service repair manual download

1. PART NO. 96889SL, Rev. A
Service Manual
Greensmaster ®
1000/1600
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing,
and repairing assemblies and components on the
Greensmaster 1000/1600.
REFER TO THE OPERATOR’S MANUAL FOR OPER-
ATING, MAINTENANCE, AND ADJUSTMENT
INSTRUCTIONS. Space is provided in Chapter 2 of this
book to insert the Operator’s Manual and Parts Catalogs
for your machine. Replacement Operator’s Manuals are
available by sending complete Model and Serial Num-
ber to:
The Toro Company
8111 Lyndale Avenue South
Minneapolis, MN 55420–1196
The Toro Company reserves the right to change product
specifications or this publication without notice.
ING, or CAUTION, PERSONAL SAFETY
Failure to obey the instructions may result in
This safety symbol means DANGER, WARN-
INSTRUCTION. When you see this symbol,
carefully read the instructions that follow.
personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing, or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
E The Toro Company – 1996, 1997

2. Table Of Contents
Chapter 1 – Safety
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 1
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 4
Chapter 2 – Product Records and Manuals
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1
Equivalents and Conversions . . . . . . . . . . . . . . . . 2 – 2
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 – 3
Operation and Service History Report . . . . . . . . . 2 – 5
Chapter 3 – Engine
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 – 4
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 6
Services and Repairs . . . . . . . . . . . . . . . . . . . . . . . 3 – 8
Kawasaki FE161 & FE170 Service Manual and
Kawasaki FE120 Service Manual Supplement
Chapter 4 – Traction and Reel Drive System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 3
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 4
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 4 – 8
Greensmaster 1000/1600
Chapter 5 – Electrical System
Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 6
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 7
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 8
Service and Repairs 5 – 13
. . . . . . . . . . . . . . . . . . . . . . .
Chapter 6 – Controls, Wheels and Accessories
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 – 4
Chapter 7 – Cutting Unit
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . 7 – 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 7
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 9
Service and Repairs 7 – 13
. . . . . . . . . . . . . . . . . . . . . . .
Chapter 8 – Grooming Reel Kit (See Note Below)
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 8 – 3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 4
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 6
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 8 – 8
Note: This chapter covers the Model 04125 Grooming
Reel Kit only (for the Greensmaster 1000).
Safety
Product
Records
and
Manuals
Engine
Drive
System
Electrical
System
Wheels
and
Cutting
Unit
Accessories
Grooming
Reel
Kit
Traction
and
Reel

3. Chapter 1
Safety
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Instructions
The GREENSMASTER 1000 was tested and certified
by TORO for compliance with the B71.4–1984 specifica-
tions of the American National Standards Institute. Al-
though hazard control and accident prevention partially
are dependent upon the design and configuration of the
machine, these factors are also dependent upon the
awareness, concern, and proper training of the person-
nel involved in the operation, transport, maintenance,
and storage of the machine. Improper use or mainte-
nance of the machine can result in injury or death.
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 2
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 3
To reduce the potential for injury or death, comply with
the following safety instructions.
or death,
comply with the following safety instructions.
To reduce the potential for injury
WARNING
Safety
Before Operating
1. Operate the machine only after reading and under-
standing the contents of this manual. A replacement
manual is available by sending the complete model and
serial number to:
The Toro Company
8111 Lyndale Avenue South
Minneapolis, Minnesota 55420–1196
2. Never allow children to operate the machine, nor al-
low adults to operate it without proper instructions.
3. Become familiar with the controls, and know how to
stop the engine quickly.
4. Keep all shields, safety devices, and decals in
place. If a shield, safety device, or decal is malfunction-
ing, illegible, or damaged, repair or replace it before op-
erating the machine.
5. Always wear substantial shoes. Do not operate ma-
chine while wearing sandals, tennis shoes or sneakers.
Do not wear loose fitting clothing which could get caught
in moving parts and cause personal injury.
6. Wearing safety glasses, safety shoes, long pants
and a helmet is advisable and required by some local
safety and insurance regulations.
7. Assure work area is clear of objects which might be
picked up and thrown by the reel.
8. Keep everyone, especially children and pets away
from the areas of operation.
9. Gasoline is highly flammable; handle it carefully.
A. Use an approved gasoline container.
B. Do not remove cap from fuel tank when engine is
hot or running.
C. Do not smoke while handling gasoline.
D. Fill fuel tank outdoors and no higher than to the
bottom of filter screen. Do not overfill.
E. Wipe up any spilled gasoline.
F. Fuel may leak from filler neck when mower is
tilted for servicing if tank is over filled.
Greensmaster 1000/1600 Page 1 – 1 Safety

4. 10. Check the safety interlock switch daily for proper op- operating machine. (After every two years, replace the
eration; see Component Testing in Chapter 5 – Electri- interlock switch in the safety system, whether it is work-
cal System. Replace malfunctioning switches before ing properly or not.)
While Operating
11. Do not run the engine in a confined area without ad-
equate ventilation. Exhaust fumes are hazardous and
could be deadly.
12. Always stand behind the handles when starting and
operating the machine.
13. To start and stop the engine:
A. Open fuel shut-off valve.
B. Verify that the traction drive lever on handle is in
NEUTRAL position and reel drive lever on mower is
DISENGAGED.
C. Move on/off switch to ON position, set choke to
full choke position (cold start) and throttle to half
throttle.
D. Pull starter cord to start engine.
E. Move throttle to SLOW and on/off switch to OFF
position to stop engine.
14. To transport mower from one area to another:
A. Install transport wheels.
B. Disengage reel drive lever.
C. Start engine.
D. Press down on handle to raise front of mower
and engage traction drive.
15. Before beginning mowing operation:
A. Stop engine.
B. Disengage traction drive.
C. Remove transport wheels.
D. Engage reel drive lever.
16. Before emptying basket of clippings, disengage
traction drive, reduce engine speed and move on/off
switch to off position.
17. Do not touch engine, muffler or exhaust pipe while
engine is running or soon after it has stopped because
these areas are hot enough to cause burns.
18. If the cutting unit strikes a solid object or vibrates ab-
normally, stop immediately, turn engine off,wait for all
motion to stop and inspect for damage. A damaged reel
or bedknife must be repaired or replaced before opera-
tion is commenced.
19. Whenever machine is left unattended, be sure en-
gine is stopped and cutting unit reel is not spinning.
Close fuel shut-off valve if machine is not to be used for
an extended period of time.
Safety
Maintenance and Service
20. Before servicing or making adjustments to the ma-
chine, stop the engine and pull the spark plug wire off
spark plug to prevent accidental starting of the engine.
21. To make sure entire machine is in good condition,
keep all nuts, bolts, screws and belts properly tightened.
22. If major repairs are ever needed or assistance is re-
quired, contact an Authorized TORO Distributor.
23. To reduce potential fire hazard, keep the engine
area free of excessive grease, grass, leaves and accu-
mulation of dirt.
24. If the engine must be running to perform a mainte-
nance adjustment, keep hands, feet, clothing, and any
parts of the body away from the cutting unit and any
moving parts. Keep everyone away.
25. Do not overspeed the engine by changing governor
settings. Maximum engine speed is 3600 rpm. To as-
sure safety and accuracy, have an Authorized Toro Dis-
tributor check maximum engine speed with a
tachometer.
26. Engine must be shut off before checking oil or ad-
ding oil to the crankcase.
27. To be sure of optimum performance and safety, al-
ways purchase genuine TORO replacement parts and
accessories. Replacement parts and accessories made
by other manufacturers could be dangerous. Such use
could void the product warranty of The Toro Company.
Safety Page 1 – 2 Greensmaster 1000/1600

5. Chapter 2
Product Records and Manuals
Table of Contents
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2
Decimal and Millimeter Equivalents . . . . . . . . . . . . 2
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2
Product Records
Record information about your Greensmaster
1000/1600 on the OPERATION AND SERVICE HISTO-
RY REPORT form. Use this information when referring
to your machine.
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 3
Capscrew Markings and Torque Values – U.S. . . 3
Capscrew Markings and Torque Values – Metric 3
OPERATION AND SERVICE HISTORY REPORT . 5
Insert Operator’s Manuals and Parts Catalogs for your
Greensmaster 1000/1600 at the end of this section.
Product
Records
and
Manuals
Greensmaster 1000/1600 Page 2 – 1 Product Records and Manuals

6. Equivalents and Conversions
Product Records and Manuals Page 2 – 2 Greensmaster 1000/1600

7. Product
Records
and
Manuals
Greensmaster 1000/1600 Page 2 – 3 Product Records and Manuals
Torque Specifications

8. Chapter 3
Engine
Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Spark Plug and Ignition Components . . . . . . . . . . 8
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . 4 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuel Shut–off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine Removal and Installation 10
. . . . . . . . . . . . .
Throttle Linkage Adjustment . . . . . . . . . . . . . . . . . . 6 Lubrication 13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Control Adjustment . . . . . . . . . . . . . . . . . . . . 6 Kawasaki FE161 & FE170 Service Manual and
Adjusting V–belts . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Kawasaki FE120 Service Manual Supplement
Greensmaster 1000/1600 Page 3 – 1 Engine
Engine

9. Introduction
This Chapter gives information about specifications,
maintenance, troubleshooting, testing, and repair of the
gasoline engine used in the Greensmaster 1000/1600
mower.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
tools are described in the Kawasaki FE161 & FE170
Service Manual and Kawasaki FE120 Service Manual
Supplement. The use of some specialized test equip-
ment is explained. However, the cost of the test equip-
ment and the specialized nature of some repairs may
dictate that the work be done at an engine repair facility.
Service and repair parts for Kawasaki engines are sup-
plied through your local Toro distributor. If no parts list is
available, be sure to provide your distributor with the
Toro model and serial number.
Engine Page 3 – 2 Greensmaster 1000/1600

10. 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 (HP) 2.8 (3.7)
Rated Output kw (HP) 2.2 (3.0)
Carburetor Float feed fixed main jet
Governor Mechanical flyweight
Idle Speed (no load) 1600 100 RPM (at crankshaft) or 800 50 RPM (at camshaft)
High Idle (no load) 3600 100 RPM (at crankshaft) or 1800 50 RPM (at camshaft)
Direction of rotation Clockwise (facing PTO shaft)
Fuel Un–leaded automotive grade gasoline
Fuel Tank Capacity liter (U.S. qt.) 2.5 (2.6)
Engine Oil See General Information
Lubrication System Splash type
Oil Capacity liter (U.S. qt.) 0.6 (0.63)
Air Cleaner Dual element
Ignition System Transistorized flywheel magneto with ignition advancing
RFI Suppressor Radio suppressor plug cap and plug
Dry Weight kg (U.S. lb) 14.6 (32.2)
Engine
Greensmaster 1000/1600 Page 3 – 3 Engine

11. General Information
Filling the Fuel Tank
DANGER
Because
must
ning,
flame
SMOKE
vent
spilled
gine.
ling
proved
ventilated
as�
Since
fumes
hale.
gasoline is flammable, caution
be used when storing or handling it.
Do not fill the fuel tank while engine is run�
hot, or in an enclosed area. Vapors
may build up and be ignited by a spark or
source many feet away. DO NOT
while filling the fuel tank to pre�
the possibility of an explosion. Al�
ways fill fuel tank outside. Wipe up any
gasoline before starting the en�
Use a funnel or spout to prevent spil�
gasoline. Fill tank no higher than to
the bottom of filter screen. DO NOT OVER
FILL. Store gasoline in a clean safety ap�
container and keep the cap on the
container. Keep gasoline in a cool, well
place; never in an enclosed
area such as a hot storage shed. To
sure volatility, do not buy more than a 30
day supply of gasoline. Gasoline is a fuel
for internal combustion engines; there�
fore do not use it for any other purpose.
many children like the smell of gas,
keep it out of their reach because the
are explosive and dangerous to in�
1
Figure 1
1. Fuel tank cap
IMPORTANT: Never use methanol, gasoline con-
taining methanol, gasoline containing more than
10% ethanol, gasoline additives, premium gasoline,
or white gas. Engine fuel system damage could re-
sult.
1. Park mower on a level surface. Make sure engine
is OFF.
2. Clean around fuel tank cap and remove cap from
tank (Fig. 1). Using unleaded gasoline, fill fuel tank to
bottom of filter screen. DO NOT OVER FILL.
3. Install fuel tank cap. Wipe up any spilled gasoline.
Engine Page 3 – 4 Greensmaster 1000/1600

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13. Fuel Shut–off Valve
The valve is located on the left front side of the engine.
It has two positions: CLOSED and OPEN. Position valve
to the closed position when storing or transporting the
machine. Open valve before starting the engine.
1
Figure 2
1. Fuel shut–off valve
Greensmaster 1000/1600 Page 3 – 5 Engine
Engine

14. Adjustments
Throttle Control Adjustment
If a new throttle cable must be installed or the cable is
out of adjustment, adjust the cable as follows:
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Move throttle lever to the SLOW position.
3. Loosen throttle cable screw securing the throttle
cable to the governor lever.
Note: Engine speed is measured at the input drive
pulley (Fig. 6). Actual engine speed is twice the input
drive pulley speed.
4. The governor lever will move to the slow idle posi-
tion if it is improperly adjusted.
A. Check low idle speed setting with a tachometer.
Low idle speed should be 750 to 850 rpm. Adjust
low speed idle screw in or out to attain the correct
speed setting.
B. Check high idle speed setting with a tachometer.
High idle speed should be 1750 to 1850 rpm. Ad-
just high speed idle screw in or out to attain the cor-
rect speed setting.
1
3
2
5
4
Figure 2
1. Throttle cable screw 4. Low speed idle screw
2. Throttle cable 5. High speed idle screw
3. Governor lever
5. Make sure throttle lever is in the SLOW position and
the governor lever is against the low speed idle screw.
6. Tighten throttle cable screw securing the throttle
cable to the governor lever.
Clutch Control Adjustment
If clutch control does not engage or it slips during opera-
tion, an adjustment is required.
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Move traction control to DISENGAGED position.
3. Loosen retainer securing V–belt cover and pivot
cover open.
4. To increase cable tension, loosen front cable jam
nut and tighten back cable jam nut (Fig. 3) until a force
of 7 to 9 lbs (31 to 40 N) is required to engage clutch con-
trol. The force should be measured at the control knob.
2
1
3
Figure 3
1. Clutch
5. Tighten front cable jam nut. 2. Front jam nut
3. Back jam nut
6. Close cover and secure retainer.
7. Check control operation.
Engine Page 3 – 6 Rev. A Greensmaster 1000/1600

15. Adjusting V–belts
To adjust belt tension on V–belts (Fig. 5), first check ad-
justment of clutch control. Refer to Clutch Control in this
section. If unable to attain the 7 to 9 lbs (31 to 40 N) of
force that is required in adjusting the clutch control, pro-
ceed to the next step.
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Loosen retainer securing the V–belt cover and pivot
cover open.
3. To increase V–belt tension, loosen cap screws se-
curing the engine to the engine base (Fig. 12). Move en-
gine backwards in slots. DO NOT OVER TENSION
BELTS. Tighten cap screws. Figure 5
2
1
1. V–belt cover 2. V–belts
4. Check that a force of 7 to 9 lbs (31 to 40 N) is re-
quired to engage the clutch control. Adjust engine in
slots as necessary to get required tension on V–belts.
5. After tensioning V–belts, check alignment of the in-
put drive pulley and input shaft pulley with a straight
edge.
A. Inside pulley faces should be flush to each other
to within 0.030 inch (0.762 mm) maximum (Fig. 6).
B. If pulleys are misaligned, loosen cap screws se
-
curing the engine mounting base to the mower
frame. Slide engine from side to side until the pul
-
leys are aligned (Fig. 7).
6. Tighten cap screws and recheck alignment.
1
2
INSIDE FACE
Figure 6
7. Close V–belt cover and secure retainer.
1. Input drive pulley 2. Input shaft pulley
3
2
1
Figure 7
1. Cap screws 3. Engine base
2. Engine
Engine
Greensmaster 1000/1600 Page 3 – 7 Engine