Form No. 3358-715 Rev B Groundsmaster® 4000-D Traction Unit Model No. 30410—Serial No. 2800000001 and Up Model No. 30410TE—Serial No. 2800000001 and Up Register at www.Toro.com.
This manual uses 2 other words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention. Warning CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. This spark ignition system complies with Canadian ICES-002. Important: This engine is not equipped with a spark arrester muffler.
Contents Cooling System Maintenance .................................. 43 Servicing the Engine Cooling System .................. 43 Brake Maintenance ................................................. 44 Adjusting the Service Brakes............................... 44 Belt Maintenance.................................................... 44 Servicing the Alternator Belt............................... 44 Re-tensioning the Blade Drive Belts .................... 44 Replacing the Blade Drive Belt ..................
Preparation Safety • While mowing, always wear substantial footwear, long trousers, hard hat, safety glasses, and ear protection. Long hair, loose clothing or jewelry may get tangled in moving parts. Do not operate the equipment when barefoot or wearing open sandals. • Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine. • Warning–fuel is highly flammable.
• • • • • • • • • – Do not stop or start suddenly when going up or downhill. – The machine speed should be kept low on slopes and during tight turns. – Stay alert for humps and hollows and other hidden hazards. – Never mow across the face of the slope, unless the machine is designed for that purpose. Stay alert for holes in the terrain and other hidden hazards. Use care when using heavy equipment. – Do not turn sharply. Use care when reversing.
wire. Wait for all movement to stop before adjusting, cleaning or repairing. • Shut off fuel while storing or transporting. Do not store fuel near flames. • • • Park machine on level ground. Never allow untrained personnel to service machine. • • Use jack stands to support components when required. • • Carefully release pressure from components with stored energy. • Disconnect battery or remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last.
• Never store the machine or fuel container inside where there is an open flame, such as near a water heater or furnace. • Keep nuts and bolts tight, especially the blade attachment bolts. Keep equipment in good condition. • Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system. • Keep your body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure.
93-7275 100-5693 1. Read the Operator’s Manual. 2. Do not use starting aids. 1. Height of cut adjustment 100-6578 93-7818 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. 1. Warning—read the Operator’s Manual for instructions on torquing the blade bolt/nut to 115 to 149 N•m (85 to 110 ft-lb). 100-5622 100-5623 1. Low height of cut adjustment 1. Height of cut adjustment 2.
100-5694 104-3579 1. Height of cut adjustment 1. Low height of cut adjustment 2. High height of cut adjustment 104-3578 1. Height of cut adjustment 1. 2. 3. 104-3599 1. 2. 3. 4. 5. 104-2277 104-2277 1. To lock the parking brake, latch the pedals together, apply the brake pedals, and pull up on the knob. 2. To unlock the parking brake, step on the brake pedals. 3. Parking brake lock indicator 4. Read the Operator’s Manual. 5. Press for optional headlights. 6.
6–6752 (Affix over part no. 112–9118 for CE*) * This safety decal includes a slope warning required on the machine for compliance to the European Lawn Mower Safety Standard EN836:1997. The conservative maximum slope angles indicated for operation of this machine are prescribed by and required by this standard. 104-8324 1. Raise cutting units 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.
Battery Symbols Some or all of these symbols are on your battery 106-6755 1. Engine coolant under pressure. 2. Explosion hazard—read the Operator’s Manual. 3. Warning—do not touch the hot surface. 4. Warning—read the Operator’s Manual. 1. Explosion hazard 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 106-6764 1.
106-2046 6. Low 7. Lock 8. Flow divider 1. Power Take-off (PTO) 2. Engage 3. Disengage 4. Transmission 5. High 11. Silencer switch 12. Press the button 13. Key switch 9. Unlock 10. Cruise control (optional) 14. Engine—preheat 15. Fast 104-8336 1. Read the Operator’s Manual. 12 16. Slow 17. Continuous variable setting 18.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Qty. 1 Seat kit (obtain separately) Seat suspension kit (obtain separately) Manual tube R-clamp Seat belt Bolt Lock washer 1 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 requiring European CE compliance.
Greasing the Bearings and Bushings procedure of Lubrication , page 32. Failure to properly grease the machine will result in premature failure of critical parts.
Product Overview 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: When in the mow position, the speed limiter screw must stop the traction pedal before the pump reaches full stroke or damage to the pump may occur.
Glow Plug Indicator Light PTO Switch When lit, the glow plug indicator light (Figure 2) indicates that the glow plugs are on. 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. Engine Temperature Gauge This gauge (Figure 2) indicates the engine coolant temperature.
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.
1. Park the machine on a level surface. Unlock the engine cover latches. If the engine has been running, the pressurized, hot coolant can escape and cause burns. 2. Open the engine cover. 3. Remove the dipstick, wipe it clean, install the dipstick into the tube, and pull it out again. The oil level should be up to the Full mark (Figure 5). • 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. 2.
flash point and cold flow characteristics which will ease starting and reduce fuel filter plugging. In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. Use of summer grade fuel above 20° F (-7° C) will contribute toward longer fuel pump life and increased power compared to winter grade fuel. Important: Do not use kerosene or gasoline instead of diesel fuel.
2. Using a clean rag, clean area around fuel tank cap. 3. Remove cap from the fuel tank (Figure 8). High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 (cont'd.) Viscosity Index ASTM D2270 Pour Point, ASTM D97 Industry Specifications: -34° F to -49° F Vickers I-286-S (Quality Level), Vickers M-2950-S (Quality Level), Denison HF-0 Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks.
Figure 9 1. Hydraulic tank cap Figure 10 4. Remove the dipstick from the filler neck and wipe it with a clean rag. Insert the dipstick into the filler neck; then remove it and check the fluid level. The fluid level should be between the two marks on the dipstick. 1. Check/drain plug 2. Remove the plug on the planetary (Figure 10) and check the plug on the back side of the brake (Figure 11). Oil should be at the bottom of the check plug hole on the back side of the brake. 5.
Checking the Rear Axle Lubricant Service Interval: Every 400 hours The rear axle is shipped from the factory filled with SAE 85W-140 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. 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.
castor forks, add or remove an equal number of spacers from the castor forks, and secure the rear chain to the desired hole. 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: 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.
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. Side Cutting Units To adjust the height-of-cut on the side cutting units, add or remove an equal number of spacers from the castor forks, position the castor wheel axles in the high or low height-of-cut holes in the castor forks, and secure the pivot arms to the selected height-of-cut bracket holes. Figure 19 1.
Figure 23 Figure 21 Adjusting the Skids 8. Remove the hairpin cotters and clevis pins securing the damper links to the cutting unit brackets (Figure 22). Align the damper link holes with the selected height-of-cut bracket holes in the cutting unit frame (Figure 23), insert the clevis pins, and install the hairpin cotters.
Front Cutting Unit Setup 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 inch shims on front castor fork(s) to match height of cut to decal (Figure 26); refer to Adjusting the Cutting Unit Pitch procedure in Mower Maintenance, page 50. Figure 25 1. Gage wheel 2. Align the roller and spacer with the top holes in the brackets and secure them with the bolt and nut.
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 inch shim from bottom of front inside castor arm of the side cutting unit and one 1/8 inch shim from the front outside castor arm of the side cutting unit. 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 inch shim to the bottom of the front inside castor arm on the side cutting unit.
of the seat while the engine is running and the traction pedal is in neutral. Although the engine will continue to run if the PTO lever is disengaged and the traction pedal is released, it is strongly recommended that the engine be stopped before rising from the seat. start after 15 seconds, turn the key to the Off position, recheck the controls and procedures, wait 15 additional seconds, and repeat the starting procedure.
Jacking Points • On the front of the machine on the frame on the inside of each drive tire • On the rear of the machine at the center of the axle Tie Downs • On each side of the frame by the side cutting unit lift arms Figure 28 • Front center of the operator’s platform 1. Bypass valve access hole • The rear bumper 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.
Operating Tips Another benefit of the brakes is to maintain traction. For example, in some slope conditions, the uphill wheel slips and loses traction. If this situation occurs, depress the uphill turn pedal gradually and intermittently until the uphill wheel stops slipping, thus, increasing traction on the downhill wheel.
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 first 10 hours • Torque the wheel lug nuts. • Check the fan and alternator belt tension. • Check the blade drive belt tension. After the first 50 hours • Change the engine oil and filter. • 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.
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 Figure 37 33
Figure 38 Front Lift Assemblies • Lift arm bushings (2) (Figure 39) • Lift cylinder bushings (4) (Figure 39) Figure 40 • 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) Figure 39 Figure 41 Side Lift Assemblies • Main lift arm bushings (6) (Figure 42 and Figure 43), 34
• Bell crank pivot bushings (2) (Figure 44) • Rear arm bushings (4) (Figure 44) • Lift cylinder bushings (4) (Figure 45) Figure 44 Figure 42 Figure 45 Figure 43 35
Engine Maintenance 3. Remove the primary filter (Figure 47). 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 (Figure 48). Air Cleaner Maintenance • Check the air cleaner body for damage which could cause an air leak. Replace if damaged.
Servicing the Engine Oil and Filter Fuel System Maintenance Service Interval: After the first 50 hours Servicing the Fuel System Every 150 hours Change the oil and filter initially after the first 50 hours of operation; thereafter change the oil and filter every 150 hours. 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. 1.
2. Loosen the drain plug on the bottom of the filter canister. 4. Tighten the pipe connector securely. 5. Repeat the procedure on the remaining nozzles. Figure 51 1. Water separator filter canister 3. Clean the area where the filter canister mounts. 4. Remove the filter canister and clean the mounting surface. 5. Lubricate the gasket on the filter canister with clean oil. 6. Install the filter canister by hand until the gasket contacts mounting surface, then rotate it an additional 1/2 turn. 7.
Electrical System Maintenance Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. Activating, Charging, and Connecting the Battery • Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands. Service Interval: Every 50 hours • Fill the battery where clean water is always available for flushing the skin.
negative (-) terminal of the battery and secure them with the bolts and nuts. Make sure that the positive (+) terminal is all of the way onto the post and the cable is positioned snug to the battery. The cable must not contact the battery cover. Slide the rubber boot over the positive terminal to prevent a possible short from occurring. a solution of baking soda and water. Rinse with clear water. Coat the battery posts and cable connectors with Grafo 112X (skin-over) grease (Toro Part No.
Drive System Maintenance ten or two o’clock position) until the level is up to the bottom of the brake housing check hole. Install the plug. 8. Repeat the procedure on the opposite gear assembly. Changing the Planetary Gear Drive Oil Service Interval: After the first 200 hours Every 800 hours Change the oil initially after first 200 hours of operation. Thereafter change the oil every 800 hours, or yearly, whichever occurs first. Use a high quality SAE 85W-140 gear lube. 1.
Checking the Rear Wheel Toe-In Service Interval: Every 800 hours 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 inch (6 mm) less than the rear measurement. 2. To adjust, loosen the clamps at both ends of the tie rods. Figure 59 3. Rotate the tie rod end to move the front of the tire inward or outward. 1. Drain plug location 4.
Cooling System Maintenance Servicing the Engine Cooling System Service Interval: Every 100 hours Every 2 years Remove debris from the oil cooler and radiator daily. Clean them more frequently in dirty conditions. Figure 62 1. Turn the engine off and raise the hood. Clean the engine area thoroughly of all debris. 1. Oil cooler 2. Remove the knobs (Figure 61) securing the oil cooler to the frame. 2. Radiator 4. Pivot the oil cooler back into position.
Brake Maintenance Belt Maintenance Adjusting the Service Brakes Servicing the Alternator Belt Adjust the service brakes when there is more than 1 inch (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. Service Interval: After the first 10 hours Every 100 hours Check the condition and tension of the belts (Figure 63) after every 100 operating hours. 1.
Note: Make sure the belt is positioned on the spring side of the belt guide (Figure 64). Figure 65 Figure 64 1. Belt 2. Eye bolt 3. Extension spring 1. Hydraulic motor 4. Belt guide 5. Flange nut 6. Stop bolt 2. Mounting bolts 5. Remove the old belt from around the spindle pulleys and idler pulley. Replacing the Blade Drive Belt 6. Route the new belt around the spindle pulleys and idler pulley assembly. Service Interval: Every 800 hours 7.
Controls System Maintenance Adjusting the Throttle Service Interval: After the first 50 hours Every 400 hours Adjust the throttle cable (Figure 66) 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. Figure 67 1. Traction pedal stop 2. Stand 3. Loosen the jam nuts on the rod end and adjust the traction rod length (Figure 68) so that the pedal contacts the pedal stop when the pump lever reaches full stroke.
Hydraulic System Maintenance Replacing the Hydraulic Filters Changing the Hydraulic Fluid Change the 2 hydraulic filters initially after the first 200 operating hours. Thereafter, change the filters after every 800 operating hours, in normal conditions. Service Interval: After the first 200 hours Every 800 hours Service Interval: After the first 200 hours Use Toro replacement filters (Part No. 94-2621 for the left side of the machine and 75-1310 for the right side of the machine).
deterioration. Make all necessary repairs before operating. 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. Figure 72 1. Test port B • Keep your body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid.
Figure 75 Figure 77 1. Test port E 1. Test port I Test Port F (Figure 76), located under the seat, is used to measure the lift circuit pressure. 2. Test port H The counterbalance test port (Figure 78) 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 78) clockwise to increase the pressure or counterclockwise to decrease the pressure.
Mower Maintenance Pivoting (Tilting) the Front Cutting Unit Upright Adjusting the Transport Latch Note: Although not needed for normal maintenance procedures, the front cutting unit can be pivoted (tilted) to an upright position (Figure 82). Should you desire to tilt the cutting unit, proceed as follows: If the transport latch (Figure 80) has to be adjusted, adjust as follows: 1. Raise the front cutting unit fully off of the floor, set the parking brake, and stop the engine. Remove the ignition key. 2.
4. Using a short ruler, measure from the floor to the front tip of the blade. Rotate the blade tip to the rear and measure from the floor to the tip of the blade. 5. Subtract the front dimension from the rear dimension to calculate the blade pitch. Adjusting the Front Cutting Unit 1. Loosen the jam nuts on the top or bottom of the height-of-cut chain U-bolt (Figure 85). 2. Adjust the other set of nuts to raise or lower the rear of the cutting unit and attain the correct cutting unit pitch. Figure 84 1.
Figure 87 1. Castor arm tube 2. Bushings 5. Apply grease to the inside and outside of the new bushings. Using a hammer and flat plate, drive the bushings into the mounting tube. 6. Inspect the castor spindle for wear and replace it if it is damaged. 7. Push the castor spindle through the bushings and mounting tube. Slide the thrust washer and spacer(s) onto the spindle. Install the tensioning cap on the castor spindle to retain all parts in place. Figure 86 1. Castor wheel 2. Tensioning cap 3.
Blade Maintenance 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 to 150 ft-lb (176 to 203 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.
Important: The curved part of the blade must be pointing toward the inside of the cutting unit to ensure proper cutting. 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. 2. Examine the cutting ends of the blade carefully, especially where the flat and curved parts of the blade meet (Figure 92).
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. If the blade is allowed to wear, a slot will form between the sail and flat part of the blade (Figure 92). Eventually a piece of the blade may break off and be thrown from under the housing, possibly resulting in serious injury to you or bystanders. 6.
Spark Arrestor Maintenance Storage Preparing for Seasonal Storage Servicing the Spark Arrestor Muffler 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 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.
Schematics Electrical Schematic (Rev.
Hydraulic Schematic (Rev.
Notes: 59
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.
