Form No. 3352–412 Rev B Groundsmaster) 4000-D Groundsmaster Traction Unit Model No. 30410—Serial No.
Pushing or Towing the Machine . . . . . . . . . . . . . . Jacking Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tie Downs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Characteristics . . . . . . . . . . . . . . . . . . . Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Maintenance Schedule . . . . . . . . . Daily Maintenance Checklist . . . . . . . . . . . . .
Introduction CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death. Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely.
• Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine. – The machine speed should be kept low on slopes and during tight turns. – Stay alert for humps and hollows and other hidden hazards. • Warning—fuel is highly flammable. Take the following precautions: – Never mow across the face of the slope, unless the machine is designed for that purpose. – Store fuel in containers specifically designed for this purpose.
• Disengage drive to attachments when transporting or not is use. • Shut off fuel while storing or transporting. Do not store fuel near flames. • Stop the engine and disengage drive to attachment: • Park machine on level ground. Never allow untrained personnel to service machine. – before refuelling; • Use jack stands to support components when required. – before making height adjustment unless adjustment can be made from the operator’s position.
• Turn off the blades when not mowing. • Wearing safety shoes and long pants is advisable and required by some local ordinances and insurance regulations. Maintenance and Storage • Keep hands, feet, and clothing away from moving parts and the mower discharge area and underside of the mower while the engine is running. • Do not touch equipment or attachment parts which may be hot from operation. Allow to cool before attempting to maintain, adjust, or service. • Fill fuel tank until level is 1 in.
Sound Pressure Level Vibration Level This unit has an equivalent continuous A–weighted sound pressure level at the operator ear of 89 dBA, based on measurements of identical machines per Directive 98/37/EC and amendments. Hand-Arm This unit does not exceed a vibration level of 2.5 m/s2 at the hands based on measurements of identical machines per ISO 5349 procedures.
104–8336 100-6578 1. Stay away from moving parts. 2. Do not operate with cutting unit covers removed. 106-6752 1. Warning—read the Operator’s Manual. 2. Warning—lock the parking brake, stop the engine, and remove the ignition key before leaving the machine. 3. Warning—wear the seat belt when seated in the operator’s position. 4. Cutting hazard of hand or foot—stay away from moving parts. 5. Tipping hazard—lower the cutting unit when driving down slopes; do not drive on slopes greater than 15 degrees. 6.
106-6754 1. Do not touch the hot surface, and keep bystanders a safe distance from the machine. 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts 106-6753 1. Thrown object hazard—keep bystanders a safe distance from the machine. 2. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts. 93-7818 1. Danger—read the operator’s manual for blade torque specification. 104-8324 1. Raise cutting units 106-6755 1.
6-2046 1. 2. 3. 4. 5. Engage Power Take-off (PTO) Disengage High Transmission 6. 7. 8. 9. 10. Low Lock Flow divider Unlock Cruise control (optional) 11. 12. 13. 14. 15. Silencer switch Press the button Key switch Engine—preheat Fast 16. Continuous variable setting 17. Slow 18. Engine coolant temperature reset switch 100-5622 1. Height of cut adjustment 104-2277 1. To lock the parking brake, latch the pedals together, apply the brake pedals, and pull up on the knob. 2.
100-5694 104-3578 1. Height of cut adjustment 1. Height of cut adjustment 104-3579 100-5623 1. Low height of cut adjustment 1. Low height of cut adjustment 2. High height of cut adjustment 2. High height of cut adjustment 100-5693 1. Height of cut adjustment 104-3599 1. 2. 3. 4. 5. 6. 104-8325 1. Lock/unlock the cutting unit service lock. 11 Do not step here. Traction pedal Traction—forward Traction—reverse Danger—shut off PTO prior to raising the cutting units.
Specifications Traction Unit Specifications Engine Cooling system Fuel system Hydraulic system Kubota, four-cycle, four cylinder, 134 in.3 displacement, water-cooled turbo diesel engine. Rated 58 hp @ 2600 RPM, 23:1 compression ratio. Low idle—1500 RPM, high idle—2800 RPM. Oil capacity is 8 qt. (7.6 l) with filter. Capacity is 2-3/4 gallons (10.4 l) of 50/50 mixture of ethylene glycol anti-freeze. Electric fuel pump. Replaceable inline filter and spin-on fuel filter/water separator.
Cutting Unit Specifications Front cutting unit 62 in. (157 cm) width of cut, 3 blades. Cutting unit can be tipped and latched for maintenance. Side cutting units Height of cut 1–5 in. (25–177 mm) adjustable in 1/2 in. (13 mm) increments. Front cutting unit adjustment is achieved by changing spacers on castor wheels and length of support chains.
Setup Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Note: Use this chart as a checklist to ensure that all parts necessary for assembly have been received. Without these parts, total setup cannot be completed. Some parts may have already been assembled at the factory. Description Qty.
Before Operating 4. If the oil is below the FULL mark, remove the fill cap (Fig. 2) and add oil until the level reaches the FULL mark. Do not overfill. Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition before you do any maintenance.
Danger Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. • Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 1/4 to 1/2 in. (6 to 13 mm) below the bottom of the filler neck.
Checking the Hydraulic Fluid change the biodegradability and toxicity of this oil. When changing from standard fluid to the biodegradable type, be certain to follow the approved flushing procedure. Contact your local Toro Distributor for details. The machines reservoir is filled at the factory with approximately 8 U.S. gallons (13.2 l) of high quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter. The recommended replacement fluid is: 1.
3. Add gear oil to the hole in the planetary, if necessary, to bring the oil up to the proper level. Install the plug. 4. Repeat steps 1–3 on the opposite gear assembly. 1 Checking the Rear Axle Lubricant The rear axle is shipped from the factory filled with SAE 85W-140 wt. gear lube. Check the oil level before the engine is first started and every 400 hours thereafter. The capacity is 80 oz. (2.4 l). Visually inspect for leaks daily. 1. Position the machine on a level surface. 2.
Adjusting the Height-of-Cut 2. Remove the check/fill plug from the left side of the gear box (Fig. 9) and make sure that lubricant is up to the bottom of the hole. If the level is low, add enough lubricant to bring the level up to the bottom of the hole. Front Cutting Unit The height-of-cut is adjustable from 1 to 5 inches (25 to 127 mm) in 1/2 inch (13 mm) increments.
6. Mount the height-of-cut chains to the desired height-of-cut hole (Fig. 13) with the clevis pin and hairpin cotter. inches (64 mm) and grass buildup is detected, reverse the machines direction to pull any clippings away from the wheel/fork area. 3. Remove the tensioning cap from the spindle shaft (Fig. 10) and slide the spindle out of the castor arm. Put the 2 shims (1/8 inch) onto the spindle shaft as they were originally installed.
4. Remove the hairpin cotter and clevis pins from the castor pivot arms (Fig. 16). 2 5. Rotate tension rod to raise or lower pivot arm until holes are aligned with selected height-of-cut bracket holes in the cutting unit frame (Fig. 16 & 17) 3 6. Insert the clevis pins and install the hairpin cotters. 7. Rotate tension rod counterclockwise (finger tight) to put tension on adjustment. 4 4 3 1 5 2 1 Figure 16 1. Castor pivot arm 2. Axle mounting holes Figure 14 1. Castor wheel 2. Tensioning cap 3.
Adjusting the Skids Important The damper link length should never be adjusted. The length between the hole centers should be 5-3/8 in. (13.7 cm). The skids should be mounted in the lower position when operating in height of cuts greater than 2-1/2 inches (64 mm) and in the higher position when operating in height of cuts lower than 2-1/2 inches (64 mm). Adjust the skids by removing the flange bolt and nuts, positioning them as desired, and installing the fasteners (Fig. 20). 1 1 Figure 20 1.
Correcting Mismatch Between Cutting Units 2 3 Due to differences in grass conditions and the counterbalance setting of the traction unit, it is advised that grass be cut and appearance checked before formal cutting is started. 4 1. Set all cutting units to the desired height of cut; refer to Adjusting the Height of Cut, page 19. 2. Check and adjust front and rear tractor tire pressure to 25–30 psi (172–207 kPa). 3. Check and adjust all castor tire pressures to 50 psi (345 kPa). 5 4.
Recheck measurement between outside edges of both side cutting units and inside edge of side cutting unit to outside edge of front cutting unit. 4. If inside edge is still too high, remove an additional 1/8 in. shim from bottom of front inside castor arm of the side cutting unit and one 1/8 in. shim from the front outside castor arm of the side cutting unit. 1 3 5. If the inside edge of the side cutting unit is too low relative to the outside edge of the front cutting unit, add one 1/8 in.
Operation pedals, and pull the parking brake latch out. To release the parking brake, depress both pedals until the parking brake latch retracts. Note: Determine the left and right sides of the machine from the normal operating position. Caution 8 10 9 This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. 7 Wear hearing protection when operating this machine.
Glow Plug Indicator Light Key Switch When lit, the glow plug indicator light (Fig. 24) indicates that the glow plugs are on. The key switch (Fig. 26) has three positions: Off, On/Preheat, and Start. Engine Temperature Gauge PTO Switch This gauge (Fig. 24) indicates the engine coolant temperature. The PTO switch (Fig. 26) has three positions: On (engage), Neutral, and Off (disengage). Carefully lift and push the PTO switch forward to the On position to start the implement or cutting unit blades.
Fuel Gauge 4. When the glow indicator dims, turn the ignition key to the Start position. Release the key immediately when the engine starts and allow it to return to the Run position. Allow engine to warm up at mid speed (without load), then, move the throttle control to the desired position. The fuel gauge (Fig. 26) indicates the level of fuel in the tank. Hour Meter Important Do not run the starter motor more than 15 seconds at a time or premature starter failure may result.
Checking the Interlock Switches Pushing or Towing the Machine In an emergency, the machine can be moved forward by actuating the bypass valve in the variable displacement hydraulic pump and pushing or towing the machine. Do not push or tow the machine for more than 1/4 mile (0.4 km). Caution If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. Important Do not push or tow the machine faster than 2–3 MPH (3–4.
are the transmission, engine speed, load on the cutting blades or other implement components, and the importance of the brakes. To maintain enough power for the traction unit and implement while operating, regulate the traction pedal to keep the engine RPM high and somewhat constant. A good rule to follow is to decrease the ground speed as the load on the implement increases, and increase the ground speed as the load decreases.
Always Mow with Sharp Blades Before stopping the engine, disengage all controls and move the throttle to Slow. Moving the throttle to Slow reduces high engine RPM, noise, and vibration. Turn the key to Off to stop the engine. A sharp blade cuts cleanly and without tearing or shredding the grass blades like a dull blade. Tearing and shredding causes the grass to turn brown at the edges which impairs growth and increases susceptibility to diseases.
Maintenance Recommended Maintenance Schedule Maintenance Service Interval After first 10 hours • Check the cutting unit drive belt tension. • Check the fan and alternator belt tension. • Torque the wheel lug nuts. After first 50 hours • Change the engine oil and filter. • Check the engine RPM (at idle and full throttle). Lubricate all grease fittings. Inspect the air cleaner. Check the battery level and cable connections. Check the cutting unit drive belt tension.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Wed. Thurs. Check the safety interlock operation. Check the brake operation. Check the engine oil and fuel level. Check the cooling system fluid level. Drain the water/fuel separator. Check the air filter restriction indicator. Check the radiator, oil cooler, and screen for debris. Check unusual engine noises.1 Check unusual operating noises. Check the hydraulic system oil level.
Service Interval Chart Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition before you do any maintenance. Greasing the Bearings and Bushings • King pin bushings (2) (Fig. 34). The top fitting on the king pin should only be lubricated annually (2 pumps). The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease.
Front Cutting Unit • Castor fork shaft bushings (2) (Fig. 35) • Spindle shaft bearings (3) (located under the pulley) (Fig.
Front Lift Assemblies Side Cutting Units • Lift arm bushings (2) (Fig. 37) • Castor fork shaft bushing (1) (Fig. 39) • Lift cylinder bushings (4) (Fig. 37) • Spindle shaft bearings (2 ea.) (located under the pulley) • Lift arm ball joints (2) (Fig. 38) Figure 37 Figure 39 Side Lift Assemblies • Main lift arm bushings (6) (Fig. 40 and 41), • Bell crank pivot bushings (2) (Fig. 42) • Rear arm bushings (4) (Fig. 42) • Lift cylinder bushings (4) (Fig.
Figure 42 Figure 40 Figure 43 Figure 41 36
General Air Cleaner Maintenance 3. Remove the primary filter (Fig. 45). Cleaning of the used element is not recommended due to the possibility of damage to the filter media. Inspect the new filter for shipping damage, checking the sealing end of the filter and the body. Do not use a damaged element. Do not remove the safety filter (Fig. 46). • Check the air cleaner body for damage which could cause an air leak. Replace if damaged. Check the whole intake system for leaks, damage or loose hose clamps.
Servicing the Fuel System 5. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister. Do not apply pressure to the flexible center of the filter. Danger 6. Clean the dirt ejection port located in the removable cover. Remove the rubber outlet valve from the cover, clean the cavity and replace the outlet valve. Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive.
1 1 2 Figure 50 1. Fuel pre-filter Figure 49 1. Water Separator 5. Slide the hose clamps onto the ends of the fuel lines. Push the fuel lines onto the fuel filter and secure them with the hose clamps. Be sure that the arrow on the side of the filter points toward the injection pump. 2. Drain plug Replace filter canister after every 400 hours of operation. A. Clean the area where the filter canister mounts. Bleeding Air from the Injectors B. Remove the filter canister and clean the mounting surface.
Servicing the Engine Cooling System 4. Pivot the oil cooler back into position. Secure it to the frame with the knobs and close the hood. Removing Debris Servicing the Alternator Belt Remove debris from the oil cooler and radiator daily. Clean them more frequently in dirty conditions. Check the condition and tension of the belts (Fig. 54) after every 100 operating hours. 1. Turn the engine off and raise the hood. Clean the engine area thoroughly of all debris. 1. Proper tension will allow 3/8 in.
Adjusting the Throttle Changing the Hydraulic Fluid Adjust the throttle cable (Fig. 55) so that the governor lever on the engine contacts the low and high speed set bolts before the throttle lever contacts the slot in the control panel. Change the hydraulic fluid after every 800 operating hours, in normal conditions. If the fluid becomes contaminated, contact your local Toro distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil. 1.
Replacing the Hydraulic Filters Checking the Hydraulic Lines and Hoses Change the 2 hydraulic filters initially after the first 200 operating hours. Thereafter, change the filters after every 800 operating hours, in normal conditions. Inspect the hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating. Use Toro replacement filters (Part No.
Test Port “B” (Fig. 59), located on the right side of the machine, is used to measure the reverse traction pressure. 1 1 Figure 61 Figure 59 1. Test port “D” 1. Test port “B” Test Port “E” (Fig. 62), located under the radiator, is used to measure the four-wheel drive pressure in reverse. Test Port “C” (Fig. 60), located on the left side of the machine, is used to measure the left cutting unit pressure. 1 1 Figure 62 Figure 60 1. Test port “E” 1. Test port “C” Test Port “D” (Fig.
the counterbalance pressure, rotate the adjusting screw (Fig. 65) clockwise to increase the pressure or counterclockwise to decrease the pressure. Test Port “F” (Fig. 63), located under the seat, is used to measure the lift circuit pressure. Test Port “G” (Fig. 63), located under the seat, is used to measure the charge circuit pressure. 2 1 1 2 Figure 65 1. Counterbalance test port Adjusting the Cutting Unit Flow Control Figure 63 1. Test port “F” 2. Counterbalance adjusting screw 2.
Adjusting the Service Brakes 2. Check the traction pedal stop adjustment. The distance from the top of the stand to the top of the stop must be 1-1/2 in. (38 mm) (Fig. 67). Loosen the nuts and adjust, as required. 1 Adjust the service brakes when there is more than 1 in. (25 mm) of “free travel” of the brake pedal, or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before braking resistance is felt. 1-1/2 in. (38 mm) 1.
2. Place a drain pan under the hub, remove the plug, and allow the oil to drain. 3. When all of the oil has drained, position the wheel so that the plug hole is at the ten or two o’clock position. 4. Place a drain pan under the brake housing on the other side of the wheel (Fig. 70). 5. Remove the plug from the bottom of the housing and allow the oil to drain. 6. When all of the oil has drained, install the plug in the housing. 7. Add approximately 16 oz. (0.5 l) of high quality SAE 85W-140 wt.
Checking the Rear Wheel Toe-In After every 800 operating hours or annually, check the rear wheel toe-in. 1. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires. The front measurement must be 1/4 in. (6 mm) less than the rear measurement. 2. To adjust, loosen the clamps at both ends of the tie rods. 1 3. Rotate the tie rod end to move the front of the tire inward or outward. 4. Tighten the tie rod clamps when the adjustment is correct.
Warning Battery terminals or metal tools could short against metal components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. • Do not allow metal tools to short between the battery terminals and metal parts of the machine. 1 Warning Figure 74 Incorrect battery cable routing could damage the machine and cables causing sparks.
Fuses 3. Move latch arm pivot in or out until rubber cushion of adjustment screw is centered under deck latch. Tighten flange nuts. There are 5 fuses in the electrical system. They are located below the operators control panel (Fig. 75 and 76). 3 1 2 1 Figure 77 1. Latch arm pivot 2. Adjustment screw 3. Deck latch Figure 75 4. Clearance between adjustment screw rubber (Fig. 78) cushion and deck latch should be .125”.
2 1 Figure 79 Figure 81 1. Raise the front cutting unit slightly off of the floor, set the parking brake, and stop the engine. Remove the ignition key. 1. Cable 2. Remove the hairpin cotter and clevis pin securing the deck transport latch to the latch plate (Fig. 80). Pivot latch toward rear of deck. 2 2. Pin Pivoting the Front Cutting Unit Down 1 1. With the help of another person, hold the cutting unit upright, remove the hairpin cotter securing the cable end, and remove the cable from the pin. 2.
3. Torque the idler nut to 60–70 ft–lbs. 2 1 1 Figure 82 Figure 83 1. Idler pulleys 1. Height-of-cut chain Adjusting the Cutting Unit Pitch Adjusting the Side Cutting Units 2. u-bolt 1. Remove the tensioning cap from the spindle shaft and slide the spindle out of the castor arm (Fig. 84). Reposition the shims, as required, to raise or lower the castor wheel until the cutting unit has the correct pitch.
Servicing the Castor Arm Bushings 2 The castor arms have bushings pressed into the top and bottom of the tube and after many hours of operation, the bushings will wear. To check the bushings, move the castor fork back and forth and from side to side. If the castor spindle is loose inside the bushings, the bushings are worn and must be replaced. 1 1. Raise the cutting unit so that the wheels are off of the floor. Block the cutting unit so that it cannot accidentally fall. 3 2.
Checking for a Bent Blade After striking a foreign object, inspect the machine for damage and make repairs before restarting and operating the equipment. Torque all the spindle pulley nuts to 130–150 ft–lbs. 2 1 1. Position the machine on a level surface. Raise the cutting unit, engage the parking brake, put the traction pedal in neutral, put the PTO lever in the Off position, stop the engine, and remove the ignition key. Block the cutting unit to prevent it from accidentally falling. Figure 89 1.
Correcting Cutting Unit Mismatch FLAT PART OF BLADE A SAIL If there is mismatch between the blades, on a single cutting unit, the grass will appear streaked when it is cut. This problem can be corrected by making sure that the blades are straight and all of the blades are cutting on the same plane. SAIL B 1. Using a 3 foot (1 meter) long carpenters level, find a level surface on the shop floor. WEAR 2. Raise the height-of-cut to the highest position; refer to Adjusting the Height-Of-Cut, page 19.
1. Lower the cutting unit to the shop floor. Remove the belt covers from the top of the cutting unit and set the covers aside. 4. Remove the old belt from around the spindle pulleys and idler pulley. 5. Route the new belt around the spindle pulleys and idler pulley assembly. 2. Loosen the nut securing the idler pulley to the cutting unit (Fig. 82). Move the pulley away from the belt to release the belt tension. 6. Position the hydraulic motor on the cutting unit after routing the belt around the pulleys.
Electrical Schematic 56
CD SV1 G G BY1 BY1 P2 P1 P2 P1 P2 14 GPM PB T .58 G 5 PSI P 1350 PSI L OIL COOLER 40 PSI PROPORTIONAL FLOW DIVIDER 14 GPM STEERING CONTROL 6.1 CU IN T R P1 TOW VALVE 2.48 250 PSI CD 1.2 3.5 GPM FILTER P2 1.2 G RV G CD 5000 PSI 4000 PSI CHG P .020 5.2:1 45% M1 2.48 55% G FRONT DR M2 2.48 5.2:1 G P2 CHG P1 RH WING DECK LIFT F CYL4 CYL2 CYL1 LH WING DECK LIFT CYL3 PR .
Preparing for Seasonal Storage Engine Traction Unit 1. Drain the engine oil from the oil pan and install the drain plug. 1. Thoroughly clean the traction unit, cutting units, and the engine. 2. Remove and discard the oil filter. Install a new oil filter. 3. Refill the oil pan with 8 qt. (7.6 l) of SAE 10W-30 CD, CE, CF, CF-4, or CG-4 motor oil. 2. Check the tire pressure; refer to Checking the Tire Pressure, page 19. 3. Check all fasteners for looseness; tighten as necessary. 4.
The Toro General Commercial Products Warranty A Two-Year 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.
