Form No. 3361-698 Rev A Groundsmaster® 4000-D Traction Unit Model No. 30412—Serial No. 29000000301 and Up Register at www.Toro.com.
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. Figure 1 1. Safety alert symbol 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.
Contents Adjusting the Service Brakes............................... 45 Belt Maintenance.................................................... 46 Servicing the Alternator Belt............................... 46 Re-tensioning the Blade Drive Belts .................... 46 Replacing the Blade Drive Belt ............................ 46 Controls System Maintenance................................. 47 Adjusting the Throttle Cable............................... 47 Adjusting the Traction Pedal Linkage ................
Preparation Safety • While mowing, always wear substantial footwear, long trousers, hard hat, safety glasses, and hearing 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.
• Park machine on level ground. Never allow untrained personnel to service machine. Engine exhaust contains carbon monoxide, which is an odorless, deadly poison that can kill you. • Use jack stands to support components when required. • Carefully release pressure from components with stored energy. Do not run engine indoors or in an enclosed area. • Disconnect battery before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last.
• • • • based on measurements of identical machines per ISO 11201 and EN 836. as required lights, slow moving vehicle signs, and reflectors. Do not mow near drop-offs, ditches, or embankments. The machine could suddenly turn over if a wheel goes over the edge of a cliff or ditch, or if an edge caves in. Do not mow on wet grass. Reduced traction could cause sliding. Use extra care with other attachments. These can change the stability of the machine. Turn off the blades when not mowing.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 93-7275 1. Read the Operator’s Manual. 2. Do not use starting aids. 100-5623 1. Low height of cut adjustment 2. High height of cut adjustment 93-7818 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). 100-5624 1.
104-3578 100-5694 1. Height of cut adjustment 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. 104-3579 1. Low height of cut adjustment 2. High height of cut adjustment 1. 2. 3. 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.
4-8325 1. Lock/unlock the cutting unit service lock. 93-7272 1. Cutting/dismemberment hazard; fan—stay away from moving parts. 104-8324 1. Raise cutting units 2. Lower cutting units 117–2754 1. 2. 3. 4. 5. 6. 7. 8. Warning—read the Operator’s Manual. Warning—do not operate this machine unless you are trained. Warning—wear the seat belt when seated in the operator’s position. Warning—wear hearing protection. Thrown object hazard—keep bystanders a safe distance from the machine.
7–2766 (Affix over part no. 117–2754 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. 1. 2. 3. 4. 5. 6. 7. 8. Warning—read the Operator’s Manual. Warning—do not operate this machine unless you are trained. Warning—wear the seat belt when seated in the operator’s position.
115-8474 1. 2. 3. 4. Power outlet Seat switch Ignition switch Power Take Off (PTO) 5. 6. 7. 8. Starter solenoid Light Kit Fan Power seat 106-6764 1. To start the engine, move the traction pedal to Neutral, press the brake pedal, move the throttle lever to mid idle, turn the ignition key to On, and then turn the ignition key to Start; read the Operators Manual. 2.
115-8456 1. Read the Operator’s Manual.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 Description Use Qty. No parts required – Grease the machine. Warning Decal 1 Used only on machines requiring European CE compliance. Operator’s Manual Engine Operator’s Manual Parts Catalog Operator Training Materials Pre-delivery Inspection Sheet Declaration of conformity 1 1 1 1 1 1 Read the manuals and view the training materials before operating the machine.
Brake Pedals Product Overview Two foot pedals (Figure 2) operate individual wheel brakes for turning assistance, parking, and to aid in obtaining better side hill traction. A latch connects the pedals for parking brake operation and transport. Pedal Locking Latch The pedal locking latch (Figure 2) connects the pedals together to engage the parking brake. Tilt Steering Lever Press the lever (Figure 2) down to tilt the steering wheel to the desired position. Then release the lever to lock the adjustment.
Speed Limiter Hi-Lo Speed Control If desired, the screw can be adjusted (Figure 3) to limit the amount the traction pedal can be depressed in the forward direction to limit the mowing speed. The control (Figure 4) allows the speed range to increase for transport of the machine. Flow Divider Switch When operating in mow (low) speed, press and hold flow divider switch (Figure 4) to enhance traction drive performance in compromised operating conditions. Figure 4 1. 2. 3. 4. 5. 6. 7. Figure 3 1.
Alarm Silence Switch Specifications This switch (Figure 4) shuts off the audible alarm. Note: Specifications and design are subject to change without notice. Throttle Control Width of cut Move the control (Figure 4) forward to increase the engine speed and rearward to decrease the speed.
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 Remove the key from the ignition before you do any maintenance. 1. 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.
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. If the engine has been running, the pressurized, hot coolant can escape and cause burns. Important: Do not use kerosene or gasoline instead of diesel fuel. Failure to observe this caution will damage the engine. • 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. Using a clean rag, clean area around fuel tank cap. 3. Remove cap from the fuel tank (Figure 8). 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. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. • Never fill the fuel tank inside an enclosed trailer.
Checking the Planetary Gear Drive Oil High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 (cont'd.) Viscosity Index ASTM D2270 Pour Point, ASTM D97 Service Interval: Every 400 hours 140 to 160 Check the oil level after every 400 hours of operation or if external leakage is noted. Use high quality SAE 85W-140 gear lube as a replacement.
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. Checking the Rear Axle Lubricant Service Interval: Every 400 hours The rear axle is 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. Figure 13 1. Position the machine on a level surface. 1.
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 position. Refer to the following chart to determine the combinations of spacers for the setting.
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 , page . 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.
Checking the Interlock Switches 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. When the temperature is less than 20°F (-75C), preheat glow plugs twice prior to initial cranking attempt. The starter motor can be run for 30 seconds on then 60 seconds off for 2 attempts. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. 5.
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. 1. Raise the seat and remove the battery cover. The bypass valve is located in front of the battery (Figure 28). 2. Rotate the valve 1/4 turn in either direction to open and allow oil to bypass internally.
speed, load on the cutting blades or other implement components, and the importance of the brakes. This cutting units are 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.
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. 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 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 alternator belt tension. • Check the blade drive belt tension. After the first 50 hours • Change the engine oil and filter. • Check the engine speed (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. Service Interval Chart Figure 32 Lubrication Traction Unit Service Interval: Every 50 hours Greasing the Bearings and Bushings • Brake shaft pivot bearings (5) (Figure 33) • Traction pedal pivot bushing (1) (Figure 34) 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 Figure 37 34
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), 35
• 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 36
Engine Maintenance Air Cleaner Maintenance • 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. • 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.
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. Air cleaner safety filter Important: Never attempt to clean the safety filter (Figure 48). Replace the safety filter with a new one after every three primary filter services. 4. Replace the primary filter (Figure 47). 5. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister.
Fuel System Maintenance 2. Loosen the drain plug on the bottom of the filter canister. 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. Figure 51 • 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. 1. Water separator filter canister 3.
Electrical System Maintenance connector. Turn the key to the Off position when solid flow is observed. 4. Tighten the tube connector securely. 5. Repeat the procedure on the remaining nozzles. Battery Care Battery type is group 24. Important: Before welding on the machine, disconnect the negative cable from the battery to prevent damage to the electrical system. Note: Check the battery condition weekly or after every 50 hours of operation.
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. Incorrect battery cable routing could damage the machine and cables causing sparks.
Drive System Maintenance 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. With the machine on a level surface, position the wheel so that the check/drain plug (Figure 57) is at the lowest position. Figure 55 1. Fuses Figure 56 1. 2. 3. 4.
the bottom of the brake housing check hole. Install the plug. 8. Repeat the procedure on the opposite gear assembly. Figure 59 1. Drain plug location 5. Clean the area around the drain plug on the bottom of the gear box (Figure 60). Figure 58 1. Brake housing 2. Drain plug 6. Remove the drain plug from the gear box and allow the oil to drain into a pan. Remove the fill plug to ease in draining of the oil. 3.
Checking the Rear Wheel Toe-In Cooling System Maintenance Service Interval: Every 800 hours After every 800 operating hours or annually, check the rear wheel toe-in. Servicing the Engine Cooling System 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. Remove debris from the oil cooler and radiator daily. Clean them more frequently in dirty conditions.
Brake Maintenance Adjusting the Service Brakes 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. 1. Disengage the locking latch from the brake pedals so that both pedals work independently of each other. 2. To reduce free travel of the brake pedals, tighten the brakes: Figure 62 1. Oil cooler A.
Belt Maintenance Note: Make sure the belt is positioned on the spring side of the belt guide (Figure 64). Servicing the Alternator Belt 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. 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 63).
Controls System Maintenance Adjusting the Throttle Cable Service Interval: After the first 50 hours—Check the engine speed (at idle and full throttle). Every 400 hours—Check the engine speed (at idle and full throttle). 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 65 1. Hydraulic motor 2. Mounting bolts 5.
Hydraulic System Maintenance Changing the Hydraulic Fluid Service Interval: After the first 200 hours Every 800 hours Figure 67 1. Traction pedal stop 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. Turn the engine off and raise the hood. 2.
Replacing the Hydraulic Filters loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating. Service Interval: After the first 200 hours Every 800 hours Change the 2 hydraulic filters initially after the first 200 operating hours. Thereafter, change the filters after every 800 operating hours, in normal conditions. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Use Toro replacement filters (Part No.
Mower Maintenance Adjusting the Cutting Unit Flow Control Adjusting the Transport Latch The flow control valve (Figure 71) is used to adjust the rate at which the front cutting unit lowers. If the transport latch (Figure 72) 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. Loosen flange nuts securing latch arm pivot to traction unit frame. 3.
Figure 73 1. Adjustment screw 2. Deck latch Figure 75 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.
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. 1. Remove the tensioning cap from the spindle shaft and slide the spindle out of the castor arm (Figure 78). Reposition the shims, as required, to raise or lower the castor wheel until the cutting unit has the correct pitch. Adjusting the Cutting Unit Pitch 2. Install the tensioning cap.
4. Insert a pin punch into the top or bottom of the mounting tube and drive the bushing out of the tube (Figure 79). Also drive the other bushing out of the tube. Clean the inside of the tubes to remove dirt. Figure 81 Figure 79 1. Castor arm tube 1. Castor wheel 2. Castor pivot arm 2. Bushings 2. Remove the bearing from the wheel hub and allow the bearing spacer to fall out (Figure 80 and Figure 81). Remove the bearing from the opposite side of the wheel hub. 5.
Blade Maintenance Important: The curved part of the blade must be pointing toward the inside of the cutting unit to ensure proper cutting. Checking for a Bent Blade Note: After striking a foreign object, torque all the spindle pulley nuts to 130 to 150 ft-lb (176 to 203 N⋅m). 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.
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 84). Since sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check the blade before using the mower.
Spark Arrestor Maintenance 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. Servicing the Spark Arrestor Muffler 6. Compare the measurements of the outer blades with the center blade. The center blade must not be more than 3/8 inch (10 mm) lower than the outer blades.
Storage 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 procedure in , page . 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.
Schematics Electrical Schematic, sheet 1 (Rev.
Electrical Schematic, sheet 2 (Rev.
Hydraulic Schematic (Rev.
Notes: 61
Notes: 62
Notes: 63
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. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
