Form No. 3378-438 Rev A Greensmaster® 1010 and 1610 Mower Model No. 04038—Serial No. 313000601 and Up Model No. 04039—Serial No. 313000601 and Up Register at 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 WARNING 1. Safety alert symbol. CALIFORNIA Proposition 65 Warning This manual uses two words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.
Contents Setting the Machine to Match Turf Conditions ............34 Servicing the Bedbar ...............................................35 Backlapping the Reel...............................................36 Storage ........................................................................36 Introduction .................................................................. 2 Safety ........................................................................... 4 Safe Operating Practices..........................
Safety • 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. Safe Operating Practices • Check that operator's presence controls, safety switches The following instructions are from the CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-2004. and shields are attached and functioning properly. Do not operate unless they are functioning properly.
• Keep hands and feet away from the cutting unit. • Slow down and use caution when making turns and This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death. crossing roads and sidewalks. Stop reels if not mowing. Use of this product for purposes other than its intended use could prove dangerous to user and bystanders.
For Model 04038 Sound Power Level This unit has a guaranteed sound power level of 92 dBA, which includes an Uncertainty Value (K) of 1 dBA. Sound power level was determined according to the procedures outlined in ISO 11094. Sound Pressure Level This unit has a sound pressure level at the operator’s ear of 84 dBA, which includes an Uncertainty Value (K) of 1 dBA. Sound pressure level was determined according to the procedures outlined in EN 836.
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. 120–2769 1. Toxic gas inhalation hazard—do not operate indoors. 93-9356 1. Entanglement hazard—stay away from moving parts. 2. Explosion hazard—stop the engine and keep away from open flames when refueling. 3. Warning—stop the engine and turn off the fuel before leaving the machine. 93-7346 1. Reel drive 4.
115-1720 1. Forward 2. Drive wheel 3. Neutral 120-2727 1. Brake—to engage, pull the 2. Parking brake—to lock, lever toward the handle; pull the lever toward the to disengage, release the handle, press the button lever. in and release the lever against the locking button; to release, pull the lever toward the handle until the button releases and release the lever. 120–2761 1. Warning—read the Operator’s Manual. 4. Thrown object hazard—keep bystanders away from the machine. 2.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 6 Description Use Qty. Handle Cable tie Kickstand assembly Spring Wheel shaft, right Wheel shaft, left 1 2 1 1 1 1 Install the kickstand. Transport wheels (optional) 2 Install the transport wheels (optional). No parts required – Adjust the cutting unit. Grass basket 1 Install the grass basket. Install the handle. Install the transport wheel shafts.
Adjusting the Handle 4. Squeeze the handle ends inward and install them on the mounting pins (Figure 3). 1. Remove the hairpin cotters from the ring pins on each side of the mower (Figure 2). 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). 1 2 4 3. Install the ring pins and hairpin cotters. 2 Installing the Kickstand (For GR1610) g021288 3 Figure 3 Parts needed for this procedure: 1. Handle end 2.
Figure 6 1. Kick stand 3. Spring stud 2. Spring bracket 4. Spring Figure 7 1. Right wheel shaft 4. Torque the shaft to 688 to 101 N-m (5 to 75 ft-lb). 3. Mount the kick stand to each side of the frame with a bolt, lockwasher, spacer, flat washer and locknut (Figure 6). Position the spacer in the kick stand mounting hole. 5. Repeat on the left side.
6 Installing the Grass Basket Parts needed for this procedure: 1 Grass basket Procedure Grasp the basket by the top lip and slide it onto the basket mounting rods (Figure 9). G017591 Figure 8 1. Locking clip 3. 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. 4. Repeat the procedure on the opposite side of the machine. Figure 9 5. Inflate the tires to 574 to 718 Pa (12 to 15 psi.). 1.
Product Overview Controls 1 2 3 4 5 6 7 G016976 Figure 11 Parking Brake G017592 The parking brake (Figure 12) is located at the base of the service brake. Fully engage the service brake and push the parking brake knob to allow the service brake to rest on the parking brake pin. Engage the service brake to release the parking brake. You must release the brake before the traction drive is engaged. Figure 10 1. Traction drive lever 2. Throttle control 5. Service brake 6. Parking brake 3.
Reel Drive Lever Recoil Starter The reel drive lever (Figure 13) is located on the right front corner of the machine. The lever has two positions: Engage and Disengage. Move the lever forward to engage the reel or rearward to disengage the reel. Pull the recoil starter handle (Figure 15) to start the engine. 1 Figure 15 1. Recoil starter 2. Kick stand G016978 Figure 13 Kickstand 1.
Attachments/Accessories Operation A selection of Toro approved attachments and accessories is available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories. Note: Determine the left and right sides of the machine from the normal operating position. Think Safety First Please carefully read all of the safety instructions and decals in the safety section.
Break-in Period the gasoline to expand. Do not fill the fuel tank completely full. 3. Install fuel tank cap and wipe up any spilled gasoline. Refer to the Engine Manual supplied with the machine for oil change and maintenance procedures recommended during the break-in period. DANGER Only 8 hours of mowing operation is required for the break-in period. In certain conditions, gasoline is extremely flammable and highly explosive.
Starting the Engine 6. Return the traction control lever to the Disengage position, the throttle to the Slow position, and stop the engine. 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. Preparing to Mow 1. If the machine is equipped with the optional transport wheels, push the kickstand down with your foot and pull up and back on the handle to raise the wheels off of the ground.
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.
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 20 hours • Change the engine oil. • Clean the fuel filter and cup. Before each use or daily • Check the interlock switch operation. • Check the engine oil level. Every 25 hours • Grease the machine. (Grease the fittings immediately after every washing regardless of the interval listed.
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.
Engine Maintenance Servicing the Engine Oil Service Interval: After the first 20 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) The crankcase must be filled with approximately 21 fluid ounces of proper viscosity oil before staring. The engine uses any high-quality oil having the American Petroleum Institute - APl - “service classification" SF, SG, SH or SJ.
1 5. Install the drain plug and refill the crankcase with the proper oil; refer to Checking the Engine Oil Level (page 15). 2 Servicing the Air Cleaner 3 4 Service Interval: Every 50 hours—Clean and oil the air cleaner foam element. (More often in dirty or dusty conditions) 5 Every 100 hours—Replace the paper air filter element. (More often in dirty or dusty conditions) Important: Service the air cleaner more often in dirty or dusty conditions 1. Make sure the wire is off of the spark plug.
Fuel System Maintenance 2. Clean around the spark plug and remove it from the cylinder head. Important: Replace a cracked, fouled, or dirty spark plug. Do not sand blast, scrape, or clean electrodes because engine damage could result from grit entering the cylinder. Cleaning the Fuel Filter Service Interval: After the first 20 hours 3. Ensure that the air gap is correct (Figure 27). Every 100 hours 1 1. Close the fuel shut–off valve and unscrew the bowl from the filter body (Figure 28).
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 the service/parking brake slips when operated, an adjustment is required. 1. Engage the service brake, push in on the parking brake knob and allow the service brake to rest on the parking brake pin (Figure 30) 1.
Figure 33 1. Service/Parking brake cable Figure 31 2. Front jam nut 1. Rear pressure on service brake lever 5. Close the cover and secure the retainer. 3. Loosen the retainer securing the V-belt cover and pivot the cover open (Figure 32). 1 2 G016991 Figure 32 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 33). Repeat steps 1 and 2 and readjust if required.
Belt Maintenance Adjusting the 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. Ensure that the belts are properly tensioned to ensure proper operation of the machine and unnecessary wear. Check the belts frequently. 6. After all bolts are installed, tighten them until the stand-offs inside the cover contact the side plate.
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. 2. Loosen the retainer securing the V-belt cover and pivot the cover open (Figure 39). 1 2 6. After all bolts are installed, tighten them until the stand-offs inside the cover contact the side plate. Do not overtighten. Adjusting the Differential Belt 1.
8. Remove the 2 bolts and locknuts securing the right rear bearing housing to the side plate (Figure 41). 8. To push or pull the machine easier without starting the engine, adjust the belt guide (Figure 40, inset) as follows: A. Engage the clutch. B. Loosen the locknut securing the idler pulley and belt guide to the idler arm. C. Rotate the belt guide clockwise until a gap of approximately 0.15 cm (0.06 inch) is obtained between the guide finger and the backside of the drive belts. D.
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 the traction control does not engage or it slips during operation, an adjustment is required. 2. Place a 0.6 x 2.5 cm (1/4 x 1 inch) flat steel strip, approximately 73.
turn the bedbar adjusting screw clockwise (on the same end of the 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 45). Figure 44 1. Driven pulley 3. Idler Pulley 2. 4 holes 8. Loosen the 4 roller bearing screws and the screw securing the idler pulley. Figure 46 9. Raise or lower the right side of the roller assembly until the gap is less than .025 cm (0.010 inch).
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). 1. Height-of-cut arm 3.
Bedbar Identification 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 53). 3. Tighten the fasteners.
Setting the Machine to Match Turf Conditions Use the following table to set the machine to match turf conditions.
Rollers: Standard and Optional Part Number Description Mower 99-6241 Narrow Wiehle Greensmaster 1010 2.0 inches Aluminum Standard, 0.2 Spacing 88-6790 Wide Wiehle Greensmaster 1010 2.0 inches Aluminum More Penetration, 0.43 Spacing 104-2642 Full Roller Greensmaster 1010 2.0 inches Steel 71-1550 Wiehle Roller Greensmaster 1010 2.0 inches Cast Iron More Penetration, 0.43 Spacing 93-9045 Wiehle Roller Greensmaster 1010 2.
Backlapping the Reel Storage 1. Remove the plug in the right reel drive cover (Figure 56). 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.
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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).
