Form No. 3409-730 Rev A Greensmaster® 800, 1000, or 1600 Mower Model No. 04054—Serial No. 400000000 and Up Model No. 04055—Serial No. 400000000 and Up Model No. 04056—Serial No. 400000000 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. Model No. Serial No. WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Contents Adjusting the Grass Shield Height.............................33 Adjusting the Cut-off Bar ........................................33 Bedbar Identification ..............................................34 Setting the Machine to Match Turf Conditions ............35 Servicing the Bedbar ...............................................36 Backlapping the Reel...............................................37 Storage ........................................................................38 Safety .....
Operation Safety • Do not operate the engine in a confined space where This machine has been designed in accordance with CEN standard EN ISO 5395:2013 and ANSI B71.4-2012 specifications in effect at the time of production when the Operator Presence Kit, Part No. 112-9282 is installed. • General Safety • This product is capable of amputating hands and feet and of throwing objects. Always follow all safety instructions to avoid serious personal injury.
• Allow the engine to cool before storing the machine in • If the engine must be running to perform a maintenance any enclosure. adjustment, keep hands, feet, clothing, and any parts of the body away from the cutting unit, attachments and any moving parts. Keep everyone away. • Check the grass catcher components frequently and replace them with the manufacturer’s recommended parts when necessary.
Safety and Instructional 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 missing. 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. decal93-9356 93-9356 1. Entanglement hazard—stay away from moving parts. decal93-7346 93-7346 1. Reel drive 3.
decal130-8322 130-8322 1. Only use 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. decal120-2769 120–2769 1. Toxic gas inhalation hazard—do not operate indoors. decal120-2727 120-2727 2. Explosion hazard—shut off the engine and keep away from open flames when refueling. 1. Brake—to engage, pull the 2.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 6 Description Use Qty. Handle Cable tie Kickstand assembly Spring Right wheel shaft Left wheel shaft 1 4 1 1 1 1 Transport wheel (optional) 2 Install the transport wheels (optional). No parts required – Adjust the cutting unit. Grass basket 1 Install the grass basket. Install the handle. Install the kickstand. Install the transport wheel shafts.
1 2 Installing and Adjusting the Handle Parts needed for this procedure: 1 Handle 4 Cable tie G017601 g017601 Figure 3 Installing the Handle 1. Handle end 2. Bolt, washer, and lock washer 1. Remove the bolts, locknuts, and washers securing the bottom of the handle arms to each side of the machine (Figure 2). 5. Secure the handle ends to the mounting pins with the bolts, washers, and lock washers previously removed (Figure 3). 6.
Adjusting the Handle 1. Remove the hairpin cotters from the ring pins on each side of the machine (Figure 2). 2. While supporting the handle, remove the ring pins from each side and raise or lower the handle to the desired operating position (Figure 2). 3. Install the ring pins and hairpin cotters. 2 g007594 Figure 6 Installing the Kickstand (Models 04054 and 04056) Parts needed for this procedure: 1 Kickstand assembly 1 Spring 1. Kickstand 3. Spring stud 2. Spring bracket 4. Spring 3.
g007595 Figure 7 1. Right wheel shaft G017591 4. Torque the shaft to 88 to 101 N∙m (65 to 75 ft-lb). 5. Repeat the procedure on the left side. g017591 Figure 8 1. Locking clip 4 3. Rotate the wheel back and forth until it slides completely onto the axle and the locking clip is secured in the groove on the axle shaft. Installing the Transport Wheels (Optional) 4. Repeat the procedure on the opposite side of the machine. 5. Inflate the tires to 83 to 103 kPa (12 to 15 psi).
Product Overview 6 Controls Installing the Grass Basket 1 2 3 4 5 6 7 Parts needed for this procedure: 1 Grass basket Procedure Grasp the basket by the top lip and slide it onto the basket mounting rods (Figure 9). G017592 g017592 Figure 10 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 g007609 Figure 9 1. Grass basket 2.
Reel-Drive Lever The reel-drive lever (Figure 13) is located on the right front corner of the machine. The lever has 2 positions: ENGAGE and DISENGAGE. Move the lever to the right to engage the reel or to the left to disengage the reel. 1 G016976 g016976 Figure 11 G016978 Parking Brake g016978 Figure 13 The parking brake (Figure 12) is located at the base of the service brake. Fully engage the service brake and push the parking-brake knob to allow the service brake to rest on the parking-brake pin.
Recoil-Start Handle Specifications Pull the recoil-start handle (Figure 15) to start the engine. Model 04054 g027896 Figure 15 1.
Operation DANGER Note: Determine the left and right sides of the machine from the normal operating position. 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. Think Safety First • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. Please carefully read all of the safety instructions and decals in the safety section.
break-in; refer to Adjusting the Service/Parking Brake (page 25). WARNING Fuel is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. Checking the Interlock Switch Operation • Avoid prolonged breathing of vapors. • Keep face away from nozzle and fuel tank or conditioner bottle opening. CAUTION If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury.
Transporting the Machine Starting and Shutting Off the Engine 1. If the machine is equipped with the optional transport wheels, push the kickstand down with your foot and pull up on the handle to raise the rear of the machine and install the transport wheels. Note: For illustrations and descriptions of the controls referenced in this section, refer to the Controls (page 12) section. Starting the Engine 2.
4. When you are finished mowing, drive off the green, move the traction-control lever to the DISENGAGED position, shut off the engine, and push the reel-drive lever into the DISENGAGED position. 5. Empty the grass basket of clippings, install the grass basket, and commence the transport operation. Operating Tips Before Mowing • Ensure that the machine is carefully adjusted and is set evenly on both sides of the reel.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 20 hours • Change the engine oil. Before each use or daily • Check the interlock switch operation. • Check the engine-oil level. Every 25 hours • Grease the machine (grease the fittings immediately after every washing regardless of the interval listed).
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.
Lubrication Greasing the Machine Service Interval: Every 25 hours Lubricate the 12 grease fittings on the machine using a No. 2 lithium grease. For best results, use a hand-operated grease gun. G016981 The grease fitting locations are as follows: g016981 Figure 20 • 2 on the front roller (Figure 18) • 2 on the reel bearings (Figure 18) • 2 on the drum axles (Figure 19) • 3 on the differential (Figure 19) • 2 on the reel countershaft bearings (Figure 20) • 1 on the power shaft bearing (Figure 21). 1.
Engine Maintenance Checking the Engine-Oil Level 1. Position the machine so that the engine is level, and clean the area around the oil-level gauge (Figure 23). Servicing the Engine Oil Service Interval: After the first 20 hours—Change the engine oil. Before each use or daily—Check the engine-oil level. Every 50 hours—Change the engine oil (more frequently in dusty or dirty conditions). The crankcase must be filled with approximately 0.62 L (21 fl oz) of proper viscosity oil before starting.
Changing the Engine Oil 1 1. Start and run the engine for a few minutes to warm the engine oil. 2 2. Place a drain pan at the rear of machine, under the drain plug (Figure 23). 3. Remove the drain plug. 3 4 4. Push down on the handle to tip the machine and the engine backward, allowing more oil to run into the drain pan. 5 5. Install the drain plug and fill the crankcase with the proper oil; refer to Servicing the Engine Oil (page 22).
Replacing the Spark Plug Fuel System Maintenance Service Interval: Every 100 hours Use an NGK BR6HS spark plug or equivalent. The correct air gap is 0.6 to 0.7 mm (0.024 to 0.028 inch). Cleaning the Fuel Filter 1. Pull the molded wire off the spark plug (Figure 27). 1. Close the fuel-shutoff valve and unscrew the sediment bowl from the carburetor body (Figure 29). 1 Note: Using a 17 mm, 12-point socket over the bottom of the sediment bowl can prevent damage to the sediment bowl.
Brake Maintenance Electrical System Maintenance Servicing the Interlock Switch Adjusting the Service/Parking Brake Use the following procedure if the switch needs adjustment or replacement. If the service/parking brake slips when operated, an adjustment is required. 1. Engage the service brake, push in on the parking brake knob and allow the service brake to rest on the parking brake pin (Figure 31). 1.
g007627 Figure 34 g008215 1. Service/parking brake cable Figure 32 2. Front jam nut 1. Rear pressure on the service-brake lever 5. Close the cover and secure the retainer. 3. Loosen the retainer securing the V-belt cover and pivot the cover open (Figure 33). 1 2 G016991 g016991 Figure 33 1. V–belt cover 2. Retainer 4. To adjust the brake cable tension, proceed as follows. • To decrease the cable tension, loosen the front cable jam nut and tighten the rear jam nut (Figure 34).
Belt Maintenance 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. 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. Note: The gap allows visual alignment of the bolts to the threaded inserts. 6.
threads engage in the insert. The gap allows visual alignment of the bolts to the threaded inserts. the belt until the desired belt tension is attained (Figure 38). 6. After all bolts are installed, tighten them until the stand-offs inside the cover contact the side plate. Do not overtighten the bolts. 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.
Adjusting the Primary V-Belts 1. To adjust the belt tension on primary V-belts, first check the adjustment of the traction control; refer to Adjusting the Traction Control (page 30). If you are unable to attain the 2.75 to 3.25 kg (6 to 7 lb) force required in adjusting the traction control, proceed to the next step. 2. Loosen the retainer securing the V-belt cover and pivot the cover open (Figure 40). 1 2 g027906 Figure 41 1. Locknut 3. Idler pulley 2. Belt guide 4. Idler arm 7.
Controls System Maintenance Adjusting the Traction Control If the traction control does not engage or it slips during operation, adjust it. 1. Move the traction control to the DISENGAGED position. 2. Loosen the retainer securing the V-belt cover and pivot the cover open (Figure 40). g007625 Figure 42 1. Differential cover sections 3. To increase the cable tension, loosen the front cable jam nut and tighten the back cable jam nut (Figure 43) until a force of 2.75 to 3.
Cutting Unit Maintenance Leveling the Rear Drum to the Reel 1. Position 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. g007599 Figure 45 3. Raise the front roller so that only the rear drum and the reel are on the surface. 1. Driven pulley 3.
Adjusting the Height of Cut 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. 1. Verify that the rear roller is level and that the bedknife-to-reel contact is correct. Tip the machine back on the handle to expose the front and rear rollers and the bedknife. 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 46). 2.
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 52). g007605 Figure 50 5. Rotate the adjusting screw until the roller contacts the front of the gauge bar. g007607 6. Adjust both ends of the roller until the entire roller is parallel to the bedknife. Figure 52 1.
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. Adjust the bar whenever you adjust the shield height or when you sharpen the reel on a reel grinder. Bedbar Identification To determine if the bedbar is standard or aggressive, check the left bedbar mounting ears.
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.
Backlapping the Reel 3. At each side of the machine, loosen the jam nut securing the bedbar bolt (Figure 56). 1. Remove the plug in the right reel-drive cover (Figure 57). 2 1 g014780 g014780 Figure 56 1. Jam nut 2. Bedbar bolt g007633 4. Remove each bedbar bolt allowing the bedbar to be pulled downward and removed from the machine. Save the 2 nylon and 2 stamped steel washers on each end of the bedbar (Figure 56). Figure 57 1. Cover plug 2.
Storage 1. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the cylinder-head fins and the blower housing. Important: You can wash the machine with mild detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the shift lever plate and engine. 2. For long-term storage (more than 90 days) add stabilizer/conditioner additive to the fuel in the tank. A.
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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).