Toro 04130 Greensmaster 500, 04215 Greensmaster 500, Greensmaster 500 Operator's Manual
Greensmaster 500
Greensmaster Walk-Behind Mower
Model No. 04130—250000001 and Up (Traction Unit)
Model No. 04215—250000001 and Up (Cutting Unit)
Form No. 3350–271
Operator ’s Manual
Domestic English (EN)
Warning
CALIFORNIA
Proposition 65 Warning
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other reproductive
harm.
This spark ignition system complies with Canadian
ICES-002.
Ce système d’allumage par étincelle de véhicule est
conforme à la norme NMB-002 du Canada.
Contents
Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3. . . . . . . . . . . . . . . . . . .
Toro Mower Safety 5. . . . . . . . . . . . . . . . . . . . . . .
Sound Pressure Level 6. . . . . . . . . . . . . . . . . . . . . .
Sound Power Level 6. . . . . . . . . . . . . . . . . . . . . . .
Vibration Level 6. . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 7. . . . . . . . . . . . . . .
General Specifications 8. . . . . . . . . . . . . . . . . . . .
Dimensions 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Equipment 9. . . . . . . . . . . . . . . . . . . . . . .
Setup 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts Chart 10. . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Handle 11. . . . . . . . . . . . . . . . . . . . . .
Adjust Handle Height And Control Bail 11. . . . . . .
Before Operating 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Add Engine Oil 12. . . . . . . . . . . . . . . . . . . . . . . . . .
Fill Fuel Tank 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Transaxle Oil Level 13. . . . . . . . . . . . . . . . .
Adjusting Height-of-cut 13. . . . . . . . . . . . . . . . . . . .
Reel To Bedknife Adjustment 14. . . . . . . . . . . . . . .
Adjust Rear Roller Scraper 15. . . . . . . . . . . . . . . . .
Check Cutting Unit Alignment 15. . . . . . . . . . . . . .
Install Grass Catcher 15. . . . . . . . . . . . . . . . . . . . . .
Page
Page
Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting And Stopping 18. . . . . . . . . . . . . . . . . . . . .
Transport Operation 18. . . . . . . . . . . . . . . . . . . . . . .
Prior To Mowing 18. . . . . . . . . . . . . . . . . . . . . . . . .
Method Of Mowing 18. . . . . . . . . . . . . . . . . . . . . . .
Operating Controls 18. . . . . . . . . . . . . . . . . . . . . . . .
After Mowing 19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grease Fittings 20. . . . . . . . . . . . . . . . . . . . . . . . . . .
Greasing Traction Clutch 20. . . . . . . . . . . . . . . . . . .
Linkage Pivot Points 20. . . . . . . . . . . . . . . . . . . . . .
Maintenance 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 21. . . . . . . .
Daily Maintenance Checklist 22. . . . . . . . . . . . . . . .
Removal And Installation Of Cutting Unit 23. . . . .
Removing Yoke Assembly 23. . . . . . . . . . . . . . . . . .
Engine Care 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Engine Oil 23. . . . . . . . . . . . . . . . . . . . . .
Traction Drive Belt Adjustment 24. . . . . . . . . . . . .
Clutch Adjustment 24. . . . . . . . . . . . . . . . . . . . . . . .
Cutting Unit Chain Adjustment 24. . . . . . . . . . . . . .
Reel Bearing Adjustment 25. . . . . . . . . . . . . . . . . . .
Backlap Operation 26. . . . . . . . . . . . . . . . . . . . . . . .
Reel And Bedknife Grinding 26. . . . . . . . . . . . . . . .
Cleaning Mower 26. . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic 27. . . . . . . . . . . . . . . . . . . . . .
Storage 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Toro General Commercial Products Warranty 28. .
2004 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
All Rights Reserved
Printed in the USA
2
Introduction
Safety
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.
Write the product model and serial numbers in the spaces
below:
Traction unit
Model No.
Serial No.
Cutting unit
Model No.
Serial No.
This machine meets or exceeds CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI
B71.4-1999 specifications in effect at the time of
production.
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 symbol, which means
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
Safe Operating Practices
The following instructions are from the CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI
B71.4-1999.
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.
• Never allow children 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.
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.
• 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.
Preparation
• While mowing, always wear substantial footwear, long
trousers, hard hat, safety glasses, and ear 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.
• Warning—Fuel is highly flammable. Take the
following precautions:
– Store fuel in containers specifically designed for
this purpose.
3
– 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.
• Watch out for traffic when crossing or near roadways.
• 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.
• 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
–5° when mowing on side hills;
–10° when mowing uphill;
–15° when mowing downhill.
• 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;
– 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.
• 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 power take-off and lower the
attachments;
– change into neutral;
– 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/catchers;
– 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 reels 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
4
• Use care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
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 and hydraulic fittings 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.
• Disconnect battery and remove spark plug wire before
making any repairs. Disconnect the negative terminal
first and the positive last. Reconnect positive first and
negative last.
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.
• 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 interlock switches in the safety system,
regardless if they are working properly or not.
• Always stand behind the handle when starting and
operating the machine.
• To start and stop the engine:
A. Open fuel shut-off valve.
B. Verify that the traction and reel drive control levers
are in Neutral position.
C. Move on/off switch to ON position, set choke to
full choke position (cold start) and throttle to half
throttle.
D. Pull starter cord to start engine.
E. Move throttle to Slow and on/off switch to Off
position to stop engine.
• To transport mower from one area to another:
F. Disengage reel drive.
Important Excessive operating of the cutting unit with
the absence of any grass clippings (lubricant) can damage
the cutting unit.
• 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.
G. Start engine.
H. Press down on handle to raise front of mower and
engage traction drive.
• Before beginning mowing operation:
I. Disengage traction drive.
J. Stop engine.
K. Engage reel drive.
L. Start engine
5
• Using the machine demands attention. To prevent loss
of control:
– Do not drive 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.
• The grass basket must be in place during operation of
the reels or thatchers for maximum safety. Shut the
engine off before emptying the baskets.
• 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.
• 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.
• 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.
Sound Pressure Level
This unit has an equivalent continuous A-weighted sound
pressure at the operator ear of: 88 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:
100 dBA/1 pW, based on measurements of identical
machines per Directive 2000/14/EC and amendments.
Vibration Level
This unit has a hand–arm vibration level of 4.00 m/s
based on measurements of identical machines per ISO
5349 procedures.
2,
• 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.
6
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.
Part No. 93-7348
1. Danger—read the operator’s manual.
2. Fire or open flame—sparks, flame, and smoking prohibited. Fill
the fuel tank no higher than to the bottom of the filler neck.
3. Thrown object hazard—keep bystanders away.
4. Cutting hazard to fingers, hands, and feet—do not open or
remove safety shields while engine is running.
Part No. 957271
1. Descriptions to come
Part No. 93-9886
1. Use unleaded fuel only.
Part No. 93-6688
1. Danger—read the
operator’s manual before
performing maintenance.
93-8069
1. Hot surface/burn hazard—stay a safe distance from the hot
surface.
Part No. 957298)
1. Descriptions to come
2. Cutting hazard to hands,
fingers, and feet—stop the
engine before going near
rotating reels.
7
General Specifications
Kawasaki, 4-cycle, 3.7 (2.7 kw) air cooled OHV engine, 3600 RPM, 7.57 cu in.
Engine
Fuel capacity 2.64 qt. (2.5 l); regular grade unleaded gasoline
Traction drive
Reel Drive
Reel Clutch Engaging jaw-type, hand operated at transaxle.
Ground speed 2.1 mph (3.4 Km/hr) at 1600 RPM and 4.0 mph (6.4 Km/hr.) at 3100 RPM.
(124 cc) displacement, cast iron cylinder sleeve; electronic ignition with integral
lighting coil; maximum noise suppression muffler; 83 dB(A) at operator ’s ear
“A” section “V” belt on 2.0 P.D. and 3.70 P.D. to countershaft (1. 85:1) 18T and
48T gear) 2.67:1 and 20T and 56T gear (2 . 8:1). All gears 16 pitch, 20_ involute
full depth, 1/2 in. (13 mm) wide. Gears running in oil.
“A” section V-belt on 2.0 P.D. and 3.70 P.D. to countershaft (1. 85:1) 3/8 in. pitch x
3/16 in. wide chain on 20T and 14T sprockets from countershaft. Reduction Engine
to Reel – 1.30:1.
Traction drum
Reduction, Engine to
Traction Drum
Traction Drive Clutch Friction Disk type – Hand operated latch and bail at handle.
Differential Enclosed spur gears
Handle
Traction unit construction Cast aluminum housing.
Reel construction
Width of cut 21 in. (53.3 cm)
Height of cut 1/8 to 11/16 in. (3 to 17 mm).(Optional micro-cut bedknife 1/16” to 11/16”)
Clip frequency 0.197 in. (5.0 mm).
Bedknife/bedbar
Front Rollers
6 in. (15.2 cm) diameter solid rubber on 16 gauge (1.5 mm) steel rims. Two
sections running on ball bearings.
13.86:1
7/8 in. diameter, 17 gauge welded steel tubing with formed steel reinforcement
panel.
Cast aluminum and zinc side plates, aluminum extrusion back plate. Reel unit
independent of traction unit and catcher. 3-1/2 in. (89 mm) diameter 9 blade,
welded tubular construction. Reel blades, high carbon heat treated steel. Reel
bearings, taper roller with adjustment.
Single edge high carbon steel knife, extra hard for long life, screwed to extruded
aluminum one-piece bed bar and back plate.
2 in. (51 mm) O.D. Steel tube with ball bearings, moisture excluding oil seals and
replaceable wear sleeves.
Weight 186 pounds with catcher and cutting unit.
Dimensions
Width 27 in. (0.69 m)
Height 44-3/4 in. (1.1 m)
with handle
Length 60 in. (1.5 m)
including handle and
catcher
8
Optional Equipment
Cutting Unit Model No. 04215
Light Kit Model No. 04058
Brush Kit Part No. 2–2949
Skid Kit Part No. 4–7299
Sectional Roller Part No. 4–7319
Urethane Comb Part No. 8–2560
Full Roller Part No. 4–7309
Micro Cut Bedknife Part No. 95–3147
Wiehle Roller (rear cutting unit) Part No. 100–1556
Spark Arrester Kit Part No. 98-3426
Low Cut Bedknife Part No. 88–8990
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