Toro Greensmaster eFlex 1021 User manual

FormNo.20248SLRevA
Greensmaster®eFlex1021
(Model04861)
©2021—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
OriginalInstructions(EN)
Contactusatwww.Toro.com.
AllRightsReserved

RevisionHistory
RevisionDateDescription
A05/2021Initialissue.
RevisionHistoryPage2Greensmaster®eFlex1021
20248SLRevA

ReaderComments
TheToroCompanyT echnicalAssistanceCentermaintainsacontinuous
efforttoimprovethequalityandusefulnessofitspublications.T odothis
effectively,weencourageuserfeedback.Pleasecommentonthecompleteness,
accuracy,organization,usability,andreadabilityofthismanualbyane-mail
to[email protected]
orMailto:
TechnicalPublicationManager,Commercial
TheToroCompany
8111LyndaleAvenueSouth
Bloomington,MN55420-1196
Phone:[phone]
Greensmaster®eFlex1021Page3ReaderComments
20248SLRevA

NOTES
NOTESPage4Greensmaster®eFlex1021
20248SLRevA

Preface
Thepurposeofthispublicationistoprovidetheservicetechnicianwiththe
informationfortroubleshooting,testing,andrepairofthemajorsystemsand
componentsontheGreensmastereFlex1021(Model04861).
RefertotheOperator’sManualsandInstallationInstructionsforinstalling,
operating,maintenance,andadjustmentinstructions.Keepacopyofthe
Operator’sManuals,InstallationInstructionsandPartsCatalogsforyour
machineanditsaccessorieswiththisServiceManualforreference.Additional
copiesoftheOperator’sManuals,InstallationInstructionsandPartsCatalogs
areavailableatwww.toro.com.
TheToroCompanyreservestherighttochangetheproductspecicationsor
thispublicationwithoutnotice.
DANGER
Thissafetysymbolmeansdanger.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscouldkillorcauseseriouspermanentinjuryordisability.
WARNING
Thissafetysymbolmeanswarning.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinseriousinjury.
CAUTION
Thissafetysymbolmeanscaution.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinminortomoderateinjury.
IMPORTANT
TheImportantnoticewillgivetheimportantinstructionswhichyou
mustfollowtopreventdamagetothesystemsorcomponentson
themachine.
Note:ANotewillgivethegeneralinformationaboutthecorrectoperation,
maintenance,service,testing,orrepairofthemachine.
Greensmaster®eFlex1021Page5Preface
20248SLRevA

g340146
Figure1
PrefacePage6Greensmaster®eFlex1021
20248SLRevA

ServiceProcedureIcons
ThefollowingiconsappearthroughoutthisServiceManualtobringattentionto
specicimportantdetailsofaserviceprocedure.
CriticalProcess
Thisiconisusedtohighlight:
•installingsafetyequipment(shields,guards,seatbelts,brakesandR.O.P .S.
components)thatmayhavebeenremoved.
•dimensionsorsettingsthatmustbemaintainedforpropermachineoperation.
•aspecicfastenertighteningsequence.
•componentorientationthatmaynotbeobvious.
CriticalTorque
Thisiconisusedtohighlightanassemblytorquerequirementthatisdifferent
thanwhatisrecommendedintheStandardTorqueT ables;refertoT orque
Specications(page2–5).
FluidSpecications
Thisiconisusedtohighlightuidspecicationsandcapacitiesthatareless
common,andmaynotappearonthemachineservicedecalorinthemachine
Operator’sManual.
Note:RefertotheservicedecalonthemachineandthemachineOperator’s
Manualforcommonlyuseduidspecicationsandcapacities.
Greensmaster®eFlex1021Page7Preface
20248SLRevA

TableofContents
Preface................................................................................................................5
Chapter1:Safety............................................................................................1–1
SafetyInstructions.......................................................................................1–2
SafetyandInstructionalDecals....................................................................1–5
Chapter2:SpecicationsandMaintenance....................................................2–1
Specications...............................................................................................2–2
TorqueSpecications...................................................................................2–5
ShopSupplies............................................................................................2–11
SpecialT ools..............................................................................................2–13
Chapter3:Troubleshooting.............................................................................3–1
GEARS–TheSystematicApproachtoDening,DiagnosingandSolving
Problems......................................................................................................3–2
OperatorAdvisories......................................................................................3–3
MachineFaults.............................................................................................3–5
BatteryChargerErrorandFaultCodes.........................................................3–8
ElectricalSystemProblems..........................................................................3–9
AftercutAppearance...................................................................................3–11
FactorsAffectingGrooming........................................................................3–12
GroomingReelMechanicalProblems.........................................................3–13
Chapter4:TractionandReelDriveSystems...................................................4–1
GeneralInformation.....................................................................................4–2
Adjustments.................................................................................................4–3
ServiceandRepairs.....................................................................................4–5
Chapter5:ElectricalSystem...........................................................................5–1
GeneralInformation.....................................................................................5–2
ElectricalSystemOperation..........................................................................5–4
Adjustments................................................................................................5–20
TestingtheElectricalComponents..............................................................5–21
ServiceandRepairs...................................................................................5–42
Chapter6:Controls,WheelsandAccessories................................................6–1
GeneralInformation.....................................................................................6–2
Adjustments.................................................................................................6–3
ServiceandRepairs.....................................................................................6–4
Chapter7:DPACuttingUnits..........................................................................7–1
GeneralInformation.....................................................................................7–2
Adjustments.................................................................................................7–3
ServiceandRepairs.....................................................................................7–4
Chapter8:UniversalGroomer(Optional)........................................................8–1
GeneralInformation.....................................................................................8–2
ServiceandRepairs.....................................................................................8–3
AppendixA......................................................................................................A–1
ElectricalDrawingDesignations....................................................................A–2
ElectricalSchematic.....................................................................................A–3
WireHarnessDrawing..................................................................................A–4
WireHarnessDrawing..................................................................................A–5
PrefacePage8Greensmaster®eFlex1021
20248SLRevA

Chapter1
Safety
TableofContents
SafetyInstructions................................................................................................................................1–2
SafetyandInstructionalDecals............................................................................................................1–5
Greensmaster®eFlex1021Page1–1Safety
20248SLRevA

SafetyInstructions
TheGreensmastereFlex1021machineistestedandcertiedbyT orofor
compliancewithexistingsafetystandardsandspecications.Althoughhazard
controlandaccidentpreventionarepartiallydependentuponthedesign
andcongurationofthemachine,thesefactorsarealsodependentonthe
awareness,concern,andpropertrainingofthepersonnelinvolvedinthe
operation,transport,maintenance,andstorageofthemachine.Theimproper
useormaintenanceofthemachinecanresultininjuryordeath.
WARNING
Toreducethepotentialofinjuryordeath,complywiththesafety
instructionsinthismanual,aswellasinformationfoundinthe
Operator’sManualsandtheOperatorandSafetyTrainingMaterials
foundonwww.toro.com.
•Avoidunexpectedstartingoftheengine…
Alwaysturnofftheengine,removethekeyandunplugthe48Vbattery
disconnectbeforecleaning,adjusting,orrepair.
•Avoidlacerationsandamputations…
Stayclearofallmovingpartswhenevertheengineisrunning.Treatall
normallymovingpartsasiftheyweremovingwhenevertheengineis
runningorhasthepotentialtostart.
•Avoidburns…
Donottouchtheengine,mufer,orothercomponents,whichmaybehot
duringoperation,whiletheunitisrunningorshortlyafterithasbeen
running.Allowtheengine,mufer,andothercomponentstocoolbefore
workingnearthem.
•Avoidresandexplosions…
Useextremecareinhandlingfuel.Fuelisammableanditsvaporsare
explosive.
–Extinguishallcigarettes,cigars,pipes,andothersourcesofignition.
–Avoidspillingfuelandneversmokewhileworkingwithanytypeoffuel
orlubricant.
–Wipeupanyspilledfueloroilimmediately.
–Neverremovethefuelcaporaddfuelwhentheengineisrunning.
–Alwaysuseapproved,labeledcontainersforstoringortransportingfuel
andlubricants.
–Donotaddordrainfuelinanenclosedspace.
–Donotstorethemachineorfuelcontainerwherethereisanopename,
spark,orpilotlight,suchasonawaterheaterorotherappliance.
•Avoidasphyxiation…
Donotoperateanengineinaconnedareawithoutproperventilation.
•Avoidinjuryfromlithium-ionbattery…
–Immediatelydiscontinueuseofthebatteryifthebatteryemitsanunusual
smell,feelshot,changescolororshape,orappearsabnormalinany
otherway.Movetheproductorbatterytoasafeoutdoorareaawayfrom
anybuilding,vehicle,orcombustiblematerial.Observethebatteryfor
atleast1hourtoensurethatanyreactionhasstopped.Ifthereaction
continues,orifanysmokeisobserved,callyourlocalemergencyservices
immediately.
Safety:SafetyInstructionsPage1–2Greensmaster®eFlex1021
20248SLRevA

–UseonlyToro-speciedlithium-ionbatterypacksdesignedforyour
machine.DonotmixbatteryofanybrandortypeinT oroproducts.
–UseonlytheToro-speciedlithium-ionchargerdesignedtochargeyour
machine.Donotattempttouseanyotherbatterycharger.
–Donotover-chargeorover-dischargelithium-ionbattery.
–Donotheat,puncture,oropenthebatterycase.
–Alwaysdisconnectthebatteryatthebatterydisconnectprovidedwhen
servicingproductswithlithium-ionbatteries.
–Alwaysservicelithium-ionbatterywiththemachineparkednearaservice
doorlargeenoughtomovetheproductorbatteryoutsideincaseofan
emergencyandkeepareblanketnearby.Donotuseareextinguisher
onlithium-ionbatteries.
•Avoidinjuryduetoinferiorparts…
Useonlyoriginalequipmentpartstoensurethatimportantsafetycriteria
aremet.
•Avoidinjurytobystanders…
Alwayscleartheareaofbystandersbeforestartingortestingpowered
equipment.
•Avoidinjuryduetoprojectiles…
Alwayscleartheareaofanydebristhatcouldbepickedupandthrown
bythepoweredequipment.
•Avoidmodications…
Donotalterormodifyanypartunlessitisafactoryapprovedprocedure.
•Avoidunsafemachineoperation…
Alwaystestthesafetyinterlocksystemaftermakingadjustmentsor
repairsonthemachine.RefertotheChapter5:ElectricalSystem(page
5–1)inthismanualformoreinformation.
•Avoidelectricalshock…
–Nevertouchelectricalwiresorcomponentswhiletheengineisrunning.
Theycanbesourcesofshock.
–De-energizethesystemifyouarehavingtodorepairs.
–Iftestingelectricalcomponentsensureyouareworkinginadry
environment.
–Donotwearmetaljewelrywhenworkingonornearelectricalcomponents
orwiring.
•Usepersonalprotectiveequipment…
–Tiebacklonghair,anddonotwearlooseclothingorjewelry.
–Useappropriatepersonalprotectiveequipment(PPE)forprotecting
yourselffrompotentialhazardsintheenvironmentinwhichyouwillwork.
–EachprocessoutlinedinthismanualmayneeddifferentPPEtoprotect
theserviceperson.UsetheproperPPEforthetaskathand.
•Usingtools…
–Alltoolsshouldbeinproperworkingorder.Donotusetoolsthatare
brokenorindisrepair.
–Usethepropertoolfortheproperapplication.
•Usinglifts,hoists,andjacks…
–Alllifts,hoists,andjacksshouldbeusedinaccordancewiththe
manufacturerinformation.
–Inspectlifts,hoists,andjackspriortouse.
–Donotoverloadlifts,hoists,andjacks.
Greensmaster®eFlex1021Page1–3Safety:SafetyInstructions
20248SLRevA

–Donotworkunderasuspendedload.
–Ensurechockblocksareusedonequipmentthatcanmove.
–Useliftsorjacksandjackstandsthatareratedtosupportthetotalweight
ofthemachineandanyattachments.
–Donotrelyonjackstosupportthemachine.
–Ifyouareunfamiliarwithanylifts,hoistsorjacks,donotusethemuntil
youknowhowtooperatethemcorrectly.
•Usingreextinguishers…
Usetheproperclassofreextinguisherincaseofre.
Ensurereextinguishersareservicedregularly,andreplaceanyre
extinguishersthataredischargedorinusebeyondtheirexpirationdates.
WARNING
Donotuseareextinguisheronlithium-ionbatteries.Ifany
smokeisobserve,movetheproductorbatterytoasafeoutdoor
areaawayfromanybuilding,vehicle,orcombustiblematerialif
possibleandcallyourlocalemergencyservicesimmediately.
Failuretodosomayresultinpersonalinjuryandproperty
damage.
–ClassAreextinguishersareforordinarycombustiblematerialssuch
aspaper,wood,cardboard,andmostplastics.Thenumericalratingon
thesetypesofextinguishersindicatestheamountofwateritholdsand
theamountofreitcanextinguish.Geometricsymbol(greentriangle).
–ClassBreextinguishersareforresthatinvolveammableor
combustibleliquidssuchasgasoline,kerosene,greaseandoil.The
numericalratingforclassBextinguishersindicatestheapproximate
numberofsquarefeetofreitcanextinguish.Geometricsymbol(red
square).
–ClassCreextinguishersareforresthatinvolveelectricalequipment
suchasappliances,wiring,circuitbreakersandoutlets.Neverusewater
toextinguishclassCres-theriskofelectricalshockisfartoogreat!
ClassCextinguishersdonothaveanumericalrating.TheCclassication
meanstheextinguishingagentisnon-conductive.Geometricsymbol
(bluecircle).
–ClassABCreextinguishersareadrychemicaltypeusedformultiple
purposes.Seeabovedescriptionsforadditionalinformation.
Safety:SafetyInstructionsPage1–4Greensmaster®eFlex1021
20248SLRevA

SafetyandInstructionalDecals
Numeroussafetyandinstructiondecalsareafxedtothetractionunitand
cuttingunitsofyourGroundsmaster.Ifanydecalbecomesillegibleordamaged,
installanewdecal.DecalpartnumbersarelistedinyourPartsCatalog.Order
replacementdecalsfromAuthorizedT oroDistributor.
Greensmaster®eFlex1021Page1–5Safety:SafetyandInstructionalDecals
20248SLRevA

Safety:SafetyandInstructionalDecalsPage1–6Greensmaster®eFlex1021
20248SLRevA

Chapter2
SpecicationsandMaintenance
TableofContents
Specications.......................................................................................................................................2–2
OverallDimensions............................................................................................................................2–2
TractionandReelDriveSystems.......................................................................................................2–3
Controls,WheelsandAccessories....................................................................................................2–3
DPACuttingUnits..............................................................................................................................2–3
UniversalGroomer.............................................................................................................................2–4
TorqueSpecications...........................................................................................................................2–5
CalculatingtheT orqueValuesWhenUsingaDrive-AdapterWrench.................................................2–6
IdentifyingtheFastener......................................................................................................................2–7
StandardT orqueforDry,ZincPlated,andSteelFasteners(InchSeries)............................................2–8
StandardT orqueforDry,ZincPlated,andSteelFasteners(MetricFasteners)...................................2–9
OtherTorqueSpecications.............................................................................................................2–10
ConversionFactors..........................................................................................................................2–10
ShopSupplies....................................................................................................................................2–11
SpecialTools......................................................................................................................................2–13
Greensmaster®eFlex1021Page2–1SpecicationsandMaintenance
20248SLRevA

Specications
OverallDimensions
g340580
Figure2
SpecicationsandMaintenance:SpecicationsPage2–2Greensmaster®eFlex1021
20248SLRevA

TractionandReelDriveSystems
ItemDescription
TransmissionElectricmotortotransmission
Transmissiondriveusesspurgears
TractionDriveTransmissiontotractiondriveusesaseriesofspurgears
DifferentialSpurgearplanetarydifferential
ParkingBrakeBandstyle(atdifferentialshaftdrive)
TractionDrumDualaluminium,19.1cm(7.5inch)diameter
CuttingReelDriveTransmissionreeloutputshaftwithdisconnect
andslidingcoupler
Finalreeldrivehas2pulleyswithpositivedrivebelt
Belttensionmaintainedbyanidler
Controls,WheelsandAccessories
ItemDescription
TransportWheel(Optional)Tire
Pressure
83to103kPa(12to15PSI)
DPACuttingUnits
Frameconstruction:Precisionmachineddiecastaluminumcrossmemberwith2bolt-on
die-castaluminumsideplates.
Reelconstruction:12.7cm(5inches)diameter,11or14carbonsteelbladeswelded
to5stampedsteelspiders.Highstrengthlowalloysteelbladesare
throughhardened.
Height-of-cut:Cuttingheightisadjustedonthefrontrollerbytwoverticalscrews.
Standardbenchheightofcutrangeis1.6to12.7mm(0.062to0.500
inch)dependingontypeofbedknifeinstalled.EffectiveHOCmayvary
dependingonturfconditions,typeofbedknife,rollers,attachments
installedandreardrumposition.
Bedknifeandbedbar:ReplaceablesingleedgedEdgemax™bedknife(solidtoolsteel
construction)isstandard.Bedknifeisfastenedtothebedbarwith
thirteenbedknifescrews.Avarietyofoptionalbedknivesareavailable.
BedknifeadjustmentDualadjustment(oneoneachsideofthebedbar)with0.018mm
(0.0007inch)bedknifemovementforeachdetent.
Rollers:Therearrollerisa5.1cm(2inches)diameteraluminumfullroller.
Thefrontrollerisa6.3cm(2.5inches)diameterrollerthatischosen
fromavarietyofcongurations.
Grassshield:Non-adjustableshieldwithadjustablecut-offbartoimprovegrass
dischargefromreelinwetconditions.
Counterbalance
weight:
Acastironweightmountedonrightendofthecuttingunitbalances
thecuttingunit.
Cuttingunitweight(approximate):
18inch21inch
11blade33.5kg(74lbs)35kg(77lbs)
14blade35kg(77lbs)36.3kg(80lbs)
Options:RefertotheCuttingUnitPartsCatalogorcontactyourlocalAuthorized
ToroDistributorforavailablecuttingunitoptions.
Greensmaster®eFlex1021Page2–3SpecicationsandMaintenance:Specications
20248SLRevA

UniversalGroomer
ItemDescription
Groomingreeldiameter6cm(2.375inch)
GroomermountingThedriveassemblyforthegroomingreelislocated
ontheoppositesideofthecuttingunitfromthebelt
drive.
GroomerheightsettingMowing:0.8to15.7mm(0.030to0.620inch).
HOCrange:1.5to19.1mm(0.060to0.750inch).
Width-of-groomer54.6cm(21.5inch).
HeightadjustmentknobAllowsa0.08mm(0.003inch)incrementofheight
adjustmentforeachclickoftheadjuster.
Quick-upfeatureAllowsgroomingreeltoberaisedabovethe
height/depthadjustmentfornogroomingreelaction
whilemowing.
SpecicationsandMaintenance:SpecicationsPage2–4Greensmaster®eFlex1021
20248SLRevA

TorqueSpecications
Therecommendedfastenertorquevaluesarelistedinthefollowingtables.For
criticalapplications,asdeterminedbyT oro,eithertherecommendedtorqueora
torquethatisuniquetotheapplicationisclearlyidentiedandspeciedinthis
ServiceManual.
Thesetorquespecicationsfortheinstallationandtighteningofthefastenerswill
applytoallthefastenerswhichdonothaveaspecicrequirementidentiedin
thisServiceManual.Thefollowingfactorsmustbeconsideredwhenapplying
thetorque:cleanlinessofthefastener,useofathreadsealant(e.g.,Loctite),
degreeoflubricationonthefastener,presenceofaprevailingtorquefeature
(e.g.,Nylocknut),hardnessofthesurfaceunderneaththeheadofthefastener,
orsimilarconditionwhichaffectstheinstallation.
Asnotedinthefollowingtables,thetorquevaluesshouldbereducedby25%
forthelubricatedfastenerstoachievethesimilarstressasadryfastener.The
torquevaluesmustbereducedwhenthefasteneristhreadedintothealuminum
orbrass.Thespecictorquevalueshouldbedeterminedbasedonthealuminum
orbrassmaterialstrength,fastenersize,lengthofthreadengagement,etc.
Thestandardmethodofcheckingthetorquecanbeperformedbymarkingaline
onthefastener(headornut)andmatingpart,thenbackoffthefastener1/4
ofaturn.Measurethetorquenecessarytotightenthefasteneruntilthelines
matchup.
Greensmaster®eFlex1021Page2–5SpecicationsandMaintenance:TorqueSpecications
20248SLRevA

CalculatingtheTorqueValuesWhenUsingaDrive-AdapterWrench
g205924
Figure3
TorqueConversionFactor=A/B
1.T orquewrench3.A(effectivelengthoftorquewrench)
2.Drive-adapterwrench(crowsfoot)4.B(effectivelengthoftorquewrenchand
drive-adapterwrench)
Usingadrive-adapterwrench(e.g.,crowfootwrench)inanypositionotherthan
90°and270°totheframeofthetorquewrenchwillaffectthetorquevalue
measuredbythetorquewrenchbecauseoftheeffectivelength(lever)ofthe
torquewrenchchanges.Whenusingatorquewrenchwithadrive-adapter
wrench,multiplythelistedtorquerecommendationbythecalculatedtorque
conversionfactor(Figure3)todeterminepropertighteningtorque.Whenusinga
torquewrenchwithadrive-adapterwrench,thecalculatedtorquewillbelower
thanthelistedtorquerecommendation.
Example:Themeasuredeffectivelengthofthetorquewrench(distancefrom
thecenterofthehandletothecenterofthesquaredrive)is457mm(18inches).
Themeasuredeffectivelengthofthetorquewrenchwiththedrive-adapter
wrenchinstalled(distancefromthecenterofthehandletothecenterofthe
drive-adapterwrench)is483mm(19inches).
Thecalculatedtorqueconversionfactorforthistorquewrenchwiththis
drive-adapterwrenchwouldbe18/19=0.947.
Ifthelistedtorquerecommendationforafasteneris103to127N∙m(76to94
ft-lb),thepropertorquewhenusingthistorquewrenchwithadrive-adapter
wrenchwouldbe98to121N∙m(72to89ft-lb).
SpecicationsandMaintenance:TorqueSpecicationsPage2–6Greensmaster®eFlex1021
20248SLRevA