Toro 04052 Greensmaster 1000, Operator'S Manual

Page 1: ...Form No 3359 317 Rev D Greensmaster 1000 and 1600 Walk Behind Mower Model No 04052 Serial No 280000001 and Up Model No 04060 Serial No 280000001 and Up Register at www Toro com Original Instructions EN ...

Page 2: ...ional information contact an Authorized Service Dealer or Toro 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 Model No Serial No This manual identifies potential hazards and has safety messages identified by the safety alert symbol Figure 1 which signals a haz...

Page 3: ... Operating Tips 18 Maintenance 19 Recommended Maintenance Schedule s 19 Daily Maintenance Checklist 20 Lubrication 21 Greasing the Machine 21 Engine Maintenance 22 Servicing the Engine Oil 22 Servicing the Air Cleaner 23 Replacing the Spark Plug 23 Fuel System Maintenance 24 Cleaning the Fuel Filter 24 Electrical System Maintenance 25 Servicing the Interlock Switch 25 Brake Maintenance 25 Adjustin...

Page 4: ...aring open sandals Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine Warning Fuel is highly flammable Take the following precautions Store fuel in containers specifically designed for this purpose Refuel outdoors only and do not smoke while refuelling Add fuel before starting the engine Never remove the cap of the fuel tank or a...

Page 5: ...n good working condition and all hardware and hydraulic fittings tightened Replace all worn or damaged parts and decals If the fuel tank has to be drained do this outdoors Be careful during adjustment of the machine to prevent entrapment of the fingers between moving blades and fixed parts of the machine Disengage drives disengage the cutting unit set parking brake stop engine and disconnect spark...

Page 6: ...a maintenance adjustment keep hands feet clothing and any parts of the body away from the cutting unit attachments and any moving parts Keep everyone away 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 100 RPM If major repairs are ever needed or if assistance is desired contact an Autho...

Page 7: ...ct hazard keep bystanders a safe distance from the machine 4 Cutting hazard of hand or foot stay away from moving parts 115 1613 1 Warning read the Operator s Manual 3 Thrown object hazard keep bystanders a safe distance from the machine 2 Warning remove the spark plug wire before performing any maintenance on the machine 4 Cutting dismemberment hazard of hand or foot stay away from moving parts 9...

Page 8: ...ore servicing or performing maintenance 2 Cutting hazard of hand or foot stop the engine and wait for moving parts to stop 115 1614 1 Warning read the Operator s Manual 3 Thrown object hazard keep bystanders a safe distance from the machine 2 Warning do not operate the machine unless you are trained 4 Warning stay away from moving parts keep all guards in place 8 ...

Page 9: ...115 1720 1 Forward 3 Neutral 2 Drive wheel 104 2618 1 Disengage lever position 3 Engage lever position 2 Parking brake 9 ...

Page 10: ... of Compliance 1 Read or view before operating the machine Note Determine the left and right sides of the machine from the normal operating position 1 Installing and Adjusting the Handle Parts needed for this procedure 1 Handle 2 Cable tie Installing the Handle 1 Remove the bolt washer and lockwasher from the mounting pin on each side of the mower Figure 2 Figure 2 1 Mounting pins 3 Bolt and lockn...

Page 11: ...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 3 Install the ring pins and hairpin cotters 2 Installing the Kickstand Model 04060 Only Parts needed for this procedure 1 Kickstand assembly 1 Spring Procedure Note The fasteners a...

Page 12: ...el onto the axle Figure 7 6 Pivot the wheel locking clip away from center of the wheel allowing it to slide farther onto the axle Figure 7 Figure 7 1 Locking clip 7 Rotate wheel back and forth until it slides completely onto axle and locking clip is secured in groove on axle shaft 8 Repeat procedure on opposite side of machine 9 Inflate the tires to 12 to 15 psi 574 to 718 Pa 4 Adjusting the Cutti...

Page 13: ... Lever The traction drive lever Figure 9 is located on the front right side of the control panel It has two positions Neutral and Forward Pushing the lever forward engages the traction drive Service Parking Brake The service parking brake Figure 9 is located on left front side of control panel You can use the brake to slow or stop the machine Pulling the lever back over center will set the parking...

Page 14: ...igure 12 1 Recoil starter 2 Kick stand Kickstand The kickstand Figure 12 is mounted to the rear of machine and is used to raise the rear of machine for installation or removal of the transport wheels Specifications Model 04052 Model 04060 Width 36 inches 91 cm 41 inches 104 cm Height 41 1 2 inches 105 cm 41 1 2 inches 105 4 cm Length with basket 59 inches 150 cm 59 inches 150 cm Dry weight with ba...

Page 15: ...ure 13 1 Fuel tank cap 2 Fuel gauge 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 Fill the fuel tank outdoors in an open area when the engine is cold Wipe up any gasoline that spills Never fill the fuel tank inside an enclosed trailer Do not fill the fuel tank completely full Add gasoline...

Page 16: ...ts wheels on the ground If this is not possible then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Gasoline is harmful or fatal if swallowed Long term exposure to vapors ...

Page 17: ...andle when rope is pulled out because rope may break or recoil assembly may be damaged 7 Move the choke to the Off position as the engine warms up Stopping the Engine 1 Move the traction and reel drive controls to the Disengaged position the throttle control to the Slow position and the On Off switch to the Off position 2 Pull the spark plug wire off of the spark plug to prevent the possibility of...

Page 18: ...reen move the traction control lever to the Disengage position stop the engine and push the reel drive lever into the Disengage position 5 Empty the grass basket of clippings install the grass basket and commence transport operation Operating Tips Before Mowing Ensure that the mower is carefully adjusted and is set evenly on both sides of the reel Improper mower adjustment is magnified many times ...

Page 19: ...d oil the air cleaner foam element More often in dirty or dusty conditions Every 50 hours Change the engine oil More frequently in dusty or dirty conditions Clean the fuel filter Every 100 hours Clean or replace the paper air filter element More often in dirty or dusty conditions Check the spark plug Every 200 hours Decarbon the engine Every 300 hours Change the air filter paper element Check the ...

Page 20: ...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 Touch up damaged paint Notation for Areas of Concern Inspection performed by Item Date Information 20 ...

Page 21: ...oller Figure 14 2 on the reel bearings Figure 14 2 on the drum axles Figure 15 3 on the differential Figure 15 2 on the reel countershaft bearings Figure 16 2 on the belt idler pivots Figure 17 1 Wipe each grease fitting with a clean rag _ 2 Pump grease into each fitting until it begins to get difficult to pump the gun Important Do not apply too much pressure or grease seals will become permanentl...

Page 22: ... 40 will increase oil consumption Check the oil level more frequently when using them Checking the Engine Oil Level 1 Position mower so the engine is level and clean around oil level gauge Figure 19 Figure 19 1 Oil level gauge 2 Drain plug 2 Remove the oil level gauge by rotating it counterclockwise 3 Wipe the oil level gauge clean and insert it into the filler port Do not screw it into the port 4...

Page 23: ...dirt but do not twist it because the foam may tear B 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 C Saturate the foam element with clean engine oil Squeeze the element to remove excess oil and to distribute the oil thoroughly An oil damp element is desirable Figure 22 1 Foam element 2 Paper element 5 Check the condition of the pa...

Page 24: ...lb 23 N m 5 Install the spark plug wire on the spark plug Fuel System Maintenance Cleaning the Fuel Filter Service Interval After the first 25 hours Every 50 hours 1 Close the fuel shut off valve and unscrew the bowl from the filter body Figure 25 Figure 25 1 Shut off valve 2 Bowl 2 Clean the bowl and filter in clean gasoline and install it 24 ...

Page 25: ...ion lever must not contact the switch 5 Engage traction lever and verify that the switch loses continuity Replace if required Brake Maintenance Adjusting the Service Parking Brake If service parking brake slips when operated an adjustment is required 1 Move service parking brake lever to the Off position 2 Loosen the retainer securing the V belt cover and pivot the cover open 3 To increase the cab...

Page 26: ...e 29 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 The gap allows visual alignment of the bolts to the threaded inserts 6 After all bolts are installed tighten them until the...

Page 27: ...over 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 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 Adjusting the Primary V Belts 1 To...

Page 28: ...ions away to expose the belt Figure 35 Figure 35 1 Differential cover sections 3 Right rear bearing housing 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 6 Remove the 2 bolts and locknuts securing the front clutch housing to the side plate Figu...

Page 29: ...e on a flat level surface preferably a precision steel work plate 2 Place a 1 4 x 1 inch 0 6 x 2 5 cm flat steel strip approximately 29 inches 73 6 cm long under the reel blades and against the front edge of the bedknife to prevent the bedbar from resting on the work surface 3 Raise the front roller so only the rear drum and reel are on the surface 4 Firmly press down on the machine above the reel...

Page 30: ... click at a time until the paper is pinched lightly when inserted from the front parallel to the bedknife which results in a slight drag when paper is pulled Figure 39 Figure 40 Note Each time the adjusting screw is rotated one click clockwise the bedknife moves 0 0007 inch 0 0017 cm closer to the reel Do not overtighten the adjusting screws 5 Check for light contact at the other end of the reel u...

Page 31: ...snug against the bedknife This ensures the height of cut is identical at both ends of the bedknife 7 Tighten nuts to lock the adjustment Important To avoid scalping on undulating turf ensure that the roller supports are positioned rearward the roller closer to the reel Note The front roller can be put in three different positions Figure 44 depending on the application and needs of the user Use the...

Page 32: ...and the bar and tighten the screws 3 Ensure that the bar and reel are equal distance apart across the entire reel 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 performan...

Page 33: ...master 1600 0 125 0 25 inches 104 2646 HighCut Greensmaster 1600 0 25 inches and up Tees 93 9015 Low Cut Greensmaster 1600 0 25 inches and up Standard Greensmaster 1600 Rollers Standard and Optional Part Number Description Mower Diameter Material Comments 99 6241 Narrow Wiehle Greensmaster 1000 2 0 inches Aluminum Standard 0 2 Spacing 88 6790 Wide Wiehle Greensmaster 1000 2 0 inches Aluminum More ...

Page 34: ...o 240 to 320 inch lb 27 to 36 N m 4 Tighten the jam nuts until the 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 Backlapping the Reel 1 Remove the plug in the right reel drive cover Figure 50 Figure 50 1 Cover plug 2 Insert a 1 2 inch socket extension connect...

Page 35: ...gine to distribute conditioned fuel through the fuel system 5 minutes B Either stop engine allow it to cool and drain the fuel tank or operate the engine until it stops C Restart the engine and run it until it stops Repeat on Choke until the engine will not restart D Dispose of fuel properly Recycle as per local codes Note Do not store stabilizer conditioned gasoline over 90 days 3 Check and tight...

Page 36: ...t is not limited to dam age to seats due to wear or abrasion worn painted surfaces scratched decals or windows etc Parts Parts scheduled for replacement as required maintenance are war ranted for the period of time up to the scheduled replacement time for that part Parts replaced under this warranty are covered for the duration of the original product warranty and become the property of Toro Toro ...