Form No. 3380-159 Rev C Greensmaster® 800, 1000, and 1600 Mower Model No. 04054—Serial No. 314000001 and Up Model No. 04055—Serial No. 314000001 and Up Model No. 04056—Serial No. 314000001 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 Height of Cut .....................................33 Adjusting the Grass Shield Height.............................34 Adjusting the Cut-Off Bar .......................................34 Bedbar Identification ..............................................35 Setting the Machine to Match Turf Conditions ............36 Servicing the Bedbar ...............................................37 Backlapping the Reel...............................................38 Storage .....................
Safety – Store fuel in containers specifically designed for this purpose. This machine meets or exceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-2004 specifications in effect at the time of production when the Operator Presence Kit, Part No. 112-9282 is installed. – Refuel outdoors only and do not smoke while refuelling. – 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. Use only Toro-approved attachments and replacement parts.
Measured values were determined according to the procedures outlined in EN 836. For 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. Sound Pressure Level This unit has a sound pressure level at the operator’s ear of 85 dBA, which includes an Uncertainty Value (K) of 1 dBA.
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. 115-7355 1. Warning—toxic gas inhalation hazard; do not use the machine indoors. 4. Warning; disconnect the spark plug wire and read the instructions before servicing or performing maintenance. 2. Explosion hazard; stop the 5. Hot surface; do not touch. engine and extinguish all flames when fueling. 93-6085 3.
115-1614 1. Warning—read the Operator's Manual. 3. Thrown object hazard—keep bystanders a safe distance from the machine. 4. Warning—stay away from moving parts; keep all guards in place. 2. Warning—do not operate the machine unless you are trained. 115-1720 1. Forward 2. Drive wheel 3. Neutral 120-2727 1. Brake—to engage, pull the 2. Parking brake—to lock, lever toward the handle; pull the lever toward the to disengage, release the handle, press the button lever.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 6 7 Description Use Qty. Handle Cable tie Kickstand assembly Spring Wheel shaft, right Wheel shaft, left 1 2 1 1 1 1 Transport wheels (optional) 2 Install the transport wheels (optional). No parts required – Adjust the cutting unit. Grass basket 1 Install the grass basket. High-altitude kit, part number 117-0073 (acquire separately as needed) 1 Install the high-altitude kit (optional).
Adjusting the Handle 4. Squeeze the handle ends inward and install them on the mounting pins (Figure 3). 1. Remove the hairpin cotters from the ring pins on each side of the mower (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). 2 3. Install the ring pins and hairpin cotters. 2 Installing the Kickstand (For GR800 and GR1600) G017601 Figure 3 1. Handle end 2.
Figure 6 1. Kick stand 3. Spring stud 2. Spring bracket 4. Spring Figure 7 1. Right wheel shaft 4. Torque the shaft to 88 to 101 N-m (65 to 75 ft-lb). 3. Mount the kick stand to each side of the frame with a bolt, lockwasher, spacer, flat washer and locknut (Figure 6). Position the spacer in the kick stand mounting hole. 5. Repeat on the left side.
6 Installing the Grass Basket 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). G017591 Figure 8 1. Locking clip 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. 4. Repeat the procedure on the opposite side of the machine. Figure 9 5. Inflate the tires to 574 to 718 Pa (12 to 15 psi.). 1.
Product Overview Controls 1 2 3 4 5 6 7 G016976 Figure 11 Parking Brake G017592 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. Engage the service brake to release the parking brake. You must release the brake before the traction drive is engaged. Figure 10 1. Traction drive lever 2. Throttle control 5. Service brake 6. Parking brake 3.
Reel Drive Lever Recoil Starter The reel drive lever (Figure 13) is located on the right front corner of the machine. The lever has two positions: Engage and Disengage. Move the lever forward to engage the reel or rearward to disengage the reel. Pull the recoil starter handle (Figure 15) to start the engine. 1 Figure 15 1. Recoil starter 2. Kick stand G016978 Figure 13 Kickstand 1.
Attachments/Accessories Operation A selection of Toro approved attachments and accessories is available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories. Note: Determine the left and right sides of the machine from the normal operating position. Think Safety First Please carefully read all of the safety instructions and decals in the safety section.
DANGER WARNING 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. Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills. • Keep face away from nozzle and gas tank or conditioner bottle opening.
break-in; refer to Adjusting the Service/Parking Brake (page 26). Checking the Interlock Switch Operation CAUTION If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. • Do not tamper with the interlock switches. Figure 17 • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine.
5. Move the choke lever halfway between the On and Off positions when starting a cold engine. The choke may not be required when starting a warm engine. 3. Slide the wheels off of the shafts. 4. Move the unit off of the kickstand. 6. Pull the recoil starter handle out until positive engagement results, then pull it vigorously to start the engine. Mowing Proper use of the machine provides the smoothest turf cutting available.
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 mower using a No. 2 multipurpose lithium base grease. A hand operated grease gun is recommended for best results.
Engine Maintenance 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 21 fluid ounces of proper viscosity oil before staring. The engine uses any high-quality oil having the American Petroleum Institute - APl - “service classification" SF, SG, SH or SJ.
1 5. Install the drain plug and refill the crankcase with the proper oil; refer to Checking the Engine Oil Level (page 16). 2 Servicing the Air Cleaner 3 4 Service Interval: Every 50 hours—Clean and oil the air cleaner foam element. (More often in dirty or dusty conditions) 5 Every 100 hours—Replace the paper air filter element. (More often in dirty or dusty conditions) Important: Service the air cleaner more often in dirty or dusty conditions 1. Make sure the wire is off of the spark plug.
Fuel System Maintenance 2. Clean around the spark plug and remove it from the cylinder head. Important: Replace a cracked, fouled, or dirty spark plug. Do not sand blast, scrape, or clean electrodes because engine damage could result from grit entering the cylinder. Cleaning the Fuel Filter Service Interval: After the first 20 hours 3. Ensure that the air gap is correct (Figure 28). Every 100 hours 1. Close the fuel shut–off valve and unscrew the bowl from the filter body (Figure 29).
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.
Figure 34 1. Service/Parking brake cable Figure 32 2. Front jam nut 1. Rear pressure on 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 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). Repeat steps 1 and 2 and readjust if required.
Belt Maintenance Adjusting the Belts 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. Ensure that the belts are properly tensioned to ensure proper operation of the machine and unnecessary wear. Check the belts frequently. 6. After all bolts are installed, tighten them until the stand-offs inside the cover contact the side plate.
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. 2. Loosen the retainer securing the V-belt cover and pivot the cover open (Figure 40). 1 2 6. After all bolts are installed, tighten them until the stand-offs inside the cover contact the side plate. Do not overtighten. Adjusting the Differential Belt 1.
8. Remove the 2 bolts and locknuts securing the right rear bearing housing to the side plate (Figure 42). 8. To push or pull the machine easier without starting the engine, adjust the belt guide (Figure 41, inset) as follows: A. Engage the clutch. B. Loosen the locknut securing the idler pulley and belt guide to the idler arm. C. Rotate the belt guide clockwise until a gap of approximately 0.15 cm (0.06 inch) is obtained between the guide finger and the backside of the drive belts. D.
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.
1 2 Figure 45 1. Driven pulley 3. Idler Pulley g026076 2. 4 holes Figure 46 1. Bedbar adjusting screw 8. Loosen the 4 roller bearing screws and the screw securing the idler pulley. 2. Nut 7. 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. Raise or lower the right side of the roller assembly until the gap is less than .025 cm (0.010 inch). 10. Tighten the roller bearing screws. 8.
Figure 49 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 50). Figure 47 Note: If excessive contact/reel drag is evident it will be either necessary to backlap, reface the front of the bedknife, or regrind the cutting unit to achieve the sharp edges needed for precision cutting (Refer to the Toro Manual for Sharpening Reel and Rotary Mowers, Form No. 09168SL).
Figure 53 1. Cut-off bar Figure 51 2. Insert a 0.15 cm (0.060 inch) feeler gauge between the top of the reel and the bar and tighten the screws. 3. Ensure that the bar and reel are equal distances apart across the entire reel. 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.
Bedbar Identification To determine if the bedbar is standard or aggressive, check the left bedbar mounting ears. If the mounting ears are rounded it is a standard bedbar. If the mounting ears have a notch in them, it is an aggressive bedbar (Figure 54). Figure 54 1. Standard bedbar 2.
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 (2.0 inches) Steel 71-1550 Wiehle Roller Greensmaster 1000 50.8 mm (2.
Storage nylon washer on each side of the side plate boss. Place a steel washer outside each of the nylon washers. 3. Torque the bolts to 27 to 36 N-m (240 to 320 inch-lb). 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 engine's cylinder head fins and blower housing. 4. Tighten the jam nuts until the outside thrust washers just rotate freely. 5.
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).
