Form No. 3389-568 Rev A Greensmaster® 800, 1000, or 1600 Mower Model No. 04054—Serial No. 314004001 and Up Model No. 04055—Serial No. 314004001 and Up Model No. 04056—Serial No. 314004001 and Up Register at www.Toro.com.
Customer Service and have the model and serial numbers of your product ready. The model and serial numbers are located on a plate on the rear frame. Write the numbers in the space provided. This product complies with all relevant European directives; for details, please see the separate product-specific Declaration of Conformity (DOC) sheet. WARNING Model No.
Contents Adjusting the Cut-off Bar ........................................35 Bedbar Identification ..............................................35 Setting the Machine to Match Turf Conditions ............36 Servicing the Bedbar ...............................................37 Backlapping the Reel...............................................38 Storage ........................................................................38 Safety ......................................................................
Safety – Fuel the machine outdoors only and do not smoke while fuelling. This machine meets or exceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-2012 specifications in effect at the time of production when the Operator Presence Kit, Part 112-9282 is installed. – Add fuel before starting the engine. Never remove the cap of the fuel tank or add fuel while the engine is running or when the engine is hot.
• Remove equipment from the truck or trailer and refuel it • Before leaving the operator's position: • • • • • • • • • – stop on level ground; – disengage the cutting unit and traction drive; – set the parking brake; – stop the engine. Disengage drive to attachments when transporting or not in use.
Toro Mower Safety • If major repairs are ever needed or if assistance is desired, The following list contains safety information specific to Toro products or other safety information that you must know that is not included in the CEN, ISO, or ANSI standard. • This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death. contact an Authorized Toro Distributor.
Measured vibration level for left hand = 2.39 m/s2 Uncertainty Value (K) = 1.3 m/s2 Measured values were determined according to the procedures outlined in EN 836. Model 04056 Sound Power Level This unit has a guaranteed sound power level of 95 dBA, which includes an Uncertainty Value (K) of 1 dBA. Sound power level was determined according to the procedures outlined in ISO 11094.
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 lost. 93-8064 1. Warning—read the instructions before servicing or performing maintenance. 2. Cutting hazard of foot or hand—stop the engine and wait for moving parts to stop. 93-9356 1. Entanglement hazard—stay away from moving parts. 93-7346 1. Reel drive 3. Disengage 2. Engage 115-1720 1. Forward 2. Drive wheel 3.
120–2769 1. Toxic gas inhalation hazard—do not operate indoors. 2. Explosion hazard—stop the engine and keep away from open flames when refueling. 3. Warning—stop the engine and turn off the fuel before leaving the machine. 4. Warning—disconnect the spark plug wire and read the instruction before servicing or performing maintenance. 5. Hot surface/burn hazard—do not touch hot surfaces. 6. Warning—read the Operator’s Manual; when adding fuel to the tank, only fill to the bottom of the fill tube.
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 Wheel shaft, right Wheel shaft, left 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 Figure 3 1. Handle end 2. Bolt, washer, and lock washer Installing the Handle 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 lockwashers 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 Figure 6 Installing the Kickstand (Models 04054 and 04056) Kickstand assembly 1 Spring 3. Spring stud 2. Spring bracket 4. Spring 3.
Figure 7 1. Right wheel shaft 4. Torque the shaft to 88 to 101 N-m (65 to 75 ft-lb). G017591 5. Repeat the procedure on the left side. 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. Parts needed for this procedure: 2 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 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 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 forward to engage the reel or rearward to disengage the reel. 1 G016976 Figure 11 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 Figure 15 1. Recoil-start handle 2.
Operation DANGER In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. Note: Determine the left and right sides of the machine from the normal operating position. Think Safety First • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline 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 27). WARNING Gasoline 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 gas 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 Stopping 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 14) section in Product Overview (page 14). 2.
Operating Tips position, stop 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. Before Mowing • Ensure that the machine is carefully adjusted and is set evenly on both sides of the reel. Improper machine adjustment is magnified many times over in the appearance of the clipped turf. • Remove all foreign objects from the turf prior to mowing.
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. • Clean the fuel filter and cup. 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 13 grease fittings on the machine using a #2 multipurpose, lithium-based grease. A hand-operated grease gun is recommended for best results.
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 22). 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 liter (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 22). 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 24).
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 26). Service Interval: After the first 20 hours 1 Every 100 hours 1. Close the fuel shut-off valve and unscrew the bowl from the filter body (Figure 28). 2 G016986 Figure 26 1. Spark-plug wire 1 2.
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 30). 1.
Figure 33 1. Service/parking brake cable Figure 31 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 32). 1 2 G016991 Figure 32 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 33).
Belt Maintenance 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 Note: 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. Ensure that the belts are properly tensioned to ensure proper operation of the machine and prevent unnecessary wear.
B. Adjusting the Primary V-Belts Tighten the nut to lock the adjustment. 4. Install the belt cover by placing it in position. 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 32). If you are unable to attain the 18 to 22 N (4 to 5 lb) force required in adjusting the traction control, proceed to the next step. 5.
12 3 4 Figure 41 G016992 Figure 40 1. Locknut 3. Idler pulley 2. Belt guide 4. Idler arm 1. Differential cover sections 2. Front clutch housing 5. Loosen the idler pulley mounting nut on the differential idler pulley and pivot the idler pulley counterclockwise away from the backside of the belt to release the belt tension. 7. Tighten the mounting screws and check the alignment. 8.
Cutting Unit Maintenance Controls System Maintenance Leveling the Rear Drum to the Reel Adjusting the Traction Control 1. Position the machine on a flat, level surface, preferably a precision steel work plate. If the traction control does not engage or it slips during operation, an adjustment is required. 2. Place a 0.6 x 2.5 cm (1/4 x 1 inch) flat steel strip, approximately 73.
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 45). 7. Remove the shim. 8. For the left side of the cutting unit, slowly rotate the reel so that the closest blade crosses the bedknife edge between the first and second screw heads. 9.
Adjusting the Height of Cut 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. 2. Loosen the locknuts securing the height-of-cut arms to the height-of-cut brackets (Figure 47). Figure 49 5. Rotate the adjusting screw until the roller contacts the front of the gauge bar. 6. Adjust both ends of the roller until the entire roller is parallel to the bedknife.
Adjusting the Grass Shield Height 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 the shield height is adjusted or when the reel is sharpened on a reel grinder. Adjust the shield to ensure proper grass clipping discharge into the basket.
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.
3. 4. 5. 6. Storage Note: Position a nylon washer on each side of the side plate boss. Place a steel washer outside each of the nylon washers. Torque the bolts to 27 to 36 N-m (20 to 27 ft-lb). Tighten the jam nuts until the outside thrust washers just rotate freely. Tighten the spring tension nut until the spring is collapsed, then back it off 1/2 turn. Adjust the bedbar; refer to Adjusting the Bedknife to the Reel (page 33). 1.
Notes: 39
The Toro Total Coverage Guarantee A 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).
