Form No. 3367-409 Rev A Greensmaster® 1000 and 1600 Walk-Behind Mower Model No. 04034—Serial No. 311000001 and Up Model No. 04035—Serial No. 311000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet. Figure 1 1. Safety alert symbol. WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. This manual uses two other words to highlight information.
Contents Leveling the Rear Drum to the Reel ..................... 27 Adjusting the Bedknife to the Reel ...................... 28 Adjusting the Height of Cut ................................ 28 Adjusting the Grass Shield Height....................... 29 Adjusting the Cut-Off Bar .................................. 30 Bedbar Identification.......................................... 30 Setting the Machine to Match Turf Conditions ..................................................... 31 Servicing the Bedbar....
Safety • 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.
• • • • • • • • • – stop on level ground; – disengage the cutting unit and traction drive; – set the parking brake; – stop the engine. Disengage drive to cutting unit when transporting or not in use. Stop the engine and disengage drive to attachment: – before refuelling; – before removing the grass catcher; – before making height adjustment. – before clearing blockages; – before checking, cleaning or working on the mower; – after striking a foreign object or if an abnormal vibration occurs.
– Do not operate close to sand traps, ditches, creeks, or other hazards. Sound Power – Reduce speed when making sharp turns. Avoid sudden stops and starts. This unit has a guaranteed sound power level of 95 dBA, based on measurements of identical machines per ISO 11094. – When near or crossing roads, always yield the right-of-way. Vibration (Model 04034) – Reduce engine speed and apply the service brake when going downhill to keep forward speed slow and to maintain control of the machine.
Safety and Instructional 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. 115-1613 1. Warning—read the Operator’s Manual. 2. Warning—remove the spark plug wire before performing any maintenance on the machine. 93-7346 3. Thrown object hazard—keep bystanders a safe distance from the machine. 4. Cutting, dismemberment hazard of hand or foot—stay away from moving parts. 1. Reel drive 2.
93-9886 1. Use unleaded gasoline. 104-2618 1. Parking brake 2. Disengage 115-1720 1. Forward 2. Drive wheel 3. Neutral 8 3.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 Description Use Qty. Handle Cable tie Kickstand assembly Spring Wheel shaft, right Wheel shaft, left Transport wheels (obtain separately) 1 2 1 1 1 1 2 No parts required – Adjust the cutting unit. Grass basket 1 Install the grass basket. Install the handle. Install the kickstand (model 04035 only). Install the transport wheels. Media and Additional Parts Description Use Qty.
2. While supporting the handle, remove the ring pins from each side and raise or lower the handle to the desired operating position (Figure 2). 5. Squeeze the handle ends inward and install them on the mounting pins (Figure 3). 3. Install the ring pins and hairpin cotters. 2 Installing the Kickstand (Model 04035 Only) Parts needed for this procedure: Figure 3 1. Handle end 6. Secure the handle ends to the mounting pins with the bolts, washers, and lockwashers previously removed (Figure 3).
3 Installing the Transport Wheels Parts needed for this procedure: 1 Wheel shaft, right 1 Wheel shaft, left 2 Transport wheels (obtain separately) Procedure 1. Push the kick stand down with your foot and pull up on the handle to support the mower on the kick stand. Figure 7 1. Locking clip 2. Apply #242 Loctite to the threads of the wheel shafts. 7. Rotate wheel back and forth until it slides completely onto axle and locking clip is secured in groove on axle shaft. 3.
Product Overview 5 Controls Installing the Grass Basket Parts needed for this procedure: 1 Grass basket Procedure Grasp basket by top lip and slide it onto the basket mounting rods (Figure 8). Figure 9 1. Traction drive lever 2. Throttle control 3. On/off switch 4. Service/parking brake Throttle Control The throttle control (Figure 9) is located on rear right side of the control panel. The lever connects to and operates throttle linkage to the carburetor.
Figure 12 Figure 10 1. Recoil starter 1. Reel drive lever 2. Kick stand Choke Lever Kickstand The choke lever (Figure 11) is located on 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 engine starts move lever to Run position. The kickstand (Figure 12) is mounted to the rear of machine and is used to raise the rear of machine for installation or removal of the transport wheels.
Operation 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. Note: Determine the left and right sides of the machine from the normal operating position. Think Safety First • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills. Please carefully read all of the safety instructions and decals in the safety section.
3. Attempt to start engine. DANGER The engine should not start. If engine starts, the interlock switch needs service. Correct problem before operating. Refer to Servicing Interlock Switch. 4. Carefully lift up on handle to release kick stand. In certain conditions during fueling, static electricity can be released causing a spark which can ignite the gasoline vapors. A fire or explosion from gasoline can burn you and others and can damage property.
Driving the Machine in Transport traveling at the desired ground speed, drive the mower onto the green, lower the front of the mower, and commence operation. 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. 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. 2.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Change the engine oil. After the first 25 hours • Clean the fuel filter. Before each use or daily • Check the interlock switch operation. • Check the engine oil level. Every 25 hours • Grease the machine.
Daily Maintenance Checklist Important: Duplicate this page for routine use. Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri. Check the safety interlock operation. Check the parking brake operation. Check the fuel level. Check the engine oil level. Check the air filter. Clean the engine cooling fins. Check for unusual engine noises. Check for unusual operating noises. Check the reel-to-bedknife adjustment. Check the height-of-cut adjustment. Grease all fittings.
Lubrication Greasing the Machine Service Interval: Every 25 hours Lubricate the 13 grease fittings on the mower using a No. 2 multipurpose lithium base grease. A hand operated grease gun is recommended for best results. The grease fitting locations are as follows: Figure 16 • 2 on the front roller (Figure 14) • 2 on the reel bearings (Figure 14) • 2 on the drum axles (Figure 15) • 3 on the differential (Figure 15) • 2 on the reel countershaft bearings (Figure 16) • 2 on the belt idler pivots (Figure 17).
Engine Maintenance Servicing the Engine Oil Service Interval: After the first 8 hours—Change the engine oil. Before each use or daily—Check the engine oil level. Every 50 hours—Change the engine oil. (More frequently in dusty or dirty conditions) Crankcase capacity: 20 oz. (.59 l) The engine uses any high-quality oil having the American Petroleum Institute - APl - “service classification" SF, SG, SH or SJ. Oil viscosity - weight - must be selected according to ambient temperature.
4. Push down on the handle to tip the mower and the engine backward, allowing more oil to run into the drain pan. 5. Install the drain plug and refill the crankcase with the proper oil; refer to Checking the Engine Oil Level. Servicing the Air Cleaner Service Interval: Every 25 hours—Clean and oil the air cleaner foam element. (More often in dirty or dusty conditions) Every 100 hours—Clean or replace the paper air filter element.
Fuel System Maintenance 3. Set the air gap at 0.028 to 0.032 inch (0.05 to 0.07 cm) (Figure 24). Cleaning the Fuel Filter Service Interval: After the first 25 hours Every 50 hours 1. Close the fuel shut off valve and unscrew the bowl from the filter body (Figure 25). Figure 24 4. Install the correctly gapped spark plug and tighten it to 17 ft.-lb (23 N-m). 5. Install the spark plug wire on the spark plug. Figure 25 1. Shut-off valve 2. Bowl 2.
Brake Maintenance Electrical System Maintenance Servicing the Interlock Switch Adjusting the Service/Parking Brake Use the following procedure if the switch needs adjustment or replacement. If service/parking brake slips when operated, an adjustment is required. 1. Make sure the engine is off and the traction lever is disengaged and resting against the neutral stop (Figure 26).. 1. Move service/parking brake lever to the Off position. 2.
Belt Maintenance Important: Do not over tension the belt. B. Tighten the nut to lock the adjustment. Adjusting the Belts 4. Install the belt cover by placing it in position. Service Interval: Every 300 hours—Check the condition and tension of belts 5. While maintaining a slight gap between the cover seal and the side plate, install each mounting bolt until the threads engage in the insert. The gap allows visual alignment of the bolts to the threaded inserts.
Adjusting the Primary V-Belts the belt until the desired belt tension is attained (Figure 31). 1. To adjust the belt tension on primary V-belts, first check the adjustment of the traction control. Refer to Adjusting the Traction Control. If unable to attain the 4 to 5 lb force required in adjusting the traction control, proceed to next step. Important: Do not over tension the belt. B. Tighten the nut to lock the adjustment. 4. Install the belt cover by placing it in position. 5.
Figure 34 1. Primary V-belts 2. Belt guide Figure 35 3. Idler pulley 1. Differential cover sections 2. Front clutch housing 7. Tighten the mounting screws and check the alignment. 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. 8.
Controls System Maintenance Cutting Unit Maintenance Leveling the Rear Drum to the Reel Adjusting the Traction Control 1. Position the machine on a flat, level surface, preferably a precision steel work plate. If traction control does not engage or it slips during operation, an adjustment is required. 2. Place a 1/4 x 1 inch (0.6 x 2.5 cm) flat steel strip, approximately 29 inches (73.
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 (Figure 39) Figure 38 1. Driven pulley 2. 4 holes 3. Idler Pulley 8. Loosen the 4 roller bearing screws and the screw securing the idler pulley. Figure 40 9. Raise or lower the right side of the roller assembly until the gap is less than 0.010 inch (.025 cm).
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 (Figure 44), depending on the application and needs of the user.
Bedbar Identification 4 inches (10 cm). Loosen the bolts and nuts securing each end of the shield to the sideplate and adjust the shield to the correct height. To determine if the bedbar is standard or aggressive, check the left bedbar mounting ears. If the mounting ears are rounded it is a standard bedbar. If the mounting ears have a notch in them, it is an aggressive bedbar (Figure 47). 3. Tighten the fasteners.
Setting the Machine to Match Turf Conditions Use the following table to set the machine to match turf conditions.
Servicing the Bedbar 5. Tighten the spring tension nut until the spring is collapsed, then back it off 1/2 turn. Removing the Bedbar 6. Adjust the bedbar; refer to Adjusting the Bedknife to the Reel. 1. Turn bedbar adjuster screw, counterclockwise, to back bedknife away from reel (Figure 48). Backlapping the Reel 1. Remove the plug in the right reel drive cover (Figure 50). Figure 48 1. Bedbar adjusting screw 2. Spring tension nut 3. Bedbar 2.
Storage 1. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine’s cylinder head fins and blower housing. Important: You can wash the machine with mild detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the shift lever plate, and engine. 2. For long-term storage (more than 90 days) add stabilizer/conditioner additive to fuel in the tank. A.
Notes: 34
Notes: 35
The Toro Total Coverage Guarantee A Limited Warranty Conditions and Products Covered The Toro® Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
