Toro 96889SL User Manual

Greensmaster ® 1000/1600

Preface

The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repairing assemblies and components on the Greensmaster 1000/1600.

REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE, AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manual and Parts Catalogs for your machine. Replacement Operator’s Manuals are available by sending complete Model and Serial Number to:

The Toro Company 8111 Lyndale Avenue South Minneapolis, MN 55420–1196

The Toro Company reserves the right to change product specifications or this publication without notice.

PART NO. 96889SL, Rev. A

Service Manual

This safety symbol means DANGER, WARNING, or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions may result in personal injury.

NOTE: A NOTE will give general information about the correct operation, maintenance, service, testing, or repair of the machine.

IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the machine.

 The Toro Company – 1996, 1997

Greensmaster 1000/1600

Table Of Contents

Chapter 1 – Safety

Safety Instructions 1 – 1. . . . . . . . . . . . . . . . . . . . . . . . . .

Safety and Instruction Decals 1 – 4. . . . . . . . . . . . . . . .

Chapter 2 – Product Records and Manuals

Product Records 2 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

Equivalents and Conversions 2 – 2. . . . . . . . . . . . . . . .

Torque Specifications 2 – 3. . . . . . . . . . . . . . . . . . . . . . .

Operation and Service History Report 2 – 5. . . . . . . . .

Chapter 3 – Engine

Introduction 3 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 3 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information 3 – 4. . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 3 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Services and Repairs 3 – 8. . . . . . . . . . . . . . . . . . . . . . .

Kawasaki FE161 & FE170 Service Manual and

Kawasaki FE120 Service Manual Supplement

Chapter 4 – Traction and Reel Drive System

Specifications 4 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools 4 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 4 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 4 – 8. . . . . . . . . . . . . . . . . . . . . . . .

Chapter 5 – Electrical System

Wiring Schematics 5 – 2. . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools 5 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Trouble Shooting 5 – 7. . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Testing 5 – 8. . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 5 – 13. . . . . . . . . . . . . . . . . . . . . . .

Chapter 6 – Controls, Wheels and Accessories

Specifications 6 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 6 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 6 – 4. . . . . . . . . . . . . . . . . . . . . . . .

Chapter 7 – Cutting Unit

Introduction 7 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 7 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information 7 – 4. . . . . . . . . . . . . . . . . . . . . . . .

Special Tools 7 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 7 – 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 7 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 7 – 13. . . . . . . . . . . . . . . . . . . . . . .

Chapter 8 – Grooming Reel Kit (See Note Below)

Specifications 8 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information 8 – 3. . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 8 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 8 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 8 – 8. . . . . . . . . . . . . . . . . . . . . . . .

SafetyProduct Records

and Manuals

Engine

Drive System

Traction and Reel

Greensmaster 1000/1600

Note: This chapter covers the Model 04125 Grooming Reel Kit only (for the Greensmaster 1000).

System

Electrical

Wheels andCutting Unit

Accessories

Kit

Grooming Reel

Greensmaster 1000/1600

Table of Contents

SAFETY INSTRUCTIONS 1. . . . . . . . . . . . . . . . . . . . . .

Before Operating 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

While Operating 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Instructions

Chapter 1

Safety

Maintenance and Service 2. . . . . . . . . . . . . . . . . . . .

SAFETY AND INSTRUCTION DECALS 3. . . . . . . . . .

The GREENSMASTER 1000 was tested and certified by TORO for compliance with the B71.4–1984 specifications of the American National Standards Institute. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine. Improper use or maintenance of the machine can result in injury or death.

Before Operating

1. Operate the machine only after reading and understanding the contents of this manual. A replacement manual is available by sending the complete model and serial number to:

The Toro Company 8111 Lyndale Avenue South Minneapolis, Minnesota 55420–1196

2. Never allow children to operate the machine, nor allow adults to operate it without proper instructions.

To reduce the potential for injury or death, comply with the following safety instructions.

WARNING

To reduce the potential for injury or death, comply with the following safety instructions.

6. Wearing safety glasses, safety shoes, long pants and a helmet is advisable and required by some local safety and insurance regulations.

7. Assure work area is clear of objects which might be picked up and thrown by the reel.

8. Keep everyone, especially children and pets away from the areas of operation.

9. Gasoline is highly flammable; handle it carefully.

3. Become familiar with the controls, and know how to stop the engine quickly.

4. Keep all shields, safety devices, and decals in place. If a shield, safety device, or decal is malfunctioning, illegible, or damaged, repair or replace it before operating the machine.

5. Always wear substantial shoes. Do not operate machine while wearing sandals, tennis shoes or sneakers. Do not wear loose fitting clothing which could get caught in moving parts and cause personal injury.

Greensmaster 1000/1600

Page 1 – 1

A. Use an approved gasoline container. B. Do not remove cap from fuel tank when engine is

hot or running. C. Do not smoke while handling gasoline. D. Fill fuel tank outdoors and no higher than to the

bottom of filter screen. Do not overfill. E. Wipe up any spilled gasoline. F. Fuel may leak from filler neck when mower is

tilted for servicing if tank is over filled.

Safety

10. Check the safety interlock switch daily for proper operation; see Component Testing in Chapter 5 – Electrical System. Replace malfunctioning switches before

While Operating

operating machine. (After every two years, replace the interlock switch in the safety system, whether it is working properly or not.)

1 1. Do not run the engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could be deadly.

12. Always stand behind the handles when starting and operating the machine.

13. To start and stop the engine: A. Open fuel shut-off valve. B. Verify that the traction drive lever on handle is in

NEUTRAL position and reel drive lever on mower is DISENGAGED.

C. Move on/of f 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.

14. To transport mower from one area to another: A. Install transport wheels. B. Disengage reel drive lever.

15. Before beginning mowing operation: A. Stop engine. B. Disengage traction drive. C. Remove transport wheels. D. Engage reel drive lever.

16. Before emptying basket of clippings, disengage

traction drive, reduce engine speed and move on/off switch to off position.

17. Do not touch engine, muffler or exhaust pipe while

engine is running or soon after it has stopped because these areas are hot enough to cause burns.

18. If the cutting unit strikes a solid object or vibrates ab-

normally, stop immediately, turn engine off,wait for all motion to stop and inspect for damage. A damaged reel or bedknife must be repaired or replaced before operation is commenced.

19. Whenever machine is left unattended, be sure en-

gine is stopped and cutting unit reel is not spinning. Close fuel shut-off valve if machine is not to be used for an extended period of time.

Safety

C. Start engine. D. Press down on handle to raise front of mower

and engage traction drive.

Maintenance and Service

20. Before servicing or making adjustments to the machine, stop the engine and pull the spark plug wire off spark plug to prevent accidental starting of the engine.

21. To make sure entire machine is in good condition, keep all nuts, bolts, screws and belts properly tightened.

22. If major repairs are ever needed or assistance is required, contact an Authorized TORO Distributor.

23. To reduce potential fire hazard, keep the engine area free of excessive grease, grass, leaves and accumulation of dirt.

24. 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 and any moving parts. Keep everyone away.

25. Do not overspeed the engine by changing governor

settings. Maximum engine speed is 3600 rpm. To assure safety and accuracy , have an Authorized Toro Distributor check maximum engine speed with a tachometer.

26. Engine must be shut off before checking oil or ad-

ding oil to the crankcase.

27. To be sure of optimum performance and safety, al-

ways purchase genuine TORO replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous. Such use could void the product warranty of The Toro Company.

Safety

Page 1 – 2

Greensmaster 1000/1600

Safety and Instruction Decals

The following safety and instruction decals are affixed to the traction unit. If any decal becomes illegible or damaged, install a new decal. Part numbers are listed below

On Control Panel

Part No. 93–6084

and in your Parts Catalog. Order replacements from your Authorized Toro Distributor.

On Front Frame Tube

Part No. 55–4300

Inside Belt Covers (3)

Part No. 88–8950

On Grass Shield

Part No. 93–6098

GAS

UNLEADED

On Fuel Tank

Part No. 53–4420

On Fuel Tank

Part No. 88–7620

On Grass Shield

Part No. 62–5070

On Control Panel

Part No. 93–6085

DANGER

DO NOT OPERATE THIS UNIT UNLESS ALL SHIELDS ARE FIRMLY SECURED.

On Fuel Tank

Part No. 63–8440

Greensmaster 1000/1600

Inside Belt Cover

Part No. 675360

Page 1 – 3

On Belt Cover

Part No. 65–7660

Safety

On Control Panel

Part No. 93–9012

Safety

Page 1 – 4

Greensmaster 1000/1600

Table of Contents

Chapter 2

Product Records and Manuals

PRODUCT RECORDS 1. . . . . . . . . . . . . . . . . . . . . . . . .

EQUIVALENTS AND CONVERSIONS 2. . . . . . . . . . .

Decimal and Millimeter Equivalents 2. . . . . . . . . . . .

U.S. to Metric Conversions 2. . . . . . . . . . . . . . . . . . .

Product Records

Record information about your Greensmaster 1000/1600 on the OPERATION AND SER VICE HISTORY REPORT form. Use this information when referring to your machine.

TORQUE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . .

Capscrew Markings and Torque Values – U.S. 3. . Capscrew Markings and Torque Values – Metric 3

OPERATION AND SERVICE HISTORY REPORT 5.

Insert Operator’s Manuals and Parts Catalogs for your Greensmaster 1000/1600 at the end of this section.

and Manuals

Product Records

Greensmaster 1000/1600

Page 2 – 1

Product Records and Manuals

Equivalents and Conversions

Product Records and Manuals

Page 2 – 2

Greensmaster 1000/1600

Torque Specifications

and Manuals

Product Records

Greensmaster 1000/1600

Page 2 – 3

Product Records and Manuals

Page 2 – 4

Greensmaster 1000/1600

EQUIPMENT OPERATION AND SERVICE HISTORY REPORT

for

GREENSMASTER® 1000

TORO Model and Serial Number:__________-__________ Engine Numbers: ____________________ Differential Numbers: ____________________ Date Purchased: ____________________ Warranty Expires__________ Purchased From: ____________________

____________________ ____________________

Contacts: Parts ____________________ Phone__________________

Service ____________________ Phone__________________ Sales ____________________ Phone__________________

See your TORO Distributor/Dealer for other Publications, Manuals, and Videos from The TORO Company.

GREENSMASTER® 1000 Maintenance Schedule

Minimum Recommended Maintenance Intervals:

Maintenance Procedure Maintenance Interval & Service

Service Air Filter Pre-Cleaner Every Lubricate All Grease Fittings Check for loose Fasteners

25hrs

A Level

Every 50hrs

Every

100hrs

Clean Fuel Filter and Sediment Bowl Adjust Traction Drive Belts B Level

† Change Engine Oil

Clean Combustion Chamber

Replace Spark Plug

Service

Check Cut-Off Bar Adjustment C Level Service Air Cleaner Filter

Clean Combustion Chamber

Replace Spark Plug D Level Adjust Valves and Torque Head Bolts

Service

† Initial Break in at 20 hours

Interval for Engine Model: FG150

Interval for Engine Model: FE120

Every

200hrs

Replace All Interlock Switches

Annual Recommendations:

Item listed is recommended every 2 years.

(See Operator's and Service Manual for specifications and procedures)

GREENSMASTER® 1000 Daily Maintenance Check List

Unit Designation:__________

Daily Maintenance:(duplicate this page for routine use) TORO ID#:_______-_______

Daily Maintenance Check For Week Of

_____________

Maintenance Check Item

Safety Interlock Operation Park Brake Operation Fuel Level Engine Oil Level Air Filter Pre-Cleaner

Clean Engine Cooling Fins Unusual Engine Noises Unusual Operating Noises Reel-to-Bedknife Adjustment Height-of-Cut Adjustment

Lubricate All Grease Fittings Touch-up damaged paint

= Immediately after every washing, regardless of the interval listed.

MON

_______HRS

TUES

______HRS

WED

______HRS

THURS

______HRSFR______HRS

SAT

______HRS

SUN

______HRS

Notation for areas of concern: Inspection performed by:________________

Item Date Information

1 2 3 4 5 6 7

(See Operator's and Service Manual for specifications and procedures)

GREENSMASTER® 1000 Supervisor Maintenance Work Order Date:______________

(duplicate this page for routine use)

Unit Designation: TORO I.D. #: Remarks:

____________-____________

Hours:

Service to perform (circle):

Technician:

A B C D Other

A -Service (every 25 hours) B -Service (every 50 hours) C -Service (every 100 hours)

Lubricate All Grease Fittings Change Engine Oil

Service Air Filter Pre-Cleaner Adjust Belts

Clean Combustion Chamber Replace Spark Plug

Check for Loose Fasteners Clean Fuel Filter & Sediment Bowl Check Cut-Off Bar Adjustment

_______________________________

A-Service required

Service Air Cleaner Filter _______________________________ _______________________________ A and B Service required _______________________________ _______________________________ ________________________________ _______________________________ _______________________________ _______________________________

D -Service (every 200 hours) Other - Annual Service and Specials Additional Servicing Items

Clean Combustion Chamber Replace Spark Plug

Adjust Valves and Torque Head Bolts _______________________________ _______________________________ A, B and C Service required

Replace all Interlock Switches ________________________________ _______________________________ _______________________________

_______________________________ _______________________________ _______________________________ _______________________________ _______________________________ _______________________________ _______________________________ _______________________________ _______________________________ _______________________________ _______________________________

Interval for Engine Model: FG150

Interval for Engine Model: FE120

(See Operator's and Service Manual for specifications and procedures) Form No. 95-843-SL

Table of Contents

Chapter 3

Engine

INTRODUCTION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICA TIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION 4. . . . . . . . . . . . . . . . . . . . .

Filling the Fuel Tank 4. . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Shut–off Valve 5. . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENTS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Throttle Linkage Adjustment 6. . . . . . . . . . . . . . . . . .

Clutch Control Adjustment 6. . . . . . . . . . . . . . . . . . . .

Adjusting V–belts 7. . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE AND REPAIRS 8. . . . . . . . . . . . . . . . . . . . . .

Engine Oil 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark Plug and Ignition Components 8. . . . . . . . . .

Air Cleaner 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Removal and Installation 10. . . . . . . . . . . . .

Lubrication 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Kawasaki FE161 & FE170 Service Manual and

Kawasaki FE120 Service Manual Supplement

Engine

Greensmaster 1000/1600 Page 3 – 1 Engine

Introduction

This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the gasoline engine used in the Greensmaster 1000/1600 mower.

Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Kawasaki FE161 & FE170 Service Manual and Kawasaki FE120 Service Manual

Supplement. The use of some specialized test equipment is explained. However, the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility .

Service and repair parts for Kawasaki engines are supplied through your local T oro distributor . If no parts list is available, be sure to provide your distributor with the Toro model and serial number.

Engine

Page 3 – 2

Greensmaster 1000/1600

Specifications

Item Description

Make / Designation Kawasaki, 4–stroke, OHV , single cylinder,

air–cooled, gasoline engine, FE120G

Bore x Stroke mm (in.) 60 x 44 (2.36 x 1.73)

Total Displacement cc (cu. in.) 124 (7.6)

Compression Ratio 8.4:1

Maximum Output kw (HP) 2.8 (3.7)

Rated Output kw (HP) 2.2 (3.0)

Carburetor Float feed fixed main jet

Governor Mechanical flyweight

Idle Speed (no load) 1600  100 RPM (at crankshaft) or 800  50 RPM (at camshaft)

High Idle (no load) 3600  100 RPM (at crankshaft) or 1800  50 RPM (at camshaft)

Direction of rotation Clockwise (facing PTO shaft)

Fuel Un–leaded automotive grade gasoline

Fuel Tank Capacity liter (U.S. qt.) 2.5 (2.6)

Engine

Engine Oil See General Information

Lubrication System Splash type

Oil Capacity liter (U.S. qt.) 0.6 (0.63)

Air Cleaner Dual element

Ignition System Transistorized flywheel magneto with ignition advancing

RFI Suppressor Radio suppressor plug cap and plug

Dry Weight kg (U.S. lb) 14.6 (32.2)

Greensmaster 1000/1600 Page 3 – 3 Engine

General Information

Filling the Fuel Tank

DANGER

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Figure 1

1. Fuel tank cap

IMPORTANT: Never use methanol, gasoline containing methanol, gasoline containing more than 10% ethanol, gasoline additives, premium gasoline, or white gas. Engine fuel system damage could result.

1. Park mower on a level surface. Make sure engine is OFF.

2. Clean around fuel tank cap and remove cap from tank (Fig. 1). Using unleaded gasoline, fill fuel tank to bottom of filter screen. DO NOT OVER FILL.

Engine

3. Install fuel tank cap. Wipe up any spilled gasoline.

Page 3 – 4

Greensmaster 1000/1600

Fuel Shut–off Valve

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

Figure 2

1. Fuel shut–off valve

Engine

Greensmaster 1000/1600 Page 3 – 5 Engine

Adjustments

Throttle Control Adjustment

If a new throttle cable must be installed or the cable is out of adjustment, adjust the cable as follows:

1.Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2.Move throttle lever to the SLOW position.

3.Loosen throttle cable screw securing the throttle cable to the governor lever.

Note: Engine speed is measured at the input drive pulley (Fig. 6). Actual engine speed is twice the input drive pulley speed.

4.The governor lever will move to the slow idle position if it is improperly adjusted.

A. Check low idle speed setting with a tachometer. Low idle speed should be 750 to 850 rpm. Adjust low speed idle screw in or out to attain the correct speed setting.

B. Check high idle speed setting with a tachometer. High idle speed should be 1750 to 1850 rpm. Adjust high speed idle screw in or out to attain the correct speed setting.

Figure 2

1. Throttle cable screw

2. Throttle cable

3. Governor lever

4. Low speed idle screw

5. High speed idle screw

5.Make sure throttle lever is in the SLOW position and the governor lever is against the low speed idle screw.

6.Tighten throttle cable screw securing the throttle cable to the governor lever.

Clutch Control Adjustment

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

1.Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2.Move traction control to DISENGAGED position.

3.Loosen retainer securing V–belt cover and pivot cover open.

4.To increase cable tension, loosen front cable jam nut and tighten back cable jam nut (Fig. 3) until a force of 7 to 9 lbs (31 to 40 N) is required to engage clutch control. The force should be measured at the control knob.

5.Tighten front cable jam nut.

6.Close cover and secure retainer.

7.Check control operation.

1. Clutch

2. Front jam nut

Figure 3

3. Back jam nut

Engine

Page 3 – 6

Rev. A

Greensmaster 1000/1600

Adjusting V–belts

T o adjust belt tension on V–belts (Fig. 5), first check adjustment of clutch control. Refer to Clutch Control in this section. If unable to attain the 7 to 9 lbs (31 to 40 N) of force that is required in adjusting the clutch control, proceed to the next step.

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

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

3. To increase V–belt tension, loosen cap screws securing the engine to the engine base (Fig. 12). Move engine backwards in slots. DO NOT OVER TENSION BELTS. Tighten cap screws.

4. Check that a force of 7 to 9 lbs (31 to 40 N) is required to engage the clutch control. Adjust engine in slots as necessary to get required tension on V–belts.

5. After tensioning V–belts, check alignment of the input drive pulley and input shaft pulley with a straight edge.

A. Inside pulley faces should be flush to each other to within 0.030 inch (0.762 mm) maximum (Fig. 6).

B. If pulleys are misaligned, loosen cap screws securing the engine mounting base to the mower frame. Slide engine from side to side until the pulleys are aligned (Fig. 7).

Figure 5

1. V–belt cover 2. V–belts

Engine

INSIDE FACE

6. Tighten cap screws and recheck alignment.

7. Close V–belt cover and secure retainer.

Figure 6

1. Input drive pulley 2. Input shaft pulley

Figure 7

1. Cap screws

2. Engine

3. Engine base

Greensmaster 1000/1600 Page 3 – 7 Engine

Service and Repairs

Engine Oil

The TORO Company recommends that the oil level be checked each time the mower is used or after every 5 operating hours. Initially, change oil after the first 20 hours of operation; thereafter, change oil after every 50 hours of operation. More frequent oil changes are re-

quired in dusty or dirty conditions. Checking the Oil Level:

1. Park mower on a level surface. Make sure engine is OFF.

2. Position mower so the engine is level. Clean around the oil level gauge.

3. Remove oil level gauge by rotating it counterclockwise.

4. Wipe oil level gauge clean and insert it into the filler port. Do not screw it into the port. Remove and check level of the oil. If the oil level is low, add only enough oil (see chart below for proper viscosity) to raise the level to the filler opening.

Use any high quality detergent oil having the American Petroleum Institute (API) “service classification”— MS or SG.

Changing the Oil:

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

2. Place a drain pan at the rear of machine under the drain plug. Remove drain plug.

3. Push down on handle to tip mower and engine backward, allowing more oil to run into the drain pan.

4. Reinstall drain plug and refill crankcase with proper oil: refer to Checking the Oil Level. The crankcase holds 6.3 qt (6.0 l).

T emperature Oil Viscosity

50 or below SAE 10W30 wt. 50 to 95 SAE 10W30 wt. or 30 wt. Above 95 SAE 40

5. Reinstall oil level gauge and wipe up any spilled oil.

Spark Plug and Ignition Components

Service of the spark plug and other ignition components is covered in Chapter 5 – Electrical System.

Figure 8

1. Oil level gauge 2. Drain plug

Engine

Page 3 – 8

Greensmaster 1000/1600

Air Cleaner

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

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Remove wing nuts securing the air cleaner cover to air cleaner and remove cover. Clean cover thoroughly (Fig. 9).

3. If the foam element is dirty , remove it from the paper element (Fig. 10). Clean foam element thoroughly.

A. WASH element in a solution of liquid soap and warm water. Squeeze it to remove dirt. Do not twist element because foam may tear.

B. DRY by wrapping the element in a clean rag. Squeeze rag and foam element to dry.

C. SATURATE element with clean engine oil. Squeeze element to remove excess oil and to distribute oil uniformly. An oil damp element is desirable.

4. When servicing the foam element, check condition of the paper element. Clean or replace as required.

5. Reinstall foam element, paper element, and air cleaner cover. Tighten wing nuts.

IMPORTANT: Do not operate engine without air cleaner element because extreme engine wear and damage will likely result.

Figure 9

1. Wing nut 2. Air cleaner cover

Engine

Figure 10

1. Foam element 2. Paper element

Fuel Filter

Clean fuel filter after every 50 hours operation.

1. Close fuel shut off valve and unscrew bowl from the filter body. Remove filter element.

2. Clean bowl and filter element in clean gasoline

3. Reinstall filter element and bowl. Open fuel shut–off valve.

Figure 11

1. Fuel shut–off valve 2. Bowl

Greensmaster 1000/1600 Page 3 – 9 Engine

Engine Removal and Installation

IDLER PULLEY

ASSEMBLY

36 33

49 13

KEY

1. Bellcrank cover

2. Flat washer

3. Stud

4. Retainer

5. Capscrew

6. Lock washer

7. Flat washer

8. Grease fitting

9. Lever

10. Bushing

11. Input drive pulley

12. Engine shaft spacer

13. Shoulder bolt

14. Torsion spring

15. Jam nut

16. Clutch switch

17. Clutch bracket

Figure 12

18. R–clamp

19. Lock washer

20. Cap screw

21. Engine

22. Wire harness

23. Capscrew

24. Throttle cable bracket

25. Washer head screw

26. Lock nut

27. Washer

28. Clutch torsion spring

29. Belt shield

30. Cap screw

31. Clutch lever

32. Cable link assembly

33. Lock washer

34. V–belt (matched set)

26 7

35. Washer

36. Cap screw

37. Lock nut

38. Pulley support spacer

39. Idler pulley

40. Ball bearing

41. Retaining ring

42. Lock nut

43. Muffler guard (European models)

44. Module bracket

45. Cap screw

46. Interlock module

47. Throttle cable and bracket

48. Clutch cable

49. Clutch cable eyelet

50. Engine base

Engine

Page 3 – 10

Greensmaster 1000/1600

Removal

1. Make sure machine is parked on a level surface with the engine OFF. Remove high tension lead from the spark plug to prevent the engine from starting. Close fuel shut–off valve.

2. Remove pulley V–belts (Fig. 12). A. Make sure clutch is DISENGAGED so the V–

belts (34) are slackened. Make sure service brake is DISENGAGED so the input shaft pulley can turn.

B. Open bellcrank cover (1) on the counter shaft housing to get access to the clutch. Remove V– belts one at a time by sliding the belt off the idler pulley (39) first.

3. Remove clutch cable (Fig. 12). A. Remove shoulder bolt (13) and lock nut (37)

from the clutch cable eyelet (49) and lever (9). B. Loosen lower jam nut holding the clutch cable to

the clutch bracket. Remove clutch cable from the clutch bracket and clear of engine (Fig. 13).

4. Remove throttle cable from engine. A. Loosen screw on governor lever enough to slide

the throttle cable out of the nut (Fig. 14). B. Remove cap screw (23), flat washers (7), and

lock nut (26) from the engine base (49) and throttle cable bracket (24). Pull throttle cable (47) and bracket clear of the engine (Fig. 12).

5. Remove engine from the engine base.

Figure 13

1. Lower jam nut 2. Clutch bracket

SLOW

Figure 14

1. Screw

2. Governor lever

3. Throttle cable

4. Nut

5. Washer head screw

Engine

A. Scribe a mark on the engine base at the bottom of the engine for reassembly purposes (Fig. 15).

B. Disconnect both black\white wires on the clutch switch (16) from both brown wires.

C. Remove remaining cap screws (23), flat washers (7), and lock nuts (26) from the engine base (49). Remove the engine from the cutting unit.

SCRIBE MARK

6. The bellcrank assembly can be removed from the

engine with minimum disassembly (Fig. 12).

A. Remove cap screw (36), lock washer (33), and washer (35) from the engine shaft. Remove pulley

1. Engine block 2. Engine base

Figure 15

(11), key, and spacer (12) from the engine shaft.

C. Remove complete bellcrank assembly from the

B. Remove five cap screws (20) and lock washers

engine.

(33) securing the belt shield (29) and clutch bracket (17) to the engine block.

Greensmaster 1000/1600 Page 3 – 11 Engine

Reinstalling the Engine

1. Make sure machine is parked on a level surface. The machine may be placed on a large work bench to make engine installation and adjustment easier. Remove high tension lead from the spark plug.

2. Make sure that all parts removed from the engine during maintenance or rebuilding are properly reinstalled to the engine.

3. Make sure bellcrank cover (1) is open on the counter shaft housing to get access to the clutch (Fig. 12).

4. If the bellcrank assembly was removed from the engine (21), reassembly as follows (Fig. 12):

A. Position clutch bracket (17) to the engine with the long arm of the clutch torsion spring (28) under the engine.

B. Position belt shield (29) to the engine. Secure belt shield and clutch bracket to the engine with five cap screws (20) and lock washers (33).

C. Hook short end of clutch torsion spring around the post on the clutch bracket.

D. Place engine shaft spacer (12) on the engine shaft and reinstall key. Apply never seize to the shaft.

E. Place input drive pulley (11) on the engine shaft with the counter bore out. Secure pulley to the shaft with cap screw (36), lock washer (33), and washer (35).

5. Reinstall engine (21) to engine base (50) (Fig. 12). A. Position engine on the engine base with the in-

put drive pulley towards the differential housing. B. Install four cap screws (23) and flat washers (7)

through the engine and engine base. Install throttle cable bracket (24) under the left front cap screw. Put flat washer and lock nut (26) on each cap screw and hand tighten.

C. Use scribe mark on engine block to align engine. The distance between engine out put shaft center and and power shaft center should be from 5.11 to

5.23 inches (130 to 133 mm). Inside pulley faces should be flush to each other to within 0.030 inch (0.762 mm) maximum (Fig. 16).

D. Tighten cap screws ensuring the engine alignment does not change.

INSIDE FACE

Figure 16

1. Input drive pulley 2. Input shaft pulley

6. Reconnect and adjust throttle cable (Fig. 14). A. Make sure screw on governor level is loose

enough to slide the throttle cable into of the nut. B. Loosen washer head screw enough to allow the

throttle cable to slide through small clamp C. Position throttle control lever to the SLOW posi-

tion and governor lever all the way up to the slow position.

D. Tighten screw on throttle lever and washer head screw to the small clamp securing the throttle cable.

7. Reinstall clutch cable. A. Reinstall clutch cable into notch of clutch bracket

and clear of engine. Tighten lower jam nut holding clutch cable to clutch bracket (Fig. 13).

B. Place shoulder bolt (13) through the clutch cable eyelet (49) and lever (9). Secure shoulder bolt with lock nut (37) (Fig. 12).

8. Reinstall pulley V–belts (Fig. 12). A. Make sure clutch is DISENGAGED. Make sure

service brake is DISENGAGED so the input shaft pulley can turn.

B. Install V–belts (34) one at a time by placing a belt into the inner groove of the input drive pulley (11) first. Place the second belt into the outer groove of the input drive pulley and then the outer groove of the input shaft pulley . Place the loose end of the first belt into the inner groove of the input drive pulley.

E. Reconnect both black\white wires on the clutch switch (16) to both brown wires.

Engine

Page 3 – 12

Greensmaster 1000/1600

Lubrication

Both fittings on the bellcrank assembly should be greased at least every 25 hours. Lubricate using No. 2 multipurpose lithium base grease. A hand operated grease gun is recommended for best results.

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Wipe each grease fitting with a clean rag.

IMPORTANT: Do not apply too much pressure or grease seals will become permanently damaged.

3. The grease fitting locations are the clutch lever pivot and the clutch spring end of the clutch bracket.

4. Wipe off excess grease.

Figure 17

Engine

Greensmaster 1000/1600 Page 3 – 13 Engine

Engine

Page 3 – 14

Greensmaster 1000/1600

Traction and Reel Drive Systems

Table of Contents

Chapter 4

SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drum Bushing Tool Kit 3. . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENTS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential Belt Adjustment 4. . . . . . . . . . . . . . . . . . .

Drum Drive Belt Adjustment 5. . . . . . . . . . . . . . . . . .

Reel Drive Belt Adjustment 6. . . . . . . . . . . . . . . . . . .

Service/Park Brake Adjustment 7. . . . . . . . . . . . . . .

SERVICE AND REPAIRS 8. . . . . . . . . . . . . . . . . . . . . .

Reel Drive Assembly 8. . . . . . . . . . . . . . . . . . . . . . . .

Reel Drive Belt Replacement 9. . . . . . . . . . . . . . . . .

Reel Drive Idler Pulley and Bearing 9. . . . . . . . . . . .

Clutch Bearing 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drum Drive Assembly 12. . . . . . . . . . . . . . . . . . . . . .

Drum Drive Belt Replacement 13. . . . . . . . . . . . . . .

Drum Drive Idler Pulley and Bearing 13. . . . . . . . . .

Differential Axle Pulley and Bearing 14. . . . . . . . . .

Drum Shaft Bearing 15. . . . . . . . . . . . . . . . . . . . . . . .

Drum Assembly with Bearings 16. . . . . . . . . . . . . . .

Drum Assembly with Bushings 18. . . . . . . . . . . . . . .

Counter Shaft Assembly 20. . . . . . . . . . . . . . . . . . . .

Brake Band Replacement 21. . . . . . . . . . . . . . . . . . .

Power Shaft Bearing 22. . . . . . . . . . . . . . . . . . . . . . .

Differential Axle Bearing

(Countershaft Housing) 23. . . . . . . . . . . . . . . . . . . . .

Differential Idler and Bearing 24. . . . . . . . . . . . . . . .

Differential Assembly and Pulley 25. . . . . . . . . . . . .

Differential Belt Replacement – Models 04051,

04052, and 04060 29. . . . . . . . . . . . . . . . . . . . . . .

Differential Belt Replacement – Model 04050 30. .

Lubrication 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive System

Traction and Reel

Greensmaster 1000/1600 Traction and Reel Drive SystemsPage 4 – 1

Specifications

Item Description

Traction Drive Engine to countershaft drive has two ”A” section V–belts.

Differential Peerless series 100

Brake Band drum

Traction Drum Dual cast aluminum, 7.5 inch (19.1 cm) diameter

Reel Clutch Jaw type

Countershaft to differential drive has 5 mm pitch timing belt.

Differential to drum drive has a 8 mm pitch timing belt.

Greensmaster 1000/1600Traction and Reel Drive Systems Page 4 – 2

Special Tools

Order special tools from the

TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS)

Drum Bushing Tool Kit – TOR4060

Note: This kit is used on mowers with drums that have

bushings instead of bearings. The kit is used for models 04051 and 04052 – 50101 to 59999 only.

This kit contains all the tools required to install and properly size the drum bushings to factory standards. These tools come as a set in a plastic tool case, or they may be ordered individually .

Some tools may have been supplied with your mower or available as TORO parts. Some tools may also be available from a local supplier.

REAMER TOR4061

PILOT

TOR4062–2

ADAPTER SLEEVE

TOR4062–3

BUSHING DRIVER

TOR4062–1

Figure 1

Drive System

Traction and Reel

Greensmaster 1000/1600 Traction and Reel Drive SystemsPage 4 – 3

Adjustments

Differential Belt Adjustment

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Check tension by depressing belt at the mid span between pulleys with 5 to 6 lbs (22 to 27 N) of force. The belt should deflect 1/4 inch. If deflection is incorrect, proceed to next step. If deflection is correct, continue operation.

3. To adjust belt tension: A. Remove capscrews securing the front and rear

box covers to countershaft housing. Slide covers away from the housing to expose the belt (Fig. 2).

B. Loosen idler pulley cap screw on the engine side of the housing (Fig. 3).

C. Pivot idler pulley clockwise against the backside of the belt until desired belt tension is attained. Do not over tension the belt (Fig. 2).

D. Tighten cap screw to lock adjustment (Fig. 3). E. Reinstall box covers by placing the covers in

position. While maintaining a slight gap between the cover seal and the side plate, install each cap screw until the threads engage in the insert. The gap will allow visual alignment of the cap screw to the threaded insert. After all cap screws are installed, tighten them until the stand offs inside the covers contact the side plate. Do not overtighten (Fig. 2).

Figure 2

1. Front box cover

2. Rear box cover

3. Countershaft housing

4. Idler pulley

5. Differential belt

Figure 3

1. Cap screw 2. Countershaft housing

Greensmaster 1000/1600Traction and Reel Drive Systems Page 4 – 4

Drum Drive Belt Adjustment

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Check tension by depressing belt at mid span between the pulleys with 4 to 5 lbs (18 to 22 N) of force. The belt should deflect 1/4 inch. If deflection is incorrect, proceed to next step. If deflection is correct, continue operation.

3. To adjust belt tension: A. Remove wheels if installed. B. Remove cap screws, lock washers, and belt cov-

ers from the side plates (Fig. 4). C. Loosen idler pulley capscrew (Fig. 5). D. Pivot the idler pulley clockwise against the back-

side of the belt until desired belt tension is attained. Do not over tension belt (Fig. 6).

E. Tighten cap screw to lock adjustment (Fig. 5).

Note: Make sure spacer is on the lower pulley before the belt cover is reinstalled.

F. Reinstall belt cover by placing the cover in position. While maintaining a slight gap between the cover seal and the side plate, install each cap screw until the threads engage in the insert. The gap will allow visual alignment of the cap screw to the threaded insert. After all capscrews are installed, tighten them until the stand offs inside the cover contact the side plate. Do not overtighten (Fig. 6).

Figure 4

1. Cap screw & lock washer 2. Belt cover

Drive System

Traction and Reel

Figure 5

1. Cap screw 2. Engine base

Greensmaster 1000/1600 Traction and Reel Drive SystemsPage 4 – 5

Figure 6

1. Drum drive belt 2. Idler pulley

Reel Drive Belt Adjustment

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Check tension by depressing the belt at mid span between pulleys with 4 to 5 lbs (18 to 22 N) of force. The belt should deflect 1/4 inch. If deflection is incorrect, proceed to next step. If deflection is correct, continue operation.

3. To adjust belt tension: A. Remove cap screws, lock washers, and belt cov-

ers to expose the belt (Fig. 7). B. Remove cap screws, flat washers, and nuts se-

curing the grass shield to the shield brackets. Move grass shield to access the cap screw securing the idler pulley (Fig. 8).

C. Loosen idler pulley cap screw (Fig. 8). D. Pivot the idler pulley clockwise against the back-

side of the belt until desired belt tension is attained. Do not over tension belt (Fig. 9).

E. Tighten cap screw to lock adjustment (Fig. 8).

Figure 7

1. Cap screw & lock washer 2.

F. Reinstall belt cover by placing the cover in position. While maintaining a slight gap between the cover seal and the side plate, install each cap screw until the threads engage in the insert. The gap will allow visual alignment of the cap screw to the threaded insert. After all cap screws are installed, tighten them until the stand offs inside the cover contact the side plate. Do not overtighten (Fig. 9).

G. Reinstall grass shield to shield brackets with cap screws, flat washers, and lock nuts (Fig. 8).

Figure 8

1. Cap screw, washer & nut

2. Grass shield

3. Shield bracket

4. Cap screw

5. Idler pulley

Figure 9

1. Reel drive belt 2. Idler pulley

Greensmaster 1000/1600Traction and Reel Drive Systems Page 4 – 6

Service/Park Brake Adjustment

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

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Move service/park brake lever to the OFF position. Note: Figure 10 is shown with the bellcrank cover re-

moved for illustrative purposes. It is not necessary to remove the cover.

3. Loosen retainer securing the bellcrank cover. Pivot cover open.

4. To increase cable tension, loosen front cable jam nut and tighten back cable jam nut until a force of 3 to 5 lbs (13 to 22 N) is required to engage brake. The force should be measured at brake lever knob. Do not over adjust, so brake band drags.

5. Close cover and secure retainer.

Figure 10

1. Brake cable 2. Front jam nut

Drive System

Traction and Reel

Greensmaster 1000/1600 Traction and Reel Drive SystemsPage 4 – 7

Service and Repairs

Reel Drive Assembly

56 57

4546

11 31

RIGHT

FRONT

1. Clutch housing

2. Cap screw

3. Lock nut

4. Ball bearing

5. Grease fitting

6. Oil seal

7. Wave washer

8. Retaining ring

9. Power shaft

10. Key (2)

11. Clutch jaw driver

12. Clutch and pulley assembly

13. Ball bearing

14. Retaining ring

15. Retaining ring

16. Lock washer

17. Jam nut

18. Felt seal

19. Actuator pin

20. Detent spring

Figure 11

21. Lock nut

22. Lock washer

23. Drive screw

24. Clutch lever

25. Spacer

26. Washer

27. Cap screw

28. Clutch boot

29. Knob

30. Groomer arm cover

31. Cover trim

32. Flat head screw

33. Nut

34. Bearing housing

35. Seal

36. Cover standoff

37. Self–aligning bearing

38. Retaining ring

39. Seal

40. Wave washer

41. Reel drive belt

42. Pulley and drive assembly

43. Idler pulley

44. Ball bearing

45. Snap ring

46. Flat washer

47. Lock washer

48. Cap screw

49. Reel drive cover

50. Front seal strip

51. Rear seal strip

52. Upper seal strip

53. Lower seal strip

54. Plug

55. Decal

56. Cap screw

57. Washer

58. Pulley support spacer

Greensmaster 1000/1600Traction and Reel Drive Systems Page 4 – 8

Reel Drive Belt Replacement

Removal

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Remove cap screws (56), washers (57) and reel drive cover (49) to expose reel drive belt (41) (Fig. 1 1).

3. Remove cap screws, flat washers, and nuts securing grass shield to shield brackets. Move grass shield to access the cap screw securing the idler pulley (Fig. 8).

4. Loosen cap screw (2) securing the pulley support spacer (58) (Fig. 11).

5. Pivot idler pulley counterclockwise away from the reel drive belt to loosen belt tension. Remove reel drive belt from the clutch pulley and drive pulley (Fig. 12).

Installation

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Place a new reel drive belt onto the clutch pulley and drive pulley (Fig. 12).

3. Adjust reel drive belt tension and reinstall reel drive cover (see Reel Drive Belt in the Adjustments section).

4. Reinstall grass shield to shield brackets with cap screws, flat washers, and lock nuts (Fig. 8).

Figure 12

1. Idler pulley

2. Reel drive belt

3. Clutch pulley

4. Drive pulley

Reel Drive Idler Pulley and Bearing

Removal

1. Remove reel drive belt from the reel drive assembly (see Reel Drive Belt Replacement Removal).

2. Remove cap screw (2) and lock washer (47) from the pulley support spacer (58). Remove idler pulley assembly from the clutch housing (Fig. 11).

Disassembly (Fig. 13) Note: The idler pulley assemblies for the reel drive

and drum drive assemblies are identical.

1. Remove cap screw, lock washer, and flat washer from the pulley support spacer. Pull spacer from the idler pulley .

2. Remove snap ring. Pull ball bearing from the idler pulley.

Assembly (Fig. 13)

1. Press new ball bearing into the idler pulley. Press pulley support spacer into the ball bearing and idler pulley.

2. Install snap ring into idler pulley . Secure flat washer, lock washer, and cap screw into the pulley support spacer. Greensmaster 1000/1600 Traction and Reel Drive SystemsPage 4 – 9

Installation

1. Make sure engine is OFF. Remove high tension lead from the spark plug. Park mower on a level surface.

1. Position cap screw (2) with lock washer (47) into the clutch housing (1). Start cap screw into pulley support spacer (58) of the idler assembly until lock washer just starts to compress. Do not over tighten (Fig. 11).

2. Reinstall reel drive belt to the reel drive assembly (see Reel Drive Belt Installation).

4 5

7 6

1. Cap screw

2. Lock washer

3. Flat washer

4. Pulley support spacer

Drive System

Traction and Reel

Figure 13

5. Idler pulley

6. Snap ring

7. Ball bearing

Clutch Bearing

Removal

1. Remove reel drive belt from the reel drive assembly

(see Reel Drive Belt Replacement Removal).

2. Remove clutch lever (24) as follows (Fig. 11): A. Remove cap screw (27), lock washer (22), belle-

ville washer (26), and spacer (25) from the clutch housing (1). Remove detent spring (20).

B. Work clutch boot (28) from the clutch housing. Pull clutch lever from the clutch housing.

C. Replace actuator pin (19) if necessary. Torque lock nut (21) from 45 to 60 in–lb (52 to 69 kg–cm).

3. Remove jam nut and lock washer from the power

shaft. Pull clutch and pulley assembly from the shaft. Slide clutch jaw driver off the power shaft being careful not to lose the keys (Fig. 14).

IMPORTANT: Make sure both keys are removed from the power shaft prior to removing the clutch housing (Fig. 14).

4. Remove both cap screws (2) and lock nuts (3) se-

curing the clutch housing (1) to the frame (Fig. 1 1). Slide clutch housing off the power shaft and away from the frame (Fig. 14).

Clutch Housing Disassembly (Fig. 11)

1. Remove retaining ring (8) from clutch housing (1).

Clutch and Pulley Assembly (Fig. 15)

1. Press new ball bearings into driver. Secure bearings with small retaining ring.

2. Place key into the keyway of the driver. Press driver through the pulley enough to expose retaining ring groove.

3. Secure large retaining ring to the driver.

RIGHT

OUTBOARD SHOULDER

FRONT

Figure 14

1. Jam nut

2. Lock washer

3. Power shaft

4. Clutch and pulley assy

5. Clutch jaw driver

6. Key

7. Clutch housing

8. Felt seal

2. Pull ball bearing (4) from the clutch housing (1). Re-

move wave washer (7); replace if damaged or worn.

3. Remove oil seal (6) from clutch housing (1).

Clutch Housing Assembly (Fig. 11)

1. Press new oil seal (6) into the clutch housing (1) on

the grease fitting (5) side. Flat side of seal must be out.

2. Place wave washer (7) into clutch housing (1). With

the seal side out, press new ball bearing (4) into the housing.

3. Install retaining ring (8) into the clutch housing (1).

Clutch and Pulley Disassembly (Fig. 15)

1. Remove large retaining ring securing the driver to

the pulley . Pull the driver out of the pulley. Remove key.

2. Remove small retaining ring from the driver. Pull ball

bearings from driver.

1. Large retaining ring

2. Driver

3. Pulley

Figure 15

4. Key

5. Small retaining ring

6. Ball bearing

Greensmaster 1000/1600Traction and Reel Drive Systems Page 4 – 10

Installation

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

C. With the actuator pin engaging in the groove of the clutch jaw driver (slide driver all the way into the housing), secure cap screw into the clutch housing (Fig. 14).

2. If the felt seal is damaged or worn, replace seal as follows (Fig. 14):

A. Completely remove seal and adhesive from the out board shoulder of the clutch housing.

B. Apply 3M adhesive EC–1099 or equivalent to the outboard shoulder of the housing. Attach seal to housing.

C. Fill clutch housing about half full with No. 2 multipurpose lithium base grease.

3. Slide clutch housing (1) onto the power shaft (9) with oil seal (6) towards the shaft. Be careful not to damage

the seal (Fig. 11).

4. Place both cap screws (2) through the bearing housing (1) and frame. Secure cap screws with both lock nuts (3). Make sure clutch housing fits tightly

against the edge of the frame (Fig. 11).

5. Tap both keys into the keyways of the power shaft. Apply Never Seize to the area of the keys and bearing journal of the clutch jaw driver (Fig. 14).

10. Make sure clutch engages and disengages with noticeable detent and without binding. It may be necessary to rotate the clutch pulley assembly (12) to achieve engagement (Fig. 11).

11. Reinstall reel drive belt to the reel drive assembly and adjust belt (see Reel Drive Belt Replacement Installation).

SPRING SHOULD BE FLUSH TO HOUSING SHOULDER

6. Place clutch jaw driver on the shaft with the jaws facing out. Align slots in the clutch jaw driver with the keys and slide into position (Fig. 14).

7. Place clutch and pulley assembly on the power shaft with the jaws facing the clutch jaw driver. Secure assembly to the shaft with the lock washer and jam nut (Fig. 14).

8. Place end of clutch lever (24) with actuator pin (19) through the clutch housing (1). Seat clutch boot (28) in the hole of the housing (Fig. 11).

9. Install clutch lever to the clutch housing (Fig. 16). A. Place lock washer , belleville washer, and spacer

on the cap screw. Make sure concave side of

belleville washer faces the clutch lever when installed.

Note: On newer models, the detent spring is symmet-

rical. The spring can be installed in either direction.

B. Insert cap screw with the washers and spacer through the hole in the clutch lever. Place detent

spring on cap screw with the two small holes down and the hole closest to the edge away from the lever.

1. Lock washer

2. Belleville washer

3. Spacer

4. Cap screw

Figure 16

5. Clutch lever

6. Detent spring

7. Clutch boot

Drive System

Traction and Reel

Greensmaster 1000/1600 Traction and Reel Drive SystemsPage 4 – 11

Drum Drive Assembly

*33

LEFT

FRONT

1. Spacer

2. Backup washer

3. Pulley (LH) * Pulley (RH)

4. Housing (LH) * Housing (RH)

5. Cap screw

6. Lock nut

7. Grease fitting

8. Seal

9. Bearing

10. Spacer

11. Grease fitting

12. Belt

13. Pulley

FRAME

14. Nut

15. Washer

16. V–ring seal

17. Bearing cover

18. Cap screw

19. Lock washer

20. Flangette

21. Bearing

22. Flangette

23. Grease fitting

24. Bearing lock nut

25. Seal

26. Bearing

27. Bearing housing

28. Closure

Figure 17

29. Bearing clamp

30. Seal

31. Lock nut

32. Cap screw

33. Drum belt cover (LH) * Drum belt cover (RH)

34. Seal strip

35. Cap screw

36. Lock washer

37. Idler pulley

38. Ball bearing

39. Snap ring

40. Flat washer

41. Spacer

Note: All parts are identical on both sides of the mow-

er frame except as noted.

Greensmaster 1000/1600Traction and Reel Drive Systems Page 4 – 12

Drum Drive Belt Replacement

Removal

1. Park mower on a level surface. Make sure engine

is OFF. Remove high tension lead from the spark plug.

2. Remove wheels if attached (see Wheels in the Ser-

vice and Repairs section of Chapter 6 – Wheels and Accessories).

3. Remove cap screws (35), lock washers (36) and

drum belt cover (33) to expose the belt (12) (Fig. 17).

4. Loosen cap screw (18) securing the spacer (41)

(Fig. 17). Pivot the idler pulley away from the drive belt to loosen belt tension (Fig. 18).

5. Remove drum drive belt from both pulleys (Fig. 18).

Installation

1. Park mower on a level surface. Make sure engine

is OFF. Remove high tension lead from the spark plug.

2. Place a new drum drive belt onto both pulleys (Fig.

18).

3. Adjust drum drive belt tension and reinstall drum

belt cover (see Drum Drive Belt in the Adjustments section).

4. Replace both wheels if they were attached (see

Wheels in the Service and Repairs section of Chapter 6 – Wheels and Accessories).

Figure 18

1. Idler pulley 2. Drum drive belt

Drive System

Traction and Reel

Drum Drive Idler Pulley and Bearing

Removal

1. Remove drum drive belt from the drum drive assem-

bly (see Drum Drive Belt Replacement Removal).

2. Remove cap screw (18) and lock washer (19) from

the spacer (41). Remove idler pulley assembly from the clutch housing (Fig. 17).

Disassembly and Reassembly Note: The idler pulley assemblies for the drum drive

reel drive assemblies are identical.

Greensmaster 1000/1600 Traction and Reel Drive SystemsPage 4 – 13

1. See Reel Drive Idler Pulley and Bearing Disassembly and Reassembly.

Installation

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Position cap screw (18) with lock washer (19) into the housing (4). Start cap screw into spacer (41) of the idler assembly until the lock washer just starts to compress. Do not over tighten (Fig. 17).

3. Reinstall drum drive belt to the drum drive assembly and adjust belt tension (see Drum Drive Belt Installation).

Differential Axle Pulley and Bearing

Removal

1. Remove drum drive belt from the drum drive assembly (see Drum Drive Belt Replacement Removal).

2. Remove nut from the differential axle. Remove pulley and woodruff key from the axle (Fig. 19).

Note: On the housing (RH), the hose clamp must be loosened and the differential boot must be removed from the housing before the housing can be removed from the frame and differential axle (Fig. 20).

3. Remove cap screw and lock nut from the housing and frame. Slide housing off of the differential axle (Fig.

19).

Disassembly (Fig. 21)

1. Remove spacer from housing and seal by . Replace if worn or damaged.

2. Remove both seals from the housing. Discard both seals and replace with new ones.

3. Pull bearing from housing and discard.

Assembly (Fig. 21)

7. Slide pulley onto the differential axle while aligning pulley keyway with the woodruff key. Secure pulley to the axle with the nut.

8. Replace drum drive belt to the drum drive assembly and adjust belt tension (see Drum Drive Belt Replacement Installation).

INBOARD SIDE

Figure 19

1. Nut

2. Differential axle

3. Pulley

4. Woodruff key

5. Cap screw

6. Lock nut

7. Housing

8. Spacer

1. Press seal with the flat side out into the housing side opposite the grease fitting.

2. Press bearing into housing.

3. Press a second seal with the flat side out into the grease fitting side of the housing

Installation (Fig. 19)

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Slide housing over the differential axle with the grease fitting towards the inboard side of the mower.

3. Secure housing to the frame with both cap screws and lock nuts.

4. On the housing (RH), attach the differential boot to the housing. Secure the hose clamp to the boot and housing (Fig. 20).

5. Slide spacer onto differential axle. Press spacer into seal until it contacts the inner race of the bearing.

1. Hose clamp

2. Housing (RH)

Figure 20

3. Differential boot

6. T ap woodruf f key into the key way of the differential axle. Apply never seize the axle in the area of the keys.

1. Spacer

2. Seal

3. Housing

Figure 21

4. Bearing

5. Grease fitting

Greensmaster 1000/1600Traction and Reel Drive Systems Page 4 – 14

Drum Shaft Bearing

Removal

1. Remove drum drive belt from the drum drive assem-

bly (see Drum Drive Belt Replacement Removal). Note: The pulley (LH) has left hand threads, while the

pulley (RH) has right hand threads. Each pulley has an arrow stamped on it for the direction of tightening.

2. Remove pulley from drum shaft as follows (Fig. 22): A. Use a suitable wrench on the flats of the drum

shaft, between the drum and the frame, to lock the shaft.

B. Unscrew pulley from the drum shaft. C. Remove backup washer and spacer from the

drum shaft.

3. Remove bearing from drum shaft and frame as fol-

lows (Fig. 23):

A. Remove four cap screws and lock washers from the flangettes, closure, frame, and bearing clamp.

B. Pull closure and flangettes with the bearing from the frame and drum shaft.

C. Remove bearing from flangettes.

Installation

1. Park mower on a level surface. Make sure engine

is OFF. Remove high tension lead from the spark plug.

C. Use a suitable wrench on the flats of the drum shaft, between the drum and the frame, to lock the shaft. Screw pulley to the drum shaft.

4. Install drum drive belt to the drum drive assembly (see Drum Drive Belt Replacement Installation).

5. Level drum to the reel (see Level Drum to Reel in the Adjustments section of Chapter 7– Cutting Unit).

Figure 22

1. Drum shaft

2. Pulley

3. Backup washer

4. Spacer

BEARING COLLAR

Drive System

Traction and Reel

2. Install bearing to the drum shaft and frame as fol-

lows (Fig. 23):

A. Place bearing between flangettes with the collar on the bearing towards the flangette without the grease fitting.

B. Insert two cap screws with lock washers through the bottom holes of the flangettes. Place closure onto capscrews. Secure assembly to frame with bearing clamps.

C. Secure remaining cap screws with lock washers through the flangettes and to the bearing clamps.

3. Install pulley to the drum shaft as follows (Fig. 22): A. Apply loctite to the threads of the drum shaft. B. Slide spacer and backup washer onto drum

shaft.

Greensmaster 1000/1600 Traction and Reel Drive SystemsPage 4 – 15

1. Bearing

2. Frame

3. Cap screws

4. Lock washers

Figure 23

5. Flangette

6. Flangette (w\grease ftg)

7. Closure

8. Bearing clamp

Drum Assembly with Bearings (Models 04050, 04052–60000 & Up, and 04060)

11 12

10. Cap screw

11. Drum shaft (LH)

12. Drum shaft (RH)

13. Cap screw

1. Drum

2. Drum spindle

3. Spring lip seal

4. Bearing

5. Bearing spacer

Figure 24

6. Seal spacer

7. Lock nut

8. Drum hub

9. Lock washer

Removal

1. Remove both drum shaft bearings from both drum shafts (see Drum Shaft Bearing Removal).

2. Pivot mower back and remove drum assembly from the mower.

Disassembly

1. Remove four cap screws, lock washers, and drum shafts from each drum.

2. Remove cap screws and lock washers securing the drum spindle and drum hub to their respective drums. Remove spindle and hub assembly from both drums.

3. Remove lock nut and seal spacer from the drum spindle. Carefully slide drum spindle out of the drum hub bearings.

4. Remove both spring lip seals from the drum hub. Pull both bearings from the hub. Remove bearing spacer from the hub.

Assembly Note: The seal side of each bearing should face the

inside of the drum hub (Fig. 25).

1. Press bearing into the drum hub. Pack bearing with grease. Fill space outside of bearing with grease. Press spring lip seal into the hub with its flat side out (Fig. 25).

2. Insert seal spacer into drum hub. Press bearing into the hub and pack with grease. Fill space outside of the bearing with grease. Press second spring lip seal into the hub with its flat side out (Fig. 25).

SEAL SIDE OF BEARING

1 5

Figure 25

1. Bearing

2. Drum hub

3. Spring lip seal

4. Bearing spacer

5. Drum spindle

6. Seal spacer

7. Lock nut

Greensmaster 1000/1600Traction and Reel Drive Systems Page 4 – 16

Note: The lock nut turns hard on the spindle shaft

when tightened. Make sure all rotation has stopped when tightening. A good solid sound indicates the nut is tight.

5. Secure drum spindle to the drum with four cap screws and lock washers. Tighten screws using an alternating pattern. Repeat tightening sequence a second time.

3. Apply grease to the shaft of the drum spindle. Care-

fully slide drum spindle into drum hub bearings. Secure lock nut and seal spacer to the drum spindle (Fig. 25).

Note: The fit between the drum hub and drum is a close tolerance and can be easily jammed. The hub can be rotated when seated properly in the bore of the drum.

4. Secure drum hub to the drum with four cap screws

and lock washers. Tighten screws using an alternating pattern. Repeat tightening sequence a second time.

6. Secure drum shaft to each drum with four cap screws and lock washers. Make sure shafts are seated properly. Tighten screws using an alternating pattern.

Installation

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Pivot mower back and position drum assembly under the mower to accept drum shaft bearings. Pivot mower back down.

3. Replace both drum shaft bearings to both drum shafts (see Drum Shaft Bearing Installation).

Drive System

Traction and Reel

Greensmaster 1000/1600 Traction and Reel Drive SystemsPage 4 – 17

Drum Assembly with Bushings (Models 04051 and 04052–50001 to 59999)

OIL SEALS NOT SHOWN

Figure 26

1. Cap screw

2. Lock washer

3. Drum

4. Drum shaft extensions

Removal

1. Remove both drum shaft bearings from both drum shafts (see Drum Shaft Bearing Removal).

2. Pivot mower back and remove drum assembly from the mower.

Disassembly

1. Remove four cap screws and lock washers from each drum. Remove both drum shafts extensions from each drum (Fig. 26).

2. Pull both drums apart and remove drum shaft from the drum (Fig. 26).

5. Drum shaft

6. Bushing

BUSHING DRIVER

Figure 27

OUTER SIDE INNER SIDE

3. Remove bushings from the drum (Fig. 27). A. Insert bushing driver against the bushing. B. Drive bushing out of the drum by striking the end

of the bushing driver with a hammer. C. Repeat Step B to remove the bushing and seal

from the other end of the drum

4. Install outer bushing into the drum (Fig. 28 and 29). A. Install adapter sleeve onto the bushing driver so

the counterbore of the sleeve is facing the bushing. B. Install a new bushing on the bushing driver , then

secure pilot to the bushing and adapter sleeve. C. Insert pilot into the bushing bore of the drum.

Install bushing until the adapter sleeve meets the drum.

BUSHING

DRIVER

ADAPTER

SLEEVE

OIL SEAL

Figure 28

BUSHING

PILOT

Figure 29

Greensmaster 1000/1600Traction and Reel Drive Systems Page 4 – 18

5. Install inner bushing into drum (Fig. 30). Note: The setting of the adapter sleeve is critical so

the bushing is inserted deep enough for oil seal installation.

A. Install adapter sleeve on the bushing driver so the counterbore of the sleeve seats 3/16 inch (0.48 cm) beyond the step on the driver.

B. Install a new bushing on the bushing driver , then secure pilot to the bushing and adapter sleeve.

C. Insert pilot into the bushing bore of the drum. Install bushing until the adapter sleeve meets the drum.

BUSHING

DRIVER

ADAPTER

SLEEVE

BUSHING

PILOT

Figure 30

6. Size bushing with reamer (Fig. 31). Note: Size only one bushing at a time.

A. Attach reamer to a T–handle. B. Size bushing with reamer being careful to keep

the reamer square with the drum race. C. Clean inside bushing so it is free of debris.

7. Install oil seal into drum (Fig. 32 and 28). A. Install adapter sleeve on the bushing driver so

the counterbore on the sleeve will be facing the oil seal.

B. Place an oil seal on the bushing driver. Install oil seal with the driver until the adapter sleeve contacts the drum.

Installation

1. Park mower on a level surface. Make sure engine

is OFF. Remove high tension lead from the spark plug.

2. Pivot mower back and position drum assembly un-

der the mower to accept drum shaft bearings. Pivot mower back down.

REAMER

RACE

Figure 31

BUSHING

DRIVER

Drive System

Traction and Reel

ADAPTER

SLEEVE

Figure 32

3. Reinstall both drum shaft bearings to both drum

shafts (see Drum Shaft Bearing Installation).

Greensmaster 1000/1600 Traction and Reel Drive SystemsPage 4 – 19

Counter Shaft Assembly

RIGHT

FRONT

40 55

2 3

2 3 4

1. Countershaft housing

2. Cap screw

3. Lock washer

4. Flat washer

5. Screw plate

6. Flangette

7. Grease fitting

8. Flangette

9. Bearing

10. Locking collar

11. Set screw

12. Lock washer

13. Jam nut

14. Shoulder bolt

15. Lock nut

16. Input shaft pulley

17. Lock nut

18. Key

19. Brake lever

20. Clevis pin

Figure 33

21. Brake support

22. Lock washer

23. Cotter pin

24. Cotter pin

25. Brake band

26. Short spacer

27. Bearing housing

28. Grease fitting

29. Seal

30. Bearing

31. Long Spacer

32. Countershaft pulley

33. Key

34. Countershaft seal

35. Belt

36. Cap screw

37. Front box cover

38. Rear box cover

39. Cap screw

40. Lock washer

41. Hose clamp

42. Hose clamp

43. Differential boot

44. Idler pulley

45. Ball bearing

46. Flat washer

47. Cap screw

48. Retaining ring

49. Cover seal strip

50. Cover seal strip

51. Cover seal strip

52. Cover bracket

53. Cap screw

54. Spacer

55. Flat washer

56. Clip

57. Power shaft

58. Differential assembly & pulley

Greensmaster 1000/1600Traction and Reel Drive Systems Page 4 – 20

Brake Band Replacement

Removal

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Remove interference to brake band (Fig. 34). A. Remove bellcrank cover by removing both cap

screws and lock washers. B. Remove belt shield by removing both cap

screws and lock washers. C. Disengage clutch and remove both V–belts.

3. Disengage brake to allow removal of brake band.

4. Remove lock nut (17) from power shaft (57). Slide

input shaft pulley (16) off the shaft. Remove key (18) from the shaft (Fig. 33).

5. Remove brake band (25) from counter shaft hous-

ing (1) as follows (Fig. 33).

A. Remove cotter pin (23) from the brake support (21).

6. Reinstall interference previously removed (Fig. 34). A. Make sure clutch is disengaged. Install both V–

belts. B. Secure belt shield to engine block with both cap

screws and lock washers. Do not over tighten. C. Secure bellcrank cover to counter shaft housing

with both cap screws and lock washers. Do not

over tighten.

B. Remove cotter pin (24) and clevis pin (20) from the brake lever (19).

C. Remove the brake band from the brake support and brake lever.

Installation

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Disengage brake to allow installation of brake band.

3. Attach new brake band to the counter shaft housing as follows (Fig. 35).

Note: Make sure both cotter pins are locked so there is no contact between the input shaft pulley and cotter pins.

A. Secure lower eye of brake band to the brake lever with the clevis pin and cotter pin. Lock cotter pin.

B. Secure upper eye of the brake band to the brake support with cotter pin. Lock cotter pin.

1. Bell crank cover

2. V–belts

Figure 35

1. Brake band

2. Counter shaft housing

3. Cotter pin

4. Input shaft pulley

5. Brake lever

Figure 34

3. Cap screw

4. Belt shield

6. Clevis pin

7. Brake support

8. Power shaft

9. Lock nut

Drive System

Traction and Reel

4. Apply never seize to the keyway area of the power shaft (57). Install key (18) to the shaft (Fig. 33).

5. Slide input shaft pulley (16) onto the power shaft (57) and through the brake band (25). Secure pulley to the power shaft with lock nut (17) (Fig. 33 and 35).

Greensmaster 1000/1600 Traction and Reel Drive SystemsPage 4 – 21

Power Shaft Bearing

Removal

1. Remove brake band from the counter shaft housing (see Brake Band Removal)

2. Remove cap screw (39) and lock washer (40) from the front box cover (37) and counter shaft housing (1). Remove cover from housing (Fig. 33).

3. Loosen cap screw (36) enough to rotate idler pulley (44) away from the belt (35). Loosen belt by rotating the idler pulley counterclockwise (Fig. 33).

4. Remove three cap screws (36) and lock washers (12) from the counter shaft housing (1) and bearing housing (27). Slide the bearing housing off the power shaft (57) (Fig. 33).

Disassembly (Fig. 36)

1. Pull short spacer from the inner seal and bearing housing.

2. Pull outer seal, bearing, and inner seal from the bearing housing.

1. Short spacer

2. Inner seal

3. Bearing housing

Figure 36

4. Outer seal

5. Bearing

6. Grease fitting

Assembly (Fig. 36)

1. Press new seal with its flat side up through the flange side of the bearing housing.

2. Press new bearing into the flange side of the bearing housing.

3. Press second new seal with its flat side up through the flange side of the bearing housing.

4. Push short spacer through inner seal until it contacts the inner race of the bearing.

Installation

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Slide the bearing housing onto the power shaft (57).

3. Secure three cap screws (36) and lock washers (12) through the counter shaft housing (1) and into the bearing housing (27) (Fig. 33).

4. Adjust idler pulley and differential belt tension. Reinstall front box cover (see Differential Belt in the Adjustments section).

5. Reinstall brake band to the counter shaft housing (see Brake Band Replacement Installation).

Greensmaster 1000/1600Traction and Reel Drive Systems Page 4 – 22

Differential Axle Bearing (Countershaft Housing)

Removal

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Lower handle to allow a clearance for the removal of the bearing and flangettes from the differential axle (see Handle in the Adjustments section of Chapter 6 – Wheels and Accessories).

Note: The locking collar securing the left differential

axle to the countershaft housing is a eccentric flange type.

3. Loosen the set screw on the locking collar. Unlock collar by striking it with a punch in the clockwise direction (Fig. 38).

4. Remove bearing housing on the side plate for the left differential axle (see Differential Axle Pulley and Bearing Removal).

5. Slide locking collar off the differential axle.

6. Remove jam nuts (13), lock washers (12), and cable clip (15) from the studs of screw plate (5) (Fig. 33).

IMPORTANT: Before removing the flangettes and bearing from the differential housing, support the axle in its original position to prevent possible damage to the remaining differential axle bearing.

7. Slide flangettes (6 and 8) and bearing (9) of the differential axle (Fig. 33).

Installation

Figure 37

1. Locking collar

2. Differential axle (LH)

3. Jam nut & lock washer

4. Flangettes

5. Cap screw

6. Lock washer

CLOCKWISE

Figure 38

1. Differential axle (LH) 2. Locking collar

Drive System

Traction and Reel

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Stack flangette (8), bearing (9), and flangette (6) together. Make sure lock collar on the bearing is positioned towards the flangette with the grease fitting (7) (Fig. 33).

Note: Before tightening jam nuts (13), make sure that the differential axles turn freely and are aligned (Fig. 33).

3. Slide flangettes (6 and 8) and bearing (9) over the differential axle. Secure assembly and cable clip (15) to the studs of screw plate (5) with the jam nuts (13) and lock washers (12) (Fig. 33).

4. Slide collar onto the differential axle. Lock collar by striking it with a punch in the counterclockwise direction. Tighten set screw on the locking collar (Fig. 38).

5. Reinstall bearing housing for the left differential axle (see Differential Axle Pulley and Bearing).

Greensmaster 1000/1600 Traction and Reel Drive SystemsPage 4 – 23

Differential Idler and Bearing

Removal

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Remove capscrews (39) and lock washers (40) securing rear and front box covers (38 and 39) to the countershaft housing (1). Pull covers from housing (Fig. 33).

3. Remove cap screw and lock washer that secure the idler pulley (Fig. 37). Remove idler pulley from countershaft housing (Fig. 39).

Disassembly (Fig 33)

1. Remove cap screw (47), lock washer (12), and flat washer (46) from the spacer (54). Remove retaining ring (48) from the pulley (44).

2. Press spacer (54) out of the pulley (44). Press bearings (45) out of the pulley.

Assembly (Fig 33)

1. Press bearings (45) into the pulley (44). Press spacer (54) into the pulley.

2. Install retaining ring (48) into the pulley (44). Secure cap screw (47), lock washer (12), and flat washer (46) into the spacer (54).

Figure 39

1. Idler pulley 2. Countershaft housing

Installation

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Reinstall idler pulley to the countershaft housing (Fig. 39). Secure idler pulley with cap screw and lock washer. Tighten cap screw until washer just starts to compress. Spacer must be free to rotate (Fig. 37).

3. Adjust differential belt tension and reinstall front and rear box covers (see Differential Belt Adjustment).

Greensmaster 1000/1600Traction and Reel Drive Systems Page 4 – 24

Differential Assembly and Pulley

Removal

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Lower handle to allow clearances for the removal of the bearing and flangettes from the differential axle and the differential assembly from the countershaft housing (see Handle in the Adjustments section of Chapter 6 – Wheels and Accessories).

3. Remove capscrews (39) and lock washers (40) securing rear and front box covers (38 and 39) to the countershaft housing (1). Pull covers from housing (Fig. 33).

4. Loosen cap screw securing the idler to the counter shaft housing (Fig. 37). Pivot idler pulley counterclockwise away from the backside of belt to release belt tension (Fig. 39).

Note: The locking collar securing the left differential axle to the countershaft housing is a eccentric flange type.

5. Loosen the set screw on the locking collar. Unlock collar by striking it with a punch in the clockwise direction (Fig. 38).

Figure 40

1. Cap screw & lock washer

2. Differential axle

3. Jam nut & lock washer

4. Flangettes

5. Locking collar

6. Screw plate stud

6. Remove bearing housing for the left differential axle (see Differential Axle Pulley and Bearing Removal).

IMPORTANT: For the remainder of this procedure, support the axle in its original position to prevent possible damage to the differential axle bearing and differential housing bearing.

7. Remove bearing housing for the right differential axle (see Differential Axle Pulley and Bearing Removal).

8. Remove differential boot (43) and rear box cover (38) from the countershaft housing (1) and differential axle (Fig. 33).

9. Remove jam nuts, lock washers, and cable clip from the studs of screw plate. Slide locking collar and flangettes with the bearing off the differential axle. This step allows the differential assembly to be positioned for clearing the frame (Fig. 40).

10. Pull differential assembly out and up from the countershaft housing.

11. Remove lock nuts and flat washers from the differential assembly and pulley . Slide pulley clear of threads and differential axle (Fig. 42).

Figure 41

1. Idler pulley 2. Countershaft housing

Figure 42

1. Lock nut

2. Flat washer

3. Differential assembly

4. Differential pulley

Drive System

Traction and Reel

Greensmaster 1000/1600 Traction and Reel Drive SystemsPage 4 – 25

BEARING RECESS (INBOARD)

0.125 TO 0.140 inch (3.18 to 3.56 mm)

INSET FOR DRIVE PIN

BEARING RECESS (OUTBOARD)

0.150 to 0.170 inch (3.81 to 4.32 mm)

Figure 43

1. Flanged hex head screw

2. Differential carrier housing

3. Differential carrier housing

4. Axle (long)

5. Axle (short)

6. Bevel gear

7. Pinion

8. Drive pin

9. Thrust washer

Note: Individual parts to the dif ferential assembly can

be obtained from your local Peerless Dealer/Distributor.

Disassembly (Fig. 43)

1. Clean outside of the differential assembly. Make sure keys are removed from the axles. Remove all burrs from the keyways and holes of the axles.

2. Remove four flanged hex head screws from the differential carrier housings. Separate both housings being careful not to drop the drive pin and pinion gears.

3. Pull each differential carrier housing from its axle and remove washer.

SEAL RECESS

0.030 TO 0.045 inch (0.76 to 1.14 mm)

10. Washer

11. Retaining ring

12. Needle bearing

13. Oil seal

6. Remove both thrust washers and bevel gears from the drive pin.

7. Clean all parts so they are free of dirt and debris. Replace any worn, chipped, bent, or cracked parts.

Assembly (Fig. 43)

1. If needle bearings are being replaced, press both new bearings and new oil seal into each differential carrier housing as follows:

A. Press bearing into the inboard side of the of each housing. The bearing should be recessed 0.125 to

0.140 inch (3.18 to 3.56 mm).

4. Remove both retaining rings from each axle. Separate the bevel gears from each axle.

Note: The differential carrier housings come assembled with both bearings and oil seal. It may be more economical to replace the both housings rather than repair them. If the needle bearings are damaged, it is recommended to replace all bearings in each housing.

5. If needle bearings are damaged, press both bearings and oil seal out of each differential carrier housing.

B. Press bearing into the outboard side of the of each housing. The bearing should be recessed

0.150 to 0.170 inch (3.81 to 4.32 mm). C. Press oil seal into the outboard side of the of

each housing. The oil seal should be recessed

0.030 to 0.045 inch (0.76 to 1.14 mm). D. Pack all bearings with molybdenum disulfide

grease.

Greensmaster 1000/1600Traction and Reel Drive Systems Page 4 – 26

Note: If any of the bevel or pinion gears need to be replaced, it is recommended to replace all four gears as a complete set.

2. Slide pulley onto differential axle so threads extend through pulley . Secure lock nuts and flat washers to the differential assembly and pulley. (Fig. 42).

2. Attach bevel gears to the axles. Lock each gear in place with both retaining rings. Make sure flat side of retaining rings are away from the gear (Fig. 44).

3. Coat both washers with molybdenum disulfide grease. Slide each washer onto an axle (Fig. 44).

4. Slide the long axle through the needle bearings of the differential carrier housing with the four threaded holes. Thoroughly coat the bevel gear with molybdenum disulfide grease. Make sure the gear back is flush against the washer and housing inside face (Fig. 44).

5. Slide the short axle through the needle bearings of the other differential carrier housing. Thoroughly coat the bevel gear with molybdenum disulfide grease. Make sure the gear back is flush against the washer and housing inside face (Fig. 44).

6. Slide both pinion gears to the drive pin. Attach both thrust washers to the drive pin. Make sure both ends of the drive pin are exposed. Thoroughly coat the pinion gears and drive shaft with molybdenum disulfide grease (Fig. 44).

7. Place pinion gear and drive shaft assembly into a differential carrier housing. Position exposed ends of the drive pin into the rounded insets of the housing. Make sure the teeth of the bevel and pinion gears mesh (Fig. 45).

8. Secure both differential carrier housings together as follows (Fig. 45):

3. Place differential assembly into the countershaft housing with the long axle first.

IMPORTANT: For the remainder of this procedure, support the axle so it is parallel to the drum. Possible damage to the bearings should be prevented.

4. Slide flangettes and bearing onto the long differential axle. Secure jam nuts, lock washers, and cable clip to the studs of screw plate (Fig. 40).

Figure 44

1. Bevel gear

2. Axle

3. Retaining ring

4. Washer

5. Carrier housing

6. Pinion gear

7. Drive pin

8. Thrust washer

Drive System

Traction and Reel

A. Position the open ends of each housing together so the teeth of both bevel gears mess with the teeth of both pinion gears.

B. While holding the housings together, twist the housings so the four holes on each housing are aligned to accept the the flanged hex head screws.

C. Insert screws. While tightening screws, make sure that all the gears stay messed together. Do not

over tighten screws.

D. Hold housing and turn one of the axles. The other axle should turn in the opposite direction without any binding.

Installation

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

Greensmaster 1000/1600 Traction and Reel Drive SystemsPage 4 – 27

ROUNDED INSET

1. Pinion gear

2. Drive shaft

3. Carrier housing

Figure 45

4. Bevel gear

5. Axle

5. Slide locking collar onto the differential axle (Fig.

38).

IMPORTANT: Align axles so they turn freely before striking the locking collar.

6. Reinstall rear box cover (38) and differential boot (43) to the differential axle and countershaft housing (1) (Fig. 33).

7. Reinstall bearing housing for the right differential axle (see Differential Axle Pulley and Bearing Installation).

8. Reinstall bearing housing for the left differential axle (see Differential Axle Pulley and Bearing Installation).

9. Lock locking collar by striking it with a punch in the counterclockwise direction. Tighten set screw on the locking collar (Fig. 38).

10. Reinstall idler pulley to the countershaft housing (Fig. 40). Secure idler pulley with cap screw and lock washer. Tighten cap screw until washer just starts to compress. Spacer must be free to rotate (Fig. 41).

1 1. Adjust differential belt tension and reinstall front and rear box covers (see Differential Belt in the Adjustments section).

Greensmaster 1000/1600Traction and Reel Drive Systems Page 4 – 28

Differential Belt Replacement – Models 04051, 04052, and 04060

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Remove capscrews and lock washers securing the drum belt and reel drive covers to the right side plate. Remove belt covers.

3. Loosen cap screws securing drum and reel drive idler pulleys and spacers to the right side plate (Fig. 46 and 47). Rotate each idler pulley counterclockwise away from the backside of each belt to release belt tension. Remove both belts(Fig.48).

4. Remove capscrews and lock washers securing the front and rear box covers to the counter shaft housing. Slide covers away from the housing to expose the belt (Fig. 48).

1. Cap screw

2. Idler pulley (Drum drive)

Figure 46

3. Lock nut

4. Cap screw

5. Loosen cap screw on the engine side of the countershaft housing that secures the idler pulley and spacer. Rotate idler pulley counterclockwise away from the backside of the belt to release belt tension. Cut belt and remove belt from the countershaft housing (Fig.48).

6. Remove both cap screws and locknuts securing the right rear bearing housing to side plate. Rotate housing 180 so the bottom of the housing points upward (Fig. 46 and 48).

7. Remove both cap screws and lock nuts securing the clutch housing to the side plate. Rotate housing 180 so the bottom of the housing points upward (Fig. 47 and

48).

8. Slide new belt over rotated housings and both box covers onto the differential and countershaft pulleys. Make sure idler pulley is positioned against the backside of the belt.

9. Rotate clutch and right rear bearing housings back into the upright position. Secure both housings to the sideplate with previously removed cap screws and lock nuts (Fig.48).

Figure 47

1. Cap screw

2. Idler pulley (Reel drive)

3. Spacer

4. Lock nut

5. Cap screw

Drive System

Traction and Reel

10. Adjust differential belt tension and reinstall rear and front box covers (see Differential Belt Adjustment).

11. Adjust belt tension on traction drive and reel drive belts and reinstall covers (see Drum Drive and Reel Drive Belt Adjustments).

Greensmaster 1000/1600 Traction and Reel Drive SystemsPage 4 – 29

Figure 48

1. Idler pulley (Drum drive)

2. Idler pulley (Reel drive)

3. Belt (Reel Drive)

4. Belt (Drum drive)

5. Front box cover

6. Rear box cover

7. Countershaft housing

8. Idler pulley (Differential)

9. Belt

10. Bearing housing

11. Clutch housing

Differential Belt Replacement – Model 04050 Only

Removal

1. Place mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. If the wheels are attached, place the mower on its kickstand and remove them.

2. Remove both drum drive covers using a 7/16–inch socket to remove the four cap screws and lock washers from each cover (Fig. 49).

3. From the mower rear, precede as follows (Fig. 50): A. Remove two cap screws and lock washers se-

curing the engine base to the back of the frame. B. Leave front two cap screws securing the engine

base to the frame in place. This will keep the engine in place.

C. Remove four capscrews, lock washers, and flat washers securing the countershaft housing to the frame.

4. Remove idler pulley from the bellcrank assembly.

Remove remaining two cap screws and lock washers securing engine base to the frame. Remove both V– belts (Fig. 51).

1. Engine base

2. Frame

Figure 50

3. Countershaft housing

4. Box cover

CAUTION

When lifting the engine from the frame, have at least two (2) people lift the engine to prevent personal injury.

5. Remove cable clips from the cables, wires, and han-

dle assembly. Removal of the wires and cables is not necessary . Lift the engine with the engine base from the frame and set them behind the mower (Fig. 52)

Figure 51

1. Idler pulley

2. Bellcrank assembly

3. Cap screw & lock washer

4. V–belt

Figure 52

5. Cap screw

6. Lock nut

7. Washer

Figure 49

Greensmaster 1000/1600Traction and Reel Drive Systems Page 4 – 30

6. Use 9/16–inch open end wrench to hold the power shaft while backing off the lock nut with a 7/8–inch socket (Fig. 53).

7. Remove nut from the short axle of the differential as follows (Fig. 54):

A. Loosen small hose clamp securing the differential boot to the bearing housing.

B. Use drift punch in the hole of the short axle while removing the nut with a 7/8–inch socket.

8. Remove belts from both drum drive assemblies as follows (Fig. 55):

A. Loosen the lower carriage bolts and lock nuts securing the idler brackets to the frame.

B. Remove upper carriage bolts and lock nuts securing the idler brackets to the frame.

C. Swing both idler pulleys forward. Remove belts.

9. Remove shaft input pulley from the power shaft. Remove key from shaft with drift punch (Fig. 56).

10. Slide pulley off the short axle on the right side of the countershaft housing. Remove key from the axle with a drift punch (Fig. 57).

Figure 55

1. Carriage bolt (Lower)

2. Carriage bolt hole (Upper)

3. Idler bracket

FORWARD

4. Idler pulley

5. Drum shaft pulley

6. Pulley

Figure 53

1. Power shaft 2. Shaft Input pulley

Figure 56

1. Power shaft 2. Key

Figure 57

1. Axle (Short)

2. Countershaft housing

3. Key

Drive System

Traction and Reel

Figure 54

1. Small hose clamp

2. Differential boot

3. Bearing housing

4. Pulley

Greensmaster 1000/1600 Traction and Reel Drive SystemsPage 4 – 31

Note: The locking collar securing the long axle to the

countershaft housing is a eccentric flange type.

11. Loosen the set screw on the locking collar. Unlock

collar by striking it with a punch in the clockwise direction (Fig. 58).

12. Remove three cap screws and lock washer secur-

ing the box cover to the countershaft housing. Pull cover from housing. Loosen both carriage bolts and lock nuts securing the idler pulley to the countershaft housing. Slide idler pulley away from the belt (Fig. 59).

13. Use a rubber hammer to carefully tap the counter-

shaft housing off the power shaft. Alternate the hammer between the long axle and the bearing housing end of the counter shaft housing to prevent damage to the bearings(Fig. 60).

14. Remove three socket head cap screws and lock

washers from the side plate (RH) and bearing housing (Fig. 61).

15. Slide differential assembly to the left to allow remov-

al of the belt without bending or twisting. Remove old belt from the differential pulley and countershaft pulley (Fig. 62).

1. Countershaft housing

2. Power shaft

Figure 60

3. Axle (Long)

4. Bearing housing

CLOCKWISE

Figure 58

1. Axle (Long) 2. Locking collar

Figure 61

1. Socket head cap screw

2. Side plate (LH shown)

3. Bearing housing

LEFT

Figure 62

1. Differential assembly 2. Belt

1. Lock nut (Idler pulley)

2. Countershaft housing

Figure 59

3. Differential boot

4. Box cover

Greensmaster 1000/1600Traction and Reel Drive Systems Page 4 – 32

Installation

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Install new belt to the differential pulley and countershaft pulley . Slide differential assembly to the right side plate (Fig. 62).

3. Secure three socket head cap screws and lock washers to the side plate (RH) and bearing housing (Fig.

61).

4. Use a rubber hammer to carefully tap the countershaft housing onto the power shaft. Alternate the hammer between the long axle and the bearing housing end of the counter shaft housing to prevent damage to the bearings (Fig. 60).

5. Secure countershaft housing to the frame with the four cap screws, lock washers, and flat washers (Fig.

50).

6. Install pulley to the short axle as follows (Fig. 57 and

54).

9. Reinstall belts to both drum drive assemblies as follows (Fig. 55):

A. Reinstall belt onto the drum shaft pulley and pulley on both sides of mower.

B. Swing idler pulley into belt. Reinstall upper carriage bolts and lock nuts to both sides of the frame. Do not tighten.

C. Keep lower carriage bolts and lock nuts on both sides of the frame loose.

CAUTION

When lifting the engine to the frame, have at least two (2) people lift the engine to prevent personal injury.

10. Lift engine with the engine base from behind the mower onto the frame. Reinstall cable clips to the cables, wires, and handle assembly (Fig. 52)

A. Apply anti–seize lubricant to the axle keyway area. Reinstall key to the axle. Slide pulley onto short axle on the right side of the countershaft housing.

B. Screw nut onto the short axle of the differential. Use drift punch in the hole of the short axle while torquing the nut from 30 to 40 ft–lb (4.1 to 5.5 kg–m).

C. Secure differential boot to the bearing housing with the small hose clamp.

7. Make sure drum belts will be properly aligned. A. Center both pulleys on the differential axles to

obtain an equal distance between the side plates and pulleys (Fig. 63).

B. Lock collar by striking it with a punch in the counterclockwise direction. Tighten set screw on the locking collar (Fig. 58).

8. Install shaft input pulley to the power shaft. A. Apply anti–seize lubricant to the power shaft

keyway area. Reinstall key to shaft keyway (Fig.

56).

Figure 63

1. Pulley 2. Side plate

Drive System

Traction and Reel

B. .Reinstall shaft input pulley to the power shaft. Screw lock nut onto shaft. Torque nut from 30 to 40 ft–lb (4.1 to 5.5 kg–m) while locking shaft with a 9/16–inch open end wrench (Fig. 64).

Greensmaster 1000/1600 Traction and Reel Drive SystemsPage 4 – 33

Figure 64

1. Shaft input pulley 2. Power shaft

11. Secure engine to the frame as follows: A. Reinstall both V–belts (Fig. 51). A. Position the engine base to obtain from 5.34 to

5.46 inches (13.6 to 13.9 cm) between the engine output shaft and power shaft center lines (Fig. 65).

B. Align machined face of input power and shaft input pulleys to within a maximum of 0.03 inch (0.76 mm) misalignment (Fig. 65).

C. Secure engine base to the front of the frame with two cap screws and lock washers (Fig. 51).

D. Secure engine base to the back of the frame with two cap screws and lock washers (Fig. 50).

E. Reinstall idler pulley to the bellcrank assembly (Fig. 51).

IMPORT ANT : Over tightening belts will overload the bearings and increase wear on the belt.

12. Adjust tensions of differential and both drum drive

belts from 20 to 25 lbs (89 to 1 11 N) of force. Use a scale to pull on the idler pulley while securing the idler brackets by tightening both carriage bolts and lock nuts (Fig.

66).

13. Secure box cover to the countershaft housing with

the three cap screws and lock washers (Fig. 50)

14. Reinstall both drum drive covers using a 7/16–inch

socket to tighten the four cap screws and lock washers to each cover (Fig. 49).

Figure 65

1. Power shaft

2. Input power pulley

3. Shaft input pulley

Figure 66

1. Idler pulley 2. Idler pulley bracket

15. Start the unit and run for a minimum of one minute.

Shut the engine off. The inside edge of the differential belt should not hang over either the idler pulley , countershaft pulley, or differential pulley (Fig. 67).

1. Differential pulley

2. Counter shaft pulley

Figure 67

3. Idler pulley

Greensmaster 1000/1600Traction and Reel Drive Systems Page 4 – 34

Lubrication

The mower should be greased at least after every 25 hours of operation. Lubricate grease fittings using No. 2 multipurpose lithium base grease. A hand operated grease gun is recommended for best results.

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Wipe each grease fitting with a clean rag.

IMPORTANT: Do not apply too much pressure or grease seals will become permanently damaged.

3. The grease fitting locations are as follows: A. Both bearing housings for the differential axles,

both flangettes for the drum shafts, and the flangette on the countershaft housing (Fig. 68).

B. The clutch housing and bearing housing for the power shaft (Fig. 69).

4. Wipe off excess grease.

Figure 68

Figure 69

Drive System

Traction and Reel

Greensmaster 1000/1600 Traction and Reel Drive SystemsPage 4 – 35

Greensmaster 1000/1600Traction and Reel Drive Systems Page 4 – 36

Table of Contents

Chapter 5

Electrical System

WIRING SCHEMATICS 2. . . . . . . . . . . . . . . . . . . . . . . .

Late Model Kawasaki FE120 Engines 2. . . . . . . . . .

Late Model Kawasaki FE120 Engines

with Operator Presence Control 3. . . . . . . . . . . . .

Early Model Kawasaki FE120 Engines 4. . . . . . . . .

Early Model Kawasaki FE120 Engines

With Operator Presence Control 5. . . . . . . . . . . . .

SPECIAL TOOLS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 7. . . . . . . . . . . . . . . . . . . . . . . . .

Engine Will Not Start 7. . . . . . . . . . . . . . . . . . . . . . . .

Engine Will Start , But Will Not Run 7. . . . . . . . . . . .

COMPONENT TESTING 8. . . . . . . . . . . . . . . . . . . . . . .

Interlock Module and Clutch (Interlock) Switch

No Operator Presence Control 8. . . . . . . . . . . . . .

With Operator Presence Control 9. . . . . . . . . . . . .

Ignition System Operation 10. . . . . . . . . . . . . . . . . . .

Igniter 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition Coil 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE AND REPAIRS 13. . . . . . . . . . . . . . . . . . . . .

Interlock Switch 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Presence Control Switch 14. . . . . . . . . . .

Spark Plug 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Greensmaster 1000/1600

Page 5 – 1

Electrical System

System

Electrical

Wiring Schematics

BLACK

HIGH TENSION LEAD

IGNITION COIL/

IGNITOR

BLACK

RED

CONNECTOR/

INTERLOCK MODULE

ABCDEF

ENGINE

MAGNETO

FLYWHEEL

Note: There are two types of ignition coils used on the Kawasaki FE120 engine. On older models, a coil is used in conjunction with an igniter. On newer models, a combination igniter/ignition coil is used which has the igniter built into the ignition coil.

BLACK

ON/OFF

BROWN

BLACK\WHITE

CLUTCH

SWITCH

GREEN

BROWN

BLACK\WHITE

RED

Electrical System

Late Model Kawasaki FE120 Engines

ON\OFF switch is open in the ON position CLUTCH SWITCH is closed when the clutch is DISENGAGED

Page 5 – 2

Greensmaster 1000/1600

BLACK

HIGH TENSION LEAD

IGNITION COIL/

IGNITOR

ENGINE

MAGNETO

BLACK

RED

BLACK

CONNECTOR/

INTERLOCK MODULE

ABCDEF

RED

BROWN

GREEN

BROWN

BLACK\WHITE

FLYWHEEL

Late Model Kawasaki FE120 Engines with Operator Presence Control

ON\OFF switch is open in the ON position CLUTCH SWITCH is closed when the clutch is DISENGAGED

OPERATOR PRESENCE SWITCH is closed when the bail is held

ON/OFF

BROWN

BLACK\WHITE

OPERATOR

PRESENCE SWITCH

BLACK\WHITE

SWITCH

CLUTCH

BLACK\WHITE

System

Electrical

Greensmaster 1000/1600

Page 5 – 3

Electrical System

IGNITOR

BLACK

HIGH TENSION LEAD

BLACK

IGNITION COIL

ENGINE

MAGNETO

FLYWHEEL

BLACK

RED

ON/OFF

BLACK

RED

CONNECTOR/

INTERLOCK MODULE

ABCDEF

GREEN

BROWN

BLACK\WHITE

BROWN

BLACK\WHITE

Electrical System

CLUTCH

SWITCH

Early Model Kawasaki FE120 Engines

ON\OFF switch is open in the ON position CLUTCH SWITCH is closed when the clutch is DISENGAGED

Page 5 – 4

Greensmaster 1000/1600

IGNITOR

BLACK

HIGH TENSION LEAD

IGNITOR

BLACK

CONNECTOR/

INTERLOCK MODULE

ABCDEF

BLACK

IGNITION COIL

ENGINE

MAGNETO

FLYWHEEL

RED

BLACK

ON/OFF

RED

BROWN

PRESENCE SWITCH

BROWN

BLACK\WHITE

OPERATOR

GREEN

BROWN

BLACK\WHITE

SWITCH

CLUTCH

BLACK\WHITE

System

Electrical

Greensmaster 1000/1600

Early Model Kawasaki FE120 Engines with Operator Presence Control

ON\OFF switch is open in the ON position CLUTCH SWITCH is closed when the clutch is DISENGAGED OPERATOR PRESENCE SWITCH is closed when the bail is held

Page 5 – 5

Electrical System

Special Tools

Order special tools from the

AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS)

TORO SPECIAL TOOLS

Multimeter

The meter can test electrical components and circuits for current, resistance, or voltage.

NOTE: Toro recommends the use of a DIGITAL Volt– Ohm–Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter. This excess current can cause damage to circuits not designed to carry it.

Skin–Over Grease – TOR50547

Some tools may also be available from a local supplier.

Figure 1

Special non–conductive grease which forms a light protective skin which helps waterproof electrical switches and contacts.

Spark Tester – TOR4036

For testing electronic ignitions. Saves time because you will know if the ignition is causing the problem on a non– starting engine. The tester determines if ignition spark is present.

Figure 2

Electrical System

Page 5 – 6

Figure 3

Greensmaster 1000/1600

Troubleshooting

The interlock switch must not be by–passed, it must be

CAUTION

Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing.

For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Wiring Schematic section of this chapter).

 

Problem Possible Causes Correction

connected for proper troubleshooting and safety. NOTE: See the Kawasaki FE161 & FE170 Service

Manual and Kawasaki FE120 Service Manual Supplement in Chapter 3 – Engine for troubleshooting of

electrical problems related to the ignition system. However, ignition system testing is covered in this chapter. The ignition system for the FE120 engine is not fully covered in the service manual.

Engine will not start ON/OFF switch is in the OFF

position or is grounded. Spark plug lead is not connected.

Electrical wires are loose or damaged.

Clutch switch is not adjusted or faulty.

Interlock module is faulty.

Engine will start , but will not run Electrical wires are loose or

damaged. Operator presence control switch is

not adjusted or faulty. Interlock module is faulty.

Turn switch to ON, or replace switch.

Make sure spark plug lead is connected.

Check electrical connections. Repair wiring.

Adjust or replace clutch switch.

Replace interlock module. Check electrical connections.

Repair wiring. Adjust or replace clutch switch.

Replace interlock module.

System

Electrical

Greensmaster 1000/1600

Page 5 – 7

Electrical System

Component Testing

For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ON/OFF switch connector before doing a continuity check). Individual components should be electrically isolated (e.g. disconnect all leads or remove from circuit) from the circuit when tested.

CAUTION

When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected.

NOTE: See the Kawasaki FE161 & FE170 Service Manual and Kawasaki FE120 Service Manual Supplement for more component testing information.

WARNING

The ignition system produces a dangerously high voltage. Do not touch the spark plug, ignition coil, igniter, or spark plug lead while the engine is running; you can receive a severe electrical shock.

Interlock Module and Clutch (Interlock) Switch – No Operator Presence Control

If the engine will not start, perform the following tests to determine if the interlock module or clutch switch is at fault.

1. Check that there is a good ground between the interlock module and the engine, Check all other electrical connections and the interlock module for damage. Replace any damaged wiring or components.

3. Start the engine. If the engine does not start, check the interlock module using the following steps.

4. Disconnect red wire (male connector) where it connects to the black wire leading to the ignition coil. On older models, disconnect red wire (male connector) where it connects to the black wires leading to the ignition coil and igniter.

A. Start the engine. The engine should start. B. Ground the red wire (male connector) to the en-

gine block and start the engine. The engine should not start.

2. Check the adjustment and continuity of the clutch switch.

A. Disconnect both black\white wires from both brown wires connected to the interlock module.

B. Place traction clutch lever in the ENGAGED position. The switch should be open.

C. Place traction clutch lever in the DISENGAGED position. The switch should be closed.

D. Adjust interlock switch until it opens and closes properly when the traction lever is in the ENGAGED and DISENGAGED positions. See Interlock Switch in the Adjustments section.

E. Reconnect both brown wires to both black\white wires connected to the clutch switch.

Electrical System

Page 5 – 8

C. Reconnect the red wire to the black wire.

5. Disconnect both brown wires from both black\white wires.

A. Start the engine. The engine should not start. B. Jumper across the two brown wires and start the

engine. The engine should start. C. Reconnect both black\white wires to both brown

wires.

6. Replace interlock module if it fails either off the tests in step 4 or 5.

Greensmaster 1000/1600

Interlock Module and Clutch (Interlock) Switch – With Operator Presence Control

The interlock module prevents the engine from starting unless the clutch switch is closed (clutch DISENGAGED). After a safe start, the engine will continue to run with the clutch switch open (clutch ENGAGED) or closed. However, the operator presence bail must be engaged (held to against the handle) for the engine to run when the clutch is ENGAGED. With the clutch ENGAGED, the engine will stop when the operator presence bail is released.

If the engine will not start, perform the following tests to determine if the interlock module or clutch switch is at fault.

1. Check that there is a good ground between the interlock module and the engine, Check all other electrical connections and the interlock module for damage. Replace any damaged wiring or components.

2. Check the adjustment and continuity of the clutch switch.

A. Disconnect both black\white wires from both brown wires connected to the interlock module that lead to the clutch switch.

B. Place traction clutch lever in the ENGAGED position. The switch should be open.

C. Place traction clutch lever in the DISENGAGED position. The switch should be closed.

D. Adjust interlock switch until it opens and closes properly when the traction lever is in the ENGAGED and DISENGAGED positions. See Interlock Switch in the Service And Repairs section.

E. Reconnect both black\white wires to the brown wires leading to the interlock module.

3. Check the adjustment and continuity of the operator presence control switch.

A. Disconnect both black\white wires at the switch from both brown wires leading from the wire harness.

B. Hold the bail against the handle. The switch should be closed.

C. Release the bail from the handle. The switch should be open.

E. Reconnect both brown wires to the black\white wires connected to the operator presence control switch.

4. Start the engine. If the engine does not start, check the interlock module using the following steps.

5. Disconnect red wire (male connector) where it connects to the black wire leading to the ignition coil. On older models, disconnect red wire (male connector) where it connects to the black wires leading to the ignition coil and igniter.

A. Start the engine. The engine should start. B. Ground the red wire (male connector) to the en-

gine block and start the engine. The engine should not start.

C. Reconnect the red wire to the black wire.

6. Disconnect both brown wires from the black/white wires leading to the clutch switch.

A. Start the engine. The engine should not start. B. Jumper across the two brown wires and start the

engine. The engine should start. C. Reconnect both black\white wires to both brown

wires.

7. Disconnect both brown wires from the black/white wires leading to the operator presence control switch.

A. Start the engine. The engine should start. B. Jumper across the two brown wires and start the

engine. The engine should start. C. Place traction clutch lever in the ENGAGED

position. The engine should continue to run. D. Remove jumper from the brown wires. The en-

gine should stop. E. Reconnect both black\white wires to the brown

wires.

8. Replace interlock module if it fails either off the tests in steps 5, 6, or 7.

System

Electrical

D. Adjust operator presence control switch until it closes and opens properly when the bail is held against and released from the handle. See Operator Presence Control Switch in the Service And Repairs section.

Greensmaster 1000/1600

Page 5 – 9

Electrical System

Ignition System Operation

Making a System Tester

This simple tester can be made if a commercial spark tester is not available. It can determine if the ignition system is operating properly.

1. Use a new NGK BPR5ES or equivalent spark plug.

2. Remove the ground electrode from the test plug. This gives the spark plug a larger gap, which simulates the spark required under actual engine conditions.

3. Use 18 gauge insulated wire, an alligator clip, and large spring clip to make a lead assembly.

SPRING CLIP

SP ARK

PLUG

4. Slide a 1–1/4 inch length of 1/2–inch I.D. clear fuel line over the threads of the spark plug. The spark will be more visible, and the fuel line will shade the plug firing tip.

Testing the Ignition System

W ARNING

The ignition system produces a dangerously high voltage. Do not touch the spark plug, ignition coil, or spark plug lead while the engine is running; you can receive a severe electrical shock.

Note: Do not remove spark plug from the engine. The

spark plug is necessary to maintain normal starting speeds.

1. Remove high–tension lead from the spark plug, and connect it to the test spark plug.

2. Connect large spring clip around the hex portion of the test spark plug. Connect alligator clip to a good ground on the engine block.

18 GUAGE

WIRE

Figure 4

4. Start the engine and observe the test spark plug. Visible and audible sparks should be produced.

5. If visible and audible sparks are produced, the ignition system is operating properly.

6. If visible and audible sparks are not produced, the ignition system is not operating properly.

A. Check wires and connectors of the ON/OFF switch, igniter, ignition coil, and combination igniter and ignition coil (on later models) for grounding or damaged insulation.

B. If wires and connectors are good, test the igniter, ignition coil, and combination igniter and ignition coil (on later models) individually.

C. If the igniter, ignition coil, and combination igniter and ignition coil (on later models) test properly see Interlock Module and Clutch (Interlock) Switch in this section for further testing.

ALLIGA T OR

CLIP

3. Make sure ON/OFF switch is in the ON position.

Electrical System

Page 5 – 10

Greensmaster 1000/1600

Igniter

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

1. Park mower on a level surface. Make sure engine is OFF.

2. Remove black wire from the bottom of the igniter.

3. Use a digital multimeter set to the ohms scale; take internal resistance of the igniter.

A. Contact black (–) test lead to the igniter mounting screw (ground).

B. Contact red (+) test lead to the terminal from which the black wire was removed.

C. The internal resistance should be about 7.8 to

8.1 KΩ.

4. If the internal resistance value is not within specification, replace old igniter with a new one. Reconnect black lead.

A. Try starting the engine. B. If the engine does not start, replace the ignition

coil.

Figure 5

1. Ground 2. Wire connector

5. If the internal resistance value is within specification, test the ignition coil.

System

Electrical

Greensmaster 1000/1600

Page 5 – 11

Electrical System

Ignition Coil

A commercial coil tester can be used to test the ignition coil. If a tester is available, test the ignition coil as suggested in the Kawasaki FE161 & FE170 Service

Manual and Kawasaki FE120 Service Manual Supplement

The coil can be tested for a badly shorted or broken winding with a digital ohmmeter. However, a ohmmeter can not detect layer shorts and shorts resulting from insulation breakdown under high running voltages.

Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together . The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value from from the measured value of the component you are testing.

1. Primary lead

2. Ground

IGNITION COIL

Figure 6

3. Secondary lead

1. Park mower on a level surface. Make sure engine is OFF

2. Isolate ignition coil. Disconnect high tension lead from spark plug and black wire on the coil.

3. Measure primary winding resistance between the primary lead and ground. Winding resistance should be from 0.8 to 1.0 ohms. Winding and circuit resistance should be from 0.6 to 1.1 ohms for new combination ig- niter/ignition coils.

A. If resistance is 0 ohms, the primary winding is shorted. Replace ignition coil.

B. If resistance is high or infinity () ohms, the primary winding is open. Replace ignition coil.

4. Measure secondary winding resistance between the secondary lead and ground. Winding resistance should be from 7.0 to 9.0 KΩ. Winding resistance should be from 5.8 to 9.6 KΩ for new combination igniter/igni- tion coils.

A. If resistance is low or 0 ohms, the primary winding is shorted. Replace ignition coil.

IGNITER/IGNITION COIL

Figure 7

1. Primary lead

2. Ground

3. Secondary lead

5. If resistances are good, the ignition coil windings are probably good. However, if the ignition still does not perform after all other components have been checked, replace coil with a new one.

B. If resistance is high or infinity () ohms, the primary winding is open. Replace ignition coil.

C. Check the high tension lead for damage. Replace ignition coil if lead is damaged.

Electrical System

Page 5 – 12

Greensmaster 1000/1600

Service and Repairs

NOTE: See the Kawasaki FE161 & FE170 Service Manual and Kawasaki FE120 Service Manual Supplement for more component repair information.

Interlock Switch

Adjustment

1. Make sure the engine is OFF and traction lever is DISENGAGED.

2. Loosen both switch mounting nuts and move switch until the switch plunger is depressed 0.18 to 0.24 inch (4.6 to 6.1 mm) (switch closed).

3. Tighten switch mounting nuts.

4. Engage traction lever and verify that the switch plunger is depressed no more than 0.06inch (1.5 mm) (switch open). Readjust as required.

Removal

A. Disconnect black\white wires at the switch from the brown wires leading from the Interlock module.

B. Remove adjusting nut from the plunger side of the switch. Remove switch from bracket.

Installation

A. Place switch into bracket with one adjusting nut and the plunger end facing the clutch lever. Thread remaining adjustment nut onto the switch.

B. Adjust switch as necessary . C. Connect black\white wires at the switch to the

brown wires from the interlock module.

1. Interlock switch

2. Adjusting nut

Figure 8

3. Bracket

System

Electrical

Greensmaster 1000/1600

Page 5 – 13

Electrical System

Operator Presence Control Switch

Adjustment

1. Make sure the engine is OFF.

2. Loosen both switch adjusting nuts. While holding the bail against the handle, move switch until the switch plunger is depressed 0.16 inch (4.1 mm) (switch closed).

3. Tighten switch mounting nuts.

4. Engage traction lever and verify that the switch plunger is depressed no more than 0.06inch (1.5 mm) (switch open). Readjust as required.

Removal

A. Disconnect black\white wires at the switch from the brown wires leading from the wire harness.

B. Remove adjusting nut from the plunger side of the switch. Remove switch from bracket.

Installation

A. Place switch into bracket with one adjusting nut and the plunger end facing the bail contact tab. Thread remaining adjustment nut onto the switch.

B. Adjust switch as necessary .

1. Operator presence switch

Figure 9

2. Adjusting nut

3. Bracket

C. Connect black\white wires at the switch to the brown wires from the wire harness.

Electrical System

Page 5 – 14

Greensmaster 1000/1600

Spark Plug

Use a NGK BPR 5ES spark plug or equivalent. Remove plug after every 100 operating hours and check its condition.

1. Make sure engine is OFF. Pull high tension lead off the spark plug.

2. Clean around spark plug and remove plug from the cylinder head.

Note: The condition of the spark plug can give an accurate picture of the overall condition of the engine. Use the chart on the following page as a guide to determine possible problems with the engine.

3. Inspect the spark plug.

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 cylinder.

0.028 to 0.31 inch (0.7 to 0.8 mm)

Figure 10

4. Set air gap at 0.028 to 0.031 inch (0.7 to 0.8 mm). Install correctly gapped spark plug and torque to 20 ft–lb (2.8 kg–m).

System

Electrical

Greensmaster 1000/1600

Page 5 – 15

Electrical System

NORMAL

OVER HEA TING FUSED SPOT DEPOSIT

Has gray or light tan deposits on the firing tip.

LEAD FOULED CARBON FOULED

Has dark black, gray, tan, or yellow deposits. May have a fused glazed coating on the insulator tip.

Caused by highly leaded gasoline.

Replace the plug.

Light gray or white insulator with small gray brown or black spots. Electrodes have a bluish burnt appearance.

May be caused by engine over heating, loose spark plugs, wrong fuel type, too hot a plug, low fuel pump pressure, or incorrect ignition timing.

Replace spark plug.

Black dry fluffy carbon deposits are found on insulator tips, electrodes, and exposed shell surfaces.

Weak ignition, too cold a plug, fuel mixture too rich, defective fuel pump, excessive idling, or improperly operating heat riser may be the cause.

Has spotty or melted deposits resembling blisters or bubbles.

Caused by sudden acceleration.

Replace spark plug.

WORN

Has a severely eroded or worn electrode.

Caused by normal wear.

Replace spark plug.

GAP BRIDGED

Gap between electrodes is closed by deposit build up.

May be caused by carbon or oil fouling.

Replace spark plug.

Electrical System

Replace spark plug.

OIL FOULED PRE–IGNITION

Wet black deposits can be found on electrodes, insulator, and in the bore.

Excessive oil entering the combustion chamber through excessive clearances between valve guides and stems, worn or loose bearings, or worn rings and pistons.

Replace spark plug.

Page 5 – 16

Electrodes are melted and the insulator may be blistered. Metallic deposits on the insulator indicate engine damage.

Engine over heating, burnt valves, too hot a plug, incorrect ignition timing or advance, or wrong type of fuel are causes.

Replace spark plug.

Greensmaster 1000/1600

Controls, Wheels and Accessories

Table of Contents

Chapter 6

SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENTS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handle Height Adjustment 3. . . . . . . . . . . . . . . . . . . .

SERVICE AND REPAIRS 4. . . . . . . . . . . . . . . . . . . . . .

Handle Assembly 4. . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake Cable Replacement 6. . . . . . . . . . . . . . . . . . .

Clutch Cable Replacement 7. . . . . . . . . . . . . . . . . . .

Throttle Cable Replacement 8. . . . . . . . . . . . . . . . . .

Wheels 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Kickstand 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Greensmaster 1000/1600

Page 6 – 1

Wheels and Accessories

Wheels and

Accessories

Specifications

Item Description

Tire pressure 12 to 15 PSI, (0.83 to 1.04 bar)

Wheel Shaft torque 65 to 75 ft–lb, (8.99 to 10.37 kg–m)

Wheels and Accessories

Page 6 – 2

Greensmaster 1000/1600

Adjustments

Handle Height Adjustment

1. Make sure mower is parked on a level surface with the engine OFF.

2. Remove cotter pins from the ring pins on each side of the mower.

3. Support handle, and remove ring pins from each side of the mower. Raise or lower handle to the desired operating position.

4. Reinstall ring pins and cotter pins.

Figure 1

1. Cotter pin 2. Ring pin

Wheels and

Accessories

Greensmaster 1000/1600

Page 6 – 3

Wheels and Accessories

Service and Repairs

Handle Assembly

RIGHT

FRONT

1. Throttle cable

2. Spring

3. Lock nut

4. Retaining washer

5. Friction washer

6. Throttle lever

7. Cap screw

8. Clutch skid bracket

9. Cap screw

10. Console bracket (RH)

11. Lock nut

12. Clutch cable

13. Screw

14. Shoulder bolt

15. Brake cable

313233

Figure 2

16. Brake skid bracket

17. Brake bracket

18. Brake lever

19. Console bracket (LH)

20. Red knob

21. Cap screw

22. Spring lock washer

23. Flat washer

24. Spacer

25. Clutch lever

26. Lock nut

27. Clutch bracket

28. Black knob

29. Console

30. Cap screw

31. Spring lock washer

32. Flat washer

33. Handle pivot pin

34. Lock insert nut

35. Handle

36. Bushing

37. Cable tie

38. Bail assembly (Europe)

39. Spacer (Europe)

40. Switch bracket (Europe)

41. Switch (Europe)

42. Jam nut (Europe)

43. Shoulder bolt (Europe)

Note: Items 38 through 43 above are part of the op-

tional Operator Presence Kit, which presently comes on all models sold in Europe.

Wheels and Accessories

Page 6 – 4

Greensmaster 1000/1600

Removal

1. Park mower on a level surface. Make sure engine is OFF.

2. Cut cable ties from the handle.

3. Remove cap screw (30), spring lock washer (31), and flat washer (32) from each handle pivot pin (33) on each of the handle (35) ends (Fig. 2 and 3).

Note: The cotter pin, ring pin, cap screw,and lock nut

may have to be removed from the handle arms to allow handle removal (Fig. 4).

4. Squeeze handle ends inward. Remove handle ends from the handle pivot pins; pull handle ends clear of the holes in the handle arms (Fig. 3).

Installation Note: The cotter pin, ring pin, cap screw,and lock nut

may have to be removed from the handle arms to allow handle installation (Fig. 4).

1. Slide handle ends through the holes in the handle arms. Squeeze handle ends inward. Install handle ends to the handle pivot pins (33) on each side of the frame. (Fig. 2 and 3).

2. If the cotter pin, ring pin, cap screw,and lock nut have been removed from the handle arms, reinstall the handle arms to the frame. Make sure spacer is installed in the handle arm. (Fig. 4).

3. Install cap screw (30), spring lock washer (31), and flat washer (32) to each handle pivot pin (33) on each of the handle (35) ends (Fig. 2 and 3).

1. Cap screw & washers

2. Handle end

3. Cotter pin

Figure 3

4. Ring pin

5. Lock nut

6. Handle arm

4. Secure cables to the handle with new cable ties.

Greensmaster 1000/1600

Page 6 – 5

1. Cotter pin

2. Ring pin

3. Cap screw

Figure 4

4. Lock nut

5. Handle arm

6. Spacer

Wheels and Accessories

Wheels and

Accessories

Brake Cable Replacement

Removal

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Disengage brake to release tension on the brake cable. Remove cable ties from the left side of the handle.

3. Remove brake cable from the countershaft housing as follows (Fig. 5):

A. Open bellcrank cover to access the brake lever. B. Remove shoulder bolt and lock nut from the

brake lever and cable eyelet. C. Loosen rear nut attaching the brake cable to the

countershaft housing. Remove brake cable from housing and brake lever

4. Make sure brake is disengaged and the clutch is engaged so the console (29) can be positioned to access the brake lever (18) and brake cable (15) (Fig. 2).

5. Remove four screws (13) securing the console (29) to the console brackets (10 and 19). Position console forward and away from the brackets (Fig. 2).

1. Brake lever

2. Shoulder bolt

3. Lock nut

4. Cable eyelet

Figure 5

5. Rear nut

6. Brake cable

7. Countershaft housing

Note: On models without the operator presence kit,

the bail assembly, switch, and switch bracket are not installed on the handle assembly . The shoulder bolt and spacer are substituted by an additional screw on both sides of the handle assembly (Fig. 2 and 6).

6. Gain access to the brake lever and brake cable as follows (Fig. 6):

A. If the operator presence kit is installed, remove both screws and switch bracket (with switch attached) from the brake skid bracket. Remove shoulder bolt and spacer from the bail assembly and brake skid bracket. Remove console bracket from the brake skid bracket.

B. If the operator presence kit is not installed, remove three screws and console bracket from the brake skid bracket.

7. Remove shoulder bolt (14) and lock nut (11) from the brake lever (18) and brake cable (15) eyelet (Fig. 2).

8. Loosen nut securing the brake cable (15) to the brake bracket (17). Remove cable from the bracket. Remove brake cable from the mower.

Figure 6

1. Screw

2. Switch bracket

3. Switch

4. Console bracket

5. Shoulder bolt

6. Spacer

7. Bail assembly

8. Brake skid bracket

Installation

1. Secure brake cable (15) eyelet to the brake lever (18) with the shoulder bolt (14) and lock nut (1 1) (Fig. 2).

Note: On models without the operator presence kit, the bail assembly, switch, and switch bracket are not installed on the handle assembly . The shoulder bolt and spacer are substituted by an additional screw on both sides of the handle assembly (Fig. 2 and 6).

2. Reinstall bail assembly and brackets. (Fig. 6). A. If the operator presence kit is installed, reinstall

console bracket and switch bracket (with switch attached) to the brake skid bracket. Secure brackets with both screws. Secure bail assembly and spacer, to the brake skid bracket with the shoulder bolt.

Wheels and Accessories

Page 6 – 6

Greensmaster 1000/1600

B. If the operator presence kit is not installed, secure console bracket to the brake skid bracket with three screws.

3. Position console (29) over the console brackets (10 and 19). Secure console to both brackets with four screws (13) (Fig. 2).

A. Attach brake cable to the counter shaft housing and tighten the rear nut.

B. Secure cable eyelet to the brake lever with shoulder bolt and lock nut.

5. Install new cable ties to the left side of the handle.

4. Run new brake cable to the countershaft assembly . Install new brake cable to the countershaft housing and brake lever as follows (Fig. 5):

6. Adjust brake cable and close bellcrank cover (see Service/Park Brake Adjustment in Chapter 7 – Traction and Reel Drive Systems).

Greensmaster 1000/1600

Page 6 – 7

Wheels and Accessories

Wheels and

Accessories

Clutch Cable Replacement

Removal

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Disengage clutch to release tension on the clutch cable. Remove cable ties from the right side of the handle.

3. Remove clutch cable from the bellcrank assembly as follows (Fig. 7):

A. Open bellcrank cover to access the clutch lever and bracket.

B. Remove shoulder bolt and lock nut securing the cable eyelet to the clutch lever.

C. Loosen rear nut attaching the clutch cable to the clutch bracket. Remove clutch cable from the clutch bracket.

4. Make sure brake is disengaged and the clutch is engaged so the console (29) can be positioned to access the clutch lever (25) and clutch cable (12) (Fig. 2).

5. Remove four screws (13) securing the console (29) to the console brackets (10 and 19). Position console forward and away from the brackets (Fig. 2).

Figure 7

1. Clutch lever

2. Clutch bracket

3. Shoulder bolt & lock nut

4. Cable eyelet

5. Rear nut

6. Clutch cable

Note: On models without the operator presence kit,

the bail assembly is not installed on the handle assembly . The shoulder bolt and spacer are substituted by an additional screw on both sides of the handle assembly (Fig. 2 and 8).

6. Gain access to the clutch lever and clutch cable as follows (Fig. 8):

A. If the operator presence kit is installed, remove both screws from clutch skid bracket. Remove shoulder bolt and spacer from the bail assembly and clutch skid bracket. Remove console bracket from the clutch skid bracket.

B. If the operator presence kit is not installed, remove three screws and console bracket from the clutch skid bracket.

7. Remove shoulder bolt (14) and lock nut (11) from the clutch lever (25) and clutch cable (12) eyelet (Fig. 2).

8. Loosen nut securing the clutch cable (12) to the clutch bracket (27). Remove cable from the clutch bracket (Fig. 2).

9. Remove clutch cable from the mower.

Figure 8

1. Screw

2. Console bracket

3. Shoulder bolt

4. Spacer

5. Bail assembly

6. Clutch skid bracket

Installation

1. Secure clutch cable (12) eyelet to the clutch lever

(25) with the shoulder bolt (14) and lock nut (1 1) (Fig. 2). Note: On models without the operator presence kit,

the bail assembly is not installed on the handle assembly . The shoulder bolt and spacer are substituted by an additional screw on both sides of the handle assembly (Fig. 2 and 8).

2. If the operator presence kit is installed, reinstall con-

sole bracket to the clutch skid bracket. Secure brackets with both screws. Secure bail assembly and spacer to the clutch skid bracket with the shoulder bolt (Fig. 8).

Wheels and Accessories

Page 6 – 8

Greensmaster 1000/1600

3. If the operator presence kit is not installed, secure console bracket to the clutch skid bracket with three screws (Fig. 8).

4. Position console (29) over both console brackets (10 and 19). Secure console to the brackets with four screws (13) (Fig. 2).

A. Attach clutch cable to the clutch bracket. Tighten nut to secure cable to the bracket.

B. Secure clutch cable eyelet to the clutch lever with shoulder bolt and lock nut.

6. Install new cable ties to the right side of the handle.

5. Run new clutch cable to the bellcrank assembly. Install new cable to the clutch lever as follows (Fig. 7).

7. Adjust clutch cable and close bellcrank cover (see Clutch Control Adjustment in Chapter 3 – Engine).

Greensmaster 1000/1600

Page 6 – 9

Wheels and Accessories

Wheels and

Accessories

Throttle Cable Replacement

Removal

1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug.

2. Remove cable ties from the right side of the handle. Remove nut and cable clip from the flangette on the countershaft housing.

3. Remove throttle cable from the governor as follows (Fig. 9):

A. Unscrew throttle cable screw enough to release the throttle cable from the nut in the governor lever.

B. Remove hex head screw from the throttle cable bracket.

C. Pull throttle cable clear of the nut in the governor lever.

4. Make sure brake is disengaged and the clutch is engaged so the console (29) can be positioned to access the throttle lever (6) and throttle cable (1) (Fig. 2).

5. Remove four screws (13) securing the console (29) to the console brackets (10 and 19). Position console forward and away from the brackets (Fig. 2).

1. Throttle cable screw

2. Throttle cable

3. Nut

Figure 9

4. Governor lever

5. Hex head screw

6. Throttle cable bracket

6. Gain access to the throttle lever and throttle cable as follows (Fig. 10):

A. Remove both screws from clutch skid bracket. B. Remove shoulder bolt and spacer from the bail

assembly and clutch skid bracket. Remove console bracket from the clutch skid bracket.

7. Snap throttle cable (1) out of the clutch skid bracket (8). Disconnect throttle cable from the throttle lever (6) (Fig. 2).

8. Remove clutch cable from the mower.

Installation

1. Connect throttle cable (1) to the throttle lever (6). Snap throttle cable to the clutch skid bracket (8) (Fig. 2).

2. Reinstall console bracket to the clutch skid bracket. Secure brackets with both screws (Fig. 10).

3. Secure bail assembly and spacer to the clutch skid bracket with the shoulder bolt (Fig. 10).

Figure 10

1. Screw

2. Console bracket

3. Shoulder bolt

4. Spacer

5. Bail assembly

6. Clutch skid bracket

4. Position console (29) over both console brackets

(10 and 19). Secure console to the brackets with four screws (13) (Fig. 2).

5. Run new throttle cable to the governor lever. Install

new cable to the governor lever as follows (Fig. 9).

A. Insert throttle cable into the nut. B. Tighten throttle cable screw to hold cable in the

nut and governor lever. Do not tighten screw.

6. Install new cable ties to the right side of the handle.

Secure throttle cable to the flangette on the countershaft housing with the cable clip and nut.

Wheels and Accessories

7. Adjust throttle cable (see Throttle Linkage Adjust-

ment in Chapter 3 – Engine).

Page 6 – 10

Greensmaster 1000/1600

Wheels

Removal

1. Park mower on a level surface. Make sure the engine is OFF.

2. Push kickstand down with one foot while pulling up on the handle. This will support the mower on the kick stand.

3. Pivot wheel locking clip away from the center of the wheel. Slide wheel off the wheel shaft.

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

4. If necessary, remove wheel shaft from the drive pulley.

Installation

1. Make sure mower is parked on a level surface and the engine is OFF.

2. Push kickstand down with one foot while pulling up on the handle. This will support the mower on the kick stand.

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

3. If the wheel shafts were removed from the drive pulleys,

A. Apply Loctite 242 or equivalent to the threads of the wheel shafts.

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

Note: The drum shafts inboard of the side plates have

flats that can be used while torquing the wheel shafts.

B. Install right hand wheel shaft into the drive pulley on the right side of the mower. Install the remaining shaft. Torque both shafts from 65 to 75 ft–lb (9.0 to

10.3 kg–m).

4. Apply anti–seize lubricant to the exposed end of the wheel shaft.

Figure 11

1. Locking clip

Figure 12

1. Wheel shaft 2. Drive pulley

Wheels and

Accessories

5. Slide wheel onto the wheel shaft. A. Pivot wheel locking clip away from the center of

the wheel. B. Allow wheel to slide onto the shaft until the lock-

ing clip is secured into the groove on the wheel shaft.

Greensmaster 1000/1600

Page 6 – 11

Wheels and Accessories

1. Cap screw

2. Lock washer

3. Shallow rim

4. Tire

5. Hub

12 3 4

6. Retaining lever

7. Spring

8. Bolt

9. Bolt

10. Deep rim

Figure 13

11. Inner tube

12. Cap screw

13. Flange nut

14. Wheel shaft

Disassembly

1. Remove three cap screws (1) and lock washers (2) from the shallow rim (3) and hub (5). Remove hub from deep rim (10).

2. Remove four cap screws (12) and flange nuts (13) from the deep rim (10) and shallow rim (3). Remove shallow rim from the deep rim.

3. Remove bolt (9) from the hub (5). Remove bolt (8), spring (7), and retaining lever (6) from the hub.

Reassembly

1. Reinstall retaining lever (6), spring (7), and bolt (8) to the hub (5). Reinstall bolt (9) to the hub. Tighten both bolts

2. Reinstall shallow rim (3) into the deep rim (10). Secure shallow rim to the deep rim with the four cap screws (12) and flange nuts (13). Tighten fasteners.

3. Reinstall hub (5) into deep rim (10). Secure hub to deep rim with three cap screws (1) and lock washers (2). Tighten fasteners.

Wheels and Accessories

Page 6 – 12

Greensmaster 1000/1600

Kickstand

FRAME

Figure 14

1. Cap screw

2. Cap screw

3. Lock washer

4. Spring bracket

5. Extension spring

6. Cap screw

7. Spring retainer

8. Kickstand

Removal

1. Park mower on a level surface. Make sure the en-

gine is OFF.

2. Pivot kickstand up against the handle and hold

there.

3. Use a pliers to remove the extension spring from the

spring retainer (Fig. 15).

4. Remove both lock nuts (10), flat washers (9), cap

screws (1), and spacers (1 1) from the kickstand (8) and frame. Remove kickstand from the frame (Fig. 14).

NOTE THE POSITION OF THE STOP

9. Flat washer

10. Lock nut

11. Spacer

12. Flange lock nut

Installation

1. Make sure mower is parked on a level surface and

the engine is OFF.

2. Position kickstand (8) inside the mower frame. In-

sert capscrews (1) through the frame, spacers (1 1), and kickstand (Fig. 14).

3. Secure cap screws (1) with flat washers (9) and lock

nuts (10). Tighten fasteners (Fig. 14).

4. Pivot kickstand up against the handle and hold

there. Use a pliers to reinstall the extension spring to the spring retainer (Fig. 15).

Greensmaster 1000/1600

Page 6 – 13

1. Kickstand

2. Extension spring

Figure 15

3. Spring retainer

4. Cap screw

Wheels and Accessories

Wheels and

Accessories

Wheels and Accessories

Page 6 – 14

Greensmaster 1000/1600

Table of Contents

Chapter 7

Cutting Unit

INTRODUCTION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICA TIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION 4. . . . . . . . . . . . . . . . . . . . .

Grass Basket Installation 4. . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 7. . . . . . . . . . . . . . . . . . . . . . . . .

Factors Affecting Quality of Cut 7. . . . . . . . . . . . . . .

ADJUSTMENTS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leveling Drum to Reel 9. . . . . . . . . . . . . . . . . . . . . . .

Bedknife to Reel Adjustment 10. . . . . . . . . . . . . . . . .

Height–of–Cut Adjustment 1 1. . . . . . . . . . . . . . . . . . .

Grass Shield Height Adjustment 12. . . . . . . . . . . . .

Cutoff Bar Adjustment 12. . . . . . . . . . . . . . . . . . . . . .

SERVICE AND REPAIRS 13. . . . . . . . . . . . . . . . . . . . .

Backlapping 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bedbar 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bedknife Replacement and Grinding 16. . . . . . . . . .

Roller 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Roller Bearing Replacement 17. . . . . . . . . . . . . . . . .

Reel 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparing Reel for Grinding 20. . . . . . . . . . . . . . . . .

Greensmaster 1000/1600 Page 7 – 1 Cutting Unit

Cutting Unit

Introduction

This Chapter covers the cutting unit section of the GR1000. The cutting unit consists of the frame assembly , reel assembly, drum assembly , and detachable basket. The reel and drum drive assemblies make up part

of the cutting unit, and their component parts that are necessary for the service of the cutting unit are covered in this chapter.

Greensmaster 1000/1600Page 7 – 2Cutting Unit

Specifications

REEL CONSTRUCTION (GR1000): 5–inch (12.7 cm)

diameter, 11 carbon steel blades (optional 8 blades) welded to 5 stamped steel spiders.

HEIGHT–OF–CUT RANGE (GR1000): 5/64 to 1 inch (2 to 25 mm)

WIDTH–OF–CUT (GR1000): 21 inches (53.3 cm) CLIP (GR1000): 0.16 inch (0.41 cm)

Figure 1

REEL CONSTRUCTION (GR1600): 5–inch (12.7 cm) diameter, 8 carbon steel blades welded to 6 stamped steel spiders.

HEIGHT–OF–CUT RANGE (GR100): 1/8 to 1–1/4 inch (3 to 32 mm)

WIDTH–OF–CUT (GR1600): 26 inches (66.0 cm) CLIP (GR1600): 0.23 inch (0.58 cm) BEDKNIFE AND BEDBAR: Single edged high carbon

steel bedknife, hardened to RC 48-54. A cast iron bedbar is fastened to the mower. T ournament bedknife (Part No. 93–4263) is standard.

Cutting Unit

Greensmaster 1000/1600 Page 7 – 3 Cutting Unit

General Information

Grass Basket Installation

1. Grasp basket by top rear lip and slide on or off the basket mounting rods.

Figure 2

1. Grass basket 2. Mounting rod

Greensmaster 1000/1600Page 7 – 4Cutting Unit

Toro 96889SL User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Introduction

Specifications

General Information

Adjustments

Service and Repairs

Specifications

Special Tools

Adjustments

Service and Repairs

Wiring Schematics

Special Tools

Troubleshooting

Component Testing

Service and Repairs

Specifications

Adjustments

Service and Repairs

Introduction

Specifications

General Information