Form No. 3358-726 Rev A Groundsmaster® 4100-D Traction Unit Model No. 30411—Serial No. 2800000001 and Up Model No. 30411TE—Serial No. 2800000001 and Up Register at www.Toro.com.
Contents Warning CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Introduction................................................................. 2 Safety ........................................................................... 3 Safe Operating Practices ....................................... 3 Toro Mower Safety ...............................................
Safety Servicing the Engine Cooling System .................. 45 Brake Maintenance ................................................. 46 Adjusting the Service Brakes............................... 46 Belt Maintenance.................................................... 46 Servicing the Alternator Belt............................... 46 Re-tensioning the Blade Drive Belts .................... 46 Replacing the Blade Drive Belt ............................ 47 Controls System Maintenance..........................
engage the parking brake. Only start the engine from the operators position. Use seat belts, if provided. ◊ incorrect hitching and load distribution. • The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people, or property. • Do not use this machine on slopes greater than 15°. • Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care.
• • • • • • • • • • • • restarting and operating the equipment. Torque all the spindle pulley nuts to 130 to 150 ft-lb (176 to 203 N⋅m); – if the machine starts to vibrate abnormally (check immediately). Disengage drive to attachments when transporting or not is use. Stop the engine and disengage drive to attachment: – before refuelling; – before making height adjustment unless adjustment can be made from the operator’s position.
Operation • Use extra care with other attachments. These can change the stability of the machine. • When a person or pet appears unexpectedly in or near the mowing area, stop mowing. Careless operation, combined with terrain angles, ricochets, or improperly positioned guards can lead to thrown object injuries. Do not resume mowing until the area is cleared. • Turn off the blades when not mowing.
Vibration Level only genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty. Hand-Arm This unit has an equivalent continuous A-weighted hand/arm vibration level of 2.5 m/s2, based on measurements of identical machines per EN 1033 and EN836.
100-5624 100-5623 1. Height of cut adjustment 1. Low height of cut adjustment 2. High height of cut adjustment 100-5693 1. Height of cut adjustment 100-5694 1. Height of cut adjustment 100-6578 1. Entanglement hazard, belt—do not operate the machine with the shields or guards removed; always keep the shields and guards in place; stay away from moving parts. 104-3578 1. Height of cut adjustment 100-5622 1.
1. 2. 3. 104-2277 104-2277 1. To lock the parking brake, latch the pedals together, apply the brake pedals, and pull up on the knob. 2. To unlock the parking brake, step on the brake pedals. 3. Parking brake lock indicator 4. Read the Operator’s Manual. 104-3599 1. 2. 3. 4. 5. 5. Press for optional headlights. 6. Press down on the lever to tilt the steering wheel. Do not step here.
4-8325 1. Lock/unlock the cutting unit service lock. 112-9118 1. Warning—read the Operator’s Manual. 2. Warning—lock the parking brake, stop the engine, and remove the ignition key before leaving the machine. 3. Warning—wear the seat belt when seated in the operator’s position. 4. Cutting hazard of hand or foot—stay away from moving parts. 5. Tipping hazard—lower the cutting unit when driving down slopes; slow machine before turning, do not turn at high speeds 6.
106-6753 1. 2. 3. 4. Engine coolant under pressure Explosion hazard—read the Operator’s Manual. Warning—do not touch the hot surface. Warning—read the Operator’s Manual. 106-6764 1. To start the engine, move the traction pedal to Neutral, press the brake pedal, move the throttle lever to Fast, turn the ignition key to On, and then turn the ignition key to Start; read the Operators Manual. 2.
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 7. Wear eye protection; explosive gases can cause blindness and other injuries 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 10. Contains lead; do not discard.
105–7358 1. Read the Operator’s Manual.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Qty. 1 Seat kit (obtain separately) Seat suspension kit (obtain separately) Manual tube R-clamp Seat belt Bolt Lock washer 1 1 1 2 1 2 2 Install the seat, seat belt, and manual tube. No parts required – Grease the machine. Warning Decal 1 Used only on machines outside the U.S.A.
Product Overview Lubrication , page 34. Failure to properly grease the machine will result in premature failure of critical parts. 3 Replacing the Warning Decal Parts needed for this procedure: 1 Warning Decal Procedure On machines requiring CE compliance, replace the warning decal, part no. 112–9118 with the warning decal part no. 106–6752. 4 Figure 2 Reading the Manuals and Review the Training Materials 1. Traction pedal 2. Brake pedals 3.
Engine Temperature Gauge load, maximum ground speed, fully press the pedal while the throttle is in Fast. This gauge (Figure 2) indicates the engine coolant temperature. To stop, reduce your foot pressure on the traction pedal and allow it to return to the center position. Speed Limiter Important: The speed limiter screw must stop the traction pedal before the pump reaches full stroke or damage to the pump may occur.
PTO Switch Temperature Override Switch The PTO switch (Figure 4) has three positions: On (engage), Neutral, and Off (disengage). Carefully lift and push the PTO switch forward to the On position to start the implement or cutting unit blades. Slowly pull the switch backward to the Off position to stop implement operation. Press and hold the reset switch (Figure 4) to start the engine after high temperature shut down. Use only for emergency operation.
Specifications Note: Specifications and design are subject to change without notice.
Operation Note: Determine the left and right sides of the machine from the normal operating position. Before Operating If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Figure 5 1. Dipstick Remove the key from the ignition before you do any maintenance. 4. If the oil is below the Full mark, remove the fill cap (Figure 6) and add oil until the level reaches the Full mark. Do not overfill.
flash point and cold flow characteristics which will ease starting and reduce fuel filter plugging. If the engine has been running, the pressurized, hot coolant can escape and cause burns. 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. • Do not open the radiator cap when the engine is running. Important: Do not use kerosene or gasoline instead of diesel fuel.
2. Using a clean rag, clean area around fuel tank cap. 3. Remove cap from the fuel tank (Figure 8). In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. • Never fill the fuel tank inside an enclosed trailer.
High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 (cont'd.) Viscosity Index ASTM D2270 Pour Point, ASTM D97 Industry Specifications: 140 to 160 -34° F to -49° F Vickers I-286-S (Quality Level), Vickers M-2950-S (Quality Level), Denison HF-0 Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic system oil is available in 2/3 oz (20 ml) bottles. One bottle is sufficient for 4-6 gallons (15-22 1) of hydraulic oil.
The capacity is 80 oz (2.4 l). Visually inspect for leaks daily. 1. Position the machine on a level surface. 2. Remove a check plug from one end of the axle (Figure 12) and make sure that the lubricant is up to the bottom of the hole. If the level is low, remove the fill plug (Figure 12) and add enough lubricant to bring the level up to the bottom of the check plug holes. Figure 10 1. Check/drain plug 2.
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 following chart to determine the correct holes for the setting. Figure 13 1. Gear box 2.
below) onto the spindle shaft to get the desired height-of-cut; then slide the washer onto the shaft. Refer to the following chart to determine the combinations of spacers for the setting: Figure 17 Note: When using 1 inch (25 mm), 1-1/2 inch (38 mm), or occasionally 2 inch (51 mm) height-of-cut, move the skids and gage wheels to the highest holes. Figure 15 Wing Cutting Units 4. Push the castor spindle through the front castor arm.
6. Insert the clevis pins and install the hairpin cotters. 7. Rotate tension rod counterclockwise (finger tight) to put tension on adjustment. Figure 20 1. Castor pivot arm 3. Clevis pin and hair pin cotter 4. Tension rod 2. Axle mounting holes Figure 18 1. Castor wheel 2. Tensioning cap 3. Spacers 4. Shims 5. Axle mounting holes Refer to the following chart to determine the combinations of spacers for the setting.
Figure 24 Figure 22 3. To adjust distance, locate adjuster bolt on rear pivot link of cutting unit (Figure 25). Loosen jam nut on adjuster bolt. Loosen or tighten adjuster bolts until 0.38-0.62 inch (10-16 mm) clearance is attained, then tighten jam nut. 4. Repeat procedure on opposite side of cutting deck. 1.
6. Cut grass in a test area to determine if all cutting units are cutting at the same height. 7. If cutting unit adjustments are still needed, find a flat surface using a 6 foot (2 m) or longer straight edge. 8. To ease measuring blade plane, raise the height of cut to the highest position; refer to Adjusting the Height of Cut. 9. Lower cutting units onto the flat surface. Remove the covers from the top of the cutting units. 10.
Checking the Interlock Switches 2. Move the throttle control to the mid-idle position. 3. Turn the ignition key to the Run position. The glow indicator will light. 4. When the glow indicator dims, turn the ignition key to the Start position. Release the key immediately when the engine starts and allow it to return to the Run position. Allow engine to warm up at mid speed (without load), then move the throttle control to the desired position.
Note: Resistance will be felt on the valve when it is moved to the open position. • Raise either wing cutting unit to the transport position. The cutting unit should turn off. If the cutting unit does not stop, there is a malfunction in the interlock system that should be corrected before resuming operation. 3. Rotate the valve 90 degrees (1/4 turn) back to close the bypass valve before starting the engine. However, do not exceed 5 to 8 ft-lb (7 to 11 N⋅m) torque to close the valve.
is for use in low speed range only. When approaching an area known to cause wheel spin, depress and hold flow divider switch until completely past the area. If a tire spins while climbing or maneuvering on slopes, depress switch and slowly drive out of area. If both a front and rear wheel spins, the steering brake can be feathered to transfer the torque from the spinning wheels to opposite front wheel. Another characteristic to consider is the operation of the pedals that are connected to the brakes.
shredding causes the grass to turn brown at the edges which impairs growth and increases susceptibility to diseases. Transporting Use the transport latches when transporting over long distances, rough terrain, or when trailering. After Operating To ensure optimum performance, clean the underside of the mower housing after each use. If residue is allowed to build up in the mower housing, cutting performance will decrease. Figure 31 1.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 10 hours • Torque the wheel lug nuts. • Check the fan and alternator belt tension. • Check the blade drive belt tension. After the first 50 hours • Change the engine oil and filter. • Check the engine RPM (at idle and full throttle). • Torque the locknuts on the pivots.
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. Premaintenance Procedures Service Interval Chart Figure 33 Lubrication bearing area. Sealed bearings, such as the castor wheel bearings, rely on an initial fill of special grease and a robust integral seal to keep contaminants and moisture out of the rolling elements.
Due to the operating conditions these bearing/seal packages are subject to (i.e. sand, turf chemicals, water, impacts, etc.) they are considered normal wear items. Bearings that fail due to causes other than defects in materials or workmanship are typically not covered under warranty. Note: Bearing life can be negatively affected by improper wash down procedures. Do not wash down the unit when it is still hot and avoid directing high-pressure or high volume spray at the bearings.
Figure 38 Figure 39 Figure 40 Center Lift Assemblies • Lift arm bushings (2) (Figure 41) • Lift cylinder bushings (4) (Figure 41) • Lift arm ball joints (2) (Figure 42) 36
Wing Cutting Units • Castor fork shaft bushing (1 each) (Figure 44) • Spindle shaft bearings (4) • Idler arm pivot bushings (1) (located on the idler arm) Figure 41 Figure 44 Figure 42 Wing Lift Assemblies Wing lift cylinder (4) (Figure 43) Figure 43 37
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). Changing the air filter before it is necessary only increases the chance of dirt entering the engine when the filter is removed.
Important: Never attempt to clean the safety filter (Figure 47). Replace the safety filter with a new one after every three primary filter services. 2. Remove the oil filter (Figure 49). Apply a light coat of clean oil to the new filter seal before screwing it on. Do not overtighten. Figure 49 1. Engine oil filter 3. Add oil to the crankcase; refer to Checking the Engine Oil. Figure 47 1. Air cleaner safety filter 4. Clean the dirt ejection port located in the removable cover.
Fuel System Maintenance 2. Loosen the drain plug on the bottom of the filter canister. 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. Figure 50 • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. 1.
Electrical System Maintenance Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. Activating, Charging, and Connecting the Battery • Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands. Service Interval: Every 50 hours • Fill the battery where clean water is always available for flushing the skin.
negative (-) terminal of the battery and secure them with the bolts and nuts. Make sure that the positive (+) terminal is all of the way onto the post and the cable is positioned snug to the battery. The cable must not contact the battery cover. Slide the rubber boot over the positive terminal to prevent a possible short from occurring. 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.
Drive System Maintenance and to the check hole in brake housing until the level is up to the bottom of the planetary and brake housing check holes. Capacity is approximately 16 oz. (0.5 l). Changing the Planetary Gear Drive Oil 9. Install the plugs. 10. Repeat the procedure on the opposite gear assembly. 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.
1. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires. The front measurement must be 1/4 inch (6 mm) less than the rear measurement. 2. To adjust, loosen the clamps at both ends of the tie rods. 3. Rotate the tie rod end to move the front of the tire inward or outward. 4. Tighten the tie rod clamps when the adjustment is correct. Figure 58 1. Drain plug location 5. Clean the area around the drain plug on the bottom of the gear box (Figure 59). 6.
Cooling System Maintenance Servicing the Engine Cooling System Service Interval: Every 100 hours Every 2 years Remove debris from the oil cooler and radiator daily. Clean them more frequently in dirty conditions. Figure 61 1. Turn the engine off and raise the hood. Clean the engine area thoroughly of all debris. 1. Oil cooler 2. Remove the knobs (Figure 60) securing the oil cooler to the frame. 2. Radiator 4. Pivot the oil cooler back into position.
Brake Maintenance Belt Maintenance Adjusting the Service Brakes Servicing the Alternator Belt 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. Service Interval: After the first 10 hours Every 100 hours Check the condition and tension of the belts (Figure 62) after every 100 operating hours. 1.
Note: Make sure the belt is positioned on the spring side of the belt guide (Figure 63). Figure 64 Figure 63 1. Belt 2. Eye bolt 3. Extension spring 1. Hydraulic motor 4. Belt guide 5. Flange nut 6. Stop bolt 2. Mounting bolts 5. Remove the old belt from around the spindle pulleys and idler pulley. Replacing the Blade Drive Belt 6. Route the new belt around the spindle pulleys and idler pulley assembly. Service Interval: Every 800 hours 7.
Controls System Maintenance Adjusting the Throttle Service Interval: After the first 50 hours Every 400 hours Adjust the throttle cable (Figure 65) 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. Figure 66 1. Traction pedal stop 2. Stand 3. Loosen the jam nuts on the rod end and adjust the traction rod length (Figure 67) so that the pedal contacts the pedal stop when the pump lever reaches full stroke.
Hydraulic System Maintenance Every 800 hours Change the 2 hydraulic filters initially after the first 200 operating hours. Thereafter, change the filters after every 800 operating hours, in normal conditions. Changing the Hydraulic Fluid Use Toro replacement filters (Part No. 94-2621 for the left side of the machine and 75-1310 for the right side of the machine). Service Interval: After the first 200 hours Every 800 hours Important: Use of any other filter may void the warranty on some components.
Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. • Keep your body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. Figure 71 1. Test port B • Use cardboard or paper to find hydraulic leaks.
Figure 74 Figure 76 1. Test port E 1. Test port I Test Port F (Figure 75), located under the seat, is used to measure the lift circuit pressure. 2. Test port H The counterbalance test port (Figure 77) is used to adjust the pressure in the counterbalance circuit. Recommended counterbalance pressure is 470 psi (3241 kPa). To adjust the counterbalance pressure, rotate the adjusting screw (Figure 77) clockwise to increase the pressure or counterclockwise to decrease the pressure.
Mower Maintenance Pivoting the Front Cutting Unit Down Pivoting (Tilting) the Front Cutting Unit Upright 1. Slowly lower wing cutting units until the center of gravity shifts and the center cutting unit rotates downward. Note: Although not needed for normal maintenance procedures, the front cutting unit can be pivoted (tilted) to an upright position. Should you desire to tilt the cutting unit, proceed as follows: 1.
the bushings will wear. To check the bushings, move the castor fork back and forth and from side to side. If the castor spindle is loose inside the bushings, the bushings are worn and must be replaced. 1. Raise the cutting unit so that the wheels are off of the floor. Block the cutting unit so that it cannot accidentally fall. 2. Remove the tensioning cap, spacer(s), and thrust washer from the top of the castor spindle. 3. Pull the castor spindle out of the mounting tube.
Replacing the Cutting Unit Hinge Covers The hinge cover prevents debris from escaping at hinge points between cutting units. If cover(s) ever become damaged or worm they must be replaced. Figure 84 1. Castor wheel 2. Castor fork 3. Bearing 4. Bearing spacer Figure 86 1. Hinge cover Tightening the Locknuts Figure 85 1. Castor wheel 2. Castor pivot arm 3. Bearing 4.
Blade Maintenance Checking for a Bent Blade 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 the Off position, stop the engine, and remove the ignition key. Block the cutting unit to prevent it from accidentally falling. Figure 88 2. Rotate the blade until the ends face forward and backward (Figure 90). Measure from the inside of the cutting unit to the cutting edge at the front of the blade.
wears down, the quality-of-cut will degrade 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. 2. Grasp the end of the blade using a rag or thickly padded glove. Remove the blade bolt, anti-scalp cup, and blade from the spindle shaft (Figure 91). 3.
If the blade is allowed to wear, a slot will form between the sail and flat part of the blade (Figure 92). Eventually a piece of the blade may break off and be thrown from under the housing, possibly resulting in serious injury to you or bystanders. • Inspect the blade periodically for wear or damage. • Never try to straighten a blade that is bent or weld a broken or cracked blade. • Replace a worn or damaged blade. Figure 93 1.
Spark Arrestor Maintenance the dimensions must not exceed 1/8 inch (3 mm). If the dimension exceeds 1/8 inch (3 mm), replace the blade because it is bent. Make sure to measure all of the blades. 6. Compare the measurements of the outer blades with the center blade. The center blade must not be more than 3/8 inch (10 mm) lower than the outer blades.
Storage Preparing for Seasonal Storage Traction Unit 1. Thoroughly clean the traction unit, cutting units, and the engine. 2. Check the tire pressure; refer to Checking the Tire Pressure procedure in Operation , page 19. 3. Check all fasteners for looseness; tighten as necessary. 4. Grease or oil all grease fittings and pivot points. Wipe up any excess lubricant. 5. Lightly sand and use touch-up paint on painted areas that are scratched, chipped, or rusted. Repair any dents in the metal body. 6.
Schematics Electrical Schematic (Rev.
Hydraulic Schematic (Rev.
Notes: 62
Notes: 63
The Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
