Toro Greenmaster 1000 Manuel utilisateur

PART NO. 96889SL, Rev. A

ServiceManual

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 OPER-

ATING, MAINTENANCE, AND ADJUSTMENT

INSTRUCTIONS.SpaceisprovidedinChapter2ofthis

booktoinserttheOperator’sManualandPartsCatalogs

foryourmachine.ReplacementOperator’sManualsare

available by sending complete Model and Serial Num-

ber to:

The Toro Company

8111 Lyndale Avenue South

Minneapolis, MN 55420–1196

TheToroCompanyreservestherighttochangeproduct

specifications or this publication without notice.

This safety symbol means DANGER, WARN-

ING, 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 re-

pair of the machine.

IMPORTANT: The IMPORTANT notice will give im-

portant instructions which must be followed to pre-

vent 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. . . . . . . . . . . . . . . . . . . . . . . .

Note: ThischaptercoverstheModel04125Grooming

Reel Kit only (for the Greensmaster 1000).

SafetyProductRecords

and Manuals

Engine

Traction and Reel

Drive System

Electrical

System

Wheels andCutting Unit Accessories

Grooming Reel

Kit

Greensmaster 1000/1600

Greensmaster 1000/1600 Page 1 – 1 Safety

Chapter 1

Safety

Table of Contents

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

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

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

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

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

Safety Instructions

The GREENSMASTER 1000 was tested and certified

byTOROforcompliancewiththeB71.4–1984specifica-

tions of the American National Standards Institute. Al-

though hazard control and accident prevention partially

aredependent upon thedesign and configurationof the

machine, these factors are also dependent upon the

awareness, concern, and proper training of the person-

nel involved in the operation, transport, maintenance,

and storage of the machine. Improper use or mainte-

nance of the machine can result in injury or death.

To reduce the potential for injury or death, comply with

the following safety instructions.

To reduce the potential for injury or death,

comply with the following safety instructions.

WARNING

Before Operating

1. Operate the machine only after reading and under-

standing the contents of this manual. A replacement

manualis available by sending thecomplete model and

serial number to:

The Toro Company

8111 Lyndale Avenue South

Minneapolis, Minnesota 55420–1196

2. Neverallowchildrentooperate themachine,noral-

low adults to operate it without proper instructions.

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 malfunction-

ing, illegible, or damaged, repair or replace it before op-

erating the machine.

5. Alwayswearsubstantialshoes.Donotoperatema-

chine while wearing sandals, tennis shoes or sneakers.

Donotwearloosefittingclothingwhichcouldgetcaught

in moving parts and cause personal injury.

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.

A. Use an approved gasoline container.

B. Donotremovecapfromfueltankwhenengineis

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

Greensmaster 1000/1600

Page 1 – 2

Safety

10. Checkthesafetyinterlockswitchdailyforproperop-

eration; see Component Testing in Chapter 5 – Electri-

cal System. Replace malfunctioning switches before

operating machine. (After every two years, replace the

interlock switch in the safety system, whether it is work-

ing properly or not.)

While Operating

11. Donot runtheengineinaconfinedareawithoutad-

equate ventilation. Exhaust fumes are hazardous and

could be deadly.

12. Alwaysstandbehindthehandleswhenstartingand

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

NEUTRALpositionandreeldrivelever on mower is

DISENGAGED.

C. Move on/off switch to ON position, set choke to

full choke position (cold start) and throttle to half

throttle.

D. Pull starter cord to start engine.

E. Move throttle to SLOW and on/off switch to OFF

position to stop engine.

14. To transport mower from one area to another:

A. Install transport wheels.

B. Disengage reel drive lever.

C. Start engine.

D. Press down on handle to raise front of mower

and engage traction drive.

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. Ifthecuttingunitstrikesasolidobjectorvibratesab-

normally, stop immediately, turn engine off,wait for all

motionto stopand inspect fordamage. Adamaged reel

or bedknife must be repaired or replaced before opera-

tion 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.

Maintenance and Service

20. Before servicing or making adjustments to the ma-

chine, 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,

keepallnuts,bolts,screwsandbeltsproperlytightened.

22. Ifmajorrepairs are ever neededorassistanceisre-

quired, contact an Authorized TORO Distributor.

23. To reduce potential fire hazard, keep the engine

area free of excessive grease, grass, leaves and accu-

mulation of dirt.

24. If the engine must be running to perform a mainte-

nance adjustment, keep hands, feet, clothing, and any

parts of the body away from the cutting unit and any

moving parts. Keep everyone away.

25. Donotoverspeed the engine bychanginggovernor

settings. Maximum engine speed is 3600 rpm. To as-

sure safety and accuracy, have an Authorized Toro Dis-

tributor 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.Replacementpartsandaccessoriesmade

by other manufacturers could be dangerous. Such use

could void the product warranty of The Toro Company.

Safety

Greensmaster 1000/1600 Page 1 – 3 Safety

Safety and Instruction Decals

Thefollowingsafetyandinstructiondecalsareaffixedto

the traction unit. If any decal becomes illegible or dam-

aged,installanewdecal.Partnumbersarelistedbelow

and in your Parts Catalog. Order replacements from

your Authorized Toro Distributor.

On Control Panel

Part No. 93–6085

On Control Panel

Part No. 93–6084

On Belt Cover

Part No. 65–7660

On Grass Shield

Part No. 62–5070

On Fuel Tank

Part No. 88–7620

On Fuel Tank

Part No. 63–8440

On Grass Shield

Part No. 93–6098

On Front Frame Tube

Part No. 55–4300

Inside Belt Covers (3)

Part No. 88–8950

DANGER

DO NOT OPERATE THIS UNIT UNLESS

ALL SHIELDS ARE FIRMLY SECURED.

Inside Belt Cover

Part No. 675360

On Fuel Tank

Part No. 53–4420

GAS

UNLEADED

Greensmaster 1000/1600

Page 1 – 4

Safety

On Control Panel

Part No. 93–9012

Greensmaster 1000/1600 Page 2 – 1 Product Records and Manuals

Chapter 2

Product Records and Manuals

Table of Contents

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

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

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

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

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

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

Capscrew Markings and Torque Values – Metric 3

OPERATION AND SERVICE HISTORY REPORT 5.

Product Records

Record information about your Greensmaster

1000/1600ontheOPERATIONANDSERVICEHISTO-

RY REPORT form. Use this information when referring

to your machine.

Insert Operator’s Manuals and Parts Catalogs for your

Greensmaster 1000/1600 at the end of this section.

ProductRecords

and Manuals

Greensmaster 1000/1600

Page 2 – 2

Product Records and Manuals

Equivalents and Conversions

Ce manuel convient aux modèles suivants

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