Form No. 3360-356 Rev B Groundsmaster® 4100-D Traction Unit Model No. 30413—Serial No. 2900000001 and Up Register at www.Toro.com.
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. Figure 1 1. Safety alert symbol This manual uses 2 other words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.
Contents Brake Maintenance ................................................. 45 Adjusting the Service Brakes............................... 45 Belt Maintenance.................................................... 46 Servicing the Alternator Belt............................... 46 Re-tensioning the Blade Drive Belts .................... 46 Replacing the Blade Drive Belt ............................ 46 Controls System Maintenance................................. 47 Adjusting the Throttle Cable.................
Safety ◊ 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. This machine meets or exceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-2004 specifications in effect at the time of production. Preparation Improper use or maintenance by the operator or owner can result in injury.
• Before attempting to start the engine, disengage all blade attachment clutches, shift into neutral, and engage the parking brake. Only start the engine from the operator’s position. Use seat belts. • 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. To guard against overturning: – Do not stop or start suddenly when going up or downhill.
• On multi-bladed machines, take care as rotating one blade can cause other blades to rotate. • When machine is to be parked, stored, or left unattended, lower the cutting units unless a positive mechanical lock is provided. • Disengage drives, lower the cutting units, move traction pedal to Neutral, set parking brake, stop engine and remove key. Wait for all movement to stop before adjusting, cleaning or repairing. • Shut off fuel while storing or transporting. Do not store fuel near flames.
• Avoid turning on slopes. If you must turn, turn slowly and gradually downhill, if possible. • Battery gases can explode. Keep cigarettes, sparks, and flames away from the battery. • Be certain that the seat belt can be released quickly if the machine is driven or rolls into a pond or water. • The engine must be shut off before checking the oil or adding oil to the crankcase. • Watch for traffic when near or crossing roads. Always yield the right-of-way.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 93-6674 1. Crushing hazard, hand—read the instructions before servicing or performing maintenance. 100-5623 1. Low height of cut adjustment 2. High height of cut adjustment 93-7272 1. Cutting/dismemberment hazard; fan—stay away from moving parts. 100-6578 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. 106-4251 1. Height of cut 106-4250 98-4387 1. Height of cut 1. Warning—wear hearing protection. 114-5605 1. 2. 3. 4. 5. 6. 7. Warning—read the Operator’s Manual. Warning—do not operate this machine unless you are trained. Thrown object hazard—keep bystanders a safe distance from the machine. Warning—wear the seat belt when seated in the operator’s position. Cutting hazard of hand or foot—stay away from moving parts; keep all guards in place.
4-5604 (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. 1. 2. 3. 4. 5. 6. 7. Warning—read the Operator’s Manual. Warning—do not operate this machine unless you are trained. Thrown object hazard—keep bystanders a safe distance from the machine.
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, or smoking. 106-6764 1. To start the engine, move the traction pedal to Neutral, press the brake pedal, move the throttle lever to mid idle, turn the ignition key to On, and then turn the ignition key to Start; read the Operators Manual. 2.
115-8455 1. Read the Operator’s Manual.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 Description Use Qty. No parts required – Grease the machine. Warning Decal 1 Used only on machines requiring European CE compliance. Operator’s Manual Engine Operator’s Manual Parts Catalog Operator Training Materials Pre-delivery Inspection Sheet Declaration of conformity 1 1 1 1 1 1 Read the manuals and training materials before operating the machine.
Product Overview load, maximum ground speed, fully press the pedal while the throttle is in Fast. To stop, reduce your foot pressure on the traction pedal and allow it to return to the center position. Brake Pedals 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.
Engine Temperature Gauge Key Switch This gauge (Figure 2) indicates the engine coolant temperature. The key switch (Figure 4) has three positions: Off, On/Preheat, and Start. Speed Limiter PTO Switch Adjust the screw (Figure 3) to limit the amount the traction pedal can be depressed in the forward direction to limit speed. The PTO switch (Figure 4) has three positions: On (engage), Neutral, and Off (disengage).
Hour Meter Throttle Control The hour meter (Figure 4) shows the total hours that the machine has been operated. Move the control (Figure 4) forward to increase the engine speed and rearward to decrease the speed. Temperature Override Switch Power Point Press and hold the reset switch (Figure 4) to start the engine after high temperature shut down. Use only for emergency operation. The power point (Figure 4) is used to power optional electrical accessories.
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.
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. Failure to observe this caution will damage the engine. • Do not open the radiator cap when the engine is running. • Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape.
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.
Checking the Planetary Gear Drive Oil High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 (cont'd.) Viscosity Index ASTM D2270 Pour Point, ASTM D97 Service Interval: Every 400 hours 140 to 160 Check the oil level after every 400 hours of operation or if external leakage is noted. Use high quality SAE 85W-140 gear lube as a replacement.
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. Check the oil level before the engine is first started and every 400 hours thereafter. The capacity is 80 oz (2.4 l). Visually inspect for leaks daily. Figure 13 1. Position the machine on a level surface. 1.
castor forks, add or remove an equal number of spacers from the castor forks, and secure the rear chain to the desired hole. 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: 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.
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 position. Wing Cutting Units To adjust the height-of-cut on the side cutting units, add or remove an equal number of spacers from the castor forks, position the castor wheel 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. Figure 18 1. Castor wheel 2.
6. Insert the clevis pins and install the hairpin cotters. 7. Rotate tension rod counterclockwise (finger tight) to put tension on adjustment. Figure 22 1. Skid Adjusting the Cutting Unit Rollers The cutting unit rollers should be mounted in the lower position when operating in height of cuts greater than 2-1/2 inches (64 mm) and in the higher position when operating in height of cuts lower than 2-1/2 inches (64 mm). 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. Figure 24 9. Lower cutting units onto the flat surface. Remove the covers from the top of the cutting units. 3.
(Figure 27). For the outside blade spindle only, refer to Adjusting the Cutting Unit Pitch procedure in Mower Maintenance, page 50. 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.
Checking the Interlock Switches • 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. • If the cutting unit is lowered again the motor should re-start. If the cutting unit does not re-start, there is a malfunction in the interlock system that should be corrected before resuming operation.
Note: Resistance will be felt on the valve when it is moved to the open position. 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. Figure 30 1. Reverse four-wheel drive pressure test port Jacking Points There are jacking points located at the front and rear of the machine. • On the frame at the inside of each front drive tire • At the center of the rear axle Figure 28 1.
The brakes can be used to assist in turning the machine. However, use them carefully, especially on soft or wet grass because the turf may be torn accidentally. Another benefit of the brakes is to maintain traction. For example, in some slope conditions, the uphill wheel slips and loses traction. If this situation occurs, depress the uphill turn pedal gradually and intermittently until the uphill wheel stops slipping, thus, increasing traction on the downhill wheel.
Figure 32 1. Deck lift cylinder 2. Foam deck pad Cutting Unit Pitch We recommend a blade pitch of 1/4 inch (6 mm). A pitch larger than 1/4 inch (6 mm) will result in less power required, larger clippings, and a poorer quality of cut. A pitch less than 1/4 inch (6 mm) will result in more power required, smaller clippings and a better quality of cut.
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 belt tension. • Check the blade drive belt tension. After the first 50 hours • Change the engine oil and filter. • Check the engine speed (at idle and full throttle).
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 33 Lubrication The sealed bearings require no lubrication or short term maintenance. This minimizes routine service required and reduces the potential of turf damage due to grease contamination.
down the unit when it is still hot and avoid directing high-pressure or high volume spray at the bearings. The grease fitting locations and quantities are: Traction Unit Service Interval: Every 50 hours • Brake shaft pivot bearings (5) (Figure 34) Figure 36 • Traction pedal pivot bushing (1) (Figure 35) • Front and rear axle pivot bushings (2) (Figure 36) • Steering cylinder ball joints (2) (Figure 37) • Tie rod ball joints (2) (Figure 37) • King pin bushings (2) (Figure 37).
Figure 40 Figure 38 1.
Center Lift Assemblies • Lift arm bushings (2) (Figure 43) • Lift cylinder bushings (4) (Figure 43) • Lift arm ball joints (2) (Figure 44) Figure 45 Wing Cutting Units • Castor fork shaft bushing (1 each) (Figure 46) • Spindle shaft bearings (4) • Idler arm pivot bushings (1) (located on the idler arm) Figure 43 Figure 44 Wing Lift Assemblies Figure 46 Wing lift cylinder (4) (Figure 45) 36
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 49). Replace the safety filter with a new one after every three primary filter services. 2. Remove the oil filter (Figure 51). Apply a light coat of clean oil to the new filter seal before screwing it on. Do not overtighten. Figure 51 Figure 49 1. Engine oil filter 1. Air cleaner safety filter 3. Add oil to the crankcase; refer to Checking the Engine Oil. 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 52 • 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 connector. Turn the key to the Off position when solid flow is observed. 4. Tighten the tube connector securely. 5. Repeat the procedure on the remaining nozzles. Activating, Charging, and Connecting the Battery Every 50 hours Battery Care Battery type is group 24. Important: Before welding on the machine, disconnect the negative cable from the battery to prevent damage to the electrical system. Note: Check the battery condition weekly or after every 50 hours of operation.
Battery terminals or metal tools could short against metal components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. • Do not allow metal tools to short between the battery terminals and metal parts of the machine. Incorrect battery cable routing could damage the machine and cables causing sparks.
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. 1. With the machine on a level surface, position the wheel so that the check/drain plug (Figure 58) is at the lowest position. Figure 56 1. Fuses Figure 57 1. 2. 3. 4.
level is up to the bottom of the planetary and brake housing check holes. Capacity is approximately 16 oz. (0.5 l). 9. Install the plugs. 10. Repeat the procedure on the opposite gear assembly. Figure 60 1. Drain plug location 5. Clean the area around the drain plug on the bottom of the gear box (Figure 61). 6. Remove the drain plug from the gear box and allow the oil to drain into a pan. Remove the fill plug to ease in draining of the oil. Figure 59 1. Brake housing 2. Drain plug 3.
Checking the Rear Wheel Toe-In Cooling System Maintenance Service Interval: Every 800 hours Servicing the Engine Cooling System After every 800 operating hours or annually, check the rear wheel toe-in. 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.
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. Disengage the locking latch from the brake pedals so that both pedals work independently of each other. 2. To reduce free travel of the brake pedals, tighten the brakes: Figure 63 1. Oil cooler A.
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 64) 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. Figure 65 2. If the deflection is not 3/8 inch (10 mm), loosen the alternator mounting bolts (Figure 64). Increase or decrease the alternator belt tension and tighten the bolts.
Controls System Maintenance Adjusting the Throttle Cable Service Interval: After the first 50 hours Every 400 hours Adjust the throttle cable (Figure 67) 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. Hydraulic motor 2. Mounting bolts 5. Remove the old belt from around the spindle pulleys and idler pulley. 6. Route the new belt around the spindle pulleys and idler pulley assembly. 7.
Hydraulic System Maintenance Changing the Hydraulic Fluid Service Interval: After the first 200 hours Every 800 hours Change the hydraulic fluid after every 800 operating hours, in normal conditions. If the fluid becomes contaminated, contact your local Toro distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil. 1. Turn the engine off and raise the hood. 2.
Replacing the Hydraulic Filters Service Interval: After the first 200 hours Every 800 hours Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Change the 2 hydraulic filters initially after the first 200 operating hours. Thereafter, change the filters after every 800 operating hours, in normal conditions. • 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.
Mower Maintenance Pivoting (Tilting) the Front Cutting Unit Upright 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. Raise the center and wing cutting units slightly off of the floor, set the parking brake, and stop the engine. Remove the ignition key. 2. Remove the hairpin cotter securing dampers to lift arms (Figure 74). Pivot damper toward deck housing.
Pivoting the Front Cutting Unit Down 1. Slowly lower wing cutting units until the center of gravity shifts and the center cutting unit rotates downward. 2. Sit on the seat, start the engine, and lower the center cutting unit until it is slightly off of the floor. 3. Secure the height-of-cut chains to the rear of the cutting unit. Figure 76 4. Pivot dampers upward into position and secure with clevis pin and cotter pin. 1. Height-of-cut chain Adjusting the Cutting Unit Pitch 2.
Servicing the Castor Arm Bushings or the castor pivot arm (Figure 80). Grasp the castor wheel and slide the bolt out of the fork or pivot arm. The castor arms have bushings pressed into the top and bottom of the tube and after many hours of operation, 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.
Blade Maintenance Replacing the Cutting Unit Hinge Covers Checking for a Bent Blade 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. 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.
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 83). 3.
If the blade is allowed to wear, a slot will form between the sail and flat part of the blade (Figure 84). 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 85 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 18. 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, sheet 1 (Rev.
Electrical Schematic, sheet 2 (Rev.
Hydraulic Schematic (Rev.
Notes: 61
Notes: 62
Notes: 63
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. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
