Form No. 3357-707 Rev B Groundsmaster® 4000-D Traction Unit Model No. 30410—Serial No. 2700000001 and Up Register your product at www.Toro.
Contents Warning CALIFORNIA Proposition 65 Warning Introduction ....................................................... 2 Safety .................................................................. 4 Safe Operating Practices ...................... 4 Toro Mower Safety .............................. 6 Sound Pressure Level........................... 8 Sound Power Level .............................. 8 Vibration Level.................................... 8 Safety and Instructional Decals ............ 8 Setup ...
Activating, Charging, and Connecting the Battery .............................. 41 Battery Care ...................................... 43 Fuses................................................. 43 Drive System Maintenance......................... 43 Changing the Planetary Gear Drive Oil..................................... 43 Changing the Rear Axle Lubricant .......................... 44 Checking the Rear Wheel Toe-In ............................... 44 Cooling System Maintenance .....................
Safety ◊ inadequate braking; ◊ the type of machine is unsuitable for its task; This machine meets or exceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-2004 specifications in effect at the time of production. ◊ lack of awareness of the effect of ground conditions, especially slopes; ◊ incorrect hitching and load distribution. Improper use or maintenance by the operator or owner can result in injury.
accessories and attachments approved by the manufacturer. • Check that operators presence controls, safety switches, and shields are attached and functioning properly. Do not operate unless they are functioning properly. • When using any attachments, never direct discharge of material toward bystanders nor allow anyone near the machine while in operation. • Never operate the machine with damaged guards, shields, or without safety protective devices in place.
• Keep hands and feet away from the cutting units. • Look behind and down before backing up to be sure of a clear path. • Slow down and use caution when making turns and crossing roads and sidewalks. • Do not operate the mower under the influence of alcohol or drugs. • Use care when loading or unloading the machine into a trailer or truck. • The operator shall turn on flashing warning lights, if provided, whenever traveling on a public road, except where such use is prohibited by law.
• Wearing safety shoes and long pants is advisable and required by some local ordinances and insurance regulations. • Keep hands, feet, and clothing away from moving parts and the mower discharge area and underside of the mower while the engine is running. • Fill fuel tank until level is 1 inch (25 mm) below the bottom of the filler neck. Do not overfill. • Check the safety interlock switches daily for proper operation. If a switch should fail, replace the switch before operating the machine.
Sound Power Level • The engine must be shut off before checking the oil or adding oil to the crankcase. This unit has an equivalent continuous A-weighted sound power level at the operator ear of 105 dBA/1 pW, based on measurements of identical machines per EN 11094. • If major repairs are ever needed or if assistance is desired, contact an Authorized Toro Distributor.
100-5624 100-5623 1. Height of cut adjustment 1. Low height of cut adjustment 2. High height of cut adjustment 100-5693 1. Height of cut adjustment 100-5694 1. Height of cut adjustment 100-6578 1. Entanglement hazard, belt—do not operate the machine with the shields or guards removed; always keep the shields and guards in place; stay away from moving parts. 104-3578 1. 100-5622 1.
1. 2. 3. 104-2277 104-2277 1. To lock the parking brake, 4. latch the pedals together, apply the brake pedals, and pull up on the knob. 2. To unlock the parking 5. brake, step on the brake pedals. 3. Parking brake lock indicator 6. Read the Operator’s Manual. 104-3599 1. 2. 3. 4. 5. Press for optional headlights. Press down on the lever to tilt the steering wheel. Do not step here.
104-8325 1. Lock/unlock the cutting unit service lock. 106-6753 1. 2. 3. 4. Engine coolant under pressure Explosion hazard—read the Operator’s Manual. Warning—do not touch the hot surface. Warning—read the Operator’s Manual. 112-9118 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.
110-3286 1. Power outlet 2. Seat switch 3. Ignition switch 4. 5. 6. Power Take Off (PTO) Starter solenoid Light Kit 106-6764 1. To start the engine, move the traction pedal to Neutral, press the brake pedal, move the throttle lever to Fast, turn the ignition key to On, and then turn the ignition key to Start; read the Operators Manual. 2.
104-8336 1. Read the Operator’s Manual.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Step 1 2 3 4 Qty. Description Use Seat kit (obtain separately) Seat suspension kit (obtain separately) Manual tube R-clamp Seat belt Bolt Lock washer 1 1 2 1 2 2 Install the seat, seat belt, and manual tube. No parts required – Grease the machine. Warning Decal 1 Used only on machines outside the U.S.A.
Step 1. Mount the manual tube to the seat suspension with the 2 R-clamps included in loose parts. 4 2. Install the seat belt to each side of the seat with a bolt and lock washer, supplied in loose parts. Important: Make sure that the seat switch wire is connected to the seat switch connector on the harness. Reading the Manuals and Viewing the DVD 3.
Product Overview pedal. For no load, maximum ground speed, fully press the pedal while the throttle is in Fast. To stop, reduce your foot pressure on the traction pedal and allow it to return to the center position. Important: The speed limiter screw must stop the traction pedal before the pump reaches full stroke or damage to the pump may occur. Brake Pedals Two foot pedals (Figure 2) operate individual wheel brakes for turning assistance, parking, and to aid in obtaining better side hill traction.
Glow Plug Indicator Light PTO Switch When lit, the glow plug indicator light (Figure 2) indicates that the glow plugs are on. This gauge (Figure 2) indicates the engine coolant temperature. The PTO switch (Figure 4) 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. Slowly pull the switch backward to the Off position to stop implement operation.
Temperature Override Switch Throttle Control Press and hold the reset switch (Figure 4) to start the engine after high temperature shut down. Use only for emergency operation. Move the control (Figure 4) forward to increase the engine speed and rearward to decrease the speed. Power Point Audible Alarm The power point (Figure 4) is used to power optional electrical accessories.
Operation Note: Determine the left and right sides of the machine from the normal operating position. Before Operating If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Figure 5 1. Remove the key from the ignition before you do any maintenance. Dipstick 4. If the oil is below the Full mark, remove the fill cap (Figure 6) and add oil until the level reaches the Full mark. Do not overfill.
If the engine has been running, the pressurized, hot coolant can escape and cause burns. • Do not open the radiator cap when the engine is running. • Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape. Figure 8 1. Fuel tank cap 2. Check the coolant level in the radiator. The radiator should be filled to the top of the filler neck and the expansion tank filled to the Full mark. Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive.
Alternate fluids: If the Toro fluid is not available, other fluids may be used provided they meet all the following material properties and industry specifications. We do not recommend the use of synthetic fluid. Consult with your lubricant distributor to identify a satisfactory product. procedure. Contact your local Toro Distributor for details.
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. Remove a check plug from one end of the axle (Figure 12) and make sure that the lubricant is up to the bottom of the hole. If the level is low, remove the fill plug (Figure 12) and add enough lubricant to bring the level up to the bottom of the check plug holes. Figure 10 1. Check/drain plug 2.
1. Start the engine and raise the cutting units so that the height-of-cut can be changed. Stop the engine and remove the key after the cutting unit is raised. 2. Position the castor wheel axles in the same holes in all castor forks. Refer to the following chart to determine the correct holes for the setting. Figure 13 1. Gear box 2. Check/ll plug Checking the Tire Pressure The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure.
inch spacers (refer to the chart below) onto the spindle shaft to get the desired height-of-cut; then slide the washer onto the shaft. Refer to the following chart to determine the combinations of spacers for the setting: Figure 17 Note: When using 1 inch (25 mm), 1-1/2 inch (38 mm), or occasionally 2 inch (51 mm) height-of-cut, move the skids and gage wheels to the highest holes.
height-of-cut bracket holes in the cutting unit frame (Figure 20 and Figure 21). 6. Insert the clevis pins and install the hairpin cotters. 7. Rotate tension rod counterclockwise (finger tight) to put tension on adjustment. Figure 20 Figure 18 1. Castor wheel 2. Tensioning cap 3. Spacers 4. 5. Shims Axle mounting holes 1. Castor pivot arm 3. 2. Axle mounting holes 4. Clevis pin and hair pin cotter Tension rod Refer to the following chart to determine the combinations of spacers for the setting.
Figure 24 1. Skid Adjusting the Cutting Unit Rollers The cutting unit rollers 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). 1. Remove the bolt and nut securing the gage wheel to the cutting unit brackets (Figure 25). Figure 22 1. Damper link Figure 25 Figure 23 1. Gage wheel Adjusting the Skids 2.
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). 4. Check charge and counterbalance pressures with engine at high idle using test ports defined in Hydraulic Systems Test Ports. Adjust counterbalance setting to be 220 psi (1517 kPa) higher than charge pressure reading. 5. Check for bent blades; refer to Checking for a Bent Blade procedure in Mower Maintenance, page 51. 6.
3. If the inside edge of the side cutting unit is too high relative to the outside edge of the front cutting unit, remove one 1/8 inch shim from the bottom of the front inside castor arm on the side cutting unit (Figure 27). 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.
Checking the Interlock Switches 3. Turn the ignition key to the Run position. The glow indicator will light. 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.
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). Important: Do not push or tow the machine faster than 2-3 MPH (3-4.8 km/h) because internal transmission damage may occur. The bypass valve must be open whenever the machine is pushed or towed. Figure 29 1. Reverse traction pressure test port 1.
Some points to consider when operating the traction unit, cutting unit, or other implements are the transmission, engine speed, load on the cutting blades or other implement components, and the importance of the brakes. This product is designed to drive objects into the ground where they lose energy quickly in grass areas. However, careless operation, combined with terrain angle, ricochets, or improperly positioned safety guard can lead to thrown object injuries.
Select the Proper Height-of-Cut Setting to Suit Conditions Remove approximately 1 inch (25 mm) or no more than 1/3 of the grass blade when cutting. In exceptionally lush and dense grass, you may have to raise the height-of-cut to the next setting. Mow at Proper Intervals Under most normal conditions you will need to mow approximately every 4-5 days. But remember, grass grows at different rates at different times.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the rst 10 operating hours • Torque the wheel lug nuts. • Check the fan and alternator belt tension. • Check the blade drive belt tension. After the rst 50 operating hours • Change the engine oil and lter. • Check the engine RPM (at idle and full throttle).
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. Premaintenance Procedures Service Interval Chart Figure 32 Lubrication • Traction pedal pivot bushing (1) (Figure 34) Greasing the Bearings and Bushings • Front and rear axle pivot bushings (2) (Figure 35) The machine has grease fittings that must be lubricated regularly with No.
Figure 33 Figure 36 Front Cutting Unit Figure 34 • Castor fork shaft bushings (2) (Figure 37) • Spindle shaft bearings (3) (located under the pulley) (Figure 38) • Idler arm pivot bushings (2) (Figure 38) Figure 35 35
Figure 39 Figure 37 Figure 38 Front Lift Assemblies • Lift arm bushings (2) (Figure 39) Figure 40 • Lift cylinder bushings (4) (Figure 39) • Lift arm ball joints (2) (Figure 40) Side Cutting Units • Castor fork shaft bushing (1) (Figure 41) • Spindle shaft bearings (2 each) (located under the pulley) • Idler arm pivot bushings (1) (located on the idler arm) 36
Figure 42 Figure 41 Side Lift Assemblies • Main lift arm bushings (6) (Figure 42 and Figure 43), • Bell crank pivot bushings (2) (Figure 44) • Rear arm bushings (4) (Figure 44) • Lift cylinder bushings (4) (Figure 45) Figure 43 37
• Service the air cleaner filter only when the service indicator requires it or every 400 hours (more frequently in extremely dusty or dirty conditions). Changing the air filter before it is necessary only increases the chance of dirt entering the engine when the filter is removed. • Be sure the cover is seated correctly and seals with the air cleaner body. Servicing the Air Cleaner 1. Pull the latch outward and rotate the air cleaner cover counterclockwise (Figure 46). 2.
Servicing the Engine Oil and Filter Change the oil and filter initially after the first 50 hours of operation; thereafter change the oil and filter every 150 hours. 1. Remove either drain plug (Figure 49) and let the oil flow into a drain pan. When the oil stops, install the drain plug. Figure 47 1. Air cleaner primary lter Figure 49 1. Engine oil drain plug 2. Remove the oil filter (Figure 50). Apply a light coat of clean oil to the new filter seal before screwing it on. Do not overtighten. Figure 48 1.
Fuel System Maintenance Servicing the Fuel System 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. Figure 51 1. Water Separator • Do not fill the fuel tank completely full.
Electrical System Maintenance Activating, Charging, and Connecting the Battery Warning CALIFORNIA Proposition 65 Warning Figure 52 Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. 1. Fuel pre-lter 3. 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.
Important: Do not overfill the battery. Electrolyte will overflow onto other parts of the machine and severe corrosion and deterioration will result. Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. 7. Install the positive cable (red) to the positive (+) terminal and the negative cable (black) to the negative (-) terminal of the battery and secure them with the bolts and nuts.
corrosion. Slide the rubber boot over the positive terminal. 9. Install the battery cover. Battery Care Battery type is group 24. Figure 57 Important: Before welding on the machine, disconnect the terminal connector from the alternator to prevent damage to the electrical system. 1. 2. 3. Note: Check the battery condition weekly or after every 50 hours of operation. Keep the terminals and the entire battery case clean because a dirty battery will discharge slowly.
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 (Figure 59). 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.
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 inch (6 mm) less than the rear measurement. 2. To adjust, loosen the clamps at both ends of the tie rods. 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. Cooling System Maintenance Figure 63 1. Oil cooler 2. Radiator Servicing the Engine Cooling System 4.
1. Proper tension will allow 3/8 inch (10 mm) deflection when a force of 10 lb is applied on the belt midway between the pulleys. 2. If the deflection is not 3/8 inch (10 mm), loosen the alternator mounting bolts (Figure 64). Increase or decrease the alternator belt tension and tighten the bolts. Check the deflection of the belt again to ensure that the tension is correct. Figure 65 1. Belt 2. Eye bolt 3. Extension spring 4. 5. 6.
Figure 67 1. Figure 66 1. Hydraulic motor 2. Throttle cable Adjusting the Traction Pedal Linkage Mounting bolts 5. Remove the old belt from around the spindle pulleys and idler pulley. 6. Route the new belt around the spindle pulleys and idler pulley assembly. 7. Position the hydraulic motor on the cutting unit after routing the belt around the pulleys. Mount the motor to the cutting unit with the bolts previously removed.
Figure 70 Figure 69 1. Rod end 3. 2. Traction rod 4. 1. Hydraulic reservoir Neutral return spring assembly Jam nut 4. Install the reservoir cap. Start the engine and use all of the hydraulic controls to distribute hydraulic fluid throughout the system. Also check for leaks; then stop the engine. 4. Turn the key switch to the run position without starting the engine. Loosen the jam nut and adjust the neutral return spring assembly shaft length until the audible alarm begins to sound.
Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. • Keep your body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. Figure 71 • Use cardboard or paper to find hydraulic leaks. 3. Lubricate the new filter gasket and fill the filter with hydraulic fluid.
Test Port E (Figure 76), located under the radiator, is used to measure the four-wheel drive pressure in reverse. Figure 73 1. Test port B Test Port C (Figure 74), located on the left side of the machine, is used to measure the left cutting unit pressure. Figure 76 1. Test port E Test Port F (Figure 77), located under the seat, is used to measure the lift circuit pressure. Test Port G (Figure 77), located under the seat, is used to measure the charge circuit pressure. Figure 74 1.
Figure 80 1. Flow control valve Figure 78 1. Test port I 2. Test port H Mower Maintenance The counterbalance test port (Figure 79) is used to adjust the pressure in the counterbalance circuit. Recommended counterbalance pressure is 470 psi (3241 kPa). To adjust the counterbalance pressure, rotate the adjusting screw (Figure 79) clockwise to increase the pressure or counterclockwise to decrease the pressure.
Figure 82 1. Adjustment screw 2. Deck latch Figure 84 Pivoting (Tilting) the Front Cutting Unit Upright 1. Transport latch 2. Latch plate 3. Remove the hairpin cotter and clevis pin securing the height-of-cut chains to the rear of the cutting unit. 4. Start the engine, slowly raise the front cutting unit, and stop the engine. Remove the ignition key. 5. Grasp the front of the cutting unit and lift it to an upright position. 6.
2. Pivot (tilt) the cutting unit downward. 3. Store the cable under the operator’s platform. 4. Sit on the seat, start the engine, and lower the cutting unit until it is slightly off of the floor. 5. Secure the height-of-cut chains to the rear of the cutting unit. 6. Pivot transport latch upward into position and secure with clevis pin and cotter pin. Figure 86 Adjusting the Cutting Unit Pitch 1. Measuring the Cutting Unit Pitch Height-of-cut chain 2.
Servicing the Castor Arm Bushings Servicing the Castor Wheels and Bearings 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.
Removing and Installing the Cutter Blade(s) 4. To assemble the castor wheel, push the bearing into the wheel hub. When installing the bearings, press on the outer race of the bearing. The blade must be replaced if a solid object is hit, the blade is out of balance, or if the blade is bent. Always use genuine Toro replacement blades to be sure of safety and optimum performance. Never use replacement blades made by other manufacturers because they could be dangerous. 5.
Inspecting and Sharpening the Cutter Blade(s) A worn or damaged blade can break, and a piece of the blade could be thrown into the operator’s or bystander’s area, resulting in serious personal injury or death. Trying to repair a damaged blade may result in discontinued safety certification of the product. • Inspect the blade periodically for wear or damage. • Never try to straighten a blade that is bent or weld a broken or cracked blade. • Replace a worn or damaged blade.
5. Rotate the blades until the ends face forward and backward. Measure from the floor to the front tip of the cutting edge. Remember this dimension. Then rotate the same blade so that the opposite end is forward, and measure again. The difference between the dimensions must not exceed 1/8 inch (3 mm). If the dimension exceeds 1/8 inch (3 mm), replace the blade because it is bent. Make sure to measure all of the blades.
The muffler may be hot and could cause injury. Be careful while working around the muffler. 2. Start the engine. Plug the normal muffler exit with a block of wood or metal plate so that the exhaust flow will be forced out of the clean-out port. Continue to block the exit until carbon deposits cease coming out of the port. Do not stand in line with the clean-out port. Always wear safety glasses. 3. Stop the engine and replace the pipe plug.
Storage 9. Seal the air cleaner inlet and the exhaust outlet with weatherproof tape. Preparing for Seasonal Storage 10. Check the anti freeze protection and add a 50/50 solution of water and ethylene glycol anti-freeze as needed for the expected minimum temperature in your area. Traction Unit 1. Thoroughly clean the traction unit, cutting units, and the engine. 2. Check the tire pressure; refer to Checking the Tire Pressure procedure in Operation, page 19. 3.
Schematics Electrical Schematic (Rev.
Hydraulic Schematic (Rev.
The Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro® Company and its afliate, 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 rst.
Notes:
