Form No. 3350–271 Greensmaster 500 Greensmaster Walk-Behind Mower Model No. 04130—250000001 and Up (Traction Unit) Model No.
Warning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting And Stopping . . . . . . . . . . . . . . . . . . . . . Transport Operation . . . . . . . . . . . . . . . . . . . . . . . Prior To Mowing . . . . . . . . . . . . . . . . . . . . . . . . . Method Of Mowing . . . . . . . . . . . . . . . . . . . . . . . Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . After Mowing . . . . . . .
Introduction Safety Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely. This machine meets or exceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-1999 specifications in effect at the time of production.
• Watch out for traffic when crossing or near roadways. – Refuel outdoors only and do not smoke while refuelling. • Stop the blades rotating before crossing surfaces other than grass. – 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. • When using any attachments, never direct discharge of material toward bystanders nor allow anyone near the machine while in operation.
• Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death. Maintenance and Storage Use of this product for purposes other than its intended use could prove dangerous to user and bystanders. • Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition.
• Using the machine demands attention. To prevent loss of control: • To ensure safety and accuracy, have an Authorized Toro Distributor check the maximum engine speed with a tachometer. Maximum governed engine speed should be 3600 RPM. – Do not drive close to sand traps, ditches, creeks, or other hazards. • If major repairs are ever needed or if assistance is desired, contact an Authorized Toro Distributor. – Reduce speed when making sharp turns. Avoid sudden stops and starts.
Safety and Instruction 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. Part No. 95 7271 1. Descriptions to come Part No. 93-7348 1. Danger—read the operator’s manual. 2. Fire or open flame—sparks, flame, and smoking prohibited. Fill the fuel tank no higher than to the bottom of the filler neck. 3. Thrown object hazard—keep bystanders away. 4.
General Specifications Engine Kawasaki, 4-cycle, 3.7 (2.7 kw) air cooled OHV engine, 3600 RPM, 7.57 cu in. (124 cc) displacement, cast iron cylinder sleeve; electronic ignition with integral lighting coil; maximum noise suppression muffler; 83 dB(A) at operator’s ear Fuel capacity 2.64 qt. (2.5 l); regular grade unleaded gasoline Traction drive “A” section “V” belt on 2.0 P.D. and 3.70 P.D. to countershaft (1. 85:1) 18T and 48T gear) 2.67:1 and 20T and 56T gear (2 . 8:1).
Optional Equipment Cutting Unit Model No. 04215 Light Kit Model No. 04058 Brush Kit Part No. 2–2949 Skid Kit Part No. 4–7299 Sectional Roller Part No. 4–7319 Urethane Comb Part No. 8–2560 Full Roller Part No. 4–7309 Micro Cut Bedknife Wiehle Roller (rear cutting unit) Part No. 95–3147 Part No. 100–1556 Spark Arrester Kit Part No. 98-3426 Low Cut Bedknife Part No.
Setup Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Chart Note: Use this chart as a checklist to ensure all parts necessary for assembly have been shipped. If any of these parts are missing, total setup cannot be completed. Loose Parts Qty. Where Used Handle Assembly 1 Throttle stop Wire retainer Retainer screw Retainer nut 1 1 1 1 Cotter pin Washer Spring 1 1 1 Mount clutch rod Gauge Bar Assembly 1 Use to set height-of-cut.
Installing the Handle 1. Remove handle mounting capscrew, washer and flange lock nut from main fame (Fig. 1). 2 3 2. Secure handle and bell cranks to frame with capscrew, washer nut previously removed (Fig. 1). 4 1 5 6 3 1 Figure 3 1. Clutch rod 2. Throttle wire 3. Throttle stop 2 Figure 1 1. Handle 2. Bellcrank–clutch 4. Throttle wire retainer 5. Return spring 6. Engine bracket 3. Bellcrank–throttle Adjust Handle Height And Control Bail 3.
Fill Fuel Tank Before Operating Refer to Engine Operator’s Manual for fuel requirements. 1. Clean around fuel tank cap and remove cap from tank (Fig. 6). Fill fuel tank no higher than to bottom of filter screen. DO NOT OVER FILL. Add Engine Oil Crankcase must be filled with the proper viscosity, grade and quantity of oil before staring. Refer to Engine Operator’s Manual for oil requirements. 1 1. Position mower so the engine is level and clean around oil level gauge (Fig. 5). Figure 6 1 1.
Check Transaxle Oil Level Adjusting Height-of-cut Check transaxle oil level before initial startup and after every 50 hours of operation. Effective cutting height is dependent upon the condition of the turf grass and the selection of various combinations of skids or rollers available for the Greensmaster 500.
1 3 2 4 2 1 Figure 12 3 1. Nut 2. Reel bracket 3. Side plate Figure 10 1. Gauge bar against rollers 2. Screw head over cutting edge 3. Top nut 4. Adjustment nut 1 5. Tighten top nuts to secure roller adjustment (Fig. 10). Turn cutting unit over and place on a level surface (Fig. 11). Press down on each end of the front and rear rollers (Fig. 11). Each roller should contact level surface completely across unit (Fig. 11). If rollers do not contact, repeat steps 3 and 4. 2 Figure 13 1.
Adjust Rear Roller Scraper 2. Slide sleeves back on each ball joint and rotate each pull arm upward off the ball studs. The adjustment of the rear roller scraper depends on the many conditions of the green (i.e. leaves, seeds, dew, etc.). 3. Align cutting unit with roller and driveshaft with transaxle shaft and lengthen or shorten pull rods by threading ball socket on rod (Fig. 15). 1. Adjust scraper rod locknuts and brackets to attain .06”–.10” clearance between scraper rod and roller surface.
Note: Basket should be lower in front to assist clipping throw into basket. Adjust screw to lower basket (Fig. 17). Make sure basket clears roller by at least 1/16 in. (1.6 mm). 3. Tighten jam nuts on each side of basket for adjusting screws (Fig. 17). Be sure dimension is equal on both sides of unit. 1 Figure 18 1.
Operation 2 Controls Throttle Control Lever Throttle control lever (Fig. 19) connects to and operates throttle linkage to carburetor. Control has two positions: SLOW and FAST. Engine speed can be varied between the two settings. 1 2 Figure 20 1 1. Fuel shut–off valve 2. Choke lever Engine Stop Switch Engine stop switch (Fig. 21) is located at front of engine. Rotate to OFF to stop engine. Figure 19 1. Throttle control lever 2. Clutch control bail Recoil Starter Pull recoil starter handle (Fig.
Reel Drive Control 7. Pull wire off spark plug to prevent possibility of accidental starting before storing machine. Reel drive control knob (Fig. 22), located at right side transaxle, has two positions: ENGAGE and DISENGAGE. Pull out knob to engage reel drive clutch. Push in to disengage. 8. Close fuel valve before storing machine (Fig. 20). Transport Operation 1. Assure clutch bail is DISENGAGED and start engine. 2. Disengage cutting unit drive (Fig. 22).
After Mowing 1. Drive off green, release clutch control bail to DISENGAGE, stop the engine and push the reel drive control knob full in to DISENGAGE. 1 2. Empty the grass catcher of clippings, install grass catcher and commence transport operation; refer to Transport Operation. 3. Chock wheels if mower is left unattended on an incline. Figure 23 1. Traction clutch control bail 1 Figure 24 1. Reel drive control knob—Pull out to Engage 3.
Lubrication Grease Fittings 2 The grease fittings on the mower should be greased at least every 25 hours. Lubricate using a No. 2 multi–purpose lithium base grease. A hand operated grease gun is recommended for best results. 1. Wipe each grease fitting with a clean rag. 2. Grease components as follows: • Cutting unit reel bearings, drive shaft bearing, front roller or support, yoke pivot and pull arm bushings and rear cutting unit and yoke rollers (Fig. 25). 1 1 Figure 26 1. Clutch assembly 2.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure After first 10 hours • Adjust traction belt drive After first 25 hours • Change the engine oil. • Clean the fuel filter. Every 25 hours • Service the air filter pre-cleaner. • Check for loose fasteners. • Lubricate all grease fittings Every 50 hours • • • • Every 100 hours • Check the cut-off bar adjustment.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Check that pivot joints operate freely. 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. Touch up damaged paint.
Removal And Installation Of Cutting Unit 2. Install the chains onto the support hooks (Fig. 29). 3. Align pull arms with ball studs, slide sleeves back on sockets, and drop arm sockets down on ball studs (Fig. 30). To remove the cutting unit: 4. Make sure the cutting unit is aligned with the yoke roller and the drive shaft with the transaxle shaft. If there is misalignment, refer to Check Cutting Unit Alignment. 1. Remove grass catcher and unhook the two chains from the support hooks (Fig. 29).
3. Install drain plug; remove oil fill plug (Fig. 31), assure engine is level and fill crankcase with fresh clean oil; refer to Engine Operator’s Manual for oil requirements. 2. Traction wheels will spin, on a cement floor, when clutch is engaged. Traction Drive Belt Adjustment 2 The belt should be tight enough so traction wheels will spin on cement floor when clutch is engaged with the engine running. Belt should be checked after first 10 hours of operation and tightened if necessary.
3. Remove (5) cover screws and (2) tapered nuts and remove cover (Fig. 34). 4. Check chain for excess slack (Fig. 35). If chain is too slack, loosen mounting screw for chain idler shoe, push down against chain to remove slack and tighten screw (Fig. 35). 3 2 5 1 4 2 3 1 1 2 3 Figure 36 Figure 35 1. Chain 2. Idler screw 1. Locknut 2. Reel adjust screw 3. Allen head screw 3. Shoe 4. Capscrew 5. Left reel bracket 5. Make sure a liberal quantity of lithium base No.
4. If torque wrench is used, there should be 5–10 in-lb (5.6–11.3 N m) drag on reel shaft. Rotate the shaft and repeat check to be sure bearings are aligned in cup and cone. 4. Use a good grade of medium grit (80) commercial lapping compound with a water soluble carrier to assure the compound will be easily washed away at the completion of the backlapping operation. Dry lapping compound should be mixed with liquid detergent (soap) until the material is of free flowing consistency. 5.
Electrical Schematic SPARK PLUG COMBINATION IGNITOR/IGNITION COIL INTEGRAL LIGHTING COIL SWITCH ENGINE IGNITION, OPEN TO RUN • Check condition of reel blades and bedknife: repair and sharpen as necessary; refer to Reel And Bedknife Grinding. Storage • Drain gasoline from fuel tank. Start engine and let it run at slow speed until it stops because all gasoline is used. • Lubricate mower: refer to Lubrication. • Clean the air cleaner. • Drain oil from crankcase: refer to Engine Operator’s Manual.
The Toro General Commercial Products 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.
