Form No. 3362-878 Rev C Groundsmaster® 4000-D & 4010–D Traction Unit Model No. 30448—Serial No. 310000001 and Up Model No. 30446—Serial No. 310000001 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. Model No. Serial No. Warning This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 1), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.
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. 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. • Use jack stands to support components when required. Do not run engine indoors or in an enclosed area. • Carefully release pressure from components with stored energy. Operation • Disconnect battery before making any repairs.
Sound Power Level as required lights, slow moving vehicle signs, and reflectors. This unit has a guaranteed sound power level of 105 dBA, which includes an Uncertainty Value (K) of 1 dBA. • 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. Sound power level was determined according to the procedures outlined in ISO 11094. • Do not mow on wet grass. Reduced traction could cause sliding.
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 to 149 N•m (85 to 110 ft-lb). 100-5693 1. Height of cut adjustment 100-5622 100-5694 1. Height of cut adjustment 1. Height of cut adjustment 100-5623 1. Low height of cut adjustment 104-3578 2.
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. Cutting hazard of hand or foot—stay away from moving parts; keep all guards in place.
117–2387 1. Raise left deck 2. Raise center deck 3. Raise right deck 4. Cooling fan 5. Reverse 6. Automatic 117-5723 1. 2. 3. 4. 5. 6. Off Headlights On Fast Slow Power Take-off (PTO) 7. 8. 9. 10. 11. 12. High Traction control Low Locked Flow divider Unlocked 117–2385 1. Read the Operators Manual. 2. Engine—start 3. Engine—preheat 4. Engine—stop 119-0067 1. To lock the parking brake, latch the pedals together, apply the brake pedals, and pull up on the knob. 2.
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 4. Headlights—10A fuse 5. Signal lights—10A fuse 6. Power Seat—10A fuse 7. Powerpoint—10A fuse 8. 9. 10. 11. Instuments—10A fuse Control module—2A fuse Control module—2A fuse Powerpoint—7.5A fuse 104-3599 1. 2. 3. 4. 5. Do not step here.
106-6754 1. Warning—do not touch the hot surface. 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts. 106-6753 1. Thrown object hazard—keep bystanders a safe distance from the machine. 2. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts. 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. 117-5735 1.
115-8456 1. Read the Operator’s Manual. Battery Symbols Some or all of these symbols are on your battery 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. 6. Keep bystanders a safe distance from the battery. 7. Wear eye protection; explosive gases can cause blindness and other injuries 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 10.
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.
Pedal Locking Latch Product Overview The pedal locking latch Figure 2 connects the pedals together to engage the parking brake. Controls Note: Determine the left and right sides of the machine from the normal operating position. 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.
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. Hi-Lo Speed Control The switch (Figure 4) allows the speed range to increase for transport of the machine. Cutting decks will not operate in high range. Also, the decks cannot be lowered from the transport position when the switch is in the high range.
Engine Cooling Fan Switch Air Conditioning Switch The machine is equipped with a hydraulically driven auto reversing engine cooling fan. The fan switch (Figure 5) has two positions R (manual reverse) and Auto (normal). Refer to Engine Cooling Fan Operation in the Operation Section of manual. Press front of switch to activate the air conditioning (Figure 6) and rear of switch to turn off the air conditioning. Fan Control Rotate the fan control knob to regulate the speed of the fan (Figure 6).
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 If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Figure 8 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 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. 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.
1. Park the machine on a level surface. 2. Using a clean rag, clean area around fuel tank cap. 3. Remove cap from the fuel tank (Figure 11). 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.) Service Interval: Every 400 hours Material Properties: Viscosity, ASTM D445 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. St @ 40° C 44 to 48 St @ 100° C 7.9 to 8.
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. Checking the Torque of the Wheel Nuts or Bolts Service Interval: After the first 10 hours Figure 14 1. Check plug Every 200 hours 2.
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 2. Spacers 3. Shims 4. Top axle mounting hole 5. Castor wheel Figure 18 Note: When operating in 2-1/2 inch (64 mm) height of cut or higher, the axle bolt must be installed in the lower castor fork hole to prevent grass buildup between the wheel and the fork.
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. 7. Rotate tension rod counterclockwise (finger tight) to put tension on adjustment. Figure 22 1. Castor pivot arm 2. Axle mounting holes 3. Clevis pin and hair pin cotter 4.
Adjusting the Cutting Unit Rollers The cutting unit rollers should be mounted in the lower position when operating in height of cuts greater than 2-1/2 inches (64 mm) and in the higher position when operating in height of cuts lower than 2-1/2 inches (64 mm). 1. Remove the bolt and nut securing the gage wheel to the cutting unit brackets (Figure 27). Figure 24 1. Damper link Figure 27 1. Gage wheel 2. Align the roller and spacer with the top holes in the brackets and secure them with the bolt and nut.
8. To ease measuring blade plane, raise the height of cut to the highest position; refer to Adjusting the Height of Cut. 9. Lower cutting units onto the flat surface. Remove the covers from the top of the cutting units. 10. Loosen the flange nut, securing the idler pulley, to release the belt tension on each cutting unit. 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.
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. Check measurement between outside edges of both side cutting units and inside edge of side cutting unit to outside edge of front cutting unit. 6.
Important: Allow engine to idle for 5 minutes before shutting it off after a full load operation. Failure to do so may lead to turbo-charger trouble. 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.
Figure 33 1. Reverse four-wheel drive pressure test port Figure 31 1. Bypass valve access hole Jacking Points There are jacking points located at the front and rear of the machine. 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.
position and depress the traction pedal slowly but fully to attain maximum ground speed. The flow divider enhances traction drive performance in compromised operating conditions. The flow divider is for use in low speed range only. When approaching an area known to cause wheel spin, depress and hold flow divider switch until completely past the area. If a tire spins while climbing or maneuvering on slopes, depress switch and slowly drive out of area.
After Operating To ensure optimum performance, clean the underside of the mower housing after each use. If residue is allowed to build up in the mower housing, cutting performance will decrease. Cutting Unit Pitch A blade pitch of 1/4 inch (6 mm) is recommended. A pitch larger than 1/4 inch (6 mm) will result in less power required, larger clippings, and a poorer quality of cut. A pitch less than 1/4 inch (6 mm) will result in more power required, smaller clippings and a better quality of cut.
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 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 bushings (
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. 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. 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. 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.
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 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.
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 2. Drain plug 3. Check plug Figure 66 1. Drain plug Changing the Rear Axle Lubricant 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. Service Interval: After the first 200 hours Every 800 hours 8. Install the plugs.
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.
Re-tensioning the Blade Drive Belts 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. Service Interval: After the first 10 hours Every 50 hours Note: If the stop bolt is ever removed from the mounting tab, make sure it is reinstalled in the hole that aligns the stop bolt head with the idler arm.
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). Figure 73 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. 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. g011538 Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Figure 76 1.
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.
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. Servicing the Castor Wheels and Bearings Figure 82 1. Tensioning cap 2. Spacers 3. Shims 4.
2. Remove the bearing from the wheel hub and allow the bearing spacer to fall out (Figure 84 and Figure 85). Remove the bearing from the opposite side of the wheel hub. Blade Maintenance 3. Check the bearings, spacer, and inside of the wheel hub for wear. Replace any damaged parts. 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.
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 88).
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. 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. Compare the measurements of the outer blades with the center blade.
Spark Arrestor Maintenance Cab Maintenance Servicing the Spark Arrestor Muffler Service Interval: Every 250 hours (Replace them if they are torn or excessively dirty.) Cleaning the Cab Air Filters 1. Remove the thumb screws and grates from over both the in-cab and rear cab air filters (Figure 90). Service Interval: Every 200 hours Every 200 hours operation, clear the muffler of carbon buildup. 1. Remove the pipe plug from the clean-out port at the lower side of the muffler.
Cleaning the Air Conditioning Coil Cleaning the A/C Condenser Screen Service Interval: Every 250 hours (Clean more frequently in extremely dusty or dirty conditions) Service Interval: Every 50 hours (Clean more frequently in extremely dusty or dirty conditions) 1. Stop the engine and remove the key. 1. Stop the engine and remove the key. 2. Remove the (4) screws securing the fan and the condenser cover to the fan mount (Figure 91). 2.
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. 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 G011533 Electrical Schematic, sheet 1 (Rev.
G011534 Electrical Schematic, sheet 2 (Rev.
G011535 Electrical Schematic, sheet 3 (Rev.
Hydraulic Schematic (Rev.
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).
