Form No. 3422-714 Rev A Greensmaster® 800, 1000, and 1600 Mowers Model No. 04054—Serial No. 400000000 and Up Model No. 04055—Serial No. 403060001 and Up Model No. 04056—Serial No. 403060001 and Up Register at www.Toro.com.
on safe operating practices, including safety tips and training materials, go to www.Toro.com. This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet. Whenever you need service, genuine Toro parts, or additional information, contact an authorized Toro distributor 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.
Contents Belt Maintenance ................................................ 32 Adjusting the Belts ............................................ 32 Replacing the Differential Belt........................... 34 Controls System Maintenance ............................. 35 Adjusting the Traction Control........................... 35 Cutting Unit Maintenance ..................................... 36 Blade Safety ..................................................... 36 Leveling the Rear Drum to the Reel...........
Safety • Do not operate the machine without all guards 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. • • 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. and other safety protective devices in place and working on the machine.
decal133-8062 133-8062 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 1 2 3 4 5 6 7 8 Description 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 Models 04055 and 04056 Only Parts needed for this procedure: 2. Right wheel shaft 1 Left wheel shaft Procedure g017948 Figure 7 1. Bolt 2. Spring stud 1 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). 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 Traction-Drive Lever The traction-drive lever (Figure 14) is located on the front right side of the control panel. It has 2 positions: NEUTRAL and FORWARD .
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. Fully engage the service brake and push the parking-brake knob to allow the service brake to rest on the parking-brake pin.
Fuel-Shutoff Valve Specifications 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.
Performing Daily Maintenance Operation Note: Determine the left and right sides of the machine from the normal operating position. Perform the daily maintenance procedures; refer to Daily Maintenance Checklist (page 25). Before Operation Before Operation Safety Checking the Engine-Oil Level General Safety Check the engine-oil level before each use or every 8 operating hours, refer to Checking the Engine-Oil Level (page 27).
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 to a Job Site Transporting the Machine Using Transport Wheels Use the transport wheels to transport the machine a shorter distance. 1. Install the transport wheels; refer to 4 Installing the Transport Wheels (page 10) 2. Ensure that the traction and reel-drive controls are in the NEUTRAL position. 3. Start the engine; refer to Starting the Engine (page 21) 4.
• Do not touch the engine, muffler, or exhaust pipe • • • • • • hazards. Tall grass can hide obstructions. Uneven terrain could overturn the machine. – Be aware that operating the machine on wet grass, across slopes, or downhill may cause the machine to lose traction. Loss of traction may result in sliding and a loss of braking and steering. – Use extreme caution when operating the machine near dropoffs, ditches, embankments, water hazards, or other hazards.
Operating the Controls while Mowing Operating Tips Important: Grass clippings act as a lubricant when mowing. Operating the cutting unit excessively without grass clippings can damage the cutting unit. 1. Start the engine, set the throttle to a reduced speed, push down on the handle to raise the cutting unit, press the operator-presence control, move the traction and reel-drive engagement lever to the FORWARD (transport) position, and transport the machine onto the collar of the green (Figure 23). 2.
Operating the Controls after Mowing 1. Drive off the green, move the reel drive and traction control levers to the DISENGAGED position, and shut off the engine. 2. Empty the grass basket of clippings, install the grass basket on the mower, and transport the machine to storage. After Operation After Operation Safety General 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 leaving the machine.
Maintenance WARNING Failure 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 Lubrication Pre-Maintenance Safety Service Interval: Every 25 hours • Disengage the drives and the cutting unit, Lubricate the 12 grease fittings on the mower using No. 2 lithium grease. For best results, use a hand-operated grease gun. Greasing the Machine 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.
Engine Maintenance 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°. If fuel comes in contact with the fuel cap, replace the cap. g016981 Figure 26 • Run the engine dry or remove the fuel with a hand pump; never siphon the fuel. If you must drain the fuel tank, do it outdoors.
2. 3. 4. g027903 Figure 29 1. Oil level gauge 5. 2. Drain plug 6. 7. 2. Remove the oil-level gauge by rotating it counterclockwise. 3. Wipe the oil-level gauge clean and insert it into the filler port, but do not screw the gauge into the port. 4. Remove the oil-level gauge and check the level of the oil. 5. If the level is low, add only enough oil to raise the level until it is between the hatch marks on the gauge (Figure 30).
B. C. remove dirt, but do not twist it, as the foam may tear. Servicing the Spark Plug Dry the foam element by wrapping it in a clean rag. Squeeze the rag and foam element to dry it, but do not twist it, as the foam may tear. 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). 1. Saturate the foam element with clean engine oil. Squeeze the element to remove excess oil and to distribute the oil.
Fuel System Maintenance Electrical System Maintenance Cleaning the Fuel-Tank Screen Servicing the Traction-Interlock Switch Service Interval: After the first 20 hours Use the following procedure if the traction-interlock switch needs adjustment or replacement. Every 100 hours/Monthly (whichever comes first) 1. 1. Unscrew and remove the fuel-tank cap from the fuel tank (Figure 35). Ensure that the engine is off and the traction lever is disengaged and resting against the neutral stop (Figure 36).
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. 5. Tighten the spring-tension nut until the spring is collapsed, then back it off 1/2 turn. 6. Adjust the bedbar; refer to Adjusting the Bedknife to the Reel (page 36). Backlapping the Reel 1. Remove the plug in the right reel-drive cover (Figure 63). g007633 Figure 63 1. Cover plug 2. Insert a 1/2 inch-drive extension bar, connected to the backlapping machine, into the square hole in the center of the reel pulley. 3.
Storage Storage Safety • Shut off the engine, wait for all moving parts to stop, and allow the machine to cool before adjusting, cleaning, storing, or repairing it. • Never store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or on other appliances. • Allow the engine to cool before storing the machine in any enclosure. Storing the Machine 1.
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California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
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).
