Form No. 96889SL Rev.
Revision History Revision Date Description -- 1996 Initial Issue. A 1997 Incorporated GR 1000. B 2012 Incorporated GR 1600. C 02/2018 Added revision history. D 04/2018 Revised bedknife installation procedure. E 03/2019 Updated Engine and Electrical chapters. F 04/2020 Added 4 schematics, 6 wire harnesses, reel restraining procedure © THE TORO COMPANY 2020 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies).
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 to servicemanuals@toro.
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FORM 96889SL Rev. F Service Manual Greensmaster 800/1000/1010/1600/1610/2000/2600 Preface The purpose of this publication was to provide the service technician with information for troubleshooting, testing, and repairing assemblies and components on Greensmaster 1000 machines built between 1990 and 1996. Information has been added to this document over the years to support a variety of fixed head walk Greensmasters built from 1990 to 2019.
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Chapter 1 − Safety Chapter 5 − Electrical System Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 − 1 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 − 3 Electrical Schematics and Wire Harnesses . . . . 5 − 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 − 15 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 − 16 Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 5 − 17 Chapter 3.
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Chapter 1 Safety Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
While Operating 1. Do not run the engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could be deadly. 5. Before beginning mowing operation: A. Stop engine. B. Disengage traction drive. 2. Always stand behind the handle when starting and operating the machine. C. Remove transport wheels. 3. To start and stop the engine: D. Engage reel drive lever. A. Open fuel shut-off valve. B.
Safety and Instruction Decals Safety Numerous safety and instruction decals are affixed to your Greensmaster. If any decal becomes illegible or damaged, install a new decal. Part numbers for replacement decals are listed in your Parts Catalog. Order replacement decals from your Authorized Toro Distributor.
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Chapter 2 Product Records and Maintenance Table of Contents 1 1 2 2 2 3 3 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . .
Equivalents and Conversions 0.
Torque Specifications These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual. The following factors shall be considered when applying torque: cleanliness of the fastener, use of a thread sealant (e.g. Loctite), degree of lubrication on the fastener, presence of a prevailing torque feature (e.g.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series Fasteners) Thread Size # 6 − 32 UNC Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in−lb in−lb N−cm 10 + 2 13 + 2 147 + 23 # 6 − 40 UNF # 8 − 32 UNC 13 + 2 25 + 5 282 + 30 # 8 − 36 UNF # 10 − 24 UNC 18 + 2 30 + 5 339 + 56 # 10 − 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in−lb 644 + 68 N−cm 78 + 8 in−lb 881 + 90 N−cm M6 X 1.0 96 + 10 in−lb 1085 + 113 N−cm 133 + 14 in−lb 1503 + 158 N−cm M8 X 1.25 19 + 2 ft−lb 26 + 3 N−m 28 + 3 ft−lb 38 + 4 N−m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Recommended Torque Thread Size Square Head Hex Socket 1/4 − 20 UNC 140 + 20 in−lb 73 + 12 in−lb 5/16 − 18 UNC 215 + 35 in−lb 145 + 20 in−lb 3/8 − 16 UNC 35 + 10 ft−lb 18 + 3 ft−lb 1/2 − 13 UNC 75 + 15 ft−lb 50 + 10 ft−lb Recommended Torque** 7/16 − 20 UNF Grade 5 65 + 10 ft−lb 88 + 14 N−m 1/2 − 20 UNF Grade 5 80 + 10 ft−lb 108 + 14 N−m M12 X 1.25 Class 8.
Chapter 3.1 Kawasaki Engine Table of Contents 2 2 3 4 4 5 6 6 6 7 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Spark Plug and Ignition Components . . . . . . . . . . 8 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine Removal and Installation . . . . . . . . . . . . . 10 Lubrication . . .
Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the Kawasaki gasoline engine used in the fixed head walk Greensmaster mowers. Supplement. The use of some specialized test equipment is explained. However, the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility. Most repairs and adjustments require tools which are commonly available in many service shops.
Specifications Item Description Make / Designation Kawasaki, 4−stroke, OHV, single cylinder, air−cooled, gasoline engine, FE120G Bore x Stroke mm (in.) 60 x 44 (2.36 x 1.73) Total Displacement cc (cu. in.) 124 (7.6) Compression Ratio 8.
General Information Filling the Fuel Tank 1 DANGER Because gasoline is flammable, caution must be used when storing or handling it. Do not fill the fuel tank while engine is running, hot, or in an enclosed area. Vapors may build up and be ignited by a spark or flame source many feet away. DO NOT SMOKE while filling the fuel tank to prevent the possibility of an explosion. Always fill fuel tank outside. Wipe up any spilled gasoline before starting the engine.
Fuel Shut−off Valve The valve is located on the left front side of the engine. It has two positions: CLOSED and OPEN. Position valve to the closed position when storing or transporting the machine. Open valve before starting the engine. 1 Figure 2 Kawasaki Engine 1. Fuel shut−off valve GR 800/1000/1010/1600/1610/2000/2600 Page 3.
Adjustments Throttle Control Adjustment If a new throttle cable must be installed or the cable is out of adjustment, adjust the cable as follows: 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 4 3 2. Move throttle lever to the SLOW position. 5 3. Loosen throttle cable screw securing the throttle cable to the governor lever. 2 Note: Engine speed is measured at the input drive pulley (Fig. 12).
Adjusting V−belts To adjust belt tension on V−belts (Fig. 5), first check adjustment of clutch control. Refer to Clutch Control in this section. If unable to attain the 7 to 9 lbs (31 to 40 N) of force that is required in adjusting the clutch control, proceed to the next step. 2 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Loosen retainer securing the V−belt cover and pivot cover open. 1 3.
Service and Repairs Engine Oil The TORO Company recommends that the oil level be checked 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. Checking the Oil Level: 1. Park mower on a level surface. Make sure engine is OFF. 2. Position mower so the engine is level. Clean around the oil level gauge.
Air Cleaner Normally, clean air filter precleaner (foam element) after every 25 operating hours and the air cleaner filter (paper element) after every 100 operating hours. More frequent cleaning is required when the mower is operated in dusty or dirty conditions. Replace air cleaner filter (paper element) after 200 operating hours. 1 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2.
Engine Removal and Installation 2 3 4 5 6 1 42 49 13 36 33 35 34 7 41 40 39 38 7 48 8 9 10 37 32 12 13 20 43 11 15 20 33 16 45 44 46 17 14 22 20 41 33 13 IDLER PULLEY ASSEMBLY 32 KEY 31 30 18 19 23 29 10 8 10 28 27 19 21 6 5 7 23 7 24 7 26 7 50 25 47 26 Figure 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Removal 1. Make sure machine is parked on a level surface with the engine OFF. Remove high tension lead from the spark plug to prevent the engine from starting. Close fuel shut−off valve. 2. Remove pulley V−belts (Fig. 12). 2 A. Make sure clutch is DISENGAGED so the V− belts (34) are slackened. Make sure service brake is DISENGAGED so the input shaft pulley can turn. B. Open bellcrank cover (1) on the counter shaft housing to get access to the clutch.
Reinstalling the Engine 1. Make sure machine is parked on a level surface. The machine may be placed on a large work bench to make engine installation and adjustment easier. Remove high tension lead from the spark plug. 1 2. Make sure that all parts removed from the engine during maintenance or rebuilding are properly reinstalled to the engine. INSIDE FACE 3. Make sure bellcrank cover (1) is open on the counter shaft housing to get access to the clutch (Fig. 12). 2 4.
Lubrication Both fittings on the bellcrank assembly should be greased at least every 25 hours. Lubricate using No. 2 multipurpose lithium base grease. A hand operated grease gun is recommended for best results. 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Wipe each grease fitting with a clean rag. IMPORTANT: Do not apply too much pressure or grease seals will become permanently damaged. 3.
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Chapter 3.2 Subaru Engine Table of Contents GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Evaporative Control System . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . SUBARU SERVICE MANUAL 1 1 1 2 This Chapter gives information about specifications and repair of the Subaru gasoline engine used on the fixed head walk Greensmaster mowers.
Specifications Item Description Make / Designation Subaru, 4−stroke, OHC single cylinder, air−cooled, gasoline engine with gear reduction Bore x Stroke 2.28 in x 1.89 in (58 mm x 48 mm) 7.69 in3 (126 cc) Total Displacement Carburetor Float feed, fixed main jet Governor Mechanical flyweight Low Idle Speed (no load) 1405 to 1715 RPM High Idle Speed (no load) 3275 to 3475 RPM Direction of rotation Clockwise (facing PTO shaft) Fuel Unleaded, automotive grade gasoline Fuel Tank Capacity 2.
Chapter 3.3 Honda Engine Table of Contents 1 1 1 2 2 2 3 4 4 General Information This Chapter gives information about specifications and repair of the Honda GX120 gasoline engine used on the fixed head walk Greensmaster mowers. Most engine repairs and adjustments require tools which are commonly available in many service shops. Service and repair parts for the Honda engine used on Greensmaster mowers are supplied through your local Toro distributor.
Engine Service Manual Detailed information on engine troubleshooting, testing, disassembly, and assembly are given in the Honda Service Manual. The use of some specialized tools and test equipment is explained in the Honda Service Manual. Contact your local Honda Engine Dealer to obtain a copy of the engine Service Manual. However, the specialized nature of some engine repairs may dictate that the work be done at a Honda engine repair facility.
Specifications Item Description Make / Designation Honda, 4−stroke, OHV single cylinder, air−cooled, gasoline engine with gear reduction, GX120 Bore x Stroke 2.36 in x 1.65 in (60 mm x 42 mm) 7.
Service and Repairs Honda Engine Gearbox Assembly Removal and Installation 1 2 23 3 22 21 19 19 20 4 18 5 17 16 6 7 15 14 8 13 11 12 10 9 Figure 18 1. 2. 3. 4. 5. 6. 7. 8. Bolts (2 each) Muffler guard Engine Flange gasket O−ring Housing Bearing Output shaft Honda Engine 9. 10. 11. 12. 13. 14. 15. 16. Bearing Wave spring Housing gasket O−ring Plug Oil seal Flange head bolt (6 used) Cover assembly Page 3.3 − 4 17. 18. 19. 20. 21. 22. 23.
Removal 6. Install the output shaft in the gearbox housing. 1. Make sure machine is parked on a level surface with the engine OFF. Remove high tension lead from the spark plug to prevent the engine from starting. Close fuel shut−off valve. 7. Place the wave spring and housing gasket on the cover assembly. Disassembly 9. Re−torque the bolts in clockwise pattern to a final torque of 84 to 95 in−lb (9.5 to 11 N−m). 1. Using Fig. 18 as a guide and disassemble the gearbox assembly from the engine. 10.
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Chapter 4 Traction and Reel Drive Systems Table of Contents GR 800/1000/1010/1600/1610/2000/2600 Drum Drive Idler Pulley and Bearing . . . . . . . . . . Differential Axle Pulley and Bearing . . . . . . . . . . . Drum Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . Drum Assembly with Bearings . . . . . . . . . . . . . . . Drum Assembly with Bushings . . . . . . . . . . . . . . . Counter Shaft Assembly . . . . . . . . . . . . . . . . . . . . Brake Band Replacement . . . . . . . . . . . . . .
Specifications Item Description Traction Drive Engine to countershaft drive has two ”A” section V−belts. Countershaft to differential drive has 5 mm pitch timing belt. Differential to drum drive has a 8 mm pitch timing belt. Differential Peerless series 100 Brake Band drum Traction Drum Dual cast aluminum, 7.5 inch (19.
Special Tools Order special tools from your Toro Distributor. Drum Bushing Tool Kit − TOR4060 Note: This kit is used on mowers with drums that have bushings instead of bearings. The kit is used for models 04051 and 04052 − 50101 to 59999 only. REAMER TOR4061 BUSHING DRIVER TOR4062−1 This kit contains all the tools required to install and properly size the drum bushings to factory standards. These tools come as a set in a plastic tool case, or they may be ordered individually.
Adjustments Differential Belt Adjustment 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 3 1 5 2. Check tension by depressing belt at the mid span between pulleys with 5 to 6 lbs (22 to 27 N) of force. The belt should deflect 1/4 inch. If deflection is incorrect, proceed to next step. If deflection is correct, continue operation. 2 3. To adjust belt tension: 4 A. Remove capscrews securing the front and rear box covers to countershaft housing.
Drum Drive Belt Adjustment 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Check tension by depressing belt at mid span between the pulleys with 4 to 5 lbs (18 to 22 N) of force. The belt should deflect 1/4 inch. If deflection is incorrect, proceed to next step. If deflection is correct, continue operation. 2 1 3. To adjust belt tension: 1 A. Remove wheels if installed. B.
Reel Drive Belt Adjustment 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2 1 2. Check tension by depressing the belt at mid span between pulleys with 4 to 5 lbs (18 to 22 N) of force. The belt should deflect 1/4 inch. If deflection is incorrect, proceed to next step. If deflection is correct, continue operation. 3. To adjust belt tension: A. Remove cap screws, lock washers, and belt covers to expose the belt (Fig. 7). B.
Service/Park Brake Adjustment If service/park brake slips when operated, an adjustment is required. 1 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2 2. Move service/park brake lever to the OFF position. Note: Figure 10 is shown with the bellcrank cover removed for illustrative purposes. It is not necessary to remove the cover. 3. Loosen retainer securing the bellcrank cover. Pivot cover open. 4.
Service and Repairs Reel Drive Assembly 52 49 55 41 17 56 57 48 16 15 14 13 12 53 19 58 11 31 8 22 27 21 24 25 29 28 5 1 10 4 7 9 40 3 51 15 20 23 42 50 26 12 47 46 45 44 43 54 18 6 42 32 47 30 39 RIGHT FRONT 38 37 36 2 34 5 33 35 Figure 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Reel Drive Belt Replacement Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Remove cap screws (56), washers (57) and reel drive cover (49) to expose reel drive belt (41) (Fig. 11). 3. Adjust reel drive belt tension and reinstall reel drive cover (see Reel Drive Belt in the Adjustments section). 4. Reinstall grass shield to shield brackets with cap screws, flat washers, and lock nuts (Fig. 8). 3.
Clutch Bearing Removal Clutch and Pulley Assembly (Fig. 15) 1. Remove reel drive belt from the reel drive assembly (see Reel Drive Belt Replacement Removal). 1. Press new ball bearings into driver. Secure bearings with small retaining ring. 2. Remove clutch lever (24) as follows (Fig. 11): 2. Place key into the keyway of the driver. Press driver through the pulley enough to expose retaining ring groove. A.
C. With the actuator pin engaging in the groove of the clutch jaw driver (slide driver all the way into the housing), secure cap screw into the clutch housing (Fig. 14). Installation 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. A. Completely remove seal and adhesive from the out board shoulder of the clutch housing. B. Apply 3M adhesive EC−1099 or equivalent to the outboard shoulder of the housing. Attach seal to housing. 10.
Drum Drive Assembly 7 18 19 6 *4 8 5 29 30 41 37 38 FRAME 9 39 40 10 19 8 13 14 34 *33 18 19 31 11 28 18 22 23 21 20 1 19 18 2 *3 LEFT 12 27 16 15 26 25 FRONT 24 36 17 32 35 Figure 17 1. 2. 3. * 4. * 5. 6. 7. 8. 9. 10. 11. 12. 13. Spacer Backup washer Pulley (LH) Pulley (RH) Housing (LH) Housing (RH) Cap screw Lock nut Grease fitting Seal Bearing Spacer Grease fitting Belt Pulley 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
Drum Drive Belt Replacement Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Remove wheels if attached (see Wheels in the Service and Repairs section of Chapter 6 − Wheels and Accessories). 1 2 3. Remove cap screws (35), lock washers (36) and drum belt cover (33) to expose the belt (12) (Fig. 17). 4. Loosen cap screw (18) securing the spacer (41) (Fig. 17). Pivot the idler pulley away from the drive belt to loosen belt tension (Fig. 18).
Differential Axle Pulley and Bearing Removal 1. Remove drum drive belt from the drum drive assembly (see Drum Drive Belt Replacement Removal). 2. Remove nut from the differential axle. Remove pulley and woodruff key from the axle (Fig. 19). 7. Slide pulley onto the differential axle while aligning pulley keyway with the woodruff key. Secure pulley to the axle with the nut. 8. Replace drum drive belt to the drum drive assembly and adjust belt tension (see Drum Drive Belt Replacement Installation).
Drum Shaft Bearing C. Use a suitable wrench on the flats of the drum shaft, between the drum and the frame, to lock the shaft. Screw pulley to the drum shaft. Removal 1. Remove drum drive belt from the drum drive assembly (see Drum Drive Belt Replacement Removal). Note: The pulley (LH) has left hand threads, while the pulley (RH) has right hand threads. Each pulley has an arrow stamped on it for the direction of tightening. 2. Remove pulley from drum shaft as follows (Fig. 22): 4.
Drum Assembly with Bearings (Models 04050, 04052−60000 & Up, and 04060) 1 2 10 3 4 5 8 9 4 3 6 7 11 12 9 13 Figure 24 1. 2. 3. 4. 5. Drum Drum spindle Spring lip seal Bearing Bearing spacer 6. 7. 8. 9. Seal spacer Lock nut Drum hub Lock washer Removal 1. Remove both drum shaft bearings from both drum shafts (see Drum Shaft Bearing Removal). 2. Pivot mower back and remove drum assembly from the mower. Disassembly 10. 11. 12. 13. Cap screw Drum shaft (LH) Drum shaft (RH) Cap screw 1.
Note: The lock nut turns hard on the spindle shaft when tightened. Make sure all rotation has stopped when tightening. A good solid sound indicates the nut is tight. 5. Secure drum spindle to the drum with four cap screws and lock washers. Tighten screws using an alternating pattern. Repeat tightening sequence a second time. 3. Apply grease to the shaft of the drum spindle. Carefully slide drum spindle into drum hub bearings. Secure lock nut and seal spacer to the drum spindle (Fig. 25). 6.
Drum Assembly with Bushings (Models 04051 and 04052−50001 to 59999) 3 5 3 6 6 6 4 OIL SEALS NOT SHOWN 1 2 Figure 26 1. Cap screw 2. Lock washer 3. Drum 4. Drum shaft extensions Removal 1. Remove both drum shaft bearings from both drum shafts (see Drum Shaft Bearing Removal). 5. Drum shaft 6. Bushing BUSHING DRIVER 2. Pivot mower back and remove drum assembly from the mower. Disassembly 1. Remove four cap screws and lock washers from each drum.
5. Install inner bushing into drum (Fig. 30). Note: The setting of the adapter sleeve is critical so the bushing is inserted deep enough for oil seal installation. BUSHING DRIVER ADAPTER SLEEVE BUSHING A. Install adapter sleeve on the bushing driver so the counterbore of the sleeve seats 3/16 inch (0.48 cm) beyond the step on the driver. PILOT B. Install a new bushing on the bushing driver, then secure pilot to the bushing and adapter sleeve. Figure 30 C.
Counter Shaft Assembly 41 43 42 39 40 51 38 50 58 57 5 48 39 40 49 2 3 1 47 46 48 44 32 21 37 54 33 8 31 36 6 7 10 22 36 20 23 12 9 52 12 35 4 45 12 34 53 40 55 2 3 4 29 30 14 56 19 12 23 13 15 29 16 17 27 RIGHT 28 FRONT 11 26 25 18 24 Figure 33 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Brake Band Replacement 6. Reinstall interference previously removed (Fig. 34). Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. A. Make sure clutch is disengaged. Install both V− belts. 2. Remove interference to brake band (Fig. 34). B. Secure belt shield to engine block with both cap screws and lock washers. Do not over tighten. A. Remove bellcrank cover by removing both cap screws and lock washers. C.
Power Shaft Bearing Removal 1. Remove brake band from the counter shaft housing (see Brake Band Removal). 2. Remove cap screw (39) and lock washer (40) from the front box cover (37) and counter shaft housing (1). Remove cover from housing (Fig. 33). 3. Loosen cap screw (36) enough to rotate idler pulley (44) away from the belt (35). Loosen belt by rotating the idler pulley counterclockwise (Fig. 33). 4 5 4.
Differential Axle Bearing (Countershaft Housing) Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Lower handle to allow a clearance for the removal of the bearing and flangettes from the differential axle (see Handle in the Adjustments section of Chapter 6 − Wheels and Accessories). Note: The locking collar securing the left differential axle to the countershaft housing is a eccentric flange type. 3.
Differential Idler and Bearing Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 1 2. Remove capscrews (39) and lock washers (40) securing rear and front box covers (38 and 39) to the countershaft housing (1). Pull covers from housing (Fig. 33). 2 3. Remove cap screw and lock washer that secure the idler pulley (Fig. 37). Remove idler pulley from countershaft housing (Fig. 39). Disassembly (Fig 33) 1.
Differential Assembly and Pulley Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 4 2 3. Remove capscrews (39) and lock washers (40) securing rear and front box covers (38 and 39) to the countershaft housing (1). Pull covers from housing (Fig. 33). 4. Loosen cap screw securing the idler to the counter shaft housing (Fig. 37). Pivot idler pulley counterclockwise away from the backside of belt to release belt tension (Fig. 39).
BEARING RECESS (INBOARD) 0.125 TO 0.140 inch (3.18 to 3.56 mm) 5 13 1 3 12 INSET FOR DRIVE PIN 10 9 7 6 11 4 12 6 11 10 8 2 7 BEARING RECESS (OUTBOARD) 0.150 to 0.170 inch (3.81 to 4.32 mm) 9 SEAL RECESS 0.030 TO 0.045 inch (0.76 to 1.14 mm) 13 Figure 43 1. 2. 3. 4. 5. Flanged hex head screw Differential carrier housing Differential carrier housing Axle (long) Axle (short) 6. 7. 8. 9. Bevel gear Pinion Drive pin Thrust washer 10. 11. 12. 13.
Note: If any of the bevel or pinion gears need to be replaced, it is recommended to replace all four gears as a complete set. 2. Slide pulley onto differential axle so threads extend through pulley. Secure lock nuts and flat washers to the differential assembly and pulley. (Fig. 42). 2. Attach bevel gears to the axles. Lock each gear in place with both retaining rings. Make sure flat side of retaining rings are away from the gear (Fig. 44). 3.
5. Slide locking collar onto the differential axle (Fig. 38). IMPORTANT: Align axles so they turn freely before striking the locking collar. 6. Reinstall rear box cover (38) and differential boot (43) to the differential axle and countershaft housing (1) (Fig. 33). 9. Lock locking collar by striking it with a punch in the counterclockwise direction. Tighten set screw on the locking collar (Fig. 38). 7.
Differential Belt Replacement − Models 04051, 04052, and 04060 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Remove capscrews and lock washers securing the drum belt and reel drive covers to the right side plate. Remove belt covers. 4. Remove capscrews and lock washers securing the front and rear box covers to the counter shaft housing. Slide covers away from the housing to expose the belt (Fig. 48). 5.
Differential Belt Replacement − Model 04050 Only Removal 4 1. Place mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. If the wheels are attached, place the mower on its kickstand and remove them. 2. Remove both drum drive covers using a 7/16−inch socket to remove the four cap screws and lock washers from each cover (Fig. 49). 1 3 2 3. From the mower rear, precede as follows (Fig. 50): A.
6. Use 9/16−inch open end wrench to hold the power shaft while backing off the lock nut with a 7/8−inch socket (Fig. 53). 6 2 3 4 7. Remove nut from the short axle of the differential as follows (Fig. 54): 1 A. Loosen small hose clamp securing the differential boot to the bearing housing. 5 B. Use drift punch in the hole of the short axle while removing the nut with a 7/8−inch socket. FORWARD 8. Remove belts from both drum drive assemblies as follows (Fig. 55): A.
Note: The locking collar securing the long axle to the countershaft housing is a eccentric flange type. 11. Loosen the set screw on the locking collar. Unlock collar by striking it with a punch in the clockwise direction (Fig. 58). 12. Remove three cap screws and lock washer securing the box cover to the countershaft housing. Pull cover from housing. Loosen both carriage bolts and lock nuts securing the idler pulley to the countershaft housing. Slide idler pulley away from the belt (Fig. 59). 13.
1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 9. Reinstall belts to both drum drive assemblies as follows (Fig. 55): A. Reinstall belt onto the drum shaft pulley and pulley on both sides of mower. 2. Install new belt to the differential pulley and countershaft pulley. Slide differential assembly to the right side plate (Fig. 62). B. Swing idler pulley into belt. Reinstall upper carriage bolts and lock nuts to both sides of the frame.
11. Secure engine to the frame as follows: 1 A. Reinstall both V−belts (Fig. 51). A. Position the engine base to obtain from 5.34 to 5.46 inches (13.6 to 13.9 cm) between the engine output shaft and power shaft center lines (Fig. 65). 1 B. Align machined face of input power and shaft input pulleys to within a maximum of 0.03 inch (0.76 mm) misalignment (Fig. 65). 3 C. Secure engine base to the front of the frame with two cap screws and lock washers (Fig. 51). D.
Lubrication The mower should be greased at least after every 25 hours of operation. Lubricate grease fittings using No. 2 multipurpose lithium base grease. A hand operated grease gun is recommended for best results. 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Wipe each grease fitting with a clean rag. IMPORTANT: Do not apply too much pressure or grease seals will become permanently damaged. 3. The grease fitting locations are as follows: A.
Traction and Reel Drive Systems Page 4 − 36 GR 800/1000/1010/1600/1610/2000/2600
Chapter 5 Electrical System Table of Contents COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . Interlock Module and Clutch (Interlock) Switch No Operator Presence Control . . . . . . . . . . . . . With Operator Presence Control . . . . . . . . . . . . Ignition System Operation . . . . . . . . . . . . . . . . . . . Igniter (Serial Number Below 60465) . . . . . . . . . Ignition Coil (Kawasaki Engine) . . . . . . . . . . . . . . Ignition Coil (Subaru Engine) . . . . . . . . . . . . . . . .
Electrical Schematics and Wire Harnesses RED HIGH TENSION LEAD CONNECTOR/ INTERLOCK MODULE BLACK IGNITION COIL/ IGNITOR B C D Note: There are two types of ignition coils used on the Kawasaki FE120 engine. On models below serial number 60465, a coil is used in conjunction with a separate igniter (shown below). On models above serial number 60464, a combination igniter/ignition coil is used. The wire harness used on the mower is the same for both styles of ignition. IGNITOR BROWN BROWN RED BLACK\WHI
HIGH TENSION LEAD RED CONNECTOR/ INTERLOCK MODULE E F BROWN CLUTCH INTERLOCK SWITCH BLACK\WHITE D BROWN ENGINE MAGNETO C ON/OFF SWITCH RED B GREEN BLACK A BROWN IGNITION COIL/ IGNITOR BROWN BLACK BLACK\WHITE IGNITOR BLACK\WHITE Note: There are two types of ignition coils used on the Kawasaki FE120 engine. On models below serial number 60465, a coil is used in conjunction with a separate igniter (shown below).
HIGH TENSION LEAD RED INTERLOCK MODULE BLACK IGNITION COIL E F WHITE ORANGE D GREEN C BLACK RED ON/OFF SWITCH ENGINE MAGNETO (FLYWHEEL) B RED BLACK BLACK A OPERATOR PRESENCE SWITCH (IF EQUIPPED) YELLOW YELLOW LIGHTING COIL HOURMETER (IF EQUIPPED) CLUTCH INTERLOCK SWITCH Drawing No. 105−5351 Rev C Serial Number From 220000000 to 270999999 Kawasaki FE120 Engine ON\OFF switch (on engine) is open in the ON position CLUTCH INTERLOCK SWITCH is closed when traction lever is in NEUTRAL OPE
HIGH TENSION LEAD INTERLOCK MODULE A B C D BLACK RED LIGHTING COIL BLACK RED ENGINE MAGNETO (FLYWHEEL) F WHITE GREEN RED E ORANGE RED IGNITION COIL OPERATOR PRESENCE SWITCH (IF EQUIPPED) 2 1 3 5 4 ON/OFF SWITCH (IN OFF) CLUTCH INTERLOCK SWITCH HOURMETER (IF EQUIPPED) Electrical System GREEN 6 Serial Number 280000000 to 280999999 Kawasaki FE120 or Subaru Engine ON\OFF switch (on console) is open in the ON position CLUTCH INTERLOCK SWITCH is closed when traction lever is in NEUTRAL
Drawing No. 112−9410 Rev C Serial Number 280000000 to 280999999 Kawasaki FE120 or Subaru Engine ON\OFF switch (on console) is open in the ON position CLUTCH INTERLOCK SWITCH is closed when traction lever is in NEUTRAL OPERATOR PRESENCE SWITCH is closed when bail is against handle Electrical System Page 5 − 6 GR 800/1000/1010/1600/1610/2000/2600
HIGH TENSION LEAD INTERLOCK MODULE B C D E LIGHTING COIL WHITE RED BLACK BLACK ENGINE MAGNETO (FLYWHEEL) F ORANGE A GREEN RED IGNITION COIL OPERATOR PRESENCE SWITCH (IF EQUIPPED) 2 1 3 5 4 RED RED ON/OFF SWITCH (IN OFF) CLUTCH INTERLOCK SWITCH HOURMETER (IF EQUIPPED) Electrical System GREEN 6 Serial Number 290000000 to 311999999 Kawasaki FE120 or Subaru Engine ON\OFF switch (on console) is open in the ON position CLUTCH INTERLOCK SWITCH is closed when traction lever is in NEUTRA
Drawing No. 115−1610 Rev C Serial Number 290000000 to 311999999 Kawasaki FE120 or Subaru Engine ON\OFF switch (on console) is open in the ON position CLUTCH INTERLOCK SWITCH is closed when traction lever is in NEUTRAL OPERATOR PRESENCE SWITCH is closed when bail is against handle Electrical System Page 5 − 8 GR 800/1000/1010/1600/1610/2000/2600
HIGH TENSION LEAD INTERLOCK MODULE B C D E LIGHTING COIL WHITE RED BLACK BLACK ENGINE MAGNETO (FLYWHEEL) F ORANGE A GREEN RED IGNITION COIL OPERATOR PRESENCE SWITCH (IF EQUIPPED) 2 1 3 5 4 RED RED ON/OFF SWITCH (IN OFF) CLUTCH INTERLOCK SWITCH HOURMETER (IF EQUIPPED) Electrical System GREEN 6 Serial Number 312000000 to 316999999 Subaru Engine NOTE: Used on model 04056 to serial number 400341548 ON\OFF switch (on console) is open in the ON position CLUTCH INTERLOCK SWITCH is clos
Drawing No. 120−6338 Rev A Serial Number 312000000 to 316999999 Subaru Engine NOTE: Used on model 04056 to serial number 400341548 ON\OFF switch (on console) is open in the ON position CLUTCH INTERLOCK SWITCH is closed when traction lever is in NEUTRAL Electrical System Page 5 − 10 GR 800/1000/1010/1600/1610/2000/2600
HIGH TENSION LEAD INTERLOCK MODULE LIGHTING COIL D E F RED YELLOW YELLOW ENGINE MAGNETO (FLYWHEEL) C ORANGE B GREEN A WHITE RED IGNITION COIL OPERATOR PRESENCE SWITCH (IF EQUIPPED) 2 1 3 5 4 RED RED CLUTCH INTERLOCK SWITCH ON/OFF SWITCH (IN OFF) HOURMETER (IF EQUIPPED) OPTIONAL LIGHT SWITCH 2 1 3 5 4 VIOLET OPTIONAL LIGHT (LH) 6 BLACK Serial Number Above 400000000 Subaru Engine OPTIONAL LIGHT (RH) NOTE: Used on model 04056 serial number above 400341549 ON\OFF switch (on co
Drawing No. 122−0964 Rev B Serial Number Above 400000000 Subaru Engine NOTE: Used on model 04056 serial number above 400341549 ON\OFF switch (on console) is open in the ON position CLUTCH INTERLOCK SWITCH is closed when traction lever is in NEUTRAL Electrical System Page 5 − 12 GR 800/1000/1010/1600/1610/2000/2600
HIGH TENSION LEAD INTERLOCK MODULE LIGHTING COIL D E F RED YELLOW YELLOW ENGINE MAGNETO (FLYWHEEL) C ORANGE B GREEN A WHITE RED IGNITION COIL OPERATOR PRESENCE SWITCH (IF EQUIPPED) 2 1 3 5 4 RED RED CLUTCH INTERLOCK SWITCH ON/OFF SWITCH (IN OFF) HOURMETER (IF EQUIPPED) OPTIONAL LIGHT SWITCH 2 1 3 5 4 VIOLET OPTIONAL LIGHT (LH) 6 BLACK OPTIONAL LIGHT (RH) Honda Engine ON\OFF switch (on console) is open in the ON position CLUTCH INTERLOCK SWITCH is closed when traction lever
Drawing No. 122−1227 Rev A Honda Engine ON\OFF switch (on console) is open in the ON position CLUTCH INTERLOCK SWITCH is closed when traction lever is in NEUTRAL Electrical System Page 5 − 14 GR 800/1000/1010/1600/1610/2000/2600
Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: Toro recommends the use of a DIGITAL Volt− Ohm−Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter.
Troubleshooting NOTE: See the Kawasaki FE161 & FE170 Service Manual and Kawasaki FE120 Service Manual Supplement for troubleshooting of electrical problems related to the Kawasaki ignition system. However, ignition system testing is covered in this chapter. The ignition system for the FE120 engine is not fully covered in the service manual. CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or 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 electrically isolated (e.g. disconnect all leads or remove from circuit) from the circuit when tested. NOTE: See the engine service manual (Kawasaki or Subaru) for engine component testing information. WARNING The ignition system produces a dangerously high voltage.
Interlock Module and Clutch (Interlock) Switch − With Operator Presence Control The interlock module prevents the engine from starting unless the clutch interlock switch is closed (clutch DISENGAGED). After a safe start, the engine will continue to run with the clutch interlock switch open (clutch ENGAGED) or closed. However, the operator presence bail must be engaged (held against the handle) for the engine to run when the clutch is ENGAGED.
Ignition System Operation Making a System Tester This simple tester can be made if a commercial spark tester is not available. It can determine if the ignition system is operating properly. SPRING CLIP Note: This tester is not necessary if spark tester TOR4036 (see Special Tools in this chapter) is available. SPARK PLUG 1. Use a new NGK BPR5ES or equivalent spark plug. 2. Remove the ground electrode from the test plug.
Igniter (Kawasaki Engine on Machine with Serial Number Below 60465) The igniter consists of transistorized circuitry that controls the firing sequence of the spark plug in conjunction with the ignition coil. Mounted on the engine block, the igniter casing is grounded directly to the engine. A single black wire makes a circuit from the igniter to the primary of the ignition coil. 1 1. Park mower on a level surface. Make sure engine is OFF. 2. Remove black wire from the bottom of the igniter. 3.
Ignition Coil (Kawasaki Engine) A commercial coil tester can be used to test the ignition coil. If a tester is available, test the ignition coil as suggested in the Kawasaki FE161 & FE170 Service Manual and Kawasaki FE120 Service Manual Supplement 1 The coil can be tested for a badly shorted or broken winding with a digital ohmmeter. However, an ohmmeter can not detect layer shorts and shorts resulting from insulation breakdown under high running voltages.
Ignition Coil (Subaru Engine) The coil can be tested for a badly shorted or broken winding with a digital ohmmeter. However, an ohmmeter can not detect layer shorts and shorts resulting from insulation breakdown under high running voltages. 1 Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads.
Spark Plug Use the correct spark plug for your Greensmaster as identified in your Operator’s Manual. Remove plug after every 100 operating hours and check its condition. Air gap 1. Make sure engine is OFF. Pull high tension lead off the spark plug. 2. Clean around spark plug and remove plug from the cylinder head. Note: The condition of the spark plug can give an accurate picture of the overall condition of the engine.
NORMAL OVER HEATING FUSED SPOT DEPOSIT Has gray or light tan deposits on the firing tip. Light gray or white insulator with small gray brown or black spots. Electrodes have a bluish burnt appearance. Has spotty or melted deposits resembling blisters or bubbles. Caused by sudden acceleration. May be caused by engine over heating, loose spark plugs, wrong fuel type, too hot a plug, low fuel pump pressure, or incorrect ignition timing. Replace spark plug. Replace spark plug.
Clutch Interlock Switch (Serial Number Below 280000000) Switch Adjustment 1. Make sure the engine is OFF and traction lever is DISENGAGED. 2 2. Loosen both switch mounting nuts and move switch until the switch plunger is depressed 0.180 to 0.240 inch (4.6 to 6.1 mm) (switch closed). 1 3. Tighten switch mounting nuts. 4. Engage traction lever and verify that the switch plunger is depressed no more than 0.060 inch (1.5 mm) (switch open). Readjust as required. 3 Switch Removal 1.
Clutch Interlock Switch (Serial Number Above 280000000) Switch Adjustment 1. Make sure the engine is OFF and the traction lever is DISENGAGED. 1 2. Remove console cover from handle to allow access to clutch interlock switch. 3. With the traction lever in the disengaged position and resting against the neutral stop, there should be from 0.032 to 0.062 inch (0.8 to 1.5 mm) clearance between the traction lever and the clutch interlock switch (Fig. 11). 3 4.
Operator Presence Control Switch (Serial Number Below 280000000) Greensmaster mowers with serial number below 280000000 that are equipped with the operator presence system use a plunger type switch that is depressed when the operator presence bail is engaged. The switch is located on the left side of the handle (Fig. 12). 1 Switch Adjustment 2 1. Make sure the engine is OFF. 2. Loosen both switch adjusting nuts.
Operator Presence Control Switch (Serial Number Above 280000000) Greensmaster mowers with serial number above 280000000 that are equipped with the operator presence system use a plunger type switch that is depressed when the operator presence bail is engaged. The switch is located on the left side of the handle (Fig. 13). 1 Switch Adjustment 5 4 1. Make sure the engine is OFF. 2. Loosen fasteners that secure switch to handle bracket.
ON/OFF Switch (Serial Number Above 280000000) Greensmaster mowers with serial number above 280000000 are equipped with a two position ON/OFF switch on the console. This rocker switch allows the engine to be turned on and off. Testing 1. Make sure the engine is OFF and the traction lever is in the NEUTRAL position. 2. Disconnect wire harness electrical connector from the on/off switch. 3.
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Chapter 6 Controls, Wheels and Accessories Table of Contents Wheels and Accessories SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Handle Height Adjustment . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Tire pressure 12 to 15 PSI (83 to 103 kPa) Wheel Shaft torque 65 to 75 ft−lb (8.99 to 10.37 kg−m) General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, adjustment procedures and general maintenance for your Greensmaster mower. Refer to the Operator’s Manual for additional information when servicing the machine. Replacement Operator’s Manuals are available on the internet at www.toro.com.
Adjustments Handle Height Adjustment 1. Make sure mower is parked on a level surface with the engine OFF. 2. Remove cotter pins from the ring pins on each side of the mower. 3. Support handle, and remove ring pins from each side of the mower. Raise or lower handle to the desired operating position. 4. Reinstall ring pins and cotter pins. 1 2 Figure 1 2. Ring pin Wheels and Accessories 1.
Service and Repairs Handle Assembly 4 5 6 5 3 2 7 39 38 1 43 19 15 8 9 10 13 11 37 35 18 12 28 27 26 14 11 17 14 36 34 25 42 24 23 22 20 21 16 40 41 RIGHT FRONT 33 32 31 30 29 13 Figure 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Throttle cable Spring Lock nut Retaining washer Friction washer Throttle lever Cap screw Clutch skid bracket Cap screw Console bracket (RH) Lock nut Clutch cable Screw Shoulder bolt Brake cable 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.
Removal 1. Park mower on a level surface. Make sure engine is OFF. 6 2. Cut cable ties from the handle. 3. Remove cap screw (30), spring lock washer (31), and flat washer (32) from each handle pivot pin (33) on each of the handle (35) ends (Fig. 2 and 3). 2 Note: The cotter pin, ring pin, cap screw,and lock nut may have to be removed from the handle arms to allow handle removal (Fig. 4). 4 3 4. Squeeze handle ends inward.
Brake Cable Replacement Removal 6 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Disengage brake to release tension on the brake cable. Remove cable ties from the left side of the handle. Figure 5 1. 2. 3. 4. Brake lever Shoulder bolt Lock nut Cable eyelet 5 6 3 5. Remove four screws (13) securing the console (29) to the console brackets (10 and 19). Position console forward and away from the brackets (Fig. 2).
A. Attach brake cable to the counter shaft housing and tighten the rear nut. B. If the operator presence kit is not installed, secure console bracket to the brake skid bracket with three screws. B. Secure cable eyelet to the brake lever with shoulder bolt and lock nut. 5. Install new cable ties to the left side of the handle. 4. Run new brake cable to the countershaft assembly. Install new brake cable to the countershaft housing and brake lever as follows (Fig. 5): 6.
Clutch Cable Replacement Removal 6 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Disengage clutch to release tension on the clutch cable. Remove cable ties from the right side of the handle. 5 1 2 3. Remove clutch cable from the bellcrank assembly as follows (Fig. 7): 4 3 A. Open bellcrank cover to access the clutch lever and bracket. B. Remove shoulder bolt and lock nut securing the cable eyelet to the clutch lever. Figure 7 1.
3. If the operator presence kit is not installed, secure console bracket to the clutch skid bracket with three screws (Fig. 8). 4. Position console (29) over both console brackets (10 and 19). Secure console to the brackets with four screws (13) (Fig. 2). B. Secure clutch cable eyelet to the clutch lever with shoulder bolt and lock nut. 6. Install new cable ties to the right side of the handle. 7. Adjust clutch cable and close bellcrank cover (see Clutch Control Adjustment in Chapter 3.
Throttle Cable Replacement Removal 2 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 6 1 3. Remove throttle cable from the governor as follows (Fig. 9): 5 A. Unscrew throttle cable screw enough to release the throttle cable from the nut in the governor lever. B. Remove hex head screw from the throttle cable bracket. 3 4 2. Remove cable ties from the right side of the handle.
Wheels Removal 1. Park mower on a level surface. Make sure the engine is OFF. 2. Push kickstand down with one foot while pulling up on the handle. This will support the mower on the kick stand. 3. Pivot wheel locking clip away from the center of the wheel. Slide wheel off the wheel shaft. Note: The right hand wheel shaft has left hand threads. 4. If necessary, remove wheel shaft from the drive pulley. 1 Installation 1. Make sure mower is parked on a level surface and the engine is OFF. Figure 11 2.
1 2 3 4 5 6 7 13 8 12 14 10 11 9 Figure 14 1. 2. 3. 4. 5. Cap screw Lock washer Shallow rim Tire Hub 6. 7. 8. 9. 10. 11. 12. 13. 14. Retaining lever Spring Bolt Bolt Deep rim Disassembly (Fig. 14) 1. Make sure that tire is fully deflated before disassembly of wheel. 2. Remove three cap screws (1) and lock washers (2) from the shallow rim (3) and hub (5). Remove hub from deep rim (10). 3. Remove four cap screws (12) and flange nuts (13) from the deep rim (10) and shallow rim (3).
Kickstand 6 1 2 34 7 9 12 5 8 NOTE THE POSITION OF THE STOP 11 9 10 FRAME Figure 16 1. 2. 3. 4. Cap screw Cap screw Lock washer Spring bracket 5. 6. 7. 8. Extension spring Cap screw Spring retainer Kickstand 9. 10. 11. 12. Flat washer Lock nut Spacer Flange lock nut Removal 1 1. Park mower on a level surface. Make sure the engine is OFF. 2. Pivot kickstand up against the handle and hold there. 3 3. Use a pliers to remove the extension spring from the spring retainer (Fig. 17). 2 4.
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Chapter 7 Cutting Unit Table of Contents SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . Backlapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bedbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bedknife Replacement and Grinding . . . . . . . . . . Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparing Reel for Grinding . . . . . . . . .
Introduction This Chapter covers the cutting unit section of your Greensmaster. The cutting unit consists of the frame assembly, reel assembly, drum assembly, and detachable basket. The reel and drum drive assemblies make up Cutting Unit part of the cutting unit, and their component parts that are necessary for the service of the cutting unit are covered in this chapter.
Specifications Figure 1 REEL CONSTRUCTION (GR1000): 5−inch (12.7 cm) diameter, 11 carbon steel blades (optional 8 blades) welded to 5 stamped steel spiders. REEL CONSTRUCTION (GR1600): 5−inch (12.7 cm) diameter, 8 carbon steel blades welded to 6 stamped steel spiders. HEIGHT−OF−CUT RANGE (GR1000): 5/64 to 1 inch (2 to 25 mm) HEIGHT−OF−CUT RANGE (GR1600): 1/8 to 1−1/4 inch (3 to 32 mm) WIDTH−OF−CUT (GR1000): 21 inches (53.3 cm) WIDTH−OF−CUT (GR1600): 26 inches (66.0 cm) CLIP (GR1000): 0.16 inch (0.
General Information Operator’s Manual The Cutting Unit Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for the cutting unit on your Greensmaster machine. Additionally, if optional kits have been installed on the cutting unit (e.g. grooming reel), the installation instructions for the kit includes set− up and operation information. Refer to those publications for additional information when servicing the cutting unit. Grass Basket Installation 1.
Special Tools Order special tools from your Toro Distributor. Some tools may have been supplied with your mower or available as TORO parts. Some tools may also be available from a local supplier. Gauge Bar Assembly − P/N 13−8199 Used to verify height−of−cut. Figure 3 Backlapping Brush Assembly − TOR299100 Used to apply lapping compound to cutting units while keeping the operator’s hands at a safe distance from the rotating reel.
Bearing Replacement Tool Kit − TOR238900A The puller is used to remove the bearings from the rollers. A driving tube is used to install bearings into the roller. A drill bushing is used to drill into bearing shafts without a removal hole. Figure 6 Diameter/Circumference Measuring Tape − TOR6023 Spring steel measuring tape for accurately measuring the circumference and outside diameter of cutting reel and other spherical components. Tape calibration is in fixed inch readings (no adjustments).
Bedknife Top Angle Indicator and Mount Toro Part Numbers: 131−6828 and 131−6829 Because the top grind angle on bedknives is critical for edge retention, and therefore after− cut appearance, Toro has developed these service tools for accurately measuring the top grind angle on all bedknives. 1 2 3 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. 1.
Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the mower. It is important to remember that the lower the height−of−cut, the more critical these factors are. See Adjustments and Service and Repairs sections for detailed adjustments and repair information.
Factor Possible Problem/Correction Height−of−cut “Effective” or actual height−of−cut depends on the mower weight and turf conditions. Effective height−of−cut will be different than the bench set height−of−cut. Proper bedknife for height−of−cut If the bedknife is too thick for effective height−of−cut, poor quality of cut will result. Front roller scraper and comb adjustment Install and/or adjust roller scrapers if grass clippings build up on the rollers.
Adjustments CAUTION Never work on the mower with the engine running. Always stop the engine and remove the high tension lead from the spark plug first. Leveling Drum to Reel 1. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Position mower on a flat level surface, preferably a precision steel work plate.
Bedknife to Reel Adjustment 1. Position mower on a flat level work surface. Make sure engine is OFF. Remove high tension lead from the spark plug. Remove reel contact: A. On the GR1000, loosen the jam nuts on the bedknife adjusting screws and rotate adjusting screws counterclockwise (Fig. 12). 1 2 B. On the GR1600, turn bedbar adjusting screws counterclockwise (Fig. 13). 2. Tilt mower back on handle to expose bedknife and reel.
Height−of−Cut Adjustment 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 4 2. Verify that the drum is level to the reel and that the bedknife to reel contact is correct. Tip mower back on its handle to expose roller, drum, and bedknife. 3 3. Loosen locknuts securing height−of−cut arms to the height−of−cut brackets (Fig. 17). 4. Loosen nut on gauge bar and set adjusting screw to desired height-of-cut.
Grass Shield Height Adjustment Adjust shield to assure proper grass clipping discharge into the basket. 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Measure distance from the top of the front support rod to the front lip of the shield at each end of cutting unit (Fig. 20). 3. The height from the support rod to the front lip of the shield for normal cutting conditions should be 4 inches. 1 2 Figure 20 1. Support rod 2.
Service and Repairs Backlapping 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Make sure clutch to the reel drive is DISENGAGED. 3. Remove the cover plug in the right reel drive cover (Fig. 23). 1 4. Insert a 1/2−inch socket extension, which is connected to a backlapping machine, into the square hole in the center of the reel pulley. 5. Backlap according to procedure in Toro General Service Training Book, Reel Mower Basics (part no. 09168SL).
Bedbar Removal 1. Position mower on a flat level work surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2 2. Loosen jam nut on the adjusting screw. Loosen adjusting screw until the thrust washer contacts the inside of the frame adjuster. Accomplish on both sides of the mower (Fig. 25). 1 WARNING Use caution when removing the bedbar. Adjusting screw springs (Fig. 26) are under tension and could release suddenly. Figure 26 1. Spring 2. Pin (Allen wrench) 3.
Installation 4 Note: Use new nylon washers and bushings for installation. 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2 2. Use grease to hold thrust washers against the inside of both frame adjusters (Fig. 29). 1 3. Install new nylon bushings into both sides of the frame (Fig. 30). 4. Put anti−seize lubricant on the threads of bedbar bolts. Install nylon washer, metal washer, and bedbar bolt to both sides of the frame (Fig. 31).
Bedknife Replacement and Grinding Bedbar Removal 1. Remove bedbar from frame (see Bedbar Removal). 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special Tools in this chapter). Discard screws. Remove bedknife from the bedbar (Fig. 34). 2 3. See bedknife grinding information on the following pages. Bedbar Installation 1. Use scraper to remove all rust, scale and corrosion from bedbar surface. Lightly oil bedbar surface before installing bedknife. 2.
Grinding Bedknife Grinding Specifications (see Fig. 37) 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. Follow the bedknife grinding specifications provided (Fig. 36). Grind only enough so the top surface of the bedknife is true (Fig. 37).
Reel Removal 2 1. Make sure engine is OFF. Remove high tension lead from the spark plug. Place mower on a flat level surface or on a stable work bench. 2. Remove bedbar from the mower (see Bedbar Removal). 5 3 6 10 17 4 7 3. If a grooming reel kit is installed, remove the cutting reel using the procedures in Frame Assembles (RH and LH) and Cutting Reel in the Service and Repairs section of Chapter 8 − Grooming Reel Kit. 8 6. Remove the pulley and drive assembly (Fig.
10. Pull both bearing housings from the frame and reel (Fig. 39 and 40). Remove the reel from the mower. 11. If bearings are worn or need replacement for maintenance purposes, remove bearings from both bearing housings as follows: Note: The two bearing housings are similar in appearance but can not be interchanged. The bearing housing (RH) was marked during disassembly. 5. Attach bearing housing (RH) through the frame onto the reel shaft (Fig. 39). A.
8. Tighten flat head screws and nuts securing the bearing housing (RH) to the frame (Fig. 39). 11. Reinstall reel drive cover with four lock washers and cap screws to the mower. Tighten cap screws (Fig. 39). 9. Remove both cap screws and lock nuts holding the bearing housing (LH) to the frame. Position bearing cover to housing and secure to frame with both cap screws and lock nuts (Fig. 40). 12. Reinstall grease fittings to both bearing housings. Lubricate both housings with No.
Preparing a Reel for Grinding Note: Check to make sure the reel bearings are in good condition and properly adjusted before grinding a reel. 4. After completing grinding process: A. Install height−of−cut arms and roller (see Roller Installation). 1. Remove bedbar assembly (see Bedbar Removal). B. Install bedbar assembly (see Bedbar Installation). 2. Raise grooming reel, if installed, by rotating both quick−up levers so they face the rear of the mower. C.
Roller Removal 9 5 6 7 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2 2. Loosen jam nut and set screw on both ends of the mower. 1 3. On one end of the mower, remove lock nut and flat washer from the carriage screw. 10 3 Note: Do not adjust the height−of−cut screw when removing the height−of cut arm. 4. Pull the height−of−cut arm from the roller shaft, carriage screw, and height−of−cut bracket. Remove the roller from the mower.
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Chapter 8 Grooming Reel Kit Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . Clutch Engagement/Disengagement . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . Factors Affecting Grooming . . . . . . . . . . . . . . . . . . . Grooming Reel Mechanical Problems . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications MOUNTING: The grooming kit is rigidity mounted to the mower reel bearing housings and frame. MICRO ADJUSTMENT KNOB: Allows a 0.007 inch (0.18 mm) increment of height adjustment REEL CONSTRUCTION: 2−1/4 inch (5.4 cm) diameter, 41 steel blades with 1/2−inch blade spacing. Spacing is also adjustable at 1/4 and 3/4−inch (6.4 and 19.1 mm) by varying the number of blades and spacers. QUICK UP−DOWN FEATURE: Allows grooming reel to be raised 5/16 inch (7.
General Information Clutch Engagement/Disengagement The grooming reel should be disengaged at all times except during grooming. IMPORTANT: When engaging or disengaging the clutch, be sure to turn the clutch knob all the way until it comes to a firm stop. Failure to do so could cause damage to the clutch. 3 1 1. Depress clutch snubber and engage the clutch by turning the clutch knob counterclockwise. 2 2. Turn clutch knob clockwise to disengage the clutch.
Troubleshooting 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. It is important to remember that factors affecting quality of cut also affect grooming performance.
Grooming Reel Mechanical Problems Problem Possible Causes The grooming reel rotates when it is Due to friction in the clutch assemin the raised position with the clutch bly, the grooming reel may still rodisengaged. tate (with minimal force) in the raised position with the clutch disengaged. The turf is damaged or has uneven grooming. The groomer reel does not raise completely to the transport position. Quick−up levers have free play or do not rotate completely to the rear.
Adjustments CAUTION Never work on the mower with the engine running. Always stop the engine and remove the high tension lead from the spark plug first. Height/Depth of Grooming Adjustment 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 4 2. Make sure rollers are clean and cutting reel is set to the desired height of cut (see Adjustments section of Chapter 7 − Cutting Unit). Position mower on a flat level working surface. 3 1 3.
Drive Belt Tension Adjustment 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Loosen both set screws in the clutch knob. Remove clutch knob and poly washer from the clutch assembly. 3. Remove three socket head cap screws and lock washers, then remove belt cover. 5 4. Check drive belt tension as follows: A. Apply 5 to 10 lb (22 to 44 N) of force on the drive belt midway between the driver pulley and driven pulley. 4 B.
Service and Repairs Reel 14 15 16 17 1 47 2 3 4 5 6 7 8 9 10 50 48 11 12 13 26 54 9 52 51 GROOMING REEL ASSEMBLY 23 27 28 24 25 7 5 53 RIGHT 18 19 20 21 22 6 29 30 31 32 39 38 33 29 40 49 48 FRONT 36 47 37 46 2 45 44 35 34 33 43 42 41 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
2 4 5 6 8 9 10 1 16 3 13 12 7 CLUTCH ASSEMBLY 11 RIGHT FRONT 14 15 Figure 6 1. 2. 3. 4. 5. 6. Belt cover Clutch drive adapter Needle bearing Clutch pin Compression spring Driver pulley 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Roller bearing Belleville washer Clutch release disc Special screw Flange bushing Set screw Clutch knob Flat washer Lock nut Poly washer The grooming reel can be removed to reverse the shaft, replace individual blades, or replace the entire shaft.
Disassembly Inspect grooming reel blades frequently for damage and wear. Straighten bent blades with a pliers. Either replace worn blades or reverse the grooming reel shaft to put the sharpest blade edge forward (Fig. 8). 6. Secure belt cover to housing with three socket head cap screws and washers (Fig. 7). Reinstall poly washer and clutch knob to clutch assembly. Tighten both set screws into the clutch knob (Fig. 6). 2 1. Remove one lock nut from either end of the shaft (Fig. 9). 3 2.
Reel Bearing Replacement 1. Remove grooming reel (see Reel Removal). Note: 2 1 Replace all four ball bearings as a complete set. 2. Check condition of groomer ball bearings and replace as necessary. A. In the bearing housing and belt drive housing, install outer ball bearing first with the seal facing out. 3 B. Install both driven pulley spacers into each housing. C. Install inner bearing in both housings so they are flush with the housing inner recess of the housing (Fig. 11). 4 Figure 12 1.
Clutch Assembly Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Loosen set screws in the clutch knob. Remove clutch knob and poly washer from the clutch assembly (Fig. 6). 1 2 3. Remove three socket head cap screws and washers, then remove belt cover (Fig. 7). 4. Loosen socket head cap screw on idler block. Pivot idler to loosen drive belt and remove belt (Fig. 14). Figure 15 5.
5. Apply Loctite 271 or equivalent to the threads of the special screw. Secure compression spring to the special screw with clutch pin. The clutch pin should extend out from 0.240 to 0.260 inch (6.10 to 6.60 mm) the face of the driver pulley when the pin is fully extended (Fig. 16). Installation 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. If removed, install clutch adapter to the reel shaft as follows (Fig. 15): A.
Frame Assemblies (RH and LH) 14 15 16 17 1 47 2 3 4 5 6 7 8 9 10 50 48 11 12 13 26 54 9 52 51 GROOMING REEL ASSEMBLY 23 27 28 24 25 7 5 53 RIGHT 18 19 20 21 22 6 29 30 31 32 39 38 33 29 40 49 48 FRONT 36 47 37 46 2 45 44 35 34 33 43 42 41 Figure 17 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
4 5 6 8 9 10 2 1 16 13 3 7 CLUTCH ASSEMBLY RIGHT 12 11 14 15 FRONT Figure 18 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Belt cover Clutch drive adapter Needle bearing Clutch pin Compression spring Driver pulley 12. 13. 14. 15. 16.
4. On older models, loosen both carriage bolts securing the reel idler bracket to the frame. Pivot idler pulley assembly away from the reel drive belt. (Fig. 22). 1 5. Remove the pulley and drive assembly and drive belt from the cutting reel shaft as follows (Fig. 22): 4 5 A. Tip up the unit to access the bottom of the reel. B. Insert a long−handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bottom of the cutting unit.
Note: The driven pulley (42) has left handed threads. 5 B. Use an allen wrench to remove driven pulley from the shaft (53). 11. Remove lock nut and flat washer from the shaft of the clutch drive adapter. Pull clutch assembly off the shaft of the clutch drive adapter (Fig. 18). 4 7 8 2 3 12. Remove the clutch adapter from reel shaft as follows (Fig. 24): A. Tip up the unit to access the bottom of the reel. B.
Installation FRAME ASSEMBLY (RH) 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2 2. If bedbar adjuster frames have not been removed, remove the following on both sides of the mower frame (Fig. 25): A. Use spring compressor or clamp to compress springs in bedbar adjuster frames to free the bedbar adjuster from the bedbar ear. 1 Figure 27 1. Bearing 2. Bearing housing B.
D. Slide adapter through the bearing and into the reel bearing housing. Install lock nuts on flat head screws and torque from 23 to 27 ft−lb (3.2 to 3.7 kg−m) (Fig. 28 and 29). Note: 3 1 The lock nut (1) has left handed threads. E. Secure the grooming reel shaft (53) to the bearing housing (4) with lock nut (1). Torque lock nut from 29 to 35 ft−lb (4.0 to 4.8 kg−m) (Fig 17). 8. Secure mounting block (22) to the frame with cap screw (11) and belleville washer (12) (Fig. 17 and 29). 2 Figure 30 1.
Cutting Reel Removal 4 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Make sure mower is on a flat level surface or on a stable work bench. 5. Remove grease fittings from both bearing housings. Mark bearing housing (RH) for reassembly purposes (Fig. 32 and 33). 6. Remove the the bearing lock nut from the reel drive shaft as follows (Fig. 33): 7 2 1 RIGHT Figure 32 1. 2. 3. 4. Grease fitting Bearing housing (RH) Frame Large seal 7.
IMPORTANT: Make sure the correct bearing housing is used when installing bearings. The grease fitting hole should face forward when the housing is placed in the frame. 6. Attach bearing housing (LH) through the frame onto the reel shaft (Fig. 33). A. Push housing onto reel shaft. If necessary, tap into position with a soft hammer. A. Bearing housing (RH) should be marked from disassembly. B. Place small seal into the bearing housing with the flat side out. C. Place new wave washer into bearing housing.
Lubrication There are two grooming reel shaft bearings on each end of the mower. 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Use a hand pump grease gun and No. 2 multipurpose lithium base grease for lubrication. 3. Pump only a maximum of 2 to 3 pumps of grease to avoid permanently damaging the grease seals.
