Toro Greensmaster 1018 Mower User manual

FormNo.18238SLRevC

Greensmaster

®

1018/1021/1026

(Models04820,04830and04840)

8111LyndaleAvenueSouth

Bloomington,MN55420

OriginalInstructions(EN)

Contactusatwww.Toro.com.

AllRightsReserved

RevisionHistory

RevisionDateDescription

A

03/2019

Initialissue.

B

03/2020

Updatedthedrumdrivegearboxassemblyandtransmissiongearboxassembly.

C07/2020

Updatedthetractionandreeldrive,cuttingunitanduniversalgroomerchapters.

RevisionHistoryPage2

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ReaderComments

TheToroCompanyT echnicalAssistanceCentermaintainsacontinuous

efforttoimprovethequalityandusefulnessofitspublications.Todothis

effectively,weencourageuserfeedback.Pleasecommentonthecompleteness,

accuracy,organization,usability,andreadabilityofthismanualbyane-mail

to[email protected]

orMailto:

TechnicalPublicationManager,Commercial

TheToroCompany

8111LyndaleAvenueSouth

Bloomington,MN55420-1196

Phone:+1952-887-8495

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ReaderComments

18238SLRevC

NOTES

Page4

Greensmaster

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Preface

Thepurposeofthispublicationistoprovidetheservicetechnicianwiththe

informationfortroubleshooting,testing,andrepairofthemajorsystemsand

componentsontheGreensmaster1018/1021/1026(Models04820,04830and

04840).

RefertotheOperator’sManualsandInstallationInstructionsforinstalling,

operating,maintenance,andadjustmentinstructions.Keepacopyofthe

Operator’sManuals,InstallationInstructionsandPartsCatalogsforyour

machineanditsaccessorieswiththisServiceManualforreference.Additional

copiesoftheOperator’sManuals,InstallationInstructionsandPartsCatalogs

areavailableatwww.toro.com.

TheToroCompanyreservestherighttochangetheproductspecicationsor

thispublicationwithoutnotice.

DANGER

Thissafetysymbolmeansdanger.Whenyouseethissymbol,

carefullyreadtheinstructionsthatfollow.Failuretoobeythe

instructionscouldkillorcauseseriouspermanentinjuryordisability.

WARNING

Thissafetysymbolmeanswarning.Whenyouseethissymbol,

carefullyreadtheinstructionsthatfollow.Failuretoobeythe

instructionscanresultinseriousinjury.

CAUTION

Thissafetysymbolmeanscaution.Whenyouseethissymbol,

carefullyreadtheinstructionsthatfollow.Failuretoobeythe

instructionscanresultinminortomoderateinjury.

IMPORTANT

TheImportantnoticewillgivetheimportantinstructionswhichyou

mustfollowtopreventdamagetothesystemsorcomponentson

themachine.

Note:ANotewillgivethegeneralinformationaboutthecorrectoperation,

maintenance,service,testing,orrepairofthemachine.

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Preface

18238SLRevC

g264048

Figure1

Model04830shown

Preface

Page6

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ServiceProcedureIcons

ThefollowingiconsappearthroughoutthisServiceManualtobringattentionto

specicimportantdetailsofaserviceprocedure.

CriticalProcess

Thisiconisusedtohighlight:

•installingsafetyequipment(shields,guards,seatbelts,brakesandR.O.P .S.

components)thatmayhavebeenremoved.

•dimensionsorsettingsthatmustbemaintainedforpropermachineoperation.

•aspecicfastenertighteningsequence.

•componentorientationthatmaynotbeobvious.

CriticalTorque

Thisiconisusedtohighlightanassemblytorquerequirementthatisdifferent

thanwhatisrecommendedintheStandardTorqueT ables;refertoT orque

Specications(page2–6).

FluidSpecications

Thisiconisusedtohighlightuidspecicationsandcapacitiesthatareless

common,andmaynotappearonthemachineservicedecalorinthemachine

Operator’sManual.

Note:RefertotheservicedecalonthemachineandthemachineOperator’s

Manualforcommonlyuseduidspecicationsandcapacities.

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Preface

18238SLRevC

TableofContents

Preface................................................................................................................5

Chapter1:Safety............................................................................................1–1

SafetyInstructions.......................................................................................1–2

SafetyandInstructionalDecals....................................................................1–6

Chapter2:SpecicationsandMaintenance....................................................2–1

Specications...............................................................................................2–2

TorqueSpecications...................................................................................2–6

ShopSupplies............................................................................................2–12

SpecialT ools..............................................................................................2–14

Chapter3:Troubleshooting.............................................................................3–1

GEARS–TheSystematicApproachtoDening,DiagnosingandSolving

Problems......................................................................................................3–2

StartingProblems.........................................................................................3–3

AftercutAppearance.....................................................................................3–4

FactorsAffectingGrooming..........................................................................3–5

GroomingReelMechanicalProblems...........................................................3–6

Chapter4:GasolineEngine............................................................................4–1

GeneralInformation.....................................................................................4–2

Adjustments.................................................................................................4–4

ServiceandRepairs.....................................................................................4–5

Chapter5:TractionandReelDriveSystems...................................................5–1

GeneralInformation.....................................................................................5–2

Adjustments.................................................................................................5–3

ServiceandRepairs.....................................................................................5–7

Chapter6:ElectricalSystem...........................................................................6–1

GeneralInformation.....................................................................................6–2

WiringSchematic..........................................................................................6–3

ComponentT esting.......................................................................................6–4

Chapter7:Controls,WheelsandAccessories................................................7–1

GeneralInformation.....................................................................................7–2

ServiceandRepairs.....................................................................................7–3

Chapter8:DPACuttingUnits..........................................................................8–1

GeneralInformation.....................................................................................8–2

Adjustments.................................................................................................8–4

ServiceandRepairs.....................................................................................8–6

Chapter9:UniversalGroomer(Optional)........................................................9–1

GeneralInformation.....................................................................................9–2

ServiceandRepairs.....................................................................................9–3

Preface

Page8

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Chapter1

Safety

TableofContents

SafetyInstructions................................................................................................................................1–2

BeforeOperatingtheMachine...........................................................................................................1–3

WhileOperatingtheMachine.............................................................................................................1–4

MaintenanceandService...................................................................................................................1–5

SafetyandInstructionalDecals............................................................................................................1–6

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Safety

18238SLRevC

SafetyInstructions

TheGreensmaster1018/1021/1026machineistestedandcertiedbyToro

forcompliancewithexistingsafetystandardsandspecications.Although

hazardcontrolandaccidentpreventionarepartiallydependentuponthedesign

andcongurationofthemachine,thesefactorsarealsodependentonthe

awareness,concern,andpropertrainingofthepersonnelinvolvedinthe

operation,transport,maintenance,andstorageofthemachine.Theimproper

useormaintenanceofthemachinecanresultininjuryordeath.

WARNING

Toreducethepotentialofinjuryordeath,complywiththefollowing

safetyinstructionsaswellasinformationfoundintheOperator’s

ManualsandtheOperatorandSafetyTrainingVideosfoundon

www.toro.com.

Safety:SafetyInstructions

Page1–2

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BeforeOperatingtheMachine

•ReviewandunderstandthecontentsoftheOperator’sManualsbefore

startingandoperatingthemachine.Becomefamiliarwiththecontrolsand

knowhowtostopthemachineandenginequickly.Additionalcopiesofthe

Operator’sManualsareavailableatwww.toro.com.

•Neverallowchildrentooperatethemachine.Neverallowadultstooperate

themachinewithoutproperinstructions.

•Becomefamiliarwiththecontrolsandknowhowtostopthemachineand

tractorenginequickly.

•Keepalltheshields,safetydevices,anddecalsinplace.Ifashield,safety

device,ordecalisillegibleordamaged,repairorreplaceitbeforeoperating

themachine.

•Alwayswearsubstantialshoes.Donotoperatemachinewhilewearing

sandals,tennisshoesorsneakers.Donotwearloosettingclothingwhich

couldgetcaughtinmovingpartsandcausepersonalinjury.

•Wearingsafetyglasses,safetyshoes,longpantsandahelmetisadvisable

andrequiredbysomelocalsafetyandinsuranceregulations.

•Makesureworkareaisclearofobjectswhichmightbepickedupandthrown

bytheattachments.

•Keepeveryone,especiallychildrenandpets,awayfromtheareasof

operation.

•Sincethegasolineishighlyammable;handleitcarefully.

–Useanapprovedgasolinecontainer.

–Donotremovecapfromfueltankwhenengineishotorrunning.

–Donotsmokewhilehandlinggasoline.

–Fillfueltankoutdoorsandnohigherthantothebottomoflterscreen.Do

notoverllfueltank.

–Wipeupanyspilledgasoline.

–Fuelmayleakfromllerneckwhenmoweristiltedforservicingiftank

isoverlled.

•Thesafetyinterlockswitchesarefortheoperator’sprotection;donot

disconnectthem.Checktheoperationoftheswitchesdailytoassurethe

interlocksystemisoperating.Iftheswitchisdefective,replaceitbefore

operatingthemachine;refertoInterlockModule(Optional)(page6–10)

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Safety:SafetyInstructions

18238SLRevC

WhileOperatingtheMachine

1.Donotruntheengineinaconnedareawithoutadequateventilation.

Exhaustfumesarehazardousandcouldbedeadly.

2.Alwaysstandbehindthehandlewhenstartingandoperatingthemachine.

3.Tostarttheengine:

A.Openfuelshut-offvalve.Makesurethatthesparkplugwireisconnected

tothesparkplug.

B.VerifythatthecontrolleveronhandleisinNEUTRALpositionforboth

tractionandreeldrives.

C.MoveON/OFFswitchtoONposition,setchoketofullchokeposition(cold

start)andthrottletohalfthrottle.

D.Pullstartercordtostartengine.

4.Tostoptheengine:

A.Disengagethereelandtractiondrivesandreduceenginespeedto

SLOW.

B.MoveON/OFFswitchtoOFFpositiontostoptheengine.

5.Beforeemptyingthebasketofclippings,disengagethetractionandreel

drives,reducetheenginespeedandmoveON/OFFswitchtoOFFpositionto

stoptheengine.Waitforallmachinemotiontostopbeforeremovingbasket.

6.Donottouchtheengine,muferorexhaustpipewhileengineisrunningor

soonafterithasstoppedbecausetheseareasarehotenoughtocauseburns.

7.Ifthecuttingunitstrikesasolidobjectorvibratesabnormally,stopmachine

operationimmediately,turntheengineOFF,waitforallmachinemotionto

stopandinspectfordamage.Adamagedreelorbedknifemustberepaired

orreplacedbeforeoperationiscommenced.

8.Whenevermachineisleftunattended,besureengineisstoppedandcutting

unitreelisnotspinning.

9.Closethefuelshut-offvalveifthemachineisnotbeusedforanextended

periodoftime.Also,closefuelshut-offvalveifthemachineistobe

transportedonatrailerorinavehicle.

Safety:SafetyInstructions

Page1–4

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MaintenanceandService

•TheTractionUnitOperator’sManual,CuttingUnitOperator’sManualand

GroomerOperator’sManualprovidestheinformationregardingtheoperation,

generalmaintenanceandmaintenanceintervalsforyourGreensmaster

machine.Refertothesepublicationsforadditionalinformationwhen

servicingthemachine.

•Beforeservicingormakingadjustmentstothemachine,stoptheengineand

waitforallmachinemotiontostop.Removethesparkplugwirefromthe

sparkplugtopreventaccidentalstartingoftheengine.

•Tomakesurethattheentiremachineisingoodcondition,keepallnuts,bolts,

screwsandbeltsproperlytightened.

•Toreducethepotentialrehazard,keeptheengineareafreeofexcessive

grease,grass,leavesandaccumulationofdirt.

•Wearheavyglovesandusecautionwhencheckingorservicingthecutting

unit.

•Iftheenginemustberunningtoperformmaintenanceormakeanadjustment,

keephands,feet,clothingandallpartsofthebodyawayfromthecuttingunit

andallmovingparts.Keepthebystandersaway.

•Donotoverspeedtheenginebychangingthegovernorsettings.

Recommendedenginehighidlespeedisfrom3,350to3,550RPM.T oensure

safetyandaccuracy,checktheenginespeedwithatachometer.

•Enginemustbeshutoffandcooleddownbeforecheckingoiloraddingoilto

theenginecrankcase.

•Ifmajorrepairsareeverneededorassistanceisrequired,contactyour

AuthorizedT orodistributor.

•Atthetimeofmanufacture,themachineconrmedtoallapplicablesafety

standards.Toassureoptimumperformanceandcontinuedsafetycertication

ofthemachine,usegenuineTororeplacementpartsandaccessories.

Replacementofpartsandaccessoriesmadebyothermanufacturersmay

resultinnon-conformancewiththesafetystandardsandcanvoidthe

warranty.

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Safety:SafetyInstructions

18238SLRevC

SafetyandInstructionalDecals

Numeroussafetyandinstructiondecalsareafxedtothetractionunitand

cuttingunitsofyourGroundsmaster.Ifanydecalbecomesillegibleordamaged,

installanewdecal.DecalpartnumbersarelistedinyourPartsCatalog.Order

replacementdecalsfromAuthorizedT oroDistributor.

Safety:SafetyandInstructionalDecals

Page1–6

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Chapter2

SpecicationsandMaintenance

TableofContents

Specications.......................................................................................................................................2–2

OverallDimensions............................................................................................................................2–2

Engine................................................................................................................................................2–3

TractionandReelDriveSystems.......................................................................................................2–4

Controls,WheelsandAccessories....................................................................................................2–4

DPACuttingUnits..............................................................................................................................2–4

UniversalGroomer.............................................................................................................................2–5

TorqueSpecications...........................................................................................................................2–6

CalculatingtheT orqueValuesWhenUsingaDrive-AdapterWrench.................................................2–7

IdentifyingtheFastener......................................................................................................................2–8

StandardT orqueforDry,ZincPlated,andSteelFasteners(InchSeries)............................................2–9

StandardT orqueforDry,ZincPlated,andSteelFasteners(MetricFasteners).................................2–10

OtherTorqueSpecications.............................................................................................................2–11

ConversionFactors..........................................................................................................................2–11

ShopSupplies....................................................................................................................................2–12

SpecialTools......................................................................................................................................2–14

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SpecicationsandMaintenance

18238SLRevC

Specications

OverallDimensions

g262214

Figure2

SpecicationsandMaintenance:Specications

Page2–2

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Engine

g238094

Figure3

1.Fueltank3.Recoilstarter

5.Sparkplug

2.Aircleaner4.Recoil-starthandle

6.Mufer

ItemDescription

Make/DesignationHonda,4-stroke,OHVsinglecylinder,

air-cooledgasolineengine,GX120

BorexStroke60mmx42mm(2.36x1.65inches)

Totaldisplacement

118cm

3

(7.2in

3

)

Compressionratio

8.5:1

CarburetorButtery

GovernorMechanicalyweight

Low-idlespeed(noload)

1,800to2,000rpm

High-idlespeed(noload)

3,350to3,550rpm

DirectionofrotationCounterclockwise(facingPTOshaft)

Fuel

unleadedgasolinefuelwithanoctaneratingof

87orhigherwithnomorethan10%Ethanol

Fueltankcapacity

2L(0.53USgallons)

Engineoil

RefertotheOperator’sManual

Lubricationsystem

Splashtype

Oilcapacity0.56L(0.14USgallons)

AircleanerDualelement

IgnitionsystemTransistorizedmagneto

SparkplugNGKBPR6ES

Sparkpluggap0.7to0.8mm(0.028to0.031inch)

Engineweight(dry)13kg(28.7lb)

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SpecicationsandMaintenance:Specications

18238SLRevC

TractionandReelDriveSystems

ItemDescription

Transmission

Enginetofrictionclutch

Transmissiondriveusesspurgears

TractionDrive

Transmissiontotractiondriveusesaseriesofspurgears

DifferentialSpurgearplanetarydifferential

ParkingBrake

Bandstyle(atdifferentialshaftdrive)

TractionDrum

Dualaluminium,19.1cm(7.5inch)diameter

CuttingReelDriveTransmissionreeloutputshaftwithdisconnect

andslidingcoupler

Finalreeldrivehas2pulleyswithpositivedrivebelt

Belttensionmaintainedbyanidler

Controls,WheelsandAccessories

ItemDescription

TransportWheel(Optional)Tire

Pressure

83to103kPa(12to15PSI)

DPACuttingUnits

Frameconstruction:Twohexagonalcrossmemberwithtwobolt-ondie-castaluminumside

plates.

Reelconstruction:

Reelsare53.3cm(21inches)inlengthand12.7cm(5inch)in

diameter.Highstrength,lowalloysteelbladesarethruhardened

andimpactresistant.Reelsareavailablein8,11and14blade

congurations.

Reelbearings:

Twostainlesssteelballbearingsarepresstontothereelshaftand

retainedbyathreadedinsert.Lowdragseals/slingersforadded

protection.Reelpositionismaintainedbyawavewasherwithnoend

playadjustmentrequired.

Reeldrive:

Thereelshaftis35mm(1.375inch)diametertubewithathreaded

nutoneachend

Height-of-cut:Cuttingheightisadjustedonthefrontrollerbytwoverticalscrews.

Standardbenchheightofcutrangeis1.6to16mm(0.062to0.625

inch)dependingontypeofbedknifeinstalled.Anoptionalhigh

height-of-cutkitisavailabletoobtainacutrangeof11.1to30mm

(0.438to1.2inch).EffectiveHOCmayvarydependingonturf

conditions,typeofbedknife,rollers,attachmentsinstalledandrear

drumposition.

Bedknifeandbedbar:ReplaceablesingleedgedEdgemax™bedknife(solidtoolsteel

construction)isstandard.Bedknifeisfastenedtothebedbarwith

thirteenbedknifescrews.Avarietyofoptionalbedknivesareavailable.

BedknifeadjustmentDualadjustment(oneoneachsideofthebedbar)with0.018mm

(0.0007inch)bedknifemovementforeachdetent.

Rollers:

Thefrontrollerisa6.3cm(2.5inches)diameterrollerthatisavailable

infull,widespacedWiehleandnarrowspacedWiehlecongurations.

Grassshield:Adjustableshieldtoimprovegrassdischargefromreelinvarying

moistureconditions.

Counterbalance

weight:

Acastironweightmountedonleftendofthecuttingunit.

SpecicationsandMaintenance:Specications

Page2–4

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DPACuttingUnits(continued)

Cuttingunitweight(approximate):

18inch21inch26inch

8blade

-

23.6kg(52lbs)26.7kg(59lbs)

11blade

23.1kg(51lbs)25kg(55lbs)28.6kg(63lbs)

14blade

24.5kg(54lbs)26.3kg(58lbs)

-

Options:RefertotheCuttingUnitPartsCatalogorcontactyourlocalAuthorized

ToroDistributorforavailablecuttingunitoptions.

UniversalGroomer

ItemDescription

Groomingreeldiameter6cm(2.375inches)

GroomermountingThedriveassemblyforthegroomingreelislocated

ontheoppositesideofthecuttingunitfromthebelt

drive.

GroomerheightsettingMowing:0.8to15.7mm(0.030to0.620inch).

HOCrange:1.5to19.1mm(0.060to0.750inch).

Width-of-groomer54.6cm(21.5inches).

Heightadjustmentknob

Allowsa0.003inch(0.08mm)incrementofheight

adjustmentforeachclickoftheadjuster.

Quick-upfeature

Allowsgroomingreeltoberaisedabovethe

height/depthadjustmentfornogroomingreelaction

whilemowing.

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SpecicationsandMaintenance:Specications

18238SLRevC

TorqueSpecications

Therecommendedfastenertorquevaluesarelistedinthefollowingtables.For

criticalapplications,asdeterminedbyT oro,eithertherecommendedtorqueora

torquethatisuniquetotheapplicationisclearlyidentiedandspeciedinthis

ServiceManual.

Thesetorquespecicationsfortheinstallationandtighteningofthefastenerswill

applytoallthefastenerswhichdonothaveaspecicrequirementidentiedin

thisServiceManual.Thefollowingfactorsmustbeconsideredwhenapplying

thetorque:cleanlinessofthefastener,useofathreadsealant(e.g.,Loctite),

degreeoflubricationonthefastener,presenceofaprevailingtorquefeature

(e.g.,Nylocknut),hardnessofthesurfaceunderneaththeheadofthefastener,

orsimilarconditionwhichaffectstheinstallation.

Asnotedinthefollowingtables,thetorquevaluesshouldbereducedby25%

forthelubricatedfastenerstoachievethesimilarstressasadryfastener.The

torquevaluesmustbereducedwhenthefasteneristhreadedintothealuminum

orbrass.Thespecictorquevalueshouldbedeterminedbasedonthealuminum

orbrassmaterialstrength,fastenersize,lengthofthreadengagement,etc.

Thestandardmethodofcheckingthetorquecanbeperformedbymarkingaline

onthefastener(headornut)andmatingpart,thenbackoffthefastener1/4

ofaturn.Measurethetorquenecessarytotightenthefasteneruntilthelines

matchup.

SpecicationsandMaintenance:TorqueSpecications

Page2–6

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