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

Installing the Transport Wheels

1. Push the kick stand down with your foot and pull up on
the handle to support the mower on the kick stand.

2. Apply #242 Loctite to the threads of the wheel shafts.

3. Thread the right hand wheel shaft into the drive pulley

on the right side of the machine (Fig. 4).

1

Figure 4

1. Right hand wheel shaft

4. Torque the shaft to 65 to 75 ft-lb. (88 to 101 N⋅m)

Note: The right hand wheel shaft has left hand threads.

5. Apply Never–Seez to the exposed ends of the axles and

slide the wheel onto the axle (Fig. 5).

6. Pivot the wheel locking clip away from center of the
wheel allowing it to slide farther onto the axle (Fig. 5).

7. Rotate the wheel back and forth until it slides
completely onto the axle and the locking clip is secured
in the groove on the axle shaft.

9. Inflate the tires to 12 to 15 psi. (574 to 718 Pa).

Before Operating

Adding Engine Oil

Fill the crankcase with the proper viscosity oil before
starting the engine.

Crankcase capacity is approximately 20 oz. (0.6 l) .

Use high-quality engine oil that meets the following
specifications:

API Classification Level Required: SJ, SK, SL or
higher.

Preferred oil: SAE 30 (above 32_F)

Alternate oil: SAE 40 (above 50_F)

SAE 10W30 (up to 95_F)
SAE 5W30 (up to 50_F)

Toro Premium Engine oil is available from your distributor
in either 15W–40 or 10W–30 viscosity. See the parts
catalog for part numbers.

1. Position the machine on a level surface.

Important Be sure to keep the engine oil level between

the upper and lower limits on the oil gauge. Engine failure
may occur as a result of over filling or under filling the
engine oil.

1. Position the mower so the engine is level (Fig. 6).

1

Figure 5

1. Locking clip

8. Repeat the procedure on the opposite side of the
machine.

1

Figure 6

1. Oil level gauge

2. Clean around the oil level gauge.

3. Remove the gauge by rotating it counterclockwise.

4. Wipe the gauge clean and insert it into the filler port,

without threading it into the port.

5. Remove the gauge and check the oil level.

11

6. If level is low, add only enough oil to raise level to filler
opening.

Danger

Note: Check the oil each time the mower is used or after
every 5 operating hours. Initially, change oil after the first 8
hours of operation; thereafter, change oil after every 50
hours of operation. More frequent oil changes are

required in dusty or dirty conditions.

Filling the Fuel Tank

Important Never use methanol, gasoline containing

methanol, gasoline containing more than 10% ethanol,
gasoline additives, premium gasoline, or white gas because

engine fuel system damage could result.

1. Clean around the fuel tank cap and remove the cap from

the tank (Fig. 7).

1

Figure 7

1. Fuel tank cap

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.

• Do not fill the fuel tank completely full. Add
gasoline to the fuel tank until the level is 1 in.
(25 mm) below the bottom of the filler neck.
This empty space in the tank allows gasoline to
expand.

• Never smoke when handling gasoline, and stay
away from an open flame or where gasoline
fumes may be ignited by a spark.

• Store gasoline in an approved container and
keep it out of the reach of children. Never buy
more than a 30-day supply of gasoline.

• Always place gasoline containers on the ground
away from your vehicle before filling.

• Do not fill gasoline 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 gas-powered equipment
from the truck or trailer and refuel the
equipment with its 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.

2. Using unleaded gasoline, fill the fuel tank no higher
than to bottom of the filter screen. Do not over fill the
tank.

3. Install the fuel tank cap and wipe up any spilled

gasoline.

12

Leveling the Rear Drum to the
Reel

1. Position the machine on a flat, level surface, preferably
a precision steel work plate.

2. Place a 1/4 x 1 in. (0.6 x 2.5 cm) flat steel strip, approx.
29 in. (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 so all
reel blades contact the steel strip.

7. Rotate the drive pulley until the holes align with the 4
roller bearing flange screws (Fig. 9).

8. Loosen the 4 roller bearing screws and the screw
securing the idler pulley.

9. Raise or lower the right side of the roller assembly until
the gap is less than 0.010 in. (.025 cm).

10. Tighten the roller bearing screws.

11. Adjust the belt tension and tighten the idler pulley

mounting screw (Fig. 9).

5. While pressing down on the reel, slide a feeler gauge
under one end of the drum, then check the other end of
the drum.

If there is a gap between the drum and the work surface,
greater than 0.010 in. (.025 cm), on either end, adjust
the drum (proceed to step 6). If the gap is less than

0.010 in. (.025 cm) no adjustment is required.

6. Remove the rear belt cover from the right side of the
machine (Fig. 8).

1

3

1

1. Drive pulley

2. 4 holes

2

Figure 9

3. Idler pulley

1. Traction drive belt cover

Figure 8

13

Adjusting the Bedknife to the
Reel

The bedknife to reel adjustment is accomplished by
loosening or tightening the bedbar adjusting screws, located
on top of the mower.

1. Position the machine on a flat, level work surface.

2. Ensure that the reel contact is removed by turning the

bedbar adjusting screws counterclockwise
(Fig. 10 or 11).

1

Figure 10

1. Bedbar adjusting screw (Greensmaster 1600)

1

4. On one end of the front side of the reel, insert a long
strip of newspaper between the reel and bedknife
(Fig. 12). While slowly rotating the reel forward, turn
the bedbar adjusting screw clockwise (on the same end
of reel, one 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 (Fig. 10 or 11).

Figure 12

Note: Each time the adjusting screw is rotated one click
clockwise, the bedknife moves 0.0007 in. (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 using
paper and adjust it as required.

Figure 11

1. Bedbar adjusting screw (Greensmaster 1000)

3. Tilt the mower back on the handle to expose the
bedknife and reel.

6. After the adjustment is accomplished, check to see if
the reel can pinch paper when inserted from the front
and cut paper when inserted at a right angle to the
bedknife (Fig. 12). It should be possible to cut paper
with minimum contact between the bedknife and the
reel blades. Should excessive reel drag be evident (more
than 7 in.-lb. (0.79 N⋅m)), either backlap or grind the
cutting unit to achieve the sharp edges needed for
precision cutting; refer to the Toro reel sharpening
manual.

14

Adjusting the Height-of-Cut

1. Verify that the rear roller is level and that the bedknife
to reel contact is correct. Tip the mower back on the
handle to expose the front and rear rollers and the
bedknife.

2. Loosen the locknuts securing the height-of-cut arms to
the height-of-cut brackets (Fig. 13).

4

1

3

Figure 13

1. Height-of-cut arm

2. Height-of-cut bracket

3. Locknut

4. Adjusting screw

3. Loosen the nut on the gauge bar (Fig. 14) and set the
adjusting screw to the desired height-of-cut. The
distance between the bottom of the screw head and the
face of the bar is the height-of-cut.

2

Figure 15

5. Rotate the adjusting screw until the roller contacts the
front of the gauge bar.

6. Adjust both ends of the roller until the entire roller is
parallel to the bedknife.

Important When set properly, the rear and front rollers

will contact the gauge bar and the screw will be 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
(Fig. 16), depending on the application and needs of the
user.

• Use the front position when a groomer is installed.

2

1

3

Figure 14

1. Gauge bar

2. Height adjusting screw

3. Nut

4. Hook the screw head on the cutting edge of the
bedknife and rest the rear end of the bar on the rear
roller (Fig. 15).

• Use the middle position without a groomer.

• Use the third position in extremely undulating turf

conditions.

Figure 16

15

Adjusting the Grass Shield
Height

Adjust the shield to ensure proper grass clipping discharge
into the basket.

1. Measure the distance from top of the front support rod
to the front lip of the shield at each end of the cutting
unit (Fig. 17).

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
performance. Adjust the bar whenever the shield height is
adjusted or when the reel is sharpened on a reel grinder.

Installing the Grass Basket

4” (10cm)

2

1. Support rod 2. Shield

2. The height of the shield from the support rod for normal
cutting conditions should be 4 in. (10 cm). Loosen the
capscrews and nuts securing each end of the shield to
the sideplate and adjust the shield to the correct height.

3. Tighten the fasteners.

Note: The shield can be lowered for drier conditions

(clippings fly over top of basket) or raised to allow for
heavy wet grass conditions (clippings build up on rear of
basket).

1

Figure 17

Adjusting the Cut-off Bar

Adjust the cut-off bar to ensure that the clippings are
cleanly discharged from the reel area.

1. Loosen the screws securing the top bar (Fig. 18) to the
cutting unit.

Grasp the basket by the top lip and slide it onto the basket
mounting rods (Fig. 19).

1

2

Figure 19

1. Grass basket 2. Basket mounting rod

Note: Model 04060 only – When cutting in higher
heights-of-cut, the basket may be lowered by removing
each basket mounting rod and installing each on the
opposite side of the machine.

1

Figure 18

1. Cut-off bar

2. Insert a 0.060 in. (.15 cm feeler gauge between the top
of the reel and the bar and tighten the screws.

Checking the Operation of the
Interlock Switch

1. Place the traction lever into the Engage position and the
engine controls in the starting position.

2. Attempt to start the engine.

The engine should not start. If the engine starts, the
interlock switch needs service. Correct the problem
before operating; refer to Adjusting the Interlock
Switch, page 29.

16

Operation

Operator Presence Control (Optional)

(Fig. 20)

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

Controls

Throttle Control (Fig. 20)

Located on the rear right side of the control panel. The
lever connects to and operates the throttle linkage to the
carburetor. The engine speed can be varied from 1600 to
3600 RPM.

Traction Drive Lever (Fig. 20)

Located on the front right side of the control panel. The
lever has two positions: Neutral and Forward. Pushing the
lever forward engages the traction drive.

1

Located on the rear of the handle. Push the operator
presence control against the handle. The operator presence
control must be engaged before moving the traction drive
lever or the engine will stop.

Reel Drive Lever (Fig. 21)

Located on the right front corner of the machine. The lever
has two positions: Engage and Disengage. Pull up on the
lever to engage the reel or push it down to disengage the
reel.

1

4

2

Figure 20

1. Throttle control

2. Traction drive lever

3. Service/parking brake

4. Operator presence control
(optional)

Service/Park Brake (Fig. 20)

Located on the left front side of the control panel. The
brake can be used to slow or stop the machine. The brake
can also be used as a parking brake. Pulling the lever back
over center will set the parking brake. The brake must be
released before the traction drive is engaged.

Figure 21

1. Reel drive lever

3

Choke Lever (Fig. 22)

Located on the left front of the engine. The lever has two
positions: Run and Choke. Move the lever to the Choke
position when starting a cold engine. After the engine starts
move the lever to the Run position.

Fuel Shut-off Valve (Fig. 22)

Located on the left front of the engine. The valve has two
positions: Closed and Open. Move the lever to the Closed
position when storing or transporting the machine. Open
the valve before starting the engine.

17

1

2

Figure 22

1. Choke lever 2. Fuel shut-off valve

Starting the Engine

Note: Ensure that the spark plug wire is installed on the
spark plug.

1. Ensure that the traction (Fig. 20) and reel drive (Fig. 21)
levers are in the Disengaged position.

Note: Engine will not start if traction lever is in the
engaged position.

2. Open the fuel shut-off valve on the engine (Fig. 22).

3. Move the On/Off switch (Fig. 23) to the On position.

4. Move the throttle control (Fig. 20) to the Fast position.

5. Move the choke lever (Fig. 22) to the half-open position

when starting a cold engine. The choke may not be
required when starting a warm engine.

6. Pull the recoil starter handle out until positive
engagement results, then pull vigorously to start the
engine.

On/Off Switch (Fig. 23)

Located on the rear of the engine. Move the switch to the
On position to start the engine and the Off position to stop
the engine.

1

2

3

Figure 23

1. Recoil starter

2. On/Off switch

3. Kick stand

Important Do not pull the recoil rope to its limit or let

go of the starter handle when rope is pulled out because the
rope may break or the recoil assembly may be damaged.

7. Close the choke 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 accidental starting before storing the
machine.

3. Close the fuel shut-off valve before storing or
transporting the mower in a vehicle.

Driving the Machine in
Transport

1. Push the kick stand down with your foot and pull up on
the handle to raise the rear of mower and install the
transport wheels.

Recoil Starter (Fig. 23)

Pull the recoil starter handle to start the engine.

Kick Stand (Fig. 23)

Mounted to rear of the machine, the kickstand is used to
raise rear of the machine for installation or removal of the
transport wheels.

2. To release the kickstand, pull up on the handle, push the
mower forward, and then lower the rear of mower onto
the transport wheels.

3. Ensure that the traction and reel drive controls are in the
Disengaged position and start the engine.

4. Set the throttle control to Slow, tip the front of the
machine up gradually, engage the traction drive and
slowly increase the engine speed.

18

5. Adjust the throttle to operate the mower at the desired
ground speed and transport the mower to the desired
destination.

Mowing Techniques

• Mow a green in a straight back and forth direction,
across the green.

Preparing to Mow

1. Return the traction control lever to the Disengage
position, the throttle to the Slow position, and stop the
engine.

2. Push the kickstand down with your foot and pull up and
back on the handle to raise the wheels off of the ground.

3. Push the locking clips on the wheels out of the grooves
in the shafts.

4. Slide the wheels off of the shafts.

5. Move the unit off of the kickstand.

Mowing Tips

Proper use of the machine provides the smoothest turf
cutting available. The fundamental suggestions given will
provide the utmost performance from your mower.

Important Excessive operation of the cutting unit with

the absence of grass clippings (lubricant) can damage the
cutting unit.

Before Mowing

• Avoid circular mowing or turning the mower on a green
because scuffing may occur. Turn the mower off of the
green by raising the cutting reel (pushing the handle
down) and turning on the traction drum.

• Mow at a normal walking pace. Fast speed saves very
little time and will result in an inferior mowing job.

Mowing

1. Start the engine, set the throttle at reduced speed, push
down on the handle to raise the cutting unit, move the
traction lever to the Engaged position, and transport the
mower onto collar of the green.

2. Move the traction lever to the Disengaged position and
move the reel drive lever to the Engaged position.

3. Move the traction lever to the Engaged position,
increase the throttle speed until the mower is traveling
at the desired ground speed, drive the mower onto the
green, lower the front of the mower, and commence
operation.

4. When finished mowing, drive off of the green, move the
traction control lever to the Disengage position, stop the
engine and push the reel drive lever into the Disengage
position.

• Ensure that the mower is carefully adjusted and is set
evenly on both sides of the reel. Improper mower
adjustment is magnified many times over in the
appearance of the clipped turf.

• Remove all foreign objects from the turf prior to
mowing.

• Ensure that everyone, especially children and pets, are
clear of the work area.

5. Empty the grass catcher of clippings, install the grass
catcher, and commence transport operation.

19

Maintenance

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

Recommended Maintenance Schedule

Maintenance Service

Interval

After first 8 Hours • Engine oil—change

25 Hours

50 Hours

100 Hours

200 Hours

Every 2 years • Interlock switches—replace

Important Refer to your engine operator’s and service manuals for additional maintenance procedures.

Maintenance Procedure

• Air filter pre-cleaner—service

• Grease fittings—lubricate

• Fasteners—check and tighten

• Fuel filter and sediment bowl—clean

• Traction drive belts—adjust

• Engine oil—change

• Cut-off bar—check adjustment

• Air cleaner filter—service

• Combustion chamber—clean

• Spark plug—replace

• Valves—adjust

• Head bolts—torque

20

Daily Maintenance Checklist

Duplicate this page for routine use.

For the week of:

Maintenance Check Item

Safety interlock operation

Parking brake operation

Fluid level

Engine oil level

Air filter

Clean the engine cooling fins

Unusual engine noise

Unusual operating noise

Reel to bedknife adjustment

Height-of-cut adjustment

Grease all fittings

Touch-up damaged paint

Notation for Areas of Concern

Inspection performed by:

Item Date Information

1

Mon. Tues. Wed. Thurs. Fri. Sat. Sun.

2

3

4

5

6

7

8

21

Greasing the Machine

The 13 grease fittings on the mower should be greased at
least every 25 hours. Lubricate using a No. 2 multi–purpose
lithium base grease. A hand operated grease gun is
recommended for best results.

The grease fitting locations are as follows:

• 2 on the front roller (Fig. 24)

• 2 on the reel bearings (Fig. 24)

• 2 on the drum axles (Fig. 25)

• 3 on the differential (Fig. 25)

• 2 on the reel countershaft bearings (Fig. 26)

• 2 on the belt idler pivots (Fig. 27).

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 permanently damaged.

3. Wipe off excess grease.

Figure 24

Figure 25

Figure 26

22

Figure 27

Checking and Changing
Engine Oil

Check the oil level each time the mower is used. Initially,
change oil after the first 8 hours of operation; thereafter,
change oil after every 50 hours of operation. More frequent
oil changes are required in dusty or dirty conditions.

Checking the Oil Level

2. Place a drain pan at the rear of machine, under the drain
plug (Fig. 28).

3. Remove the drain plug.

4. Push down on the handle to tip the mower and the

engine backward, allowing more oil to run into the
drain pan.

5. Install the drain plug and refill the crankcase with the
proper oil; refer to Checking the Oil Level.

1. Position the mower so the engine is level.

2. Clean around the oil level gauge (Fig. 28).

1

2

Figure 28

1. Oil level gauge 2. Drain plug

3. Remove the oil level gauge by rotating it
counterclockwise.

4. Wipe the oil level gauge clean and insert it into the filler
port. Do not screw it into the port.

Servicing the Air Cleaner

Normally, clean the air cleaner after every 25 operating
hours. Clean it more frequently when the mower is
operated in dusty or dirty conditions.

1. Ensure that the wire is off of the spark plug.

2. Remove the wing nuts securing the air cleaner cover to

the air cleaner and remove the cover (Fig. 29).

3. Clean the cover thoroughly (Fig. 29).

1

5. Remove the gauge and check the level of the oil.

6. If the level is low, add only enough oil to raise the level

to the filler opening.

7. Install the oil level gauge and wipe up any spilled oil.

Changing the Oil

1. Start and run the engine for a few minutes to warm the
engine oil.

Figure 29

1. Air cleaner cover

4. If the foam element is dirty, remove it from the paper
element (Fig. 30) and clean it thoroughly.

23

1

2

Figure 30

1. Foam element 2. Paper element

1

Figure 31

1. Spark plug

3. Set the air gap at 0.028 to 0.032 in. (0.05 to 0.07 cm)
(Fig. 32).

A. Wash the foam element in a solution of liquid soap

and warm water.

B. Squeeze to remove dirt, but do not twist it because

the foam may tear.

C. Dry it by wrapping it in a clean rag. Squeeze rag and

foam element to dry it.

D. Saturate the element with clean engine oil.

E. Squeeze the element to remove excess oil and to

distribute the oil thoroughly. An oil damp element is
desirable.

5. Check condition of the paper element. Clean or replace
it as required.

6. Install the foam element, paper element, and air cleaner
cover.

Important Do not operate the engine without the air

cleaner element because extreme engine wear and
damage will likely result.

Replacing the Spark Plug

Use an NGK BPR 5ES spark plug or equivalent. The
correct air gap is 0.028 to 0.032 in. (0.05 to 0.07 cm).
Remove the plug after every 100 operating hours and check
its condition.

4. Install the correctly gapped spark plug and tighten it to
17 ft.-lb. (23 N⋅m).

0.028–0.032 in.

0.05–0.07 cm

Figure 32

Cleaning the Fuel Filter

Initially, clean the fuel filter after the first 20 hours of
operation; thereafter clean it after every 50 hours operation.

1. Close the fuel shut off valve and unscrew the bowl from
the filter body (Fig. 33).

1

1. Pull the wire off of the spark plug.

2. Clean around the spark plug and remove it from the

cylinder head (Fig. 31)

Important Replace a cracked, fouled, or dirty spark

plug. Do not sand blast, scrape, or clean electrodes
because engine damage could result from grit entering
the cylinder.

2

Figure 33

1. Shut-off valve 2. Bowl

2. Clean the bowl and filter in clean gasoline and install it.

24

Adjusting Belts

Ensure that the belts are properly tensioned to ensure
proper operation of the machine and unnecessary wear.
Check belts frequently.

Adjusting the Reel Drive Belt

Check the tension by pressing the belt at mid span of the
pulleys with 3 to 5 lb. of force. The belt should deflect 1/4
in. (0.63 cm). If the deflection is incorrect, adjust the belt as
follows:

1. Remove the belt cover mounting screws and the belt
cover (Fig. 34).

6. After all bolts are installed, tighten them until the
stand-offs inside the cover contact the side plate. Do not
overtighten.

1

2

Figure 35

1. Reel drive belt 2. Idler pulley

1

Figure 34

1. Reel drive belt cover

2. Loosen the idler pulley mounting nut and pivot the idler
pulley clockwise against the backside of the belt until
you attain the desired belt tension.

Important Do not over tension the belt.

3. Tighten the nut to lock the adjustment.

Adjusting the Traction Drive Belt

Check the tension by pressing the belt at mid span of the
pulleys with 3 to 5 lb. (1.5 to 2.3 kg) of force. The belt
should deflect 1/4 in. (0.63 cm). If the deflection is
incorrect, adjust the belt as follows:

1. Remove the belt cover mounting screws and belt cover
to expose the belt (Fig. 36).

1

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.

Figure 36

1. Traction drive belt cover

25

2. Loosen the idler pulley mounting nut and pivot the idler
pulley clockwise against the backside of the belt until
the desired belt tension is attained (Fig. 37).

Important Do not over tension the belt.

2

1

Figure 37

1. Traction drive belt 2. Idler pulley

3. Tighten the nut to lock 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.

2

Figure 38

1. Differential belt 2. Idler pulley

2. Loosen the idler pulley mounting nut and pivot the idler
pulley clockwise against the backside of the belt until
the desired belt tension is attained.

Important Do not over tension the belt.

3. Tighten the nut to lock 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
stand-offs inside the cover contact the side plate. Do not
overtighten.

1

Adjusting the Primary V-Belts

6. After all bolts are installed, tighten them until the
stand-offs inside the cover contact the side plate. Do not
overtighten.

Adjusting the Differential Belt

Check the tension by pressing the belt at mid span of the
pulleys with 4 to 6 lb. of force. The belt should deflect 1/4
in. (0.63 cm). If the deflection is incorrect, adjust the belt as
follows:

1. Remove the capscrews securing the front and rear
sections of the differential cover to the differential
housing and slide the cover sections away to expose the
belt.

1. To adjust the belt tension on primary V-belts, first check
the adjustment of the traction control. Refer to
Adjusting the Traction Control, page 28. If unable to
attain the 3 to 5 lb. (1.5 to 2.3 kg) force required in
adjusting the traction control, proceed to next step.

2. Loosen the retainer securing the V-belt cover and pivot
the cover open.

26

8. To push or pull the machine easier without starting the
engine, adjust the belt guide (Fig. 40, inset) as follows:

1

A. Engage the clutch.

B. Loosen the capscrew securing the idler pulley and

2

belt guide to the idler arm.

C. Rotate the belt guide clockwise until a gap of

approximately 0.06 in. (0.15 cm) is obtained
between the guide finger and the backside of the
drive belts.

D. Tighten the capscrew and locknut securing the idler

pulley and belt guide to the idler arm.

Figure 39

1. V-belt cover 2. Retainer

3. To increase belt tension, loosen the engine mounting
bolts and move engine backwards in the slots.

Important Do not over tension the belt.

4. Tighten the mounting bolts.

Note: The distance between the centers of the driver and

the driven pulleys should be approximately 5.18 in.
(13.15 cm) after new V-belts are installed.

5. After tensioning the primary V-belts, check the
alignment of the engine output shaft pulley and the
countershaft pulley with a straight edge.

6. If the pulleys are misaligned, loosen the screws securing
the engine mounting base to the mower frame and slide
the engine from side to side until the pulleys are aligned
within 0.030 in. (0.07 cm).

3

9. Close the cover and secure the retainer.

Replacing the Differential Belt

1. Remove the capscrews securing the traction drive and
reel drive belt covers to the right side plate and remove
the belt covers.

2. Loosen the idler pulley mounting nut, on each idler
pulley, and pivot each idler pulley counterclockwise
away from the backside of each belt to release belt
tension.

3. Remove the belts.

4. Remove the capscrews securing the front and rear

sections of the differential cover to the differential
housing and slide the cover sections away to expose the
belt (Fig. 41).

1

2

1

Figure 40

1. Primary V-belts

2. Belt guide

3. Idler pulley

7. Tighten the mounting screws and check the alignment.

3

1. Differential cover sections

2. Front clutch housing

27

2

Figure 41

3. Right rear bearing
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 capscrews and locknuts securing the front
clutch housing to the side plate (Fig. 41).

7. Rotate the housing 180° so the bottom of the housing
points upward.

8. Remove the 2 capscrews and locknuts securing the right
rear bearing housing to the side plate (Fig. 41).

9. Rotate the housing 180° so the bottom of the housing
points upward. Remove old belt.

10. Slide the new belt over the rotated housing covers, the
differential cover sections, and onto the differential
pulleys.

11. Ensure that the idler pulley is positioned against the
backside of belt.

2

1

Figure 42

1. Traction cable 2. Front jam nut

12. Rotate both housings back into the upright position and
secure them to the sideplate with the capscrews and nuts
previously removed.

13. Adjust the differential belt tension; refer to Adjusting
the Differential Belt, page 27.

14. Adjust the belt tension on the traction drive and reel
drive belts; refer to Adjusting the Traction Drive Belt,
page 26, and Adjusting the Reel Drive Belt, page 26.

15. Install the differential, traction drive, and reel drive
covers.

Adjusting the Traction Control

If the traction control does not engage or it slips during
operation, an adjustment is required.

1. Move the traction control to the Disengaged position.

2. Loosen the retainer securing the V-belt cover and pivot

the cover open (Fig. 39).

3. To increase the cable tension, loosen the front cable jam
nut and tighten the back cable jam nut (Fig. 42) until a
force of 3 to 5 lb. (1.5 to 2.3 kg) is required to engage
the traction control. Measure the force at the control
knob.

4. Tighten the front cable jam nut.

Adjusting the Service/Park
Brake

If the service/park brake slips when operated, an adjustment
is required.

1. Move the service/park brake lever to the Off position.

2. Loosen the retainer securing the V-belt cover and pivot

the cover open (Fig. 43).

1

2

Figure 43

1. Service/park brake cable 2. Front jam nut

5. Close the cover and secure the retainer.

6. Check the control operation.

3. To increase the cable tension, loosen the front cable jam

nut and tighten the back cable jam nut (Fig. 43) until a
force of 3 to 5 lb. (1.5 to 2.3 kg) is required to engage
brake. Measure the force at the lever knob. Do not over
adjust it so that the brake band drags.

4. Close the cover and secure the retainer.

28

Adjusting the Interlock Switch

To adjust or replace the interlock switch, complete the
following procedure:

1. Ensure that the engine is Off and the traction lever is
disengaged.

2. Loosen the 2 switch mounting nuts (Fig. 44) and move
the switch until the switch plunger is depressed 0.12 to

0.24 in. (0.3 to 0.6 cm) (switch closed).

2. Using a 7/8 in. standard wrench, back out the spring
tension screw until the thrust washer is no longer
tensioned against the bedbar (Fig. 45).

3. On each side of the machine, loosen the jam nut
securing the bedbar bolt (Fig. 45).

1

Figure 44

1. Interlock switch 2. Mounting nuts

3. Tighten the switch mounting nuts.

4. Engage the traction lever and verify that the switch

plunger is depressed between 0.12 to 0.24 in. (0.3 to

0.65 cm).

5. Adjust the switch as required.

2

Servicing the Bedbar

Greensmaster 1600 only

Removing the Bedbar

1. Turn the bedbar adjuster screw, counterclockwise, until
the channel bottoms out in the adjuster frame (Fig. 45).

4

5

1

3

2

1

Figure 46

1. Jam nut 2. Bedbar bolt

4. Remove each bedbar bolt allowing the bedbar to be
pulled downward and removed from the machine. Save
the 2 nylon and 2 stamped steel washers on each end of
bedbar (Fig. 45).

2

Installing the Bedbar

1. Install the bedbar, positioning the mounting ears
between the thrust washer and the channel on the
bedbar adjuster.

2. Secure the bedbar to each side plate with the bedbar
bolts (flange nuts on the bolts) and 8 washers. Position a
nylon washer each side of the side plate boss. Place a
steel washer outside each of the nylon washers.

3. Torque bolts to 240 to 320 in.-lb. (27 to 36 N⋅m).

4. Tighten the flange nuts until the thrust washers just

rotate freely.

5. Adjust the bedbar; refer to Adjusting the Bedknife to
the Reel, page 14.

Servicing the Bedbar

Greensmaster 1000 only

6

1. Bedbar adjusting screw

2. Spring tension screw

3. Thrust Washer

Removing the Bedbar

1. Turn bedbar adjuster screw, counterclockwise, to back
bedknife away from reel (Fig. 47).

Figure 45

4. Bedbar

5. Channel

6. Adjuster frame

29

3

2

3

Backlapping the Reel

1. Remove the plug in the right reel drive cover (Fig. 49).

1

Figure 47

1. Bedbar adjusting screw

2. Spring tension nut

2. Back out the spring tension nut, until the washer is no
longer tensioned against the bedbar (Fig. 47).

3. On each side of the machine, loosen the jam nut
securing the bedbar bolt (Fig. 48).

4. Remove each bedbar bolt allowing bedbar to be pulled
downward and removed from machine. Save the 2
nylon and 2 stamped steel washers on each end of
bedbar (Fig. 48).

1

3. Bedbar

2

1

Figure 49

1. Cover plug

2. Insert a 1/2 in. socket extension, connected to the
backlapping machine, into the square hole in the center
of the reel pulley.

3. Backlap according to the procedure in the Toro
Sharpening Reel and Rotary Mowers Manual, Form

No. 80-300 PT.

Warning

Contact with the reels or other moving parts can
result in personal injury.

Keep fingers, hands, and clothing away from the
reels or other moving parts.

Figure 48

1. Jam nut 2. Bedbar bolt

Assembling the Bedbar

1. Install bedbar, positioning mounting ears between
washer and bedbar adjuster.

2. Secure bedbar to each side plate with bedbar bolts (jam
nuts on bolts) and 8 washers. A nylon washer is to be
positioned on each side of side plate boss. Place a steel
washer outside each of the nylon washers. Torque bolts
to 240–320 in.-lb. (27 to 36 N⋅m) Tighten jam nuts
until thrust washers just rotate freely.

3. Tighten spring tension nut until spring is collapsed, then
back off 1/2 turn.

4. Adjust bedbar; refer to Adjusting the Bedknife to the
Reel, page 14.

Danger

Using a short handled brush when backlapping
will cause you to come into contact with moving
parts, causing serious injury.

Only use brush handle assembly 29-9100 available
from your Authorized Toro Distributor when
backlapping.

Note: For a better cutting edge, run a file across the front

face of the bedknife when the lapping operation is
completed. This will remove any burrs or rough edges that
may have built up on the cutting edge.

4. Install the plug in the cover when finished.

30

Evaporative Emission Control Warranty Statement

California Evaporative Emission Control Warranty Statement

Your Warranty Rights and Obligations

Introduction

The California Air Resources Board and The Toro® Company are pleased to explain the evaporative emission control system’s warranty on
your 2006 model year equipment. In California, new equipment that use small off–road engines must be designed, built, and equipped to
meet the State’s stringent anti–smog standards. The Toro) Company must warrant the evaporative emission control system on your
equipment for two years provided there has been no abuse, neglect or improper maintenance of your equipment.
Your evaporative emission control system may include parts such as: fuel lines, fuel line fittings, and clamps.

Manufacturer’s Warranty Coverage:

This evaporative emission control system is warranted for two years. If any evaporative emission–related part on your equipment is
defective, the part will be repaired or replaced by The Toro

®

Company.

Owner’s Warranty Responsibilities:

• As the equipment owner, you are responsible for performance of the required maintenance listed in your Operator’s Manual. The Toro
Company recommends that you retain all receipts covering maintenance on your equipment, but The Toro® Company cannot deny
warranty solely for the lack of receipts.

• As the equipment owner, you should however be aware that The Toro

®

Company may deny you warranty coverage if your emission

warranty parts have failed due to abuse, neglect, or improper maintenance or unapproved modifications.

• You are responsible for presenting your equipment to an Authorized Service Dealer as soon as the problem exists. The warranty repairs
should be completed in a reasonable amount of time, not to exceed 30 days. If you have a question regarding your warranty coverage,
you should contact The Toro

®

Company at 1–952–948–4027 or call us toll free at the number listed in your Toro Warranty statement.

Defects Warranty Requirements:

5. The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser.

6. General Evaporative Emissions Warranty Coverage. The emission warranty parts must be warranted to the ultimate purchaser and any
subsequent owner that the evaporative emission control system when installed was

A. Designed, built, and equipped so as to conform with all applicable regulations; and
B. Free from defects in materials and workmanship that causes the failure of a warranted part for a period of two years.

7. The warranty on evaporative emissions–related parts will be interpreted as follows:

A. Any warranted part that is not scheduled for replacement as required maintenance in the written instructions must be warranted for

the warranty period of two years. If any such part fails during the period of warranty coverage, it must be repaired or replaced by The

®

Toro

Company. Any such part repaired or replaced under the warranty must be warranted for a time not less than the remaining

warranty period.

B. Any warranted part that is scheduled only for regular inspection in the written instructions must be warranted for the warranty period

of two years. A statement in such written instructions to the effect of ”repair or replace as necessary” will not reduce the period of
warranty coverage. Any such part repaired or replaced under warranty must be warranted for a time not less than the remaining
warranty period.

C. Any warranted part that is scheduled for replacement as required maintenance in the written instructions must be warranted for the

period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the
part must be repaired or replaced by The Toro

®

Company. Any such part repaired or replaced under warranty must be warranted for a

time not less than the remainder of the period prior to the first scheduled replacement point for the part.

D. Repair or replacement of any warranted part under the warranty provisions of this article must be performed at no charge to the

owner at an Authorized Service Dealer.

E. Notwithstanding the provisions of subsection (D) above, warranty services or repairs must be provided at an Authorized Service

Dealer.

F. The owner must not be charged for diagnostic labor that leads to the determination that a warranted part is in fact defective, provided

that such diagnostic work is performed at an Authorized Service Dealer.

G. Throughout the evaporative emission control system’s two year warranty period, The Toro

®

Company must maintain a supply of

warranted parts sufficient to meet the expected demand for such parts.

H. Manufacturer approved replacement parts must be used in the performance of any warranty maintenance or repairs and must be

provided without charge to the owner. Such use will not reduce the warranty obligations of The Toro

I. The use of any add–on or modified parts will be grounds for disallowing a warranty claim made in accordance with this article. The

®

Toro

Company will not be liable under this Article to warrant failures of warranted parts caused by the use of an add–on or modified

®

Company.

part.

J. The Toro

®

Company shall provide any documents that describe the warranty procedures or policies within five working days of

request by the Air Resources Board.

Emission Warranty Parts List:

The following list includes the parts covered under this warranty:

• Fuel Lines

• Fuel Line Fittings

• Clamps

374–0094 Rev. A

®

The Toro General Commercial Products Warranty

A Two-Year Limited Warranty

Conditions and Products Covered

The Toro Company and its affiliate, Toro Warranty Company,
pursuant to an agreement between them, jointly warrant your Toro
Commercial Product (“Product”) to be free from defects in
materials or workmanship for two years or 1500 operational
hours*, whichever occurs first. Where a warrantable condition
exists, we will repair the Product at no cost to you including
diagnosis, labor, parts, and transportation. This warranty begins
on the date the Product is delivered to the original retail purchaser.

* Product equipped with hour meter

Instructions for Obtaining Warranty Service

You are responsible for notifying the Commercial Products
Distributor or Authorized Commercial Products Dealer from whom
you purchased the Product as soon as you believe a warrantable
condition exists.

If you need help locating a Commercial Products Distributor or
Authorized Dealer, or if you have questions regarding your
warranty rights or responsibilities, you may contact us at:

Toro Commercial Products Service Department
Toro Warranty Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
952-888-8801 or 800-982-2740
E-mail: [e-mail]

Owner Responsibilities

As the Product owner, you are responsible for required mainte­nance and adjustments stated in your operator’s manual. Failure
to perform required maintenance and adjustments can be grounds
for disallowing a warranty claim.

Items and Conditions Not Covered

Not all product failures or malfunctions that occur during the
warranty period are defects in materials or workmanship. This
express warranty does not cover the following:

• Product failures which result from the use of non-Toro
replacement parts, or from installation and use of add-on,
modified, or unapproved accessories

• Product failures which result from failure to perform required
maintenance and/or adjustments

• Product failures which result from operating the Product in an
abusive, negligent or reckless manner

• Parts subject to consumption through use unless found to be
defective. Examples of parts which are consumed, or used up,
during normal Product operation include, but are not limited to,
blades, reels, bedknives, tines, spark plugs, castor wheels,
tires, filters, belts, and certain sprayer components such as
diaphragms, nozzles, and check valves, etc.

• Failures caused by outside influence. Items considered to be
outside influence include, but are not limited to, weather,
storage practices, contamination, use of unapproved coolants,
lubricants, additives, or chemicals, etc.

• Normal “wear and tear” items. Normal “wear and tear” includes,
but is not limited 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 become the property of Toro.
Toro will make the final decision whether to repair any existing part
or assembly or replace it. Toro may use factory remanufactured
parts rather than new parts for some warranty repairs.

General Conditions

Repair by an Authorized Toro Distributor or Dealer is your sole
remedy under this warranty.

Neither The Toro Company nor Toro Warranty Company is
liable for indirect, incidental or consequential damages in
connection with the use of the Toro Products covered by this
warranty, including any cost or expense of providing substi­tute equipment or service during reasonable periods of
malfunction or non-use pending completion of repairs under
this warranty. Except for the Emissions warranty referenced
below, if applicable, there is no other express warranty. All
implied warranties of merchantability and fitness for use are
limited to the duration of this express warranty.

Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so
the above exclusions and limitations may not apply to you.

This warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.

Note regarding engine warranty: The Emissions Control System
on your Product may be covered by a separate warranty meeting
requirements established by the U.S. Environmental Protection
Agency (EPA) and/or the California Air Resources Board (CARB).
The hour limitations set forth above do not apply to the Emissions
Control System Warranty. Refer to the Engine Emission Control
Warranty Statement printed in your operator’s manual or con­tained in the engine manufacturer’s documentation for details.

Countries Other than the United States or Canada

Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer)
to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor’s service or
have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty
Company.

Part No. 374-0031 Rev. C