Toro Groundsmaster 4000-D Operator'S Manual Download

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Form No. 3376-251 Rev B

Groundsmaster

4010-D and

4000-D Rotary Mower

Model No. 30607—Serial No. 313000001 and Up

Model No. 30609—Serial No. 313000001 and Up

*3376-251* B

Summary of Contents for Groundsmaster 4000-D

Page 1: ...No 3376 251 Rev B Groundsmaster 4010 D and 4000 D Rotary Mower Model No 30607 Serial No 313000001 and Up Model No 30609 Serial No 313000001 and Up Register at www Toro com Original Instructions EN 3376 251 B ...

Page 2: ...ufacturer Introduction This machine is a ride on rotary blade lawnmower intended to be used by professional hired operators in commercial applications It is primarily designed for cutting grass on well maintained lawns in parks sports fields and on commercial grounds It is not designed for cutting brush mowing grass and other growth alongside highways or for agricultural uses Read this information...

Page 3: ...Maintenance 42 Servicing the Fuel System 42 Servicing the Water Separator 42 Servicing the Engine Fuel Filter 43 Electrical System Maintenance 44 Battery Care 44 Fuses 45 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 C...

Page 4: ...s 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 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...

Page 5: ...e 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 do not store near flame To reduce the fire hazard keep the engine silencer muffler battery compartment cutting units drives and fuel storage area free of grass leaves or excessiv...

Page 6: ...at 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 moving vehicle If you must cross or travel on a public road you should be aware of and comply with local regulations such as required li...

Page 7: ...el Model 30607 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 836 Whole Body Measured vibration level 0 26 m s2 Uncertainty Value K 0 13 m s2 Measured values were determined according to the procedures outlined in EN 836 Vibration Lev...

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: ...ariable 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 117 2718 10 ...

Page 11: ... fuse 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 E...

Page 12: ...lowly when turning 121 1592 1 Cruise control not set 4 Raise the left deck 2 Cruise control switch 5 Raise the middle deck 3 Cruise control set 6 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 br...

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: ...121 1677 Groundsmaster 4000 1 Read the Operator s Manual for maintenance information 120 0250 Cab models 1 Slow moving vehicle 93 7275 1 Read the Operator s Manual 2 Do not use starting aids 14 ...

Page 15: ...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 in Lubrication Failure to properly grease the machine will r...

Page 16: ...Press the lever Figure 3 down to 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 p...

Page 17: ...ll not raise or lower if the operator is out of the seat when the engine is running Also the decks will lower with the key in the On position and the operator in the seat Cruise Control Switch The cruise control switch Figure 4 locks in the pedal position to maintain the desired ground speed Pressing the rear of the switch turns off the cruise control the middle position of the switch enables the ...

Page 18: ...tioning Figure 7 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 7 Temperature Control Rotate the temperature control knob to regulate the air temperature in the cab Figure 7 Figure 7 1 Wind shield wiper switch 3 Fan control 2 Air conditioning switch 4 Temperature control Wind Shield Latch Lift up on latches to ope...

Page 19: ... this button to open a menu where a right arrow indicates additional content Beeper activated when lowering the decks or for advisories and faults Note The purpose of each button may change depending on what is required at 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 En...

Page 20: ... 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 contains a list of the recent machine faults Refer to the Service Manual or your Authorized Toro Distributor ...

Page 21: ...tem 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 InfoCenter Revision Lists the software revision of the InfoCenter CAN Bus Lists the machine communication bus status Protected Menus There are 4 operating configuration settings that are adjustable within the Settings...

Page 22: ... Regeneration icon appears on the InfoCenter refer to the Service Manual or contact your Toro Distributor for the maintenance procedure 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 side cutting unit 246 cm 97 inches Overall width cutting ...

Page 23: ...king If the oil level is at or below 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 Th...

Page 24: ...s can cause serious injury and illness Avoid prolonged breathing of vapors Keep face away from nozzle and fuel 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 B7 7 biodiesel 93 petrodiesel The petrodiesel portion must be ultra low sulfur Observe the following precautions The biodiesel portion of the fuel must...

Page 25: ...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 Alternate fluids If the Toro fluid is not available other fluids may be u...

Page 26: ...f 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 2 Remove a check plug from o...

Page 27: ... 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 foll...

Page 28: ...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 29: ... 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 30: ...eck and 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 6 Cut grass in a test area to determine if all cutting units are cutting at the same height 7 If cutting unit adju...

Page 31: ... 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 32: ... 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 leaving the work area entering the shop or storage area Auto Idle The machine is equipped with auto idle wh...

Page 33: ...switches perform the following procedure 1 Drive the machine slowly to a large relatively open area Lower the cutting unit stop the engine and apply the parking brake 2 Sit on the seat and depress the traction pedal Try to start the engine The engine should not crank If the engine cranks there is a malfunction in the interlock system that should be corrected before beginning operation 3 Sit on the...

Page 34: ... damaging the transmission 3 Close the bypass valves before starting the engine Torque to 70 N m 52 ft lb to close the valve Figure 33 1 Bypass valve 2 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 Hydrau...

Page 35: ...s Remove approximately 25 mm 1 inch or no more than 1 3 of the grass blade when cutting In exceptionally lush and dense grass you may have to raise the height of cut to the next setting Mow at Proper Intervals Under most normal conditions you will need to mow approximately every 4 5 days But remember grass grows at different rates at different times This means that in order to maintain the same he...

Page 36: ...ions 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 frequently in extremely dusty or dirty conditions Every ...

Page 37: ...Flush the cooling system and replace fluid Replace moving hoses 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 Service Interval Chart Figure 35 37 ...

Page 38: ...tions and quantities are Traction Unit Service Interval Every 50 hours Brake pedal pivot shaft bearings 2 Figure 36 Front and rear axle pivot bushings 2 Figure 37 Steering cylinder ball joints 2 Figure 38 Tie rod ball joints 2 Figure 38 King pin bushings 2 Figure 38 The top fitting on the king pin should only be lubricated annually 2 pumps Figure 36 Figure 37 Figure 38 Front Cutting Unit Castor fo...

Page 39: ...its Castor fork shaft bushing 1 Figure 43 Spindle shaft bearings 2 each located under the pulley Idler arm pivot bushings 1 located on the idler arm Figure 43 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 Figure 44 Figure 45 39 ...

Page 40: ...l the latch outward and rotate the air cleaner cover counterclockwise Figure 48 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 41: ... from the cover clean the cavity and replace the outlet valve 7 Install the cover orienting the rubber outlet valve Figure 48 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 51 and let the oil flow into a d...

Page 42: ...ttom of the filler neck This empty space in the tank allows the fuel to expand Never smoke when handling fuel and stay away from an open flame or where fuel fumes may be ignited by a spark Store fuel in a clean safety approved container and keep the cap in place Fuel Tank Service Interval Every 800 hours Drain and clean the fuel tank every 800 hours Also drain and clean the tank if fuel system bec...

Page 43: ...cing the Engine Fuel Filter Service Interval Every 400 hours The engine fuel filter should be replaced after every 400 hours of operation 1 Clean the area around the fuel filter head Figure 54 Figure 54 1 Fuel Filter head 2 Fuel Filter 2 Remove the filter and clean the filter head mounting surface Figure 54 3 Lubricate the filter gasket with clean lubricating engine oil Refer to the Engine Operato...

Page 44: ...ttery cover to ease cover removal Figure 55 2 g020758 Figure 55 1 Battery cover 2 Press down here Figure 56 1 Battery WARNING Charging the battery produces gasses that can explode Never smoke near the battery and keep sparks and flames away from battery 2 Remove the rubber boot from the positive terminal and inspect the battery WARNING Battery terminals or metal tools could short against metal com...

Page 45: ...are located under the power center cover Remove the two Allen head screws securing the power center cover to the frame and remove the cover Figure 57 Figure 57 1 Power center cover 2 Allen head screws 2 Figure 58 1 Fuses Figure 59 The cab fuses Figure 60 Figure 61 are located in the fuse box in the cab headliner Cab model only Figure 60 1 Cab fuse box 2 Fuses Figure 61 45 ...

Page 46: ...lugs is at the lowest 6 o clock position Figure 63 Figure 63 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 64 g020680 Figure 64 1 Drain plug 2 Brake housing 4 When all of the oil has drained from both locations re install the plug in the brake hous...

Page 47: ... and allow the oil to drain into a pan Remove the fill plug to ease in draining of the oil Figure 66 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 8 Install the plugs Checking the Rear Wheel Toe In Service Interval Every 800 hours After every 800 operating hours or an...

Page 48: ...e fan side and blow the 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 67 1 Radiator oil cooler 3 Close the hood Brake Maintenance Adjusting the Service Brakes Adjust the serv...

Page 49: ...ch loosen the alternator mounting bolts Figure 70 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 70 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: ...de 2 Loosen the eye bolt allowing the removal of the extension spring Figure 71 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 71 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 a...

Page 51: ...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 mach...

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 76 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 80 Also drive the other bushing out of the tube Clean the inside of the tubes to remove dirt Figure 80 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: ...ckward Figure 83 Measure from the inside of the cutting unit to the cutting edge at the front of the blade Remember this dimension Figure 83 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 exce...

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: ...he 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 mm 1 8 inch...

Page 58: ...usty or dirty conditions 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 88 3 Carefully lift the fan out of the condenser cover Figure 88 1 Cabin roof 5 Fan 2 Condenser cover 6 Screw 3 Washer 7 Air conditioning condenser 4 Nut 4 Remove the two nuts and washers securing the front of the condenser cover to the cab roof Figur...

Page 59: ...sted Repair any dents in the metal body 6 Service the battery and cables as follows A Remove the battery terminals from the battery 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 da...

Page 60: ...Schematics Hydraulic Schematic Rev B 60 ...

Page 61: ...Notes 61 ...

Page 62: ...Notes 62 ...

Page 63: ...Notes 63 ...

Page 64: ...ted 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 make the f...

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