Page 1 Form No. 96889SL Rev. F ® Greensmaster 800/1000/1010/1600/1610/2000/2600 Original Instructions (EN)
Page 2: Revision History
THE TORO COMPANY 2020 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be...
Page 3: Reader Comments
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.com...
Page 4 NOTES...
Page 5 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 on the internet at www.toro.com. E The Toro Company − 1996, 1997, 2012, 2018, 2019, 2020...
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Page 7 Table Of Contents Chapter 1 − Safety Chapter 5 − Electrical System 1 − 1 5 − 2 Safety Instructions ......Electrical Schematics and Wire Harnesses .
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Page 9: Table Of Contents
Safety Instructions Your GREENSMASTER mower has been tested and To reduce the potential for injury or death, comply with certified by TORO for compliance with existing safety the following safety instructions. standards and specifications. Although hazard control and accident prevention partially are dependent upon...
Page 10: While Operating
Replacement parts and accessories made mulation of dirt. by other manufacturers could be dangerous. Such use could void the product warranty of The Toro Company. 5. 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.
Page 11: Safety And Instruction Decals
Greensmaster. If any decal becomes illegible or damaged, install a new decal. Part numbers for replace- ment decals are listed in your Parts Catalog. Order re- placement decals from your Authorized Toro Distributor. Page 1 − 3 GR 800/1000/1010/1600/1610/2000/2600...
Page 12 This page is intentionally blank. Page 1 − 4 Safety GR 800/1000/1010/1600/1610/2000/2600...
Page 13: Product Records
Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......MAINTENANCE ......EQUIVALENTS AND CONVERSIONS .
Page 14: Equivalents And Conversions
Equivalents and Conversions 0.09375 Page 2 − 2 Product Records and Maintenance GR 800/1000/1010/1600/1610/2000/2600...
Page 15: Torque Specifications
For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
Page 16: Standard Torque For Dry, Zinc Plated And Steel Fasteners (Inch Series Fasteners)
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series Fasteners) Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
Page 17: Standard Torque For Dry, Zinc Plated And Steel Fasteners (Metric Fasteners)
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws and Studs with Class 10.9 Bolts, Screws and Studs with Thread Size Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in−lb 644 + 68 N−cm...
Page 18: Other Torque Specifications
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size 7/16 − 20 UNF Square Head Hex Socket 65 + 10 ft−lb 88 + 14 N−m Grade 5 1/4 −...
Page 19: Kawasaki Engine
Chapter 3.1 Kawasaki Engine Table of Contents INTRODUCTION ......SERVICE AND REPAIRS .
Page 20: Introduction
Service and repair parts for Kawasaki engines are sup- commonly available in many service shops. Special plied through your local Toro distributor. If no parts list is tools are described in the Kawasaki FE161 & FE170 available, be sure to provide your distributor with the Service Manual and Kawasaki FE120 Service Manual Toro model and serial number.
Page 21: Specifications
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 Carburetor Float feed fixed main jet Governor Mechanical flyweight 1600 100 RPM (at crankshaft) or 800 50 RPM (at camshaft)
Page 22: General Information
General Information Filling the Fuel Tank DANGER Because gasoline is flammable, caution must be used when storing or handling it. Do not fill the fuel tank while engine is running, hot, or in an enclosed area. Va- pors may build up and be ignited by a spark or flame source many feet away.
Page 23: Fuel Shut−Off Valve
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.
Page 24: Adjustments
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.
Page 25: Adjusting V−Belts
Adjusting V−belts To adjust belt tension on V−belts (Fig. 5), first check ad- justment 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, pro- ceed to the next step.
Page 26: Service And Repairs
Service and Repairs Engine Oil The TORO Company recommends that the oil level be Changing the Oil: checked each time the mower is used or after every 5 1. Start and run engine for a few minutes to warm the operating hours.
Page 27: Air Cleaner
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 (pa- per element) after 200 operating hours.
Page 28: Engine Removal And Installation
Engine Removal and Installation IDLER PULLEY ASSEMBLY Figure 12 1. Bellcrank cover 18. R−clamp 35. Washer 2. Flat washer 19. Lock washer 36. Cap screw 3. Stud 20. Cap screw 37. Lock nut 4. Retainer 21. Engine 38. Pulley support spacer 5.
Page 29 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.
Page 30 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. Re- move high tension lead from the spark plug. 2. Make sure that all parts removed from the engine INSIDE FACE during maintenance or rebuilding are properly rein- stalled to the engine.
Page 31: Lubrication
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.
Page 32 This page is intentionally blank. Kawasaki Engine Page 3.1 − 14 GR 800/1000/1010/1600/1610/2000/2600...
Page 33 Subaru gasoline engine used on the fixed Greensmaster mowers are supplied through your local head walk Greensmaster mowers. Toro distributor. Be prepared to provide your distributor with the Toro model and serial number. Most engine repairs and adjustments require tools Note: Refer to Chapter 3.1 −...
Page 34: Specifications
Specifications Item Description Make / Designation Subaru, 4−stroke, OHC single cylinder, air−cooled, gasoline engine with gear reduction Bore x Stroke 2.28 in x 1.89 in (58 mm x 48 mm) Total Displacement 7.69 in (126 cc) Carburetor Float feed, fixed main jet Governor Mechanical flyweight Low Idle Speed (no load)
Page 35 Honda GX120 gasoline engine used on the Greensmaster mowers are supplied through your local fixed head walk Greensmaster mowers. Toro distributor. Be prepared to provide your distributor with the Toro model and serial number. Most engine repairs and adjustments require tools Note: Refer to Chapter 3.1 −...
Page 36: Engine Identification
Engine Service Manual Detailed information on engine troubleshooting, testing, Contact your local Honda Engine Dealer to obtain a disassembly, and assembly are given in the Honda Ser- copy of the engine Service Manual. However, the spe- vice Manual. The use of some specialized tools and test cialized nature of some engine repairs may dictate that equipment is explained in the Honda Service Manual.
Page 37 Specifications Item Description Make / Designation Honda, 4−stroke, OHV single cylinder, air−cooled, gasoline engine with gear reduction, GX120 Bore x Stroke 2.36 in x 1.65 in (60 mm x 42 mm) Total Displacement 7.2 in (118 cc) Carburetor Butterfly Governor Mechanical flyweight Low Idle Speed (no load) 1800 to 2000 RPM...
Page 38 Service and Repairs Honda Engine Gearbox Assembly Removal and Installation Figure 18 1. Bolts (2 each) 9. Bearing 17. Set screw (2 used) 2. Muffler guard 10. Wave spring 18. Gear 3. Engine 11. Housing gasket 19. Bolt (5 used) 4.
Page 39 Removal 6. Install the output shaft in the gearbox housing. 1. Make sure machine is parked on a level surface with 7. Place the wave spring and housing gasket on the the engine OFF. Remove high tension lead from the cover assembly.
Page 40 This page is intentionally blank. Page 3.3 − 6 Honda Engine GR 800/1000/1010/1600/1610/2000/2600...
Page 41 Chapter 4 Traction and Reel Drive Systems Table of Contents SPECIFICATIONS ......Drum Drive Idler Pulley and Bearing .
Page 42: Specifications
Greensmaster mower. Refer to the Operator’s Manual for additional information when servicing the machine. Replacement Operator’s Manu- als are available on the internet at www.toro.com. Page 4 − 2 Traction and Reel Drive Systems GR 800/1000/1010/1600/1610/2000/2600...
Page 43: Special Tools
Special Tools Order special tools from your Toro Distributor. Drum Bushing Tool Kit − TOR4060 Note: This kit is used on mowers with drums that have REAMER bushings instead of bearings. The kit is used for models TOR4061 BUSHING DRIVER 04051 and 04052 −...
Page 44: Adjustments
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.
Page 45: Drum Drive Belt Adjustment
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 be- tween the pulleys with 4 to 5 lbs (18 to 22 N) of force. The belt should deflect 1/4 inch.
Page 46: Reel Drive Belt Adjustment
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.
Page 47: Service/Park Brake Adjustment
Service/Park Brake Adjustment If service/park brake slips when operated, an adjust- ment 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.
Page 48: Service And Repairs
Service and Repairs Reel Drive Assembly 56 57 RIGHT FRONT Figure 11 1. Clutch housing 21. Lock nut 40. Wave washer 2. Cap screw 22. Lock washer 41. Reel drive belt 3. Lock nut 23. Drive screw 42. Pulley and drive assembly 4.
Page 49: Reel Drive Belt Replacement
Reel Drive Belt Replacement Removal 3. Adjust reel drive belt tension and reinstall reel drive cover (see Reel Drive Belt in the Adjustments section). 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 4.
Page 50: Clutch Bearing
Clutch Bearing Removal Clutch and Pulley Assembly (Fig. 15) 1. Remove reel drive belt from the reel drive assembly 1. Press new ball bearings into driver. Secure bearings (see Reel Drive Belt Replacement Removal). with small retaining ring. 2. Remove clutch lever (24) as follows (Fig. 11): 2.
Page 51 Installation C. With the actuator pin engaging in the groove of the clutch jaw driver (slide driver all the way into the 1. Park mower on a level surface. Make sure engine housing), secure cap screw into the clutch housing is OFF.
Page 52: Drum Drive Assembly
Drum Drive Assembly FRAME LEFT FRONT Figure 17 1. Spacer 14. Nut 29. Bearing clamp 2. Backup washer 15. Washer 30. Seal 3. Pulley (LH) 16. V−ring seal 31. Lock nut Pulley (RH) 17. Bearing cover 32. Cap screw 4. Housing (LH) 18.
Page 53: Drum Drive Belt Replacement
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 Ac- cessories).
Page 54: Differential Axle Pulley And Bearing
Differential Axle Pulley and Bearing Removal 7. Slide pulley onto the differential axle while aligning pulley keyway with the woodruff key. Secure pulley to 1. Remove drum drive belt from the drum drive assem- the axle with the nut. bly (see Drum Drive Belt Replacement Removal). 8.
Page 55: Drum Shaft Bearing
Drum Shaft Bearing Removal C. Use a suitable wrench on the flats of the drum shaft, between the drum and the frame, to lock the 1. Remove drum drive belt from the drum drive assem- shaft. Screw pulley to the drum shaft. bly (see Drum Drive Belt Replacement Removal).
Page 56: Drum Assembly With Bearings
Drum Assembly with Bearings (Models 04050, 04052−60000 & Up, and 04060) Figure 24 1. Drum 6. Seal spacer 10. Cap screw 2. Drum spindle 7. Lock nut 11. Drum shaft (LH) 3. Spring lip seal 8. Drum hub 12. Drum shaft (RH) 4.
Page 57 Note: The lock nut turns hard on the spindle shaft 5. Secure drum spindle to the drum with four cap when tightened. Make sure all rotation has stopped screws and lock washers. Tighten screws using an alter- when tightening. A good solid sound indicates the nut is nating pattern.
Page 58: Drum Assembly With Bushings
Drum Assembly with Bushings (Models 04051 and 04052−50001 to 59999) OIL SEALS NOT SHOWN Figure 26 1. Cap screw 3. Drum 5. Drum shaft 2. Lock washer 4. Drum shaft extensions 6. Bushing Removal BUSHING DRIVER 1. Remove both drum shaft bearings from both drum shafts (see Drum Shaft Bearing Removal).
Page 59 5. Install inner bushing into drum (Fig. 30). BUSHING DRIVER Note: The setting of the adapter sleeve is critical so the bushing is inserted deep enough for oil seal installa- ADAPTER SLEEVE tion. BUSHING A. Install adapter sleeve on the bushing driver so the counterbore of the sleeve seats 3/16 inch (0.48 PILOT cm) beyond the step on the driver.
Page 60: Counter Shaft Assembly
Counter Shaft Assembly 39 40 RIGHT FRONT Figure 33 1. Countershaft housing 21. Brake support 40. Lock washer 2. Cap screw 22. Lock washer 41. Hose clamp 3. Lock washer 23. Cotter pin 42. Hose clamp 4. Flat washer 24. Cotter pin 43.
Page 61: Brake Band Replacement
Brake Band Replacement Removal 6. Reinstall interference previously removed (Fig. 34). 1. Park mower on a level surface. Make sure engine A. Make sure clutch is disengaged. Install both V− is OFF. Remove high tension lead from the spark plug. belts.
Page 62: Power Shaft Bearing
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.
Page 63: Differential Axle Bearing (Countershaft Housing)
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 −...
Page 64: Differential Idler And Bearing
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) se- curing rear and front box covers (38 and 39) to the coun- tershaft housing (1).
Page 65: Differential Assembly And Pulley
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 −...
Page 66 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) SEAL RECESS 0.030 TO 0.045 inch (0.76 to 1.14 mm) Figure 43 1. Flanged hex head screw 6.
Page 67 Note: If any of the bevel or pinion gears need to be re- 2. Slide pulley onto differential axle so threads extend placed, it is recommended to replace all four gears as a through pulley. Secure lock nuts and flat washers to the complete set.
Page 68 5. Slide locking collar onto the differential axle (Fig. IMPORTANT: Align axles so they turn freely before 38). striking the locking collar. 6. Reinstall rear box cover (38) and differential boot 9. Lock locking collar by striking it with a punch in the (43) to the differential axle and countershaft housing (1) counterclockwise direction.
Page 69: Differential Belt Replacement − Models 04051, 04052, And 04060
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.
Page 70: Differential Belt Replacement − Model 04050
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 kick- stand and remove them. 2.
Page 71 6. Use 9/16−inch open end wrench to hold the power shaft while backing off the lock nut with a 7/8−inch sock- et (Fig. 53). 7. Remove nut from the short axle of the differential as follows (Fig. 54): A. Loosen small hose clamp securing the differen- tial boot to the bearing housing.
Page 72 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.
Page 73 Installation 9. Reinstall belts to both drum drive assemblies as fol- lows (Fig. 55): 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. A. Reinstall belt onto the drum shaft pulley and pulley on both sides of mower.
Page 74 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.
Page 75: Lubrication
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.
Page 76 Page 4 − 36 Traction and Reel Drive Systems GR 800/1000/1010/1600/1610/2000/2600...
Page 77 Chapter 5 Electrical System Table of Contents ELECTRICAL SCHEMATICS and COMPONENT TESTING ..... . WIRE HARNESSES ......Interlock Module and Clutch (Interlock) Switch Serial Number Below 220000000 No Operator Presence Control...
Page 78: Electrical Schematics And Wire Harnesses
Electrical Schematics and Wire Harnesses HIGH TENSION LEAD CONNECTOR/ INTERLOCK MODULE BLACK IGNITION COIL/ IGNITOR C D E F ENGINE MAGNETO FLYWHEEL Note: There are two types of ignition IGNITOR coils used on the Kawasaki FE120 en- gine. On models below serial number 60465, a coil is used in conjunction with a separate igniter (shown below).
Page 79: Serial Number Below 220000000 With Operator Presence Control Kawasaki Fe120 Engine
HIGH TENSION LEAD CONNECTOR/ INTERLOCK MODULE BLACK IGNITION COIL/ IGNITOR ENGINE MAGNETO FLYWHEEL Note: There are two types of ignition IGNITOR coils used on the Kawasaki FE120 en- gine. On models below serial number 60465, a coil is used in conjunction with a separate igniter (shown below).
Page 80: Serial Number From 220000000 To 270999999 Kawasaki Fe120 Engine
HIGH TENSION LEAD INTERLOCK MODULE BLACK IGNITION COIL ENGINE MAGNETO (FLYWHEEL) LIGHTING COIL OPERATOR PRESENCE SWITCH (IF EQUIPPED) HOURMETER CLUTCH (IF EQUIPPED) INTERLOCK SWITCH Drawing No. 105−5351 Rev C Serial Number From 220000000 to 270999999 Kawasaki FE120 Engine ON\OFF switch (on engine) is open in the ON position CLUTCH INTERLOCK SWITCH is closed when traction lever is in NEUTRAL OPERATOR PRESENCE SWITCH is closed when bail is against handle Page 5 −...
Page 81: Kawasaki Fe120 Or Subaru Engine
HIGH TENSION LEAD INTERLOCK MODULE IGNITION COIL ENGINE MAGNETO (FLYWHEEL) LIGHTING COIL OPERATOR PRESENCE SWITCH (IF EQUIPPED) ON/OFF HOURMETER CLUTCH SWITCH (IF EQUIPPED) INTERLOCK (IN OFF) SWITCH Serial Number 280000000 to 280999999 Kawasaki FE120 or Subaru Engine ON\OFF switch (on console) is open in the ON position CLUTCH INTERLOCK SWITCH is closed when traction lever is in NEUTRAL OPERATOR PRESENCE SWITCH is closed when bail is against handle Page 5 −...
Page 82 Drawing No. 112−9410 Rev C Serial Number 280000000 to 280999999 Kawasaki FE120 or Subaru Engine ON\OFF switch (on console) is open in the ON position CLUTCH INTERLOCK SWITCH is closed when traction lever is in NEUTRAL OPERATOR PRESENCE SWITCH is closed when bail is against handle Page 5 −...
Page 83 HIGH TENSION LEAD INTERLOCK MODULE IGNITION COIL ENGINE MAGNETO (FLYWHEEL) LIGHTING COIL OPERATOR PRESENCE SWITCH (IF EQUIPPED) HOURMETER CLUTCH ON/OFF (IF EQUIPPED) INTERLOCK SWITCH SWITCH (IN OFF) Serial Number 290000000 to 311999999 Kawasaki FE120 or Subaru Engine ON\OFF switch (on console) is open in the ON position CLUTCH INTERLOCK SWITCH is closed when traction lever is in NEUTRAL OPERATOR PRESENCE SWITCH is closed when bail is against handle Page 5 −...
Page 84 Drawing No. 115−1610 Rev C Serial Number 290000000 to 311999999 Kawasaki FE120 or Subaru Engine ON\OFF switch (on console) is open in the ON position CLUTCH INTERLOCK SWITCH is closed when traction lever is in NEUTRAL OPERATOR PRESENCE SWITCH is closed when bail is against handle Page 5 −...
Page 85: Subaru Engine
HIGH TENSION LEAD INTERLOCK MODULE IGNITION COIL ENGINE MAGNETO (FLYWHEEL) LIGHTING COIL OPERATOR PRESENCE SWITCH (IF EQUIPPED) HOURMETER CLUTCH ON/OFF (IF EQUIPPED) INTERLOCK SWITCH SWITCH (IN OFF) Serial Number 312000000 to 316999999 Subaru Engine NOTE: Used on model 04056 to serial number 400341548 ON\OFF switch (on console) is open in the ON position CLUTCH INTERLOCK SWITCH is closed when traction lever is in NEUTRAL Page 5 −...
Page 86 Drawing No. 120−6338 Rev A Serial Number 312000000 to 316999999 Subaru Engine NOTE: Used on model 04056 to serial number 400341548 ON\OFF switch (on console) is open in the ON position CLUTCH INTERLOCK SWITCH is closed when traction lever is in NEUTRAL Page 5 −...
Page 87: Serial Number Above 400000000 Subaru Engine
HIGH TENSION LEAD INTERLOCK MODULE IGNITION COIL ENGINE MAGNETO (FLYWHEEL) LIGHTING COIL OPERATOR PRESENCE SWITCH (IF EQUIPPED) HOURMETER CLUTCH ON/OFF (IF EQUIPPED) INTERLOCK SWITCH SWITCH (IN OFF) OPTIONAL LIGHT SWITCH VIOLET OPTIONAL LIGHT (LH) BLACK OPTIONAL LIGHT (RH) Serial Number Above 400000000 Subaru Engine NOTE: Used on model 04056 serial number above 400341549 ON\OFF switch (on console) is open in the ON position...
Page 88 Drawing No. 122−0964 Rev B Serial Number Above 400000000 Subaru Engine NOTE: Used on model 04056 serial number above 400341549 ON\OFF switch (on console) is open in the ON position CLUTCH INTERLOCK SWITCH is closed when traction lever is in NEUTRAL Page 5 −...
Page 89: Honda Engine
HIGH TENSION LEAD INTERLOCK MODULE IGNITION COIL ENGINE MAGNETO (FLYWHEEL) LIGHTING COIL OPERATOR PRESENCE SWITCH (IF EQUIPPED) HOURMETER CLUTCH ON/OFF (IF EQUIPPED) INTERLOCK SWITCH SWITCH (IN OFF) OPTIONAL LIGHT SWITCH VIOLET OPTIONAL LIGHT (LH) BLACK OPTIONAL LIGHT (RH) Honda Engine ON\OFF switch (on console) is open in the ON position CLUTCH INTERLOCK SWITCH is closed when traction lever is in NEUTRAL Page 5 −...
Page 90 Drawing No. 122−1227 Rev A Honda Engine ON\OFF switch (on console) is open in the ON position CLUTCH INTERLOCK SWITCH is closed when traction lever is in NEUTRAL Page 5 − 14 Electrical System GR 800/1000/1010/1600/1610/2000/2600...
Page 91: 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 me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
Page 92: Troubleshooting
Troubleshooting NOTE: See the Kawasaki FE161 & FE170 Service Manual and Kawasaki FE120 Service Manual Sup- CAUTION plement for troubleshooting of electrical problems re- lated to the Kawasaki ignition system. However, ignition Remove all jewelry, especially rings and system testing is covered in this chapter. The ignition watches, before doing any electrical trou- system for the FE120 engine is not fully covered in the bleshooting or testing.
Page 93: Component Testing
Component Testing For accurate resistance and/or continuity checks, elec- NOTE: See the engine service manual (Kawasaki or trically disconnect the component being tested from the Subaru) for engine component testing information. circuit (e.g. unplug the ON/OFF switch connector before doing a continuity check). Individual components should be electrically isolated (e.g.
Page 94: With Operator Presence Control
Interlock Module and Clutch (Interlock) Switch − With Operator Presence Control The interlock module prevents the engine from starting E. Reconnect wire harness connectors to the oper- unless the clutch interlock switch is closed (clutch DIS- ator presence switch. ENGAGED). After a safe start, the engine will continue 4.
Page 95: Ignition System Operation
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 sys- tem is operating properly. SPRING CLIP Note: This tester is not necessary if spark tester TOR4036 (see Special Tools in this chapter) is avail- able.
Page 96 Igniter (Kawasaki Engine on Machine with Serial Number Below 60465) The igniter consists of transistorized circuitry that con- trols 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.
Page 97: Ignition Coil (Kawasaki Engine)
Ignition Coil (Kawasaki Engine) A commercial coil tester can be used to test the ignition coil. If a tester is available, test the ignition coil as sug- gested in the Kawasaki FE161 & FE170 Service Manual and Kawasaki FE120 Service Manual Sup- plement The coil can be tested for a badly shorted or broken winding with a digital ohmmeter.
Page 98: Ignition Coil (Subaru Engine)
Ignition Coil (Subaru Engine) The coil can be tested for a badly shorted or broken winding with a digital ohmmeter. However, an ohmmeter can not detect layer shorts and shorts resulting from in- sulation breakdown under high running voltages. Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together.
Page 99: Spark Plug
Spark Plug Use the correct spark plug for your Greensmaster as identified in your Operator’s Manual. Remove plug after every 100 operating hours and check its condition. Air gap 1. Make sure engine is OFF. Pull high tension lead off the spark plug.
Page 100 NORMAL OVER HEATING FUSED SPOT DEPOSIT Has gray or light tan deposits on the firing Light gray or white insulator with small gray Has spotty or melted deposits resembling tip. brown or black spots. Electrodes have a blisters or bubbles. bluish burnt appearance.
Page 101: Clutch Interlock Switch (Serial Number Below 280000000)
Clutch Interlock Switch (Serial Number Below 280000000) 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 0.180 to 0.240 inch (4.6 to 6.1 mm) (switch closed).
Page 102: Clutch Interlock Switch (Serial Number Above 280000000)
Clutch Interlock Switch (Serial Number Above 280000000) Switch Adjustment 1. Make sure the engine is OFF and the traction lever is DISENGAGED. 2. Remove console cover from handle to allow access to clutch interlock switch. 3. With the traction lever in the disengaged position and resting against the neutral stop, there should be from 0.032 to 0.062 inch (0.8 to 1.5 mm) clearance be- tween the traction lever and the clutch interlock switch...
Page 103: Operator Presence Control Switch (Serial Number Below 280000000)
Operator Presence Control Switch (Serial Number Below 280000000) Greensmaster mowers with serial number below 280000000 that are equipped with the operator pres- ence system use a plunger type switch that is depressed when the operator presence bail is engaged. The switch is located on the left side of the handle (Fig.
Page 104: Operator Presence Control Switch (Serial Number Above 280000000)
Operator Presence Control Switch (Serial Number Above 280000000) Greensmaster mowers with serial number above 280000000 that are equipped with the operator pres- ence system use a plunger type switch that is depressed when the operator presence bail is engaged. The switch is located on the left side of the handle (Fig.
Page 105: On/Off Switch
ON/OFF Switch (Serial Number Above 280000000) Greensmaster mowers with serial number above 280000000 are equipped with a two position ON/OFF switch on the console. This rocker switch allows the en- gine to be turned on and off. Testing 1. Make sure the engine is OFF and the traction lever is in the NEUTRAL position.
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Page 107 Chapter 6 Controls, Wheels and Accessories Table of Contents SPECIFICATIONS ......GENERAL INFORMATION .
Page 108: Specifications
Greensmaster mower. Refer to the Operator’s Manual for additional information when servicing the machine. Replacement Operator’s Manu- als are available on the internet at www.toro.com. Page 6 − 2 Wheels and Accessories GR 800/1000/1010/1600/1610/2000/2600...
Page 109: Adjustments
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.
Page 110: Service And Repairs
Service and Repairs Handle Assembly RIGHT FRONT Figure 2 1. Throttle cable 16. Brake skid bracket 30. Cap screw 2. Spring 17. Brake bracket 31. Spring lock washer 3. Lock nut 18. Brake lever 32. Flat washer 4. Retaining washer 19.
Page 111 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.
Page 112: Brake Cable Replacement
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.
Page 113 B. If the operator presence kit is not installed, se- A. Attach brake cable to the counter shaft housing cure console bracket to the brake skid bracket with and tighten the rear nut. three screws. B. Secure cable eyelet to the brake lever with 3.
Page 114: Clutch Cable Replacement
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 han- dle.
Page 115 3. If the operator presence kit is not installed, secure A. Attach clutch cable to the clutch bracket. Tighten console bracket to the clutch skid bracket with three nut to secure cable to the bracket. screws (Fig. 8). B. Secure clutch cable eyelet to the clutch lever 4.
Page 116: Throttle Cable Replacement
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.
Page 117: Wheels
Wheels Removal 1. Park mower on a level surface. Make sure the en- gine 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.
Page 118 Figure 14 1. Cap screw 6. Retaining lever 11. Inner tube 2. Lock washer 7. Spring 12. Cap screw 3. Shallow rim 8. Bolt 13. Flange nut 4. Tire 9. Bolt 14. Wheel shaft 5. Hub 10. Deep rim Disassembly (Fig. 14) 2.
Page 119: Kickstand
Kickstand 1 2 3 4 NOTE THE POSITION OF THE STOP FRAME Figure 16 1. Cap screw 5. Extension spring 9. Flat washer 2. Cap screw 6. Cap screw 10. Lock nut 3. Lock washer 7. Spring retainer 11. Spacer 4.
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Page 121: Cutting Unit
Chapter 7 Cutting Unit Table of Contents INTRODUCTION ......SERVICE AND REPAIRS .
Page 122: Introduction
Introduction This Chapter covers the cutting unit section of your part of the cutting unit, and their component parts that Greensmaster. The cutting unit consists of the frame as- are necessary for the service of the cutting unit are cov- sembly, reel assembly, drum assembly, and detachable ered in this chapter.
Page 123: Specifications
Specifications Figure 1 REEL CONSTRUCTION (GR1000): 5−inch (12.7 cm) REEL CONSTRUCTION (GR1600): 5−inch (12.7 cm) diameter, 11 carbon steel blades (optional 8 blades) diameter, 8 carbon steel blades welded to 6 stamped welded to 5 stamped steel spiders. steel spiders. HEIGHT−OF−CUT RANGE (GR1000): 5/64 to 1 inch HEIGHT−OF−CUT RANGE (GR1600): 1/8 to 1−1/4 (2 to 25 mm)
Page 124: General Information
General Information Operator’s Manual The Cutting Unit Operator’s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for the cutting unit on your Greensmaster machine. Additionally, if optional kits have been installed on the cutting unit (e.g. grooming reel), the installation instructions for the kit includes set−...
Page 125: Special Tools
Special Tools Order special tools from your Toro Distributor. Some tools may have been supplied with your mower or avail- able as TORO parts. Some tools may also be available from a local supplier. Gauge Bar Assembly − P/N 13−8199 Used to verify height−of−cut.
Page 126 This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the Turf Evaluator (Toro part no. 97931SL).
Page 127: Bedknife Top Angle Indicator And Mount
Because the top grind angle on bedknives is critical for edge retention, and therefore after− cut appearance, Toro has developed these service tools for accurately measuring the top grind angle on all bedknives. Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar.
Page 128: Troubleshooting
Troubleshooting There are a number of factors that can contribute to un- mower. It is important to remember that the lower the satisfactory quality of cut, some of which may be turf height−of−cut, the more critical these factors are. See conditions.
Page 129 Factor Possible Problem/Correction Height−of−cut “Effective” or actual height−of−cut depends on the mower weight and turf conditions. Effective height−of−cut will be different than the bench set height−of−cut. Proper bedknife for height−of−cut If the bedknife is too thick for effective height−of−cut, poor quality of cut will result. Front roller scraper and comb adjustment Install and/or adjust roller scrapers if grass clippings build up on the rollers.
Page 130: Adjustments
Adjustments CAUTION Never work on the mower with the engine running. Always stop the engine and re- move the high tension lead from the spark plug first. Leveling Drum to Reel 1. Make sure engine is OFF. Remove high tension lead from the spark plug.
Page 131: Bedknife To Reel Adjustment
(8 kg−cm) be evident, it will be either necessary to backlap or regrind the reel and bedknife to achieve the sharp edges needed for precision cutting (see Toro General Service Training Book, Reel Mower Figure 15 Basics (part no. 09168SL).
Page 132: Height−Of−Cut Adjustment
Height−of−Cut Adjustment 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Verify that the drum is level to the reel and that the bedknife to reel contact is correct. Tip mower back on its handle to expose roller, drum, and bedknife.
Page 133: Grass Shield Height Adjustment
Grass Shield Height Adjustment Adjust shield to assure proper grass clipping discharge into the basket. 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Measure distance from the top of the front support rod to the front lip of the shield at each end of cutting unit (Fig.
Page 134: Service And Repairs
4. Insert a 1/2−inch socket extension, which is con- nected to a backlapping machine, into the square hole in the center of the reel pulley. 5. Backlap according to procedure in Toro General Service Training Book, Reel Mower Basics (part no. 09168SL).
Page 135: Bedbar
Bedbar Removal 1. Position mower on a flat level work surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Loosen jam nut on the adjusting screw. Loosen ad- justing screw until the thrust washer contacts the inside of the frame adjuster.
Page 136 Installation Note: Use new nylon washers and bushings for instal- lation. 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Use grease to hold thrust washers against the in- side of both frame adjusters (Fig.
Page 137: Bedknife Replacement And Grinding
Bedknife Replacement and Grinding Bedbar Removal 1. Remove bedbar from frame (see Bedbar Removal). 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special Tools in this chap- ter). Discard screws. Remove bedknife from the bedbar (Fig.
Page 138 1. Use Toro General Service Training Book, Reel Mow- er Basics (part no. 09168SL) and grinder manufactur- er’s instructions for bedknife grinding information. 2. After bedknife grinding is complete, install bedbar to cutting unit (see Bedbar Installation in this section).
Page 139: Reel
Reel Removal 1. Make sure engine is OFF. Remove high tension lead from the spark plug. Place mower on a flat level sur- face or on a stable work bench. 2. Remove bedbar from the mower (see Bedbar Re- moval). 3.
Page 140 10. Pull both bearing housings from the frame and reel Note: The two bearing housings are similar in appear- (Fig. 39 and 40). Remove the reel from the mower. ance but can not be interchanged. The bearing housing (RH) was marked during disassembly. 11.
Page 141 8. Tighten flat head screws and nuts securing the 11. Reinstall reel drive cover with four lock washers and bearing housing (RH) to the frame (Fig. 39). cap screws to the mower. Tighten cap screws (Fig. 39). 9. Remove both cap screws and lock nuts holding the 12.
Page 142: Preparing Reel For Grinding
Preparing a Reel for Grinding Note: Check to make sure the reel bearings are in 4. After completing grinding process: good condition and properly adjusted before grinding a A. Install height−of−cut arms and roller (see Roller reel. Installation). 1. Remove bedbar assembly (see Bedbar Removal). B.
Page 143: Roller
Roller Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Loosen jam nut and set screw on both ends of the mower. 3. On one end of the mower, remove lock nut and flat washer from the carriage screw.
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Page 145 Greensmaster, use the information in this chapter along with the Installation Instruction for your grooming reel kit. Installation Instructions for the grooming reel kit can be obtained on the internet at www.toro.com. Page 8 − 1 Greensmaster 1000 Grooming Reel Kit...
Page 146: Specifications
Specifications MOUNTING: The grooming kit is rigidity mounted to the MICRO ADJUSTMENT KNOB: Allows a 0.007 inch mower reel bearing housings and frame. (0.18 mm) increment of height adjustment REEL CONSTRUCTION: 2−1/4 inch (5.4 cm) diameter, QUICK UP−DOWN FEATURE: Allows grooming reel to 41 steel blades with 1/2−inch blade spacing.
Page 147: General Information
General Information Clutch Engagement/Disengagement The grooming reel should be disengaged at all times ex- cept during grooming. IMPORTANT: When engaging or disengaging the clutch, be sure to turn the clutch knob all the way until it comes to a firm stop. Failure to do so could cause damage to the clutch.
Page 148: Troubleshooting
Troubleshooting Factors Affecting Grooming There are a number of factors that can affect the perfor- IMPORTANT: Improper or overaggressive use of mance of grooming. These factors vary for different golf the grooming reel, such as too deep or frequent courses and from green to green. It is important to in- grooming, may cause unnecessary stress on the spect the turf frequently and vary the grooming practice turf leading to severe turf damage.
Page 149: Grooming Reel Mechanical Problems
Grooming Reel Mechanical Problems Problem Possible Causes Correction The grooming reel rotates when it is Due to friction in the clutch assem- This condition may change over a in the raised position with the clutch bly, the grooming reel may still ro- period of time.
Page 150: Adjustments
Adjustments CAUTION Never work on the mower with the engine running. Always stop the engine and re- move the high tension lead from the spark plug first. Height/Depth of Grooming Adjustment 1. Park mower on a level surface. Make sure engine is OFF.
Page 151: Drive Belt Tension Adjustment
Drive Belt Tension Adjustment 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Loosen both set screws in the clutch knob. Remove clutch knob and poly washer from the clutch assembly. 3.
Page 152: Service And Repairs
Service and Repairs Reel 2 3 4 5 6 GROOMING REEL RIGHT ASSEMBLY FRONT Figure 5 1. Lock nut 19. Roll pin 37. Socket head cap screw 2. Ball bearing 20. Cap 38. Idler pulley spacer 3. Lock nut 21. Ramp 39.
Page 153 CLUTCH ASSEMBLY RIGHT FRONT Figure 6 1. Belt cover 7. Roller bearing 12. Set screw 2. Clutch drive adapter 8. Belleville washer 13. Clutch knob 3. Needle bearing 9. Clutch release disc 14. Flat washer 4. Clutch pin 10. Special screw 15.
Page 154 Disassembly 6. Secure belt cover to housing with three socket head cap screws and washers (Fig. 7). Reinstall poly washer Inspect grooming reel blades frequently for damage and and clutch knob to clutch assembly. Tighten both set wear. Straighten bent blades with a pliers. Either replace screws into the clutch knob (Fig.
Page 155: Reel Bearing Replacement
Reel Bearing Replacement 1. Remove grooming reel (see Reel Removal). Note: Replace all four ball bearings as a complete set. 2. Check condition of groomer ball bearings and re- place as necessary. A. In the bearing housing and belt drive housing, install outer ball bearing first with the seal facing out.
Page 156: Clutch Assembly
Clutch Assembly Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Loosen set screws in the clutch knob. Remove clutch knob and poly washer from the clutch assembly (Fig.
Page 157 5. Apply Loctite 271 or equivalent to the threads of the 3. Place clutch assembly on the shaft of the clutch special screw. Secure compression spring to the special drive adapter. Secure flat washer and lock nut the shaft screw with clutch pin. The clutch pin should extend out of the clutch drive adapter (Fig.
Page 158: Frame Assemblies (Rh And Lh)
Frame Assemblies (RH and LH) 2 3 4 5 6 GROOMING REEL RIGHT ASSEMBLY FRONT Figure 17 1. Lock nut 19. Roll pin 37. Socket head cap screw 2. Ball bearing 20. Cap 38. Idler pulley spacer 3. Lock nut 21.
Page 159 CLUTCH ASSEMBLY RIGHT FRONT Figure 18 1. Belt cover 7. Roller bearing 12. Set screw 2. Clutch drive adapter 8. Belleville washer 13. Clutch knob 3. Needle bearing 9. Clutch release disc 14. Flat washer 4. Clutch pin 10. Special screw 15.
Page 160 4. On older models, loosen both carriage bolts secur- ing the reel idler bracket to the frame. Pivot idler pulley assembly away from the reel drive belt. (Fig. 22). 5. Remove the pulley and drive assembly and drive belt from the cutting reel shaft as follows (Fig. 22): A.
Page 161 Note: The driven pulley (42) has left handed threads. B. Use an allen wrench to remove driven pulley from the shaft (53). 11. Remove lock nut and flat washer from the shaft of the clutch drive adapter. Pull clutch assembly off the shaft of the clutch drive adapter (Fig.
Page 162 Installation FRAME ASSEMBLY (RH) 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. If bedbar adjuster frames have not been removed, remove the following on both sides of the mower frame (Fig.
Page 163 D. Slide adapter through the bearing and into the reel bearing housing. Install lock nuts on flat head screws and torque from 23 to 27 ft−lb (3.2 to 3.7 kg−m) (Fig. 28 and 29). Note: The lock nut (1) has left handed threads. E.
Page 164: Cutting Reel
Cutting Reel Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Make sure mower is on a flat level surface or on a stable work bench. 3. Remove grooming reel kit following the Removal instructions in Frame Assemblies (RH and LH).
Page 165 IMPORTANT: Make sure the correct bearing hous- 6. Attach bearing housing (LH) through the frame onto ing is used when installing bearings. The grease fit- the reel shaft (Fig. 33). ting hole should face forward when the housing is A. Push housing onto reel shaft. If necessary, tap placed in the frame.
Page 166: Lubrication
Lubrication There are two grooming reel shaft bearings on each end of the mower. 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Use a hand pump grease gun and No. 2 multipur- pose lithium base grease for lubrication.

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