Toro Greensmaster eFlex 1800 User manual

FormNo.12189SLRevE
Greensmaster®eFlex1800,2100
and2120
(Model04042—SerialNo.312000001andUp)
(Model04043—SerialNo.312000001andUp)
(Model04046—SerialNo.400000000andUp)
(Model04049—SerialNo.400000000andUp)
©2018—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
OriginalInstructions(EN)
Contactusatwww.Toro.com.
AllRightsReserved

RevisionHistory
RevisionDateDescription
A2012Initialissue.
B2017AddedeFlex2120.
C01/2018AddedRevisionHistory.
D04/2018UpdatedCuttingUnitchapter.
E03/2019AddedModel04049andupdatedmodels04042,04043,and04046ttedwith04069.
RevisionHistoryPage2Greensmaster®eFlex1800,2100and2120
12189SLRevE

ReaderComments
TheToroCompanyT echnicalAssistanceCentermaintainsacontinuous
efforttoimprovethequalityandusefulnessofitspublications.Todothis
effectively,weencourageuserfeedback.Pleasecommentonthecompleteness,
accuracy,organization,usability,andreadabilityofthismanualbyane-mail
to[email protected]
orMailto:
TechnicalPublicationManager,Commercial
TheToroCompany
8111LyndaleAvenueSouth
Bloomington,MN55420-1196
Phone:[phone]
Greensmaster®eFlex1800,2100and2120Page3ReaderComments
12189SLRevE

NOTES:
NOTES:Page4Greensmaster®eFlex1800,2100and2120
12189SLRevE

Preface
Thepurposeofthispublicationistoprovidetheservicetechnicianwith
theinformationfortroubleshooting,testing,andrepairingassembliesand
componentsontheGreensmastereFlex1800(Model04043),eFlex2100(Model
04042),eFlex2120(Models04046and04049),eFlex1800(Model04043tted
with04069),eFlex2100(Model04042ttedwith04069)andeFlex2120(Models
04046and04049ttedwith04069).
RefertotheOperator’sManualsforoperating,maintenance,andadjustment
instructions.SpaceisprovidedinChapter2(page2–1)ofthisbooktoinsertthe
Operator’sManualsandPartsCatalogsforyourmachine.Additionalcopies
oftheOperator’sManualsandPartsCatalogsareavailableontheinternetat
www.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®eFlex1800,2100and2120Page5Preface
12189SLRevE

g207825
Figure1
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(page2–7).
FluidSpecications
Thisiconisusedtohighlightuidspecicationsandcapacitiesthatareless
common,andmaynotappearonthemachineservicedecalorinthemachine
Operator’sManual.
Note:RefertotheservicedecalonthemachineandthemachineOperator’s
Manualforcommonlyuseduidspecicationsandcapacities.
PrefacePage6Greensmaster®eFlex1800,2100and2120
12189SLRevE

TableofContents
Preface................................................................................................................5
Chapter1:Safety............................................................................................1–1
SafetyInstructions.......................................................................................1–2
SafetyandInstructionalDecals....................................................................1–7
Chapter2:SpecicationsandMaintenance....................................................2–1
Specications...............................................................................................2–2
TorqueSpecications...................................................................................2–7
ShopSupplies............................................................................................2–12
SpecialT ools..............................................................................................2–14
Chapter3:Troubleshooting.............................................................................3–1
GEARS–TheSystematicApproachtoDening,DiagnosingandSolving
Problems......................................................................................................3–2
ElectricalSystem:Troubleshooting..............................................................3–3
FactorsThatCanAffectQualityofCut..........................................................3–6
FactorsAffectingGrooming..........................................................................3–7
GroomingReelMechanicalProblems...........................................................3–8
Chapter4:TractionandReelDriveSystem.....................................................4–1
GeneralInformation.....................................................................................4–2
SpecialTools.................................................................................................4–7
Adjustments...............................................................................................4–10
ServiceandRepairs...................................................................................4–14
Chapter5:ElectricalSystem...........................................................................5–1
GeneralInformation.....................................................................................5–3
ElectricalSystemOperation..........................................................................5–8
LithiumBatteryPackChargerOperation(forModels04042,04043and
04046)........................................................................................................5–10
SpecialT ools...............................................................................................5–16
InfoCenterDisplay......................................................................................5–19
Adjustments................................................................................................5–33
TestingtheElectricalComponents..............................................................5–39
ServiceandRepairs...................................................................................5–69
Chapter6:ChassisandControls.....................................................................6–1
GeneralInformation.....................................................................................6–2
ServiceandRepairs.....................................................................................6–4
Chapter7:CuttingUnit....................................................................................7–1
GeneralInformation.....................................................................................7–2
Adjustments.................................................................................................7–6
ServiceandRepairs.....................................................................................7–8
Chapter8:BeltDrivenGroomer......................................................................8–1
GeneralInformation.....................................................................................8–2
Adjustments..................................................................................................8–4
ServiceandRepairs.....................................................................................8–6
Chapter9:UniversalGroomer(Optional)........................................................9–1
GeneralInformation.....................................................................................9–2
ServiceandRepairs.....................................................................................9–4
AppendixA......................................................................................................A–1
ElectricalDrawingDesignations....................................................................A–2
ElectricalSchematic-1800/2100,and2120(forModels04042,04043,and
04046)..........................................................................................................A–3
ElectricalSchematic-1800/2100,and2120(forModels04042,04043,
04046and04049ttedwith04069)..............................................................A–4
WireHarnessDrawing-Main-1800/2100(forModels04042and
04043)..........................................................................................................A–5
WireHarnessDiagram-Main-1800/2100(forModels04042and
04043)..........................................................................................................A–6
WireHarnessDrawing-Main-2120(forModel04046)...................................A–7
Greensmaster®eFlex1800,2100and2120Page7Preface
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WireHarnessDiagram-Main-2120(forModel04046)...................................A–8
WireHarnessDrawing-Main-1800/2100and2120(forModels04042,
04043,04046and04049ttedwith04069)..................................................A–9
WireHarnessDrawing-Main-1800/2100and2120(forModels04042,
04043,04046and04049ttedwith04069)................................................A–10
WireHarness-LiBattery-1800/2100,and2120(forModel04042,04043
and04046)..................................................................................................A–11
WireHarness-LiDiagnostic-1800/2100,and2120(forModel04042,
04043and04046).......................................................................................A–12
WireHarness-LiAdapater-1800/2100,and2120(forModel04042,04043
and04046)..................................................................................................A–13
PrefacePage8Greensmaster®eFlex1800,2100and2120
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Chapter1
Safety
TableofContents
SafetyInstructions................................................................................................................................1–2
BeforeOperatingtheMachine...........................................................................................................1–3
WhileOperatingtheMachine.............................................................................................................1–4
MaintenanceandService...................................................................................................................1–5
ConnectingtheLithiumBatteryPack.................................................................................................1–6
SafetyandInstructionalDecals............................................................................................................1–7
Greensmaster®eFlex1800,2100and2120Page1–1Safety
12189SLRevE

SafetyInstructions
TheGreensmastereFlex1800/2100,and2120machineshavebeentestedand
certiedbyT oroforcompliancewithexistingsafetystandardsandspecications.
Althoughhazardcontrolandaccidentpreventionarepartiallydependentupon
thedesignandcongurationofthemachine,thesefactorsarealsodependent
ontheawareness,concern,andpropertrainingofthepersonnelinvolvedinthe
operation,transport,maintenance,andstorageofthemachine.Theimproper
useormaintenanceofthemachinecanresultininjuryordeath.
WARNING
Toreducethepotentialofinjuryordeath,complywiththefollowing
safetyinstructions.
WARNING
TheeFlexlithiumbatterypackcontainshighvoltagewhichcould
burnorelectrocuteyou.
•Donotattempttoopenthebatterypack.
•Donotplaceanythingintheconnectorofthebatterypackother
thanthewireharnessconnectorthatcamewiththeproduct.
•Useextremecarewhenhandlingabatterypackwithacracked
case.
•Onlyusethechargerdesignedforthebatterypack.
Safety:SafetyInstructionsPage1–2Greensmaster®eFlex1800,2100and2120
12189SLRevE

BeforeOperatingtheMachine
•ReviewandunderstandthecontentsoftheOperator’sManualsand
Operator'sTrainingDVDbeforestartingandoperatingthemachine.
AdditionalcopiesoftheOperator’sManualsareavailableontheinternet
atwww.toro.com.
•Donotallowchildrentooperatethemachineorallowadultstooperateit
withoutproperinstructions.
•Becomefamiliarwiththecontrolsandknowhowtostopthemachineand
electricmotorquickly.
•Keepalltheshields,safetydevices,anddecalsinplace.Ifashield,safety
device,ordecalismalfunctioning,illegible,ordamaged,repairorreplaceit
beforeoperatingthemachine.
•Alwayswearsubstantialshoes.Donotoperatethemachinewhilewearing
sandals,tennisshoes,orsneakers.Donotwearloosettingclothingwhich
couldgetcaughtinmovingpartsandcausepersonalinjury.
•Wearingsafetyglasses,safetyshoes,longpants,earprotection,andahard
hatisadvisableandrequiredbysomelocalsafetyandinsuranceregulations.
•Ensurethattheworkareaisclearofobjectswhichmightbepickedupand
thrownbythecuttingunit.
•Keepeveryone,especiallychildrenandpets,awayfromtheareasof
operation.
•Thesafetyinterlockswitchesarefortheoperator’sprotection;donot
disconnectthem.Checktheoperationoftheswitchesdailytoensurethat
theinterlocksystemisoperating.Ifaswitchisdamaged,replaceitbefore
operatingthemachine.RefertoT estingtheElectricalComponents(page
5–39).
Greensmaster®eFlex1800,2100and2120Page1–3Safety:SafetyInstructions
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WhileOperatingtheMachine
1.Alwaysstandbehindthehandlewhenstartingandoperatingthemachine.
2.Tobeginthemachineoperation:
A.Ensurethatthemachinewireharnessisconnectedtothebatterypack.
B.CheckthatthecontrolleveronthehandleisintheNEUTRALposition
forbothtractionandreeldrives.
C.TurnthekeyswitchtotheSTARTpositionuntiltheInfoCenterdisplay
lightsup,thenreleasetheswitchtotheRUNposition.
3.Beforeleavingtheoperator’spositionofthemower:
A.Stopthemachineonalevelground.
B.Disengageboththetractionandreeldriveswiththecontrolleverand
settheparkingbrake.
C.TurnthekeyswitchtotheOFFpositionandwaitforallthemachine
movementtostop.
4.Beforeyouremovethebasketofclippings,disengagethetractionandreel
drives,settheparkingbrake,turnthekeyswitchtotheOFFpositionandwait
fortheelectricmotortostop.Waitforallthemachinemovementtostop
beforeremovingthebasket.
5.Ifthecuttingunitstrikesasolidobjectorvibratesabnormally,stopthe
machineoperationimmediately.Disengagethetraction/mowlever,turnthe
keyswitchtotheOFFposition,waitforallthemachinemovementtostop.
Then,disconnectthebatterypack(refertoConnectingtheLithiumBattery
Pack(page1–6))andinspectthecuttingunitfordamage.Adamagedreelor
bedknifemustberepairedorreplacedbeforeoperationisstarted.
6.Wheneverthemachineisleftunattended,ensurethattheelectricmotor
isstopped,cuttingunitreelisnotspinning,andkeyswitchisintheOFF
position.Removethekeyfromthekeyswitch.
Safety:SafetyInstructionsPage1–4Greensmaster®eFlex1800,2100and2120
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MaintenanceandService
•TheTractionUnitOperator’sManuals,CuttingUnitOperator’sManuals,and
GroomerOperator’sManualsprovideinformationregardingtheoperation,
generalmaintenance,andmaintenanceintervalsforyourGreensmaster
machine.Refertothesepublicationsforadditionalinformationwhen
servicingthemachine.
•Beforeservicingormakinganyadjustmentstothemachine,settheparking
brake,turnthekeyswitchtotheOFFpositionandwaitforallthemachine
movementtostop.Removethekeyfromthekeyswitch.Disconnectthe
batterypack(refertoConnectingtheLithiumBatteryPack(page1–6))to
preventunintentionalmachineoperation.
•Ensurethatthemachineisinsafeoperatingconditionbykeepingallthe
nuts,bolts,screws,andbeltstight.
•Toreducepotentialrehazard,keepthebatterypack,electricalconnectors,
cuttingunit,anddrivecomponentsfreeofunwantedmaterial.
•Wearheavyglovesandusecautionwhencheckingorservicingthecutting
unit.
•Iftheelectricmotormustberunningtoperformmaintenanceormakean
adjustment,keepyourhands,feet,clothing,andallpartsofthebodyaway
fromthecuttingunitandallmovingparts.Keepbystandersaway.
•Beforeinstalling,removing,orworkingonthecuttingunit,disconnectthe
batterypack(refertoConnectingtheLithiumBatteryPack(page1–6))to
preventunintentionalmachineoperation.
•Donotopenorchangethebatterypackinanyway.Openingthebattery
packmayexposeyoutodangerouselectricalvoltage.Thewarrantywillbe
voidedifyouattempttoopenthebatterypack.Withtheexceptionofthe
batterypackfuse,fusecoverandlabels,therearenoconsumerserviceable
partsonorinthebatterypack.
•IfyoumustshipthebatterypackfromyoureFlexmachine,youwillneed
specialpackagingtocomplywithshippingregulations.Refertothe
Operator’sManualforadditionalbatteryshippinginformation.
•Ifmajorrepairsarenecessary,contactyourAuthorizedT oroDistributor.
•Atthetimeofmanufacture,themachineconformedtoallapplicablesafety
standards.Toensureoptimumperformanceandcontinuedsafetycertication
ofthemachine,usegenuineT ororeplacementpartsandaccessories.The
replacementpartsandaccessoriesofothermanufacturerscanresultin
non-conformancewiththesafetystandardsandcanvoidthewarranty.
Greensmaster®eFlex1800,2100and2120Page1–5Safety:SafetyInstructions
12189SLRevE

ConnectingtheLithiumBatteryPack
WARNING
TheeFlexlithiumbatterypackcontainshighvoltagewhichcould
burnorelectrocuteyou.
•Donotattempttoopenthebatterypack.
•Donotplaceanythingintheconnectorofthebatterypackother
thanthewireharnessconnectorthatcamewiththeproduct.
•Useextremecarewhenhandlingabatterypackwithacracked
case.
•Onlyusethechargerdesignedforthebatterypack.
CAUTION
Beforeservicingthemachine,disconnectthemachinefromthe
batterypack.
Thiswillpreventunexpectedmachineoperation.
g202195
Figure2
eFlex2120Model04046(shown)
1.Machineconnector2.Batterypack3.Batteryconnector
Topreventunexpectedmachineoperationduringservice,disconnectthe
machinefromthebatterypackastherststepinanyrepair(Figure2).Once
thebatterypackhasbeendisconnected,theelectricalsystemonthemachine
canbesafelyworkedon.Duringrepairs,ensurethatyoudonotallowtoolsor
machinecomponentstocompletethebatterycircuitthatwasopenedwiththe
cableremoval.
Connectthemachinewireharnesstothebatterypackasthelaststepinany
repair.
Safety:SafetyInstructionsPage1–6Greensmaster®eFlex1800,2100and2120
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SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocated
nearanyareaofpotentialdanger.Replaceanydecalthatisdamagedorlost.
ThedecalpartnumbersarelistedinyourPartsCatalog.Orderreplacement
decalsfromyourAuthorizedT oroDistributor.
Greensmaster®eFlex1800,2100and2120Page1–7Safety:SafetyandInstructionalDecals
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Safety:SafetyandInstructionalDecalsPage1–8Greensmaster®eFlex1800,2100and2120
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Chapter2
SpecicationsandMaintenance
TableofContents
Specications.......................................................................................................................................2–2
OverallDimensions............................................................................................................................2–2
TractionandReelDriveSystem.........................................................................................................2–3
ElectricalSystem...............................................................................................................................2–3
ChassisandControls.........................................................................................................................2–3
CuttingUnit........................................................................................................................................2–4
BeltDrivenGroomer..........................................................................................................................2–5
UniversalGroomer(Optional)............................................................................................................2–6
TorqueSpecications...........................................................................................................................2–7
IdentifyingtheFastener......................................................................................................................2–8
StandardT orqueforDry,ZincPlated,andSteelFasteners(InchSeries)............................................2–9
StandardT orqueforDry,ZincPlated,andSteelFasteners(MetricFasteners).................................2–10
OtherTorqueSpecications.............................................................................................................2–11
ConversionFactors..........................................................................................................................2–11
ShopSupplies....................................................................................................................................2–12
SpecialTools......................................................................................................................................2–14
Greensmaster®eFlex1800,2100and2120Page2–1SpecicationsandMaintenance
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Specications
OverallDimensions
g272543
Figure3
SpecicationsandMaintenance:SpecicationsPage2–2Greensmaster®eFlex1800,2100and2120
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TractionandReelDriveSystem
ItemDescription
TransmissionPermanentmagnetDCmotordirectlycoupledto
rststageofamulti-ribbedpoly-Vbeltdrive
Belttensionmaintainedbyspringloadedidlerpulley
TractiondriveTransmissiontotractiondriveusesa
multi-ribbedpoly-Vbelt
Belttensionmaintainedbyspringloadedidlerpulley
DifferentialSpurgearplanetarydifferential
TractionbrakeBandstyle(atdifferentialshaftdrive)
TractiondrumDualcastaluminum,19cm(7.5inches)diameter
withtaperonouter5.08cm(2inches)
CuttingunitdriveTransmissionreelclutchshafttotelescoping
driveshaft
2beamstylecouplersusedinreeldrivesystem
Finalreeldrivehas3pulleyswithpositivedrivebelt
Pulleycongurationallows6clipadjustments
ElectricalSystem
ItemDescription
PowerLithium-Ionbatterypack–nominal53
V35Ah(42to64V,1.68kWh)with
integratedbatterymanagementsystem
utilizingCANcommunicationwiththeTEC
andcharger.Singlebatteryafxedto
unitandchargedonboard.
ElectricmotorBrushlesspermanentmagnetDCmotor
–nominal1.2kW(~20Acontinuous,
30Apeak)withintegralmotorcontroller
andhelicalgearreduction.
BatterychargerVoltageandcurrentcontrolledwithCAN
communicationtomanagestoragewake-up
andmaintenancefeatures.Compliesto
maximumvoltageandcurrentlimitsdirected
bythebatterymanagementsystem.
ChassisandControls
ItemDescription
Transportwheel(optional)tirepressure83to103kPa(12to15psi)
Greensmaster®eFlex1800,2100and2120Page2–3SpecicationsandMaintenance:Specications
12189SLRevE

CuttingUnit
g207099
Figure4
Reelconstruction:12.7cm(5inches)diameter,11or14carbonsteelblades
weldedto5stampedsteelspiders.Highstrengthlowalloysteelbladesare
throughhardenedandimpactresistant.
Frameconstruction:Precisionmachineddiecastaluminumcrossmemberwith
2bolt-ondie-castaluminumsideplates.
Height-of-cut:Cuttingheightisadjustedonthefrontrollerby2verticalscrews
andheldby2locknuts.Standardbenchheightofcutrangeis1.6to12.7mm
(0.062to0.500inch)dependingontypeofbedknifeinstalled.Anoptionalhigh
heightofcutkitisavailableforhigherHOCadjustments.EffectiveHOCmayvary
dependingonturfconditions,typeofbedknife,rollers,andattachmentsinstalled.
Clip:Clipfrequencyisadjustedbymovingthepulleysonthecuttingunitreel
drivehousing.6clipadjustmentsarepossiblebasedonpulleyconguration.
Rollers:Therearrollerisa5.1cm(2inches)diameteraluminumfullroller.The
frontrollerisa6.3cm(2.5inches)diameterrollerthatischosenfromavarietyof
congurations(narrowspacedWiehlefrontrollerisshowninFigure4).
Bedknifeandbedbar:SingleedgedEdgemax™bedknife(solidtoolsteel
construction)usedwith11and14bladecuttingunit.Acastironbedbaris
fastenedtothecuttingunit.Otheroptionalbedknivesandalessaggressive
bedbarareavailable.
Grassshield:Non-adjustableshieldwithadjustablecut-offbartoimprovegrass
dischargefromreelinwetconditions.
Counterbalanceweight:Acastironweightmountedonrightendofthecutting
unitbalancesthecuttingunit.
SpecicationsandMaintenance:SpecicationsPage2–4Greensmaster®eFlex1800,2100and2120
12189SLRevE