Toro Groundsmaster 4000-D User Manual

Maintenance
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
MaintenanceProcedure
Aftertherst10hours
•Torquethewheellugnuts.
•Checkthealternatorbelttension.
•Checkthebladedrivebelttension.
Aftertherst50hours
•Changetheengineoilandlter.
•Checktheenginespeed(atidleandfullthrottle).
Aftertherst200hours
•Changethefrontplanetarygearoil.
•Changetherearaxleoil.
•Changethehydraulicoil.
•Changethehydraulicoillters.
Beforeeachuseordaily
•Checktheengineoillevel.
•Checkthecoolantlevel.
•Checkthehydraulicuidlevel.
•Checkthetirepressure.
•Checktheaircleanerindicator
•Checktheinterlockswitchoperation
Every50hours
•Lubricateallgreasettings.
•Inspecttheaircleaner.
•Checkthebladedrivebelttension.
•Removealldebrisandchafffromtheradiatorandoilcooler.
Every100hours
•Inspectthecoolingsystemhosesandclamps.
•Checkthefanandalternatorbelttension.
Every150hours
•Changetheengineoilandlter.
Every200hours
•Torquethewheellugnuts.
•Servicethesparkarrestormufer.
Every400hours
•Checktheplanetarygeardriveoil.
•Checktherearaxlelubricant.
•Checktherearaxlegearboxlubricant.
•Servicetheairlter(iftheindicatorshowsred).
•Inspectthefuellinesandconnections.
•Replacethefuelltercanister.
•Checktheenginespeed(atidleandfullthrottle).
Every800hours
•Drainandcleanthefueltank.
•Changethefrontplanetarygearoil.
•Changetherearaxleoil.
•Checktherearwheeltoe-in.
•Inspectthebladedrivebelts.
•Changethehydraulicoil.
•Changethehydraulicoillters.
•Inspectthesidecuttingunitdamper.
•Inspectthecuttingunitcastorwheelassemblies.
•Checkandadjustthevalveclearance.
Every2years
•Flushthecoolingsystemandreplaceuid.
•Replacemovinghoses.
32

Toro Groundsmaster 4000-D Specifications

General

Brand	Toro
Model	Groundsmaster 4000-D
Category	Lawn Mower
Language	English

Summary

California Proposition 65 Warning

Introduction to the Operator's Manual

Understanding Safety Symbols and Terms

Explanation of safety alert symbols, Caution, Warning, and Danger terms used in the manual.

General Safety Information

Safe Operating Practices

Operational safety guidelines based on international standards.

Operator Training and Responsibility

Emphasis on operator training, familiarity with controls, and owner responsibility.

Pre-Operation Safety Checks and Preparation

Essential pre-operation checks including safety gear, area inspection, and fuel handling.

Engine Starting Procedure

Steps for safely starting the engine, including disengaging controls and using safety features.

Safe Slope Operation

Precautions for operating on slopes, including reasons for loss of control.

Operating the Machine Safely

Slope Handling and Hazard Avoidance

Techniques for safe operation on slopes and avoiding terrain hazards.

Attachment Safety and Machine Integrity

Ensuring proper use of attachments, guards, interlocks, and engine settings.

Securing the Machine Before Leaving

Procedure for safely stopping the engine and securing the machine before exiting.

Safety Procedures for Maintenance and Clearing

Steps to take before clearing blockages, maintenance, or after striking an object.

Safe Transport and Storage Procedures

Guidelines for safe transport, storage, refueling, and road travel.

Maintenance and Storage Guidelines

General Maintenance and Fire Prevention

Key maintenance tasks and fire hazard reduction for the machine.

Parts Replacement and Storage Precautions

Procedures for replacing parts and safely storing the machine.

Toro Specific Safety Information

Product Hazards and Intended Use

Warning about amputating hazards, thrown objects, and proper product use.

Carbon Monoxide Hazard Warning

Warning about carbon monoxide from engine exhaust and avoiding enclosed areas.

Safe Operation Procedures and Precautions

Comprehensive safety guidelines for operation, including ROPS, footwear, clearances, and slope handling.

Road Travel and Attachment Safety

Maintenance Safety and Battery Hazards

Safety precautions for hot parts, fuel storage, battery handling, and general maintenance.

Safety Decal Meanings and Locations

Slope and Hazard Warning Decals

Decals related to slope limitations, thrown objects, and operator safety.

Component Hazard Warnings

Warnings related to hot surfaces, engine coolant, and entanglement hazards.

Battery Safety and Symbols

Engine Starting and Stopping Procedures

Detailed instructions for safely starting and stopping the engine.

Operator Control Panel Functions

Control Panel Safety Warnings

Crucial safety warnings associated with operating the control panel.

Groundsmaster 4000 Quick Reference Aid

Daily Checks and Services

Fluid Specifications and Change Intervals

Specifications for fluids and recommended change intervals for maintenance.

Operating the Machine

Before Operating Safety Precautions

Checking Engine Oil Level

Procedure and specifications for checking engine oil level before use.

Checking the Cooling System

Procedure for checking the engine coolant level and system capacity.

Coolant Safety and Fueling Precautions

Fuel System Maintenance

Fuel Handling and Storage Safety

Safety measures for handling flammable fuel, including filling and storage.

Fuel Handling Safety

Safety precautions for handling flammable diesel fuel and vapors.

Servicing the Water Separator

Bleeding Air from Injectors

Hydraulic System Maintenance

Checking Hydraulic Fluid Level

Procedure for checking and refilling the hydraulic fluid reservoir.

Changing the Hydraulic Fluid

Procedure for draining, refilling, and checking the hydraulic fluid reservoir.

Replacing the Hydraulic Filters

Adjusting Counterbalance Pressure

Checking Lubricants and Tire Pressure

Checking Rear Axle Lubricant

Checking Rear Axle Gear Box Lubricant

Checking Tire Pressure

Checking Wheel Nut Torque

Adjusting Front Cutting Unit Height

Procedure for adjusting the height of cut for the front cutting unit.

Height-of-Cut Adjustment Procedure

Side Cutting Unit Height-of-Cut Adjustment

Cutting Unit Adjustments

Measuring and Adjusting Cutting Unit Pitch

Procedure for measuring and adjusting the pitch of the cutting unit.

Servicing the Castor Arm Bushings

Cutting Unit Setup and Mismatch Correction

Matching Cutting Units and Engine Operation

Matching Height of Cut Between Units

Procedure for ensuring consistent cutting height across all units.

Starting and Stopping the Engine

Detailed instructions for safely starting and stopping the engine.

Operating Tips

Operating Tips for Slopes and Traction

Advice on managing ground speed, using flow divider, and brake application on slopes.

Safety During Operation

Critical safety warnings regarding thrown objects and stopping for bystanders.

Maintenance Schedule

Initial Maintenance (First 10-200 Hours)

Daily and 50-Hour Maintenance

100-400 Hour Maintenance

800 Hour and 2-Year Maintenance

Lubrication Procedures

Greasing Bearings and Bushings

Traction Unit Grease Points (50 Hours)

Front Cutting Unit Grease Points

Front Lift Assemblies Grease Points

Side Cutting Units Grease Points

Side Lift Assemblies Grease Points

Engine Maintenance

Air Cleaner Maintenance and Inspection

Procedure for inspecting, cleaning, and replacing the air cleaner filter and safety filter.

Servicing the Air Cleaner

Servicing the Engine Oil and Filter

Electrical System Maintenance

Battery Care and Cleaning

Instructions for cleaning battery terminals, posts, and cables to prevent corrosion.

California Proposition 65 Warning (Battery)

Warning about lead content in battery components and reproductive harm.

Battery Installation and Cable Routing

Fuse Identification and Location

Drive System Maintenance

Changing Planetary Gear Drive Oil

Procedure for changing the oil in the planetary gear drive.

Changing the Rear Axle Lubricant

Brake Maintenance

Adjusting the Service Brakes

Procedure for adjusting service brakes to reduce free travel.

Belt Maintenance

Servicing the Alternator Belt

Re-tensioning Blade Drive Belts

Replacing the Blade Drive Belt

Controls System Maintenance

Adjusting the Throttle Cable

Adjusting the Traction Pedal Linkage

Mower Maintenance

Adjusting Cutting Unit Flow Control

Servicing Castor Wheels and Bearings

Blade Maintenance

Checking for a Bent Blade

Procedure for checking blades for bends after striking an object.

Inspecting and Sharpening Cutter Blades

Guidelines for inspecting blade condition and sharpening cutting edges.

Blade Maintenance Procedures

Removing and Installing Cutter Blades

Procedure for replacing blades, including torque specifications.

Correcting Cutting Unit Mismatch

Steps to correct streaked cutting caused by blade height differences.

Spark Arrestor Maintenance

Servicing the Spark Arrestor Muffler

Procedure for clearing carbon buildup from the spark arrestor muffler.

Storage and Seasonal Preparation

Traction Unit Seasonal Storage

Engine Seasonal Storage