Form No. 3350–250 Rev.

Greensmaster
800, 1000 and 1600

Greensmaster Mower
Model No. 04048—Serial No. 240000001 and Up
Model No. 04052—Serial No. 240000001 and Up
Model No. 04060—Serial No. 240000001 and Up

Operator’s Manual

English (EN, GB)

 Servicing the Air Cleaner . . . . . . . . . . . . . . . . . . . . 24
Contents Replacing the Spark Plug . . . . . . . . . . . . . . . . . . . . 25
Page Cleaning the Fuel Filter . . . . . . . . . . . . . . . . . . . . . 25
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Adjusting Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Replacing the Differential Belt . . . . . . . . . . . . . . . 28
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adjusting the Traction Control . . . . . . . . . . . . . . . 29
Safe Operating Practices . . . . . . . . . . . . . . . . . . . . 3 Adjusting the Service/Park Brake . . . . . . . . . . . . . 29
Toro Mower Safety . . . . . . . . . . . . . . . . . . . . . . . . 4 Adjusting the Interlock Switch . . . . . . . . . . . . . . . 30
Sound Pressure Level Servicing the Bedbar
All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Greensmaster 800 & 1600 only . . . . . . . . . . . . . . 30
Sound Power Level Servicing the Bedbar
Models 04052 and 04060 . . . . . . . . . . . . . . . . . . 5 Greensmaster 1000 only . . . . . . . . . . . . . . . . . . . 30
Sound Power Level Backlapping the Reel . . . . . . . . . . . . . . . . . . . . . . . 31
Model 04048 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 The Toro General Commercial Products Warranty . . . 32
Vibration Level
Models 04048 and 04052 . . . . . . . . . . . . . . . . . .
Vibration Level
5
Introduction
Model 04060 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Read this manual carefully to learn how to operate and
Safety and Instruction Decals . . . . . . . . . . . . . . . . . 6 maintain your product properly. The information in this
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 manual can help you and others avoid injury and product
General Specifications . . . . . . . . . . . . . . . . . . . . . 8 damage. Although Toro designs and produces safe
products, you are responsible for operating the product
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . 9
properly and safely.
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Loose Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Installing and Adjusting the Handle . . . . . . . . . . . . 11
Dealer or Toro Customer Service and have the model and
Installing the Kick Stand serial numbers of your product ready. The model and serial
Model 04060 only . . . . . . . . . . . . . . . . . . . . . . . . 11 numbers are located on a plate on the rear frame.
Installing the Transport Wheels . . . . . . . . . . . . . . . 12
Write the product model and serial numbers in the space
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
below:
Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . 12
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . 13
Leveling the Rear Drum to the Reel . . . . . . . . . . . 14 Model No.
Adjusting the Bedknife to the Reel . . . . . . . . . . . . 15
Adjusting the Height-of-Cut . . . . . . . . . . . . . . . . . 16 Serial No.
Adjusting the Grass Shield Height . . . . . . . . . . . . . 17
Adjusting the Cut-off Bar . . . . . . . . . . . . . . . . . . . . 17 This manual identifies potential hazards and has special
Installing the Grass Basket . . . . . . . . . . . . . . . . . . . 17 safety messages that help you and others avoid personal
Checking the Operation of the Interlock Switch . . 17 injury and even death. Danger, Warning, and Caution are
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . 19 Danger signals an extreme hazard that will cause serious
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . 19 injury or death if you do not follow the recommended
precautions.
Driving the Machine in Transport . . . . . . . . . . . . . 19
Preparing to Mow . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Mowing Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Mowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Caution signals a hazard that may cause minor or moderate
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 injury if you do not follow the recommended precautions.
Recommended Maintenance Schedule . . . . . . . . . 21 This manual uses two other words to highlight information.
Daily Maintenance Checklist . . . . . . . . . . . . . . . . . 22 Important calls attention to special mechanical
Greasing the Machine . . . . . . . . . . . . . . . . . . . . . . 23 information and Note: emphasizes general information
Checking and Changing Engine Oil . . . . . . . . . . . . 24 worthy of special attention.
 2003 by The Toro Company All Rights Reserved
8111 Lyndale Avenue South Printed in the USA
Bloomington, MN 55420-1196 2
 – Add fuel before starting the engine. Never remove
Safety the cap of the fuel tank or add fuel while the engine
is running or when the engine is hot.
This machine meets or exceeds CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI – If fuel is spilled, do not attempt to start the engine
B71.4-1999 specifications in effect at the time of but move the machine away from the area of
production when the Operator Presence Kit, Part No. spillage and avoid creating any source of ignition
105–5363 is installed. until fuel vapors have dissipated.

Improper use or maintenance by the operator or owner – Replace all fuel tanks and container caps securely.
can result in injury. To reduce the potential for injury, • Replace faulty silencers.
comply with these safety instructions and always pay
attention to the safety alert symbol, which means • Evaluate the terrain to determine what accessories and
CAUTION, WARNING, or DANGER—“personal attachments are needed to properly and safely perform
safety instruction.” Failure to comply with the the job. Only use accessories and attachments approved
instruction may result in personal injury or death. by the manufacturer.

Safe Operating Practices • Check that operator’s presence controls, safety switches
and shields are attached and functioning properly. Do
The following instructions are from the CEN standard EN
not operate unless they are functioning properly.
836:1997, ISO standard 5395:1990, and ANSI B71.4-1999.
Training Operation
• Read the Operator’s Manual and other training material • Do not operate the engine in a confined space where
carefully. Be familiar with the controls, safety signs, dangerous carbon monoxide fumes can collect.
and the proper use of the equipment.
• Mow only in daylight or in good artificial light.
• Never allow children or people unfamiliar with these
instructions to use or service the mower. Local • Before attempting to start the engine, disengage all
regulations may restrict the age of the operator. blade attachment clutches, shift into neutral, and engage
the parking brake.
• Never mow while people, especially children, or pets
are nearby. • Do not use on slopes of more than 15°.
• Keep in mind that the operator or user is responsible for • Remember there is no such thing as a safe slope. Travel
accidents or hazards occurring to other people or their on grass slopes requires particular care. To guard
property. against overturning:
• The owner/user can prevent and is responsible for – do not stop or start suddenly when going up or
accidents or injuries occurring to himself or herself, downhill;
other people, or property.
– engage clutch slowly, always keep machine in gear,
especially when travelling downhill;
Preparation
– machine speeds should be kept low on slopes and
• While mowing, always wear substantial footwear, long during tight turns;
trousers, hard hat, safety glasses, and ear protection.
Long hair, loose clothing, or jewelry may get tangled in – stay alert for humps and hollows and other hidden
moving parts. Do not operate the equipment when hazards;
barefoot or wearing open sandals. – never mow across the face of the slope, unless the
• Thoroughly inspect the area where the equipment is to mower is designed for this purpose.
be used and remove all objects which may be thrown by • Stay alert for holes in the terrain and other hidden
the machine. hazards.
• Warning—Fuel is highly flammable. Take the • Watch out for traffic when crossing or near roadways.
following precautions:
• Stop the blades rotating before crossing surfaces other
– Store fuel in containers specifically designed for this than grass.
purpose.
• When using any attachments, never direct discharge of
– Refuel outdoors only and do not smoke while material toward bystanders nor allow anyone near the
refuelling. machine while in operation.

3
• Never operate the machine with damaged guards, • Allow the engine to cool before storing in any
shields, or without safety protective devices in place. Be enclosure.
sure all interlocks are attached, adjusted properly, and
functioning properly. • To reduce the fire hazard, keep the engine, silencer,
battery compartment and fuel storage area free of grass,
• Do not change the engine governor settings or leaves, or excessive grease.
overspeed the engine. Operating the engine at excessive
speed may increase the hazard of personal injury. • Check the grass catcher frequently for wear or
deterioration.
• Before leaving the operator’s position:
• Keep all parts in good working condition and all
– stop on level ground; hardware and hydraulic fittings tightened. Replace all
worn or damaged parts and decals.
– disengage the power take-off and lower the
attachments; • If the fuel tank has to be drained, do this outdoors.
– change into neutral and set the parking brake; • Be careful during adjustment of the machine to prevent
entrapment of the fingers between moving blades and
– stop the engine. fixed parts of the machine.
• Disengage drive to attachments when transporting or • Disengage drives, disengage the cutting unit, set
not in use. parking brake, stop engine and disconnect spark plug
• Stop the engine and disengage drive to attachment wire. Wait for all movement to stop before adjusting,
cleaning or repairing.
– before refuelling;
• Clean grass and debris from cutting unit, drives,
– before removing the grass catcher/catchers; mufflers, and engine to help prevent fires. Clean up oil
or fuel spillage.
– before making height adjustment unless adjustment
can be made from the operator’s position. • Carefully release pressure from components with stored
energy.
– before clearing blockages;
• Disconnect battery and remove spark plug wire before
– before checking, cleaning or working on the mower; making any repairs. Disconnect the negative terminal
– after striking a foreign object or if an abnormal first and the positive last. Reconnect positive first and
vibration occurs. Inspect the mower for damage and negative last.
make repairs before restarting and operating the • Use care when checking the reel. Wear gloves and use
equipment. caution when servicing them.
• Reduce the throttle setting during engine run-out and, if • Keep hands and feet away from moving parts. If
the engine is provided with a shut-off valve, turn the possible, do not make adjustments with the engine
fuel off at the conclusion of mowing. running.
• Keep hands and feet away from the cutting unit.
• Slow down and use caution when making turns and Toro Mower Safety
crossing roads and sidewalks. Stop reels if not mowing.
The following list contains safety information specific to
• Do not operate the mower under the influence of Toro products or other safety information that you must
alcohol or drugs know that is not included in the CEN, ISO, or ANSI
• Use care when loading or unloading the machine into a standard.
trailer or truck This product is capable of amputating hands and feet and
• Use care when approaching blind corners, shrubs, trees, throwing objects. Always follow all safety instructions to
or other objects that may obscure vision. avoid serious injury or death.
Use of this product for purposes other than its intended use
could prove dangerous to user and bystanders.
Maintenance and Storage
• Know how to stop the engine quickly.
• Keep all nuts, bolts and screws tight to be sure the
equipment is in safe working condition. • Do not operate the machine while wearing tennis shoes
or sneakers.
• Never store the equipment with fuel in the tank inside a
building where fumes may reach an open flame or
spark.

4
• Wearing safety shoes and long pants is advisable and • Use only Toro-approved attachments and replacement
required by some local ordinances and insurance parts. The warranty may be voided if used with
regulations. unapproved attachments.
• Handle gasoline carefully. Wipe up any spills.
• Check the safety interlock switches daily for proper Sound Pressure Level
operation. If a switch should fail, replace the switch All Models
before operating the machine. After every two years,
replace all four interlock switches in the safety system, This unit has an equivalent continuous A-weighted sound
regardless if they are working properly or not. pressure at the operator ear of: 84 dB(A), based on
measurements of identical machines per procedures
• Using the machine demands attention. To prevent loss outlined in Directive 98/37/EC and amendments.
of control:
– Do not drive close to sand traps, ditches, creeks, or
other hazards. Sound Power Level
– Reduce speed when making sharp turns. Avoid Models 04052 and 04060
sudden stops and starts. This unit has a guaranteed sound power level of: 95 dBA/1
– When near or crossing roads, always yield the pW, based on measurements of identical machines per
right-of-way. Directive 2000/14/EC and amendments.

– Apply the service brakes when going downhill to

keep forward speed slow and to maintain control of Sound Power Level
the machine.
Model 04048
• The grass basket must be in place during operation of
the reels or thatchers for maximum safety. Shut the This unit has a guaranteed sound power level of:
engine off before emptying the baskets. 96 dBA/1 pW, based on measurements of identical
machines per Directive 2000/14/EC and amendments.
• Do not touch the engine, muffler, or exhaust pipe while
the engine is running or soon after it has stopped
because these areas could be hot enough to cause burns. Vibration Level
• Stay clear of the rotating screen at the side of the engine Models 04048 and 04052
to prevent direct contact with your body or clothing.
This unit has a hand–arm vibration level of 7.00 m/s2, based
• When a person or pet appears unexpectedly in or near on measurements of identical machines per ISO 5349
the mowing area, stop mowing. Careless operation, procedures.
combined with terrain angles, ricochets, or improperly
positioned guards can lead to thrown object injuries. Do
not resume mowing until the area is cleared. Vibration Level
Model 04060
Maintenance and Storage
This unit has a hand–arm vibration level of 4.50 m/s2, based
• Check all fuel lines for tightness and wear on a regular on measurements of identical machines per ISO 5349
basis. Tighten or repair them as needed. procedures.
• 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, attachments, and
any moving parts, especially the screen at the side of the
engine. Keep everyone away.
• To ensure safety and accuracy, have an Authorized Toro
Distributor check the maximum engine speed with a
tachometer. Maximum governed engine speed should be
3600 RPM.
• If major repairs are ever needed or if assistance is
desired, contact an Authorized Toro Distributor.

5
Safety and Instruction Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger. Replace any decal that is damaged or lost.

105–5359 (Model 04048)

105–5360 (Model 04052)
105–5361 (Model 04060)
1. Disengage 3. Parking brake 5. Disengage—neutral 6. Clutch
2. Engage 4. Engage—forward

93-7273
93-9356
1. Thrown object 2. Cutting hazard, hand and
hazard—Keep bystanders foot—Stay away from 1. Entanglement hazard—Stay away from moving parts.
away moving parts

6
 105-5309
1. Hot surface/burn hazard—stay a safe distance from the hot
surface. 93-6085
1. Fast 3. Slow
2. Increasing/decreasing
scale.

93-8064
1. Warning—Read the 2. Cutting Hazard, hand and
Operator’s Manual before foot—Stop the engine and
servicing wait for moving parts to
stop

93-7348
1. Warning—Read the 3. Thrown object
Operator’s Manual hazard—Keep bystanders
2. Fire hazard—No open away
flames or sparks and fill 4. Cutting hazard, hand and 93-9886
the tank only to the level foot—Stay away from 1. Use only unleaded gasoline
shown moving parts

93-7346
1. Reel drive 3. Disengage
2. Engage

7
Specifications
General Specifications
Kawasaki, air cooled, overhead valve, 4 cycle, 3.7 horsepower, 2.36 x 1.73 bore
and stroke, 7.57 cu. in. (124 cc) displacement, 8.4:1 compression ratio, 11 ft.-lb.
Engine
(15 N⋅m) @ 1400 rpm. Electronic ignition, maximum noise suppression muffler.
2.64 quart (2.5 l) fuel tank capacity.
Engine to countershaft drive: two “A” section V-belts. Countershaft to differential
Traction Drive
drive: 5 mm pitch timing belt. Differential to drum drive: 8 mm pitch timing belt.
Differential Peerless Series 100
Transport Clutch Belt idler
Brake Band drum
Transport Tires Quick detachable, 3.00/3.25 x 6, 32.5 tread width
Traction Drum Dual cast aluminum, 7.5 in. (19 cm) dia.
Engine has recoil starter, On/Off switch and choke. Handle has throttle lever,
Controls traction engage lever and service/ park brake lever. Mower has reel drive engage
lever. Safety devices: neutral interlock system.
Handle Loop style, 1 in. (2.5 cm) dia.
Reel Construction 5 in. (12.7 cm) dia., 8 carbon steel blades welded to 6 stamped steel spiders
Single edged high carbon steel bedknife, hardened to Rc 48-54. Fastened to
Bedknife and Bedbar
machined, cast iron bedbar. 1/8 in. (0.3 cm) bedknife, standard
Height-of-Cut Range 1/8 to 1-1/4 in. (0.3 to 3.2 cm)
Reel Clutch Jaw type
Grass Basket Molded polyethylene

Model 04048 Model 04052 Model 04060

Clip .16 in. (.4 cm) .16 in. (.4 cm) .23 in. (58.4 cm)
Width of Cut 18 in. (46 cm) 21 in. (53 cm) 26 in. (66 cm)
Total Width 33 in. (84 cm) 36 in. (91 cm) 41 in. (104 cm)
Total Height 41-1/2 in. (105.4 cm) 47 in. (119 cm) 41-1/2 in. (105.4 cm)
Total Length 54-1/4 in. (137.8 cm) 59 in. (150 cm) 54-1/4 in. (137.8 cm)
Dry Weight 200 lb. (91 kg.) 1 208 lb. (94 kg.) 1 229 lb. (104 kg) 1

1With basket and Wiehle roller, without wheels or grooming reel

8
Optional Equipment
Model 04048 Model 04052 Model 04060
Light Kit Model No. 04058 Model No. 04058 Model No. 04058
Wheel Kit Model No. 04122 Model No. 04122 Model No. 04122
Height of Cut Bar Part No. 94–9010 Part No. 94–9010 Part No. 94–9010
Operator Presence Kit Part No. 105–5363 Part No. 105–5363 Part No. 105–5363
Clip Kit Part No. 65-9000 Part No. 65-9000 Part No. 65-9000
High Altitude Jet for Part No. 98-8735 Part No. 98-8735 Part No. 98-8735
altitudes of 3000 to 6000 ft.
(900 to 1800 m)
High Altitude Jet for Part No. 98-8736 Part No. 98-8736 Part No. 98-8736
altitudes above 6000 ft.
(1800 m)
Spark Arrester Part No. 98–3426 Part No. 98–3426 Part No. 98–3426
Grooming Reel Kit Model No. 04108 Model No. 04125 Model No. 04110
Micro–cut Bedknife Part No. 98–7261 Part No. 93–4262 Part No. 94–5885
Full Roller Part No. 104–2640 Part No. 104–2642 Part No. 95–0930
Wiehle Roller Part No. 98–7264 Part No. 88–6790
(.43 spacing)
Swaged Roller Part No. 52–3590
Auxiliary Roller KIt Part No. 65–8560 Part No. 65–8560
Wiehle Roller Scraper Part No. 98–5920–01 Part No. 65–8340–01 Part No. 94–9012–01
(.43 spacing)
Dethatching Reel Kit Model No. 04111
Scraper Comb Part No. 11–0070
Scraper Brush Part No. 33–1000
Wiehle Roller (Cast Iron) Part No. 71–1550
Groomer Brush Assembly Part No. 105–9640
1/8” Bedknife Part No. 93–4264
Extended 2.5” Dia. Wiehle Part No. 93-9045
Roller
Full Roller Scraper Part No. 98–7257–01 Part No. 65–8360–01
Wiehle Roller Scraper Part No. 99–6239–01 Part No. 104–0509–01
(.20 spacing)
High Penetration Bedbar Part No. 98–5907–03 Part No. 92–9204–03
Extended Height of Cut Arm Part No. 99–4286
Hour Meter Kit Part No. 105–5350 Part No. 105–5350 Part No. 105–5350
Out Front Broom Part No. 105–9600 Part No. 105–9600

9
Setup
Note: Determine the left and right sides of the machine from the normal operating position.

Loose Parts
Note: Use this chart as a checklist to ensure all parts necessary for assembly have been shipped. If any of these parts are
missing, total set–up cannot be completed.

Description Qty. Use

Handle assembly 1 Install the handle on the machine
Cable tie 2 Secure the control cables to the handle
Wheel Shaft, right hand 1
Use when installing optional transport wheels
Wheel Shaft, left hand 1
Spring 1 Mount kickstand, Model 04060 only
Grass basket 1 Install on the machine
Operator’s Manual 1 Read before operating
Engine Owner’s Manual 1 Read before operating
Part’s Catalog 1 Use for ordering parts
Registration card 1 Fill out and return to Toro
Operator video 1 View before operating
Certificate of Compliance 1

10
Installing and Adjusting the 7. Secure the handle ends to the mounting pins with the
capscrews, washers, and lockwashers previously
Handle removed (Fig. 2).

Installing the Handle 8. Secure the bottom of handle arms to each side of the
mower with the capscrews and locknuts previously
2. Remove the capscrew, washer, and lockwasher from the removed (Fig. 2). Ensure that you install the bushings in
mounting pin on each side of the mower, as shown in the handle arm mounting holes.
Fig. 1.
Important Do not overtighten the capscrews. The
handle arms must pivot freely.
2
9. Secure the handle arms to the rear of the frame with the
hairpin cotters and ring pins previously removed
1 (Fig. 2).
10. Secure the cables to the handle with cable ties.

Adjusting the Handle

4
1. Remove the hairpin cotters from the ring pins on each
3 side of the mower (FIg. 1).
2. While supporting the handle, remove the ring pins from
Figure 1 each side and raise or lower the handle to the desired
1. Mounting pins 3. Capscrew and locknut operating position. (Fig. 1).
2. Handle arms 4. Hairpin cotter and ring pin
3. Install the ring pins and hairpin cotters.

3. Remove the capscrews and locknuts securing the

bottom of the handle arms to each side of the mower, as Installing the Kick Stand
shown in Figure 1. Model 04060 only
4. Remove the hairpin cotters and ring pins securing the Note: Fasteners shipped loosely on kick stand.
handle arms to the rear of the frame (Fig. 1).
1. Hook spring into hole in spring bracket and onto spring
5. Insert the handle ends thru the holes in the handle arms retainer while aligning kick stand with mounting holes
and align the holes with the mounting pins (Fig. 1). in rear frame (Fig. 3).
6. Squeeze the handle ends inward and install them on the
mounting pins (Fig. 2).

2
1
4

Figure 3
1. Kick stand 3. Spring retainer
Figure 2 2. Spring bracket 4. Spring

1. Handle end
2. Mount kick stand to each side of frame with a capscrew,
lockwasher, spacer flat washer and lock nut (Fig. 3).
Spacer to be positioned in kick stand mounting hole.

11
Installing the Transport Wheels 9. Inflate the tires to 12 to 15 psi. (574 to 718 Pa).

1. Push the kick stand down with your foot and pull up on
the handle to support the mower on the kick stand. Before Operating
2. Apply #242 Loctite to the threads of the wheel shafts.
3. Thread the right hand wheel shaft into the drive pulley
Adding Engine Oil
on the right side of the machine (Fig. 4). Fill the crankcase with approximately 20 oz. (0.6 l) of
proper viscosity oil before staring. The engine uses any
high-quality oil having the American Petroleum Institute —
APl—service classification SC, SD, SE, SF, SG, or SH. Oil
viscosity (weight) must be selected according to the
ambient temperature. Figure 6 illustrates the temperature/
viscosity recommendations.
1
–20
C –10
C 0
C 10
C 20
C 30
C 40
C

SAE 40

Figure 4
SAE 30
1. Right hand wheel shaft

4. Torque the shaft to 65 to 75 ft-lb. (88 to 101 N⋅m) SAE 10W30/ SAE 10W–40

Note: The right hand wheel shaft has left hand threads.
SAE 5W20
5. Apply Never–Seez to the exposed ends of the axles and
slide the wheel onto the axle (Fig. 5).
–4
F 14
F 32
F 50
F 68
F 86
F 104
F
6. Pivot the wheel locking clip away from center of the
wheel allowing it to slide farther onto the axle (Fig. 5). Figure 6
7. Rotate the wheel back and forth until it slides
completely onto the axle and the locking clip is secured
Note: Using multi grade oils (5W–20, 10W–30 and
in the groove on the axle shaft.
10W–40) will increase oil consumption. Check the oil level
more frequently when using multi grade oils.
1. Position the mower so the engine is level (Fig. 7).

Figure 7
Figure 5
1. Oil level gauge
1. Locking clip

2. Clean around the oil level gauge.

8. Repeat the procedure on the opposite side of the
machine. 3. Remove the gauge by rotating it counterclockwise.

12
4. Wipe the gauge clean and insert it into the filler port,
without threading it into the port. Danger
5. Remove the gauge and check the oil level.
In certain conditions, gasoline is extremely
6. If level is low, add only enough oil to raise level to filler flammable and highly explosive. A fire or
opening. explosion from gasoline can burn you and others
Note: Check the oil each time the mower is used or after and can damage property.
every 5 operating hours. Initially, change oil after the first • Fill the fuel tank outdoors, in an open area,
20 hours of operation; thereafter, change oil after every 50 when the engine is cold. Wipe up any gasoline
hours of operation. More frequent oil changes are that spills.
required in dusty or dirty conditions. • Do not fill the fuel tank completely full. Add
gasoline to the fuel tank until the level is 1 in.
(25 mm) below the bottom of the filler neck.
Filling the Fuel Tank This empty space in the tank allows gasoline to
expand.
Important Never use methanol, gasoline containing • Never smoke when handling gasoline, and stay
methanol, gasoline containing more than 10% ethanol, away from an open flame or where gasoline
gasoline additives, premium gasoline, or white gas because fumes may be ignited by a spark.
engine fuel system damage could result. • Store gasoline in an approved container and
1. Clean around the fuel tank cap and remove the cap from keep it out of the reach of children. Never buy
the tank (Fig. 8). more than a 30-day supply of gasoline.
• Always place gasoline containers on the ground
away from your vehicle before filling.
1 • Do not fill gasoline containers inside a vehicle or
on a truck or trailer bed because interior
carpets or plastic truck bed liners may insulate
the container and slow the loss of any static
charge.
• When practical, remove gas-powered equipment
from the truck or trailer and refuel the
equipment with its wheels on the ground.
• If this is not possible, then refuel such
equipment on a truck or trailer from a portable
container, rather than from a gasoline dispenser
nozzle.
• If a gasoline dispenser nozzle must be used, keep
the nozzle in contact with the rim of the fuel
tank or container opening at all times until
fueling is complete.

Figure 8
1. Fuel tank cap

2. Using unleaded gasoline, fill the fuel tank no higher

than to bottom of the filter screen. Do not over fill the
tank.
3. Install the fuel tank cap and wipe up any spilled
gasoline.

13
Leveling the Rear Drum to the 7. Rotate the drive pulley until the holes align with the 4
roller bearing flange screws (Fig. 10).
Reel 8. Loosen the 4 roller bearing screws and the screw
1. Position the machine on a flat, level surface, preferably securing the idler pulley.
a precision steel work plate.
9. Raise or lower the right side of the roller assembly until
2. Place a 1/4 x 1 in. (0.6 x 2.5 cm) flat steel strip, approx. the gap is less than 0.010 in.
29 in. (73.6 cm) long, under the reel blades and against
the front edge of the bedknife to prevent the bedbar 10. Tighten the roller bearing screws.
from resting on the work surface. 11. Adjust the belt tension and tighten the idler pulley
3. Raise the front roller so only the rear drum and reel are mounting screw (Fig. 10).
on the surface.
4. Firmly press down on the machine above the reel so all
reel blades contact the steel strip.
5. While pressing down on the reel, slide a feeler gauge
3
under one end of the drum, then check the other end of
the drum.
If there is a gap between the drum and the work surface,
greater than 0.010 in., on either end, adjust the drum
(proceed to step 6). If the gap is less than 0.010 in. no 1
adjustment is required.
6. Remove the rear belt cover from the right side of the
machine (Fig. 9).

1
2

Figure 10
1. Drive pulley 3. Idler pulley
2. 4 holes

Figure 9
1. Traction drive belt cover

14
Adjusting the Bedknife to the 4. On one end of the front side of the reel, insert a long
strip of newspaper between the reel and bedknife
Reel (Fig. 13). While slowly rotating the reel forward, turn
the bedbar adjusting screw clockwise (on the same end
The bedknife to reel adjustment is accomplished by of reel, one click at a time, until the paper is pinched
loosening or tightening the bedbar adjusting screws, located lightly, when inserted from the front, parallel to the
on top of the mower. bedknife, which results in a slight drag when paper is
1. Position the machine on a flat, level work surface. pulled (Fig. 11 or 12).

2. Ensure that the reel contact is removed by turning the

bedbar adjusting screws counterclockwise
(Fig. 11 or 12).

Figure 13
Figure 11
1. Bedbar adjusting screw (Greensmaster 800 & 1600)
Note: Each time the adjusting screw is rotated one click
clockwise, the bedknife moves 0.0007 in. (0.0017 cm)
closer to the reel. Do not overtighten the adjusting screws.
1
5. Check for light contact at the other end of the reel using
paper and adjust it as required.
6. After the adjustment is accomplished, check to see if
the reel can pinch paper when inserted from the front
and cut paper when inserted at a right angle to the
bedknife (Fig. 13). It should be possible to cut paper
with minimum contact between the bedknife and the
reel blades. Should excessive reel drag be evident (more
Figure 12 than 7 in.-lb. (0.79 N⋅m)), either backlap or grind the
1. Bedbar adjusting screw (Greensmaster 1000) cutting unit to achieve the sharp edges needed for
precision cutting; refer to the Toro reel sharpening
manual.
3. Tilt the mower back on the handle to expose the
bedknife and reel.

15
Adjusting the Height-of-Cut
1. Verify that the rear roller is level and that the bedknife
to reel contact is correct. Tip the mower back on the
handle to expose the front and rear rollers and the
bedknife.
2. Loosen the locknuts securing the height-of-cut arms to
the height-of-cut brackets (Fig. 14).

Figure 16

1
5. Rotate the adjusting screw until the roller contacts the
front of the gauge bar.
6. Adjust both ends of the roller until the entire roller is
parallel to the bedknife.
Important When set properly, the rear and front rollers
will contact the gauge bar and the screw will be snug
3 2 against the bedknife. This ensures the height-of-cut is
identical at both ends of the bedknife.
Figure 14
7. Tighten nuts to lock the adjustment.
1. Height-of-cut arm 3. Locknut
2. Height-of-cut bracket 4. Adjusting screw Important To avoid scalping on undulating turf, ensure
that the roller supports are positioned rearward (the roller
closer to the reel).
3. Loosen the nut on the gauge bar (Fig. 15) and set the
adjusting screw to the desired height-of-cut. The Note: The front roller can be put in three different positions
distance between the bottom of the screw head and the (Fig. 17), depending on the application and needs of the
face of the bar is the height-of-cut. user.
• Use the front position when a groomer is installed.
• Use the middle position without a groomer.
• Use the third position in extremely undulating turf
conditions.

1
3

Figure 15
1. Gauge bar 3. Nut Figure 17
2. Height adjusting screw

4. Hook the screw head on the cutting edge of the

bedknife and rest the rear end of the bar on the rear
roller (Fig. 16).

16
Adjusting the Grass Shield 3. Ensure that the bar and reel are equal distance apart
across the entire reel.
Height Note: The bar is adjustable to compensate for changes in
Adjust the shield to ensure proper grass clipping discharge turf conditions. Adjust the bar closer to the reel when the
into the basket. turf is extremely wet. By contrast, adjust the bar further
away from the reel when turf conditions are dry. The bar
1. Measure the distance from top of the front support rod should be parallel to the reel to ensure optimum
to the front lip of the shield at each end of the cutting performance. Adjust the bar whenever the shield height is
unit (Fig. 18). adjusted or when the reel is sharpened on a reel grinder.

Installing the Grass Basket

4” (10cm) Grasp the basket by the top lip and slide it onto the basket
mounting rods (Fig. 20).

2 1
Figure 18
1. Support rod 2. Shield

2. The height of the shield from the support rod for normal
cutting conditions should be 4 in. (10 cm). Loosen the
capscrews and nuts securing each end of the shield to
the sideplate and adjust the shield to the correct height. 1
3. Tighten the fasteners.
Note: The shield can be lowered for drier conditions
(clippings fly over top of basket) or raised to allow for
heavy wet grass conditions (clippings build up on rear of 2
basket).
Figure 20
Adjusting the Cut-off Bar 1. Grass basket 2. Basket mounting rod

Adjust the cut-off bar to ensure that the clippings are

cleanly discharged from the reel area. Note: Model 04060 only – When cutting in higher
heights-of-cut, the basket may be lowered by removing
1. Loosen the screws securing the top bar (Fig. 19) to the each basket mounting rod and installing each on the
cutting unit. opposite side of the machine.

Checking the Operation of the

Interlock Switch
1. Place the traction lever into the Engage position and the
engine controls in the starting position.
1 2. Attempt to start the engine.
Figure 19 The engine should not start. If the engine starts, the
1. Cut-off bar
interlock switch needs service. Correct the problem
before operating; refer to Adjusting the Interlock
Switch, page 30.
2. Insert a 0.060 in. feeler gauge between the top of the
reel and the bar and tighten the screws.

17
 Operator Presence Control (Optional)
Operation (Fig. 21)
Note: Determine the left and right sides of the machine Located on the rear of the handle. Push the operator
from the normal operating position. presence control against the handle. The operator presence
control must be engaged before moving the traction drive
lever or the engine will stop.
Controls
Reel Drive Lever (Fig. 22)
Throttle Control (Fig. 21)
Located on the right front corner of the machine. The lever
Located on the rear right side of the control panel. The has two positions: Engage and Disengage. Pull up on the
lever connects to and operates the throttle linkage to the lever to engage the reel or push it down to disengage the
carburetor. The engine speed can be varied from 1600 to reel.
3600 RPM.
1
Traction Drive Lever (Fig. 21)
Located on the front right side of the control panel. The
lever has two positions: Neutral and Forward. Pushing the
lever forward engages the traction drive.

Figure 22
2 1. Reel drive lever

Choke Lever (Fig. 23)

Figure 21 Located on the left front of the engine. The lever has two
positions: Run and Choke. Move the lever to the Choke
1. Throttle control 4. Operator presence control
(optional) position when starting a cold engine. After the engine starts
2. Traction drive lever
move the lever to the Run position.
3. Service/parking brake

Fuel Shut-off Valve (Fig. 23)

Service/Park Brake (Fig. 21) Located on the left front of the engine. The valve has two
positions: Closed and Open. Move the lever to the Closed
Located on the left front side of the control panel. The position when storing or transporting the machine. Open
brake can be used to slow or stop the machine. The brake the valve before starting the engine.
can also be used as a parking brake. Pulling the lever back
over center will set the parking brake. The brake must be
released before the traction drive is engaged.

18
 Starting the Engine
Note: Ensure that the spark plug wire is installed on the
spark plug.
1. Ensure that the traction (Fig. 21) and reel drive (Fig. 22)
levers are in the Disengaged position.
Note: Engine will not start if traction lever is in the
engaged position.
2. Open the fuel shut-off valve on the engine (Fig. 23).
3. Move the On/Off switch (Fig. 24) to the On position.
4. Move the throttle control (Fig. 21) to the Fast position.
1
2 5. Move the choke lever (Fig. 23) to the half-open position
when starting a cold engine. The choke may not be
Figure 23 required when starting a warm engine.
1. Choke lever 2. Fuel shut-off valve 6. Pull the recoil starter handle out until positive
engagement results, then pull vigorously to start the
engine.
On/Off Switch (Fig. 24) Important Do not pull the recoil rope to its limit or let
go of the starter handle when rope is pulled out because the
Located on the rear of the engine. Move the switch to the
rope may break or the recoil assembly may be damaged.
On position to start the engine and the Off position to stop
the engine. 7. Close the choke as the engine warms up.
1
Stopping the Engine
1. Move the traction and reel drive controls to the
Disengaged position, the throttle control to the Slow
position, and the On/Off switch to the Off position.
2. Pull the spark plug wire off of the spark plug to prevent
the possibility of accidental starting before storing the
2 machine.
3. Close the fuel shut-off valve before storing or
transporting the mower in a vehicle.

3
Driving the Machine in
Figure 24
1. Recoil starter 3. Kick stand
Transport
2. On/Off switch 1. Push the kick stand down with your foot and pull up on
the handle to raise the rear of mower and install the
transport wheels.

Recoil Starter (Fig. 24) 2. To release the kickstand, pull up on the handle, push the
mower forward, and then lower the rear of mower onto
Pull the recoil starter handle to start the engine. the transport wheels.
3. Ensure that the traction and reel drive controls are in the
Kick Stand (Fig. 24) Disengaged position and start the engine.
Mounted to rear of the machine, the kickstand is used to 4. Set the throttle control to Slow, tip front of the machine
raise rear of the machine for installation or removal of the up gradually to the engage traction drive and slowly
transport wheels. increase the engine speed.

19
5. Adjust the throttle to operate the mower at the desired Mowing Techniques
ground speed and transport the mower to the desired
destination. • Mow a green in a straight back and forth direction,
across the green.
• Avoid circular mowing or turning the mower on a green
Preparing to Mow because scuffing may occur. Turn the mower off of the
1. Return the traction control lever to the Disengage green by raising the cutting reel (pushing the handle
position, the throttle to the Slow position, and stop the down) and turning on the traction drum.
engine. • Mow at a normal walking pace. Fast speed saves very
2. Push the kickstand down with your foot and pull up and little time and will result in an inferior mowing job.
back on the handle to raise the wheels off of the ground.
3. Push the locking clips on the wheels out of the grooves Mowing
in the shafts.
1. Start the engine, set the throttle at reduced speed, push
4. Slide the wheels off of the shafts. down on the handle to raise the cutting unit, move the
traction lever to the Engaged position, and transport the
5. Move the unit off of the kickstand.
mower onto collar of the green.
2. Move the traction lever to the Disengaged position and
Mowing Tips move the reel drive lever to the Engaged position.
Proper use of the machine provides the smoothest turf 3. Move the traction lever to the Engaged position,
cutting available. The fundamental suggestions given will increase the throttle speed until the mower is traveling
provide the utmost performance from your mower. at the desired ground speed, drive the mower onto the
green, lower the front of the mower, and commence
Important Excessive operation of the cutting unit with operation.
the absence of grass clippings (lubricant) can damage the
cutting unit. 4. When finished mowing, drive off of the green, move the
traction control lever to the Disengage position, stop the
engine and push the reel drive lever into the Disengage
Before Mowing position.
• Ensure that the mower is carefully adjusted and is set 5. Empty the grass catcher of clippings, install the grass
evenly on both sides of the reel. Improper mower catcher, and commence transport operation.
adjustment is magnified many times over in the
appearance of the clipped turf.
• Remove all foreign objects from the turf prior to
mowing.
• Ensure that everyone, especially children and pets, are
clear of the work area.

20
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.

Recommended Maintenance Schedule

Maintenance Service
Maintenance Procedure
Interval
• Air filter pre-cleaner—service
25 Hours • Grease fittings—lubricate
• Fasteners—check and tighten
• Fuel filter and sediment bowl—clean
50 Hours • Traction drive belts—adjust
• Engine oil—change1
• Cut-off bar—check adjustment
100 Hours
• Air cleaner filter—service
• Combustion chamber—clean
• Spark plug—replace
200 Hours
• Valves—adjust
• Head bolts—torque
Every 2 years • Interlock switches—replace

1Initial break in at 20 hours

Important Refer to your engine operator’s and service manuals for additional maintenance procedures.

21
Daily Maintenance Checklist
Duplicate this page for routine use.

For the week of:

Maintenance Check Item Mon. Tues. Wed. Thurs. Fri. Sat. Sun.
Safety interlock operation
Parking brake operation
Fluid level
Engine oil level
Air filter
Clean the engine cooling fins
Unusual engine noise
Unusual operating noise
Reel to bedknife adjustment
Height-of-cut adjustment
Grease all fittings
Touch-up damaged paint

Notation for Areas of Concern

Inspection performed by:
Item Date Information
1
2
3
4
5
6
7
8

22
Greasing the Machine
The 13 grease fittings on the mower should be greased at
least every 25 hours. Lubricate using a No. 2 multi–purpose
lithium base grease. A hand operated grease gun is
recommended for best results.
The grease fitting locations are as follows:
• 2 on the front roller (Fig. 25)
• 2 on the reel bearings (Fig. 25)
• 2 on the drum axles (Fig. 26)
• 3 on the differential (Fig. 26)
Figure 26
• 2 on the reel countershaft bearings (Fig. 27)
• 2 on the belt idler pivots (Fig. 28).
1. Wipe each grease fitting with a clean rag.
2. Pump grease into each fitting until it begins to get
difficult to pump the gun.
Important Do not apply too much pressure or grease
seals will become permanently damaged.
3. Wipe off excess grease.

Figure 27

Figure 25

Figure 28

23
Checking and Changing 2. Place a drain pan at the rear of machine, under the drain
plug (Fig. 29).
Engine Oil 3. Remove the drain plug.
Check the oil level each time the mower is used or after
every 5 operating hours. Initially, change oil after the first 4. Push down on the handle to tip the mower and the
20 hours of operation; thereafter, change oil after every 50 engine backward, allowing more oil to run into the
hours of operation. More frequent oil changes are required drain pan.
in dusty or dirty conditions. 5. Install the drain plug and refill the crankcase with the
proper oil; refer to Checking the Oil Level.
Checking the Oil Level
1. Position the mower so the engine is level. Servicing the Air Cleaner
2. Clean around the oil level gauge (Fig. 29). Normally, clean the air cleaner after every 25 operating
hours. Clean it more frequently when the mower is
operated in dusty or dirty conditions.
1
1. Ensure that the wire is off of the spark plug.
2. Remove the wing nuts securing the air cleaner cover to
the air cleaner and remove the cover (Fig. 30).
3. Clean the cover thoroughly (Fig. 30).

Figure 29
1. Oil level gauge 2. Drain plug

3. Remove the oil level gauge by rotating it

counterclockwise.
4. Wipe the oil level gauge clean and insert it into the filler
port. Do not screw it into the port.
5. Remove the gauge and check the level of the oil.
6. If the level is low, add only enough oil to raise the level
to the filler opening.
7. Install the oil level gauge and wipe up any spilled oil.
Figure 30
1. Air cleaner cover
Changing the Oil
1. Start and run the engine for a few minutes to warm the
engine oil. 4. If the foam element is dirty, remove it from the paper
element (Fig. 31) and clean it thoroughly.

24
 1

Figure 32
1. Spark plug

Figure 31
1. Foam element 2. Paper element 3. Set the air gap at 0.028 to 0.032 in. (0.05 to 0.07 cm)
(Fig. 33).

A. Wash the foam element in a solution of liquid soap 4. Install the correctly gapped spark plug and tighten it to
and warm water. 17 ft.-lb. (23 N⋅m).

B. Squeeze to remove dirt, but do not twist it because

the foam may tear. 0.028–0.032 in.
C. Dry it by wrapping it in a clean rag. Squeeze rag and 0.05–0.07 cm
foam element to dry it.
D. Saturate the element with clean engine oil.
E. Squeeze the element to remove excess oil and to
distribute the oil thoroughly. An oil damp element is
desirable. Figure 33
5. Check condition of the paper element. Clean or replace
it as required.
6. Install the foam element, paper element, and air cleaner Cleaning the Fuel Filter
cover.
Initially, clean the fuel filter after the first 20 hours of
Important Do not operate the engine without the air operation; thereafter clean it after every 50 hours operation.
cleaner element because extreme engine wear and
1. Close the fuel shut off valve and unscrew the bowl from
damage will likely result.
the filter body (Fig. 34).

Replacing the Spark Plug

Use an NGK BPR 5ES spark plug or equivalent. The
correct air gap is 0.028 to 0.032 in. (0.05 to 0.07 cm).
Remove the plug after every 100 operating hours and check 1
its condition.
1. Pull the wire off of the spark plug.
2. Clean around the spark plug and remove it from the 2
cylinder head (Fig. 32)
Figure 34
Important Replace a cracked, fouled, or dirty spark 1. Shut-off valve 2. Bowl
plug. Do not sand blast, scrape, or clean electrodes
because engine damage could result from grit entering
the cylinder. 2. Clean the bowl and filter in clean gasoline and install it.

25
Adjusting Belts 6. After all bolts are installed, tighten them until the
stand-offs inside the cover contact the side plate. Do not
Ensure that the belts are properly tensioned to ensure overtighten.
proper operation of the machine and unnecessary wear.
Check belts frequently.

Adjusting the Reel Drive Belt

Check the tension by pressing the belt at mid span of the
pulleys with 3 to 5 lb. of force. The belt should deflect 1/4
in. (0.63 cm). If the deflection is incorrect, adjust the belt as 1
follows:
1. Remove the belt cover mounting screws and the belt
cover (Fig. 35).

Figure 36
1. Reel drive belt 2. Idler pulley

1
Adjusting the Traction Drive Belt
Check the tension by pressing the belt at mid span of the
pulleys with 3 to 5 lb. of force. The belt should deflect 1/4
in. (0.63 cm). If the deflection is incorrect, adjust the belt as
follows:
1. Remove the belt cover mounting screws and belt cover
to expose the belt (Fig. 37).

1
Figure 35
1. Reel drive belt cover

2. Loosen the idler pulley mounting nut and pivot the idler
pulley clockwise against the backside of the belt until
you attain the desired belt tension.
Important Do not over tension the belt.
3. Tighten the nut to lock the adjustment.
4. Install the belt cover by placing it in position.
5. While maintaining a slight gap between the cover seal Figure 37
and the side plate, install each mounting bolt until the 1. Traction drive belt cover
threads engage in the insert. The gap allows visual
alignment of the bolts to the threaded inserts.

26
2. Loosen the idler pulley mounting nut and pivot the idler
pulley clockwise against the backside of the belt until
the desired belt tension is attained (Fig. 38).
Important Do not over tension the belt.

2 2 1

Figure 39
1. Differential belt 2. Idler pulley

2. Loosen the idler pulley mounting nut and pivot the idler
pulley clockwise against the backside of the belt until
the desired belt tension is attained.
Important Do not over tension the belt.
3. Tighten the nut to lock adjustment.
4. Install the belt cover by placing it in position.
Figure 38
1. Traction drive belt 2. Idler pulley
5. While maintaining a slight gap between the cover seal
and the side plate, install each mounting bolt until the
threads engage in the insert. The gap allows visual
3. Tighten the nut to lock adjustment. alignment of the bolts to the threaded inserts.

4. Install the belt cover by placing it in position. 6. After all bolts are installed, tighten them until the
stand-offs inside the cover contact the side plate. Do not
5. While maintaining a slight gap between the cover seal overtighten.
and the side plate, install each mounting bolt until the
threads engage in the insert. The gap allows visual
alignment of the bolts to the threaded inserts. Adjusting the Primary V-Belts
6. After all bolts are installed, tighten them until the 1. To adjust the belt tension on primary V-belts, first check
stand-offs inside the cover contact the side plate. Do not the adjustment of the traction control. Refer to
overtighten. Adjusting the Traction Control, page 29. If unable to
attain the 3 to 5 lb. force required in adjusting the
traction control, proceed to next step.
Adjusting the Differential Belt
2. Loosen the retainer securing the V-belt cover and pivot
Check the tension by pressing the belt at mid span of the the cover open.
pulleys with 4 to 6 lb. of force. The belt should deflect 1/4
in. (0.63 cm). If the deflection is incorrect, adjust the belt as
follows:
1. Remove the capscrews securing the front and rear
sections of the differential cover to the differential
housing and slide the cover sections away to expose the
belt.

27
 8. To push or pull the machine easier without starting the
engine, adjust the belt guide (Fig. 41, inset) as follows:
1
A. Engage the clutch.
B. Loosen the capscrew securing the idler pulley and
2 belt guide to the idler arm.
C. Rotate the belt guide clockwise until a gap of
approximately 0.06 in. (0.15 cm) is obtained
between the guide finger and the backside of the
drive belts.
D. Tighten the capscrew and locknut securing the idler
pulley and belt guide to the idler arm.
9. Close the cover and secure the retainer.
Figure 40
1. V-belt cover 2. Retainer
Replacing the Differential Belt
3. To increase belt tension, loosen the engine mounting 1. Remove the capscrews securing the traction drive and
bolts and move engine backwards in the slots. reel drive belt covers to the right side plate and remove
the belt covers.
Important Do not over tension the belt.
2. Loosen the idler pulley mounting nut, on each idler
4. Tighten the mounting bolts. pulley, and pivot each idler pulley counterclockwise
away from the backside of each belt to release belt
Note: The distance between the centers of the driver and
tension.
the driven pulleys should be approximately 5.18 in.
(13.15 cm) after new V-belts are installed. 3. Remove the belts.
5. After tensioning the primary V-belts, check the 4. Remove the capscrews securing the front and rear
alignment of the engine output shaft pulley and the sections of the differential cover to the differential
countershaft pulley with a straight edge. housing and slide the cover sections away to expose the
belt (Fig. 42).
6. If the pulleys are misaligned, loosen the screws securing
the engine mounting base to the mower frame and slide
the engine from side to side until the pulleys are aligned
within 0.030 in. (0.07 cm).

2
2 1
3

Figure 41
Figure 42
1. Primary V-belts 3. Idler pulley
1. Differential cover sections 3. Right rear bearing
2. Belt guide
2. Front clutch housing housing

7. Tighten the mounting screws and check the alignment.

28
5. Loosen the idler pulley mounting nut on the differential
idler pulley and pivot the idler pulley counterclockwise
away from the backside of the belt to release the belt
tension.
2
6. Remove the 2 capscrews and locknuts securing the front
clutch housing to the side plate (Fig. 42).
7. Rotate the housing 180° so the bottom of the housing
points upward.
1
8. Remove the 2 capscrews and locknuts securing the right
rear bearing housing to the side plate (Fig. 42).
9. Rotate the housing 180° so the bottom of the housing
points upward. Remove old belt.
10. Slide the new belt over the rotated housing covers, the
differential cover sections, and onto the differential
pulleys. Figure 43
1. Traction cable 2. Front jam nut
11. Ensure that the idler pulley is positioned against the
backside of belt.
12. Rotate both housings back into the upright position and
secure them to the sideplate with the capscrews and nuts Adjusting the Service/Park
previously removed. Brake
13. Adjust the differential belt tension; refer to Adjusting
If the service/park brake slips when operated, an adjustment
the Differential Belt, page 27.
is required.
14. Adjust the belt tension on the traction drive and reel
1. Move the service/park brake lever to the Off position.
drive belts; refer to Adjusting the Traction Drive Belt,
page 26, and Adjusting the Reel Drive Belt, page 2. Loosen the retainer securing the V-belt cover and pivot
NO TAG. the cover open (Fig. 44).
15. Install the differential, traction drive, and reel drive
covers.

Adjusting the Traction Control

If the traction control does not engage or it slips during
operation, an adjustment is required. 1

1. Move the traction control to the Disengaged position. 2

2. Loosen the retainer securing the V-belt cover and pivot
the cover open (Fig. 40).
3. To increase the cable tension, loosen the front cable jam
nut and tighten the back cable jam nut (Fig. 43) until a
force of 3 to 5 lb. is required to engage the traction
control. Measure the force at the control knob. Figure 44
1. Service/park brake cable 2. Front jam nut
4. Tighten the front cable jam nut.
5. Close the cover and secure the retainer.
3. To increase the cable tension, loosen the front cable jam
6. Check the control operation. nut and tighten the back cable jam nut (Fig. 44) until a
force of 3 to 5 lb. is required to engage brake. Measure
the force at the lever knob. Do not over adjust it so that
the brake band drags.
4. Close the cover and secure the retainer.

29
Adjusting the Interlock Switch 2. Using a 7/8 in. standard wrench, back out the spring
tension screw until the thrust washer is no longer
To adjust or replace the interlock switch, complete the tensioned against the bedbar (Fig. 46).
following procedure:
3. On each side of the machine, loosen the jam nut
1. Ensure that the engine is Off and the traction lever is securing the bedbar bolt (Fig. 46).
disengaged.
2. Loosen the 2 switch mounting nuts (Fig. 45) and move
the switch until the switch plunger is depressed 0.12 to
0.24 in. (0.3 to 0.6 cm) (switch closed).

1 2

2
1
Figure 47
1. Jam nut 2. Bedbar bolt

4. Remove each bedbar bolt allowing the bedbar to be

pulled downward and removed from the machine. Save
Figure 45 the 2 nylon and 2 stamped steel washers on each end of
1. Interlock switch 2. Mounting nuts
bedbar (Fig. 46).

3. Tighten the switch mounting nuts.

Installing the Bedbar
1. Install the bedbar, positioning the mounting ears
4. Engage the traction lever and verify that the switch
between the thrust washer and the channel on the
plunger is depressed between 0.12 to 0.24 in. (0.3 to
bedbar adjuster.
0.65 cm).
2. Secure the bedbar to each side plate with the bedbar
5. Adjust the switch as required.
bolts (flange nuts on the bolts) and 8 washers. Position a
nylon washer each side of the side plate boss. Place a
steel washer outside each of the nylon washers.
Servicing the Bedbar
Greensmaster 800 & 1600 only 3. Torque bolts to 240 to 320 in.-lb. (27 to 36 N⋅m).
4. Tighten the flange nuts until the thrust washers just
Removing the Bedbar rotate freely.
1. Turn the bedbar adjuster screw, counterclockwise, until 5. Adjust the bedbar; refer to Adjusting the Bedknife to
the channel bottoms out in the adjuster frame (Fig. 46). the Reel, page 15.
4 3 2

1
5 Servicing the Bedbar
Greensmaster 1000 only

Removing the Bedbar

1. Turn bedbar adjuster screw, counterclockwise, to back
6 bedknife away from reel (Fig. 48).

Figure 46
1. Bedbar adjusting screw 4. Bedbar
2. Spring tension screw 5. Channel
3. Thrust Washer 6. Adjuster frame

30
 3 Backlapping the Reel
2
1. Remove the plug in the right reel drive cover (Fig. 50).

1 1
Figure 48
1. Bedbar adjusting screw 3. Bedbar
2. Spring tension nut

2. Back out the spring tension nut, until the washer is no

longer tensioned against the bedbar (Fig. 48). Figure 50
1. Cover plug
3. On each side of the machine, loosen the jam nut
securing the bedbar bolt (Fig. 49).
4. Remove each bedbar bolt allowing bedbar to be pulled 2. Insert a 1/2 in. socket extension, connected to the
downward and removed from machine. Account for 2 backlapping machine, into the square hole in the center
nylon and 2 stamped steel washers on each end of of the reel pulley.
bedbar (Fig. 49).
3. Backlap according to the procedure in the Toro
Sharpening Reel and Rotary Mowers Manual, Form
No. 80-300 PT.

Warning
Contact with the reels or other moving parts can
result in personal injury.
Keep fingers, hands, and clothing away from the
reels or other moving parts.
2
1
Figure 49
1. Jam nut 2. Bedbar bolt
Danger
Using a short handled brush when backlapping
will cause you to come into contact with moving
Assembling the Bedbar parts, causing serious injury.
1. Install bedbar, positioning mounting ears between Only use brush handle assembly 29-9100 available
washer and bedbar adjuster. from your Authorized Toro Distributor when
backlapping.
2. Secure bedbar to each side plate with bedbar bolts (jam
nuts on bolts) and 8 washers. A nylon washer is to be
positioned on each side of side plate boss. Place a steel Note: For a better cutting edge, run a file across the front
washer outside each of the nylon washers. Torque bolts face of the bedknife when the lapping operation is
to 240–320 in.-lb. Tighten jam nuts until thrust washers completed. This will remove any burrs or rough edges that
just rotate freely. may have built up on the cutting edge.

3. Tighten spring tension nut until spring is collapsed, then 4. Install the plug in the cover when finished.
back off 1/2 turn.
4. Adjust bedbar; refer to Adjusting the Bedknife to the
Reel, page 15.

31
 The Toro General Commercial Products Warranty
A Two-Year Limited Warranty

Conditions and Products Covered • Failures caused by outside influence. Items considered to be
The Toro Company and its affiliate, Toro Warranty Company, outside influence include, but are not limited to, weather,
pursuant to an agreement between them, jointly warrant your Toro storage practices, contamination, use of unapproved coolants,
Commercial Product (“Product”) to be free from defects in lubricants, additives, or chemicals, etc.
materials or workmanship for two years or 1500 operational • Normal “wear and tear” items. Normal “wear and tear”
hours*, whichever occurs first. Where a warrantable condition includes, but is not limited to, damage to seats due to wear or
exists, we will repair the Product at no cost to you including abrasion, worn painted surfaces, scratched decals or win-
diagnosis, labor, parts, and transportation. This warranty begins dows, etc.
on the date the Product is delivered to the original retail purchaser.
Parts
* Product equipped with hour meter
Parts scheduled for replacement as required maintenance are
Instructions for Obtaining Warranty Service warranted for the period of time up to the scheduled replacement
You are responsible for notifying the Commercial Products time for that part.
Distributor or Authorized Commercial Products Dealer from whom Parts replaced under this warranty become the property of Toro.
you purchased the Product as soon as you believe a warrantable Toro will make the final decision whether to repair any existing part
condition exists. or assembly or replace it. Toro may use factory remanufactured
If you need help locating a Commercial Products Distributor or parts rather than new parts for some warranty repairs.
Authorized Dealer, or if you have questions regarding your General Conditions
warranty rights or responsibilities, you may contact us at:
Repair by an Authorized Toro Distributor or Dealer is your sole
Toro Commercial Products Service Department remedy under this warranty.
Toro Warranty Company Neither The Toro Company nor Toro Warranty Company is
8111 Lyndale Avenue South liable for indirect, incidental or consequential damages in
Bloomington, MN 55420-1196 connection with the use of the Toro Products covered by this
952-888-8801 or 800-982-2740 warranty, including any cost or expense of providing substi-
E-mail: commercial.service@toro.com tute equipment or service during reasonable periods of
malfunction or non-use pending completion of repairs under
Owner Responsibilities this warranty. Except for the Emissions warranty referenced
As the Product owner, you are responsible for required mainte- below, if applicable, there is no other express warranty. All
nance and adjustments stated in your operator’s manual. Failure implied warranties of merchantability and fitness for use are
to perform required maintenance and adjustments can be grounds limited to the duration of this express warranty.
for disallowing a warranty claim. Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so
Items and Conditions Not Covered
the above exclusions and limitations may not apply to you.
Not all product failures or malfunctions that occur during the
This warranty gives you specific legal rights, and you may also
warranty period are defects in materials or workmanship. This
have other rights which vary from state to state.
express warranty does not cover the following:
• Product failures which result from the use of non-Toro
replacement parts, or from installation and use of add-on, Note regarding engine warranty: The Emissions Control
modified, or unapproved accessories System on your Product may be covered by a separate warranty
meeting requirements established by the U.S. Environmental
• Product failures which result from failure to perform required
Protection Agency (EPA) and/or the California Air Resources
maintenance and/or adjustments
Board (CARB). The hour limitations set forth above do not apply to
• Product failures which result from operating the Product in an the Emissions Control System Warranty. Refer to the Engine
abusive, negligent or reckless manner Emission Control Warranty Statement printed in your operator’s
• Parts subject to consumption through use unless found to be manual or contained in the engine manufacturer’s documentation
defective. Examples of parts which are consumed, or used up, for details.
during normal Product operation include, but are not limited to,
blades, reels, bedknives, tines, spark plugs, castor wheels,
tires, filters, belts, etc.
Countries Other than the United States or Canada
Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer)
to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor’s service or
have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty
Company.
Part No. 374-0031 Rev. a