Form No. 3391-680 Rev A Groundsmaster® 4100 Rotary Mower Model No. 30604—Serial No. 315000001 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. your product ready. Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided. 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 Belt Maintenance ......................................................48 Servicing the Alternator Belt ....................................48 Re-tensioning the Blade Drive Belts ..........................48 Replacing the Blade Drive Belt .................................49 Hydraulic System Maintenance ....................................50 Changing the Hydraulic Fluid...................................50 Replacing the Hydraulic Filters .................................
Safety • Thoroughly inspect the area where the equipment is to This machine has been designed in accordance with EN ISO 5395:2013 and ANSI B71.4-2012. • 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.
– Do not turn sharply. Use care when reversing. Maintenance and Storage – Use counterweight(s) or wheel weights when suggested in the Operator's Manual. • Keep all nuts, bolts, and screws tight to be sure the equipment is in safe working condition. • Watch out for traffic when crossing or near roadways. • Stop the blades from rotating before crossing surfaces • Never store the equipment with fuel in the tank inside a building where fumes may reach an open flame or spark. other than grass.
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 This unit has a sound pressure level at the operator’s ear of 92 dBA, which includes an Uncertainty Value (K) of 1 dBA. Sound pressure level was determined according to the procedures outlined in EN 836. Vibration Level Hand-Arm Measured vibration level for right hand = 1.1 m/s2 Measured vibration level for left hand = 1 m/s2 Uncertainty Value (K) = 0.5 m/s2 Measured values were determined according to the procedures outlined in EN 836. Whole Body Measured vibration level = 0.
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 127-3700 1. Raise left deck 4. Lock engine speed 2. Raise center deck 5. Unlock engine speed 1.
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.
130-6042 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.
Tilt Steering Lever Product Overview 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 A knob on the left side of the console actuates the parking brake lock (Figure 3). To engage the parking brake, connect the pedals with the locking latch, push down on both pedals, and pull the parking brake latch out.
Seat Back Adjusting Lever high range. To switch between the High and Low 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. Move the lever to adjust the seat back angle (Figure 6). Weight gauge Lift Switches Indicates when the seat is adjusted to the weight of the operator (Figure 6). Height adjustment is made by positioning the suspension within the range of the green region.
Using the InfoCenter LCD Display InfoCenter Icon Description SERVICE DUE The InfoCenter LCD display shows information about your machine such as the operating status, various diagnostics and other information about the machine (Figure 7) 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.
InfoCenter Icon Description (cont'd.) InfoCenter Icon Description (cont'd.) Denied or not allowed Operator should change to indicated state Engine Start Symbols are often combined to form sentences.
Settings About The Settings menu allows you to customize and modify configuration variables on the InfoCenter display. Service 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. The About menu lists the model number, serial number, and software version of your machine.
Setting 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, and 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 217 cm (85.
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 2. Oil fill cap Checking the Engine Oil 4. If the oil level is low, remove the fill cap (Figure 8) and add oil until it is between the full and add marks.
Biodiesel Ready 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. Figure 9 • Use B5 (biodiesel content of 5%) or lesser blends in cold 1. Expansion tank 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 L (7.75 US 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 13) 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 21). 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 21 and Figure 22). Figure 23 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 (page 27) 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 25 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 29 1. Side view mirrors 2. Rear view mirror Figure 28 1. Front castor arm 2. Shims 3. Lever 3. Front castor fork Aiming the Headlights Matching the 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.
Operator 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. Allows the operator to adjust the machine’s maximum mowing speed (low range), within the supervisors pre-adjusted settings.
Important: Lower the roll bar only when absolutely necessary. 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 30). 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.
• Only use DOT approved straps when securing the machine can be slowly moved without damaging the transmission. machine to a trailer. 3. Close the bypass valves before starting the engine. Torque to 70 N-m (52 ft-lb) to close the valve. • Secure in all four corners. Operating Characteristics Practice driving the machine because it has a hydrostatic transmission and its characteristics are different than many turf maintenance machines.
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 33). Figure 32 1. Transport latch (side cutting units) Figure 33 Operating Tips 1. Deck lift cylinder 2.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Download a free copy of the schematic by visiting www.Toro.com and searching for your machine from the Manuals link on the home page. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 10 hours • Torque the wheel lug nuts. • Check the alternator belt tension. • Check the blade drive belt tension.
Service Interval Chart Figure 34 37
Lubrication Greasing the Bearings and Bushings The machine has grease fittings that must be lubricated regularly with No. 2 general-purpose, lithium-based 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 39 • Castor fork shaft bushings (2) (Figure 40) • Spindle shaft bearings (3) (located under the pulley) (Figure 41) • Idler arm pivot bushings (2) (Figure 41) Figure 40 Figure 41 Center Lift Assemblies • Lift arm cylinder bushings (2 each) (Figure 42) • Lift arm ball joints (2) (Figure 43) Figure 43 Figure 42 39
Engine Maintenance Wing Lift Assemblies Wing lift cylinder (4) (Figure 44) 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 49) and let the oil flow into a drain pan. When all the oil is drained, install the drain plug. Figure 47 1. Air cleaner primary filter Figure 49 1. Engine oil drain plug Figure 48 2. Remove the oil filter (Figure 50). 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 51 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.
Drive System Maintenance jelly, or light grease to prevent corrosion. Slide the rubber boot over the positive terminal. 4. Close the battery cover. Fuses Adjusting the Traction Pedal Angle The traction unit fuses (Figure 54 thru Figure 56) are located under the power center cover. The traction pedal operating angle can be adjusted for operator comfort. Remove the two Allen head screws securing the power center cover to the frame and remove the cover (Figure 54). 1.
Figure 58 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). g020680 Figure 59 1. Drain plug 2. Brake housing 4. When all of the oil has drained from both locations, re-install the plug in the brake housing. 5. Rotate the wheel until the open plug hole in the planetary is at the twelve o'clock position. 6.
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 (page 26), and Checking the Rear Axle Gear Box Lubricant (page 26). 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 65) 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 65). Increase or decrease the alternator belt tension and tighten the bolts.
Note: Make sure the belt is positioned on the spring side of the belt guide (Figure 66). Figure 67 1. Hydraulic motor 5. Remove the old belt from around the spindle pulleys and idler pulley. Figure 66 1. Belt 4. Belt guide 2. Eye bolt 5. Flange nut 3. Extension spring 6. Stop bolt 2. Mounting bolts 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.
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 71) 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 71) 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 76).
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 77 1. Castor bolt 3. Bearing 2. Castor fork 4. Bearing spacer Figure 79 Figure 78 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 77 and Figure 78).
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 81 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 83 1. Sharpen at original angle Note: Remove the blades and sharpen them on a grinder.
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. Storage 7. Remove the bolts, flat washers, lock washers, and nuts from the outer spindle in the area where the shims must be added.
Notes: 58
International Distributor List Distributor: Country: Phone Number: Distributor: Phone Number: 57 1 236 4079 Colombia Japan 81 3 3252 2285 Czech Republic 420 255 704 220 420 255 704 Slovakia 220 Argentina 54 11 4 821 9999 Russia 7 495 411 61 20 Ecuador 593 4 239 6970 Finland 358 987 00733 Agrolanc Kft Balama Prima Engineering Equip. B-Ray Corporation Hungary Hong Kong Korea 36 27 539 640 852 2155 2163 82 32 551 2076 Maquiver S.A. Maruyama Mfg. Co. Inc. Mountfield a.s.
Toro General Commercial Product 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).
