Toro 4038 User manual

FormNo.3385-993RevA
Greensmaster®1010and1616
Mower
ModelNo.04038—SerialNo.314004001andUp
ModelNo.04039—SerialNo.314004001andUp
Registeratwww.Toro.com.
OriginalInstructions(EN)*3385-993*A

ThisproductcomplieswithallrelevantEuropeandirectives,
fordetailspleaseseetheseparateproductspecicDeclaration
ofConformity(DOC)sheet.
WARNING
CALIFORNIA
Proposition65Warning
Thisproductcontainsachemicalorchemicals
knowntotheStateofCaliforniatocausecancer,
birthdefects,orreproductiveharm.
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
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
Introduction..................................................................2
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
Breaking-intheMachine..........................................17
CheckingtheInterlockSwitchOperation...................17
StartingandStoppingtheEngine..............................17
TransportingtheMachine........................................17
PreparingtoMow...................................................18
Mowing................................................................18
OperatingTips......................................................18
Maintenance.................................................................19
RecommendedMaintenanceSchedule(s)......................19
DailyMaintenanceChecklist....................................20
Lubrication...............................................................21
GreasingtheMachine.............................................21
EngineMaintenance..................................................22
ServicingtheEngineOil..........................................22
ServicingtheAirCleaner.........................................23
ReplacingtheSparkPlug.........................................24
FuelSystemMaintenance...........................................24
CleaningtheFuelFilter...........................................24
ElectricalSystemMaintenance....................................25
ServicingtheInterlockSwitch.................................25
BrakeMaintenance....................................................25
AdjustingtheService/ParkingBrake.........................25
BeltMaintenance......................................................27
AdjustingtheBelts.................................................27
ReplacingtheDifferentialBelt..................................29
ControlsSystemMaintenance.....................................30
AdjustingtheTractionControl.................................30
CuttingUnitMaintenance...........................................30
LevelingtheRearDrumtotheReel...........................30
AdjustingtheBedknifetotheReel............................31
AdjustingtheHeight-of-Cut....................................32
AdjustingtheGrassShieldHeight.............................33
AdjustingtheCut-offBar........................................33
BedbarIdentication..............................................33
SettingtheMachinetoMatchTurfConditions............34
ServicingtheBedbar...............................................35
BacklappingtheReel...............................................36
Storage........................................................................36
3

Safety
SafeOperatingPractices
ThefollowinginstructionsareadaptedfromtheCEN
standardEN836:1997,ISOstandard5395:1990,andANSI
B71.4-2012.
Whenoperatingthismachinebetween5000to8000feet
abovesealevelyouwillneedtoobtainthehigh-altitude
kit.SeeyourAuthorizedToroDealer.
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,alwayswearsubstantialfootwear,long
trousers,hardhat,safetyglasses,andhearingprotection.
Longhair,looseclothing,orjewelrymaygettangled
inmovingparts.Donotoperatetheequipmentwhen
barefootorwearingopensandals.
•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
dangerouscarbonmonoxidefumescancollect.
•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;
–beforemakingheightadjustments;
–beforeclearingblockages;
–beforechecking,cleaningorworkingonthemower;
–afterstrikingaforeignobjectorifanabnormal
vibrationoccurs.Inspectthemowerfordamage
4

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.
ToroMowerSafety
ThefollowinglistcontainssafetyinformationspecictoToro
productsorothersafetyinformationthatyoumustknowthat
isnotincludedintheCEN,ISO,orANSIstandard.
Thisproductiscapableofamputatinghandsandfeetand
throwingobjects.Alwaysfollowallsafetyinstructionsto
avoidseriousinjuryordeath.
Useofthisproductforpurposesotherthanitsintendeduse
couldprovedangeroustouserandbystanders.
•Knowhowtostoptheenginequickly.
•Donotoperatethemachinewhilewearingtennisshoes
orsneakers.
•Wearingsafetyshoesandlongpantsisadvisableand
requiredbysomelocalordinancesandinsurance
regulations.
•Handlegasolinecarefully.Wipeupanyspills.
•Checkthesafetyinterlockswitchesdailyforproper
operation.Ifaswitchshouldfail,replacetheswitch
beforeoperatingthemachine.
•Usingthemachinedemandsattention.Topreventloss
ofcontrol:
–Donotoperateclosetosandtraps,ditches,creeks,or
otherhazards.
–Reducespeedwhenmakingsharpturns.Avoid
suddenstopsandstarts.
5

–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.
Hauling
•Usecarewhenloadingorunloadingthemachineintoa
trailerortruck.
•Usefullwidthrampsforloadingmachineintotraileror
truck.
•Tiethemachinedownsecurelyusingstraps,chains,cable,
orropes.Bothfrontandrearstrapsshouldbedirected
downandoutwardfromthemachine.
Model04038
SoundPowerLevel
Thisunithasaguaranteedsoundpowerlevelof92dBA,
whichincludesanUncertaintyValue(K)of1dBA.
Soundpowerlevelwasdeterminedaccordingtothe
proceduresoutlinedinISO11094.
SoundPressureLevel
Thisunithasasoundpressurelevelattheoperator’searof84
dBA,whichincludesanUncertaintyValue(K)of1dBA.
Soundpressurelevelwasdeterminedaccordingtothe
proceduresoutlinedinEN836.
VibrationLevel
Hand-Arm
Measuredvibrationlevelforrighthand=2.31m/s2
Measuredvibrationlevelforlefthand=2.55m/s2
UncertaintyValue(K)=1.28m/s2
Measuredvaluesweredeterminedaccordingtotheprocedures
outlinedinEN836.
Model04039
SoundPowerLevel
Thisunithasaguaranteedsoundpowerlevelof94dBA,
whichincludesanUncertaintyValue(K)of1dBA.
Soundpowerlevelwasdeterminedaccordingtothe
proceduresoutlinedinISO11094.
SoundPressureLevel
Thisunithasasoundpressurelevelattheoperator’searof86
dBA,whichincludesanUncertaintyValue(K)of1dBA.
Soundpressurelevelwasdeterminedaccordingtothe
proceduresoutlinedinEN836.
VibrationLevel
Hand-Arm
Measuredvibrationlevelforrighthand=2.76m/s2
Measuredvibrationlevelforlefthand=2.85m/s2
UncertaintyValue(K)=1.42m/s2
Measuredvaluesweredeterminedaccordingtotheprocedures
outlinedinEN836.
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.
7

115-1720
1.Forward3.Neutral
2.Drivewheel
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:
•LevelingtheRearDrumtotheReel(page30).
•AdjustingtheBedknifetotheReel(page31).
•AdjustingtheHeight-of-Cut(page32).
•AdjustingtheGrassShieldHeight(page33).
•AdjustingtheCut-offBar(page33).
RefertotheCuttingUnitMaintenancesectioninMaintenance
forinstructionsonperformingtheseprocedures.
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,High
idle–3375±100
RPM
Lowidle–1565
±150RPM,High
idle–3375±100
RPM
14

Attachments/Accessories
AselectionofToroapprovedattachmentsandaccessoriesis
availableforusewiththemachinetoenhanceandexpand
itscapabilities.ContactyourAuthorizedServiceDealeror
Distributororgotowww .Toro.comforalistofallapproved
attachmentsandaccessories.
Operation
Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.
ThinkSafetyFirst
Pleasecarefullyreadallofthesafetyinstructionsanddecals
inthesafetysection.Knowingthisinformationcouldhelp
youorbystandersavoidinjury.
CheckingtheEngineOilLevel
Checktheengineoillevelbeforeeachuseorevery8operating
hours,refertoCheckingtheEngineOilLevel(page22)in
EngineMaintenance(page22).
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

Breaking-intheMachine
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
25).
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(page25).
4.Carefullyliftuponthehandletoreleasethekickstand.
StartingandStoppingthe
Engine
Note:Forillustrationsanddescriptionsofthecontrols
referencedinthissection,refertotheControls(page13)
sectioninProductOverview(page13).
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.
TransportingtheMachine
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.
PreparingtoMow
1.Ifthemachineisequippedwiththeoptionaltransport
wheels,pushthekickstanddownwithyourfootand
pullupandbackonthehandletoraisethewheelsoff
oftheground.
2.Pushthelockingclipsonthewheelsoutofthegrooves
intheshafts.
3.Slidethewheelsoffoftheshafts.
4.Movetheunitoffofthekickstand.
Mowing
Properuseofthemachineprovidesthesmoothestturf
cuttingavailable.ReferalsotoOperatingTips(page18)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.
18

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.
19

DailyMaintenanceChecklist
Important:Duplicatethispageforroutineuse.
Fortheweekof:
Maintenance
CheckItemMon.Tues.Wed.Thurs.Fri.Sat.Sun.
Checkthe
safetyinterlock
operation.
Checkthe
parkingbrake
operation.
Checkthefuel
level.
Checktheengine
oillevel.
Checktheair
lter.
Cleantheengine
coolingns.
Checkfor
unusualengine
noises.
Checkfor
unusual
operatingnoises.
Checkthe
reel-to-bedknife
adjustment.
Checkthe
height-of-cut
adjustment.
Greaseall
ttings.
Touchup
damagedpaint.
NotationforAreasofConcern
Inspectionperformedby:
ItemDateInformation
20