Form No. 3362-891 Rev C Groundsmaster® 4110-D and 4100-D Traction Unit Model No. 30447—Serial No. 310000001 and Up Model No. 30449—Serial No. 310000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet. Model No. Serial No. 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.
Contents Adjusting the Service Brakes............................... 46 Belt Maintenance.................................................... 47 Servicing the Alternator Belt............................... 47 Re-tensioning the Blade Drive Belts .................... 47 Replacing the Blade Drive Belt ............................ 47 Controls System Maintenance................................. 48 Adjusting the Throttle Cable............................... 48 Adjusting the Traction Pedal Linkage ................
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.
• Replace worn or damaged parts for safety. • If the fuel tank has to be drained, do this outdoors. • 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.
• Avoid turning on slopes. If you must turn, turn slowly and gradually downhill, if possible. • Be certain that the seat belt can be released quickly if the machine is driven or rolls into a pond or water. • Watch for traffic when near or crossing roads. Always yield the right-of-way. • • • • • • The engine must be shut off before checking the oil or adding oil to the crankcase. • If major repairs are ever needed or if assistance is desired, contact an Authorized Toro Distributor.
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. 93-7818 1. Warning—read the Operator’s Manual for instructions on torquing the blade bolt/nut to 115-149 N-m (85-110 ft-lb). 106-4250 1. Height of cut 93-6674 100-5622 1. Crushing hazard, hand—read the instructions before servicing or performing maintenance. 1. Height of cut adjustment 58-6520 1.
117–2754 1. 2. 3. 4. 5. 6. 7. 8. Warning—read the Operator’s Manual. Warning—do not operate this machine unless you are trained. Warning—wear the seat belt when seated in the operator’s position. Warning—wear hearing protection. Thrown object hazard—keep bystanders a safe distance from the machine. Cutting hazard of hand or foot—stay away from moving parts; keep all guards in place.
117–2387 1. Raise left deck 2. Raise center deck 3. Raise right deck 4. Cooling fan 5. Reverse 6. Automatic 117-5723 1. 2. 3. 4. 5. 6. Off Headlights On Fast Slow Power Take-off (PTO) 7. 8. 9. 10. 11. 12. High Traction control Low Locked Flow divider Unlocked 106-4251 1. Height of cut 119-0067 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 10 4.
104-3579 1. Low height of cut adjustment 2. High height of cut adjustment 119-0075 1. Read the Operator’s Manual for fuse information. 2. Engine preheat—60A fuse 3. Engine, start—20A fuse 4. Headlights—10A fuse 5. Turn signal—10A fuse 6. Power seat—10A fuse 7. Powerpoint—10A fuse 8. 9. 10. 11. Instuments—10A fuse Control module—2A fuse Control module—2A fuse Powerpoint—7.5A fuse 104-3599 1. 2. 3. 4. 5. Do not step here.
106-6754 1. Warning—do not touch the hot surface. 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts. 106-6755 1. Engine coolant under pressure. 2. Explosion hazard—read the Operator’s Manual. 3. Warning—do not touch the hot surface. 4. Warning—read the Operator’s Manual. 106-6753 1. Thrown object hazard—keep bystanders a safe distance from the machine. 2. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts.
117-5735 1. Read the Operators Manual; to start the engine, move the traction pedal to Neutral, apply the brake, move the throttle switch to slow, turn the ignition key to Preheat. When the Wait to Start Advisory clears on the Info Center then turn the ignition key to Start. 2. Read the Operators Manual; to stop the engine, move the throttle lever to slow, disengage the PTO, set the parking brake, wait 5 minutes, turn the ignition key to Stop, and remove the key; read the Operators Manual. 3.
115-8455 1. Read the Operator’s Manual.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 2 Use Qty. No parts required – Grease the machine. Warning Decal 1 Used only on machines requiring European CE compliance. Media and Additional Parts Description Use Qty.
Tilt Steering Lever Product Overview Press the lever Figure 2 down to tilt the steering wheel to the desired position. Then release the lever to lock the adjustment. Controls Note: Determine the left and right sides of the machine from the normal operating position. Parking Brake Latch A knob on the left side of the console actuates the parking brake lock (Figure 2). To engage the parking brake, connect the pedals with the locking latch, push down on both pedals, and pull the parking brake latch out.
Flow Divider Switch (optional) When operating in mow (low) speed, press and hold flow divider switch (Figure 4) to enhance traction drive performance in compromised operating conditions. Hi-Lo Speed Control The switch (Figure 4) allows the speed range to increase for transport of the machine. Cutting decks will not operate in high range. Also, the decks cannot be lowered from the transport position when the switch is in the high range.
Engine Cooling Fan Switch Air Conditioning Switch The machine is equipped with a hydraulically driven auto reversing engine cooling fan. The fan switch (Figure 5) has two positions R (manual reverse) and Auto (normal). Refer to Engine Cooling Fan Operation in the Operation Section of manual. Press front of switch to activate the air conditioning (Figure 6) and rear of switch to turn off the air conditioning. Fan Control Rotate the fan control knob to regulate the speed of the fan (Figure 6).
Specifications Pull out and down on latch to close and secure wind shield. Note: Specifications and design are subject to change without notice. Width of cut overall 124 inch (315 cm) front cutting unit 54 inch (137 cm) side cutting unit 37 inch (94 cm) front and one side cutting unit 89 inch (226 cm) Overall width cutting units down cutting units up (transports) Overall length Figure 7 1.
Operation Note: Determine the left and right sides of the machine from the normal operating position. Before Operating CAUTION 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. Figure 8 1. Dipstick Checking the Engine Oil 4. If the oil is below the Full mark, remove the fill cap (Figure 9) 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. CAUTION 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.
DANGER 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. • Never smoke when handling fuel, and stay away from an open flame or where fuel fumes may be ignited by a spark.
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.
correct air pressure in the front and rear tires is 25-30 psi (172-207 kPa). Important: Maintain even pressure in all tires to ensure a good quality-of-cut and proper machine performance. Do not under-inflate. Checking the Torque of the Wheel Nuts or Bolts Service Interval: After the first 10 hours Figure 14 1. Check plug Every 200 hours 2. Fill plug WARNING Failure to maintain proper torque of the wheel nuts could result in failure or loss of wheel and may result in personal injury.
spindle shaft. Install the tensioning cap to secure the assembly. 5. Remove the hairpin cotter and clevis pin securing the height-of-cut chains to the rear of the cutting unit (Figure 18). Figure 16 1. Tensioning cap 2. Spacers 3. Shims 4. Top axle mounting hole 5. Castor wheel Figure 18 Note: When operating in 2-1/2 inch (64 mm) height of cut or higher, the axle bolt must be installed in the lower castor fork hole to prevent grass buildup between the wheel and the fork.
6. Insert the clevis pins and install the hairpin cotters. 2. Remove the tensioning cap from the spindle shaft (Figure 20) and slide the spindle out of castor arm. Put the two shims (1/8 inch [3 mm]) onto spindle shaft as they were originally installed. These shims are required to achieve a level across the entire width of the cutting units. Slide the appropriate number of 1/2 inch spacers onto the spindle shaft to get the desired height-of-cut; then slide the washer onto the shaft. 7.
blade tips, distance should be approximately 0.38-0.62 inch (10-16 mm) (Figure 26). Figure 26 Figure 24 1. Skid 3. To adjust distance, locate adjuster bolt on rear pivot link of cutting unit (Figure 27). 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.
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.
Important: Do not run the starter motor more than 15 seconds at a time or premature starter failure may result. If the engine fails to start after 15 seconds, turn the key to the Off position, recheck the controls and procedures, 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 attempt. The starter motor can be run for 30 seconds on then 60 seconds off for 2 attempts. Figure 30 1.
The machine has interlock switches in the electrical system. These switches are designed to stop the engine when the operator gets off of the seat when the traction pedal is depressed. However, the operator may get off of the seat while the engine is running and the traction pedal is in neutral. Although the engine will continue to run if the PTO lever is disengaged and the traction pedal is released, it is strongly recommended that the engine be stopped before rising from the seat.
Coupler Fitting No. 95-0985 [Qty. 2], and Hydraulic Fitting No. 340-77 [Qty. 2]) to the reverse traction pressure test port (Figure 32) and the reverse four-wheel drive pressure port (Figure 33). • Front center of the operator’s platform • The rear bumper Operating Characteristics Practice driving the machine because it has a hydrostatic transmission and its characteristics are different than many turf maintenance machines.
Always Mow with Sharp Blades Before stopping the engine, disengage all controls and move the throttle to Slow. Moving the throttle to Slow reduces high engine speed, noise, and vibration. Turn the key to Off to stop the engine. A sharp blade cuts cleanly and without tearing or shredding the grass blades like a dull blade. Tearing and shredding causes the grass to turn brown at the edges which impairs growth and increases susceptibility to diseases.
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).
CAUTION 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 36 Lubrication and reduces the potential of turf damage due to grease contamination.
Traction Unit Service Interval: Every 50 hours • Brake shaft pivot bearings (5) (Figure 37) • Traction pedal pivot bushing (1) (Figure 38) • Front and rear axle pivot bushings (2) (Figure 39) • Steering cylinder ball joints (2) (Figure 40) • Tie rod ball joints (2) (Figure 40) • King pin bushings (2) (Figure 40). The top fitting on the king pin should only be lubricated annually (2 pumps).
Figure 42 • Lower link pivot (4) (Figure 43) • Upper link pivot (4) (Figure 43) • Castor fork shaft bushings (2) (Figure 44) • Spindle shaft bearings (3) (Figure 45) Figure 44 • Idler arm pivot bushings (2) (Figure 45) Figure 43 Figure 45 36
Center Lift Assemblies Wing Lift Assemblies • Lift arm bushings (2) (Figure 46) Wing lift cylinder (4) (Figure 48) • Lift cylinder bushings (4) (Figure 46) • Lift arm ball joints (2) (Figure 47) Figure 48 Wing Cutting Units • Castor fork shaft bushing (1 each) (Figure 49) • Spindle shaft bearings (4) Figure 46 • Idler arm pivot bushings (1) (located on the idler arm) Figure 47 Figure 49 37
Engine Maintenance large accumulations of debris packed between outside of primary filter and the canister. Avoid using high pressure air which could force dirt through the filter into the intake area. This cleaning process prevents debris from migrating into the intake when the primary filter is removed. 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.
Fuel System Maintenance 5. Install the cover orienting the rubber outlet valve in a downward position - between approximately 5:00 to 7:00 when viewed from the end. 6. Reset the indicator (Figure 50) if it shows red. Servicing the Fuel System Servicing the Engine Oil and Filter DANGER 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.
4. Tighten the tube connector securely. 5. Repeat the procedure on the remaining nozzles. Figure 55 1. Water separator filter canister 3. Clean the area where the filter canister mounts. 4. Remove the filter canister and clean the mounting surface. 5. Lubricate the gasket on the filter canister with clean oil. 6. Install the filter canister by hand until the gasket contacts mounting surface, then rotate it an additional 1/2 turn. 7. Tighten the drain plug on the bottom of the filter canister.
Electrical System Maintenance 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. Keep the terminals and the entire battery case clean because a dirty battery will discharge slowly. To clean the battery, wash the entire case with a solution of baking soda and water. Rinse with clear water.
1 WARNING 10 7.5 7.5 10 10 2 7.5 7.5 2 7.5 7.5 • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. 10 20 Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • Always connect the positive (red) battery cable before connecting the negative (black) cable. G011542 Figure 60 4.
Drive System Maintenance Note: The cab fuses (Figure 62) are located in the fuse box in the cab headliner (model 30447 only). 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. Jack up the front of the machine and support with jack stands. 2. Remove the front wheels.
bottom of the brake housing check hole. Install the plug. 10. Repeat the procedure on the opposite gear assembly. Figure 65 1. Drain plug location 5. Clean the area around the drain plug on the bottom of the gear box (Figure 66). 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 64 1. Brake housing 2. Drain plug 3.
Checking the Rear Wheel Toe-In Cooling System Maintenance Service Interval: Every 800 hours After every 800 operating hours or annually, check the rear wheel toe-in. Servicing the Engine Cooling System 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. Remove debris from the oil cooler and radiator daily. Clean them more frequently in dirty conditions.
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 68 1. Oil cooler A.
Belt Maintenance Note: Make sure the belt is positioned on the spring side of the belt guide (Figure 70). Servicing the Alternator Belt Service Interval: After the first 10 hours Every 100 hours Check the condition and tension of the belts (Figure 69) 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. 2. If the deflection is not 3/8 inch (10 mm), loosen the alternator mounting bolts (Figure 69).
Controls System Maintenance Adjusting the Throttle Cable Service Interval: After the first 50 hours Every 400 hours Adjust the throttle cable (Figure 72) 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 71 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 Checking the Hydraulic Lines and Hoses Service Interval: After the first 200 hours Every 800 hours Service Interval: Every 2 years Change the 2 hydraulic filters initially after the first 200 operating hours. Thereafter, change the filters after every 800 operating hours, in normal conditions. Inspect the hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration.
1 Mower Maintenance 2 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. g011538 Figure 76 1. Counterbalance test port 2.
4. Start the engine and slowly raise the center cutting unit. 5. Slowly raise each wing cutting until the center of gravity shifts and the deck starts to rotate into the upright position. Stop the engine and remove the ignition key. 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. Figure 79 1. Height-of-cut chain 2. U-bolt 2.
Servicing the Castor Arm Bushings or the castor pivot arm (Figure 83). 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.
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 86). 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. 3. Install the blade, anti-scalp cup, and blade bolt.
DANGER If the blade is allowed to wear, a slot will form between the sail and flat part of the blade (Figure 87). 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 88 1.
Spark Arrestor Maintenance 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. If the center blade is more than 3/8 inch (10 mm) lower than the outer blades, proceed to step 7 and add shims between the spindle housing and the bottom of the cutting unit.
Cab Maintenance Cleaning the Cab Air Filters Service Interval: Every 250 hours (Replace them if they are torn or excessively dirty.) 1. Remove the thumb screws and grates from over both the in-cab and rear cab air filters (Figure 89). Figure 89 1. Thumb screw 2. Grate 3. Air filter 2. Clean the filters by blowing clean, oil free, compressed air through them. Important: If either filter has a hole, tear, or other damage, replace it. 3. Install the filters and grate, securing them with the thumb screws.
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. 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 G011533 Electrical Schematic, sheet 1 (Rev.
G011534 Electrical Schematic, sheet 2 (Rev.
G011535 Electrical Schematic, sheet 3 (Rev.
Hydraulic Schematic (Rev.
The Toro Total Coverage Guarantee A 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).
