Greensmaster® 800, 1000, and 1600 Mowers

1. Remove the bolts (5/16 inch), locknuts, ring pins, and hairpin cotters that secure the bottom of the handle arms to each side of the machine (Figure 3).

   

   Figure 3

   1. Hairpin cotter
   2. Mounting pin
   3. Washer
   4. Lock washer
   5. Bolt (3/8 inch)
   6. Locknut
   7. Bolt (5/16 inch)
   8. Ring pin
   9. Handle arm

2. Remove the bolts (3/8 inch), washers, and lock washers from the mounting pins on each side of the machine (Figure 3).

3. Insert the handle ends through the holes in the handle arms and align the holes with the mounting pins (Figure 3).

4. Squeeze the handle ends inward and install them on the mounting pins (Figure 4).

   

   Figure 4

   1. Handle
   2. Handle arm
   3. Mounting pin
   4. Washer
   5. Lock washer
   6. Bolt (3/8 inch)

5. Secure the handle to the mounting pins with the bolts (3/8 inch), washers, and lock washers that you previously removed (Figure 4).

6. Use the bolts (5/16 inch), locknuts, hairpin cotters, and ring pins that you previously removed to secure the handle arms to the rear of the frame (Figure 3).

7. Secure the cables and wire harness to the handle with the cable ties (Figure 5).

   

   Figure 5

   1. Cable ties

Refer to Figure 6 for this procedure.

Figure 6

1. Handle
2. Hairpin cotter
3. Ring pin

1. Remove the hairpin cotters from the ring pins on each side of the machine.

2. While supporting the handle, remove the ring pins from each side and raise or lower the handle to the desired operating position.

3. Install the ring pins and hairpin cotters.

Perform the daily maintenance procedures; refer to Daily Maintenance Checklist.

Check the engine-oil level before each use or every 8 operating hours, refer to Checking the Engine-Oil Level.

Fuel tank capacity: 2.7L (0.71 US gallons)

Recommended fuel: Unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method)

Ethanol: Gasoline with up to 10% ethanol (gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and MTBE are not the same. Gasoline with 15% ethanol (E15) by volume is not approved for use.

• Never use gasoline that contains more than 10% ethanol by volume, such as E15 (contains 15% ethanol), E20 (contains 20% ethanol), or E85 (contains up to 85% ethanol).

• Do not use gasoline containing methanol.

• Do not store fuel either in the fuel tank or fuel containers over the winter unless you use a fuel stabilizer.

• Do not add oil to gasoline.

• For best results, use only clean, fresh fuel less than 30 days old.

• Using unapproved gasoline may cause performance problems and/or engine damage, which may not be covered under the warranty.

1. Clean around the fuel-tank cap and remove the cap from the tank (Figure 21). Fill the fuel tank no higher than to the bottom of the filter screen.

   Important: Do not overfill the tank with fuel.

   

   Figure 21

   1. Fuel-tank cap

2. Install the fuel-tank cap and wipe up any spilled fuel.

Use the following table to set the machine to match turf conditions.

1. Push the kickstand down with your foot and pull up and back on the handle to raise the wheels off the ground.

2. Place the traction lever into the ENGAGE position and the engine controls in the starting position.

3. Attempt to start the engine.

   The engine should not start. If the engine starts, the interlock switch needs service. Correct the problem before operating the machine. Refer to Servicing the Traction-Interlock Switch

4. Carefully lift up on the handle to release the kickstand.

1. Return the traction control lever to the NEUTRAL position, the throttle to the SLOW position, and shut off the engine.

2. Push the kickstand down with your foot and pull up on the handle support until the kickstand has rotated forward, over center.

3. Remove the transport wheels by pushing the wheel locking clips out of the hex-shaft grooves.

4. Carefully lower the machine off of the kickstand by pushing forward slowly or by lifting the lower handle support, allowing the kickstand to spring back to the STORAGE position.

Note: For illustrations and descriptions of the controls referenced in this section, refer to Controls.

Note: Ensure that the spark-plug wire is installed on the spark plug.

1. Ensure that the traction and reel drive levers are in the DISENGAGED position.

   Note: The engine will not start if the traction lever is in the ENGAGED position.

2. Ensure that the fuel-shutoff valve is open.

3. Move the On/Off switch to the ON position.

4. Move the throttle control to the FAST position.

5. Move the choke lever halfway between the CHOKE and RUN positions when starting a cold engine.

   Note: The choke may not be required when starting a warm engine.

6. Pull the recoil-start handle out until positive engagement results, then pull it vigorously to start the engine.

   Important: Do not pull the recoil rope to its limit or let go of the starter handle when the rope is pulled out; the rope may break or the recoil assembly may be damaged.

7. Move the choke lever to the RUN position as the engine warms up.

1. Move the traction and reel drive controls to the DISENGAGED position.

2. Move the throttle control to the SLOW position.

3. Move the On/Off switch to the OFF position.

4. Close the fuel-shutoff valve before you store or transport the machine

Important: Grass clippings act as a lubricant when mowing. Operating the cutting unit excessively without grass clippings can damage the cutting unit.

• Mow the greens in a straight back-and-forth direction across the green.

• Avoid circular mowing or turning the machine on the greens areas to prevent scuffing.

• Turn the machine off the green by raising the cutting reel (pushing the handle down) and turning on the traction drum.

• Mow at a normal walking pace. Fast speeds saves little time and results in an inferior mowing job.

• To assist in maintaining a straight line across the green and to keep the machine an equal distance from the edge of the previous cut, use the alignment stripes on the basket (Figure 22).

  

  Figure 22

  1. Alignment stripes

After mowing, transport the machine away from the job site; refer to Installing the Transport Wheels or Transporting the Machine Using a Trailer and Hauling the Machine.

Lubricate the 12 grease fittings on the mower using No. 2 lithium grease. For best results, use a hand-operated grease gun.

The grease fitting locations are as follows:

• 2 on the front roller (Figure 24)

• 2 on the reel bearings (Figure 24)

• 2 on the drum axles (Figure 25)

• 3 on the differential (Figure 25)

• 2 on the reel countershaft bearings (Figure 26)

• 1 on the belt idler pivots (Figure 27).

1. Wipe each grease fitting with a clean rag.

2. Pump grease into each fitting.

   Important: Do not apply too much pressure or the grease seals may become permanently damaged.

3. Wipe off any excess grease.

Figure 24

Figure 25

Figure 26

Figure 27

Fill the crankcase with approximately 0.6 L (20 fl oz) of the proper viscosity oil before starting. The engine uses a high-quality oil that has the American Petroleum Institute (API) service classification of SE or higher. Select the proper oil viscosity (weight) based on the ambient temperature. Figure 28 illustrates the temperature/viscosity recommendations.

Figure 28

Note: Multi-grade oils (5W-20, 10W-30 and 10W-40) increase oil consumption. Check the engine-oil level more frequently when you use these oils.

Important: Service the air cleaner more often in dirty or dusty conditions

1. Ensure that the spark-plug wire is removed from the spark plug.

2. Remove the wing nut that secures the air-cleaner cover, and remove the cover (Figure 31).

   

   Figure 31

   1. Air-cleaner cover

3. Clean the cover.

4. If the foam element is dirty, remove it from the paper element (Figure 32) and clean it as follows:

   1. Wash the foam element in a solution of liquid soap and warm water. Squeeze it to remove dirt, but do not twist it, as the foam may tear.

   2. Dry the foam element by wrapping it in a clean rag. Squeeze the rag and foam element to dry it, but do not twist it, as the foam may tear.

   3. Saturate the foam element with clean engine oil. Squeeze the element to remove excess oil and to distribute the oil.

      Note: A foam element that is damp with oil is desirable.

      

      Figure 32

      1. Wing nut
      2. Air-cleaner cover
      3. Plastic wing nut
      4. Foam element
      5. Paper element

5. Check the condition of the paper element. Clean it by gently tapping or replace it as necessary.

   Important: Do not use compressed air to clean the paper element.

6. Install the foam element, paper element, and air-cleaner cover.

   Important: Do not operate the engine without the air-cleaner element, as extreme engine wear and damage can result.

Use an NGK BR6HS spark plug or equivalent. The correct air gap is 0.6 to 0.7 mm (0.024 to 0.028 inch).

1. Pull the molded wire off the spark plug (Figure 33).

   

   Figure 33

   1. Spark-plug wire

2. Clean around the spark plug and remove the plug from the cylinder head.

   Important: Replace a cracked, fouled, or dirty spark plug. Do not sand blast, scrape, or clean the electrodes because engine damage could result from grit entering the cylinder.

3. Set the air gap at 0.6 to 0.7 mm (0.024 to 0.028 inch) as shown in Figure 34. Install the correctly gapped spark plug and tighten it firmly to 23 N∙m (17ft-lb).

   

   Figure 34

   1. Center-electrode insulator
   2. Side electrode
   3. Air gap—0.6 to 0.7 mm (0.024 to 0.028 inch)

1. Unscrew and remove the fuel-tank cap from the fuel tank (Figure 35).

   

   Figure 35

   1. Fuel-tank cap
   2. Fuel-tank screen

2. Remove the fuel-tank screen from inside the fuel tank.

3. Clean the screen in clean fuel and install it in the tank.

4. Install the fuel-tank cap to the fuel tank.

Use the following procedure if the traction-interlock switch needs adjustment or replacement.

1. Ensure that the engine is off and the traction lever is disengaged and resting against the neutral stop (Figure 36).

   

   Figure 36

   1. Traction lever
   2. Neutral stop
   3. Interlock switch
   4. 0.8 mm (0.032 inch) gap

2. Loosen the interlock switch mounting fasteners (Figure 36).

3. Place a 0.8 mm (0.032 inch) thick shim between the traction lever and the interlock switch (Figure 36).

4. Tighten the interlock switch mounting fasteners and check the gap again.

   Note: The traction lever must not contact the switch.

5. Engage the traction lever and verify that the switch loses continuity.

   Note: Replace the switch if necessary.

If the service/parking brake slips during operation, adjust it.

1. Engage the service brake, push in the parking brake knob, and allow the service brake to rest on the parking-brake pin (Figure 37).

   

   Figure 37

2. Using a spring scale, press rearward on the service-brake lever (Figure 38). The parking brake should release when a force of 13.5 to 18 kg (30 to 40 lb) is attained. If the parking brake releases before 13.5 to 18 kg (30 to 40 lb) of force is attained, adjust the brake cable.

   

   Figure 38

   1. Rear pressure on the service-brake lever

3. Loosen the retainer that secures the V-belt cover and pivot the cover open (Figure 39).

   

   Figure 39

   1. V–belt cover
   2. Retainer

4. To adjust the brake cable tension, proceed as follows.

   • To decrease the cable tension, loosen the front cable jam nut and tighten the rear jam nut (Figure 40). Repeat steps 1 and 2 and adjust the tension if necessary.

   • To increase the cable tension, tighten the front cable jam nut and loosen the rear jam nut (Figure 40). Repeat steps 1 and 2 and adjust the tension if necessary.

     Note: You can adjust the cable at the jam nut brackets by the control panel or at the bracket at the base of the engine.

   

   Figure 40

   1. Service/parking brake cable
   2. Front jam nut

5. Close the cover and secure the retainer.

Ensure that the belts are properly tensioned to ensure proper operation of the machine and prevent unnecessary wear. Check the belts frequently.

1. Remove the bolts that secure the traction drive and reel-drive belt covers to the right side plate and remove the belt covers.

2. Loosen the idler pulley mounting nut on each idler pulley and pivot each idler pulley counterclockwise away from the backside of each belt to release the belt tension.

3. Remove the belts.

4. Remove the bolts that secure the front and rear sections of the differential cover to the differential housing and slide the cover sections away to expose the belt (Figure 48).

   

   Figure 48

   1. Differential cover sections
   2. Front clutch housing
   3. Right rear bearing housing

5. Loosen the idler pulley mounting nut on the differential idler pulley and pivot the idler pulley counterclockwise away from the backside of the belt to release the belt tension.

6. Remove the 2 bolts and 2 locknuts that secure the front clutch housing to the side plate (Figure 48).

7. Rotate the housing 180° so that the bottom of the housing points upward.

8. Remove the 2 bolts and 2 locknuts that secure the right rear bearing housing to the side plate (Figure 48).

9. Rotate the housing 180° so that the bottom of the housing points upward.

10. Remove the old belt.

11. Slide the new belt over the rotated housing covers, the differential cover sections, and onto the differential pulleys.

12. Ensure that the idler pulley is positioned against the backside of the belt.

13. Rotate both housings back into the upright position and secure them to the side plate with the bolts and nuts that you previously removed.

14. Adjust the differential belt tension; refer to Adjusting the Differential Belt.

15. Adjust the belt tension on the traction drive and reel-drive belts; refer to Adjusting the Traction-Drive Belt, and Adjusting the Reel-Drive Belt.

16. Install the differential, traction drive, and reel-drive covers.

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

1. Move the traction control to the DISENGAGED position.

2. Loosen the retainer that secures the V-belt cover and pivot the cover open (Figure 46).

3. To increase the cable tension, loosen the front-cable jam nut and tighten the back-cable jam nut (Figure 49) until a force of 8 to 9 Nm (6 to 7 lb) is created to engage the traction control.

   Note: Measure the force at the control knob.

   

   Figure 49

   1. Traction cable
   2. Front-cable jam nut
   3. Back-cable jam nut

4. Tighten the front-cable jam nut.

5. Close the cover and secure the retainer.

6. Check the traction-control operation.

1. Turn the bedbar-adjuster screw counterclockwise to back the bedknife away from the reel (Figure 61).

   

   Figure 61

   1. Bedbar-adjusting screw
   2. Spring-tension nut
   3. Bedbar

2. Back out the spring-tension nut until the washer is no longer tensioned against the bedbar (Figure 61).

3. On each side of the machine, loosen the jam nut that secures the bedbar bolt (Figure 62).

   

   Figure 62

   1. Jam nut
   2. Bedbar bolt

4. Remove each bedbar bolt allowing the bedbar to be pulled downward and removed from the machine. Save the 2 nylon and 2 stamped steel washers on each end of the bedbar (Figure 62).

1. Install the bedbar, positioning the mounting ears between the washer and the bedbar adjuster.

2. Secure the bedbar to each side plate with the bedbar bolts (jam nuts on the bolts) and 8 washers.

   Note: Position a nylon washer on each side of the side plate boss. Place a steel washer outside each of the nylon washers.

3. Torque the bolts to 27 to 36 N∙m (20 to 27 ft-lb).

4. Tighten the jam nuts until the outside thrust washers just rotate freely.

5. Tighten the spring-tension nut until the spring is collapsed, then back it off 1/2 turn.

6. Adjust the bedbar; refer to Adjusting the Bedknife to the Reel.