Form No. 3418-639 Rev C Greensmaster® 1000 and 1600 Mower Model No. 04055—Serial No. 401375001 and Up Model No. 04056—Serial No. 401380001 and Up Register at www.Toro.com.
This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet.
Contents Belt Maintenance ................................................ 33 Adjusting the Belts ............................................ 33 Replacing the Differential Belt........................... 35 Controls System Maintenance ............................. 36 Adjusting the Traction Control........................... 36 Cutting Unit Maintenance ..................................... 37 Blade Safety ..................................................... 37 Leveling the Rear Drum to the Reel...........
Safety • Do not operate the machine without all guards and other safety protective devices in place and working on the machine. This machine has been designed in accordance with EN ISO 5395:2013 and ANSI B71.4-2017 and meets these standards when you add the Operator Presence Kit and required decals. • Keep clear of any discharge opening. Keep bystanders a safe distance away from the machine. • Keep children out of the operating area. Never allow children to operate the machine.
decal117-2718 117–2718 decal93-6085 93-6085 1. Fast 2. Continuous variable setting 3. Slow decal93-8064 93-8064 1. Warning—read the instructions before servicing or performing maintenance. 2. Cutting hazard of foot or hand—shut off the engine and wait for moving parts to stop. decal120-2727 120-2727 1. Brake—to engage, pull the 2. Parking brake—to lock, pull the lever toward the lever toward the handle; handle, press the button to disengage, release the in and release the lever lever.
decal120-2769 120-2769 decal130-8322 130-8322 1. Use only gasoline that contains 10% ethanol by volume (E10) or less. 3. Do not use gasoline that contains more than 10% ethanol by volume (E10). 2. Read the Operator's Manual. 1. Toxic gas inhalation hazard—do not operate indoors. 4. Warning—disconnect the spark plug wire and read the Operator’s Manual before servicing or performing maintenance. 2. Explosion hazard—shut off the engine and keep away from open flames when refueling. 5.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 2 3 4 5 6 7 8 Use Qty. Handle Cable tie Kickstand assembly Spring Right wheel shaft Left wheel shaft 1 4 1 1 1 1 Install the kickstand (Models 04054 and 04056 only). Transport wheel 2 Install the transport wheels (optional). No parts required – Adjust the cutting unit. Production-year decal CE-mark decal 1 1 Install the CE decals (if required). Grass basket 1 Install the grass basket.
1 Installing and Adjusting the Handle Parts needed for this procedure: 1 Handle 4 Cable tie Installing the Handle 1. Remove the bolts (5/16 inch), locknuts, ring pins, and hairpin cotters that secure the bottom of the handle arms to each side of the machine (Figure 3). g240404 Figure 4 1. Handle 2. Handle arm 3. Mounting pin g240399 Figure 3 1. Hairpin cotter 6. Locknut 2. Mounting pin 7. Bolt (5/16 inch) 3. Washer 8. Ring pin 4. Lock washer 5. Bolt (3/8 inch) 9. Handle arm 2.
Adjusting the Handle Refer to Figure 6 for this procedure. g017590 Figure 5 g240512 1. Cable ties Figure 6 1. Handle 3. Ring pin 2. Hairpin cotter 1. Remove the hairpin cotters from the ring pins on each side of the machine. While supporting the handle, remove the ring pins from each side and raise or lower the handle to the desired operating position. Install the ring pins and hairpin cotters. 2. 3.
3 Installing the Transport Wheel Shafts Parts needed for this procedure: 1 Right wheel shaft 1 Left wheel shaft Procedure 1. Push the kickstand down with your foot and pull up on the handle to support the machine on the kickstand. 2. Apply thread-locking adhesive to the threads of the wheel shafts. 3. Thread the right wheel shaft into the drive pulley on the right side of the machine (Figure 9). g017948 Figure 7 1. Bolt 2. Spring stud 2. 3. Washer 4.
4 5 Installing the Transport Wheels Adjusting the Cutting Unit No Parts Required Optional Procedure Parts needed for this procedure: 2 Before operating the machine, complete the following adjustments: Transport wheel • • • • • Procedure 1. Push the kickstand down with your foot and pull up on the handle to support the machine on the kickstand. 2. Slide a wheel onto an axle. 3. Pivot the wheel locking clip away from center of the wheel allowing it to slide farther onto the axle (Figure 10).
7 8 Installing the Grass Basket Breaking in the Machine Parts needed for this procedure: No Parts Required 1 Grass basket Procedure Only 8 hours of mowing operation is required for the break-in period. Procedure Grasp the basket by the top lip and slide it onto the basket mounting rods (Figure 12). The first several hours of operation are critical to future dependability of the machine.
Controls Product Overview g017592 Figure 14 1. Traction-drive lever 2. Throttle control 5. Service brake 6. Parking brake 3. On/Off switch 7. Operator-presence control (optional) 4. Hour meter g232664 Figure 13 1. Control panel 5. Cutting unit 2. Handle 6. Transport wheel axle 3. Fuel tank 4. Grass basket 7. Kickstand Throttle Control The throttle control (Figure 14) is located on the rear, right side of the control panel.
operator-presence control must be engaged before moving the traction-drive lever. If you release the operator-presence control, the engine shuts off. Reel-Drive Lever The reel-drive lever (Figure 17) is located on the right front corner of the machine. The lever has 2 positions: • ENGAGE—move the lever forward to engage the reel. • DISENGAGE—move the lever rearward to disengage the reel. g016976 Figure 15 Parking Brake The parking brake (Figure 16) is located at the base of the service brake.
Fuel-Shutoff Valve Recoil-Starter Handle The fuel-shutoff valve (Figure 18 and Figure 19) is located on the left front of the engine near the choke lever. The valve has 2 positions: CLOSED and OPEN. Move the lever up to the CLOSED position when you store or transport the machine. Open the valve before you start the engine by rotating the lever down. Pull the recoil-starter handle (Figure 20) to start the engine. g027896 Figure 20 1. Recoil-starter handle 2.
Checking the Engine-Oil Level Operation Before Operation Check the engine-oil level before each use or every 8 operating hours, refer to Checking the Engine-Oil Level (page 28). Before Operation Safety Fuel Specifications General Safety Fuel tank capacity: 2.7 L (0.71 US gallons) • Never allow children or untrained people to operate or service the machine. Local regulations may restrict the age of the operator. The owner is responsible for training all operators and mechanics.
Filling the Fuel Tank WARNING Fuel is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. • Never fill the fuel tank inside an enclosed trailer. • Do not fill the fuel tank completely full.
Setting the Machine to Match Turf Conditions Use the following table to set the machine to match turf conditions.
Rollers: Standard and Optional Part Number Description Mower 99-6240 Narrow Wiehle Greensmaster 800 50.8 mm (2.0 inches) Aluminum Standard, 0.20 inch spacing 99-6241 Narrow Wiehle Greensmaster 1000 50.8 mm (2.0 inches) Aluminum Standard, 0.20 inch spacing 88-6790 Wide Wiehle Greensmaster 1000 50.8 mm (2.0 inches) Aluminum More penetration, 0.43 inch spacing 104-2642 Full roller Greensmaster 1000 50.8 mm (2.
Transporting the Machine Using a Trailer Checking the Interlock-Switch Operation Use a trailer to transport the machine a considerable distance. Use caution while loading and unloading the machine onto the trailer. CAUTION If the safety interlock switches are disconnected or damaged, the machine could operate unexpectedly causing personal injury. • Do not tamper with the interlock switches.
• • • • • • • • • • • • • • • • Do not change the engine governor settings or footwear; and hearing protection. Tie back long hair, secure loose clothing, and do not wear loose jewelry. Use your full attention while operating the machine. Do not engage in any activity that causes distractions; otherwise, injury or property damage may occur. Do not operate the machine while ill, tired, or under the influence of alcohol or drugs. Keep bystanders, especially small children, out of the operating area.
1. Ensure that the traction and reel drive levers are in the DISENGAGED position. Note: The engine will not start if the traction lever is in the ENGAGED position. 2. Ensure that the fuel-shutoff valve is open. 3. Move the On/Off switch to the ON position. 4. Move the throttle control to the FAST position. 5. Move the choke lever halfway between the CHOKE and RUN positions when starting a cold engine. Note: The choke may not be required when starting a warm engine. 6.
After Operation After Operation Safety General Safety • Reduce the throttle setting before shutting off the engine and, if the engine has a fuel-shutoff valve, turn off the valve after mowing. • Clean grass and debris from the machine to help prevent fires. Clean up oil or fuel spills.
Maintenance WARNING Failing to properly maintain the machine could result in premature failure of machine systems, causing possible harm to you or bystanders. Keep the machine well maintained and in good working order as indicated in these instructions. Note: Determine the left and right sides of the machine from the normal operating position. Important: Do not tip the machine at an angle greater than 25°.
Daily Maintenance Checklist Important: Duplicate this page for routine use. Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri. Check the safety interlock operation. Check the parking brake operation. Check the fuel level. Check the engine oil level. Check the air filter. Clean the engine cooling fins. Check for unusual engine noises. Check for unusual operating noises. Check the reel-to-bedknife adjustment. Check the height-of-cut adjustment. Grease all fittings.
Pre-Maintenance Procedures Maintenance Safety • Disengage the drives and the cutting unit, engage the parking brake, shut off the engine, and disconnect the spark-plug wire. Wait for all movement to stop before adjusting, cleaning, or repairing the machine. • If the engine must be running to perform a maintenance adjustment, keep your hands, feet, clothing, and any parts of the body away from the cutting unit, attachments, and any moving parts. Keep bystanders away.
Lubrication Greasing the Machine Service Interval: Every 25 hours Lubricate the 12 grease fittings on the mower using a No. 2 lithium grease. For best results, use a hand-operated grease gun. The grease fitting locations are as follows: g016981 Figure 26 • 2 on the front roller (Figure 24) • 2 on the reel bearings (Figure 24) • 2 on the drum axles (Figure 25) • 3 on the differential (Figure 25) • 2 on the reel countershaft bearings (Figure 26) • 1 on the belt idler pivots (Figure 27). 1.
Engine Maintenance for the day. If you have already ran the engine, allow the oil to drain back down to the sump for at least 10 minutes before you check the engine-oil level. Engine Safety • Fuel is flammable and explosive, and can cause • • • personal injury. Check all fuel lines for tightness and wear regularly. Tighten or repair them as needed. Tipping the machine may cause the fuel to leak. Do not tip the machine at an angle greater than 25°.
7. Install the dipstick and wipe up any oil that may have spilled. Changing the Engine Oil Service Interval: After the first 20 hours Every 50 hours 1. Start and run the engine for a few minutes to warm the engine oil. 2. At the rear of the machine, place a drain pan under the drain plug (Figure 29). Loosen the drain plug. 3. Push down on the handle to tip the machine and engine backward, allowing all the oil to run into the drain pan. g016984 Figure 31 1.
5. Check the condition of the paper element. Clean it by gently tapping or replace it as necessary. Important: Do not use compressed air to clean the paper element. 6. Install the foam element, paper element, and air-cleaner cover. Important: Do not operate the engine without the air-cleaner element, as extreme engine wear and damage can result. g019300 Figure 34 Servicing the Spark Plug 1. Center-electrode insulator Service Interval: Every 100 hours 2.
Fuel System Maintenance Electrical System Maintenance Cleaning the Fuel Filter Servicing the Traction-Interlock Switch 1. Close the fuel-shutoff valve and unscrew the sediment bowl from the carburetor body (Figure 35). Use the following procedure if the traction-interlock switch needs adjustment or replacement. Note: Using a 17 mm, 12-point socket over the bottom of the sediment bowl can prevent damage to the sediment bowl. 1.
Brake Maintenance Adjusting the Service/Parking Brake If the service/parking brake slips during operation, adjust it. 1. Engage the service brake, push in the parking brake knob, and allow the service brake to rest on the parking-brake pin (Figure 37). g008215 Figure 38 1. Rear pressure on the service-brake lever 3. Loosen the retainer that secures the V-belt cover and pivot the cover open (Figure 39). g016991 Figure 39 1. V–belt cover 4. 2.
Belt Maintenance Adjusting the Belts Ensure that the belts are properly tensioned to ensure proper operation of the machine and prevent unnecessary wear. Check the belts frequently. Adjusting the Reel-Drive Belt 1. g007627 Figure 40 1. Service/parking brake cable 5. Remove the belt-cover mounting fasteners and the belt cover to expose the belt (Figure 41). 2. Front jam nut Close the cover and secure the retainer. g007618 Figure 41 1. Belt cover 2.
Important: Do not over-tension the belt. B. Tighten the nut to lock the adjustment. 4. Install the belt cover by placing it in position. 5. While maintaining a slight gap between the cover seal and the side plate, install each mounting bolt until the threads engage in the insert. 6. A. 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 (Figure 44). Important: Do not over-tension the belt. B.
5. While maintaining a slight gap between the cover seal and the side plate, install each mounting bolt until the threads engage in the insert. The gap allows visual alignment of the bolts to the threaded inserts. 6. After all bolts are installed, tighten them until the stand-offs inside the cover contact the side plate. Do not overtighten the bolts. Adjusting the Primary V-Belts 1. 2.
Controls System Maintenance Adjusting the Traction Control If the traction control does not engage or it slips during operation, an adjustment is necessary. 1. Move the traction control to the DISENGAGED position. 2. Loosen the retainer that secures the V-belt cover and pivot the cover open (Figure 46). 3. To increase the cable tension, loosen the front-cable jam nut and tighten the back-cable jam nut (Figure 49) until a force of 8 to 9 N·m (6 to 7 lb) is created to engage the traction control.
Cutting Unit Maintenance Blade Safety Use care when checking the cutting-unit reel. Wear gloves and use caution when servicing the reel. Leveling the Rear Drum to the Reel g007599 Figure 51 1. Park the machine on a flat, level surface, preferably a precision steel work plate. 2. Place a 0.6 x 2.5 cm (1/4 x 1 inch) flat steel strip, approximately 73.6 cm (29 inches) long, under the reel blades and against the front edge of the bedknife to prevent the bedbar from resting on the work surface. 2.
g014840 Figure 52 1. Bedbar-adjusting screw g007602 4. Figure 53 Rotate the reel so that a blade crosses the bedknife edge between the first and second bedknife screw heads on the right side of the cutting unit. 5. Insert the 0.05 mm (0.002 inch) shim between the marked blade and the bedknife edge at the point where the marked blade crosses the bedknife edge. 6. Turn the right bedbar-adjusting screw until you feel light pressure (i.e., drag) on the shim by sliding it side-to-side (Figure 52). 7.
g000489 Figure 55 g007596 Figure 57 3. Nut 1. Gauge bar 2. Height-adjusting screw 4. Hook the screw head on the cutting edge of the bedknife and rest the rear end of the bar on the rear roller (Figure 56). Adjusting the Grass Shield Height Adjust the shield to ensure proper grass clipping discharge into the basket. 1. Measure the distance from the top of the front support rod to the front lip of the shield at each end of the cutting unit (Figure 58). g007605 Figure 56 g007607 5.
Adjusting the Cut-Off Bar Servicing the Bedbar Adjust the cut-off bar to ensure that the clippings are cleanly discharged from the reel area. Removing the Bedbar 1. 1. Loosen the screws that secure the top bar (Figure 59) to the cutting unit. Turn the bedbar-adjuster screw counterclockwise to back the bedknife away from the reel (Figure 61). g027395 Figure 59 g007631 1. Cut-off bar Figure 61 1. Bedbar-adjusting screw 2. Insert a 1.5 mm (0.
4. Tighten the jam nuts until the outside thrust washers just rotate freely. Bedknife Specifications 5. Tighten the spring-tension nut until the spring is collapsed, then back it off 1/2 turn. Bedknife Installation 6. Adjust the bedbar; refer to Adjusting the Bedknife to the Reel (page 37). 1. Use a scraper to remove all rust, scale, and corrosion from the bedbar surface. 2. Lightly oil the bedbar surface before installing the bedknife. 3. Ensure that all the bedbar screw threads are clean. 4.
Bedknife Grinding Specifications Relief-Grinding the Reel The new reel has a land width of 1.3 to 1.5 mm (0.050 to 0.060 inch) and a 30° relief grind. When the land width gets larger than 3 mm (0.120 inch) wide, do the following: 1. Apply a 30° relief grind on all reel blades until the land width is 1.3 mm (0.050 inch) wide (Figure 64. g032182 Figure 65 1. Relief angle 4. Front face 2. Top face 5. Front angle 3. Remove burr g028800 Figure 64 1. 30° 2. 2. 1.3 mm (0.
Backlapping the Reel Checking the Top Grind Angle The angle that you use to grind your bedknives is very important. 1. Remove the plug in the right reel-drive cover (Figure 68). Use the angle indicator (Toro Part No. 131-6828) and the angle-indicator mount (Toro Part No. 131-6829) to check the angle that your grinder produces and then correct for any grinder inaccuracy. 1. Place the angle indicator on the bottom side of the bedknife as shown in Figure 66. g007633 Figure 68 1.
Storage Storage Safety • Park the machine on a level surface, engage the parking brake, shut off the engine, remove the key, and wait for all movement to stop before storing the machine. Never store the machine where there is an open flame, spark, or pilot light, such as on a water heater or on other appliances. Allow the machine to cool before you store the machine in any enclosure. • • Storing the Machine 1.
Notes:
Notes:
European Privacy Notice The Information Toro Collects Toro Warranty Company (Toro) respects your privacy. In order to process your warranty claim and contact you in the event of a product recall, we ask you to share certain personal information with us, either directly or through your local Toro company or dealer. The Toro warranty system is hosted on servers located within the United States where privacy law may not provide the same protection as applies in your country.
The Toro 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 Toro Commercial product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
