Form No. 3376-200 Rev B Groundsmaster® 4100-D and 4110-D Rotary Mower Model No. 30602—Serial No. 313000001 and Up Model No. 30604—Serial No. 313000001 and Up Register at www.Toro.com.
This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet. 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 Air Cleaner Maintenance .........................................40 Servicing the Engine Oil and Filter............................41 Fuel System Maintenance ...........................................42 Servicing the Fuel System ........................................42 Servicing the Water Separator ..................................42 Electrical System Maintenance ....................................43 Battery Care...........................................................43 Fuses .............
Safety This machine meets or exceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-2012 specifications in effect at the time of production. • Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means Caution, Warning, or Danger—personal safety instruction. Failure to comply with the instruction may result in personal injury or death.
Maintenance and Storage • Stay alert for holes in the terrain and other hidden hazards. • Use care when using heavy equipment. • • • • • • • • • • • • • • • • • Keep all nuts, bolts, and screws tight to be sure the equipment is in safe working condition. – Do not turn sharply. Use care when reversing. – Use counterweight(s) or wheel weights when suggested in the Operator's Manual. Watch out for traffic when crossing or near roadways.
Toro Mower Safety • This machine is not designed or equipped for on-road use and is a “slow-moving vehicle”. If you must cross or travel on a public road, you should be aware of and comply with local regulations, such as required lights, slow moving vehicle signs, and reflectors. The following list contains safety information specific to Toro products or other safety information that you must know that is not included in the CEN, ISO, or ANSI standards.
Sound Pressure Level-Model 30602 This unit has a sound pressure level at the operator’s ear of 90 dBA, which includes an Uncertainty Value (K) of 1 dBA. Sound pressure level was determined according to the procedures outlined in EN 836. Sound Pressure Level-Model 30604 This unit has a sound pressure level at the operator’s ear of 90 dBA, which includes an Uncertainty Value (K) of 1 dBA. Sound pressure level was determined according to the procedures outlined in EN 836.
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 100-5622 1. Height of cut adjustment 106-4251 1. Height of cut 100-5623 1. Low height of cut adjustment 2. High height of cut adjustment 104-3579 1.
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. Tipping hazard—lower the cutting unit when driving down slopes; slow machine before turning, do not turn at high speeds 8.
93-7275 1. Read the Operator's Manual. 2. Do not use starting aids. 120–4159 106-6754 1. Off 2. Lights 1. Warning—do not touch the hot surface. 3. On 4. Light switch location 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts. 8. High 9. Traction drive 10. Low 11. Power take-off (PTO) 5. Fast 12. Lower left deck 6. Variable speed adjustment 13. Lower center deck 7. Slow 14. Lower right deck 100-6578 1.
7–2718 106-6754 1. Warning—do not touch the hot surface. 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts. 93-7272 1. Cutting/dismemberment hazard; fan—stay away from moving parts. 106-6755 1. Engine coolant under pressure. 3. Warning—do not touch the hot surface. 2. Explosion hazard—read the Operator's Manual. 4. Warning—read the Operator's Manual. 117–2787 1. Headlights, 15A fuse 2. Heater, 15A fuse 4. Windshield wipers, 15A fuse 5.
0–4129 1. Beacon 3. Left turn signal 2. Hazard light 4. Right turn signal 120–8947 1. Warning—read the Operator’s Manual. 4. If the roll bar is raised, wear the seat belt. 2. There is no rollover 5. If the roll bar is lowered, protection when the roll do not wear the seat belt. bar is down. 3. There is rollover protection 6. Drive slowly when turning. when the roll bar is up. 120–4130 121–1592 1. Cruise control not set 2. Cruise control switch 3. Cruise control set 1. Read the Operator’s Manual.
121–1599 1. Read the Operator’s Manual for information on fuses. 114–0846 1. Read the Operator’s Manual for information on starting the engine—1)Set to neutral; 2)Engage the brake; 3)Set the engine speed to slow; 4)Turn the ignition key to preheat; 5)Turn the ignition key to engine start. 4. Pull the knob out to engage the PTO. 2.
121–1678 1. Read the Operator’s Manual for maintenance information.
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.
Product Overview Tilt Steering Lever Controls Press the lever (Figure 3) 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 This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure.
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. To switch between the High and Lo range, the decks must be raised, PTO disengaged, cruise control disengaged, traction pedal in neutral position and the machine must be moving at a slow speed. Lift Switches The lift switches (Figure 4) raise and lower the cutting units.
Using the InfoCenter LCD Display The InfoCenter LCD display shows information about your machine such as the operating status, various diagnostics and other information about the machine (Figure 9) There is a splash screen and main information screen of the InfoCenter. You can switch between the splash screen and main information screen, at any time, by pressing any of the InfoCenter buttons and then selecting the appropriate directional arrow. 1 TORO Figure 7 1. Wind shield wiper switch 3.
InfoCenter Icon Description SERVICE DUE InfoCenter Icon Description (cont'd.
InfoCenter Icon Description (cont'd.) Service Symbols are often combined to form sentences. Some examples are shown below Menu Item Description Hours Lists the total number of hours that the machine, engine and fan have been on, as well as the number of hours the machine has been transported and has overheated. Counts Lists the number of preheats and starts the machine has experienced.
To Set the Auto Idle * Only "operator-faced" text is translated. Faults, Service, and Diagnostics screens are "service-faced". Titles will be in the selected language, but menu items are in English. • In the Settings Menu, scroll down to Auto Idle. • Press the right button to change the auto idle time About between OFF, 8S, 10S, 15S, 20s, & 30S. Menu Item Description Model Lists the model number of the machine. SN Lists the serial number of the machine.
Specifications Note: Specifications and design are subject to change without notice. Width of cut overall 315 cm (124 inches) front cutting unit 137 cm (54 inches) side cutting unit 94 cm (37 inches) front and one side cutting unit 226 cm (89 inches) Overall width cutting units down 323 cm (127 inches) cutting units up (transports) 180 cm (71 inches) Overall length 366 cm (144 inches) Height 140 cm (55 inches) Height with ROPS Height with cab 217 cm (85.3 inches) 237 cm (93.
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 10 1. Dipstick 2. Oil fill cap Checking the Engine Oil 4. If the oil level is low, remove the fill cap (Figure 10) and add oil until it is between the full and add marks.
This machine can also use a biodiesel blended fuel of up to B20 (20% biodiesel, 80% petrodiesel). The petrodiesel portion should be low or ultra low sulfur. Observe the following precautions: • The biodiesel portion of the fuel must meet specification ASTM D6751 or EN14214. • The blended fuel composition should meet ASTM D975 or EN590. • Painted surfaces may be damaged by biodiesel blends. • Use B5 (biodiesel content of 5%) or lesser blends in cold Figure 11 weather.
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 29.3 liters (7.75 U.S. gallons) of high quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter.
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 2.4 liters (80 oz.). 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 15) and make sure that the lubricant is up to the bottom of the hole.
height-of-cut on the front cutting unit, position the castor wheel axles in the upper or lower holes of the 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.
Note: When using 25 mm (1 inch), 38 mm (1-1/2 inch), or occasionally 51 mm (2 inch) 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. 1.
3. Push the castor spindle through the castor arm. Install the shims (as originally installed) and the remaining spacers onto the spindle shaft. Install the tensioning cap to secure the assembly. 4. Remove the hairpin cotter and clevis pins from the castor pivot arms (Figure 23). 5. Rotate tension rod to raise or lower pivot arm until holes are aligned with selected height-of-cut bracket holes in the cutting unit frame (Figure 23 and Figure 24). Figure 25 6.
8. To ease measuring blade plane, raise the height of cut to 7.6 to 10.1 cm (3 to 4 inches); 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. Loosen the flange nut, securing the idler pulley, to release the belt tension on each cutting unit. Figure 27 Front Cutting Unit Setup Rotate blade on each spindle until the ends face forward and backward. Measure from the floor to the front tip of the cutting edge.
Figure 31 1. Side view mirrors 2. Rear view mirror Figure 30 1. Front castor arm 2. Shims 3. Lever 3. Front castor fork Aiming the Headlights Matching Height Of Cut Between Cutting Units 1. Loosen the mounting nuts and position each headlight so that it points straight ahead. Tighten the mounting nut just enough to hold the headlight in position. 1. Position blade side to side on outside spindle of both side cutting units.
4. To stop the engine, move the PTO switch to the Off position, set the parking brake, return the throttle setting to low idle and rotate the ignition key to Off. Remove the key from the switch to prevent accidental starting. Operator Allows the operator to adjust the machine’s maximum mowing speed (low range), within the supervisors pre-adjusted settings.
strongly recommended that the engine be stopped before rising from the seat. 1. To lower the roll bar, remove the hairpin cotters and the two pins (Figure 32). To check the operation of the interlock switches, perform the following procedure: 1. Drive the machine slowly to a large, relatively open area. Lower the cutting unit, stop the engine, and apply the parking brake. 2. Sit on the seat and depress the traction pedal. Try to start the engine. The engine should not crank.
Power prevents bogging down in heavy turf by automatically controlling the machine speed and optimizing cutting performance. 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.
Select the Proper Height-of-Cut Setting to Suit Conditions Maximizing Air Conditioner Performance Remove approximately 25 mm (1 inch) or no more than 1/3 of the grass blade when cutting. In exceptionally lush and dense grass, you may have to raise the height-of-cut to the next setting. • To limit solar heating, park the machine in a shaded area Mow at Proper Intervals • Operate the air conditioner blower at the mid speed Under most normal conditions you will need to mow approximately every 4-5 days.
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 • • • • After the first 200 hours • Change the front planetary gear oil. • Change the rear axle oil. Before each use or daily • • • • • • • Check the engine oil level. Check the coolant level. Check the hydraulic fluid level. Check the tire pressure.
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.
Lubrication Greasing the Bearings and Bushings The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If the machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation or immediately after every washing.
Figure 41 • Castor fork shaft bushings (2) (Figure 42) • Spindle shaft bearings (3) (located under the pulley) (Figure 43) • Idler arm pivot bushings (2) (Figure 43) Figure 42 Figure 43 Center Lift Assemblies • Lift arm cylinder bushings (2 each) (Figure 44) • Lift arm ball joints (2) (Figure 45) Figure 45 Figure 44 39
Engine Maintenance Wing Lift Assemblies Wing lift cylinder (4) (Figure 46) 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 Service Interval: Every 250 hours Change the oil and filter every 250 hours. 1. Remove the drain plug (Figure 51) and let the oil flow into a drain pan. When all the oil is drained, install the drain plug. Figure 49 1. Air cleaner primary filter Figure 51 1. Engine oil drain plug Figure 50 2. Remove the oil filter (Figure 52). Apply a light coat of clean oil to the new filter seal before screwing it on. Do not overtighten. 1.
Fuel System Maintenance Servicing the Fuel System 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. Figure 53 1. Water separator filter canister • 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. 3. Clean the area where the filter canister mounts. 4.
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.
jelly, or light grease to prevent corrosion. Slide the rubber boot over the positive terminal. The cab fuses (Figure 59 & Figure 60) are located in the fuse box in the cab headliner (Cab model only). 4. Close the battery cover. Fuses The traction unit fuses (Figure 56 thru Figure 58) are located under the power center cover. Remove the two Allen head screws securing the power center cover to the frame and remove the cover (Figure 56). Figure 59 1. Cab fuse box 2. Fuses Figure 56 1.
Drive System Maintenance Adjusting the Traction Pedal Angle The traction pedal operating angle can be adjusted for operator comfort. Figure 62 1. Loosen the two nuts and bolts securing the left side of the traction pedal to the bracket (Figure 61). 1. Check/drain plug 2. Place a drain pan under the planetary hub, remove plug and allow oil to drain. 3. Place a drain pan under the brake housing, remove the drain plug and allow the oil to drain (Figure 42). Figure 61 1. Traction pedal g020680 2.
Changing the Rear Axle Lubricant 7. Add enough oil to bring the level up to the bottom of the check plug holes; refer to Checking the Rear Axle Lubricant, and Checking the Rear Axle Gear Box Lubricant. Service Interval: After the first 200 hours 8. Install the plugs. Every 800 hours Change the oil initially after the first 200 hours of operation and every 800 hours of operation thereafter. Checking the Rear Wheel Toe-In 1. Position the machine on a level surface. 2.
Cooling System Maintenance Brake Maintenance Servicing the Engine Cooling System Adjust the service brakes when there is more than 25 mm (1 inch) 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. Adjusting the Service Brakes Remove debris from the oil radiator/oil cooler daily. Clean them more frequently in dirty conditions. 1.
Belt Maintenance Servicing the Alternator Belt Service Interval: After the first 10 hours Every 100 hours Check the condition and tension of the belt (Figure 69) after every 100 operating hours. 1. Proper tension will allow 10 mm (3/8 inch) deflection when a force of 44 N (10 lb) is applied on the belt midway between the pulleys. 2. If the deflection is not 10 mm (3/8 inch), loosen the alternator mounting bolts (Figure 69). Increase or decrease the alternator belt tension and tighten the bolts.
Re-tensioning the Blade Drive Belts idler arm to pass by the stop bolt (Figure 70). Move the idler pulley away from the belt to release belt tension. Note: If the stop bolt is ever removed from the mounting tab, make sure it is reinstalled in the hole that aligns the stop bolt head with the idler arm. Service Interval: After the first 10 hours Every 50 hours 4. Remove the bolts securing the hydraulic motor to the cutting unit (Figure 71).
Replacing the Hydraulic Filters Hydraulic System Maintenance Service Interval: Every 800 hours Change the 2 hydraulic 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: Every 800 hours Change the hydraulic fluid after every 800 operating hours, in normal conditions.
Adjusting the Counterbalance Pressure The counterbalance test port (Figure 75) is used to test the pressure in the counterbalance circuit. Recommended counterbalance pressure is 2241 kPa (325 psi). To adjust the counterbalance pressure, loosen the locknut, rotate the adjusting screw (Figure 75) clockwise to increase the pressure or counterclockwise to decrease the pressure and tighten the locknut. The engine must be running at high idle, the deck lowered and in float to check pressure.
Mower Maintenance 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 (Tilting) the Front Cutting Unit Upright Pivoting the Front Cutting Unit Down 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.
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. 1 3. Pull the castor spindle out of the mounting tube. Allow the thrust washer and spacer(s) to remain on the bottom of the spindle. 2 4. Insert a pin punch into the top or bottom of the mounting tube and drive the bushing out of the tube (Figure 80).
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 81 1. Castor bolt 3. Bearing 2. Castor fork 4. Bearing spacer Figure 83 Figure 82 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 81 and Figure 82).
Blade Maintenance Checking for a Bent Blade After striking a foreign object, inspect the machine for damage and make repairs before restarting and operating the equipment. Torque all the spindle pulley nuts to 176 to 203 N-m (130 to 150 ft-lb). Figure 85 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.
DANGER If the blade is allowed to wear, a slot will form between the sail and flat part of the blade. 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 87 1. Sharpen at original angle Note: Remove the blades and sharpen them on a grinder.
Cab Maintenance 6. Compare the measurements of the outer blades with the center blade. The center blade must not be more than 10 mm (3/8 inch) lower than the outer blades. If the center blade is more than 10 mm (3/8 inch) lower than the outer blades, proceed to step 7 and add shims between the spindle housing and the bottom of the cutting unit. Cleaning the Cab Air Filters Service Interval: Every 250 hours (Replace them if they are torn or excessively dirty.) 7.
Cleaning the Air Conditioning Coil Cleaning the A/C Condenser Screen Service Interval: Every 250 hours (Clean more frequently in extremely dusty or dirty conditions) Service Interval: Every 50 hours (Clean more frequently in extremely dusty or dirty conditions) 1. Stop the engine and remove the key. 1. Stop the engine and remove the key. 2. Remove the (4) screws securing the fan and the condenser cover to the fan mount (Figure 89). 2.
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 Hydraulic Schematic (Rev.
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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).
