Page 1 8111 Lyndale Avenue South vent damage to systems or components on the Minneapolis, MN 55420–1196 machine. The Toro Company reserves the right to change product specifications or this publication without notice. E The Toro Company – 2001, 2002, 2004, 2006...
Page 2 This page is intentionally blank. Greensmaster Flex 21...
Page 3 ......5 – 6 Service and Repairs ......5 – 8 Rev. B Greensmaster Flex 21...
Page 4 This page is intentionally blank. Greensmaster Flex 21...
Page 5 A replacement picked up and thrown by the reel. manual is available on the internet at www.toro.com or 8. Keep everyone, especially children and pets away by sending the complete model and serial number to: from the areas of operation.
Page 6 Such use parts of the body away from the cutting unit and any could void the product warranty of The Toro Company. moving parts. Keep everyone away. Safety Greensmaster Flex 21 Page 1 –...
Page 7 Safety decals and instructions are easily visible to the numbers are listed in your Parts Catalog. Order replace- operator and are located near any area of potential dan- ment decals from your Authorized TORO Distributor. ger. Replace any decal that is damaged or lost. Part Greensmaster Flex 21 Safety Page 1 –...
Page 8 This page is intentionally blank. Safety Greensmaster Flex 21 Page 1 – 4...
Page 9 ......Product Records Insert Operator’s Manuals and Parts Catalogs for your Greensmaster Flex 21 at the end of this section. Greensmaster Flex 21 Product Records and Manuals...
Page 10 Equivalents and Conversions Product Records and Manuals Greensmaster Flex 21 Page 2 – 2...
Page 11 For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
Page 12 + 10% of the nominal torque value. Thin The specific torque value should be determined based height nuts include jam nuts. Product Records and Manuals Greensmaster Flex 21 Page 2 – 4...
Page 13 NOTE: Torque values may have to be reduced when SAE J1199. The tolerance is approximately + 10% of the installing fasteners into threaded aluminum or brass. nominal torque value. The specific torque value should be determined based Greensmaster Flex 21 Product Records and Manuals Page 2 – 5...
Page 14 All torque values are based on non–lubricated fasteners. Conversion Factors in–lb X 11.2985 = N–cm N–cm X 0.08851 = in–lb ft–lb X 1.3558 = N–m N–m X 0.7376 = ft–lb Product Records and Manuals Greensmaster Flex 21 Page 2 – 6...
Page 15: Table Of Contents
......Engine Removal and Installation ... . . Kawasaki FE120 Service Manual Rev. B Greensmaster Flex 21 Page 3 – 1 Engine...
Page 16: Introduction
However, the cost of the test equipment and the special- gasoline engine used in the Greensmaster Flex 21 ized nature of some repairs may dictate that the work be mower.
Page 17: Specifications
Air Cleaner Dual element Ignition System Transistorized flywheel magneto with ignition advance RFI Suppressor Radio suppressor plug cap and spark plug Spark Plug NGK BPR 5ES Dry Weight kg (U.S. lb.) 14.6 (32.2) Greensmaster Flex 21 Page 3 – 3 Engine...
Page 18: General Information
Figure 1 all times until fueling is complete. 1. Fuel tank cap 2. Fuel gauge Engine Greensmaster Flex 21 Page 3 – 4...
Page 19: Fuel Shut-Off Valve
It has two positions: CLOSED and OPEN. Position valve to the closed position when stor- ing or transporting the machine. Rotate valve to the open position before starting the engine. Figure 2 1. Fuel shut–off valve Greensmaster Flex 21 Page 3 – 5 Engine...
Page 20: Adjustments
A. Low idle speed should be 2300 to 2500 rpm. Adjust low speed idle screw in or out to attain the cor- rect low idle speed setting. B. High idle speed should be 3500 to 3700 rpm. Engine Greensmaster Flex 21 Page 3 – 6...
Page 21: Service And Repairs
Service and Repairs Engine Oil The TORO Company recommends that the oil level be –20 C –10 C 20 C 40 checked each time the mower is used or after every 5 operating hours. Initially, change oil after the first 20 SAE 40 hours of operation;...
Page 22: Air Cleaner
5. Reinstall foam element, paper element, and air cleaner cover. Tighten wing nuts. IMPORTANT: Do not operate engine without air Figure 7 cleaner element because extreme engine wear and 1. Foam element 2. Paper element damage will likely result. Engine Greensmaster Flex 21 Page 3 – 8...
Page 23: Fuel Filter
3. Inspect the spark plug. IMPORTANT: Replace a cracked, fouled, or dirty spark plug. Do not sand blast, scrape, or clean elec- Figure 10 trodes because engine damage could result from grit entering cylinder. Greensmaster Flex 21 Page 3 – 9 Engine...
Page 24 Engine overheating, burnt valves, plug heat Replace spark plug. stems, rings, piston, and/or cylinder bore. range too hot, incorrect ignition timing or ad- vance, or wrong type of fuel are causes. Replace spark plug. Replace spark plug. Engine Greensmaster Flex 21 Page 3 – 10...
Page 25: Ignition Components
Overheating and engine damage will result. 4. Make sure blower housing and/or engine cylinder shroud are reinstalled to the engine if removed. Figure 12 1. Blower housing air intake Greensmaster Flex 21 Page 3 – 11 Engine...
Page 26: Engine Removal And Installation
30. Muffler guard bracket 9. Lock washer 20. Flat washer 31. Decal: Hot surface 10. Engine base 21. Lock nut 32. Decal: Danger 11. Cap screw 22. Cap screw 33. Decal: Fuel Engine Greensmaster Flex 21 Page 3 – 12...
Page 27 Re- move and discard flange gasket. E. Remove the engine from the traction unit. Figure 16 1. Gearbox flange nuts 2. Engine mounting screws Greensmaster Flex 21 Page 3 – 13 Engine...
Page 28 6. Refill transmission to proper fluid level (See Check Gearbox Fluid in the General Information section of Chapter 4 – Traction and Reel Drive Systems). 7. Check and adjust engine oil level as needed (See Checking Engine Oil Level). Engine Greensmaster Flex 21 Page 3 – 14...
Page 29 Reel Drive Assembly ..... . . Greensmaster Flex 21 Page 4 – 1 Traction and Reel Drive System (Rev. C)
Page 30: Specifications
Gear driven countershaft (in gearbox) with cone wet clutch Flexible coupler shaft used in reel drive system Gearbox to reel drive has 8 mm pitch positive drive belts Traction and Reel Drive System (Rev. C) Page 4 – 2 Greensmaster Flex 21...
Page 31: General Information
Cannister seals will also cause a slightly higher amount of drag than other seal types. Greensmaster Flex 21 Page 4 – 3 Traction and Reel Drive System (Rev. C)
Page 32: Adjustments
4. Tighten front traction cable jam nut. Figure 3 1. Traction cable 3. Back cable jam nut 2. Front cable jam nut 5. Check traction control operation. Traction and Reel Drive System (Rev. C) Page 4 – 4 Greensmaster Flex 21...
Page 33: Reel Control Cable Adjustment
(Fig. 4) until the proper adjustment is achieved. 5. Tighten front reel control cable jam nut. 6. Check reel control operation. Greensmaster Flex 21 Page 4 – 5 Traction and Reel Drive System (Rev. C)
Page 34: Traction Drive Belt Adjustment
Wheels in the Service and Repairs section of Chapter 6 – Chassis and Controls). Figure 7 1. Side plate (backside) 3. Belt cover flange nut 2. Idler bracket cap screw Traction and Reel Drive System (Rev. C) Page 4 – 6 Greensmaster Flex 21...
Page 35: Reel Drive Belt Adjustment
4. Place belt cover in position and secure with flange nut. Figure 9 1. Reel drive belt 2. Bearing housing nuts Figure 10 1. Bearing housing 2. Torque wrench position Greensmaster Flex 21 Page 4 – 7 Traction and Reel Drive System (Rev. C)
Page 36: Transmission Coupler Drive Belt Adjustment
Figure 12 lb (114 kg–cm). 1. Drive belt 2. Bearing housing nuts Figure 13 1. Bearing housing 3. Belt cover flange nut 2. Torque wrench position Traction and Reel Drive System (Rev. C) Page 4 – 8 Greensmaster Flex 21...
Page 37: Service And Repairs
3. Adjust drive belt tension (see Reel Drive Belt Adjust- ment in this section). 4. Reinstall belt cover. Figure 15 1. LH reel drive belt 3. LH cutting reel sideplate 2. Bearing housing nuts Greensmaster Flex 21 Page 4 – 9 Traction and Reel Drive System (Rev. C)
Page 38: Reel Drive Assembly
32. Cap screw 9. Carriage screw 10. Bearing housing 22. Cover spacer 33. Plug 11. Spacer 23. Hex tube 34. Retaining ring (if equipped) 12. Flange nut Traction and Reel Drive System (Rev. C) Page 4 – 10 Greensmaster Flex 21...
Page 39: Reel Drive And Transmission Coupler Bearing Housing
4. Install retaining ring and oil seal into housing. 2. Flange nut/washer 4. Pulley flange nut 5. Position coupler onto shaft and secure with new spring pin. Greensmaster Flex 21 Page 4 – 11 Traction and Reel Drive System (Rev. C)
Page 40 9. Re–attach cutting unit to the traction unit (see Sepa- rating Cutting Unit From Traction Unit in the General In- formation section of Chapter 7 – Cutting Unit). Traction and Reel Drive System (Rev. C) Page 4 – 12 Greensmaster Flex 21...
Page 41 This page is intentionally blank. Greensmaster Flex 21 Page 4 – 13 Traction and Reel Drive System (Rev. C)
Page 42: Traction Drive Assembly
12. Idler 25. Pulley washer 37. Locking collar w/setscrew 13. Idler arm spacer NOTE: Parts on both sides of the mower frame are identical except as noted. Traction and Reel Drive System (Rev. C) Page 4 – 14 Greensmaster Flex 21...
Page 43: Traction Drive Belt Replacement
Wheels in the Service and Repairs section of Chapter 6 Figure 23 – Chassis and Controls. 1. Side plate 3. Belt cover flange nut 2. Idler bracket cap screw Greensmaster Flex 21 Page 4 – 15 Traction and Reel Drive System (Rev. C)
Page 44: Traction Drive Idler Pulley And Bearings
Adjustment in this chapter). Reinstall drive belt cover. 6. Replace transport wheels if they were attached (see Wheels in the Service and Repairs section of Chapter 6 – Chassis and Controls). Traction and Reel Drive System (Rev. C) Page 4 – 16 Greensmaster Flex 21...
Page 45 This page is intentionally blank. Greensmaster Flex 21 Page 4 – 17 Traction and Reel Drive System (Rev. C)
Page 46: Traction Drum Assembly (Serial Number Below 240001001)
It is not necessary to remove drum pulley from hex shaft prior to shaft re- moval. Traction and Reel Drive System (Rev. C) Page 4 – 18 Greensmaster Flex 21...
Page 47 Wheels in the Service and Repairs section of Chapter 6 2. Pivot mower back and position drum assembly un- – Chassis and Controls). der the mower. Pivot mower back down. Greensmaster Flex 21 Page 4 – 19 Traction and Reel Drive System (Rev. C)
Page 48: Traction Drum Assembly (Serial Number Above 240001000)
(Fig. 29). 4. Loosen set screws that secure bearings (item 8) to 8. Unscrew both drum shafts (item 6) from traction drum shafts. drum assembly. Traction and Reel Drive System (Rev. C) Page 4 – 20 Greensmaster Flex 21...
Page 49 2. If removed, loosely install bearings (item 8) and bearing flangettes (item 7) to machine frame. Make sure that extended race of bearings is positioned to the out- side of the frame. Greensmaster Flex 21 Page 4 – 21 Traction and Reel Drive System (Rev. C)
Page 50 Torque set screws from 40 to 50 in–lb (4.5 to 5.7 N–m). Wheels in the Service and Repairs section of Chapter 6 – Chassis and Controls). Traction and Reel Drive System (Rev. C) Page 4 – 22 Greensmaster Flex 21...
Page 51: Change Gearbox Fluid
Fluid or equivalent) until the level reaches the bottom of the check/fill hole (see Check Gearbox Fluid). 8. Install the check/fill plug with O–ring and torque plug to 240 in–lb (276 kg–cm). Greensmaster Flex 21 Page 4 – 23 Traction and Reel Drive System (Rev. C)
Page 52: Gearbox (Serial Number Below 240001001)
(Fig. 32) on both sides of mower. Remove pulley wash- and Repairs section of Chapter 6 – Chassis and Con- er, pulley and woodruff key from both sides. trols). Traction and Reel Drive System (Rev. C) Page 4 – 24 Greensmaster Flex 21...
Page 53 Figure 34 gearbox flange onto setscrews. Install and tighten four 1. Gearbox axle (LH) 2. Locking collar (loosen) flange nuts that secure gearbox to engine (Fig 35). Greensmaster Flex 21 Page 4 – 25 Traction and Reel Drive System (Rev. C)
Page 54 2. Locking collar (tighten) chapter). 14.Install transport wheels if they were attached (see Wheels in the Service and Repairs section of Chapter 6 – Chassis and Controls). Traction and Reel Drive System (Rev. C) Page 4 – 26 Greensmaster Flex 21...
Page 55 This page is intentionally blank. Greensmaster Flex 21 Page 4 – 27 Traction and Reel Drive System (Rev. C)
Page 56: Gearbox (Serial Number Above 240001000)
(see Traction Drive Belt Replace- cable attached. Note that lever and shaft splines identify ment in this section). correct lever location on shaft. Traction and Reel Drive System (Rev. C) Page 4 – 28 Greensmaster Flex 21...
Page 57 Wheels in the Service and Repairs section of Chapter 6 11. Install traction belts, properly tension belts, and install belt covers (see Traction Drive Belt Replacement – Chassis and Controls). in this section). Greensmaster Flex 21 Page 4 – 29 Traction and Reel Drive System (Rev. C)
Page 58: Gearbox Assembly
Service to the dif- ferential, bushings and bearings requires removal of the gearbox from the traction unit. Traction and Reel Drive System (Rev. C) Page 4 – 30 Greensmaster Flex 21...
Page 59 1. Traction shaft with band 5. Clutch thrust washer 2. Planetary assembly 6. Link 3. Differential assembly 7. Clutch fork shaft 4. Reel drive clutch shaft 8. Clutch fork Greensmaster Flex 21 Page 4 – 31 Traction and Reel Drive System (Rev. C)
Page 60 (with cable) 1.05” 1.05” should be installed onto brake shaft as planetary as- Figure 46 sembly is installed into gearbox. Traction and Reel Drive System (Rev. C) Page 4 – 32 Greensmaster Flex 21...
Page 61 (see Transmission Coupler Drive Belt Adjustment in this chapter). C. Tighten flange nut to secure pulley. 16.Mount gearbox to machine (see Gearbox Installation in this section). Greensmaster Flex 21 Page 4 – 33 Traction and Reel Drive System (Rev. C)
Page 62: Differential Assembly
(see Gearbox Assembly). Install el gears are only available as a complete set. gearbox to mower (see Gearbox Installation). Traction and Reel Drive System (Rev. C) Page 4 – 34 Greensmaster Flex 21...
Page 63 ..... . . Operator Presence Switch ....Greensmaster Flex 21 Electrical System Page 5 – 1...
Page 64: Wiring Schematics
MAGNETO (FLYWHEEL) LIGHTING COIL HOUR METER (OPTIONAL) CONNECTOR INTERLOCK SWITCH Kawasaki FE120 Engine ON\OFF SWITCH is open in the ON position INTERLOCK SWITCH is closed when traction lever is in NEUTRAL Electrical System Greensmaster Flex 21 Page 5 – 2...
Page 65: Later Models (With Operator Presence)
Kawasaki FE120 Engine ON\OFF SWITCH is open in the ON position INTERLOCK SWITCH is closed when traction lever is in NEUTRAL OPERATOR PRESENCE SWITCH is closed when bail is against handle Greensmaster Flex 21 Electrical System Page 5 – 3...
Page 66: Special Tools
Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: Toro recommends the use of a DIGITAL Volt– Ohm–Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
Page 67: Troubleshooting
Replace interlock module. Engine will start, but will not Electrical wires are loose or Check electrical connections. continue to run. damaged. Repair wiring. Interlock module is faulty. Replace interlock module. Greensmaster Flex 21 Electrical System Page 5 – 5 Rev. C...
Page 68: Component Testing
Kawasaki FE120 Service Manual in Chapter 3 – En- winding with a digital multimeter. However, a multimeter gine for ignition component testing information. can not detect layer shorts and shorts resulting from in- Electrical System Greensmaster Flex 21 Page 5 – 6 Rev. C...
Page 69: Interlock Module And Switch
A. Attempt to start the engine. The engine should start. Lighting Coil The engine on the Greensmaster Flex 21 is equipped wheel and uses permanent magnets on the flywheel to with a lighting coil to provide electrical current for an op- operate.
Page 70: Service And Repairs
3. Connect switch to wires from the interlock module. Figure 7 5. Spacer 1. Interlock switch 2. Control bracket 6. Flat washer (early units) 3. Handle 7. Locking nut 4. Cap screw 8. Console Electrical System Greensmaster Flex 21 Page 5 – 8 Rev. C...
Page 71 Operator Presence Kit switch (Fig. 8). 2. With the bail held against the handle, there should be continuity between the same two terminals. Figure 8 1. Plunger 3. Not used 2. Switch terminals used Greensmaster Flex 21 Electrical System Page 5 – 9...
Page 72 This page is intentionally blank. Electrical System Greensmaster Flex 21 Page 5 – 10...
Page 73 ....... . . Parking Brake Cable Replacement ... . Greensmaster Flex 21 Chassis and Controls Page 6 – 1...
Page 74: Specifications
Specifications Item Description Tire Pressure 12 to 15 PSI (0.83 to 1.04 bar) Chassis and Controls Greensmaster Flex 21 Page 6 – 2...
Page 75: Adjustments
Raise or lower handle to the de- sired operating position. 4. Align holes. Reinstall ring pins and hairpin cotters. Figure 1 1. Ring pin 2. Hairpin cotter Greensmaster Flex 21 Chassis and Controls Page 6 – 3...
Page 76: Service And Repairs
48. Detent spring 32. Brake cable spacer 15. Socket head cap screw 49. Flat washer 16. Roll pin 33. Cable tie 17. Handle rod 34. Brake cable 50. Traction control lever Chassis and Controls Greensmaster Flex 21 Page 6 – 4...
Page 77 6. Flange nut 3. Secure cables with cable ties. 2. Handle arm 7. Cap screw 8. Ring pin 3. Handle grommet 4. Handle support spacer 9. Hairpin cotter 5. Pivot pin Greensmaster Flex 21 Chassis and Controls Page 6 – 5...
Page 78: Parking Brake Cable Replacement
C. Slide brake lever toward gearbox and secure with locknut. D. Attach brake cable to the casting slot on gearbox with a washer and jam nut on each side of the slot. Chassis and Controls Greensmaster Flex 21 Page 6 – 6...
Page 79: Traction Cable Replacement
3. Adjust traction cable (see Traction Control Adjust- ment in Chapter 4 – Traction and Reel Drive Systems). 4. Install cable ties to secure traction cable. Greensmaster Flex 21 Chassis and Controls Page 6 – 7...
Page 80: Reel Control Cable Replacement
3. Adjust reel control cable (see Reel Control Adjust- ment in Chapter 4 – Traction and Reel Drive Systems). 4. Secure reel control cable with cable ties. Chassis and Controls Greensmaster Flex 21 Page 6 – 8...
Page 81: Throttle Cable Replacement
4. Control bracket 5. Adjust throttle cable (see Throttle Linkage Adjust- 2. Throttle cable 5. Console ment in Chapter 3 – Engine). 3. Throttle lever 6. Secure throttle cable with cable tie. Greensmaster Flex 21 Chassis and Controls Page 6 – 9...
Page 82: Wheels
4. Slide wheel completely onto the wheel hex shaft until the locking clip is secured into the groove on the wheel hex shaft. Anti–seize lubricant Figure 15 1. Wheel hex shaft 2. Kickstand Chassis and Controls Greensmaster Flex 21 Page 6 – 10...
Page 83 3. Remove bolt from the hub. Remove bolt, spring, and 3. Reinstall hub into deep rim. Secure hub to deep rim locking clip from the hub. with three cap screws and lock washers. Tighten fasten- ers. Greensmaster Flex 21 Chassis and Controls Page 6 – 11...
Page 84 Note: long spacer and torsion spring is on the left side of the machine and short spacer is on the right. 5. Remove kickstand from the frame. Figure 18 1. Kickstand 3. Torsion spring end 2. Torsion spring Chassis and Controls Greensmaster Flex 21 Page 6 – 12...
Page 85 ....Cut–off Bar Adjustment ..... Greensmaster Flex 21 Page 7 – 1 Cutting Unit (Rev. C)
Page 86: Specifications
BEDKNIFE AND BEDBAR: Single edged high carbon HEIGHT–OF–CUT RANGE: 1/16 to 19/64 inch (1.6 to steel bedknife, hardened to RC 48-54. A cast iron bed- 7.5 mm). bar is fastened to the mower. Cutting Unit (Rev. C) Page 7 – 2 Greensmaster Flex 21...
Page 87: General Information
General Information Grass Basket Installation 1. Grasp basket by top lip and slide the basket frame into the receivers. Figure 1 1. Grass basket 2. Basket receivers Greensmaster Flex 21 Page 7 – 3 Cutting Unit (Rev. C)
Page 88: Separating Cutting Unit From Traction Unit
Cannister seals will also cause a slightly higher amount of drag than other seal types. Cutting Unit (Rev. C) Page 7 – 4 Greensmaster Flex 21...
Page 89: Special Tools
Order special tools from the TORO SPECIAL TOOLS Some tools may have been supplied with your mower or AND APPLICATIONS GUIDE (COMMERCIAL PROD- available as TORO parts. Some tools may also be avail- UCTS). able from a local supplier. Gauge Bar Assembly (13–8199) Used to verify height–of–cut.
Page 90 Figure 10 Sleeve Driver and Bearing and Seal Installer Set (TOR4108) Set includes both TOR4105 and TOR4107 in a plastic storage case with foam inserts. Figure 11 Cutting Unit (Rev. C) Page 7 – 6 Greensmaster Flex 21...
Page 91: Troubleshooting
Effective height–of–cut will be different than the bench set height–of–cut. Proper bedknife for height–of–cut. If the bedknife is too thick for effective height–of–cut, poor quality of cut will result. Greensmaster Flex 21 Page 7 – 7 Cutting Unit (Rev. C)
Page 92 Chapter 4 – Traction and Reel Drive System. Also, see Service and Repairs section in Chapter 4. Groomer reel operation. See Troubleshooting section of Chapter 8 – Groomer (Model 04201) or Chapter 9 – Groomer (Model 04204). Cutting Unit (Rev. C) Page 7 – 8 Greensmaster Flex 21...
Page 93: Adjustments
A. Paper should be cut with minimum contact be- tween the bedknife and the reel blades. NOTE: The Flex 21 will have slightly greater reel drag than other Toro greens mowers due to the reel seal de- Figure 13 sign.
Page 94: Leveling Rear Roller
6. Verify level of roller by attempting to insert piece of paper under each end of roller. 7. Tighten locknuts on roller bracket when roller is level. Cutting Unit (Rev. C) Page 7 – 10 Greensmaster Flex 21...
Page 95: Rear Roller Height Adjustment
1. RH rear roller bracket 3. Cutting unit sideplate 4. Re–install rear roller to brackets (see Roller Installa- 2. Locknut tion). 5. Level rear roller (see Leveling Rear Roller). Tighten locknuts. Greensmaster Flex 21 Page 7 – 11 Cutting Unit (Rev. C)
Page 96: Height-Of-Cut Adjustment
2. Gauge bar 8. Tighten both lock nuts to secure the height–of–cut adjustment (Fig. 17). Figure 19 1. Gauge bar 3. Rear roller 2. Front roller Cutting Unit (Rev. C) Page 7 – 12 Greensmaster Flex 21...
Page 97: Cut-Off Bar Adjustment
Use thicker or thinner feeler gauge based on turf conditions. 3. Tighten screws so that the distance between the cut– off bar and reel is equal for the complete length of the reel. Greensmaster Flex 21 Page 7 – 13 Cutting Unit (Rev. C)
Page 98: Service And Repairs
Authorized Toro Distributor. 5. Backlap according to procedure in TORO Sharpen- ing Reel and Rotary Mowers Manual, Form No. 80300 NOTE: For a better cutting edge, run a file across the front face of the bedknife when the lapping operation is completed.
Page 99: Bedbar
5. Jam nut jam nut tightening, the washers next to the bedbar might 2. Bedknife 6. Flat washer (metal) 3. Bedknife screw 7. Flat washer (nylon) be loose. 4. Bedbar bolt Greensmaster Flex 21 Page 7 – 15 Cutting Unit (Rev. C)
Page 100: Bedknife Service
NOTE: When grinding, be careful to not overheat the Figure 26 bedknife. Remove small amounts of material with each pass of the grinder. 1. For bedknife grinding information, refer to TORO Sharpening Reel and Rotary Mowers Manual, Form No. Standard Bedknife 80-300 PT.
Page 101 This page is intentionally blank. Greensmaster Flex 21 Page 7 – 17 Cutting Unit (Rev. C)
Page 102: Rollers
7. Cap screw 12. Front roller assembly 3. Flat washer 8. Height–of–cut screw 13. Eccentric bolt 4. Carriage screw 9. Flange nut 14. Carriage screw 5. Shoulder bolt 10. Height–of–cut washer Cutting Unit (Rev. C) Page 7 – 18 Greensmaster Flex 21...
Page 103 (see Level- ing Rear Roller) and rear roller height (see Rear Roller C. Remove roller from the other roller bracket. Height Adjustment). Adjust as necessary. Greensmaster Flex 21 Page 7 – 19 Cutting Unit (Rev. C)
Page 104: Roller Service (Roller Shaft With Circlip)
4. Clean bearing cavity in roller and remove any rust ers. Do not re–use seals that have been removed. with crocus cloth. 5. Inspect bearings, shaft, retaining rings and roller for damage. Replace components as needed. Cutting Unit (Rev. C) Page 7 – 20 Greensmaster Flex 21...
Page 105 Mea- sure rolling resistance. If necessary, continue this pro- cess until the rolling resistance is correct. Greensmaster Flex 21 Page 7 – 21 Cutting Unit (Rev. C)
Page 106: Roller Service (Threaded Roller Shaft)
This will preserve the patch lock feature in the new lock nuts. Use the new nuts only after new bearings and Figure 35 seals have been installed. 1. Bearing lock nut 3. Bearing 2. Black assembly washer Cutting Unit (Rev. C) Page 7 – 22 Greensmaster Flex 21...
Page 107 2. Yellow assembly washer 4. Seal 12.Install bearing lock nut with V–ring onto each end of the roller shaft. Torque lock nuts from 25 to 30 ft–lb (34 to 41 N–m). Greensmaster Flex 21 Page 7 – 23 Cutting Unit (Rev. C)
Page 108: Cutting Reel
Repairs Section of Chapter 8 – Groomer (Model 04201) the reel shaft. Pull pulley from the shaft. Remove wood- or Chapter 9 – Groomer (Model 04204). ruff key and pulley spacer from reel shaft. Cutting Unit (Rev. C) Page 7 – 24 Greensmaster Flex 21...
Page 109 1. Cutting reel 4. Pitch arm bushing 2. Wear sleeve 5. Pitch arm 4. If equipped, install wear sleeve and v–ring seal to 3. V–Ring reel (Fig. 42 and 43). Greensmaster Flex 21 Page 7 – 25 Cutting Unit (Rev. C)
Page 110 Use heavy gloves when handling the cutting reel. NOTE: The Flex 21 will have slightly greater reel drag than other Toro greens mowers due to the reel seal de- sign. 5. Position reel with pitch arms and bushings in frame to accept bearing housings.
Page 111 This page is intentionally blank. Greensmaster Flex 21 Page 7 – 27 Cutting Unit (Rev. C)
Page 112: Cutting Reel Bearing Service (Cannister Style Seals)
(see Cutting Reel Bearing Service (V–Ring Style Seals) in this section). Cutting Unit (Rev. C) Page 7 – 28 Greensmaster Flex 21...
Page 113 C. With the flat side of the seal out, push seals into the bearing housing by hand. Seals should be flush with the housing. Do not strike seals during installa- tion as seal damage could occur. Greensmaster Flex 21 Page 7 – 29 Cutting Unit (Rev. C)
Page 114: Cutting Reel Bearing Service (V-Ring Style Seals)
Such a conversion requires that reel seals, v–ring seals, wear sleeves, reel bearing lock nut and pulley spacer be installed. Cutting Unit (Rev. C) Page 7 – 30 Greensmaster Flex 21...
Page 115 Inner seal should be flush with the housing and outer seal should be flush with the step in the housing. Greensmaster Flex 21 Page 7 – 31 Cutting Unit (Rev. C)
Page 116: Preparing Reel For Grinding
0.030 to 0.060 in (0.7 to 1.5 mm) each pass of the grinder. Max. Reel Taper 0.040 in (1.0 mm) 4. Grind cutting reel (refer to TORO Sharpening Reel and Rotary Mowers Manual, Form No. 80-300 PT). BLADE RELIEF ANGLE REEL DIAMETER...
Page 117 ....... Height/Depth of Grooming Adjustment ..Greensmaster Flex 21 Page 8 – 1 Groomer (Model 04201) (Rev. B)
Page 118: Specifications
1/4 and 3/4–inch (6.4 and 19.1 mm) spacing by varying the number of blades and spacers. grooming while cutting or transport. GROOMING PENETRATION: Maximum of 0.125 inch WIDTH–OF–GROOMING: 19 inches (48.3 cm). (3.2 mm). Groomer (Model 04201) (Rev. B) Page 8 – 2 Greensmaster Flex 21...
Page 119: General Information
2. To position the groomer reel for operation (groom- ing), pull up on both quick–up levers. Figure 1 1. Raised position (transport) Figure 2 1. Lowered position (grooming) Greensmaster Flex 21 Page 8 – 3 Groomer (Model 04201) (Rev. B)
Page 120: Troubleshooting
10.The overall turf management program – irrigation, fertilizing, weed control, coring, overseeding, sand dressing, and disease and pest control. 11. Stress periods for turf – high temperatures, high hu- midity, unusually high traffic. Groomer (Model 04201) (Rev. B) Page 8 – 4 Greensmaster Flex 21...
Page 121: Groomer Reel Mechanical Problems
Adjust depth if necessary. Check both ends of groomer reel. and adjust cutting unit set up (level bedknife to reel, level rear roller to reel, set height–of–cut, etc.). Greensmaster Flex 21 Page 8 – 5 Groomer (Model 04201) (Rev. B)
Page 122 Then, recheck setting on the first side of groomer. Height setting on both ends of groomer should be identi- cal. 6. Raise groomer reel to the transport position. Groomer (Model 04201) (Rev. B) Page 8 – 6 Greensmaster Flex 21...
Page 123: Service And Repairs
5. Secure belt cover to housing with two lock nuts. Figure 5 1. Drive pulley 4. Driven pulley 2. Idler pulley 5. Groomer drive belt 3. Idler pulley nut Greensmaster Flex 21 Page 8 – 7 Groomer (Model 04201) (Rev. B)
Page 124: Groomer Reel
RH adjuster arm assembly to mower side plate. Do 2. Front roller shaft 4. RH adjuster arm not change height–of–cut screw adjustment. Remove 3. Cap screw 5. Height–of–cut screw RH adjuster arm. Groomer (Model 04201) (Rev. B) Page 8 – 8 Greensmaster Flex 21...
Page 125 RH groomer side plate pin. 1. LH side plate (reel drive removed) 2. Seal nut 9. Center front roller and tighten cap screws on roller ends. Greensmaster Flex 21 Page 8 – 9 Groomer (Model 04201) (Rev. B)
Page 126 (230 to 288 kg–cm) so spacers are not free to ro- 2. Shaft 4. Blade tate. 6. Install groomer reel back on cutting unit (see Groom- er Reel Installation in this section). Groomer (Model 04201) (Rev. B) Page 8 – 10 Greensmaster Flex 21...
Page 127: Groomer Reel Bearing Replacement
Groomer Reel Installation in this section). 6. Check and adjust groomer reel height and mower height–of–cut settings. Figure 15 1. LH groomer side plate 3. Ball bearing 2. Retaining ring 4. Seal Greensmaster Flex 21 Page 8 – 11 Groomer (Model 04201) (Rev. B)
Page 128: Idler Assembly
2. Reassemble components using Figures 16 and 17 as guides. NOTE: When properly installed, the idler pulley should move freely from side to side on the idler bracket pin. Groomer (Model 04201) (Rev. B) Page 8 – 12 Greensmaster Flex 21...
Page 129: Adjuster Arm Assembly
Figure 18 for proper washer installation. 3. Install adjuster arm onto cutting unit (see Groomer Reel Installation in this section). 4. Check height–of–cut and adjust as needed. Greensmaster Flex 21 Page 8 – 13 Groomer (Model 04201) (Rev. B)
Page 130: Cutting Reel
Figure 20 3. Slide spacers from LH reel shaft and LH reel bearing 1. Groomer LH side plate 3. Reel housing spacer housing (Fig. 20). 2. Reel shaft spacer Groomer (Model 04201) (Rev. B) Page 8 – 14 Greensmaster Flex 21...
Page 131 Position reel with pitch arms and bushings in frame to accept bearing housings. The reel shaft end with keyway should be on the left side of the frame. Greensmaster Flex 21 Page 8 – 15 Groomer (Model 04201) (Rev. B)
Page 132 This page is intentionally blank. Groomer (Model 04201) (Rev. B) Page 8 – 16 Greensmaster Flex 21...
Page 133 Groomer Brush ......Greensmaster Flex 21 Page 9 – 1 Groomer (Model 04204) (Rev. B)
Page 134: Specifications
WIDTH–OF–GROOMER: 19 inches (48.3 cm). mm) above ground level to 0.125 inch (3.2 mm) below ground level, at mowing HOC range of .062 to .296 inch (1.6 to 7.5 mm). Groomer (Model 04204) (Rev. B) Page 9 – 2 Greensmaster Flex 21...
Page 135: General Information
Install the lock screw to retain the groomer reel in the grooming position (Fig. 2). Figure 2 1. Lift arm 2. Lock screw (grooming) Greensmaster Flex 21 Page 9 – 3 Groomer (Model 04204) (Rev. B)
Page 136: Troubleshooting
10.The overall turf management program – irrigation, fertilizing, weed control, coring, overseeding, sand dressing and disease and pest control. 11. Stress periods for turf – high temperatures, high hu- midity, unusually high traffic. Groomer (Model 04204) (Rev. B) Page 9 – 4 Greensmaster Flex 21...
Page 137: Groomer Reel Mechanical Problems
Adjust depth if necessary. Check both ends of groomer reel. and adjust cutting unit set up (level bedknife to reel, level rear roller to reel, set height–of–cut, etc.). Greensmaster Flex 21 Page 9 – 5 Groomer (Model 04204) (Rev. B)
Page 138: Height/Depth Of Groomer Adjustment
5. Repeat step 4 on the opposite end of the groomer. Then, recheck setting on the first side of groomer. Height setting on both ends of groomer should be identi- cal. Groomer (Model 04204) (Rev. B) Page 9 – 6 Greensmaster Flex 21...
Page 139: Service And Repairs
5. Secure belt cover to housing with two lock nuts. 1. Groomer belt cover 2. Lock nut Figure 5 1. Drive pulley 4. Driven pulley 2. Idler pulley 5. Groomer drive belt 3. Idler pulley nut Greensmaster Flex 21 Page 9 – 7 Groomer (Model 04204) (Rev. B)
Page 140: Groomer Reel
4. Remove lock nut (item 27) and spring washer (item 28) that secure RH groomer arm lift rod to RH side plate (Fig. 7). Groomer (Model 04204) (Rev. B) Page 9 – 8 Greensmaster Flex 21...
Page 141 Torque flange nuts from 100 to 120 in–lb (11.3 to 13.6 N–m). 8. Install cap plug (item 22) into LH side plate (Fig. 8). 9. Insert front roller into LH groomer arm. Greensmaster Flex 21 Page 9 – 9 Groomer (Model 04204) (Rev. B)
Page 142 (Figs. 7 and 8). settings. Adjust as needed. 13.Reinstall groomer drive belt and belt cover to right side of mower (see Groomer Belt Replacement in this section). Groomer (Model 04204) (Rev. B) Page 9 – 10 Greensmaster Flex 21...
Page 143: Groomer Reel Service
6. Install groomer reel back on cutting unit (see Groom- 2. Location mark 4. Dull (rounded) edge er Reel Installation in this section). CENTER BLADES Figure 12 1. Lock nut 3. Spacer 2. Shaft 4. Blade Greensmaster Flex 21 Page 9 – 11 Groomer (Model 04204) (Rev. B)
Page 144: Groomer Reel Bearing Replacement
B. Remove lock nut and spring washer that secure If equipped, locate and retrieve spacer. LH groomer arm lift rod to LH groomer side plate (Fig. 14). Remove LH groomer side plate from mower. Groomer (Model 04204) (Rev. B) Page 9 – 12 Greensmaster Flex 21...
Page 145 NOTE: After greasing groomer bearings, operate groomer for 30 seconds, stop machine and wipe excess grease from groomer shaft and seals. 5. Check and adjust groomer reel height and mower height–of–cut settings. Greensmaster Flex 21 Page 9 – 13 Groomer (Model 04204) (Rev. B)
Page 146: Idler Assembly
2. Install drive pulley, drive belt and belt cover to right side of mower (see Groomer Reel Installation in this sec- tion). Groomer (Model 04204) (Rev. B) Page 9 – 14 Greensmaster Flex 21...
Page 147: Groomer Arm Assembly
Figure 17 are the same on both sides of machine. NOTE: Grooved pin (item 3) is used to retain lock screw (item 6) to lift arm assembly. Greensmaster Flex 21 Page 9 – 15 Groomer (Model 04204) (Rev. B)
Page 148: Cutting Reel
Figure 19 3. Slide spacers from LH reel shaft and LH reel bearing 1. Spacer 3. Spacer housing (Fig. 19). 2. Retaining ring 4. Cutting reel shaft Groomer (Model 04204) (Rev. B) Page 9 – 16 Greensmaster Flex 21...
Page 149 5. Pitch arm 3. V–ring CAUTION Contact with the reel, bedknife or other cutting unit parts can result in personal injury. Use heavy gloves when handling the cutting reel. Greensmaster Flex 21 Page 9 – 17 Groomer (Model 04204) (Rev. B)
Page 150: Groomer Brush
Figure 22 threaded portion on the outside of the brush (Fig. 22). Torque lock nuts from 20 to 25 in–lb (2.3 to 2.8 N–m). 1. J–bolt 2. Lock nut Groomer (Model 04204) (Rev. B) Page 9 – 18 Greensmaster Flex 21...

Toro Greensmaster Flex 21 Service Manual

Chapter 3 Engine

Chapter 4 Traction and Reel Drive System

Chapter 5 Electrical System

Chapter 6 Chassis and Controls

Chapter 7 Cutting Unit

Chapter 8 Groomer (Model 04201)

Chapter 9 Groomer (Model 04204)

Quick Links

Chapters

Troubleshooting

Related Manuals for Toro Greensmaster Flex 21

Summary of Contents for Toro Greensmaster Flex 21

Table of Contents