Page 1 Form No. 20247SL Rev A Greensmaster ® Flex 1018/1021 (Models 04850 and 04860) © 2020—The Toro® Company Original Instructions (EN) 8111 Lyndale Avenue South Contact us at www.Toro.com. Bloomington, MN 55420 All Rights Reserved...
Page 2 Revision History Revision Date Description Initial issue. 02/2020 Revision History Page 2 Greensmaster ® Flex 1018/1021 20247SL Rev A...
Page 3 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail servicemanuals@toro.com...
Page 4 NOTES NOTES Page 4 Greensmaster ® Flex 1018/1021 20247SL Rev A...
Page 5 Service Manual for reference. Additional copies of the Operator’s Manuals, Installation Instructions and Parts Catalogs are available at www.toro.com. The Toro Company reserves the right to change the product specifications or this publication without notice. DANGER This safety symbol means danger.
Page 6 g311923 Figure 1 Preface Page 6 Greensmaster ® Flex 1018/1021 20247SL Rev A...
Page 7 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.
Page 8 Table of Contents Preface ........................ 5 Chapter 1: Safety .................... 1–1 Safety Instructions ..................1–2 Safety and Instructional Decals ..............1–6 Chapter 2: Specifications and Maintenance ............ 2–1 Specifications ....................2–2 Torque Specifications ................... 2–6 Shop Supplies .................... 2–12 Special Tools ....................2–14 Chapter 3: Troubleshooting ................
Page 9 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........................1–5 Safety and Instructional Decals ......................1–6 Greensmaster ® Flex 1018/1021 Page 1–1 Safety 20247SL Rev A...
Page 10 Safety Instructions The Greensmaster Flex 1018/1021 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.
Page 11 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.
Page 12 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.
Page 13 At the time of manufacture, the machine confirmed to all applicable safety standards. To assure optimum performance and continued safety certification of the machine, use genuine Toro replacement parts and accessories. Replacement of parts and accessories made by other manufacturers may result in non-conformance with the safety standards and can void the warranty.
Page 14 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. Safety: Safety and Instructional Decals Page 1–6 Greensmaster ®...
Page 15 Chapter 2 Specifications and Maintenance Table of Contents Specifications ............................2–2 Overall Dimensions..........................2–2 Engine..............................2–3 Traction and Reel Drive Systems ....................... 2–4 Controls, Wheels and Accessories ....................2–4 DPA Cutting Units ..........................2–4 Universal Groomer..........................2–5 Torque Specifications ........................... 2–6 Calculating the Torque Values When Using a Drive-Adapter Wrench ..........
Page 16 Specifications Overall Dimensions g312133 Figure 2 Specifications and Maintenance: Specifications Page 2–2 Greensmaster ® Flex 1018/1021 20247SL Rev A...
Page 17 Engine g238094 Figure 3 Fuel tank Recoil starter Spark plug Air cleaner Recoil-start handle 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 cm (7.2 in Compression ratio...
Page 18 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 (7.5 inch) diameter Cutting Reel Drive...
Page 19 35 kg (77 lbs) 14 blade 35 kg (77 lbs) 36.3 kg (80 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 (2.375 inch)
Page 20 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.
Page 21 Calculating the Torque Values When Using a Drive-Adapter Wrench g205924 Figure 4 Torque Conversion Factor = A / B Torque wrench A (effective length of torque wrench) Drive-adapter wrench (crowsfoot) B (effective length of torque wrench and drive-adapter wrench) Using a drive-adapter wrench (e.g., crowfoot wrench) in any position other than 90°...
Page 22 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 a locking feature; apply a thread locking compound (Loctite for example) to the fastener during installation.
Page 23 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, and 8 with Studs, and Sems with Studs, and Sems with Studs, and Sems with Thin Height Regular Height Nuts...
Page 24 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Class 10.9 Bolts, Screws, and Thread Size Studs with Regular Height Nuts Studs with Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8 57 ±...
Page 25 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 ±...
Page 26 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.
Page 27 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.
Page 28 This excess current can damage the circuits that are not designed to carry it. Dielectric Gel Toro Part No. 107-0342 Use the dielectric gel to prevent corrosion of unsealed connection terminals. To ensure complete coating of the...
Page 29 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 K Line Part No.
Page 30 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.
Page 31 Bedknife Screw Tool K-Line Part No. TOR510880A 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.
Page 32 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.
Page 33: Table Of Contents
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.......................... 3–2 Repair ..............................3–2 Solution Confirmation......................... 3–2 Starting Problems ..........................3–3 Aftercut Appearance..........................
Page 34: Gears - The Systematic Approach To Defining, Diagnosing And Solving Problems
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 •...
Page 35: Starting Problems
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.
Page 36: Aftercut Appearance
Note: For additional information regarding cutting unit troubleshooting, a number of Reel Mower and Aftercut Appearance General Training Books can be found on the Service Reference Set available from your Authorized Toro Distributor. Factors That Can Affect Quality of Cut...
Page 37: Factors Affecting Grooming
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.
Page 38 Grooming Reel Mechanical Problems Problem Possible Causes Correction No rotation of the grooming Groomer drive gears are worn Inspect groomer drive reel. or damaged. assembly and replace damaged drive components. The turf is damaged or has The groomer is set too Refer to groomer Installation uneven grooming.
Page 39 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 ........................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..........................
Page 40: General Information
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.
Page 41: Fuel Evaporative Control System
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.
Page 42: Adjustments
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.
Page 43: Service And Repairs
Service and Repairs Cooling System g258391 Figure 10 Engine cylinder shroud 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.
Page 44 Cooling System (continued) g258392 Figure 11 Blower housing 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.
Page 45: 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.
Page 46: Engine
Engine g255888 Figure 13 Bolts (2 each) Carriage bolts (4 each) Lock nuts (2 each) Transmission gear box Muffler guard Clutch cover Nuts (4 each) Bolt (4 each) Bolt (2 each) Flat washer (4 each) Washer (4 each) Engine Engine base Clutch hub clamp Bolt (2 each) Removing the Engine...
Page 47 Removing the Engine (continued) g261801 Figure 14 Governor lever Cable clamp Throttle cable 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.
Page 48 Removing the Engine (continued) g262386 Figure 15 Armature wire Alternator wire 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 the engine by removing the LH rear cap screw, flat washer and a flange nut.
Page 49 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.
Page 50: Engine Base
Engine Base g256199 Figure 16 Engine base Flat washer (2 each) Flat head bolt (5 each) Slider adapter Frame assembly Transmission gear box assembly Jam nut Bolt Flat head nut Tube clamp Jack screw Removing the Engine Base Note: Refer to Figure 16 during this procedure.
Page 51 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 washer that secures the 2 splined couplers to the transmission gear box assembly and drum drive gear box assembly.
Page 52 Removing the Engine Base (continued) g256200 Figure 17 Flat head nut Washer (3 each) Compression spring Long reel lever Carriage bolt Reel selector hub Straight bushing Engine mount bracket Retaining ring Short reel lever Bolt Reel selector shaft Flat head bolt Cable guide Extension spring Washer...
Page 53 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).
Page 54 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.
Page 55 Chapter 5 Traction and Reel Drive Systems Table of Contents General Information ..........................5–2 Disengaging The Drum Drive From Transmission................5–2 Adjustments ............................5–3 Adjusting the Reel Drive Belt......................5–3 Service and Repairs ..........................5–5 Reel Drive Belt ........................... 5–5 Reel Drive Assembly..........................
Page 56: General Information
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 Transmission gear box assembly Traction engage/disengage lever The traction drum is driven by series of spur gears inside the transmission gear box assembly.
Page 57: Adjustments
Adjustments g312311 Figure 20 Reel drive box assembly Carriage Bolt Socket head screw (4 each) Reel belt Gasket Idler arm Reel drive cover 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.
Page 58 Adjusting the Reel Drive Belt (continued) 4. Adjust belt (2) tension 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) and tighten the nut of carriage bolt (4).
Page 59: Service And Repairs
Service and Repairs Reel Drive Belt g312311 Figure 21 Reel drive box assembly Carriage Bolt Socket head screw (4 each) Reel belt Gasket Idler arm Reel drive cover The greensmaster machines use a positive drive belt on the right side of the machine to operate the cutting unit.
Page 60 Removing the Reel Drive Belt (continued) 5. Remove the reel drive belt (2) from the pulleys. Installing the Reel Drive Belt 1. Ensure that the carriage bolt (4) is loose enough to move the idler arm (3) freely. 2. Place the new drive belt (2) onto the pulleys. 3.
Page 61: Reel Drive Assembly
Reel Drive Assembly g312399 Figure 22 Expansion plug Hipro key Reel drive cover Reel shaft-driver Washer Reel drive gasket Helical coupling Reel drive housing Retaining ring Spring pin (2 each) Socket head screw (2 each) Ball bearing (2 each) Coupler shaft Reel pulley - 24 tooth Carriage bolt Snap ring...
Page 62 Removing the Reel Drive Assembly (continued) 3. Remove the reel drive belt; refer to Removing the Reel Drive Assembly (page 5–7). 4. Remove and discard the reel drive gasket (3) from the housing (25). 5. If necessary remove the expansion plug (1) from the reel drive cover (2). 6.
Page 63 Installing the Reel Drive Assembly Note: Refer to Figure 22 during the procedure. 1. Use a press to install the 4 ball bearings (items 2 and 5 in Figure 23) into the reel drive housing (6). 2. Secure the ball bearings with 2 retaining rings (item 3 and 4 in Figure into the reel drive housing (6).
Page 64 Installing the Reel Drive Assembly (continued) 24. Adjust the reel drive belt; refer to Adjusting the Reel Drive Belt (page 5–3). 25. Install the cutting unit onto the machine; refer to the Operator’s Manual. 26. Attach the spark plug wire to the spark plug. Traction and Reel Drive Systems: Service and Repairs Page 5–10 Greensmaster...
Page 65: Drum Drive Gear Box Assembly
Drum Drive Gear Box Assembly g258813 Figure 25 Transmission gear box assembly Lock nut Frame assembly Traction drum Shoulder bolt (3 each) Shoulder bolt Splined coupler (2 each) RH hex shaft Truss screw Washer Drum drive gear box assembly Removing the Drum Drive Gear Box Assembly Note: Refer to Figure 25 during this procedure.
Page 66 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.
Page 67 Disassembly of Drum Drive Gear Box Assembly g258844 Figure 26 Oil seal Drum drive housing Washer Drum drive cover Retaining ring Outer drum hub Socket head screw (5 each) Oil seal V-ring seal Plug (2 each) Retaining ring Drum drive shaft Flange nut O-ring Ball bearing (2 each)
Page 68 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.
Page 69 Assembly of Drum Drive Gear Box Assembly g263151 Figure 27 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.
Page 70 Assembly of Drum Drive Gear Box Assembly (continued) 12. Torque tighten the hollow plugs (16) from 12.4 to 14.6 N·m (110 to 130 in-lb). 13. Install the gasket (8) to the drum drive housing. 14. Install the drum drive cover (14) to the drum drive housing (25) and secure with 5 socket head screws (15).
Page 71: Drum Assembly
Drum Assembly g258878 Figure 28 Transmission gear box assembly Lock nut (2 each) Frame assembly Traction drum Shoulder bolt (6 each) Shoulder bolt (2 each) Splined coupler (4 each) RH hex shaft Truss screw Washer (4 each) Drum drive gear box assembly (2 LH hex shaft each) Removing the Drum Assembly...
Page 72 Disassembly of Drum Drive Assembly g258879 Figure 29 Traction drum (2 each) Drum spindle Spacer Bolt (8 each) Seal (2 each) Drum hub Lock washer (8 each) Ball bearing (2 each) Shoulder bolt (6 each) Drum hub plate (2 each) Spacer Lock nut Note: Refer to...
Page 73 Assembly of Drum Drive Assembly g258942 Figure 30 Drum hub Spacer Ball bearing (2 each) Spacer Drum spindle Lock nut Seal (2 each) Note: The seal side of each bearing (item 7 in Figure 30) should face inside of the drum hub; refer to Figure 1.
Page 74 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 and traction drum (2) onto the frame assembly (9).
Page 75: Clutch Bearing
Clutch Bearing g259013 Figure 31 Bolt (2 each) Self aligning sealed bearing Fork shaft Clutch hub clamp Flange bush (2 each) Bell housing External clutch hub Clutch cover Engine base Retaining ring Bolt (2 each) Transmission gear box assembly Clutch disc Retaining ring (2 each) Bolt (2 each) Friction plate...
Page 76 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).
Page 77 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 6.7 to 9 N∙m (60 to 80 in-lb). 14. Attach the spark plug wire to the spark plug. Greensmaster ®...
Page 78: Transmission Gear Box Assembly
Transmission Gear Box Assembly g312756 Figure 32 Truss screw (3 each) Slide adaptor Coupler shaft Splined coupler (6 each) Jam nut Compression Spring Washer (3 each) Bolt (2 each) Collar lock Lock nut (3 each) Transmission gear box assembly Hex tube Drive shaft Helical coupling Engine base...
Page 79 Removing the Transmission Gear Box Assembly (continued) 7. 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. 8. Remove the 2 bolts that secures the clutch cover. Remove the clutch cover. 9.
Page 80 Disassembling the Transmission Gear Box Assembly g259588 Figure 33 Retaining ring Grease seal Brake mount pin Spacer bushing Ball bearing (2 each) Transmission gasket O-ring Spacer Transmission cover Straight bushing (2 each) Oil seal (2 each) Socket head screw (12 each) Retaining ring (2 each) Oil seal Ball bearing (2 each)
Page 81 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 34 External retaining ring...
Page 82 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.
Page 83 Disassembling the Transmission Gear Box Assembly (continued) g259589 Figure 35 Short bearing pin Flange nut (2 each) Reel clutch shoe O-ring Wave spring Reel clutch actuator Long bearing pin Ball bearing (2 each) Spur gear Thin lock nut Bearing spacer (2 each) Retaining ring (2 each) Retaining ring (4 each) Reel drive shaft...
Page 84 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).
Page 85 Assembling the Transmission Gear Box Assembly g259789 Figure 36 Ball bearing (2 each) Grease seal Spacer Straight bushing (2 each) 1. Use a press to install the spacer (item 13 in Figure 33) and new ball bearings (12 and 25) into the transmission housing (26). 2.
Page 86 Assembling the Transmission Gear Box Assembly (continued) g259956 Figure 37 Sleeve bushing Press flush Oil seal 7. Insert the sleeve bushing (Item 16 in Figure 33) into the transmission housing (26) until the sleeve bushing is flush with the transmission housing; refer Figure 8.
Page 87 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 35) into the spur gear (7) and secure with the 2 retaining rings (5).
Page 88 Assembling the Transmission Gear Box Assembly (continued) 25. Slide and install the brake lever assembly (item 19 in Figure 34) 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 34) and place the flat wire spring (22) onto the transmission housing assembly.
Page 89 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 46. Install the new transmission gasket (item 22 in Figure 33) and transmission cover assembly (23) onto the transmission housing (26) by aligning the holes.
Page 90: Differential Assembly
Differential Assembly g259590 Figure 39 External retaining ring O-ring (2 each) Brake lever Fitting plug Retaining ring (2 each) O-ring Wave washer Flange bearing (2 each) Brake clevis pin Ball bearing (2 each) Ball bearing (2 each) Flat wire spring Neutral spur gear Differential assembly Transmission housing assembly...
Page 91 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).
Page 92 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 41 Differential spur gears with shoulder up 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;...
Page 93 Chapter 6 Electrical System Table of Contents General Information ..........................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 (For backlap kit only) ..................... 6–10 Lighting Coil ............................. 6–11 Greensmaster ®...
Page 94: General Information
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. Electrical System: General Information Page 6–2 Greensmaster ®...
Page 95: Wiring Schematic
Wiring Schematic g268165 Figure 42 Greensmaster ® Flex 1018/1021 Page 6–3 Electrical System: Wiring Schematic 20247SL Rev A...
Page 96: Component Testing
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.
Page 97: Ignition System Operation
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.
Page 98: On/Off Switch
ON/OFF Switch g262080 Figure 43 Handle assembly On/Off switch 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.
Page 99 Testing the ON/OFF switch (continued) SWITCH POSITION NORMAL CIRCUITS OTHER CIRCUITS 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 ®...
Page 100: Hour Meter
Hour Meter g262085 Figure 45 Hour meter Handle assembly Controls cover 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.
Page 101 Testing the Hour Meter (continued) g238110 Figure 46 Hourglass icon Positive terminal (Y) Negative terminal (BK) 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.
Page 102: Interlock Module (For Backlap Kit Only)
Interlock Module (For backlap kit only) g262116 Figure 47 Bolt (2 each) Handle assembly Interlock module 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.
Page 103: Lighting Coil
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.
Page 104 Electrical System: Component Testing Page 6–12 Greensmaster ® Flex 1018/1021 20247SL Rev A...
Page 105 Chapter 7 Controls, Wheels and Accessories Table of Contents General Information ..........................7–2 Operator’s Manual ..........................7–2 Service and Repairs ..........................7–3 Replacing the Throttle Cable ......................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 ...............
Page 106: General Information
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. Controls, Wheels and Accessories : General Information Page 7–2 Greensmaster ®...
Page 107: Service And Repairs
Service and Repairs Replacing the Throttle Cable g261770 Figure 48 Upper receiver weldment Compression spring Throttle arm Lock nut (2 each) Bolt Flange nut Throttle cable Throttle lever Handle assembly Bolt Flange bushing (2 each) Washer Removing the Throttle Cable Note: Refer to Figure 48 during this procedure.
Page 108 Removing the Throttle Cable (continued) g261801 Figure 49 Governor lever Cable clamp Throttle cable High speed screw 2. Remove the throttle cable (item 2 in Figure 49) 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).
Page 109 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.
Page 110: Replacing The Brake Cable
Replacing the Brake Cable g261822 Figure 50 Upper receiver weldment Brake cable spring Shoulder screw Flange bushing (2 each) Flange nut Jam nut Lever Handle assembly Brake cable Removing the Brake Cable Note: Refer to Figure 50 during this procedure. 1.
Page 111 Removing the Brake Cable (continued) g261858 Figure 51 Retaining ring Brake lever Brake cable Cable eyelet Jam nut 3. Remove the brake cable (item 5 in Figure 51) from the brake lever shaft on the transmission gear box assembly as follows: A.
Page 112 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.
Page 113: Replacing The Clutch Cable
Replacing the Clutch Cable g261995 Figure 52 Clutch cable Split bushing Link assembly Jam nut Main control shaft Clip pin Cable spring Clevis pin Upper receiver weldment Removing the Clutch 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.
Page 114 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 52).
Page 115: Replacing The Reel Cable
Replacing the Reel Cable g262019 Figure 54 Reel cable V-ring seal Clevis pin Jam nut Reel lever assembly Upper receiver weldment Cable spring Cotter pin clip Retaining ring Knob Split bushing Reel lever handle rod Clevis connector Removing the Reel Cable Note: Refer to Figure 54 during this procedure.
Page 116 Removing the Reel Cable (continued) g262054 Figure 55 Retaining ring Jam nut Reel selector assembly Reel cable 3. Remove the reel cable (item 4 in Figure 55) 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.
Page 117 Installing the Reel Cable 1. Secure the reel cable (item 1 in Figure 54) 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.
Page 118: Clutch And Reel Drive Engagement Lever Assembly
Clutch and Reel Drive Engagement Lever Assembly g260277 Figure 56 V-ring seal Lower handle cover Clevis connector Reel lever handle rod Reel cable Clevis pin (4 each) Knob Clutch cable Extension spring Retaining ring Cotter pin clip Shoulder screw Control shaft clamp (2 each) Link assembly Reel lock lever assembly Socket head screw (4 each)
Page 119 Disassembling the Clutch and Reel Drive Engagement Lever Assembly (continued) 3. Remove the bolts and washers (item 9 in Figure 56) 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.
Page 120: Brake Latch Shaft
Brake Latch Shaft g260416 Figure 57 Shoulder bolt Roll pin Brake latch shaft Bolt Torsion spring Flange bushing (2 each) Lever Flange bushing (2 each) Flange nut Brake lock lever Flange nut Upper receiver weldment Disassembling the Brake Latch Shaft Note: Refer to Figure 57 during this procedure.
Page 121 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.
Page 122: Handle Assembly
Handle Assembly g260770 Figure 58 Plastite screw (4 each) Lift assist handle Notepad plate Nut (4 each) Jam nut Handle Bolt Bolt Shoulder screw Brake cable Bolt Flange bushing (2 each) Throttle cable Compression spring Lever Lower handle assembly Bolt Flange nut (4 each) Spacer (3 each) Bolt (2 each)
Page 123 Disassembling the Handle Assembly Note: Refer to Figure 58 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.
Page 124 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 59 LH bail bracket Flange nut (4 each) Upper receiver weldment Bolt (2 each) Cotter pin Bolt (2 each) Flange bushing (4 each)
Page 125 Disassembling the Handle Assembly (continued) 29. Remove the flange nut (item 8 in Figure 59), 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.
Page 126 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.
Page 127 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.
Page 128: Kickstand
Kickstand g260946 Figure 61 Lower handle assembly Lock nut Plain washer (2 each) LH torsion spring Dowel pin (4 each) Spring retainer (2 each) Spring mount pin Frame assembly Nut (2 each) Bolt Spacer (2 each) Kickstand Bolt (2 each) Flat washer (2 each) Bolt (2 each) Removing the Kickstand...
Page 129 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.
Page 130 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).
Page 131: Transport Wheels (Optional)
Transport Wheels (Optional) g200275 Figure 63 Bolt (3 each) Deep rim Hub bushing Flange nut (4 each) Bolt (4 each) Shallow rim Torsion spring Lock washer (3 each) Tire Wheel retaining lever Inner tube Shoulder screw (2 each) Removing the Transport Wheel 1.
Page 132 Removing the Transport Wheel (continued) g200276 Figure 64 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 65 Wheel hex shaft 1.
Page 133 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.
Page 134: Rail Kit Wheels (Optional)
Rail Kit Wheels (Optional) g261683 Figure 66 Wheel hex shaft Rail kit wheel Wheel clip 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.
Page 135: Flex Frame Assembly
Flex Frame Assembly g313494 Figure 67 Machine assembly Socket head screws (4 each) Flex frame assembly Removing the Flex Frame Assembly 1. Park the machine on a level surface. Ensure that the engine is OFF and the traction control is in NEUTRAL. 2.
Page 136 Disassembly of the Flex Frame Assembly g313493 Figure 68 Pivot pin latch (2 each) LH hub end Isolator E-ring (2 each) Roll frame assembly Flange nut (3 each) Lever (2 each) Flange nut (8 each) Frame link Pivot pin (2 each) Flex link (4 each) Carriage bolt (3 each) Spring (2 each)
Page 137 Chapter 8 DPA Cutting Units Table of Contents General Information ..........................8–2 Cutting Unit Operator's Manual ......................8–2 Supporting the Cutting Unit when Servicing ..................8–2 Adjustments ............................8–3 DPA Cutting Unit Characteristics......................8–3 Service and Repairs ..........................8–4 Bedbar Assembly..........................8–4 Servicing the Bedbar Adjuster......................
Page 138: General Information
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.
Page 139: Adjustments
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.
Page 140: Service And Repairs
Service and Repairs Bedbar Assembly g312976 Figure 70 Bedbar adjuster shaft (2 each) Wave washer (2 each) Washer (2 each) Keyed flanged bushing (4 each) Retaining ring (2 each) Compression spring Detent (2 each) Bedbar adjuster screw (2 each) Nut (2 each) Bolt (2 each) Bedbar assembly Side plate...
Page 141 Removing the Bedbar Note: Refer to Figure 70 during this procedure. 1. Remove the cutting unit from the machine and place the cutting unit on a flat work surface; refer to Operator’s Manual. 2. Loosen the nuts (11) on the end of each bedbar adjuster assembly (1) until the washers (9) are loose.
Page 142 Installing the Bedbar g226763 Figure 72 Metal washer Side plate Rubber bushing Bedbar Nylon bushing Bedbar pivot bolt Plastic washer (2 each) Lock nut 1. If rubber bushing (item 2 in Figure 72) was removed from either side plate, apply grease to outside surface of new bushing and install into side plate (1).
Page 143 Installing the Bedbar (continued) 7. Install the bedbar bolt assemblies (item 7 in Figure 72). Make sure that the washers are not caught on the threads of the pivot bolts. Torque tighten each bedbar bolt (7) 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.
Page 144: Servicing The Bedbar Adjuster
Servicing the Bedbar Adjuster Removing the Bedbar Adjuster g312976 Figure 73 Bedbar adjuster shaft (2 each) Wave washer (2 each) Washer (2 each) Keyed flanged bushing (4 each) Retaining ring (2 each) Compression spring Detent (2 each) Bedbar adjuster screw (2 each) Nut (2 each) Bedbar assembly Bolt (2 each)
Page 145 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.
Page 146: Bedknife
Bedknife Removing the Bedknife g227001 Figure 74 Bedknife screw (13 used) Bedbar Bedknife Remove the bedbar from the cutting unit; refer to Removing the Bedbar (page 8–5). Remove screws from bedbar using a socket wrench and bedknife screw tool; refer to Special Tools (page 2–14).
Page 147 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.
Page 148 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 76 Top angle Front surface Top surface Front angle 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.
Page 149 Angle Indicator and Magnetic Mount (page 2–16). 1. Use Toro General Service Training Book, Reel Mower Basics (part no. 09168SL) and grinder manufacturer's instructions for bedknife grinding information. After grinding the bedknife, install the bedbar assembly in the cutting unit;...
Page 150: Reel Assembly
Reel Assembly g313076 Figure 78 Drive spline Bolt Reel assembly Reel nut - LH Cutoff bar Flange shoulder bolt Strip seal RH side plate LH side plate Crossmember Bearing lock screw Grass shield Gasket Mount pin Bolt Reel weight Bushing Flat wire spring Bolt Pitch arm...
Page 151 Removing the Reel Assembly (continued) CAUTION Contact with the reel, bedknife or other cutting unit parts can result in personal injury. Use heavy gloves when removing the cutting reel. 3. If the cutting unit is equipped with an optional groomer, remove the drive components for those options from cutting unit.
Page 152 Removing 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. C. Move the pry bar against the weld side of the reel support plate closest to the bearing lock screw.
Page 153 Inspecting the Reel Assembly g287676 Figure 80 Cutting reel Reel nut (black – left hand thread) Flocked seal (2 each) Groove indication left hand threads Bearing (2 each) Left-most reel spider reel nut (right hand thread) Bearing shoulder Remove the reel nuts from the cutting reel. Slide the bearings and seals from the reel shaft.
Page 154 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.
Page 155 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.
Page 156 8–20). 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. 09168SL) found on the Service Reference Set available from your Authorized Toro Distributor.
Page 157 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.
Page 158: Roller Assemblies
Roller Assemblies Removing the Front Roller g313144 Figure 83 Plow bolt (2 each) Lock nut (2 each) Front roller assembly Pinch bolt (2 each) Height-of-cut arm (2 each) Height-of-cut screw (2 each) Note: Refer to Figure 83 during this procedure. 1.
Page 159 Installing the Front Roller (continued) 6. Center the front roller in the cutting unit and tighten the pinch bolts that secure the front roller shaft to the height-of-cut arms. 7. Adjust the cutting unit height-of-cut; refer to the Cutting Unit Operator’s Manual.
Page 160 Installing the Rear Roller (continued) 5. Center the rear roller in the cutting unit and tighten the flange nuts at each of the retainer assemblies. 6. Adjust the rear roller height; refer to the Cutting Unit Operator’s Manual. Disassembling the Roller g313345 Figure 85 Bearing lock nut (2 each)
Page 161 Assembling the Roller g261670 Figure 86 Roller Bearing lock nut Ball bearing Roller shaft Seal g261681 Figure 87 Bearing Bearing lock nut Seal Note: The rear roller is a low drag roller. 1. Press the bearing into the roller (support both inner and outer raceways). 2.
Page 162 Installing the Front Roller (continued) 4. Slide the front roller shaft (3) into the height-of-cut arm (5) attached to the cutting unit (10). 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.
Page 163 Chapter 9 Universal Groomer (Optional) Table of Contents General Information ..........................9–2 Installation Instructions ........................9–2 Grooming Performance........................9–2 Service and Repairs ..........................9–3 The Gear Box Assembly ........................9–4 Idler Assembly ..........................9–13 Groomer Reel ..........................9–15 The Height Adjuster Assembly ......................9–18 The Grooming Brush (Optional) .......................
Page 164: General Information
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.
Page 165: Service And Repairs
Service and Repairs g251028 Figure 88 Gear box assembly Height adjuster assembly (2 each) Idler assembly Groomer reel 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.
Page 166: The Gear Box Assembly
The Gear Box Assembly g323289 Figure 89 Gear box assembly Cotter pin Input shaft Drive shield Clevis pin The groomer gear box assembly is located on the opposite side of the cutting unit from the reel drive. Removing the Gear Box Assembly Refer to Figure 89 for this procedure.
Page 167 Weld side of reel support plate Groomer gear box assembly 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 5.
Page 168 Removing the Gear Box Assembly (continued) IMPORTANT You must use a 6-point socket with a heavy wall to remove the gear box from the reel. Do not use an impact wrench. Groomer gear boxes installed on the right side of the cutting unit use a standard right hand thread;...
Page 169 Removing the Gear Box Assembly (continued) F. Slide the groomer housing assembly from the drive shaft. G. Tip up the cutting unit to access the bottom of the reel to remove the drive shaft assembly. g323372 Figure 92 Damaged input shaft assembly Weld side of reel support plate Drive shaft removal tool Pry bar...
Page 170 Removing the Gear Box Assembly (continued) 12. Clean the threads in the end of the reel shaft. A right-hand thread and left-hand thread tap is available to clean or repair the threads if necessary; refer to Special Tools (page 2–14). Universal Groomer (Optional): Service and Repairs Page 9–8 Greensmaster...
Page 171 Servicing the Gear Box g285711 Figure 93 Drive adapter – silver Thrust washer Ring gear Input shaft O-ring Flange bushing O-ring (3 each) O-ring Sun gear V-ring Bearing Dowel pin (2 each) Oil seal Drain/fill plug (4 each) Planet gear (3 each) Groomer housing Straight bushing (2 each) Flange bushing (3 each)
Page 172 Servicing the Gear Box (continued) 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. 5. If the drive adapter requires replacement, apply medium strength thread locking compound (Loctite 243 or equivalent) to the internal threads of the drive shaft and the larger threads of the drive adapter (reel end).
Page 173 Installing the Gear Box Assembly Refer to Figure 89 for this procedure. 1. Apply medium strength thread locking compound (Loctite 243 or equivalent) to the threads in the reel and allow the thread locking compound to cure for 15 minutes before continuing this procedure. 2.
Page 174 Installing the Gear Box Assembly (continued) 8. Apply a retaining compound (Loctite 609 or equivalent) to the lip of the drive housing and install the drive shield. 9. Install the groomer reel assembly; refer to Installing the Groomer Reel (page 9–17).
Page 175: Idler Assembly
Idler Assembly g285713 Figure 95 Socket-head screw (2 each) Lock nut (2 each) Flange nut Bolt Shield Clevis pin Motor adapter Stub shaft Cotter pin Bushing Flocked seal (2 each) Collar Idler arm Bearing O-ring Retaining ring Note: The groomer idler assembly is located on the opposite side of the groomer gearbox assembly.
Page 176 Installing the Idler Assembly (continued) C. Install the bearing shields with flocked side of shield toward the bearing. D. Check the idler arm orientation (left or right cutting unit) and insert the stub shaft (item 10 in Figure 94) through shields and bearing. Use the through hole in the shaft to prevent shaft from rotating, tighten the flange nut to 37 to 45 N∙m (27 to 33 ft-lb).
Page 177: Groomer Reel
Groomer Reel g313422 Figure 96 Shaft clamp (4 each) Bolt (4 each) Jam nut (4 each) 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...
Page 178 Servicing the Groomer Reel g282211 Figure 97 Groomer reel shaft Spacer (50 each) Groomer blade (51 each) 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 1.
Page 179 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).
Page 180: The Height Adjuster Assembly
The Height Adjuster Assembly g251107 Figure 98 Height adjuster knob Washer (2 each) Quick up lever Carriage bolt Compression spring Quick up cover Height-of-cut bracket Flange nut Detent spring Flange nut Height adjustment rod Button-head screw Height adjustment bolt Groomer hose Groomer pin Note: Early universal groomers used 2 compression springs on non-adjustable height adjustment rods.
Page 181 Assembling the Height Adjuster 1. Apply anti-seize lubricant to the upper threads of the adjustment rod and lower threads of the height adjusters. Assemble the height adjuster assembly. 2. If both the height adjusters are removed, fit 1 height adjuster assembly to the cutting unit side plate and secure it with the carriage bolt and flange nut.
Page 182: The Grooming Brush (Optional)
The Grooming Brush (Optional) g285731 Figure 100 Spiral brush Lock nut (2 each) Brush shaft Grooming brush J-bolt (2 each) 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;...

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