Toro 04831 Service Manual Download

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Disassembling the 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). Remove the
differential gear from the differential housing assembly.

2. Place the differential housing assembly on workbench. Pull each differential

housings (1) apart.

3. Use a press to remove the 6 differential pins (2) and 6 differential spur gears

(3) from the differential housings (1).

Inspecting the Differential Assembly

1. Clean all the differential assembly components.

2. Inspect all the differential spur gears (3) carefully looking for chipped teeth,

wear or other damage. Because gear tooth damage is rarely isolated to 1
gear, replace the gears as complete set if there is a internal damage.

3. Inspect the differential pins (2) for the scoring or wear.

4. Replace all the differential assembly components that are worn or damaged.

Greensmaster

e1021/e1026

Page 4–33

Traction and Reel Drive Systems: Service and Repairs

20246SL Rev A

Summary of Contents for 04831

Page 1: ... No 20246SL Rev A Greensmaster e1021 e1026 Models 04831 and 04841 2021 The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 Original Instructions EN Contact us at www Toro com All Rights Reserved ...

Page 2: ...Revision History Revision Date Description A 06 2021 Initial issue Revision History Page 2 Greensmaster e1021 e1026 20246SL Rev A ...

Page 3: ...ly we encourage user feedback Please comment on the completeness accuracy organization usability and readability of this manual by an e mail to servicemanuals toro com or Mail to Technical Publication Manager Commercial The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 1196 Phone 1 952 887 8495 Greensmaster e1021 e1026 Page 3 Reader Comments 20246SL Rev A ...

Page 4: ...NOTES NOTES Page 4 Greensmaster e1021 e1026 20246SL Rev A ...

Page 5: ... publication without notice DANGER This safety symbol means danger When you see this symbol carefully read the instructions that follow Failure to obey the instructions could kill or cause serious permanent injury or disability WARNING This safety symbol means warning When you see this symbol carefully read the instructions that follow Failure to obey the instructions can result in serious injury ...

Page 6: ...g340650 Figure 1 Model 04831 shown Preface Page 6 Greensmaster e1021 e1026 20246SL Rev A ...

Page 7: ...uence component orientation that may not be obvious Critical Torque This icon is used to highlight an assembly torque requirement that is different than what is recommended in the Standard Torque Tables refer to Torque Specifications page 2 5 Fluid Specifications This icon is used to highlight fluid specifications and capacities that are less common and may not appear on the machine service decal ...

Page 8: ...13 Chapter 4 Traction and Reel Drive Systems 4 1 General Information 4 2 Adjustments 4 3 Service and Repairs 4 5 Chapter 5 Electrical System 5 1 General Information 5 2 Electrical System Operation 5 4 Adjustments 5 20 Testing the Electrical Components 5 21 Service and Repairs 5 42 Chapter 6 Controls Wheels and Accessories 6 1 General Information 6 2 Adjustments 6 3 Service and Repairs 6 4 Chapter ...

Page 9: ...Chapter 1 Safety Table of Contents Safety Instructions 1 2 Safety and Instructional Decals 1 5 Greensmaster e1021 e1026 Page 1 1 Safety 20246SL Rev A ...

Page 10: ...e the unit is running or shortly after it has been running Allow the engine muffler and other components to cool before working near them Avoid fires and explosions Use extreme care in handling fuel Fuel is flammable and its vapors are explosive Extinguish all cigarettes cigars pipes and other sources of ignition Avoid spilling fuel and never smoke while working with any type of fuel or lubricant ...

Page 11: ...proved procedure Avoid unsafe machine operation Always test the safety interlock system after making adjustments or repairs on the machine Refer to the Chapter 5 Electrical System page 5 1 in this manual for more information Avoid electrical shock Never touch electrical wires or components while the engine is running They can be sources of shock De energize the system if you are having to do repai...

Page 12: ... fire extinguishers are for ordinary combustible materials such as paper wood cardboard and most plastics The numerical rating on these types of extinguishers indicates the amount of water it holds and the amount of fire it can extinguish Geometric symbol green triangle Class B fire extinguishers are for fires that involve flammable or combustible liquids such as gasoline kerosene grease and oil T...

Page 13: ...nit 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 e1021 e1026 Page 1 5 Safety Safety and Instructional Decals 20246SL Rev A ...

Page 14: ...Safety Safety and Instructional Decals Page 1 6 Greensmaster e1021 e1026 20246SL Rev A ...

Page 15: ...ications 2 5 Calculating the Torque Values When Using a Drive Adapter Wrench 2 6 Identifying the Fastener 2 7 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 2 8 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners 2 9 Other Torque Specifications 2 10 Conversion Factors 2 10 Shop Supplies 2 11 Special Tools 2 13 Greensmaster e1021 e1026 Page 2 1 Specificatio...

Page 16: ...Specifications Overall Dimensions g340649 Figure 2 Specifications and Maintenance Specifications Page 2 2 Greensmaster e1021 e1026 20246SL Rev A ...

Page 17: ...ations Height of cut Cutting height is adjusted on the front roller by two vertical screws Standard bench height of cut range is 1 6 to 16 mm 0 062 to 0 625 inch depending on type of bedknife installed An optional high height of cut kit is available to obtain a cut range of 11 1 to 30 mm 0 438 to 1 2 inch Effective HOC may vary depending on turf conditions type of bedknife rollers attachments inst...

Page 18: ...ting 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 Width of groomer 54 6 cm 21 5 inches Height adjustment knob Allows a 0 003 inch 0 08 mm increment of height adjustment for each click of the adjuster Quick up feature Allow...

Page 19: ...que feature e g Nylocknut hardness of the surface underneath the head of the fastener or similar condition which affects the installation As noted in the following tables the torque values should be reduced by 25 for the lubricated fasteners to achieve the similar stress as a dry fastener The torque values must be reduced when the fastener is threaded into the aluminum or brass The specific torque...

Page 20: ...rque When using a torque wrench with a drive adapter wrench the calculated torque will be lower than the listed torque recommendation Example The measured effective length of the torque wrench distance from the center of the handle to the center of the square drive is 457 mm 18 inches The measured effective length of the torque wrench with the drive adapter wrench installed distance from the cente...

Page 21: ...ed into the fastener and pre applied dry thread locking compound Keep in mind a fastener with a locking feature usually means there will be friction during initial installation and during removal 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 wi...

Page 22: ... 50 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 6 75 8 77 8 104 11 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 11 142 15 1 2 20 UNF 32 4 53 7 72 9 85 9 115 12 120 12 163 16 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 21 285 28 5 8 18 UNF 75 10 95 15 129 20 170 18 230 24 240 24 325 33 3 4 10 UNC 93 12 140 20 190 27 265 27 359 37 375 38 508 52 3 4 16 UNF 115 15 165 25 224 34 300 30 407 41 420 4...

Page 23: ... M20 X 2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610 62 N m Note Reduce the torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or a thread sealant such as Loctite Note The torque values must be reduced when installing the fasteners into threaded aluminum or brass The specified torque value sho...

Page 24: ...lb 88 14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1 5 Class 8 8 80 10 ft lb 108 14 N m For steel wheels and non lubricated fasteners Thread Cutting Screws Zinc Plated Steel Threads per Inch Thread Size Type A Type B Baseline Torque No 6 18 20 20 5 in lb No 8 15 18 30 5 in lb No 10 12 16 38 7 in lb No 12 11 14 85 15 in lb The hole size material...

Page 25: ...tener installation Most thread locking compounds allow the fastener to be removed with standard tools once cured High strength thread locking compounds may require applying heat to the fastener and the surrounding area to allow fastener removal Note Some fasteners have a dry thread locking compound pre applied Patch Loc so no additional thread locking compound is necessary when installing a new fa...

Page 26: ...due and previously used gaskets or gasket compounds SILICONE SEALANT Designed for a broad variety of sealing and bonding requirements silicone sealants are usually room temperature vulcanizing RTV which form a flexible silicone rubber that bonds to a wide variety of smooth or porous materials when cured Standard silicone sealants are designed to perform in temperatures from 51F to 232C 60F to 400F...

Page 27: ...prevent corrosion of unsealed connection terminals To ensure complete coating of the terminals liberally apply the gel to the component and wire harness connector plug the connector into the component unplug the connector apply the gel to both surfaces again and connect the harness connector to the component again The connectors must be fully packed with gel for effective results Note Do not use t...

Page 28: ... clearance Backlapping Brush Assembly K Line Part No 29 9100 For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel Components for the brush assembly are also available individually Brush 36 4310 Handle 29 9080 Handle cap 2410 18 Reel Drive Shaft K Line Part No TOR4112 Use the drive shaft for rotating the reel during cutting unit adjustment or any...

Page 29: ...rind the bedknife after installing it to the bedbar 1 Place the angle indicator on the bottom side of the bedknife with the digital display facing you as shown 2 Press the Alt Zero button on the angle indicator g223327 Figure 6 1 Bedknife 3 Bedbar 2 Angle Indicator 3 Remove the angle indicator and place the magnetic mount on the edge of the bedknife so the face of the magnet is flat against the to...

Page 30: ... of cutting reel and other spherical components Tape calibration is in fixed inch readings no adjustments Roller Rebuilding Tools The following combination of washers and spacers can be used to install bearings and seals into the front and rear rollers 2 each required Bearing installation washer 107 8133 black Seal installation spacer 107 3505 Seal installation washer 104 6126 yellow K Line Part N...

Page 31: ... Performance and Using the Turf Evaluator Toro part no 97931SL available from your local authorized Toro Distributor Drive Shaft Removal Tool Toro Part No 137 0920 Use to remove the optional Universal Groomer drive shaft from the reel if the drive shaft hex is damaged Adapter Wrench Toro Part No 137 0921 Use to hold the optional Universal Groomer drive shaft securely when removing or installing th...

Page 32: ... and install the rotor from the electric motor housing The tool includes the puller hub threaded shaft handle and four screws Lithium Ion Battery Service Wire Harness Toro Part No 122 1947 Use to identify a failing battery or determine if the lithium ion battery controller or battery interface harness is working correctly 1 Disconnect the battery interface harness from the BMS and the battery 2 Co...

Page 33: ...Potential Causes 3 2 Assess Performance 3 2 Repair 3 2 Solution Confirmation 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 3 12 Grooming Reel Mechanical Problems 3 13 Greensmaster e1021 e1026 Page 3 1 Troubleshooting 20246SL Rev A ...

Page 34: ...rrow down the focus of the problem Assess Performance Ensure you have all the necessary tools for testing Test all potential causes of the failure Reevaluate and create a new hypothesis if necessary Repair Return the unit to service by repairing rebuilding or replacing Solution Confirmation Did the issue go away Was the root cause of the issue correctly repaired Are there any other new symptoms Tr...

Page 35: ...onality cutting unit disengaged and reduced traction speed Battery charging is necessary before returning the machine to normal operation 204 Energy Saving Mode Warning If the battery state of charge is too low for normal machine operation the energy saving mode warning advisory will notify the operator that the machine will start operating with reduced functionality cutting unit disengaged and re...

Page 36: ...fies that the battery operating temperature is too high and the controller was denied the motor operation 216 Battery Voltage Too High This advisory notifies that the battery operating voltage is too high and the controller was denied the motor operation 217 Battery Draw Too High This advisory notifies an over current situation and the controller was denied the motor operation 218 Backlap Enabled ...

Page 37: ...unctions to stop Then attempt to restart the machine to see if operation has returned to normal Some faults will be reset during the restart and will then allow normal function If a fault continues to occur further system evaluation and possible component repair or replacement will be necessary To return to the main menu screen from the faults screen press the menu back button as indicated by the ...

Page 38: ...fault is that the motor output torque will be limited This will result in reduced reel speed and potential stall 1 Let machine cool Note that this fault is not produced by a bad sensor 2 Open the rear discharge of the cutting unit 3 Reduce reel speed 4 Reduce mow speed 9 Internal Motor Fault Motor The motor detected an internal fault condition 1 Verify the battery is charged 2 Test for proper supp...

Page 39: ...contactor is opened and the bus discharged before shutting the machine down This discharge failed to go below the threshold in the required amount of time Most likely cause is a shorted contactor 17 Throttle Sensor Fault Master The sensor signals are outside the expected range Traction is disabled 1 Test the throttle sensor 2 Test the throttle sensor circuit wiring and connector P05 3 Replace thro...

Page 40: ... clean and secure Code E 0 2 3 High AC voltage error greater than 270 VAC Connect the charger to an AC power source that provides stable AC power between 85 270 VAC at 45 65 Hz Code E 0 2 4 Charger failed to initialize Disconnect the charger AC input and battery connections for 30 seconds then reconnect the charger Code E 0 2 5 Low AC voltage oscillation error The charger requires an AC power sour...

Page 41: ...damaged Check the key switch and circuit wires Repair as necessary The main contactor is damaged Check the main contactor and circuit wires Repair as necessary The wire harness connections or wires are loose or damaged Check the electrical connections Repair the wire harness as necessary The TEC is damaged Replace the TEC Traction Circuit is Inoperative Possible Causes Correction The speed control...

Page 42: ...e machine operation has returned to normal If the fault still remains use the Faults screen information in the InfoCenter section of this chapter to help identify source of problem Machine Operates But InfoCenter Display is Not Working Possible Causes Correction The wire harness connections or wires to the InfoCenter display are loose or damaged Check the electrical connections Repair the wiring a...

Page 43: ...e to reel contact Grind the reel to remove taper and or rifling Grind the bedknife to sharpen and or remove rifling A new bedknife must be ground or backlapped after installation to the bedbar Refer to Grinding the Bedknife page 7 13 for grinding information or the Traction Unit Operator s Manual for backlapping information Height of cut Effective or actual height of cut depends on the mower weigh...

Page 44: ... affect grooming performance Variables that Affect the Use and Performance of Grooming Reels 1 The growing season and weather conditions 2 General turf conditions 3 The frequency of grooming cutting number of cuttings per week and how many passes per cutting 4 The blade spacing on the grooming reel 5 The height of cut 6 The grooming depth 7 The type of grass on the green 8 The amount of time that ...

Page 45: ...t up information The grooming reel blades are bent damaged or missing Repair or replace blades if necessary The grooming reel shaft is bent or damaged Replace grooming reel shaft The turf is damaged or has uneven grooming Grooming depth is not equal on both ends of grooming reel Adjust depth if necessary Check and adjust cutting unit set up level bed knife to reel set height of cut etc Greensmaste...

Page 46: ...Troubleshooting Battery Charger Error and Fault Codes Page 3 14 Greensmaster e1021 e1026 20246SL Rev A ...

Page 47: ...ission 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 4 7 Drum Drive Gear Box Assembly 4 11 Drum Assembly 4 17 Transmission Gear Box Assembly 4 21 Differential Assembly 4 32 Greensmaster e1021 e1026 Page 4 1 Traction and Reel Drive Systems 20246SL Rev A ...

Page 48: ... the following procedure 1 Park the machine on a level surface Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 5 3 2 Locate the traction engage disengage lever on top of the transmission gear box assembly 3 To disengage the drum drive rotate the traction engage disengage lever to clockwise direction away from the center of transmission gear box assembly 4 To engage th...

Page 49: ...he 3 socket head screws 7 that secures the reel drive cover 6 to the reel drive assembly 1 and remove the reel drive cover to expose the reel drive belt 2 3 Check tension by depressing the belt item 2 in Figure 12 at mid span between pulleys with 18 to 22 N 4 to 5 lbs of force The belt should deflect 6 35 mm 0 25 inch If deflection is incorrect proceed to next step If deflection is correct continu...

Page 50: ...the bolt 4 Check the belt tension as per para 3 C Ensure that the reel drive gasket 5 is in position and install the reel drive cover 6 to the reel drive assembly 1 and secure with the 3 socket head screws 7 D 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 5 Connect the ba...

Page 51: ...cutting unit Removing the Reel Drive Belt Note Refer to Figure 13 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 Remove the 3 socket head screws 7 that secures the reel drive cover 6 to reel drive assembly 1 and remove the reel drive cover to expose the reel drive belt 2 Greensmaster e1021 e1026 Page 4...

Page 52: ...ive belt 2 onto the pulleys 3 Adjust the reel belt tension refer to Adjusting the Reel Drive Belt page 4 3 4 Ensure that the reel drive gasket 5 is in position and install the reel drive cover 6 to the reel drive assembly 1 and secure with the 3 socket head screws 7 5 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 hea...

Page 53: ... to Connecting the Lithium Battery Pack page 5 3 2 Slide the telescopic coupler item 8 in Figure 14 on the reel drive assembly 6 and disconnect the reel drive shaft from the transmission drive shaft 10 3 Loosen and remove the 2 screws 1 and the nut 7 that secures the reel drive assembly 6 to RH side plate 9 Remove the reel drive assembly 6 flat washers 3 spring washers 4 and spacers 2 and 11 from ...

Page 54: ... refer to Removing the Reel Drive Belt page 4 5 2 Remove and discard the reel drive gasket 4 from the reel drive housing 22 3 If necessary remove the expansion plug 13 from the reel drive cover 14 4 Remove the hex bolt 28 and plain washer 27 from the idler arm 26 and the nut 25 from the reel drive housing 22 5 Loosen and remove the socket head screw 11 that secures the idler arm 26 to the reel dri...

Page 55: ...ft driver 4 Install the reel shaft driver 21 into the reel drive housing 22 5 Install the retaining ring 17 to the reel drive housing 22 6 Slide the spacer 7 onto the reel shaft driver 21 7 Install hipro key 20 to then reel shaft driver 21 Apply anti seize lubricant at the top of the key 8 Install the reel pulley 15 onto the reel shaft driver 21 Secure the reel pulley 15 with the lock nut 9 9 Torq...

Page 56: ... refer to Adjusting the Reel Drive Belt page 4 3 Installing the Reel Drive Assembly Note Refer to Figure 14 during this procedure 1 Place the V ring seal 5 into the reel drive assembly 6 2 Install telescopic coupler 8 to the reel drive shaft 3 Install the reel drive assembly 6 washers 3 spring washer 4 and spacers 2 and 11 to the RH side plate 9 and secure the reel drive assembly 6 with 2 screws 1...

Page 57: ...e Refer to Figure 17 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 Remove the transport wheel if attached refer to Removing the Transport Wheel page 6 22 Note Support the machine on kickstand during this operation 3 Move the traction engage disengage lever to the disengage position to remove torque fr...

Page 58: ...the RH drum drive gear box assembly 5 8 Remove the truss screw 12 nut 9 and washer 11 that secures the 2 splined couplers 11 to the transmission gear box assembly 1 and LH drum drive gear box assembly 5 9 Remove the shoulder bolt 8 that secures the LH drum drive gear box assembly 5 to the frame assembly 7 10 Remove the 3 shoulder bolts 3 that secures the LH drum drive gear box assembly 5 to the tr...

Page 59: ...r 32 O ring 9 Wire spring 21 Spur gear 33 Dowel pin 2 each 10 Oil seal 22 Socket head screw 34 Bearing spacer 11 Spur gear 23 Ball bearing 2 each 12 Nut 24 Wave washer Note Refer to Figure 18 during this procedure 1 Remove the 5 socket head screws 15 that secures the drum drive cover 14 to the drum drive housing 25 2 Remove and discard the gasket 8 from the drum drive housing 25 3 If necessary rem...

Page 60: ...l bearings after removal 8 Remove the nut 17 and bearing pin 31 that secures the spur gear 20 to the drum drive housing 25 9 Remove the spur gear 20 and bearing spacer 34 from the drum drive housing 25 10 Remove and discard the O ring 32 from the bearing pin 31 11 If the spur gear bearings 19 are to be removed remove the retaining rings 18 and use a press to remove the ball bearings 19 Discard the...

Page 61: ...ings 6 bearing spacer 7 spring washer 9 and drum drive shaft 5 to the drum drive housing 25 Note The outer diameter and inner diameter of the ball bearings 6 must be slip fit 6 Install the V ring seal 4 onto the drum outer hub 3 Install the key 30 to the drum drive shaft 5 and apply anti seize lubricant at the top of the key Slide the drum outer hub 3 to the drum drive shaft 5 and secure with the ...

Page 62: ...e tighten the hexagonal shaft to 54 to 67 7 N m 40 to 50 ft lb 2 Apply a light coat of grease and install the O ring 29 to the drum drive housing 25 3 If removed slide the drive tube item 6 in Figure 17 onto the transmission gear box assembly 1 4 Install the LH and RH drum drive gear box assemblies Item 5 in Figure 17 to the frame assembly 7 and secure with the shoulder bolts 8 5 Install the LH an...

Page 63: ...emoving the Drum Assembly Note Refer to Figure 20 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 Remove the LH and RH drum drive gear box assemblies 5 refer to Removing the Drum Drive Gear Box Assembly page 4 11 3 Remove the traction drum 2 from the frame assembly 7 Greensmaster e1021 e1026 Page 4 17 T...

Page 64: ...e 5 2 Remove the 4 bolts 2 and lock washers 3 that secures the drum hub plate 4 to the drum hub 10 3 Remove the shoulder bolts 11 that secures the drum hub plate 4 to the traction drum 1 4 Remove the lock nut 12 that secures the drum spindle 5 and drum hub 10 together Carefully slide and remove the drum spindle 5 out of the drum hub 10 5 Remove the 2 seals 6 from the drum hub 10 Use a press to rem...

Page 65: ... spindle 5 can move axially relative to the drum hub 1 Note The lock nut 3 turns hard on the drum spindle 5 when tightened Ensure that all rotation has stopped when tightening A good solid sound indicates the nut is full tight 4 Install the drum hub plate 4 into the traction drum 1 and secure with shoulder bolt 11 Note The fit between the drum hub plate item 4 in Figure 21 and drum 1 is a close to...

Page 66: ...ox assembly item 5 in Figure 20 and traction drum 2 onto the frame assembly 7 3 Secure the LH and RH drum drive gear box assembly 5 to the traction drum 2 refer to Installing the Drum Drive Gear Box Assembly page 4 16 4 Connect the battery pack refer to Connecting the Lithium Battery Pack page 5 3 Traction and Reel Drive Systems Service and Repairs Page 4 20 Greensmaster e1021 e1026 20246SL Rev A ...

Page 67: ... O ring 4 Lock nut 2 each 11 Socket head screw 4 each 18 Reel drive coupling 5 Drive shaft 12 Motor adaptor 19 Drive tube 6 Frame assembly 13 Socket head screw 3 each 7 Slide adaptor 14 V ring seal Removal of transmission gear box assembly is necessary in order to service the internal components Greensmaster e1021 e1026 Page 4 21 Traction and Reel Drive Systems Service and Repairs 20246SL Rev A ...

Page 68: ...lined couplers from the drive shaft 5 Remove the socket head screw 13 that secures the motor adaptor 12 and transmission gear box assembly 10 to the frame assembly 6 6 Remove the two flange head bolts 9 that secures the transmission gear box assembly 10 to the frame assembly 6 Remove the transmission gear box assembly with electric motor 16 from the frame assembly 6 7 Remove the two socket head sc...

Page 69: ...ORB plug 18 O ring seal 28 E ring 9 Detent spring 19 Traction selector shaft 29 Adapter vent 10 Detent ball 20 Groomer pin 30 Breather vent Note Refer to Figure 24 during this procedure 1 Remove the hollow hex plug item 27 in Figure 24 breather vent 30 and adapter vent 29 from the transmission gear box assembly 26 2 Remove the 12 socket head screws 24 that secures the transmission cover assembly 2...

Page 70: ...ake plate retainer 25 Bolt 8 Bolt 2 each 17 Retaining ring 9 Differential shaft 2 each 18 Brake band 4 Remove the neutral spur gear assembly item 5 in Figure 25 and wave washer 3 from the transmission housing assembly 23 5 Use a press to remove the ball bearings 4 from the neutral slider shaft 6 Remove the square keys 7 from the neutral slider shaft 6 Discard the ball bearings 6 Remove the differe...

Page 71: ...n housing assembly 23 Remove the retainer plate 15 from the transmission housing assembly 23 12 Slide and remove the brake lever assembly 19 from the transmission housing assembly 23 Remove the flat wire spring 22 from the transmission housing assembly 23 13 Disassemble the brake lever assembly 19 as follows A Remove the retaining ring 17 from the brake clevis pin 21 B Slide and remove the brake c...

Page 72: ...ear 14 Slider spur gear 14 Slide and remove the reel clutch actuator item 16 in Figure 26 from the transmission housing assembly 20 If necessary remove the reel clutch shoe 15 from the reel clutch actuator 16 15 Remove the reel drive shaft assembly 12 ball bearing 10 and wave spring 9 from the transmission housing assembly 20 If necessary disassemble the drive shaft assembly 12 as follows A Use a ...

Page 73: ... the 2 ball bearings 6 from the spur gear 17 Discard the ball bearings 6 22 Remove the thin lock nut 18 that secures the input shaft 19 to the transmission housing assembly 20 Slide and remove the input shaft 23 Remove the ORB plug item 8 in Figure 24 detent spring 9 and detent ball 10 from the transmission housing assembly 26 24 Loosen and remove the groomer pin item 20 in Figure 24 from the trac...

Page 74: ...Figure 24 and slide onto the groove of the traction selector shaft 19 10 Insert the straight bushings item 4 in Figure 24 into the transmission housing 26 Press the straight bushings into the transmission housing bore so that the bushings are recessed from the edge of the transmission housing 11 Apply a coat of grease to the O ring item 18 in Figure 24 and slide onto the traction selector shaft it...

Page 75: ...in through brake band into the transmission housing assembly item 23 in Figure 25 place the flat wire spring 22 and brake plate retainer 16 onto the transmission housing assembly 27 Place the retainer plate pin item 15 in Figure 25 onto the transmission housing assembly 23 and secure it with the 2 bolts 8 28 Slide and install the external retaining ring item 1 in Figure 25 cable brake lever 24 ont...

Page 76: ...ng 44 If removed insert the 2 dowel pins item 17 in Figure 24 into the transmission housing assembly 26 45 Install the new transmission gasket item 22 in Figure 24 and transmission cover assembly 23 onto the transmission housing 26 by aligning the holes Secure the transmission cover assembly with 12 bolts 24 and torque tighten to 1 7 to 4 5 N m 15 to 40 in lb Use an alternation pattern and torque ...

Page 77: ...osition with jam nut 8 onto the transmission gear box assembly 10 4 Install the splined couplers 2 to the drive shaft 5 and secure with truss screws 1 washers 3 and nuts 4 Torque tighten the truss screws to 10 to 12 4 N m 90 to 110 in lb 5 Slide the hex tube 16 onto the reel drive box assembly and lock with collar lock 15 6 If removed install the reel cable refer to Installing the Reel Cable page ...

Page 78: ...embly 23 Transmission housing assembly 6 Neutral slider shaft 15 Retainer plate pin 24 Cable brake lever 7 Square key 2 each 16 Brake plate retainer 25 Bolt 8 Bolt 2 each 17 Retaining ring 9 Differential shaft 2 each 18 Brake band Removing the Differential Assembly To remove the differential assembly from the transmission gear box assembly refer to Disassembling the Transmission Gear Box Assembly ...

Page 79: ...ousings 1 apart 3 Use a press to remove the 6 differential pins 2 and 6 differential spur gears 3 from the differential housings 1 Inspecting the Differential Assembly 1 Clean all the differential assembly components 2 Inspect all the differential spur gears 3 carefully looking for chipped teeth wear or other damage Because gear tooth damage is rarely isolated to 1 gear replace the gears as comple...

Page 80: ... 5 Insert the differential spur gears 3 to the differential pins 2 by pointing the gears shoulder up 6 Fill the differential housing assembly 1 with 0 08 lb 1 25 oz of grease 7 Attach the 2 differential housings 1 to each other 8 Slide and install the differential housing assembly 1 into the differential gear 4 and secure with the 6 socket head screws 5 9 In alternate pattern torque tighten the so...

Page 81: ...play 5 10 Adjustments 5 20 Traction Bail Proximity Sensor 5 20 Testing the Electrical Components 5 21 Fuses 5 22 CAN bus 5 24 Toro Electronic Controller TEC 5 26 Lithium Ion Battery Controller BMS 5 28 Electric Motor 5 30 Key Switch 5 31 Throttle Potentiometer and Clutch Bail Potentiometer 5 33 Main Contactor 5 36 CAN bus Terminator Resistor 5 39 Relay 5 40 Service and Repairs 5 42 Electric Motor ...

Page 82: ...e parts Operator s Manual The Traction Unit Operator s Manual and Lithium Battery Pack Charger Operator s Manual provide information regarding the operation general maintenance and maintenance intervals for your Greensmaster machine and charger Refer to these Operator s Manuals for additional information when servicing the machine Electrical Schematics and Diagrams Refer to the Electrical Schemati...

Page 83: ...me with the product Only use the charger designed for the battery CAUTION Always disconnect the batteries at the battery disconnect provided when servicing products with lithium ion batteries Failure to do so may result in personal injury and property damage g338368 Figure 30 1 Machine connector 3 Battery connector 2 Battery pack To prevent unexpected machine operation during service disconnect th...

Page 84: ...al controllers in the battery pack and electric motor along with direction from the machine TEC via the CAN bus system The InfoCenter display provides information to the operator during the operation of the machine provides electrical system diagnostic assistance for the technicians and allows inputs for the adjustable machine settings The status of TEC inputs and outputs can be monitored with the...

Page 85: ...achine will be ready for operation 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 Actual motor speed is monitored by the TEC...

Page 86: ...s controlled by the CAN bus link only needs four 4 wires to operate and communicate to the system CAN High CAN Low power and ground The key switch needs to be in the RUN or START position for the components on the network to be activated Two specially designed twisted wires form the CAN bus These wires provide the data pathways between the components on the network The engineering term for these c...

Page 87: ...nsole If a problem exists that could prevent normal operation the InfoCenter display will display an operator advisory or fault code to assist in identifying the problem The TEC is attached to the battery mount inside the battery cover refer to Figure 32 IMPORTANT Before performing any welding on the machine do the following to prevent damaging the electrical system of the machine Disconnect the m...

Page 88: ... connected before machine operation can occur 2 Protects the battery from operating discharging and charging outside their safe operating voltage amperage and temperature ranges 3 Operates an internal contactor to connect and disconnect the battery from the machine and the battery charger Note When the key switch is set to the Off position the BMS delays disconnecting the battery from the machine ...

Page 89: ...u will void the warranty The controller case is protected by tamper alerting devices 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 e1021 e1026 Page 5 9 Electrical System Electrical System Operat...

Page 90: ...or the InfoCenter is available when energized by the TEC the key switch is in the START or RUN position A CAN bus system involving the TEC electric motor controller and lithium ion battery pack provides necessary machine communication for the InfoCenter operation Note Icons that are used on the InfoCenter display are identified in the Traction Unit Operator s Manual Note If the InfoCenter display ...

Page 91: ...KEY SWITCHED ON AFTER 5 SECONDS MAIN INFORMATION SCREEN g339628 Figure 35 Greensmaster e1021 e1026 Page 5 11 Electrical System Electrical System Operation 20246SL Rev A ...

Page 92: ...InfoCenter splash screen appears Figure 36 The splash screen provides the hour meter information After the splash screen has been displayed for 5 seconds the main information screen will appear on the InfoCenter screen Main Information Screen g339629 Figure 37 1 Speed control setting 4 Menu back button 2 Left right button 5 Fault log indicator 3 Down button 6 Battery indicator Electrical System El...

Page 93: ...InfoCenter screen will be displayed to notify the operator that recent machine faults have occurred Accessing the fault log is described below in the Faults Screen page 5 15 Main Menu Service Diagnostics g339630 Figure 38 1 Main menu 4 Menu back button 2 Left right button 5 Menu items 3 Down button The main menu and additional information screens can be accessed from the InfoCenter main informatio...

Page 94: ...igure 40 1 Main menu 4 Menu back button 2 Left right button 5 Menu items 3 Down button The main menu screen can be accessed from the InfoCenter main information screen by pressing and releasing the menu back button as indicated by at the bottom of the screen on the display Once to the main menu screen Figure 40 navigation to the 5 different menu items can occur The main menu screen provides access...

Page 95: ...ed in the Machine Faults page 3 5 The InfoCenter fault log can be cleared by selecting the clear system faults menu item The cleared faults will be removed from the InfoCenter but will be retained in the TEC memory If a fault occurs during machine use there may be a change in machine functionality due to the fault Should there be machine operation issues due to a fault a first step to remedy the i...

Page 96: ...ry current amps delivered by battery Battery volts battery potential in volts Total usage total usage of the battery over its entire life in Amp hours Capacity total capacity of the battery in Amp hours Charge cycles Total number of charge cycles Battery hours Total number of hours of battery usage Backlap Enable disable the backlap Values listed for service menu items cannot be changed To return ...

Page 97: ...key switch is in the RUN position Key Start indicates that the key switch is in the START position or not Note The key start position can be verified in the diagnostics screen by rotating the switch to the START position The motor will re initialize Traction identifies that the traction lever is engaged or not engaged Throttle identifies the throttle control setting in volts that is used by the TE...

Page 98: ... the operator to customize the backlight brightness and contrast settings for the InfoCenter display Units Use the left right button as indicated by the at the bottom of the screen to select between metric or English units of measure Allow the desired selection to remain in view for 5 seconds Language Use the left right button as indicated by the at the bottom of the screen to select from numerous...

Page 99: ... 3 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 Greensmaster e1021 e1026 Page 5 19 Electrical System Electrical System Operation 20246SL Rev A ...

Page 100: ... control cover from the machine 4 Get access to the proximity sensor Pull up and release the traction bail 5 When the bail is open adjust the proximity sensor gap to 2 3 to 3 8 mm 0 09 to 0 15 in 6 If the clearance is incorrect loosen the proximity sensor jam nuts and adjust the clearance 7 After achieving the required clearance torque tighten the proximity sensor jam nuts to 18 3 to 22 3 N m 13 5...

Page 101: ...it The machine frame is not used for any ground connections For accurate resistance and or continuity checks electrically disconnect the component being tested from the circuit e g unplug the key switch connector before doing a continuity check on switch Individual components should be electrically isolated e g disconnect all the leads or remove the leads from the circuit from the circuit when tes...

Page 102: ...es the battery cover to the battery mount refer to Figure 47 Remove the battery cover from the battery mount Fuse Identification and Function g338649 Figure 48 1 Fuse F1 1 30 A 3 Fuse F1 3 3 A 2 Fuse F1 2 3 A 4 Fuse F1 4 open Refer to Figure 48 to identify each individual fuse and its correct amperage The fuses for the Greensmaster e1021 e1026 machines have the following functions Fuse F1 1 30 A P...

Page 103: ...s necessary ensure to use the fuses as identified in your e1021 e1026 Parts Catalog Do not use regular automotive fuses in your e1021 e1026 machine 4 Carefully install the functional fuse into the fuse holder 5 After you complete the fuse service secure the battery cover to the machine with the 4 bolts 6 Connect the battery pack refer to Connecting the Lithium Battery Pack page 5 3 Greensmaster e1...

Page 104: ...rate and communicate to the system CAN High CAN Low power and ground The key switch needs to be in the RUN or START position for the components on the network to be activated Two specially designed twisted wires form the CAN bus These wires provide the data pathways between the components on the network The ering term for these cables are CAN High and CAN Low The CAN bus wires are red white CAN Hi...

Page 105: ...ohms indicates the CAN bus terminator resistor is not connected or damaged 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 e1021 e1026 Page 5 25 Electrical System Testing the Electrical Components 20246SL Rev A ...

Page 106: ...ry mount inside the battery cover refer to Figure 51 IMPORTANT Before performing any welding on the machine do the following to prevent damaging the electrical system of the machine Disconnect the machine connector from the lithium battery pack Disconnect the wire harness connectors from the Toro Electronic Controller Note If the TEC is replaced for any reason the machine software must be updated ...

Page 107: ...d outputs of the controller used on your Greensmaster refer to InfoCenter Display page 5 10 The InfoCenter display can also be used to identify faults and operator advisories that indicate operation issues with the machine Because of the solid state circuitry built into the controller there is no method to test it directly The controller may be damaged if an attempt is made to test it with an elec...

Page 108: ... uses the sub net to verify the presence and condition of the battery before allowing battery power to the machine The BMS is also connected to the CAN bus which allows it to forward battery information to the rest of the machine 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 updat...

Page 109: ...arness connector pin 6 and the BMS B terminal 3 An audible Click should come from the BMS shortly after the key switch is set to the ON position The Click sound indicates the contactor inside the BMS has closed and battery power should be available to the machine 4 Once the BMS internal contactor has closed battery pack voltage can be tested across the BMS positive and negative terminals 5 If CAN ...

Page 110: ...n 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 2 Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 5 3 3 Locate and disconnect the electric motor cable electrical connections at the machine wire harness Check the motor and the harness connector for damage or corr...

Page 111: ...ion suggests a damaged key switch proceed to the key switch testing below Note If the e1021 e1026 machine is sitting idle for 5 minutes with the key switch in the RUN position the machine will shut off Note A damaged key switch may cause a 12 fault to be generated and displayed on the InfoCenter Refer to the Faults Screen page 5 15 for information on faults Testing the Key Switch 1 Park the machin...

Page 112: ... Table page 5 32 Check the continuity between the switch terminals Circuit Logic Table Switch Position Circuits OFF None RUN B C F D E START A B C 6 Replace the key switch if necessary 7 After you complete the testing connect the wire harness electrical connector to the key switch 8 Install the InfoCenter mount to the handle refer to Figure 57 9 Connect the battery pack refer to Connecting the Lit...

Page 113: ... 8 Link shaft 18 Proximity sensor 28 Lock 9 Washer 19 Screw 2 each 29 Lock nut 2 each 10 Clevis pin 20 Screw 2 each The throttle and clutch bail potentiometers controls the electric motor speed which determines the traction speed The TEC uses the potentiometers setting as an input to determine the necessary signal output for the motor controller for correct electric motor speed The throttle potent...

Page 114: ...igure 59 Note Before taking the small resistance readings with a digital multimeter short the multimeter test leads together The meter displays a small resistance value usually 0 5 ohms or less This resistance is because of the internal resistance of the multimeter and test leads Subtract this value from the measured value of the component that you are testing g202576 Figure 60 1 Terminal A 3 Term...

Page 115: ...nstalling the potentiometers a minimum voltage reading of 0 5V for proper function is required This can be read in the InfoCenter The adjustment is completed by rotating the potentiometers in the mounting slots until the minimum voltage at the neutral position is achieved 7 Connect the battery pack refer to Connecting the Lithium Battery Pack page 5 3 Greensmaster e1021 e1026 Page 5 35 Electrical ...

Page 116: ...ck as each of these contactors are energized Note A damaged main contactor may cause a 16 fault to be generated and displayed on the InfoCenter Refer to the Faults Screen page 5 15 for information on faults Testing the Main Contactor 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 k...

Page 117: ... ground connection for main contactor voltage testing A Locate the wire harness connector for work lights located on the left side of the upper handle The connector will be identified with a tag and will have a pink and a black wire attached to the connector B Remove the plug or work light harness connector if the machine is equipped with optional work lights from the machine wire harness work lig...

Page 118: ...e system voltage 42 V to 64 V 100 state of charge present Figure 63 If 1 or more posts do not have system voltage present the contactor is damaged If none of the posts have voltage present ensure that common test probe is still connected to the work light connector and if so look for electrical issues at other machine components as the contactor is not being energized correctly F Turn the key swit...

Page 119: ...us terminator resistor Figure 64 can be tested using a digital multimeter ohms setting Locate the CAN bus terminator resistor and remove the cable tie that secures the resistor to the wire harness Unplug the resistor from the wire harness for testing 2 Check the resistor and resistor holder for damage or corrosion and clean or repair if necessary 3 Use a digital multimeter ohms setting to measure ...

Page 120: ... 3 Remove the four bolts that secures the battery cover to the battery mount Remove the battery cover from the machine 4 Disconnect the machine wire harness connector from the relay Remove the relay from the machine for ease of testing Note Prior to taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small resistance value usually...

Page 121: ...hould make and break continuity between terminals 30 and 87 as voltage is applied and removed from terminal 85 8 Replace the relay as necessary 9 If the relay tests correctly and a circuit problem still exists check the wire harnesses refer to Appendix A page A 1 10 Install the relay and connect the wire harness 11 Install the battery cover onto the battery mount Secure the battery cover with four...

Page 122: ...the Faults Screen page 5 15 for information on faults Removing the Electric Motor 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 2 Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 5 3 3 Disconnect the electric motor connections from the machi...

Page 123: ...l 6 onto the electric motor shaft 2 Apply a coat of anti seize to the key 7 and install the key onto the motor shaft 3 Position the electric motor to the transmission align the key of the motor shaft to the transmission coupler and insert the motor shaft into the coupler Slide the motor fully to the motor adaptor 4 4 Secure the electric motor to the motor adaptor 4 with the 4 socket head screws 3 ...

Page 124: ... to Special Tools page 2 13 Note When servicing the electric motor use a clean work space with a non metal surface The motor rotor includes very powerful magnets that can cause the rotor to move unexpectedly if working on a metal surface Also any metallic debris that gets attracted to the rotor can damage the motor after assembly Disassembling the Electric Motor Refer to Figure 68 for this procedu...

Page 125: ...revent it from falling during removal 7 Remove the motor cover and wave washer from the rotor assembly 8 Remove and discard the O rings from the motor cover 9 Remove and discard the O ring from the motor housing 10 If necessary remove and discard the bearings from the rotor 11 Inspect the electric motor components for wear or damage Replace components or complete electric motor assembly if necessa...

Page 126: ... magnets are very powerful and can cause the rotor to shift position very rapidly during installation Be cautious during rotor installation to prevent component damage or personal injury 7 While supporting the rotor and cover assembly slowly turn the rotor tool shaft to allow the rotor to be drawn into the housing assembly Once the rotor and cover assembly is fully seated in the housing remove the...

Page 127: ...er 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 g349592 Figure 71 1 Nut 3 Battery cable terminal typical 2 Washer 4 1 2 inch ID rubber hose Greensmaster e1021 e1026 Page 5 47 Electrical Syste...

Page 128: ... that secures the battery cover to the battery mount Remove the battery cover from the machine g338794 Figure 72 1 Lithium Ion battery controller 5 B terminal 2 Positive terminal 6 Negative terminal 3 B terminal 7 COM terminal 4 M S terminal 4 Label and disconnect the negative battery cable positive battery cable from the lithium ion battery controller B and B terminals 5 Label and disconnect the ...

Page 129: ...personal injury and property damage 9 Install the lithium ion battery controller in reverse order Install the controller with the positive terminals upward refer to Figure 70 and Figure 72 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 c...

Page 130: ...cipality or recycling facility Caring for the Lithium Ion Battery When mowing use the InfoCenter to monitor the state of charge of the lithium ion battery pack Consistently operating the machine with a very low state of charge will adversely affect the life of the battery If problems with the battery exist an advisory or fault may be identified on the IntoCenter refer to InfoCenter Display page 5 ...

Page 131: ...arger is disconnected and reconnected Shipping and Transporting the Lithium Ion Battery The US Department of Transportation and international transportation authorities require that lithium ion battery be shipped using special packaging and only be handled by carriers certified to haul them Use the original packaging whenever possible when shipping lithium ion battery in the USA If the original pa...

Page 132: ...battery pack whenever the machine is not in use Refer to the Operator s Manual for battery charging and battery charger operation information Refer to Battery Charger Error and Fault Codes in this manual for battery charger troubleshooting information Removing the Lithium Ion Battery WARNING When removing or installing the battery Always disconnect the battery at the battery disconnect provided wh...

Page 133: ...e CAUTION To prevent accidentally shorting a disconnected battery cable across other components or tools insulate the battery cable terminal with a 76 mm 3 inch length of 1 2 inch internal diameter rubber hose immediately after disconnecting the cables Failure to do so may result in personal injury and property damage refer to Figure 73 g339372 Figure 73 1 Battery cable terminal typical 2 1 2 inch...

Page 134: ...m Battery Pack page 5 3 3 Remove the four bolts that secures the battery cover to the battery mount Remove the battery cover from the machine 4 Label and disconnect the negative battery cable positive battery cable and battery interface harness from the lithium ion battery refer to Figure 74 g361750 Figure 75 1 Bolt 4 each 4 Battery mount 2 Washer 4 each 5 Nut 4 each 3 Lithium ion battery 5 Remove...

Page 135: ...ith the positive terminal towards the front side and the negative terminal towards rear side of the machine 2 After installing the battery into the battery mount secure the battery with four bolts washers and nuts 3 Torque tighten the bolts 1 from 2 8 to 3 9 N m 25 to 35 in lb 4 Using the labels that attached during the removal connect the battery interface cable positive battery cable and negativ...

Page 136: ...Electrical System Service and Repairs Page 5 56 Greensmaster e1021 e1026 20246SL Rev A ...

Page 137: ... 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 6 9 Brake Latch Shaft 6 11 Handle Assembly 6 13 Kickstand 6 20 Transport Wheels Optional 6 22 Rail Kit Wheels Optional 6 25 Greensmaster e1021 e1026 Page 6 1 Controls Wheels and Accessories 20246SL Rev A ...

Page 138: ...egarding 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 e1021 e1026 20246SL Rev A ...

Page 139: ... parking brake is released 2 Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 5 3 3 To remove slack from the reel cable perform the following steps A Move the reel selector knob to the high reel speed position refer to Figure 76 B Loosen the rear jam nut and tighten the front jam nut refer to Figure 77 4 Connect the battery pack refer to Connecting the Lithium Battery ...

Page 140: ...able Removing the Brake Cable Note Refer to Figure 78 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 and parking brake is released 2 Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 5 3 Controls Wheels and Accessories Service and Repairs Page 6 4 Greensmaster e1021 e1026 2...

Page 141: ... spring 7 from the spring anchor on the brake lever assembly 3 Note the orientation of the brake cable spring hook on the brake lever assembly for assembly purpose 6 Remove the brake cable 9 from the machine Installing the Brake Cable 1 Secure the brake cable 9 to the brake lever assembly as follows A Install the cable spring 7 to the spring anchor on the brake lever assembly 3 B Slide the brake c...

Page 142: ...t the brake cable lever assembly Adjust the cable jam nuts to remove the slack in the brake cable 4 Check the brake cable adjustment refer to Operator s Manual 5 Install the lower cover and control cover to the handle assembly 6 Connect the battery pack refer to Connecting the Lithium Battery Pack page 5 3 Controls Wheels and Accessories Service and Repairs Page 6 6 Greensmaster e1021 e1026 20246S...

Page 143: ...r Removing the Reel Cable Note Refer to Figure 80 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 g361589 Figure 81 1 Retaining ring 3 Jam nut 2 Reel selector assembly 4 Reel cable Greensmaster e1021 e1026 Page 6 7 Cont...

Page 144: ...as follows A Install the cable spring 3 to the clevis connector 10 on the reel lever assembly 7 Orientate the cable spring hook end toward front of the machine B Slide the cable 1 into the upper receiver weldment 12 Ensure that the jam nut 2 flat washer and lock washer are on both sides of the bracket Adjust jam nuts so that equal amount of cable threads are visible above the jam nuts Leave the ja...

Page 145: ... spacer 7 Extension spring 2 each 16 Split bushing 25 Upper receiver weldment 8 Controls cover 17 Socket cap 26 Flange nut 9 Bolt and washer assembly 8 each 18 Cotter pin clip 27 Reel lever assembly Disassembling the Cutting Unit Drive Lever Assembly Note Refer to Figure 82 during this procedure 1 Park the machine on a level surface Ensure that the key switch is in OFF position and the traction co...

Page 146: ... 16 and 12 from the main control shaft Assembling the Cutting Unit Drive Lever Assembly 1 If removed apply a coat of grease in inner diameter of split bushings item 16 and 12 in Figure 82 and install the split bushing onto the main control shaft 15 2 Position the main control shaft 15 on the upper receiver weldment 25 and secure the main control shaft 15 with control shaft clamps 5 and the bolts 6...

Page 147: ... the traction control is in NEUTRAL 2 Disconnect the battery pack refer to Connecting the Lithium Battery Pack page 5 3 3 Remove the bolts and washers that secures the controls covers to the upper receiver weldment 4 Using the drift pin remove the roll pin 5 from the brake lock lever 4 5 Slide and remove the brake lock lever 4 from the brake latch shaft 9 6 Slide and remove the brake latch shaft 9...

Page 148: ...t 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 4 Install the control covers to the handle assembly with bolts and washers 5 Connect the battery pack refer to Connecting the Lithium Battery Pack page 5 3 Controls Wheels and Accessories Service and Repairs Page 6 12 Greensmaster e1021 e1026 20246SL Rev A ...

Page 149: ...Flange bushing 2 each 17 Brake cable 29 Bolt 6 Lever 18 Cotter pin 30 Bolt 7 Flange nut 4 each 19 Lower handle assembly 31 Flange bushing 2 each 8 Upper receiver weldment 20 Flange nut 32 Bolt 9 Nut 21 Bolt 33 Bolt 2 each 10 Bolt 22 Handle adjuster assembly 34 Throttle lever 11 Bolt 23 Handle torsion spring 12 Bolt 24 Spring spacer Greensmaster e1021 e1026 Page 6 13 Controls Wheels and Accessories...

Page 150: ...k nut 24 Screw 2 each 5 Key switch 15 Lock 25 Potentiometer sensor 6 Bail catch fork 16 Potentiometer sensor 26 Control bail lever 7 Clip pin 2 each 17 Mount 27 Throttle cable 8 Link shaft 18 Proximity sensor 28 Lock 9 Washer 19 Screw 2 each 29 Lock nut 2 each 10 Clevis pin 20 Screw 2 each Controls Wheels and Accessories Service and Repairs Page 6 14 Greensmaster e1021 e1026 20246SL Rev A ...

Page 151: ...dment 8 which acts as a throttle arm stop bolt 14 Remove the nut 20 washer 2 and bolt 30 that secures the throttle arm 1 to the handle assembly 3 Remove the throttle arm from the handle assembly 15 If necessary remove the screw 32 that secures the throttle lever 34 to the throttle arm 1 Slide and remove the throttle lever from the throttle arm 16 If necessary remove the flange bushings 31 from the...

Page 152: ... Handle 5 Clutch bail link 11 Bolt 2 each 17 Bolt 2 each 6 Compression spring 12 Flange bushing 2 each 26 Remove the 2 nuts item 8 in Figure 86 and 2 bolts 17 that secures the handle 16 to handle mount 7 Remove the handle from the clutch bail assembly and the handle mount 27 If necessary remove the 2 screws 14 that secures the LH and RH bail brackets 1 and 15 to the handle 16 28 Remove the flange ...

Page 153: ... 3 and bolt 2 that secures the lower handle assembly 1 to the frame assembly 5 Assembling the Handle Assembly 1 If removed install the lower handle assembly item 1 in Figure 87 onto the frame assembly 5 and secure with the bolt 2 washers 3 and nut 4 2 Lift the lower handle assembly to maximum top position and torque tighten the bolt 2 to 5 6 to 6 2 N m 50 to 55 ft lb 3 Install the handle mount ite...

Page 154: ...iver weldment 8 and secure with the shoulder screw 4 and flange nut 7 14 Install the InfoCenter mount item 4 in Figure 85 onto the handle and secure with the 4 screws 1 15 Install the wire harness 16 If removed install the flange bushings item 31 in Figure 84 inside the throttle arm 1 17 If removed slide the throttle lever 34 onto the throttle arm 1 and secure with bolt 32 18 Torque tighten the bo...

Page 155: ...bly and secure with the 4 bolts 29 Install the controls 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 Greensmaster e1021 e1026 Page 6 19 Controls Wheels and Accessories Service and Repairs 20246SL Rev A ...

Page 156: ...8 Compression spring 5 Nut 12 Bolt 2 each 19 E ring 6 Flat washer 2 each 13 Plain washer 2 each 7 Lock nut 14 Spring retainer 2 each Removing the Kickstand CAUTION Be careful when removing or applying tension from or to the torsion spring of the kickstand The spring is under heavy load and may cause personal injury Controls Wheels and Accessories Service and Repairs Page 6 20 Greensmaster e1021 e1...

Page 157: ...the kickstand 16 from the frame 1 8 If necessary remove the spring retainer 14 by removing the nut 15 washer 13 and bolt 12 9 If necessary remove the spacers 10 from the kickstand 16 Installing the Kickstand g337280 Figure 89 1 Kickstand raised 3 Kickstand lowered 2 Torsion spring 1 If removed install the spacers 10 to the kickstand 16 2 If removed secure the spring retainer 14 to kickstand with t...

Page 158: ...4 Tire 9 Wheel retaining lever 5 Inner tube 10 Shoulder screw 2 each Removing the Transport 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 Support the machine onto the machine onto the kickstand Controls Wheels and Accessories Service and Repairs Page 6 22 Greensmaster e1021 e1026 20246SL Rev A ...

Page 159: ...bly of the wheel 2 Remove the 3 bolts and 3 lock washers from the shallow rim and hub Remove the hub from the deep rim 3 Inspect the hub bushing Replace the bushing if worn or damaged 4 Remove the 4 bolts and 4 flange nuts from the deep rim and shallow rim Remove the shallow rim from the deep rim 5 Separate the tire tube and deep rim 6 If necessary remove the shoulder screws torsion spring and ret...

Page 160: ...lange nuts Tighten the fasteners 4 Install the hub into the deep rim Secure the hub to the deep rim with the 3 bolts and 3 lock washers Tighten the fasteners 5 Inflate the tire to 83 to 103 kPa 12 to 15 psi Installing the Transport Wheel 1 Ensure that the machine is parked on a level surface 2 Support the machine onto the kickstand 3 Slide the transport wheel completely onto the wheel hex shaft un...

Page 161: ...rom the wheel hex shaft on each side 4 If necessary install the transport wheels refer to Installing the Transport Wheel page 6 24 Installing the Rail Kit Wheel 1 Ensure that the machine is parked on a level surface 2 Support the machine onto the kickstand 3 If installed remove the transport wheels refer to Removing the Transport Wheel page 6 22 4 Slide the rail kit wheel onto the wheel hex shaft ...

Page 162: ...Controls Wheels and Accessories Service and Repairs Page 6 26 Greensmaster e1021 e1026 20246SL Rev A ...

Page 163: ...e Cutting Unit when Servicing 7 3 Adjustments 7 4 DPA Cutting Unit Characteristics 7 4 Grass Shield Height Adjustment 7 5 Service and Repairs 7 6 Bedbar Assembly 7 6 Servicing the Bedbar Adjuster 7 10 Bedknife 7 12 Cutting Unit Assembly 7 15 Reel Assembly 7 17 Roller Assemblies 7 25 Greensmaster e1021 e1026 Page 7 1 DPA Cutting Units 20246SL Rev A ...

Page 164: ... groomer the Installation Instructions for the kit includes set up operation and maintenance information Refer to the Cutting Unit Operator s Manual and the kit Installation Instructions for additional information when servicing the cutting units Grass Basket Installation g278331 Figure 94 1 Grass basket 2 Mounting rod Grasp the grass basket by top rear lip and slide on or off the basket mounting ...

Page 165: ...rt Whenever the cutting unit has to be tipped to expose the bedknife or cutting reel support the rear of the cutting unit making sure the back of the bedbar adjuster screws are not resting on the work surface Greensmaster e1021 e1026 Page 7 3 DPA Cutting Units General Information 20246SL Rev A ...

Page 166: ...ble with this design gives the necessary control to provide a continual self sharpening action This feature maintains sharp cutting edges assures good quality of cut and greatly reduces the need for routine backlapping If a cutting unit is determined to be out of adjustment complete the following procedures in the specified order to adjust the cutting unit properly 1 Adjust the bedknife to reel co...

Page 167: ...ne spark plug 3 Place 1 5 mm 0 06 inch shim between the reel assembly and grass shield Note The shield can be lowered for drier conditions clippings fly over top of the basket or raised to allow for heavy wet grass conditions clippings build up on rear of the basket 4 Loosen the bolts that secures each end of the shield to the side plates Adjust the shield to the correct height and tighten the fas...

Page 168: ... 3 Bedbar adjuster shaft 2 each 10 Wave washer 2 each 17 Washer 2 each 4 Rubber bushing assembly 2 each 11 Retaining ring 2 each 18 Compression spring 5 Nylon bushing 2 each 12 Bedbar adjuster screw 2 each 19 Nut 2 each 6 Plastic washer 2 each 13 Detent 2 each 7 Flat washer 2 each 14 Bolt 2 each DPA Cutting Units Service and Repairs Page 7 6 Greensmaster e1021 e1026 20246SL Rev A ...

Page 169: ...uts 9 on each bedbar bolt 8 5 Remove the 2 bedbar bolts 8 2 flat washers 7 and 4 plastic washers 6 and 15 from the cutting unit side plates 1 CAUTION Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when handling the bedbar 6 Remove the bedbar assembly 6 from the cutting unit 7 Inspect the nylon bushings 5 and rubber bushings 4 in the side p...

Page 170: ...e or other cutting unit parts can result in personal injury Use heavy gloves when handling the bedbar Note If a new bedknife is attached to the bedbar there may be interference between the bedknife and the reel when installing the bedbar Turn the bedbar adjusting screws counterclockwise to increase bedknife clearance if necessary 4 Position the bedbar assembly 16 into the cutting unit Make sure th...

Page 171: ...e lock nut is correctly tightened the inside washers may be loose 8 Tighten both lock nuts 9 until outside metal washers do not have any end play and can still can be rotated 9 Tighten the nut 19 on each bedbar adjuster assembly 16 until the adjuster spring 18 is fully compressed then loosen the nut 19 to 1 2 turn 10 Adjust the bedknife to reel contact refer to the Cutting Unit Operator s Manual 1...

Page 172: ... refer to Removing the Bedbar page 7 7 2 Remove the lock nut 11 compression spring 10 and washer 9 from the bedbar adjuster screw 7 Note The bedbar adjuster shaft 1 has left hand threads 3 Unscrew the bedbar adjuster shaft 1 from the bedbar adjuster screw 7 4 Remove the retaining ring 6 and wave washer 5 from the adjuster shaft 7 and remove the adjuster shaft 5 Inspect the flange bushings 2 in the...

Page 173: ...her 5 and a retaining ring 6 Note The bedbar adjuster shaft 1 has left hand threads 4 Apply anti seize lubricant to the threads of the bedbar adjuster screw 7 that fit into adjuster shaft 1 the left hand threads and thread the bedbar adjuster screw into the adjuster shaft 5 Install the washer 9 compression spring 10 and lock nut 11 onto the adjuster screw 7 6 Install the bedbar 8 refer to Installi...

Page 174: ...e 2 15 Discard the screws Remove bedknife from the bedbar 3 Refer to Grinding the Bedknife page 7 13 for additional information Installing the Bedknife 1 Use a scraper to remove all rust scale and corrosion from the bedbar surface under the bedknife Lightly oil the bedbar surface before installing the bedknife 2 Make sure that screw threads in bedbar 5 16 18UNC 2A are clean g226894 Figure 101 DPA ...

Page 175: ...dknife to bedbar grind the bedknife 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 102 1 Top angle 4 Front surface 2 Top surface 5 Front angle 3 Remove burr Since there can be variations in the mounting surface of the bedbar it ...

Page 176: ...ng a diamond grinding wheel is recommended to prevent overheating or damaging the bedknife edge while grinding Because the top grind angle on bedknives is critical for edge retention and therefore after cut appearance Toro has developed special service tools for accurately measuring the top grind angle on all bedknives refer to Angle Indicator and Magnetic Mount page 2 15 1 Use Toro General Servic...

Page 177: ...lug 3 Slide the telescopic coupler on the reel drive assembly 2 from the transmission drive shaft Note If necessary remove the reel drive assembly 2 from the cutting unit assembly 1 refer to Removing the Reel Drive Assembly page 4 7 4 Remove the 4 socket head screws 3 that secures the cutting unit assembly 1 to the frame assembly 5 Note Support the traction unit and lock the kick stand 5 Slide and...

Page 178: ...4 10 3 Install the cutting unit assembly 1 onto the frame assembly 5 4 Secure the cutting unit assembly 1 with 4 socket head screws 3 5 Align the reel drive assembly shaft to transmission gear box driveshaft Slide the telescopic coupler on the reel drive assembly 2 to the transmission gear shaft 6 Attach the spark plug wire to the engine spark plug DPA Cutting Units Service and Repairs Page 7 16 G...

Page 179: ...l Assembly Note Refer to Figure 105 during this procedure 1 Park the machine on a level surface Ensure that the engine is OFF and the traction control is in NEUTRAL 2 Remove the spark plug wire from the engine spark plug 3 If the cutting unit is equipped with an optional groomer remove the drive components for those options from cutting unit Refer to Removing the Gear Box Assembly page 8 4 for uni...

Page 180: ...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 refer to Figure 106 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 th...

Page 181: ...th a groove cut just inside of the left most reel spider The reel nut on the right end of the cutting reel has a silver finish and has right hand threads 9 Support the cutting reel to prevent it from shifting or falling and remove the 2 socket head screws 3 and 17 that secure the LH side plate 4 to the reel assembly 8 10 Remove the bolt 16 and washer 15 that secures the grass shield assembly 18 to...

Page 182: ...xial play 3 Inspect the reel as follows A Place the reel shaft ends in V blocks and check the reel shaft for distortion B Check the threads in the ends of the reel shaft C Check the reel blades for bending or cracking D Check the service limit of the reel diameter refer to Preparing the Reel for Grinding page 7 23 4 Replace the reel if damage is evident IMPORTANT The seal must be installed with th...

Page 183: ...reel nut on the left exposed end of the cutting reel has a black finish 3 Place the grass shield assembly 18 frame support rods 9 and 14 onto the RH side plate 10 4 Place the flat wire spring into bearing bore of LH side plate and carefully slide the left side plate onto the cutting reel assembly as far as possible 5 Install the 4 socket head screws 3 and 17 that secure the RH and LH side plates 4...

Page 184: ...the reel drive shaft from 123 to 149 N m 90 to 110 ft lb 7 Secure the grass shield assembly 18 to the RH and LH side plates 4 and 10 with the 2 washers 15 and 2 bolts 16 8 If the reel nuts were loosened during cutting reel service put a block of wood between the cutting reel blades to prevent the reel from rotating and tighten the reel nuts from 123 to 149 N m 90 to 110 ft lb 9 Install the reel dr...

Page 185: ...utting reel blades Remove small amounts of material with each pass of the grinder Follow reel grinder manufacturer s instructions to grind cutting reel to Toro specifications refer to Reel Grinding Specifications page 7 23 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 ...

Page 186: ...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 DPA Cutting Units Service and Repairs Page 7 24 Greensmaster e1021 e1026 20246SL Rev A ...

Page 187: ...ing this procedure 1 Loosen the pinch bolts 8 that secure the front roller shaft 3 to the front height of cut arms 5 2 Remove the lock nut 6 height of cut washer 7 and plow bolt 1 that secures one of the height of cut arms 5 to the cutting unit side plate 10 and remove the height of cut arm 3 Slide the front roller assembly 3 from the remaining height of cut arm 5 4 Remove the remaining height of ...

Page 188: ...ighten the jam nut against the roller shaft Remove the bearing lock nuts 1 2 Carefully inspect the seating surface and threads of the bearing lock nuts 1 and replace them if damaged 3 Loosely secure the roller assembly 4 in a bench vise and lightly tap on the roller shaft 5 to remove the sealing washers 2 and bearings 3 Discard the sealing washers 2 4 Clean and carefully remove any corrosion from ...

Page 189: ...ise the front of the cutting unit off of the work surface 2 Inspect the condition of both height of cut screws 9 and replace them if necessary Apply anti seize lubricant to the threads of a new height of cut screw 9 Note When installing the height of cut arms 5 make sure that the tab of the side plate fits between the head and the washer of the height of cut screw 9 3 Secure one of the height of c...

Page 190: ...ter the front roller 3 in the cutting unit and tighten the pinch bolts 8 that secure the front roller shaft to the height of cut arms 7 Install the cutting unit assembly to the frame assembly refer to Installing the Cutting Unit Assembly page 7 16 If necessary 8 Adjust the cutting unit height of cut refer to the Cutting Unit Operator s Manual DPA Cutting Units Service and Repairs Page 7 28 Greensm...

Page 191: ...lation Instructions 8 2 Grooming Performance 8 2 Service and Repairs 8 3 The Gear Box Assembly 8 4 The Idler Assembly 8 12 The Groomer Reel 8 14 The Height Adjuster Assembly 8 17 The Grooming Brush Optional 8 19 Greensmaster e1021 e1026 Page 8 1 Universal Groomer Optional 20246SL Rev A ...

Page 192: ... damage Use the groomer carefully Read and understand the groomer operation instructions before operating or testing the groomer performance It is important to remember that the same factors that affect quality of cut also affect grooming performance Variables that Affect the Use and Performance of the Groomer 1 The growing season and weather conditions 2 General turf conditions 3 The frequency of...

Page 193: ...embly 4 Height adjuster assembly 2 each CAUTION Never work on the groomer with the engine running Always stop the engine and wait for all machine movement to stop before working on the groomer Greensmaster e1021 e1026 Page 8 3 Universal Groomer Optional Service and Repairs 20246SL Rev A ...

Page 194: ...y refer to Removing the Groomer Reel page 8 14 2 Safely prevent the reel from rotating by blocking the cutting reel with a piece of wood near one of the reel spiders IMPORTANT The groomer gear box for this machine is installed on the left side of the cutting unit Groomer gear boxes installed on the left side of the cutting unit use a left hand thread Turn the input shaft clockwise to remove the ge...

Page 195: ... 8 x 12 inch with screwdriver handle recommended through the bottom 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 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 8 Move the pry bar against th...

Page 196: ... 10 If the hex head on the end of the drive shaft is damaged during removal A Remove the drain fill plug and drain the oil from the gear box B Remove the 4 socket head screws and remove the gear box cover assembly and driven gear Remove and discard the cover gasket C Slide the thrust washer ring gear and bushing from the gear box housing D Slide the sun gear and planet gears and bushings from the ...

Page 197: ...rive shaft assembly J Use the drive shaft removal tool on the large flats of the drive shaft assembly refer to Special Tools page 2 13 K Rest the handle of the pry bar against the front roller and turn the drive shaft counterclockwise to loosen it from the reel 11 Tip the cutting unit back onto its rollers 12 Clean the threads in the end of the reel shaft A right hand thread and left hand thread t...

Page 198: ...using 20 Straight bushing 2 each 34 Flange bushing 3 each 7 Ball bearing 2 each 21 Detent ball 35 Locknut 8 Retaining ring 22 Detent spring 36 Driver gear 9 Driven gear 23 Oil seal 37 Bearing 2 each 10 Actuator shaft 24 Socket head screw 4 each 38 Oil seal 11 Pin 25 Groomer cover 39 Driven shaft 12 O ring 26 Gasket 40 Shield 13 Knob 27 Thrust washer 14 Retaining ring 28 Ball bearing Universal Groo...

Page 199: ...maged or worn components as necessary 8 If the sun gear ring gear or the gear box housing bearings are replaced press the bearings all the way to shoulder into the part 9 If the flange bushings are replaced ensure that the flange bushing is fully seated against the part 10 Assembly the gearbox Ensure that all the retaining rings and O rings are fully seated in the ring groove during assembly Lubri...

Page 200: ...e of the reel support plate closest to the gear box assembly and rest the handle of the pry bar against the front roller 4 Position the gear box assembly against the cutting unit and turn the drive shaft assembly clockwise until it is seated against the reel IMPORTANT You must use a 6 point socket with a heavy wall to install the gear box to the reel Do not use an impact wrench Groomer gear boxes ...

Page 201: ... the Gear Box Assembly continued 9 Install the groomer reel assembly refer to Installing the Groomer Reel page 8 16 Greensmaster e1021 e1026 Page 8 11 Universal Groomer Optional Service and Repairs 20246SL Rev A ...

Page 202: ...ting unit refer to Removing the Reel Drive Assembly page 4 7 2 Remove the groomer reel assembly refer to Removing the Groomer Reel page 8 14 3 Remove the cotter pin and clevis pin from the height adjustment rod at the front of the idler arm Discard the cotter pin 4 Remove the flange nut that secures the idler arm to the stub shaft Remove the idler assembly 5 Inspect the shields bearing and bushing...

Page 203: ... bearing shields with the flocked side of the shield toward the bearing D Insert the stub shaft through the shields and bearing Use the through hole in the shaft to prevent the shaft from rotating and tighten the flange nut from 37 to 45 N m 27 to 33 ft lb 2 Install the clevis pin and a new cotter pin to secure the height adjustment rod to the front of the idler arm 3 Install the reel drive refer ...

Page 204: ... unit parts can result in personal injury Use heavy gloves when handling the groomer reel 1 Carefully remove the 4 jam nuts 4 bolts and 4 shaft clamps that secure the groomer reel to the output and stub shafts 2 Lift the groomer reel from the cutting unit 3 Inspect the shields stub shaft driven shaft and shaft bearings for wear or damage and replace components as necessary refer to Figure 123 and ...

Page 205: ...the blades from the groomer shaft If necessary remove second lock nut from the shaft 4 Inspect and replace worn or damaged components 5 Assemble the groomer reel as follows Note New lock nuts have an adhesive patch to prevent the lock nut from loosening If a used lock nut is being installed apply a medium strength thread locker Loctite 242 or equivalent to the threads of the lock nut A Install a l...

Page 206: ...otate and the groomer blades should be centered on the shaft 6 Install the groomer reel back onto the cutting unit refer to Installing the Groomer Reel page 8 16 Installing the Groomer Reel 1 Position the groomer reel between the groomer driven and stub shafts 2 Secure the groomer reel to the cutting unit with the 4 jam nuts 4 bolts and 4 shaft clamps Tighten the bolts from 5 to 7 N m 45 to 60 in ...

Page 207: ...ment rods Retrofitting the assemblies on each side of the cutting unit with new compression springs height adjustment rods and adding flange nuts to enable spring adjustment is recommended refer to Figure 125 Disassembling the Height Adjuster Note Refer to Figure 124 during this procedure 1 Remove the cutting unit from the machine 2 Remove the cotter pins and clevis pins that secure the height adj...

Page 208: ...ed washer and lock nut Tighten the lock nut finger tight 3 Position front roller between the height adjuster assemblies and secure the remaining height adjuster assembly to the cutting unit side plate with a plow bolt and lock nut Tighten the lock nut finger tight 4 Center the front roller between the height of cut brackets and tighten the front roller pinch bolts 5 Install new cotter pins and cle...

Page 209: ...e Groomer Reel page 8 14 The grooming brush element or shaft can be serviced separately To remove the spiral grooming brush from the shaft remove the lock nut and J bolt from both ends of the brush assembly and slide the brush from the shaft When assembling the spiral brush to the shaft make sure that the J bolts are installed with the threaded portion on the outside of the brush and tighten the l...

Page 210: ...Universal Groomer Optional Service and Repairs Page 8 20 Greensmaster e1021 e1026 20246SL Rev A ...

Page 211: ... 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 e1021 e1026 Page A 1 Foldout Drawings 20246SL Rev A ...

Page 212: ... 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 Wire Size The individual wires of the electrical harness diagrams in this chapter identify both the wire color and the wire size Examples 16 BK 16 A...

Page 213: ...Greensmaster e1021 e1026 Drawing 122 1647 Rev A Sheet 1 of 1 20246SL Rev A Page A 3 Electrical Schematic g361655 ...

Page 214: ...Page A 4 20246SL Rev A Greensmaster e1021 e1026 Drawing 122 1734 Rev D Sheet 1 of 2 Wire Harness Drawing CV g361656 ...

Page 215: ...Greensmaster e1021 e1026 Drawing 122 1734 Rev D Sheet 2 of 2 20246SL Rev A Page A 5 Wire Harness Drawing g361657 ...

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