Backlap Kit

Greensmaster® 1021 or 1026 Mower

Model No. 04800-Serial No. and Up

Installation

Preparing the Machine

  1. Park the machine on a level surface.

  2. Engage the parking brake.

  3. Shut off the engine.

  4. Remove the spark-plug wire from the spark plug; refer to your machine Operator’s Manual.

Removing the Control Cover

  1. Disconnect the wire-harness connector from the hour meter (Figure 1).

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    Figure 1

    1. Wire-harness connector
    2. Hour meter

  2. Remove the control cover by removing the screws that secure the control cover to the rear panel (Figure 2).

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    Figure 2

    1. Screw
    2. Control cover

Installing the Proximity-Sensor Assembly and Interlock Module

Parts needed for this procedure:

Proximity-sensor assembly1
Double-ended screw2
Flange nut (1/4 inch)2
Interlock module1
Hex-head bolt (3/8 inch)2

Installing the Proximity-Sensor Assembly

Refer to Figure 3 for this procedure.

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Figure 3

  1. Spacer
  2. Socket-head screw
  3. Double-ended screw
  4. Flange nut (1/4 inch)
  5. Proximity-sensor assembly

  1. Remove the socket-head screws from the spacer on the control shaft

  2. Use 2 double-ended screw and 2 flange nuts (1/4 inch) to install the proximity-sensor assembly to the spacer on the control shaft.

  3. Torque the screws and nuts to 9 to 12 N∙m (7 to 9 ft-lb).

Installing the Interlock Module

Use 2 hex-head bolts (3/8 inch) to install the interlock module to the cable bulkhead (Figure 4).

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Figure 4

  1. Screw
  2. Interlock module
  3. Cable bulkhead

Installing the Wire Harness

Parts needed for this procedure:

Wire harness1

Install the wire harness as follows:

  • Wire-harness end with the 6-socket connector: install to the interlock module.

  • Wire-harness end labeled : install to the proximity-sensor connector.

  • Wire-harness end labeled : install to the machine-wire-harness end labeled TO INTERLOCK MODULE.

Installing the Control Cover

Refer to the illustrations in Removing the Control Cover for this procedure.

  1. Use the previously-removed screws to install the control cover.

  2. Connect the wire-harness connector to the hour meter.

Installing the Backlap Knob to the Reel-Drive Assembly

Parts needed for this procedure:

Drive hub1
Seal1

  1. Remove the plug from the top of the reel-drive assembly (Figure 5).

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    Figure 5

    1. Plug

  2. Remove the 3 bolts that secure the cover to the reel-drive assembly and remove the reel-drive cover (Figure 6).

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    Figure 6

    1. Bolt

  3. While securing the drive pulley from movement, remove the nut from the reel-drive shaft (Figure 7).

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    Figure 7

    1. Reel-drive shaft
    2. Pulley
    3. Nut

  4. While securing the drive pulley from movement, install the drive hub to the reel-drive shaft (Figure 8).

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    Figure 8

    1. Reel-drive shaft
    2. Pulley
    3. Drive hub

  5. While securing the drive pulley from movement, torque the drive hub to 37 to 44 N⋅m (27 to 32 ft-lb).

  6. Lubricate the lip of the reel-drive cover and press the seal flush into the cover (Figure 9).

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    Figure 9

    1. Lip
    2. Seal

  7. Install the cover to the reel-drive assembly with the bolts that you removed in step 2; refer to Figure 6.

Preparing to Backlap

Parts needed for this procedure:

Bail catch1
Knob1
Axle-lock bracket1
Transport Wheel Kit (order separately; contact your authorized Toro distributor)1

  1. Install the spark-plug wire to the spark plug; refer to your machine Operator’s Manual.

  2. Gather the remaining loose parts (i.e., the bail catch, knob, and axle-lock bracket) and the transport wheels for use in Backlapping the Cutting Unit.

Operation

Backlapping the Cutting Unit

Preparing the Machine for Backlapping

  1. Move the kickstand to the TRANSPORT-WHEEL SERVICE position; refer to your machine Operator’s Manual.

  2. Note the position of the traction drum (refer to your machine Operator’s Manual) and install the axle-lock bracket to the left axle shaft as follows:

    • Drum set to the LOW position: slide the bracket over the shaft with the shorter prong facing toward the machine.

    • Drum set to the HIGH position: slide the bracket over the shaft with the longer prong facing toward the machine (as shown in Figure 10).

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    Figure 10

    1. Left axle shaft
    2. Axle-lock bracket
    3. Kickstand

  3. Install the transport wheels onto the right-wheel shaft and the drive hub; refer to Figure 11.

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    Figure 11

    1. Transport wheel—right-wheel shaft
    2. Knob
    3. Transport wheel—drive hub

  4. Remove the coupler from the transmission driveshaft and adjust the reel-drive assembly to ensure that the wheels are contacting; refer to the cutting unit maintenance section of your machine Operator’s Manual.

  5. Install the knob over the wheel on the drive hub (Figure 11).

Performing a Backlapping Job

Danger

Contact with the reel or other moving parts can result in personal injury.

  • Stay away from the reel while backlapping.

  • Do not use a short-handled paint brush for backlapping. A brush and handle assembly (Part No. 29-9100) is available from your authorized Toro distributor.

  1. Start the engine; refer to your machine Operator’s Manual.

  2. Engage the traction drive as follows:

    • Machines equipped with the clutch bail: Engage the clutch bail and install the bail catch (Figure 12).

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      Figure 12

      1. Bail catch
      2. Clutch bail

    • Machines equipped with the Traction Lever Kit: Move the traction lever down to the ENGAGED position; refer to the kit Installation Instructions.

  3. Use a long-handled brush to apply lapping compound to the rotating reel.

  4. When the backlapping operation is completed and cutting reel is not moving, perform the following steps:

    1. Run a file across the front face of the bedknife.

      Note: This will remove any burrs or rough edges that may have built up on the cutting edge.

    2. Remove the bail catch and axle-lock bracket.

    3. Align the reel-drive assembly with the transmission driveshaft and Install the reel-drive coupler to the driveshaft; refer to the cutting unit maintenance section of your machine Operator’s Manual.