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.
This safety symbol means DANGER, WARN-
ING, or CAUTION, PERSONAL SAFETY
INSTRUCTION. When you see this symbol,
carefully read the instructions that follow.
Failure to obey the instructions may result in
personal injury.
REFER TO THE OPERATOR’S MANUAL FOR OPER-
ATING, MAINTENANCE, AND ADJUSTMENT
INSTRUCTIONS. Space is provided in Chapter 2 of this
booktoinserttheOperator’sManualandPartsCatalogs
for your machine. Replacement Operator’s Manuals are
available by sending complete Model and Serial Num-
ber to:
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing, or re-
pair of the machine.
The Toro Company
8111 Lyndale Avenue South
Minneapolis, MN 55420–1196
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
The Toro Company reserves the right to change product
specifications or this publication without notice.
E The Toro Company – 1996, 1997
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Table Of Contents
Chapter 1 – Safety
Chapter 5 – Electrical System
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 1
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 4
Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 6
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 7
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 8
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 – 13
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 6 – Controls, Wheels and Accessories
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 – 4
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
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
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
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: ThischaptercoverstheModel04125Grooming
Reel Kit only (for the Greensmaster 1000).
Greensmaster 1000/1600
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Greensmaster 1000/1600
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Chapter 1
Safety
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 2
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 3
Safety Instructions
The GREENSMASTER 1000 was tested and certified
byTOROforcompliancewiththeB71.4–1984specifica-
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.
To reduce the potential for injury or death, comply with
the following safety instructions.
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
Before Operating
1. Operate the machine only after reading and under-
standing the contents of this manual. A replacement
manual is available by sending the complete model and
serial number to:
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.
The Toro Company
8111 Lyndale Avenue South
Minneapolis, Minnesota 55420–1196
8. Keep everyone, especially children and pets away
from the areas of operation.
2. Never allow children to operate the machine, nor al-
low adults to operate it without proper instructions.
9. Gasoline is highly flammable; handle it carefully.
A. Use an approved gasoline container.
3. Become familiar with the controls, and know how to
stop the engine quickly.
B. Do not remove cap from fuel tank when engine is
hot or running.
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.
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.
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.
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
Safety
Page 1 – 1
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10. Checkthesafetyinterlockswitchdailyforproperop-
eration; see Component Testing in Chapter 5 – Electri-
cal System. Replace malfunctioning switches before
operating machine. (After every two years, replace the
interlock switch in the safety system, whether it is work-
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.
15. Before beginning mowing operation:
A. Stop engine.
B. Disengage traction drive.
C. Remove transport wheels.
D. Engage reel drive lever.
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.
16. Before emptying basket of clippings, disengage
traction drive, reduce engine speed and move on/off
switch to off position.
B. Verify that the traction drive lever on handle is in
NEUTRAL position and reel drive lever on mower is
DISENGAGED.
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.
C. Move on/off switch to ON position, set choke to
full choke position (cold start) and throttle to half
throttle.
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.
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.
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.
B. Disengage reel drive lever.
C. Start engine.
D. Press down on handle to raise front of mower
and engage traction drive.
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.
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
tachometer.
a
21. To make sure entire machine is in good condition,
keep all nuts, bolts, screws and belts properly tightened.
26. Engine must be shut off before checking oil or ad-
ding oil to the crankcase.
22. If major repairs are ever needed or assistance is re-
quired, contact an Authorized TORO Distributor.
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.
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.
Safety
Greensmaster 1000/1600
Page 1 – 2
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Safety and Instruction Decals
The following safety and instruction decals are affixed to
the 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 from
your Authorized Toro Distributor.
On Front Frame Tube
Part No. 55–4300
On Control Panel
Part No. 93–6084
On Fuel Tank
Part No. 88–7620
On Grass Shield
Part No. 93–6098
On Grass Shield
Part No. 62–5070
GAS
UNLEADED
On Fuel Tank
Part No. 53–4420
Inside Belt Covers (3)
Part No. 88–8950
On Control Panel
Part No. 93–6085
DANGER
DO NOT OPERATE THIS UNIT UNLESS
ALL SHIELDS ARE FIRMLY SECURED.
On Fuel Tank
Part No. 63–8440
Inside Belt Cover
Part No. 675360
On Belt Cover
Part No. 65–7660
Greensmaster 1000/1600
Safety
Page 1 – 3
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On Control Panel
Part No. 93–9012
Safety
Greensmaster 1000/1600
Page 1 – 4
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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
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 3
Capscrew Markings and Torque Values – U.S. . . 3
Capscrew Markings and Torque Values – Metric
3
OPERATION AND SERVICE HISTORY REPORT . 5
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.
Insert Operator’s Manuals and Parts Catalogs for your
Greensmaster 1000/1600 at the end of this section.
Greensmaster 1000/1600
Product Records and Manuals
Page 2 – 1
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Equivalents and Conversions
Product Records and Manuals
Greensmaster 1000/1600
Page 2 – 2
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Torque Specifications
Greensmaster 1000/1600
Product Records and Manuals
Page 2 – 3
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Product Records and Manuals
Greensmaster 1000/1600
Page 2 – 4
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EQUIPMENT OPERATION AND SERVICE HISTORY REPORT
for
GREENSMASTER® 1000
TORO Model and Serial Number:__________-__________
Engine Numbers:
Differential Numbers:
Date Purchased:
Purchased From:
____________________
____________________
____________________ Warranty Expires__________
____________________
____________________
____________________
Contacts:
Parts
____________________ Phone__________________
____________________ Phone__________________
____________________ Phone__________________
Service
Sales
See your TORO Distributor/Dealer for other Publications, Manuals, and Videos from The TORO Company.
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GREENSMASTER® 1000 Maintenance Schedule
Minimum Recommended Maintenance Intervals:
Maintenance Procedure
Maintenance Interval & Service
Every
200hrs
Every
100hrs
Every
50hrs
Service Air Filter Pre-Cleaner
Lubricate All Grease Fittings
Check for loose Fasteners
Clean Fuel Filter and Sediment Bowl
Adjust Traction Drive Belts
† Change Engine Oil
Every
25hrs
A Level
B Level
Service
1
Clean Combustion Chamber
1
Replace Spark Plug
Check Cut-Off Bar Adjustment
Service Air Cleaner Filter
C Level
Service
2
Clean Combustion Chamber
2
Replace Spark Plug
D Level
Service
Adjust Valves and Torque Head Bolts
† Initial Break in at 20 hours
1
Interval for Engine Model: FG150
2
Interval for Engine Model: FE120
Annual Recommendations:
Item listed is recommended every 2 years.
Replace All Interlock Switches
(See Operator's and Service Manual for specifications and procedures)
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GREENSMASTER® 1000 Daily Maintenance Check List
Unit Designation:__________
Daily Maintenance:(duplicate this page for routine use)
TORO ID#:_______-_______
Daily Maintenance Check For Week Of
_____________
MON
TUES
WED
THURS
FR
SAT
SUN
Maintenance Check Item
Safety Interlock Operation
Park Brake Operation
Fuel Level
_______HRS
______HRS
______HRS
______HRS
______HRS
______HRS
______HRS
Engine Oil Level
Air Filter Pre-Cleaner
Clean Engine Cooling Fins
Unusual Engine Noises
Unusual Operating Noises
Reel-to-Bedknife Adjustment
Height-of-Cut Adjustment
1
Lubricate All Grease Fittings
Touch-up damaged paint
1
= Immediately after every washing, regardless of the interval listed.
Notation for areas of concern:
Inspection performed by:________________
Item
Date
Information
1
2
3
4
5
6
7
(See Operator's and Service Manual for specifications and procedures)
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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 -Service (every 100 hours)
1
Lubricate All Grease Fittings
Change Engine Oil
Clean Combustion Chamber
1
Service Air Filter Pre-Cleaner
Adjust Belts
Replace Spark Plug
Check for Loose Fasteners
Clean Fuel Filter & Sediment Bowl
A-Service required
Check Cut-Off Bar Adjustment
Service Air Cleaner Filter
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
A and B Service required
________________________________
_______________________________
D -Service (every 200 hours)
Other - Annual Service and Specials
Additional Servicing Items
2
Replace all Interlock Switches
________________________________
Clean Combustion Chamber
2
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
Replace Spark Plug
Adjust Valves and Torque Head Bolts
A, B and C Service required
_______________________________
_______________________________
_______________________________
1 Interval for Engine Model: FG150
2 Interval for Engine Model: FE120
(See Operator's and Service Manual for specifications and procedures)
Form No. 95-843-SL
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Chapter 3
Engine
Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel Shut–off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Throttle Linkage Adjustment . . . . . . . . . . . . . . . . . . 6
Clutch Control Adjustment . . . . . . . . . . . . . . . . . . . . 6
Adjusting V–belts . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Spark Plug and Ignition Components . . . . . . . . . . 8
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine Removal and Installation . . . . . . . . . . . . . 10
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Kawasaki FE161 & FE170 Service Manual and
Kawasaki FE120 Service Manual Supplement
Greensmaster 1000/1600
Page 3 – 1
Engine
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Introduction
This Chapter gives information about specifications,
maintenance, troubleshooting, testing, and repair of the
gasoline engine used in the Greensmaster 1000/1600
mower.
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.
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
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
Greensmaster 1000/1600
Page 3 – 2
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Specifications
Item
Description
Make / Designation
Kawasaki, 4–stroke, OHV, single cylinder,
air–cooled, gasoline engine, FE120G
Bore x Stroke mm (in.)
Total Displacement cc (cu. in.)
Compression Ratio
Maximum Output kw (HP)
Rated Output kw (HP)
Carburetor
60 x 44 (2.36 x 1.73)
124 (7.6)
8.4:1
2.8 (3.7)
2.2 (3.0)
Float feed fixed main jet
Governor
Mechanical flyweight
Idle Speed (no load)
High Idle (no load)
Direction of rotation
Fuel
1600 ꢀ 100 RPM (at crankshaft) or 800 ꢀ 50 RPM (at camshaft)
3600 ꢀ 100 RPM (at crankshaft) or 1800 ꢀ 50 RPM (at camshaft)
Clockwise (facing PTO shaft)
Un–leaded automotive grade gasoline
Fuel Tank Capacity liter (U.S. qt.)
Engine Oil
2.5 (2.6)
See General Information
Lubrication System
Oil Capacity liter (U.S. qt.)
Air Cleaner
Splash type
0.6 (0.63)
Dual element
Ignition System
Transistorized flywheel magneto with ignition advancing
Radio suppressor plug cap and plug
14.6 (32.2)
RFI Suppressor
Dry Weight kg (U.S. lb)
Greensmaster 1000/1600
Page 3 – 3
Engine
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General Information
Filling the Fuel Tank
1
DANGER
Because gasoline is flammable, caution
must be used when storing or handling
Do not fill the fuel tank while engine is
ning, hot, or in an enclosed area. Vapo
may build up and be ignited by
a
spar
flame source many feet away. DO NOT
SMOKE while filling the fuel tank to pr
vent the possibility of an explosion. AlĆ
ways fill fuel tank outside. Wipe up an
spilled gasoline before starting the enĆ
gine. Use
a
funnel or spout to prevent s
ling gasoline. Fill tank no higher than to
the bottom of filter screen. DO NOT OVER
Figure 1
1. Fuel tank cap
FILL. Store gasoline in
a
clean safety apĆ
proved container and keep the cap on the
IMPORTANT: Never use methanol, gasoline con-
taining methanol, gasoline containing more than
10% ethanol, gasoline additives, premium gasoline,
container. Keep gasoline in
ventilated place; never in an enclosed
area such as hot storage shed. To asĆ
sure volatility, do not buy more than
a
cool, well
a
or white gas. Engine fuel system damage could re-
sult.
fuel
a
30
day supply of gasoline. Gasoline is
for internal combustion engines; thereĆ
a
1. Park mower on a level surface. Make sure engine
fore do not use it for any other purpose.
is OFF.
Since many children like the smell of gas,
keep it out of their reach because the
fumes are explosive and dangerous to inĆ
hale.
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
Greensmaster 1000/1600
Page 3 – 4
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Fuel Shut–off Valve
The valve is located on the left front side of the engine.
It hastwopositions:CLOSEDandOPEN. Positionvalve
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
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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.
4
3
2. Move throttle lever to the SLOW position.
5
3. Loosen throttle cable screw securing the throttle
cable to the governor lever.
1
2
Note: Engine speed is measured at the input drive
pulley (Fig. 6). Actual engine speed is twice the input
drive pulley speed.
Figure 2
4. The governor lever will move to the slow idle posi-
tion if it is improperly adjusted.
1. Throttle cable screw
2. Throttle cable
3. Governor lever
4. Low speed idle screw
5. High speed idle screw
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.
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.
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.
Clutch Control Adjustment
If clutch control does not engage or it slips during opera-
tion, an adjustment is required.
2
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
1
2. Move traction control to DISENGAGED position.
3
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.
Figure 3
1. Clutch
2. Front jam nut
3. Back jam nut
5. Tighten front cable jam nut.
6. Close cover and secure retainer.
7. Check control operation.
Engine
Greensmaster 1000/1600
Page 3 – 6 Rev. A
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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.
2
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.
1
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
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.
1
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).
INSIDE FACE
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).
2
6. Tighten cap screws and recheck alignment.
7. Close V–belt cover and secure retainer.
Figure 6
1. Input drive pulley
2. Input shaft pulley
2
3
1
Figure 7
1. Cap screws
2. Engine
3. Engine base
Greensmaster 1000/1600
Page 3 – 7
Engine
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Service and Repairs
Engine Oil
The TORO Company recommends that the oil level be
checked each time the mower is used or after every 5
operating hours. Initially, change oil after the first 20
hours of operation; thereafter, change oil after every 50
hours of operation. More frequent oil changes are re-
quired in dusty or dirty conditions.
Changing the Oil:
1. Start and run engine for a few minutes to warm the
engine oil.
2. Place a drain pan at the rear of machine under the
drain plug. Remove drain plug.
Checking the Oil Level:
3. Pushdownonhandletotipmowerandengineback-
ward, allowing more oil to run into the drain pan.
1. Park mower on a level surface. Make sure engine
is OFF.
4. Reinstall drain plug and refill crankcase with proper
oil: refer to Checking the Oil Level. The crankcase
holds 6.3 qt (6.0 l).
2. Position mower so the engine is level. Clean around
the oil level gauge.
3. Remove oil level gauge by rotating it counterclock-
wise.
4. Wipe oil level gauge clean and insert it into the filler
port. Do not screw it into the port. Remove and check
level of the oil. If the oil level is low, add only enough oil
(see chart below for proper viscosity) to raise the level
to the filler opening.
1
Use any high quality detergent oil having the American
Petroleum Institute (API) “service classification”— MS
or SG.
Temperature
Oil Viscosity
2
50_ or below
50_ to 95_
SAE 10W30 wt.
SAE 10W30 wt. or 30 wt.
SAE 40
Figure 8
1. Oil level gauge
2. Drain plug
Above 95_
5. Reinstall oil level gauge and wipe up any spilled oil.
Spark Plug and Ignition Components
Service of the spark plug and other ignition components
is covered in Chapter 5 – Electrical System.
Engine
Greensmaster 1000/1600
Page 3 – 8
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Air Cleaner
Normally, clean air filter precleaner (foam element) after
every 25 operating hours and the air cleaner filter (paper
element)afterevery100operatinghours. Morefrequent
cleaning is required when the mower is operated in
dusty or dirty conditions. Replace air cleaner filter (pa-
per element) after 200 operating hours.
1
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Remove wing nuts securing the air cleaner cover to
air cleaner and remove cover. Clean cover thoroughly
(Fig. 9).
1
2
3. If the foam element is dirty, remove it from the paper
element (Fig. 10). Clean foam element thoroughly.
A. WASH element in a solution of liquid soap and
warm water. Squeeze it to remove dirt. Do not twist
element because foam may tear.
Figure 9
1. Wing nut
2. Air cleaner cover
B. DRY by wrapping the element in a clean rag.
Squeeze rag and foam element to dry.
C. SATURATE element with clean engine oil.
Squeeze element to remove excess oil and to dis-
tribute oil uniformly. An oil damp element is desir-
able.
1
2
4. When servicing the foam element, check condition
of the paper element. Clean or replace as required.
5. Reinstall foam element, paper element, and air
cleaner cover. Tighten wing nuts.
IMPORTANT: Do not operate engine without air
cleaner element because extreme engine wear and
damage will likely result.
Figure 10
1. Foam element
2. Paper element
Fuel Filter
Clean fuel filter after every 50 hours operation.
1. Close fuel shut off valve and unscrew bowl from the
filter body. Remove filter element.
1
2. Clean bowl and filter element in clean gasoline.
3. Reinstall filter element and bowl. Open fuel shut–off
valve.
2
Figure 11
1. Fuel shut–off valve
2. Bowl
Greensmaster 1000/1600
Page 3 – 9
Engine
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Engine Removal and Installation
3
4
2
5
1
48
6
7
8
43
9
49
13
20
45
10
11
33
41
15
44
16
36
33
37
20
46
17
14
35
34
13
22
20
32
12
42
7
41
40
33
39
38
13
32
19
KEY
27
18
19
IDLER PULLEY
ASSEMBLY
31
23
5
30
29
10
8
10
28
21
7
6
23
7
24
7
26
7
25
47
50
26
Figure 12
1. Bellcrank cover
2. Flat washer
3. Stud
18. R–clamp
19. Lock washer
20. Cap screw
21. Engine
22. Wire harness
35. Washer
36. Cap screw
37. Lock nut
38. Pulley support spacer
39. Idler pulley
40. Ball bearing
41. Retaining ring
42. Lock nut
43. Muffler guard (European models)
44. Module bracket
45. Cap screw
46. Interlock module
47. Throttle cable and bracket
48. Clutch cable
49. Clutch cable eyelet
50. Engine base
4. Retainer
5. Capscrew
6. Lock washer
7. Flat washer
8. Grease fitting
9. Lever
10. Bushing
11. Input drive pulley
12. Engine shaft spacer
13. Shoulder bolt
14. Torsion spring
15. Jam nut
16. Clutch switch
17. Clutch bracket
23. Capscrew
24. Throttle cable bracket
25. Washer head screw
26. Lock nut
27. Washer
28. Clutch torsion spring
29. Belt shield
30. Cap screw
31. Clutch lever
32. Cable link assembly
33. Lock washer
34. V–belt (matched set)
Engine
Greensmaster 1000/1600
Page 3 – 10
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Removal
1. Makesuremachineisparkedonalevelsurfacewith
the engine OFF. Remove high tension lead from the
spark plug to prevent the engine from starting. Close
fuel shut–off valve.
2. Remove pulley V–belts (Fig. 12).
2
A. Make sure clutch is DISENGAGED so the V–
belts (34)areslackened. Makesureservicebrakeis
DISENGAGED so the input shaft pulley can turn.
1
B. Open bellcrank cover (1) on the counter shaft
housing to get access to the clutch. Remove V–
belts one at a time by sliding the belt off the idler
pulley (39) first.
Figure 13
1. Lower jam nut
2. Clutch bracket
3. Remove clutch cable (Fig. 12).
A. Remove shoulder bolt (13) and lock nut (37)
from the clutch cable eyelet (49) and lever (9).
2
SLOW
B. Loosen lower jam nut holding the clutch cable to
the clutch bracket. Remove clutch cable from the
clutch bracket and clear of engine (Fig. 13).
1
3
4. Remove throttle cable from engine.
4
A. Loosen screw on governor lever enough to slide
the throttle cable out of the nut (Fig. 14).
5
B. Remove cap screw (23), flat washers (7), and
lock nut (26) from the engine base (49) and throttle
cable bracket (24). Pull throttle cable (47) and
bracket clear of the engine (Fig. 12).
Figure 14
1. Screw
2. Governor lever
3. Throttle cable
4. Nut
5. Washer head screw
5. Remove engine from the engine base.
A. Scribe a mark on the engine base at the bottom
of the engine for reassembly purposes (Fig. 15).
B. Disconnect both black\white wires on the clutch
switch (16) from both brown wires.
1
C. Remove remaining cap screws (23), flat wash-
ers(7), andlocknuts(26)fromtheenginebase(49).
Remove the engine from the cutting unit.
SCRIBE MARK
2
6. The bellcrank assembly can be removed from the
engine with minimum disassembly (Fig. 12).
A. Remove cap screw (36), lock washer (33), and
washer (35) from the engine shaft. Remove pulley
(11), key, and spacer (12) from the engine shaft.
Figure 15
1. Engine block
2. Engine base
C. Remove complete bellcrank assembly from the
engine.
B. Remove five cap screws (20) and lock washers
(33) securing the belt shield (29) and clutch bracket
(17) to the engine block.
Greensmaster 1000/1600
Page 3 – 11
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Reinstalling the Engine
1. Make sure machine is parked on a level surface.
The machine may be placed on a large work bench to
make engine installation and adjustment easier. Re-
move high tension lead from the spark plug.
1
2. Make sure that all parts removed from the engine
during maintenance or rebuilding are properly rein-
stalled to the engine.
INSIDE FACE
3. Make sure bellcrank cover (1) is open on the count-
er shaft housing to get access to the clutch (Fig. 12).
2
4. If the bellcrank assembly was removed from the en-
gine (21), reassembly as follows (Fig. 12):
Figure 16
A. Position clutch bracket (17) to the engine with
the long arm of the clutch torsion spring (28) under
the engine.
1. Input drive pulley
2. Input shaft pulley
6. Reconnect and adjust throttle cable (Fig. 14).
B. Position belt shield (29) to the engine. Secure
belt shield and clutch bracket to the engine with five
cap screws (20) and lock washers (33).
A. Make sure screw on governor level is loose
enough to slide the throttle cable into of the nut.
B. Loosen washer head screw enough to allow the
throttle cable to slide through small clamp
C. Hook short end of clutch torsion spring around
the post on the clutch bracket.
C. Position throttle control lever to the SLOW posi-
tion and governor lever all the way up to the slow
position.
D. Place engine shaft spacer (12) on the engine
shaft and reinstall key. Apply never seize to the
shaft.
D. Tighten screw on throttle lever and washer head
screw to the small clamp securing the throttle cable.
E. Place input drive pulley (11) on the engine shaft
with the counter bore out. Secure pulley to the shaft
with cap screw (36), lock washer (33), and washer
(35).
7. Reinstall clutch cable.
A. Reinstallclutchcableintonotchofclutchbracket
and clear of engine. Tighten lower jam nut holding
clutch cable to clutch bracket (Fig. 13).
5. Reinstall engine (21) to engine base (50) (Fig. 12).
A. Position engine on the engine base with the in-
put drive pulley towards the differential housing.
B. Place shoulder bolt (13) through the clutch cable
eyelet (49) and lever (9). Secure shoulder bolt with
lock nut (37) (Fig. 12).
B. Install four cap screws (23) and flat washers (7)
through the engine and engine base. Install throttle
cable bracket (24) under the left front cap screw. Put
flat washer and lock nut (26) on each cap screw and
hand tighten.
8. Reinstall pulley V–belts (Fig. 12).
A. Make sure clutch is DISENGAGED. Make sure
service brake is DISENGAGED so the input shaft
pulley can turn.
C. Use scribe mark on engine block to align engine.
The distance between engine out put shaft center
and and power shaft center should be from 5.11 to
5.23 inches (130 to 133 mm). Inside pulley faces
should be flush to each other to within 0.030 inch
(0.762 mm) maximum (Fig. 16).
B. Install V–belts (34) one at a time by placing a belt
into the inner groove of the input drive pulley (11)
first. Place the second belt into the outer groove of
the input drive pulley and then the outer groove of
the input shaft pulley. Place the loose end of the first
belt into the inner groove of the input drive pulley.
D. Tighten cap screws ensuring the engine align-
ment does not change.
E. Reconnect both black\white wires on the clutch
switch (16) to both brown wires.
Engine
Greensmaster 1000/1600
Page 3 – 12
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Lubrication
Both fittings on the bellcrank assembly should be
greased at least every 25 hours. Lubricate using No. 2
multipurpose lithium base grease. A hand operated
grease gun is recommended for best results.
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Wipe each grease fitting with a clean rag.
IMPORTANT: Do not apply too much pressure or
grease seals will become permanently damaged.
3. The grease fitting locations are the clutch lever pivot
and the clutch spring end of the clutch bracket.
Figure 17
4. Wipe off excess grease.
Greensmaster 1000/1600
Page 3 – 13
Engine
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Engine
Greensmaster 1000/1600
Page 3 – 14
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Chapter 4
Traction and Reel Drive Systems
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drum Bushing Tool Kit . . . . . . . . . . . . . . . . . . . . . . . 3
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Differential Belt Adjustment . . . . . . . . . . . . . . . . . . . 4
Drum Drive Belt Adjustment . . . . . . . . . . . . . . . . . . 5
Reel Drive Belt Adjustment . . . . . . . . . . . . . . . . . . . 6
Service/Park Brake Adjustment . . . . . . . . . . . . . . . 7
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8
Reel Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . 8
Reel Drive Belt Replacement . . . . . . . . . . . . . . . . . 9
Reel Drive Idler Pulley and Bearing . . . . . . . . . . . . 9
Clutch Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drum Drive Assembly . . . . . . . . . . . . . . . . . . . . . . 12
Drum Drive Belt Replacement . . . . . . . . . . . . . . . 13
Drum Drive Idler Pulley and Bearing . . . . . . . . . . 13
Differential Axle Pulley and Bearing . . . . . . . . . . 14
Drum Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . 15
Drum Assembly with Bearings . . . . . . . . . . . . . . . 16
Drum Assembly with Bushings . . . . . . . . . . . . . . . 18
Counter Shaft Assembly . . . . . . . . . . . . . . . . . . . . 20
Brake Band Replacement . . . . . . . . . . . . . . . . . . . 21
Power Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . 22
Differential Axle Bearing
(Countershaft Housing) . . . . . . . . . . . . . . . . . . . . . 23
Differential Idler and Bearing . . . . . . . . . . . . . . . . 24
Differential Assembly and Pulley . . . . . . . . . . . . . 25
Differential Belt Replacement – Models 04051,
04052, and 04060 . . . . . . . . . . . . . . . . . . . . . . . 29
Differential Belt Replacement – Model 04050 . . 30
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Greensmaster 1000/1600
Page 4 – 1
Traction and Reel Drive Systems
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Specifications
Item
Description
Traction Drive
Engine to countershaft drive has two ”A” section V–belts.
Countershaft to differential drive has 5 mm pitch timing belt.
Differential to drum drive has a 8 mm pitch timing belt.
Differential
Brake
Peerless series 100
Band drum
Dual cast aluminum, 7.5 inch (19.1 cm) diameter
Jaw type
Traction Drum
Reel Clutch
Traction and Reel Drive Systems
Page 4 – 2
Greensmaster 1000/1600
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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 or
available as TORO parts. Some tools may also be avail-
able from a local supplier.
Drum Bushing Tool Kit – TOR4060
Note: This kit is used on mowers with drums that have
bushings instead of bearings. The kit is used for models
04051 and 04052 – 50101 to 59999 only.
REAMER
TOR4061
BUSHING DRIVER
TOR4062–1
This kit contains all the tools required to install and prop-
erly size the drum bushings to factory standards. These
tools come as a set in a plastic tool case, or they may be
ordered individually.
ADAPTER SLEEVE
TOR4062–3
PILOT
TOR4062–2
Figure 1
Greensmaster 1000/1600
Page 4 – 3
Traction and Reel Drive Systems
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Adjustments
Differential Belt Adjustment
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
3
1
5
2. Check tension by depressing belt at the mid span
between pulleys with 5 to 6 lbs (22 to 27 N) of force. The
belt should deflect 1/4 inch. If deflection is incorrect, pro-
ceed to next step. If deflection is correct, continue op-
eration.
2
3. To adjust belt tension:
4
A. Remove capscrews securing the front and rear
box covers to countershaft housing. Slide covers
away from the housing to expose the belt (Fig. 2).
Figure 2
B. Loosen idler pulley cap screw on the engine side
of the housing (Fig. 3).
1. Front box cover
2. Rear box cover
4. Idler pulley
5. Differential belt
3. Countershaft housing
C. Pivot idler pulley clockwise against the backside
of the belt until desired belt tension is attained. Do
not over tension the belt (Fig. 2).
D. Tighten cap screw to lock adjustment (Fig. 3).
1
E. Reinstall box covers by placing the covers in
position. Whilemaintainingaslightgapbetweenthe
cover seal and the side plate, install each cap screw
until the threads engage in the insert. The gap will
allow visual alignment of the cap screw to the
threaded insert. After all cap screws are installed,
tighten them until the stand offs inside the covers
contact the side plate. Do not overtighten (Fig. 2).
2
Figure 3
1. Cap screw
2. Countershaft housing
Traction and Reel Drive Systems
Page 4 – 4
Greensmaster 1000/1600
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Drum Drive Belt Adjustment
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Check tension by depressing belt at mid span be-
tween the pulleys with 4 to 5 lbs (18 to 22 N) of force. The
belt should deflect 1/4 inch. If deflection is incorrect, pro-
ceed to next step. If deflection is correct, continue op-
eration.
2
1
3. To adjust belt tension:
1
A. Remove wheels if installed.
B. Removecapscrews, lockwashers, andbeltcov-
ers from the side plates (Fig. 4).
Figure 4
C. Loosen idler pulley capscrew (Fig. 5).
1. Cap screw & lock washer
2. Belt cover
D. Pivot the idler pulley clockwise against the back-
side of the belt until desired belt tension is attained.
Do not over tension belt (Fig. 6).
E. Tighten cap screw to lock adjustment (Fig. 5).
Note: Make sure spacer is on the lower pulley before
1
the belt cover is reinstalled.
2
F. Reinstall belt cover by placing the cover in posi-
tion. While maintaining a slight gap between the
cover seal and the side plate, install each cap screw
until the threads engage in the insert. The gap will
allow visual alignment of the cap screw to the
threaded insert. After all capscrews are installed,
tighten them until the stand offs inside the cover
contact the side plate. Do not overtighten (Fig. 6).
Figure 5
1. Cap screw
2. Engine base
1
2
Figure 6
1. Drum drive belt
2. Idler pulley
Greensmaster 1000/1600
Page 4 – 5
Traction and Reel Drive Systems
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Reel Drive Belt Adjustment
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
3
3
2. Check tension by depressing the belt at mid span
between pulleys with 4 to 5 lbs (18 to 22 N) of force. The
belt should deflect 1/4 inch. If deflection is incorrect, pro-
ceed to next step. If deflection is correct, continue op-
eration.
3. To adjust belt tension:
A. Removecapscrews, lockwashers, andbeltcov-
ers to expose the belt (Fig. 7).
B. Remove cap screws, flat washers, and nuts se-
curing the grass shield to the shield brackets. Move
grass shield to access the cap screw securing the
idler pulley (Fig. 8).
Figure 7
1. Cap screw & lock washer
2.
C. Loosen idler pulley cap screw (Fig. 8).
D. Pivot the idler pulley clockwise against the back-
side of the belt until desired belt tension is attained.
Do not over tension belt (Fig. 9).
5
4
E. Tighten cap screw to lock adjustment (Fig. 8).
1
F. Reinstall belt cover by placing the cover in posi-
tion. While maintaining a slight gap between the
cover seal and the side plate, install each cap screw
until the threads engage in the insert. The gap will
allow visual alignment of the cap screw to the
threaded insert. After all cap screws are installed,
tighten them until the stand offs inside the cover
contact the side plate. Do not overtighten (Fig. 9).
3
2
Figure 8
1. Cap screw, washer & nut
2. Grass shield
4. Cap screw
5. Idler pulley
3. Shield bracket
G. Reinstall grass shield to shield brackets with cap
screws, flat washers, and lock nuts (Fig. 8).
1
2
Figure 9
1. Reel drive belt
2. Idler pulley
Traction and Reel Drive Systems
Page 4 – 6
Greensmaster 1000/1600
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Service/Park Brake Adjustment
If service/park brake slips when operated, an adjust-
ment is required.
1
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2
2. Move service/park brake lever to the OFF position.
Note: Figure 10 is shown with the bellcrank cover re-
moved for illustrative purposes. It is not necessary to re-
move the cover.
3. Loosen retainer securing the bellcrank cover. Pivot
cover open.
Figure 10
4. To increase cable tension, loosen front cable jam
nut and tighten back cable jam nut until a force of 3 to 5
lbs (13 to 22 N) is required to engage brake. The force
should be measured at brake lever knob. Do not over
adjust, so brake band drags.
1. Brake cable
2. Front jam nut
5. Close cover and secure retainer.
Greensmaster 1000/1600
Page 4 – 7
Traction and Reel Drive Systems
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Service and Repairs
Reel Drive Assembly
52
49
55
41
17
16
15
56 57
14
13
43
26
12
58
22
18
12
27
19
29
28
20
23
21
48
47
46 45
44
25
24
5
1
10
11
8
42
7
40
4
9
54
50
6
31
53
3
51
15
42
32
47
30
39
38
RIGHT
37
36
2
34
5
FRONT
35
33
Figure 11
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 driver
12. Clutch and pulley assembly
13. Ball bearing
14. Retaining ring
15. Retaining ring
16. Lock washer
17. Jam nut
21. Lock nut
40. Wave washer
41. Reel drive belt
42. Pulley and drive assembly
43. Idler pulley
44. Ball bearing
45. Snap ring
46. Flat washer
47. Lock washer
48. Cap screw
49. Reel drive cover
50. Front seal strip
51. Rear seal strip
52. Upper seal strip
53. Lower seal strip
54. Plug
22. Lock washer
23. Drive screw
24. Clutch lever
25. Spacer
26. Washer
27. Cap screw
28. Clutch boot
29. Knob
30. Groomer arm cover
31. Cover trim
32. Flat head screw
33. Nut
34. Bearing housing
35. Seal
36. Cover standoff
37. Self–aligning bearing
38. Retaining ring
39. Seal
55. Decal
56. Cap screw
57. Washer
58. Pulley support spacer
18. Felt seal
19. Actuator pin
20. Detent spring
Traction and Reel Drive Systems
Page 4 – 8
Greensmaster 1000/1600
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Reel Drive Belt Replacement
Removal
3. Adjust reel drive belt tension and reinstall reel drive
cover (see Reel Drive Belt in the Adjustments section).
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
4. Reinstall grass shield to shield brackets with cap
screws, flat washers, and lock nuts (Fig. 8).
2. Remove cap screws (56), washers (57) and reel
drive cover (49) to expose reel drive belt (41) (Fig. 11).
3. Remove cap screws, flat washers, and nuts secur-
ing grass shield to shield brackets. Move grass shield to
access the cap screw securing the idler pulley (Fig. 8).
3
1
4. Loosen cap screw (2) securing the pulley support
spacer (58) (Fig. 11).
5. Pivot idler pulley counterclockwise away from the
reel drive belt to loosen belt tension. Remove reel drive
belt from the clutch pulley and drive pulley (Fig. 12).
2
4
Installation
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
Figure 12
1. Idler pulley
2. Reel drive belt
3. Clutch pulley
4. Drive pulley
2. Placeanewreeldrivebeltontotheclutchpulleyand
drive pulley (Fig. 12).
Reel Drive Idler Pulley and Bearing
Removal
Installation
1. Remove reel drive belt from the reel drive assembly
(see Reel Drive Belt Replacement Removal).
1. Make sure engine is OFF. Remove high tension
lead from the spark plug. Park mower on a level surface.
2. Remove cap screw (2) and lock washer (47) from
the pulley support spacer (58). Remove idler pulley as-
sembly from the clutch housing (Fig. 11).
1. Position cap screw (2) with lock washer (47) into the
clutch housing (1). Start cap screw into pulley support
spacer (58) of the idler assembly until lock washer just
starts to compress. Do not over tighten (Fig. 11).
Disassembly (Fig. 13)
2. Reinstall reel drive belt to the reel drive assembly
(see Reel Drive Belt Installation).
Note: The idler pulley assemblies for the reel drive
and drum drive assemblies are identical.
4
5
1. Remove cap screw, lock washer, and flat washer
from the pulley support spacer. Pull spacer from the idler
pulley.
7
6
3
2. Remove snap ring. Pull ball bearing from the idler
pulley.
Assembly (Fig. 13)
1. Press new ball bearing into the idler pulley. Press
pulley support spacer into the ball bearing and idler
pulley.
1
2
Figure 13
1. Cap screw
2. Lock washer
3. Flat washer
5. Idler pulley
6. Snap ring
7. Ball bearing
2. Install snap ring into idler pulley. Secure flat washer,
lock washer, and cap screw into the pulley support
spacer.
4. Pulley support spacer
Greensmaster 1000/1600
Page 4 – 9
Traction and Reel Drive Systems
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Clutch Bearing
Removal
Clutch and Pulley Assembly (Fig. 15)
1. Remove reel drive belt from the reel drive assembly
(see Reel Drive Belt Replacement Removal).
1. Pressnewballbearingsintodriver. Securebearings
with small retaining ring.
2. Remove clutch lever (24) as follows (Fig. 11):
2. Place key into the keyway of the driver. Press driver
through the pulley enough to expose retaining ring
groove.
A. Remove cap screw (27), lock washer (22), belle-
ville washer (26), and spacer (25) from the clutch
housing (1). Remove detent spring (20).
3. Secure large retaining ring to the driver.
B. Work clutch boot (28) from the clutch housing.
Pull clutch lever from the clutch housing.
1
4
2
OUTBOARD
SHOULDER
C. Replace actuator pin (19) if necessary. Torque
lock nut (21) from 45 to 60 in–lb (52 to 69 kg–cm).
5
3
3. Remove jam nut and lock washer from the power
shaft. Pull clutch and pulley assembly from the shaft.
Slide clutch jaw driver off the power shaft being careful
not to lose the keys (Fig. 14).
IMPORTANT: Make sure both keys are removed
from the power shaft prior to removing the clutch
housing (Fig. 14).
6
RIGHT
8
FRONT
4. Remove both cap screws (2) and lock nuts (3) se-
curing the clutch housing (1) to the frame (Fig. 11). Slide
clutch housing off the power shaft and away from the
frame (Fig. 14).
7
Figure 14
1. Jam nut
5. Clutch jaw driver
2. Lock washer
3. Power shaft
4. Clutch and pulley assy
6. Key
7. Clutch housing
8. Felt seal
Clutch Housing Disassembly (Fig. 11)
1. Remove retaining ring (8) from clutch housing (1).
1
2. Pull ball bearing (4) from the clutch housing (1). Re-
move wave washer (7); replace if damaged or worn.
5
3. Remove oil seal (6) from clutch housing (1).
4
Clutch Housing Assembly (Fig. 11)
1. Press new oil seal (6) into the clutch housing (1) on
thegreasefitting(5)side. Flatsideofsealmustbeout.
2. Place wave washer (7) into clutch housing (1). With
the seal side out, press new ball bearing (4) into the
housing.
6
3
3. Install retaining ring (8) into the clutch housing (1).
2
Clutch and Pulley Disassembly (Fig. 15)
Figure 15
1. Large retaining ring
2. Driver
3. Pulley
4. Key
5. Small retaining ring
6. Ball bearing
1. Remove large retaining ring securing the driver to
the pulley. Pull the driver out of the pulley. Remove key.
2. Removesmallretainingringfromthedriver. Pullball
bearings from driver.
Traction and Reel Drive Systems
Page 4 – 10
Greensmaster 1000/1600
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Installation
C. With the actuator pin engaging in the groove of
the clutch jaw driver (slide driver all the way into the
housing), secure cap screw into the clutch housing
(Fig. 14).
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. If the felt seal is damaged or worn, replace seal as
follows (Fig. 14):
10. Make sure clutch engages and disengages with no-
ticeable detent and without binding. It may be necessary
to rotate the clutch pulley assembly (12) to achieve en-
gagement (Fig. 11).
A. Completely remove seal and adhesive from the
out board shoulder of the clutch housing.
11. Reinstall reel drive belt to the reel drive assembly
and adjust belt (see Reel Drive Belt Replacement Instal-
lation).
B. Apply 3M adhesive EC–1099 or equivalent to
the outboard shoulder of the housing. Attach seal to
housing.
4
1
C. Fill clutch housing about half full with No. 2 multi-
purpose lithium base grease.
3. Slideclutchhousing(1)ontothepowershaft(9)with
oil seal (6) towards the shaft. Be careful not to damage
the seal (Fig. 11).
2
6
3
4. Place both cap screws (2) through the bearing
housing(1)andframe. Securecapscrewswithbothlock
nuts (3). Make sure clutch housing fits tightly
against the edge of the frame (Fig. 11).
SPRING SHOULD BE
FLUSH TO HOUSING
SHOULDER
5. Tap both keys into the keyways of the power shaft.
Apply Never Seize to the area of the keys and bearing
journal of the clutch jaw driver (Fig. 14).
5
7
6. Placeclutchjawdriverontheshaftwiththejawsfac-
ing out. Align slots in the clutch jaw driver with the keys
and slide into position (Fig. 14).
Figure 16
1. Lock washer
2. Belleville washer
3. Spacer
5. Clutch lever
6. Detent spring
7. Clutch boot
4. Cap screw
7. Place clutch and pulley assembly on the power
shaft with the jaws facing the clutch jaw driver. Secure
assembly to the shaft with the lock washer and jam nut
(Fig. 14).
8. Place end of clutch lever (24) with actuator pin (19)
through the clutch housing (1). Seat clutch boot (28) in
the hole of the housing (Fig. 11).
9. Install clutch lever to the clutch housing (Fig. 16).
A. Place lock washer, belleville washer, and spacer
on the cap screw. Make sure concave side of
belleville washer faces the clutch lever when
installed.
Note: On newer models, the detent spring is symmet-
rical. The spring can be installed in either direction.
B. Insert cap screw with the washers and spacer
through the hole in the clutch lever. Place detent
spring on cap screw with the two small holes
down and the hole closest to the edge away
from the lever.
Greensmaster 1000/1600
Page 4 – 11
Traction and Reel Drive Systems
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Drum Drive Assembly
7
*4
18
19
6
8
9
10
8
12
13
14
34
5
*33
41
29
37
38
39
40
19
18
30
FRAME
19
31
28
18
11
22
21
20
23
1
19
18
2
*3
16
15
27
LEFT
26
25
24
FRONT
36
17
35
32
Figure 17
1. Spacer
2. Backup washer
3. Pulley (LH)
14. Nut
15. Washer
29. Bearing clamp
30. Seal
31. Lock nut
32. Cap screw
16. V–ring seal
17. Bearing cover
18. Cap screw
19. Lock washer
20. Flangette
*
Pulley (RH)
4. Housing (LH)
Housing (RH)
33. Drum belt cover (LH)
Drum belt cover (RH)
*
*
5. Cap screw
6. Lock nut
7. Grease fitting
8. Seal
9. Bearing
10. Spacer
11. Grease fitting
12. Belt
13. Pulley
34. Seal strip
35. Cap screw
36. Lock washer
37. Idler pulley
38. Ball bearing
39. Snap ring
40. Flat washer
41. Spacer
21. Bearing
22. Flangette
23. Grease fitting
24. Bearing lock nut
25. Seal
26. Bearing
27. Bearing housing
28. Closure
Note: All parts are identical on both sides of the mow-
er frame except as noted.
Traction and Reel Drive Systems
Page 4 – 12
Greensmaster 1000/1600
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Drum Drive Belt Replacement
Removal
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Remove wheels if attached (see Wheels in the Ser-
vice and Repairs section of Chapter 6 – Wheels and Ac-
cessories).
1
2
3. Remove cap screws (35), lock washers (36) and
drum belt cover (33) to expose the belt (12) (Fig. 17).
4. Loosen cap screw (18) securing the spacer (41)
(Fig. 17). Pivot the idler pulley away from the drive belt
to loosen belt tension (Fig. 18).
Figure 18
1. Idler pulley
2. Drum drive belt
5. Remove drum drive belt from both pulleys (Fig. 18).
Installation
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Place a new drum drive belt onto both pulleys (Fig.
18).
3. Adjust drum drive belt tension and reinstall drum
belt cover (see Drum Drive Belt in the Adjustments sec-
tion).
4. Replace both wheels if they were attached (see
Wheels in the Service and Repairs section of Chapter 6
– Wheels and Accessories).
Drum Drive Idler Pulley and Bearing
Removal
1. See Reel Drive Idler Pulley and Bearing Disassem-
bly and Reassembly.
1. Removedrumdrivebeltfromthedrumdriveassem-
bly (see Drum Drive Belt Replacement Removal).
Installation
2. Remove cap screw (18) and lock washer (19) from
the spacer (41). Remove idler pulley assembly from the
clutch housing (Fig. 17).
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Position cap screw (18) with lock washer (19) into
the housing (4). Start cap screw into spacer (41) of the
idler assembly until the lock washer just starts to com-
press. Do not over tighten (Fig. 17).
Disassembly and Reassembly
Note: The idler pulley assemblies for the drum drive
reel drive assemblies are identical.
3. Reinstall drum drive belt to the drum drive assembly
and adjust belt tension (see Drum Drive Belt Installa-
tion).
Greensmaster 1000/1600
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Differential Axle Pulley and Bearing
Removal
7. Slide pulley onto the differential axle while aligning
pulley keyway with the woodruff key. Secure pulley to
the axle with the nut.
1. Removedrumdrivebeltfromthedrumdriveassem-
bly (see Drum Drive Belt Replacement Removal).
8. Replace drum drive belt to the drum drive assembly
and adjust belt tension (see Drum Drive Belt Replace-
ment Installation).
2. Remove nut from the differential axle. Remove
pulley and woodruff key from the axle (Fig. 19).
Note: On the housing (RH), the hose clamp must be
loosened and the differential boot must be removed
from the housing before the housing can be removed
from the frame and differential axle (Fig. 20).
INBOARD
SIDE
4
1
2
3. Remove cap screw and lock nut from the housing
and frame. Slide housing off of the differential axle (Fig.
19).
8
Disassembly (Fig. 21)
3
7
6
5
1. Remove spacer from housing and seal by. Replace
if worn or damaged.
Figure 19
1. Nut
5. Cap screw
6. Lock nut
7. Housing
8. Spacer
2. Differential axle
3. Pulley
4. Woodruff key
2. Remove both seals from the housing. Discard both
seals and replace with new ones.
3. Pull bearing from housing and discard.
1
Assembly (Fig. 21)
1. Press seal with the flat side out into the housing side
opposite the grease fitting.
2. Press bearing into housing.
2
3. Press a second seal with the flat side out into the
grease fitting side of the housing
3
Installation (Fig. 19)
Figure 20
1. Hose clamp
2. Housing (RH)
3. Differential boot
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Slide housing over the differential axle with the
grease fitting towards the inboard side of the mower.
2
4
3. Secure housing to the frame with both cap screws
and lock nuts.
5
4. On the housing (RH), attach the differential boot to
the housing. Secure the hose clamp to the boot and
housing (Fig. 20).
3
2
5. Slidespacer onto differential axle. Press spacer into
seal until it contacts the inner race of the bearing.
1
Figure 21
6. Tap woodruff key into the key way of the differential
axle. Apply never seize the axle in the area of the keys.
1. Spacer
2. Seal
4. Bearing
5. Grease fitting
3. Housing
Traction and Reel Drive Systems
Page 4 – 14
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Drum Shaft Bearing
Removal
C. Use a suitable wrench on the flats of the drum
shaft, between the drum and the frame, to lock the
shaft. Screw pulley to the drum shaft.
1. Removedrumdrivebeltfromthedrumdriveassem-
bly (see Drum Drive Belt Replacement Removal).
4. Install drum drive belt to the drum drive assembly
(see Drum Drive Belt Replacement Installation).
Note: The pulley (LH) has left hand threads, while the
pulley (RH) has right hand threads. Each pulley has an
arrow stamped on it for the direction of tightening.
5. Leveldrumtothereel(seeLevelDrumtoReelinthe
Adjustments section of Chapter 7– Cutting Unit).
2. Remove pulley from drum shaft as follows (Fig. 22):
A. Use a suitable wrench on the flats of the drum
shaft, between the drum and the frame, to lock the
shaft.
B. Unscrew pulley from the drum shaft.
1
C. Remove backup washer and spacer from the
drum shaft.
3. Remove bearing from drum shaft and frame as fol-
lows (Fig. 23):
2
A. Remove four cap screws and lock washers from
the flangettes, closure, frame, and bearing clamp.
4
3
B. Pull closure and flangettes with the bearing from
the frame and drum shaft.
Figure 22
1. Drum shaft
2. Pulley
3. Backup washer
4. Spacer
C. Remove bearing from flangettes.
Installation
BEARING COLLAR
8
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
5
6
2. Install bearing to the drum shaft and frame as fol-
lows (Fig. 23):
A. Place bearing between flangettes with the collar
on the bearing towards the flangette without the
grease fitting.
7
B. Insert two cap screws with lock washers through
the bottom holes of the flangettes. Place closure
onto capscrews. Secure assembly to frame with
bearing clamps.
2
1
4
3
Figure 23
1. Bearing
2. Frame
3. Cap screws
4. Lock washers
5. Flangette
6. Flangette (w\grease ftg)
7. Closure
C. Secure remaining cap screws with lock washers
through the flangettes and to the bearing clamps.
8. Bearing clamp
3. Install pulley to the drum shaft as follows (Fig. 22):
A. Apply loctite to the threads of the drum shaft.
B. Slide spacer and backup washer onto drum
shaft.
Greensmaster 1000/1600
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Drum Assembly with Bearings (Models 04050, 04052–60000 & Up, and 04060)
1
2
3
4
5
8
4
10
9
3
6
7
11
12
9
13
Figure 24
6. Seal spacer
1. Drum
10. Cap screw
2. Drum spindle
3. Spring lip seal
4. Bearing
7. Lock nut
8. Drum hub
9. Lock washer
11. Drum shaft (LH)
12. Drum shaft (RH)
13. Cap screw
5. Bearing spacer
Removal
1. Press bearing into the drum hub. Pack bearing with
grease. Fill space outside of bearing with grease. Press
spring lip seal into the hub with its flat side out (Fig. 25).
1. Remove both drum shaft bearings from both drum
shafts (see Drum Shaft Bearing Removal).
2. Insert seal spacer into drum hub. Press bearing into
the hub and pack with grease. Fill space outside of the
bearing with grease. Press second spring lip seal into
the hub with its flat side out (Fig. 25).
2. Pivot mower back and remove drum assembly from
the mower.
Disassembly
2
1. Remove four cap screws, lock washers, and drum
shafts from each drum.
SEAL SIDE OF BEARING
2. Remove cap screws and lock washers securing the
drum spindle and drum hub to their respective drums.
Remove spindle and hub assembly from both drums.
6
3. Remove lock nut and seal spacer from the drum
spindle. Carefully slide drum spindle out of the drum hub
bearings.
4. Remove both spring lip seals from the drum hub.
Pull both bearings from the hub. Remove bearing
spacer from the hub.
3
1
5
4
7
Assembly
Figure 25
1. Bearing
2. Drum hub
3. Spring lip seal
4. Bearing spacer
5. Drum spindle
6. Seal spacer
7. Lock nut
Note: The seal side of each bearing should face the
inside of the drum hub (Fig. 25).
Traction and Reel Drive Systems
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Note: The lock nut turns hard on the spindle shaft
when tightened. Make sure all rotation has stopped
when tightening. A good solid sound indicates the nut is
tight.
5. Secure drum spindle to the drum with four cap
screwsandlockwashers. Tightenscrewsusinganalter-
nating pattern. Repeat tightening sequence a second
time.
3. Apply grease to the shaft of the drum spindle. Care-
fully slide drum spindle into drum hub bearings. Secure
lock nut and seal spacer to the drum spindle (Fig. 25).
6. Secure drum shaft to each drum with four cap
screws and lock washers. Make sure shafts are seated
properly. Tighten screws using an alternating pattern.
Note: The fit between the drum hub and drum is a
close tolerance and can be easily jammed. The hub can
be rotated when seated properly in the bore of the drum.
Installation
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
4. Secure drum hub to the drum with four cap screws
and lock washers. Tighten screws using an alternating
pattern. Repeat tightening sequence a second time.
2. Pivot mower back and position drum assembly un-
der the mower to accept drum shaft bearings. Pivot
mower back down.
3. Replace both drum shaft bearings to both drum
shafts (see Drum Shaft Bearing Installation).
Greensmaster 1000/1600
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Drum Assembly with Bushings (Models 04051 and 04052–50001 to 59999)
3
5
3
6
6
4
6
OIL SEALS NOT SHOWN
1
2
Figure 26
1. Cap screw
2. Lock washer
3. Drum
5. Drum shaft
6. Bushing
4. Drum shaft extensions
Removal
BUSHING
DRIVER
1. Remove both drum shaft bearings from both drum
shafts (see Drum Shaft Bearing Removal).
2. Pivot mower back and remove drum assembly from
the mower.
Disassembly
1. Remove four cap screws and lock washers from
each drum. Remove both drum shafts extensions from
each drum (Fig. 26).
Figure 27
OUTER SIDE
BUSHING
INNER SIDE
2. Pull both drums apart and remove drum shaft from
the drum (Fig. 26).
3. Remove bushings from the drum (Fig. 27).
A. Insert bushing driver against the bushing.
B. Drive bushing out of the drum by striking the end
of the bushing driver with a hammer.
OIL SEAL
C. Repeat Step B to remove the bushing and seal
from the other end of the drum
Figure 28
4. Install outer bushing into the drum (Fig. 28 and 29).
BUSHING
DRIVER
A. Install adapter sleeve onto the bushing driver so
the counterbore of the sleeve is facing the bushing.
BUSHING
PILOT
ADAPTER
SLEEVE
B. Install a new bushing on the bushing driver, then
secure pilot to the bushing and adapter sleeve.
C. Insert pilot into the bushing bore of the drum.
Install bushing until the adapter sleeve meets the
drum.
Figure 29
Greensmaster 1000/1600
Traction and Reel Drive Systems
Page 4 – 18
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5. Install inner bushing into drum (Fig. 30).
BUSHING
DRIVER
Note: The setting of the adapter sleeve is critical so
the bushing is inserted deep enough for oil seal installa-
tion.
ADAPTER
SLEEVE
BUSHING
PILOT
A. Install adapter sleeve on the bushing driver so
the counterbore of the sleeve seats 3/16 inch (0.48
cm) beyond the step on the driver.
B. Install a new bushing on the bushing driver, then
secure pilot to the bushing and adapter sleeve.
Figure 30
Figure 31
Figure 32
C. Insert pilot into the bushing bore of the drum.
Install bushing until the adapter sleeve meets the
drum.
REAMER
6. Size bushing with reamer (Fig. 31).
Note: Size only one bushing at a time.
A. Attach reamer to a T–handle.
RACE
B. Size bushing with reamer being careful to keep
the reamer square with the drum race.
C. Clean inside bushing so it is free of debris.
7. Install oil seal into drum (Fig. 32 and 28).
A. Install adapter sleeve on the bushing driver so
the counterbore on the sleeve will be facing the oil
seal.
BUSHING
DRIVER
B. Place an oil seal on the bushing driver. Install oil
seal with the driver until the adapter sleeve contacts
the drum.
ADAPTER
SLEEVE
Installation
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Pivot mower back and position drum assembly un-
der the mower to accept drum shaft bearings. Pivot
mower back down.
3. Reinstall both drum shaft bearings to both drum
shafts (see Drum Shaft Bearing Installation).
Greensmaster 1000/1600
Page 4 – 19
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Counter Shaft Assembly
41
43
42
39
40
51
38
50
58
5
57
53
40
55
2
3
1
48
4
8
9
39
40
6
45
7
47
10
49
12
46
48
21
32
44
22
54
52
34
37
12
36
35
11
33
20
56
23
31
12
36
14
13
12
19
2
3
4
23
15
16
17
29
30
29
27
RIGHT
26
25
28
FRONT
18
24
Figure 33
1. Countershaft housing
2. Cap screw
3. Lock washer
4. Flat washer
5. Screw plate
6. Flangette
7. Grease fitting
8. Flangette
9. Bearing
10. Locking collar
11. Set screw
12. Lock washer
13. Jam nut
14. Shoulder bolt
15. Lock nut
21. Brake support
22. Lock washer
23. Cotter pin
40. Lock washer
41. Hose clamp
42. Hose clamp
43. Differential boot
44. Idler pulley
45. Ball bearing
46. Flat washer
47. Cap screw
48. Retaining ring
49. Cover seal strip
50. Cover seal strip
51. Cover seal strip
52. Cover bracket
53. Cap screw
24. Cotter pin
25. Brake band
26. Short spacer
27. Bearing housing
28. Grease fitting
29. Seal
30. Bearing
31. Long Spacer
32. Countershaft pulley
33. Key
34. Countershaft seal
35. Belt
36. Cap screw
37. Front box cover
38. Rear box cover
39. Cap screw
54. Spacer
55. Flat washer
56. Clip
57. Power shaft
58. Differential assembly & pulley
16. Input shaft pulley
17. Lock nut
18. Key
19. Brake lever
20. Clevis pin
Traction and Reel Drive Systems
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Brake Band Replacement
Removal
6. Reinstall interference previously removed (Fig. 34).
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
A. Make sure clutch is disengaged. Install both V–
belts.
2. Remove interference to brake band (Fig. 34).
B. Secure belt shield to engine block with both cap
screws and lock washers. Do not over tighten.
A. Remove bellcrank cover by removing both cap
screws and lock washers.
C. Secure bellcrank cover to counter shaft housing
with both cap screws and lock washers. Do not
over tighten.
B. Remove belt shield by removing both cap
screws and lock washers.
C. Disengage clutch and remove both V–belts.
3
3. Disengage brake to allow removal of brake band.
4
4. Remove lock nut (17) from power shaft (57). Slide
input shaft pulley (16) off the shaft. Remove key (18)
from the shaft (Fig. 33).
3
2
5. Remove brake band (25) from counter shaft hous-
ing (1) as follows (Fig. 33).
1
A. Remove cotter pin (23) from the brake support
(21).
B. Remove cotter pin (24) and clevis pin (20) from
the brake lever (19).
Figure 34
1. Bell crank cover
2. V–belts
3. Cap screw
4. Belt shield
C. Remove the brake band from the brake support
and brake lever.
Installation
1
9
2
3
7
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Disengage brake to allow installation of brake band.
3. Attach new brake band to the counter shaft housing
as follows (Fig. 35).
8
Note: Make sure both cotter pins are locked so there
is no contact between the input shaft pulley and cotter
pins.
5
6
4
Figure 35
A. Secure lower eye of brake band to the brake le-
ver with the clevis pin and cotter pin. Lock cotter pin.
1. Brake band
6. Clevis pin
7. Brake support
8. Power shaft
9. Lock nut
2. Counter shaft housing
3. Cotter pin
B. Secure upper eye of the brake band to the brake
support with cotter pin. Lock cotter pin.
4. Input shaft pulley
5. Brake lever
4. Apply never seize to the keyway area of the power
shaft (57). Install key (18) to the shaft (Fig. 33).
5. Slide input shaft pulley (16) onto the power shaft
(57) and through the brake band (25). Secure pulley to
the power shaft with lock nut (17) (Fig. 33 and 35).
Greensmaster 1000/1600
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Power Shaft Bearing
Removal
1. Remove brake band from the counter shaft housing
(see Brake Band Removal)
2. Remove cap screw (39) and lock washer (40) from
the front box cover (37) and counter shaft housing (1).
Remove cover from housing (Fig. 33).
4
3. Loosen cap screw (36) enough to rotate idler pulley
(44) away from the belt (35). Loosen belt by rotating the
idler pulley counterclockwise (Fig. 33).
5
6
2
4. Remove three cap screws (36) and lock washers
(12) from the counter shaft housing (1) and bearing
housing (27). Slide the bearing housing off the power
shaft (57) (Fig. 33).
1
3
Disassembly (Fig. 36)
1. Pull short spacer from the inner seal and bearing
housing.
Figure 36
1. Short spacer
2. Inner seal
3. Bearing housing
4. Outer seal
5. Bearing
6. Grease fitting
2. Pull outer seal, bearing, and inner seal from the
bearing housing.
Assembly (Fig. 36)
1. Press new seal with its flat side up through the
flange side of the bearing housing.
2. Press new bearing into the flange side of the bear-
ing housing.
3. Press second new seal with its flat side up through
the flange side of the bearing housing.
4. Push short spacer through inner seal until it con-
tacts the inner race of the bearing.
Installation
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Slide the bearing housing onto the power shaft (57).
3. Securethreecapscrews(36)andlockwashers(12)
through the counter shaft housing (1) and into the bear-
ing housing (27) (Fig. 33).
4. Adjustidler pulley and differential belt tension. Rein-
stall front box cover (see Differential Belt in the Adjust-
ments section).
5. Reinstall brake band to the counter shaft housing
(see Brake Band Replacement Installation).
Traction and Reel Drive Systems
Page 4 – 22
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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.
3
5
4
2. Lower handle to allow a clearance for the removal
of the bearing and flangettes from the differential axle
(see Handle in the Adjustments section of Chapter 6 –
Wheels and Accessories).
6
2
Note: The locking collar securing the left differential
axle to the countershaft housing is a eccentric flange
type.
1
3. Loosen the set screw on the locking collar. Unlock
collarbystrikingitwithapunchintheclockwisedirection
(Fig. 38).
Figure 37
1. Locking collar
4. Flangettes
5. Cap screw
6. Lock washer
2. Differential axle (LH)
3. Jam nut & lock washer
4. Remove bearing housing on the side plate for the
left differential axle (see Differential Axle Pulley and
Bearing Removal).
5. Slide locking collar off the differential axle.
6. Removejamnuts(13), lockwashers(12), andcable
clip (15) from the studs of screw plate (5) (Fig. 33).
IMPORTANT: Before removing the flangettes and
bearing from the differential housing, support the
axle in its original position to prevent possible dam-
age to the remaining differential axle bearing.
1
2
CLOCKWISE
7. Slide flangettes (6 and 8) and bearing (9) of the dif-
ferential axle (Fig. 33).
Figure 38
1. Differential axle (LH)
2. Locking collar
Installation
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Stack flangette (8), bearing (9), and flangette (6) to-
gether. Make sure lock collar on the bearing is posi-
tioned towards the flangette with the grease fitting (7)
(Fig. 33).
Note: Before tightening jam nuts (13), make sure that
thedifferentialaxlesturnfreelyandarealigned(Fig. 33).
3. Slide flangettes (6 and 8) and bearing (9) over the
differential axle. Secure assembly and cable clip (15) to
the studs of screw plate (5) with the jam nuts (13) and
lock washers (12) (Fig. 33).
4. Slide collar onto the differential axle. Lock collar by
striking it with a punch in the counterclockwise direction.
Tighten set screw on the locking collar (Fig. 38).
5. Reinstall bearing housing for the left differential
axle (see Differential Axle Pulley and Bearing).
Greensmaster 1000/1600
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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.
1
2. Remove capscrews (39) and lock washers (40) se-
curing rear and front box covers (38 and 39) to the coun-
tershaft housing (1). Pull covers from housing (Fig. 33).
2
3. Remove cap screw and lock washer that secure the
idler pulley (Fig. 37). Remove idler pulley from counter-
shaft housing (Fig. 39).
Disassembly (Fig 33)
Figure 39
1. Remove cap screw (47), lock washer (12), and flat
washer (46) from the spacer (54). Remove retaining ring
(48) from the pulley (44).
1. Idler pulley
2. Countershaft housing
2. Press spacer (54) out of the pulley (44). Press bear-
ings (45) out of the pulley.
Assembly (Fig 33)
1. Press bearings (45) into the pulley (44). Press
spacer (54) into the pulley.
2. Install retaining ring (48) into the pulley (44). Secure
cap screw (47), lock washer (12), and flat washer (46)
into the spacer (54).
Installation
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Reinstall idler pulley to the countershaft housing
(Fig. 39). Secure idler pulley with cap screw and lock
washer. Tighten cap screw until washer just starts to
compress. Spacer must be free to rotate (Fig. 37).
3. Adjust differential belt tension and reinstall front and
rear box covers (see Differential Belt Adjustment).
Traction and Reel Drive Systems
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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.
6
1
3
2. Lower handle to allow clearances for the removal of
the bearing and flangettes from the differential axle and
the differential assembly from the countershaft housing
(see Handle in the Adjustments section of Chapter 6 –
Wheels and Accessories).
4
2
3. Remove capscrews (39) and lock washers (40) se-
curing rear and front box covers (38 and 39) to the coun-
tershaft housing (1). Pull covers from housing (Fig. 33).
5
Figure 40
4. Loosen cap screw securing the idler to the counter
shaft housing (Fig. 37). Pivot idler pulley counterclock-
wise away from the backside of belt to release belt ten-
sion (Fig. 39).
1. Cap screw & lock washer 4. Flangettes
2. Differential axle
5. Locking collar
6. Screw plate stud
3. Jam nut & lock washer
Note: The locking collar securing the left differential
axle to the countershaft housing is a eccentric flange
type.
1
5. Loosen the set screw on the locking collar. Unlock
collarbystrikingitwithapunchintheclockwisedirection
(Fig. 38).
2
6. Remove bearing housing for theleft differentialaxle
(see Differential Axle Pulley and Bearing Removal).
IMPORTANT: For the remainder of this procedure,
support the axle in its original position to prevent
possible damage to the differential axle bearing and
differential housing bearing.
Figure 41
1. Idler pulley
2. Countershaft housing
7. Remove bearing housing for the right differential
axle (see DifferentialAxlePulleyandBearingRemoval).
3
8. Remove differential boot (43) and rear box cover
(38) from the countershaft housing (1) and differential
axle (Fig. 33).
4
2
1
9. Remove jam nuts, lock washers, and cable clip from
the studs of screw plate. Slide locking collar and flan-
gettes with the bearing off the differential axle. This step
allows the differential assembly to be positioned for
clearing the frame (Fig. 40).
10. Pull differential assembly out and up from the coun-
tershaft housing.
Figure 42
1. Lock nut
2. Flat washer
3. Differential assembly
4. Differential pulley
11. Remove lock nuts and flat washers from the differ-
ential assembly and pulley. Slide pulley clear of threads
and differential axle (Fig. 42).
Greensmaster 1000/1600
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BEARING RECESS (INBOARD)
0.125 TO 0.140 inch
(3.18 to 3.56 mm)
1
5
13
3
12
10
INSET FOR DRIVE PIN
9
7
11
6
4
6
11
10
12
8
7
2
BEARING RECESS (OUTBOARD)
0.150 to 0.170 inch
9
(3.81 to 4.32 mm)
SEAL RECESS
0.030 TO 0.045 inch
(0.76 to 1.14 mm)
13
Figure 43
6. Bevel gear
7. Pinion
8. Drive pin
9. Thrust washer
1. Flanged hex head screw
2. Differential carrier housing
3. Differential carrier housing
4. Axle (long)
10. Washer
11. Retaining ring
12. Needle bearing
13. Oil seal
5. Axle (short)
Note: Individual parts to the differential assembly can
be obtained from your local Peerless Dealer/Distributor.
6. Remove both thrust washers and bevel gears from
the drive pin.
Disassembly (Fig. 43)
7. Cleanallpartssotheyarefreeofdirtanddebris. Re-
place any worn, chipped, bent, or cracked parts.
1. Clean outside of the differential assembly. Make
sure keys are removed from the axles. Remove all burrs
from the keyways and holes of the axles.
Assembly (Fig. 43)
1. If needle bearings are being replaced, press both
new bearings and new oil seal into each differential car-
rier housing as follows:
2. Remove four flanged hex head screws from the dif-
ferential carrier housings. Separate both housings be-
ing careful not to drop the drive pin and pinion gears.
A. Pressbearingintotheinboardsideoftheofeach
housing. The bearing should be recessed 0.125 to
0.140 inch (3.18 to 3.56 mm).
3. Pull each differential carrier housing from its axle
and remove washer.
4. Remove both retaining rings from each axle. Sepa-
rate the bevel gears from each axle.
B. Press bearing into the outboard side of the of
each housing. The bearing should be recessed
0.150 to 0.170 inch (3.81 to 4.32 mm).
Note: The differential carrier housings come as-
sembled with both bearings and oil seal. It may be more
economical to replace the both housings rather than re-
pair them. If the needle bearings are damaged, it is rec-
ommended to replace all bearings in each housing.
C. Press oil seal into the outboard side of the of
each housing. The oil seal should be recessed
0.030 to 0.045 inch (0.76 to 1.14 mm).
D. Pack all bearings with molybdenum disulfide
grease.
5. If needle bearings are damaged, press both bear-
ings and oil seal out of each differential carrier housing.
Traction and Reel Drive Systems
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Note: If any of the bevel or pinion gears need to be re-
placed, it is recommended to replace all four gears as a
complete set.
2. Slide pulley onto differential axle so threads extend
through pulley. Secure lock nuts and flat washers to the
differential assembly and pulley. (Fig. 42).
2. Attach bevel gears to the axles. Lock each gear in
place with both retaining rings. Make sure flat side of re-
taining rings are away from the gear (Fig. 44).
3. Place differential assembly into the countershaft
housing with the long axle first.
IMPORTANT: For the remainder of this procedure,
support the axle so it is parallel to the drum. Pos-
sible damage to the bearings should be prevented.
3. Coat both washers with molybdenum disulfide
grease. Slide each washer onto an axle (Fig. 44).
4. Slide the long axle through the needle bearings of
the differential carrier housing with the four threaded
holes. Thoroughly coat the bevel gear with molybdenum
disulfide grease. Make sure the gear back is flush
against the washer and housing inside face (Fig. 44).
4. Slide flangettes and bearing onto the long differen-
tial axle. Secure jam nuts, lock washers, and cable clip
to the studs of screw plate (Fig. 40).
5. Slide the short axle through the needle bearings of
the other differential carrier housing. Thoroughly coat
the bevel gear with molybdenum disulfide grease. Make
sure the gear back is flush against the washer and hous-
ing inside face (Fig. 44).
4
3
6. Slide both pinion gears to the drive pin. Attach both
thrust washers to the drive pin. Make sure both ends of
the drive pin are exposed. Thoroughly coat the pinion
gears and drive shaft with molybdenum disulfide grease
(Fig. 44).
2
1
5
7. Place pinion gear and drive shaft assembly into a
differential carrier housing. Position exposed ends of
the drive pin into the rounded insets of the housing.
Make sure the teeth of the bevel and pinion gears mesh
(Fig. 45).
6
7
8
Figure 44
1. Bevel gear
2. Axle
3. Retaining ring
4. Washer
5. Carrier housing
6. Pinion gear
7. Drive pin
8. Securebothdifferentialcarrierhousingstogetheras
follows (Fig. 45):
8. Thrust washer
A. Position the open ends of each housing together
so the teeth of both bevel gears mess with the teeth
of both pinion gears.
2
3
B. While holding the housings together, twist the
housings so the four holes on each housing are
aligned to accept the the flanged hex head screws.
C. Insert screws. While tightening screws, make
sure that all the gears stay messed together. Do not
over tighten screws.
D. Hold housing and turn one of the axles. The oth-
er axle should turn in the opposite direction without
any binding.
1
4
2
ROUNDED INSET
Figure 45
Installation
1. Pinion gear
2. Drive shaft
3. Carrier housing
4. Bevel gear
5. Axle
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
Greensmaster 1000/1600
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5. Slide locking collar onto the differential axle (Fig.
38).
IMPORTANT: Align axles so they turn freely before
striking the locking collar.
6. Reinstall rear box cover (38) and differential boot
(43) to the differential axle and countershaft housing (1)
(Fig. 33).
9. Lock locking collar by striking it with a punch in the
counterclockwise direction. Tighten set screw on the
locking collar (Fig. 38).
7. Reinstall bearing housing for the right differential
axle (see Differential Axle Pulley and Bearing Installa-
tion).
10. Reinstall idler pulley to the countershaft housing
(Fig. 40). Secure idler pulley with cap screw and lock
washer. Tighten cap screw until washer just starts to
compress. Spacer must be free to rotate (Fig. 41).
8. Reinstall bearing housing for the left differential
axle (see Differential Axle Pulley and Bearing Installa-
tion).
11. Adjust differential belt tension and reinstall front and
rear box covers (see Differential Belt in the Adjustments
section).
Traction and Reel Drive Systems
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Differential Belt Replacement – Models 04051, 04052, and 04060
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Remove capscrews and lock washers securing the
drum belt and reel drive covers to the right side plate.
Remove belt covers.
3
3. Loosen cap screws securing drum and reel drive
idler pulleys and spacers to the right side plate (Fig. 46
and 47). Rotate each idler pulley counterclockwise
away from the backside of each belt to release belt ten-
sion. Remove both belts(Fig.48).
4
1
2
Figure 46
4. Remove capscrews and lock washers securing the
front and rear box covers to the counter shaft housing.
Slide covers away from the housing to expose the belt
(Fig. 48).
1. Cap screw
3. Lock nut
2. Idler pulley (Drum drive)
4. Cap screw
5. Loosencapscrewontheenginesideofthecounter-
shaft housing that secures the idler pulley and spacer.
Rotate idler pulley counterclockwise away from the
backside of the belt to release belt tension. Cut belt and
remove belt from the countershaft housing (Fig.48).
4
2
5
6. Remove both cap screws and locknuts securing the
right rear bearing housing to side plate. Rotate housing
180_ so the bottom of the housing points upward (Fig.
46 and 48).
3
1
7. Removebothcapscrewsandlocknutssecuringthe
clutch housing to the side plate. Rotate housing 180_ so
the bottom of the housing points upward (Fig. 47 and
48).
Figure 47
1. Cap screw
4. Lock nut
2. Idler pulley (Reel drive)
3. Spacer
5. Cap screw
8. Slide new belt over rotated housings and both box
covers onto the differential and countershaft pulleys.
Makesureidlerpulleyispositionedagainstthebackside
of the belt.
7
6
11
10
5
8
9. Rotate clutch and right rear bearing housings back
into the upright position. Secure both housings to the
sideplate with previously removed cap screws and lock
nuts (Fig.48).
9
4
1
10. Adjust differential belt tension and reinstall rear and
front box covers (see Differential Belt Adjustment).
11. Adjust belt tension on traction drive and reel drive
belts and reinstall covers (see Drum Drive and Reel
Drive Belt Adjustments).
2
3
Figure 48
1. Idler pulley (Drum drive)
2. Idler pulley (Reel drive)
3. Belt (Reel Drive)
4. Belt (Drum drive)
5. Front box cover
7. Countershaft housing
8. Idler pulley (Differential)
9. Belt
10. Bearing housing
11. Clutch housing
6. Rear box cover
Greensmaster 1000/1600
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Differential Belt Replacement – Model 04050 Only
Removal
4
1. Place mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
If the wheels are attached, place the mower on its kick-
stand and remove them.
1
2. Remove both drum drive covers using a 7/16–inch
3
socket to remove the four cap screws and lock washers
from each cover (Fig. 49).
2
3. From the mower rear, precede as follows (Fig. 50):
A. Remove two cap screws and lock washers se-
curing the engine base to the back of the frame.
Figure 50
1. Engine base
2. Frame
3. Countershaft housing
4. Box cover
B. Leave front two cap screws securing the engine
base to the frame in place. This will keep the engine
in place.
1
3
C. Remove four capscrews, lock washers, and flat
washers securing the countershaft housing to the
frame.
6
2
7
4. Remove idler pulley from the bellcrank assembly.
Remove remaining two cap screws and lock washers
securing engine base to the frame. Remove both V–
belts (Fig. 51).
7
5
2
3
CAUTION
Figure 51
When lifting the engine from the frame,
have at least two (2) people lift the engine
to prevent personal injury.
1. Idler pulley
2. Bellcrank assembly
5. Cap screw
6. Lock nut
3. Cap screw & lock washer 7. Washer
4. V–belt
5. Removecableclipsfromthecables, wires, andhan-
dle assembly. Removal of the wires and cables is not
necessary. Lift the engine with the engine base from the
frame and set them behind the mower (Fig. 52)
Figure 52
Figure 49
Traction and Reel Drive Systems
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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).
6
2
3
4
7. Remove nut from the short axle of the differential as
follows (Fig. 54):
1
A. Loosen small hose clamp securing the differen-
tial boot to the bearing housing.
5
B. Use drift punch in the hole of the short axle while
removing the nut with a 7/8–inch socket.
FORWARD
Figure 55
8. Remove belts from both drum drive assemblies as
follows (Fig. 55):
1. Carriage bolt (Lower)
2. Carriage bolt hole (Upper) 5. Drum shaft pulley
3. Idler bracket
4. Idler pulley
A. Loosenthelowercarriageboltsandlocknutsse-
curing the idler brackets to the frame.
6. Pulley
B. Remove upper carriage bolts and lock nuts se-
curing the idler brackets to the frame.
C. Swing both idler pulleys forward. Remove belts.
2
9. Remove shaft input pulley from the power shaft. Re-
move key from shaft with drift punch (Fig. 56).
10. Slide pulley off the short axle on the right side of the
countershaft housing. Remove key from the axle with a
drift punch (Fig. 57).
1
Figure 56
1
2
1. Power shaft
2. Key
2
3
Figure 53
1. Power shaft
2. Shaft Input pulley
1
2
Figure 57
1. Axle (Short)
2. Countershaft housing
3. Key
1
4
3
Figure 54
1. Small hose clamp
2. Differential boot
3. Bearing housing
4. Pulley
Greensmaster 1000/1600
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Note: The locking collar securing the long axle to the
countershaft housing is a eccentric flange type.
11. Loosen the set screw on the locking collar. Unlock
collarbystrikingitwithapunchintheclockwisedirection
(Fig. 58).
3
1
12. Remove three cap screws and lock washer secur-
ing the box cover to the countershaft housing. Pull cover
from housing. Loosen both carriage bolts and lock nuts
securing the idler pulley to the countershaft housing.
Slide idler pulley away from the belt (Fig. 59).
2
4
13. Use a rubber hammer to carefully tap the counter-
shaft housing off the power shaft. Alternate the hammer
between the long axle and the bearing housing end of
the counter shaft housing to prevent damage to the
bearings(Fig. 60).
Figure 60
1. Countershaft housing
2. Power shaft
3. Axle (Long)
4. Bearing housing
14. Remove three socket head cap screws and lock
washers from the side plate (RH) and bearing housing
(Fig. 61).
15. Slide differential assembly to the left to allow remov-
al of the belt without bending or twisting. Remove old
belt from the differential pulley and countershaft pulley
(Fig. 62).
3
3
3
Figure 61
1. Socket head cap screw
3. Bearing housing
2. Side plate (LH shown)
1
2
3
3
CLOCKWISE
Figure 58
1. Axle (Long)
2. Locking collar
3
4
2
LEFT
Figure 62
1. Differential assembly
2. Belt
1
Figure 59
1. Lock nut (Idler pulley)
2. Countershaft housing
3. Differential boot
4. Box cover
Traction and Reel Drive Systems
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Installation
9. Reinstall belts to both drum drive assemblies as fol-
lows (Fig. 55):
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
A. Reinstall belt onto the drum shaft pulley and
pulley on both sides of mower.
2. Install new belt to the differential pulley and counter-
shaft pulley. Slide differential assembly to the right side
plate (Fig. 62).
B. Swing idler pulley into belt. Reinstall upper car-
riage bolts and lock nuts to both sides of the frame.
Do not tighten.
3. Secure three socket head cap screws and lock
washerstothesideplate(RH)andbearinghousing(Fig.
61).
C. Keep lower carriage bolts and lock nuts on both
sides of the frame loose.
4. Use a rubber hammer to carefully tap the counter-
shaft housing onto the power shaft. Alternate the ham-
mer between the long axle and the bearing housing end
of the counter shaft housing to prevent damage to the
bearings (Fig. 60).
CAUTION
When lifting the engine to the frame, have
at least two (2) people lift the engine to
prevent personal injury.
5. Secure countershaft housing to the frame with the
four cap screws, lock washers, and flat washers (Fig.
50).
10. Lift engine with the engine base from behind the
mower onto the frame. Reinstall cable clips to the
cables, wires, and handle assembly (Fig. 52)
6. Install pulley to the short axle as follows (Fig. 57 and
54).
A. Apply anti–seize lubricant to the axle keyway
area. Reinstall key to the axle. Slide pulley onto
short axle on the right side of the countershaft hous-
ing.
3
3
B. Screw nut onto the short axle of the differential.
Use drift punch in the hole of the short axle while
torquing the nut from 30 to 40 ft–lb (4.1 to 5.5 kg–m).
C. Secure differential boot to the bearing housing
with the small hose clamp.
7. Make sure drum belts will be properly aligned.
A. Center both pulleys on the differential axles to
obtain an equal distance between the side plates
and pulleys (Fig. 63).
Figure 63
1. Pulley
2. Side plate
B. Lock collar by striking it with a punch in the coun-
terclockwise direction. Tighten set screw on the
locking collar (Fig. 58).
1
2
8. Install shaft input pulley to the power shaft.
A. Apply anti–seize lubricant to the power shaft
keyway area. Reinstall key to shaft keyway (Fig.
56).
B. .Reinstall shaft input pulley to the power shaft.
Screw lock nut onto shaft. Torque nut from 30 to 40
ft–lb (4.1 to 5.5 kg–m) while locking shaft with a
9/16–inch open end wrench (Fig. 64).
Figure 64
1. Shaft input pulley
2. Power shaft
Greensmaster 1000/1600
Page 4 – 33
Traction and Reel Drive Systems
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11. Secure engine to the frame as follows:
A. Reinstall both V–belts (Fig. 51).
1
A. Position the engine base to obtain from 5.34 to
5.46 inches (13.6 to 13.9 cm) between the engine
output shaft and power shaft center lines (Fig. 65).
1
B. Align machined face of input power and shaft in-
put pulleys to within a maximum of 0.03 inch (0.76
mm) misalignment (Fig. 65).
3
C. Secure engine base to the front of the frame with
two cap screws and lock washers (Fig. 51).
Figure 65
D. Secure engine base to the back of the frame with
two cap screws and lock washers (Fig. 50).
1. Power shaft
2. Input power pulley
3. Shaft input pulley
E. Reinstall idler pulley to the bellcrank assembly
(Fig. 51).
IMPORTANT: Overtighteningbeltswilloverloadthe
bearings and increase wear on the belt.
2
12. Adjust tensions of differential and both drum drive
belts from 20 to 25 lbs (89 to 111 N) of force. Use a scale
to pull on the idler pulley while securing the idler brack-
ets by tightening both carriage bolts and lock nuts (Fig.
66).
1
13. Secure box cover to the countershaft housing with
the three cap screws and lock washers (Fig. 50)
Figure 66
14. Reinstall both drum drive covers using a 7/16–inch
socket to tighten the four cap screws and lock washers
to each cover (Fig. 49).
1. Idler pulley
2. Idler pulley bracket
15. Start the unit and run for a minimum of one minute.
Shut the engine off. The inside edge of the differential
belt should not hang over either the idler pulley, counter-
shaft pulley, or differential pulley (Fig. 67).
1
3
2
Figure 67
1. Differential pulley
3. Idler pulley
2. Counter shaft pulley
Traction and Reel Drive Systems
Page 4 – 34
Greensmaster 1000/1600
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Lubrication
The mower should be greased at least after every 25
hours of operation. Lubricate grease fittings using No. 2
multipurpose lithium base grease. A hand operated
grease gun is recommended for best results.
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Wipe each grease fitting with a clean rag.
IMPORTANT: Do not apply too much pressure or
grease seals will become permanently damaged.
3. The grease fitting locations are as follows:
A. Both bearing housings for the differential axles,
bothflangettesforthedrumshafts, andtheflangette
on the countershaft housing (Fig. 68).
Figure 68
B. The clutch housing and bearing housing for the
power shaft (Fig. 69).
4. Wipe off excess grease.
Figure 69
Greensmaster 1000/1600
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Traction and Reel Drive Systems
Page 4 – 36
Greensmaster 1000/1600
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Chapter 5
Electrical System
Table of Contents
WIRING SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 2
Late Model Kawasaki FE120 Engines . . . . . . . . . . 2
Late Model Kawasaki FE120 Engines
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . 8
Interlock Module and Clutch (Interlock) Switch
No Operator Presence Control . . . . . . . . . . . . . . 8
With Operator Presence Control . . . . . . . . . . . . . 9
Ignition System Operation . . . . . . . . . . . . . . . . . . . 10
Igniter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 13
Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operator Presence Control Switch . . . . . . . . . . . 14
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
with Operator Presence Control . . . . . . . . . . . . . 3
Early Model Kawasaki FE120 Engines . . . . . . . . . 4
Early Model Kawasaki FE120 Engines
With Operator Presence Control . . . . . . . . . . . . . 5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine Will Start , But Will Not Run . . . . . . . . . . . . 7
Greensmaster 1000/1600
Electrical System
Page 5 – 1
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Wiring Schematics
BLACK
HIGH TENSION LEAD
RED
CONNECTOR/
INTERLOCK MODULE
BLACK
IGNITION COIL/
IGNITOR
A
B
C D E F
RED
ENGINE
MAGNETO
FLYWHEEL
Note: There are two types of ignition coils used
on the Kawasaki FE120 engine. On older models,
a coil is used in conjunction with an igniter. On
newer models, a combination igniter/ignition coil is
used which has the igniter built into the ignition
coil.
CLUTCH
SWITCH
Late Model Kawasaki FE120 Engines
ON\OFF switch is open in the ON position
CLUTCH SWITCH is closed when the clutch is DISENGAGED
Electrical System
Greensmaster 1000/1600
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BLACK
HIGH TENSION LEAD
RED
CONNECTOR/
INTERLOCK MODULE
BLACK
IGNITION COIL/
IGNITOR
A
B
C
D
E
F
RED
ENGINE
MAGNETO
FLYWHEEL
Note: There are two types of ignition coils used
on the Kawasaki FE120 engine. On older models,
a coil is used in conjunction with an igniter. On
newer models, a combination igniter/ignition coil is
used which has the igniter built into the ignition
coil.
OPERATOR
PRESENCE SWITCH
Late Model Kawasaki FE120 Engines
with Operator Presence Control
ON\OFF switch is open in the ON position
CLUTCH SWITCH is closed when the clutch is DISENGAGED
OPERATOR PRESENCE SWITCH is closed when the bail is held
Greensmaster 1000/1600
Electrical System
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IGNITOR
IGNITOR
BLACK
RED
HIGH TENSION LEAD
RED
CONNECTOR/
INTERLOCK MODULE
BLACK
IGNITION COIL
A
B
C D E F
ENGINE
MAGNETO
FLYWHEEL
Note: There are two types of ignition coils used
on the Kawasaki FE120 engine. On older models,
a coil is used in conjunction with an igniter. On
newer models, a combination igniter/ignition coil is
used which has the igniter built into the ignition
coil.
CLUTCH
SWITCH
Early Model Kawasaki FE120 Engines
ON\OFF switch is open in the ON position
CLUTCH SWITCH is closed when the clutch is DISENGAGED
Electrical System
Greensmaster 1000/1600
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IGNITOR
IGNITOR
CONNECTOR/
INTERLOCK MODULE
BLACK
HIGH TENSION LEAD
A
B
C
D
E
F
RED
BLACK
RED
IGNITION COIL
ENGINE
MAGNETO
FLYWHEEL
Note: There are two types of ignition coils used
on the Kawasaki FE120 engine. On older models,
a coil is used in conjunction with an igniter. On
newer models, a combination igniter/ignition coil is
used which has the igniter built into the ignition
coil.
OPERATOR
PRESENCE SWITCH
Early Model Kawasaki FE120 Engines
with Operator Presence Control
ON\OFF switch is open in the ON position
CLUTCH SWITCH is closed when the clutch is DISENGAGED
OPERATOR PRESENCE SWITCH is closed when the bail is held
Greensmaster 1000/1600
Electrical System
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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 circuits
for current, resistance, or voltage.
NOTE: Toro recommends the use of a DIGITAL Volt–
Ohm–Amp multimeter when testing electrical circuits.
Thehighimpedance(internalresistance)ofadigitalme-
ter in the voltage mode will make sure that excess cur-
rent is not allowed through the meter. This excess
current can cause damage to circuits not designed to
carry it.
Figure 1
Skin–Over Grease – TOR50547
Special non–conductive grease which forms a light pro-
tective skin which helps waterproof electrical switches
and contacts.
Figure 2
Spark Tester – TOR4036
For testing electronic ignitions. Saves time because you
will know if the ignition is causing the problem on a non–
starting engine. The tester determines if ignition spark
is present.
Figure 3
Electrical System
Greensmaster 1000/1600
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Troubleshooting
The interlock switch must not be by–passed, it must be
connected for proper troubleshooting and safety.
CAUTION
NOTE: See the Kawasaki FE161 & FE170 Service
Manual and Kawasaki FE120 Service Manual Sup-
plement in Chapter 3 – Engine for troubleshooting of
electrical problems related to the ignition system. How-
ever, ignition system testing is covered in this chapter.
The ignition system for the FE120 engine is not fully cov-
ered in the service manual.
Remove all jewelry, especially rings and
watches, before doing any electrical trou-
bleshooting or testing.
For effective troubleshooting and repairs, you must
have a good understanding of the electrical circuits and
components used on this machine (see Wiring Sche-
matic section of this chapter).
. L0rLBFA , rG3l; mK
Problem
Possible Causes
Correction
Engine will not start
ON/OFF switch is in the OFF
position or is grounded.
Turn switch to ON, or replace
switch.
Spark plug lead is not connected.
Make sure spark plug lead is
connected.
Electrical wires are loose or
damaged.
Check electrical connections.
Repair wiring.
Clutch switch is not adjusted or
faulty.
Adjust or replace clutch switch.
Interlock module is faulty.
Replace interlock module.
Engine will start , but will not run
Electrical wires are loose or
damaged.
Check electrical connections.
Repair wiring.
Operator presence control switch is Adjust or replace clutch switch.
not adjusted or faulty.
Interlock module is faulty.
Replace interlock module.
Greensmaster 1000/1600
Electrical System
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Component Testing
For accurate resistance and/or continuity checks, elec-
trically disconnect the component being tested from the
circuit (e.g. unplug the ON/OFF switch connector before
doingacontinuitycheck). Individualcomponentsshould
be electrically isolated (e.g. disconnect all leads or re-
move from circuit) from the circuit when tested.
NOTE: See the Kawasaki FE161 & FE170 Service
Manual and Kawasaki FE120 Service Manual Sup-
plement for more component testing information.
WARNING
The ignition system produces a danger-
ously high voltage. Do not touch the
spark plug, ignition coil, igniter, or spark
plug lead while the engine is running;
you can receive a severe electrical
shock.
CAUTION
When testing electrical components for
continuity with a multimeter (ohms set-
ting), make sure that power to the circuit
has been disconnected.
Interlock Module and Clutch (Interlock) Switch – No Operator Presence Control
The interlock module prevents the engine from starting
unless the clutch switch is closed (clutch DISEN-
GAGED). After a safe start, the engine will continue to
run with the clutch switch open (clutch ENGAGED) or
closed.
3. Start the engine. If the engine does not start, check
the interlock module using the following steps.
4. Disconnect red wire (male connector) where it con-
nects to the black wire leading to the ignition coil. On old-
er models, disconnect red wire (male connector) where
it connects to the black wires leading to the ignition coil
and igniter.
If the engine will not start, perform the following tests to
determine if the interlock module or clutch switch is at
fault.
A. Start the engine. The engine should start.
1. Check that there is a good ground between the in-
terlock module and the engine, Check all other electrical
connections and the interlock module for damage. Re-
place any damaged wiring or components.
B. Ground the red wire (male connector) to the en-
gine block and start the engine. The engine should
not start.
C. Reconnect the red wire to the black wire.
2. Check the adjustment and continuity of the clutch
switch.
5. Disconnect both brown wires from both black\white
wires.
A. Disconnect both black\white wires from both
brown wires connected to the interlock module.
A. Start the engine. The engine should not start.
B. Place traction clutch lever in the ENGAGED
position. The switch should be open.
B. Jumper across the two brown wires and start the
engine. The engine should start.
C. Place traction clutch lever in the DISENGAGED
position. The switch should be closed.
C. Reconnect both black\white wires to both brown
wires.
D. Adjust interlock switch until it opens and closes
properly when the traction lever is in the ENGAGED
and DISENGAGED positions. See Interlock Switch
in the Adjustments section.
6. Replace interlock module if it fails either off the tests
in step 4 or 5.
E. Reconnect both brown wires to both black\white
wires connected to the clutch switch.
Electrical System
Greensmaster 1000/1600
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Interlock Module and Clutch (Interlock) Switch – With Operator Presence Control
The interlock module prevents the engine from starting
unless the clutch switch is closed (clutch DISEN-
GAGED). After a safe start, the engine will continue to
run with the clutch switch open (clutch ENGAGED) or
closed. However, the operator presence bail must be
engaged (held to against the handle) for the engine to
run when the clutch is ENGAGED. With the clutch EN-
GAGED, the engine will stop when the operator pres-
ence bail is released.
E. Reconnect both brown wires to the black\white
wires connected to the operator presence control
switch.
4. Start the engine. If the engine does not start, check
the interlock module using the following steps.
5. Disconnect red wire (male connector) where it con-
nects to the black wire leading to the ignition coil. On old-
er models, disconnect red wire (male connector) where
it connects to the black wires leading to the ignition coil
and igniter.
If the engine will not start, perform the following tests to
determine if the interlock module or clutch switch is at
fault.
A. Start the engine. The engine should start.
1. Check that there is a good ground between the in-
terlock module and the engine, Check all other electrical
connections and the interlock module for damage. Re-
place any damaged wiring or components.
B. Ground the red wire (male connector) to the en-
gine block and start the engine. The engine should
not start.
C. Reconnect the red wire to the black wire.
2. Check the adjustment and continuity of the clutch
switch.
6. Disconnect both brown wires from the black/white
wires leading to the clutch switch.
A. Disconnect both black\white wires from both
brown wires connected to the interlock module that
lead to the clutch switch.
A. Start the engine. The engine should not start.
B. Jumper across the two brown wires and start the
engine. The engine should start.
B. Place traction clutch lever in the ENGAGED
position. The switch should be open.
C. Reconnect both black\white wires to both brown
wires.
C. Place traction clutch lever in the DISENGAGED
position. The switch should be closed.
7. Disconnect both brown wires from the black/white
wires leading to the operator presence control switch.
D. Adjust interlock switch until it opens and closes
properly when the traction lever is in the ENGAGED
and DISENGAGED positions. See Interlock Switch
in the Service And Repairs section.
A. Start the engine. The engine should start.
B. Jumper across the two brown wires and start the
engine. The engine should start.
E. Reconnect both black\white wires to the brown
wires leading to the interlock module.
C. Place traction clutch lever in the ENGAGED
position. The engine should continue to run.
3. Check the adjustment and continuity of the operator
presence control switch.
D. Remove jumper from the brown wires. The en-
gine should stop.
A. Disconnect both black\white wires at the switch
from both brown wires leading from the wire har-
ness.
E. Reconnect both black\white wires to the brown
wires.
B. Hold the bail against the handle. The switch
should be closed.
8. Replace interlock module if it fails either off the tests
in steps 5, 6, or 7.
C. Release the bail from the handle. The switch
should be open.
D. Adjust operator presence control switch until it
closes and opens properly when the bail is held
againstandreleasedfromthehandle. SeeOperator
PresenceControlSwitchintheServiceAndRepairs
section.
Greensmaster 1000/1600
Electrical System
Page 5 – 9
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Ignition System Operation
Making a System Tester
This simple tester can be made if a commercial spark
tester is not available. It can determine if the ignition sys-
tem is operating properly.
SPRING CLIP
1. Use a new NGK BPR5ES or equivalent spark plug.
2. Remove the ground electrode from the test plug.
This gives the spark plug a larger gap, which simulates
the spark required under actual engine conditions.
SPARK
PLUG
3. Use 18 gauge insulated wire, an alligator clip, and
large spring clip to make a lead assembly.
4. Slide a 1–1/4 inch length of 1/2–inch I.D. clear fuel
line over the threads of the spark plug. The spark will be
more visible, and the fuel line will shade the plug firing
tip.
18 GUAGE
WIRE
ALLIGATOR
CLIP
Figure 4
Testing the Ignition System
4. Start the engine and observe the test spark plug.
Visible and audible sparks should be produced.
5. If visible and audible sparks are produced, the igni-
tion system is operating properly.
WARNING
The ignition system produces a danger-
ously high voltage. Do not touch the
spark plug, ignition coil, or spark plug
lead while the engine is running; you can
receive a severe electrical shock.
6. If visible and audible sparks are not produced, the
ignition system is not operating properly.
A. Check wires and connectors of the ON/OFF
switch, igniter, ignition coil, and combination igniter
and ignition coil (on later models) for grounding or
damaged insulation.
Note: Do not remove spark plug from the engine. The
spark plug is necessary to maintain normal starting
speeds.
B. If wires and connectors are good, test the igniter,
ignitioncoil, andcombinationigniterandignitioncoil
(on later models) individually.
1. Remove high–tension lead from the spark plug, and
connect it to the test spark plug.
C. Iftheigniter, ignitioncoil, andcombinationigniter
and ignition coil (on later models) test properly see
Interlock Module and Clutch (Interlock) Switch in
this section for further testing.
2. Connect large spring clip around the hex portion of
the test spark plug. Connect alligator clip to a good
ground on the engine block.
3. Make sure ON/OFF switch is in the ON position.
Electrical System
Greensmaster 1000/1600
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Igniter
The igniter consists of transistorized circuitry that con-
trols the firing sequence of the spark plug in conjunction
with the ignition coil. Mounted on the engine block, the
igniter casing is grounded directly to the engine. A single
black wire makes a circuit from the igniter to the primary
of the ignition coil.
1
1. Park mower on a level surface. Make sure engine
is OFF.
2. Remove black wire from the bottom of the igniter.
3. Use a digital multimeter set to the ohms scale; take
internal resistance of the igniter.
1
A. Contact black (–) test lead to the igniter mount-
ing screw (ground).
Figure 5
1. Ground
2. Wire connector
B. Contact red (+) test lead to the terminal from
which the black wire was removed.
5. If the internal resistance value is within specifica-
tion, test the ignition coil.
C. The internal resistance should be about 7.8 to
8.1 KΩ.
4. If the internal resistance value is not within specifi-
cation, replace old igniter with a new one. Reconnect
black lead.
A. Try starting the engine.
B. If the engine does not start, replace the ignition
coil.
Greensmaster 1000/1600
Electrical System
Page 5 – 11
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Ignition Coil
A commercial coil tester can be used to test the ignition
coil. If a tester is available, test the ignition coil as sug-
gested in the Kawasaki FE161 & FE170 Service
Manual and Kawasaki FE120 Service Manual Sup-
plement
1
The coil can be tested for a badly shorted or broken
winding with a digital ohmmeter. However, a ohmmeter
can not detect layer shorts and shorts resulting from in-
sulation breakdown under high running voltages.
Note: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The me-
ter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal re-
sistance of the meter and test leads. Subtract this value
from from the measured value of the component you are
testing.
2
3
Note: There are two types of ignition coils used on the
KawasakiFE120 engine. On older models, a coil is used
in conjunction with an igniter. On newer models, a com-
bination igniter/ignition coil is used which has the igniter
built into the ignition coil.
IGNITION COIL
Figure 6
1. Primary lead
2. Ground
3. Secondary lead
1. Park mower on a level surface. Make sure engine
is OFF
2. Isolate ignition coil. Disconnect high tension lead
from spark plug and black wire on the coil.
1
3. Measure primary winding resistance between the
primary lead and ground. Winding resistance should be
from 0.8 to 1.0 ohms. Winding and circuit resistance
should be from 0.6 to 1.1 ohms for new combination ig-
niter/ignition coils.
3
2
A. If resistance is 0 ohms, the primary winding is
shorted. Replace ignition coil.
IGNITER/IGNITION COIL
Figure 7
B. If resistance is high or infinity (1) ohms, the pri-
mary winding is open. Replace ignition coil.
1. Primary lead
2. Ground
3. Secondary lead
4. Measure secondary winding resistance between
the secondary lead and ground. Winding resistance
should be from 7.0 to 9.0 KΩ. Winding resistance should
be from 5.8 to 9.6 KΩ for new combination igniter/igni-
tion coils.
5. Ifresistancesaregood, theignitioncoilwindingsare
probably good. However, if the ignition still does not per-
form after all other components have been checked, re-
place coil with a new one.
A. If resistance is low or 0 ohms, the primary wind-
ing is shorted. Replace ignition coil.
B. If resistance is high or infinity (1) ohms, the pri-
mary winding is open. Replace ignition coil.
C. Check the high tension lead for damage. Re-
place ignition coil if lead is damaged.
Electrical System
Greensmaster 1000/1600
Page 5 – 12
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Service and Repairs
NOTE: See the Kawasaki FE161 & FE170 Service
Manual 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
DISENGAGED.
2
2. Loosen both switch mounting nuts and move switch
until the switch plunger is depressed 0.18 to 0.24 inch
(4.6 to 6.1 mm) (switch closed).
1
3. Tighten switch mounting nuts.
4. Engage traction lever and verify that the switch
plunger is depressed no more than 0.06inch (1.5 mm)
(switch open). Readjust as required.
3
Removal
A. Disconnect black\white wires at the switch from
the brown wires leading from the Interlock module.
Figure 8
1. Interlock switch
2. Adjusting nut
3. Bracket
B. Remove adjusting nut from the plunger side of
the switch. Remove switch from bracket.
Installation
A. Place switch into bracket with one adjusting nut
and the plunger end facing the clutch lever. Thread
remaining adjustment nut onto the switch.
B. Adjust switch as necessary.
C. Connect black\white wires at the switch to the
brown wires from the interlock module.
Greensmaster 1000/1600
Electrical System
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Operator Presence Control Switch
Adjustment
1. Make sure the engine is OFF.
1
2. Loosen both switch adjusting nuts. While holding
the bail against the handle, move switch until the switch
plunger is depressed 0.16 inch (4.1 mm) (switch
closed).
2
3. Tighten switch mounting nuts.
3
4. Engage traction lever and verify that the switch
plunger is depressed no more than 0.06inch (1.5 mm)
(switch open). Readjust as required.
Removal
A. Disconnect black\white wires at the switch from
the brown wires leading from the wire harness.
Figure 9
1. Operator presence
switch
2. Adjusting nut
3. Bracket
B. Remove adjusting nut from the plunger side of
the switch. Remove switch from bracket.
Installation
A. Place switch into bracket with one adjusting nut
and the plunger end facing the bail contact tab.
Thread remaining adjustment nut onto the switch.
B. Adjust switch as necessary.
C. Connect black\white wires at the switch to the
brown wires from the wire harness.
Electrical System
Greensmaster 1000/1600
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Spark Plug
Use a NGK BPR 5ES spark plug or equivalent. Remove
plug after every 100 operating hours and check its
condition.
0.028 to 0.31 inch
(0.7 to 0.8 mm)
1. Make sure engine is OFF. Pull high tension lead off
the spark plug.
2. Clean around spark plug and remove plug from the
cylinder head.
Note: The condition of the spark plug can give an ac-
curate picture of the overall condition of the engine. Use
the chart on the following page as a guide to determine
possible problems with the engine.
Figure 10
3. Inspect the spark plug.
IMPORTANT: Replace a cracked, fouled, or dirty
spark plug. Do not sand blast, scrape, or clean elec-
trodes because engine damage could result from
grit entering cylinder.
4. Set air gap at 0.028 to 0.031 inch (0.7 to 0.8 mm).
Install correctly gapped spark plug and torque to 20 ft–lb
(2.8 kg–m).
Greensmaster 1000/1600
Electrical System
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NORMAL
OVER HEATING
FUSED SPOT DEPOSIT
Has gray or light tan deposits on the firing
tip.
Light gray or white insulator with small gray
brown or black spots. Electrodes have a
bluish burnt appearance.
Has spotty or melted deposits resembling
blisters or bubbles.
Caused by sudden acceleration.
Replace spark plug.
May be caused by engine over heating,
loose spark plugs, wrong fuel type, too hot
a plug, low fuel pump pressure, or incorrect
ignition timing.
Replace spark plug.
LEAD FOULED
CARBON FOULED
WORN
Has dark black, gray, tan, or yellow depos-
its. May have a fused glazed coating on the
insulator tip.
Black dry fluffy carbon deposits are found
on insulator tips, electrodes, and exposed
shell surfaces.
Has a severely eroded or worn electrode.
Caused by normal wear.
Replace spark plug.
Caused by highly leaded gasoline.
Replace the plug.
Weak ignition, too cold a plug, fuel mixture
too rich, defective fuel pump, excessive id-
ling, or improperly operating heat riser may
be the cause.
Replace spark plug.
GAP BRIDGED
OIL FOULED
PRE–IGNITION
Gap between electrodes is closed by de-
posit build up.
Wet black deposits can be found on elec-
trodes, insulator, and in the bore.
Electrodes are melted and the insulator
may be blistered. Metallic deposits on the
insulator indicate engine damage.
May be caused by carbon or oil fouling.
Replace spark plug.
Excessive oil entering the combustion
chamber through excessive clearances be-
tween valve guides and stems, worn or
loose bearings, or worn rings and pistons.
Engine over heating, burnt valves, too hot a
plug, incorrect ignition timing or advance, or
wrong type of fuel are causes.
Replace spark plug.
Replace spark plug.
Electrical System
Greensmaster 1000/1600
Page 5 – 16
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Chapter 6
Controls, Wheels and Accessories
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Handle Height Adjustment . . . . . . . . . . . . . . . . . . . . 3
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4
Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Brake Cable Replacement . . . . . . . . . . . . . . . . . . . 6
Clutch Cable Replacement . . . . . . . . . . . . . . . . . . . 7
Throttle Cable Replacement . . . . . . . . . . . . . . . . . . 8
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Kickstand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Greensmaster 1000/1600
Wheels and Accessories
Page 6 – 1
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Specifications
Item
Description
12 to 15 PSI, (0.83 to 1.04 bar)
65 to 75 ft–lb, (8.99 to 10.37 kg–m)
Tire pressure
Wheel Shaft torque
Wheels and Accessories
Greensmaster 1000/1600
Page 6 – 2
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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. Raise or lower handle to the desired
operating position.
1
4. Reinstall ring pins and cotter pins.
2
Figure 1
1. Cotter pin
2. Ring pin
Greensmaster 1000/1600
Wheels and Accessories
Page 6 – 3
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Service and Repairs
Handle Assembly
4
5
6
5
7
8
39
3
2
1
38
43
19
14
15
9
18
11
10
17
13 11
12
37
28
27
14
42
26
36
35
34
25
16
24
23
22
40
41
21
20
RIGHT
FRONT
30
33 32 31
29
13
Figure 2
1. Throttle cable
2. Spring
3. Lock nut
16. Brake skid bracket
17. Brake bracket
18. Brake lever
30. Cap screw
31. Spring lock washer
32. Flat washer
4. Retaining washer
5. Friction washer
6. Throttle lever
7. Cap screw
8. Clutch skid bracket
9. Cap screw
10. Console bracket (RH)
11. Lock nut
12. Clutch cable
13. Screw
14. Shoulder bolt
15. Brake cable
19. Console bracket (LH)
20. Red knob
21. Cap screw
22. Spring lock washer
23. Flat washer
24. Spacer
25. Clutch lever
26. Lock nut
33. Handle pivot pin
34. Lock insert nut
35. Handle
36. Bushing
37. Cable tie
38. Bail assembly (Europe)
39. Spacer (Europe)
40. Switch bracket (Europe)
41. Switch (Europe)
42. Jam nut (Europe)
43. Shoulder bolt (Europe)
27. Clutch bracket
28. Black knob
29. Console
Note: Items 38 through 43 above are part of the op-
tional Operator Presence Kit, which presently comes on
all models sold in Europe.
Wheels and Accessories
Greensmaster 1000/1600
Page 6 – 4
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Removal
1. Park mower on a level surface. Make sure engine
is OFF.
6
2. Cut cable ties from the handle.
3. Remove cap screw (30), spring lock washer (31),
and flat washer (32) from each handle pivot pin (33) on
each of the handle (35) ends (Fig. 2 and 3).
2
Note: The cotter pin, ring pin, cap screw,and lock nut
may have to be removed from the handle arms to allow
handle removal (Fig. 4).
4
3
4. Squeezehandleendsinward. Removehandleends
from the handle pivot pins; pull handle ends clear of the
holes in the handle arms (Fig. 3).
1
5
Installation
Figure 3
Note: The cotter pin, ring pin, cap screw,and lock nut
may have to be removed from the handle arms to allow
handle installation (Fig. 4).
1. Cap screw & washers
2. Handle end
4. Ring pin
5. Lock nut
6. Handle arm
3. Cotter pin
1. Slide handle ends through the holes in the handle
arms. Squeeze handle ends inward. Install handle ends
to the handle pivot pins (33) on each side of the frame.
(Fig. 2 and 3).
5
6
2. If the cotter pin, ring pin, cap screw,and lock nut
have been removed from the handle arms, reinstall the
handle arms to the frame. Make sure spacer is installed
in the handle arm. (Fig. 4).
1
4
2
3. Install cap screw (30), spring lock washer (31), and
flat washer (32) to each handle pivot pin (33) on each of
the handle (35) ends (Fig. 2 and 3).
4. Secure cables to the handle with new cable ties.
3
Figure 4
1. Cotter pin
2. Ring pin
3. Cap screw
4. Lock nut
5. Handle arm
6. Spacer
Greensmaster 1000/1600
Wheels and Accessories
Page 6 – 5
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Brake Cable Replacement
Removal
6
2
5
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
7
2. Disengage brake to release tension on the brake
cable. Removecabletiesfromtheleftsideofthehandle.
3
3. Remove brake cable from the countershaft housing
as follows (Fig. 5):
1
4
A. Open bellcrank cover to access the brake lever.
B. Remove shoulder bolt and lock nut from the
brake lever and cable eyelet.
Figure 5
1. Brake lever
2. Shoulder bolt
3. Lock nut
5. Rear nut
6. Brake cable
7. Countershaft housing
C. Loosen rear nut attaching the brake cable to the
countershaft housing. Remove brake cable from
housing and brake lever
4. Cable eyelet
7
4. Make sure brake is disengaged and the clutch is en-
gaged so the console (29) can be positioned to access
the brake lever (18) and brake cable (15) (Fig. 2).
5
6
3
5. Remove four screws (13) securing the console (29)
to the console brackets (10 and 19). Position console
forward and away from the brackets (Fig. 2).
4
Note: On models without the operator presence kit,
the bail assembly, switch, and switch bracket are not
installed on the handle assembly. The shoulder bolt and
spacer are substituted by an additional screw on both
sides of the handle assembly (Fig. 2 and 6).
8
1
2
Figure 6
6. Gain access to the brake lever and brake cable as
follows (Fig. 6):
1. Screw
2. Switch bracket
3. Switch
5. Shoulder bolt
6. Spacer
7. Bail assembly
8. Brake skid bracket
4. Console bracket
A. If the operator presence kit is installed, remove
both screws and switch bracket (with switch at-
tached) from the brake skid bracket. Remove shoul-
der bolt and spacer from the bail assembly and
brake skid bracket. Remove console bracket from
the brake skid bracket.
Installation
1. Secure brake cable (15) eyelet to the brake lever
(18) with the shoulder bolt (14) and lock nut (11) (Fig. 2).
Note: On models without the operator presence kit,
the bail assembly, switch, and switch bracket are not
installed on the handle assembly. The shoulder bolt and
spacer are substituted by an additional screw on both
sides of the handle assembly (Fig. 2 and 6).
B. If the operator presence kit is not installed, re-
move three screws and console bracket from the
brake skid bracket.
7. Remove shoulder bolt (14) and lock nut (11) from
the brake lever (18) and brake cable (15) eyelet (Fig. 2).
2. Reinstall bail assembly and brackets. (Fig. 6).
8. Loosen nut securing the brake cable (15) to the
brake bracket (17). Remove cable from the bracket. Re-
move brake cable from the mower.
A. If the operator presence kit is installed, reinstall
console bracket and switch bracket (with switch at-
tached) to the brake skid bracket. Secure brackets
with both screws. Secure bail assembly and spacer,
to the brake skid bracket with the shoulder bolt.
Wheels and Accessories
Greensmaster 1000/1600
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B. If the operator presence kit is not installed, se-
cure console bracket to the brake skid bracket with
three screws.
A. Attach brake cable to the counter shaft housing
and tighten the rear nut.
B. Secure cable eyelet to the brake lever with
shoulder bolt and lock nut.
3. Position console (29) over the console brackets (10
and 19). Secure console to both brackets with four
screws (13) (Fig. 2).
5. Install new cable ties to the left side of the handle.
6. Adjust brake cable and close bellcrank cover (see
Service/Park Brake Adjustment in Chapter 7 – Traction
and Reel Drive Systems).
4. Run new brake cable to the countershaft assembly.
Install new brake cable to the countershaft housing and
brake lever as follows (Fig. 5):
Greensmaster 1000/1600
Wheels and Accessories
Page 6 – 7
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Clutch Cable Replacement
Removal
6
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Disengage clutch to release tension on the clutch
cable. Remove cable ties from the right side of the han-
dle.
5
1
2
3. Remove clutch cable from the bellcrank assembly
as follows (Fig. 7):
4
3
A. Open bellcrank cover to access the clutch lever
and bracket.
Figure 7
B. Remove shoulder bolt and lock nut securing the
cable eyelet to the clutch lever.
1. Clutch lever
2. Clutch bracket
3. Shoulder bolt & lock nut
4. Cable eyelet
5. Rear nut
6. Clutch cable
C. Loosen rear nut attaching the clutch cable to the
clutch bracket. Remove clutch cable from the clutch
bracket.
5
4
4. Make sure brake is disengaged and the clutch is en-
gaged so the console (29) can be positioned to access
the clutch lever (25) and clutch cable (12) (Fig. 2).
3
5. Remove four screws (13) securing the console (29)
to the console brackets (10 and 19). Position console
forward and away from the brackets (Fig. 2).
6
Note: On models without the operator presence kit,
the bail assembly is not installed on the handle assem-
bly. The shoulder bolt and spacer are substituted by an
additional screw on both sides of the handle assembly
(Fig. 2 and 8).
1
2
Figure 8
6. Gain access to the clutch lever and clutch cable as
follows (Fig. 8):
1. Screw
2. Console bracket
3. Shoulder bolt
4. Spacer
5. Bail assembly
6. Clutch skid bracket
A. If the operator presence kit is installed, remove
both screws from clutch skid bracket. Remove
shoulderboltandspacerfromthebailassemblyand
clutch skid bracket. Remove console bracket from
the clutch skid bracket.
Installation
1. Secure clutch cable (12) eyelet to the clutch lever
(25) with the shoulder bolt (14) and lock nut (11) (Fig. 2).
B. If the operator presence kit is not installed, re-
move three screws and console bracket from the
clutch skid bracket.
Note: On models without the operator presence kit,
the bail assembly is not installed on the handle assem-
bly. The shoulder bolt and spacer are substituted by an
additional screw on both sides of the handle assembly
(Fig. 2 and 8).
7. Remove shoulder bolt (14) and lock nut (11) from
the clutch lever (25) and clutch cable (12) eyelet (Fig. 2).
2. If the operator presence kit is installed, reinstall con-
sole bracket to the clutch skid bracket. Secure brackets
with both screws. Secure bail assembly and spacer to
the clutch skid bracket with the shoulder bolt (Fig. 8).
8. Loosen nut securing the clutch cable (12) to the
clutch bracket (27). Remove cable from the clutch
bracket (Fig. 2).
9. Remove clutch cable from the mower.
Wheels and Accessories
Greensmaster 1000/1600
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3. If the operator presence kit is not installed, secure
console bracket to the clutch skid bracket with three
screws (Fig. 8).
A. Attach clutch cable to the clutch bracket. Tighten
nut to secure cable to the bracket.
B. Secure clutch cable eyelet to the clutch lever
with shoulder bolt and lock nut.
4. Position console (29) over both console brackets
(10 and 19). Secure console to the brackets with four
screws (13) (Fig. 2).
6. Install new cable ties to the right side of the handle.
7. Adjust clutch cable and close bellcrank cover (see
Clutch Control Adjustment in Chapter 3 – Engine).
5. Run new clutch cable to the bellcrank assembly.
Install new cable to the clutch lever as follows (Fig. 7).
Greensmaster 1000/1600
Wheels and Accessories
Page 6 – 9
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Throttle Cable Replacement
Removal
2
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
3
4
2. Remove cable ties from the right side of the handle.
Remove nut and cable clip from the flangette on the
countershaft housing.
6
1
3. Remove throttle cable from the governor as follows
(Fig. 9):
5
A. Unscrew throttle cable screw enough to release
the throttle cable from the nut in the governor lever.
Figure 9
1. Throttle cable screw
2. Throttle cable
3. Nut
4. Governor lever
5. Hex head screw
6. Throttle cable bracket
B. Remove hex head screw from the throttle cable
bracket.
C. Pull throttle cable clear of the nut in the governor
lever.
4. Make sure brake is disengaged and the clutch is en-
gaged so the console (29) can be positioned to access
the throttle lever (6) and throttle cable (1) (Fig. 2).
5
4
3
5. Remove four screws (13) securing the console (29)
to the console brackets (10 and 19). Position console
forward and away from the brackets (Fig. 2).
6
6. Gain access to the throttle lever and throttle cable
as follows (Fig. 10):
1
2
A. Remove both screws from clutch skid bracket.
B. Remove shoulder bolt and spacer from the bail
assembly and clutch skid bracket. Remove console
bracket from the clutch skid bracket.
Figure 10
1. Screw
2. Console bracket
3. Shoulder bolt
4. Spacer
5. Bail assembly
6. Clutch skid bracket
7. Snap throttle cable (1) out of the clutch skid bracket
(8). Disconnect throttle cable from the throttle lever (6)
(Fig. 2).
4. Position console (29) over both console brackets
(10 and 19). Secure console to the brackets with four
screws (13) (Fig. 2).
8. Remove clutch cable from the mower.
5. Run new throttle cable to the governor lever. Install
new cable to the governor lever as follows (Fig. 9).
Installation
1. Connect throttle cable (1) to the throttle lever (6).
Snap throttle cable to the clutch skid bracket (8) (Fig. 2).
A. Insert throttle cable into the nut.
B. Tighten throttle cable screw to hold cable in the
nut and governor lever. Do not tighten screw.
2. Reinstall console bracket to the clutch skid bracket.
Secure brackets with both screws (Fig. 10).
6. Install new cable ties to the right side of the handle.
Secure throttle cable to the flangette on the countershaft
housing with the cable clip and nut.
3. Secure bail assembly and spacer to the clutch skid
bracket with the shoulder bolt (Fig. 10).
7. Adjust throttle cable (see Throttle Linkage Adjust-
ment in Chapter 3 – Engine).
Wheels and Accessories
Greensmaster 1000/1600
Page 6 – 10
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Wheels
Removal
1. Park mower on a level surface. Make sure the en-
gine is OFF.
2. Push kickstand down with one foot while pulling up
on the handle. This will support the mower on the kick
stand.
3. Pivot wheel locking clip away from the center of the
wheel. Slide wheel off the wheel shaft.
Note: The right hand wheel shaft has left hand
threads.
4. If necessary, remove wheel shaft from the drive
pulley.
1
Installation
1. Make sure mower is parked on a level surface and
the engine is OFF.
2. Push kickstand down with one foot while pulling up
on the handle. This will support the mower on the kick
stand.
Figure 11
1. Locking clip
Note: The right hand wheel shaft has left hand
threads.
3. If the wheel shafts were removed from the drive pul-
leys,
A. Apply Loctite 242 or equivalent to the threads of
the wheel shafts.
IMPORTANT:The right hand wheel shaft has left
hand threads.
Note: The drum shafts inboard of the side plates have
flats that can be used while torquing the wheel shafts.
1
B. Install right hand wheel shaft into the drive pulley
on the right side of the mower. Install the remaining
shaft. Torque both shafts from 65 to 75 ft–lb (9.0 to
10.3 kg–m).
2
Figure 12
1. Wheel shaft
2. Drive pulley
4. Apply anti–seize lubricant to the exposed end of the
wheel shaft.
5. Slide wheel onto the wheel shaft.
A. Pivot wheel locking clip away from the center of
the wheel.
B. Allow wheel to slide onto the shaft until the lock-
ing clip is secured into the groove on the wheel
shaft.
Greensmaster 1000/1600
Wheels and Accessories
Page 6 – 11
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1
2
3
4
5
6
7
8
13
12
10
14
11
9
Figure 13
6. Retaining lever
7. Spring
1. Cap screw
11. Inner tube
2. Lock washer
3. Shallow rim
4. Tire
12. Cap screw
13. Flange nut
14. Wheel shaft
8. Bolt
9. Bolt
5. Hub
10. Deep rim
Disassembly
Reassembly
1. Remove three cap screws (1) and lock washers (2)
from the shallow rim (3) and hub (5). Remove hub from
deep rim (10).
1. Reinstall retaining lever (6), spring (7), and bolt (8)
to the hub (5). Reinstall bolt (9) to the hub. Tighten both
bolts
2. Remove four cap screws (12) and flange nuts (13)
from the deep rim (10) and shallow rim (3). Remove
shallow rim from the deep rim.
2. Reinstall shallow rim (3) into the deep rim (10). Se-
cure shallow rim to the deep rim with the four cap screws
(12) and flange nuts (13). Tighten fasteners.
3. Remove bolt (9) from the hub (5). Remove bolt (8),
spring (7), and retaining lever (6) from the hub.
3. Reinstall hub (5) into deep rim (10). Secure hub to
deep rim with three cap screws (1) and lock washers (2).
Tighten fasteners.
Wheels and Accessories
Greensmaster 1000/1600
Page 6 – 12
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Kickstand
NOTE THE POSITION
OF THE STOP
9
FRAME
Figure 14
5. Extension spring
6. Cap screw
1. Cap screw
2. Cap screw
3. Lock washer
4. Spring bracket
9. Flat washer
10. Lock nut
11. Spacer
7. Spring retainer
8. Kickstand
12. Flange lock nut
Removal
1
1. Park mower on a level surface. Make sure the en-
gine is OFF.
2. Pivot kickstand up against the handle and hold
there.
3
3. Use a pliers to remove the extension spring from the
spring retainer (Fig. 15).
2
4. Remove both lock nuts (10), flat washers (9), cap
screws (1), and spacers (11) from the kickstand (8) and
frame. Remove kickstand from the frame (Fig. 14).
4
Figure 15
Installation
1. Kickstand
2. Extension spring
3. Spring retainer
4. Cap screw
1. Make sure mower is parked on a level surface and
the engine is OFF.
2. Position kickstand (8) inside the mower frame. In-
sert capscrews (1) through the frame, spacers (11), and
kickstand (Fig. 14).
3. Secure cap screws (1) with flat washers (9) and lock
nuts (10). Tighten fasteners (Fig. 14).
4. Pivot kickstand up against the handle and hold
there. Use a pliers to reinstall the extension spring to the
spring retainer (Fig. 15).
Greensmaster 1000/1600
Wheels and Accessories
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Wheels and Accessories
Greensmaster 1000/1600
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Chapter 7
Cutting Unit
Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4
Grass Basket Installation . . . . . . . . . . . . . . . . . . . . . 4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 7
Factors Affecting Quality of Cut . . . . . . . . . . . . . . . 7
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Leveling Drum to Reel . . . . . . . . . . . . . . . . . . . . . . . 9
Bedknife to Reel Adjustment . . . . . . . . . . . . . . . . . 10
Height–of–Cut Adjustment . . . . . . . . . . . . . . . . . . . 11
Grass Shield Height Adjustment . . . . . . . . . . . . . 12
Cutoff Bar Adjustment . . . . . . . . . . . . . . . . . . . . . . 12
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 13
Backlapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Bedbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Bedknife Replacement and Grinding . . . . . . . . . . 16
Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Roller Bearing Replacement . . . . . . . . . . . . . . . . . 17
Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Preparing Reel for Grinding . . . . . . . . . . . . . . . . . 20
Greensmaster 1000/1600
Page 7 – 1
Cutting Unit
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Introduction
This Chapter covers the cutting unit section of the
GR1000. The cutting unit consists of the frame assem-
bly, reel assembly, drum assembly, and detachable bas-
ket. The reel and drum drive assemblies make up part
of the cutting unit, and their component parts that are
necessary for the service of the cutting unit are covered
in this chapter.
Cutting Unit
Page 7 – 2
Greensmaster 1000/1600
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Specifications
Figure 1
REEL CONSTRUCTION (GR1000): 5–inch (12.7 cm)
diameter, 11 carbon steel blades (optional 8 blades)
welded to 5 stamped steel spiders.
REEL CONSTRUCTION (GR1600): 5–inch (12.7 cm)
diameter, 8 carbon steel blades welded to 6 stamped
steel spiders.
HEIGHT–OF–CUT RANGE (GR1000): 5/64 to 1 inch
HEIGHT–OF–CUT RANGE (GR100): 1/8 to 1–1/4 inch
(2 to 25 mm)
(3 to 32 mm)
WIDTH–OF–CUT (GR1000): 21 inches (53.3 cm)
CLIP (GR1000): 0.16 inch (0.41 cm)
WIDTH–OF–CUT (GR1600): 26 inches (66.0 cm)
CLIP (GR1600): 0.23 inch (0.58 cm)
BEDKNIFE AND BEDBAR: Single edged high carbon
steel bedknife, hardened to RC 48-54. A cast iron bed-
bar is fastened to the mower. Tournament bedknife (Part
No. 93–4263) is standard.
Greensmaster 1000/1600
Page 7 – 3
Cutting Unit
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General Information
Grass Basket Installation
1. Grasp basket by top rear lip and slide on or off the
basket mounting rods.
2
1
Figure 2
1. Grass basket
2. Mounting rod
Cutting Unit
Page 7 – 4
Greensmaster 1000/1600
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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 or
available as TORO parts. Some tools may also be avail-
able from a local supplier.
Gauge Bar Assembly – P/N 13–8199
Used to verify height–of–cut.
Figure 3
Backlapping Brush Assembly – TOR299100
Used to apply lapping compound to cutting units while
keeping the operator’s hands at a safe distance from the
rotating reel.
Figure 4
Bedknife Screw Tool – TOR510880
This screwdriver–type bit is made to fit Toro bedknife at-
taching screws. Use this bit with a torque wrench to se-
cure the bedknife to the bedbar.
DO NOT use and air or manual impact wrench with this
tool.
Figure 5
Greensmaster 1000/1600
Page 7 – 5
Cutting Unit
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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 shafts
without a removal hole.
Figure 6
Cutting Unit
Page 7 – 6
Greensmaster 1000/1600
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Troubleshooting
There are a number of factors that can contribute to un-
satisfactory quality of cut, some of which may be turf
conditions. Turf conditions such as excessive thatch,
“sponginess” or attempting to cut off too much grass
height may not always be overcome by adjusting the
mower. It is important to remember that the lower the
height–of–cut, the more critical these factors are. See
Adjustments and Service and Repairs sections for de-
tailed adjustments and repair information.
Factors That Can Affect Quality of Cut
Factor
Possible Problem/Correction
Governed engine speed
Check maximum governed engine speed. Adjust
engine to specifications if necessary.
See Adjustments section in Chapter 3 – Engine.
Reel bearing condition
Check and replace bearings if necessary. Make sure
bearing housings are secured properly.
See Reel and Reel Bearings in the Service and
Repairs section.
Reel and bedknife sharpness
A reel and/or bedknife that has rounded cutting edges
or ”rifling (grooved or wavy appearance) cannot be
corrected by tightening the bedknife to reel contact.
Grind reel to remove taper and/or rifling. Grind
bedknife to sharpen and/or remove rifling.
The most common cause of rifling is bedknife to reel
contact that is too tight.
A new bedknife must be ground or backlapped
after installation to the bedbar.
Bedknife to reel adjustment
Check bedknife to reel contact daily. The bedknife
must have light contact across the entire reel. No
contact will dull the cutting edges. Excessive contact
accelerates wear of both edges. Quality of cut is
adversely affected by both conditions (see Bedknife to
Reel Adjustment).
Slightly dull cutting edges may be corrected by
backlapping (see Backlapping).
Excessively dull cutting edges must be corrected by
grinding the reel to and bedknife (see Preparing Reel
for Grinding).
Drum parallel to reel
Check and adjust as necessary. The Drum must be
leveled so it is parallel with the reel before setting the
height–of–cut.
See Leveling Rear Drum to Reel in Adjustments
section.
Greensmaster 1000/1600
Page 7 – 7
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Factor
Possible Problem/Correction
Height–of–cut
“Effective” or actual height–of–cut depends on the
mower weight and turf conditions. Effective
height–of–cut will be different than the bench set
height–of–cut.
Proper bedknife for height–of–cut
If the bedknife is too thick for effective height–of–cut,
poor quality of cut will result.
Front roller scraper and comb adjustment
Install and/or adjust roller scrapers if grass clippings
build up on the rollers. Set clearance between the
scraper and roller at 1/32 inch (0.8 mm).
Stability of bedbar
Make sure bedbar pivot bolts are securely seated.
Check condition of the bushings in the side plates.
See Bedbar in Service and Repairs section.
Number of reel blades
Roller condition
Use correct number of blades for clip frequency and
optimum height–of–cut range.
Make sure rollers rotate freely. Grease roller when
needed, or repair bearings as necessary.
See Roller Bearing Replacement in Service and
Repairs section.
Traction speed
Check maximum governed engine speed. Adjust
engine to specifications if necessary. The drive belts
may be loose or worn. Check the condition of the belts
and adjust or replace as necessary.
See Adjustments section in Chapter 3 – Engine and
Chapter 4 – Traction and Reel Drive System. Also, see
Service and Repairs section in Chapter 4.
Grooming reel operation
See Troubleshooting section of Chapter 8 – Grooming
Reel Kit.
Cutting Unit
Page 7 – 8
Greensmaster 1000/1600
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Adjustments
CAUTION
Never work on the mower with the engine
running. Always stop the engine and re-
move the high tension leadfromthespark
plug first.
Leveling Drum to Reel
1. Make sure engine is OFF. Remove high tension
lead from the spark plug.
2. Position mower on a flat level surface, preferably a
precision steel work plate. Place a 1/4–inch x 1–inch flat
steel strip, approximately 24 inches long, under the reel
blades and against the front edge of the bedknife to pre-
vent the bedbar from resting on the work surface.
3
1
3. Raise front roller so only the rear drum and reel are
on the surface.
4. Firmly press down on mower above the reel so all
reel blades contact the steel strip.
2
5. While pressing down on reel, slide a feeler gauge
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 inch (0.254 mm), on ei-
ther end, an adjustment to the drum is required, proceed
to step 5. If the gap is less than 0.010 inch (0.254 mm)
no adjustment is required.
Figure 7
1. Drive pulley
2. Four holes
3. Idler pulley
6. Remove rear belt cover from right side of mower.
7. Rotatedrivepulleyuntilholesalignwithallfourroller
bearing flange screws (Fig. 7).
8. Loosen all four roller bearing screws and screw se-
curing idler pulley. Raise or lower right side of drum as-
sembly until the gap is reduced to less than 0.010 inch
(0.254 mm). Torque drum bearing cap screws from 16
to 20 ft–lbs (2.2 to 2.8 kg–m) (Fig. 7). Adjust belt ten-
sion and tighten idler pulley mounting screw (see Drive
Belt in Adjustments section of Chapter 4 – Traction and
Reel Drive System).
Greensmaster 1000/1600
Page 7 – 9
Cutting Unit
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Bedknife to Reel Adjustment
1. Position mower on a flat level work surface. Make
sure engine is OFF. Remove high tension lead from the
spark plug. Remove reel contact:
2
A. On the GR1000, loosen the jam nuts on the bed-
knife adjusting screws and rotate adjusting screws
counterclockwise (Fig. 8).
1
B. On the GR1600, turn bedbar adjusting screws
counterclockwise (Fig. 9).
3
2. Tilt mower back on handle to expose bedknife and
reel.
Figure 8
1. Jam nut
3. Spring
2. Adjusting screw
Note: Each time adjusting screw is rotated one flat on
the GR1000, the bedknife moves 0.003 inch (0.076 mm)
closer to the reel. Each time adjusting screw is rotated
one click on the GR1600, the bedknife moves 0.0007
inch (0.018 mm) closer to the reel. DO NOT OVER-
TIGHTEN ADJUSTING SCREWS.
3. On one end of the reel do the following (Fig. 10):
A. Insert a long strip of newspaper between the reel
and bedknife.
1
B. On the GR1000, while slowly rotating the reel
forward, tighten bedknife adjusting screw one flat at
a time until the paper is pinched lightly.
1. Bedbar adjusting screw
Figure 9
C. On the GR1600, while slowly rotating the reel
forward, tighten bedbar adjusting screw clockwise
one click at a time until the paper is pinched lightly.
D. When inserted from the front and parallel to the
bedknife, a slight drag on the paper should result
when the paper is pulled.
4. Check for light contact at the other end of the reel
using paper and adjust as required. On the GR1000,
make sure jam nuts on the adjusting screws are tight-
ened upon completion of the adjustment (Fig. 8).
5. After the adjustment is accomplished, check to see
if the reel can pinch a strip of paper when inserted from
the front and cut the paper when inserted at a right angle
to the bedknife (Fig. 11).
Figure 10
A. It should be possible to cut the paper with mini-
mum contact between the bedknife and the reel
blades.
B. Should excessive reel drag of more than 7 in–lb
(8 kg–cm) be evident, it will be either necessary to
backlap or regrind the reel and bedknife to achieve
the sharp edges needed for precision cutting (see
TORO Sharpening Reel and Rotary Mowers Manu-
al, Form No. 80-300 PT).
Figure 11
Greensmaster 1000/1600
Cutting Unit
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Height–of–Cut Adjustment
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
4
2. Verify that the drum is level to the reel and that the
bedknife to reel contact is correct. Tip mower back on its
handle to expose roller, drum, and bedknife.
3
3. Loosen locknuts securing height–of–cut arms to the
height–of–cut brackets (Fig. 13).
4. Loosen nut on gauge bar and set adjusting screw to
desired height-of-cut. Distance between bottom of
screw head and face of bar is height-of-cut (Fig. 14).
1
5. Hook adjusting screw head on the cutting edge of
the bedknife. Rest the rear end of the bar on the drum
(Fig. 15).
2
6. Rotate height–of–cut screw until the roller contacts
the front of the gauge bar. Adjust both ends of the roller
until the entire roller is parallel to the bedknife (Fig. 13).
Figure 13
1. Lock nut
3. Height–of–cut bracket
4. Height–of–cut screw
2. Height–of–cut arm
IMPORTANT: When set properly, the roller and
drum should contact the gauge bar, and the adjust-
ing screw should be snug against the bedknife. This
assures that the height–of–cut is identical at both
ends of the bedknife.
3
2
7. Tighten both lock nuts to lock the height adjustment
(Fig. 13).
Note: The front roller can be put in three different posi-
tions depending on the application and needs of the
user (Fig. 12).
1
Figure 14
D
The front position is used when a groomer is
installed.
1. Nut
2. Gauge bar
3. Adjusting screw
D
D
The middle position is used without a groomer.
The third position can be used in extremely undulat-
ing turf conditions.
FRONT
MIDDLE
THIRD
Figure 12
Figure 15
Greensmaster 1000/1600
Page 7 – 11
Cutting Unit
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Grass Shield Height Adjustment
Adjust shield to assure proper grass clipping dis
into the basket.
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Measure distance from the top of the front
rod to the front lip of the shield at each end
1
2
(Fig. 16).
Figure 16
3. The height from the support rod to the front lip of the
shield for normal cutting conditions should be
4
1in. chSuepsp.ort rod
2. Shield
Note: Shield can be lowered for drier conditions (clipĆ
pings fly over top of basket) or raised to allow
wet grass conditions (clippings build up on rear
ket).
1
4. Loosen capscrews and nuts securing each e
the shield to the side plates. Adjust shield to
height and tighten fasteners (Fig. 17).
4
2
3
Figure 17
1. Grass shield
2. Cap screw
3. Lock nut
4. Side plate
Cutoff Bar Adjustment
Adjust cutoff bar to assure clippings are cleanly dis-
charged from the reel area.
1
Note: The cutoff bar is adjustable to compensate for
changes in turf conditions. The bar should be adjusted
closer to the reel for extremely wet turf. However, adjust
cutoff bar further away from the reel for dry turf. The bar
should be parallel to the reel to assure optimum perfor-
mance. Make sure cutoff bar is adjusted whenever the
shield height is adjusted or the reel is sharpened.
2
Figure 18
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
1. Screw
2. Cutoff bar
2. Loosen screws securing the cutoff bar. Insert a
0.060 inch (0.152 mm) feeler gauge between the top of
the reel and the bar.
3. Tighten screws so that the distance between the
cutoff bar and reel is equal for the complete length of the
reel.
Cutting Unit
Page 7 – 12
Greensmaster 1000/1600
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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.
1
3. Remove the cover plug in the right reel drive cover
(Fig. 19).
4. Insert a 1/2–inch socket extension, which is con-
nected to a backlapping machine, into the square hole
in the center of the reel pulley.
5. Backlap according to procedure in TORO Sharpen-
ing Reel and Rotary Mowers Manual, Form No. 80-300
PT.
Figure 19
1. Cover plug
Lubrication
The grease fittings on the mower should be greased at
least every 25 hours. Grease immediately after wash-
ing regardless of the service interval listed. Lubri-
cate using No. 2 multipurpose lithium base grease. A
hand operated grease gun is recommended for the best
results.
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Wipe each grease fittings with a clean rag.
IMPORTANT: Do not apply too much pressure, or
grease seals will become permanently damaged.
Figure 20
3. There are two fittings on the front roller and one on
both reel bearing housings. Grease all fittings. Wipe off
excess grease.
Greensmaster 1000/1600
Page 7 – 13
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Bedbar
Removal
1. Position mower on a flat level work surface. Make
sure engine is OFF. Remove high tension lead from the
spark plug.
2
2. Loosen jam nut on the adjusting screw. Loosen ad-
justing screw until the thrust washer contacts the inside
of the frame adjuster. Accomplish on both sides of the
mower (Fig. 21).
1
WARNING
Use caution when removing the bedbar. Ad-
justing screw springs (Fig. 22) are under ten-
sion and could release suddenly.
Figure 22
1. Spring
2. Pin (Allen wrench)
3. Compress spring with a pair of channel lock pliers.
Insert a pin to hold the spring in position (Fig. 22).
4. Loosen flange nuts on both sides of the mower. Re-
move both bedbar bolts on each side of the mower with
the metal and nylon washers. Discard nylon washer
(Fig. 23).
3
2
5. Remove bedbar from the mower. Keep metal wash-
ers and discard nylon washers. Remove and discard
both nylon bushings (Fig. 24).
4
1
3
Figure 23
4
1. Flange nut
2. Bedbar bolt
3. Metal washer
4. Nylon washer
1
2
1
Figure 21
1. Jam nut
2. Adjusting screw
3. Thrust washer
4. Frame adjuster
2
Figure 24
1. Bedbar
2. Nylon bushing
Cutting Unit
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Greensmaster 1000/1600
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Installation
4
Note: Use new nylon washers and bushings for instal-
lation.
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2
3
2. Use grease to hold thrust washers against the in-
side of both frame adjusters (Fig. 25).
1
3. Install new nylon bushings into both sides of the
frame (Fig. 26).
Figure 27
1. Nylon washer
2. Metal washer
3. Bedbar bolt
4. Flange nut
4. Put anti–seize lubricant on the threads of bedbar
bolts. Install nylon washer, metal washer, and bedbar
bolt to both sides of the frame (Fig. 27).
WARNING
Use caution when removing the bedbar. Ad-
justing screw springs are under tension and
could release suddenly (Fig. 28).
2
5. Compress spring with channel lock pliers. Remove
pin from both frame adjusters. (Fig. 28).
1
6. Tighten and then torque both bedbar bolts from 240
to 320 in–lb (280 to 370 kg–cm). Tighten both flange
nuts until metal washers can just rotate freely (Fig. 29).
Figure 28
1. Spring
2. Pin (Allen wrench)
2
1
2
1
Figure 25
1. Thrust washer
2. Frame adjuster
1
Torque to
240 to 320 in–lb
(280 to 370 kg–cm)
2
Figure 29
Figure 26
1. Flange nut
2. Bedbar bolt
1. Nylon bushing
2. Bedbar
Greensmaster 1000/1600
Page 7 – 15
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Bedknife Replacement and Grinding
Removal
2
1. Remove bedbar from frame (see Bedbar Removal).
1
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 remove all rust, scale and corro-
sion from bedbar surface before installing new bedknife
(Fig. 31).
3
4. Install bedbar to frame (see Bedbar Installation).
Replacement
Figure 30
1. Screw
2. Bedbar
3. Bedknife
1. Make sure bedbar threads are clean.
2. Use new screws. Apply anti–seize lubricant to the
screw before installing.
IMPORTANT: Do not use an impact wrench to tight-
en screws into the bedbar.
3. Using a torque wrench and bedknife screw tool,
tighten screws to a torque of 200 to 250 in–lb (230 to 288
kg–cm). Use a torquing pattern working from the center
toward each end of the bedknife (Fig. 32).
Figure 31
Grinding
Since there can be variations in the mounting surface of
the bedbar, a new bedknife will not be perfectly flat after
it is installed. Because of this, it is necessary to backlap
or grind a new bedknife after installing it to the bedbar.
Follow the existing angle that was ground into the bed-
knifeandgrindonlyenoughtomakesurethetopsurface
is true (Fig. 33).
1. Remove bedbar from the mower (see Bedbar Re-
moval).
Note: When grinding, be careful to not overheat the
bedknife. Remove small amounts of material with each
pass of the grinder.
12 11
9
7
5
3
1
2
4
6
8
10 12
Figure 32
2. Use TORO Sharpening Reel and Rotary Mowers
Manual, Form No. 80-300 PT, for grinding the bedknife.
Top Face
Relief Angle
Bedknife Grinding Specifications
Relief Angle
5_
Front
Face
Relief Angle Range
Front Angle
3_ to 6_
15_
Front Angle Range
13_ to 17_
Front Angle
Figure 33
3. Reinstall bedbar to the mower (see Bedbar Installa-
tion).
Cutting Unit
Page 7 – 16
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Roller
Removal
9
5
6
7
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2
2. Loosen jam nut and set screw on both ends of the
mower.
1
3. On one end of the mower, remove lock nut and flat
washer from the carriage screw.
10
Note: Do not adjust the height–of–cut screw when re-
3
moving the height–of cut arm.
8
4
4. Pull the height–of–cut arm from the roller shaft, car-
riage screw, and height–of–cut bracket. Remove the
roller from the mower.
Figure 34
1. Jam nut
6. Height–of–cut screw
7. Height–of–cut arm
8. Roller
9. Height–of–cut bracket
10. Frame
2. Set screw
3. Lock nut
4. Flat washer
Installation
5. Carriage screw
1. Place roller shaft into the height–of–cut arm that is
still attached to the mower.
3. Center roller evenly between both height–of–cut
arms. Tight roller shafts in place by tightening the set
screw and then the jam nut.
2. Placetheremovedheight–of–cutarmontotheroller
shaft. Secure height–of–cut arm into the height–of–cut
bracket with with the carriage screw, flat washer, and
lock nut.
4. Adjustrollerforheight–of–cut(seeHeight–of–Cutin
the Adjustments section).
Roller Bearing Replacement
Note: A Wiehle roller is shown. Bearing configura-
tions is the same for full, swaged, and wiehle rollers.
2
1
3
Remove Bearings
Note: Use the bearing replacement tool kit, described
in the Special Tools section, to remove the roller bear-
ings.
Note: It is recommended to replace bearings at both
ends of the roller after bearing failure.
BEARING AND ROLLER
1. If a hole is not on the bearing shaft, use drill bushing
to drill a hole in the bearing shaft.
SURFACE MUST BE FLUSH
Figure 35
2. Remove roller bearing with bearing puller.
1. Roller bearing
2. Roller (Wiehle)
3. Grease fitting
3. Clean roller bearing cavity and remove any rust with
crocus cloth.
2. Press roller bearing into roller so that the outside
surface of the bearing is flush with the end of the roller.
4. Repeat above steps for the other roller bearing.
3. Grease the bearing with No. 2 multipurpose lithium
based grease until grease appears at the seal of the
bearing.
Install New Bearings
1. Make sure roller bearing cavity is clean and free of
dirt. Apply No. 2 multipurpose lithium based grease to
the roller bearing.
4. Repeat above steps for the other roller bearing.
Greensmaster 1000/1600
Page 7 – 17
Cutting Unit
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Reel
Removal
2
5
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.
3
6
10
2. Remove bedbar from the mower (see Bedbar Re-
moval).
17
13
4
18
7
12
3. If a grooming reel kit is installed, remove the cutting
reel using the procedures in Frame Assembles (RH and
LH) and Cutting Reel in the Service and Repairs section
of Chapter 8 – Grooming Reel Kit.
8
14
16
RIGHT
11
4. Remove four cap screws, four lock washers, and
reel drive cover from the mower. Mark bearing housing
(RH) for reassembly purposes (Fig. 36).
1
FRONT
9
15
Figure 36
5. Remove reel drive belt from the pulley and drive as-
sembly (see Service and Repair section of Chapter 4 –
Traction and Reel Drive Systems.
1. Grease fitting
2. Cap screw
10. Groomer arm cover
11. Cover standoff
12. Bearing housing (RH)
13. Frame
14. Large seal
15. Small seal
16. Retaining ring
17. Bearing
18. Wave washer
3. Lock washer
4. Reel drive cover
5. Reel drive belt
6. Pulley and drive assy
7. Retaining ring
8. Flat head screw
9. Nut
IMPORTANT: Do not disassemble the pulley and
drive assembly and retaining ring.
6. Use a 1/2–inch drive in the pulley and drive assem-
bly (Fig. 36) to remove the assembly from the reel drive
shaft. Also, remove bearing lock nut (Fig. 37) from the
reel drive shaft at the same time.
8
4
10
1
2
7. Use an allen wrench and remove both flat head
screws, groomer arm cover, and both cover standoffs
from the bearing housing (Fig. 36).
7
5
8. Remove both cap screws, lock nuts, and bearing
cover from the bearing housing (LH) (Fig. 37).
9. Remove grease fittings from both bearing housings
(Fig. 36 and 37).
RIGHT
9
FRONT
6
10. Pull both bearing housings from the frame and reel
(Fig. 36 and 37). Remove the reel from the mower.
3
Figure 37
11. If bearings are worn or need replacement for main-
tenance purposes, remove bearings from both bearing
housings as follows:
1. Grease fitting
6. Bearing lock nut
7. Large seal
8. Small seal
9. Bearing
2. Bearing housing (LH)
3. Cap screw
4. Lock nut
5. Bearing cover
10. Frame
A. Remove large seal, small seal, and bearing from
the bearing housing (Fig. 37).
B. Remove bearing seal, retaining ring, bearing,
andwavewasherfromthebearinghousing. Discard
wave washer (Fig. 36).
Cutting Unit
Page 7 – 18
Greensmaster 1000/1600
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Installation
B. Make sure grease fitting hole is position to the
front of the mower.
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.
C. Attach the groomer arm cover to the bearing
housing and frame with the two flat head screws,
cover standoffs, and lock nuts. Do not tighten down
fasteners.
IMPORTANT: Make sure the correct bearing hous-
ing is used when installing bearings. The grease fit-
ting hole should face forward when the housing is
placed in the frame.
6. Attach bearing housing (LH) through the frame onto
the reel shaft (Fig. 37).
2. Reassemble bearing housing (LH) components
(Fig. 37).
A. Push housing onto reel shaft. If necessary, tap
into position with a soft hammer.
A. Place small seal into the bearing housing with
the flat side out.
B. Make sure grease fitting hole is position to the
front of the mower.
B. Press new bearing into the bearing housing with
a bearing driver.
C. Align housing holes to frame holes with both cap
screws and lock nuts. Fasteners should be only fin-
ger tight.
C. Place large seal on the bearing housing with the
flat side out. Press seal in with a seal driver.
7. While tightening the bearing lock nut (Fig. 37) to the
reel shaft, tighten pulley and drive assembly (Fig. 36) to
thereelshaftatthesametime. Torqueassemblyandnut
to 50 ft–lb (6.9 kg–m).
3. Reassemble bearing housing (RH) components
(Fig. 36).
A. Bearing housing (RH) should be marked from
disassembly.
8. Tighten flat head screws and nuts securing the
bearing housing (RH) to the frame (Fig. 36).
B. Place small seal into the bearing housing with
the flat side out.
9. Remove both cap screws and lock nuts holding the
bearing housing (LH) to the frame. Position bearing cov-
er to housing and secure to frame with both cap screws
and lock nuts (Fig. 37).
C. Place new wave washer into housing. Press
new bearing into the bearing housing with a bearing
driver.
10. Reinstall reel drive belt to the pulley and drive as-
sembly (see Service and Repair section of Chapter 4
Traction and Reel Drive Systems).
D. Install and seat retaining ring into the groove of
the housing.
11. Reinstall reel drive cover with four lock washers and
cap screws to the mower. Tighten cap screws (Fig. 36).
E. Place large seal on the bearing housing with the
flat side out. Press seal in with a seal driver.
12. Reinstall grease fittings to both bearing housings.
Lubricate both housings with No. 2 multipurpose lithium
base grease (Fig. 37 and 36).
4. Position reel in frame to accept bearing housings.
The reel shaft end with internal threads should be on the
right side of the frame.
13. Reinstall bedbar to the mower (see Bedbar Remov-
al).
Note: The two bearing housings are similar in appear-
ance but can not be interchanged. The bearing housing
(RH) was marked during disassembly.
14. Complete mower set–up and adjustment sequence
(see Adjustments section).
5. Attachbearinghousing(RH)throughtheframeonto
the reel shaft (Fig. 36).
A. Push housing onto reel shaft. If necessary, tap
into position with a soft hammer.
Greensmaster 1000/1600
Page 7 – 19
Cutting Unit
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Preparing a Reel for Grinding
Note: Check to make sure the reel bearings are in
good condition and properly adjusted before grinding a
reel.
4. After completing grinding process:
A. Install height–of–cut arms and roller (see Roller
Installation).
1. Remove bedbar assembly (see Bedbar Removal).
B. Install bedbar assembly (see Bedbar Installa-
tion).
2. Raise grooming reel, if installed, by rotating both
quick–up levers so they face the rear of the mower.
C. Complete mower set–up and adjustment se-
quence (see Adjustments section).
Note: Some older grinding machines may require that
the cutting reel be removed.
Reel Grinding Specifications
3. Remove roller and both height–of–cut arms (see
Roller Removal).
Nominal Reel Diameter
5 in (126 mm)
Service Limit Reel Diameter
4.5 in (114 mm)
Note: The cutting unit must be aligned so the grinding
wheel will travel parallel to the reel shaft. This will result
in the the reel being ground to the desired cylinder
shape.
Blade Relief Angle
Relief Angle Range
Blade Land Width
30_
20_ to 40_
0.040 in (1.0 mm)
0.030 to 0.060 in (0.7 to 1.5 mm)
0.040 in (1.0 mm)
Land Width Range
Max. Reel Taper
Note: When grinding, be careful to not overheat the
reel blades. Remove small amounts of material with
each pass of the grinder.
BLADE RELIEF ANGLE
REEL DIAMETER
BLADE
LAND
WIDTH
D
2
D
1
REEL DIAMETER TAPER = D – D
1
2
Figure 38
Cutting Unit
Page 7 – 20
Greensmaster 1000/1600
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Chapter 8
Grooming Reel Kit
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Clutch Engagement/Disengagement . . . . . . . . . . . 3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4
Factors Affecting Grooming . . . . . . . . . . . . . . . . . . 4
Grooming Reel Mechanical Problems . . . . . . . . . . 5
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Height/Depth of Grooming Adjustment . . . . . . . . . 6
Drive Belt Tension Adjustment . . . . . . . . . . . . . . . . 7
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8
Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Reel Bearing Replacement . . . . . . . . . . . . . . . . . . . 11
Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . 11
Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Frame Assemblies (RH and LH) . . . . . . . . . . . . . 14
Cutting Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Note: This chapter covers the grooming reel kit (Mod-
el No. 04125), which is used only on the Greensmaster
1000.
Greensmaster 1000
Page 8 – 1
Grooming Reel Kit
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Specifications
MOUNTING: The grooming kit is rigidity mounted to the
MICRO ADJUSTMENT KNOB: Allows a 0.007 inch
mower reel bearing housings and frame.
(0.18 mm) increment of height adjustment
REEL CONSTRUCTION: 2–1/4 inch (5.4 cm) diameter,
41 steel blades with 1/2–inch blade spacing. Spacing is
also adjustable at 1/4 and 3/4–inch (6.4 and 19.1 mm)
by varying the number of blades and spacers.
QUICK UP–DOWN FEATURE: Allows grooming reel to
be raised 5/16 inch (7.9 mm) above the height/depth ad-
justment for no grooming reel action while cutting.
WIDTH–OF–GROOMING: 19 inches (48.3 cm)
GROOMING PENETRATION: Maximum of 0.18 inch
(4.6 mm)
OPTIONAL EQUIPMENT:
Groomer Brush Assembly
Part No. 65–8330
Grooming Reel Kit
Page 8 – 2
Greensmaster 1000
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General Information
Clutch Engagement/Disengagement
The grooming reel should be disengaged at all times ex-
cept during grooming.
IMPORTANT: When engaging or disengaging the
clutch, be sure to turn the clutch knob all the way
until it comes to a firm stop. Failure to do so could
cause damage to the clutch.
3
1
1. Depress clutch snubber and engage the clutch by
turning the clutch knob counterclockwise.
2
2. Turn clutch knob clockwise to disengage the clutch.
Figure 1
Transport Mode
1. Clutch snubber
2. Clutch knob
3. Quick–up lever
IMPORTANT: When transporting the mower, make
sure groomer clutch is disengaged and the groom-
ing reel is raised to its transport position.
1. To raise the grooming reel, rotate both quick–up le-
vers so they face to the rear of the mower.
2. To lower the grooming reel, rotate both quick–up le-
vers so they face to the front of the mower, then engage
the clutch.
Greensmaster 1000
Page 8 – 3
Grooming Reel Kit
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Troubleshooting
Factors Affecting Grooming
There are a number of factors that can affect the perfor-
mance of grooming. These factors vary for different golf
courses and from green to green. It is important to in-
spect the turf frequently and vary the grooming practice
with turf needs.
IMPORTANT: Improper or overaggressive use of
the grooming reel, such as too deep or frequent
grooming, may cause unnecessary stress on the
turf leading to severe turf damage. Use the groomer
carefully. READ AND UNDERSTAND THE OPERA-
TOR’S BEFORE OPERATING OR TESTING GROOM-
ER PERFORMANCE.
It is important to remember that factors affecting quality
of cut also affect grooming performance.
Variables That Affect the Use and Performance of Grooming Reels
1. The Growing season and weather conditions
2. General turf conditions
7. The amount of time that a grooming reel has been
in use on a particular turf area
8. The type of grass on the green
3. The frequency of grooming/cutting – number of cut-
tings per week and how many passes per cutting
9. The overall turf management program – irrigation,
fertilizing, weed control, coring, overseeding, sand
dressing, and disease and pest control
4. The blade spacing on the grooming reel
5. The height of cut
10. The amount of traffic on the turf
6. The grooming depth
11. Stress periods for turf – high temperatures, high hu-
midity, unusually high traffic
Grooming Reel Kit
Page 8 – 4
Greensmaster 1000
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Grooming Reel Mechanical Problems
Problem
Possible Causes
Correction
The grooming reel rotates when it is Due to friction in the clutch assem- This condition may change over a
in the raised position with the clutch bly, the grooming reel may still ro-
period of time. Disassemble and
clean clutch assembly.
disengaged.
tate (with minimal force) in the
raised position with the clutch dis-
engaged.
The clutch is not fully disengaged.
Make sure clutch knob set screws
are tight against the flats on the re-
lease disk, and they do not allow
the knob to slip.
The clutch pulley bearing may be
seized.
Replace pulley bearing.
The clutch may be damaged or as- Repair or replace clutch if neces-
sembled incorrectly.
sary.
The clutch is engaged but does not The clutch is not fully engaged.
provide power to the grooming reel.
Make sure clutch knob set screws
are tight against the flats on the re-
lease disk and do not allow clutch
knob to slip. IMPORTANT. When
engaging or disengaging the clutch,
be sure to push the snubber down
and turn the knob all the way until it
comes to a firm stop.
The clutch is damaged or as-
sembled incorrectly.
Repair or replace clutch if neces-
sary.
The belt is out of adjustment.
If the belt slips, it probably is dam-
aged and must be replaced.
The belt broken or damaged.
Repair or replace belt if necessary.
A broken or worn belt could be the
result of improper belt adjustment or
seized grooming reel bearings.
The turf is damaged or has uneven The grooming reel blades are bent, Replace blades if necessary.
grooming.
damaged, or missing.
The grooming reel shaft is bent or
damaged.
Replace grooming reel shaft.
Grooming depth is not equal on
both ends of groomer reel.
Adjust depth if necessary. Check
and adjust cutting unit set up (level
bedknife to reel, level rear roller to
reel, set height of cut, etc.)
The groomer reel does not raise
Groomer reel interfering with cutting Check side plate for proper cut–out
completely to the transport position. unit frame side plate.
Quick–up levers have free play or
and modify if necessary.
do not rotate completely to the rear.
Greensmaster 1000
Page 8 – 5
Grooming Reel Kit
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Adjustments
CAUTION
Never work on the mower with the engine
running. Always stop the engine and re-
move the high tension leadfromthespark
plug first.
Height/Depth of Grooming Adjustment
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
4
2. Make sure rollers are clean and cutting reel is set to
the desired height of cut (see Adjustments section of
Chapter 7 – Cutting Unit). Position mower on a flat level
working surface.
3
1
3. Hold clutch snubber down and disengage the clutch
by turning the clutch knob clockwise. Use quick–up le-
vers on both sides of the mower to lower the grooming
reel into the grooming position (Fig. 2).
2
Figure 2
4. .On one end of the grooming reel, measure the dis-
tance from the lowest tip of the groomer blade to the
working surface (Fig. 3). Lift and turn micro adjustment
knob to raise or lower the tip (Fig. 2). Each notch on the
micro adjustment knob is approximately equal to 0.007
inch (0.178 mm).
1. Clutch snubber
2. Clutch knob
3. Quick–up lever
4. Micro adjustment knob
5. Repeat step 3 above on the opposite end of the
groomer. Then, recheck setting on the first side of
groomer.
6. Raise grooming reel to the transport position.
1
Figure 3
1. Grooming reel
Grooming Reel Kit
Page 8 – 6
Greensmaster 1000
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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 three socket head cap screws and lock
washers, then remove belt cover.
5
4. Check drive belt tension as follows:
4
A. Apply 5 to 10 lb (22 to 44 N) of force on the drive
belt midway between the driver pulley and driven
pulley.
B. Drive belt deflection should be about 0.25 inch
(6.4 mm).
2
1
3
5 to 10 lbf
C. If belt tension is not acceptable, loosen the sock-
et head cap screw on the idler block.
(22 to 44 N)
Figure 4
D. Pivot idler to get proper tension on the drive belt.
Tighten the socket head cap screw.
1. Drive belt
2. Driver pulley
3. Driven pulley
4. Socket head cap screw
5. Idler pulley
E. Verify drive belt tension and readjust it as neces-
sary. Torque the socket head cap screw from 7 to 10
ft–lb (1.0 to 1.4 kg–m).
5. Secure belt cover to housing with three socket head
cap screws and lock washers.
6. Reinstall poly washer and clutch knob to the clutch
assembly. Tighten both set screws in the clutch knob.
Greensmaster 1000
Page 8 – 7
Grooming Reel Kit
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Service and Repairs
Reel
14
15
16
17
1
2 3 4 5 6
7
8 9
10 11
12
13
18
19
20
21
22
23
27
28
24
25
47
26
50
48
54
7
5
6
29
30
31
32
33
53
29
9
39
38
52
40
51
49
36
GROOMING REEL
ASSEMBLY
48
35
37
RIGHT
34
47
46
2
FRONT
45
33
44
43
42
41
Figure 5
1. Lock nut
2. Ball bearing
3. Lock nut
19. Roll pin
20. Cap
21. Ramp
37. Socket head cap screw
38. Idler pulley spacer
39. Spacer
4. Bearing housing
5. Spacer
6. Adapter
22. Mounting block
23. Spring
24. Pop rivet
40. Retaining ring
41. Driven pulley
42. Drive belt
7. Bearing
25. Caution plate
26. Spring
27. Lock nut
28. Spring spacer
29. Clutch assembly
30. Flat head socket screw
31. Belt cover
43. Carriage bolt
44. Lock washer
45. Idler block
46. Belt drive housing
47. Grease fitting
48. Driven pulley spacer
49. Lock nut
8. Side plate
9. Adapter ring
10. Lock nut
11. Cap screw
12. Belleville washer
13. Cap
14. Plug
15. Driver
16. Spring
17. Adjustment knob
18. Pin cover
32. Lock washer
50. Flat head socket screw
51. Spacer
52. Blade
53. Shaft
54. Slot cover
33. Socket head cap screw
34. Shoulder screw
35. Bearing
36. Idler pulley
Grooming Reel Kit
Page 8 – 8
Greensmaster 1000
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2
4
5
6
8
9
10
1
16
13
3
12
7
CLUTCH
ASSEMBLY
11
RIGHT
FRONT
14
15
Figure 6
1. Belt cover
7. Roller bearing
8. Belleville washer
9. Clutch release disc
10. Special screw
12. Set screw
2. Clutch drive adapter
3. Needle bearing
4. Clutch pin
13. Clutch knob
14. Flat washer
15. Lock nut
5. Compression spring
11. Flange bushing
16. Poly washer
6. Driver pulley
The grooming reel can be removed to reverse the shaft,
replace individual blades, or replace the entire shaft.
The shaft is reversed so that the sharpest edge of the
blades are forward.
Removal
2
3
3
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
1
2. Loosen both set screws in the clutch knob. Remove
clutch knob and poly washer from the clutch assembly
(Fig. 6).
Figure 7
1. Clutch knob
2. Belt cover
3. Socket head cap screw
and washer
3. Remove three socket head cap screws and wash-
ers, then remove belt cover (Fig. 7).
4. In the belt drive housing (46), disassemble the fol-
lowing parts (Fig. 5):
5. From the right side of the mower, remove the follow-
ing (Fig. 5):
A. Loosen socket head cap screw (37). Pivot idler
pulley (36) away from the drive belt (42). Remove
drive belt from the driven pulley (41).
A. Remove lock nut (1) that secures the shaft (53)
to the bearing housing (4).
B. Remove three flat head socket screws (50) and
lock nuts (3), then remove bearing housing from the
side plate (8) and shaft.
Note: The driven pulley (41) has left handed threads.
B. Use an allen wrench to remove driven pulley
from the shaft (53).
C. Pull grooming reel assembly from the belt drive
housing (46).
Greensmaster 1000
Page 8 – 9
Grooming Reel Kit
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Disassembly
6. Secure belt cover to housing with three socket head
cap screws and washers (Fig. 7). Reinstall poly washer
and clutch knob to clutch assembly. Tighten both set
screws into the clutch knob (Fig. 6).
Inspect grooming reel blades frequently for damage and
wear. Straightenbentbladeswithapliers. Eitherreplace
worn blades or reverse the grooming reel shaft to put the
sharpest blade edge forward (Fig. 8).
2
1. Remove one lock nut from either end of the shaft
(Fig. 9).
3
2. Remove spacers and blades as necessary.
Reassembly
1
1. Startplacingtwospacersagainstthelocknut. Then,
place blade against spacers (Fig. 9).
4
2. Rotate location mark on each blade one flat of the
shaft, either in a clockwise or counterclockwise direc-
tion. The direction of rotation must remain constant on
the shaft (Fig. 8).
5
ROTATION
Figure 8
3. Make sure there are two spacers between each
blade. Blades and spacers should be centered on the
shaft (Fig. 9).
1. Dull rounded edge
2. Sharp pointed edge
3. Grooming blade
4. Location mark
5. Shaft
4. Screw lock nut on the shaft and torque both lock
nuts from 200 to 250 ft–lb (27.7 to 34.6 kg–m) so
spacers are not free to rotate.
CENTER BLADES
Installation
Note: The driven pulley (42) has left handed threads.
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
1
2
2. Place grooming reel shaft (53) into the belt drive
housing (46). Screw driven pulley (41) on the shaft. Do
not tighten (Fig. 5).
3
4
Figure 9
1. Lock nut
2. Shaft
3. Spacer
4. Blade
3. Fromtherightsideofthemower, installthefollowing
(Fig. 5):
A. Install bearing housing (4) onto the other end of
the shaft (53) and side plate (8).
B. Secure the bearing housing to the side plate with
three flat head socket screws (50) and lock nuts (3).
C. Secure lock nut (1) to the shaft.
1
4. While holding the lock nut (1), tighten driven pulley
(42) to the shaft (53) (Fig. 5).
3
2
5. Reinstall drive belt onto the driven pulley. Adjust
drivebelttension(seeDriveBeltTensioninAdjustments
section) and torque socket head cap screw from 7 to 10
ft–lb (1.0 to 1.4 kg–m) (Fig. 10).
Figure 10
1. Drive belt
3. Socket head cap screw
2. Driven pulley
Grooming Reel Kit
Page 8 – 10
Greensmaster 1000
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Reel Bearing Replacement
1. Remove grooming reel (see Reel Removal).
Note: Replaceall four ball bearings as a complete set.
2
1
2. Check condition of groomer ball bearings and re-
place as necessary.
A. In the bearing housing and belt drive housing,
install outer ball bearing first with the seal facing out.
3
B. Installbothdrivenpulleyspacersintoeachhous-
ing.
4
C. Install inner bearing in both housings so they are
flush with the housing inner recess of the housing
(Fig. 11).
Figure 12
1. Outer ball bearing
2. Bearing housing
3. Driven pulley spacer
4. Inner ball bearing
3. Install grooming reel (see Reel Installation).
4. Lubricate bearings with No. 2 multipurpose lithium
base grease.
1
3
2
4
0.020 INCH
(0.51 mm) RECESS
Figure 13
1. Outer ball bearing
2. Bearing housing
3. Driven pulley spacer
4. Inner ball bearing
Figure 11
Drive Belt Replacement
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
(Fig. 6).
3. Remove three socket head cap screws and wash-
ers, then remove belt cover (Fig. 7).
2
1
4. Loosen socket head cap screw on the idler block.
Pivot idler to loosen drive belt and remove belt (Fig. 14).
5. Install new drive belt. Tension drive belt and tighten
socket head cap screw (see Drive Belt Tension Adjust-
ment).
3
Figure 14
6. Secure belt cover to housing with three socket head
cap screws and lock washers (Fig. 7).
1. Socket head cap screw
2. Idler
3. Drive belt
7. Reinstall poly washer and clutch knob to the clutch
assembly. Tighten set screws in the clutch knob (Fig. 6).
Greensmaster 1000
Page 8 – 11
Grooming Reel Kit
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Clutch Assembly
CAUTION
Do not use your hand to prevent the cutting
reel from turning while servicing; this can
result in personal injury. Insert a block of
hard wood into the front of the cutting unit
between the reel blades to prevent the reel
from turning.
1
2
Removal
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
Figure 15
1. Clutch drive adapter
2. Reel shaft
2. Loosen set screws in the clutch knob. Remove
clutch knob and poly washer from the clutch assembly
(Fig. 6).
1
3
0.240 to 0.260 inch
(6.10 to 6.60 mm)
2
3. Remove three socket head cap screws and wash-
ers, then remove belt cover (Fig. 7).
4. Loosen socket head cap screw on idler block. Pivot
idler to loosen drive belt and remove belt (Fig. 14).
5. Remove lock nut and flat washer from the shaft of
the clutch drive adapter. Pull clutch assembly off the
shaft of the clutch drive adapter (Fig. 6).
6. Remove clutch adapter from the reel shaft if neces-
sary (Fig. 15).
Figure 16
1. Belleville washers
2. Clutch pin
3. Driver pulley
Disassembly (Fig. 6)
Note: The special screw and clutch pin were as-
sembled with Loctite 271. It might be necessary to apply
heat to these parts prior to disassembly.
IMPORTANT: Keep grease off special screw
threads.
2. Applya thick coat of grease to the special screw and
the cam surface of the clutch release disc.
1. Remove special screw, clutch pin, andcompression
spring from the driver pulley.
IMPORTANT: Make sure belleville washers are
installed correctly (Fig. 16).
2. Separate flange bushing, clutch release disc, and
both belleville washers from the driver pulley.
3. Assemble both belleville washers, clutch release
disc, and flange bushing to the driver pulley.
3. Inspect needle and roller bearings for damage. Re-
place bearings if worn or damaged.
4. Insert special screw through the clutch release disk,
driver pulley and compression spring.
Reassembly (Fig. 6)
1. Pack needle and roller bearings and the inside of
the driver pulley with No. 2 multipurpose lithium based
grease. Press both bearings into the driver pulley with
seal side out.
5. Apply Loctite 271 or equivalent to the threads of the
special screw. Secure compression spring to the special
screw with clutch pin. The clutch pin should extend out
from 0.240 to 0.260 inch (6.10 to 6.60 mm) the face of
the driver pulley when the pin is fully extended (Fig. 16).
Grooming Reel Kit
Page 8 – 12
Greensmaster 1000
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Installation
5. Secure flat washer to the clutch adapter shaft with
the lock nut. Torque lock nut from 120 to 150 in–lb (138
to 173 kg–cm) removing all clutch assembly end play
(Fig. 6).
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. If removed, reinstall clutch adapter to the reel shaft
(Fig. 15). Torque clutch adapter to 17 ft–lb (2.4 kg–m).
6. Tension drive belt (see Drive Belt Tension in the Ad-
justments section) and tighten socket head cap screw
(Fig. 14).
3. Place clutch assembly on the shaft of the clutch
drive adapter. Secure flat washer and lock nut the shaft
of the clutch drive adapter (Fig. 6).
7. Place belt cover on housing and secure with three
socket head cap screws and washers (Fig. 7).
4. Hold drive belt on the driver pulley and slide clutch
onto the clutch adapter shaft while sliding the belt onto
the driven pulley (Fig. 14).
8. Reinstall clutch knob and poly washer to the clutch
assembly. Tighten both set screws in the clutch knob
(Fig. 6).
Greensmaster 1000
Page 8 – 13
Grooming Reel Kit
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Frame Assemblies (RH and LH)
14
15
16
17
1
2 3 4 5 6
7
8 9
10 11
12
13
18
19
20
21
22
23
27
28
24
25
47
26
50
48
54
7
5
6
29
30
31
32
33
53
29
9
39
38
52
40
51
49
36
GROOMING REEL
ASSEMBLY
48
35
37
RIGHT
34
47
46
2
FRONT
45
33
44
43
42
41
Figure 17
1. Lock nut
2. Ball bearing
3. Lock nut
19. Roll pin
20. Cap
21. Ramp
37. Socket head cap screw
38. Idler pulley spacer
39. Spacer
4. Bearing housing
5. Spacer
6. Adapter
22. Mounting block
23. Spring
24. Pop rivet
40. Retaining ring
41. Driven pulley
42. Drive belt
7. Bearing
25. Caution plate
26. Spring
27. Lock nut
28. Spring spacer
29. Clutch assembly
30. Flat head socket screw
31. Belt cover
43. Carriage bolt
44. Lock washer
45. Idler block
46. Belt drive housing
47. Grease fitting
48. Driven pulley spacer
49. Lock nut
8. Side plate
9. Adapter Ring
10. Lock nut
11. Cap screw
12. Belleville washer
13. Cap
14. Plug
15. Driver
16. Spring
17. Adjustment knob
18. Pin cover
32. Lock washer
50. Flat head socket screw
51. Spacer
52. Blade
53. Shaft
54. Slot cover
33. Socket head cap screw
34. Shoulder screw
35. Bearing
36. Idler pulley
Grooming Reel Kit
Page 8 – 14
Greensmaster 1000
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4
5
6
8
9
10
2
1
16
13
3
12
7
CLUTCH
ASSEMBLY
11
14
RIGHT
15
FRONT
Figure 18
1. Belt cover
7. Roller bearing
8. Belleville washer
9. Clutch release disc
10. Special screw
12. Set screw
13. Clutch knob
14. Flat washer
15. Lock nut
2. Clutch drive adapter
3. Needle bearing
4. Clutch pin
5. Compression spring
11. Flange bushing
16. Poly washer
6. Driver pulley
Removal
1
Note: An older model of the GR 1000 has be used for
illustrating purposes The procedures are the same for
both older and newer models except as noted.
3
2
1. Make sure engine is OFF. Remove high tension
leadfromthesparkplug. Placemoweronalevelsurface
or on a workbench.
4
2. Remove four cap crews and lock washers and then
the reel drive cover (Fig. 19).
NEWER MODELS
Figure 20
3. On newer models, loosen drive belt on the reel drive
assembly as follows:
1. Grass shield
2. Cap screw
3. Lock nut
4. Frame
A. Lower grass shield by loosening both cap
screws and lock nuts securing the shield to the
frame (Fig. 20).
4
2
B. Loosen cap screw on clutch housing. Pivot idler
pulley counterclockwise (arrow direction) to loosen
reel drive belt. Remove reel drive belt (Fig. 21).
2
3
NEWER MODELS
1
1
Figure 21
1. Cap screw
2. Clutch housing
3. Idler pulley
4. Drive belt
Figure 19
1. Cap screw & lock washer
2. Reel drive cover
Greensmaster 1000
Page 8 – 15
Grooming Reel Kit
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4. On older models, loosen both carriage bolts secur-
ing the reel idler bracket to the frame. Pivot idler pulley
assembly away from the reel drive belt. (Fig. 22).
1
2
3
5. Secure cutting reel from turning with a block of hard
wood. Use a 1/2–inch drive ratchet with an extension to
remove the drive pulley and drive belt from the cutting
reel shaft (Fig. 22).
4
5
OLDER MODELS
6. From the right side of the mower, remove the follow-
ing (Fig. 17):
Figure 22
1. Reel idler bracket
2. Idler pulley assembly
3. Reel drive belt
4. Flat head screw
5. Groomer arm cover
A. Remove lock nut (1) securing the shaft (53) to
the bearing housing (4).
B. Use allen wrench to remove both flat head
screws. Remove groomer arm cover from reel bear-
ing housing (Fig. 22).
1
2
C. Remove adapter (6), bearing (7) if necessary,
spacers (5), and adapter ring (9) from the side plate
(8).
3
4
7. On both sides of the mower (Fig. 23),
A. Use spring compressor or clamp to compress
springs in bedbar adjuster frames to free the bedbar
adjuster from the bedbar ear.
5
6
B. Remove both cap screws and washers securing
the bedbar adjuster frame to the mower frame.
Figure 23
1. Bedbar adjuster frame
2. Cap screw and washer
3. Side plate
4. Groomer adjuster
5. Bearing housing
6. Grooming reel shaft
C. Remove cap screw (11) and belleville washer
(12) (inside of frame) securing mounting block (22)
to the mower frame (Fig. 17).
8. Loosenbothsetscrewsontheclutchknob. Remove
the clutch knob and the poly washer behind it from the
clutch assembly (Fig. 18).
9. Remove the three socket head cap screws (33) and
lock washers (32). Remove belt cover (31) from the belt
drive housing (46) (Fig. 17).
10. In the belt drive housing (46), disassemble the fol-
lowing parts (Fig. 17):
A. Loosen socket head cap screw (37) and idler
pulley (36), then remove drive belt (42) from the
driven pulley (41).
1
Figure 24
1. Clutch adapter
3. Adapter
2. Flat head socket screw
Note: The driven pulley (42) has left handed threads.
13. Pull side plate with the groomer adjuster and bear-
ing housing from the grooming reel shaft and reel bear-
ing housing (Fig. 23).
B. Use an allen wrench to remove driven pulley
from the shaft (53).
11. Remove lock nut and flat washer from the shaft of
the clutch drive adapter. Pull clutch assembly off the
shaft of the clutch drive adapter (Fig. 18).
14. Remove grooming reel from the belt drive housing
(46) (Fig. 17).
12. Secure cutting reel from turning with a block of hard
wood. Remove clutch adapter from reel shaft (Fig. 24).
Grooming Reel Kit
Page 8 – 16
Greensmaster 1000
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15. Use allen wrench to remove flat head socketscrews
from the adapter (Fig. 25).
5
16. Remove adapter (6), bearing (7), both spacers (5)
from the belt drive housing (46) (Fig. 17).
4
17. Pull belt drive housing with the groomer adjuster
from the reel bearing housing (Fig. 25).
8
7
1
2
6
3
18. Remove adapter ring (9) and both slot covers (54)
from the reel bearing housing (Fig. 17).
19. If removing the cutting reel, see Cutting Reel Re-
moval in this section..
10
9
1
2
Installation
Figure 25
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
1. Flat head socket screw
2. Adapter
3. Belt drive housing
4. Groomer adjuster
5. Bedbar adjuster frame
6. Adapter ring
7. Reel bearing housing
8. Spacer
9. Reel bearing lock nut
10. Driven pulley (removed)
2. If bedbar adjuster frames have not been removed,
remove the following on both sides of the mower frame
(Fig. 25):
FRAME ASSEMBLY (LH)
A. Use spring compressor or clamp to compress
springs in bedbar adjuster frames to free the bedbar
adjuster from the bedbar ear.
7
1
10
11
12
3
6
B. Remove both cap screws and washers securing
the bedbar adjuster frame to the mower frame.
4
9
3. Install frame assembly (LH) to the left side of the
mower frame (Fig. 25 and 26).
A. If removed, press new bearing into belt drive
housing.
8
1
2
5
B. Insert adapter ring into the reel bearing housing.
C. Insert both flat head socket screws through the
adapter. Position spacers on the screws.
Figure 26
1. Bearing
2. Adapter ring
3. Reel bearing housing
4. Flat head socket screws
5. Adapter
7. Belt drive housing
8. Slot cover
9. Lock nuts
10. Mounting block
11. Cap screw
12. Belleville washer
D. Align adapter, spacers, and flat head socket
screws with the slots in the belt drive housing. Slide
adapter through the bearing, then slide the screws
through the slots in the housing.
6. Spacers
E. Insert a slot cover onto each flat head socket
screw while aligning the curved side of the cover
with the curve of the belt drive cover. Covers should
curve away from the housing.
4. Place one end of shaft (53) into the bearing support
of the belt drive housing (46). Mount driven pulley (41)
to the shaft. Torque pulley from 29 to 35 ft–lb (4.0 to 4.8
kg–m) using a 3/8–inch allen socket on the torque
wrench (Fig. 17).
Note: Itmaybenecessarytomoveorremovethebed-
bar tho gain access to the lock nuts.
5. Secure mounting block to the frame with cap screw
and belleville washer (Fig. 26).
F. Slide flat head socket screws through the reel
bearing housing. Screw lock nuts on both screws.
Torque screws from 23 to 27 ft–lb (3.2 to 3.7 kg–m).
6. Reinstall bedbar adjuster frame to mower frame
with cap screws and washers previously removed (Fig.
25).
Note: The driven pulley (42) has left handed threads.
Greensmaster 1000
Page 8 – 17
Grooming Reel Kit
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7. Install frame assembly (RH) onto the right reel bear-
ing housing using the following procedure (Fig. 27):
FRAME ASSEMBLY (RH)
2
A. Slide bearing housing of frame assembly (RH)
over the end of the grooming reel shaft (Fig. 28)
1
B. Insert adapter ring (9) into the reel bearing hous-
ing (Fig 17).
C. Insertbothflatheadscrewsthroughthegroomer
arm cover and adapter. Put a spacer over each
screw before placing the adapter into the reel bear-
ing housing (Fig. 28 and 29).
Figure 27
1. Bearing
2. Bearing housing
D. Slide adapter through the bearing and into the
reel bearing housing. Install lock nuts on flat head
screws and torque from 23 to 27 ft–lb (3.2 to 3.7
kg–m) (Fig. 28 and 29).
1
2
Note: The lock nut (1) has left handed threads.
3
4
E. Secure the grooming reel shaft (53) to the bear-
ing housing (4) with lock nut (1). Torque lock nut
from 29 to 35 ft–lb (4.0 to 4.8 kg–m) (Fig 17).
8. Secure mounting block (22) to the frame with cap
screw (11) and belleville washer (12) (Fig. 17 and 29).
5
6
9. Reinstall bedbar adjuster frame to the mower frame
with cap screws and washers previously removed (Fig.
28).
Figure 28
1. Bedbar adjuster frame
2. Cap screw and washer
3. Side plate
4. Groomer adjuster
5. Bearing housing
6. Grooming reel shaft
IMPORTANT: If the clutch assembly was disas-
sembled, make sure it is reassembled properly (see
Clutch Assembly Reassembly).
1
2
10. Complete the reinstallation of the clutch assembly
and belt drive housing by following the instructions in
Clutch Assembly Reinstallation (Fig. 30).
3
6
4
7
8
5
11. Use a 1/2–inch drive ratchet and extension to rein-
stall drive pulley and reel drive belt to cutting reel shaft.
Torque drive pulley from 40 to 60 ft–lb (5.5 to 8.3 kg–m)
(Fig. 29).
Figure 29
1. Reel idler bracket
2. Idler pulley assembly
3. Reel drive belt
5. Groomer arm cover
6. Mounting block
7. Drive pulley
12. On newer models, tighten reel drive belt as follows:
A. Pivot idler pulley clockwise (opposite arrow
direction) to tighten reel drive belt. Tighten belt from
20 to 25 lb (89 to 111 N) of force. Tighten cap screw
on clutch housing. (Fig. 21).
4. Flat head screw
8. Reel drive belt
B. Raise grass shield to 4 inches from the top of the
support rod. Tighten both cap screws and lock nuts
securing the shield to the frame (Fig. 20).
3
1
13. On older model, pivot idler pulley assembly against
the reel drive belt. Apply 20 to 25 lb (89 to 111 N) of force
to the idler pulley. Tighten both carriage bolts securing
the reel idler bracket to the frame (Fig. 29).
2
Figure 30
1. Drive belt
3. Clutch drive housing
2. Driven pulley
Grooming Reel Kit
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14. Check groomer assembly (Fig. 31).
4
A. Rotate both quick–up levers to raise the groom-
ing reel into the transport position.
1
B. Hold the clutch snubber down and rotate the
clutch knob clockwise to disengage the clutch.
2
C. Correct any problems and recheck assembly.
3
Figure 31
1. Quick–up lever
2. Clutch snubber
3. Clutch knob
4. Micro adjustment knob
Greensmaster 1000
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Grooming Reel Kit
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Cutting Reel
Removal
4
8
3
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.
6
7
3. Remove grooming reel kit following the Removal
instructions in Frame Assemblies (RH and LH).
2
1
4. Remove bedbar from the mower (see Bedbar Re-
movalinServiceandRepairssectionofChapter7–Cut-
ting Unit).
RIGHT
5
FRONT
5. Removegreasefittingsfrombothbearinghousings.
Mark bearing housing (RH) for reassembly purposes
(Fig. 32 and 33).
Figure 32
1. Grease fitting
2. Bearing housing (RH)
3. Frame
5. Small seal
6. Retaining ring
7. Bearing
6. Secure cutting reel from turning with a block of hard
wood, and remove lock nut from the cutting reel shaft
(Fig. 33).
4. Large seal
8. Wave washer
7. Pull both bearing housings from the frame and reel
(Fig. 32 and 33). Remove the reel from the mower.
7
5
1
8. If bearings are worn or need replacement for main-
tenance purposes, remove bearings from both bearing
housings as follows:
2
4
A. Remove bearing seal, retaining ring, bearing,
and wave washer from the bearing housing (RH).
Discard wave washer (Fig. 32).
LEFT
B. Remove large seal, small seal, and bearing from
the bearing housing (LH) (Fig. 33).
6
FRONT
3
Installation
Figure 33
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.
1. Grease fitting
5. Small seal
6. Bearing
7. Frame
2. Bearing housing (LH)
3. Bearing lock nut
4. Large seal
IMPORTANT: Make sure correct bearing housing is
used when installing bearings. The grease fitting
hole should face forward when the housing is
placed in the frame.
B. Place small seal into the bearing housing with
the flat side out.
C. Place new wave washer into bearing housing.
Press new bearing into the bearing housing with a
bearing driver.
2. Reassemble bearing housing (RH) components
(Fig. 32).
IMPORTANT: Make sure the correct bearing hous-
ing is used when installing bearings. The grease fit-
ting hole should face forward when the housing is
placed in the frame.
D. Install and seat retaining ring into the groove of
the housing.
E. Place large seal on the bearing housing with the
flat side out. Press seal in with a seal driver.
A. Bearing housing (RH) should be marked from
disassembly.
Grooming Reel Kit
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Greensmaster 1000
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3. Reassemble bearing housing (LH) components
(Fig. 33).
6. Attach bearing housing (LH) through the frame onto
the reel shaft (Fig. 33).
A. Place small seal into the bearing housing with
the flat side out.
A. Push housing onto reel shaft. If necessary, tap
into position with a soft hammer.
B. Press new bearing into the bearing housing with
a bearing driver.
B. Make sure grease fitting hole is positioned to the
front of the mower.
C. Place large seal on the bearing housing with the
flat side out. Press seal in with a seal driver.
7. Secure cutting reel from turning with a block of hard
wood. Tighten lock nut to the cutting reel shaft (Fig. 33).
Torque lock nut to 50 ft–lb (6.9 kg–m).
4. Position reel in frame to accept bearing housings.
The reel shaft end with internal threads should be on the
right side of the frame.
8. Reinstall grease fittings to both bearing housings.
Lubricate both housings with No. 2 multipurpose lithium
base grease (Fig. 32 and 33).
Note: The two bearing housings are similar in appear-
ance but can not be interchanged. The bearing housing
(RH) was marked prior to removal.
9. Reinstall bedbar to the mower (see Bedbar Installa-
tion in the Service and Repairs section of Chapter 7 –
Cutting Unit).
5. Attachbearinghousing(RH)throughtheframeonto
the reel shaft (Fig. 32).
10. Reinstall grooming reel kit following the Installation
instructions in Frame Assemblies (RH and LH).
A. Push housing onto reel shaft. If necessary, tap
into position with a soft hammer.
B. Make sure grease fitting hole is positioned to the
front of the mower.
Lubrication
Therearetwogroomingreelshaftbearingsoneachend
of the mower.
1. Park mower on a level surface. Make sure engine
is OFF. Remove high tension lead from the spark plug.
2. Use a hand pump grease gun and No. 2 multipur-
pose lithium base grease for lubrication.
3. Pump only a maximum of 2 to 3 pumps of grease to
avoid permanently damaging the grease seals.
Figure 34
Greensmaster 1000
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Grooming Reel Kit
Page 8 – 22
Greensmaster 1000
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Commercial Products
PART NO. 96889SL, Rev. A
E The Toro Company – 1996, 1997
Printed in U.S.A.
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