Toro 04054, 04055, 04056, Greensmaster 800, Greensmaster 1000 Operator's Manual

...
FormNo.3376-120RevB
Greensmaster
®
800,1000,and
1600Mower
ModelNo.04054—SerialNo.313000001andUp
ModelNo.04055—SerialNo.313000001andUp
ModelNo.04056—SerialNo.313000001andUp
Registeratwww.T oro.com. OriginalInstructions(EN)
ThisproductcomplieswithallrelevantEuropeandirectives,
G019969
1
fordetailspleaseseetheseparateproductspecicDeclaration ofConformity(DOC)sheet.
WARNING
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Becauseinsomeareastherearelocal,state,orfederal regulationsrequiringthatasparkarresterbeusedonthe engineofthismachine,asparkarresterisincorporatedwith themuferassembly.
GenuineTorosparkarrestersareapprovedbytheUSDA ForestryService.
Important:Thisengineisequippedwithaspark arrestermufer.ItisaviolationofCaliforniaPublic ResourceCodeSection4442touseoroperatetheengine onanyforest-covered,brush-covered,orgrass-covered landwithoutasparkarrestermufermaintainedin workingorder,ortheengineconstricted,equipped,and maintainedforthepreventionofre.Otherstatesor federalareasmayhavesimilarlaws.
Figure1
1.Locationofthemodelandserialnumbers-Tractionunit
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhassafety messagesidentiedbythesafetyalertsymbol(Figure2), whichsignalsahazardthatmaycauseseriousinjuryordeath ifyoudonotfollowtherecommendedprecautions.
Figure2
1.Safetyalertsymbol.
ThissparkignitionsystemcomplieswithCanadianICES-002.
Introduction
Thismachineisawalk-behind,reel-bladelawnmower intendedtobeusedbyprofessional,hiredoperatorsin commercialapplications.Itisprimarilydesignedforcutting grassonwell-maintainedlawnsinparks,golfcourses,sports elds,andoncommercialgrounds.Itisnotdesignedfor cuttingbrush,mowinggrassandothergrowthalongside highways,orforagriculturaluses.
Readthisinformationcarefullytolearnhowtooperateand maintainyourproductproperlyandtoavoidinjuryand productdamage.Youareresponsibleforoperatingthe productproperlyandsafely .
YoumaycontactTorodirectlyatwww .Toro.comforproduct andaccessoryinformation,helpndingadealer,ortoregister yourproduct.
Wheneveryouneedservice,genuineToroparts,oradditional information,contactanAuthorizedServiceDealerorToro CustomerServiceandhavethemodelandserialnumbersof yourproductready .Figure1identiesthelocationofthe modelandserialnumbersontheproduct.Writethenumbers inthespaceprovided.
Thismanualusestwootherwordstohighlightinformation. Importantcallsattentiontospecialmechanicalinformation andNoteemphasizesgeneralinformationworthyofspecial attention.
©2013—TheToro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
Contactusatwww.T oro.com.
2
PrintedintheUSA.
AllRightsReserved
Contents
Introduction..................................................................2
Safety...........................................................................4
SafeOperatingPractices...........................................4
ToroMowerSafety..................................................5
ForModel04054.....................................................6
ForModel04055.....................................................6
ForModel04056.....................................................6
SafetyandInstructionalDecals.................................7
Setup............................................................................9
1InstallingandAdjustingtheHandle.........................9
2InstallingtheKickstand(ForGR800and
GR1600)...........................................................10
3InstallingtheTransportWheelShafts(For
GR1000andGR1600).........................................11
4InstallingtheTransportWheels(Optional)..............11
5AdjustingtheCuttingUnit....................................12
6InstallingtheGrassBasket....................................12
ProductOverview.........................................................13
Controls...............................................................13
Specications........................................................15
Attachments/Accessories........................................16
Operation....................................................................16
ThinkSafetyFirst...................................................16
CheckingtheEngineOilLevel.................................16
FillingtheFuelTank...............................................16
CheckingtheInterlockSwitchOperation...................17
StartingandStoppingtheEngine..............................18
DrivingtheMachineinTransport.............................18
PreparingtoMow...................................................18
PriortoMowing.....................................................18
MethodofMowing.................................................18
ControlOperation..................................................18
Maintenance.................................................................20
RecommendedMaintenanceSchedule(s)......................20
DailyMaintenanceChecklist....................................21
Lubrication...............................................................22
GreasingtheMachine.............................................22
EngineMaintenance..................................................23
ServicingtheEngineOil..........................................23
ServicingtheAirCleaner.........................................24
ReplacingtheSparkPlug.........................................24
FuelSystemMaintenance...........................................25
CleaningtheFuelFilter...........................................25
ElectricalSystemMaintenance....................................26
ServicingtheInterlockSwitch.................................26
BrakeMaintenance....................................................26
AdjustingtheService/ParkingBrake.........................26
BeltMaintenance......................................................28
AdjustingtheBelts.................................................28
ReplacingtheDifferentialBelt..................................30
ControlsSystemMaintenance.....................................31
AdjustingtheTractionControl.................................31
CuttingUnitMaintenance...........................................31
LevelingtheRearDrumtotheReel...........................31
AdjustingtheBedknifetotheReel............................32
AdjustingtheHeightofCut.....................................32
AdjustingtheGrassShieldHeight.............................33
AdjustingtheCut-OffBar.......................................34
BedbarIdentication..............................................34
SettingtheMachinetoMatchTurfConditions............35
ServicingtheBedbar...............................................36
BacklappingtheReel...............................................36
Storage........................................................................37
3
Safety
ThismachinemeetsorexceedsCENstandardEN836:1997, ISOstandard5395:1990,andANSIB71.4-2004specications ineffectatthetimeofproductionwhentheOperator PresenceKit,PartNo.112-9282isinstalled.
Improperuseormaintenancebytheoperatororownercan resultininjury.Toreducethepotentialforinjury,comply withthesesafetyinstructionsandalwayspayattentiontothe safetyalert Danger—personalsafetyinstruction.Failuretocomplywith theinstructionmayresultinpersonalinjuryordeath.

SafeOperatingPractices

ThefollowinginstructionsarefromtheCENstandardEN 836:1997,ISOstandard5395:1990,andANSIB71.4-2004.
Training
ReadtheOperator'sManualandothertrainingmaterial
carefully.Befamiliarwiththecontrols,safetysigns,and theproperuseoftheequipment.
Neverallowchildrenorpeopleunfamiliarwiththese
instructionstouseorservicethemower.Local regulationsmayrestricttheageoftheoperator.
Nevermowwhilepeople,especiallychildren,oranimals
arenearby.
Keepinmindthattheoperatororuserisresponsiblefor
accidentsorhazardsoccurringtootherpeopleortheir property.
Theowner/usercanpreventandisresponsiblefor
accidentsorinjuriesoccurringtohimselforherself,other people,orproperty.
Preparation
Whilemowing,alwayswearsubstantialfootwear,long
trousers,hardhat,safetyglasses,andhearingprotection. Longhair,looseclothing,orjewelrymaygettangled inmovingparts.Donotoperatetheequipmentwhen barefootorwearingopensandals.
Thoroughlyinspecttheareawheretheequipmentisto
beusedandremoveallobjectswhichmaybethrownby themachine.
Warning—Fuelishighlyammable.Takethefollowing
precautions:
Storefuelincontainersspecicallydesignedforthis
Refueloutdoorsonlyanddonotsmokewhile
Addfuelbeforestartingtheengine.Neverremove
Iffuelisspilled,donotattempttostarttheengine
symbol,whichmeansCaution,Warning,or
purpose.
refuelling.
thecapofthefueltankoraddfuelwhiletheengineis runningorwhentheengineishot.
butmovethemachineawayfromtheareaofspillage
andavoidcreatinganysourceofignitionuntilfuel vaporshavedissipated.
Secureallfueltanksandcontainercaps.
Replacefaultysilencers.
Evaluatetheterraintodeterminewhataccessoriesand
attachmentsareneededtoproperlyandsafelyperform thejob.Onlyuseaccessoriesandattachmentsapproved bythemanufacturer.
Checkthatoperator'spresencecontrols,safetyswitches
andshieldsareattachedandfunctioningproperly .Donot operateunlesstheyarefunctioningproperly.
Operation
Donotoperatetheengineinaconnedspacewhere
dangerouscarbonmonoxidefumescancollect.
Mowonlyindaylightoringoodarticiallight.
Beforeattemptingtostarttheengine,disengageallblade
attachmentclutches,shiftintoneutral,andengagethe parkingbrake.
Stayalertforholesintheterrainandotherhiddenhazards.
Watchoutfortrafcwhencrossingornearroadways.
Stopthebladesrotatingbeforecrossingsurfacesother
thangrass.
Whenusinganyattachments,neverdirectdischargeof
materialtowardbystandersnorallowanyonenearthe machinewhileinoperation.
Neveroperatethemachinewithdamagedguards,shields,
orwithoutsafetyprotectivedevicesinplace.Besureall interlocksareattached,adjustedproperly,andfunctioning properly.
Donotchangetheenginegovernorsettingsoroverspeed
theengine.Operatingtheengineatexcessivespeedmay increasethehazardofpersonalinjury.
Beforeleavingtheoperator'sposition:
stoponlevelground; –disengagethepowertake-offandlowerthe
attachments; –changeintoneutralandsettheparkingbrake; –stoptheengine.
Disengagedrivetoattachmentswhentransportingornot
inuse.
Stoptheengineanddisengagedrivetoattachment:
beforerefuelling; –beforeremovingthegrassbasket; –beforemakingheightadjustmentunlessadjustment
canbemadefromtheoperator'sposition; –beforeclearingblockages; –beforechecking,cleaningorworkingonthemower; –afterstrikingaforeignobjectorifanabnormal
vibrationoccurs.Inspectthemowerfordamage
andmakerepairsbeforerestartingandoperatingthe
equipment.
4
Reducethethrottlesettingbeforestoppingengineand,if
theengineisprovidedwithafuelshut-offvalve,turnthe valveoffattheconclusionofmowing.
Keephandsandfeetawayfromthecuttingunit.
Slowdownandusecautionwhenmakingturnsand
crossingroadsandsidewalks.Stopreelsifnotmowing.
Donotoperatethemowerundertheinuenceofalcohol
ordrugs.
Lightningcancausesevereinjuryordeath.Iflightning
isseenorthunderisheardinthearea,donotoperate themachine;seekshelter.
Usecarewhenloadingorunloadingthemachineintoa
trailerortruck.
Usecarewhenapproachingblindcorners,shrubs,trees,
orotherobjectsthatmayobscurevision.
MaintenanceandStorage
Keepallnuts,boltsandscrewstighttobesurethe
equipmentisinsafeworkingcondition.
Neverstoretheequipmentwithfuelinthetankinsidea
buildingwherefumesmayreachanopenameorspark.
Allowtheenginetocoolbeforestoringinanyenclosure.
Toreducetherehazard,keeptheengine,silencer,and
fuelstorageareafreeofgrass,leaves,orexcessivegrease.
Checkthegrassbasketfrequentlyforwearor
deterioration.
Keepallpartsingoodworkingconditionandallhardware
andhydraulicttingstightened.Replaceallwornor damagedpartsanddecals.
Ifthefueltankhastobedrained,dothisoutdoors.
Becarefulduringadjustmentofthemachinetoprevent
entrapmentofthengersbetweenmovingbladesand xedpartsofthemachine.
Disengagedrives,disengagethecuttingunit,setparking
brake,stopengineanddisconnectsparkplugwire.W ait forallmovementtostopbeforeadjusting,cleaningor repairing.
Cleangrassanddebrisfromcuttingunit,drives,mufers,
andenginetohelppreventres.Cleanupoilorfuel spillage.
Carefullyreleasepressurefromcomponentswithstored
energy.
Removethesparkplugwirebeforemakinganyrepairs.
Usecarewhencheckingthereel.Wearglovesanduse
cautionwhenservicingthem.
Keephandsandfeetawayfrommovingparts.Ifpossible,
donotmakeadjustmentswiththeenginerunning.

ToroMowerSafety

ThefollowinglistcontainssafetyinformationspecictoToro productsorothersafetyinformationthatyoumustknowthat isnotincludedintheCEN,ISO,orANSIstandard.
Thisproductiscapableofamputatinghandsandfeetand throwingobjects.Alwaysfollowallsafetyinstructionsto avoidseriousinjuryordeath.
Useofthisproductforpurposesotherthanitsintendeduse couldprovedangeroustouserandbystanders.
Knowhowtostoptheenginequickly.
Donotoperatethemachinewhilewearingtennisshoes
orsneakers.
Wearingsafetyshoesandlongpantsisadvisableand
requiredbysomelocalordinancesandinsurance regulations.
Handlegasolinecarefully .Wipeupanyspills.
Checkthesafetyinterlockswitchesdailyforproper
operation.Ifaswitchshouldfail,replacetheswitch beforeoperatingthemachine.
Alwaysstandbehindthehandlewhenstartingand
operatingthemachine.
Usingthemachinedemandsattention.Topreventloss
ofcontrol:
Donotoperateclosetosandtraps,ditches,creeks,or
otherhazards.
Reducespeedwhenmakingsharpturns.Avoid
suddenstopsandstarts.
Whennearorcrossingroads,alwaysyieldthe
right-of-way.
Thegrassbasketmustbeinplace,duringthemowing
operation,formaximumsafety.Shuttheengineoff beforeemptyingthebasket.
Donottouchtheengine,mufer,orexhaustpipewhile
theengineisrunningorsoonafterithasstoppedbecause theseareascouldbehotenoughtocauseburns.
Whenapersonorpetappearsunexpectedlyinornear
themowingarea,stopmowing.Carelessoperation, combinedwithterrainangles,ricochets,orimproperly positionedguardscanleadtothrownobjectinjuries.Do notresumemowinguntiltheareaiscleared.
MaintenanceandStorage
Checkallfuellinesfortightnessandwearonaregular
basis.Tightenorrepairthemasneeded.
Iftheenginemustberunningtoperformamaintenance
adjustment,keephands,feet,clothing,andanypartsof thebodyawayfromthecuttingunit,attachments,andany movingparts.Keepeveryoneaway .
Toensuresafetyandaccuracy,haveanAuthorizedToro
Distributorcheckthemaximumenginespeedwitha tachometer.Maximumgovernedenginespeedshould be3375±100RPM.
Ifmajorrepairsareeverneededorifassistanceisdesired,
contactanAuthorizedToroDistributor.
UseonlyToro-approvedattachmentsandreplacement
parts.Thewarrantymaybevoidedifusedwith unapprovedattachments.
5

ForModel04054

ForModel04056

SoundPowerLevel
Thisunithasaguaranteedsoundpowerlevelof95dBA, whichincludesanUncertaintyValue(K)of1dBA.
Soundpowerlevelwasdeterminedaccordingtothe proceduresoutlinedinISO11094.
SoundPressureLevel
Thisunithasasoundpressurelevelattheoperator’searof85 dBA,whichincludesanUncertaintyValue(K)of1dBA.
Soundpressurelevelwasdeterminedaccordingtothe proceduresoutlinedinEN836.
VibrationLevel
Hand-Arm
Measuredvibrationlevelforlefthand=4.00m/s
Measuredvibrationlevelforrighthand=2.87m/s
UncertaintyValue(K)=0.5m/s
Measuredvaluesweredeterminedaccordingtotheprocedures outlinedinEN836.
2
2
2
SoundPowerLevel
Thisunithasaguaranteedsoundpowerlevelof95dBA, whichincludesanUncertaintyValue(K)of1dBA.
Soundpowerlevelwasdeterminedaccordingtothe proceduresoutlinedinISO11094.
SoundPressureLevel
Thisunithasasoundpressurelevelattheoperator’searof85 dBA,whichincludesanUncertaintyValue(K)of1dBA.
Soundpressurelevelwasdeterminedaccordingtothe proceduresoutlinedinEN836.
VibrationLevel
Hand-Arm
Measuredvibrationlevelforrighthand=3.35m/s
Measuredvibrationlevelforlefthand=2.59m/s
UncertaintyValue(K)=1.7m/s
Measuredvaluesweredeterminedaccordingtotheprocedures outlinedinEN836.
2
2
2

ForModel04055

SoundPowerLevel
Thisunithasaguaranteedsoundpowerlevelof95dBA, whichincludesanUncertaintyValue(K)of1dBA.
Soundpowerlevelwasdeterminedaccordingtothe proceduresoutlinedinISO11094.
SoundPressureLevel
Thisunithasasoundpressurelevelattheoperator’searof84 dBA,whichincludesanUncertaintyValue(K)of1dBA.
Soundpressurelevelwasdeterminedaccordingtothe proceduresoutlinedinEN836.
VibrationLevel
Hand-Arm
Measuredvibrationlevelforrighthand=2.52m/s
Measuredvibrationlevelforlefthand=2.39m/s
2
2
UncertaintyValue(K)=1.3m/s
Measuredvaluesweredeterminedaccordingtotheprocedures outlinedinEN836.
2
6
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential danger.Replaceanydecalthatisdamagedorlost.
120–2769
1.Toxicgasinhalation hazard—donotoperate indoors.
2.Explosionhazard—stop theengineandkeepaway fromopenameswhen refueling.
3.Warning—stoptheengine andturnoffthefuelbefore leavingthemachine.
4.Warning—disconnectthe sparkplugwireandread theinstructionbefore servicingorperforming maintenance.
5.Hotsurface/burn hazard—donottouch hotsurfaces.
6.Warning—readthe Operator’sManual;when addingfueltothetank, onlylltothebottomof thelltube.
93-9356
1.Entanglementhazard—stayawayfrommovingparts.
93-6085
1.Fast
2.Continuousvariable setting
3.Slow
93-8064
1.Warning—readtheinstructionsbeforeservicingor performingmaintenance.
2.Cuttinghazardoffootorhand—stoptheengineandwait formovingpartstostop.
1.Reeldrive3.Disengage
2.Engage
93-7346
7
115-1614
1.Warning—readtheOperator'sManual.3.Thrownobjecthazard—keepbystandersasafedistancefrom
2.Warning—donotoperatethemachineunlessyouaretrained.
themachine.
4.Warning—stayawayfrommovingparts;keepallguardsin place.
115-1720
1.Forward3.Neutral
2.Drivewheel
120-2727
1.Brake—toengage,pullthe levertowardthehandle; todisengage,releasethe lever.
2.Parkingbrake—tolock, pullthelevertowardthe handle,pressthebutton inandreleasethelever againstthelockingbutton; torelease,pullthelever towardthehandleuntil thebuttonreleasesand releasethelever..
106-8120
1.Thrownobjecthazard—keepbystandersasafedistance fromthemachine.
2.Cuttinghazardofhandandfoot—stayawayfrommoving parts.
8
Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescription
1 2 3
4 5 6
MediaandAdditionalParts
Description
Operator'sManual EngineOperator'sManual PartsCatalog OperatorTrainingMaterial CerticateofCompliance
Handle1 Cabletie Kickstandassembly1 Spring Wheelshaft,right Wheelshaft,left
Transportwheels(optional)
Nopartsrequired
Grassbasket
Qty.
1 1 1 1 1
Readorviewbeforeoperatingthemachine
Qty.
4
1 1 1
2
1Installthegrassbasket.
Installthehandle.
Installthekickstand.
Installthetransportwheelshafts.
Installthetransportwheels(optional).
Adjustthecuttingunit.
Use
Use
Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.
1

InstallingandAdjustingthe Handle

Partsneededforthisprocedure:
1Handle
4
Cabletie
InstallingtheHandle
1.Removetheboltsandlocknutssecuringthebottomof thehandlearmstoeachsideofthemower(Figure3).
Figure3
1.Mountingpins3.Boltandlocknut
2.Handlearms4.Hairpincotterandringpin
2.Removethehairpincottersandringpinssecuringthe handlearmstotherearoftheframe(
3.Insertthehandleendsthroughtheholesinthehandle armsandaligntheholeswiththemountingpins (Figure3).
4.Squeezethehandleendsinwardandinstallthemonthe mountingpins(Figure4).
Figure3).
9
2
G017601
G017590
1
AdjustingtheHandle
G017948
1
2
3
4
1.Removethehairpincottersfromtheringpinsoneach sideofthemower(Figure3).
2.Whilesupportingthehandle,removetheringpins fromeachsideandraiseorlowerthehandletothe desiredoperatingposition(
3.Installtheringpinsandhairpincotters.
Figure3).
Figure4
1.Handleend
2.Bolt,washer,andlockwasher
5.Securethehandleendstothemountingpinswiththe bolts,washers,andlockwashersprovided(Figure4).
6.Securethebottomofthehandlearmstoeachside ofthemowerwiththeboltsandlocknutspreviously removed(Figure4).Ensurethatyouinstallthe bushingsinthehandlearmmountingholes.
7.Securethehandlearmstotherearoftheframewith thehairpincottersandringpinspreviouslyremoved (Figure4).
8.Securethecablesandwireharnesstothehandlewith cableties(
Figure5).
2

InstallingtheKickstand(For GR800andGR1600)

Partsneededforthisprocedure:
1Kickstandassembly
1
Spring
Procedure
Note:Thefastenersareshippedlooselyinstalledonthe
kickstandassembly.
1.OntheGR1600only,connectthespringstudtothe righthandsideofthekickstand(Figure6)usingthe bolt,washer,andange-headnutprovided.
1.Cableties
Figure5
1.Bolt3.Washer
2.Springstud
2.Hookthespringintotheholeinthespringbracketand ontothespringstudwhilealigningthekickstandwith themountingholesintherearframe(
10
Figure6
4.Flange-headnut
Figure7).
Figure7
G019968
1
Figure8
1.Kickstand
2.Springbracket4.Spring
3.Mountthekickstandtoeachsideoftheframewith abolt,lockwasher,spacer,atwasherandlocknut (Figure7).Positionthespacerinthekickstand mountinghole.
3.Springstud
3

InstallingtheTransportWheel Shafts(ForGR1000and GR1600)

Partsneededforthisprocedure:
1
Wheelshaft,right
1
Wheelshaft,left
Procedure
1.Rightwheelshaft
4.Torquetheshaftto65to75ft-lb(88to101N-m).
5.Repeatontheleftside.
4

InstallingtheTransport Wheels(Optional)

Partsneededforthisprocedure:
2
Transportwheels(optional)
Procedure
1.Pushthekickstanddownwithyourfootinthecenter ofthekickstandandpulluponthemachinehandle
untilthekickstandhasrotatedforward,overcenter (Figure9).
1.Pushthekickstanddownwithyourfootandpullup onthehandletosupportthemoweronthekickstand.
2.Apply#242Loctitetothethreadsofthewheelshafts.
3.Threadtherightwheelshaftintothedrivepulleyon therightsideofthemachine(Figure8).
Note:Therightwheelshafthaslefthandthreads.
Figure9
1.Kickstand
2.Pressthewheellockingcliptowardthecenterofthe wheelontothewheelshaft(Figure10).
11
G017591
Figure10
1.Lockingclip
3.Rotatethewheelbackandforthuntilitslides completelyontotheaxleandthelockingclipissecured inthegrooveontheaxleshaft.
4.Repeattheprocedureontheoppositesideofthe machine.
5.Inatethetiresto12to15psi.(574to718Pa).
6.Carefullylowerthemachineoffthekickstandby pushingforwardslowly,allowingthekickstandto springbacktoitsnormalposition.
6

InstallingtheGrassBasket

Partsneededforthisprocedure:
1
Grassbasket
Procedure
Graspthebasketbythetoplipandslideitontothebasket mountingrods(Figure11).
Figure11
1.Grassbasket
Note:Model04056only—Whencuttinginhigher heights-of-cut,thebasketmaybeloweredbyremovingeach basketmountingrodandinstallingeachontheoppositeside ofthemachine.
2.Basketmountingrod
5

AdjustingtheCuttingUnit

NoPartsRequired
Procedure
Beforeoperatingthemachine,completethefollowing adjustments:
LevelingtheRearDrumtotheReel(page31).
AdjustingtheBedknifetotheReel(page32).
AdjustingtheHeightofCut(page32).
AdjustingtheGrassShieldHeight(page33).
AdjustingtheCut-OffBar(page34).
RefertotheCuttingUnitMaintenancesectioninMaintenance forinstructionsonperformingtheseprocedures.
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