figure 118 Roller Bearing lock nut Ball bearing Roller shaft Seal g261681 Figure 119 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 197 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 198 DPA Cutting Units: Service and Repairs Page 7–32 Greensmaster ® eFlex 1021 20248SL Rev C...
Page 199 Chapter 8 Universal Groomer (Optional) Table of Contents General Information ..........................8–2 Installation Instructions ........................8–2 Service and Repairs ..........................8–3 Groomer Drive Gearbox........................8–4 Idler Plate............................8–16 Groomer Reel ..........................8–19 The Height Adjuster Assembly ......................8–22 The Height Adjuster Assembly ......................8–26 The Grooming Brush (Optional) .......................
Page 200: 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 201: Service And Repairs
Service and Repairs g395660 Figure 120 Gearbox 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. Greensmaster ®...
Page 202: Groomer Drive Gearbox
Groomer Drive Gearbox g395659 Figure 121 Reel shaft 2-lug groomer gearbox Shim washer Adapter Gearbox cover lip Single-lug groomer gearbox The groomer gearbox assembly is located on the opposite side of the cutting unit from the reel drive. Removing the Gearbox Assembly Refer to Figure 121 Figure 122...
Page 203 Removing the Gearbox Assembly (continued) 1. Ensure that the cutting-unit-drive lever is in the D position, park the ISENGAGE machine on a level surface, release the clutch bail, engage the service and parking brake, rotate the key switch to O , and remove the key;...
Page 204 Hardened washer Single-lug groomer gearbox 9. Install a 5/16-18 X 5/8 inch square head set screw (Toro Part No.1-803022) into the end of the drive shaft for the groomer drive gearbox, and tighten the set screw to 13 N·m (120 in-lb); refer to Figure 122.
Page 205 Removing the Gearbox Assembly (continued) • Machines with a 2-Lug Groomer Gearbox: remove the cotter pin and adjuster pin from the eye bolt and gearbox-cover lugs. Discard the cotter pin. IMPORTANT You must use a 6-point socket with a heavy wall to remove the gearbox from the reel.
Page 206 Removing the Gearbox Assembly (continued) g395722 Figure 123 Fill/drain plug Planetary gear and bushing (3 each) Gasket Ring gear Thrust washer O-ring Driver gear Sun gear Retaining ring 2-lug gearbox cover Damaged drive shaft Single lug gearbox cover Gearbox housing Socket head screw (4 each) B.
Page 207 Removing the Gearbox Assembly (continued) g285909 Figure 124 Damaged input shaft assembly Pry bar Reel shaft Drive shaft removal tool Weld side of reel support plate Insert a long-handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bottom of the cutting unit. The pry bar should pass between the bottom of the reel shaft and the backs of the reel blades so that the reel will not move.
Page 208 Servicing the Gearbox Assembly g395734 Figure 125 Drive adapter Knob (2-lug gearbox) Detent ball Ring gear Input shaft Pin (2-lug gearbox) Detent spring Bearing O-ring (3 each) O-ring (2-lug gearbox) Oil seal Planet gear (3 each) V-ring Socket-head screw Socket-head screw(4 Flange bushing (3 each) each) Oil seal...
Page 209 Servicing the Gearbox Assembly (continued) Note: Refer to Figure 125 during this procedure. 1. Remove the drain/fill plug and drain the oil from the gearbox, and drain the oil. 2. Remove the 4 socket-head screws and separate the gearbox cover and housing.
Page 210 Servicing the Gearbox Assembly (continued) 15. If removed, lubricate the O-rings for the drain/fill plug with Mobile XHP-222 or an equivalent grease. g396286 Figure 126 Gearbox cover Drain/fill plug 16. Install all the plugs into the gearbox cover, except for the plug for the face of the cover (located between the 4 socket-head screws).
Page 211 Figure 127 for this procedure. 1. Install a 5/16-18 X 5/8 inch square head set screw (Toro Part No.1-803022) into the end of the drive shaft for the groomer drive gearbox, and tighten the set screw to 13 N·m (120 in-lb); refer to Figure 127.
Page 212 Installing the Gearbox Assembly (continued) IMPORTANT The square head set screw is needed to reinforce the hex end of the drive shaft when you remove or install the gearbox. Do not apply thread-locking compound to the square head set screw. 2.
Page 213 Installing the Gearbox Assembly (continued) g396135 Figure 129 Single-lug groomer gearbox Cotter pin Hardened washer 2-lug groomer gearbox Eye bolt Adjuster pin Shoulder screw 10. Assemble the eye bolt of the groomer adjuster to the gearbox cover (Figure 129). • Cutting Units with a Single-Lug Groomer Gearbox A.
Page 214: Idler Plate
Idler Plate g395810 Figure 130 Bushing Adjuster pin (with a 2-lug groomer Retainer gearbox) Idler plate Cotter pin (with a 2-lug groomer Shaft gearbox) Flange nut Spring pin (idler plate)—cross drilled Shield (with a single-lug groomer gearbox) Spring pin (idler plate)—threaded Bearing shield (with a 2-lug groomer gearbox) Shoulder screw—threaded (with a...
Page 215 Removing the Idler Assembly (continued) • Cutting units with a Single-Lug Groomer Gearbox: remove the shoulder screw and hardened washer that secure the eye bolt to the spring pin of the idler plate. • Cutting units with a 2-Lug Groomer-Drive Gearbox: remove the cotter pin and adjuster pin that secure the eye bolt to the spring pin of the idler plate.
Page 216 Installing the Idler Assembly (continued) g396158 Figure 131 Spring pin (idler plate)—threaded (with a Cotter pin single-lug groomer gearbox) Eye bolt Spring pin (idler plate)—cross drilled (with a 2-lug groomer gearbox) Shoulder screw Adjuster pin 3. Install the reel drive; refer to Installing the Reel Drive Assembly (page 4–10).
Page 217: Groomer Reel
Groomer Reel g397172 Figure 132 2lug groomer gearbox Shaft clamp (4 each) Single lug groomer gearbox 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 218 Servicing the Groomer Reel g282211 Figure 133 Groomer reel shaft Spacer (50 each) Groomer blade (51 each) Lock nut (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 133.
Page 219 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 220: The Height Adjuster Assembly
The Height Adjuster Assembly Single-Lug Groomer Gearbox and Idler Plate g396678 Figure 134 Height of cut screw Washer 20.6 x 14.3 mm (0.813 x 0.563 inch) Plow bolt Lock screw Height adjuster knob Shim washers Screw Compression spring (inner) Detent spring Compression spring (outer) Quick up cover Belleville washer...
Page 221 Disassembling the Height Adjuster Note: Refer to Figure 134 during this procedure. 1. Ensure that the cutting-unit-drive lever is in the D position, park the ISENGAGE machine on a level surface, release the clutch bail, engage the service and parking brake, rotate the key switch to O , and remove the key;...
Page 222 Assembling the Height Adjuster (continued) g396899 Figure 135 Transport position Operating position 14. Measure the distance between the washers (the current spring length) as shown in g396935 Figure 136 Top washer Desired spring length with optional washers—19 mm (0.75 inch) Original spring length (distance between Belleville washer top and bottom washers)
Page 223 Assembling the Height Adjuster (continued) 16. Repeat steps and 15. 17. Remove the eye bolts and hardened washers from the groomer gearbox and idler arm lugs, and adjust the shim washers as you calculated in step 15. 18. Apply medium strength thread locking compound to the threads of the shoulder screws.
Page 224: The Height Adjuster Assembly
The Height Adjuster Assembly 2-Lug Groomer Gearbox and Idler Plate g396679 Figure 137 Height of cut Quick up handle 13. Washer 20.6 x Adjuster pin screw 14.3 mm (0.813 x 0.563 inch) Plow bolt Groomer height of Compression 2-lug cut arm spring (inner) groomer-drive gearbox...
Page 225 Disassembling the Height Adjuster 1. Ensure that the cutting-unit-drive lever is in the D position, park the ISENGAGE machine on a level surface, release the clutch bail, engage the service and parking brake, rotate the key switch to O , and remove the key; refer to the Operator's Manual.
Page 226 Assembling the Height Adjuster (continued) 12. Secure the eye bolts to the groomer gearbox and idler arm lugs with the adjuster pin and cotter pin. 13. Adjust the cutting unit height-of-cut; refer to Cutting Unit Operators Manual. 14. Adjust the groomer reel height; refer to Universal Groomer Drive Kit Installation Instructions.
Page 227: The Grooming Brush (Optional)
The Grooming Brush (Optional) g285731 Figure 140 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 228 Universal Groomer (Optional): Service and Repairs Page 8–30 Greensmaster ® eFlex 1021 20248SL Rev C...
Page 229 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 C...
Page 230: 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 231: Electrical Schematic
Electrical Schematic g349607 Greensmaster eFlex 1021, Drawing 122-1647 Rev A, Sheet 1 of 1 20248SL Rev C Page A–3...
Page 232: Wire Harness Drawing
Wire Harness Drawing g349608 Page A–4 20248SL Rev C Greensmaster eFlex 1021, Drawing 122-1734 Rev D, Sheet 1 of 2...
Page 233 Wire Harness Drawing g349609 Greensmaster eFlex 1021, Drawing 122-1734 Rev D, Sheet 2 of 2 20248SL Rev C Page A–5...

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