Toro Greenmaster 1000 Service Manual
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Toro Greenmaster 1000 Service Manual

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Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing,
and repairing assemblies and components on the
Greensmaster 1000/1600.
REFER TO THE OPERATOR'S MANUAL FOR OPER-
ATING,
MAINTENANCE,
INSTRUCTIONS. Space is provided in Chapter 2 of this
book to insert the Operator's Manual and Parts Catalogs
for your machine. Replacement Operator's Manuals are
available by sending complete Model and Serial Num-
ber to:
The Toro Company
8111 Lyndale Avenue South
Minneapolis, MN 55420–1196
The Toro Company reserves the right to change product
specifications or this publication without notice.
Greensmaster
AND
ADJUSTMENT
The Toro Company – 1996, 1997
®
This safety symbol means DANGER, WARN-
ING, or CAUTION, PERSONAL SAFETY
INSTRUCTION. When you see this symbol,
carefully read the instructions that follow.
Failure to obey the instructions may result in
personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing, or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
PART NO. 96889SL, Rev. A

Service Manual

1000/1600

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  • Page 1: Service Manual

    Minneapolis, MN 55420–1196 IMPORTANT: The IMPORTANT notice will give im- portant instructions which must be followed to pre- The Toro Company reserves the right to change product vent damage to systems or components on the specifications or this publication without notice.
  • Page 2 Greensmaster 1000/1600...

  • Page 3: Table Of Contents

    Table Of Contents Chapter 1 – Safety Chapter 5 – Electrical System Safety Instructions ......1 –...

  • Page 4: Greensmaster

    Greensmaster 1000/1600...

  • Page 5: Safety Instructions

    Safety Instructions The GREENSMASTER 1000 was tested and certified To reduce the potential for injury or death, comply with by TORO for compliance with the B71.4–1984 specifica- the following safety instructions. tions of the American National Standards Institute. Al- though hazard control and accident prevention partially...
  • Page 6 Maximum engine speed is 3600 rpm. To as- spark plug to prevent accidental starting of the engine. sure safety and accuracy, have an Authorized Toro Dis- tributor check maximum engine speed with a 21. To make sure entire machine is in good condition, tachometer.

  • Page 7: Safety And Instruction Decals

    The following safety and instruction decals are affixed to and in your Parts Catalog. Order replacements from the traction unit. If any decal becomes illegible or dam- your Authorized Toro Distributor. aged, install a new decal. Part numbers are listed below On Front Frame Tube Part No.
  • Page 8 On Control Panel Part No. 93–9012 Safety Greensmaster 1000/1600 Page 1 – 4...

  • Page 9: Product Records

    Chapter 2 Product Records and Manuals Table of Contents PRODUCT RECORDS ......TORQUE SPECIFICATIONS ....EQUIVALENTS AND CONVERSIONS .

  • Page 10: Equivalents And Conversions

    Equivalents and Conversions Product Records and Manuals Greensmaster 1000/1600 Page 2 – 2...

  • Page 11: Torque Specifications

    Torque Specifications Greensmaster 1000/1600 Product Records and Manuals Page 2 – 3...
  • Page 12 Product Records and Manuals Greensmaster 1000/1600 Page 2 – 4...

  • Page 13: Operation And Service History Report

    Engine Numbers: ____________________ Differential Numbers: ____________________ Date Purchased: ____________________ Warranty Expires__________ Purchased From: ____________________ ____________________ ____________________ Contacts: Parts ____________________ Phone__________________ Service ____________________ Phone__________________ Sales ____________________ Phone__________________ See your TORO Distributor/Dealer for other Publications, Manuals, and Videos from The TORO Company.

  • Page 14: Specifications

    GREENSMASTER® 1000 Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Maintenance Interval & Service Every Every Every Service Air Filter Pre-Cleaner Every 200hrs 100hrs 50hrs 25hrs Lubricate All Grease Fittings A Level Check for loose Fasteners Clean Fuel Filter and Sediment Bowl Adjust Traction Drive Belts B Level Service...

  • Page 15: Adjustments

    GREENSMASTER® 1000 Daily Maintenance Check List Unit Designation:__________ Daily Maintenance: TORO ID#:_______-_______ (duplicate this page for routine use) Daily Maintenance Check For Week Of _____________ TUES THURS Maintenance Check Item _______HRS ______HRS ______HRS ______HRS ______HRS ______HRS ______HRS Safety Interlock Operation...
  • Page 16 GREENSMASTER® 1000 Supervisor Maintenance Work Order Date:______________ (duplicate this page for routine use) Unit Designation: TORO I.D. #: Remarks: ____________-____________ Hours: Service to perform (circle): A B C D Other Technician: -Service (every 25 hours) -Service (every 50 hours) -Service (every 100 hours)

  • Page 17: Introduction

    Chapter 3 Engine Table of Contents INTRODUCTION ......SERVICE AND REPAIRS .

  • Page 18: Introduction

    Most repairs and adjustments require tools which are commonly available in many service shops. Special plied through your local Toro distributor. If no parts list is tools are described in the Kawasaki FE161 & FE170 available, be sure to provide your distributor with the Service Manual and Kawasaki FE120 Service Manual Toro model and serial number.

  • Page 19: Specifications

    Specifications Item Description Make / Designation Kawasaki, 4–stroke, OHV, single cylinder, air–cooled, gasoline engine, FE120G Bore x Stroke mm (in.) 60 x 44 (2.36 x 1.73) Total Displacement cc (cu. in.) 124 (7.6) Compression Ratio 8.4:1 Maximum Output kw (HP) 2.8 (3.7) Rated Output kw (HP) 2.2 (3.0)

  • Page 20: General Information

    General Information Filling the Fuel Tank DANGER Figure 1 1. Fuel tank cap IMPORTANT: Never use methanol, gasoline con- taining methanol, gasoline containing more than 10% ethanol, gasoline additives, premium gasoline, or white gas. Engine fuel system damage could re- sult.

  • Page 21: Fuel Shut-Off Valve

    Fuel Shut–off Valve The valve is located on the left front side of the engine. It has two positions: CLOSED and OPEN. Position valve to the closed position when storing or transporting the machine. Open valve before starting the engine. Figure 2 1.

  • Page 22: Adjustments

    Adjustments Throttle Control Adjustment If a new throttle cable must be installed or the cable is out of adjustment, adjust the cable as follows: 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2.

  • Page 23: Adjusting V-Belts

    Adjusting V–belts To adjust belt tension on V–belts (Fig. 5), first check ad- justment of clutch control. Refer to Clutch Control in this section. If unable to attain the 7 to 9 lbs (31 to 40 N) of force that is required in adjusting the clutch control, pro- ceed to the next step.

  • Page 24: Service And Repairs

    Service and Repairs Engine Oil The TORO Company recommends that the oil level be Changing the Oil: checked each time the mower is used or after every 5 1. Start and run engine for a few minutes to warm the operating hours.

  • Page 25: Air Cleaner

    Air Cleaner Normally, clean air filter precleaner (foam element) after every 25 operating hours and the air cleaner filter (paper element) after every 100 operating hours. More frequent cleaning is required when the mower is operated in dusty or dirty conditions. Replace air cleaner filter (pa- per element) after 200 operating hours.

  • Page 26: Engine Removal And Installation

    Engine Removal and Installation IDLER PULLEY ASSEMBLY Figure 12 1. Bellcrank cover 18. R–clamp 35. Washer 2. Flat washer 19. Lock washer 36. Cap screw 3. Stud 20. Cap screw 37. Lock nut 4. Retainer 21. Engine 38. Pulley support spacer 5.
  • Page 27 Removal 1. Make sure machine is parked on a level surface with the engine OFF. Remove high tension lead from the spark plug to prevent the engine from starting. Close fuel shut–off valve. 2. Remove pulley V–belts (Fig. 12). A. Make sure clutch is DISENGAGED so the V– belts (34) are slackened.
  • Page 28 Reinstalling the Engine 1. Make sure machine is parked on a level surface. The machine may be placed on a large work bench to make engine installation and adjustment easier. Re- move high tension lead from the spark plug. 2. Make sure that all parts removed from the engine INSIDE FACE during maintenance or rebuilding are properly rein- stalled to the engine.

  • Page 29: Lubrication

    Lubrication Both fittings on the bellcrank assembly should be greased at least every 25 hours. Lubricate using No. 2 multipurpose lithium base grease. A hand operated grease gun is recommended for best results. 1. Park mower on a level surface. Make sure engine is OFF.
  • Page 30 Engine Greensmaster 1000/1600 Page 3 – 14...
  • Page 31 Chapter 4 Traction and Reel Drive Systems Table of Contents SPECIFICATIONS ......Differential Axle Pulley and Bearing .

  • Page 32: Specifications

    Specifications Item Description Traction Drive Engine to countershaft drive has two ”A” section V–belts. Countershaft to differential drive has 5 mm pitch timing belt. Differential to drum drive has a 8 mm pitch timing belt. Differential Peerless series 100 Brake Band drum Traction Drum Dual cast aluminum, 7.5 inch (19.1 cm) diameter...

  • Page 33: Special Tools

    Order special tools from the TORO SPECIAL TOOLS Some tools may have been supplied with your mower or AND APPLICATIONS GUIDE (COMMERCIAL PROD- available as TORO parts. Some tools may also be avail- UCTS) . able from a local supplier.

  • Page 34: Adjustments

    Adjustments Differential Belt Adjustment 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Check tension by depressing belt at the mid span between pulleys with 5 to 6 lbs (22 to 27 N) of force. The belt should deflect 1/4 inch.

  • Page 35: Drum Drive Belt Adjustment

    Drum Drive Belt Adjustment 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Check tension by depressing belt at mid span be- tween the pulleys with 4 to 5 lbs (18 to 22 N) of force. The belt should deflect 1/4 inch.

  • Page 36: Reel Drive Belt Adjustment

    Reel Drive Belt Adjustment 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Check tension by depressing the belt at mid span between pulleys with 4 to 5 lbs (18 to 22 N) of force. The belt should deflect 1/4 inch.

  • Page 37: Service/Park Brake Adjustment

    Service/Park Brake Adjustment If service/park brake slips when operated, an adjust- ment is required. 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Move service/park brake lever to the OFF position. Note: Figure 10 is shown with the bellcrank cover re- moved for illustrative purposes.

  • Page 38: Service And Repairs

    Service and Repairs Reel Drive Assembly 56 57 RIGHT FRONT Figure 11 1. Clutch housing 21. Lock nut 40. Wave washer 2. Cap screw 22. Lock washer 41. Reel drive belt 3. Lock nut 23. Drive screw 42. Pulley and drive assembly 4.

  • Page 39: Reel Drive Belt Replacement

    Reel Drive Belt Replacement Removal 3. Adjust reel drive belt tension and reinstall reel drive cover (see Reel Drive Belt in the Adjustments section). 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 4.

  • Page 40: Clutch Bearing

    Clutch Bearing Removal Clutch and Pulley Assembly (Fig. 15) 1. Remove reel drive belt from the reel drive assembly 1. Press new ball bearings into driver. Secure bearings (see Reel Drive Belt Replacement Removal). with small retaining ring. 2. Remove clutch lever (24) as follows (Fig. 11): 2.
  • Page 41 Installation C. With the actuator pin engaging in the groove of the clutch jaw driver (slide driver all the way into the 1. Park mower on a level surface. Make sure engine housing), secure cap screw into the clutch housing is OFF.

  • Page 42: Drum Drive Assembly

    Drum Drive Assembly FRAME LEFT FRONT Figure 17 1. Spacer 14. Nut 29. Bearing clamp 2. Backup washer 15. Washer 30. Seal 3. Pulley (LH) 16. V–ring seal 31. Lock nut Pulley (RH) 17. Bearing cover 32. Cap screw 4. Housing (LH) 18.

  • Page 43: Drum Drive Belt Replacement

    Drum Drive Belt Replacement Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Remove wheels if attached (see Wheels in the Ser- vice and Repairs section of Chapter 6 – Wheels and Ac- cessories).

  • Page 44: Differential Axle Pulley And Bearing

    Differential Axle Pulley and Bearing Removal 7. Slide pulley onto the differential axle while aligning pulley keyway with the woodruff key. Secure pulley to 1. Remove drum drive belt from the drum drive assem- the axle with the nut. bly (see Drum Drive Belt Replacement Removal). 8.

  • Page 45: Drum Shaft Bearing

    Drum Shaft Bearing Removal C. Use a suitable wrench on the flats of the drum shaft, between the drum and the frame, to lock the 1. Remove drum drive belt from the drum drive assem- shaft. Screw pulley to the drum shaft. bly (see Drum Drive Belt Replacement Removal).

  • Page 46: Drum Assembly With Bearings

    Drum Assembly with Bearings (Models 04050, 04052–60000 & Up, and 04060) Figure 24 1. Drum 6. Seal spacer 10. Cap screw 2. Drum spindle 7. Lock nut 11. Drum shaft (LH) 3. Spring lip seal 8. Drum hub 12. Drum shaft (RH) 4.
  • Page 47 Note: The lock nut turns hard on the spindle shaft 5. Secure drum spindle to the drum with four cap when tightened. Make sure all rotation has stopped screws and lock washers. Tighten screws using an alter- when tightening. A good solid sound indicates the nut is nating pattern.

  • Page 48: Drum Assembly With Bushings

    Drum Assembly with Bushings (Models 04051 and 04052–50001 to 59999) OIL SEALS NOT SHOWN Figure 26 1. Cap screw 3. Drum 5. Drum shaft 2. Lock washer 4. Drum shaft extensions 6. Bushing Removal BUSHING DRIVER 1. Remove both drum shaft bearings from both drum shafts (see Drum Shaft Bearing Removal).
  • Page 49 5. Install inner bushing into drum (Fig. 30). BUSHING DRIVER Note: The setting of the adapter sleeve is critical so the bushing is inserted deep enough for oil seal installa- ADAPTER SLEEVE tion. BUSHING A. Install adapter sleeve on the bushing driver so the counterbore of the sleeve seats 3/16 inch (0.48 PILOT cm) beyond the step on the driver.

  • Page 50: Counter Shaft Assembly

    Counter Shaft Assembly 39 40 RIGHT FRONT Figure 33 1. Countershaft housing 21. Brake support 40. Lock washer 2. Cap screw 22. Lock washer 41. Hose clamp 3. Lock washer 23. Cotter pin 42. Hose clamp 4. Flat washer 24. Cotter pin 43.

  • Page 51: Brake Band Replacement

    Brake Band Replacement Removal 6. Reinstall interference previously removed (Fig. 34). A. Make sure clutch is disengaged. Install both V– 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. belts.

  • Page 52: Power Shaft Bearing

    Power Shaft Bearing Removal 1. Remove brake band from the counter shaft housing (see Brake Band Removal) 2. Remove cap screw (39) and lock washer (40) from the front box cover (37) and counter shaft housing (1). Remove cover from housing (Fig. 33). 3.

  • Page 53: Differential Axle Bearing (Countershaft Housing)

    Differential Axle Bearing (Countershaft Housing) Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Lower handle to allow a clearance for the removal of the bearing and flangettes from the differential axle (see Handle in the Adjustments section of Chapter 6 –...

  • Page 54: Differential Idler And Bearing

    Differential Idler and Bearing Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Remove capscrews (39) and lock washers (40) se- curing rear and front box covers (38 and 39) to the coun- tershaft housing (1).

  • Page 55: Differential Assembly And Pulley

    Differential Assembly and Pulley Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Lower handle to allow clearances for the removal of the bearing and flangettes from the differential axle and the differential assembly from the countershaft housing (see Handle in the Adjustments section of Chapter 6 –...
  • Page 56 BEARING RECESS (INBOARD) 0.125 TO 0.140 inch (3.18 to 3.56 mm) INSET FOR DRIVE PIN BEARING RECESS (OUTBOARD) 0.150 to 0.170 inch (3.81 to 4.32 mm) SEAL RECESS 0.030 TO 0.045 inch (0.76 to 1.14 mm) Figure 43 1. Flanged hex head screw 6.
  • Page 57 Note: If any of the bevel or pinion gears need to be re- 2. Slide pulley onto differential axle so threads extend placed, it is recommended to replace all four gears as a through pulley. Secure lock nuts and flat washers to the complete set.
  • Page 58 5. Slide locking collar onto the differential axle (Fig. IMPORTANT: Align axles so they turn freely before 38). striking the locking collar. 6. Reinstall rear box cover (38) and differential boot 9. Lock locking collar by striking it with a punch in the (43) to the differential axle and countershaft housing (1) counterclockwise direction.

  • Page 59: Differential Belt Replacement - Models 04051, 04052, And 04060

    Differential Belt Replacement – Models 04051, 04052, and 04060 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Remove capscrews and lock washers securing the drum belt and reel drive covers to the right side plate. Remove belt covers.

  • Page 60: Differential Belt Replacement - Model 04050

    Differential Belt Replacement – Model 04050 Only Removal 1. Place mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. If the wheels are attached, place the mower on its kick- stand and remove them. 2.
  • Page 61 6. Use 9/16–inch open end wrench to hold the power shaft while backing off the lock nut with a 7/8–inch sock- et (Fig. 53). 7. Remove nut from the short axle of the differential as follows (Fig. 54): A. Loosen small hose clamp securing the differen- tial boot to the bearing housing.
  • Page 62 Note: The locking collar securing the long axle to the countershaft housing is a eccentric flange type. 11. Loosen the set screw on the locking collar. Unlock collar by striking it with a punch in the clockwise direction (Fig. 58). 12.
  • Page 63 Installation 9. Reinstall belts to both drum drive assemblies as fol- lows (Fig. 55): 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. A. Reinstall belt onto the drum shaft pulley and pulley on both sides of mower.
  • Page 64 11. Secure engine to the frame as follows: A. Reinstall both V–belts (Fig. 51). A. Position the engine base to obtain from 5.34 to 5.46 inches (13.6 to 13.9 cm) between the engine output shaft and power shaft center lines (Fig. 65). B.

  • Page 65: Lubrication

    Lubrication The mower should be greased at least after every 25 hours of operation. Lubricate grease fittings using No. 2 multipurpose lithium base grease. A hand operated grease gun is recommended for best results. 1. Park mower on a level surface. Make sure engine is OFF.
  • Page 66 Traction and Reel Drive Systems Page 4 – 36 Greensmaster 1000/1600...
  • Page 67 Chapter 5 Electrical System Table of Contents WIRING SCHEMATICS ......COMPONENT TESTING ..... . . Late Model Kawasaki FE120 Engines .

  • Page 68: Wiring Schematics

    Wiring Schematics BLACK HIGH TENSION LEAD CONNECTOR/ INTERLOCK MODULE BLACK IGNITION COIL/ IGNITOR C D E F ENGINE MAGNETO FLYWHEEL Note: There are two types of ignition coils used on the Kawasaki FE120 engine. On older models, a coil is used in conjunction with an igniter. On newer models, a combination igniter/ignition coil is used which has the igniter built into the ignition coil.

  • Page 69: Late Model Kawasaki Fe120 Engines With Operator Presence Control

    BLACK HIGH TENSION LEAD CONNECTOR/ INTERLOCK MODULE BLACK IGNITION COIL/ IGNITOR ENGINE MAGNETO FLYWHEEL Note: There are two types of ignition coils used on the Kawasaki FE120 engine. On older models, a coil is used in conjunction with an igniter. On newer models, a combination igniter/ignition coil is used which has the igniter built into the ignition coil.

  • Page 70: Early Model Kawasaki Fe120 Engines

    IGNITOR IGNITOR BLACK HIGH TENSION LEAD CONNECTOR/ BLACK INTERLOCK MODULE IGNITION COIL C D E F ENGINE MAGNETO FLYWHEEL Note: There are two types of ignition coils used on the Kawasaki FE120 engine. On older models, a coil is used in conjunction with an igniter. On newer models, a combination igniter/ignition coil is used which has the igniter built into the ignition coil.

  • Page 71: Early Model Kawasaki Fe120 Engines With Operator Presence Control

    IGNITOR IGNITOR CONNECTOR/ INTERLOCK MODULE BLACK HIGH TENSION LEAD BLACK IGNITION COIL ENGINE MAGNETO FLYWHEEL Note: There are two types of ignition coils used on the Kawasaki FE120 engine. On older models, a coil is used in conjunction with an igniter. On OPERATOR newer models, a combination igniter/ignition coil is PRESENCE SWITCH...

  • Page 72: Special Tools

    Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: Toro recommends the use of a DIGITAL Volt– Ohm–Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.

  • Page 73: Troubleshooting

    Troubleshooting The interlock switch must not be by–passed, it must be connected for proper troubleshooting and safety. CAUTION NOTE: See the Kawasaki FE161 & FE170 Service Remove all jewelry, especially rings and Manual and Kawasaki FE120 Service Manual Sup- watches, before doing any electrical trou- plement in Chapter 3 –...

  • Page 74: Component Testing

    Component Testing For accurate resistance and/or continuity checks, elec- NOTE: See the Kawasaki FE161 & FE170 Service trically disconnect the component being tested from the Manual and Kawasaki FE120 Service Manual Sup- circuit (e.g. unplug the ON/OFF switch connector before plement for more component testing information.

  • Page 75: With Operator Presence Control

    Interlock Module and Clutch (Interlock) Switch – With Operator Presence Control The interlock module prevents the engine from starting E. Reconnect both brown wires to the black\white unless the clutch switch is closed (clutch DISEN- wires connected to the operator presence control switch.

  • Page 76: Ignition System Operation

    Ignition System Operation Making a System Tester This simple tester can be made if a commercial spark tester is not available. It can determine if the ignition sys- tem is operating properly. SPRING CLIP 1. Use a new NGK BPR5ES or equivalent spark plug. 2.

  • Page 77: Igniter

    Igniter The igniter consists of transistorized circuitry that con- trols the firing sequence of the spark plug in conjunction with the ignition coil. Mounted on the engine block, the igniter casing is grounded directly to the engine. A single black wire makes a circuit from the igniter to the primary of the ignition coil.

  • Page 78: Ignition Coil

    Ignition Coil A commercial coil tester can be used to test the ignition coil. If a tester is available, test the ignition coil as sug- gested in the Kawasaki FE161 & FE170 Service Manual and Kawasaki FE120 Service Manual Sup- plement The coil can be tested for a badly shorted or broken winding with a digital ohmmeter.

  • Page 79: Service And Repairs

    Service and Repairs NOTE: See the Kawasaki FE161 & FE170 Service Manual and Kawasaki FE120 Service Manual Sup- plement for more component repair information. Interlock Switch Adjustment 1. Make sure the engine is OFF and traction lever is DISENGAGED. 2. Loosen both switch mounting nuts and move switch until the switch plunger is depressed 0.18 to 0.24 inch (4.6 to 6.1 mm) (switch closed).

  • Page 80: Operator Presence Control Switch

    Operator Presence Control Switch Adjustment 1. Make sure the engine is OFF. 2. Loosen both switch adjusting nuts. While holding the bail against the handle, move switch until the switch plunger is depressed 0.16 inch (4.1 mm) (switch closed). 3. Tighten switch mounting nuts. 4.

  • Page 81: Spark Plug

    Spark Plug Use a NGK BPR 5ES spark plug or equivalent. Remove plug after every 100 operating hours and check its condition. 0.028 to 0.31 inch (0.7 to 0.8 mm) 1. Make sure engine is OFF. Pull high tension lead off the spark plug.
  • Page 82 NORMAL OVER HEATING FUSED SPOT DEPOSIT Has gray or light tan deposits on the firing Light gray or white insulator with small gray Has spotty or melted deposits resembling tip. brown or black spots. Electrodes have a blisters or bubbles. bluish burnt appearance.
  • Page 83 Chapter 6 Controls, Wheels and Accessories Table of Contents SPECIFICATIONS ......Brake Cable Replacement .

  • Page 84: Specifications

    Specifications Item Description Tire pressure 12 to 15 PSI, (0.83 to 1.04 bar) Wheel Shaft torque 65 to 75 ft–lb, (8.99 to 10.37 kg–m) Wheels and Accessories Greensmaster 1000/1600 Page 6 – 2...

  • Page 85: Adjustments

    Adjustments Handle Height Adjustment 1. Make sure mower is parked on a level surface with the engine OFF. 2. Remove cotter pins from the ring pins on each side of the mower. 3. Support handle, and remove ring pins from each side of the mower.

  • Page 86: Service And Repairs

    Service and Repairs Handle Assembly RIGHT FRONT Figure 2 1. Throttle cable 16. Brake skid bracket 30. Cap screw 2. Spring 17. Brake bracket 31. Spring lock washer 3. Lock nut 18. Brake lever 32. Flat washer 4. Retaining washer 19.
  • Page 87 Removal 1. Park mower on a level surface. Make sure engine is OFF. 2. Cut cable ties from the handle. 3. Remove cap screw (30), spring lock washer (31), and flat washer (32) from each handle pivot pin (33) on each of the handle (35) ends (Fig.

  • Page 88: Brake Cable Replacement

    Brake Cable Replacement Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Disengage brake to release tension on the brake cable. Remove cable ties from the left side of the handle. 3.
  • Page 89 B. If the operator presence kit is not installed, se- A. Attach brake cable to the counter shaft housing cure console bracket to the brake skid bracket with and tighten the rear nut. three screws. B. Secure cable eyelet to the brake lever with 3.

  • Page 90: Clutch Cable Replacement

    Clutch Cable Replacement Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Disengage clutch to release tension on the clutch cable. Remove cable ties from the right side of the han- dle.
  • Page 91 3. If the operator presence kit is not installed, secure A. Attach clutch cable to the clutch bracket. Tighten console bracket to the clutch skid bracket with three nut to secure cable to the bracket. screws (Fig. 8). B. Secure clutch cable eyelet to the clutch lever 4.

  • Page 92: Throttle Cable Replacement

    Throttle Cable Replacement Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Remove cable ties from the right side of the handle. Remove nut and cable clip from the flangette on the countershaft housing.

  • Page 93: Wheels

    Wheels Removal 1. Park mower on a level surface. Make sure the en- gine is OFF. 2. Push kickstand down with one foot while pulling up on the handle. This will support the mower on the kick stand. 3. Pivot wheel locking clip away from the center of the wheel.
  • Page 94 Figure 13 1. Cap screw 6. Retaining lever 11. Inner tube 2. Lock washer 7. Spring 12. Cap screw 3. Shallow rim 8. Bolt 13. Flange nut 4. Tire 9. Bolt 14. Wheel shaft 5. Hub 10. Deep rim Disassembly Reassembly 1.

  • Page 95: Kickstand

    Kickstand 1 2 3 4 NOTE THE POSITION OF THE STOP FRAME Figure 14 1. Cap screw 5. Extension spring 9. Flat washer 2. Cap screw 6. Cap screw 10. Lock nut 3. Lock washer 7. Spring retainer 11. Spacer 4.
  • Page 96 Wheels and Accessories Greensmaster 1000/1600 Page 6 – 14...
  • Page 97 Chapter 7 Cutting Unit Table of Contents INTRODUCTION ......SERVICE AND REPAIRS .

  • Page 98: Introduction

    Introduction This Chapter covers the cutting unit section of the of the cutting unit, and their component parts that are GR1000. The cutting unit consists of the frame assem- necessary for the service of the cutting unit are covered bly, reel assembly, drum assembly, and detachable bas- in this chapter.

  • Page 99: Specifications

    Specifications Figure 1 REEL CONSTRUCTION (GR1000): 5–inch (12.7 cm) REEL CONSTRUCTION (GR1600): 5–inch (12.7 cm) diameter, 11 carbon steel blades (optional 8 blades) diameter, 8 carbon steel blades welded to 6 stamped welded to 5 stamped steel spiders. steel spiders. HEIGHT–OF–CUT RANGE (GR1000): 5/64 to 1 inch HEIGHT–OF–CUT RANGE (GR100): 1/8 to 1–1/4 inch (2 to 25 mm)

  • Page 100: General Information

    General Information Grass Basket Installation 1. Grasp basket by top rear lip and slide on or off the basket mounting rods. Figure 2 1. Grass basket 2. Mounting rod Cutting Unit Page 7 – 4 Greensmaster 1000/1600...

  • Page 101: Special Tools

    Order special tools from the TORO SPECIAL TOOLS Some tools may have been supplied with your mower or AND APPLICATIONS GUIDE (COMMERCIAL PROD- available as TORO parts. Some tools may also be avail- UCTS) . able from a local supplier.
  • Page 102 Bearing Replacement Tool Kit – TOR238900A The puller is used to remove the bearings from the roll- ers. A driving tube is used to install bearings into the roll- er. A drill bushing is used to drill into bearing shafts without a removal hole.

  • Page 103: Troubleshooting

    Troubleshooting There are a number of factors that can contribute to un- mower. It is important to remember that the lower the satisfactory quality of cut, some of which may be turf height–of–cut, the more critical these factors are. See conditions.
  • Page 104 Factor Possible Problem/Correction Height–of–cut “Effective” or actual height–of–cut depends on the mower weight and turf conditions. Effective height–of–cut will be different than the bench set height–of–cut. Proper bedknife for height–of–cut If the bedknife is too thick for effective height–of–cut, poor quality of cut will result. Front roller scraper and comb adjustment Install and/or adjust roller scrapers if grass clippings build up on the rollers.

  • Page 105: Adjustments

    Adjustments CAUTION Never work on the mower with the engine running. Always stop the engine and re- move the high tension lead from the spark plug first. Leveling Drum to Reel 1. Make sure engine is OFF. Remove high tension lead from the spark plug.

  • Page 106: Bedknife To Reel Adjustment

    (8 kg–cm) be evident, it will be either necessary to backlap or regrind the reel and bedknife to achieve the sharp edges needed for precision cutting (see TORO Sharpening Reel and Rotary Mowers Manu- Figure 11 al, Form No. 80-300 PT).

  • Page 107: Height-Of-Cut Adjustment

    Height–of–Cut Adjustment 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Verify that the drum is level to the reel and that the bedknife to reel contact is correct. Tip mower back on its handle to expose roller, drum, and bedknife.

  • Page 108: Grass Shield Height Adjustment

    Grass Shield Height Adjustment 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. Figure 16 1. Support rod 2. Shield Note: Figure 17 1. Grass shield 3. Lock nut 2.

  • Page 109: Service And Repairs

    4. Insert a 1/2–inch socket extension, which is con- nected to a backlapping machine, into the square hole in the center of the reel pulley. 5. Backlap according to procedure in TORO Sharpen- ing Reel and Rotary Mowers Manual, Form No. 80-300 Figure 19 1.

  • Page 110: Bedbar

    Bedbar Removal 1. Position mower on a flat level work surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Loosen jam nut on the adjusting screw. Loosen ad- justing screw until the thrust washer contacts the inside of the frame adjuster.
  • Page 111 Installation Note: Use new nylon washers and bushings for instal- lation. 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Use grease to hold thrust washers against the in- side of both frame adjusters (Fig.

  • Page 112: Bedknife Replacement And Grinding

    10 12 bedknife. Remove small amounts of material with each pass of the grinder. Figure 32 2. Use TORO Sharpening Reel and Rotary Mowers Manual, Form No. 80-300 PT, for grinding the bedknife. Top Face Relief Angle Bedknife Grinding Specifications...

  • Page 113: Roller

    Roller Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Loosen jam nut and set screw on both ends of the mower. 3. On one end of the mower, remove lock nut and flat washer from the carriage screw.

  • Page 114: Reel

    Reel Removal 1. Make sure engine is OFF. Remove high tension lead from the spark plug. Place mower on a flat level sur- face or on a stable work bench. 2. Remove bedbar from the mower (see Bedbar Re- moval). 3.
  • Page 115 Installation B. Make sure grease fitting hole is position to the front of the mower. 1. Make sure engine is OFF. Remove high tension lead from the spark plug. Place mower on a flat level sur- C. Attach the groomer arm cover to the bearing housing and frame with the two flat head screws, face or on a stable work bench.
  • Page 116 Preparing a Reel for Grinding Note: Check to make sure the reel bearings are in 4. After completing grinding process: good condition and properly adjusted before grinding a A. Install height–of–cut arms and roller (see Roller reel. Installation). 1. Remove bedbar assembly (see Bedbar Removal). B.
  • Page 117 Chapter 8 Grooming Reel Kit Table of Contents SPECIFICATIONS ......SERVICE AND REPAIRS .

  • Page 118: Specifications

    Specifications MOUNTING: The grooming kit is rigidity mounted to the MICRO ADJUSTMENT KNOB: Allows a 0.007 inch mower reel bearing housings and frame. (0.18 mm) increment of height adjustment REEL CONSTRUCTION: 2–1/4 inch (5.4 cm) diameter, QUICK UP–DOWN FEATURE: Allows grooming reel to be raised 5/16 inch (7.9 mm) above the height/depth ad- 41 steel blades with 1/2–inch blade spacing.

  • Page 119: General Information

    General Information Clutch Engagement/Disengagement The grooming reel should be disengaged at all times ex- cept during grooming. IMPORTANT: When engaging or disengaging the clutch, be sure to turn the clutch knob all the way until it comes to a firm stop. Failure to do so could cause damage to the clutch.

  • Page 120: Troubleshooting

    Troubleshooting Factors Affecting Grooming There are a number of factors that can affect the perfor- IMPORTANT: Improper or overaggressive use of mance of grooming. These factors vary for different golf the grooming reel, such as too deep or frequent courses and from green to green. It is important to in- grooming, may cause unnecessary stress on the spect the turf frequently and vary the grooming practice turf leading to severe turf damage.

  • Page 121: Grooming Reel Mechanical Problems

    Grooming Reel Mechanical Problems Problem Possible Causes Correction The grooming reel rotates when it is Due to friction in the clutch assem- This condition may change over a in the raised position with the clutch bly, the grooming reel may still ro- period of time.

  • Page 122: Adjustments

    Adjustments CAUTION Never work on the mower with the engine running. Always stop the engine and re- move the high tension lead from the spark plug first. Height/Depth of Grooming Adjustment 1. Park mower on a level surface. Make sure engine is OFF.

  • Page 123: Drive Belt Tension Adjustment

    Drive Belt Tension Adjustment 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Loosen both set screws in the clutch knob. Remove clutch knob and poly washer from the clutch assembly. 3.

  • Page 124: Service And Repairs

    Service and Repairs Reel 2 3 4 5 6 GROOMING REEL RIGHT ASSEMBLY FRONT Figure 5 1. Lock nut 19. Roll pin 37. Socket head cap screw 2. Ball bearing 20. Cap 38. Idler pulley spacer 3. Lock nut 21. Ramp 39.
  • Page 125 CLUTCH ASSEMBLY RIGHT FRONT Figure 6 1. Belt cover 7. Roller bearing 12. Set screw 2. Clutch drive adapter 8. Belleville washer 13. Clutch knob 3. Needle bearing 9. Clutch release disc 14. Flat washer 4. Clutch pin 10. Special screw 15.
  • Page 126 Disassembly 6. Secure belt cover to housing with three socket head cap screws and washers (Fig. 7). Reinstall poly washer Inspect grooming reel blades frequently for damage and and clutch knob to clutch assembly. Tighten both set wear. Straighten bent blades with a pliers. Either replace screws into the clutch knob (Fig.

  • Page 127: Reel Bearing Replacement

    Reel Bearing Replacement 1. Remove grooming reel (see Reel Removal). Note: Replace all four ball bearings as a complete set. 2. Check condition of groomer ball bearings and re- place as necessary. A. In the bearing housing and belt drive housing, install outer ball bearing first with the seal facing out.

  • Page 128: Clutch Assembly

    Clutch Assembly CAUTION Do not use your hand to prevent the cutting reel from turning while servicing; this can result in personal injury. Insert a block of hard wood into the front of the cutting unit between the reel blades to prevent the reel from turning.
  • Page 129 Installation 5. Secure flat washer to the clutch adapter shaft with the lock nut. Torque lock nut from 120 to 150 in–lb (138 1. Park mower on a level surface. Make sure engine to 173 kg–cm) removing all clutch assembly end play is OFF.

  • Page 130: Frame Assemblies (Rh And Lh)

    Frame Assemblies (RH and LH) 2 3 4 5 6 GROOMING REEL RIGHT ASSEMBLY FRONT Figure 17 1. Lock nut 19. Roll pin 37. Socket head cap screw 2. Ball bearing 20. Cap 38. Idler pulley spacer 3. Lock nut 21.
  • Page 131 CLUTCH ASSEMBLY RIGHT FRONT Figure 18 1. Belt cover 7. Roller bearing 12. Set screw 2. Clutch drive adapter 8. Belleville washer 13. Clutch knob 3. Needle bearing 9. Clutch release disc 14. Flat washer 4. Clutch pin 10. Special screw 15.
  • Page 132 4. On older models, loosen both carriage bolts secur- ing the reel idler bracket to the frame. Pivot idler pulley assembly away from the reel drive belt. (Fig. 22). 5. Secure cutting reel from turning with a block of hard wood.
  • Page 133 15. Use allen wrench to remove flat head socket screws from the adapter (Fig. 25). 16. Remove adapter (6), bearing (7), both spacers (5) from the belt drive housing (46) (Fig. 17). 17. Pull belt drive housing with the groomer adjuster from the reel bearing housing (Fig.
  • Page 134 7. Install frame assembly (RH) onto the right reel bear- ing housing using the following procedure (Fig. 27): FRAME ASSEMBLY (RH) A. Slide bearing housing of frame assembly (RH) over the end of the grooming reel shaft (Fig. 28) B. Insert adapter ring (9) into the reel bearing hous- ing (Fig 17).
  • Page 135 14. Check groomer assembly (Fig. 31). A. Rotate both quick–up levers to raise the groom- ing reel into the transport position. B. Hold the clutch snubber down and rotate the clutch knob clockwise to disengage the clutch. C. Correct any problems and recheck assembly. Figure 31 1.

  • Page 136: Cutting Reel

    Cutting Reel Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Make sure mower is on a flat level surface or on a stable work bench. 3. Remove grooming reel kit following the Removal instructions in Frame Assemblies (RH and LH).

  • Page 137: Lubrication

    3. Reassemble bearing housing (LH) components 6. Attach bearing housing (LH) through the frame onto (Fig. 33). the reel shaft (Fig. 33). A. Place small seal into the bearing housing with A. Push housing onto reel shaft. If necessary, tap the flat side out.
  • Page 138 Grooming Reel Kit Page 8 – 22 Greensmaster 1000...
  • Page 140 Commercial Products PART NO. 96889SL, Rev. A The Toro Company – 1996, 1997 Printed in U.S.A.

This manual is also suitable for:

Greenmaster 1600

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