Toro 96889SL Rev A Service Owners Manual Greensmaster 1000 1600 Preface Publication - English

PART NO. 96889SL, Rev. A Service 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 55420­1196 The Toro Company reserves the right to change product specifications or this publication without notice. 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. E 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 . Equivalents and Conversions Torque Specifications . Operation and Service History Report . Chapter 3 ­ Engine Introduction Specifications General Information Adjustments . Services and Repairs . Kawasaki FE161 & FE170 Service Manual and Kawasaki FE120 Service Manual Supplement Chapter 4 ­ Traction and Reel Drive System Specifications Special Tools Adjustments . Service and Repairs 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 General Information Troubleshooting Adjustments . Service and Repairs 8­2 8­3 8­4 8­6 8­8 Product Records and Manuals Grooming Reel Kit Cutting Unit Greensmaster 1000/1600 Wheels and Accessories Electrical System Traction and Reel Drive System Engine Note: This chapter covers the Model 04125 Grooming Reel Kit only (for the Greensmaster 1000). Safety Greensmaster 1000/1600 Chapter 1 Safety SAFETY INSTRUCTIONS 1 Before Operating 1 While Operating 2 Maintenance and Service 2 SAFETY AND INSTRUCTION DECALS 3 Safety To reduce the potential for injury or death, comply with the following safety instructions. Table of Contents Safety Instructions The GREENSMASTER 1000 was tested and certified by TORO for compliance with the B71.4­1984 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. WARNING To reduce the potential for injury or death, comply with the following safety instructions. 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 55420­1196 2. Never allow children to operate the machine, nor allow 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 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. 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. 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. Greensmaster 1000/1600 Page 1 ­ 1 Safety 10. Check the safety interlock switch daily for proper operation; see Component Testing in Chapter 5 ­ Electrical System. Replace malfunctioning switches before operating machine. (After every two years, replace the interlock switch in the safety system, whether it is working properly or not.) While Operating 11. 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/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: Safety 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 abnormally, 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 engine 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 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. Safety 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 adding oil to the crankcase. 27. To be sure of optimum performance and safety, always 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.

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