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
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
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
1
Clean Combustion Chamber
1
Replace Spark Plug
Service
Check Cut-Off Bar Adjustment C Level
Service Air Cleaner Filter
2
Clean Combustion Chamber
2
Replace Spark Plug D Level
Adjust Valves and Torque Head Bolts
Service
Service
† Initial Break in at 20 hours
1
Interval for Engine Model: FG150
2
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
1
= Immediately after every washing, regardless of the interval listed.
1
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
1
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
_______________________________ _______________________________ ________________________________
_______________________________ _______________________________ _______________________________
1
D -Service (every 200 hours) Other - Annual Service and Specials Additional Servicing Items
Clean Combustion Chamber
Replace Spark Plug
2
2
Adjust Valves and Torque Head Bolts _______________________________ _______________________________
A, B and C Service required
Replace all Interlock Switches ________________________________
_______________________________ _______________________________
_______________________________ _______________________________
_______________________________ _______________________________ _______________________________
_______________________________ _______________________________ _______________________________
_______________________________ _______________________________ _______________________________
1
Interval for Engine Model: FG150
2
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
+) )&#!% !) #$$# +*!&%
$+)* +) - % )*&(!% &( %#!% !*
& %&* !## * +# *%" - !# %!% !) (+%0
%!% &* &( !% % %#&) ( '&()
$/ +!# +' % !%!* / )'(" &(
#$ )&+( $%/ * -/
- !# !##!% * +# *%" *& '(0
,%* * '&))!!#!*/ & % .'#&)!&% #0
-/) !## +# *%" &+*)! !' +' %/
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/ )+''#/ & )&#!% )&#!% !) +#
&( !%*(%# &$+)*!&% %!%) * (0
&( & %&* +) !* &( %/ &* ( '+('&)
!% $%/ !#(% #!" * )$## & )
"' !* &+* & * !( ( +) *
+$) ( .'#&)!, % %(&+) *& !%0
#
1
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.
1
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.
4
3
5
1
2
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.
3
1. Clutch
2. Front jam nut
2
1
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).
2
1
Figure 5
1. V–belt cover 2. V–belts
1
Engine
INSIDE FACE
2
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
2
3
1
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).
1
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.
2
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).
1
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.
1
Figure 9
1. Wing nut 2. Air cleaner cover
1
2
2
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.
2
Figure 11
1. Fuel shut–off valve 2. Bowl
Greensmaster 1000/1600 Page 3 – 9 Engine
1
Engine Removal and Installation
3
2
1
42
7
41
40
39
38
IDLER PULLEY
ASSEMBLY
13
36
33
32
49
13
35
34
31
37
20
4
30
29
33
5
6
7
8
9
10
11
15
14
32
13
12
KEY
10
8
10
28
27
16
6
23
5
48
43
20
45
33
44
17
46
22
41
20
19
18
19
21
7
23
7
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)
7
26 7
50
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
26
25
24
47
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.
2
1
Figure 13
1. Lower jam nut 2. Clutch bracket
2
SLOW
3
4
5
Figure 14
1. Screw
2. Governor lever
3. Throttle cable
4. Nut
5. Washer head screw
1
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.
1
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
2
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.
1
INSIDE FACE
2
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
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