Form No. 3370-863 Rev A Groundsmaster® 4000-D and 4010-D Rotary Mower Model No. 30446—Serial No. 312000001 and Up Model No. 30448—Serial No. 312000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet. and serial numbers of your product ready. Write the numbers in the space provided. Model No. WARNING Serial No. 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.
Contents Brake Maintenance ................................................. 46 Adjusting the Service Brakes............................... 46 Belt Maintenance.................................................... 46 Servicing the Alternator Belt............................... 46 Servicing the Compressor Belt ............................ 46 Re-tensioning the Blade Drive Belts .................... 47 Replacing the Blade Drive Belt ............................ 47 Controls System Maintenance....................
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.
• Shut off fuel while storing or transporting. Do not store fuel near flames. WARNING Engine exhaust contains carbon monoxide, which is an odorless, deadly poison that can kill you. • Park machine on level ground. Never allow untrained personnel to service machine. Do not run engine indoors or in an enclosed area. • Use jack stands to support components when required.
Sound Power Level over if a wheel goes over the edge of a cliff or ditch, or if an edge caves in. This unit has a guaranteed sound power level of 105 dBA, which includes an Uncertainty Value (K) of 1 dBA. • Do not mow on wet grass. Reduced traction could cause sliding. Sound power level was determined according to the procedures outlined in ISO 11094. • 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. 93-7818 1. Warning—read the Operator's Manual for instructions on torquing the blade bolt/nut to 115-149 N-m (85-110 ft-lb). 100-5693 1. Height of cut adjustment 100-5622 1. Height of cut adjustment 100-5694 1. Height of cut adjustment 100-5623 1. Low height of cut adjustment 104-3578 2.
117–2754 1. Warning—read the Operator's Manual. 2. Warning—do not operate this machine unless you are trained. 3. Warning—wear the seat belt when seated in the operator's position. 4. Warning—wear hearing protection. 5. Thrown object hazard—keep bystanders a safe distance from the machine. 6. Cutting hazard of hand or foot—stay away from moving parts; keep all guards in place. 7. Tipping hazard—lower the cutting unit when driving down slopes; slow machine before turning, do not turn at high speeds 8.
117–2387 1. Raise left deck 4. Cooling fan 2. Raise center deck 3. Raise right deck 5. Reverse 6. Automatic 117-5723 1. Off 7. High 2. Headlights 8. Traction control 3. 4. 5. 6. On Fast Slow Power Take-off (PTO) 9. 10. 11. 12. Low Locked Flow divider Unlocked 117–2385 1. Read the Operators Manual. 2. Engine—start 3. Engine—preheat 4. Engine—stop 119-0067 117–2718 1. To lock the parking brake, latch the pedals together, apply the brake pedals, and pull up on the knob. 4.
104-3579 1. Low height of cut adjustment 2. High height of cut adjustment 119-0075 1. Read the Operator's Manual for fuse information. 2. Engine preheat—60A fuse 3. Engine, start—20A fuse 7. Powerpoint—10A fuse 8. Instuments—10A fuse 9. Control module—2A fuse 4. Headlights—10A fuse 10. Control module—2A fuse 5. Turn signal—10A fuse 11. Powerpoint—7.5A fuse 104-3599 1. Do not step here. 6. Power seat—10A fuse 2. Traction pedal 3. Traction—forward 4. Traction—reverse 5.
117-5735 1. Read the Operators Manual; to start the engine, move the traction pedal to Neutral, apply the brake, move the throttle switch to slow, turn the ignition key to Preheat. When the Wait to Start Advisory clears on the Info Center then turn the ignition key to Start. 2. Read the Operators Manual; to stop the engine, move the throttle lever to slow, disengage the PTO, set the parking brake, wait 5 minutes, turn the ignition key to Stop, and remove the key; read the Operators Manual. 3.
106-6754 Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or smoking. 7. Wear eye protection; explosive gases can cause blindness and other injuries 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 5. Read the Operator's Manual. 1.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 2 Use Qty. No parts required – Grease the machine. Warning Decal 1 Used only on machines requiring European CE compliance. Media and Additional Parts Description Use Qty.
Product Overview Tilt Steering Lever Controls Press the lever Figure 2 down to tilt the steering wheel to the desired position. Then release the lever to lock the adjustment. Note: Determine the left and right sides of the machine from the normal operating position. Parking Brake Latch CAUTION A knob on the left side of the console actuates the parking brake lock (Figure 2).
PTO Switch pump reaches full stroke or damage to the pump may occur. The PTO switch (Figure 4) has two positions: Out (start) and In (stop). Pull the PTO button out to engage the cutting unit blades. Push in the button to disengage the cutting unit blades. Diagnostic Light The diagnostic light (Figure 4) will illuminate should a system fault be recognized.
Engine Coolant Temperature Warning Light Cab Controls Model 30446 only The light (Figure 4) illuminates and the cutting units shut down (PTO disengages) if the engine reaches an unsafe operating temperature. If the temperature continues to rise the engine will shut down. Wind Shield Wiper Switch Press front of switch to activate the wind shield wipers (Figure 6) and rear of switch to turn off the wipers.
Specifications Note: Specifications and design are subject to change without notice. Width of cut overall 132 inch (335 cm) front cutting unit 62 inch (157 cm) side cutting unit 42 inch (107 cm) front and one side cutting unit 97 inch (246 cm) Overall width cutting units down Figure 7 cutting units up (transports) 1. Wind shield latch Overall length Rear Window Latch Lift up on latches to open the rear window. Press in on latch to lock window in open position.
Operation Note: Determine the left and right sides of the machine from the normal operating position. Before Operating 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. Figure 8 1. Dipstick Checking the Engine Oil 4. If the oil is below the Full mark, remove the fill cap (Figure 9) 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. CAUTION 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.
DANGER 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. • Never smoke when handling fuel, and stay away from an open flame or where fuel fumes may be ignited by a spark.
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.
Checking the Tire Pressure Service Interval: Before each use or daily The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure. The correct air pressure in the front and rear tires is 25-30 psi (172-207 kPa). Important: Maintain even pressure in all tires to ensure a good quality-of-cut and proper machine performance. Do not under-inflate. Figure 14 1. Check plug 2.
installed) and the remaining spacers onto the spindle shaft. Install the tensioning cap to secure the assembly. 5. Remove the hairpin cotter and clevis pin securing the height-of-cut chains to the rear of the cutting unit (Figure 18). Figure 16 1. Tensioning cap 4. Top axle mounting hole 2. Spacers 5. Castor wheel 3.
2. Remove the tensioning cap from the spindle shaft (Figure 20) and slide the spindle out of castor arm. Put the two shims (1/8 inch [3 mm]) onto spindle shaft as they were originally installed. These shims are required to achieve a level across the entire width of the cutting units. Slide 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. 6. Insert the clevis pins and install the hairpin cotters. 7.
Figure 26 2. Remove the flange-head bolts and nuts from each skid (Figure 26). Figure 24 1. Damper link 3. Move each skid to the desired position and secure them with the flange-head bolts and nuts. Note: Only use the top or center sets of holes to adjust the skids. The bottom holes are used when switching sides at which time they become the top holes on the other side of the mower. 4. Torque the screw at the front of each skid to 80 to 100 in-lb (9 to 11 N⋅m).
Correcting Mismatch Between Cutting Units Due to differences in grass conditions and the counterbalance setting of the traction unit, it is advised that a sample area of grass be cut and the appearance checked before formal cutting is started. 1. Set all cutting units to the desired height of cut; refer to Adjusting the Height of Cut. 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). Figure 28 4.
Adjusting the Mirrors 2. Position blade side to side on inside spindle of side cutting unit and corresponding outside spindle of front cutting unit. Measure from the floor to the tip of the cutting edge on inside edge of side cutting unit to corresponding outside edge of front cutting unit and compare. The side cutting unit measurement should be approximately 3/8 inch less than the front cutting unit measurement to be correct.
fan when the rear screen is clogged or prior to entering the shop or the storage area. • The engine has ceased running due to lack of fuel. • Maintenance has been performed upon the fuel system components. Checking the Interlock Switches 1. Ensure that the parking brake is set. Remove your foot from the traction pedal and ensure that it is in neutral. CAUTION 2. Move the throttle control to the mid-idle position.
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. 1. Raise the seat and remove the battery cover. The bypass valve is located in front of the battery (Figure 31). 2.
Operating Characteristics WARNING Practice driving the machine because it has a hydrostatic transmission and its characteristics are different than many turf maintenance machines. 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.
Operating Tips • Check to make sure the air conditioning condenser fins are clean. Mow When Grass is Dry • Operate the air conditioner blower at the mid speed setting. Mow either in the late morning to avoid the dew, which causes grass clumping, or in late afternoon to avoid the damage that can be caused by direct sunlight on the sensitive, freshly mowed grass. • Verify continuous seal between the roof and the headliner. Correct as required.
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 • • • • After the first 50 hours • Change the engine oil and filter. • Check the engine speed (at idle and full throttle).
Maintenance Service Interval Every 800 hours Every 2 years Maintenance Procedure • • • • • • • • • • Drain and clean the fuel tank. Change the front planetary gear oil. Change the rear axle oil. Check the rear wheel toe-in. Inspect the blade drive belts. Change the hydraulic oil. Change the hydraulic oil filters. Inspect the side cutting unit damper. Inspect the cutting unit castor wheel assemblies. Check and adjust the valve clearance. • Flush the cooling system and replace fluid.
Lubrication Greasing the Bearings and Bushings The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If the machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation or immediately after every washing.
Front Cutting Unit • Castor fork shaft bushings (2) (Figure 40) • Spindle shaft bearings (3) (located under the pulley) (Figure 41) • Idler arm pivot bushings (2) (Figure 41) Figure 40 Figure 42 g017810 Figure 41 Figure 43 Front Lift Assemblies • Lift arm bushings (2) (Figure 42) • Lift cylinder bushings (4) (Figure 42) Side Cutting Units • Lift arm ball joints (2) (Figure 43) • Castor fork shaft bushing (1) (Figure 44) • Spindle shaft bearings (2 each) (located under the pulley) • Idler arm pivot b
Figure 47 Figure 44 Side Lift Assemblies • Main lift arm bushings (6) (Figure 45 and Figure 46) • Bell crank pivot bushings (2) (Figure 47) • Rear arm bushings (4) (Figure 47) • Lift cylinder bushings (4) (Figure 48) Figure 48 Figure 45 Figure 46 37
Engine Maintenance 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 51). 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.
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. DANGER Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage.
4. Tighten the tube connector securely. 5. Repeat the procedure on the remaining nozzles. Figure 54 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. Tighten the drain plug on the bottom of the filter canister.
Electrical System Maintenance 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. Keep the terminals and the entire battery case clean because a dirty battery will discharge slowly. To clean the battery, wash the entire case with a solution of baking soda and water. Rinse with clear water.
1 WARNING 10 7.5 7.5 10 10 2 7.5 7.5 2 7.5 7.5 • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. 10 20 Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • Always connect the positive (red) battery cable before connecting the negative (black) cable. G011542 Figure 59 4.
Drive System Maintenance The cab fuses (Figure 61 & Figure 62) are located in the fuse box in the cab headliner (model 30446 only). 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. Figure 61 1. Cab fuse box 2. Fuses 1.
5. Clean the area around the drain plug on the bottom of the gear box (Figure 66). 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. Figure 64 1. Brake housing 3. Check plug 2. Drain plug Figure 66 Changing the Rear Axle Lubricant 1. Drain plug 7. Add enough oil to bring the level up to the bottom of the check plug holes; refer to Checking the Rear Axle Lubricant, and Checking the Rear Axle Gear Box Lubricant.
Cooling System Maintenance Servicing the Engine Cooling System Remove debris from the oil cooler and radiator daily. Clean them more frequently in dirty conditions. This machine is equipped with a hydraulically driven fan drive system that automatically (or manually) reverses to reduce radiator and screen debris build-up. While this feature can help reduce the time required to clean radiators and coolers, it does not eliminate the need for routine cleaning.
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 belt (Figure 69) after every 100 operating hours. 1.
bolt. Check the deflection of the belt again to ensure that the tension is correct. 2. Loosen the eye bolt allowing the removal of the extension spring (Figure 70). 3. Loosen the flange nut securing the stop bolt to the mounting tab. Back off the nut enough to allow the idler arm to pass by the stop bolt (Figure 70). Move the idler pulley away from the belt to release belt tension.
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 72) 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 73 1. Traction pedal stop 2. Jam nuts 3.
Replacing the Hydraulic Filters Hydraulic System Maintenance Service Interval: After the first 200 hours Every 800 hours 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 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).
Checking the Hydraulic Lines and Hoses 1 2 Service Interval: Every 2 years 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. WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
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. Should you desire to tilt the cutting unit, proceed as follows: If the transport latch (Figure 77) 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. 1.
Adjusting the Front Cutting Unit 1. Loosen the jam nuts on the top or bottom of the height-of-cut chain U-bolt (Figure 81). 2. Adjust the other set of nuts to raise or lower the rear of the cutting unit and attain the correct cutting unit pitch. 3. Tighten the jam nuts. Figure 80 1. Cable 2. Pin Pivoting the Front Cutting Unit Down Figure 81 1. With the help of another person, hold the cutting unit upright, remove the hairpin cotter securing the cable end, and remove the cable from the pin. 2.
Servicing the Castor Arm Bushings or the castor pivot arm (Figure 85). Grasp the castor wheel and slide the bolt out of the fork or pivot arm. 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.
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.
traction pedal in neutral, put the PTO lever in the Off position, stop the engine, and remove the ignition key. DANGER If the blade is allowed to wear, a slot will form between the sail and flat part of the blade. 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. 2. Examine the cutting ends of the blade carefully, especially where the flat and curved parts of the blade meet (Figure 88).
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.
Cleaning the Air Conditioning Coil Cab Maintenance Cleaning the Cab Air Filters Service Interval: Every 250 hours (Clean more frequently in extremely dusty or dirty conditions) Service Interval: Every 250 hours (Replace them if they are torn or excessively dirty.) 1. Stop the engine and remove the key. 1. Remove the thumb screws and grates from over both the in-cab and rear cab air filters (Figure 90). 2. Remove the (4) screws securing the fan and the condenser cover to the fan mount (Figure 91). 3.
Cleaning the A/C Condenser Screen Storage Preparing for Seasonal Storage Service Interval: Every 50 hours (Clean more frequently in extremely dusty or dirty conditions) Traction Unit 1. Stop the engine and remove the key. 1. Thoroughly clean the traction unit, cutting units, and the engine. 2. Check the tire pressure; refer to Checking the Tire Pressure. 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 G011533 Electrical Schematic (Rev.
G011534 Electrical Schematic (Rev.
G011535 Electrical Schematic (Rev.
Electrical Schematic, EU-GM 4000/4100 (Rev.
g017778 Electrical Schematic, EU-GM 4010 (Rev.
g017779 Electrical Schematic, US-GM 4000/4100 (Rev.
g017780 Electrical Schematic, US-GM 4010 (Rev.
g017781 Electrical Schematic, US-GM 4110 (Rev.
g017782 Electrical Schematic, GM 4010 (Rev.
g017783 Electrical Schematic, GM 4110 (Rev.
g017784 Electrical Schematic, GM 4110 Cab (Rev.
g017785 Electrical Schematic, GM 4110 Cab (Rev.
Hydraulic Schematic (Rev.
The Toro Total Coverage Guarantee A 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).
