Toro 108-3160 User manual

1
All Rights Reserved
Printed in the USA
W2005 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Reel Seal Rebuild Kit
Greensmaster)Flex 21
Part No. 108–3160
Form No. 3353–630 Rev. A
Installation Instructions
1. Position the mower on a flat, level work surface. Make
sure the engine is OFF. Remove the spark plug wire
from the spark plug.
2. Separate the cutting unit from the traction unit. Refer
to the Operator’s Manual for the procedure.
Note: If a grooming reel kit is installed to the cutting unit,
remove the grooming reel. Refer to the Grooming Reel
Operator’s Manual for the procedure.
3. Remove the bedbar from the cutting unit. Refer to the
Operator’s Manual for the removal procedure.
4. Remove the belt cover and the reel drive belt from the
left side of the cutting unit. Refer to the Operator’s
Manual for the procedure.
5. Block the reel with a piece of wood to prevent it from
turning. Remove the flange nut securing the drive
pulley to the reel shaft (Fig. 1). Remove the pulley
from the shaft. Remove the woodruff key and the
spacer from the reel shaft.
3
5
2
4
1
Figure 1
1. Reel drive plate assembly
2. Capscrew w/lockwasher
3. Locknut
4. Reel drive pulley
5. Reel drive belt
6. Loosen and remove the two locknuts, capscrew and
lockwasher securing the reel drive plate assembly to
the left side of the cutting unit (Fig. 1). Remove the
assembly from cutting unit sideplate. Remove the
spacer from behind the reel drive plate.
7. Remove the front roller. Refer to the Operator’s
Manual for the removal procedure.
8. Remove the two locknuts securing the counterweight
to the right end of the cutting unit (Fig. 2). Remove the
counterweight.
1
Figure 2
1. Counterweight
9. Remove the reel bearing lock nut from the right side of
the reel (Fig. 3). The reel bearing lock nut has left
hand threads.
10. Remove the two tapered nuts and plow bolts securing
each reel bearing housing to the cutting unit side plates
(Fig. 3).
Note: If this kit is being used to retrofit the cannister seals
to oil seals, a new bearing locknut and spacer (Fig. 3,
items 4 & 6) are required. The oil seals in this kit require
the bearing locknut and spacer to have a 1.25” O.D. (old
parts have a 1.125” O.D.). Order part no. 107–3227
bearing locknut and 107–3228 spacer from you local
authorized Toro Distributor
Contact with the reel, bedknife, or any other
cutting unit parts may result in personal injury.
Use heavy gloves when handling the cutting unit.
Caution
Important Support the reel to prevent it from falling
when bearing housings are removed.
11. Remove both the oil seals from each bearing housings
(Fig. 3).

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12. Remove both of the bearing housings from the frame
and reel. Remove the reel from the mower.
Note: If the reel bearings (Fig. 3) are worn or need
replacement, refer to the Service Manual for bearing
replacement instructions.
FRONT
RIGHT
5
6
7
12
3
4
14
20
15
19 9
18
17
14
8
11
13
16
16
13
12
14
14
15
10
21 22
Figure 3
1. Reel drive pulley
2. Flange nut
3. Woodruff key
4. Spacer
5. Counterweight
6. Reel bearing locknut
7. Tapered nut
8. Plow bolt
9. R.H. Bearing housing
10. L.H. Bearing housing
11. R.H. Pitch arm
12. L.H. Pitch arm
13. Bushing
14. Oil seal
15. Reel bearing
16. Bearing journals
17. Retaining ring
18. Washer (if required)
19. Wave washer
20. Retaining ring
21. Spacer
22. Retaining ring
Note: Make sure each bearing housing cavity is
approximately half full of multi–purpose grease.
13. Install the new oil seals into the bearing housings as
follows:
•Insert an oil seal into each side of the bearing housing
positioning them flat side out (Fig. 5).
•On bearing housings with a bore length of 1.578
inches (Fig. 4), use the large washer (included in the
kit) to press each seal into the bearing housing until
the washer is flush with the outer edge of the bearing
housing.
1.578“
1.766“
Figure 4

3
1
2
3
5
4
78
9
6
1
2
3
5
4
78
9
6
Figure 5
1. Wave washer
2. Reel bearing
3. Retaining ring
4. Oil seal
5. Large washer
6. Bearing housing
7. Washer (if required)
8. Retaining ring
9. Oil seal
•On bearing housings with a bore length of 1.766
inches (Fig. 4), press the inner seal into the bearing
housing an additional .188” using the spacer and the
large washer included in the kit (Fig. 6). The spacer is
.188” thick. Remove the spacer when it is flush with
the outer edge of the bearing housing.
1
2
3
4
6
8
9
5
3
10
7
Figure 6
1. Wave washer
2. Reel bearing
3. Retaining ring
4. Oil seal (outer)
5. Bearing housing
6. Washer (if required)
7. Retaining ring
8. Oil seal (inner)
9. Spacer
10. Large washer
14. Remove the V–ring from the sleeve on each end of the
reel shaft (Fig. 7).
Note: Inspect the sleeves and replace as required. A
special sleeve driver is available, contact your Toro
Distributor to obtain this tool. Press a new sleeve onto the
end of each reel shaft until the sleeve is flush with the step
in the shaft.
Note: If replacing the reel, order part no. 107–7635
(11 blade) or 107–7634 (8 blade) which have factory
installed sleeves.
15. Install a new V–ring, flat side first, onto each end of
reel shaft until it is completely inserted into sleeve.
1
2
Figure 7
1. V–Ring 2. Sleeve
16. Apply anti–seize lubricant to the bearing journals of
the cutting reel (Fig. 3). Position the reel with the pitch
arms and the bushings in the frame to accept the
bearing housings. The reel shaft end with the keyway
should be on the left side of the frame.
Contact with the reel, bedknife, or any other
cutting unit parts may result in personal injury.
Use heavy gloves when handling the cutting unit.
Caution
17. Insert both the bearing housings (Fig. 3) through the
frame onto the reel shaft.
A. Push the housing onto the reel shaft. If necessary,
tap it into position with a soft hammer.
B. Attach the bearing housing to the side plate of the
cutting unit with the two plow bolts and tapered
nuts. Tighten the fasteners.
Note: The reel bearing lock nut has left hand threads.
18. Apply anti–seize lubricant to the internal threads of the
bearing lock nut (Fig. 3). Block the reel with a piece of
wood to prevent it from turning. Install and tighten the
bearing lock nut to the reel shaft.
19. Install the counterweight to the right side of the cutting
unit with two lock nuts (Fig. 2).

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20. Install the spacer in the left side reel bearing housing
(Fig. 3). Mount the reel drive plate assembly to the
side of cutting unit with two locknuts, capscrew, and
lockwasher. Tighten the fasteners to secure the
assembly.
21. Install the spacer and woodruff key to the reel shaft
(Fig. 3). Apply anti–seize lubricant to the internal bore
of the drive pulley and position the pulley onto the reel
shaft. Install and tighten the flange nut that secures the
pulley to the reel shaft.
22. Check for free movement of the reel assembly by
rotating the pulley. If binding is noted, identify and
correct the problem.
Note: The Flex 21 will have slightly greater reel drag,
than other Toro greens mowers, due to the reel seal
design.
23. Reinstall the reel drive belt to the pulley and drive
assembly (Fig. 1). Adjust the drive belt tension and
install the belt cover. Refer to the Operator’s Manual
for the adjustment procedure.
24. Install the front roller.
25. Reinstall the bedbar to the cutting unit.
26. Install the cutting unit to the traction unit.