Form No. 3326-863 Groundsmaster 4000-D Groundsmaster Traction Unit Model No. 30410—Serial No.
Warning Jacking Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tie Downs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Characteristics . . . . . . . . . . . . . . . . . . . . Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Maintenance Schedule . . . . . . . . . Daily Maintenance Checklist . . . . . . . . . . . . . . . . . Service Interval Chart . . . .
CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death. Introduction 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. – Engage the clutch slowly, always keep the machine in gear, especially when travelling downhill. – The machine speed should be kept low on slopes and during tight turns. • Warning—fuel is highly flammable. Take the following precautions: – Stay alert for humps and hollows and other hidden hazards. – Store fuel in containers specifically designed for this purpose.
• Disengage drives, lower the cutting units, move traction pedal to Neutral, set parking brake, stop engine and remove key and disconnect spark plug wire. Wait for all movement to stop before adjusting, cleaning or repairing. – if the machine starts to vibrate abnormally (check immediately). • Disengage drive to attachments when transporting or not is use. • Stop the engine and disengage drive to attachment: – before refuelling; • Shut off fuel while storing or transporting. Do not store fuel near flames.
• Do not mow on wet grass. Reduced traction could cause sliding. Operation • Before operating a machine with ROPS (roll over protection system), be certain that the seat bets are attached and the seat is latched to prevent the seat from pivoting forward. • Do not try to stabilize the machine by putting your foot on the ground. • Use extra care with other attachments. These can change the stability of the machine. • Know how to stop the machine and engine quickly.
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.
93-5620 (replaces 93-5622 for CE) 1. Warning—read the operator’s manual. 2. Tipping hazard—Do not operate two wheel drive machines on slopes greater than 10 degrees and lower the cutting units to the ground. Do not operate four wheel drive machines on slopes greater than 15 degrees, use the ROPS, fasten the seat belt, and lower the cutting units to the ground. 3. Thrown object hazard—keep bystanders away. 4. Cutting hazard to hands and feet—stay away from rotating blades and moving parts. 5.
105-0781 1. 2. 3. 4. 5. PTO switch PTO switch—off PTO switch—on Hi–Lo speed control Hi–Lo speed control—high 6. 7. 8. 9. Hi–Lo speed control—low Cruise control Cruise control—unlock Cruise control—lock 14. 15. 16. 17. 10. Push temperature reset switch 11. Temperature reset 12. Push silencer switch 13. Silencer switch—off Throttle—slow Throttle—fast Key switch Preheat 104-8325 1. Lock/unlock the cutting unit service lock. 100-6578 1. Stay away from moving parts. 2.
0-5624 100-5694 1. Height of cut adjustment 1. Height of cut adjustment 104-3578 104-3579 1. Height of cut adjustment 1. Low height of cut adjustment 2. High height of cut adjustment 100-5623 1. Low height of cut adjustment 2. High height of cut adjustment 104-3599 1. 2. 3. 4. 5. 6. 100-5693 1. Height of cut adjustment 10 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 42 in. (107 cm) width of cut, 2 blades Height of cut 1-5 in. (25-177 mm) adjustable in 1/2 in. (13 mm) increments. Front cutting unit ad justment 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.
Checking the Cooling System Check level of coolant at the beginning of each day. Capacity of system is 2-3/4 gal. (10.4 l). 1. Carefully remove the radiator cap and expansion tank cap (Fig. 3). Caution 1 If the engine has been running, the pressurized, hot coolant can escape and cause burns. Figure 1 • 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. 1. Dipstick 4.
Filling the Fuel Tank products listed. Toro will not assume responsibility for damage caused by improper substitutions, so use only products from reputable manufacturers who will stand behind their recommendation. The capacity of the fuel tank is 19 gallons (72 l). 1. Remove the fuel tank cap (Fig. 4). Multigrade Hydraulic Fluid – ISO VG 46 2. Fill the tank to about 1 inch (25 mm) below the top of the tank, not the filler neck, with No. 2 diesel fuel. Then install the cap.
1 1 2 Figure 5 1. Hydraulic tank cap Figure 7 Checking the Planetary Gear Drive Oil 1. Brake housing 2. Check plug 3. Add gear oil to the hole in the planetary, if necessary, to bring the oil up to the proper level. Install the plug. Check the oil level after every 400 hours of operation or if external leakage is noted. Use high quality SAE 85W-140 wt. gear lube as a replacement. 4. Repeat steps 1–3 on the opposite gear assembly. The capacity of the system is approximately 16 oz. (0.5 l).
Checking the Rear Axle Gear Box Lubricant Checking the Torque of the Wheel Nuts or Bolts The gear box 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 16 oz. (0.5 l). Visually inspect for leaks daily. Warning Failure to maintain proper torque of the wheel nuts could result in failure or loss of wheel and may result in personal injury. 1. Position the machine on a level surface. 2.
5. Remove the hairpin cotter and clevis pin securing the height-of-cut chains to the rear of the cutting unit (Fig. 12). 2 3 2 4 1 5 Figure 12 1. Height-of-cut chain 2. U-bolt 6. Mount the height-of-cut chains to the desired height-of-cut hole (Fig. 13) with the clevis pin and hairpin cotter. 1 Figure 10 1. Castor wheel 2. Tensioning cap 3. Spacers 4. Shims 5. Axle mounting holes Refer to the following chart to determine the combinations of spacers for the setting.
the appropriate number of 1/2 inch spacers onto the spindle shaft to get the desired height-of-cut; then slide the washer onto the shaft. 3. Push the castor spindle through the front castor arm. Install the shims (as originally installed) and the remaining spacers onto the spindle shaft. Install the tensioning cap to secure the assembly. 4. Remove the hairpin cotter and clevis pins from the castor pivot arms (Fig. 16).
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.
Front Cutting Unit Setup Correcting Mismatch Between Cutting Units Rotate blade on each spindle until the ends face forward and backward. Measure from the floor to the front tip of the cutting edge. Adjust 1/8 in. shims on front castor fork(s) to match height of cut to decal (Fig. 22); refer to Adjusting the Cutting Unit Pitch, page 48.
Side Cutting Unit Setup Note: If adjustments need to be made to match the cut between the front and side cutting units, make the adjustments to the side cutting units only. Rotate blade of each spindle until the ends face forward and backward. Measure from the floor to the front tip of the cutting edge. Adjust 1/8 in. shims on front castor arm(s) to match height of cut to decal (Fig. 23). For the outside blade spindle only, refer to Adjusting the Cutting Unit Pitch, page 48. 3.
Tilt Steering Lever To stop, reduce your foot pressure on the traction pedal and allow it to return to the center position. Press the lever (Fig. 24) down to tilt the steering wheel to the desired position. Then release the lever to lock the adjustment. Important The speed limiter screw must stop the traction pedal before the pump reaches full stroke or damage to the pump may occur. Parking Brake Latch A knob on the left side of the console actuates the parking brake lock (Fig. 24).
Fuel Gauge The fuel gauge (Fig. 26) indicates the level of fuel in the tank. Hour Meter The hour meter (Fig. 26) shows the total hours that the machine has been operated. 1 Temperature Override Switch Press and hold the reset switch (Fig. 26) to start the engine after high temperature shut down. Use only for emergency operation. 2 1 Figure 25 3 1. Speed limiter 4 13 5 12 Lift Levers 6 11 The levers (Fig. 26) raise and lower the cutting units.
Alarm Silence Switch wheel to the left and right to check steering response. Then shut the engine off and check for oil leaks, loose parts, and any other noticeable difficulties. This switch (Fig. 26) shuts off the audible alarm. Caution Throttle Control Move the control (Fig. 26) forward to increase the engine speed and rearward to decrease the speed. Shut the engine off and wait for all moving parts to stop before checking for oil leaks, loose parts, and other malfunctions.
2. Sit on the seat and depress the traction pedal. Try to start the engine. The engine should not crank. If the engine cranks, there is a malfunction in the interlock system that should be corrected before beginning operation. 3. Sit on the seat and start the engine. Rise from the seat and move the PTO lever to On. The PTO should not engage. If the PTO engages, there is a malfunction in the interlock system that should be corrected before beginning operation. 1 4.
Operating Characteristics Important If the machine must to be pushed or towed in reverse, the check valve in the four-wheel drive manifold must also be bypassed. To bypass the check valve, connect a hose assembly (Hose Part No. 95-8843, Coupler Fitting No. 95-0985 [Qty. 2], and Hydraulic Fitting No. 340-77 [Qty. 2]) to the reverse traction pressure test port (Fig. 29) and the reverse four-wheel drive pressure port (Fig. 30).
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. This means that in order to maintain the same height-of-cut, which is a good practice, you will need to cut more frequently in early spring; as the grass growth rate slows in mid summer, cut only every 8–10 days.
Maintenance Service Interval Every 50 hours • • • • Every 100 hours • Change the engine oil and filter. • Inspect the cooling system hoses. • Check the fan and alternator belt tension. After first 200 hours • • • • Lubricate all grease fittings. Inspect the air cleaner. Check the battery level and cable connections. Check the cutting unit drive belt tension. Change the hydraulic oil. Change the hydraulic oil filters. Change the front planetary gear lube. Change the rear axle oil level.
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. • King pin bushings (2) (Fig. 35). The top fitting on the king pin should only be lubricated annually (2 pumps). Greasing the Bearings and Bushings 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. 36) • Spindle shaft bearings (3) (located under the pulley) (Fig.
Front Lift Assemblies Side Cutting Units • Lift arm bushings (2) (Fig. 38) • Castor fork shaft bushing (1) (Fig. 40) • Lift cylinder bushings (4) (Fig. 38) • Spindle shaft bearings (2 ea.) (located under the pulley) • Lift arm ball joints (2) (Fig. 39) Figure 38 Figure 40 Side Lift Assemblies • Main lift arm bushings (6) (Fig. 41 and 42), • Bell crank pivot bushings (2) (Fig. 43) • Rear arm bushings (4) (Fig. 43) • Lift cylinder bushings (4) (Fig.
Figure 43 Figure 41 Figure 44 Figure 42 34
Servicing the Air Cleaner Check the air cleaner body for damage which could possibly cause an air leak. Replace a damaged air cleaner body. 1 Service the air cleaner filters when the air cleaner indicator (Fig. 45) shows red or every 400 hours (more frequently in extremely dusty or dirty conditions). Do not over-service the air filter. Be sure that the cover is sealing around the air cleaner body. 1. Pull the latch outward and rotate the air cleaner cover counterclockwise.
6. Insert the new filter properly into the air cleaner body. Make sure that the filter is sealed properly by applying pressure to the outer rim of the filter when installing it. Do not press on the flexible center of the filter. 7. Install the cover and secure the latch. Make sure that the cover is positioned with the TOP side up. 1 8. Reset the indicator (Fig. 45) if it shows red.
Fuel Lines and Connections 4. Loosen the hose clamps at both ends of the filter and pull the fuel lines off of the filter. Check the fuel lines and connections every 400 hours or yearly, whichever comes first. Inspect them for deterioration, damage, or loose connections. Water Separator Drain water or other contaminants from the water separator (Fig. 50) daily. 1 1. Place a clean container under the fuel filter. 2. Loosen the drain plug on the bottom of the filter canister (Fig. 50).
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. 55) 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. 56) 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. 60), located on the right side of the machine, is used to measure the reverse traction pressure. 1 1 Figure 62 Figure 60 1. Test port “D” 1. Test port “B” Test Port “E” (Fig. 63), located under the radiator, is used to measure the four-wheel drive pressure in reverse. Test Port “C” (Fig. 61), located on the left side of the machine, is used to measure the left cutting unit pressure. 1 1 Figure 63 Figure 61 1. Test port “E” 1. Test port “C” Test Port “D” (Fig.
Test Port “F” (Fig. 64), located under the seat, is used to measure the lift circuit pressure. the counterbalance pressure, rotate the adjusting screw (Fig. 66) clockwise to increase the pressure or counterclockwise to decrease the pressure. Test Port “G” (Fig. 64), located under the seat, is used to measure the charge circuit pressure. 2 1 1 2 Figure 66 1. Counterbalance test port Adjusting the Cutting Unit Flow Control Figure 64 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. 68). 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. 71). 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 75 Incorrect battery cable routing could damage the machine and cables causing sparks.
Fuses 4. Grasp the front of the cutting unit and lift it to an upright position. There are 5 fuses in the electrical system. They are located below the operators control panel (Fig. 76 and 77). 5. Hold the cutting unit upright, fit the cable end over the pin on the cutting unit lift arm and secure it with the hairpin cotter (Fig. 78). 2 1 1 Figure 78 1. Cable Figure 76 2. Pin 1.
Tensioning the Cutting Unit Drive Belts 2 Check the condition and tension of the cutting unit drive belts initially after 8 hours of operation and every 50 operating hours thereafter. The proper belt tension will be attained when a force of 45 lb. on a used belt (90 lb. on a new belt) is applied to the idler pulley (Fig. 80) when sliding it into the belt. 1 Figure 81 1. Height-of-cut chain 2. u-bolt Adjusting the Side Cutting Units 1 1.
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 3. Install the blade, anti-scalp cup, and blade bolt. Tighten the blade bolt to 85–110 ft.-lb. (115–149 N⋅m). 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.
FLAT PART OF BLADE A Correcting Cutting Unit Mismatch 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 17.
Replacing the Drive Belt The blade drive belt, tensioned by the stationary idler pulley, is very durable. However, after many hours of use, the belt will show signs of wear. Signs of a worn belt are: squealing when belt is rotating, blades slipping when cutting grass, frayed edges, burn marks and cracks. Replace the belt if any of these conditions are evident. 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. 2.
Y R R R PK R F8 F7 R F6 R F5 R 10 AF 3 Y BK GY R/BK W FUEL PUMP R/BK ENGINE OVER TEMP. 110 C BU GN ENGINE OIL PRESSURE R I B S X A Y (+) Y VIO GN LAMP 2 START + 12V3 Y 1 OR 4 THERMO 5 GLOW BN 6 GND BK CONTROLER GLOW PLUG KUBOTA (+) (–) 6500 PTO SHUTDOWN DELAY MFD IGNITION SW.
Hydraulic Schematic 54
Preparing for Seasonal Storage Traction Unit 1. Thoroughly clean the traction unit, cutting units, and the engine. 2. Check the tire pressure; refer to Checking the Tire Pressure, page 17. 3. Check all fasteners for looseness; tighten as necessary. 4. Grease or oil all grease fittings and pivot points. Wipe up any excess lubricant. 5. Lightly sand and use touch–up paint on painted areas that are scratched, chipped, or rusted. Repair any dents in the metal body. 6.
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 1996 or newer Toro Commercial Product (“Product”) purchased after January 1, 1997, to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
