Form No. 3400-910 Rev A Groundsmaster® 4100 Rotary Mower Model No. 30604—Serial No. 316000001 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. 1 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. g028455 Figure 1 Genuine Toro spark arresters are approved by the USDA Forestry Service. 1.
Electrical System Safety...........................................44 Servicing the Battery...............................................44 Locating the Fuses..................................................45 Drive System Maintenance .........................................46 Adjusting the Traction-Pedal Angle...........................46 Checking the Planetary-Gear-Drive Oil .....................46 Changing the Planetary-Gear-Drive Oil .....................46 Checking the Rear-Axle Lubricant...........
Sound Pressure Level Safety This unit has a sound pressure level at the operator’s ear of 92 dBA, which includes an Uncertainty Value (K) of 1 dBA. This machine has been designed in accordance with EN ISO 5395:2013 and ANSI B71.4-2012. Sound pressure level was determined according to the procedures outlined in EN ISO 5395:2013. Improper use or maintenance by the operator or owner can result in injury.
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 58-6520 1. Warning—read the Operator's Manual for instructions on torquing the blade bolt/nut to 115 to 149 N∙m (85 to 110 ft-lb). 1. Grease 93-6674 98-4387 1. Crushing hazard, hand—read the instructions before servicing or performing maintenance. 1. Warning—wear hearing protection. 93-7272 1.
100-6578 1. Entanglement hazard, belt—do not operate the machine with the shields or guards removed; always keep the shields and guards in place; stay away from moving parts. 106-6754 1. Warning—do not touch the hot surface. 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts. 104-3579 1. Low height-of-cut adjustment 2. High height-of-cut adjustment 106-6755 1. Engine coolant under pressure. 3. Warning—do not touch the hot surface. 2.
114-0846 4. Pull the knob out to 1. Read the Operator’s engage the PTO. 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. 2.
120-4159 120-4129 1. Off 1. Beacon 3. Left-turn signal 2. Lights 2. Hazard light 4. Right-turn signal 3. On 4. Light-switch location 8. High 9. Traction drive 10. Low 11. Power takeoff (PTO) 5. Fast 12. Lower, left deck 6. Variable-speed adjustment 13. Lower, center deck 7. Slow 120-4130 1. Read the Operator’s Manual. 2. To engage the parking brake—1) Lock the pedals together; 2) Push down on the brake; 3) Pull out the parking brake knob. 14. Lower, right deck 120-6604 3. Parking brake 1.
121-3884 1. Engine—stop 3. Engine—start 2. Engine—preheat 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. 121-3887 1. Read the Operator’s Manual. 121-1599 1. Read the Operator’s Manual for information on fuses. 127-3700 1. Raise the left deck 4.
Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or smoking. 7. Wear eye protection; explosive gases can cause blindness and other injuries. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection. 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 5. Read the Operator's Manual. 10. Contains lead; do not discard.
7-2766 (Affix over Part No. 117-2754 for CE*) * This safety decal includes a slope warning required on the machine for compliance to the European Lawn Mower Safety Standard EN836:1997. The conservative maximum slope angles indicated for operation of this machine are prescribed by and required by this standard. 1. 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.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 2 3 4 Use Qty. No parts required – Grease the machine. Warning decal 1 Replace the warning decal. No parts required – Check the tire pressure. No parts required – Check the fluid levels. Media and Additional Parts Description Use Qty.
Product Overview 3 Controls Checking the Tire Pressure Note: Determine the left and right sides of the machine from the normal operating position. No Parts Required Procedure Check the tire pressure; refer to Checking the Tire Pressure (page 21). 9 Important: Maintain pressure in all tires to ensure a good quality-of-cut and proper machine performance. Do not underinflate the tires. 4 10 Checking the Fluid Levels g020756 Figure 3 1. Brake pedals 6. Hazard-light switch (optional) 2.
Parking-Brake Latch PTO Switch A knob on the left side of the console actuates the parking-brake lock (Figure 3). The PTO switch has 2 positions: OUT (START) and IN (STOP). Pull the PTO button out to engage the mower-deck blades. Push the button in to disengage the mower-deck blades (Figure 4). To engage the parking brake, connect the pedals with the locking latch, push down on both pedals, and pull the parking-brake latch out.
Power-Point Port Using the InfoCenter Control The power-point port is used to power optional electrical accessories (Figure 5). 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.
InfoCenter Icon Description SERVICE DUE InfoCenter Icon Description (cont'd.
InfoCenter Icon Description (cont'd.) Operator should change to the indicated state Symbols are often combined to form sentences. Some examples are shown below Settings The Settings menu allows you to customize and modify configuration variables on the InfoCenter display. About The About menu lists the model number, serial number, and software version of your machine.
Trans Speed Controls the maximum speed while in transport (high range) Smart Power Smart Power prevents bogging down in heavy turf by automatically controlling the machine speed and optimizing cutting performance. the passcode. Changing Protect Settings to the ON position hides the protected options and requires entering a passcode to change the setting in the Protected Menu. After you have set the passcode, you must turn the key switch off and then on to enable and save this feature.
Specifications Operation Note: Specifications and design are subject to change without notice. Note: Determine the left and right sides of the machine from the normal operating position.
Fuel Safety Checking the Engine-Oil Level Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine-Oil Level (page 41). 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. Checking the Cooling System • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills.
Checking the Tire Pressure • Monitor seals, hoses, and gaskets in contact with fuel as they may be degraded over time. Service Interval: Before each use or daily • Fuel-filter plugging may be expected for a time after converting to biodiesel blends. DANGER • Contact your distributor if you wish for more information Low tire pressure decreases machine side-hill stability. This could cause a rollover, which may result in personal injury or death. on biodiesel. Do not underinflate the tires.
Adjusting the Rollover Protection System (ROPS) Checking the Torque of the Wheel-Lug Nuts Service Interval: After the first hour WARNING After the first 10 hours To avoid injury or death from rollover: keep the roll bar in the raised locked position and use the seat belt. Every 200 hours Torque the wheel-lug nuts to 115 to 136 N∙m (85 to 100 ft-lb) in the order shown in Figure 10 and Figure 11. Ensure that the seat is secured with the seat latch.
Lowering the ROPS Adjusting the Height of Cut Important: Lower the roll bar only when absolutely necessary. Center Mower Deck The height of cut is adjustable from 25 to 127 mm (1 to 5 inches) in 13 mm (1/2 inch) increments. To adjust the height of cut on the center mower deck, 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.
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 Mower Decks To adjust the height of cut on the wing mower decks, add or remove an equal number of spacers from the caster forks, position the caster-wheel axles in the high or low height-of-cut holes in the caster forks, and secure the pivot arms to the selected height-of-cut bracket holes. Figure 15 6.
Adjusting the Skids Mount the skids in the lower position when operating at heights of cut greater than 64 mm (2-1/2 inches) and in the higher position when operating at heights of cut lower than 64 mm (2-1/2 inches). Figure 19 4. Push the caster spindle through the front caster arm. 5. Install the shims (as they were originally installed) and the remaining spacers onto the spindle shaft. 6. Remove the hairpin cotter and clevis pins from the caster-pivot arms (Figure 20). 7.
Adjusting the Blade Correcting a Mismatch Between Mower Decks To ensure proper operation of the mower deck, there must be a 10 to 16 mm (0.38 to 0.62 inch) clearance between the tips of the side and center mower-deck blades (Figure 24). 1. Raise mower deck so the blades are visible and block the center deck section so it cannot fall accidentally.
Setting up the Center Mower Deck Setting up the Wing Mower Decks 1. Rotate the blade on each spindle until the ends face forward and backward. 1. Rotate the blade of each spindle until the ends face forward and backward. 2. Measure from the floor to the front tip of the cutting edge. 2. Measure from the floor to the front tip of the cutting edge. 3.
Checking the Safety-Interlock Switches • Do not operate the machine while ill, tired, or under the • Service Interval: Before each use or daily • The machine has interlock switches in the electrical system. These switches are designed to stop the engine when operator rises from the seat while pressing the traction pedal. However, the operator may rise from the seat while the engine is running and the traction pedal is in NEUTRAL.
Rollover Protection System (ROPS) Safety 3. Turn the ignition key to the RUN position. • Do not remove the ROPS from the machine. 4. When the glow indicator dims, turn the ignition key to the START position. Release the key immediately when the engine starts and allow it to return to the RUN position. Note: The glow indicator will light. • Ensure that the seat belt is attached and that you can release it quickly in the event of an emergency. • Always wear your seat belt when the ROPS is up.
Reversing Fan Operation Adjusting the Mowing Speed The fan speed is controlled by the hydraulic-oil temperature and engine-coolant temperature. A reverse cycle is automatically initiated when either the engine coolant or hydraulic-oil temperature reaches a certain point. This reversal helps blow debris off the rear screen and lower the engine and hydraulic-oil temperatures. By simultaneously pressing the right and left buttons on the InfoCenter, the fan will complete a manually-initiated reverse cycle.
Selecting the Proper Height-of-Cut Setting Power prevents bogging down in heavy turf by automatically controlling the machine speed and optimizing cutting 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 need to raise your height-of-cut setting. 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.
After Operation After Operation Safety General Safety • Clean grass and debris from the cutting units, drives, mufflers, and engine to help prevent fires. Clean up oil or fuel spills. • Shut off the fuel while storing or transporting the machine. • Disengage the drive to the attachment whenever you are transporting or not using the machine. • Allow the engine to cool before storing the machine in Figure 30 any enclosure. 1.
Hauling the Machine • Use care when loading or unloading the machine into a trailer or a truck. • Use full-width ramps for loading the machine into a trailer or a truck. • Tie the machine down securely using straps, chains, cable, or ropes. Both front and rear straps should be directed down and outward from the machine. Locating the Tie-Down Points There are tie downs located at the front and rear sides of the machine (Figure 31).
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 After the first hour Maintenance Procedure • Torque the wheel-lug nuts. After the first 10 hours • Torque the wheel-lug nuts. • Check the alternator-belt tension. • Check the blade-drive-belt tension.
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. Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Monday Tuesday Wednesday Thursday Friday Saturday Check the safety-interlock operation. Check the brake operation. Check the engine-oil level. Check the cooling-system-fluid level.
Notation for Areas of Concern Inspection performed by: Item Date Information Service Interval Chart Figure 32 Premaintenance Procedures Pre-Maintenance Safety • • Keep all parts of the machine in good working condition • • and all hardware tightened, especially blade-attachment hardware. Replace all worn or damaged decals. Never allow untrained personnel to service the machine. Before adjusting, cleaning, or repairing the machine, do the following: 1. Move the machine to level ground. 2.
Lubrication • Use jack stands to support the machine and/or its components when required. • Carefully release pressure from components with stored Greasing the Bearings and Bushings energy. • If your machine requires major repairs or if you desire assistance, contact an Authorized Toro Distributor. Service Interval: Every 50 hours • Use only genuine Toro replacement parts and accessories. The machine has grease fittings that you must lubricate regularly with No. 2 lithium grease.
Figure 38 Figure 36 Figure 39 Center Mower Deck Note: You may need to raise the deck to expose the grease fittings for the latch pivot and the lower link. • 2 latch pivots (Figure 38) Note: You may need to manually trip the latches to gain access to the grease fittings (Figure 37). Use a prybar to close and open the latch. • 2 castor-fork-shaft bushings (Figure 39) • 3 spindle-shaft bearings—located under the pulley (Figure 40) • 2 idler-arm-pivot bushings (Figure 40) Figure 37 1.
Figure 40 Center-Deck-Lift Assemblies Wing-Deck-Lift Assemblies • 2 (each side) lift-arm-cylinder bushings (Figure 41) 4 wing-deck-lift cylinder (Figure 43) • 2 lift-arm ball joints (Figure 42) Figure 41 Figure 43 Figure 42 39
Engine Maintenance Wing Mower Decks • 1 caster-fork-shaft bushing (Figure 44) • 2 (each side) spindle-shaft bearings—located under the Engine Safety pulley Shut off the engine before checking the oil or adding oil to the crankcase. • 1 idler-arm-pivot bushings—located on the idler arm Servicing the Air Cleaner Service Interval: Before each use or daily—Check the air-cleaner indicator Every 50 hours—Inspect the air cleaner.
Figure 47 1. Air-cleaner safety filter 2. Reset the indicator (Figure 45) if it shows red. Checking the Engine-Oil Level Service Interval: Before each use or daily The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started. The crankcase capacity is approximately 5.7 L (6 US qt) with the filter. Use high-quality engine oil that meets the following specifications: • API Classification Level Required: CH-4, CI-4, or higher.
Changing the Engine Oil and Filter Service Interval: Every 250 hours 1. Start the engine and let it run 5 minutes to allow the oil to warm up. 2. Park the machine on a level surface, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Replace the engine oil and filter (Figure 49). Figure 48 Note: When using different oil, drain all old oil from the crankcase before adding new oil. Figure 49 4.
Servicing the Water Separator Fuel System Maintenance Service Interval: Before each use or daily—Drain water or other contaminants from the water separator. Servicing the Fuel System Every 400 hours Service the water separator as shown in Figure 50. Draining the Fuel Tank Service Interval: Every 800 hours (also if the fuel system is contaminated). Use clean fuel to flush out the tank.
Electrical System Maintenance 2 Electrical System Safety • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. • Battery acid is poisonous and can cause burns. Avoid g020758 contact with your skin, eyes, and clothing. Protect your face, eyes, and clothing when working with a battery. Figure 51 1. Battery cover • Battery gases can explode. Keep cigarettes, sparks, and 2.
Locating the Fuses 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. The traction-unit fuses are located under the power-center cover (Figure 53, Figure 54, and Figure 55). Remove the 2 screws securing the power-center cover to the frame and remove the cover (Figure 53). • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
Drive System Maintenance Note: The oil level should be at the bottom of the check-plug hole. 3. If the oil level is low, remove the plug at the 12 o’clock position and add oil until it begins to flow out of the hole at the 3 o’clock position. Adjusting the Traction-Pedal Angle 4. Install both plugs. 1. Loosen the 2 nuts and bolts securing the left side of the traction pedal to the bracket (Figure 56).
Note: If the level is low, add enough lubricant to bring the level up to the bottom of the hole. 6. Through the open hole, slowly fill the planetary with 0.65 L (22 oz) of high quality SAE 85W-140 wt gear lube. Important: If the planetary fills before the 0.65 L (22 oz) of oil is added, wait 1 hour or install the plug and move the machine approximately 10 feet to distribute the oil through the brake system. Then, remove the plug and add the remaining oil. 7. Install the plug. 8.
Cooling System Maintenance 6. Remove the drain plug from the gearbox and allow the oil to drain into a pan. Note: Remove the fill plug to ease in the draining of the oil. Cooling System Safety CAUTION Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns. • Do not remove the radiator cap when the engine is hot.
Brake Maintenance 3. If the coolant is low, add a 50/50 mixture of water and ethylene glycol anti-freeze. Important: Do not use water only or alcohol/methanol base coolants, as this may cause damage. 4. Install the radiator cap and expansion-tank cap. Adjusting the Service Brakes 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.
Belt Maintenance Servicing the Alternator Belt Service Interval: After the first 10 hours Every 100 hours Proper tension allows 10 mm (3/8 inch) of deflection when a force of 44 N∙m (10 ft-lb) is applied on the belt midway between the pulleys. If the deflection is not 10 mm (3/8 inch), loosen the alternator-mounting bolts (Figure 68). Note: Increase or decrease the alternator-belt tension and tighten the bolts. Check the deflection of the belt again to ensure that the tension is correct. Figure 67 1.
Figure 70 1. Hydraulic motor 2. Mounting bolts Figure 69 1. Belt 4. Belt guide 2. Eye bolt 5. Flange nut 3. Extension spring 6. Stop bolt 5. Lift the motor off the mower deck and lay it on top of the mower deck. 6. Remove the old belt from around the spindle pulleys and idler pulley. 7. Route the new belt around the spindle pulleys and idler-pulley assembly. Replacing the Blade-Drive Belt 8. Position the hydraulic motor on the mower deck after routing the belt around the pulleys.
Hydraulic System Maintenance High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 Material Properties: Viscosity, ASTM D445 Hydraulic System Safety St @ 40° C 44 to 48 St @ 100° C 7.9 to 8.5 140 to 160 Viscosity Index ASTM D2270 WARNING Pour Point, ASTM D97 Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
Changing the Hydraulic Fluid Service Interval: 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. Position the machine on a level surface, lower the mower decks, shut off the engine, and remove the key. 2.
Replacing the Hydraulic Filters Adjusting the Counterbalance Pressure Service Interval: After the first 200 hours Every 800 hours The counterbalance test port is used to test the pressure in the counterbalance circuit (Figure 74). The recommended counterbalance pressure is 2,241 kPa (325 psi). To adjust the counterbalance pressure, loosen the locknut, rotate the adjusting screw (Figure 74) clockwise to increase the pressure, or counterclockwise to decrease the pressure and tighten the locknut.
Mower Maintenance Pivoting (Tilting) the Center Mower Deck to the Upright Position 1 Note: Although not needed for normal maintenance procedures, the center mower deck can be pivoted (tilted) to an upright position. Should you desire to tilt the mower deck, proceed as follows: 2 1. Raise the center mower deck slightly off the floor, set the parking brake, and shut off the engine, and remove the ignition key. g020969 2. Remove the hairpin cotter securing the dampers to lift arms (Figure 75).
Adjusting the Mower-Deck Pitch Adjusting the Wing Mower Decks 1. Remove the cap screws and nuts securing the castor arm to the castor fork (Figure 78). Measuring the Mower-Deck Pitch 2. Position the shims, as required, to raise or lower the castor wheel until the mower deck has the correct pitch. Mower-deck pitch is the difference in height of cut from the front of the blade plane to the back of the blade plane. Use s a blade pitch of 8 to 11 mm (5/16 to 7/16 inch).
Figure 79 1. Caster-arm tube 2. Bushings Figure 81 5. Apply grease to the inside and outside of the new bushings. 6. Using a hammer and flat plate, drive the bushings into the mounting tube. 5. To assemble the caster wheel, push the bearing into the wheel hub. Servicing the Caster Wheels and Bearings Note: When installing the bearings, press on the outer face of the bearing. 6.
Blade Maintenance Replacing the Mower-Deck-Hinge Covers Blade Safety The hinge cover prevents debris from escaping at hinge points between mower decks. If cover(s) ever become damaged or worn they must be replaced. DANGER A worn or damaged blade can break, and a piece of the blade could be thrown at you or bystanders, resulting in serious personal injury or death. Trying to repair a damaged blade may result in discontinued safety certification of the product.
Removing and Installing the Mower Blade(s) 1. Position the machine on a level surface, raise the mower deck, engage the parking brake, put the traction pedal in NEUTRAL, put the PTO lever in the OFF position, shut off the engine, and remove the ignition key. The blade must be replaced if a solid object is hit, the blade is out of balance, or if the blade is bent. Always use genuine Toro replacement blades to ensure safety and optimum performance. 2.
Correcting a Mower-Deck Mismatch If there is mismatch between the blades, on a single mower deck, the grass will appear streaked when it is cut. This problem can be corrected by ensuring that the blades are straight and all of the blades are cutting on the same plane. Figure 86 1. Park the machine on a level surface of the shop floor. 1. Sharpen at the original angle. 2. Raise the height of cut to the highest position; refer to Adjusting the Height of Cut (page 23).
Storage Preparing for Seasonal Storage Traction Unit 1. Thoroughly clean the traction unit, mower decks, and the engine. 2. Check the tire pressure; refer to Checking the Tire Pressure (page 21). 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.
Notes: 62
International Distributor List Distributor: Agrolanc Kft Asian American Industrial (AAI) B-Ray Corporation Brisa Goods LLC Casco Sales Company Ceres S.A. CSSC Turf Equipment (pvt) Ltd. Cyril Johnston & Co. Cyril Johnston & Co. Fat Dragon Femco S.A. FIVEMANS New-Tech Co., Ltd ForGarder OU G.Y.K. Company Ltd. Geomechaniki of Athens Golf international Turizm Hako Ground and Garden Hako Ground and Garden Hayter Limited (U.K.) Hydroturf Int. Co Dubai Hydroturf Egypt LLC Irrimac Irrigation Products Int'l Pvt Ltd.
The Toro 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).
