Form No. 3374-304 Rev A Groundsmaster®4100-D and 4110-D Rotary Mower Model No. 30447N—Serial No. 313000001 and Up Model No. 30449N—Serial No. 313000001 and Up Register at www.Toro.com.
This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 1), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. 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.
Contents Replacing the Hydraulic Filters .................................47 Checking the Hydraulic Lines and Hoses....................48 Adjusting the Counterbalance Pressure......................48 Mower Maintenance ...................................................49 Pivoting (Tilting) the Front Cutting Unit Upright .............................................................49 Pivoting the Front Cutting Unit Down.......................49 Adjusting the Cutting Unit Pitch ..............................
Preparation Safety • While mowing, always wear substantial footwear, long trousers, hard hat, safety glasses, and hearing protection. Long hair, loose clothing or jewelry may get tangled in moving parts. Do not operate the equipment when barefoot or wearing open sandals. This machine meets or exceeds ISO standard 5395:1990 and ANSI B71.4-2004 specifications in effect at the time of production. Improper use or maintenance by the operator or owner can result in injury.
• • • • • • • • • • • • • • Look behind and down before backing up to be sure of – Do not stop or start suddenly when going up or downhill. – Engage the clutch slowly, always keep the machine in gear, especially when travelling downhill. – The machine speed should be kept low on slopes and during tight turns. – Stay alert for humps and hollows and other hidden hazards. – Never mow across the face of the slope, unless the machine is designed for that purpose.
• Use care when checking blades. Wrap the blades or • • • • • Check the safety interlock switches daily for proper wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them. Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running. Charge batteries in an open well ventilated area, away from spark and flames. Unplug charger before connecting or disconnecting from battery.
• • • • • If major repairs are ever needed or if assistance is desired, the body away from the cutting units, attachments, and any moving parts. Keep everyone away. Check brake operation frequently. Adjust and service as required. Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes, and clothing. Protect your face, eyes, and clothing when working with a battery. Battery gases can explode. Keep cigarettes, sparks, and flames away from the battery.
58-6520 1. Grease 117–2385 1. Read the Operators Manual. 2. Engine—start 3. Engine—preheat 4. Engine—stop 117–2754 1. Warning—read the Operator's Manual. 2. Warning—do not operate this machine unless you are trained. 3. Warning—wear the seat belt when seated in the operator's position. 4. Warning—wear hearing protection. 5. Thrown object hazard—keep bystanders a safe distance from the machine. 6. Cutting hazard of hand or foot—stay away from moving parts; keep all guards in place. 7.
117–2387 1. Raise left deck 4. Cooling fan 2. Raise center deck 3. Raise right deck 5. Reverse 6. Automatic 117-5723 1. Off 7. High 2. Headlights 8. Traction control 3. 4. 5. 6. On Fast Slow Power Take-off (PTO) 9. 10. 11. 12. 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. 4. Read the Operator's Manual. 2. To unlock the parking brake, step on the brake pedals. 5.
4-3599 1. Do not step here. 2. Traction pedal 3. Traction—forward 4. Traction—reverse 5. Danger—shut off PTO prior to raising the cutting units; do not operate the cutting units when they are in the raised position. 119-0075 1. Read the Operator's Manual for fuse information. 2. Engine preheat—60A fuse 3. Engine, start—20A fuse 7. Powerpoint—10A fuse 8. Instuments—10A fuse 9. Control module—2A fuse 4. Headlights—10A fuse 10. Control module—2A fuse 5. Turn signal—10A fuse 11. Powerpoint—7.
7-5735 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. 106-6754 1. Warning—do not touch the hot surface. 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts. 120-6604 1. Thrown object hazard—keep bystanders away from the machine. 2. Cutting/dismemberment hazard of hand, mower blade—stay away from moving parts, keep all guards and shields in place. 106-6755 1. Engine coolant under pressure. 3. Warning—do not touch the hot surface. 2.
Setup Media and Additional Parts Description Use Qty. Operator's Manual 1 Review before operating machine Engine Operator's Manual 1 Use to reference engine information Parts Catalog 1 Use to reference part numbers Operator Training Materials 1 Review before operating machine Pre-delivery Inspection Sheet 1 Note: Determine the left and right sides of the machine from the normal operating position.
Tilt Steering Lever Product Overview Controls Press the lever Figure 2 down to tilt the steering wheel to the desired position. Then release the lever to lock the adjustment. 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.
Fan Control two positions R (manual reverse) and Auto (normal). Refer to Engine Cooling Fan Operation in the Operation Section of manual. Rotate the fan control knob to regulate the speed of the fan (Figure 6). Temperature Control Rotate the temperature control knob to regulate the air temperature in the cab (Figure 6). 1 2 3 G011547 Figure 5 1. Power point 3. Hour meter 2. Engine cooling fan switch Hour Meter The hour meter (Figure 5) shows the total hours that the machine has been operated.
Specifications 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 Figure 7 cutting units up (transports) 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.
Important: Do not use kerosene or gasoline instead of diesel fuel. Failure to observe this caution will damage the engine. CAUTION If the engine has been running, the pressurized, hot coolant can escape and cause burns. • 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. WARNING Fuel is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness.
Checking the Hydraulic Fluid DANGER Service Interval: Before each use or daily In certain conditions during fueling, static electricity can be released causing a spark which can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property. The machines reservoir is filled at the factory with approximately 8 U.S. gallons (30.2 l) of high quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter.
Checking the Planetary Gear Drive Oil Service Interval: Every 400 hours 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. The capacity of the system is approximately 16 oz (0.5 l). 1. With the machine on a level surface, position the wheel so that the check/drain plug (Figure 13) is at either the 3 or 9 o'clock position. Figure 12 1. Hydraulic tank cap 4.
Checking the Rear Axle Gear Box Lubricant Checking the Tire Pressure Service Interval: Every 400 hours The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure. The correct air pressure in the front and rear tires is 25-30 psi (172-207 kPa). Service Interval: Before each use or daily The gear box 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 16 oz (0.5 l).
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 4. Top axle mounting hole 2. Spacers 5. Castor wheel Figure 18 1. Height-of-cut chain 3. Shims 2. Clevis pin & hair pin cotter 6. Mount the height-of-cut chains to the desired height-of-cut hole (Figure 19) with the clevis pin and hairpin cotter.
onto the spindle shaft to get the desired height-of-cut; then slide the washer onto the shaft. Figure 22 1. Castor pivot arm 2. Axle mounting holes Figure 20 1. Tensioning cap 4. Top axle mounting hole 2. Spacers 5. Castor wheel 3. Clevis pin and hair pin cotter 4. Tension rod 3. Shims Refer to the following chart to determine the combinations of spacers for the setting.
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. Remove the bolt and nut securing the gage wheel to the cutting unit brackets (Figure 25). Figure 27 1. Adjuster bolt 2.
Adjusting the Mirrors Model 30447 only Rear View Mirror While sitting in the seat, adjust the rear view mirror (Figure 30) to attain the best view out the rear window. Pull the lever rearward to tilt the mirror to reduce the brightness and glare of light. Side View Mirrors While sitting in the seat, have a helper adjust the side view mirrors (Figure 30) to attain the best view around the side of the machine. Figure 28 1. Tensioning cap 4. Top axle mounting hole 2. Spacers 5. Castor wheel 3.
Checking the Interlock Switches 1. Ensure that the parking brake is set. Remove your foot from the traction pedal and ensure that it is in neutral. 2. Move the throttle control to the mid-idle position. CAUTION 3. Turn the ignition key to the Run position. The glow indicator will light. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. • Do not tamper with the interlock switches.
• Part No. 95-8843, 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). a malfunction in the interlock system that should be corrected before resuming operation.
Operating Characteristics Practice driving the machine because it has a hydrostatic transmission and its characteristics are different than many turf maintenance machines. Some points to consider when operating the traction unit, cutting unit, or other implements are the transmission, engine speed, load on the cutting blades or other implement components, and the importance of the brakes.
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. Also, remove any debris which may have collected between the deck lift cylinders and the foam deck pads (Figure 35). Figure 35 1. Deck lift cylinder 2.
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 inspections of bearing condition and seal integrity should be conducted to avoid downtime. These bearings should be inspected seasonally and replaced if damaged or worn.
• 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 40 Figure 37 Center Cutting Unit Note: Deck may have to be raised to expose the grease fittings for the latch pivot and the lower link.
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 34
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 35
Engine Maintenance 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. • Service the air cleaner filter only when the service indicator requires it or every 400 hours (more frequently in extremely dusty or dirty conditions).
Servicing the Engine Oil and Filter Fuel System Maintenance Service Interval: After the first 50 hours Servicing the Fuel System Every 150 hours Change the oil and filter initially after the first 50 hours of operation; thereafter change the oil and filter every 150 hours. DANGER 1. Remove either drain plug (Figure 53) and let the oil flow into a drain pan. When the oil stops, install the drain plug. Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive.
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. Figure 55 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.
WARNING 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 disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Always connect the positive (red) battery cable before connecting the negative (black) cable. 4. Coat both battery connections with Grafo 112X (skin-over) grease, Toro Part No.
Figure 62 1. Fuses Figure 61 1. Read the Operator's Manual for fuse information. 2. Engine preheat—60A fuse 7. Powerpoint—10A fuse 8. Instuments—10A fuse 3. Engine, start—20A fuse 9. Control module—2A fuse 4. Headlights—10A fuse 10. Control module—2A fuse 5. Turn signal—10A fuse 11. Powerpoint—7.5A fuse 6. Power Seat—10A fuse Note: The cab fuses (Figure 62) are located in the fuse box in the cab headliner (model 30447 only). 40 2.
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. Jack up the front of the machine and support with jack stands. Figure 64 2. Remove the front wheels. 1. Brake housing 3.
Checking the Rear Wheel Toe-In 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. Service Interval: Every 800 hours 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. 2.
Cooling System Maintenance Servicing the Engine Cooling System Remove debris from the oil cooler and radiator daily. Clean them more frequently in dirty conditions. This machine is equipped with a hydraulically driven fan drive system that automatically (or manually) reverses to reduce radiator and screen debris build-up. While this feature can help reduce the time required to clean radiators and coolers, it does not eliminate the need for routine cleaning.
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 69) after every 100 operating hours. 1.
Figure 71 1. Hydraulic motor 2. Mounting bolts Figure 70 1. Belt 4. Belt guide 2. Eye bolt 5. Flange nut 3. Extension spring 6. Stop bolt 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. Position the hydraulic motor on the cutting unit after routing the belt around the pulleys. Mount the motor to the cutting unit with the bolts previously removed.
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 73 1. Traction pedal stop 2. Jam nuts 3.
Hydraulic System Maintenance Replacing the Hydraulic Filters Changing the Hydraulic Fluid Change the 2 hydraulic filters initially after the first 200 operating hours. Thereafter, change the filters after every 800 operating hours, in normal conditions. Service Interval: After the first 200 hours Every 800 hours Service Interval: After the first 200 hours Every 800 hours 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).
Checking the Hydraulic Lines and Hoses 1 2 Service Interval: Every 2 years Inspect the hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating. WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
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: 2.
Servicing the Castor Arm Bushings 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. Raise the cutting unit so that the wheels are off of the floor. Block the cutting unit so that it cannot accidentally fall. Figure 79 1. Height-of-cut chain 2.
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 82 1. Castor wheel 3. Bearing 2. Castor fork 4. Bearing spacer Figure 84 1. Hinge cover Figure 83 1. Castor wheel 3. Bearing 2. Castor pivot arm 4. Bearing spacer 2. Remove the bearing from the wheel hub and allow the bearing spacer to fall out (Figure 82 and Figure 83).
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 86 1. Blade bolt 2. Rotate the blade until the ends face forward and backward (Figure 85). Measure from the inside of the cutting unit to the cutting edge at the front of the blade.
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 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. Servicing the Spark Arrestor Muffler 7.
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 g014815 Electrical Schematic (Rev.
g017775 Electrical Schematic (Rev.
g017776 Electrical Schematic (Rev.
g017779 Electrical Schematic, GM 4000/4100 (Rev.
g017780 Electrical Schematic, GM 4010 (Rev.
g017781 Electrical Schematic, GM 4110 (Rev.
g017782 Electrical Schematic, GM 4010 (Rev.
g017783 Electrical Schematic, GM 4110 (Rev.
g017784 Electrical Schematic, GM 4110 Cab (Rev.
g017785 Electrical Schematic, GM 4110 Cab (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).
