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Toro 30412 Groundsmaster 4000-D Operator's Manual
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Toro 30412 Groundsmaster 4000-D Operator's Manual

Toro 30412 Groundsmaster 4000-D Operator's Manual

Traction unit
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Form No. 3360-344 Rev B
Groundsmaster
®
4000-D Traction
Unit
Model No. 30412—Serial No. 2900000001 and Up
Register at www.Toro.com.
Original Instructions (EN)

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Summary of Contents for Toro 30412 Groundsmaster 4000-D

  • Page 1 Form No. 3360-344 Rev B Groundsmaster ® 4000-D Traction Unit Model No. 30412—Serial No. 2900000001 and Up Register at www.Toro.com. Original Instructions (EN)

  • Page 2: Introduction

    Genuine Toro spark arresters are approved by the USDA Forestry Service. Important: This engine is equipped with a spark arrester muffler.

  • Page 3: Table Of Contents

    Safety ................4 Controls System Maintenance......... 47 Safe Operating Practices ........4 Adjusting the Throttle Cable....... 47 Toro Mower Safety ..........6 Adjusting the Traction Pedal Linkage ....47 Sound Pressure Level ........... 7 Hydraulic System Maintenance ....... 48 Sound Power Level..........7 Changing the Hydraulic Fluid ......

  • Page 4: Safety

    Preparation Safety • While mowing, always wear substantial footwear, This machine meets or exceeds CEN standard long trousers, hard hat, safety glasses, and hearing protection. Long hair, loose clothing or jewelry may EN 836:1997, ISO standard 5395:1990, and ANSI get tangled in moving parts. Do not operate the B71.4-2004 specifications in effect at the time of production.

  • Page 5: Maintenance And Storage

    – Do not stop or start suddenly when going up or • Stop the engine and disengage drive to attachment: downhill. – before refuelling; – The machine speed should be kept low on slopes – before making height adjustment unless and during tight turns.

  • Page 6: Toro Mower Safety

    The following list contains safety information specific cutting units on a slope. to Toro products or other safety information that you must know that is not included in the CEN, ISO, or • Avoid turning on slopes. If you must turn, turn ANSI standards.

  • Page 7: Sound Pressure Level

    • To make sure of optimum performance and or if an edge caves in. continued safety certification of the machine, use only genuine Toro replacement parts and accessories. • Do not mow on wet grass. Reduced traction could Replacement parts and accessories made by other cause sliding.
  • Page 8 93-7275 100-5624 1. Read the Operator’s Manual. 1. Height of cut adjustment 2. Do not use starting aids. 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 110 100-5693 ft-lb).
  • Page 9 104-2277 104-2277 1. To lock the parking brake, 4. Read the Operator’s 104-3599 latch the pedals together, Manual. apply the brake pedals, 1. Do not step here. and pull up on the knob. 2. Traction pedal 2. To unlock the parking 5.
  • Page 10 98-4387 104-8325 1. Warning—wear hearing protection. 1. Lock/unlock the cutting unit service lock. 114-5604 (Affix over part no. 114–5605 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.
  • Page 11 115-8474 106-6755 1. Power outlet 5. Starter solenoid 1. Engine coolant under 3. Warning—do not touch 2. Seat switch 6. Light Kit pressure. the hot surface. 3. Ignition switch 7. Fan 2. Explosion hazard—read 4. Warning—read the 4. Power Take Off (PTO) 8.
  • Page 12 114-5605 1. Warning—read the Operator’s Manual. 2. Warning—do not operate this machine unless you are trained. 3. Thrown object hazard—keep bystanders a safe distance from the machine. 4. Warning—wear the seat belt when seated in the operator’s position. 5. Cutting hazard of hand or foot—stay away from moving parts; keep all guards in place. 6.
  • Page 13 115-8456 1. Read the Operator’s Manual.

  • Page 14: Setup

    Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Qty. – No parts required Grease the machine. Used only on machines requiring Warning Decal European CE compliance. Operator’s Manual Engine Operator’s Manual Read the manuals and view the Parts Catalog training materials before operating the...

  • Page 15: Product Overview

    Brake Pedals Product Overview Two foot pedals (Figure 2) operate individual wheel brakes for turning assistance, parking, and to aid in obtaining better side hill traction. A latch connects the pedals for parking brake operation and transport. Pedal Locking Latch The pedal locking latch (Figure 2) connects the pedals together to engage the parking brake.

  • Page 16: Speed Limiter

    Speed Limiter pull the switch backward to the Off position to stop implement operation. If desired, the screw can be adjusted (Figure 3) to limit the amount the traction pedal can be depressed in the Hi-Lo Speed Control forward direction to limit the mowing speed. The control (Figure 4) allows the speed range to increase Important: The traction pedal must contact the for transport of the machine.

  • Page 17: Specifications

    Contact your Authorized Service Dealer or Distributor or go to Power Point www.Toro.com for a list of all approved attachments and accessories. The power point (Figure 4) is used to power optional electrical accessories.

  • Page 18: Operation

    • Alternate oil: SAE 10W-30 or 5W-30 (all 1. Oil fill cap temperatures) Toro Premium Engine Oil is available from your 5. Install the oil fill cap and dipstick. distributor in either 15W-40 or 10W-30 viscosity. See the parts catalog for part numbers.

  • Page 19: Adding Fuel

    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.
  • Page 20 Toro distributor for part numbers.) carpets or plastic truck bed liners may Alternate fluids: If the Toro fluid is not available, other insulate the container and slow the loss of fluids may be used provided they meet all the following any static charge.
  • Page 21 One bottle is sufficient for 4-6 gallons (15-22 1) of hydraulic oil. Order part no. 44-2500 from your authorized Toro distributor. 1. Position the machine on a level surface, lower the cutting units, stop the engine, and remove the key.

  • Page 22: Checking The Tire Pressure

    3. Add gear oil to the hole in the planetary, if necessary, to bring the oil up to the proper level. Install the plug. 4. Repeat steps 1-3 on the opposite gear assembly. Checking the Rear Axle Lubricant Service Interval: Every 400 hours The rear axle is filled with SAE 85W-140 gear lube.
  • Page 23 castor forks, add or remove an equal number of spacers below) onto the spindle shaft to get the desired from the castor forks, and secure the rear chain to the height-of-cut; then slide the washer onto the shaft. desired hole. Refer to the following chart to determine the combinations of spacers for the setting: 1.
  • Page 24 Note: When using 1 inch (25 mm), 1-1/2 inch (38 Refer to the following chart to determine the mm), or occasionally 2 inch (51 mm) height-of-cut, combinations of spacers for the setting. move the skids and gage wheels to the highest position.
  • Page 25 Figure 23 Figure 21 Adjusting the Skids 8. Remove the hairpin cotters and clevis pins securing the damper links to the cutting unit brackets The skids should be mounted in the lower position (Figure 22). Align the damper link holes with the when operating in height of cuts greater than 2-1/2 selected height-of-cut bracket holes in the cutting inches (64 mm) and in the higher position when...
  • Page 26 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. Adjust 1/8 inch shims on front castor fork(s) to match height of cut to decal (Figure 26);...

  • Page 27: Starting And Stopping The Engine

    edge of side cutting unit to outside edge of front cutting unit. 4. If inside edge is still too high, remove an additional 1/8 inch shim from bottom of front inside castor arm of the side cutting unit and one 1/8 inch shim from the front outside castor arm of the side cutting unit.

  • Page 28: Engine Cooling Fan Operation

    Checking the Interlock start after 15 seconds, turn the key to the Off position, recheck the controls and procedures, Switches wait 15 additional seconds, and repeat the starting procedure. When the temperature is less than 20°F (-75C), preheat glow plugs twice prior to initial cranking If safety interlock switches are disconnected attempt.

  • Page 29: Jacking Points

    Do not push or tow the machine for more than 1/4 mile (0.4 km). Important: Do not push or tow the machine faster than 2-3 MPH (3-4.8 km/h) because internal transmission damage may occur. The bypass valve must be open whenever the machine is pushed or towed.

  • Page 30: Operating Tips

    speed, load on the cutting blades or other implement components, and the importance of the brakes. This cutting units are designed to drive objects To maintain enough power for the traction unit and into the ground where they lose energy quickly implement while operating, regulate the traction pedal in grass areas.
  • Page 31 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 height-of-cut, which is a good practice, you will need to cut more frequently in early spring;...

  • Page 32: Maintenance

    Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Maintenance Procedure Interval • Torque the wheel lug nuts. • Check the alternator belt tension. After the first 10 hours •...

  • Page 33: Service Interval Chart

    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 32 Lubrication Traction Unit Service Interval: Every 50 hours Greasing the Bearings and •...
  • Page 34 Figure 33 Figure 36 Front Cutting Unit Figure 34 • Castor fork shaft bushings (2) (Figure 37) • Spindle shaft bearings (3) (located under the pulley) (Figure 38) • Idler arm pivot bushings (2) (Figure 38) Figure 35 Figure 37...
  • Page 35 Figure 38 Front Lift Assemblies • Lift arm bushings (2) (Figure 39) • Lift cylinder bushings (4) (Figure 39) Figure 40 • Lift arm ball joints (2) (Figure 40) Side Cutting Units • Castor fork shaft bushing (1) (Figure 41) •...
  • Page 36 • Bell crank pivot bushings (2) (Figure 44) • Rear arm bushings (4) (Figure 44) • Lift cylinder bushings (4) (Figure 45) Figure 44 Figure 42 Figure 45 Figure 43...

  • Page 37: Engine Maintenance

    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).

  • Page 38: Servicing The Engine Oil And Filter

    Figure 49 1. Engine oil drain plug 2. Remove the oil filter (Figure 50). Apply a light coat of clean oil to the new filter seal before screwing it on. Do not overtighten. Figure 48 1. Air cleaner safety filter Important: Never attempt to clean the safety filter (Figure 48).

  • Page 39: Fuel System Maintenance

    Fuel System 2. Loosen the drain plug on the bottom of the filter canister. Maintenance Servicing the Fuel System 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.

  • Page 40: Electrical System Maintenance

    To clean the battery, wash the entire case with a solution of baking soda and water. Rinse with clear water. Coat the battery posts and cable connectors with Grafo 112X (skin-over) grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion. Warning...

  • Page 41: Fuses

    (black) cable. 4. Coat both battery connections with Grafo 112X (skin-over) grease, Toro Part No. 505-47, petroleum jelly, or light grease to prevent corrosion. Slide the rubber boot over the positive terminal. 5. Install the battery cover.

  • Page 42: Drive System Maintenance

    Drive System Maintenance 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.

  • Page 43: Changing The Rear Axle Lubricant

    the bottom of the brake housing check hole. Install the plug. 8. Repeat the procedure on the opposite gear assembly. Figure 59 1. Drain plug location 5. Clean the area around the drain plug on the bottom of the gear box (Figure 60). Figure 58 6.

  • Page 44: Checking The Rear Wheel Toe-In

    Checking the Rear Wheel Cooling System Toe-In Maintenance Service Interval: Every 800 hours Servicing the Engine Cooling After every 800 operating hours or annually, check the rear wheel toe-in. System 1. Measure the center-to-center distance (at axle height) Service Interval: Every 100 hours at the front and rear of the steering tires.

  • Page 45: Brake Maintenance

    Brake Maintenance Adjusting the Service Brakes 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. 1.

  • Page 46: Belt Maintenance

    Belt Maintenance Servicing the Alternator Belt Service Interval: After the first 10 hours Every 100 hours Check the condition and tension of the belts (Figure 63) after every 100 operating hours. 1. Proper tension will allow 3/8 inch (10 mm) deflection when a force of 10 lb is applied on the belt midway between the pulleys.

  • Page 47: Controls System Maintenance

    Controls System Maintenance Adjusting the Throttle Cable Service Interval: After the first 50 hours—Check the engine speed (at idle and full throttle). Every 400 hours—Check the engine speed (at idle and full throttle). Adjust the throttle cable (Figure 66) 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.

  • Page 48: Hydraulic System Maintenance

    Every 800 hours Change the hydraulic fluid after every 800 operating hours, in normal conditions. If the fluid becomes Figure 67 contaminated, contact your local Toro distributor 1. Traction pedal stop 2. Stand because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil.

  • Page 49: Replacing The Hydraulic Filters

    800 operating hours, in normal conditions. penetrate skin and cause injury. Use Toro replacement filters (Part No. 94-2621 for the • Make sure all hydraulic fluid hoses and left side of the machine and 75-1310 for the right side lines are in good condition and all hydraulic of the machine).

  • Page 50: Adjusting The Cutting Unit Flow Control

    Adjusting the Cutting Unit Mower Maintenance Flow Control Adjusting the Transport Latch The flow control valve (Figure 72) is used to adjust the rate at which the front cutting unit lowers. If the transport latch (Figure 73) has to be adjusted, adjust as follows: 1.

  • Page 51: Pivoting (Tilting) The Front Cutting Unit Upright

    Figure 74 1. Adjustment screw 2. Deck latch Figure 76 Pivoting (Tilting) the Front 1. Transport latch 2. Latch plate Cutting Unit Upright 3. Remove the hairpin cotter and clevis pin securing the Note: Although not needed for normal maintenance height-of-cut chains to the rear of the cutting unit.

  • Page 52: Adjusting 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 the blade plane. Toro recommends a blade pitch of 1/4 inch (6 mm). That is the back of the blade plane is 1/4 inch (6 mm) higher than the front.

  • Page 53: Servicing The Castor Wheels And Bearings

    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 82 Figure 80 1.

  • Page 54: Blade Maintenance

    The blade must be replaced if a solid object is hit, the blade is out of balance, or if the blade is bent. Always use genuine Toro replacement blades to be sure of safety Two areas must be considered when checking and and optimum performance.

  • Page 55: Correcting Cutting Unit Mismatch

    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 If the blade is allowed to wear, a slot will form the Off position, stop the engine, and remove the between the sail and flat part of the blade ignition key.

  • Page 56: Spark Arrestor Maintenance

    Spark Arrestor forward, and measure again. The difference between the dimensions must not exceed 1/8 inch (3 mm). Maintenance If the dimension exceeds 1/8 inch (3 mm), replace the blade because it is bent. Make sure to measure all of the blades. Servicing the Spark Arrestor 6.

  • Page 57: Storage

    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.

  • Page 58: Schematics

    Schematics Electrical Schematic, sheet 1 (Rev. B)
  • Page 59 Electrical Schematic, sheet 2 (Rev. A)
  • Page 60 Hydraulic Schematic (Rev. A)
  • Page 61 Notes:...
  • Page 62 Notes:...
  • Page 63 Notes:...
  • Page 64 Countries Other than the United States or Canada Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfi ed with your Distributor’s service or have diffi...

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