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  9. Toro Groundsmaster 4000-D User manual

Toro Groundsmaster 4000-D User manual

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(8
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 
!
 
     6+47
  ! 9'
     6+47
  ! 9'
  !

2 71'(456$1' 6+,5 342'7&6 $1' )24 5$)(6: $1'
236,070 3(4)240$1&( 4($' 6+,5 0$17$/ %()24(
56$46,1* 6+( (1*,1( $: 53(&,$/ $66(16,21 62  #
 !  +,*+/,*+6(' %: 6+,5 5:0%2/
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6 0($15 !  " 24  
3(4521$/ 5$)(6: ,15647&6,21  $,/74( 62 &203/: 9,6+
6+( ,15647&6,21 0$: 4(57/6 ,1 3(4521$/ ,1-74:
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56$1'$4'5 )24 4,',1* 029(45 9+(1 4($4 6,4(5 $4(
),//(' 9,6+ &$/&,70 &+/24,'( $1' 692 4($4 9+((/
9(,*+6 .,65 $46 2  $4( ,156$//('


his operator's manual has instructions on safety, proper set-up and operation, adjustments and maintenance.
herefore, anyone involved with the product, including the operator, should read and understand this manual.
Major sections are:
- Safety Instructions
- Specifications
- Before Operating
- Know Your Controls
- Operating Instructions
- Maintenance
- Schematics
his manual emphasizes safety, mechanical and general product information. DANGER, WARNING and CAU ION
identify safety messages.  Whenever the triangular safety alert symbol appears, understand the safety message
that follows. For complete safety instructions, read pages 4 - 5. IMPOR AN  highlights special mechanical
information and NO E emphasizes general product information worthy of special attention.
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
or other reproductive harm.
 
Because in some areas there are local, state or federal regulations requiring that a spark arrestor muffler be used on
the engine of this mower, a spark arrestor muffler is available as an option. If a spark arrestor muffler is required,
order one of the following parts from your local Authorized oro Distributor.
(1)   74-2900   Spark Arrestor Muffler  ( wo wheel drive model only)
(1)   92-6074   Spark Arrestor Muffler  (Four wheel drive model only)
When the mower is used or operated on any California forest, brush or grass covered land, a properly operating
spark arrester must be attached to the muffler. he operator is violating state law, Section 442 Public Resources
Code if a spark arrester is not used.
Whenever you have questions or need service, contact your local authorized oro Distributor. In addition to having a
complete line of accessories and professional turf care service technicians, the distributor has a complete line of
genuine ORO replacement parts to keep your machine operating properly. Keep your ORO all ORO. Buy
genuine ORO parts and accessories.

  
#                      
#           
                        
                    
Check Engine Oil 11. . . . . . . . . . . . . . . . . . . . . . . . .
Check Cooling System 11. . . . . . . . . . . . . . . . . . . .
Fill Fuel Tank 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Hydraulic System 12. . . . . . . . . . . . . . . . . .
Check Reel to Bedknife Contact 12. . . . . . . . . . .
Check Tire Pressure 12. . . . . . . . . . . . . . . . . . . . . .
Rear Ballast 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
" #                  
              
Starting and Stopping 16. . . . . . . . . . . . . . . . . . . .
Priming Fuel System 16. . . . . . . . . . . . . . . . . . . . .
Checking Warning Indicator Lights 17. . . . . . . . .
Checking Interlock System 17. . . . . . . . . . . . . . . .
Pushing or Towing Traction Unit 17. . . . . . . . . . . .
Operating Characteristics 18. . . . . . . . . . . . . . . . .
Cutting Charts 20. . . . . . . . . . . . . . . . . . . . . . . . . . .
                               
          
                         
General Air Cleaner Maintenance 23. . . . . . . . . . .
Servicing Air Cleaner 23. . . . . . . . . . . . . . . . . . . . .
Engine Oil and Filter  24. . . . . . . . . . . . . . . . . . . . . .
Fuel System 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling System 25. . . . . . . . . . . . . . . . . . .
Alternator Belt  25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Care  26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Hand Brake & Traction Switches 26. .
Adding Hydraulic Oil 26. . . . . . . . . . . . . . . . . . . . .
Draining Water From Hydraulic Reservoir 26. . .
Changing Hydraulic Oil 27. . . . . . . . . . . . . . . . . . .
Replacing Hydraulic Filter 27. . . . . . . . . . . . . . . . .
Replacing Hydraulic System Breather 28. . . . . .
Checking Hydraulic Lines and Hoses  28. . . . . . .
Hydraulic System Test Ports  28. . . . . . . . . . . . . .
Rear Wheel Toe-In 29. . . . . . . . . . . . . . . . . . . . . . .
Checking Planetary Gear Drive 29. . . . . . . . . . . .
Engine alve Clearance 29. . . . . . . . . . . . . . . . . . .
                     
#                       
                   
                   
"#  !                     

 
Improper use or maintenance by the operator or owner
of the machine can result in injury. Reduce the potential
for any injury by complying with the following safety
instructions.
 
 Read and understand the contents of the traction
unit and cutting unit operator's manuals before
operating the machine. To get replacement manuals,
send complete model and serial number to:
The Toro Company
8111 Lyndale Avenue outh
Minneapolis, MN 55420-1196
 Never allow children to operate the machine or
adults to operate it without proper instruction.
 Become familiar with the controls and know how to
stop the machine and engine quickly.
 Keep all shields, safety devices and decals in
place.  If a shield, safety device or decal is damaged,
repair or replace it before operating the machine.
 Always wear substantial shoes.  Do not operate
machine while wearing sandals, tennis shoes,
sneakers or when barefoot. Do not wear loose fitting
clothing that could get caught in moving parts and
possibly cause personal injury.
 Wearing safety glasses, safety shoes, long pants
and a helmet is advisable and required by some local
ordinances and insurance regulations.
 Make sure the work area is clear of objects which
might be picked up and thrown by the reels.
 Do not carry passengers on the machine. Keep
everyone, especially children and pets, away from the
areas of operation.
 ince diesel fuel is highly flammable, handle it
carefully:
A.  Use an approved fuel container.
B.  Do not remove fuel tank cap while engine is hot
or running.
C.  Do not smoke while handling fuel.
D.  Fill fuel tank outdoors and only to within an inch
(25 mm) from the top of the tank, not the filler neck.
Do not overfill.
E.  Wipe up any spilled fuel.
 
 Do not run engine in a confined area without
adequate ventilation. Exhaust is hazardous and could
be deadly.
 it on the seat when starting and operating the
machine.
 Check interlock switches daily for proper
operation. If a switch fails, replace it before operating
the machine. The interlock system is for your
protection, so do not bypass it. Replace all interlock
switches every two years.
 This product may exceed noise levels of 85 dB(A)
at the operator position. Ear protectors are
recommended for prolonged exposure to reduce the
potential of permanent hearing damage.
 Before starting the engine each day, check
indicator lights, warning buzzer and signal lights to
assure proper operation.
 Pay attention when using the machine.  To prevent
loss of control:
A.  Mow only in daylight or when there is good
artificial light.
B.  Watch for holes or other hidden hazards.
C.  Be extremely careful when operating close to
sand traps, ditches, creeks, steep hillsides or other
hazards.
D.  Reduce speed when making sharp turns. Avoid
sudden stops and starts. Use ground speed limiter
lever to set pedal travel so excessive ground speed
will be avoided during mowing and transport.
E.  Look to the rear to assure no one is behind the
machine before backing up.
F.  Watch for traffic when near or crossing roads.
Always yield the right-of-way.
G.  Reduce speed when driving downhill.
 Keep hands, feet and clothing away from moving
parts and the reel.
 Traverse slopes carefully. Do not start or stop
suddenly when traveling uphill or downhill.
 Operator must be skilled and trained in how to
drive on hillsides. Failure to use caution on slopes or
hills may cause loss of control and vehicle to tip or roll
possibly resulting in personal injury or death.
 When operating 4 wheel drive machine, always
use the seat belt and ROP  together and have seat
pivot retaining pin installed.
 If engine stalls or loses traction and cannot make it
to the top of a slope, do not turn machine around.
Always back slowly straight down the slope.
 Raise cutting units and latch them securely in
transport position before driving from one work area to
another.
 Do not touch engine, muffler or exhaust pipe while
engine is running or soon after it is stopped.  These
areas could be hot enough to cause burns.

   
 If cutting unit strikes a solid object or vibrates
abnormally, stop immediately, turn engine off, set
parking brake and wait for all motion to stop. Inspect
for damage. If reel or bedknife is damaged, repair or
replace it before operating. Do not attempt to free
blocked cutting unit by moving Mow/Backlap lever
rapidly between F RWARD and BACKLAP. Damage to
hydraulic system may result. Lever should easily return
and hold in the ST P position.
 Before getting off the seat:
A. Disengage cutting units and wait for reels to
stop.
B.  Move traction pedal to neutral.
C.  Set parking brake.
D.  Stop engine and remove key from switch.
E. Do not park on slopes unless wheels are
chocked or blocked.
 The optional T R  tow bar (Part No. 58-7020) is
for emergency towing only. Use only the special tow
bar if it becomes necessary to tow machine. Use trailer
for normal transport. Refer to page 18 for towing
procedure.

 Before servicing or making adjustments, stop
engine and remove key from the switch.
  Assure entire machine is properly maintained and
in good operating condition. Make sure all nuts, bolts
and screws are tight.
 Frequently check all hydraulic line connectors and
fittings. Assure all hydraulic hoses and lines are in
good condition before applying pressure to the
system.
  Keep body and hands away from pin hole leaks or
nozzles that eject high pressure hydraulic fluid.  Use
cardboard or paper to find hydraulic leaks. Hydraulic
fluid escaping under pressure can penetrate skin and
cause injury. Fluid accidentally injected into the skin
must be surgically removed within a few hours by a
doctor or gangrene may occur.
 Before any hydraulic system maintenance, stop
engine and lower cutting units to the ground so all
pressure is relieved.
 For major repairs or other assistance, contact your
local Toro Distributor.
 To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt.  Clean
protective screen on back of engine frequently.
 If engine must be running to perform maintenance
or an adjustment, keep hands, feet, clothing and other
parts of the body away from cutting units and other
moving parts. Keep everyone away.
 Do not overspeed the engine by changing
governor setting. Maximum engine speed is 2500 rpm
+ or - 100 rpm. To assure safety and accuracy, have
an Authorized Toro Distributor check maximum engine
speed.
 Shut engine off before checking or adding oil to the
crankcase.
 Disconnect battery before servicing the machine.
If battery voltage is required for troubleshooting or test
procedures, temporarily connect the battery.
 Toro recommends that two people be used to
backlap reels. Each person has specific duties and you
must communicate with one another.
 For optimum performance and safety, use genuine
Toro replacement parts and accessories.
Replacement parts and accessories made by other
manufacturers could be dangerous and may void the
product warranty of The Toro Company.
  
This unit has an equivalent continuous AĆweighted
sound pressure at the operator ear of: 90 dB(A), based
on measurements of identical machines per Directive
84/538/EEC and amendments.
 
!$"&%#
This unit does not exceed a vibration level of 2.5 m/s@,
at the hands based on measurements of identical
machines per IS  5349 procedures.
 
This unit does not exceed a vibration level of 0.5 m/s@
at the posterior based on measurements of identical
machines per IS  2631 procedures.

 $    
The following safety and instruction decals are installed on the traction unit. If any become damaged, replace them.
Decals are listed in your Parts Catalog. Order replacements from your Authori ed TORO Distributor.

%'(&

%'(&

%'(&

%'(&
#!
%'(&

%'(&
!"
%'(&

  %   !  
! 
 
&()'
&()'
! 
&()'
$     
&()'
!
&()'
"#
&()'
 
&()'
! !
&()'

 "   
 
#%&$

#%&$
!
#%&$

#%&$


& "&  ubota, four-cycle, four cylinder, 134 cu-in.
displacement, water cooled diesel engine. Rated 40 hp
@ 2300 rpm, 23:1 compression ratio.  Low idle - 1200
rpm, high idle  - 2500 rpm. Injection Timing - 17-18_
BTDC. Oil capacity is 8 qt. (7.6 L) with filter.
''$"&  0*+%  Capacity is 3.7 gal. (14 L) of 50/50
mixture of ethylene glycol anti-freeze.
,$ 0*+%  Capacity is 15 gal. (56.8 L) of #2 diesel
fuel.
0),$" 0*+%  Reservoir capacity is 9.3 gal.
(35.2 L) and total system capacity is 18.2 gal. (69 L).
Replaceable breather element. Replaceable spin-on
filter element.
)+"'& 0*+%  Ground speed is 0-12.5 mph
(0-20 km/h).
,++"&  &"+ )"- 0*+%  Adjustable reel speed to
match clip to ground speed. Backlap reel speed is 385
rpm.
+  Adjusts 6 in. (15.2 cm) forward and backward.
Adjustable backrest and three-positions for operator
weight. Integral seat switch at rear of bottom seat
cushion.
" &'*+" 0*+%  Test ports for traction system,
cutting unit drive system, lift/counterbalance, lift/relief,
steering circuits and charge pressure are located near
individual components.
+)"&  0*+%  Automotive type, full power.
)#*  Hand brake automatically locks traction
linkage in neutral. With traction motor wheel locks
engaged, twin disc brakes provide positive,
emergency braking.
$+)"$ 0*+%  12 volt, 66 amp hour (DIN) battery
and 40 amp alternator.  Negative ground.
&+)$'# 0*+%  Designed to stop engine if operator
gets off seat while cutting unit drive lever is either in
forward or reverse. Prevents engine from starting
unless parking brake is engaged, traction pedal is in
neutral and cutting units are disengaged. Low
hydraulic oil level and high engine temperature
protection systems stop engine from running.
)&"&  0*+%*
Water in fuel
Hydraulic oil filter
Engine coolant temperature
Engine oil pressure
Voltage Indicator
Air Cleaner Clogged
Hydraulic oil temperature
Hydraulic oil level
&)$ (""+"'&* (()'/
"+!',+ :
5 Cutting Units 137 in.  (348 cm)
4 Cutting Units 110 in.  (279 cm)
3 Cutting Units 83 in.  (211 cm)
1 Cutting Unit 29 1/2 in.   (75 cm)
-)$$ "+!:
Cutting Units Raised 91 1/2 in.  (232 cm)
Cutting Units Down 147 in.  (373 cm)
-)$$ & +! 110 in.  (282 cm)
" !+ 55 1/2 in.  (141 cm)
" !+ . 82 in.  (208 cm)
)',& $)& approx. 7 in.  (17.8 cm)
'%%& " !+',+
5 Blade Cutting Unit: 1 - 3 in.  (25 - 76 mm)
7 Blade Cutting Unit:
3/8 - 1 3/4 in.  (9.5 - 45 mm)
11 Blade Cutting Unit:
3/8 - 3/4 in. (9.5 - 19 mm)
!$ ) 53 in.  (135 cm)
!$ * 57 in.  (145 cm)
()+"&  ")$ 60 in.  (152 cm)
)0 " !+ 4360 lbs.  (1717 kg)
$ ( 800 - 1000 rpm
Note: 1200 rpm is attainable with a special coupler.
$"( (variable to match conditions):
5 Blade Cutting Unit: .176 in. per mph
 (.352 in. at 2 mph - 1.32 in. at 7.5 mph)
7 Blade Cutting Unit: .126 in. per mph
(.252 in. at 2 mph - .945 in. at 7.5 mph)
11 Blade Cutting Unit: .080 in. per mph
(.16 in. at 2 mph - .600 in. at 7.5 mph)
$,"*
& "& "$ See page 11 for specifications
"*$ ,$ #2
''$"&  0*+% 50/50 Water & Anti-Freeze
0),$" "$* (Interchangeable):
Mobil DTE 26/Shell Tellus 68 Equivalent*
  *Equivalent Hydraulic Oils (Interchangeable)
Mobil DTE 15 M
Amoco Rykon Oil #68
Conoco Super Hydraulic Oil 68
Exxon Nuto H 68
endall enoil R & 0 AW 68
Pennzoil Penreco 68
Phillips Magnus A 68
Standard Energol HLP 68
Sun Sunvis 831 WR
Union Unax AW 68


 
5 Blade L. H. Cutting Unit, Model No. 03752
(2 per machine)
5 Blade R. H. Cutting Unit, Model No. 03753
(3 per machine)
7 Blade L. H. Cutting Unit, Model No. 03754
(2 per machine)
7 Blade R. H. Cutting Unit, Model No. 03756
(3 per machine)
11 Blade L. H. Cutting Unit, Model No. 03741
(2 per machine)
11 Blade R. H. Cutting Unit, Model No. 03751
(3 per machine)
L. H. Dethatcher Kit, Model No. 03730
(2 per machine)
R. H. Dethatcher Kit, Model No. 03732
(3 per machine)
Cutting Unit Fixed Head Kit, Model 03762
(1 per machine)
Cutting Unit Floatation Kit, Model No. 03760
(1 per machine)
Front Roller Kit, Model No. 03742 (
1 per machine)
iehle Roller Kit, Model No. 03740
(1 per machine)
Rear Roller Scraper Kit, Part No. 59-6090
(1 per cutting unit)
Front Roller Scraper Kit, Part No. 62-6220
(1 per cutting unit)
Side Skid Kit, Model No. 03744
(1 per machine)
Spark Arrester Muffler Kit, Part No. 74-2900
(2 wheel drive only)
Spark Arrester Muffler Kit, Part No. 92-6074
(4 wheel drive only)
R.O.P.S. Kit, Part No. 92-9286
(Standard on 4 wheel drive machines)