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Disassembly of Differential Assembly

g259978

Figure 40

Differential housing (2 each)

Differential spur gear (6 each)

Socket head screw (6 each)

Differential pin (6 each)

Differential gear

1. Remove the 6 socket head screws (item 5 in

Figure 40

) that secures the

differential housing assembly (1) to the differential gear (4). Remove the
differential gear from the differential housing assembly.

2. Place the differential housing assembly on workbench. Pull each differential

housings (1) apart.

3. Use a press to remove the 6 differential pins (2) and 6 differential spur gears

(3) from the differential housings (1).

Inspecting the Differential Assembly

1. Clean all the differential assembly components.

2. Inspect all the differential spur gears (3) carefully looking for chipped teeth,

wear or other damage. Because gear tooth damage is rarely isolated to 1
gear, replace the gears as complete set if there is a internal damage.

3. Inspect the differential pins (2) for the scoring or wear.

4. Replace all the differential assembly components that are worn or damaged.

Greensmaster

1018/1021/1026

Page 5–37

Traction and Reel Drive Systems: Service and Repairs

18238SL Rev B

Summary of Contents for Greensmaster 1018

Page 1: ...8238SL Rev B Greensmaster 1018 1021 1026 Models 04820 04830 and 04840 2019 The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 Original Instructions EN Contact us at www Toro com All Rights Reserved ...

Page 2: ... History Revision Date Description A 03 2019 Initial issue B 03 2020 Updated the drum drive gear box assembly and transmission gear box assembly Revision History Page 2 Greensmaster 1018 1021 1026 18238SL Rev B ...

Page 3: ... we encourage user feedback Please comment on the completeness accuracy organization usability and readability of this manual by an e mail to servicemanuals toro com or Mail to Technical Publication Manager Commercial The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 1196 Phone 1 952 887 8495 Greensmaster 1018 1021 1026 Page 3 Reader Comments 18238SL Rev B ...

Page 4: ...NOTES NOTES Page 4 Greensmaster 1018 1021 1026 18238SL Rev B ...

Page 5: ...his publication without notice DANGER This safety symbol means danger When you see this symbol carefully read the instructions that follow Failure to obey the instructions could kill or cause serious permanent injury or disability WARNING This safety symbol means warning When you see this symbol carefully read the instructions that follow Failure to obey the instructions can result in serious inju...

Page 6: ...g264048 Figure 1 Model 04830 shown Preface Page 6 Greensmaster 1018 1021 1026 18238SL Rev B ...

Page 7: ...ence component orientation that may not be obvious Critical Torque This icon is used to highlight an assembly torque requirement that is different than what is recommended in the Standard Torque Tables refer to Torque Specifications page 2 6 Fluid Specifications This icon is used to highlight fluid specifications and capacities that are less common and may not appear on the machine service decal o...

Page 8: ...roblems 3 6 Chapter 4 Gasoline Engine 4 1 General Information 4 2 Adjustments 4 4 Service and Repairs 4 5 Chapter 5 Traction and Reel Drive Systems 5 1 General Information 5 2 Adjustments 5 3 Service and Repairs 5 5 Chapter 6 Electrical System 6 1 General Information 6 2 Wiring Schematic 6 3 Component Testing 6 4 Chapter 7 Controls Wheels and Accessories 7 1 General Information 7 2 Service and Rep...

Page 9: ... of Contents Safety Instructions 1 2 Before Operating the Machine 1 3 While Operating the Machine 1 4 Maintenance and Service 1 5 Safety and Instructional Decals 1 6 Greensmaster 1018 1021 1026 Page 1 1 Safety 18238SL Rev B ...

Page 10: ...t on the awareness concern and proper training of the personnel involved in the operation transport maintenance and storage of the machine The improper use or maintenance of the machine can result in injury or death WARNING To reduce the potential of injury or death comply with the following safety instructions as well as information found in the Operator s Manuals and the Operator and Safety Trai...

Page 11: ...g safety glasses safety shoes long pants and a helmet is advisable and required by some local safety and insurance regulations Make sure work area is clear of objects which might be picked up and thrown by the attachments Keep everyone especially children and pets away from the areas of operation Since the gasoline is highly flammable handle it carefully Use an approved gasoline container Do not r...

Page 12: ...gs disengage the traction and reel drives reduce the engine speed and move ON OFF switch to OFF position to stop the engine Wait for all machine motion to stop before removing basket 6 Do not touch the engine muffler or exhaust pipe while engine is running or soon after it has stopped because these areas are hot enough to cause burns 7 If the cutting unit strikes a solid object or vibrates abnorma...

Page 13: ... unit If the engine must be running to perform maintenance or make an adjustment keep hands feet clothing and all parts of the body away from the cutting unit and all moving parts Keep the bystanders away Do not overspeed the engine by changing the governor settings Recommended engine high idle speed is from 3 350 to 3 550 RPM To ensure safety and accuracy check the engine speed with a tachometer ...

Page 14: ...t and cutting units of your Groundsmaster If any decal becomes illegible or damaged install a new decal Decal part numbers are listed in your Parts Catalog Order replacement decals from Authorized Toro Distributor Safety Safety and Instructional Decals Page 1 6 Greensmaster 1018 1021 1026 18238SL Rev B ...

Page 15: ...cifications 2 6 Calculating the Torque Values When Using a Drive Adapter Wrench 2 7 Identifying the Fastener 2 8 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 2 9 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners 2 10 Other Torque Specifications 2 11 Conversion Factors 2 11 Shop Supplies 2 12 Special Tools 2 14 Greensmaster 1018 1021 1026 Page 2 1 Speci...

Page 16: ...Specifications Overall Dimensions g262214 Figure 2 Specifications and Maintenance Specifications Page 2 2 Greensmaster 1018 1021 1026 18238SL Rev B ...

Page 17: ... rpm High idle speed no load 3 350 to 3 550 rpm Direction of rotation Counterclockwise facing PTO shaft Fuel unleaded gasoline fuel with an octane rating of 87 or higher with no more than 10 Ethanol Fuel tank capacity 2 L 0 53 US gallons Engine oil Refer to the Operator s Manual Lubrication system Splash type Oil capacity 0 56 L 0 14 US gallons Air cleaner Dual element Ignition system Transistoriz...

Page 18: ...is maintained by a wave washer with no end play adjustment required Reel drive The reel shaft is 35 mm 1 375 inch diameter tube with a threaded nut on each end Height of cut Cutting height is adjusted on the front roller by two vertical screws Standard bench height of cut range is 1 6 to 16 mm 0 062 to 0 625 inch depending on type of bedknife installed An optional high height of cut kit is availab...

Page 19: ...nches Groomer mounting The drive assembly for the grooming reel is located on the opposite side of the cutting unit from the belt drive Groomer height setting Mowing 0 8 to 15 7 mm 0 030 to 0 620 inch HOC range 1 5 to 19 1 mm 0 060 to 0 750 inch Width of groomer 54 6 cm 21 5 inches Height adjustment knob Allows a 0 003 inch 0 08 mm increment of height adjustment for each click of the adjuster Quic...

Page 20: ...ue feature e g Nylocknut hardness of the surface underneath the head of the fastener or similar condition which affects the installation As noted in the following tables the torque values should be reduced by 25 for the lubricated fasteners to achieve the similar stress as a dry fastener The torque values must be reduced when the fastener is threaded into the aluminum or brass The specific torque ...

Page 21: ...ue When using a torque wrench with a drive adapter wrench the calculated torque will be lower than the listed torque recommendation Example The measured effective length of the torque wrench distance from the center of the handle to the center of the square drive is 457 mm 18 inches The measured effective length of the torque wrench with the drive adapter wrench installed distance from the center ...

Page 22: ... into the fastener and pre applied dry thread locking compound Keep in mind a fastener with a locking feature usually means there will be friction during initial installation and during removal Toro recommends replacing fasteners with a locking feature once they have been removed because the effectiveness of the locking feature diminishes with each reuse If it is necessary to reuse a fastener with...

Page 23: ...0 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 6 75 8 77 8 104 11 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 11 142 15 1 2 20 UNF 32 4 53 7 72 9 85 9 115 12 120 12 163 16 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 21 285 28 5 8 18 UNF 75 10 95 15 129 20 170 18 230 24 240 24 325 33 3 4 10 UNC 93 12 140 20 190 27 265 27 359 37 375 38 508 52 3 4 16 UNF 115 15 165 25 224 34 300 30 407 41 420 43 ...

Page 24: ...20 X 2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610 62 N m Note Reduce the torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or a thread sealant such as Loctite Note The torque values must be reduced when installing the fasteners into threaded aluminum or brass The specified torque value shoul...

Page 25: ... 88 14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1 5 Class 8 8 80 10 ft lb 108 14 N m For steel wheels and non lubricated fasteners Thread Cutting Screws Zinc Plated Steel Threads per Inch Thread Size Type A Type B Baseline Torque No 6 18 20 20 5 in lb No 8 15 18 30 5 in lb No 10 12 16 38 7 in lb No 12 11 14 85 15 in lb The hole size material s...

Page 26: ...ener installation Most thread locking compounds allow the fastener to be removed with standard tools once cured High strength thread locking compounds may require applying heat to the fastener and the surrounding area to allow fastener removal Note Some fasteners have a dry thread locking compound pre applied Patch Loc so no additional thread locking compound is necessary when installing a new fas...

Page 27: ...e and previously used gaskets or gasket compounds SILICONE SEALANT Designed for a broad variety of sealing and bonding requirements silicone sealants are usually room temperature vulcanizing RTV which form a flexible silicone rubber that bonds to a wide variety of smooth or porous materials when cured Standard silicone sealants are designed to perform in temperatures from 51F to 232C 60F to 400F w...

Page 28: ...ly the gel to the component and wire harness connector plug the connector into the component unplug the connector apply the gel to both surfaces again and connect the harness connector to the component again The connectors must be fully packed with gel for effective results Note Do not use the dielectric gel on the sealed connection terminals as the gel can unseat the connector seals during assemb...

Page 29: ... clearance Backlapping Brush Assembly Toro Part No 29 9100 For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel Components for the brush assembly are also available individually Brush 36 4310 Handle 29 9080 Handle cap 2410 18 Reel Drive Shaft K Line Part No TOR4112 Use the drive shaft for rotating the reel during cutting unit adjustment or any t...

Page 30: ...ind the bedknife after installing it to the bedbar 1 Place the angle indicator on the bottom side of the bedknife with the digital display facing you as shown 2 Press the Alt Zero button on the angle indicator g223327 Figure 7 1 Bedknife 3 Bedbar 2 Angle Indicator 3 Remove the angle indicator and place the magnetic mount on the edge of the bedknife so the face of the magnet is flat against the top...

Page 31: ...cutting reel and other spherical components Tape calibration is in fixed inch readings no adjustments Roller Rebuilding Tools The following combination of washers and spacers can be used to install bearings and seals into the front and rear rollers 2 each required Bearing installation washer 107 8133 black Seal installation spacer 107 3505 Seal installation washer 104 6126 yellow K Line Part No TO...

Page 32: ...icians in determining causes for poor reel mower performance and in comparing the effective height of cut of one mowed surface to another This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the Turf Evaluator Toro part no 97931SL available from your local authorized Toro Distributor Specifications and Maintenance Special Tools Page 2 18 Greensmaster 1018 102...

Page 33: ...g Problems 3 2 Gather Information 3 2 Evaluate Potential Causes 3 2 Assess Performance 3 2 Repair 3 2 Solution Confirmation 3 2 Starting Problems 3 3 Aftercut Appearance 3 4 Factors Affecting Grooming 3 5 Grooming Reel Mechanical Problems 3 6 Greensmaster 1018 1021 1026 Page 3 1 Troubleshooting 18238SL Rev B ...

Page 34: ...p a hypothesis Narrow down the focus of the problem Assess Performance Ensure you have all the necessary tools for testing Test all potential causes of the failure Reevaluate and create a new hypothesis if necessary Repair Return the unit to service by repairing rebuilding or replacing Solution Confirmation Did the issue go away Was the root cause of the issue correctly repaired Are there any othe...

Page 35: ...park plug Connect the spark plug wire to the spark plug Optional Traction control is not in the NEUTRAL position Place the traction lever in the NEUTRAL position An engine problem exists that prevents the engine from running Repair the engine ON OFF switch is faulty Replace the ON OFF switch Electrical wires are loose or damaged Check the electrical connections Repair the wiring as needed The fuel...

Page 36: ...nd or bedknife that has rounded cutting edges or rifling grooved or wavy appearance cannot be corrected by tightening the bedknife to reel contact Grind the reel to remove taper and or rifling Grind the bedknife to sharpen and or remove rifling A new bedknife must be ground or backlapped after installation to the bedbar Refer to Grinding the Bedknife page 8 14 for grinding information or the Tract...

Page 37: ...uality of cut also affect grooming performance Variables that Affect the Use and Performance of Grooming Reels 1 The growing season and weather conditions 2 General turf conditions 3 The frequency of grooming cutting number of cuttings per week and how many passes per cutting 4 The blade spacing on the grooming reel 5 The height of cut 6 The grooming depth 7 The type of grass on the green 8 The am...

Page 38: ...structions for groomer set up information The grooming reel blades are bent damaged or missing Repair or replace blades if necessary The grooming reel shaft is bent or damaged Replace grooming reel shaft The turf is damaged or has uneven grooming Grooming depth is not equal on both ends of grooming reel Adjust depth if necessary Check and adjust cutting unit set up level bed knife to reel set heig...

Page 39: ...er s Manual 4 2 Engine Service Manual 4 2 Engine Identification 4 2 Fuel Evaporative Control System 4 3 Adjustments 4 4 Throttle Cable Adjustment 4 4 Service and Repairs 4 5 Cooling System 4 5 Spark Plug 4 7 Engine 4 8 Engine Base 4 12 Greensmaster 1018 1021 1026 Page 4 1 Gasoline Engine 18238SL Rev B ...

Page 40: ...he Honda GX120 engine used on your Greensmaster machines Contact your local Honda Engine Dealer or visit http engines honda com to obtain a copy of the Engine Owner s Manual Refer to the Engine Owner s Manual for additional information when servicing the machine Engine Service Manual Detailed information on engine troubleshooting testing disassembly and assembly is given in the Honda Service Manua...

Page 41: ...Note To prevent saturating the carbon canister in the fuel cap it is important to ensure that the fuel tank is not overfilled The maximum fuel level for the fuel tank is to the bottom of the fuel tank insert Figure 9 The insert also prevents the fuel from saturating the fuel cap during machine movement Do not overfill the tank when refueling Refer to the Honda GX120 Owner s Manual for additional i...

Page 42: ...900 rpm 5 Tighten the screw to secure the throttle cable conduit 6 Check the engine speed with a tachometer A Low idle speed should be 1 800 to 2 000 RPM refer to Operator s Manual B High idle speed should be 3 350 to 3 550 RPM Adjust the throttle stop at throttle lever to attain the correct high idle speed setting refer to Operator s Manual IMPORTANT The engine governor control is equipped with a...

Page 43: ...nd damage 1 Park the machine on a level surface Ensure that the engine is OFF position Remove the spark plug wire from the spark plug IMPORTANT Never clean the engine with pressurized water Water could enter and contaminate the fuel system 2 Clean the cooling fins on the cylinder and cylinder head Remove the engine cylinder shroud from the engine for more thorough cleaning refer to Figure 10 Green...

Page 44: ...cessary IMPORTANT Never operate engine with the cylinder shroud and blower housing removed Overheating and engine damage will result 4 Ensure that the blower housing and or engine cylinder shroud are installed to the engine if removed 5 Attach the spark plug wire to the spark plug Gasoline Engine Service and Repairs Page 4 6 Greensmaster 1018 1021 1026 18238SL Rev B ...

Page 45: ...d 3 Inspect the spark plug IMPORTANT Replace a cracked fouled or dirty spark plug Do not sand blast scrape or clean spark plug electrodes because engine damage could result from grit enter cylinder 4 Set spark plug electrode gap from 0 7 to 0 8 mm 5 Install correctly gapped spark plug into the cylinder head and torque the spark plug to 23 N m 17 ft lb 6 Connect the spark plug wire to the spark plu...

Page 46: ...2 each Removing the Engine Note Refer to Figure 13 during this procedure 1 Park the machine on a level surface with the engine OFF Remove the spark plug wire from the spark plug to prevent the engine from starting Close the fuel shut off valve on the engine 2 If the engine is to be disassembled it may be easier to drain oil from engine before removing the engine from the traction unit Gasoline Eng...

Page 47: ...A Loosen the screw that secures the cable clamp 3 to the engine Remove the cable clamp B Loosen the screw that secures the throttle cable 2 to the governor lever 1 Slide and remove the throttle cable from the governor lever C Position the throttle cable 2 away from the engine Greensmaster 1018 1021 1026 Page 4 9 Gasoline Engine Service and Repairs 18238SL Rev B ...

Page 48: ...emove the 2 bolts 13 that secures the clutch cover 12 to the bell housing Remove the clutch cover from the bell housing 6 Remove the 2 bolts 15 and 2 nuts 11 that secures the clutch hub clamp 10 to the external clutch hub Remove the clutch hub clamp from the external clutch hub 7 Remove the 4 bolts 8 and 4 washers 9 that secures the engine 14 to the bell housing 8 Remove the 4 nuts 3 4 washers 4 a...

Page 49: ...lb 10 Connect the electrical connections to the engine A Apply dielectric gel to wire harness connectors B Connect the wire harness connectors to the engine armature wire item 1 in Figure 15 C Connect the wire harness ground wire 3 to the engine by installing the LH rear cap screw flat washer and a flange nut D Apply a coat of dielectric grease to the wire harness ground terminal to prevent corros...

Page 50: ...el surface with the engine OFF Remove the spark plug wire from the spark plug to prevent the engine from starting Close the fuel shut off valve on the engine 2 Remove the throttle cable refer to Removing the Throttle Cable page 7 3 3 Remove the clutch cable refer to Removing the Clutch Cable page 7 9 4 Remove the brake cable refer to Removing the Brake Cable page 7 6 5 Remove the reel cable refer ...

Page 51: ...ts 11 and 2 tube clamps 8 that secures the engine base 1 to rear side of the frame assembly 6 WARNING Support the engine and transmission to prevent it from dropping and causing personal injury when removing 11 Lift the engine base with engine and transmission together from the frame assembly 12 Remove the 4 carriage bolts that secures the engine to the engine base 13 Remove the 2 bolts 9 that sec...

Page 52: ...asher 8 Reel bellcrank 16 Engine base 15 Carefully remove the nut 1 in Figure 17 and compression spring 2 that secures the reel selector hub 3 to the reel selector shaft 5 Remove the reel selector hub 16 Carefully remove the extension spring 6 from the long and short reel levers 10 and 12 17 Remove the bolt 13 that secures the reel selector shaft 5 to the engine base 16 18 Remove the washer 9 long...

Page 53: ...ort reel levers 10 and 12 using an arbor press Ensure that the straight bushings 3 are flush to top of the long and short reel levers 1 and 2 refer to Figure 18 3 If removed install the flange bushing 7 into the reel bellcrank 8 using an arbor press 4 Slide the reel bellcrank 8 washer 9 short reel lever 12 washer 9 long reel lever 10 and washer 9 onto the reel selector shaft 5 5 Install the reel s...

Page 54: ...em 2 in Figure 16 and secure with a jam nut 3 onto the transmission gear box assembly 10 Adjust the slider adapter to make sure that the transmission output shaft is in neutral position 15 Install the 2 splined couplers onto the transmission gear box assembly and drum drive gear box assembly and secure with the truss screw 2 washers and nut 16 Torque tighten the truss screw to 10 to 12 4 N m 90 to...

Page 55: ...djustments 5 3 Adjusting the Reel Drive Belt 5 3 Service and Repairs 5 5 Reel Drive Belt 5 5 Reel Drive Assembly 5 7 Drum Drive Gear Box Assembly 5 11 Drum Assembly 5 17 Clutch Bearing 5 21 Transmission Gear Box Assembly 5 24 Differential Assembly 5 36 Greensmaster 1018 1021 1026 Page 5 1 Traction and Reel Drive Systems 18238SL Rev B ...

Page 56: ...transmission do the following procedure 1 Park the machine on a level surface Ensure that the engine is OFF Remove the spark plug wire from the engine spark plug 2 Locate the traction engage disengage lever on top of the transmission gear box assembly 3 To disengage the drum drive rotate the traction engage disengage lever to clockwise direction away from the center of transmission gear box assemb...

Page 57: ...he 3 socket head screws 7 that secures the reel drive cover 6 to the reel drive assembly 1 and remove the reel drive cover to expose the reel drive belt 2 3 Check tension by depressing the belt item 2 in Figure 20 at mid span between pulleys with 18 to 22 N 4 to 5 lbs of force The belt should deflect 6 35 mm 0 25 inch If deflection is incorrect proceed to next step If deflection is correct continu...

Page 58: ...idler arm with the bolt 4 Check the belt tension as per para 3 C Ensure that the reel drive gasket 5 is in position and install the reel drive cover 6 to the reel drive assembly 1 and secure with the 3 socket head screws 7 D Torque tighten the socket head screws to 1 7 to 4 5 N m 15 to 40 in lb Use an alternation pattern and torque tighten the socket head screws to 9 6 to 10 7 N m 85 to 95 in lb 5...

Page 59: ...ting unit Removing the Reel Drive Belt Note Refer to Figure 21 during this procedure 1 Park the machine on a level surface Ensure that the engine is OFF Remove the spark plug wire from the engine spark plug 2 Remove the 3 socket head screws 7 that secures the reel drive cover 6 to reel drive assembly 1 and remove the reel drive cover to expose the reel drive belt 2 Greensmaster 1018 1021 1026 Page...

Page 60: ...Place the new drive belt 2 onto the pulleys 3 Adjust the reel belt tension refer to Adjusting the Reel Drive Belt page 5 3 4 Ensure that the reel drive gasket 5 is in position and install the reel drive cover 6 to the reel drive assembly 1 and secure with the 3 socket head screws 7 5 Torque tighten the socket head screws to 1 7 to 4 5 N m 15 to 40 in lb Use an alternation pattern and torque tighte...

Page 61: ... OFF Remove the spark plug wire from the engine spark plug 2 Slide the telescopic coupler item 8 in Figure 22 on the reel drive assembly 6 and disconnect the reel drive shaft from the transmission drive shaft 10 3 Loosen and remove the 2 screws 1 and the nut 12 that secures the reel drive assembly 6 to RH side plate 9 Remove the reel drive assembly 6 flat washers 3 spring washers 4 and spacers 2 a...

Page 62: ...ure 23 refer to Removing the Reel Drive Belt page 5 5 2 Remove and discard the reel drive gasket 4 from the reel drive housing 22 3 If necessary remove the expansion plug 13 from the reel drive cover 14 4 Remove the hex bolt 28 and plain washer 27 from the idler arm 26 and the nut 25 from the reel drive housing 22 5 Loosen and remove the socket head screw 11 that secures the idler arm 26 to the re...

Page 63: ... shaft driver 4 Install the reel shaft driver 21 into the reel drive housing 22 5 Install the retaining ring 17 to the reel drive housing 22 6 Slide the spacer 7 onto the reel shaft driver 21 7 Install hipro key 20 to then reel shaft driver 21 Apply anti seize lubricant at the top of the key 8 Install the reel pulley 15 onto the reel shaft driver 21 Secure the reel pulley 15 with the lock nut 9 9 ...

Page 64: ...usting the Reel Drive Belt page 5 3 Installing the Reel Drive Assembly Note Refer to Figure 22 during this procedure 1 Place the V ring seal 5 into the reel drive assembly 6 2 Install the compression spring 7 and telescopic coupler 8 to the reel drive shaft 3 Install the reel drive assembly 6 washers 3 spring washer 4 and spacers 2 and 11 to the RH side plate 9 and secure the reel drive assembly 6...

Page 65: ...igure 25 during this procedure 1 Park the machine on a level surface Ensure that the engine is OFF Remove the spark plug wire from the engine spark plug 2 Remove the transport wheel if attached refer to Removing the Transport Wheel page 7 27 Note Support the machine on kickstand during this operation 3 Move the traction engage disengage lever to the disengage position to remove torque from the dru...

Page 66: ... secures the drum drive gear box assembly 8 to the frame assembly 9 6 Remove the 3 shoulder bolts 6 that secures the drum drive gear box assembly 8 to the traction drum 2 Remove the drum drive gear box assembly from the frame assembly Support the drum assembly 7 If necessary remove the hexagonal shaft 7 from the drum drive gear box assembly 8 Traction and Reel Drive Systems Service and Repairs Pag...

Page 67: ...2 O ring 9 Wire spring 21 Spur gear 33 Dowel pin 2 each 10 Oil seal 22 Socket head screw 34 Bearing spacer 11 Spur gear 23 Ball bearing 2 each 12 Nut 24 Wave washer Note Refer to Figure 26 during this procedure 1 Remove the 5 socket head screws 15 that secures the drum drive cover 14 to the drum drive housing 25 2 Remove and discard the gasket 8 from the drum drive housing 25 3 If necessary remove...

Page 68: ...earings after removal 8 Remove the nut 17 and bearing pin 31 that secures the spur gear 20 to the drum drive housing 25 9 Remove the spur gear 20 and bearing spacer 34 from the drum drive housing 25 10 Remove and discard the O ring 32 from the bearing pin 31 11 If the spur gear bearings 19 are to be removed remove the retaining rings 18 and use a press to remove the ball bearings 19 Discard the be...

Page 69: ...s 6 bearing spacer 7 spring washer 9 and drum drive shaft 5 to the drum drive housing 25 Note The outer diameter and inner diameter of the ball bearings 6 must be slip fit 6 Install the V ring seal 4 onto the drum outer hub 3 Install the key 30 to the drum drive shaft 5 and apply anti seize lubricant at the top of the key Slide the drum outer hub 3 to the drum drive shaft 5 and secure with the was...

Page 70: ... drum drive gear box assembly 8 Torque tighten the hexagonal shaft to 67 7 N m 50 ft lb 2 Apply a light coat of grease and install the O ring 29 to the drum drive housing 25 3 Install the drum drive gear box assembly 8 to the frame assembly 9 and secure with the shoulder bolt 10 4 Install the drum drive gear box assembly 8 to the traction drum 2 and secure with the 3 shoulder bolts 6 5 Install the...

Page 71: ... Removing the Drum Assembly Note Refer to Figure 28 during this procedure 1 Park the machine on a level surface Ensure that the engine is OFF Remove the spark plug wire from the engine spark plug 2 Remove the LH and RH drum drive gear box assemblies item 8 in Figure 28 refer to Removing the Drum Drive Gear Box Assembly page 5 11 3 Remove the traction drum 2 from the frame assembly 9 Greensmaster 1...

Page 72: ...spindle 5 2 Remove the 4 bolts 2 and lock washers 3 that secures the drum hub plate 4 to the drum hub 10 3 Remove the shoulder bolts 11 that secures the drum hub plate 4 to the traction drum 1 4 Remove the lock nut 12 that secures the drum spindle 5 and drum hub 10 together Carefully slide and remove the drum spindle 5 out of the drum hub 10 5 Remove the 2 seals 6 from the drum hub 10 Use a press ...

Page 73: ...indle 5 can move axially relative to the drum hub 1 Note The lock nut 3 turns hard on the drum spindle 5 when tightened Ensure that all rotation has stopped when tightening A good solid sound indicates the nut is full tight 4 Install the drum hub plate 4 into the traction drum 1 and secure with shoulder bolt 11 Note The fit between the drum hub plate item 4 in Figure 29 and drum 1 is a close toler...

Page 74: ...rum drive gear box assembly item 8 in Figure 28 and traction drum 2 onto the frame assembly 9 3 Secure the LH and RH drum drive gear box assembly 8 to the traction drum 2 refer to Installing the Drum Drive Gear Box Assembly page 5 16 4 Attach the spark plug wire to the spark plug Traction and Reel Drive Systems Service and Repairs Page 5 20 Greensmaster 1018 1021 1026 18238SL Rev B ...

Page 75: ...te 14 Clutch fork 22 Lock nut 2 each 7 Clutch compression spring 15 Bolt 3 each 8 Slider clutch disc 16 Bushing Removing the Clutch Bearing Note Refer to Figure 31 during this procedure 1 Park the machine on a level surface Ensure that the engine is OFF Remove the spark plug wire from the engine spark plug 2 Remove the 2 bolts 12 that secures the clutch cover 11 to the bell housing 18 Remove the c...

Page 76: ... the clutch components are cleaned before assembly 2 If removed install the bushing 16 and flange bushing 10 to the bell housing 18 3 Use a press to install the bearing 9 to the slider clutch disk 8 4 Slide and install the slider clutch disk assembly 8 compression spring 7 friction plate 6 and clutch disk 5 onto the transmission gearbox shaft 20 and secure with a retaining ring 4 5 Install the tra...

Page 77: ...1 onto the bell housing 18 and secure with the 2 bolts 12 13 Torque tighten the bolts 12 to 6 8 to 9 N m 60 to 80 in lb 14 Attach the spark plug wire to the spark plug Greensmaster 1018 1021 1026 Page 5 23 Traction and Reel Drive Systems Service and Repairs 18238SL Rev B ...

Page 78: ...to service the internal components Removing the Transmission Gear Box Assembly Note Refer to Figure 32 during this procedure 1 Park the machine on a level surface Ensure that the engine is OFF Remove the spark plug wire from the engine spark plug 2 Disconnect the clutch cable refer to Removing the Clutch Cable page 7 9 3 Disconnect the brake cable refer to Removing the Brake Cable page 7 6 4 Disco...

Page 79: ...move the fork shaft from the bell housing 9 Loosen the nuts on the external clutch hub and slide the external clutch hub towards the engine 10 Loosen the jam nut 10 and remove the slider adapter 9 from the transmission gear box assembly 12 11 Remove the 3 bolts that secures the bell housing onto the transmission gear box assembly 12 Remove the two flange head bolts 11 that secures the transmission...

Page 80: ...el pin 27 Hollow hex plug 2 each 8 ORB plug 18 O ring seal 28 E ring 9 Detent spring 19 Traction selector shaft 10 Detent ball 20 Groomer pin Note Refer to Figure 33 during this procedure 1 Remove the 2 hollow hex plugs item 27 in Figure 33 from the transmission gear box assembly 26 2 Remove the 12 socket head screws 24 that secures the transmission cover assembly 23 to the transmission housing as...

Page 81: ...ring seal 24 Cable brake lever 7 Square key 2 each 16 Retainer plate 25 Bolt 8 Bolt 4 each 17 Retaining ring 26 Brake gasket plate 9 Differential shaft 2 each 18 Brake band 4 Remove the neutral spur gear assembly item 5 in Figure 34 and wave washer 3 from the transmission housing assembly 23 5 Use a press to remove the ball bearings 4 from the neutral slider shaft 6 Remove the square keys 7 from t...

Page 82: ... 11 Remove the 4 bolts 8 that secures the retainer plate 16 to the transmission housing assembly 23 Remove the retainer plate 16 from the transmission housing assembly 23 12 Slide and remove the brake lever assembly 19 from the transmission housing assembly 23 Remove the flat wire spring 22 from the transmission housing assembly 23 13 Disassemble the brake lever assembly 19 as follows A Remove the...

Page 83: ...r 14 Slider spur gear 14 Slide and remove the reel clutch actuator item 16 in Figure 35 from the transmission housing assembly 20 If necessary remove the reel clutch shoe 15 from the reel clutch actuator 16 15 Remove the reel drive shaft assembly 14 ball bearing 10 and wave spring 9 from the transmission housing assembly 20 If necessary disassemble the drive shaft assembly 12 as follows A Use a pr...

Page 84: ...the 2 ball bearings 6 from the spur gear 17 Discard the ball bearings 6 22 Remove the thin lock nut 18 that secures the input shaft 19 to the transmission housing assembly 20 Slide and remove the input shaft 23 Remove the ORB plug item 8 in Figure 33 detent spring 9 and detent ball 10 from the transmission housing assembly 26 24 Loosen and remove the groomer pin item 20 in Figure 33 from the tract...

Page 85: ...h to the edge of the transmission housing 4 Install the new oil seal item 6 in Figure 33 into the transmission housing Ensure that the seal lip is orientated toward the center of the transmission housing Press the seal into the transmission housing bore so that the seal is flush to the edge of the transmission housing 5 Install the new oil seal item 14 in Figure 33 into the transmission housing En...

Page 86: ...m 18 in Figure 33 and slide onto the traction selector shaft item 19 in Figure 33 Insert the traction selector shaft item 19 in Figure 33 into the transmission housing 26 12 Apply a coat of a grease to the O ring item 3 in Figure 33 and slide onto the groove of the traction selector shaft 19 Slide the spacer bushing 2 onto the traction selector shaft 19 and secure with a retaining ring 1 13 Instal...

Page 87: ... spur gear item 14 in Figure 35 onto the reel drive shaft 12 and secure with the retaining rings 11 Press the new ball bearings 10 onto the reel drive shaft 12 22 Install the wave spring item 9 in Figure 35 and reel drive assembly 14 into the transmission housing assembly 20 23 Insert the reel clutch shoe item 15 in Figure 35 into the reel clutch actuator 16 Slide the reel clutch actuator 16 into ...

Page 88: ...igure 34 into the neutral slider shaft 6 Apply a coat of grease to outer surface of the square keys 7 36 Insert the neutral slider shaft item 6 in Figure 34 into the neutral spur gear 5 37 Use a press and insert the bearings item 4 in Figure 34 onto the neutral slider shaft 6 38 Insert the wave washer item 3 in Figure 34 and neutral spur gear assembly 5 into the transmission housing assembly 23 Ma...

Page 89: ...sion assembly laterally until the transmission contacts the mounting surface on the engine base Tighten the engine bolts and secure the transmission with 2 flange bolts 3 Install and adjust the slider adapter 9 until the neutral position is achieved and lock the position with jam nut 10 onto the transmission gear box assembly 12 4 Slide the external clutch hub onto the slider clutch disc and secur...

Page 90: ... 23 Transmission housing assembly 6 Neutral slider shaft 15 V ring seal 24 Cable brake lever 7 Square key 2 each 16 Retainer plate 25 Bolt 8 Bolt 4 each 17 Retaining ring 26 Brake gasket plate 9 Differential shaft 2 each 18 Brake band Removing the Differential Assembly To remove the differential assembly from the transmission gear box assembly refer to Disassembling the Transmission Gear Box Assem...

Page 91: ...ings 1 apart 3 Use a press to remove the 6 differential pins 2 and 6 differential spur gears 3 from the differential housings 1 Inspecting the Differential Assembly 1 Clean all the differential assembly components 2 Inspect all the differential spur gears 3 carefully looking for chipped teeth wear or other damage Because gear tooth damage is rarely isolated to 1 gear replace the gears as complete ...

Page 92: ...Insert the differential spur gears 3 to the differential pins 2 by pointing the gears shoulder up 6 Fill the differential housing assembly 1 with 0 08 lb 1 25 oz of grease 7 Attach the 2 differential housings 1 to each other 8 Slide and install the differential housing assembly 1 into the differential gear 4 and secure with the 6 socket head screws 5 9 In alternate pattern torque tighten the socke...

Page 93: ...ormation 6 2 Operator s Manual 6 2 Wiring Schematic 6 3 Component Testing 6 4 Ignition System Operation 6 5 ON OFF Switch 6 6 Hour Meter 6 8 Interlock Module Optional 6 10 Lighting Coil 6 11 Greensmaster 1018 1021 1026 Page 6 1 Electrical System 18238SL Rev B ...

Page 94: ...tion 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 Electrical System General Information Page 6 2 Greensmaster 1018 1021 1026 18238SL Rev B ...

Page 95: ...Wiring Schematic g268165 Figure 42 Greensmaster 1018 1021 1026 Page 6 3 Electrical System Wiring Schematic 18238SL Rev B ...

Page 96: ...sted Note See the Honda Service Manual for the engine components testing information CAUTION When testing the electrical components for the continuity with a multimeter ohm setting ensure that the power to the circuit has been disconnected WARNING The ignition system produces a dangerously high voltage Do not touch the spark plug lead ignition coil igniter or spark plug lead while the engine is ru...

Page 97: ... ignition system is operating properly Note If a sheared flywheel key exists the spark tester may indicate an operating ignition system but ignition timing will be incorrect 5 If visible and audible sparks are not produced a problem exists either with engine ignition components or with machine components To identify whether the problem exists with the engine or the machine disconnect the wire harn...

Page 98: ...ccess to the ON OFF switch 3 Disconnect the wire harness electrical connector from the ON OFF switch 3 1 10 8 2 7 6 5 4 9 g262084 Figure 44 4 With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position The switch terminals are marked as shown in Figure 44 The circuitry of the ON OFF switc...

Page 99: ...FF ON 2 3 5 Replace the switch if necessary 6 When the switch testing is complete connect the wire harness electrical connector to the ON OFF switch 7 Install the control cover to the handle assembly Greensmaster 1018 1021 1026 Page 6 7 Electrical System Component Testing 18238SL Rev B ...

Page 100: ...e engine is running Testing the Hour Meter 1 Ensure that the key switch is in the OFF position 2 Remove the spark plug wire from the engine spark plug 3 Locate the wire harness connector at the rear of the hour meter Unplug the harness connector from the hour meter Electrical System Component Testing Page 6 8 Greensmaster 1018 1021 1026 18238SL Rev B ...

Page 101: ...egative terminal of the voltage source to the other terminal of the hour meter 6 The hour meter should move 1 10 of an hour in 6 minutes 7 Disconnect the voltage source from the hour meter 8 Replace the hour meter if necessary 9 Connect the wire harness connector to the hour meter 10 Connect the spark plug wire to the engine spark plug Greensmaster 1018 1021 1026 Page 6 9 Electrical System Compone...

Page 102: ... start and run Once running the interlock module allows the engine to continue to operate If the engine will not start perform the following tests to determine if the interlock module is at fault 1 Check operation of the engine ignition system refer to Ignition System Operation page 6 5 2 Check the operation of traction switch Adjust or replace switch if necessary 3 Check wire harness for damage s...

Page 103: ...ng coil has a 12 VAC output that is rated at 50 watts See the Honda Service Manual for additional lighting coil information Note If lights are desired on the Greensmaster machine use the recommended Toro LED light kit that is available from your Toro Distributor Incandescent or halogen lights will not operate with the engine lighting coil that is on these machines Greensmaster 1018 1021 1026 Page ...

Page 104: ...Electrical System Component Testing Page 6 12 Greensmaster 1018 1021 1026 18238SL Rev B ...

Page 105: ...able 7 3 Replacing the Brake Cable 7 6 Replacing the Clutch Cable 7 9 Replacing the Reel Cable 7 11 Clutch and Reel Drive Engagement Lever Assembly 7 14 Brake Latch Shaft 7 16 Handle Assembly 7 18 Kickstand 7 24 Transport Wheels Optional 7 27 Rail Kit Wheels Optional 7 30 Greensmaster 1018 1021 1026 Page 7 1 Controls Wheels and Accessories 18238SL Rev B ...

Page 106: ...garding the operation adjustment procedures and general maintenance for your Greensmaster machine Refer to the Operator s Manual for additional information when servicing the machine Controls Wheels and Accessories General Information Page 7 2 Greensmaster 1018 1021 1026 18238SL Rev B ...

Page 107: ...3 Throttle cable 7 Throttle lever 11 Handle assembly 4 Bolt 8 Flange bushing 2 each 12 Washer Removing the Throttle Cable Note Refer to Figure 48 during this procedure 1 Park the machine on a level surface Ensure that the engine is OFF and the traction control is in NEUTRAL Greensmaster 1018 1021 1026 Page 7 3 Controls Wheels and Accessories Service and Repairs 18238SL Rev B ...

Page 108: ... 1 Slide the throttle cable from the governor lever C Separate the throttle cable 2 from the engine 3 Remove the control cover and lower cover from the handle assembly to allow access to upper end of the throttle cable item 3 in Figure 48 4 Remove the throttle arm from the handle assembly Loosen the lock nut 2 on the throttle cable and slide the throttle cable and throttle arm from the upper recei...

Page 109: ...e governor linkages 1 as follows A Slide and secure the throttle cable end into the governor lever 1 B Place the throttle cable under the cable clamp 3 C Ensure that the throttle cable is in the SLOW position and with engine running slide the cable through the cable clamp to achieve 1850 to 1950 rpm D Tighten the screw on the cable clamp to secure the throttle cable 6 Check the throttle cable adju...

Page 110: ... 9 Brake cable Removing the Brake Cable Note Refer to Figure 50 during this procedure 1 Park the machine on a level surface Ensure that the engine is OFF and the traction control is in NEUTRAL and parking brake is released 2 Remove the spark plug wire from the engine spark plug Controls Wheels and Accessories Service and Repairs Page 7 6 Greensmaster 1018 1021 1026 18238SL Rev B ...

Page 111: ...rake cable eyelet 2 from the brake lever 3 4 Remove the control cover and lower cover from the handle assembly to allow access to upper end of the brake cable 5 Remove the brake cable item 9 in Figure 50 from the brake lever assembly as follows A Loosen the lower brake cable jam nut 8 that secures the brake cable 9 to the upper receiver weldment 4 Slide the brake cable from the upper receiver weld...

Page 112: ...all the brake cable eyelet 2 onto the brake lever 3 on transmission gear box assembly and secure with a snap ring 1 B Position the brake cable 5 to the casting slot of the transmission gear box assembly with a jam nut 4 flat washer and lock washer on each side of the slot Adjust and tighten the jam nuts so that equal amount of cable threads are visible above and below jam nuts 3 Make final adjustm...

Page 113: ...re that the engine is OFF and the traction control is in NEUTRAL 2 Remove the spark plug wire from the engine spark plug g262017 Figure 53 1 Clutch cable 3 Cable eyelet 5 Clutch lever 2 Jam nut 4 Retaining ring 3 Remove the clutch cable item 1 in Figure 53 from the transmission assembly as follows A Loosen the front cable jam nut 2 and lift the clutch cable 1 from the casting slot of the engine ba...

Page 114: ...entate the cable spring hook end toward front of the machine B Slide the cable housing into the upper receiver weldment 9 Ensure that the jam nut 2 flat washer and lock washer are on both sides of the bracket Adjust jam nuts so that equal amount of cable threads are visible above the jam nuts Leave the jam nuts snug until final cable adjustment 2 Route the clutch cable item 1 in Figure 53 to the t...

Page 115: ...ob 9 Split bushing 5 Reel lever handle rod 10 Clevis connector Removing the Reel Cable Note Refer to Figure 54 during this procedure 1 Park the machine on a level surface Ensure that the engine is OFF and the traction control is in NEUTRAL 2 Remove the spark plug wire from the engine spark plug Greensmaster 1018 1021 1026 Page 7 11 Controls Wheels and Accessories Service and Repairs 18238SL Rev B ...

Page 116: ...Remove the control cover and lower cover from the handle assembly to allow access to upper end of the reel cable 5 Remove the reel cable item 1 in Figure 54 from the traction lever assembly as follows A Loosen the lower cable jam nut 2 that secures the reel cable 1 to the upper receiver weldment 12 Slide the cable from the upper receiver weldment B Remove the cable spring 3 from the clevis connect...

Page 117: ...eel cable to the reel selector assembly item 2 in Figure 55 and install the reel cable 4 as follows A Slide the cable eyelet to the reel selector assembly 2 and secure with a retaining ring 1 B Position the reel cable 4 to the casting slot of the engine base with a jam nut 3 flat washer and a lock washer on each side of the slot 3 Make final adjustment of the reel cable at the reel cable lever ass...

Page 118: ...ft 24 Bail latch spacer 7 Extension spring 2 each 16 Split bushing 2 each 25 Upper receiver weldment 8 Controls cover 17 Socket cap 26 Flange nut 9 Bolt and washer assembly 8 each 18 Cotter pin clip 27 Reel lever assembly Disassembling the Clutch and Reel Drive Engagement Lever Assembly Note Refer to Figure 56 during this procedure 1 Park the machine on a level surface Ensure that the engine is OF...

Page 119: ...main control shaft 15 If necessary remove the split bushing 16 from the main control shaft Assembling the Clutch and Reel Drive Engagement Lever Assembly 1 If removed install the split bushing item 16 in Figure 56 onto the main control shaft 15 2 Position the main control shaft 15 on the upper receiver weldment 25 and secure the main control shaft 15 with control shaft clamps 5 and the bolts 6 3 S...

Page 120: ...ocedure 1 Park the machine on a level surface Ensure that the engine is OFF and the traction control is in NEUTRAL 2 Remove the spark plug wire from the engine spark plug 3 Remove the bolts and washers that secures the controls covers to the upper receiver weldment 4 Using the drift pin remove the roll pin 5 from the brake lock lever 4 5 Slide and remove the brake lock lever 4 from the brake latch...

Page 121: ...g 10 onto the brake latch shaft 9 2 Slide and position the brake latch shaft 9 into the upper receiver weldment 12 3 Slide and position the brake lock lever 4 onto the brake latch shaft 9 Secure the brake lock lever with the roll pin 5 4 Install the control covers to the handle assembly with bolts and washers 5 Attach the spark plug wire to the engine spark plug Greensmaster 1018 1021 1026 Page 7 ...

Page 122: ...dle assembly 32 Delta screw 7 Flange nut 4 each 20 Spacer 3 each 33 Bolt 2 each 8 Upper receiver weldment 21 Bolt 4 each 34 Throttle lever 9 Nut 22 Handle adjuster assembly 35 Flange bushing 2 each 10 Bolt 23 Handle torsion spring 36 Throttle arm 11 Bolt 24 Spring spacer 37 Flange nut 12 Bolt 25 Screw and washer assembly 2 each 38 Bolt 13 Flange nut 26 Bottom control cover Controls Wheels and Acce...

Page 123: ...1 that secures the throttle arm 36 to the handle assembly 3 Remove the throttle arm from the handle assembly 15 If necessary remove the screw 32 that secures the throttle lever 34 to the throttle arm 36 Slide and remove the throttle lever from the throttle arm 16 If necessary remove the flange bushings 35 from the throttle arm 36 17 Disconnect the wire harness 18 Remove the engine ON OFF switch fr...

Page 124: ...ead screw 2 each 18 Delta screw 2 each 5 Clutch bail link 12 Flange bushing 2 each 19 RH bail bracket 6 Compression spring 13 Clevis pin 20 Handle 7 Handle mount 14 Nut 2 each 21 Bolt 2 each 27 Remove the 2 nuts item 8 in Figure 59 and 2 bolts 21 that secures the handle 20 to handle mount 7 Remove the handle from the clutch bail assembly and the handle mount 28 If necessary remove the 2 screws 18 ...

Page 125: ... Remove the handle mount from the upper receiver weldment g313848 Figure 60 1 Lower handle assembly 4 Nut 2 Bolt 5 Frame assembly 3 Washer 2 each 32 If necessary remove the nut item 4 in Figure 60 washers 3 and bolt 2 that secures the lower handle assembly 1 to the frame assembly 5 Assembling the Handle Assembly 1 If removed install the lower handle assembly item 1 in Figure 60 onto the frame asse...

Page 126: ... wire harness 13 Install the conduit clamps 10 to the upper receiver weldment 8 and lower handle assembly 19 and secure with screws 11 14 If removed install the flange bushings 5 bolt 12 and flange nut 13 into the brake lever 6 15 Position the brake lever 6 to the upper receiver weldment 8 and secure with the shoulder screw 4 and flange nut 7 16 Install the handle notepad plate 2 to the handle ass...

Page 127: ... the upper receiver weldment and secure with the 4 bolts and 2 nuts 31 Install the lower handle cover to the handle assembly and secure with the 4 bolts 32 Install the controls cover to the handle assembly and secure with the 4 bolts 33 Attach the spark plug wire to the engine spark plug Greensmaster 1018 1021 1026 Page 7 23 Controls Wheels and Accessories Service and Repairs 18238SL Rev B ...

Page 128: ...Nut 2 each 4 Bolt 10 Spacer 2 each 16 Kickstand 5 Nut 11 Bolt 2 each 6 Flat washer 2 each 12 Bolt 2 each Removing the Kickstand CAUTION Be careful when removing or applying tension from or to the torsion spring of the kickstand The spring is under heavy load and may cause personal injury Controls Wheels and Accessories Service and Repairs Page 7 24 Greensmaster 1018 1021 1026 18238SL Rev B ...

Page 129: ...tand 16 5 Remove the spring mount pin 3 and torsion spring 2 from the kickstand 16 6 Remove the bolt 11 spacer 10 and nut 5 that secures the kickstand 16 to the frame 9 7 Remove the kickstand 16 from the frame 1 8 If necessary remove the spring retainer 14 by removing the nut 15 washer 13 and bolt 12 9 If necessary remove the spacers 10 from the kickstand 16 Installing the Kickstand g260998 Figure...

Page 130: ...bolt 12 washer 13 and nut 15 3 Secure the kickstand 16 to the frame 9 with the torsion spring 2 spring mount pin 3 and bolt 11 4 Secure the kickstand 16 to the frame 9 with spacer 10 bolt 11 and nut 5 5 Attach the spark plug wire to the engine spark plug Controls Wheels and Accessories Service and Repairs Page 7 26 Greensmaster 1018 1021 1026 18238SL Rev B ...

Page 131: ...3 each 4 Tire 9 Wheel retaining lever 5 Inner tube 10 Shoulder screw 2 each Removing the Transport Wheel 1 Park the machine on a level surface Ensure that the engine is OFF and the traction control is in NEUTRAL 2 Support the machine onto the machine onto the kickstand Greensmaster 1018 1021 1026 Page 7 27 Controls Wheels and Accessories Service and Repairs 18238SL Rev B ...

Page 132: ...ly of the wheel 2 Remove the 3 bolts and 3 lock washers from the shallow rim and hub Remove the hub from the deep rim 3 Inspect the hub bushing Replace the bushing if worn or damaged 4 Remove the 4 bolts and 4 flange nuts from the deep rim and shallow rim Remove the shallow rim from the deep rim 5 Separate the tire tube and deep rim 6 If necessary remove the shoulder screws torsion spring and reta...

Page 133: ...ange nuts Tighten the fasteners 4 Install the hub into the deep rim Secure the hub to the deep rim with the 3 bolts and 3 lock washers Tighten the fasteners 5 Inflate the tire to 83 to 103 kPa 12 to 15 psi Installing the Transport Wheel 1 Ensure that the machine is parked on a level surface 2 Support the machine onto the kickstand 3 Slide the transport wheel completely onto the wheel hex shaft unt...

Page 134: ...he wheel hex shaft on each side 4 If necessary install the transport wheels refer to Transport Wheels Optional page 7 27 Installing the Rail Kit Wheel 1 Ensure that the machine is parked on a level surface 2 Support the machine onto the kickstand 3 If installed remove the transport wheels refer to Transport Wheels Optional page 7 27 4 Slide the rail kit wheel onto the wheel hex shaft and secure th...

Page 135: ... Cutting Unit when Servicing 8 3 Adjustments 8 4 DPA Cutting Unit Characteristics 8 4 Grass Shield Height Adjustment 8 5 Service and Repairs 8 6 Bedbar Assembly 8 6 Servicing the Bedbar Adjuster 8 10 Bedknife 8 12 Cutting Unit Assembly 8 16 Reel Assembly 8 18 Roller Assemblies 8 24 Greensmaster 1018 1021 1026 Page 8 1 DPA Cutting Units 18238SL Rev B ...

Page 136: ...groomer the Installation Instructions for the kit includes set up operation and maintenance information Refer to the Cutting Unit Operator s Manual and the kit Installation Instructions for additional information when servicing the cutting units Grass Basket Installation g278331 Figure 67 1 Grass basket 2 Mounting rod Grasp the grass basket by top rear lip and slide on or off the basket mounting r...

Page 137: ...t Whenever the cutting unit has to be tipped to expose the bedknife or cutting reel support the rear of the cutting unit making sure the back of the bedbar adjuster screws are not resting on the work surface Greensmaster 1018 1021 1026 Page 8 3 DPA Cutting Units General Information 18238SL Rev B ...

Page 138: ...timum mowing performance The precise adjustment possible with this design gives the necessary control to provide a continual self sharpening action This feature maintains sharp cutting edges assures good quality of cut and greatly reduces the need for routine backlapping If a cutting unit is determined to be out of adjustment complete the following procedures in the specified order to adjust the c...

Page 139: ... spark plug 3 Place 1 5 mm 0 06 inch shim between the reel assembly and grass shield Note The shield can be lowered for drier conditions clippings fly over top of the basket or raised to allow for heavy wet grass conditions clippings build up on rear of the basket 4 Loosen the bolts that secures each end of the shield to the side plates Adjust the shield to the correct height and tighten the faste...

Page 140: ... Bedbar adjuster shaft 2 each 10 Wave washer 2 each 17 Washer 2 each 4 Rubber bushing assembly 2 each 11 Retaining ring 2 each 18 Compression spring 5 Nylon bushing 2 each 12 Bedbar adjuster screw 2 each 19 Nut 2 each 6 Plastic washer 2 each 13 Detent 2 each 7 Flat washer 2 each 14 Bolt 2 each DPA Cutting Units Service and Repairs Page 8 6 Greensmaster 1018 1021 1026 18238SL Rev B ...

Page 141: ...ts 9 on each bedbar bolt 8 5 Remove the 2 bedbar bolts 8 2 flat washers 7 and 4 plastic washers 6 and 15 from the cutting unit side plates 1 CAUTION Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when handling the bedbar 6 Remove the bedbar assembly 6 from the cutting unit 7 Inspect the nylon bushings 5 and rubber bushings 4 in the side pl...

Page 142: ... or other cutting unit parts can result in personal injury Use heavy gloves when handling the bedbar Note If a new bedknife is attached to the bedbar there may be interference between the bedknife and the reel when installing the bedbar Turn the bedbar adjusting screws counterclockwise to increase bedknife clearance if necessary 4 Position the bedbar assembly 16 into the cutting unit Make sure tha...

Page 143: ...lock nut is correctly tightened the inside washers may be loose 8 Tighten both lock nuts 9 until outside metal washers do not have any end play and can still can be rotated 9 Tighten the nut 19 on each bedbar adjuster assembly 16 until the adjuster spring 18 is fully compressed then loosen the nut 19 to 1 2 turn 10 Adjust the bedknife to reel contact refer to the Cutting Unit Operator s Manual 11 ...

Page 144: ...fer to Removing the Bedbar page 8 7 2 Remove the lock nut 11 compression spring 10 and washer 9 from the bedbar adjuster screw 7 Note The bedbar adjuster shaft 1 has left hand threads 3 Unscrew the bedbar adjuster shaft 1 from the bedbar adjuster screw 7 4 Remove the retaining ring 6 and wave washer 5 from the adjuster shaft 7 and remove the adjuster shaft 5 Inspect the flange bushings 2 in the cu...

Page 145: ...er 5 and a retaining ring 6 Note The bedbar adjuster shaft 1 has left hand threads 4 Apply anti seize lubricant to the threads of the bedbar adjuster screw 7 that fit into adjuster shaft 1 the left hand threads and thread the bedbar adjuster screw into the adjuster shaft 5 Install the washer 9 compression spring 10 and lock nut 11 onto the adjuster screw 7 6 Install the bedbar 8 refer to Installin...

Page 146: ... 2 16 Discard the screws Remove bedknife from the bedbar 3 Refer to Grinding the Bedknife page 8 14 for additional information Installing the Bedknife 1 Use a scraper to remove all rust scale and corrosion from the bedbar surface under the bedknife Lightly oil the bedbar surface before installing the bedknife 2 Make sure that screw threads in bedbar 5 16 18UNC 2A are clean g226894 Figure 74 DPA Cu...

Page 147: ...lubricant to the taper of the screw heads 4 Install all screws but do not tighten 5 Using a torque wrench and bedknife screw tool tighten the 2 outer screws to 1 N m 10 in lb 6 Working from the center of the bedknife toward each end tighten screws from 23 to 28 N m 200 to 250 in lb 7 After installing the bedknife to bedbar grind the bedknife Greensmaster 1018 1021 1026 Page 8 13 DPA Cutting Units ...

Page 148: ...n 2 Service limit bottom of bedknife scallop reached when grinding IMPORTANT Do not grind the bedknife below it s service limit refer to Figure 76 Operating the cutting unit with the bedknife below the service limit may result in poor after cut appearance and reduce the structural integrity of the bedknife The bedknife service limit occurs when the reel contacts the back of the bedknife scallop du...

Page 149: ...rinder manufacturer s instructions for bedknife grinding information 2 After grinding the bedknife install the bedbar assembly in the cutting unit refer to Installing the Bedbar page 8 8 Note Always adjust the cutting unit after grinding the reel and or bedknife refer to the Cutting Unit Operator s Manual If a properly adjusted cutting unit does not cut paper cleanly after grinding the grind angle...

Page 150: ...g 3 Slide the telescopic coupler on the reel drive assembly 2 from the transmission drive shaft Note If necessary remove the reel drive assembly 2 from the cutting unit assembly 1 refer to Removing the Reel Drive Assembly page 5 7 4 Remove the 4 socket head screws 3 that secures the cutting unit assembly 1 to the frame assembly 5 Note Support the traction unit and lock the kick stand 5 Slide and r...

Page 151: ...10 3 Install the cutting unit assembly 1 onto the frame assembly 5 4 Secure the cutting unit assembly 1 with 4 socket head screws 3 5 Align the reel drive assembly shaft to transmission gear box driveshaft Slide the telescopic coupler on the reel drive assembly 2 to the transmission gear shaft 6 Attach the spark plug wire to the engine spark plug Greensmaster 1018 1021 1026 Page 8 17 DPA Cutting U...

Page 152: ...e machine on a level surface Ensure that the engine is OFF and the traction control is in NEUTRAL 2 Remove the spark plug wire from the engine spark plug 3 If the cutting unit is equipped with an optional groomer remove the drive components for those options from cutting unit Refer to Removing the Gear Box Assembly page 9 4 for universal groomer and Universal Groomer page 2 5 for additional inform...

Page 153: ...ews 3 and 17 that secure the LH side plate 4 to the reel assembly 8 9 Remove the bolt 16 and washer 15 that secures the grass shield assembly 18 to the LH side plate 4 10 Remove the LH side plate 4 from the reel assembly 8 11 Remove the 2 socket head screws 3 and 17 that secure the RH side plate 10 to the reel assembly 8 12 Remove the bolt 16 and washer 15 that secures the grass shield assembly 18...

Page 154: ...al play 3 Inspect the reel as follows A Place the reel shaft ends in V blocks and check the reel shaft for distortion B Check the threads in the ends of the reel shaft C Check the reel blades for bending or cracking D Check the service limit of the reel diameter refer to Preparing the Reel for Grinding page 8 22 4 Replace the reel if damage is evident IMPORTANT The seal must be installed with the ...

Page 155: ...onto the cutting reel assembly as far as possible 5 Install the 4 socket head screws 3 and 17 that secure the RH and LH side plates 4 and 10 to the frame support rods 9 and 14 Tighten the socket head screws from 24 to 27 N m 18 to 20 ft lb 6 Secure the grass shield assembly 18 to the RH and LH side plates 4 and 10 with the 2 washers 15 and 2 bolts 16 7 If the reel nuts were loosened during cutting...

Page 156: ...ting reel blades Remove small amounts of material with each pass of the grinder Follow reel grinder manufacturer s instructions to grind cutting reel to Toro specifications refer to Reel Grinding Specifications page 8 22 Additional reel grinding information can be found in the Cutting Unit Operator s Manual An additional resource is the Toro Basics Series Training Book Reel Mower Basics part no 09...

Page 157: ...it Operator s Manual To extend the cutting unit performance by allowing the reel and the bedknife to hold their edge longer an additional adjustment may be required after the first few minutes of operation as the reel and bedknife conform to each other Greensmaster 1018 1021 1026 Page 8 23 DPA Cutting Units Service and Repairs 18238SL Rev B ...

Page 158: ... this procedure 1 Loosen the pinch bolts 8 that secure the front roller shaft 3 to the front height of cut arms 5 2 Remove the lock nut 6 height of cut washer 7 and plow bolt 1 that secures one of the height of cut arms 5 to the cutting unit side plate 10 and remove the height of cut arm 3 Slide the front roller assembly 3 from the remaining height of cut arm 5 4 Remove the remaining height of cut...

Page 159: ...hten the jam nut against the roller shaft Remove the bearing lock nuts 1 2 Carefully inspect the seating surface and threads of the bearing lock nuts 1 and replace them if damaged 3 Loosely secure the roller assembly 4 in a bench vise and lightly tap on the roller shaft 5 to remove the sealing washers 2 and bearings 3 Discard the sealing washers 2 4 Clean and carefully remove any corrosion from th...

Page 160: ...e the front of the cutting unit off of the work surface 2 Inspect the condition of both height of cut screws 9 and replace them if necessary Apply anti seize lubricant to the threads of a new height of cut screw 9 Note When installing the height of cut arms 5 make sure that the tab of the side plate fits between the head and the washer of the height of cut screw 9 3 Secure one of the height of cut...

Page 161: ...er the front roller 3 in the cutting unit and tighten the pinch bolts 8 that secure the front roller shaft to the height of cut arms 7 Install the cutting unit assembly to the frame assembly refer to Installing the Cutting Unit Assembly page 8 17 If necessary 8 Adjust the cutting unit height of cut refer to the Cutting Unit Operator s Manual Greensmaster 1018 1021 1026 Page 8 27 DPA Cutting Units ...

Page 162: ...DPA Cutting Units Service and Repairs Page 8 28 Greensmaster 1018 1021 1026 18238SL Rev B ...

Page 163: ...ation Instructions 9 2 Grooming Performance 9 2 Service and Repairs 9 3 The Gear Box Assembly 9 4 The Idler Assembly 9 9 The Groomer Reel 9 11 The Height Adjuster Assembly 9 14 The Grooming Brush Optional 9 16 Greensmaster 1018 1021 1026 Page 9 1 Universal Groomer Optional 18238SL Rev B ...

Page 164: ...amage Use the groomer carefully Read and understand the groomer operation instructions before operating or testing the groomer performance It is important to remember that the same factors that affect quality of cut also affect grooming performance Variables that Affect the Use and Performance of the Groomer 1 The growing season and weather conditions 2 General turf conditions 3 The frequency of g...

Page 165: ...bly 4 Height adjuster assembly 2 each CAUTION Never work on the groomer with the engine running Always stop the engine and wait for all machine movement to stop before working on the groomer Greensmaster 1018 1021 1026 Page 9 3 Universal Groomer Optional Service and Repairs 18238SL Rev B ...

Page 166: ...refer to Removing the Groomer Reel page 9 11 2 Safely prevent the reel from rotating by blocking the cutting reel with a piece of wood near one of the reel spiders IMPORTANT The groomer gear box for this machine is installed on the left side of the cutting unit Groomer gear boxes installed on the left side of the cutting unit use a left hand thread Turn the input shaft clockwise to remove the gear...

Page 167: ...el B Remove the cotter pin and clevis pin from the height adjustment rod at the front of the groomer gear box Discard the cotter pin C Continue to unscrew the input shaft and remove the gear box from the cutting unit D Retrieve the shim item 6 in Figure 86 Greensmaster 1018 1021 1026 Page 9 5 Universal Groomer Optional Service and Repairs 18238SL Rev B ...

Page 168: ...ing 20 Straight bushing 2 each 34 Flange bushing 3 each 7 Ball bearing 2 each 21 Detent ball 35 Locknut 8 Retaining ring 22 Detent spring 36 Driver gear 9 Driven gear 23 Oil seal 37 Bearing 2 each 10 Actuator shaft 24 Socket head screw 4 each 38 Oil seal 11 Pin 25 Groomer cover 39 Driven shaft 12 O ring 26 Gasket 40 Shield 13 Knob 27 Thrust washer 14 Retaining ring 28 Ball bearing Universal Groome...

Page 169: ...ged or worn components as necessary 8 If the sun gear ring gear or the gear box housing bearings are replaced press the bearings all the way to shoulder into the part 9 If the flange bushings are replaced ensure that the flange bushing is fully seated against the part 10 Assembly the gearbox Ensure that all the retaining rings and O rings are fully seated in the ring groove during assembly Lubrica...

Page 170: ...item 6 in Figure 86 over the input shaft B Apply medium strength thread locking compound to the input shaft threads and turn the input shaft counter clockwise until it is seated against the reel C Install the clevis pin and a new cotter pin to secure the height adjustment rod to the front of the groomer gear box D Tighten the input shaft from 136 to 149 N m 100 to 110 ft lb 3 Apply a retaining com...

Page 171: ...tting unit refer to Removing the Reel Assembly page 8 18 2 Remove the groomer reel assembly refer to Removing the Groomer Reel page 9 11 3 Remove the cotter pin and clevis pin from the height adjustment rod at the front of the idler arm Discard the cotter pin 4 Remove the flange nut that secures the idler arm to the stub shaft Remove the idler assembly 5 Inspect the shields bearing and bushing in ...

Page 172: ...e bearing shields with the flocked side of the shield toward the bearing D Insert the stub shaft through the shields and bearing Use the through hole in the shaft to prevent the shaft from rotating and tighten the flange nut from 37 to 45 N m 27 to 33 ft lb 2 Install the clevis pin and a new cotter pin to secure the height adjustment rod to the front of the idler arm 3 Install the reel drive refer...

Page 173: ... can result in personal injury Use heavy gloves when handling the groomer reel 1 Carefully remove the 4 jam nuts 4 bolts and 4 shaft clamps that secure the groomer reel to the output and stub shafts 2 Lift the groomer reel from the cutting unit 3 Inspect the shields stub shaft driven shaft and shaft bearings for wear or damage and replace components as necessary refer to The Gear Box Assembly page...

Page 174: ...e blades from the groomer shaft If necessary remove second lock nut from the shaft 4 Inspect and replace worn or damaged components 5 Assemble the groomer reel as follows Note New lock nuts have an adhesive patch to prevent the lock nut from loosening If a used lock nut is being installed apply a medium strength thread locker Loctite 242 or equivalent to the threads of the lock nut A Install a loc...

Page 175: ...tate and the groomer blades should be centered on the shaft 6 Install the groomer reel back onto the cutting unit refer to Installing the Groomer Reel page 9 13 Installing the Groomer Reel 1 Position the groomer reel between the groomer driven and stub shafts 2 Secure the groomer reel to the cutting unit with the 4 jam nuts 4 bolts and 4 shaft clamps Tighten the bolts from 5 to 7 N m 45 to 60 in l...

Page 176: ...ent rods Retrofitting the assemblies on each side of the cutting unit with new compression springs height adjustment rods and adding flange nuts to enable spring adjustment is recommended refer to Figure 91 Disassembling the Height Adjuster Note Refer to Figure 91 during this procedure 1 Remove the cutting unit from the machine 2 Remove the cotter pins and clevis pins that secure the height adjust...

Page 177: ...d washer and lock nut Tighten the lock nut finger tight 3 Position front roller between the height adjuster assemblies and secure the remaining height adjuster assembly to the cutting unit side plate with a plow bolt and lock nut Tighten the lock nut finger tight 4 Center the front roller between the height of cut brackets and tighten the front roller pinch bolts 5 Install new cotter pins and clev...

Page 178: ...Groomer Reel page 9 11 The grooming brush element or shaft can be serviced separately To remove the spiral grooming brush from the shaft remove the lock nut and J bolt from both ends of the brush assembly and slide the brush from the shaft When assembling the spiral brush to the shaft make sure that the J bolts are installed with the threaded portion on the outside of the brush and tighten the loc...

Page 179: ......

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