Form No. 3328–162 Greensmaster 800, 1000 and 1600 Greensmaster Mower Model No. 04048—Serial No. 230000001 and Up Model No. 04052—Serial No. 230000001 and Up Model No. 04060—Serial No.
Servicing the Air Cleaner . . . . . . . . . . . . . . . . . . . . Replacing the Spark Plug . . . . . . . . . . . . . . . . . . . . Cleaning the Fuel Filter . . . . . . . . . . . . . . . . . . . . . Adjusting Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Differential Belt . . . . . . . . . . . . . . . Adjusting the Traction Control . . . . . . . . . . . . . . . Adjusting the Service/Park Brake . . . . . . . . . . . . . Adjusting the Interlock Switch . . . . . . . . . . . . . . .
Safety – Add fuel before starting the engine. Never remove the cap of the fuel tank or add fuel while the engine is running or when the engine is hot. This machine meets or exceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-1999 specifications in effect at the time of production when the Operator Presence Kit, Part No. 105–5363 is installed.
• Stop the blades rotating before crossing surfaces other than grass. Maintenance and Storage • Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition. • When using any attachments, never direct discharge of material toward bystanders nor allow anyone near the machine while in operation. • Never store the equipment with fuel in the tank inside a building where fumes may reach an open flame or spark.
• Know how to stop the engine quickly. • To ensure safety and accuracy, have an Authorized Toro Distributor check the maximum engine speed with a tachometer. Maximum governed engine speed should be 3600 RPM. • Do not operate the machine while wearing tennis shoes or sneakers. • If major repairs are ever needed or if assistance is desired, contact an Authorized Toro Distributor. • Wearing safety shoes and long pants is advisable and required by some local ordinances and insurance regulations.
Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 105–5359 (Model 04048) 105–5360 (Model 04052) 105–5361 (Model 04060) 1. Disengage 2. Engage 3. Parking brake 4. Engage—forward 5. Disengage—neutral 6. Clutch 93-7273 1. Thrown object hazard—Keep bystanders away 93-9356 2. Cutting hazard, hand and foot—Stay away from moving parts 1.
105-5309 1. Hot surface/burn hazard—stay a safe distance from the hot surface. 93-6085 1. Fast 2. Increasing/decreasing scale. 3. Slow 93-8064 1. Warning—Read the Operator’s Manual before servicing 2. Cutting Hazard, hand and foot—Stop the engine and wait for moving parts to stop 93-7348 1. Warning—Read the Operator’s Manual 2. Fire hazard—No open flames or sparks and fill the tank only to the level shown 3. Thrown object hazard—Keep bystanders away 4.
Specifications General Specifications Engine Kawasaki, air cooled, overhead valve, 4 cycle, 3.7 horsepower, 2.36 x 1.73 bore and stroke, 7.57 cu. in. (124 cc) displacement, 8.4:1 compression ratio, 11 ft.-lb. (15 N⋅m) @ 1400 rpm. Electronic ignition, maximum noise suppression muffler. 2.64 quart (2.5 l) fuel tank capacity. Traction Drive Engine to countershaft drive: two “A” section V-belts. Countershaft to differential drive: 5 mm pitch timing belt. Differential to drum drive: 8 mm pitch timing belt.
Optional Equipment Model 04048 Model 04052 Model 04060 Light Kit Model No. 04058 Model No. 04058 Model No. 04058 Wheel Kit Model No. 04122 Model No. 04122 Model No. 04122 Height of Cut Bar Part No. 94–9010 Part No. 94–9010 Part No. 94–9010 Operator Presence Kit Part No. 105–5363 Part No. 105–5363 Part No. 105–5363 Clip Kit Part No. 65-9000 Part No. 65-9000 Part No. 65-9000 High Altitude Jet for altitudes of 3000 to 6000 ft. (900 to 1800 m) Part No. 98-8735 Part No. 98-8735 Part No.
Setup Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Note: Use this chart as a checklist to ensure all parts necessary for assembly have been shipped. If any of these parts are missing, total set–up cannot be completed. Description Qty.
Installing and Adjusting the Handle 7. Secure the handle ends to the mounting pins with the capscrews, washers, and lockwashers previously removed (Fig. 2). Installing the Handle 8. Secure the bottom of handle arms to each side of the mower with the capscrews and locknuts previously removed (Fig. 2). Ensure that you install the bushings in the handle arm mounting holes. 2. Remove the capscrew, washer, and lockwasher from the mounting pin on each side of the mower, as shown in Fig. 1.
Installing the Transport Wheels 9. Inflate the tires to 12 to 15 psi. (574 to 718 Pa). 1. Push the kick stand down with your foot and pull up on the handle to support the mower on the kick stand. Before Operating 2. Apply #242 Loctite to the threads of the wheel shafts. Adding Engine Oil 3. Thread the right hand wheel shaft into the drive pulley on the right side of the machine (Fig. 4). Fill the crankcase with approximately 20 oz. (0.6 l) of proper viscosity oil before staring.
4. Wipe the gauge clean and insert it into the filler port, without threading it into the port. Danger 5. Remove the gauge and check the oil level. In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. 6. If level is low, add only enough oil to raise level to filler opening. Note: Check the oil each time the mower is used or after every 5 operating hours.
Leveling the Rear Drum to the Reel 7. Rotate the drive pulley until the holes align with the 4 roller bearing flange screws (Fig. 10). 8. Loosen the 4 roller bearing screws and the screw securing the idler pulley. 1. Position the machine on a flat, level surface, preferably a precision steel work plate. 9. Raise or lower the right side of the roller assembly until the gap is less than 0.010 in. 2. Place a 1/4 x 1 in. (0.6 x 2.5 cm) flat steel strip, approx. 29 in. (73.
Adjusting the Bedknife to the Reel 4. On one end of the front side of the reel, insert a long strip of newspaper between the reel and bedknife (Fig. 13). While slowly rotating the reel forward, turn the bedbar adjusting screw clockwise (on the same end of reel, one click at a time, until the paper is pinched lightly, when inserted from the front, parallel to the bedknife, which results in a slight drag when paper is pulled (Fig. 11 or 12).
Adjusting the Height-of-Cut 1. Verify that the rear roller is level and that the bedknife to reel contact is correct. Tip the mower back on the handle to expose the front and rear rollers and the bedknife. 2. Loosen the locknuts securing the height-of-cut arms to the height-of-cut brackets (Fig. 14). 4 Figure 16 1 5. Rotate the adjusting screw until the roller contacts the front of the gauge bar. 6. Adjust both ends of the roller until the entire roller is parallel to the bedknife.
Adjusting the Grass Shield Height 3. Ensure that the bar and reel are equal distance apart across the entire reel. Note: The bar is adjustable to compensate for changes in turf conditions. Adjust the bar closer to the reel when the turf is extremely wet. By contrast, adjust the bar further away from the reel when turf conditions are dry. The bar should be parallel to the reel to ensure optimum performance.
Operation Operator Presence Control (Optional) Note: Determine the left and right sides of the machine from the normal operating position. Located on the rear of the handle. Push the operator presence control against the handle. The operator presence control must be engaged before moving the traction drive lever or the engine will stop. (Fig. 21) Controls Reel Drive Lever (Fig. 22) Throttle Control (Fig. 21) Located on the right front corner of the machine.
Starting the Engine Note: Ensure that the spark plug wire is installed on the spark plug. 1. Ensure that the traction (Fig. 21) and reel drive (Fig. 22) levers are in the Disengaged position. Note: Engine will not start if traction lever is in the engaged position. 2. Open the fuel shut-off valve on the engine (Fig. 23). 3. Move the On/Off switch (Fig. 24) to the On position. 4. Move the throttle control (Fig. 21) to the Fast position. 1 5. Move the choke lever (Fig.
5. Adjust the throttle to operate the mower at the desired ground speed and transport the mower to the desired destination. Mowing Techniques Preparing to Mow • Avoid circular mowing or turning the mower on a green because scuffing may occur. Turn the mower off of the green by raising the cutting reel (pushing the handle down) and turning on the traction drum. • Mow a green in a straight back and forth direction, across the green. 1.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Safety interlock operation Parking brake operation Fluid level Engine oil level Air filter Clean the engine cooling fins Unusual engine noise Unusual operating noise Reel to bedknife adjustment Height-of-cut adjustment Grease all fittings Touch-up damaged paint Notation for Areas of Concern Inspection performed by: Item Date Information 1 2 3 4 5 6 7 8 22 Wed. Thurs. Fri. Sat.
Greasing the Machine The 13 grease fittings on the mower should be greased at least every 25 hours. Lubricate using a No. 2 multi–purpose lithium base grease. A hand operated grease gun is recommended for best results. The grease fitting locations are as follows: • 2 on the front roller (Fig. 25) • 2 on the reel bearings (Fig. 25) • 2 on the drum axles (Fig. 26) • 3 on the differential (Fig. 26) Figure 26 • 2 on the reel countershaft bearings (Fig. 27) • 2 on the belt idler pivots (Fig. 28). 1.
Checking and Changing Engine Oil 2. Place a drain pan at the rear of machine, under the drain plug (Fig. 29). 3. Remove the drain plug. Check the oil level each time the mower is used or after every 5 operating hours. Initially, change oil after the first 20 hours of operation; thereafter, change oil after every 50 hours of operation. More frequent oil changes are required in dusty or dirty conditions. 4.
1 1 2 Figure 32 1. Spark plug Figure 31 1. Foam element 3. Set the air gap at 0.028 to 0.032 in. (0.05 to 0.07 cm) (Fig. 33). 2. Paper element 4. Install the correctly gapped spark plug and tighten it to 17 ft.-lb. (23 N⋅m). A. Wash the foam element in a solution of liquid soap and warm water. B. Squeeze to remove dirt, but do not twist it because the foam may tear. 0.028–0.032 in. 0.05–0.07 cm C. Dry it by wrapping it in a clean rag. Squeeze rag and foam element to dry it. D.
Adjusting Belts 6. After all bolts are installed, tighten them until the stand-offs inside the cover contact the side plate. Do not overtighten. Ensure that the belts are properly tensioned to ensure proper operation of the machine and unnecessary wear. Check belts frequently. Adjusting the Reel Drive Belt Check the tension by pressing the belt at mid span of the pulleys with 3 to 5 lb. of force. The belt should deflect 1/4 in. (0.63 cm). If the deflection is incorrect, adjust the belt as follows: 1 1.
2. Loosen the idler pulley mounting nut and pivot the idler pulley clockwise against the backside of the belt until the desired belt tension is attained (Fig. 38). Important Do not over tension the belt. 2 2 1 1 Figure 39 1. Differential belt 2. Idler pulley 2. Loosen the idler pulley mounting nut and pivot the idler pulley clockwise against the backside of the belt until the desired belt tension is attained. Important Do not over tension the belt. 3. Tighten the nut to lock adjustment. 4.
8. To push or pull the machine easier without starting the engine, adjust the belt guide (Fig. 41, inset) as follows: 1 A. Engage the clutch. B. Loosen the capscrew securing the idler pulley and belt guide to the idler arm. 2 C. Rotate the belt guide clockwise until a gap of approximately 0.06 in. (0.15 cm) is obtained between the guide finger and the backside of the drive belts. D. Tighten the capscrew and locknut securing the idler pulley and belt guide to the idler arm. 9.
5. Loosen the idler pulley mounting nut on the differential idler pulley and pivot the idler pulley counterclockwise away from the backside of the belt to release the belt tension. 2 6. Remove the 2 capscrews and locknuts securing the front clutch housing to the side plate (Fig. 42). 7. Rotate the housing 180° so the bottom of the housing points upward. 1 8. Remove the 2 capscrews and locknuts securing the right rear bearing housing to the side plate (Fig. 42). 9.
Adjusting the Interlock Switch 2. Using a 7/8 in. standard wrench, back out the spring tension screw until the thrust washer is no longer tensioned against the bedbar (Fig. 46). To adjust or replace the interlock switch, complete the following procedure: 3. On each side of the machine, loosen the jam nut securing the bedbar bolt (Fig. 46). 1. Ensure that the engine is Off and the traction lever is disengaged. 2. Loosen the 2 switch mounting nuts (Fig.
Backlapping the Reel 3 2 1. Remove the plug in the right reel drive cover (Fig. 50). 3 1 1 Figure 48 1. Bedbar adjusting screw 2. Spring tension nut 3. Bedbar 2. Back out the spring tension nut, until the washer is no longer tensioned against the bedbar (Fig. 48). Figure 50 3. On each side of the machine, loosen the jam nut securing the bedbar bolt (Fig. 49). 1. Cover plug 4. Remove each bedbar bolt allowing bedbar to be pulled downward and removed from machine.
The Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your 1996 or newer Toro Commercial Product (“Product”) purchased after January 1, 1997, to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
