Page 3 - Table Of Contents
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 . . . . . . . . . . . . . . . . ...
Page 5 - Chapter 1; Safety; Table of Contents; WARNING; Safety
Greensmaster 1000/1600 Page 1 – 1 Safety Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS 1 . . . . . . . . . . . . . . . . . . . . . . Before Operating 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenan...
Page 6 - While Operating; Maintenance and Service
Greensmaster 1000/1600 Page 1 – 2 Safety 10. Check the safety interlock switch daily for proper op-eration; see Component Testing in Chapter 5 – Electri-cal System. Replace malfunctioning switches before operating machine. (After every two years, replace theinterlock switch in the safety system, whe...
Page 7 - Safety and Instruction Decals; DANGER; GAS; UNLEADED
Greensmaster 1000/1600 Page 1 – 3 Safety Safety and Instruction Decals The following safety and instruction decals are affixed tothe traction unit. If any decal becomes illegible or dam-aged, install a new decal. Part numbers are listed below and in your Parts Catalog. Order replacements fromyour Au...
Page 9 - Chapter 2; Product Records and Manuals; Product Records
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...
Page 10 - Equivalents and Conversions
Greensmaster 1000/1600 Page 2 – 2 Product Records and Manuals Equivalents and Conversions
Page 11 - Torque Specifications
Product Records and Manuals Greensmaster 1000/1600 Page 2 – 3 Product Records and Manuals Torque Specifications
Page 14 - GREENSMASTER® 1000 Maintenance Schedule; Minimum Recommended Maintenance Intervals:; Annual Recommendations:
GREENSMASTER® 1000 Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Maintenance Interval & Service Every 200hrs Every 100hrs Every 50hrs Service Air Filter Pre-Cleaner Every 25hrs A Level Lubricate All Grease Fittings Check for loose Fasteners Clean Fuel Filt...
Page 15 - GREENSMASTER® 1000 Daily Maintenance Check List; Daily Maintenance Check For Week
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 MON _______HRS TUES ______HRS WED ______HRS THURS ______HRS FR ______...
Page 16 - B Service; Other; - Annual Service and Specials; Additional Servicing Items; C Service
GREENSMASTER® 1000 Supervisor Maintenance Work Order Date:______________ (duplicate this page for routine use) Unit Designation: TORO I.D. #: Remarks: ____________-____________ Hours: Service to perform (circle): A B C D Other Technician: A -Service (every 25 hours) B -Service (every 50 hours) C -Se...
Page 17 - Chapter 3; Engine; Engine
Greensmaster 1000/1600 Page 3 – 1 Engine Chapter 3 Engine Table of Contents INTRODUCTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 4 . . . . . . . . . . . . . . . . . . . . . Filling the ...
Page 18 - Introduction
Greensmaster 1000/1600 Page 3 – 2 Engine Introduction This Chapter gives information about specifications,maintenance, troubleshooting, testing, and repair of thegasoline engine used in the Greensmaster 1000/1600mower. Most repairs and adjustments require tools which arecommonly available in many se...
Page 19 - Specifications
Greensmaster 1000/1600 Page 3 – 3 Engine 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 (...
Page 20 - General Information; Filling the Fuel Tank
Greensmaster 1000/1600 Page 3 – 4 Engine General Information Filling the Fuel Tank DANGER +) )&#!% !) #$$# +*!&% $+)* +) - % )*&(!% &( %#!% !* & %&* !## * +# *%" - !# %!% !) (+%0 %!% &* &( !% % %#&) ( '&() $/ +!# +' % !%!* / )'(" &( #$ )&+( $%/...
Page 21 - Fuel Shut–off Valve
Greensmaster 1000/1600 Page 3 – 5 Engine Fuel Shut–off Valve The valve is located on the left front side of the engine.It has two positions: CLOSED and OPEN. Position valveto the closed position when storing or transporting themachine. Open valve before starting the engine. Figure 2 1. Fuel shut–off...
Page 22 - Adjustments; Throttle Control Adjustment
Greensmaster 1000/1600 Page 3 – 6 Engine Rev. A Adjustments Throttle Control Adjustment If a new throttle cable must be installed or the cable isout 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 23 - Adjusting V–belts; INSIDE FACE
Greensmaster 1000/1600 Page 3 – 7 Engine Adjusting V–belts To adjust belt tension on V–belts (Fig. 5), first check ad-justment of clutch control. Refer to Clutch Control in thissection. If unable to attain the 7 to 9 lbs (31 to 40 N) offorce that is required in adjusting the clutch control, pro-ceed...
Page 24 - Service and Repairs; Engine Oil
Greensmaster 1000/1600 Page 3 – 8 Engine Service and Repairs Engine Oil The TORO Company recommends that the oil level bechecked each time the mower is used or after every 5operating hours. Initially, change oil after the first 20hours of operation; thereafter, change oil after every 50hours of oper...
Page 25 - Air Cleaner
Greensmaster 1000/1600 Page 3 – 9 Engine Air Cleaner Normally, clean air filter precleaner (foam element) afterevery 25 operating hours and the air cleaner filter (paperelement) after every 100 operating hours. More frequentcleaning is required when the mower is operated industy or dirty conditions....
Page 26 - Engine Removal and Installation
Greensmaster 1000/1600 Page 3 – 10 Engine Engine Removal and Installation Figure 12 1. Bellcrank cover 2. Flat washer 3. Stud4. Retainer5. Capscrew6. Lock washer 7. Flat washer 8. Grease fitting 9. Lever10. Bushing11. Input drive pulley12. Engine shaft spacer13. Shoulder bolt14. Torsion spring15. Ja...
Page 27 - SLOW; SCRIBE MARK
Greensmaster 1000/1600 Page 3 – 11 Engine Removal 1. Make sure machine is parked on a level surface with the engine OFF. Remove high tension lead from thespark plug to prevent the engine from starting. Closefuel shut–off valve. 2. Remove pulley V–belts (Fig. 12). A. Make sure clutch is DISENGAGED so...
Page 28 - Reinstalling the Engine
Greensmaster 1000/1600 Page 3 – 12 Engine Reinstalling the Engine 1. Make sure machine is parked on a level surface. The machine may be placed on a large work bench tomake engine installation and adjustment easier. Re-move high tension lead from the spark plug. 2. Make sure that all parts removed fr...
Page 29 - Lubrication
Greensmaster 1000/1600 Page 3 – 13 Engine Lubrication Both fittings on the bellcrank assembly should begreased at least every 25 hours. Lubricate using No. 2multipurpose lithium base grease. A hand operatedgrease gun is recommended for best results. 1. Park mower on a level surface. Make sure engine...
Page 31 - Chapter 4; Traction and Reel Drive Systems; Traction and Reel
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 1 Chapter 4 Traction and Reel Drive Systems Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drum Bushing Tool Kit 3 . ....
Page 33 - Special Tools; Drum Bushing Tool Kit – TOR4060
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 3 Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PROD-UCTS). Some tools may have been supplied with your mower oravailable as TORO parts. Some tools may also be avail-able from a local s...
Page 34 - Differential Belt Adjustment
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 4 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 ...
Page 35 - Drum Drive Belt Adjustment
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 5 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 ...
Page 36 - Reel Drive Belt Adjustment
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 6 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 fo...
Page 37 - Service/Park Brake Adjustment
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 7 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 l...
Page 38 - Reel Drive Assembly
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 8 Service and Repairs Reel Drive Assembly 1. Clutch housing 2. Cap screw 3. Lock nut 4. Ball bearing 5. Grease fitting 6. Oil seal 7. Wave washer 8. Retaining ring 9. Power shaft 10. Key (2)11. Clutch jaw driver12. Clutch and pulley ass...
Page 39 - Reel Drive Belt Replacement; Reel Drive Idler Pulley and Bearing; Removal
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 9 Reel Drive Belt Replacement Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Remove cap screws (56), washers (57) and reel drive cover (49) to expose reel drive belt (...
Page 40 - Clutch Bearing
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 10 Clutch Bearing Removal 1. Remove reel drive belt from the reel drive assembly (see Reel Drive Belt Replacement Removal). 2. Remove clutch lever (24) as follows (Fig. 11): A. Remove cap screw (27), lock washer (22), belle-ville washer...
Page 42 - Drum Drive Assembly
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 12 Drum Drive Assembly 1. Spacer2. Backup washer 3. Pulley (LH) * Pulley (RH) 4. Housing (LH) * Housing (RH) 5. Cap screw 6. Lock nut 7. Grease fitting 8. Seal9. Bearing10. Spacer11. Grease fitting12. Belt13. Pulley 14. Nut15. Washer16....
Page 43 - Drum Drive Belt Replacement; Drum Drive Idler Pulley and Bearing
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 13 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 –...
Page 44 - Differential Axle Pulley and Bearing
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 14 Differential Axle Pulley and Bearing Removal 1. Remove drum drive belt from the drum drive assem- bly (see Drum Drive Belt Replacement Removal). 2. Remove nut from the differential axle. Remove pulley and woodruff key from the axle (...
Page 45 - Drum Shaft Bearing
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 15 Drum Shaft Bearing Removal 1. Remove drum drive belt from the drum drive assem- bly (see Drum Drive Belt Replacement Removal). Note: The pulley (LH) has left hand threads, while thepulley (RH) has right hand threads. Each pulley has ...
Page 50 - Counter Shaft Assembly
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 20 Counter Shaft Assembly 1. Countershaft housing 2. Cap screw 3. Lock washer 4. Flat washer 5. Screw plate 6. Flangette7. Grease fitting 8. Flangette9. Bearing10. Locking collar11. Set screw12. Lock washer13. Jam nut14. Shoulder bolt15...
Page 51 - Brake Band Replacement
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 21 Brake Band Replacement Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Remove interference to brake band (Fig. 34). A. Remove bellcrank cover by removing both capscr...
Page 52 - Power Shaft Bearing
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 22 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 hous...
Page 53 - Differential Axle Bearing (Countershaft Housing)
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 23 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...
Page 54 - Differential Idler and Bearing
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 24 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 a...
Page 55 - Differential Assembly and Pulley
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 25 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 ...
Page 58 - Reinstall bearing housing for the right differential
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 28 5. Slide locking collar onto the differential axle (Fig. 38). 6. Reinstall rear box cover (38) and differential boot (43) to the differential axle and countershaft housing (1)(Fig. 33). 7. Reinstall bearing housing for the right diff...
Page 60 - Differential Belt Replacement – Model 04050 Only; CAUTION
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 30 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 remov...
Page 61 - FORWARD
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 31 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 securin...
Page 62 - LEFT
Greensmaster 1000/1600 Traction and Reel Drive Systems Page 4 – 32 Note: The locking collar securing the long axle to thecountershaft housing is a eccentric flange type. 11. Loosen the set screw on the locking collar. Unlockcollar by striking it with a punch in the clockwise direction(Fig. 58). 12. ...
Page 67 - Chapter 5; Electrical System; Electrical
Greensmaster 1000/1600 Page 5 – 1 Electrical System Chapter 5 Electrical System Table of Contents WIRING SCHEMATICS 2 . . . . . . . . . . . . . . . . . . . . . . . . Late Model Kawasaki FE120 Engines 2 . . . . . . . . . . Late Model Kawasaki FE120 Engines with Operator Presence Control 3 . . . . . ....
Page 68 - Wiring Schematics; Late Model Kawasaki FE120 Engines
Greensmaster 1000/1600 Page 5 – 2 Electrical System Wiring Schematics A B C D E F GREEN RED BROWN BROWN CLUTCH SWITCH ENGINE MAGNETO CONNECTOR/ INTERLOCK MODULE BLACK\WHITE BLACK\WHITE ON/OFF IGNITION COIL/ IGNITOR BLACK BLACK BLACK Late Model Kawasaki FE120 Engines ON\OFF switch is open in the ON p...
Page 70 - Early Model Kawasaki FE120 Engines
Greensmaster 1000/1600 Page 5 – 4 Electrical System A B C D E F GREEN RED BROWN BROWN CLUTCH SWITCH ENGINE MAGNETO CONNECTOR/ INTERLOCK MODULE BLACK\WHITE BLACK\WHITE ON/OFF IGNITION COIL BLACK BLACK BLACK IGNITOR BLACK Early Model Kawasaki FE120 Engines ON\OFF switch is open in the ON positionCLUTC...
Page 71 - with Operator Presence Control
Greensmaster 1000/1600 Page 5 – 5 Electrical System ENGINE MAGNETO ON/OFF IGNITION COIL BLACK BLACK BLACK IGNITOR BLACK Early Model Kawasaki FE120 Engines ON\OFF switch is open in the ON positionCLUTCH SWITCH is closed when the clutch is DISENGAGED HIGH TENSION LEAD FLYWHEEL RED A B C D E F GREEN BR...
Page 72 - Multimeter
Greensmaster 1000/1600 Page 5 – 6 Electrical System Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PROD-UCTS). Some tools may also be available from a local supplier. Multimeter The meter can test electrical components and circuitsfor current, resist...
Page 73 - Troubleshooting; Problem
Greensmaster 1000/1600 Page 5 – 7 Electrical System Troubleshooting CAUTION Remove all jewelry, especially rings andwatches, before doing any electrical trou-bleshooting or testing. For effective troubleshooting and repairs, you musthave a good understanding of the electrical circuits andcomponents ...
Page 74 - Component Testing
Greensmaster 1000/1600 Page 5 – 8 Electrical System Component Testing For accurate resistance and/or continuity checks, elec-trically disconnect the component being tested from thecircuit (e.g. unplug the ON/OFF switch connector beforedoing a continuity check). Individual components shouldbe electri...
Page 76 - Ignition System Operation; Making a System Tester
Greensmaster 1000/1600 Page 5 – 10 Electrical System Ignition System Operation Making a System Tester This simple tester can be made if a commercial sparktester is not available. It can determine if the ignition sys-tem is operating properly. 1. Use a new NGK BPR5ES or equivalent spark plug. 2. Remo...
Page 77 - Igniter
Greensmaster 1000/1600 Page 5 – 11 Electrical System Igniter The igniter consists of transistorized circuitry that con-trols the firing sequence of the spark plug in conjunctionwith the ignition coil. Mounted on the engine block, theigniter casing is grounded directly to the engine. A singleblack wi...
Page 78 - Ignition Coil
Greensmaster 1000/1600 Page 5 – 12 Electrical System Ignition Coil A commercial coil tester can be used to test the ignitioncoil. If a tester is available, test the ignition coil as sug-gested in the Kawasaki FE161 & FE170 ServiceManual and Kawasaki FE120 Service Manual Sup-plement The coil can ...
Page 79 - Interlock Switch; Adjustment
Greensmaster 1000/1600 Page 5 – 13 Electrical System Service and Repairs NOTE: See the Kawasaki FE161 & FE170 ServiceManual and Kawasaki FE120 Service Manual Sup-plement for more component repair information. Interlock Switch Adjustment 1. Make sure the engine is OFF and traction lever is DISENG...
Page 80 - Operator Presence Control Switch
Greensmaster 1000/1600 Page 5 – 14 Electrical System Operator Presence Control Switch Adjustment 1. Make sure the engine is OFF. 2. Loosen both switch adjusting nuts. While holding the bail against the handle, move switch until the switchplunger is depressed 0.16 inch (4.1 mm) (switchclosed). 3. Tig...
Page 81 - Spark Plug
Greensmaster 1000/1600 Page 5 – 15 Electrical System Spark Plug Use a NGK BPR 5ES spark plug or equivalent. Removeplug after every 100 operating hours and check itscondition. 1. Make sure engine is OFF. Pull high tension lead off the spark plug. 2. Clean around spark plug and remove plug from the cy...
Page 83 - Wheels and Accessories; Chapter 6; Controls, Wheels and Accessories; Wheels and
Greensmaster 1000/1600 Page 6 – 1 Wheels and Accessories Chapter 6 Controls, Wheels and Accessories Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handle Height Adjustment 3 . . . . ...
Page 85 - Handle Height Adjustment
Greensmaster 1000/1600 Page 6 – 3 Wheels and Accessories 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 86 - Handle Assembly
Greensmaster 1000/1600 Page 6 – 4 Wheels and Accessories Service and Repairs Handle Assembly Figure 2 1. Throttle cable 2. Spring3. Lock nut 4. Retaining washer 5. Friction washer 6. Throttle lever 7. Cap screw 8. Clutch skid bracket9. Cap screw 10. Console bracket (RH)11. Lock nut12. Clutch cable13...
Page 88 - Brake Cable Replacement
Greensmaster 1000/1600 Page 6 – 6 Wheels and Accessories Brake Cable Replacement Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Disengage brake to release tension on the brake cable. Remove cable ties from the left side of the hand...
Page 90 - Clutch Cable Replacement
Greensmaster 1000/1600 Page 6 – 8 Wheels and Accessories Clutch Cable Replacement Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Disengage clutch to release tension on the clutch cable. Remove cable ties from the right side of the ...
Page 92 - Throttle Cable Replacement
Greensmaster 1000/1600 Page 6 – 10 Wheels and Accessories Throttle Cable Replacement Removal 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Remove cable ties from the right side of the handle. Remove nut and cable clip from the flangette o...
Page 93 - Wheels
Greensmaster 1000/1600 Page 6 – 11 Wheels and Accessories 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 kickstand. 3. Pivot wheel locking clip away from the cente...
Page 94 - Disassembly
Greensmaster 1000/1600 Page 6 – 12 Wheels and Accessories 1. Cap screw 2. Lock washer 3. Shallow rim 4. Tire5. Hub 6. Retaining lever 7. Spring8. Bolt9. Bolt10. Deep rim 11. Inner tube12. Cap screw13. Flange nut14. Wheel shaft Figure 13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Disassembly 1. Remove three ca...
Page 95 - Kickstand
Greensmaster 1000/1600 Page 6 – 13 Wheels and Accessories Kickstand 1. Cap screw 2. Cap screw 3. Lock washer 4. Spring bracket 5. Extension spring 6. Cap screw 7. Spring retainer 8. Kickstand 9. Flat washer 10. Lock nut11. Spacer12. Flange lock nut Figure 14 1 2 3 4 5 6 7 8 9 10 11 12 9 FRAME NOTE T...
Page 97 - Chapter 7; Cutting Unit; Cutting Unit
Greensmaster 1000/1600 Page 7 – 1 Cutting Unit Chapter 7 Cutting Unit Table of Contents INTRODUCTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 4 . . . . . . . . . . . . . . . . . . . . . ...
Page 100 - Grass Basket Installation
Greensmaster 1000/1600 Page 7 – 4 Cutting Unit General Information Grass Basket Installation 1. Grasp basket by top rear lip and slide on or off the basket mounting rods. Figure 2 1 1. Grass basket 2. Mounting rod 2
Page 102 - Bearing Replacement Tool Kit – TOR238900A
Greensmaster 1000/1600 Page 7 – 6 Cutting Unit Bearing Replacement Tool Kit – TOR238900A The puller is used to remove the bearings from the roll-ers. A driving tube is used to install bearings into the roll-er. A drill bushing is used to drill into bearing shaftswithout a removal hole. Figure 6
Page 103 - Factors That Can Affect Quality of Cut; Factor
Greensmaster 1000/1600 Page 7 – 7 Cutting Unit Troubleshooting There are a number of factors that can contribute to un-satisfactory quality of cut, some of which may be turfconditions. Turf conditions such as excessive thatch,“sponginess” or attempting to cut off too much grassheight may not always ...
Page 106 - Bedknife to Reel Adjustment
Greensmaster 1000/1600 Page 7 – 10 Cutting Unit Bedknife to Reel Adjustment 1. Position mower on a flat level work surface. Make sure engine is OFF. Remove high tension lead from thespark plug. Remove reel contact: A. On the GR1000, loosen the jam nuts on the bed-knife adjusting screws and rotate ad...
Page 107 - Height–of–Cut Adjustment
Greensmaster 1000/1600 Page 7 – 11 Cutting Unit 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 itshandle...
Page 108 - Grass Shield Height Adjustment
Greensmaster 1000/1600 Page 7 – 12 Cutting Unit Grass Shield Height Adjustment " ! ! " ! ! ! 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. " ! ! ! ! ! "! ! ! ! ! ! "!! "! 3. ! ! "! ! ! ! ! "!! ! " Note:...
Page 109 - Backlapping
Greensmaster 1000/1600 Page 7 – 13 Cutting Unit Service and Repairs Backlapping 1. Park mower on a level surface. Make sure engine is OFF. Remove high tension lead from the spark plug. 2. Make sure clutch to the reel drive is DISENGAGED. 3. Remove the cover plug in the right reel drive cover (Fig. 1...
Page 110 - Bedbar
Greensmaster 1000/1600 Page 7 – 14 Cutting Unit Bedbar Removal 1. Position mower on a flat level work surface. Make sure engine is OFF. Remove high tension lead from thespark plug. 2. Loosen jam nut on the adjusting screw. Loosen ad- justing screw until the thrust washer contacts the insideof the fr...
Page 112 - Bedknife Replacement and Grinding
Greensmaster 1000/1600 Page 7 – 16 Cutting Unit Bedknife Replacement and Grinding Removal 1. Remove bedbar from frame (see Bedbar Removal). 2. Remove screws from bedbar using a socket wrench and bedknife screw tool. Discard screws. Remove bed-knife from the bedbar (Fig. 30). 3. Use a scraper to remo...
Page 113 - Roller; Roller Bearing Replacement; Remove Bearings
Greensmaster 1000/1600 Page 7 – 17 Cutting Unit 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 carr...
Page 114 - Reel
Greensmaster 1000/1600 Page 7 – 18 Cutting Unit 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. If a grooming reel kit is installed, remov...
Page 116 - Preparing a Reel for Grinding
Greensmaster 1000/1600 Page 7 – 20 Cutting Unit Preparing a Reel for Grinding Note: Check to make sure the reel bearings are ingood condition and properly adjusted before grinding areel. 1. Remove bedbar assembly (see Bedbar Removal). 2. Raise grooming reel, if installed, by rotating both quick–up l...
Page 117 - Chapter 8; Grooming Reel Kit; Grooming Reel
Greensmaster 1000 Grooming Reel Kit Page 8 – 1 Chapter 8 Grooming Reel Kit Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Clutch Engagement/Disengagement 3 . . . . . . . . . . . TROUBLESHOOTIN...
Page 119 - Clutch Engagement/Disengagement; Transport Mode
Greensmaster 1000 Grooming Reel Kit Page 8 – 3 General Information Clutch Engagement/Disengagement The grooming reel should be disengaged at all times ex-cept during grooming. IMPORTANT: When engaging or disengaging theclutch, be sure to turn the clutch knob all the wayuntil it comes to a firm stop....
Page 120 - Factors Affecting Grooming; Variables That Affect the Use and Performance of Grooming Reels
Greensmaster 1000 Grooming Reel Kit Page 8 – 4 Troubleshooting Factors Affecting Grooming There are a number of factors that can affect the perfor-mance of grooming. These factors vary for different golfcourses and from green to green. It is important to in-spect the turf frequently and vary the gro...
Page 121 - Grooming Reel Mechanical Problems
Greensmaster 1000 Grooming Reel Kit Page 8 – 5 Grooming Reel Mechanical Problems Problem Possible Causes Correction The grooming reel rotates when it isin the raised position with the clutchdisengaged. Due to friction in the clutch assem-bly, the grooming reel may still ro-tate (with minimal force) ...
Page 123 - Drive Belt Tension Adjustment
Greensmaster 1000 Grooming Reel Kit Page 8 – 7 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. Remove t...
Page 127 - Reel Bearing Replacement; Note: Replace all four ball bearings as a complete set.; Drive Belt Replacement
Greensmaster 1000 Grooming Reel Kit Page 8 – 11 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,instal...
Page 128 - Clutch Assembly
Greensmaster 1000 Grooming Reel Kit Page 8 – 12 Clutch Assembly CAUTION Do not use your hand to prevent the cuttingreel from turning while servicing; this canresult in personal injury. Insert a block ofhard wood into the front of the cutting unitbetween the reel blades to prevent the reelfrom turnin...
Page 132 - OLDER MODELS
Greensmaster 1000 Grooming Reel Kit Page 8 – 16 4. On older models, loosen both carriage bolts secur- ing the reel idler bracket to the frame. Pivot idler pulleyassembly away from the reel drive belt. (Fig. 22). 5. Secure cutting reel from turning with a block of hard wood. Use a 1/2–inch drive ratc...
Page 136 - Cutting Reel
Greensmaster 1000 Grooming Reel Kit Page 8 – 20 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 ins...
Page 140 - Commercial Products
Commercial Products PART NO. 96889SL, Rev. A The Toro Company – 1996, 1997 Printed in U.S.A.
