Toro 04060 Greensmaster 1600 User manual

Operator’s Manual
English (EN, GB)
Form No. 3350–250 Rev. A
Greensmaster800, 1000 and 1600
Greensmaster Mower
Model No. 04048—Serial No. 240000001 and Up
Model No. 04052—Serial No. 240000001 and Up
Model No. 04060—Serial No. 240000001 and Up

2
All Rights Reserved
Printed in the USA
2003 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Contents
Page
Contents 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .
Toro Mower Safety 4. . . . . . . . . . . . . . . . . . . . . . . .
Sound Pressure Level
All Models 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound Power Level
Models 04052 and 04060 5. . . . . . . . . . . . . . . . . .
Sound Power Level
Model 04048 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vibration Level
Models 04048 and 04052 5. . . . . . . . . . . . . . . . . .
Vibration Level
Model 04060 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 6. . . . . . . . . . . . . . . . .
Specifications 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 8. . . . . . . . . . . . . . . . . . . . .
Optional Equipment 9. . . . . . . . . . . . . . . . . . . . . . . .
Setup 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing and Adjusting the Handle 11. . . . . . . . . . . .
Installing the Kick Stand
Model 04060 only 11. . . . . . . . . . . . . . . . . . . . . . . .
Installing the Transport Wheels 12. . . . . . . . . . . . . . .
Before Operating 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adding Engine Oil 12. . . . . . . . . . . . . . . . . . . . . . . . .
Filling the Fuel Tank 13. . . . . . . . . . . . . . . . . . . . . . .
Leveling the Rear Drum to the Reel 14. . . . . . . . . . .
Adjusting the Bedknife to the Reel 15. . . . . . . . . . . .
Adjusting the Height-of-Cut 16. . . . . . . . . . . . . . . . .
Adjusting the Grass Shield Height 17. . . . . . . . . . . . .
Adjusting the Cut-off Bar 17. . . . . . . . . . . . . . . . . . . .
Installing the Grass Basket 17. . . . . . . . . . . . . . . . . . .
Checking the Operation of the Interlock Switch 17. .
Operation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Engine 19. . . . . . . . . . . . . . . . . . . . . . . . .
Stopping the Engine 19. . . . . . . . . . . . . . . . . . . . . . . .
Driving the Machine in Transport 19. . . . . . . . . . . . .
Preparing to Mow 20. . . . . . . . . . . . . . . . . . . . . . . . . .
Mowing Tips 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mowing 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 21. . . . . . . . .
Daily Maintenance Checklist 22. . . . . . . . . . . . . . . . .
Greasing the Machine 23. . . . . . . . . . . . . . . . . . . . . .
Checking and Changing Engine Oil 24. . . . . . . . . . . .
Servicing the Air Cleaner 24. . . . . . . . . . . . . . . . . . . .
Replacing the Spark Plug 25. . . . . . . . . . . . . . . . . . . .
Cleaning the Fuel Filter 25. . . . . . . . . . . . . . . . . . . . .
Adjusting Belts 26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Differential Belt 28. . . . . . . . . . . . . . .
Adjusting the Traction Control 29. . . . . . . . . . . . . . .
Adjusting the Service/Park Brake 29. . . . . . . . . . . . .
Adjusting the Interlock Switch 30. . . . . . . . . . . . . . .
Servicing the Bedbar
Greensmaster 800 & 1600 only 30. . . . . . . . . . . . . .
Servicing the Bedbar
Greensmaster 1000 only 30. . . . . . . . . . . . . . . . . . .
Backlapping the Reel 31. . . . . . . . . . . . . . . . . . . . . . .
The Toro General Commercial Products Warranty 32. . .
Introduction
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready. The model and serial
numbers are located on a plate on the rear frame.
Write the product model and serial numbers in the space
below:
Model No.
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
This manual uses two other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information
worthy of special attention.

3
Safety
This machine meets or exceeds CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI
B71.4-1999 specifications in effect at the time of
production when the Operator Presence Kit, Part No.
105–5363 is installed.
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert symbol, which means
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
Safe Operating Practices
The following instructions are from the CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI B71.4-1999.
Training
•Read the Operator’s Manual and other training material
carefully. Be familiar with the controls, safety signs,
and the proper use of the equipment.
•Never allow children or people unfamiliar with these
instructions to use or service the mower. Local
regulations may restrict the age of the operator.
•Never mow while people, especially children, or pets
are nearby.
•Keep in mind that the operator or user is responsible for
accidents or hazards occurring to other people or their
property.
•The owner/user can prevent and is responsible for
accidents or injuries occurring to himself or herself,
other people, or property.
Preparation
•While mowing, always wear substantial footwear, long
trousers, hard hat, safety glasses, and ear protection.
Long hair, loose clothing, or jewelry may get tangled in
moving parts. Do not operate the equipment when
barefoot or wearing open sandals.
•Thoroughly inspect the area where the equipment is to
be used and remove all objects which may be thrown by
the machine.
•Warning—Fuel is highly flammable. Take the
following precautions:
– Store fuel in containers specifically designed for this
purpose.
– Refuel outdoors only and do not smoke while
refuelling.
– Add fuel before starting the engine. Never remove
the cap of the fuel tank or add fuel while the engine
is running or when the engine is hot.
– If fuel is spilled, do not attempt to start the engine
but move the machine away from the area of
spillage and avoid creating any source of ignition
until fuel vapors have dissipated.
– Replace all fuel tanks and container caps securely.
•Replace faulty silencers.
•Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Only use accessories and attachments approved
by the manufacturer.
•Check that operator’s presence controls, safety switches
and shields are attached and functioning properly. Do
not operate unless they are functioning properly.
Operation
•Do not operate the engine in a confined space where
dangerous carbon monoxide fumes can collect.
•Mow only in daylight or in good artificial light.
•Before attempting to start the engine, disengage all
blade attachment clutches, shift into neutral, and engage
the parking brake.
•Do not use on slopes of more than 15°.
•Remember there is no such thing as a safe slope. Travel
on grass slopes requires particular care. To guard
against overturning:
– do not stop or start suddenly when going up or
downhill;
– engage clutch slowly, always keep machine in gear,
especially when travelling downhill;
– machine speeds should be kept low on slopes and
during tight turns;
– stay alert for humps and hollows and other hidden
hazards;
– never mow across the face of the slope, unless the
mower is designed for this purpose.
•Stay alert for holes in the terrain and other hidden
hazards.
•Watch out for traffic when crossing or near roadways.
•Stop the blades rotating before crossing surfaces other
than grass.
•When using any attachments, never direct discharge of
material toward bystanders nor allow anyone near the
machine while in operation.

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

5
•Wearing safety shoes and long pants is advisable and
required by some local ordinances and insurance
regulations.
•Handle gasoline carefully. Wipe up any spills.
•Check the safety interlock switches daily for proper
operation. If a switch should fail, replace the switch
before operating the machine. After every two years,
replace all four interlock switches in the safety system,
regardless if they are working properly or not.
•Using the machine demands attention. To prevent loss
of control:
– Do not drive close to sand traps, ditches, creeks, or
other hazards.
– Reduce speed when making sharp turns. Avoid
sudden stops and starts.
– When near or crossing roads, always yield the
right-of-way.
– Apply the service brakes when going downhill to
keep forward speed slow and to maintain control of
the machine.
•The grass basket must be in place during operation of
the reels or thatchers for maximum safety. Shut the
engine off before emptying the baskets.
•Do not touch the engine, muffler, or exhaust pipe while
the engine is running or soon after it has stopped
because these areas could be hot enough to cause burns.
•Stay clear of the rotating screen at the side of the engine
to prevent direct contact with your body or clothing.
•When a person or pet appears unexpectedly in or near
the mowing area, stop mowing. Careless operation,
combined with terrain angles, ricochets, or improperly
positioned guards can lead to thrown object injuries. Do
not resume mowing until the area is cleared.
Maintenance and Storage
•Check all fuel lines for tightness and wear on a regular
basis. Tighten or repair them as needed.
•If the engine must be running to perform a maintenance
adjustment, keep hands, feet, clothing, and any parts of
the body away from the cutting unit, attachments, and
any moving parts, especially the screen at the side of the
engine. Keep everyone away.
•To ensure safety and accuracy, have an Authorized Toro
Distributor check the maximum engine speed with a
tachometer. Maximum governed engine speed should be
3600 RPM.
•If major repairs are ever needed or if assistance is
desired, contact an Authorized Toro Distributor.
•Use only Toro-approved attachments and replacement
parts. The warranty may be voided if used with
unapproved attachments.
Sound Pressure Level
All Models
This unit has an equivalent continuous A-weighted sound
pressure at the operator ear of: 84 dB(A), based on
measurements of identical machines per procedures
outlined in Directive 98/37/EC and amendments.
Sound Power Level
Models 04052 and 04060
This unit has a guaranteed sound power level of: 95 dBA/1
pW, based on measurements of identical machines per
Directive 2000/14/EC and amendments.
Sound Power Level
Model 04048
This unit has a guaranteed sound power level of:
96 dBA/1 pW, based on measurements of identical
machines per Directive 2000/14/EC and amendments.
Vibration Level
Models 04048 and 04052
This unit has a hand–arm vibration level of 7.00 m/s2, based
on measurements of identical machines per ISO 5349
procedures.
Vibration Level
Model 04060
This unit has a hand–arm vibration level of 4.50 m/s2, based
on measurements of identical machines per ISO 5349
procedures.

6
Safety and Instruction Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger. Replace any decal that is damaged or lost.
105–5359 (Model 04048)
105–5360 (Model 04052)
105–5361 (Model 04060)
1. Disengage
2. Engage 3. Parking brake 4. Engage—forward 5. Disengage—neutral 6. Clutch
93-7273
1. Thrown object
hazard—Keep bystanders
away
2. Cutting hazard, hand and
foot—Stay away from
moving parts
93-9356
1. Entanglement hazard—Stay away from moving parts.

7
105-5309
1. Hot surface/burn hazard—stay a safe distance from the hot
surface.
93-7348
1. Warning—Read the
Operator’s Manual
2. Fire hazard—No open
flames or sparks and fill
the tank only to the level
shown
3. Thrown object
hazard—Keep bystanders
away
4. Cutting hazard, hand and
foot—Stay away from
moving parts
93-7346
1. Reel drive
2. Engage 3. Disengage
93-6085
1. Fast
2. Increasing/decreasing
scale.
3. Slow
93-8064
1. Warning—Read the
Operator’s Manual before
servicing
2. Cutting Hazard, hand and
foot—Stop the engine and
wait for moving parts to
stop
93-9886
1. Use only unleaded gasoline

8
Specifications
General Specifications
Engine Kawasaki, air cooled, overhead valve, 4 cycle, 3.7 horsepower, 2.36 x 1.73 bore
and stroke, 7.57 cu. in. (124 cc) displacement, 8.4:1 compression ratio, 11 ft.-lb.
(15 N⋅m) @ 1400 rpm. Electronic ignition, maximum noise suppression muffler.
2.64 quart (2.5 l) fuel tank capacity.
Traction Drive Engine to countershaft drive: two “A” section V-belts. Countershaft to differential
drive: 5 mm pitch timing belt. Differential to drum drive: 8 mm pitch timing belt.
Differential Peerless Series 100
Transport Clutch Belt idler
Brake Band drum
Transport Tires Quick detachable, 3.00/3.25 x 6, 32.5 tread width
Traction Drum Dual cast aluminum, 7.5 in. (19 cm) dia.
Controls Engine has recoil starter, On/Off switch and choke. Handle has throttle lever,
traction engage lever and service/ park brake lever. Mower has reel drive engage
lever. Safety devices: neutral interlock system.
Handle Loop style, 1 in. (2.5 cm) dia.
Reel Construction 5 in. (12.7 cm) dia., 8 carbon steel blades welded to 6 stamped steel spiders
Bedknife and Bedbar Single edged high carbon steel bedknife, hardened to Rc 48-54. Fastened to
machined, cast iron bedbar. 1/8 in. (0.3 cm) bedknife, standard
Height-of-Cut Range 1/8 to 1-1/4 in. (0.3 to 3.2 cm)
Reel Clutch Jaw type
Grass Basket Molded polyethylene
Model 04048 Model 04052 Model 04060
Clip .16 in. (.4 cm) .16 in. (.4 cm) .23 in. (58.4 cm)
Width of Cut 18 in. (46 cm) 21 in. (53 cm) 26 in. (66 cm)
Total Width 33 in. (84 cm) 36 in. (91 cm) 41 in. (104 cm)
Total Height 41-1/2 in. (105.4 cm) 47 in. (119 cm) 41-1/2 in. (105.4 cm)
Total Length 54-1/4 in. (137.8 cm) 59 in. (150 cm) 54-1/4 in. (137.8 cm)
Dry Weight 200 lb. (91 kg.) 1208 lb. (94 kg.) 1229 lb. (104 kg) 1
1With basket and Wiehle roller, without wheels or grooming reel

9
Optional Equipment
Model 04048 Model 04052 Model 04060
Light Kit Model No. 04058 Model No. 04058 Model No. 04058
Wheel Kit Model No. 04122 Model No. 04122 Model No. 04122
Height of Cut Bar Part No. 94–9010 Part No. 94–9010 Part No. 94–9010
Operator Presence Kit Part No. 105–5363 Part No. 105–5363 Part No. 105–5363
Clip Kit Part No. 65-9000 Part No. 65-9000 Part No. 65-9000
High Altitude Jet for
altitudes of 3000 to 6000 ft.
(900 to 1800 m)
Part No. 98-8735 Part No. 98-8735 Part No. 98-8735
High Altitude Jet for
altitudes above 6000 ft.
(1800 m)
Part No. 98-8736 Part No. 98-8736 Part No. 98-8736
Spark Arrester Part No. 98–3426 Part No. 98–3426 Part No. 98–3426
Grooming Reel Kit Model No. 04108 Model No. 04125 Model No. 04110
Micro–cut Bedknife Part No. 98–7261 Part No. 93–4262 Part No. 94–5885
Full Roller Part No. 104–2640 Part No. 104–2642 Part No. 95–0930
Wiehle Roller
(.43 spacing) Part No. 98–7264 Part No. 88–6790
Swaged Roller Part No. 52–3590
Auxiliary Roller KIt Part No. 65–8560 Part No. 65–8560
Wiehle Roller Scraper
(.43 spacing) Part No. 98–5920–01 Part No. 65–8340–01 Part No. 94–9012–01
Dethatching Reel Kit Model No. 04111
Scraper Comb Part No. 11–0070
Scraper Brush Part No. 33–1000
Wiehle Roller (Cast Iron) Part No. 71–1550
Groomer Brush Assembly Part No. 105–9640
1/8” Bedknife Part No. 93–4264
Extended 2.5” Dia. Wiehle
Roller Part No. 93-9045
Full Roller Scraper Part No. 98–7257–01 Part No. 65–8360–01
Wiehle Roller Scraper
(.20 spacing) Part No. 99–6239–01 Part No. 104–0509–01
High Penetration Bedbar Part No. 98–5907–03 Part No. 92–9204–03
Extended Height of Cut Arm Part No. 99–4286
Hour Meter Kit Part No. 105–5350 Part No. 105–5350 Part No. 105–5350
Out Front Broom Part No. 105–9600 Part No. 105–9600

10
Setup
Note: Determine the left and right sides of the machine from the normal operating position.
Loose Parts
Note: Use this chart as a checklist to ensure all parts necessary for assembly have been shipped. If any of these parts are
missing, total set–up cannot be completed.
Description Qty. Use
Handle assembly
Cable tie 1 2Install the handle on the machine Secure the control cables to the handle
Wheel Shaft, right hand
Wheel Shaft, left hand 1 1Use when installing optional transport wheels
Spring 1 Mount kickstand, Model 04060 only
Grass basket 1Install on the machine
Operator’s Manual 1Read before operating
Engine Owner’s Manual 1Read before operating
Part’s Catalog 1Use for ordering parts
Registration card 1Fill out and return to Toro
Operator video 1View before operating
Certificate of Compliance 1

11
Installing and Adjusting the
Handle
Installing the Handle
2. Remove the capscrew, washer, and lockwasher from the
mounting pin on each side of the mower, as shown in
Fig. 1.
1
4
2
3
Figure 1
1. Mounting pins
2. Handle arms 3. Capscrew and locknut 4. Hairpin cotter and ring pin
3. Remove the capscrews and locknuts securing the
bottom of the handle arms to each side of the mower, as
shown in Figure 1.
4. Remove the hairpin cotters and ring pins securing the
handle arms to the rear of the frame (Fig. 1).
5. Insert the handle ends thru the holes in the handle arms
and align the holes with the mounting pins (Fig. 1).
6. Squeeze the handle ends inward and install them on the
mounting pins (Fig. 2).
1
Figure 2
1. Handle end
7. Secure the handle ends to the mounting pins with the
capscrews, washers, and lockwashers previously
removed (Fig. 2).
8. Secure the bottom of handle arms to each side of the
mower with the capscrews and locknuts previously
removed (Fig. 2). Ensure that you install the bushings in
the handle arm mounting holes.
Important Do not overtighten the capscrews. The
handle arms must pivot freely.
9. Secure the handle arms to the rear of the frame with the
hairpin cotters and ring pins previously removed
(Fig. 2).
10.Secure the cables to the handle with cable ties.
Adjusting the Handle
1. Remove the hairpin cotters from the ring pins on each
side of the mower (FIg. 1).
2. While supporting the handle, remove the ring pins from
each side and raise or lower the handle to the desired
operating position. (Fig. 1).
3. Install the ring pins and hairpin cotters.
Installing the Kick Stand
Model 04060 only
Note: Fasteners shipped loosely on kick stand.
1. Hook spring into hole in spring bracket and onto spring
retainer while aligning kick stand with mounting holes
in rear frame (Fig. 3).
1
2
4
3
Figure 3
1. Kick stand
2. Spring bracket 3. Spring retainer 4. Spring
2. Mount kick stand to each side of frame with a capscrew,
lockwasher, spacer flat washer and lock nut (Fig. 3).
Spacer to be positioned in kick stand mounting hole.

12
Installing the Transport Wheels
1. Push the kick stand down with your foot and pull up on
the handle to support the mower on the kick stand.
2. Apply #242 Loctite to the threads of the wheel shafts.
3. Thread the right hand wheel shaft into the drive pulley
on the right side of the machine (Fig. 4).
1
Figure 4
1. Right hand wheel shaft
4. Torque the shaft to 65 to 75 ft-lb. (88 to 101 N⋅m)
Note: The right hand wheel shaft has left hand threads.
5. Apply Never–Seez to the exposed ends of the axles and
slide the wheel onto the axle (Fig. 5).
6. Pivot the wheel locking clip away from center of the
wheel allowing it to slide farther onto the axle (Fig. 5).
7. Rotate the wheel back and forth until it slides
completely onto the axle and the locking clip is secured
in the groove on the axle shaft.
1
Figure 5
1. Locking clip
8. Repeat the procedure on the opposite side of the
machine.
9. Inflate the tires to 12 to 15 psi. (574 to 718 Pa).
Before Operating
Adding Engine Oil
Fill the crankcase with approximately 20 oz. (0.6 l) of
proper viscosity oil before staring. The engine uses any
high-quality oil having the American Petroleum Institute —
APl—service classification SC, SD, SE, SF, SG, or SH. Oil
viscosity (weight) must be selected according to the
ambient temperature. Figure 6 illustrates the temperature/
viscosity recommendations.
SAE 5W20
–4F14F32F50F68F86F 104F
SAE 10W30/ SAE 10W–40
SAE 30
SAE 40
–20C –10C0C10C20C30C40C
Figure 6
Note: Using multi grade oils (5W–20, 10W–30 and
10W–40) will increase oil consumption. Check the oil level
more frequently when using multi grade oils.
1. Position the mower so the engine is level (Fig. 7).
1
Figure 7
1. Oil level gauge
2. Clean around the oil level gauge.
3. Remove the gauge by rotating it counterclockwise.

13
4. Wipe the gauge clean and insert it into the filler port,
without threading it into the port.
5. Remove the gauge and check the oil level.
6. If level is low, add only enough oil to raise level to filler
opening.
Note: Check the oil 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
required in dusty or dirty conditions.
Filling the Fuel Tank
Important Never use methanol, gasoline containing
methanol, gasoline containing more than 10% ethanol,
gasoline additives, premium gasoline, or white gas because
engine fuel system damage could result.
1. Clean around the fuel tank cap and remove the cap from
the tank (Fig. 8).
1
Figure 8
1. Fuel tank cap
2. Using unleaded gasoline, fill the fuel tank no higher
than to bottom of the filter screen. Do not over fill the
tank.
3. Install the fuel tank cap and wipe up any spilled
gasoline.
Danger
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and others
and can damage property.
•Fill the fuel tank outdoors, in an open area,
when the engine is cold. Wipe up any gasoline
that spills.
•Do not fill the fuel tank completely full. Add
gasoline to the fuel tank until the level is 1 in.
(25 mm) below the bottom of the filler neck.
This empty space in the tank allows gasoline to
expand.
•Never smoke when handling gasoline, and stay
away from an open flame or where gasoline
fumes may be ignited by a spark.
•Store gasoline in an approved container and
keep it out of the reach of children. Never buy
more than a 30-day supply of gasoline.
•Always place gasoline containers on the ground
away from your vehicle before filling.
•Do not fill gasoline containers inside a vehicle or
on a truck or trailer bed because interior
carpets or plastic truck bed liners may insulate
the container and slow the loss of any static
charge.
•When practical, remove gas-powered equipment
from the truck or trailer and refuel the
equipment with its wheels on the ground.
•If this is not possible, then refuel such
equipment on a truck or trailer from a portable
container, rather than from a gasoline dispenser
nozzle.
•If a gasoline dispenser nozzle must be used, keep
the nozzle in contact with the rim of the fuel
tank or container opening at all times until
fueling is complete.

14
Leveling the Rear Drum to the
Reel
1. Position the machine on a flat, level surface, preferably
a precision steel work plate.
2. Place a 1/4 x 1 in. (0.6 x 2.5 cm) flat steel strip, approx.
29 in. (73.6 cm) long, under the reel blades and against
the front edge of the bedknife to prevent the bedbar
from resting on the work surface.
3. Raise the front roller so only the rear drum and reel are
on the surface.
4. Firmly press down on the machine above the reel so all
reel blades contact the steel strip.
5. While pressing down on the reel, slide a feeler gauge
under one end of the drum, then check the other end of
the drum.
If there is a gap between the drum and the work surface,
greater than 0.010 in., on either end, adjust the drum
(proceed to step 6). If the gap is less than 0.010 in. no
adjustment is required.
6. Remove the rear belt cover from the right side of the
machine (Fig. 9).
1
Figure 9
1. Traction drive belt cover
7. Rotate the drive pulley until the holes align with the 4
roller bearing flange screws (Fig. 10).
8. Loosen the 4 roller bearing screws and the screw
securing the idler pulley.
9. Raise or lower the right side of the roller assembly until
the gap is less than 0.010 in.
10.Tighten the roller bearing screws.
11. Adjust the belt tension and tighten the idler pulley
mounting screw (Fig. 10).
1
3
2
Figure 10
1. Drive pulley
2. 4 holes 3. Idler pulley

15
Adjusting the Bedknife to the
Reel
The bedknife to reel adjustment is accomplished by
loosening or tightening the bedbar adjusting screws, located
on top of the mower.
1. Position the machine on a flat, level work surface.
2. Ensure that the reel contact is removed by turning the
bedbar adjusting screws counterclockwise
(Fig. 11 or 12).
1
Figure 11
1. Bedbar adjusting screw (Greensmaster 800 & 1600)
1
Figure 12
1. Bedbar adjusting screw (Greensmaster 1000)
3. Tilt the mower back on the handle to expose the
bedknife and reel.
4. On one end of the front side of the reel, insert a long
strip of newspaper between the reel and bedknife
(Fig. 13). While slowly rotating the reel forward, turn
the bedbar adjusting screw clockwise (on the same end
of reel, one click at a time, until the paper is pinched
lightly, when inserted from the front, parallel to the
bedknife, which results in a slight drag when paper is
pulled (Fig. 11 or 12).
Figure 13
Note: Each time the adjusting screw is rotated one click
clockwise, the bedknife moves 0.0007 in. (0.0017 cm)
closer to the reel. Do not overtighten the adjusting screws.
5. Check for light contact at the other end of the reel using
paper and adjust it as required.
6. After the adjustment is accomplished, check to see if
the reel can pinch paper when inserted from the front
and cut paper when inserted at a right angle to the
bedknife (Fig. 13). It should be possible to cut paper
with minimum contact between the bedknife and the
reel blades. Should excessive reel drag be evident (more
than 7 in.-lb. (0.79 N⋅m)), either backlap or grind the
cutting unit to achieve the sharp edges needed for
precision cutting; refer to the Toro reel sharpening
manual.

16
Adjusting the Height-of-Cut
1. Verify that the rear roller is level and that the bedknife
to reel contact is correct. Tip the mower back on the
handle to expose the front and rear rollers and the
bedknife.
2. Loosen the locknuts securing the height-of-cut arms to
the height-of-cut brackets (Fig. 14).
1
4
2
3
Figure 14
1. Height-of-cut arm
2. Height-of-cut bracket 3. Locknut 4. Adjusting screw
3. Loosen the nut on the gauge bar (Fig. 15) and set the
adjusting screw to the desired height-of-cut. The
distance between the bottom of the screw head and the
face of the bar is the height-of-cut.
1
2
3
Figure 15
1. Gauge bar
2. Height adjusting screw 3. Nut
4. Hook the screw head on the cutting edge of the
bedknife and rest the rear end of the bar on the rear
roller (Fig. 16).
Figure 16
5. Rotate the adjusting screw until the roller contacts the
front of the gauge bar.
6. Adjust both ends of the roller until the entire roller is
parallel to the bedknife.
Important When set properly, the rear and front rollers
will contact the gauge bar and the screw will be snug
against the bedknife. This ensures the height-of-cut is
identical at both ends of the bedknife.
7. Tighten nuts to lock the adjustment.
Important To avoid scalping on undulating turf, ensure
that the roller supports are positioned rearward (the roller
closer to the reel).
Note: The front roller can be put in three different positions
(Fig. 17), depending on the application and needs of the
user.
•Use the front position when a groomer is installed.
•Use the middle position without a groomer.
•Use the third position in extremely undulating turf
conditions.
Figure 17

17
Adjusting the Grass Shield
Height
Adjust the shield to ensure proper grass clipping discharge
into the basket.
1. Measure the distance from top of the front support rod
to the front lip of the shield at each end of the cutting
unit (Fig. 18).
1
4” (10cm)
2
Figure 18
1. Support rod 2. Shield
2. The height of the shield from the support rod for normal
cutting conditions should be 4 in. (10 cm). Loosen the
capscrews and nuts securing each end of the shield to
the sideplate and adjust the shield to the correct height.
3. Tighten the fasteners.
Note: The shield can be lowered for drier conditions
(clippings fly over top of basket) or raised to allow for
heavy wet grass conditions (clippings build up on rear of
basket).
Adjusting the Cut-off Bar
Adjust the cut-off bar to ensure that the clippings are
cleanly discharged from the reel area.
1. Loosen the screws securing the top bar (Fig. 19) to the
cutting unit.
1
Figure 19
1. Cut-off bar
2. Insert a 0.060 in. feeler gauge between the top of the
reel and the bar and tighten the screws.
3. Ensure that the bar and reel are equal distance apart
across the entire reel.
Note: The bar is adjustable to compensate for changes in
turf conditions. Adjust the bar closer to the reel when the
turf is extremely wet. By contrast, adjust the bar further
away from the reel when turf conditions are dry. The bar
should be parallel to the reel to ensure optimum
performance. Adjust the bar whenever the shield height is
adjusted or when the reel is sharpened on a reel grinder.
Installing the Grass Basket
Grasp the basket by the top lip and slide it onto the basket
mounting rods (Fig. 20).
2
1
Figure 20
1. Grass basket 2. Basket mounting rod
Note: Model 04060 only – When cutting in higher
heights-of-cut, the basket may be lowered by removing
each basket mounting rod and installing each on the
opposite side of the machine.
Checking the Operation of the
Interlock Switch
1. Place the traction lever into the Engage position and the
engine controls in the starting position.
2. Attempt to start the engine.
The engine should not start. If the engine starts, the
interlock switch needs service. Correct the problem
before operating; refer to Adjusting the Interlock
Switch, page 30.

18
Operation
Note: Determine the left and right sides of the machine
from the normal operating position.
Controls
Throttle Control (Fig. 21)
Located on the rear right side of the control panel. The
lever connects to and operates the throttle linkage to the
carburetor. The engine speed can be varied from 1600 to
3600 RPM.
Traction Drive Lever (Fig. 21)
Located on the front right side of the control panel. The
lever has two positions: Neutral and Forward. Pushing the
lever forward engages the traction drive.
2
1
4
3
Figure 21
1. Throttle control
2. Traction drive lever
3. Service/parking brake
4. Operator presence control
(optional)
Service/Park Brake (Fig. 21)
Located on the left front side of the control panel. The
brake can be used to slow or stop the machine. The brake
can also be used as a parking brake. Pulling the lever back
over center will set the parking brake. The brake must be
released before the traction drive is engaged.
Operator Presence Control (Optional)
(Fig. 21)
Located on the rear of the handle. Push the operator
presence control against the handle. The operator presence
control must be engaged before moving the traction drive
lever or the engine will stop.
Reel Drive Lever (Fig. 22)
Located on the right front corner of the machine. The lever
has two positions: Engage and Disengage. Pull up on the
lever to engage the reel or push it down to disengage the
reel.
1
Figure 22
1. Reel drive lever
Choke Lever (Fig. 23)
Located on the left front of the engine. The lever has two
positions: Run and Choke. Move the lever to the Choke
position when starting a cold engine. After the engine starts
move the lever to the Run position.
Fuel Shut-off Valve (Fig. 23)
Located on the left front of the engine. The valve has two
positions: Closed and Open. Move the lever to the Closed
position when storing or transporting the machine. Open
the valve before starting the engine.

19
2
1
Figure 23
1. Choke lever 2. Fuel shut-off valve
On/Off Switch (Fig. 24)
Located on the rear of the engine. Move the switch to the
On position to start the engine and the Off position to stop
the engine.
1
2
3
Figure 24
1. Recoil starter
2. On/Off switch 3. Kick stand
Recoil Starter (Fig. 24)
Pull the recoil starter handle to start the engine.
Kick Stand (Fig. 24)
Mounted to rear of the machine, the kickstand is used to
raise rear of the machine for installation or removal of the
transport wheels.
Starting the Engine
Note: Ensure that the spark plug wire is installed on the
spark plug.
1. Ensure that the traction (Fig. 21) and reel drive (Fig. 22)
levers are in the Disengaged position.
Note: Engine will not start if traction lever is in the
engaged position.
2. Open the fuel shut-off valve on the engine (Fig. 23).
3. Move the On/Off switch (Fig. 24) to the On position.
4. Move the throttle control (Fig. 21) to the Fast position.
5. Move the choke lever (Fig. 23) to the half-open position
when starting a cold engine. The choke may not be
required when starting a warm engine.
6. Pull the recoil starter handle out until positive
engagement results, then pull vigorously to start the
engine.
Important Do not pull the recoil rope to its limit or let
go of the starter handle when rope is pulled out because the
rope may break or the recoil assembly may be damaged.
7. Close the choke as the engine warms up.
Stopping the Engine
1. Move the traction and reel drive controls to the
Disengaged position, the throttle control to the Slow
position, and the On/Off switch to the Off position.
2. Pull the spark plug wire off of the spark plug to prevent
the possibility of accidental starting before storing the
machine.
3. Close the fuel shut-off valve before storing or
transporting the mower in a vehicle.
Driving the Machine in
Transport
1. Push the kick stand down with your foot and pull up on
the handle to raise the rear of mower and install the
transport wheels.
2. To release the kickstand, pull up on the handle, push the
mower forward, and then lower the rear of mower onto
the transport wheels.
3. Ensure that the traction and reel drive controls are in the
Disengaged position and start the engine.
4. Set the throttle control to Slow, tip front of the machine
up gradually to the engage traction drive and slowly
increase the engine speed.

20
5. Adjust the throttle to operate the mower at the desired
ground speed and transport the mower to the desired
destination.
Preparing to Mow
1. Return the traction control lever to the Disengage
position, the throttle to the Slow position, and stop the
engine.
2. Push the kickstand down with your foot and pull up and
back on the handle to raise the wheels off of the ground.
3. Push the locking clips on the wheels out of the grooves
in the shafts.
4. Slide the wheels off of the shafts.
5. Move the unit off of the kickstand.
Mowing Tips
Proper use of the machine provides the smoothest turf
cutting available. The fundamental suggestions given will
provide the utmost performance from your mower.
Important Excessive operation of the cutting unit with
the absence of grass clippings (lubricant) can damage the
cutting unit.
Before Mowing
•Ensure that the mower is carefully adjusted and is set
evenly on both sides of the reel. Improper mower
adjustment is magnified many times over in the
appearance of the clipped turf.
•Remove all foreign objects from the turf prior to
mowing.
•Ensure that everyone, especially children and pets, are
clear of the work area.
Mowing Techniques
•Mow a green in a straight back and forth direction,
across the green.
•Avoid circular mowing or turning the mower on a green
because scuffing may occur. Turn the mower off of the
green by raising the cutting reel (pushing the handle
down) and turning on the traction drum.
•Mow at a normal walking pace. Fast speed saves very
little time and will result in an inferior mowing job.
Mowing
1. Start the engine, set the throttle at reduced speed, push
down on the handle to raise the cutting unit, move the
traction lever to the Engaged position, and transport the
mower onto collar of the green.
2. Move the traction lever to the Disengaged position and
move the reel drive lever to the Engaged position.
3. Move the traction lever to the Engaged position,
increase the throttle speed until the mower is traveling
at the desired ground speed, drive the mower onto the
green, lower the front of the mower, and commence
operation.
4. When finished mowing, drive off of the green, move the
traction control lever to the Disengage position, stop the
engine and push the reel drive lever into the Disengage
position.
5. Empty the grass catcher of clippings, install the grass
catcher, and commence transport operation.