Toro 04054 Greensmaster 800, Operator'S Manual

Page 1: ...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 Original Instructions EN 3422 714 A ...

Page 2: ...on well maintained lawns in parks golf courses sports fields and on commercial grounds It is not designed for cutting brush mowing grass and other growth alongside highways or for agricultural uses Important To maximize the safety performance and proper operation of this machine carefully read and fully understand the contents of this Operator s Manual Failing to follow these operating instruction...

Page 3: ...s 22 After Operation 23 After Operation Safety 23 Transporting the Machine 23 Maintenance 24 Recommended Maintenance Schedule s 24 Daily Maintenance Checklist 25 Pre Maintenance Procedures 26 Pre Maintenance Safety 26 Lubrication 26 Greasing the Machine 26 Engine Maintenance 27 Engine Safety 27 Servicing the Engine Oil 27 Servicing the Air Cleaner 28 Servicing the Spark Plug 29 Fuel System Mainten...

Page 4: ...ystanders a safe distance away from the machine Keep children out of the operating area Never allow children to operate the machine Stop the machine and shut off the engine before servicing fueling or unclogging the machine Improperly using or maintaining this machine can result in injury To reduce the potential for injury comply with these safety instructions and always pay attention to the safet...

Page 5: ...tral 2 Drive wheel decal133 8062 133 8062 decal120 2727 120 2727 1 Brake to engage pull the lever toward the handle to disengage release the lever 2 Parking brake to lock pull the lever toward the handle press the button in and release the lever against the locking button to release pull the lever toward the handle until the button releases and release the lever decal125 5245 125 5245 1 Cutting ha...

Page 6: ...ion hazard shut off the engine and keep away from open flames when refueling 5 Hot surface burn hazard do not touch hot surfaces 3 Warning shut off the engine and turn off the fuel before leaving the machine 6 Warning read the Operator s Manual when adding fuel to the tank fill only to the bottom of the fill tube decal120 2761 120 2761 1 Warning read the Operator s Manual 4 Thrown object hazard ke...

Page 7: ...056 only 4 Transport wheel 2 Install the transport wheels optional 5 No parts required Adjust the cutting unit Production year decal 1 6 CE mark decal 1 Install the CE decals if required 7 Grass basket 1 Install the grass basket 8 No parts required Break in the machine Media and Additional Parts Description Qty Use Operator s Manual 1 Engine Owner s Manual 1 Certificate of Compliance 1 Read or vie...

Page 8: ...ach side of the machine Figure 3 3 Insert the handle ends through the holes in the handle arms and align the holes with the mounting pins Figure 3 4 Squeeze the handle ends inward and install them on the mounting pins Figure 4 g240404 Figure 4 1 Handle 4 Washer 2 Handle arm 5 Lock washer 3 Mounting pin 6 Bolt 3 8 inch 5 Secure the handle to the mounting pins with the bolts 3 8 inch washers and loc...

Page 9: ...ach side and raise or lower the handle to the desired operating position 3 Install the ring pins and hairpin cotters 2 Installing the Kickstand Models 04054 and 04056 Only Parts needed for this procedure 1 Kickstand assembly 1 Spring Procedure Note The machine is shipped with the fasteners loosely installed on the kickstand assembly 1 On Model 04056 only connect the spring stud to the right hand s...

Page 10: ... hole 3 Installing the Transport Wheel Shafts Models 04055 and 04056 Only Parts needed for this procedure 1 Right wheel shaft 1 Left wheel shaft Procedure 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 ...

Page 11: ...he machine 6 Inflate the tires to 83 to 103 kPa 12 to 15 psi 7 Carefully lower the machine off the kickstand 5 Adjusting the Cutting Unit No Parts Required Procedure Before operating the machine complete the following adjustments Leveling the Rear Drum to the Reel page 36 Adjusting the Bedknife to the Reel page 36 Adjusting the Height of Cut page 37 Adjusting the Grass Shield Height page 38 Adjust...

Page 12: ... the machine 8 Breaking in the Machine No Parts Required Procedure Only 8 hours of mowing operation is required for the break in period The first several hours of operation are critical to future dependability of the machine You must monitor the machine performance closely so that minor difficulties which could lead to major problems are noted and can be corrected During the first few hours of ope...

Page 13: ...UTRAL and FORWARD Pushing the lever forward engages the traction drive Throttle Control The throttle control Figure 14 is located on the rear right side of the control panel The lever connects to and operates the throttle linkage to the carburetor Refer to Specifications page 15 for the engine speed On Off Switch The On Off switch Figure 14 is located on the top of the control panel Move the switc...

Page 14: ... the handle You must engage the operator presence control before moving the traction drive lever If you release the operator presence control the engine shuts off 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 g01697...

Page 15: ... 59 inches Dry weight with basket and Wiehle roller without wheels or grooming reel 97 kg 216 lb 100 kg 220 lb 105 kg 232 lb Width of cut 46 cm 18 inches 53 cm 21 inches 66 cm 26 inches Height of cut 1 6 mm to 31 8 mm 0 063 to 1 25 inches 1 6 mm to 31 8 mm 0 063 to 1 25 inches 3 1 mm to 31 7 mm 0 125 to 1 25 inches Clip 3 3 mm 0 13 inches 4 3 mm 0 16 inch 5 8 mm 0 23 inch Engine speed Low idle 1 5...

Page 16: ... tank while the engine is running or hot Do not add or drain the fuel in an enclosed space Do not store the machine or fuel container where there is an open flame spark or pilot light such as on a water heater or other appliance If you spill fuel do not attempt to start the engine avoid creating any source of ignition until the fuel vapors have dissipated Performing Daily Maintenance Perform the d...

Page 17: ... and can damage property Always place fuel containers on the ground away from your vehicle before filling Do not fill fuel containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove equipment from the truck or trailer and fuel it on the ground If this is not po...

Page 18: ...ment Greensmaster 800 3 1 6 0 mm 0 125 0 250 inch Longer wearing 110 2300 Extended Microcut Greensmaster 800 1 57 3 1 mm 0 062 0 125 inch Less aggressive 110 2301 Low cut Greensmaster 800 6 0 mm 0 250 inch and up 93 4262 Microcut Greensmaster 1000 1 57 3 1 mm 0 062 0 125 inch 115 1880 EdgeMax Microcut Greensmaster 1000 1 57 3 1 mm 0 062 0 125 inch Standard Greensmaster 1000 93 4263 Tournament Gree...

Page 19: ...lade 3 8 mm 0 15 inch 14 blade 4 3 mm 0 17 inch 11 blade 5 6 mm 0 22 inch 04055 11 blade 4 1 mm 0 16 inch 14 blade 3 3 mm 0 13 inch 8 blade 5 8 mm 0 23 inch 11 blade 6 4 mm 0 25 inch 14 blade 4 8 mm 0 19 inch 8 blade 8 6 mm 0 34 inch 11 blade 3 8 mm 0 15 inch 14 blade 3 0 mm 0 12 inch 8 blade 5 1 mm 0 20 inch 11 blade 5 6 mm 0 22 inch 14 blade 4 3 mm 0 17 inch 8 blade 7 6 mm 0 30 inch 04056 8 blad...

Page 20: ...on the handle support until the kickstand has rotated forward over center 3 Remove the transport wheels by pushing the wheel locking clips out of the hex shaft grooves 4 Carefully lower the machine off of the kickstand by pushing forward slowly or by lifting the lower handle support allowing the kickstand to spring back to the STORAGE position During Operation During Operation Safety General Safet...

Page 21: ...lowly and gradually Do not operate a machine under any conditions where traction steering or stability is in question Remove or mark obstructions such as ditches holes ruts bumps rocks or other hidden 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 Lo...

Page 22: ...itions contact your authorized Toro distributor Important Do not use other light systems with this machine as they will not operate properly with the engine AC output Operating the Controls while Mowing 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...

Page 23: ...gage the parking brake shut off the engine remove the key and wait for all movement to stop before leaving the machine Reduce the throttle setting before shutting off the engine and if the engine has a fuel shutoff valve turn off the valve after mowing Clean grass and debris from the machine to help prevent fires Clean up oil or fuel spills Transporting the Machine After mowing transport the machi...

Page 24: ...e Schedule s Maintenance Service Interval Maintenance Procedure After the first 20 hours After the first 20 hours Change the engine oil Change the engine oil Clean the fuel tank screen Before each use or daily Check the interlock switch operation Before each use or daily Check the engine oil level Every 25 hours Grease the machine Grease the fittings immediately after every washing regardless of t...

Page 25: ...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 25 ...

Page 26: ...ressure from components with stored energy Replace faulty silencers If major repairs are ever needed or if assistance is desired contact an authorized Toro distributor To ensure optimum performance and continued safety certification of the machine use only genuine Toro replacement parts and accessories Replacement parts and accessories made by other manufacturers could be dangerous and such use co...

Page 27: ...Oil Service Interval After the first 20 hours Before each use or daily Every 50 hours Fill the crankcase with approximately 0 6 L 20 fl oz of the proper viscosity oil before starting The engine uses a high quality oil that has the American Petroleum Institute API service classification of SE or higher Select the proper oil viscosity weight based on the ambient temperature Figure 28 illustrates the...

Page 28: ...tant Do not tip the machine at an angle greater than 25 Tipping the machine beyond 25 leads to oil leaking into the combustion chamber and or fuel leaking out of the fuel tank cap 4 Install the drain plug and refill the crankcase with the specified oil 5 Torque the drain plug to 20 to 23 N m 15 to 17 ft lbs 6 Wipe up any spilled oil 7 Dispose of the used oil properly Recycle as per local codes Ser...

Page 29: ...r cover Important Do not operate the engine without the air cleaner element as extreme engine wear and damage can result Servicing the Spark Plug 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 Pull the molded wire off the spark plug Figure 33 g016986 Figure 33 1 Spark plug wire 2 Clean around the spark plug and ...

Page 30: ...e the following procedure if the traction interlock switch needs adjustment or replacement 1 Ensure that the engine is off and the traction lever is disengaged and resting against the neutral stop Figure 36 g027905 Figure 36 1 Traction lever 3 Interlock switch 2 Neutral stop 4 0 8 mm 0 032 inch gap 2 Loosen the interlock switch mounting fasteners Figure 36 3 Place a 0 8 mm 0 032 inch thick shim be...

Page 31: ...ed adjust the brake cable 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 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 40 Repeat steps 1 and 2 and ad...

Page 32: ...elt cover mounting fasteners and the belt cover to expose the belt Figure 41 g007618 Figure 41 1 Belt cover 2 Check the tension by pressing the belt at mid span of the pulleys Figure 42 with 18 to 22 N 4 to 5 lb of force The belt should deflect 6 mm 1 4 inch g007619 Figure 42 1 Reel drive belt 2 Idler pulley 3 Complete the following steps to adjust the belt tension A Loosen the idler pulley mounti...

Page 33: ... is attained Figure 44 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 Note The gap allows visual alignment of the bolts to the threaded inserts 6 After all bolts are installed...

Page 34: ...t pulley and the counter shaft pulley with a straightedge 6 If the pulleys are misaligned loosen the screws that secure the engine mounting base to the machine frame and slide the engine from side to side until the pulleys are aligned within 0 7 mm 0 030 inch g027906 Figure 47 1 Locknut 3 Idler pulley 2 Belt guide 4 Idler arm 7 Tighten the mounting screws and check the alignment 8 To push or pull ...

Page 35: ...ure them to the side plate with the bolts and nuts that you previously removed 14 Adjust the differential belt tension refer to Adjusting the Differential Belt page 33 15 Adjust the belt tension on the traction drive and reel drive belts refer to Adjusting the Traction Drive Belt page 33 and Adjusting the Reel Drive Belt page 32 16 Install the differential traction drive and reel drive covers Cont...

Page 36: ...er from the right side of the machine Figure 50 g007598 Figure 50 1 Traction drive belt cover 7 Rotate the driven pulley until the holes align with the 4 roller bearing flange screws Figure 51 g007599 Figure 51 1 Driven pulley 3 Idler pulley 2 4 holes 8 Loosen the 4 roller bearing screws and the screw that secures the idler pulley 9 Raise or lower the right side of the roller assembly until the ga...

Page 37: ...e bedknife edge closer to the reel and counterclockwise rotation move the bedknife edge away from the reel 12 Test the cutting performance by inserting a long strip of cutting performance paper between the reel and bedknife perpendicular to the bedknife Figure 53 Slowly rotate the reel forward it should cut the paper g007602 Figure 53 Note If you see excessive contact reel drag it will be necessar...

Page 38: ...ferent positions Figure 57 depending on the application and needs of the user Use the front position when a groomer is installed Use the middle position without a groomer Use the third position in extremely undulating turf conditions g007596 Figure 57 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...

Page 39: ...ard bedbar If the mounting ears have a notch in them it is an aggressive bedbar Figure 60 g008800 Figure 60 1 Standard bedbar 2 Aggressive bedbar Servicing the Bedbar Removing the Bedbar 1 Turn the bedbar adjuster screw counterclockwise to back the bedknife away from the reel Figure 61 g007631 Figure 61 1 Bedbar adjusting screw 3 Bedbar 2 Spring tension nut 2 Back out the spring tension nut until ...

Page 40: ...ey 3 Backlap according to the procedure in the Toro Sharpening Reel and Rotary Mowers Manual Form 80 300 PT DANGER Contact with the reel or other moving parts can result in personal injury Stay away from the reel while backlapping Do not use a short handled paint brush for backlapping Part No 29 9100 Handle assembly complete or as individual parts are available from your local authorized Toro dist...

Page 41: ...or long term storage more than 30 days add stabilizer conditioner additive to the fuel in the tank A Run the engine to distribute conditioned fuel through the fuel system for 5 minutes B Either shut off the engine allow it to cool and drain the fuel tank or operate the engine until it shuts off C Start the engine and run it until it shuts off Start the engine again with the choke closed until the ...

Page 42: ...f these activities We will not sell your personal information to any other company We reserve the right to disclose personal information in order to comply with applicable laws and with requests by the appropriate authorities to operate our systems properly or for our own protection or that of other users Retention of your Personal Information We will keep your personal information as long as we n...

Page 43: ...to restaurants grocery stores hotels schools and hospitals and on a wide variety of products Additionally some online and mail order retailers provide Prop 65 warnings on their websites or in catalogs How do the California warnings compare to federal limits Prop 65 standards are often more stringent than federal and international standards There are various substances that require a Prop 65 warnin...

Page 44: ...to damage to seats due to wear or abrasion worn painted surfaces scratched decals or windows etc Parts Parts scheduled for replacement as required maintenance are warranted 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 will make the final...