Toro 04052, 04060, greensmaster 1000, greensmaster 1600, 04048 Operator's Manual

Form No. 3357–349 Rev. A

Greensmaster) 1000 and 1600

Greensmaster Mower

Model No. 04052—Serial No. 260003001 and Up
Model No. 04060—Serial No. 260003001 and Up

Operator’s Manual

English (EN, GB)

Contents

Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .

Toro Mower Safety 4. . . . . . . . . . . . . . . . . . . . . . . .

Sound Pressure Level 5. . . . . . . . . . . . . . . . . . . . . . .

Sound Power Level 5. . . . . . . . . . . . . . . . . . . . . . . .

Vibration Level

Model 04052 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vibration Level

Model 04060 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety and Instruction Decals 6. . . . . . . . . . . . . . . . .

Specifications 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Specifications 8. . . . . . . . . . . . . . . . . . . . .

Setup 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing and Adjusting the Handle 10. . . . . . . . . . . .

Installing the Kick Stand

Model 04060 only 10. . . . . . . . . . . . . . . . . . . . . . . .

Installing the Transport Wheels 11. . . . . . . . . . . . . . .

Before Operating 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adding Engine Oil 11. . . . . . . . . . . . . . . . . . . . . . . . .

Filling the Fuel Tank 12. . . . . . . . . . . . . . . . . . . . . . .

Leveling the Rear Drum to the Reel 13. . . . . . . . . . .

Adjusting the Bedknife to the Reel 14. . . . . . . . . . . .

Adjusting the Height-of-Cut 15. . . . . . . . . . . . . . . . .

Adjusting the Grass Shield Height 16. . . . . . . . . . . . .

Adjusting the Cut-off Bar 16. . . . . . . . . . . . . . . . . . . .

Installing the Grass Basket 16. . . . . . . . . . . . . . . . . . .

Checking the Operation of the Interlock Switch 16. .

Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controls 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Engine 18. . . . . . . . . . . . . . . . . . . . . . . . .

Stopping the Engine 18. . . . . . . . . . . . . . . . . . . . . . . .

Driving the Machine in Transport 18. . . . . . . . . . . . .

Preparing to Mow 19. . . . . . . . . . . . . . . . . . . . . . . . . .

Mowing Tips 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mowing 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 20. . . . . . . . .

Daily Maintenance Checklist 21. . . . . . . . . . . . . . . . .

Greasing the Machine 22. . . . . . . . . . . . . . . . . . . . . .

Checking and Changing Engine Oil 23. . . . . . . . . . . .

Servicing the Air Cleaner 23. . . . . . . . . . . . . . . . . . . .

Replacing the Spark Plug 24. . . . . . . . . . . . . . . . . . . .

Cleaning the Fuel Filter 24. . . . . . . . . . . . . . . . . . . . .

Adjusting Belts 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Differential Belt 27. . . . . . . . . . . . . . .

Page

Adjusting the Traction Control 28. . . . . . . . . . . . . . .

Adjusting the Service/Park Brake 28. . . . . . . . . . . . .

Adjusting the Interlock Switch 29. . . . . . . . . . . . . . .

Servicing the Bedbar

Greensmaster 1600 only 29. . . . . . . . . . . . . . . . . . .

Servicing the Bedbar

Greensmaster 1000 only 29. . . . . . . . . . . . . . . . . . .

Backlapping the Reel 30. . . . . . . . . . . . . . . . . . . . . . .

Evaporative Emission Control Warranty Statement 31. .
The Toro General Commercial Products Warranty 32. . .

Introduction

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.

Whenever you need service, genuine Toro parts, or
additional 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 product model and serial numbers in the space
below:

Model No.

Serial No.

This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.

Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.

Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.

Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.

This manual uses two other words to highlight information.

Important calls attention to special mechanical

information and Note: emphasizes general information
worthy of special attention.

W 2006 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196

All Rights Reserved

Printed in the USA

2

Safety

• Warning—Fuel is highly flammable. Take the
following precautions:

This machine meets or exceeds CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI
B71.4-2004 specifications in effect at the time of
production when the Operator Presence Kit, Part No.
105–5363 is installed.

Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.

symbol, which means

Safe Operating Practices

The following instructions are from the CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI B71.4-2004.

Training

• Read the Operator’s Manual and other training material
carefully. Be familiar with the controls, safety signs,
and the proper use of the equipment.

• If the operator or mechanic can not read the language of
is the owner’s responsibility to explain this material to
them.

• Never allow children, untrained people or people
unfamiliar with these instructions to use or service the
mower. Local regulations may restrict the age of the
operator.

• Never mow while people, especially children, or pets
are nearby.

• Keep in mind that the operator or user is responsible for
accidents or hazards occurring to other people or their
property.

• The owner/user can prevent and is responsible for
accidents or injuries occurring to himself or herself,
other people, or property.

• All operators or mechanics musted be trained. It is the
owner’s responsibility for training users.

• o explain this material to them.

– 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 add fuel while the engine
is running or when the engine is hot.

– If fuel is spilled, do not attempt to start the engine

but move the machine away from the area of
spillage and avoid creating any source of ignition
until fuel vapors have dissipated.

– Replace all fuel tanks and container caps securely.

• Replace faulty silencers.

• Evaluate the terrain to determine what accessories and

attachments are needed to properly and safely perform
the job. Only use accessories and attachments approved
by the manufacturer.

• Check that operator’s presence controls, safety switches
and shields are attached and functioning properly. Do
not operate unless they are functioning properly.

Operation

• Do not operate the engine in a confined space where
dangerous carbon monoxide fumes can collect.

• Mow only in daylight or in good artificial light.

• Before attempting to start the engine, disengage all

blade attachment clutches, shift into neutral, and engage
the parking brake.

• Do not use on slopes of more than 15°.

• Remember there is no such thing as a safe slope. Travel

on grass slopes requires particular care. To guard
against overturning:

– do not stop or start suddenly when going up or

downhill;

– engage clutch slowly, always keep machine in gear,

especially when travelling downhill;

Preparation

• While mowing, always wear substantial footwear, long
trousers, hard hat, safety glasses, and hearing
protection. Long hair, loose clothing, or jewelry may
get tangled in moving parts. Do not operate the
equipment when barefoot or wearing open sandals.

• Thoroughly inspect the area where the equipment is to
be used and remove all objects which may be thrown by
the machine.

– machine speeds should be kept low on slopes and

during tight turns;

– stay alert for humps and hollows and other hidden

hazards;

– never mow across the face of the slope, unless the

mower is designed for this purpose.

• Stay alert for holes in the terrain and other hidden
hazards.

• Watch out for traffic when crossing or near roadways.

3

• Stop the blades rotating before crossing surfaces other
than grass.

• When using any attachments, never direct discharge of
material toward bystanders nor allow anyone near the
machine while in operation.

• Never operate the machine with damaged guards,
shields, or without safety protective devices in place. Be
sure all interlocks are attached, adjusted properly, and
functioning properly.

• Do not change the engine governor settings or
overspeed the engine. Operating the engine at excessive
speed may increase the hazard of personal injury.

• Before leaving the operator’s position:

– stop on level ground;

– disengage the cutting unit and traction drive;

– set the parking brake;

– stop the engine.

• Disengage drive to attachments when transporting or
not in use.

• Stop the engine and disengage drive to attachment

– before refuelling;

– before removing the grass catcher;

– before making height adjustment unless adjustment

can be made from the operator’s position.

– before clearing blockages;

– before checking, cleaning or working on the mower;

– after striking a foreign object or if an abnormal

vibration occurs. Inspect the mower for damage and
make repairs before restarting and operating the
equipment.

• Reduce the throttle setting during engine run-out and, if
the engine is provided with a shut-off valve, turn the
fuel off at the conclusion of mowing.

• Keep hands and feet away from the cutting unit.

• Slow down and use caution when making turns and

crossing roads and sidewalks. Stop reel if not mowing.

• Do not operate the mower under the influence of
alcohol or drugs

• Use care when loading or unloading the machine into a
trailer or truck

• Use care when approaching blind corners, shrubs, trees,
or other objects that may obscure vision.

Maintenance and Storage

• Keep all nuts, bolts and screws tight to be sure the
equipment is in safe working condition.

• Never store the equipment with fuel in the tank inside a
building where fumes may reach an open flame or
spark.

• Allow the engine to cool before storing in any
enclosure.

• To reduce the fire hazard, keep the engine, silencer,
battery compartment and fuel storage area free of grass,
leaves, or excessive grease.

• Check the grass catcher frequently for wear or
deterioration.

• Keep all parts in good working condition and all
hardware 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 plug
wire. Wait for all movement to stop before adjusting,
cleaning or repairing.

• Clean grass and debris from cutting unit, drives,
mufflers, and engine to help prevent fires. Clean up oil
or fuel spillage.

• Carefully release pressure from components with stored
energy.

• Remove spark plug wire before making any repairs.
Disconnect the negative terminal first and the positive
last. Reconnect positive first and negative last.

• Use care when checking the reel. Wear gloves and use
caution when servicing them.

• Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.

Toro Mower Safety

The following list contains safety information specific to
Toro products or other safety information that you must
know that is not included in the CEN, ISO, or ANSI
standard.

This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.

4

Use of this product for purposes other than its intended use
could prove dangerous to user and bystanders.

• Know how to stop the engine quickly.

• Do not operate the machine while wearing tennis shoes

or sneakers.

• Wearing safety shoes and long pants is advisable and
required by some local ordinances and insurance
regulations.

• Handle gasoline carefully. Wipe up any spills.

• 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.

• If major repairs are ever needed or if assistance is
desired, contact an Authorized Toro Distributor.

• Use only Toro-approved attachments and replacement
parts. The warranty may be voided if used with
unapproved attachments.

• Check the safety interlock switches daily for proper
operation. If a switch should fail, replace the switch
before operating the machine. After every two years,
replace all four interlock switches in the safety system,
regardless if they are working properly or not.

• Using the machine demands attention. To prevent loss
of control:

– Do not operate close to sand traps, ditches, creeks,

or other hazards.

– Reduce speed when making sharp turns. Avoid

sudden stops and starts.

– When near or crossing roads, always yield the

right-of-way.

– Apply the service brakes when going downhill to

keep forward speed slow and to maintain control of
the machine.

• The grass basket must be in place during operation of
the reels for maximum safety. Shut the engine off
before emptying the basket.

• Do not touch the engine, muffler, or exhaust pipe while
the engine is running or soon after it has stopped
because these areas could be hot enough to cause burns.

• Stay clear of the rotating screen at the side of the engine
to prevent direct contact with your body or clothing.

Sound Pressure Level

This unit has an equivalent continuous A-weighted sound
pressure at the operator ear of: 84 dB(A), based on
measurements of identical machines per procedures
outlined in Directive 98/37/EC and amendments.

Sound Power Level

This unit has a guaranteed sound power level of: 95 dBA/1
pW, based on measurements of identical machines per
Directive 2000/14/EC and amendments.

Vibration Level

Model 04052

2,

This unit has a hand–arm vibration level of 7.00 m/s
on measurements of identical machines per ISO 5349
procedures.

based

Vibration Level

Model 04060

This unit has a hand–arm vibration level of 4.50 m/s
on measurements of identical machines per ISO 5349
procedures.

2,

based

• When a person or pet appears unexpectedly in or near
the mowing area, stop mowing. Careless operation,
combined with terrain angles, ricochets, or improperly
positioned guards can lead to thrown object injuries. Do
not resume mowing until the area is cleared.

Maintenance and Storage

• Check all fuel lines for tightness and wear on a regular
basis. Tighten or repair them as needed.

• If the engine must be running to perform a maintenance
adjustment, keep hands, feet, clothing, and any parts of
the body away from the cutting unit, attachments, and
any moving parts, especially the screen at the side of the
engine. Keep everyone away.

5

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.

1. Parking brake

2. Disengage

1. Thrown object
hazard—Keep bystanders
away

3. Engage

4. Clutch

93-7273

2. Cutting hazard, hand and
foot—Stay away from
moving parts

105-5360

5. Engage—forward 6. Disengage—neutral

93-9356

1. Entanglement hazard—Stay away from moving parts.

6

105-5309

1. Hot surface/burn hazard—stay a safe distance from the hot
surface.

1. Fast

2. Increasing/decreasing
scale.

1. Warning—Read the
Operator’s Manual before
servicing

93-6085

3. Slow

93-8064

2. Cutting Hazard, hand and
foot—Stop the engine and
wait for moving parts to
stop

1. Warning—Read the

Operator’s Manual

2. Fire hazard—No open
flames or sparks and fill
the tank only to the level
shown

1. Reel drive

2. Engage

93-7348

93-7346

3. Thrown object
hazard—Keep bystanders
away

4. Cutting hazard, hand and
foot—Stay away from
moving parts

3. Disengage

93-9886

1. Use only unleaded gasoline

7

Specifications

General Specifications

Kawasaki, air cooled, overhead valve, 4 cycle, 3.7 horsepower, 2.36 x 1.73 bore

Engine

Traction Drive

Differential Peerless Series 100

Transport Clutch Belt idler

Brake Band drum

Transport Tires Quick detachable, 3.00/3.25 x 6, 32.5 tread width

Traction Drum Dual cast aluminum, 7.5 in. (19 cm) dia.

Controls

Handle Loop style, 1 in. (2.5 cm) dia.

Reel Construction 5 in. (12.7 cm) dia., 8 carbon steel blades welded to 6 stamped steel spiders

and stroke, 7.57 cu. in. (124 cc) displacement, 8.4:1 compression ratio, 11 ft.-lb.
(15 N⋅m) @ 1400 rpm. Electronic ignition, maximum noise suppression muffler.

2.64 quart (2.5 l) fuel tank capacity.

Engine to countershaft drive: two “A” section V-belts. Countershaft to differential
drive: 5 mm pitch timing belt. Differential to drum drive: 8 mm pitch timing belt.

Engine has recoil starter, On/Off switch and choke. Handle has throttle lever,
traction engage lever and service/ park brake lever. Mower has reel drive engage
lever. Safety devices: neutral interlock system.

Bedknife and Bedbar

Height-of-Cut Range 1/8 to 1-1/4 in. (0.3 to 3.2 cm)

Reel Clutch Jaw type

Grass Basket Molded polyethylene

Clip .16 in. (.4 cm) .23 in. (58.4 cm)

Width of Cut 21 in. (53 cm) 26 in. (66 cm)

Total Width 36 in. (91 cm) 41 in. (104 cm)

Total Height 47 in. (119 cm) 41-1/2 in. (105.4 cm)

Total Length 59 in. (150 cm) 54-1/4 in. (137.8 cm)

Dry Weight 208 lb. (94 kg.)

1

With basket and Wiehle roller, without wheels or grooming reel

Single edged high carbon steel bedknife, hardened to Rc 48-54. Fastened to
machined, cast iron bedbar. 1/8 in. (0.3 cm) bedknife, standard

Model 04052 Model 04060

1

229 lb. (104 kg)

1

8

Setup

Note: Determine the left and right sides of the machine from the normal operating position.

Loose Parts

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 set–up cannot be completed.

Description

Handle assembly

Cable tie

Wheel Shaft, right hand

Wheel Shaft, left hand

Spring 1 Mount kickstand, Model 04060 only

Grass basket 1 Install on the machine

Certificate of Compliance 1

Operator’s Manual 1 Read before operating

Engine Owner’s Manual 1 Read before operating

Part’s Catalog 1 Use for ordering parts

Operator video 1 View before operating

Qty. Use

1

2

1

1

Install the handle on the machine

Secure the control cables to the handle

Use when installing optional transport wheels

9

Installing and Adjusting the
Handle

6. Secure the handle ends to the mounting pins with the
capscrews, washers, and lockwashers previously
removed (Fig. 2).

Installing the Handle

1. Remove the capscrew, washer, and lockwasher from the
mounting pin on each side of the mower, as shown in
Fig. 1.

2

1

4

3

Figure 1

1. Mounting pins

2. Handle arms

2. Remove the capscrews and locknuts securing the
bottom of the handle arms to each side of the mower, as
shown in Figure 1.

3. Remove the hairpin cotters and ring pins securing the
handle arms to the rear of the frame (Fig. 1).

4. Insert the handle ends thru the holes in the handle arms
and align the holes with the mounting pins (Fig. 1).

5. Squeeze the handle ends inward and install them on the
mounting pins (Fig. 2).

3. Capscrew and locknut

4. Hairpin cotter and ring pin

7. Secure the bottom of handle arms to each side of the
mower with the capscrews and locknuts previously
removed (Fig. 2). Ensure that you install the bushings in
the handle arm mounting holes.

Important Do not overtighten the capscrews. The

handle arms must pivot freely.

8. Secure the handle arms to the rear of the frame with the
hairpin cotters and ring pins previously removed
(Fig. 2).

9. Secure the cables to the handle with cable ties.

Adjusting the Handle

1. Remove the hairpin cotters from the ring pins on each
side of the mower (FIg. 1).

2. While supporting the handle, remove the ring pins from
each side and raise or lower the handle to the desired
operating position. (Fig. 1).

3. Install the ring pins and hairpin cotters.

Installing the Kick Stand

Model 04060 only

Note: Fasteners shipped loosely on kick stand.

1. Hook spring into hole in spring bracket and onto spring

retainer while aligning kick stand with mounting holes
in rear frame (Fig. 3).

1. Handle end

Figure 2

2

1

4

3

1

Figure 3

1. Kick stand

2. Spring bracket

2. Mount kick stand to each side of frame with a capscrew,
lockwasher, spacer flat washer and lock nut (Fig. 3).
Spacer to be positioned in kick stand mounting hole.

10

3. Spring retainer

4. Spring