Form No. 18238SL Rev C Greensmaster® 1018/1021/1026 (Models 04820, 04830 and 04840) © 2020—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision Date A 03/2019 Initial issue. B 03/2020 Updated the drum drive gear box assembly and transmission gear box assembly. C 07/2020 Updated the traction and reel drive, cutting unit and universal groomer chapters.
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NOTES NOTES Page 4 Greensmaster® 1018/1021/1026 18238SL Rev C
Preface The purpose of this publication is to provide the service technician with the information for troubleshooting, testing, and repair of the major systems and components on the Greensmaster 1018/1021/1026 (Models 04820, 04830 and 04840). Refer to the Operator’s Manuals and Installation Instructions for installing, operating, maintenance, and adjustment instructions.
g264048 Figure 1 Model 04830 shown Preface Page 6 Greensmaster® 1018/1021/1026 18238SL Rev C
Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S. components) that may have been removed. • dimensions or settings that must be maintained for proper machine operation. • a specific fastener tightening sequence. • component orientation that may not be obvious.
Table of Contents Preface ................................................................................................................ 5 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Safety and Instructional Decals ....................................................................
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Before Operating the Machine ........................................................................................................... 1–3 While Operating the Machine ............................................................................................................. 1–4 Maintenance and Service.................
Safety Instructions The Greensmaster 1018/1021/1026 machine is tested and certified by Toro for compliance with existing safety standards and specifications. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, these factors are also dependent on the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
Before Operating the Machine • Review and understand the contents of the Operator’s Manuals before starting and operating the machine. Become familiar with the controls and know how to stop the machine and engine quickly. Additional copies of the Operator’s Manuals are available at www.toro.com. • Never allow children to operate the machine. Never allow adults to operate the machine without proper instructions.
While Operating the Machine 1. Do not run the engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could be deadly. 2. Always stand behind the handle when starting and operating the machine. 3. To start the engine: A. Open fuel shut-off valve. Make sure that the spark plug wire is connected to the spark plug. B. Verify that the control lever on handle is in NEUTRAL position for both traction and reel drives. C.
Maintenance and Service • The Traction Unit Operator’s Manual, Cutting Unit Operator’s Manual and Groomer Operator’s Manual provides the information regarding the operation, general maintenance and maintenance intervals for your Greensmaster machine. Refer to these publications for additional information when servicing the machine. • Before servicing or making adjustments to the machine, stop the engine and wait for all machine motion to stop.
Safety and Instructional Decals Numerous safety and instruction decals are affixed to the traction unit 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.
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Overall Dimensions............................................................................................................................ 2–2 Engine................................................................................................................................................
Specifications Overall Dimensions g262214 Figure 2 Specifications and Maintenance: Specifications Page 2–2 Greensmaster® 1018/1021/1026 18238SL Rev C
Engine g238094 Figure 3 1. Fuel tank 3. Recoil starter 5. Spark plug 2. Air cleaner 4. Recoil-start handle 6. Muffler Item Description Make/Designation Honda, 4-stroke, OHV single cylinder, air-cooled gasoline engine, GX120 Bore x Stroke 60 mm x 42 mm (2.36 x 1.65 inches) Total displacement 118 cm3 (7.2 in3) Compression ratio 8.
Traction and Reel Drive Systems Item Description Transmission Engine to friction clutch Transmission drive uses spur gears Traction Drive Transmission to traction drive uses a series of spur gears Differential Spur gear planetary differential Parking Brake Band style (at differential shaft drive) Traction Drum Dual aluminium, 19.1 cm (7.
DPA Cutting Units (continued) Cutting unit weight (approximate): 18 inch 21 inch 26 inch 8 blade - 23.6 kg (52 lbs) 26.7 kg (59 lbs) 11 blade 23.1 kg (51 lbs) 25 kg (55 lbs) 28.6 kg (63 lbs) 14 blade 24.5 kg (54 lbs) 26.3 kg (58 lbs) - Options: Refer to the Cutting Unit Parts Catalog or contact your local Authorized Toro Distributor for available cutting unit options. Universal Groomer Item Description Grooming reel diameter 6 cm (2.
Torque Specifications The 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 the fasteners will apply to all the fasteners which do not have a specific requirement identified in this Service Manual.
Calculating the Torque Values When Using a Drive-Adapter Wrench g205924 Figure 4 Torque Conversion Factor = A / B 1. Torque wrench 3. A (effective length of torque wrench) 2. Drive-adapter wrench (crowsfoot) 4. B (effective length of torque wrench and drive-adapter wrench) Using a drive-adapter wrench (e.g.
Identifying the Fastener g206088 Figure 5 Inch Series Bolts and Screws 1. Grade 1 2. Grade 5 3. Grade 8 g206089 Figure 6 Metric Bolts and Screws 1. Class 8.8 2. Class 10.9 Fasteners with a Locking Feature IMPORTANT If a fastener with a locking feature or previously applied thread locking compound is reused, clean the fastener threads and apply new thread locker to the fastener during installation. Locking features are designed to create friction and prevent a fastener from loosening.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC # 8 - 36 UNF # 10 - 24 UNC # 10 - 32 UNF Grade 1, 5 and 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in-lb in-lb N∙cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 56 18 ± 2 30 ± 5 339 ± 56 SAE Grade 5 Bolts, Screws, Studs, and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Thread Size 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.
Other Torque Specifications SAE Grade 8 Steel Set Screws 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 Thread Cutting Screws (Zinc Plated Steel) Type 1, Type 23 or Type F Thread Size Baseline Torque** No. 6 - 32 UNC 20 ± 5 in-lb No. 8 - 32 UNC 30 ± 5 in-lb No.
Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply. IMPORTANT Always follow manufacturers instructions when using or storing shop supplies.
GASKET COMPOUND Used to create a seal between mating parts. Gasket compounds may be used with or without the presence of a pre-formed gasket. Gasket compounds may be solvent or silicone based, and cure when exposed to air or designed to cure in an air-less environment (anaerobic). Most gasket compounds are designed to be applied to clean surfaces free of oil, chemical residue and previously used gaskets or gasket compounds.
Special Tools Multimeter Obtain this tool locally The meter can test the electrical components and circuits for current, resistance, or voltage. Note: Use a digital multimeter when testing the electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode ensures that the excess current is not allowed through the meter. This excess current can damage the circuits that are not designed to carry it. Dielectric Gel Toro Part No.
Cutting Reel Shim Toro Part No. 125–5611 Use the 0.05 mm (0.002 in) shim like a feeler gauge to measure the gap between the reel and the bedknife during reel adjustment. Cutting Performance Paper Toro Part No. 125–5610 (300 strips) Cutting performance paper is used to test the cutting reel performance after adjusting the reel to bedknife 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.
Reel Thread Repair Taps 15/16–16 Right-Hand Thread – Toro Part No. 137–0926 15/16–16 Left-Hand Thread – Toro Part No. 137–0927 Use to clean or repair the internal threads of cutting unit reels. Angle Indicator and Magnetic Mount Angle Indicator: Toro Part No. 131–6828 Magnetic Mount: Toro Part No.
Bedknife Screw Tool (continued) Toro Part No. TOR510880 This screwdriver-type bit is made to fit Toro bedknife attaching screws. Use this bit with a torque wrench to secure the bedknife to the bedbar. IMPORTANT Important: To prevent damage to the bedbar, DO NOT use an air or manual impact wrench with this tool. Diameter/Circumference Measuring Tape Toro Part No.
Turf Evaluator Tool Toro Part No. 04399 Many turf discrepancies are subtle and require closer examination. In these instances, the Turf Evaluator grass viewing tool is helpful. It can assist turf managers and service technicians 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.
Chapter 3 Troubleshooting Table of Contents GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems ............................. 3–2 Gather Information ............................................................................................................................. 3–2 Evaluate Potential Causes ................................................................................................................. 3–2 Assess Performance.............................................
GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems Gather Information • Information reported by the customer • Information observed by you • Establish the what, where and when of the issue Evaluate Potential Causes • Consider possible causes of the problem to develop 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 nece
Starting Problems For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components that are used on this machine; refer to the Electrical schematics in this chapter. If the machine has any interlock switches that are bypassed, connect the switches for the correct troubleshooting and safety. Note: For engine component testing information, refer to the Honda Service Manual.
Aftercut Appearance 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. Refer to the Cutting Unit Operator’s Manual detailed adjustment procedures.
Factors Affecting Grooming 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. IMPORTANT Improper or overaggressive use of the grooming reel, such as too deep or frequent grooming, may cause unnecessary stress on the turf leading to severe turf damage. Use the groomer carefully.
Grooming Reel Mechanical Problems Troubleshooting: Problem Possible Causes Correction No rotation of the grooming reel. Groomer drive gears are worn or damaged. Inspect groomer drive assembly and replace damaged drive components. The turf is damaged or has uneven grooming. The groomer is set too aggressively. Refer to groomer Installation Instructions for groomer set-up information. The grooming reel blades are bent, damaged or missing. Repair or replace blades if necessary.
Chapter 4 Gasoline Engine Table of Contents General Information .............................................................................................................................. 4–2 Operator’s Manual ............................................................................................................................. 4–2 Engine Owner’s Manual..................................................................................................................... 4–2 Engine Service Manual ...
General Information This chapter gives the information about specifications and repair of the Honda GX120 gasoline engine used in the Greensmaster. Described adjustments and repairs require tools that are commonly available in many service shops. When disposing of hazardous waste products (fuel, engine oil, hydraulic fluid, filters, etc.), take them to an authorized disposal site. Waste products must not be allowed to contaminate surface water, drains, or sewer systems.
Fuel Evaporative Control System To meet worldwide emission standards, the engine that powers your Greensmaster is equipped with a fuel cap that has an integrated carbon canister. This fuel cap captures fuel vapors from the fuel tank before venting to atmosphere. g282215 Figure 9 1. Fuel tank insert Note: To prevent saturating the carbon canister in the fuel cap, it is important to ensure that the fuel tank is not overfilled.
Adjustments Throttle Cable Adjustment If a new throttle cable must be installed or the cable is our of adjustment, adjust the cable as follows: 1. Park the mower on a level surface. Note: Make sure that the engine is at normal operating temperature before you adjust the throttle cable. 2. Start the engine and move the throttle lever to the SLOW position. 3. Loosen the clamp retaining cable conduit. 4. Make sure that the throttle control is in the SLOW position and move the cable conduit until 1900 rpm. 5.
Service and Repairs Cooling System g258391 Figure 10 1. Engine cylinder shroud 2. Cooling fins IMPORTANT The engine that powers the machine 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. 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.
Cooling System (continued) g258392 Figure 11 1. Blower housing 2. Rewind starter 3. Clean the blower housing of dirt and debris; refer to Figure 11. Remove the housing if necessary. 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.
Spark Plug 0.7 to 0.8 mm (0.027 to 0.031 in) g258393 Figure 12 Use a NGK BPR6ES spark plug or equivalent. 1. Ensure that the engine is OFF. Carefully remove the spark plug wire from the spark plug. 2. Clean the cylinder head area around the spark plug and remove the plug from the cylinder head. 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.
Engine g255888 Figure 13 1. Bolts (2 each) 6. Carriage bolts (4 each) 11. Lock nuts (2 each) 2. Muffler guard 7. Transmission gear box 12. Clutch cover 3. Nuts (4 each) 8. Bolt (4 each) 13. Bolt (2 each) 4. Flat washer (4 each) 9. Washer (4 each) 14. Engine 5. Engine base 10. Clutch hub clamp 15. Bolt (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.
Removing the Engine (continued) g261801 Figure 14 1. Governor lever 3. Cable clamp 2. Throttle cable 4. High speed screw 3. Remove the throttle cable (2) from the engine: 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.
Removing the Engine (continued) g262386 Figure 15 1. Armature wire 2. Alternator wire 3. Harness ground wire 4. Disconnect the electrical connections from the engine: A. Unplug the wire harness connector from the engine armature wire (1). B. Disconnect the wire harness ground wire (3) from engine by removing LH rear cap screw, flat washer and a flange nut. C. If the machine is equipped with optional lighting kit, disconnect the wire harness connectors from the engine alternator wires (2). 5.
Installing the Engine 1. If removed, install the muffler (2) onto the engine (14) and secure with the 2 bolts (1). 2. Torque tighten the bolts (1) from 4 to 5.6 N∙m (35 to 50 in-lb). 3. Position the engine (14) onto the engine base (5) and engine output shaft in the bell housing and external clutch hub. 4. Secure the engine (14) onto the bell housing with the 4 bolts (8) and 4 washers (9). In an alternating cross pattern, torque tighten the bolts (8) from 10 to 11.3 N∙m (90 to 100 in-lb). 5.
Engine Base g256199 Figure 16 1. Engine base 5. Flat washer (2 each) 2. Slider adapter 6. Frame assembly 10. Transmission gear box assembly 3. 4. Jam nut Flat head nut 7. 8. Bolt Tube clamp 11. 12. Nut Jack screw 9. Flat head bolt (5 each) Removing the Engine Base Note: Refer to Figure 16 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.
Removing the Engine Base (continued) 6. Slide the telescopic coupler on the reel drive assembly and disconnect the reel drive shaft from the transmission drive shaft. 7. Remove the truss screw, nut and 2 washers that secures the 2 splined couplers to the transmission gear box assembly and drum drive gear box assembly. 8. Loosen the jam nut (3) and remove the slider adaptor (2) from the transmission gear box assembly (10). 9.
Removing the Engine Base (continued) g256200 Figure 17 1. Flat head nut 9. Washer (3 each) 17. Nut 2. Compression spring 10. Long reel lever 18. Carriage bolt 3. Reel selector hub 11. Straight bushing 19. Engine mount bracket 4. Retaining ring 12. Short reel lever 20. Bolt 5. Reel selector shaft 13. Flat head bolt 21. Cable guide 6. Extension spring 14. Nut 22. Washer 7. Flange bushing 15. Socket head screw 23. Washer 8. Reel bellcrank 16. Engine base 15.
Removing the Engine Base (continued) 19. If necessary, remove the flange bushing (7) from the reel bellcrank (8). Remove the straight bushing (11) from the long and short reel lever (10 and 12). 20. If necessary, remove the nut (14), washer (23) and socket head screw (15) from the engine base (16). Installing the Engine Base 1. If removed, install the socket head screw (item 15 in Figure 17), washer (23) and nut (14) into the engine base (16). g262534 Figure 18 1. Long reel lever 2.
Installing the Engine Base (continued) 8. Install the engine and transmission gear box assembly on the engine base. 9. Secure the transmission gear box to engine base with 2 bolts (9). Do not tighten the bolts (9). 10. Secure the engine to the engine base with 4 carriage bolts, washers and nuts. 11. Secure the engine base (item 1 in Figure 16) to the frame assembly (6) with a bolt (7), 2 washers (5) and nut (4) in front side and 2 tube clamps (8) and 4 nuts (11) in rear side of the frame assembly (6).
Chapter 5 Traction and Reel Drive Systems Table of Contents General Information .............................................................................................................................. 5–2 Disengaging The Drum Drive From Transmission.............................................................................. 5–2 Adjustments ..........................................................................................................................................
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine. Disengaging The Drum Drive From Transmission g258467 Figure 19 1. Transmission gear box assembly 2. Traction engage/disengage lever The traction drum is driven by series of spur gears inside the transmission gear box assembly.
Adjustments g258535 Figure 20 1. Reel drive box assembly 4. Bolt 2. 3. Reel belt Idler arm 5. 6. Gasket Reel drive cover 7. Socket head screw (3 each) Adjusting the Reel Drive Belt 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 the reel drive assembly (1) and remove the reel drive cover to expose the reel drive belt (2). 3.
Adjusting the Reel Drive Belt (continued) 4. Adjust belt tension (2) as follows: A. Loosen the bolt (4) and rotate the idler arm (3) to release the tension on the reel drive belt (2). B. Pivot the idler arm (3) clockwise against the backside of the belt and apply a torque 3.9 to 4.5 N∙m (35 to 40 in-lb) to internal hex socket on the idler arm (3). Secure the idler arm with the bolt (4). Check the belt tension as per para 3. C.
Aligning the Transmission Output Shaft to the Reel Drive Input Shaft g256199 Figure 21 1. Engine base 5. Flat washer (2 each) 2. Slider adapter 6. Frame assembly 10. Transmission gear box assembly 3. 4. Jam nut Flat head nut 7. 8. Bolt U-Tube clamp 11. 12. Nut Jack screw 9. Flat head bolt (5 each) 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.
Aligning the Transmission Output Shaft to the Reel Drive Input Shaft (continued) g278571 Figure 22 1. Reel-drive assembly 2. Nut A. Loosen the nut (item 2 in Figure 22) that secures the reel drive assembly to the side-plate. B. Loosen the four nuts (item 11 in Figure 21) on the two U-tube clamps that secures the engine base to the rear side of the frame assembly. C. Loosen the nut (item 4 in Figure 21) that secures the engine base to the front side of the frame assembly. D.
Service and Repairs Reel Drive Belt g258535 Figure 23 1. Reel drive box assembly 4. Bolt 2. 3. Reel belt Idler arm 5. 6. Gasket Reel drive cover 7. Socket head screw (3 each) The greensmaster machines use a positive drive belt on the right side of the machine to operate the cutting unit. Removing the Reel Drive Belt Note: Refer to Figure 23 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.
Removing the Reel Drive Belt (continued) 3. Remove and inspect the reel drive gasket (5) from the reel drive assembly (1). Discard the reel drive gasket (5), if damaged. 4. Loosen the bolt (4) and rotate the idler arm (3) to release the tension on the reel drive belt (2). 5. Remove the reel drive belt (2) from the pulleys. Installing the Reel Drive Belt 1. Ensure that the bolt (4) is loose enough to move the idler arm (3) freely. 2. Place the new drive belt (2) onto the pulleys. 3.
Reel Drive Assembly g258675 Figure 24 1. Screw (2 each) 5. V-ring seal 2. Spacer (2 each) 6. Reel drive assembly 9. 3. Washer (2 each) 7. 4. Spring washer (2 each) 8. RH side plate 10. Transmission drive shaft Compression spring 11. Spacer Telescopic coupler 12. Nut Removing the Reel Drive Assembly Note: Refer to Figure 24 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.
Disassembly of Reel Drive Assembly g258688 Figure 25 1. 2. Reel shaft-driven O-ring 11. 12. Socket head screw Socket head screw (3 each) 21. 22. Reel shaft-driver Reel drive housing 3. Pivot sleeve 13. Expansion plug 23. O-ring 4. Reel drive gasket 14. Reel drive cover 24. Bolt 5. Ball bearing (2 each) 15. Reel pulley - 22 tooth 25. Lock nut (2 each) 6. Internal snap ring 16. Reel belt 26. Idler arm 7. Reel pulley spacer (2 each) 17. Retaining ring 27. Plain washer 8.
Disassembly of Reel Drive Assembly (continued) 9. Remove the retaining ring (6) from the reel drive housing (22). 10. Slide the reel shaft-driven from the bearings. 11. Use a press to remove the 2 ball bearings (5) and reel shaft-driven (1) from the reel drive housing (22). Discard the ball bearings after removal. 12. If necessary, remove the pivot sleeve (3) from the reel drive housing (22). Remove and discard the O-ring from the pilot sleeve. 13.
Assembly of Reel Drive Assembly (continued) 19. Install the bolt (28), washer (27) and nut (25) to the idler arm (26) and reel drive housing (22). Do not tighten the bolt (28). g258764 Figure 26 1. Press flush 20. If removed, install the expansion plug (13) to the reel drive cover (14) and press flush to outer surface (refer to Figure 26) of the reel drive cover. 21. Install the reel drive belt; refer to Installing the Reel Drive Belt (page 5–8). 22.
Drum Drive Gear Box Assembly g258813 Figure 27 1. Transmission gear box assembly 5. Lock nut 2. Traction drum 6. Shoulder bolt (3 each) 10. 9. Shoulder bolt 11. Truss screw 3. Splined coupler (2 each) 7. RH hex shaft 4. Washer 8. Drum drive gear box assembly Frame assembly Removing the Drum Drive Gear Box Assembly Note: Refer to Figure 27 during this procedure. 1. Park the machine on a level surface. Ensure that the engine is OFF.
Removing the Drum Drive Gear Box Assembly (continued) 4. Remove the truss screw (11), nut (5) and washer (4) that secures the 2 splined couplers (3) to the transmission gear box assembly (1) and drum drive gear box assembly (8). 5. Remove the shoulder bolt (10) that 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).
Disassembly of Drum Drive Gear Box Assembly g258844 Figure 28 1. Nut 13. Oil seal 25. Drum drive housing 2. Washer 14. Drum drive cover 26. Retaining ring 3. Outer drum hub 15. Socket head screw (5 each) 27. Oil seal 4. V-ring seal 16. Plug (2 each) 28. Retaining ring 5. Drum drive shaft 17. Flange nut 29. O-ring 6. Ball bearing (2 each) 18. Retaining ring 30. Key 7. Spacer 19. Ball bearing (2 each) 31. Short bearing pin 8. Drum driver gasket 20. Spur gear 32.
Disassembly of Drum Drive Gear Box Assembly (continued) 5. Remove the nut (12) that secures the spur gear (11) to the drum drive shaft (5). Slide and remove the spur gear (11) from the drum drive shaft (5). Locate and retrieve the key (30) from the drum drive shaft (5). 6. Remove the nut (1) and washer (2) that secures the outer drum hub (3) to the drum drive shaft (5). Slide and remove the outer drum hub (3) and V-ring seal (4) from the drum drive shaft (5).
Assembly of Drum Drive Gear Box Assembly g263151 Figure 29 1. Install the ball bearings (23), wave washer (24) and spur gear (21) to the drum drive housing (25). Note: The outer diameter and inner diameter of the ball bearings (23) must be slip fit. 2. Install the retaining ring (26) to the spur gear (21). Apply a light coat of oil to the oil seal (27). Install the oil seal (27) and retaining ring (28) to the drum driving housing (25). 3.
Assembly of Drum Drive Gear Box Assembly (continued) 12. Install the drum drive cover (14) to the drum drive housing (25) and secure with 5 socket head screws (15). 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). 13. Fill the drum drive gear box assembly with 10 oz (0.56 lb) of Mobil SCH007 grease. 14. Torque tighten the hollow plugs (16) from 12.4 to 14.
Drum Assembly g258878 Figure 30 1. Transmission gear box assembly 5. Lock nut (2 each) 2. Traction drum 6. Shoulder bolt (6 each) 9. Frame assembly 10. Shoulder bolt (2 each) 3. Splined coupler (4 each) 7. RH hex shaft 11. Truss screw 4. Washer (4 each) 8. Drum drive gear box assembly (2 each) 12. LH hex shaft Removing the Drum Assembly Note: Refer to Figure 30 during this procedure. 1. Park the machine on a level surface. Ensure that the engine is OFF.
Disassembly of Drum Drive Assembly g258879 Figure 31 1. Traction drum (2 each) 5. Drum spindle 9. 2. Bolt (8 each) 6. Seal (2 each) 10. Drum hub Spacer 3. Lock washer (8 each) 7. Ball bearing (2 each) 11. Shoulder bolt (6 each) 4. Drum hub plate (2 each) 8. Spacer 12. Lock nut Note: Refer to Figure 31 during this procedure. 1. Remove the 4 bolts (item 2 in Figure 31) and lock washers (3) that secures the drum hub plate (4) to the drum spindle (5). 2.
Assembly of Drum Drive Assembly g258942 Figure 32 1. Drum hub 4. Spacer 2. Spacer 5. Drum spindle 3. Lock nut 6. Seal (2 each) 7. Ball bearing (2 each) Note: The seal side of each bearing (item 7 in Figure 32) should face inside of the drum hub; refer to Figure 32. 1. Use a press to install the bearings (7) and spacer (8) into the drum hub (10). Pack the bearings with grease. Fill outside space of the bearing with the grease. 2. Apply a coat of grease to the seals (6).
Installing the Drum Drive Assembly 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. Position the LH and RH drum drive gear box assembly (item 8 in Figure 30) 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 5–18). 4. Attach the spark plug wire to the spark plug.
Clutch Bearing g259013 Figure 33 1. Bolt (2 each) 2. Clutch hub clamp 3. External clutch hub 4. 5. 6. 9. Self aligning sealed bearing 17. Fork shaft 10. Flange bush (2 each) 18. Bell housing 11. Clutch cover 19. Engine base Retaining ring 12. Bolt (2 each) 20. Transmission gear box assembly Clutch disc 13. Retaining ring (2 each) 21. Bolt (2 each) Friction plate 14. Clutch fork 22. Lock nut (2 each) 7. Clutch compression spring 15. Bolt (3 each) 8.
Removing the Clutch Bearing (continued) 3. Remove the clutch cable from the fork shaft (17); refer to Removing the Clutch Cable (page 7–9). 4. Remove the retaining ring (13) from the fork shaft (17). 5. Slide and remove the fork shaft (17) and clutch fork (14) from the bell housing (18). 6. If necessary, remove the flange bushing (10) from the clutch fork (14). 7. Remove the 2 locknuts (22), 2 bolts (1) and clutch hub clamp (2) that secures the external clutch hub (3) to the engine drive shaft.
Installing the Clutch Bearing (continued) 12. Install the clutch cover (11) 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.
Transmission Gear Box Assembly g259091 Figure 34 1. Truss screw (3 each) 6. Engine base 11. Bolt (2 each) 2. Splined coupler (6 each) 7. Telescopic coupler 12. Transmission gear box assembly 13. Compression spring 3. Washer (3 each) 8. Reel drive box assembly 4. Lock nut (3 each) 9. Slide adaptor 5. Drive shaft 10. Jam nut Removal of transmission gear box assembly is necessary in order to service the internal components.
Removing the Transmission Gear Box Assembly (continued) 5. Slide the telescopic coupler (item 7 in Figure 34) on the reel drive box assembly (8) and disconnect the reel drive box assembly from the transmission gear box assembly (12). 6. Remove the nuts (4), washers (3) and truss screws (1) that secures the splined couplers (2) to the drive shaft (5). Remove the splined couplers from the drive shafts. 7. Remove the 2 bolts that secures the clutch cover. Remove the clutch cover. 8.
Disassembling the Transmission Gear Box Assembly g259588 Figure 35 1. Retaining ring 11. Grease seal 21. Brake mount pin 2. Spacer bushing 12. Ball bearing (2 each) 22. Transmission gasket 3. O-ring 13. Spacer 23. Transmission cover 4. Straight bushing (2 each) 14. Oil seal (2 each) 24. Socket head screw (12 each) 5. Retaining ring (2 each) 15. Oil seal 25. Ball bearing (2 each) 6. Oil seal (2 each) 16. Sleeve bushing (2 each) 26. Transmission housing 7.
Disassembling the Transmission Gear Box Assembly (continued) 3. Remove the oil seal (6), retaining ring (5) from the transmission cover (23). Use a press to remove the ball bearing (25) from the transmission cover (23). Discard the oil seals and ball bearing. g259590 Figure 36 1. External retaining ring 10. O-ring (2 each) 19. Brake lever 2. 3. Fitting plug 11. Retaining ring (2 each) 20. O-ring Wave washer 12. Flange bearing (2 each) 21. Brake clevis pin 4. Ball bearing (2 each) 13.
Disassembling the Transmission Gear Box Assembly (continued) 8. Use a press to remove the 2 ball bearings (13) and 2 flange bearings (12) from the differential assembly (14). Remove the V-ring seal (15) from the differential assembly (14). Discard the ball bearings (13). 9. If necessary, disassemble the differential assembly (14); refer to Disassembly of Differential Assembly (page 5–39). 10. Remove the bolt (25) that secures the cable brake lever (24) onto the brake lever (19).
Disassembling the Transmission Gear Box Assembly (continued) g259589 Figure 37 1. Short bearing pin 8. Flange nut (2 each) 15. Reel clutch shoe 2. O-ring 9. Wave spring 16. Reel clutch actuator 3. Long bearing pin 10. Ball bearing (2 each) 17. Spur gear 4. Bearing spacer (2 each) 11. Retaining ring (2 each) 18. Thin lock nut 5. Retaining ring (4 each) 12. Reel drive shaft 19. Input shaft 6. Ball bearing (5 each) 13. Square key (2 each) 20.
Disassembling the Transmission Gear Box Assembly (continued) C. Slide and remove the slider spur gear (14) from the reel drive shaft (12). D. Remove the two key squares (13) from the reel drive shaft (12). 16. Remove the nut (8) and long bearing pin (3) that secures the spur gear assembly (7) to the transmission housing assembly (20). Remove the spur gear (7) and bearing spacer (4) from the transmission housing assembly (20). 17. Remove and discard the O-ring (2) from the long bearing pin (3). 18.
Assembling the Transmission Gear Box Assembly g259789 Figure 38 1. Ball bearing (2 each) 3. Grease seal 2. Spacer 4. Straight bushing (2 each) 1. Use a press to install the spacer (item 13 in Figure 35) and new ball bearings (12 and 25) into the transmission housing (26). 2. Install the retaining ring (item 5 in Figure 35) into the transmission housing (26). 3. Install the new grease seal (item 11 in Figure 35) into the transmission housing (26).
Assembling the Transmission Gear Box Assembly (continued) g259956 Figure 39 1. Sleeve bushing 2. Oil seal 3. Press flush 7. Insert the sleeve bushing (Item 16 in Figure 35) into the transmission housing (26) until the sleeve bushing is flush with the transmission housing; refer to Figure 39. 8. Press the oil seal (item 15 in Figure 35) into the transmission housing (26) so that the seal is recessed from 1.27 mm (0.05 in) from the edge of the transmission housing; refer to Figure 39.
Assembling the Transmission Gear Box Assembly (continued) bearing spacer (4) onto the transmission housing assembly (20) and secure with the short bearing pin and nut (8). 18. Use a press to install the 3 new ball bearings (item 6 in Figure 37) into the spur gear (7) and secure with the 2 retaining rings (5). 19. Apply a coat of grease to the O-ring (item 2 in Figure 37) and slide the O-ring onto the long bearing pin (3).
Assembling the Transmission Gear Box Assembly (continued) 25. Slide and install the brake lever assembly (item 19 in Figure 36) into the transmission housing assembly (23). 26. If removed, insert the brake mount pin through brake band into the transmission housing assembly (item 23 in Figure 36) and place the flat wire spring (22) onto the transmission housing assembly. 27. Place the retainer plate (item 16 in Figure 36) onto the transmission housing assembly (23) and secure it with the 4 bolts (8). 28.
Assembling the Transmission Gear Box Assembly (continued) Note: Ensure that the dowel pins is recessed outboard to 4.5 mm (0.18 in) from the edge of the transmission housing; refer to Figure 40. 46. Install the new transmission gasket (item 22 in Figure 35) and transmission cover assembly (23) onto the transmission housing (26) by aligning the holes. Secure the transmission cover assembly with 12 bolts (24) and torque tighten to 1.7 to 4.5 N∙m (15 to 40 in-lb).
Differential Assembly g259590 Figure 41 1. External retaining ring 10. O-ring (2 each) 19. Brake lever 2. Fitting plug 11. Retaining ring (2 each) 20. O-ring 3. Wave washer 12. Flange bearing (2 each) 21. Brake clevis pin 4. Ball bearing (2 each) 13. Ball bearing (2 each) 22. Flat wire spring 5. Neutral spur gear 14. Differential assembly 23. Transmission housing assembly 6. Neutral slider shaft 15. V-ring seal 24. Cable brake lever 7. Square key (2 each) 16.
Disassembly of Differential Assembly g259978 Figure 42 1. Differential housing (2 each) 3. Differential spur gear (6 each) 2. Differential pin (6 each) 4. Differential gear 5. Socket head screw (6 each) 1. Remove the 6 socket head screws (item 5 in Figure 42) 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.
Assembly of Differential Assembly 1. Place the differential housings (1) on the work bench. 2. Insert the 3 differential pins (2) in each differential housing. g260016 Figure 43 1. Differential spur gears with shoulder up 2. Press flush 3. The differential pins (2) must be inserted in alternate holes of the differential housing (1) and ensure that the differential pins (2) are flush to the surface of the differential housing; refer to Figure 43. 4.
Chapter 6 Electrical System Table of Contents General Information .............................................................................................................................. 6–2 Operator's Manual.............................................................................................................................. 6–2 Wiring Schematic...................................................................................................................................
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.
Wiring Schematic g268165 Figure 44 Greensmaster® 1018/1021/1026 18238SL Rev C Page 6–3 Electrical System: Wiring Schematic
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 electronically isolated (e.g. disconnect all leads or remove the circuit) from the circuit when tested. Note: See the Honda Service Manual for the engine components testing information.
Ignition System Operation The engine on the Greensmaster has a magneto ignition system consists of an ignition coil, a spark plug and permanent flywheel magnets. A flywheel key maintains proper ignition timing. Testing the Ignition System Note: Do not remove the spark plug from the engine when testing the ignition system. The spark plug is necessary to maintain normal starting speeds. 1. With the engine not running, remove the spark plug wire from the spark plug and connect it to the spark tester. 2.
ON/OFF Switch g262080 Figure 45 1. 2. On/Off switch Handle assembly The ON/OFF switch is located on the console on the handle. This rocker switch allows the engine to be turned on and off. Testing the ON/OFF switch 1. Ensure that the engine is OFF and the traction control is in the NEUTRAL position. 2. Remove the controls cover from the handle assembly to allow access to the ON/OFF switch. 3. Disconnect the wire harness electrical connector from the ON/OFF switch.
Testing the ON/OFF switch (continued) SWITCH POSITION NORMAL CIRCUITS OTHER CIRCUITS OFF - - 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.
Hour Meter g262085 Figure 47 1. Hour meter 2. Controls cover 3. Handle assembly The hour meter used on the Greensmower records the amount of time that the 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.
Testing the Hour Meter (continued) g238110 Figure 48 1. Hourglass icon 2. Negative terminal (BK) 3. Positive terminal (Y) 4. Connect the positive (+) terminal of a 12 VDC source to the positive (+) terminal of the hour meter. 5. Connect the negative (-) 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.
Interlock Module (Optional) g262116 Figure 49 1. Bolt (2 each) 2. Interlock module 3. Handle assembly The interlock module prevents the engine from starting unless the traction control is disengaged. The interlock module controls grounding of the engine ignition system. When the engine starter rope is pulled, the engine magneto will begin to create current. The interlock module uses that current through the traction switch to determine the state of the switch.
Lighting Coil The engine on Greensmaster machines is equipped with a lighting coil to provide electrical current for an optional LED light kit. The coil is located under the engine flywheel and uses permanent magnets on the flywheel to operate. The lighting coil has a 12 VAC output that is rated at 50 watts. See the Honda Service Manual for additional lighting coil information.
Electrical System: Component Testing Page 6–12 Greensmaster® 1018/1021/1026 18238SL Rev C
Chapter 7 Controls, Wheels and Accessories Table of Contents General Information .............................................................................................................................. 7–2 Operator’s Manual ............................................................................................................................. 7–2 Service and Repairs .............................................................................................................................
General Information Operator’s Manual 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.
Service and Repairs Replacing the Throttle Cable g261770 Figure 50 1. Upper receiver weldment 5. Compression spring 9. Throttle arm 2. Lock nut (2 each) 6. Delta screw 10. Flange nut 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 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.
Removing the Throttle Cable (continued) g261801 Figure 51 1. Governor lever 3. Cable clamp 2. Throttle cable 4. High speed screw 2. Remove the throttle cable (item 2 in Figure 51) from the engine governor linkage (1) as follows: A. Loosen the screw that secures the cable clamp (3) to engine bracket. Remove the throttle cable (2) from the cable clamp (3). B. Loosen the screws that secure the throttle cable (2) to the governor lever (1). Slide the throttle cable from the governor lever. C.
Installing the Throttle Cable 1. Connect the throttle cable end to the throttle arm (9). 2. Slide the throttle cable (3) into the upper receiver weldment (1) and tighten the lock nut (2). 3. Install the throttle arm to the handle assembly. 4. Route the throttle cable (3) to the engine. Ensure that the throttle cable is routed on the left side of the engine. 5. Install the throttle cable (item 2 in Figure 51) to the engine governor linkages (1) as follows: A.
Replacing the Brake Cable g261822 Figure 52 1. Shoulder screw 4. Upper receiver weldment 7. Brake cable spring 2. Flange bushing (2 each) 5. Flange nut 8. Jam nut 3. Lever 6. Handle assembly 9. Brake cable Removing the Brake Cable Note: Refer to Figure 52 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.
Removing the Brake Cable (continued) g261858 Figure 53 1. Retaining ring 3. Brake lever 2. Cable eyelet 4. Jam nut 5. Brake cable 3. Remove the brake cable (item 5 in Figure 53) from the brake lever shaft on the transmission gear box assembly as follows: A. Loosen the front cable jam nut (4) that secures the brake cable to the casting slot on the transmission gear box assembly. Remove the brake cable from the slot. B.
Installing the Brake Cable 1. Secure the brake cable (9) to the brake lever assembly as follows: A. Install the cable spring (7) to the spring anchor on the brake lever assembly (3). B. Slide the brake cable into the shift mount bracket slot. Ensure that the jam nut (8), flat washer and lock washer are both sides of the bracket. Adjust the jam nuts so that equal amount of cable threads are visible above and below jam nuts. Leave jam nuts snug until final cable adjustment. 2.
Replacing the Clutch Cable g261995 Figure 54 7. Link assembly 1. Clutch cable 4. Split bushing 2. Jam nut 5. Main control shaft 8. Cotter pin 3. Cable spring 6. Clevis pin 9. Upper receiver weldment Removing the Clutch 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. g262017 Figure 55 1. Clutch cable 3.
Removing the Clutch Cable (continued) B. Remove the retaining ring (4) that secures the clutch cable eyelet (3) to the clutch lever (5) and slide and remove the clutch cable eyelet from the clutch lever. 4. Remove the control cover and lower cover from the handle assembly to allow access to upper end of the clutch cable (item 1 in Figure 54). 5. Remove the clutch cable (1) from the link assembly (7) as follows: A.
Replacing the Reel Cable g262019 Figure 56 1. Reel cable 6. V-ring seal 11. Clevis pin 2. Jam nut 7. Reel lever assembly 12. Upper receiver weldment 3. Cable spring 8. Cotter pin clip 13. Retaining ring 4. Knob 9. Split bushing 5. Reel lever handle rod 10. Clevis connector Removing the Reel Cable Note: Refer to Figure 56 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.
Removing the Reel Cable (continued) g262054 Figure 57 1. Retaining ring 3. Jam nut 2. Reel selector assembly 4. Reel cable 3. Remove the reel cable (item 4 in Figure 57) from the reel selector assembly (2) as follows: A. Loosen the front cable jam nut (3) and lift the reel cable (4) from the casting slot of the engine base. B. Remove the retaining ring (1) that secures the reel cable eyelet to the reel selector assembly (2) and slide the reel cable eyelet from the selector assembly. 4.
Installing the Reel Cable 1. Secure the reel cable (item 1 in Figure 56) to the traction lever assembly as follows: A. Install the cable spring (3) to the clevis connector (10) on the reel lever assembly (7). Orientate the cable spring hook end toward front of the machine. B. Slide the cable (1) into the upper receiver weldment (12). 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.
Clutch and Reel Drive Engagement Lever Assembly g260277 Figure 58 1. V-ring seal 10. Lower handle cover 19. Clevis connector 2. Reel lever handle rod 11. Reel cable 20. Clevis pin (4 each) 3. Knob 12. Clutch cable 21. Extension spring 4. Retaining ring 13. Cotter pin clip 22. Shoulder screw 5. Control shaft clamp (2 each) 14. Link assembly 23. Reel lock lever assembly 6. Socket head screw (4 each) 15. Main control shaft 24. Bail latch spacer 7.
Disassembling the Clutch and Reel Drive Engagement Lever Assembly (continued) 3. Remove the bolts and washers (item 9 in Figure 58) that secures the controls covers (item 8 and 10) to the upper receiver weldment (25) and handle assembly. 4. Remove the reel lever handle rod (2) from the reel lever assembly (27). 5. If necessary, remove the reel lever knob (3) from the reel lever handle (2). 6. Remove the cotter pin (18) and clevis pin (20) that secures the link assembly (14) to the main control shaft (15).
Brake Latch Shaft g260416 Figure 59 1. Shoulder bolt 7. Flange bushing (2 each) 2. Flange bushing (2 each) 8. Flange nut 3. 4. Lever Brake lock lever 9. 10. Brake latch shaft Torsion spring 5. Roll pin 11. Flange nut 6. Bolt 12. Upper receiver weldment Disassembling the Brake Latch Shaft Note: Refer to Figure 59 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.
Disassembling the Brake Latch Shaft (continued) 6. Slide and remove the brake latch shaft (9) from the upper receiver weldment (12). 7. Slide and remove the torsion spring (10) from the brake latch shaft (9). Assembling the Brake Latch Shaft 1. Slide and position the torsion spring (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).
Handle Assembly g260770 Figure 60 1. Plastite screw (4 each) 14. Nut 27. Lift assist handle 2. Notepad plate 15. Nut (4 each) 28. Jam nut 3. 4. 5. Handle Shoulder screw Flange bushing (2 each) 16. 17. 18. Bolt Brake cable Throttle cable 29. 30. 31. Bolt Bolt Compression spring 6. Lever 19. Lower handle 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.
Disassembling the Handle Assembly Note: Refer to Figure 60 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. 3. Remove the 4 bolts that secures the controls cover to the handle assembly. Remove the controls cover from the handle assembly. 4. Remove the 4 bolts that secures the lower handle cover to the handle assembly. Remove the lower handle cover. 5.
Disassembling the Handle Assembly (continued) 26. If necessary, remove the 3 nuts (15), 3 bolts (21) and 3 spacers (20) from the upper receiver weldment (8). g260771 Figure 61 1. LH bail bracket 8. 2. Bolt (2 each) 3. Flange bushing (4 each) 9. 4. 5. Flange nut (4 each) 15. Upper receiver weldment Cotter pin 16. Bolt (2 each) 10. Conduit clamp (2 each) 17. Spacer (2 each) Clutch bail assembly 11. Socket head screw (2 each) 18. Delta screw (2 each) Clutch bail link 12.
Disassembling the Handle Assembly (continued) 29. Remove the flange nut (item 8 in Figure 61), and bolt (2) that secure the clutch bail link (5) to the handle mount (7). Remove the 2 flange bushings (3) and spacer tube (17) from the handle mount. 30. Remove the flange nut (8) and bolt (2) that secure the clutch bail assembly (4) to the handle mount (7). Remove the clutch bail assembly from the handle mount. Remove the compression spring (6), 2 flange bushings (3) and spacer tube (17) from the handle mount.
Assembling the Handle Assembly (continued) 4. Position the clutch bail link (5) in the handle mount (7). Install the spacer tube (17) and 2 flange bushings (3) to the handle mount. Secure the clutch bail link to the handle mount with the bolt (2) and flange nut (8). 5. Position the compression spring (6), spacer tube (17) and 2 bushings (3) into the handle mount (7). Install the clutch bail assembly (4) to the handle mount (7) and secure with the bolt (2) and flange nut (8). 6.
Assembling the Handle Assembly (continued) 29. Install the throttle cable; refer to Installing the Throttle Cable (page 7–5). 30. Install the bottom controls cover and re-position the wire harness to 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.
Kickstand g260946 Figure 63 1. Lower handle assembly 7. Lock nut 13. Plain washer (2 each) 2. LH torsion spring 8. Dowel pin (4 each) 14. Spring retainer (2 each) 3. Spring mount pin 9. Frame assembly 15. 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.
Removing the Kickstand (continued) 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. Pivot the kickstand up and hold against the frame stops. 4. Remove the bolt (item 11 in Figure 63) that secures the spring mount pin (3) and torsion spring (2) to the kickstand (16). 5. Remove the spring mount pin (3) and torsion spring (2) from the kickstand (16). 6.
Installing the Kickstand (continued) 1. If removed, install the spacers (10) to the kickstand (16). 2. If removed, secure the spring retainer (14) to kickstand with the 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.
Transport Wheels (Optional) g200275 Figure 65 1. Bolt (3 each) 6. Deep rim 11. Hub bushing 2. Flange nut (4 each) 7. Hub 12. Bolt (4 each) 3. Shallow rim 8. Torsion spring 13. Lock washer (3 each) 9. Wheel retaining lever 4. Tire 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.
Removing the Transport Wheel (continued) g200276 Figure 66 1. Wheel retaining lever 3. Pivot the wheel retaining lever away from the center of the wheel. Slide the transport wheel off the wheel hex shaft. Disassembling the Transport Wheel g261682 Figure 67 1. Wheel hex shaft 1. Ensure that the tire is fully deflated before disassembly 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.
Assembling the Transport Wheel 1. If the shoulder screws were removed from the hub, apply Loctite #242 (or equivalent) to the threads of the shoulder screws. Secure the torsion spring and retaining lever to the hub with the shoulder screws. 2. Assemble the tire, tube, and deep rim. 3. Install the shallow rim into the tire. Align and secure the shallow rim tot he deep rim with 4 bolts and 4 flange nuts. Tighten the fasteners. 4. Install the hub into the deep rim.
Rail Kit Wheels (Optional) g261683 Figure 68 1. 2. 3. Wheel hex shaft Wheel clip Rail kit wheel Removing the Rail Kit 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 kickstand. 3. Remove the wheel clip, and remove the rail kit wheel from the 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.
Chapter 8 DPA Cutting Units Table of Contents General Information .............................................................................................................................. 8–2 Cutting Unit Operator's Manual .......................................................................................................... 8–2 Grass Basket Installation ...................................................................................................................
General Information Cutting Unit Operator's Manual The Cutting Unit Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for the cutting units on your machine. Additionally, if optional kits have been installed on the cutting units (e.g. groomer), the Installation Instructions for the kit includes set-up, operation and maintenance information.
Supporting the Cutting Unit when Servicing g261159 Figure 70 1. Bedbar adjuster screws 2. Support 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.
Adjustments DPA Cutting Unit Characteristics CAUTION Never install or work on or near a cutting unit or cutting unit suspension with the engine running. Always stop the engine and remove the key before working on or near a cutting unit. Note: When adjusting reel to bedknife or grinding/backlapping, cutting unit assembly must be attached to traction unit or frame fixture.
Grass Shield Height Adjustment g261274 Figure 71 1. Grass shield 3. Side plate 2. Bolt (2 each) 4. Support rod Adjust the grass shield to assure proper grass clipping discharge into the basket. 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. Place 1.5 mm (0.06 inch) shim between the reel assembly and grass shield.
Service and Repairs Bedbar Assembly g261369 Figure 72 1. Side plate 8. Bedbar bolt (2 each) 15. Plastic washer (2 each) 2. Keyed flanged bushing (4 each) 9. Lock nut (2 each) 16. Bedbar assembly 3. 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.
Removing the Bedbar Note: Refer to Figure 72 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. 3. Loosen the nuts (19) on the end of each bedbar adjuster assembly (3) until the washer (17) is loose. 4. Loosen the locknuts (9) on each bedbar bolt (8). 5.
Installing the Bedbar g226763 Figure 73 1. Side plate 5. Metal washer 2. Rubber bushing 6. Bedbar 3. Nylon bushing 7. Bedbar pivot bolt 4. Plastic washer (2 each) 8. Lock nut 1. If rubber bushing (item 4 in Figure 73) was removed from either side plate, apply grease to outside surface of new bushing and install into side plate (1). The bushing (4) should be installed flush with the inside surface of the side plate; refer to Figure 73. 2.
Installing the Bedbar (continued) 7. Install the bedbar bolt assemblies (8). Make sure that the washers are not caught on the threads of the pivot bolts. Torque tighten each bedbar bolt (8) from 22 to 27 N∙m (190 to 240 in-lb). IMPORTANT Do not over tighten the lock nuts as this can distort the side plates and affect reel bearing alignment. When the lock nut is correctly tightened, the inside washers may be loose. 8.
Servicing the Bedbar Adjuster Removing the Bedbar Adjuster g261412 Figure 74 1. Bedbar adjuster shaft (2 each) 5. Wave washer (2 each) 9. Washer (2 each) 2. Keyed flanged bushing (4 each) 6. Retaining ring (2 each) 10. Compression spring 3. Detent (2 each) 7. Bedbar adjuster screw (2 each) 11. Nut (2 each) 4. Bolt (2 each) 8. Bedbar assembly 12. Side plate Note: Refer to Figure 74 during this procedure. 1. Remove bedbar; refer to Removing the Bedbar (page 8–7). 2.
Installing the Bedbar Adjuster 1. If previously removed, secure the detent (3) to the side plate (12) with the bolt (4). 2. If previously removed, align the key on the flange bushings (2) to the slots in the cutting unit side plate (12) and install. 3. Slide adjuster shaft (1) into flange bushings (2) and secure with a wave washer (5) and a retaining ring (6). Note: The bedbar adjuster shaft (1) has left-hand threads. 4.
Bedknife Removing the Bedknife g227001 Figure 75 1. Bedknife screw (13 used) 2. Bedknife 3. Bedbar 1. Remove the bedbar from the cutting unit; refer to Removing the Bedbar (page 8–7). 2. Remove screws from bedbar using a socket wrench and bedknife screw tool; refer to Bedknife Screw Tool (page 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.
Installing the Bedknife (continued) IMPORTANT Do not use an impact wrench to tighten screws into the bedbar. 3. Use new screws to secure bedknife to bedbar. Apply anti-seize lubricant to the threads of new screws. Do not apply anti-seize 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.
Grinding the Bedknife Bedknife Grinding Specifications Standard Bedknife Relief Angle 3° minimum Fairway Bedknife Relief Angle 3° minimum Extended Bedknife Relief Angle 7° minimum Front Angle Range 13° to 17° g207289 Figure 77 1. Top angle 4. Front surface 2. Top surface 5. Front angle 3. Remove burr Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar.
Grinding the Bedknife (continued) IMPORTANT EdgeMax® bedknives are extremely hard. Using a diamond grinding wheel is recommended to prevent overheating or damaging the bedknife edge while grinding. Because the top grind angle on bedknives is critical for edge retention, and therefore after−cut appearance, Toro has developed special service tools for accurately measuring the top grind angle on all bedknives; refer to Angle Indicator and Magnetic Mount (page 2–16). 1.
Cutting Unit Assembly g261511 Figure 79 1. Cutting unit assembly 4. Dowel pin (4 each) 2. Reel drive assembly 5. Frame assembly 3. Socket head screw (4 each) Removing the Cutting Unit Assembly Note: Refer to Figure 79 during this procedure. 1. Park the machine on a level surface on the traction drum. 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.
Installing the Cutting Unit Assembly 1. If removed, install the dowel pins (4) into the frame assembly (5). 2. If removed, install the reel drive assembly (2) onto the cutting unit assembly (item 1); refer to Installing the Reel Drive Assembly (page 5–12). 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.
Reel Assembly g261490 Figure 80 1. Expansion plug 7. Seal (2 each) 13. Drive spline 2. Bearing lock screw 8. Reel assembly 14. Frame support rod Frame support rod 15. Washer (2 each) 10. RH side plate 16. Bolt (2 each) Flat wire spring 11. Reel drive nut 17. Socket head screw (2 each) Sealed bearing (2 each) 12. V ring seal 18. Grass shield assembly 3. Socket head screw (2 each) 4. LH side plate 5. 6. 9.
Removing the Reel Assembly (continued) IMPORTANT If the reel bearings or seals are being replaced, the bearing lock screw and the reel drive shaft must be removed. Use the following procedure to restrain the reel and loosen the components before removing the rollers. g330864 Figure 81 1. Bearing lock screw 3. Support plate, weld side 2. Reel shaft 4. Pry bar 6. Loosen the reel drive nut (11) and bearing lock nut (2). A. Tip up the cutting unit to access the bottom of the reel. B.
Removing the Reel Assembly (continued) IMPORTANT Do not use 1/2” extension on end of reel drive shaft when loosening or tightening drive shaft. The 1/2” hex is intended for back lapping only. E. Position the pry bar in the same manner on the opposite end of the reel and use the appropriate wrench or socket on the 1” hex portion of the shaft to loosen the reel drive shaft. F. Tip the cutting unit back onto its rollers. 7. Remove the bedbar; refer to Removing the Bedbar (page 8–7). 8.
Inspecting the Reel Assembly g287676 Figure 82 1. Cutting reel 5. Reel nut (black – left hand thread) 2. Flocked seal (2 each) 6. Groove indication left hand threads 3. Bearing (2 each) 7. Left-most reel spider 4. reel nut (right hand thread) 8. Bearing shoulder 1. 2. Remove the reel nuts from the cutting reel. Slide the bearings and seals from the reel shaft. Discard the seals and inspect the reel bearings to insure that they spin freely and have a minimal amount of axial play. 3.
Inspecting the Reel Assembly (continued) Note: The reel nut on the left end of the cutting reel has a black finish and has left-hand threads. The left end of the cutting reel shaft is identified with a groove cut just inside of the left-most reel spider. Tighten the reel nuts to the specified torque once the cutting reel is installed in the cutting unit. 6. Install the reel nuts finger tight. Installing the Reel Assembly 1. Position the cutting unit on a flat work area.
Installing the Reel Assembly (continued) IMPORTANT To avoid grinding the reel, do not contact the cutting edge of any blade with the pry bar as this may damage the cutting edge and/or cause a high blade. B. Move the pry bar against the weld side of the reel support plate closest to the bearing lock screw. IMPORTANT The reel drive shaft on the left end of the cutting reel has left hand threads. The bearing lock screw on the right end of the cutting reel has right- hand threads. C.
Preparing the Reel for Grinding Reel Grinding Specifications Reel Diameter New (D) 128.5 mm (5.06 inch) Reel Diameter Service Limit 114.3 mm (4.50 inch) Reel Diameter Taper Limit (D1 – D2) 0.25 mm (0.01 inch) Blade Land Width 0.8 to 1.2 mm (0.03 to 0.05 inch) Blade Relief Angle 30° ±2° Reel Shaft Diameter 34.9 mm (1.375 inch) g227307 Figure 84 (R = Direction of Rotation) Before grinding a cutting reel, make sure that all the cutting unit components are in good condition.
Preparing the Reel for Grinding (continued) Note: Always adjust the cutting unit after grinding the reel and/or bedknife; refer to the Cutting Unit 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.
Roller Assemblies Removing the Front Roller g261580 Figure 85 1. Plow bolt (2 each) 6. Lock nut (2 each) 2. Socket head screw (4 each) 7. Height-of-cut washer (2 each) 3. Front roller assembly 8. Pinch bolt (2 each) 4. Mounting rod (2 each) 9. Height-of-cut screw (2 each) 5. Height-of-cut arm (2 each) 10. Cutting unit assembly Note: Refer to Figure 85 during this procedure. 1. Loosen the pinch bolts (8) that secure the front roller shaft (3) to the front height-of-cut arms (5). 2.
Disassembling the Roller g261615 Figure 86 1. Bearing lock nut (2 each) 3. Ball bearing (2 each) 2. Sealing washer (2 each) 4. Wiehle roller 5. Roller shaft 1. To hold the roller shaft (5) stationary while removing the bearing lock nut (1), install a 3/8-24 UNF 2B screw with a jam nut into the threaded end of the roller shaft (5) and tighten the jam nut against the roller shaft. Remove the bearing lock nuts (1). 2.
Assembling the Roller g261670 Figure 87 1. Roller 4. Bearing lock nut 2. Ball bearing 5. Roller shaft 3. Seal g261681 Figure 88 1. Bearing 2. Seal 3. Bearing lock nut 1. Press the bearing into the roller (support both inner and outer raceways). 2. Place the roller shaft into the roller. 3. Press the 2nd bearing into the roller (support both). 4. Install the sealing washer and bearing lock nut onto each end of the roller shaft. Tighten the lock nuts to 34 to 41 N∙m (25 to 30 ft-lb).
Installing the Front Roller (continued) 5. Slide the remaining height-of-cut arm (5) onto the other end of roller shaft. Secure the remaining height-of-cut arm to the side plate with a plow bolt (2), height-of-cut washer and lock nut. 6. Center 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.
DPA Cutting Units: Service and Repairs Page 8–30 Greensmaster® 1018/1021/1026 18238SL Rev C
Chapter 9 Universal Groomer (Optional) Table of Contents General Information .............................................................................................................................. 9–2 Installation Instructions ...................................................................................................................... 9–2 Grooming Performance......................................................................................................................
General Information Installation Instructions The Installation Instructions for the groomer provides information regarding the set-up, operation, general maintenance procedures, and maintenance intervals for the groomer assembly on your Greensmaster machine. Refer to the Installation Instructions for additional information when servicing the groomer assembly. Grooming Performance There are a number of factors that can affect the performance of grooming.
Service and Repairs g282166 Figure 89 1. Gear box assembly 3. Groomer reel 2. Idler assembly 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.
The Gear Box Assembly g287374 Figure 90 1. Gear box assembly 4. Clevis pin 2. Drive shield 5. Input shaft 3. Cotter pin 6. Shim 7. Adapter The groomer gear box assembly is located on the opposite side of the cutting unit from the reel drive. Removing the Gear Box Assembly 1. Remove the groomer reel assembly; refer to Removing the Groomer Reel (page 9–14). 2. Safely prevent the reel from rotating by blocking the cutting reel with a piece of wood near one of the reel spiders.
Removing the Gear Box Assembly (continued) 3. Remove the drive shield. g330867 Figure 91 1. 5/16–18 X 5/8 inch square head set screw 4. Reel shaft 2. Input shaft assembly 5. Weld side of reel support plate 3. Groomer gear box assembly 6. Pry bar 4. Install a 5/16–18 X 5/8 inch square head set screw (Toro p/n 1-803022) in the end of the drive shaft and tighten to 13 N·m (120 in-lb); refer to Figure 91. 5.
Removing the Gear Box Assembly (continued) 9. Rest the handle of the pry bar against the front roller and turn the drive shaft counterclockwise to loosen it from the reel. Continue to unscrew the drive shaft and remove the gear box from the cutting unit. g330869 Figure 92 1. Socket head screw (4 each) 2. Gear box cover assembly 3. Cover gasket 8. Sun gear 9. Planet gear (3 each) 10. Flange bushing (3 each) 4. Driven gear 11. Retaining ring 5. Thrust washer 12.
Removing the Gear Box Assembly (continued) g330868 Figure 93 H. Insert a long-handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bottom of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move. I. Move the pry bar against the weld side of the reel support plate closest to the drive shaft assembly. J.
Servicing the Gear Box g251182 Figure 94 1. Drive adapter 15. Thrust washer 29. Ring gear 2. Input shaft 16. O-ring 30. Flange bushing 3. O-ring (3 each) 17. O-ring 31. Sun gear 4. V-ring 18. Dowel pin (2 each) 32. Bearing 5. Oil seal 19. Drain/fill plug (4 each) 33. Planet gear (3 each) 6. Groomer housing 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.
Servicing the Gear Box (continued) Note: Refer to Figure 94 during this procedure. 1. Remove the drain/fill plug and drain the oil from the gear box. 2. Remove the 4 socket-head screws and separate the gear box cover and housing. Remove and discard the cover gasket. 3. Slide the sun gear, ring gear, and planet gears from the pins on the gear box housing. 4. Continue to disassemble the gear box as necessary.
Installing the Gear Box Assembly 1. 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 counter-clockwise to install the gear box. 2. Insert a long-handled pry bar through the front of the cutting unit.
Installing the Gear Box Assembly (continued) 9. Install the groomer reel assembly; refer to Installing the Groomer Reel (page 9–16).
The Idler Assembly g282209 Figure 96 1. Cotter pin 6. Shield 2. Flange nut 7. Retaining ring 3. Flocked seal (2 each) 8. Bearing 4. Bushing 9. Idler arm 5. Stub shaft 10. Clevis pin The groomer idler assembly is located on the opposite side of the groomer gear box. Removing the Idler Assembly Note: Refer to during this procedure. 1. Remove the reel drive from the cutting unit; refer to Removing the Reel Assembly (page 8–18). 2.
Installing the Idler Assembly 1. If the shields, bearing, or bushing was removed from the idler arm: A. Press the bushing into a groomer plate until the bushing is centered in the idler arm bore. B. Press the bearing into the idler arm so that the bearing contacts the shoulder in idler arm bore and install the bearing retaining ring. C. Install the bearing shields with the flocked side of the shield toward the bearing. D. Insert the stub shaft through the shields and bearing.
The Groomer Reel g282210 Figure 97 1. Shaft clamp (4 each) 3. Bolt (4 each) 2. Jam nut (4 each) 4. Groomer reel Remove the groomer reel to replace individual groomer blades or replace the shaft. The groomer reel can be reversed to provide additional blade life. Removing the Groomer Reel CAUTION Contact with the reel or other cutting unit parts can result in personal injury. Use heavy gloves when handling the groomer reel. 1.
Servicing the Groomer Reel g282211 Figure 98 1. Groomer reel shaft 3. Spacer (50 each) 2. Groomer blade (51 each) 4. Locknut (2 each) Inspect the groomer reel blades frequently for any damage and wear. Straighten the bent blades. Either replace the worn blades or reverse the individual blades to put the sharpest blade edge forward: refer to Figure 98. 1. Remove the groomer reel from the cutting unit; refer to Removing the Groomer Reel (page 9–14). 2.
Servicing the Groomer Reel (continued) D. When all the blades have been installed, install the second lock nut onto the shaft. Center the blades and spacers on the shaft by adjusting the lock nuts. E. Use the through holes in shaft to prevent the shaft from rotating and tighten the second lock nut to 42 to 48 N∙m (375 to 425 in-lb). After tightening the lock nut, spacers should not be free to rotate and the groomer blades should be centered on the shaft. 6.
The Height Adjuster Assembly g282214 Figure 99 1. Cotter pin 7. Compression spring 13. Quick up cover 2. Clevis pin 8. Bumper 14. Detent spring 3. Height adjustment rod Lock nut 15. Button-head screw 4. Flange nut 10. 9. Pinch bolt 16. Height adjuster knob 5. Washer (2 each) 11. Height-of-cut bracket 17. Height adjustment bolt 6. Compression spring 12. Quick up lever 18.
Disassembling the Height Adjuster (continued) 4. Remove the hex nuts and plow bolts that secure the height-of-cut brackets to the cutting unit side plates, and remove the height adjusters and front roller from the cutting unit. 5. Disassemble the height adjuster assembly as necessary. 6. Replace components that are worn or damaged. Assembling the Height Adjuster 1. Apply anti-seize lubricant to the upper threads of the adjustment rod and lower threads of the height adjusters.
The Grooming Brush (Optional) g229629 Figure 101 1. Spiral brush 4. Lock nut (2 each) 2. Brush shaft 5. Grooming brush 3. J-bolt (2 each) 6. Roll pin (2 each) The optional grooming brush attaches to the groomer in place of the groomer reel. The grooming brush is removed and installed from the groomer in the same manner as the groomer reel; refer to The Groomer Reel (page 9–14). The grooming brush element or shaft can be serviced separately.
