Main
(Model 30413)
Service Manual
EThe Toro Company -- 2008, 2012
GroundsmasterR4100--D
Preface
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Safety
General Safety Instructions
Before Operating
While Operating
Maintenance and Service
Jacking Instructions
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Chapter 2
Product Records and Maintenance
Table of Contents
Product Records
Maintenance
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Torque Specifications
Fastener Identification
Using a Torque Wrench with an Offset Wrench
Groundsmaster 4100--DPage 2 --4Product Records and Maintenance
Standard Torque for Dry,Zinc Plated and Steel Fasteners (Inch Series)
Standard Torque for Dry,Zinc Plated and Steel Fasteners (Metric Series)
Other Torque Specifications
Conversion Factors
Chapter 3
Kubota Diesel Engine
Stopping the Engine
Groundsmaster 4100--D Page 3 --3 KubotaDiesel Engine
Kubota Diesel Engine
Groundsmaster 4100--DPage 3 --4Kubota Diesel Engine
Air Filter System
Figure 1
VACUATOR DIRECTION
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Groundsmaster 4100--DPage 3 --6Kubota Diesel Engine
Exhaust System
Figure 5
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Groundsmaster 4100--DPage 3 --8Kubota Diesel Engine
Fuel System
Figure 7
DANGER
Groundsmaster 4100--DPage 3 --10Kubota Diesel Engine
Radiator
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Groundsmaster 4100--DPage 3 --12Kubota Diesel Engine
Engine
Figure 9
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Groundsmaster 4100--DPage 3 --16Kubota Diesel Engine
Spring Coupler
Figure 16
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Chapter 4
Hydraulic System
Groundsmaster 4100--DHydraulic System Page 4 -- 2
Towing TractionUnit
Check Hydraulic Fluid
Hydraulic Hoses
Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting)
Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port)
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Hydraulic Schematic
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Groundsmaster 4100--DHydraulic System Page4 -- 10
Hydraulic Flow Diagrams
Traction Circuit (4WD Forward Shown)
Traction Circuit: 4WD (Mow)
Groundsmaster 4100--DHydraulic System Page4 -- 12
Traction Circuit (TransportForward Shown)
Traction Circuit: Transport( 2WD)
Groundsmaster 4100--DHydraulic System Page4 -- 14
Lower Cutting Deck (LH Deck Shown)
Lower Cutting Deck
Groundsmaster 4100--DHydraulic System Page4 -- 16
Raise Cutting Deck (LH Deck Shown)
Raise Cutting Deck
Groundsmaster 4100--DHydraulic System Page4 -- 18
Mow Circuit (All Deck Motors Rotating)
Mow Circuit
Mow Circuit Cutting Deck Blade Braking
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Groundsmaster 4100--DHydraulic System Page4 -- 22
Steering Circuit (Left Turn Shown)
Steering Circuit
Groundsmaster 4100--DHydraulic System Page4 -- 24
Engine Cooling Fan Circuit (Forward Direction Shown)
Engine Cooling Fan Circuit
Special Tools
Hydraulic Pressure Test Kit
Hydraulic Tester (Pressureand Flow)
Hydraulic Test Fitting Kit
Measuring Container
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Testing
Groundsmaster 4100--DHydraulic System Page4 -- 32
Traction Circuit Charge Pressure (Using Pressure Gauge)
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Groundsmaster 4100--DHydraulic System Page4 -- 34
Traction Circuit Relief Pressure (Using Pressure Gauge)
FORWARD TRACTION CIRCUIT RELIEF PRESSURE TEST SHOWN
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Groundsmaster 4100--DHydraulic System Page4 -- 36
Counterbalance Pressure (Using Pressure Gauge)
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Groundsmaster 4100--DHydraulic System Page4 -- 38
Rear Traction Circuit (RV) Relief Pressure (Using Pressure Gauge)
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Groundsmaster 4100--DHydraulic System Page4 -- 40
Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge)
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Groundsmaster 4100--DHydraulic System Page4 -- 42
Cutting Deck Circuit Pressure (Using Pressure Gauge)
NOTE: CENTER DECK PRESSURE TEST SHOWN
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Groundsmaster 4100--DHydraulic System Page4 -- 44
PTO Relief Pressure (Using Tester with Pressure Gauges and Flow Meter)
CENTER DECK PTO RELIEF PRESSURE TEST SHOWN
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Groundsmaster 4100--DHydraulic System Page4 -- 46
Cutting Deck Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter)
NOTE:CENTERGEARPUMP SECTION FLOW TEST SHOWN
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Groundsmaster 4100--DHydraulic System Page4 -- 48
Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauges and Flow Meter)
CENTER CUTTING DECK MOTOR CASE DRAIN LEAKAGE TEST SHOWN
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Groundsmaster 4100--DHydraulic System Page4 -- 50
Steering Circuit Relief Pressure (Using Pressure Gauge)
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Groundsmaster 4100--DHydraulic System Page4 -- 52
Lift/Lower Circuit Relief Pressure (Using Pressure Gauge)
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Groundsmaster 4100--DHydraulic System Page4 -- 54
Steering and Lift/Lower Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter)
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Groundsmaster 4100--DHydraulic System Page4 -- 56
Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac)
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Groundsmaster 4100--DHydraulic System Page4 -- 58
Engine Cooling Fan Circuit Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter)
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Adjustments
Adjust Cutting Deck Flow Control Valve
General Precautions for Removing and Installing Hydraulic System Components
Check Hydraulic Lines and Hoses
Flush Hydraulic System
Charge Hydraulic System
Groundsmaster 4100--DHydraulic System Page4 -- 64
Hydraulic Reservoir
Figure 47
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Groundsmaster 4100--DHydraulic System Page4 -- 66
Hydraulic Oil Cooler
Figure 48
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Groundsmaster 4100--DHydraulic System Page4 -- 68
Gear Pump
Figure 49
79 to 84 ft--lb (108 to 113 N-- m)
103to 118ft--lb (140 to 160 N--m)
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Gear Pump Service
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Traction Circuit
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Groundsmaster 4100--DHydraulic System Page4 -- 74
Piston (Traction) Pump
Figure 53
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Groundsmaster 4100--DHydraulic System Page4 -- 76
Piston (Traction) Pump Service
Figure 55
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Groundsmaster 4100--DHydraulic System Page4 -- 78
Rear Axle Motor
Figure 56
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Groundsmaster 4100--DHydraulic System Page4 -- 80
Front Wheel Motors
Figure 57
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Rear Axle and Front Wheel Motor Service
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Groundsmaster 4100--DHydraulic System Page4 -- 84
4WD Manifold
Figure 59
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4WD Manifold Service
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Groundsmaster 4100--DHydraulic System Page4 -- 88
Filter Manifold
RIGHT
Figure 61
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Filter Manifold Service
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Steering and Cooling Fan Circuits
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Groundsmaster 4100--DHydraulic System Page4 -- 94
Steering Valve
Figure 64
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Steering Valve Service
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Groundsmaster 4100--DHydraulic System Page4 -- 98
Steering Cylinder
Figure 67
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Groundsmaster 4100--DHydraulic System Page 4 --100
Steering Cylinder Service
Figure 68
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Groundsmaster 4100--DHydraulic System Page 4 --102
Engine Cooling Fan Motor
Figure 69
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Engine Cooling Fan Motor Service
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Groundsmaster 4100--DHydraulic System Page 4 --108
Fan Drive Manifold
Figure 75
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Fan Drive Manifold Service
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Mow Circuit
Cutting Deck Motor
Cutting Deck Motor Service
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Groundsmaster 4100--DHydraulic System Page 4 --118
Deck Manifolds
Figure 85
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Deck Manifold Service
RH WING DECK PTO MANIFOLD SHOWN
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Lift/Lower Circuit
Page
Groundsmaster 4100--DHydraulic System Page 4 --124
Lift/Lower Control Valve
Figure 88
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Groundsmaster 4100--DHydraulic System Page 4 --126
Lift/Lower Control Valve Service
Figure 89
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Groundsmaster 4100--DHydraulic System Page 4 --128
Front Deck Lift Cylinder
Figure 90
RIGHT
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Groundsmaster 4100--DHydraulic System Page 4 --130
Wing Deck Lift Cylinder
Figure 91
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Groundsmaster 4100--DHydraulic System Page 4 --132
Deck Lift Cylinder Service
Figure 93
Figure 92
FRONTDECKLIFTCYLINDER
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Counterbalance Manifold
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Counterbalance Manifold Service
Chapter 5
Electrical System
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Special Tools
Multimeter
Skin--Over Grease
Deck Proximity Switch Adjustment Tool
Dielectric Gel
Battery Terminal Protector
Battery Hydrometer
Starting Problems
General Run and Transport Problems
Cutting Deck Operating Problems
Electrical System Quick Checks
Battery Test (Open Circuit Test)
Charging System Test
Check Operation of Interlock Switches
Adjustments
Wing Deck Position Switches
Cutting Deck Raise and Lower Switches
Component Testing
Ignition Switch
Fuses
A B
C
1234
Warning Lights
PTO Switch
Alarm Silence and Temperature Override Switches
Transport / 4WD Switch
Cooling Fan Switch
Seat Switch
Parking Brake Switch
Hour Meter
Audio Alarm
Glow and Power Relays
Start, Engine Shutdown, Seat, Alarm, PTO, PTO Overtemp, Down Latching and Over Temperature Relays
Hydraulic Valve Solenoids
TEC--5002 Controller
Fuel Sender
Fuel Gauge
Fuel Pump
Glow Controller
Temperature Sender
Dual Temperature Switch
Temperature Gauge
Traction Neutral Switch
Diode Assemblies
Diode Circuit Board
Fusible Links
Wing Deck Position Switches
Cutting Deck Raise and Lower Switches
Engine Coolant and Hydraulic Oil Temperature Senders
Battery Storage
Battery Care
Battery Service
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Chapter 6
Axles, Planetaries and Brakes
Groundsmaster 4100--DPage 6 --2Axles, Planetaries and Brakes
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Brake Assembly
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Brake Service
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Groundsmaster 4100--DPage 6 --8Axles, Planetaries and Brakes
Planetary Wheel Drive Assembly
Figure 6
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Groundsmaster 4100--DPage 6 --10Axles, Planetaries and Brakes
Planetary Wheel Drive Service
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Rear Axle Assembly
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Bevel Gear Case and Axle Case
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Differential Shafts
Axle Shafts
Input Shaft/Pinion Gear
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Differential Gear
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Pinion Gear to Ring Gear Engagement
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Chapter 7
Chassis
Groundsmaster 4100--DPage 7 --2Chassis
Steering Tower
Figure 1
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Groundsmaster 4100--DPage 7 --4Chassis
Cutting Deck Lift Arms
Figure 2
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Groundsmaster 4100--DPage 7 --6Chassis
Operator Seat
Figure 5
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Groundsmaster 4100--DPage 7 --8Chassis
Operator Seat Service
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Groundsmaster 4100--DPage 7 --10Chassis
Operator Seat Suspension
Figure 9
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Groundsmaster 4100--DPage 7 --12Chassis
Hood
Figure 11
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Chapter 8
Cutting Deck
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Castor Wheel Tire Pressure
Blade Stopping Time
Factors That Can Affect Quality of Cut
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Cutting Deck
Page
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Groundsmaster 4100--DCutting Deck Page 8 --10
Wing Deck Service
Figure 6
30 to 40 ft--lb (41to54N--m)
160 to 180 ft--lb (217 to 244 N--m)
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Cutting Deck Link Service
Wing Deck Latch
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Blade Spindle
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Blade Spindle Service
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Idler Assembly
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Groundsmaster 4100--DCutting Deck Page 8 --22
Castor Forks and Wheels
CASTOR WHEEL
Figure 22
60 to 80 ft--lb (81 to 108 N--m)
DECK CASTOR ARM WING DECK CASTOR FORK
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Deck Rollers and Skids
Chapter 9
Foldout Drawings
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Hydraulic Schematic
Page 9 - 3
Electrical Schematic
Sheet 1 of 2
Page 9 - 4
All relays and solenoids are shown as de--energized. All ground wires are black.
Page
Page 9 - 6
Glow Plug Circuits
Page 9 - 7
Crank Circuits
Page 9 - 8
Run (Transport) Circuits
Page 9 - 9
Run (Mow) Circuits
Page 9 - 10
High Temperature Warning Circuits
oo
C),THE DUALF(105 TOTHE DE CK PTO SOLENOIDS.
Page 9 - 11
Over Temperature Shutdown Circuits
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Page 9 - 13
Console Wire Harness
Sheet 1 of 2
Page 9 - 14
Console Wire Harness Sheet 2 of 2
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Page 9 - 16
Front Wire Harness
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Page 9 - 18
Groundsmaster 4000--D Engine Wire Harness