Form No. 3376-213 Rev C Groundsmaster® 4010-D and 4000-D Rotary Mower Model No. 30603—Serial No. 313000001 and Up Model No. 30605—Serial No. 313000001 and Up Register at www.Toro.com.
This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet. which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. g000502 Figure 2 Introduction 1. Safety alert symbol This machine is a ride-on, rotary-blade lawnmower intended to be used by professional, hired operators in commercial applications.
Contents Belt Maintenance ......................................................49 Servicing the Alternator Belt ....................................49 Servicing the Compressor Belt .................................49 Re-tensioning the Blade Drive Belts ..........................50 Replacing the Blade Drive Belt .................................50 Hydraulic System Maintenance ....................................51 Changing the Hydraulic Fluid...................................
Safety Tie back long hair. Do not wear jewelry. Do not operate the equipment when barefoot or wearing open sandals. This machine meets or exceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-2012 specifications in effect at the time of production. • Thoroughly inspect the area where the equipment is to Improper use or maintenance by the operator or owner can result in injury.
• Use care when loading or unloading the machine into a – Never mow across the face of the slope, unless the machine is designed for that purpose. trailer or truck. • Stay alert for holes in the terrain and other hidden hazards. • Use care when using heavy equipment. • The operator shall turn on flashing warning lights, if provided, whenever traveling on a public road, except where such use is prohibited by law. – Do not turn sharply. Use care when reversing.
• When operating a machine with a ROPS, always use a Use paper or cardboard, not your hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. seat belt. • Be certain that the seat belt can be released quickly if the machine is driven or rolls into a pond or water.
Sound Power Level This unit has a guaranteed sound power level of 104 dBA, which includes an Uncertainty Value (K) of 1 dBA. Sound power level was determined according to the procedures outlined in ISO 11094. Sound Pressure Level-Model 30603 This unit has a sound pressure level at the operator’s ear of 83 dBA, which includes an Uncertainty Value (K) of 1 dBA. Sound pressure level was determined according to the procedures outlined in EN 836.
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. decal93-7818 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). decal100-5624 100-5624 1. Height of cut adjustment decal100-5622 100-5622 decal100-5693 100-5693 1. Height of cut adjustment 1.
decal100-6578 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. decal104-3578 104-3578 1. Height of cut adjustment decal117-2754 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.
decal117-2766 117–2766 (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. 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.
decalbatterysymbols 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. decal121-3884 121–3884 1. Engine—stop 3.
decal106-6754 106-6754 1. Warning—do not touch the hot surface. 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts. decal120-6604 120-6604 1. Thrown object hazard—keep bystanders away from the machine. 2. Cutting/dismemberment hazard of hand, mower blade—stay away from moving parts, keep all guards and shields in place. decal106-6755 106-6755 1. Engine coolant under pressure. 3. Warning—do not touch the hot surface. 2.
decal120-4129 120–4129 1. Beacon 3. Left turn signal 2. Hazard light 4. Right turn signal decal120-8947 120–8947 1. Warning—read the Operator’s Manual. 4. If the roll bar is raised, wear the seat belt. 2. There is no rollover 5. If the roll bar is lowered, protection when the roll do not wear the seat belt. bar is down. 3. There is rollover protection 6. Drive slowly when turning. when the roll bar is up. decal120-4130 120–4130 decal121-1592 121–1592 1. Cruise control not set 2.
decal121-1599 121–1599 decal114-0846 1. Read the Operator’s Manual for information on fuses. 114–0846 1. Read the Operator’s Manual for information on starting the engine—1)Set to neutral; 2)Engage the brake; 3)Set the engine speed to slow; 4)Turn the ignition key to preheat; 5)Turn the ignition key to engine start. 4. Pull the knob out to engage the PTO. 2.
decal121-1676 121–1676 Groundsmaster 4000 shown 1. Read the Operator’s Manual for maintenance information.
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.
Tilt Steering Lever Product Overview Press the lever (Figure 3) down to tilt the steering wheel to the desired position. Then release the lever to lock the adjustment. Controls Note: Determine the left and right sides of the machine from the normal operating position. Parking Brake Latch CAUTION This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure.
Hi-Lo Speed Control Weight gauge The switch (Figure 4) allows the speed range to increase for transport of the machine. Cutting decks will not operate in high range. To switch between the High and Lo range, the decks must be raised, PTO disengaged, cruise control disengaged, traction pedal in neutral position and the machine must be moving at a slow speed. Indicates when the seat is adjusted to the weight of the operator (Figure 6).
Temperature Control Using the InfoCenter LCD Display Rotate the temperature control knob to regulate the air temperature in the cab (Figure 7). The InfoCenter LCD display shows information about your machine such as the operating status, various diagnostics and other information about the machine (Figure 9) There is a splash screen and main information screen of the InfoCenter.
InfoCenter Icon Description SERVICE DUE InfoCenter Icon Description (cont'd.
InfoCenter Icon Description (cont'd.) Operator should change to indicated state Symbols are often combined to form sentences. Some examples are shown below Settings The Settings menu allows you to customize and modify configuration variables on the InfoCenter display. About The About menu lists the model number, serial number, and software version of your machine.
Trans Speed Controls the maximum speed while in transport (high range). Smart Power Smart Power prevents bogging down in heavy turf by automatically controlling the machine speed and optimizing cutting performance. accessed, scroll down to Protect Settings. Using the right button, changing Protect Settings to OFF will allow the ability to view and change the settings in the Protected Menu without entering the passcode.
Specifications Operation Note: Specifications and design are subject to change without notice. Note: Determine the left and right sides of the machine from the normal operating position.
g020441 Figure 11 1. Expansion tank g020435 Figure 10 1. Dipstick 3. If the coolant is low, add a 50/50 mixture of water and ethylene glycol anti-freeze. Do not use water only or alcohol/methanol base coolants. 4. Install the radiator cap and expansion tank cap. 2. Oil fill cap 4. If the oil is below the Full mark, remove the fill cap (Figure 10) and add oil until the level reaches the Full mark. Do not overfill. Adding Fuel 5. Install the oil fill cap and dipstick.
portion should be low or ultra low sulfur. Observe the following precautions: DANGER In certain conditions during fueling, static electricity can be released causing a spark which can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property. • The biodiesel portion of the fuel must meet specification ASTM D6751 or EN14214. • The blended fuel composition should meet ASTM D975 or EN590. • Painted surfaces may be damaged by biodiesel blends.
Checking the Hydraulic Fluid Service Interval: Before each use or daily The machines reservoir is filled at the factory with approximately 29.3 liters (7.75 U.S. gallons) of high quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter. The recommended replacement fluid is: Toro Premium All Season Hydraulic Fluid (Available in 18.9 liter (5 gallon) pails or 208 liter (55 gallon) drums. See parts catalog or Toro distributor for part numbers.
3. If the oil level is low, remove the plug at the 12 o’clock position and add oil until it begins to flow out of the hole at the 3 o’clock position. 4. Re-install both plugs. 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 2.4 liters (80 oz.). Visually inspect for leaks daily. 1. Position the machine on a level surface. g011488 2.
height-of-cut on the front cutting unit, position the castor wheel axles in the upper or lower holes of the castor forks, add or remove an equal number of spacers from the castor forks, and secure the rear chain to the desired hole. 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. Position the castor wheel axles in the same holes in all castor forks.
spacers onto the spindle shaft. Install the tensioning cap to secure the assembly. 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. 1. Position the castor wheel axles in the same holes in all of the castor forks (Figure 21 and Figure 23).
g008867 Figure 27 g011549 2. Remove the flange-head bolts and nuts from each skid (Figure 27). Figure 25 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 9 to 11 N⋅m (80 to 100 in-lbs).
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 172-207 kPa (25-30 psi). 3. Check and adjust all castor tire pressures to 345 kPa (50 psi). g008866 4.
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 within 3 mm (1/8 inch) of the front cutting unit. Note: All three cutting units castor wheels should remain on the ground with counterbalance applied. Note: If adjustments need to be made to match the cut between the front and side cutting units, make the adjustments to the side cutting units only. 3.
Refer to Using the InfoCenter LCD Display, in the Operation section of this manual, for the procedure to set the mow speed. additional seconds, and repeat the starting procedure. 4. To stop the engine, move the PTO switch to the Off position, set the parking brake, return the throttle setting to low idle and rotate the ignition key to Off. Remove the key from the switch to prevent accidental starting.
The machine has interlock switches in the electrical system. These switches are designed to stop traction when the operator gets off of the seat when the traction pedal is depressed. Although the engine will continue to run, it is strongly recommended that the engine be stopped before rising from the seat. WARNING There is no rollover protection when the roll bar is in the down position. • Lower the roll bar only when absolutely necessary.
Pushing or Towing the Machine • On the frame at the inside of each front drive tire In an emergency, the machine can be moved forward by actuating the bypass valve in the variable displacement hydraulic pump and pushing or towing the machine. Tie Downs • At the center of the rear axle There are tie downs located at the front, rear and sides of the machine. Important: Do not push or tow the machine faster than 3-4.8 km/h (2-3 MPH) because internal transmission damage may occur.
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 8 to 11 mm (5/16 to 7/16 inch) is recommended. A pitch larger than 8 to 11 mm (5/16 to 7/16 inch) will result in less power required, larger clippings, and a poorer 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 200 hours • Change the front planetary gear oil. • Change the rear axle oil. Before each use or daily • • • • • • • Check the engine oil level. Check the coolant level. Check the hydraulic fluid level. Check the tire pressure.
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.
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.
g017810 g017810 Figure 40 g011557 Front Lift Assemblies Figure 43 • Lift arm cylinder bushings (2 each) (Figure 41) • Lift arm ball joints (2) (Figure 42) Side Lift Assemblies • • • • Main lift arm bushings (6) (Figure 44 and Figure 45) Bell crank pivot bushings (2) (Figure 46) Rear arm bushings (4) (Figure 46) Lift cylinder bushings (4) (Figure 47) g020455 Figure 41 g011552 Figure 44 g011551 Figure 42 Side Cutting Units • Castor fork shaft bushing (1) (Figure 43) • Spindle shaft bearings (2 ea
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.
Servicing the Engine Oil and Filter Service Interval: Every 250 hours Change the oil and filter every 250 hours. 1. Remove the drain plug (Figure 51) and let the oil flow into a drain pan. When all the oil is drained, install the drain plug. g011504 Figure 49 1. Air cleaner primary filter g020434 Figure 51 1. Engine oil drain plug g011505 Figure 50 2. Remove the oil filter (Figure 52). Apply a light coat of clean oil to the new filter seal before screwing it on. Do not overtighten. 1.
Fuel System Maintenance 2. Loosen the drain plug on the bottom of the filter canister. Servicing the Fuel System 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. g007367 Figure 53 • 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 Charging the battery produces gasses that can explode. Battery Care Never smoke near the battery and keep sparks and flames away from battery. WARNING Battery type is group 24. 2. Remove the rubber boot from the positive terminal and inspect the battery. Important: Before welding on the machine, disconnect the negative cable from the battery to prevent damage to the electrical system. WARNING Note: Check the battery condition weekly or after every 50 hours of operation.
The cab fuses (Figure 59 & Figure 60) are located in the fuse box in the cab headliner (Cab model only). g020440 Figure 56 1. Power center cover 2. Allen head screws (2) g009239 Figure 59 1. Cab fuse box 2. Fuses g020439 Figure 57 1.
Drive System Maintenance Adjusting the Traction Pedal Angle The traction pedal operating angle can be adjusted for operator comfort. g008862 Figure 62 1. Loosen the two nuts and bolts securing the left side of the traction pedal to the bracket (Figure 61). 1. Check/drain plug 2. Place a drain pan under the planetary hub, remove plug and allow oil to drain. 3. Place a drain pan under the brake housing, remove the drain plug and allow the oil to drain (Figure 42). g009745 Figure 61 g020680 1.
Changing the Rear Axle Lubricant Service Interval: After the first 200 hours Every 800 hours Change the oil initially after the first 200 hours of operation and every 800 hours of operation thereafter. 1. Position the machine on a level surface. 2. Clean the area around the 3 drain plugs; 1 on each end and 1 in the center (Figure 64). 3. Remove the check plugs to ease in draining of the oil. 4. Remove the drain plugs and allow the oil to drain into the pans. g011558 Figure 65 1. Drain plug 7.
Brake Maintenance Cooling System Maintenance Adjusting the Service Brakes Servicing the Engine Cooling System Adjust the service brakes when there is more than 25 mm (1 inch) 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. Remove debris from the oil radiator/oil cooler daily. Clean them more frequently in dirty conditions. 1.
Belt Maintenance Servicing the Alternator Belt 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. Proper tension will allow 10 mm (3/8 inch) deflection when a force of 44 N (10 lb) is applied on the belt midway between the pulleys. 2. If the deflection is not 10 mm (3/8 inch), loosen the alternator mounting bolts (Figure 69). Increase or decrease the alternator belt tension and tighten the bolts.
1. Lower the cutting unit to the shop floor. Remove the belt covers from the top of the cutting unit and set the covers aside. decrease the compressor belt tension and tighten the 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). Re-tensioning the Blade Drive Belts 3. Loosen the flange nut securing the stop bolt to the mounting tab.
Replacing the Hydraulic Filters Hydraulic System Maintenance Service Interval: Every 800 hours Changing the Hydraulic Fluid Change the 2 hydraulic filters after every 800 operating hours, in normal conditions. 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). Service Interval: Every 800 hours Change the hydraulic fluid after every 800 operating hours, in normal conditions.
Adjusting the Counterbalance Pressure The counterbalance test port (Figure 75) is used to test the pressure in the counterbalance circuit. Recommended counterbalance pressure is 2241 kPa (325 psi). To adjust the counterbalance pressure, loosen the locknut, rotate the adjusting screw (Figure 75) clockwise to increase the pressure or counterclockwise to decrease the pressure and tighten the locknut. The engine must be running, the deck lowered and in float to check pressure.
Mower Maintenance 4. Sit on the seat, start the engine, and lower the cutting unit until it is slightly off of the floor. 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. Pivoting (Tilting) the Front Cutting Unit Upright Note: Although not needed for normal maintenance procedures, the front cutting unit can be pivoted (tilted) to an upright position.
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. g004737 Figure 79 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. g008866 Figure 78 1.
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 176 to 203 N-m (130 to 150 ft-lb). 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.
g004741 Figure 83 1. Blade bolt 2. Anti-scalp cup Inspecting and Sharpening the Cutter Blade(s) DANGER A worn or damaged blade can break, and a piece of the blade could be thrown into the operator's or bystander's area, resulting in serious personal injury or death. Trying to repair a damaged blade may result in discontinued safety certification of the product. • Inspect the blade periodically for wear or damage. • Never try to straighten a blade that is bent or weld a broken or cracked blade.
blade because it is bent. Make sure to measure all of the blades. 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. 6. Compare the measurements of the outer blades with the center blade. The center blade must not be more than 10 mm (3/8 inch) 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 86). 2. Remove the (4) screws securing the fan and the condenser cover to the fan mount (Figure 87). 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) 1. Stop the engine and remove the key. Traction Unit 2. On the rear of the fan mount, rotate the latch to the side (Figure 88). 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.
Schematics g020462 Hydraulic Schematic (Rev.
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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).
