Toro Greensmaster 04134 User manual

FormNo.3414-906RevA
GroomerDriveSystem
forGreensmaster®800/1000/1010/1600/1610Mower
ModelNo.04134
InstallationInstructions
WARNING
CALIFORNIA
Proposition65Warning
ThisproductcontainsachemicalorchemicalsknowntotheStateofCalifornia
tocausecancer,birthdefects,orreproductiveharm.
Important:Readtheseinstructionsthoroughlybeforesettinguporoperatingthegroomer.Failure
tofollowthesetuporoperatinginstructionsinthismanualmayresultindamagetothemachine,
groomer,andtheturf.
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachine.
2Nopartsrequired–Movethefrontroller.
Groomer-housingassembly1
Flat-headscrew(3/8x2inches)2
Locknut(3/8inch)2
Bearingadapter1
Spacer2
O-ring1
Syntheticgrease-
Slotcover1
3
Adapterring1
Installthegroomerhousing.
Shaftassembly1
Drivegear1
4Syntheticgrease–
Installthedrivegear.
5ForwardRotationKit-obtainseparately1Setthegroomerforforwardrotation
(optional).
Groomer-housingcoverassembly1
Gasket1
Flange-headbolt(1/4x3/4inch)5
6Syntheticgrease(3.0oz)1
Installthegroomer-housingcover.
©2017—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3414-906*A

ProcedureDescriptionQty.Use
BearingAdapter1
Spacer2
Groomer-plateassembly1
Adapterring1
Bolt(1/4x3-3/4inches)2
Starwasher2
Fastenerretainer2
7
Weight1
Installthegroomerontherightsideof
themachine.
Groomer-shaftclamp4
Socket-headscrew(1/4x1-1/4inches)4
8Groomerreel(obtainseparately)1
Installthegroomingreel.
1
PreparingtheMachine
NoPartsRequired
Procedure
1.Parkthemachineonalevelsurface.
2.Engagetheparkingbrake.
3.Shutofftheengineandremovethekeyfrom
theswitch.
2
MovingtheFrontRoller
NoPartsRequired
Procedure
1.Loosenthejamnutsandsetscrewssecuring
eachendofthefrontrollertotheheight-of-cut
arms(Figure1).
g017178
1
2
3
4
5
6
g017178
Figure1
1.Height-of-cutarm4.Height-of-cutadjusting
screw
2.Jamnutandsetscrew5.Height-of-cutbracket
3.Carriagebolt,washer,and
locknut
6.Taper-facebolt(bolthead
ontheothersideofthe
sideplate)
2.Removethecarriageboltsandlocknutssecuring
theheight-of-cutarmstotheadjustingbrackets
(Figure1).
3.Removetheheight-of-cutarmsfromtheside
platesandrollerassembly.
4.Removetheheight-of-cuthardwareasfollows:
•Greensmaster1600mowers—removethe
height-of-cutadjustingscrews,jamnuts,
andsetscrewsfromtheheight-of-cutarms
(Figure1).
•Greensmaster800and1000
mowers—removethe2taper-face
boltssecuringtherightandleftheight-of-cut
bracketstothesideplates(Figure1).Install
theheight-of-cutbracketstotheopposite
2

sidesofthemachinewiththe2taper-face
bolts,usingtherearsetsofmountingholes
inthesideplates.
5.Installtheheight-of-cutarmsasfollows:
•Greensmaster1600mowers—obtain2new
height-of-cutarmsfromyourAuthorizedT oro
Distributorandinstallthemontotheroller
assemblyandsideplateswiththefasteners
removedpreviously(Figure2).
•Greensmaster800and1000mowers—rotate
theheight-of-cutarmsyouremoved
previouslytotheforwardpositionandinstall
themontotherollerassemblyandside
plateswiththefastenersremovedpreviously
(Figure2).
g017179
1
g017179
Figure2
1.Height-of-cutarmintheforwardposition
3
InstallingtheGroomer
Housing
Partsneededforthisprocedure:
1Groomer-housingassembly
2Flat-headscrew(3/8x2inches)
2Locknut(3/8inch)
1Bearingadapter
2Spacer
1O-ring
-Syntheticgrease
1Slotcover
1Adapterring
Procedure
1.Removethe2boltsandlocknutssecuringthe
endcaptotheleft,reel-bearinghousingandthe
sideplate.
2.Removeandretaintheendcapandfasteners
foruseifyoueverremovethegroomer(Figure
3).
1
42
3
G017288
g017288
Figure3
1.Endcap3.Springtensionscrew
2.Bedbar-adjusterframe4.Boltsandwashers
3.IfyouareinstallingthiskitonaGreensmaster
800mowerwithaserialnumberpriorto
230999999,aGreensmaster1000mower
withaserialnumberpriorto229999999,or
3

aGreensmaster1600mowerwithaserial
numberpriorto260001401,completethe
following:
A.Usinga7/8inchstandardwrench,loosen
thespringtensionscrewsontherightand
leftbedbaradjusters(Figure4).
1
2g020979
g020979
Figure4
1.Springtension
screw—loosen
2.Boltsand
washers—remove
B.Backoutthescrewsuntilthethrustwashers
arenolongertensionedagainstthebedbar.
C.Removethe2boltsandwasherssecuring
left,bedbar-adjusterframetothesideplate
(Figure4).
4.Removethe40toothidlergear.
g022023
1
g022023
Figure5
1.40toothidlergear.
5.Removethecurvedwasherandthebolt(3/8x
5/8inch)fromtheadjustment-knobmounting
block(Figure6).
g020842
Figure6
1.Locknut4.Mountingblock7.Bearingadapter10.O-ring
2.Bolt(3/8x5/8inch)5.Adjustmentknobassembly8.Flat-headscrew11.Slotcover(atedge
orienteddown)
3.Curvedwasher6.Spacer9.Groomerhousing12.Adapterring
4

6.InstalltheO-ringintothebackofthegroomer
housing(Figure6andFigure7)andlightly
lubricatetheexposedsurfacesoftheO-ringwith
syntheticgrease(suppliedwiththekit).
g020843
Figure7
1.O-ring
7.Inserttheadapterringintothereelbearing
housing(Figure6andFigure8).
g020844
Figure8
1.Groomerhousing5.Spacer
2.Slotcover6.Flat-headscrew
3.O-ring7.Locknut
4.Adapterring8.Bearingadapter
8.Insertthe2at-headscrews(3/8x2inch)
throughthebearingadapterandpositionthe
spacersontheendsofthescrews(Figure6and
Figure8).
9.Alignthebearingadapter,spacers,andscrews
withthebronzebushingandtheslotsinthe
groomerhousing.
10.Slidethebearingadapterthroughthebronze
bushingandthescrewsthroughtheslotsinthe
groomerhousingassembly(Figure6andFigure
8).
Important:Ensurethatthebearingadapter
isorientedasshowninFigure9.
g020854
Figure9
1.Bearingadapter
11.Placetheslotcoveroverthescrewsandup
againstthelubricatedO-ring(Figure6).
12.Ensurethattheatedgeoftheslotcoveris
orientedatthebottom.
13.Inserttheat-headscrewsthroughthe
reel-bearinghousingandsecurethemwith
locknuts.
14.Torquethelocknutsto31to37N∙m(23to27
ft-lb)(Figure6andFigure8).
Note:T ogainaccesstothelocknutsyoumay
needtomoveorremovethebedbar.
15.Mounttheadjustmentknobmountingblockto
theleftsideplatewiththebolt(3/8x5/8inch)
andcurvedwasheryouremovedpreviously
(Figure6).
16.IfyouareinstallingthiskitonaGreensmaster
800mowerwithaserialnumberpriorto
230999999,aGreensmaster1000mower
withaserialnumberpriorto229999999,or
aGreensmaster1600mowerwithaserial
numberpriorto260001401,installtheleft,
bedbar-adjusterframetothesideplatewith
theboltsandwashersyouremovedpreviously
(Figure4).
5

4
InstallingtheDriveGear
Partsneededforthisprocedure:
1Shaftassembly
1Drivegear
–Syntheticgrease
Procedure
1.Removethereel-bearinglocknutfromthereel
shaft(Figure10).
Note:Thereel-bearinglocknuthas
right-handedthreads.
g022029
g022029
Figure10
1.Reel-bearinglocknut
2.Securethereelfromturningwithawoodblock.
3.Threadtheshaftassemblyontothereel-shaft
extension(Figure11).
4
1
2
3
g022024
g022024
Figure11
1.Shaftassembly3.Groove
2.Drivegear4.40toothidlergear
4.Securethereelfromturningwithawoodblock
andtorquetheshaftassemblyto54to81N∙m
(40to60ft-lb).
5.Applysyntheticgrease(suppliedwiththekit)to
themalesplineoftheshaftassembly(Figure
11).
6.Slidethedrivegearwiththegrooveoriented
outwardontotheshaftassembly(Figure11).
7.Installthe40toothidlergear(Figure11).
5
SettingtheGroomerfor
ForwardRotation(Optional)
Partsneededforthisprocedure:
1ForwardRotationKit-obtainseparately
Procedure
Thegroomercomesdesignedtorotateintheopposite
directionofthereel.Optionally,youcansetittorotate
inthesamedirectionasthereelbyobtainingthe
ForwardRotationKitusingthefollowingprocedure:
1.Removethe2socket-headboltsandlocknuts
fromthecover(Figure12).
g020880
Figure12
1.Socket-headbolts—keep
one
2.Locknuts—discard
2.Keeponeoftheboltsanddiscardtherestofthe
fasteners.
3.Removethecentergearassembly,savingthe
gearanddiscardingthebushingandbolt(Figure
13).
6

g020881
Figure13
1.Bushing—discard3.Bolt—discard
2.Centergear—keep
4.Installthesocket-headboltyouremovedfrom
thecoverintotheholewherethecentergear
wasinstalled(Figure14).
g020882
Figure14
1.Socket-headboltpreviouslyremovedfromthecover
5.Presstthecentergearremovedpreviously
ontothehub(Figure15).
Important:Supporttheinnerraceofthe
gearbearingwhilepressingitontothehub.
g020883
Figure15
1.Gearassembly—fromthe
forwardrotationkit
3.Gearhub—fromthe
forwardrotationkit
2.Flange-headbolt—from
theforwardrotationkit
4.Centergearassembly
6.Installthecentergearandhubassemblyand
thegearassembly,fromtheforwardrotationkit,
tothecoverwith2ange-headboltsasshown
inFigure15.
6
Installingthe
Groomer-HousingCover
Partsneededforthisprocedure:
1Groomer-housingcoverassembly
1Gasket
5Flange-headbolt(1/4x3/4inch)
1Syntheticgrease(3.0oz)
Procedure
1.Coattheteethofthegearswiththesynthetic
greasesuppliedwiththekit.Usetheremaining
greasetollintheareaaroundthegears.
2.Placethegasketoverthedowelpinsonthe
groomerhousing(Figure16).
7

g020848
Figure16
1.Actuatorpininthegroove
onthedrivegear
3.Flange-headbolt
2.Clutchassembly4.Gasket
3.Installthecoverontothegroomerhousing,
insertingtheactuatorpinoftheclutchassembly
intothegrooveofthedrivegear(Figure16).
4.Securethecoverwith5ange-headbolts
(Figure16)andtorquethemto9.6to10.5N∙m
(85to95in-lb).
7
InstallingtheGroomer
ontheRightSideofthe
Machine
Partsneededforthisprocedure:
1BearingAdapter
2Spacer
1Groomer-plateassembly
1Adapterring
2Bolt(1/4x3-3/4inches)
2Starwasher
2Fastenerretainer
1Weight
Procedure
1.Removethe4boltssecuringthereel-drive-belt
covertotheright,sideplateandremovethe
cover(Figure17).
g017184
1
g017184
Figure17
1.Reel-drive-beltcover
2.Loosentheidlerpulleytorelievethebelttension
andremovethereel-drivebeltfromthepulleys
(Figure18).
8

g017185
1
2
34
g017185
Figure18
1.Reeldrivebelt3.Drivepulley
2.Idlerpulley4.Flat-headscrew
3.Usinga1/2inchdriveratchetandextension,
removethedrivepulleyfromthereelshaft
(Figure18).
Note:Thedrivepulleyhasright-handthreads.
4.Securethereelfromturningwithawoodblock.
5.Removethe2at-headscrewsandnuts
securingthegroomerarmcovertothebearing
housingandsideplate(Figure18).
6.Removethegroomerarmcover(Figure19);
retaintheat-headscrewsanddiscardthe
spacersunderthecover.
7.IfyouareinstallingthiskitonaGreensmaster
800mowerwithaserialnumberpriorto
230999999,aGreensmaster1000mower
withaserialnumberpriorto229999999,or
aGreensmaster1600mowerwithaserial
numberpriorto260001401,removethe2bolts
andwasherssecuringtherightbedbaradjuster
frametothesideplate.
8.Removethecurvedwasherandthebolt(3/8x
5/8inch)fromtheadjustment-knob,mounting
block(Figure19).
9.Insertanadapterringintothereel-bearing
housing(Figure19).
g020847
Figure19
1.Flat-headscrew4.Spacer7.Bolt
2.Groomerarmcover5.Adjustment-knob,mountingblock8.Adapterring
3.Bearingadapter6.Curvedwasher9.Groomer-plateassembly
10.Insertthe2at-headscrews(3/8x2inch)
throughthegroomerarmcoverandthebearing
adapterandputaspacerovereachscrew
(Figure19).
11.Installthegroomerarmcover,bearingadapter,
spacers,andgroomer-plateassemblyto
thereel-bearinghousing,slidingtheadapter
throughthebronzebushinginthegroomerplate
assemblyandintothereelbearinghousing
(Figure19).
12.Installthelocknutsontheat-headscrewsand
torquethemto31to37N∙m(23to27ft-lb).
13.Securethemountingblockofthegroomer
adjustmentknobassemblytotherightsideplate
withthebolt(3/8x5/8inch)andcurvedwasher
removedpreviously(Figure19).
9

14.IfyouareinstallingthiskitonaGreensmaster
800mowerwithaserialnumberpriorto
230999999,aGreensmaster1000mower
withaserialnumberpriorto229999999,or
aGreensmaster1600mowerwithaserial
numberpriorto260001401,installtheright,
bedbar-adjusterframetothesideplatewiththe
boltsandwashersyouremovedpreviously.
15.Usinga1/2inchdriveratchetandextension,
installthedrivepulley(right-handthreads)tothe
reelshaft(Figure20).
g017188
1
2
3
4
g017188
Figure20
1.Drivepulley3.Quick-uplever
2.Idlerpulley4.Microadjustmentknob
16.Securethereelfromturningwithawoodblock.
17.Torquethepulleyto54to81N∙m(40to60ft-lb).
18.Installreeldrivebeltandcheckthebelttension
bypressingthebeltatthemidspanofthe
pulleyswith1.5to2.5kg(3to5lb)offorce.
Thebeltshoulddeect6mm(1/4inch).
Repositiontheidlerpulleytoadjustthebelt
tension.Tightenthescrewsonceyouachieve
thepropertension.
19.Installthereel-drive-beltcovertothesideplate
asfollows:
•Greensmaster800mowers—installthereel
drivecovertothesideplatewiththe4bolts
youremovedpreviously.
•Greensmaster1000/1600mowers—install
thecoverusingtheupperandlowerbolts
removedpreviouslyandtheweightandnew
fastenersasshowninFigure21.Usethe
fastenerretainersasrequiredbyyourlocal
codes.
g020853
Figure21
1.Bolt3.Weight
2.Starwasher4.Fastenerretainer
8
InstallingtheGrooming
Reel
Partsneededforthisprocedure:
4Groomer-shaftclamp
4Socket-headscrew(1/4x1-1/4inches)
1Groomerreel(obtainseparately)
Procedure
1.Obtainagroomerreelappropriateforyour
needsandcuttingunit;refertothefollowing
tableforalistofgroomerreels:
ModelNumberGroomer
0428018inchgroomer,springsteel
0428118inchgroomer,carbide
0428218inchgroomer,brush
0428321inchgroomer,springsteel
0428421inchgroomer,carbide
0428521inchgroomer,brush
0428626inchgroomer,springsteel
0428726inchgroomer,carbide
0428826inchgroomer,brush
0426818inchsoftgroomingbrush
0426918inchstiffgroomingbrush
0427021inchsoftgroomingbrush
0427121inchstiffgroomingbrush
0427626inchstiffgroomingbrush
10