Form No. 3385-993 Rev A Greensmaster® 1010 and 1616 Mower Model No. 04038—Serial No. 314004001 and Up Model No. 04039—Serial No. 314004001 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 product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
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 and avoid creating any source of ignition until fuel vapors have dissipated. – Secure all fuel tanks and container caps. Safe Operating Practices • Replace faulty silencers. • Evaluate the terrain to determine what accessories and The following instructions are adapted from the CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-2012. attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer.
• • • • • • • • To reduce the fire hazard, keep the engine, silencer, and and make repairs before restarting and operating the equipment. Reduce the throttle setting before stopping engine and, if the engine is provided with a fuel shut-off valve, turn the valve 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.
• • Sound pressure level was determined according to the procedures outlined in EN 836. – When near or crossing roads, always yield the right-of-way. – Reduce engine speed and apply the service brakes when going downhill to keep forward speed slow and to maintain control of the machine. 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.
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 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 kickstand. 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 (Model 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, lock washer, spacer, flat washer and locknut (Figure 6). 5. Repeat on the left side. 4 4. Position the spacer in the kick stand mounting hole.
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 2 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.
DANGER WARNING 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. Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills. • Keep face away from nozzle and gas tank or conditioner bottle opening.
Breaking-in the Machine Starting and Stopping the Engine Refer to the Engine Manual supplied with the machine for oil change and maintenance procedures recommended during the break-in period. Note: For illustrations and descriptions of the controls referenced in this section, refer to the Controls (page 13) section in Product Overview (page 13). Only 8 hours of mowing operation is required for the break-in period.
Operating Tips 4. Set the throttle control to Slow, raise the front of the machine up slightly, gradually engage the traction drive and slowly increase the engine speed. Before Mowing 5. Adjust the throttle to operate the mower at the desired ground speed and transport the mower to the desired destination. • 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. 6.
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 Checking the Engine Oil Level 1. Position the mower so that the engine is level and clean around the oil level gauge (Figure 22). 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.
Changing the Engine Oil distribute the oil thoroughly. An oil damp element is desirable. 1. Start and run the engine for a few minutes to warm the engine oil. 1 2. Place a drain pan at the rear of machine, under the drain plug (Figure 22). 2 3. Remove the drain plug. 4. Push down on the handle to tip the mower and the engine backward, allowing more oil to run into the drain pan. 3 4 5.
Replacing the Spark Plug Fuel System Maintenance Service Interval: Every 100 hours Use an NGK BR6HS spark plug or equivalent. The correct air gap is 0.6 to 0.7 mm (0.024 to 0.028 inches). Cleaning the Fuel Filter 1. Pull the molded wire off of the spark plug (Figure 26). Service Interval: After the first 20 hours 1 Every 100 hours 1. Close the fuel shut–off valve and unscrew the bowl from the filter body (Figure 28). 2 G016986 Figure 26 1. Spark plug wire 1 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 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.
Adjusting the Primary V-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. 1. To adjust the belt tension on primary V-belts, first check the adjustment of the traction control. Refer to Adjusting the Traction Control (page 30).
12 3 4 Figure 41 G016992 Figure 40 1. Locknut 3. Idler pulley 2. Belt guide 4. Idler arm 1. Differential cover sections 2. Front clutch 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. 7. Tighten the mounting screws and check the alignment. 8.
Cutting Unit Maintenance Controls System 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. Insert the 0.05 mm (0.002 inch) shim between the marked blade and the bedknife edge at the point where the marked blade crosses the bedknife edge. 6. Turn the right bedbar adjusting screw until you feel light pressure (i.e. drag) on the shim by sliding it side-to-side (Figure 45). Remove the shim. 7. For the left side of the cutting unit, slowly rotate the reel so that the closest blade crosses the bedknife edge between the first and second screw heads. 8.
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 (Figure 47). Figure 49 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.
Adjusting the Grass Shield Height 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. Adjust the shield to ensure proper grass clipping discharge into the basket. 1.
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).
