Toro 30635 Operator'S Manual Download

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Form No. 3388-892 Rev A

Groundsmaster

4010 Rotary

Mower

Model No. 30635—Serial No. 315000001 and Up

*3388-892* A

Summary of Contents for 30635

Page 1: ...Form No 3388 892 Rev A Groundsmaster 4010 Rotary Mower Model No 30635 Serial No 315000001 and Up Register at www Toro com Original Instructions EN 3388 892 A ...

Page 2: ...lp finding a dealer or to register your product Whenever you need service genuine Toro parts or additional information contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready Figure 1 identifies the location of the model and serial numbers on the product Write the numbers in the space provided g028455 1 Figure 1 1 Model and serial n...

Page 3: ...ystem Maintenance 44 Battery Care 44 Fuses 44 Drive System Maintenance 46 Adjusting the Traction Pedal Angle 46 Changing the Planetary Gear Drive Oil 46 Changing the Rear Axle Lubricant 47 Checking the Rear Wheel Toe In 47 Cooling System Maintenance 48 Servicing the Engine Cooling System 48 Brake Maintenance 48 Adjusting the Service Brakes 48 Belt Maintenance 49 Servicing the Alternator Belt 49 Se...

Page 4: ...quipment 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 Take the following precautions Store fuel in containers specifically designed for this purpose Refuel outdoors only and do not smoke while refuelling Add fuel before starting the engine Never remove t...

Page 5: ...lashing warning lights if provided whenever traveling on a public road except where such use is prohibited by law Maintenance and Storage Keep all nuts bolts and screws tight to be sure the equipment is in safe working condition Never store the equipment with fuel in the tank inside a building where fumes may reach an open flame or spark Allow the engine to cool before storing in any enclosure and...

Page 6: ...d turning on slopes If you must turn turn slowly and gradually downhill if possible When operating a machine with a ROPS always use a seat belt Be certain that the seat belt can be released quickly if the machine is driven or rolls into a pond or water Watch for traffic when near or crossing roads Always yield the right of way This machine is not designed or equipped for on road use and is a slow ...

Page 7: ...termined according to the procedures outlined in EN ISO 5395 2013 Vibration Level Hand Arm Measured vibration level for right hand 0 58 m s2 Measured vibration level for left hand 0 63 m s2 Uncertainty Value K 0 32 m s2 Measured values were determined according to the procedures outlined in EN ISO 5395 2013 Whole Body Measured vibration level 0 26 m s2 Uncertainty Value K 0 13 m s2 Measured values...

Page 8: ...e blade bolt nut to 115 149 N m 85 110 ft lb 100 5622 1 Height of cut adjustment 100 5623 1 Low height of cut adjustment 2 High height of cut adjustment 100 5624 1 Height of cut adjustment 100 5693 1 Height of cut adjustment 100 5694 1 Height of cut adjustment 104 3578 1 Height of cut adjustment 100 6578 1 Entanglement hazard belt do not operate the machine with the shields or guards removed alway...

Page 9: ...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 t...

Page 10: ... 6 Variable speed adjustment 13 Lower center deck 7 Slow 14 Lower right deck 121 3887 1 Read the Operator s Manual 58 6520 1 Grease 121 3884 1 Engine stop 3 Engine start 2 Engine preheat 104 3579 1 Low height of cut adjustment 2 High height of cut adjustment 93 7272 1 Cutting dismemberment hazard fan stay away from moving parts 10 ...

Page 11: ... 3 Air conditioning 30A fuse 119 0124 Cab models 1 Warning when the cab windows are open wear hearing protection 2 Close the rear window before attempting to open the hood 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 6755 1 Engine coolant under pressure 3 Warning do not touch the hot surface 2 Explos...

Page 12: ...s up 6 Drive slowly when turning 127 3700 1 Raise the left deck 4 Lock engine speed 2 Raise the center deck 5 Unlock engine speed 3 Raise the right deck 120 4129 1 Beacon 3 Left turn signal 2 Hazard light 4 Right turn signal 120 4130 1 Read the Operator s Manual 3 Parking brake 2 To engage the parking brake 1 Lock the pedals together 2 Push down on the brake 3 Pull out the parking brake knob 4 To ...

Page 13: ...t 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 Read the Operator s Manual for information on stopping the engine 1 Set the engine speed to slow 2 Disengage the deck 3 Lock the parking brake 4 Wait 5 minutes 5 Turn the ignition key to engine stop 6 Remove the key from the ignition 5 Push the knob in to di...

Page 14: ...130 6043 1 Read the Operator s Manual 14 ...

Page 15: ...130 6046 1 Read the Operator s Manual 15 ...

Page 16: ... 1 Review before operating machine Declaration of conformity 1 Note Determine the left and right sides of the machine from the normal operating position 1 Greasing the Machine No Parts Required Procedure Before the machine is operated it must be greased to ensure proper lubricating characteristics refer to Greasing the Bearings and Bushings page 39 Failure to properly grease the machine will resul...

Page 17: ...o tilt the steering wheel to the desired position Then release the lever to lock the adjustment Parking Brake Latch A knob on the left side of the console actuates the parking brake lock Figure 3 To engage the parking brake connect the pedals with the locking latch push down on both pedals and pull the parking brake latch out To release the parking brake press both pedals until the parking brake l...

Page 18: ...n and the front of the switch sets the desired ground speed Note Pressing either brake pedal or moving the traction pedal into the reverse position for one second will also disengage the pedal position Power Point The power point Figure 5 is used to power optional electrical accessories g028454 1 2 Figure 5 1 Power point 2 Cruise control switch Seat Adjustments Fore and Aft Adjusting Lever Pull ou...

Page 19: ...t on or off Figure 7 Flashers Switch Use this switch to turn the flashers hazard lights on or off Figure 7 Air Conditioning Switch Use this switch to turn the air conditioning on or off Figure 7 Wind Shield Latch Lift up on latches to open the wind shield Figure 8 Press in on latch to lock wind shield in open position Pull out and down on latch to close and secure wind shield Figure 8 1 Wind shiel...

Page 20: ...t the time Each button will be labeled with an icon displaying its current function InfoCenter Icon Description SERVICE DUE Indicates when scheduled service should be performed Engine rpm status indicates the engine rpm Hour meter Info icon Sets the maximum traction speed Fast Slow Fan Reversal indicates when the fan is reversed Fuel level Stationary regeneration required Air intake heater is acti...

Page 21: ...ne start denied Engine shutdown Engine coolant too hot Hydraulic oil too hot or Sit down or set parking brake Using the Menus To access the InfoCenter menu system press the menu access button while at the main screen This will bring you to the main menu Refer to the following tables for a synopsis of the options available from the menus Main Menu Menu Item Description Faults The Faults menu contai...

Page 22: ...ptimizing cutting performance Only operator faced text is translated Faults Service and Diagnostics screens are service faced Titles will be in the selected language but menu items are in English About Menu Item Description Model Lists the model number of the machine SN Lists the serial number of the machine Machine Controller Revision Lists the software revision of the master controller InfoCente...

Page 23: ...ransport speed 50 75 or 100 Press the left button to exit When finished with the Protected Menu press the left button to exit to the Main Menu then press the left button to exit to the Run Menu Specifications Note Specifications and design are subject to change without notice Width of cut overall 335 cm 132 inches front cutting unit 157 cm 62 inches side cutting unit 107 cm 42 inches front and one...

Page 24: ...the add mark on the dipstick add oil to bring the oil level to the full mark Do not overfill If the oil level is between the full and add marks no additional oil is required 1 Park the machine on a level surface Unlock the engine cover latches 2 Open the engine cover 3 Remove the dipstick wipe it clean install the dipstick into the tube and pull it out again The oil level should be up to the Full ...

Page 25: ... away from nozzle and gas tank or conditioner opening Keep fuel away from eyes and skin Biodiesel Ready This machine can also use a biodiesel blended fuel of up to B20 20 biodiesel 80 petrodiesel The petrodiesel portion should be low or ultra low sulfur Observe the following precautions The biodiesel portion of the fuel must meet specification ASTM D6751 or EN14214 The blended fuel composition sho...

Page 26: ...gh 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 L 5 US gallons pails or 208 L 55 US gallons drums See parts catalog or Toro distributor for part numbers Alternate fluids If the Toro fluid is not available other fluids may be used p...

Page 27: ...out of the hole at the 3 o clock position 4 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 L 80 oz Visually inspect for leaks daily 1 Position the machine on a level surface 2 Remove a check plug from one ...

Page 28: ... 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 Refer to the f...

Page 29: ...el 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 Refer to the following chart to determine the correct hole for the setting 2 Remove the tensioning cap from the spindle shaft Figure 21 and slide the spindle o...

Page 30: ... links to the cutting unit brackets Figure 25 Align the damper link holes with the selected height of cut bracket holes in the cutting unit frame Figure 26 insert the clevis pins and install the hairpin cotters Important The damper link length should never be adjusted The length between the hole centers should be 13 7 cm 5 3 8 inches Figure 25 1 Damper link Figure 26 Adjusting the Skids The skids ...

Page 31: ...nd adjust all castor tire pressures to 345 kPa 50 psi 4 Check charge and counterbalance pressures with engine at high idle using test ports defined in Hydraulic Systems Test Ports Adjust counterbalance to 2241 kPa 325 psi 5 Check for bent blades refer to Checking for a Bent Blade page 55 6 Cut grass in a test area to determine if all cutting units are cutting at the same height 7 If cutting unit a...

Page 32: ... 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 3 mm 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...

Page 33: ...atically initiated when either the engine coolant or hydraulic oil temperature reaches a certain point This reversal will help blow debris off the rear screen and lower the engine and hydraulic oil temperatures By simultaneously pressing the right and left buttons on the InfoCenter the fan will complete a manually initiated reverse cycle It is recommended to manually reverse the fan prior to leavi...

Page 34: ... beginning operation 4 Sit on the seat engage the parking brake and start the engine Move the traction pedal out of the neutral position The InfoCenter will display traction not allowed and the machine should not move If the engine does move there is a malfunction in the interlock system that should be corrected before beginning operation Pushing or Towing the Machine In an emergency the machine c...

Page 35: ...en operating the machine on slopes Make sure that the ROPS is in the raised position the seat latch is properly secured and the seat belt is buckled Drive slowly and avoid sharp turns on slopes to prevent roll overs For steering control the cutting unit must be lowered when going downhill Before stopping the engine disengage all controls and change the throttle to Slow Changing the throttle to Slo...

Page 36: ...1 mm 5 16 to 7 16 inch will result in more power required smaller clippings and a better quality of cut Maximizing Air Conditioner Performance To limit solar heating park the machine in a shaded area or leave the doors open in direct sun Check to make sure the air conditioning condenser fins are clean Operate the air conditioner blower at the mid speed setting Verify continuous seal between the ro...

Page 37: ...s Inspect the air cleaner Check the blade drive belt tension Every 100 hours Inspect the cooling system hoses and clamps Check the alternator belt tension Check the compressor belt tension Every 200 hours Torque the wheel lug nuts Every 250 hours Change the engine oil and filter Clean the cab air filters Replace them if they are torn or excessively dirty Clean the air conditioning coil Clean more ...

Page 38: ...ve 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 34 38 ...

Page 39: ...tions and quantities are Traction Unit Service Interval Every 50 hours Brake pedal pivot shaft bearings 2 Figure 35 Front and rear axle pivot bushings 2 Figure 36 Steering cylinder ball joints 2 Figure 37 Tie rod ball joints 2 Figure 37 King pin bushings 2 Figure 37 The top fitting on the king pin should only be lubricated annually 2 pumps Figure 35 Figure 36 Figure 37 Front Cutting Unit Castor fo...

Page 40: ...its Castor fork shaft bushing 1 Figure 42 Spindle shaft bearings 2 each located under the pulley Idler arm pivot bushings 1 located on the idler arm Figure 42 Side Lift Assemblies Main lift arm bushings 6 Figure 43 and Figure 44 Bell crank pivot bushings 2 Figure 45 Rear arm bushings 4 Figure 45 Lift cylinder bushings 4 Figure 46 Figure 43 Figure 44 40 ...

Page 41: ...l the latch outward and rotate the air cleaner cover counterclockwise Figure 47 2 Remove the cover from the air cleaner body Before removing the filter use low pressure air 40 psi clean and dry to help remove large accumulations of debris packed between outside of primary filter and the canister Avoid using high pressure air which could force dirt through the filter into the intake area This clean...

Page 42: ...m the cover clean the cavity and replace the outlet valve 7 Install the cover orienting the rubber outlet valve Figure 47 in a downward position between approximately 5 00 to 7 00 when viewed from the end Secure the latch 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 50 and let the oil flow into a drain...

Page 43: ...n the tank if fuel system becomes contaminated or if the machine will be stored for an extended period of time Use clean fuel to flush out the tank Fuel Lines and Connections Service Interval Every 400 hours Check the fuel lines and connections every 400 hours or yearly whichever comes first Inspect them for deterioration damage or loose connections Servicing the Water Separator Service Interval E...

Page 44: ...oot from the positive terminal and inspect the battery WARNING 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 termina...

Page 45: ...ower center cover 2 Allen head screws 2 Figure 56 1 Fuses Figure 57 The cab fuses Figure 58 and Figure 59 are located in the fuse box in the cab headliner Cab model only Figure 58 1 Cab fuse box 2 Fuses Figure 59 45 ...

Page 46: ...he check plugs is at the lowest 6 o clock position Figure 61 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 62 g020680 Figure 62 1 Drain plug 2 Brake housing 4 When all of the oil has drained from both locations re install the plug in the ...

Page 47: ...g 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 Drain plug 7 Add enough oil to bring the level up to the bottom of the check plug holes refer to Changing the Rear Axle Lubricant page 47 8 Install the plugs Checking the Rear Wheel Toe In Service Interval Every 800 hours After every 800 operating hours or annually check the re...

Page 48: ... debris out towards the back Then clean from the back side and blow towards the front Repeat procedure several times until all chaff and debris is removed Important Cleaning the radiator oil cooler with water can promote premature corrosion and damage to components Figure 65 1 Radiator oil cooler 3 Close the hood Brake Maintenance Adjusting the Service Brakes Adjust the service brakes when there i...

Page 49: ...ch loosen the alternator mounting bolts Figure 68 Increase or decrease the alternator belt tension and tighten the bolts Check the deflection of the belt again to ensure that the tension is correct Figure 68 1 Alternator 3 Compressor 2 Mounting bolt 4 Idler pulley Servicing the Compressor Belt Service Interval After the first 10 hours Every 100 hours Cab model only Check the condition and tension ...

Page 50: ... 2 Loosen the eye bolt allowing the removal of the extension spring Figure 69 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 69 Move the idler pulley away from the belt to release belt tension Note If the stop bolt is ever removed from the mounting tab make sure it is reinstalled in the hole that ali...

Page 51: ...uid throughout the system Also check for leaks then stop the engine 5 Check the fluid level and add enough to raise level the level to the Full mark on the dipstick Do not overfill Replacing the Hydraulic Filters Service Interval Every 800 hours 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 ...

Page 52: ...p your body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Safely relieve all pressure in the hydraulic system before performing any work on the hydraulic system Seek immediate medical attention if fluid is injected into skin Adjusting the Counterbalance Pressure The counterbalance test port Figure 74 is used to...

Page 53: ...rt 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 Adjusting the Cutting Unit Pitch Measuring the Cutting Unit Pitch Cutting unit pitch is the difference in height of cut from the front of the blade plane to the back of...

Page 54: ...sher and spacer s to remain on the bottom of the spindle 4 Insert a pin punch into the top or bottom of the mounting tube and drive the bushing out of the tube Figure 78 Also drive the other bushing out of the tube Clean the inside of the tubes to remove dirt Figure 78 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 ...

Page 55: ...d Figure 81 Measure from the inside of the cutting unit to the cutting edge at the front of the blade Remember this dimension Figure 81 3 Rotate the opposite end of the blade forward Measure between the cutting unit and cutting edge of the blade at the same position as in step 2 The difference between the dimensions obtained in steps 2 and 3 must not exceed 3 mm 1 8 inch If the dimension exceeds 3...

Page 56: ... somewhat although the cutting edges are sharp The cutting edge of the blade must be sharp so that the grass is cut rather than torn A dull cutting edge is evident when the tips of the grass appear brown and shredded Sharpen the cutting edges to correct this condition 1 Position the machine on a level surface Raise the cutting unit engage the parking brake put the traction pedal in neutral put the...

Page 57: ... 4 Loosen the flange nut securing the idler pulley to release the belt tension 5 Rotate the blades until the ends face forward and backward Measure from the floor to the front tip of the cutting edge Remember this dimension Then rotate the same blade so that the opposite end is forward and measure again The difference between the dimensions must not exceed 3 mm 1 8 inch If the dimension exceeds 3 ...

Page 58: ...n oil free compressed air through them Important If either filter has a hole tear or other damage replace it 3 Install the filters and grate securing them with the thumb screws Cleaning the Air Conditioning Coil Service Interval Every 250 hours Clean more frequently in extremely dusty or dirty conditions 1 Stop the engine and remove the key 2 Remove the 6 nuts and washers from the bottom of the re...

Page 59: ...y posts B Clean the battery terminals and posts with a wire brush and baking soda solution C Coat the cable terminals and battery posts with Grafo 112X skin over grease Toro Part No 505 47 or petroleum jelly to prevent corrosion D Slowly recharge the battery every 60 days for 24 hours to prevent lead sulfation of the battery Engine 1 Drain the engine oil from the oil pan and install the drain plug...

Page 60: ...not limited to damage to seats due to wear or abrasion worn painted surfaces scratched decals or windows etc Parts Parts scheduled for replacement as required maintenance are warranted for the period of time up to the scheduled replacement time for that part Parts replaced under this warranty are covered for the duration of the original product warranty and become the property of Toro Toro will ma...

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