Toro 4038 User manual

FormNo.3391-564RevA
Greensmaster®1010and1610
Mower
ModelNo.04038—SerialNo.315000001andUp
ModelNo.04039—SerialNo.315000001andUp
Registeratwww.Toro.com.
OriginalInstructions(EN)*3391-564*A

ThisproductcomplieswithallrelevantEuropeandirectives,
fordetailspleaseseetheseparateproductspecicDeclaration
ofConformity(DOC)sheet.
WARNING
CALIFORNIA
Proposition65Warning
Thisproductcontainsachemicalorchemicals
knowntotheStateofCaliforniatocausecancer,
birthdefects,orreproductiveharm.
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Becauseinsomeareastherearelocal,state,orfederal
regulationsrequiringthatasparkarresterbeusedonthe
engineofthismachine,asparkarresterisincorporatedwith
themuferassembly.
GenuineTorosparkarrestersareapprovedbytheUSDA
ForestryService.
Important:Thisengineisequippedwithaspark
arrestermufer.ItisaviolationofCaliforniaPublic
ResourceCodeSection4442touseoroperatetheengine
onanyforest-covered,brush-covered,orgrass-covered
landwithoutasparkarrestermufermaintainedin
workingorder,ortheengineconstricted,equipped,and
maintainedforthepreventionofre.Otherstatesor
federalareasmayhavesimilarlaws.
ThissparkignitionsystemcomplieswithCanadianICES-002.
Introduction
Thismachineisawalkbehind,reel-bladelawnmower
intendedtobeusedbyprofessional,hiredoperatorsin
commercialapplications.Itisprimarilydesignedforcutting
grassonwell-maintainedlawnsinparks,golfcourses,sports
elds,andoncommercialgrounds.Itisnotdesignedfor
cuttingbrush,mowinggrassandothergrowthalongside
highways,orforagriculturaluses.
Readthisinformationcarefullytolearnhowtooperateand
maintainyourproductproperlyandtoavoidinjuryand
productdamage.Youareresponsibleforoperatingthe
productproperlyandsafely.
YoumaycontactTorodirectlyatwww.Toro.comforproduct
andaccessoryinformation,helpndingadealer,ortoregister
yourproduct.
Wheneveryouneedservice,genuineToroparts,oradditional
information,contactanAuthorizedServiceDealerorToro
CustomerServiceandhavethemodelandserialnumbers
ofyourproductready.Themodelandserialnumbersare
locatedonaplateontherearframe.Writethenumbersin
thespaceprovided.
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhassafety
messagesidentiedbythesafetyalertsymbol(Figure1),
whichsignalsahazardthatmaycauseseriousinjuryordeath
ifyoudonotfollowtherecommendedprecautions.
Figure1
1.Safetyalertsymbol.
Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanicalinformation
andNoteemphasizesgeneralinformationworthyofspecial
attention.
©2014—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUSA
AllRightsReserved

Contents
Safety...........................................................................4
SafeOperatingPractices...........................................4
ToroMowerSafety..................................................5
Model04038...........................................................6
Model04039...........................................................6
SafetyandInstructionalDecals.................................7
Setup............................................................................9
1InstallingandAdjustingtheHandle.........................9
2InstallingtheKickstand(ModelGR1610)................10
3InstallingtheTransportWheelShafts......................11
4InstallingtheTransportWheels(Optional)..............11
5AdjustingtheCuttingUnit....................................12
6InstallingtheGrassBasket....................................12
ProductOverview.........................................................13
Controls...............................................................13
Specications........................................................14
Attachments/Accessories........................................15
Operation....................................................................15
ThinkSafetyFirst...................................................15
CheckingtheEngineOilLevel.................................15
FillingtheFuelTank...............................................15
BreakingintheMachine..........................................17
CheckingtheInterlockSwitchOperation...................17
StartingandStoppingtheEngine..............................17
UsingtheTransportWheels.....................................17
TransportingtheMachine........................................18
LoadingtheMachine..............................................18
PreparingtoMow...................................................19
Mowing................................................................19
OperatingTips......................................................19
Maintenance.................................................................20
RecommendedMaintenanceSchedule(s)......................20
DailyMaintenanceChecklist....................................21
Lubrication...............................................................22
GreasingtheMachine.............................................22
EngineMaintenance..................................................23
ServicingtheEngineOil..........................................23
ServicingtheAirCleaner.........................................24
ReplacingtheSparkPlug.........................................25
FuelSystemMaintenance...........................................25
CleaningtheFuelFilter...........................................25
ElectricalSystemMaintenance....................................26
ServicingtheInterlockSwitch.................................26
BrakeMaintenance....................................................26
AdjustingtheService/ParkingBrake.........................26
BeltMaintenance......................................................28
AdjustingtheBelts.................................................28
ReplacingtheDifferentialBelt..................................30
ControlsSystemMaintenance.....................................31
AdjustingtheTractionControl.................................31
CuttingUnitMaintenance...........................................31
LevelingtheRearDrumtotheReel...........................31
AdjustingtheBedknifetotheReel............................32
AdjustingtheHeight-of-Cut....................................33
AdjustingtheGrassShieldHeight.............................34
AdjustingtheCut-offBar........................................34
BedbarIdentication..............................................34
SettingtheMachinetoMatchTurfConditions............35
ServicingtheBedbar...............................................36
BacklappingtheReel...............................................37
Storage........................................................................37
3

Safety
ThismachinehasbeendesignedinaccordancewithEN
ISO5395:2013andANSIB71.4-2012whentheOperator
PresenceKit,Part112–9282isinstalled..
Improperuseormaintenancebytheoperatororownercan
resultininjury.Toreducethepotentialforinjury,comply
withthesesafetyinstructionsandalwayspayattentiontothe
safetyalertsymbol,whichmeansCAUTION,WARNING,
orDANGER-“personalsafetyinstruction."Failuretocomply
withtheinstructionmayresultinpersonalinjuryordeath.
Whenoperatingthismachinebetween5000to8000feet
abovesealevelyouwillneedtoobtainthehigh-altitude
kit.SeeyourAuthorizedToroDealer.
SafeOperatingPractices
Training
•ReadtheOperator'sManualandothertrainingmaterial
carefully.Befamiliarwiththecontrols,safetysigns,and
theproperuseoftheequipment.
•Iftheoperatorormechaniccannotreadthelanguage
oftheOperator'sManualitistheowner’sresponsibilityto
explainthismaterialtothem.
•Neverallowchildrenorpeopleunfamiliarwiththese
instructionstouseorservicethemower.Local
regulationsmayrestricttheageoftheoperator.
•Nevermowwhilepeople,especiallychildren,orpetsare
nearby.
•Keepinmindthattheoperatororuserisresponsiblefor
accidentsorhazardsoccurringtootherpeopleortheir
property.
•Theowner/usercanpreventandisresponsiblefor
accidentsorinjuriesoccurringtopeople,ordamageto
property.
•Alloperatorsormechanicsmustbetrained.Itisthe
owner’sresponsibilityfortrainingusers.
Preparation
•Whilemowing,alwayswearsubstantial,slip-resistant
footwear,longtrousers,hardhat,safetyglasses,and
hearingprotection.Longhair,looseclothing,orjewelry
maygettangledinmovingparts.Donotoperatethe
equipmentwhenbarefootorwearingopensandals.
•Thoroughlyinspecttheareawheretheequipmentisto
beusedandremoveallobjectswhichmaybethrownby
themachine.
•Warning—Fuelishighlyammable.Takethefollowing
precautions:
–Storefuelincontainersspecicallydesignedforthis
purpose.
–Refueloutdoorsonlyanddonotsmokewhile
refuelling.
–Addfuelbeforestartingtheengine.Neverremove
thecapofthefueltankoraddfuelwhiletheengineis
runningorwhentheengineishot.
–Iffuelisspilled,donotattempttostarttheengine
butmovethemachineawayfromtheareaofspillage
andavoidcreatinganysourceofignitionuntilfuel
vaporshavedissipated.
–Secureallfueltanksandcontainercaps.
•Replacefaultysilencers.
•Evaluatetheterraintodeterminewhataccessoriesand
attachmentsareneededtoproperlyandsafelyperform
thejob.Onlyuseaccessoriesandattachmentsapproved
bythemanufacturer.
•Checkthatoperator'spresencecontrols,safetyswitches
andshieldsareattachedandfunctioningproperly.Donot
operateunlesstheyarefunctioningproperly.
Operation
•Donotoperatetheengineinaconnedspacewhere
dangerouscarbonmonoxideandotherexhaustgasses
cancollect.
•Mowonlyindaylightoringoodarticiallight.
•Beforeattemptingtostarttheengine,disengageallblade
attachmentclutches,shiftintoneutral,andengagethe
parkingbrake.
•Stayalertforholesintheterrainandotherhiddenhazards.
•Watchoutfortrafcwhencrossingornearroadways.
•Stopthebladesrotatingbeforecrossingsurfacesother
thangrass.
•Whenusinganyattachments,neverdirectdischargeof
materialtowardbystandersnorallowanyonenearthe
machinewhileinoperation.
•Neveroperatethemachinewithdamagedguards,shields,
orwithoutsafetyprotectivedevicesinplace.Besureall
interlocksareattached,adjustedproperly,andfunctioning
properly.
•Donotchangetheenginegovernorsettingsoroverspeed
theengine.Operatingtheengineatexcessivespeedmay
increasethehazardofpersonalinjury.
•Beforeleavingtheoperator'sposition:
–stoponlevelground;
–disengagethecuttingunitandtractiondrive;
–settheparkingbrake;
–stoptheengine.
•Disengagedrivetoattachmentswhentransportingornot
inuse.
•Stoptheengineanddisengagedrivetoattachment:
–beforerefuelling;
–beforeremovingthegrasscatcher;
4

–beforemakingheightadjustments;
–beforeclearingblockages;
–beforechecking,cleaningorworkingonthemower;
–afterstrikingaforeignobjectorifanabnormal
vibrationoccurs.Inspectthemowerfordamage
andmakerepairsbeforerestartingandoperatingthe
equipment.
•Reducethethrottlesettingbeforestoppingengineand,if
theengineisprovidedwithafuelshut-offvalve,turnthe
valveoffattheconclusionofmowing.
•Keephandsandfeetawayfromthecuttingunit.
•Slowdownandusecautionwhenmakingturnsand
crossingroadsandsidewalks.Stopreelsifnotmowing.
•Donotoperatethemowerundertheinuenceofalcohol
ordrugs
•Lightningcancausesevereinjuryordeath.Iflightning
isseenorthunderisheardinthearea,donotoperate
themachine;seekshelter.
•Usecarewhenloadingorunloadingthemachineintoa
trailerortruck.
•Usecarewhenapproachingblindcorners,shrubs,trees,
orotherobjectsthatmayobscurevision.
SafeHandlingofFuels
•Toavoidpersonalinjuryorpropertydamage,use
extremecareinhandlinggasoline.Gasolineisextremely
ammableandthevaporsareexplosive.
•Extinguishallcigarettes,cigars,pipes,andothersources
ofignition.
•Useonlyanapprovedfuelcontainer.
•Neverremovefuelcaporaddfuelwiththeengine
running.
•Allowenginetocoolbeforerefueling.
•Neverrefuelthemachineindoors.
•Neverstorethemachineorfuelcontainerwherethereis
anopename,spark,orpilotlightsuchasonawater
heateroronotherappliances.
•Neverllcontainersinsideavehicleoronatruckor
trailerbedwithaplasticliner.Alwaysplacecontainerson
thegroundawayfromyourvehiclebeforelling.
•Removeequipmentfromthetruckortrailerandrefuelit
ontheground.Ifthisisnotpossible,thenrefuelsuch
equipmentwithaportablecontainer,ratherthanfroma
fueldispensernozzle.
•Keepthenozzleincontactwiththerimofthefueltank
orcontaineropeningatalltimesuntilfuelingiscomplete.
•Donotuseanozzlelockopendevice.
•Iffuelisspilledonclothing,changeclothingimmediately.
•Neveroverllfueltank.Replacefuelcapandtighten
securely.
MaintenanceandStorage
•Keepallnuts,boltsandscrewstighttobesurethe
equipmentisinsafeworkingcondition.
•Neverstoretheequipmentwithfuelinthetankinsidea
buildingwherefumesmayreachanopenameorspark.
•Allowtheenginetocoolbeforestoringinanyenclosure.
•Toreducetherehazard,keeptheengine,silencer,and
fuelstorageareafreeofgrass,leaves,orexcessivegrease.
•Checkthegrasscatcherfrequentlyforwearor
deterioration.
•Keepallpartsingoodworkingconditionandallhardware
andhydraulicttingstightened.Replaceallwornor
damagedpartsanddecals.
•Ifthefueltankhastobedrained,dothisoutdoors.
•Becarefulduringadjustmentofthemachinetoprevent
entrapmentofthengersbetweenmovingbladesand
xedpartsofthemachine.
•Disengagedrives,disengagethecuttingunit,setparking
brake,stopengineanddisconnectsparkplugwire.Wait
forallmovementtostopbeforeadjusting,cleaningor
repairing.
•Cleangrassanddebrisfromcuttingunit,drives,mufers,
andenginetohelppreventres.Cleanupoilorfuel
spillage.
•Carefullyreleasepressurefromcomponentswithstored
energy.
•Removethesparkplugwirebeforemakinganyrepairs.
•Usecarewhencheckingthereel.Wearglovesanduse
cautionwhenservicingthem.
•Keephandsandfeetawayfrommovingparts.Ifpossible,
donotmakeadjustmentswiththeenginerunning.
Hauling
•Usecarewhenloadingorunloadingthemachineintoa
trailerortruck.
•Usefullwidthrampsforloadingmachineintotraileror
truck.
•Tiethemachinedownsecurelyusingstraps,chains,cable,
orropes.Bothfrontandrearstrapsshouldbedirected
downandoutwardfromthemachine.
ToroMowerSafety
ThefollowinglistcontainssafetyinformationspecictoToro
productsorothersafetyinformationthatyoumustknowthat
isnotincludedintheCEN,ISO,orANSIstandard.
Thisproductiscapableofamputatinghandsandfeetand
throwingobjects.Alwaysfollowallsafetyinstructionsto
avoidseriousinjuryordeath.
Useofthisproductforpurposesotherthanitsintendeduse
couldprovedangeroustouserandbystanders.
5

•Knowhowtostoptheenginequickly.
•Donotoperatethemachinewhilewearingtennisshoes
orsneakers.
•Wearingsafetyshoesandlongpantsisadvisableand
requiredbysomelocalordinancesandinsurance
regulations.
•Handlegasolinecarefully.Wipeupanyspills.
•Checkthesafetyinterlockswitchesdailyforproper
operation.Ifaswitchshouldfail,replacetheswitch
beforeoperatingthemachine.
•Usingthemachinedemandsattention.Topreventloss
ofcontrol:
–Donotoperateclosetosandtraps,ditches,creeks,or
otherhazards.
–Reducespeedwhenmakingsharpturns.Avoid
suddenstopsandstarts.
–Whennearorcrossingroads,alwaysyieldthe
right-of-way.
–Reduceenginespeedandapplytheservicebrakes
whengoingdownhilltokeepforwardspeedslowand
tomaintaincontrolofthemachine.
•Donottouchtheengine,mufer,orexhaustpipewhile
theengineisrunningorsoonafterithasstoppedbecause
theseareascouldbehotenoughtocauseburns.
•Whenapersonorpetappearsunexpectedlyinornearthe
mowingarea,stopmowing.Carelessoperation,combined
withterrainangles,ricochets,orimproperlypositioned
guardscanleadtothrownobjectinjuries.Donotresume
mowinguntiltheareaiscleared.
MaintenanceandStorage
•Checkallfuellinesfortightnessandwearonaregular
basis.Tightenorrepairthemasneeded.
•Iftheenginemustberunningtoperformamaintenance
adjustment,keephands,feet,clothing,andanypartsof
thebodyawayfromthecuttingunit,attachments,andany
movingparts.Keepeveryoneaway.
•Toensuresafetyandaccuracy,haveanAuthorizedToro
Distributorcheckthemaximumenginespeedwitha
tachometer.Maximumgovernedenginespeedshould
be3475±100RPM.
•Ifmajorrepairsareeverneededorifassistanceisdesired,
contactanAuthorizedToroDistributor.
•UseonlyToro-approvedattachmentsandreplacement
parts.Thewarrantymaybevoidedifusedwith
unapprovedattachments.
Model04038
SoundPowerLevel
Thisunithasaguaranteedsoundpowerlevelof92dBA,
whichincludesanUncertaintyValue(K)of1dBA.
Soundpowerlevelwasdeterminedaccordingtothe
proceduresoutlinedinISO11094.
SoundPressureLevel
Thisunithasasoundpressurelevelattheoperator’searof84
dBA,whichincludesanUncertaintyValue(K)of1dBA.
Soundpressurelevelwasdeterminedaccordingtothe
proceduresoutlinedinENISO5395:2013.
VibrationLevel
Hand-Arm
Measuredvibrationlevelforrighthand=2.31m/s2
Measuredvibrationlevelforlefthand=2.55m/s2
UncertaintyValue(K)=1.28m/s2
Measuredvaluesweredeterminedaccordingtotheprocedures
outlinedinENISO5395:2013.
Model04039
SoundPowerLevel
Thisunithasaguaranteedsoundpowerlevelof94dBA,
whichincludesanUncertaintyValue(K)of1dBA.
Soundpowerlevelwasdeterminedaccordingtothe
proceduresoutlinedinISO11094.
SoundPressureLevel
Thisunithasasoundpressurelevelattheoperator’searof86
dBA,whichincludesanUncertaintyValue(K)of1dBA.
Soundpressurelevelwasdeterminedaccordingtothe
proceduresoutlinedinENISO5395:2013.
VibrationLevel
Hand-Arm
Measuredvibrationlevelforrighthand=2.76m/s2
Measuredvibrationlevelforlefthand=2.85m/s2
UncertaintyValue(K)=1.42m/s2
Measuredvaluesweredeterminedaccordingtotheprocedures
outlinedinENISO5395:2013.
6

SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential
danger.Replaceanydecalthatisdamagedorlost.
93-9356
1.Entanglementhazard—stayawayfrommovingparts.
93-7346
1.Reeldrive3.Disengage
2.Engage
93-6085
1.Fast3.Slow
2.Continuousvariable
setting
120–2769
1.Toxicgasinhalation
hazard—donotoperate
indoors.
4.Warning—disconnectthe
sparkplugwireandread
theinstructionbefore
servicingorperforming
maintenance.
2.Explosionhazard—stop
theengineandkeepaway
fromopenameswhen
refueling.
5.Hotsurface/burn
hazard—donottouch
hotsurfaces.
3.Warning—stoptheengine
andturnoffthefuelbefore
leavingthemachine.
6.Warning—readthe
Operator’sManual;when
addingfueltothetank,
onlylltothebottomof
thelltube.
93-8064
1.Warning—readtheinstructionsbeforeservicingor
performingmaintenance.
2.Cuttinghazardoffootorhand—stoptheengineandwait
formovingpartstostop.
125–5245
1.Cuttinghazardofhandorfoot—keepawayfrommoving
parts;keepallguardsandshieldsinplace.
117–2718
7

115-1720
1.Forward3.Neutral
2.Drivewheel
130-8322
1.Onlyusegasolinethat
contains10%ethanolby
volume(E10)orless.
3.Donotusegasolinethat
containsmorethan10%
ethanolbyvolume(E10).
2.ReadtheOperator's
Manual.
120-2727
1.Brake—toengage,pullthe
levertowardthehandle;
todisengage,releasethe
lever.
2.Parkingbrake—tolock,
pullthelevertowardthe
handle,pressthebutton
inandreleasethelever
againstthelockingbutton;
torelease,pullthelever
towardthehandleuntil
thebuttonreleasesand
releasethelever.
120–2761
1.Warning—readtheOperator’sManual.4.Thrownobjecthazard—keepbystandersawayfromthe
machine.
2.Warning—donotoperatethemachineunlesstheyaretrained.5.Warning—keepawayfrommovingparts;keepallguardsin
place.
3.Warning—wearhearingprotection.
8

Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
Handle1
1Cabletie2Installthehandle.
Kickstandassembly1
2Spring1Installthekickstand.
Wheelshaft,right1
3Wheelshaft,left1Installthetransportwheelshafts.
4Transportwheels(optional)2Installthetransportwheels(optional).
5Nopartsrequired–Adjustthecuttingunit.
6Grassbasket1Installthegrassbasket.
MediaandAdditionalParts
DescriptionQty.Use
Operator'sManual1
EngineOperator'sManual1
PartsCatalog1
OperatorTrainingMaterial1
CerticateofCompliance1
Readorviewbeforeoperatingthemachine.
Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.
1
InstallingandAdjustingthe
Handle
Partsneededforthisprocedure:
1Handle
2Cabletie
InstallingtheHandle
1.Removethebolts,locknuts,andwasherssecuringthe
bottomofthehandlearmstoeachsideofthemower
(Figure2).
1
2
3
4
g021285
Figure2
1.Handlearms3.Bolt,locknutandwasher
2.Mountingpins4.Hairpincotterandringpin
2.Removethehairpincottersandringpinssecuringthe
handlearmstotherearoftheframe(Figure2).
3.Insertthehandleendsthroughtheholesinthehandle
armsandaligntheholeswiththemountingpins
(Figure2).
9

4.Squeezethehandleendsinwardandinstallthemonthe
mountingpins(Figure3).
g021288
1
2
3
4
Figure3
1.Handleend
2.Bolt,washer,andlockwasher
3.Hairpincotterandringpin
4.Handlearm
5.Securethehandleendstothemountingpinswiththe
bolts,washers,andlockwasherspreviouslyremoved
(Figure3).
6.Securethehandlearmstotherearoftheframewith
thehairpincottersandringpinspreviouslyremoved
(Figure3).
7.Securethecablesandwireharnesstothehandlewith
cableties(Figure4).
G017590
1
Figure4
1.Cableties
AdjustingtheHandle
1.Removethehairpincottersfromtheringpinsoneach
sideofthemower(Figure2).
2.Whilesupportingthehandle,removetheringpins
fromeachsideandraiseorlowerthehandletothe
desiredoperatingposition(Figure2).
3.Installtheringpinsandhairpincotters.
2
InstallingtheKickstand(Model
GR1610)
Partsneededforthisprocedure:
1Kickstandassembly
1Spring
Procedure
Note:Thefastenersareshippedlooselyinstalledonthe
kickstandassembly.
1.Connectthespringstudtotherighthandsideof
thekickstand(Figure5)usingthebolt,washer,and
ange-headnutprovided.
G017948
1
2
34
Figure5
1.Bolt3.Washer
2.Springstud4.Flange-headnut
2.Hookthespringintotheholeinthespringbracketand
ontothespringstudwhilealigningthekickstandwith
themountingholesintherearframe(Figure6).
10

Figure6
1.Kickstand3.Springstud
2.Springbracket4.Spring
3.Mountthekickstandtoeachsideoftheframewith
abolt,lockwasher,spacer,atwasherandlocknut
(Figure6).
4.Positionthespacerinthekickstandmountinghole.
3
InstallingtheTransportWheel
Shafts
Partsneededforthisprocedure:
1Wheelshaft,right
1Wheelshaft,left
Procedure
1.Pushthekickstanddownwithyourfootandpullup
onthehandletosupportthemoweronthekickstand.
2.Applythread-lockingadhesivetothethreadsofthe
wheelshafts.
3.Threadtherightwheelshaftintothedrivepulleyon
therightsideofthemachine(Figure7).
Note:Therightwheelshafthaslefthandthreads.
Figure7
1.Rightwheelshaft
4.Torquetheshaftto688to101N-m(5to75ft-lb).
5.Repeatontheleftside.
4
InstallingtheTransport
Wheels(Optional)
Partsneededforthisprocedure:
2Transportwheels(optional)
Procedure
1.Slidethewheelontotheaxle(Figure8).
2.Pivotthewheellockingclipawayfromcenterofthe
wheelallowingittoslidefartherontotheaxle(Figure
8).
11

G017591
Figure8
1.Lockingclip
3.Rotatethewheelbackandforthuntilitslides
completelyontotheaxleandthelockingclipissecured
inthegrooveontheaxleshaft.
4.Repeattheprocedureontheoppositesideofthe
machine.
5.Inatethetiresto574to718Pa(12to15psi.).
5
AdjustingtheCuttingUnit
NoPartsRequired
Procedure
Beforeoperatingthemachine,completethefollowing
adjustments:
•AdjustingtheBedknifetotheReel(page32).
•AdjustingtheHeight-of-Cut(page33).
•AdjustingtheGrassShieldHeight(page34).
•AdjustingtheCut-offBar(page34).
6
InstallingtheGrassBasket
Partsneededforthisprocedure:
1Grassbasket
Procedure
Graspthebasketbythetoplipandslideitontothebasket
mountingrods(Figure9).
Figure9
1.Grassbasket2.Basketmountingrod
Note:Model04039only—Whencuttinginhigher
heights-of-cut,thebasketmaybeloweredbyremovingeach
basketmountingrodandinstallingeachontheoppositeside
ofthemachine.
12

ProductOverview
Controls
1234567
G017592
Figure10
1.Tractiondrivelever5.Servicebrake
2.Throttlecontrol6.Parkingbrake
3.On/offswitch7.Operatorpresencecontrol
(optional)
4.Hourmeter
ThrottleControl
Thethrottlecontrol(Figure10)islocatedontherearright
sideofthecontrolpanel.Theleverconnectstoandoperates
thethrottlelinkagetothecarburetor.SeeSpecications(page
14)forenginespeed.
TractionDriveLever
Thetractiondrivelever(Figure10)islocatedonthefront
rightsideofthecontrolpanel.Ithas2positions:Neutral
andForward.Pushingtheleverforwardengagesthetraction
drive.
ServiceBrake
Theservicebrake(Figure11)islocatedonthetopleftfront
sideofthecontrolpanel.Youcanusethebraketoslowor
stopthemachine.
G016976
Figure11
ParkingBrake
Theparkingbrake(Figure12)islocatedatthebaseofthe
servicebrake.Fullyengagetheservicebrakeandpushthe
parkingbrakeknobtoallowtheservicebraketorestonthe
parkingbrakepin.Engagetheservicebraketoreleasethe
parkingbrake.Youmustreleasethebrakebeforethetraction
driveisengaged.
G016977
Figure12
On/OffSwitch
Theon/offswitch(Figure10)islocatedonthetopofthe
controlpanel.MovetheswitchtotheOnpositiontostartthe
engineandtheOffpositiontostoptheengine.
OperatorPresenceControl(Optional)
Ifequipped,theoperatorpresencecontrol(Figure10)is
locatedontherearofthehandle.Pushtheoperatorpresence
controlagainstthehandle.Ifequipped,theoperatorpresence
controlmustbeengagedbeforemovingthetractiondrive
leverortheenginewillstop.
13

ReelDriveLever
Thereeldrivelever(Figure13)islocatedontherightfront
cornerofthemachine.Theleverhas2positions:Engage
andDisengage.Movetheleverforwardtoengagethereelor
rearwardtodisengagethereel.
G016978
1
Figure13
1.Reeldrivelever
ChokeLever
Thechokelever(Figure14)islocatedontheleftfrontofthe
engine.Theleverhas2positions:RunandChoke.Movethe
levertotheChokepositionwhenstartingacoldengine.After
theenginestarts,movethelevertotheRunposition.
1
G019637
2
Figure14
1.Chokelever2.Fuelshut-offvalve
FuelShut-offValve
Thefuelshut-offvalve(Figure14)islocatedontheleftfront
oftheenginenearthechokelever.Thevalvehas2positions:
ClosedandOpen.Movetheleveruptotheclosedposition
whenstoringortransportingthemachine.Openthevalve
beforestartingtheenginebyrotatingtheleverdown.
RecoilStarter
Pulltherecoilstarterhandle(Figure15)tostarttheengine.
Figure15
1.Recoilstarter2.Kickstand
Kickstand
Thekickstand(Figure15)ismountedtotherearofthe
machineandisusedtoraisetherearofthemachinefor
installationorremovalofthetransportwheels.
Specications
Model04038Model04039
Width91cm(36inches)104cm(41inches)
Height99cm(39inches)99cm(39inches)
Lengthwithbasket140cm(55inches)142cm(56inches)
Dryweight(with
basketandWiehle
roller;without
wheelsorgrooming
reel)
100kg(220lb)105kg(232lb)
Widthofcut53cm(21inches)66cm(26inches)
Heightofcut1.6mmto31.8
mm(0.063to1.25
inches)
3.1mmto31.7
mm(0.125to1.25
inches)
Clip3.6mm(0.14inch)3.6mm(0.14inch)
EnginespeedLowidle–1565
±150rpm,Highidle
–3375±100rpm
Lowidle–1565
±150rpm,Highidle
–3375±100rpm
14

Attachments/Accessories
AselectionofToroapprovedattachmentsandaccessoriesis
availableforusewiththemachinetoenhanceandexpand
itscapabilities.ContactyourAuthorizedServiceDealeror
Distributororgotowww .Toro.comforalistofallapproved
attachmentsandaccessories.
Operation
Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.
ThinkSafetyFirst
Pleasecarefullyreadallofthesafetyinstructionsanddecals
inthesafetysection.Knowingthisinformationcouldhelp
youorbystandersavoidinjury.
CheckingtheEngineOilLevel
Checktheengineoillevelbeforeeachuseorevery8operating
hours,refertoCheckingtheEngineOilLevel(page23)in
EngineMaintenance(page23).
FillingtheFuelTank
Note:Thefueltankcapacityis3.0liters(0.69gallons).
•Forbestresults,useonlyclean,fresh(lessthan30days
old),unleadedgasolinewithanoctaneratingof87or
higher((R+M)/2ratingmethod).
•Ethanol:Gasolinewithupto10%ethanol(gasohol)
or15%MTBE(methyltertiarybutylether)byvolume
isacceptable.EthanolandMTBEarenotthesame.
Gasolinewith15%ethanol(E15)byvolumeisnot
approvedforuse.Neverusegasolinethatcontains
morethan10%ethanolbyvolume,suchasE15
(contains15%ethanol),E20(contains20%ethanol),or
E85(containsupto85%ethanol).Usingunapproved
gasolinemaycauseperformanceproblemsand/orengine
damagewhichmaynotbecoveredunderwarranty.
•Donotusegasolinecontainingmethanol.
•Donotstorefueleitherinthefueltankorfuelcontainers
overthewinterunlessafuelstabilizerisused.
•Donotaddoiltogasoline.
15

DANGER
Incertainconditions,gasolineisextremely
ammableandhighlyexplosive.Areorexplosion
fromgasolinecanburnyouandothersandcan
damageproperty.
•Fillthefueltankoutdoors,inanopenarea,
whentheengineiscold.Wipeupanygasoline
thatspills.
•Neverllthefueltankinsideanenclosedtrailer.
•Donotllthefueltankcompletelyfull.Add
gasolinetothefueltankuntilthelevelis6to13
mm(1/4to1/2inch)belowthebottomofthe
llerneck.Thisemptyspaceinthetankallows
gasolinetoexpand.
•Neversmokewhenhandlinggasoline,andstay
awayfromanopenameorwheregasoline
fumesmaybeignitedbyaspark.
•Storegasolineinanapprovedcontainerand
keepitoutofthereachofchildren.Neverbuy
morethana30-daysupplyofgasoline.
•Donotoperatewithoutentireexhaustsystemin
placeandinproperworkingcondition.
DANGER
Incertainconditionsduringfueling,static
electricitycanbereleasedcausingasparkwhich
canignitethegasolinevapors.Areorexplosion
fromgasolinecanburnyouandothersandcan
damageproperty.
•Alwaysplacegasolinecontainersontheground
awayfromyourvehiclebeforelling.
•Donotllgasolinecontainersinsideavehicleor
onatruckortrailerbedbecauseinteriorcarpets
orplastictruckbedlinersmayinsulatethe
containerandslowthelossofanystaticcharge.
•Whenpractical,removegas-poweredequipment
fromthetruckortrailerandrefueltheequipment
withitswheelsontheground.
•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfromaportable
container,ratherthanfromagasolinedispenser
nozzle.
•Ifagasolinedispensernozzlemustbeused,
keepthenozzleincontactwiththerimofthe
fueltankorcontaineropeningatalltimesuntil
fuelingiscomplete.
WARNING
Gasolineisharmfulorfatalifswallowed.Long-term
exposuretovaporscancauseseriousinjuryand
illness.
•Avoidprolongedbreathingofvapors.
•Keepfaceawayfromnozzleandgastankor
conditionerbottleopening.
•Avoidcontactwithskin;washoffspillagewith
soapandwater.
1.Cleanaroundthefueltankcapandremovethecap
fromthetank(Figure16).
G017594
1
Figure16
1.Fueltankcap
2.Usingunleadedgasoline,llthefueltanknohigher
thanthebottomofthelterscreen.Thisspaceallows
thegasolinetoexpand.Donotllthefueltank
completelyfull.
3.Installfueltankcapandwipeupanyspilledgasoline.
16

BreakingintheMachine
RefertotheEngineManualsuppliedwiththemachineforoil
changeandmaintenanceproceduresrecommendedduring
thebreak-inperiod.
Only8hoursofmowingoperationisrequiredforthebreak-in
period.
Sincethersthoursofoperationarecriticaltofuture
dependabilityofthemachine,monitoritsfunctionsand
performancecloselysothatminordifculties,whichcould
leadtomajorproblems,arenotedandcanbecorrected.
Inspectthemachinefrequentlyduringbreak-inforsignsof
oilleakage,loosefasteners,oranyothermalfunction.
Toensureoptimumperformanceofthebrakesystem,burnish
(break-in)thebrakesbeforeusingthemachine.Toburnish
thebrakes,rmlyapplythebrakesanddrivethemachineat
mowingspeeduntilthebrakesarehot,asindicatedbytheir
smell.Anadjustmenttothebrakesmayberequiredafter
break-in;refertoAdjustingtheService/ParkingBrake(page
26).
CheckingtheInterlockSwitch
Operation
CAUTION
Ifsafetyinterlockswitchesaredisconnectedor
damagedthemachinecouldoperateunexpectedly
causingpersonalinjury.
•Donottamperwiththeinterlockswitches.
•Checktheoperationoftheinterlockswitches
dailyandreplaceanydamagedswitchesbefore
operatingthemachine.
1.Pushthekickstanddownwithyourfootandpullup
andbackonthehandletoraisethewheelsoffofthe
ground.
2.PlacethetractionleverintotheEngagepositionand
theenginecontrolsinthestartingposition.
3.Attempttostarttheengine.
Theengineshouldnotstart.Iftheenginestarts,the
interlockswitchneedsservice.Correcttheproblem
beforeoperating.RefertoServicingtheInterlock
Switch(page26).
4.Carefullyliftuponthehandletoreleasethekickstand.
StartingandStoppingthe
Engine
Note:Forillustrationsanddescriptionsofthecontrols
referencedinthissection,refertotheProductOverview
(page13)section.
StartingtheEngine
Note:Ensurethatthesparkplugwireisinstalledonthe
sparkplug.
1.Ensurethatthetractionandreeldriveleversareinthe
Disengagedposition.
Note:Theenginewillnotstartifthetractionleveris
intheEngagedposition.
2.Openthefuelshut-offvalveontheengine.
3.Movetheon/offswitchtotheOnposition.
4.MovethethrottlecontroltotheFastposition.
5.MovethechokeleverhalfwaybetweentheOnandOff
positionswhenstartingacoldengine.Thechokemay
notberequiredwhenstartingawarmengine.
6.Pulltherecoilstarterhandleoutuntilpositive
engagementresults,thenpullitvigorouslytostartthe
engine.
Important:Donotpullrecoilropetoitslimitor
letgoofstarterhandlewhenropeispulledout
becauseropemaybreakorrecoilassemblymay
bedamaged.
7.MovethechoketotheOffpositionastheengine
warmsup.
StoppingtheEngine
1.Movethetractionandreeldrivecontrolstothe
Disengagedposition,thethrottlecontroltotheSlow
position,andtheOn/OffswitchtotheOffposition.
2.Pullthesparkplugwireoffofthesparkplugtoprevent
thepossibilityofaccidentalstartingbeforestoringthe
machine.
3.Closethefuelshut-offvalvebeforestoringor
transportingthemowerinavehicle.
UsingtheTransportWheels
1.Ifthemachineisequippedwiththeoptionaltransport
wheels,pushthekickstanddownwithyourfootand
pulluponthehandletoraisetherearofthemower
andinstallthetransportwheels.
2.Toreleasethekickstand,pulluponthehandle,push
themowerforward,andthenlowertherearofthe
mowerontothetransportwheels.
3.Ensurethatthetractionandreeldrivecontrolsarein
theDisengagedpositionandstarttheengine.
17

4.SetthethrottlecontroltoSlow ,raisethefrontofthe
machineupslightly,graduallyengagethetractiondrive
andslowlyincreasetheenginespeed.
5.Adjustthethrottletooperatethemoweratthedesired
groundspeedandtransportthemowertothedesired
destination.
6.ReturnthetractioncontrollevertotheDisengage
position,thethrottletotheSlowposition,andstop
theengine.
TransportingtheMachine
Useaheavy-dutytrailerortrucktotransportthemachine.
Ensurethatthetrailerortruckhasallnecessarybrakes,
lighting,andmarkingasrequiredbylaw .Pleasecarefullyread
allthesafetyinstructions.Knowingthisinformationcould
helpyou,yourfamily,pets,orbystandersavoidinjury.
WARNING
Drivingonthestreetorroadwaywithoutturn
signals,lights,reectivemarkings,oraslow
movingvehicleemblemisdangerousandcanlead
toaccidentscausingpersonalinjury.
Donotdrivemachineonapublicstreetorroadway.
Totransportthemachine:
1.Ifusingatrailer,connectittothetowingvehicleand
connectthesafetychains.
2.Ifapplicable,connectthetrailerbrakes.
3.Loadthemachineontothetrailerortruck.
4.Stoptheengine,removethekey,setthebrake,and
closethefuelvalve.
5.Usethemetaltiedownloopsonthemachineto
securelyfastenthemachinetothetrailerortruckwith
straps,chains,cable,orropes.
LoadingtheMachine
Useextremecautionwhenloadingthemachineontoatrailer
oratruck.Onefull-widthrampthatiswideenoughtoextend
beyondthereartiresisrecommendedinsteadofindividual
rampsforeachsideofthemachine(Figure17).Thelower
rearsectionofthemachineframeextendsbackbetweenthe
rearwheelsandservesasastopfortippingbackward.Having
afull-widthrampprovidesasurfacefortheframemembers
tocontactifthemachinestartstotipbackward.Ifitisnot
possibletouseonefull-widthramp,useenoughindividual
rampstosimulateafull-widthcontinuousramp.
Therampshouldbelongenoughsothattheanglesdonot
exceed15degrees(Figure17).Asteeperanglemaycause
mowercomponentstogetcaughtastheunitmovesfromthe
ramptothetrailerortruck.Steeperanglesmayalsocause
themachinetotipbackward.Ifloadingonornearaslope,
positionthetrailerortrucksothatitisonthedownside
oftheslopeandtherampextendsuptheslope.Thiswill
minimizetherampangle.Thetrailerortruckshouldbeas
levelaspossible.
Important:Donotattempttoturnthemachinewhile
ontheramp;youmaylosecontrolanddriveofftheside.
Avoidsuddenaccelerationwhendrivinguparampand
suddendecelerationwhenbackingdownaramp.Both
maneuverscancausethemachinetotipbackward.
WARNING
Loadingamachineontoatrailerortruckincreases
thepossibilityofbackwardtip-overandcouldcause
seriousinjuryordeath.
•Useextremecautionwhenoperatingamachine
onaramp.
•EnsurethattheROPSisintheuppositionwhile
usingtheseatbeltwhenloadingthemachine.
EnsurethattheROPSwillclearthetopofan
enclosedtrailer.
•Useonlyasingle,full-widthramp;donotuse
individualrampsforeachsideofthemachine.
•Ifindividualrampsmustbeused,useenough
rampstocreateanunbrokenrampsurfacewider
thanthemachine.
•Donotexceeda15-degreeanglebetweenthe
rampandthegroundorbetweentherampand
thetrailerortruck.
•Avoidsuddenaccelerationwhiledrivingthe
machineuparamp,toavoidtippingbackward.
•Avoidsuddendecelerationwhilebacking
themachinedownaramp,toavoidtipping
backward.
18

Figure17
1.Trailer3.Notgreaterthan15
degrees
2.Full-widthramp4.Full-widthramp—side
view
PreparingtoMow
1.Ifthemachineisequippedwiththeoptionaltransport
wheels,pushthekickstanddownwithyourfootand
pullupandbackonthehandletoraisethewheelsoff
oftheground.
2.Pushthelockingclipsonthewheelsoutofthegrooves
intheshafts.
3.Slidethewheelsoffoftheshafts.
4.Movetheunitoffofthekickstand.
Mowing
Properuseofthemachineprovidesthesmoothestturf
cuttingavailable.ReferalsotoOperatingTips(page19)for
fundamentalsuggestionstoobtaintheutmostperformance
fromyourmower.
Important:Excessiveoperationofthecuttingunitwith
theabsenceofgrassclippings(lubricant)candamage
thecuttingunit.
1.Starttheengine,setthethrottleatareducedspeed,
pushdownonthehandletoraisethecuttingunit,
movethetractionlevertotheEngagedposition,and
transportthemowerontothecollarofthegreen.
2.MovethetractionlevertotheDisengagedpositionand
movethereeldrivelevertotheEngagedposition.
3.MovethetractionlevertotheEngagedposition,
increasethethrottlespeeduntilthemoweristraveling
atthedesiredgroundspeed,drivethemowerontothe
green,lowerthefrontofthemower,andcommence
operation.
4.Whennishedmowing,driveoffofthegreen,move
thetractioncontrollevertotheDisengageposition,
stoptheengineandpushthereeldriveleverintothe
Disengageposition.
5.Emptythegrassbasketofclippings,installthegrass
basket,andcommencetransportoperation.
OperatingTips
BeforeMowing
•Ensurethatthemoweriscarefullyadjustedandisset
evenlyonbothsidesofthereel.Impropermower
adjustmentismagniedmanytimesoverinthe
appearanceoftheclippedturf.
•Removeallforeignobjectsfromtheturfpriortomowing.
•Ensurethateveryone,especiallychildrenandpets,are
clearoftheworkarea.
MowingTechniques
•Mowagreeninastraightbackandforthdirection,across
thegreen.
•Avoidcircularmowingorturningthemoweronagreen
becausescufngmayoccur.Turnthemoweroffofthe
greenbyraisingthecuttingreel(pushingthehandle
down)andturningonthetractiondrum.
•Mowatanormalwalkingpace.Fastspeedsavesvery
littletimeandwillresultinaninferiormowingjob.
19

Maintenance
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
RecommendedMaintenanceSchedule(s)
MaintenanceService
IntervalMaintenanceProcedure
Aftertherst20hours•Changetheengineoil.
•Cleanthefuellterandcup.
Beforeeachuseordaily•Checktheinterlockswitchoperation.
•Checktheengineoillevel.
Every25hours•Greasethemachine.(Greasethettingsimmediatelyaftereverywashing
regardlessoftheintervallisted.)
Every50hours•Changetheengineoil.(Morefrequentlyindustyordirtyconditions)
•Cleanandoiltheaircleanerfoamelement.(Moreoftenindirtyordustyconditions)
Every100hours
•Replacethepaperairlterelement.(Moreoftenindirtyordustyconditions)
•Checkthesparkplug.
•Cleanthefuellterandcup.
Every500hours•Checkintakeandexhaustvalves.Adjustasnecessary.
•Cleanthecarburetor.
Every1,000hours
•Replacethefuelline.
•Checkthetransmissiondrivebelts.
•Checkthetransmissionbearings.
Important:Refertoyour Engine Operator's Man ual foradditionalmaintenanceprocedures.
20