Service Manual

ManualsBrandsToro ManualsWalk-Behind MowersGreensmaster Flex 18 Traction Unit

Table Of Contents

(Models 04018, 04019, 04030, 04022, 04024, 04025, 04031)

PART NO. 06149SL

Service Manual

Greensmaster



Flex 18/21

Preface

The purpose of this publication is to provide the service

technician with information for troubleshooting, testing

and repairing assemblies and components on the

Greensmaster Flex 18 (Model 04018) and Flex 21

(Model 04022).

REFER TO THE OPERATOR’S MANUAL FOR OPER-

ATING, MAINTENANCE AND ADJUSTMENT

INSTRUCTIONS. Space is provided in Chapter 2 of this

book to insert the Operator’s Manual and Parts Catalogs

for your machine. Replacement Operator’s Manuals

and Parts Catalogs are available on the internet at

www.toro.com or by sending complete Model and Serial

Number to:

The Toro Company

Attn. Technical Publications

8111 Lyndale Avenue South

Minneapolis, MN 55420–1196

The Toro Company reserves the right to change product

specifications or this publication without notice.

This safety symbol means DANGER, WARNING

or CAUTION, PERSONAL SAFETY INSTRUC-

TION. When you see this symbol, carefully read

the instructions that follow. Failure to obey the

instructions may result in personal injury.

NOTE: A NOTE will give general information about the

correct operation, maintenance, service, testing or re-

pair of the machine.

IMPORTANT: The IMPORTANT notice will give im-

portant instructions which must be followed to pre-

vent damage to systems or components on the

machine.

 The Toro Company – 2006

Summary of content (114 pages)

PAGE 1
PART NO. 06149SL Service Manual (Models 04018, 04019, 04030, 04022, 04024, 04025, 04031) Greensmaster Flex 18/21 Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing and repairing assemblies and components on the Greensmaster Flex 18 (Model 04018) and Flex 21 (Model 04022). REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.
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Chapter 6 – Chassis and Controls Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 2 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 – 4 Chapter 2 – Product Records and Maintenance Chapter 7 – Cutting Unit Specifications . . . . . . . .
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Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
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Safety Instructions Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine. Improper use or maintenance of the machine can result in injury or death. To reduce the potential for injury or death, comply with the following safety instructions.
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1. Do not run the engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could be deadly. 5. Before emptying basket of clippings, disengage traction and reel drives, reduce engine speed and move on/ off switch to OFF position to stop engine. 2. Always stand behind the handle when starting and operating the machine. 6. Do not touch engine, muffler or exhaust pipe while engine is running or soon after it has stopped because these areas are hot enough to cause burns. 3.
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Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. Decal part numbers are listed in your Parts Catalog. Order replacement decals from your Authorized TORO Distributor.
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Chapter 2 Product Records and Maintenance Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . .
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Equivalents and Conversions 0.
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Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series Fasteners) Thread Size Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in–lb in–lb N–cm 10 + 2 13 + 2 147 + 23 # 6 – 32 UNC # 6 – 40 UNF # 8 – 32 UNC 13 + 2 25 + 5 # 10 – 24 UNC 30 + 5 SAE Grade 8 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 5 or Stronger Nuts) in–lb N–cm in–lb N–cm 15 + 2 169 + 23 23 + 3
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in–lb 644 + 68 N–cm 78 + 8 in–lb 881 + 90 N–cm M6 X 1.0 96 + 10 in–lb 1085 + 113 N–cm 133 + 14 in–lb 1503 + 158 N–cm M8 X 1.25 19 + 2 ft–lb 26 + 3 N–m 28 + 3 ft–lb 38 + 4 N–m M10 X 1.
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Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Square Head Hex Socket 1/4 – 20 UNC 140 + 20 in–lb 73 + 12 in–lb 5/16 – 18 UNC 215 + 35 in–lb 145 + 20 in–lb 3/8 – 16 UNC 35 + 10 ft–lb 18 + 3 ft–lb 1/2 – 13 UNC 75 + 15 ft–lb 50 + 10 ft–lb 7/16 – 20 UNF Grade 5 65 + 10 ft–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.
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Chapter 3 Engine Table of Contents Greensmaster Flex 18/21 2 3 3 3 4 4 5 5 5 6 8 Page 3 – 1 Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Cable Adjustment . . . . . . . . . . . . . . . . .
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Specifications Item Description Make / Designation Kawasaki, 4–stroke, OHV, single cylinder, air–cooled, gasoline engine, FE120D 2.36” x 1.73” (60 mm x 44 mm) Total Displacement 7.6 in3 (124 cc) Compression Ratio 8.4:1 Carburetor Float feed, fixed main jet Governor Mechanical flyweight Low Idle Speed (no load) 2400 + 100 RPM High Idle Speed (no load) 3600 + 100 RPM Direction of rotation Counter clockwise (facing PTO shaft) Fuel Unleaded, automotive grade gasoline Fuel Tank Capacity 2.
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Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing and repair of the gasoline engine used in the Greensmaster Flex 18 and Flex 21 mowers. use of some specialized test equipment is explained. However, the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility. Most repairs and adjustments require tools which are commonly available in many service shops.
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Adjustments Throttle Cable Adjustment If a new throttle cable must be installed or the cable is out of adjustment, adjust the cable as follows: 4 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the spark plug. 2. Move throttle control lever on the handle to the FAST position. 3 2 5 3. Loosen throttle cable screw that secures the throttle cable to the governor lever. 4.
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Service and Repairs Cooling System IMPORTANT: The engine that powers the Flex 18 and Flex 21 is air–cooled. Operating the engine with dirty or plugged cooling fins or a plugged or dirty blower housing will result in engine overheating and damage. IMPORTANT: Never clean engine with pressurized water. Water could enter and contaminate the fuel system. Engine 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the spark plug. 1 2.
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Spark Plug Use a NGK BPR 5ES spark plug or equivalent. 1. Make sure engine is OFF. Carefully pull spark plug wire off the spark plug. 0.028” to 0.032“ (0.7 to 0.8 mm) 2. Clean around spark plug and remove plug from the cylinder head. NOTE: The condition of the spark plug can give an accurate picture of the overall condition of the engine. Use the chart on the following page as a guide to determine possible problems with the engine. 3. Inspect the spark plug.
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NORMAL Has gray or light tan deposits on the firing tip. OVER HEATING Light gray or white insulator with small gray brown or black spots. Electrode has a bluish burnt appearance. FUSED SPOT DEPOSIT Has spotty or melted deposits resembling blisters or bubbles. Replace spark plug. Engine May be caused by engine overheating, loose spark plug, wrong fuel type, plug heat range too hot or incorrect ignition timing. Replace spark plug.
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Engine Loctite #242 1 17 18 19 3 4 2 16 32 11 18 22 20 13 12 31 14 7 21 30 28 11 29 11 33 26 27 27 9 5 34 8 15 6 RIGHT 10 23 FRONT 7 25 7 to 10 in–lb (0.8 to 1.1 N–m) 24 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Gearbox assembly Flange gasket Engine gear Engine adapter Engine Flat washer (4 used) Flange nut (8 used) Cap screw (4 used) Hourmeter bracket Damper Cap screw (3 used) Wire harness Engine 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
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Engine Removal (Fig. 5) 1. Make sure machine is parked on a level surface with the engine OFF. Remove spark plug wire from the spark plug to prevent the engine from starting. Close fuel shut–off valve. 1 2. If engine is to be disassembled, it may be easier to drain oil from engine before removing engine from traction unit. 2 3. Drain oil from gearbox. 2 3 A. Remove cap screw and flange nut that secure cable clamp to traction unit frame (Fig. 6). Locate and retrieve three (3) washers from under clamp.
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5. Connect electrical connections to engine (Fig. 8): Engine Installation (Fig. 5) 1. Position machine on a level surface. Make sure that spark plug wire is not connected to engine spark plug. A. Connect wire harness connectors to engine stop switch and armature wires. 2. Make sure that all parts removed from the engine during maintenance or rebuilding are properly installed to the engine. B. Secure ground wire to engine with cap screw and lock washer. C. Connect wire harness to interlock module. 3.
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Chapter 4 Traction and Reel Drive System Table of Contents Greensmaster Flex 18/21 Page 4 – 1 Traction and Reel Drive System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Gearbox Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
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Specifications Item Description Traction Drive Integral Gearbox Assembly Attached Directly to Engine Differential to Traction Drive has 8 mm Pitch Positive Drive Belts Gearbox Fluid Dexron III Automatic Transmission Fluid (or equivalent) Gearbox Fluid Capacity 2.9 U.S. qt (2.8 l) Differential Integral in Gearbox Assembly Parking Brake Band Drum (in gearbox) Traction Drum Dual Cast Aluminum, 7.5 inch (19.
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General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Greensmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine. Gearbox Seals Greensmaster Flex 18/21 Page 4 – 3 Traction and Reel Drive System The Greensmaster Flex 18 and Flex 21 use cannister seals in the gearbox.
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Service and Repairs Reel Drive and Transmission Coupler Drive Belt Replacement (Fig. 1 and 2) Flex 18 and Flex 21 machines use two identical positive drive belts to operate the cutting unit. Replacement of these belts requires the same procedure. Removal 1 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 2 2 2. Remove belt cover to expose appropriate drive belt: right side (Fig. 1) or left side (Fig. 2). 3 4.
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Reel Drive Assembly 40 to 50 ft–lb (54 to 68 N–m) 17 Antiseize Lubricant 18 16 15 19 RIGHT 14 FRONT 24 12 100 in–lb (11.3 N–m) 10 25 7 8 7 6 5 14 4 3 2 1 17 3 15 11 12 23 13 9 40 to 50 ft–lb (54 to 68 N–m) Antiseize Lubricant 3 1 2 Antiseize Lubricant 4 5 6 7 8 7 10 11 26 14 40 to 50 ft–lb (54 to 68 N–m) 13 33 16 12 9 18 17 27 32 31 30 22 29 13 Antiseize Lubricant 12 21 20 15 28 17 100 in–lb (11.3 N–m) 40 to 50 ft–lb (54 to 68 N–m) Figure 3 1. 2. 3. 4. 5.
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Reel Drive and Transmission Coupler Bearing Housing (Fig. 3) Service of the reel drive bearing housings on either side of the machine requires similar procedures. 4 Removal 2 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the spark plug. 1 2. Remove the cutting unit from the traction unit (see Separating Cutting Unit From Traction Unit in the General Information section of Chapter 7 – Cutting Unit). 3 3.
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3. Apply grease to the bore of the bearing housing. Install shaft with bearings and spacer into housing and secure with retaining ring. 4. Fill small cavity between outer bearing and seal location in bearing housing approximately half full of Mobil High Temperature XHP–222 grease (or equivalent) (Fig. 8). 7. Install reel drive belt to the reel drive assembly and adjust belt (see Reel Drive and Transmission Coupler Drive Belt Replacement in this section).
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Traction Drive Belt Replacement The traction drive system on Flex 18 and Flex 21 machines uses a positive drive belt on both sides of the traction drum. Belt replacement on either side requires the same procedure. 1 Removal 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 2 2. Remove transport wheels if attached (see Transport Wheels in the Service and Repairs section of Chapter 6 – Chassis and Controls). 3.
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Traction Drive Idler Pulley and Bearings Removal 7 6 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 5 4 2 3 2. Remove transport wheels if attached (see Transport Wheels in the Service and Repairs section of Chapter 6 – Chassis and Controls). 12 8 11 9 4. Remove cap screw and tab washer that secures the idler bracket to the side plate of the mower (Fig. 14). 5.
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Traction Drum Assembly 100 in–lb (11.3 N–m) 40 to 50 in–lb (4.5 to 5.7 N–m) 40 to 50 ft–lb (54 to 68 N–m) 21 24 Antiseize Lubricant 26 16 33 33 27 15 18 25 35 11 20 34 25 32 2 17 45 to 55 ft–lb 19 (61 to 75 N–m) Loctite #242 13 12 23 33 8 29 35 30 32 14 65 to 75 ft–lb (88 to 102 N–m) 10 5 11 28 10 4 22 31 9 3 4 Antiseize Lubricant 28 6 RIGHT 7 1 FRONT 100 in–lb (11.3 N–m) Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
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Traction Drum Removal (Fig. 15) RIGHT HAND THREADS 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 2 LOCTITE #242 3 1 2. If installed, remove transport wheels (see Transport Wheels in the Service and Repairs section of Chapter 6 – Chassis and Controls). LEFT HAND THREADS ANTISIEZE LUBRICANT 3. Remove belt cover and traction drive belt from each side of mower (see Traction Drive Belt Replacement in this section). 4.
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Traction Drum Assembly (Fig. 15) 4. Position drum spacers to sides of drum. 1. Assemble hub/spindle assembly (Fig. 17): 5. Insert bar stock or other suitable tool through spokes of drum to keep drum from turning. A. Press one bearing into drum hub by applying pressure to outer bearing race. Install bearing spacer into drum hub and fill cavity between spacer and drum hub with Mobil High Temperature XHP–222 grease (or equivalent).
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Gearbox 1 7 8 9 3 4 2 6 11 10 5 RIGHT FRONT Figure 18 1. 2. 3. 4. Gearbox assembly Flange gasket Engine gear Engine adapter 5. 6. 7. 8. Engine Set screw (4 used) Cap screw Lock washer 9. Washer 10. Flange nut (4 used) 11. Key 7. Loosen set screws that secure extended race bearings to gearbox axles (Fig. 19). Gearbox Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove spark plug wire from the spark plug. 2. Drain oil from gearbox assembly. 8.
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11. Slide gearbox assembly to the right side of mower, away from the engine. This should allow the left gearbox axle to clear the frame and the gearbox to separate from the engine gear. Rotate and pivot gearbox assembly and then slide right side axle from frame to complete gearbox removal. 40 to 50 in–lb (4.5 to 5.7 N–m) Antiseize Lubricant 4 3 3 6 1 7 2 12.Slide bearings and bearing flangettes from gearbox axle shafts. 13.Remove and discard flange gasket from between engine and gearbox.
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Gearbox Service 240 in–lb (27 N–m) 56 45 47 46 26 13 30 32 32 23 7 66 63 26 32 65 33 2 50 64 51 11 43 72 27 20 25 26 5 15 14 19 55 18 37 40 49 38 69 42 7 6 8 71 1 29 19 39 54 73 62 53 44 16 19 10 120 to 140 in–lb (13.6 to 15.8 N–m) 57 36 3 60 56 61 17 19 61 40 41 4 8 70 34 35 4 9 9 28 23 32 21 22 52 58 RIGHT FRONT 68 48 67 59 10 31 9 72 12 85 to 105 in–lb (9.6 to 11.8 N–m) Figure 21 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
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Disassembly (Fig. 21) 4 1. Clean outside of the gearbox assembly. 3 2. Remove reel drive assembly from gearbox (Fig. 22): 2 A. Loosen flange nut that secures reel drive pulley to gearbox clutch shaft. 1 B. Remove reel drive belt. C. Remove flange nut and pulley washer from gearbox clutch shaft and slide pulley from shaft. Take woodruff key from shaft. D. Pull drive shaft plate from gearbox after removing three (3) fasteners: two socket head screws and one cap screw with lock washer. 5 Figure 22 4.
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13.Gearbox seals can be removed as follows: A. Using a 1/4” thick, 3” X 3” square piece of steel, make a seal removal tool as shown in Fig. 27. B. If seal is secured with retaining ring, remove retaining ring. Slide seal removal tool over shaft. 7. Install planetary assembly (with brake band installed) into gearbox, engaging gears of differential assembly.
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8. If traction band is replaced, the new band will have an ink mark on the upper end of the band (Fig. 28). MARK LOCATION 9. Carefully fit traction shaft with band to the planetary assembly and gearbox base taking care not to distort traction band. Traction band should easily slide over traction drum during installation. If traction band is improperly placed on the traction shaft or if the band is distorted, it will not fit easily on the drum.
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Differential Service 7 9 11 5 3 8 5 7 1 10 6 11 4 RIGHT 2 6 FRONT Figure 31 1. 2. 3. 4. RH (short) axle LH (long) axle Retaining ring Driven bevel gear 5. 6. 7. 8. 9. Input gear/housing 10. Gear shaft 11. Bushing Drive bevel gear Washer Washer Roll pin The differential assembly is an integral component of the gearbox assembly. Service of the differential assembly requires removal and disassembly of the gearbox. Inspection (Fig. 31) Disassembly (Fig. 31) 2.
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Assembly (Fig. 31) 1. Insert RH (short) axle into input gear/housing on the gear side. Install washer, drive bevel gear and new retaining ring on short axle. Install LH (long) axle into remaining side of input gear/housing using the same procedure. 4. Check gear and shaft alignment by rotating one axle. The other axle should turn in the opposite direction without any binding. Once free axle movement is checked, install new roll pin to secure gear shaft. 5.
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Chapter 5 Electrical System Table of Contents 2 3 5 5 6 6 6 7 7 8 8 9 Electrical System WIRING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . Ignition System Operation . . . . . . . . . . . . . . . . . . . .
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Wiring Schematic HIGH TENSION LEAD RED INTERLOCK MODULE BLACK IGNITION COIL WHITE BLACK RED F CONNECTOR E ORANGE D GREEN C OPERATOR PRESENCE SWITCH (OPTIONAL) YELLOW YELLOW LIGHTING COIL B RED BLACK ENGINE MAGNETO (FLYWHEEL) ON/OFF SWITCH BLACK A CONNECTOR HOURMETER INTERLOCK SWITCH 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 Electrical Syst
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Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may also be available from a local supplier. Multimeter The multimeter 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.
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Spark Tester Toro Part Number: TOR4036 For testing electronic ignitions. Saves time because you will know if the ignition is causing the problem on a non– starting engine. The tester determines if ignition spark is present.
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Troubleshooting The interlock switch must not be by–passed, it must be connected for proper electrical troubleshooting and safety. CAUTION Remove all jewelry, especially rings and watches, before doing any electrical testing or troubleshooting. NOTE: See the Kawasaki FE120 Service Manual at the end of Chapter 3 – Engine for additional engine ignition system troubleshooting information.
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Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ON/OFF switch connector before doing a continuity check). Individual components should be electrically isolated (e.g. disconnect all leads or remove from circuit) from the circuit when tested.
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Interlock Module and Switch The interlock module prevents the engine from starting unless the interlock switch is closed (traction lever in NEUTRAL). After a safe start, the engine will continue to run with the interlock switch open (traction lever FORWARD) or closed. C. Ground the red wire (male connector) to the engine block and attempt to start the engine. The engine should not start.
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Service and Repairs NOTE: See the Kawasaki FE120 Service Manual at the end of Chapter 3 – Engine for additional repair information. Interlock Switch Adjustment 1. Make sure the engine is OFF and the traction lever is in the NEUTRAL position. 1 2 2. Loosen interlock switch mounting fasteners. 4 3. Hold traction lever against the neutral stop (Fig. 6). 3 4. Position switch to allow from 0.032“ to 0.062” (0.81 to 1.58 mm) clearance between the traction lever and the interlock switch (Fig. 6). 5.
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Operator Presence Switch (Optional) The optional Operator Presence Kit for the Flex 18 and Flex 21 uses a switch mounted on the equipment handle that is operated by a bail. When the operator holds the bail against the handle, the switch closes, allowing the engine to run. 1 The common terminal and normally open terminal of the switch are used for the operator presence system on the Flex 18 and Flex 21 (Fig. 8). The normally closed terminal is not used.
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Chapter 6 Chassis and Controls Table of Contents Chassis and Controls SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Parking Brake Cable Replacement . . . . . . . . . . . .
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Specifications Item Description Transport Wheel (Optional) Tire Pressure Chassis and Controls 12 to 15 PSI (0.83 to 1.
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General Information Operator’s Manual Chassis and Controls The Operator’s Manual provides information regarding the operation, adjustment procedures and general maintenance for your Greensmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine.
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Service and Repairs Handle Assembly 42 23 24 18 45 25 7 10 21 5 45 17 41 11 27 13 16 15 6 29 24 37 32 34 31 1 38 18 3 33 28 26 31 19 20 36 18 20 43 40 11 22 31 33 39 44 2 33 43 14 10 32 9 35 8 28 30 12 4 42 RIGHT FRONT Figure 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
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Handle Removal 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 2 2. Note location of cable ties used to secure control cables. Remove cable ties. 1 4 3 3. Disconnect: A. Reel control and traction cables from gearbox (see Cable Replacement in this section). 5 6 B. Parking brake cable from brake bracket assembly (see Cable Replacement in this section). Figure 2 C.
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Parking Brake Cable Replacement Removal 4. Adjust brake cable (see Operator’s Manual). 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 5. Secure brake cable with cable ties. 6. Attach spark plug wire to spark plug. 2. Disengage parking brake to release tension on the brake cable. Remove cable ties that secure cable. 2 3. Remove parking brake cable from the gearbox as follows (Fig. 4): 3 1 5 A.
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Traction Control Cable Replacement Removal 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 2. Move traction lever to the DISENGAGED position. Remove cable ties that secure traction cable. 1 4 3. Remove traction cable from the gearbox as follows (Fig. 6): 3 A. Loosen front cable jam nut and lift traction cable free from casting slot of gearbox. B. Remove retaining ring that secures cable eyelet to gearbox traction lever. 2 5 Figure 6 4.
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Reel Control Cable Replacement Removal 2 4 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 5 2. Assure reel drive lever is in the DISENGAGED position. Remove cable ties that secure reel control cable. 3 1 3. Remove reel control cable from the gearbox as follows (Fig. 8): A. Loosen front cable jam nut and lift cable free from casting slot of gearbox. Figure 8 4. Reel control bellcrank 5. Retaining ring 1. Reel control cable 2.
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Throttle Cable Replacement Removal 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the spark plug. 4 2 2. Remove cable tie that secures throttle cable. 3. Remove throttle cable from the engine governor linkage as follows (Fig. 10): 1 A. Unscrew throttle cable screw enough to release the throttle cable from the nut in the governor lever. 3 B. Remove cap screw and flange nut that secure cable clamp to traction unit frame (Fig. 11).
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Transport Wheels (Optional) 2 1 13 9 Loctite #242 3 12 8 4 11 10 5 7 6 Figure 13 1. 2. 3. 4. 5. Cap screw (3 used) Lock washer (3 used) Shallow rim Tire Hub Chassis and Controls 6. 7. 8. 9. Wheel retaining lever Torsion spring Shoulder screw (2 used) Cap screw (4 used) Page 6 – 10 10. 11. 12. 13.
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Wheel Removal (Fig. 14) 1. Park machine on a level surface. Make sure the engine is OFF. 2. Support the machine on the kickstand. 3. Pivot wheel retaining lever away from the center of the wheel. Slide transport wheel off the wheel hex shaft. 2 1 Wheel Disassembly (Fig. 13) 1. Remove three (3) cap screws and lock washers from the shallow rim and hub. Remove hub from deep rim. 2. Inspect hub bushing (item 12). If worn or damaged, replace bushing. 3.
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Kickstand 11 10 8 12 2 8 1 8 10 3 7 10 3 4 6 9 5 8 RIGHT FRONT Figure 16 1. 2. 3. 4. 5. 6. 7. 8. Kickstand Cap screw Flat washer Long spacer 9. 10. 11. 12. Torsion spring Cap screw Spacer Flange nut Cap screw Support bushing Cap screw Frame assembly Removal (Fig. 16) Installation (Fig. 16) 1. Park machine on a level surface. Make sure the engine is OFF. 1. Make sure machine is parked on a level surface and the engine is OFF. 2. Pivot kickstand up and hold against the frame stops. 2.
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Chapter 7 Cutting Unit Table of Contents Cutting Unit SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Separating Cutting Unit From Traction Unit . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FACTORS THAT CAN AFFECT QUALITY OF CUT 6 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Specifications REEL CONSTRUCTION: 5–inch (12.7 cm) diameter, 11 carbon steel blades welded to 5 stamped steel spiders. High strength low alloy steel blades are thru hardened and impact resistant. An optional 8 blade cutting reel is available. FRAME CONSTRUCTION: Precision machined die cast aluminum cross member with two bolt–on die–cast aluminum side plates. HEIGHT–OF–CUT: Cutting height is adjusted on the front roller by two vertical screws and held by two lock nuts.
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General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for the cutting unit on your Greensmaster machine. Refer to this publication for additional information when servicing the cutting unit. Separating Cutting Unit from Traction Unit 1. Position mower on a flat, level work surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 2 2. Lower kickstand.
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Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may have been supplied with your mower or are available as TORO parts. Some tools may also be available from a local supplier. Gauge Bar Assembly Toro Part Number: 13–8199 Used to verify height–of–cut.
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Bearing and Seal Installer Toro Part Number: TOR4105 Used to install bearings and seals into front and rear rollers. NOTE: TOR4105 is an alternative to using washers and spacers listed above. Figure 8 Sleeve Driver Toro Part Number: TOR4107 Used to drive the wear sleeve into position on the cutting reel shaft. Figure 9 Sleeve Driver and Bearing and Seal Installer Set Toro Part Number: TOR4108 Cutting Unit Set includes both TOR4105 and TOR4107 in a plastic storage case with foam inserts.
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Factors That Can Affect Quality of Cut There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess,” or attempting to cut off too much grass height may not always be overcome by adjusting the cutting unit. It is important to remember that the lower the height–of–cut, the more critical these factors are.
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Factor Possible Problem/Correction Rear roller level. Reel and rear roller should be parallel for proper cutting performance (see Leveling Rear Roller in Adjustments section of this chapter). Roller condition. Make sure rollers rotate freely. Repair roller bearings if necessary (see Roller Service in Service and Repairs section of this chapter). Traction speed. Check maximum governed engine speed. Adjust engine to specifications if necessary (see Adjustments section in Chapter 3 – Engine).
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Adjustments DANGER CAUTION Never work on the cutting unit with the engine running. Always stop the engine and remove the spark plug wire from the spark plug first. Contact with the reel, bedknife or other cutting unit parts can result in personal injury. Use heavy gloves when handling the cutting reel or bedknife. Leveling Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment (parallel).
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Service and Repairs Backlapping 1. Park cutting unit on a level surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 2. Make sure reel drive lever is DISENGAGED. 3. Remove plug from the reel drive cover on the left side of the reel assembly (Fig. 13). 4. Insert a 18 mm socket onto hex flange nut on left side of reel shaft. 1 DANGER Contact with the reel or other moving parts can result in personal injury. Figure 13 1. Cover plug Stay away from the reel when backlapping.
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Bedbar 2 190 to 240 in–lb (21.5 to 27.1 N–m) 16 17 1 8 Antiseize Lubricant 6 7 8 9 3 15 4 12 Antiseize Lubricant 17 5 18 13 200 to 250 in–lb (22.6 to 28.2 N–m) 10 18 11 14 RIGHT FRONT Figure 14 1. 2. 3. 4. 5. 6. Grass shield Washer head screw (3 used) Bedbar Bedknife Screw Bedbar bolt (2 used) 7. 8. 9. 10. 11. 12. Flange nut (2 used) Flat washer (4 used) Plastic washer (4 used) Cutoff bar Screw (4 used) Cap screw (2 used) 13. 14. 15. 16. 17. 18.
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Installation (Fig. 14) 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the spark plug. 2. Install bedbar from bottom of cutting unit frame making sure that bedbar mounting ears are positioned between washer and bedbar adjuster screw (Fig. 15). 2 3 1 6 4 3. Thread flange nuts fully onto bedbar pivot bolts with flange away from head of pivot bolt. Apply antiseize lubricant to threads and shank of pivot bolts. 4.
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Bedknife Service Bedknife Removal 2. After bedknife grinding is complete, install bedbar to the mower (see Bedbar Installation in this section). 1. Remove bedbar from cutting unit frame (see Bedbar Removal in this section). 2. Remove screws that fasten bedknife to bedbar using a socket wrench and bedknife screw tool (see Special Tools). Discard screws. Remove bedknife from bedbar (Fig. 17). 3 2 Bedknife Installation 1.
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Bedbar Adjuster Service 8 7 6 12 5 4 11 9 2 10 13 3 2 1 Antiseize Lubricant Figure 21 1. 2. 3. 4. 5. Adjuster shaft Flange bushing Cutting unit frame Wave washer Retaining ring 6. 7. 8. 9. 10. 11. 12. 13. Adjuster screw Detent Lock washer Cap screw Washer Spring Lock nut Cutting unit side plate (LH shown) Removal (Fig. 21) Installation (Fig. 21) 1. Position machine on a flat, level work surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 1.
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Rollers 14 15 16 Antiseize Lubricant 17 1 6 7 12 8 18 9 10 2 14 15 3 16 17 4 11 13 5 RIGHT FRONT 18 Figure 22 1. 2. 3. 4. 5. 6. Rear roller Roller shim (2 used) Flange nut (4 used) Shaft retainer (2 used) Socket head screw (4 used) Height–of–cut screw (2 used) Cutting Unit 7. 8. 9. 10. 11. 12. Lock nut (2 used) Height–of–cut washer (2 used) Height–of–cut arm (2 used) Roller spacer (2 used) Plow bolt (2 used) Cap screw (2 used) Page 7 – 16 13. 14. 15. 16. 17. 18.
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Roller Removal (Fig. 22) Roller Installation (Fig. 22) 1. Park machine on a level surface. Make sure engine is OFF. Remove spark plug wire from the engine spark plug. 1. To install front roller: A. Insert one end of front roller into height–of–cut arm that is secured to cutting unit side plate. 2. To remove front roller assembly: A. Loosen cap screw that secures front roller shaft to height–of–cut arm on both sides of the mower. B. Slide second height–of–cut arm onto front roller shaft.
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Roller Service 1 6 5 4 2 7 25 to 30 ft–lb (34 to 41 N–m) 4 5 6 25 to 30 ft–lb (34 to 41 N–m) 7 3 Figure 23 1. Wiehle roller 2. Smooth roller 3. Roller shaft 4. Ball bearing 5. Seal 6. V–ring 7. Bearing lock nut NOTE: Several different rollers are available for the Flex 18 and Flex 21 cutting unit. Roller service procedures are identical for all types of rollers. 1 3 2 4 5 6 Disassembly (Fig. 23) 1.
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2. If tool TOR4105 is not available, install seals and bearings with installation washers and spacers (see Special Tools) as follows: NOTE: If bearing lock nuts are being replaced, use original lock nuts for assembly purposes, if possible. This will preserve the patch lock feature in the new lock nuts. Use the new nuts only after new bearings and seals have been installed. A. Position a new bearing, black assembly washer (see Special Tools) and original lock nut onto each end of the roller shaft (Fig. 25).
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Cutting Reel 2 190 to 240 in–lb (21.5 to 27.1 N–m) 16 17 1 8 Antiseize Lubricant 6 7 8 9 3 15 4 12 17 24 5 Antiseize Lubricant 18 13 19 10 20 21 18 11 14 RIGHT 23 22 FRONT Antiseize Lubricant 21 20 Figure 29 1. 2. 3. 4. 5. 6. 7. 8. Grass shield Washer head screw (3 used) Bedbar Bedknife Screw (11 used) Bedbar bolt (2 used) Flange nut (2 used) Flat washer (4 used) 9. 10. 11. 12. 13. 14. 15. 16.
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C. If cutting unit is equipped with a groomer, remove LH groomer side plate (see Groomer Reel Bearing Replacement in the Service and Repairs section of Chapter 8 – Groomer). 3 1 D. Locate and retrieve three (3) spacers (items 4 and 5) from between reel drive plate and side plate. 7. Remove front and rear rollers from cutting unit (see Roller Removal in this section). 2 8. Support reel weight on right side of the cutting unit to prevent it from falling.
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DANGER Contact with the reel, bedknife or other cutting unit parts can result in personal injury. Use heavy gloves when handling the cutting reel. IMPORTANT: When installing cutting reel, take care to not nick or scratch the wear sleeve surfaces as grease seal failure could result. 6. Carefully insert cutting reel into LH side plate grease seals and bearing taking care to not damage wear seal or grease seals. The reel shaft end with keyway should be on the left side of the frame. 7.
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Cutting Reel Service (Fig. 33) NOTE: Install new reel components on each end of the reel shaft that mates with newly serviced side plate components. WEAR SLEEVE TO BE FLUSH TO 0.015” (0.4 MM) PAST BEARING SHOULDER 1. Remove the v–ring seal from the reel shaft. 2. Using a flat blade screw driver or similar tool, carefully remove wear sleeve from the reel shaft taking care to not damage the reel shaft surface. Discard wear sleeve after removal. 3. Inspect the reel shaft as follows.
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Side Plate Service 5 13 11 10 12 7 9 8 6 21 4 22 16 1 18 210 to 240 in–lb (23.7 to 27.1 N–m) 4 17 14 2 16 23 19 15 23 16 25 FRONT RIGHT 24 3 20 18 24 16 Figure 34 1. 2. 3. 4. 5. 6. 7. 8. 9. Crossmember Adjuster shaft (2 used) Thrust washer Flange bushing (4 used) Cap screw (2 used) Lock washer (2 used) Detent (2 used) Wave washer (2 used) Retaining ring (2 used) 10. 11. 12. 13. 14. 15. 16. 17.
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Assembly (Fig. 34) 1. On RH side plate, if inner retaining ring (item 24) was removed, install inner retaining ring. Insert thrust washer (item 3) and then wave washer (item 20) into the side plate. FILL 75% TO 95% WITH MOBIL HIGH TEMP XHP–222 GREASE FILL 75% TO 95% WITH MOBIL HIGH TEMP XHP–222 GREASE 2. On LH side plate, insert o–ring (item 17) into groove in side plate. Make sure that o–ring is not twisted and is seated in side plate groove.
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Preparing Reel for Grinding NOTE: Check to make sure the reel bearings are in good condition before grinding a reel. 5. After completing grinding process: 1. Remove bedbar assembly (see Bedbar Removal in this section). A. If equipped, install grooming reel (see Grooming Reel in the Service and Repairs Section of Chapter 8 – Groomer). 2. Remove front roller (see Roller Removal in this section). B. Install front roller (see Roller Installation in this section). 3.
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Chapter 8 Groomer Table of Contents Groomer SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Transport Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4 Factors Affecting Grooming Performance . . . . . . 4 Grooming Reel Mechanical Problems . . . . . . . . . . 5 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Specifications MOUNTING: The groomer drive kit is mounted to the mower reel bearing housings and frame. REEL CONSTRUCTION: 2.375 inch (6 cm) diameter, 35 steel blades with 1/2 inch (12.7 mm) blade spacing. Spacing is also adjustable to 1/4 and 3/4 inch (6.4 and 19.1 mm) spacing by varying the number of blades and spacers. GROOMER PENETRATION: From .410 inch (10.4 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).
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General Information Transport Mode IMPORTANT: Before changing groomer position, make certain that the reel drive lever is in the disengaged position and that the cutting reel is not rotating. IMPORTANT: When transporting the mower, make sure the cutting unit is disengaged and the grooming reel is raised to its transport position. To place the grooming reel in the raised, transport position, remove the lock screw and rotate the lift arm to raise the grooming reel.
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Troubleshooting Factors Affecting Grooming Performance There are a number of factors that can affect the performance of grooming. These factors vary for different golf courses and from green to green. It is important to inspect the turf frequently and vary the grooming practice with turf needs. It is important to remember that factors affecting quality of cut also affect grooming performance.
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Grooming Reel Mechanical Problems Problem Possible Causes Correction The grooming reel rotates when it is The grooming reel should rotate in the raised, transport position. whenever the cutting reel is engaged. Normal operation. No rotation of the grooming reel. Seized grooming reel or idler bearing(s) in groomer side plate(s). Identify and replace faulty bearing(s). Broken or damaged idler spring. Replace spring. The groomer belt is worn, broken or If the groomer belt slips, it probably damaged.
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Adjustments CAUTION Never work on the mower with the engine running. Always stop the engine and remove the high tension lead from the spark plug before working on the mower. Height/Depth of Groomer Adjustment NOTE: Grooming is performed above the soil level. When adjusting groomer height/depth, grooming blades should never penetrate the soil. 3 1. Position mower on a flat, level working surface. Make sure engine is OFF. Remove high tension lead from the engine spark plug. 2.
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Service and Repairs Groomer Drive Belt Replacement 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the engine spark plug. 1 2. Remove two (2) lock nuts that secure groomer belt cover to cutting unit, then remove cover (Fig. 4). 3. Pivot idler pulley by placing a 10mm wrench on pulley nut and rotating clockwise to relax belt tension. Slip groomer drive belt off pulleys (Fig. 5). Release idler.
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Grooming Reel 20 19 12 17 13 25 4 24 26 18 16 Loctite #242 60 to 80 ft–lb (82 to 108 N–m) 15 17 to 21 ft–lb (23 to 28 N–m) 5 6 17 to 21 ft–lb (23 to 28 N–m) 7 2 11 8 23 3 27 9 RIGHT 16 10 21 28 FRONT 22 14 1 Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. LH groomer arm RH groomer arm Non–drive side plate Drive side plate Bushing (2 used) Spring washer (2 used) Lock nut (2 used) Grooming shaft assembly Extended race bearing (2 used) Front roller 11. 12. 13. 14. 15. 16. 17. 18. 19.
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NOTE: The drive pulley has left handed threads. To prevent cutting reel from turning when removing drive pulley, block reel with piece of wood. 4 3 8. Use a 3/8” drive socket wrench to remove drive pulley (item 17) from the cutting reel shaft. 9. Remove two (2) shoulder nuts (item 13) that secure the groomer RH side plate to the cutting unit side plate. Remove the groomer RH side plate. 10.Remove the cap plug from LH side plate (Fig. 8).
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NOTE: To prevent grooming shaft from turning when installing flange nuts, use wrench on shaft flats to hold shaft. 7. Secure grooming reel by tightening flange nuts on both ends of grooming shaft. Torque flange nuts from 17 to 21 ft–lb (23 to 28 N–m). 8. Insert front roller into LH groomer arm. 9. Position RH groomer arm to front roller, groomer RH side plate and mower frame. Secure groomer arm to mower with carriage bolt, washer and flange nut. 10.
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Grooming Reel Service Inspect grooming reel blades frequently for damage and wear. Straighten bent blades with a pliers. Replace blades that are worn or damaged (Fig. 12). Blades that are rounded to the midpoint of the blade tip must be replaced. CENTER BLADES ON SHAFT 2 3 Carbide tipped grooming blades (Fig. 11) should be replaced if the carbide tip is worn, loose or missing. Also, if the blade is eroded around the carbide insert, the blade should be replaced.
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Groomer Reel Bearing Replacement Seal lip 4 3 5 3 2 2 Seal lip 1 7 2 6 6 Seal lip 5 3 Figure 13 1. RH groomer side plate 2. Oil seal 3. Bearing (w/extended inner race) Groomer 4. Grease fitting 5. Bushing Page 8 – 12 6. Side plate bushing 7.
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Bearing Removal (Fig. 13) 1 1. Remove front roller, RH groomer side plate and grooming reel (see Grooming Reel Removal in this section). 3 2 2. Remove LH groomer side plate: A. Take reel drive assembly from left side of cutting unit (see Cutting Reel Removal in the Service and Repairs section of Chapter 7 – Cutting Unit). B. Remove lock nut and spring washer that secure LH groomer arm lift rod to LH groomer side plate (Fig. 14). Remove LH groomer side plate from mower. Figure 14 1.
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Idler Assembly 3 4 5 1 6 2 7 8 Seal lip 7 13 Seal lip 12 6 9 10 11 Figure 15 1. 2. 3. 4. 5. Lock nut Flat washer Retaining ring Idler bearing Idler pulley 6. 7. 8. 9. 10. 11. 12. 13. Seal Bearing Grease fitting RH side plate The right side plate assembly of the groomer drive kit incorporates the idler system for tensioning the groomer drive belt. The idler system uses a spring to maintain proper belt tension. 1 Pivot hub Bushing Idler bracket Retaining ring 2 4 Removal 1.
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Groomer Arm Assembly 1 14 2 13 7 12 11 10 8 Antiseize Lubricant 9 7 3 4 Antiseize Lubricant Antiseize Lubricant 6 5 Figure 17 1. 2. 3. 4. 5. HOC groomer arm (LH shown) Flange nut Grooved pin E–ring Groomer lift rod Groomer 6. 7. 8. 9. 10. Lock screw Bushing Lift arm assembly (LH shown) Detent spring Spring washer Page 8 – 16 11. 12. 13. 14.
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Disassembly (Fig. 17) 1 1. Remove groomer arm from cutting unit (Fig. 18): A. Loosen cap screw that secures front roller to groomer arm. B. Remove lock nut and spring washer that secure groomer lift rod to cutting unit side plate. 2 8 C. Remove lock nut and HOC washer that secure groomer arm to cutting unit side plate. D. Slide groomer arm from front roller and cutting unit. 2. Disassemble groomer arm using Figure 17 as a guide.
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Grooming Brush 3 20 to 25 in–lb (2.3 to 2.8 N–m) 1 2 3 4 20 to 25 in–lb (2.3 to 2.8 N–m) 2 Figure 20 1. Grooming brush shaft 2. Lock nut 3. J–bolt 4. Grooming brush The grooming brush attaches to the groomer drive in place of the grooming reel. Removal and installation of the grooming brush use the same procedure as removal and installation of the grooming reel (see Grooming Reel in this section).