Toro 30447 Manuals

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. Original Instructions (EN) *3374-304* A 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. Because in some areas there are local, state, or federal regulations requiring that a spark arrester be used on the engine of this machine, a spark arrester is incorporated with the muffler assembly. Genuine Toro spark arresters are approved by the USDA Forestry Service. Important: This engine is equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land without a spark arrester muffler maintained in working order, or the engine constricted, equipped, and maintained for the prevention of fire. Other states or federal areas may have similar laws. Introduction This machine is a ride-on, rotary-blade lawnmower intended to be used by professional, hired operators in commercial applications. It is primarily designed for cutting grass on well-maintained lawns in parks, sports fields, and on commercial grounds. It is not designed for cutting brush, mowing grass and other growth alongside highways, or for agricultural uses. Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product. Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Write the numbers in the space provided. Model No. Serial No. 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. Figure 1 1. Safety alert symbol This manual uses 2 other words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention. © 2012—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 2 Contact us at www.Toro.com. Printed in the USA. All Rights Reserved Contents Introduction .................................................................. 2 Safety ........................................................................... 4 Safe Operating Practices........................................... 4 Toro Mower Safety .................................................. 6 Engine Emission Certification................................... 7 Safety and Instructional Decals ................................. 7 Setup ...........................................................................13 Greasing the Machine .............................................13 Product Overview .........................................................14 Controls ...............................................................14 Specifications ........................................................17 Attachments/Accessories........................................17 Operation ....................................................................18 Before Operating ...................................................18 Adjusting the Mirrors..............................................26 Aiming the Headlights ............................................26 Starting and Stopping the Engine..............................26 Engine Cooling Fan Operation.................................27 Checking the Interlock Switches ...............................27 Pushing or Towing the Machine................................28 Jacking Points ........................................................28 Tie Downs ............................................................28 Operating Characteristics ........................................29 Operating Tips ......................................................29 Maintenance .................................................................31 Recommended Maintenance Schedule(s) ......................31 Service Interval Chart .............................................32 Lubrication ...............................................................32 Greasing the Bearings and Bushings..........................32 Engine Maintenance ..................................................36 Air Cleaner Maintenance .........................................36 Servicing the Engine Oil and Filter............................37 Fuel System Maintenance ...........................................37 Servicing the Fuel System ........................................37 Bleeding Air from the Injectors ................................38 Electrical System Maintenance ....................................38 Battery Care...........................................................38 Fuses ....................................................................39 Drive System Maintenance .........................................41 Changing the Planetary Gear Drive Oil......................41 Changing the Rear Axle Lubricant.............................41 Checking the Rear Wheel Toe-In ..............................42 Changing the Front Tires.........................................42 Cooling System Maintenance ......................................43 Servicing the Engine Cooling System ........................43 Brake Maintenance ....................................................44 Adjusting the Service Brakes ....................................44 Belt Maintenance ......................................................44 Servicing the Alternator Belt....................................44 Re-tensioning the Blade Drive Belts ..........................44 Replacing the Blade Drive Belt .................................45 Controls System Maintenance .....................................46 Adjusting the Throttle Cable....................................46 Adjusting the Traction Pedal Linkage ........................46 Hydraulic System Maintenance ....................................47 Changing the Hydraulic Fluid...................................47 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...............................49 Servicing the Castor Arm Bushings...........................50 Servicing the Castor Wheels and Bearings ..................50 Replacing the Cutting Unit Hinge Covers...................51 Blade Maintenance.....................................................52 Checking for a Bent Blade........................................52 Removing and Installing the Cutter Blade(s) ...............52 Inspecting and Sharpening the Cutter Blade(s) ............52 Correcting Cutting Unit Mismatch............................53 Spark Arrestor Maintenance ........................................54 Servicing the Spark Arrestor Muffler .........................54 Cab Maintenance .......................................................55 Cleaning the Cab Air Filters .....................................55 Storage ........................................................................56 Preparing for Seasonal Storage .................................56 Schematics ...................................................................57 3

Form No. 3370-876 Rev B Groundsmaster® 4100-D and 4110-D Rotary Mowers Model No. 30447—Serial No. 312000001 and Up Model No. 30449—Serial No. 312000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com. Original Instructions (EN) 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. Because in some areas there are local, state, or federal regulations requiring that a spark arrester be used on the engine of this machine, a spark arrester is incorporated with the muffler assembly. Genuine Toro spark arresters are approved by the USDA Forestry Service. Important: This engine is equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land without a spark arrester muffler maintained in working order, or the engine constricted, equipped, and maintained for the prevention of fire. Other states or federal areas may have similar laws. Introduction This machine is a ride-on, rotary-blade lawnmower intended to be used by professional, hired operators in commercial applications. It is primarily designed for cutting grass on well-maintained lawns in parks, sports fields, and on commercial grounds. It is not designed for cutting brush, mowing grass and other growth alongside highways, or for agricultural uses. Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product. Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Write the numbers in the space provided. Model No. Serial No. 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. Figure 1 1. Safety alert symbol This manual uses 2 other words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention. © 2012—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 2 Contact us at www.Toro.com. Printed in the USA. All Rights Reserved Contents Introduction................................................................. 2 Safety ........................................................................... 4 Safe Operating Practices....................................... 4 Toro Mower Safety............................................... 6 Sound Power Level............................................... 7 Sound Pressure Level ........................................... 7 Vibration Level .................................................... 7 Engine Emission Certification.............................. 7 Safety and Instructional Decals............................. 8 Setup ......................................................................... 14 1 Greasing the Machine ...................................... 14 2 Replacing the Warning Decal............................ 14 Product Overview...................................................... 15 Controls............................................................. 15 Specifications ..................................................... 18 Attachments/Accessories................................... 18 Operation................................................................... 19 Before Operating................................................ 19 Adjusting the Mirrors ......................................... 27 Aiming the Headlights........................................ 28 Starting and Stopping the Engine........................ 28 Engine Cooling Fan Operation ........................... 28 Checking the Interlock Switches ......................... 28 Pushing or Towing the Machine.......................... 29 Jacking Points..................................................... 30 Tie Downs ......................................................... 30 Operating Characteristics ................................... 30 Operating Tips................................................... 31 Maintenance............................................................... 33 Recommended Maintenance Schedule(s) ................ 33 Service Interval Chart......................................... 34 Lubrication............................................................. 34 Greasing the Bearings and Bushings.................... 34 Engine Maintenance............................................... 38 Air Cleaner Maintenance .................................... 38 Servicing the Engine Oil and Filter...................... 39 Fuel System Maintenance ....................................... 39 Servicing the Fuel System ................................... 39 Bleeding Air from the Injectors........................... 40 Electrical System Maintenance................................ 41 Battery Care ....................................................... 41 Fuses.................................................................. 42 Drive System Maintenance ..................................... 43 Changing the Planetary Gear Drive Oil.................................................................. 43 Changing the Rear Axle Lubricant....................... 44 Checking the Rear Wheel Toe-In......................... 45 Changing the Front Tires.................................... 45 Cooling System Maintenance.................................. 45 Servicing the Engine Cooling System .................. 45 Brake Maintenance................................................. 46 Adjusting the Service Brakes............................... 46 Belt Maintenance.................................................... 47 Servicing the Alternator Belt............................... 47 Re-tensioning the Blade Drive Belts .................... 47 Replacing the Blade Drive Belt............................ 47 Controls System Maintenance................................. 48 Adjusting the Throttle Cable............................... 48 Adjusting the Traction Pedal Linkage .................. 48 Hydraulic System Maintenance ............................... 49 Changing the Hydraulic Fluid ............................. 49 Replacing the Hydraulic Filters ........................... 50 Checking the Hydraulic Lines and Hoses............. 50 Adjusting the Counterbalance Pressure ............... 50 Mower Maintenance............................................... 51 Pivoting (Tilting) the Front Cutting Unit Upright .......................................................... 51 Pivoting the Front Cutting Unit Down ................ 52 Adjusting the Cutting Unit Pitch ......................... 52 Servicing the Castor Arm Bushings..................... 53 Servicing the Castor Wheels and Bearings............ 53 Replacing the Cutting Unit Hinge Covers ............ 54 Blade Maintenance ................................................. 54 Checking for a Bent Blade................................... 54 Removing and Installing the Cutter Blade(s).......................................................... 54 Inspecting and Sharpening the Cutter Blade(s).......................................................... 55 Correcting Cutting Unit Mismatch...................... 56 Spark Arrestor Maintenance ................................... 57 Servicing the Spark Arrestor Muffler................... 57 Cab Maintenance.................................................... 58 Cleaning the Cab Air Filters ................................ 58 Storage....................................................................... 59 Preparing for Seasonal Storage............................ 59 Schematics ................................................................. 60 3

(Models 30449 and 30447) Part No. 10177SL (Rev. A) Service Manual GroundsmasterR 4100--D & 4110--D Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing and repair of major systems and components on the Groundsmaster 4100--D (Model 30449) and 4110--D (Model 30447). REFER TO THE OPERATOR’S MANUAL FOR OPER- ATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. For reference, insert a copy of the Operator’s Manual and Parts Catalog for your machine into Chapter 2 of this service manual. Additional copies of the Operator’s Manual and Parts Catalog are avail- able on the internet at www.Toro.com. The Toro Company reserves the right to change product specifications or this publication without notice. This safety symbol means DANGER, WARNING or CAUTION, PERSONAL SAFETY INSTRUC- TION. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions may result in personal injury. NOTE: A NOTE will give general information about the correct operation, maintenance, service, testing or re- pair of the machine. IMPORTANT: The IMPORTANT notice will give im- portant instructions which must be followed to pre- vent damage to systems or components on the machine. E The Toro Company -- 2010, 2012 Groundsmaster 4110--D Groundsmaster 4100--D Groundsmaster 4100--D/4110--D This page is intentionally blank. Groundsmaster 4100--D/4110--D Table Of Contents Chapter 1 -- Safety General Safety Instructions 1 -- 2 . . . . . . . . . . . . . . . . . . Jacking Instructions 1 -- 5 . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals 1 -- 6 . . . . . . . . . . . . . . . . Chapter 2 -- Product Records and Maintenance Product Records 2 -- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance 2 -- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions 2 -- 2 . . . . . . . . . . . . . . . . Torque Specifications 2 -- 3 . . . . . . . . . . . . . . . . . . . . . . . Chapter 3 -- Kubota Diesel Engine Specifications 3 -- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 3 -- 3 . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs 3 -- 4 . . . . . . . . . . . . . . . . . . . . . . . . KUBOTA WORKSHOP MANUAL, DIESEL ENGINE, 03--M--E3B SERIES Chapter 4 -- Hydraulic System Specifications 4 -- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 4 -- 3 . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Schematic 4 -- 9 . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Flow Diagrams 4 -- 10 . . . . . . . . . . . . . . . . . . . Special Tools 4 -- 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 4 -- 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing 4 -- 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments 4 -- 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs 4 -- 74 . . . . . . . . . . . . . . . . . . . . . . . EATON MODEL 72400 SERVO CONTROLLED PIS- TON PUMP REPAIR INFORMATION EATON MODEL 74318 and 74348 PISTON MOTORS: FIXED DISPLACEMENT, VALVE PLATE DESIGN REPAIR INFORMATION Chapter 5 -- Electrical System General Information 5 -- 2 . . . . . . . . . . . . . . . . . . . . . . . . Special Tools 5 -- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 5 -- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical System Quick Checks 5 -- 17 . . . . . . . . . . . . . Adjustments 5 -- 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Testing 5 -- 20 . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs 5 -- 44 . . . . . . . . . . . . . . . . . . . . . . . Chapter 6 -- Axles, Planetaries and Brakes Specifications 6 -- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 6 -- 3 . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs 6 -- 4 . . . . . . . . . . . . . . . . . . . . . . . . Chapter 7 -- Chassis General Information 7 -- 1 . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs 7 -- 2 . . . . . . . . . . . . . . . . . . . . . . . . Chapter 8 -- Cutting Deck Specifications 8 -- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 8 -- 3 . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 8 -- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs 8 -- 6 . . . . . . . . . . . . . . . . . . . . . . . . Safety Product Records and Maintenance Kubota Diesel Engine Hydraulic System Electrical System Axles, Planetaries and Brakes Chassis Cutting Deck Groundsmaster 4100--D/4110--D This page is intentionally blank.