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Toro 4100-D service manual This page is intentionally blank

Models: 4100-D

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Troubleshooting Specs Install Error codes Hydraulic Schematic Audio Alarm Console Wire Harness Maintenance Problem Assembly Fig

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Safety

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Groundsmaster 4100--D

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Toro 4100-D service manual This page is intentionally blank

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Contents

Preface Toro Company 2008 This page is intentionally blank Table Of Contents This page is intentionally blank Groundsmaster 4100--D Safety Chapter Before Operating General Safety InstructionsSafety Groundsmaster 4100--D While Operating Maintenance and Service Jacking Instructions Jacking the Rear End Fig Safety and Instruction Decals This page is intentionally blank Maintenance Product Records Product Records and Maintenance Groundsmaster 4100--D Equivalents and Conversions Using a Torque Wrench with an Offset Wrench Torque SpecificationsFastener Identification In-lb Groundsmaster 4100--D Product Records and Maintenance Class 8.8 Bolts, Screws and Studs with Other Torque Specifications Conversion Factors Kubota Diesel Engine Groundsmaster 4100--D Kubota Diesel Engine Operator’s Manual General InformationStopping the Engine Specifications Description Air Filter System Service and RepairsKubota Diesel Engine Groundsmaster 4100--D Removal Fig Exhaust System Installation Fig Groundsmaster 4100--D 3 -- 7 Rev. a Kubota Diesel Engine Fuel System 60 to 80 in-lb Fuel Tank Installation Fig Empty and Clean Fuel TankFuel Tank Removal Fig Radiator Removal Fig Engine Engine Removal Fig Engine Installation Fig Cap screw 4 used Spring Coupler Coupler Installation Fig Coupler Removal Fig This page is intentionally blank Hydraulic System Groundsmaster 4100--D Hydraulic System Hydraulic System Groundsmaster 4100--D Towing Traction Unit Check Hydraulic Fluid Hydraulic Hoses 18 to 22 ft Lb 25 to 29 N Non--Adjustable Fitting Fig Aluminum Port Adjustable Fitting Fig Hydraulic Schematic Hydraulic Hydraulic Flow Traction Circuit 4WD Forward Shown Forward Direction Traction Circuit 4WD MowReverse Direction Traction Circuit Transport Forward Shown Traction Circuit Transport 2WD Lower Cutting Deck LH Deck Shown Working Pressure Low Pressure Charge Return Or Suction Flow Lower Cutting Deck Raise Cutting Deck LH Deck Shown Raise Cutting Deck Mow Circuit All Deck Motors Rotating Mow Circuit Mow Circuit Cutting Deck Blade Braking This page is intentionally blank Steering Circuit Left Turn Shown Left Turn Steering CircuitRight Turn Engine Cooling Fan Circuit Forward Direction Shown Forward Direction Fan Operation Engine Cooling Fan CircuitReverse Direction Fan Operation Fig Hydraulic Tester Pressure and Flow Special ToolsHydraulic Pressure Test Kit Hydraulic System 4 -- 26 Rev. a Groundsmaster 4100--D Hydraulic Test Fitting Kit Measuring Container Troubleshooting Problem Possible Cause Problem Possible Causes Problem Possible Causes Testing Before Performing Hydraulic Tests Traction Circuit Charge Pressure Using Pressure Gauge Procedure for Traction Circuit Charge Pressure Test Gauge Reading to be 200 to 300 PSI 13.8 to 20.6 bar Traction Circuit Relief Pressure Using Pressure Gauge Forward Traction Circuit Relief Pressure Test Shown Procedure for Traction Circuit Relief Pressure Test Gauge Reading to be Counterbalance Pressure Using Pressure Gauge Procedure for Counterbalance Pressure Test From Deck Manifolds From Deck Manifolds and FAN Motor Gauge Reading to be 750 PSI 52 bar approximate HydraulicSystem Hydraulic System Groundsmaster 4100--D Gauge Reading to be 650 PSI 45 bar Cutting Deck Circuit Pressure Using Pressure Gauge Procedure for Cutting Deck Circuit Pressure Test Center Deck PTO Relief Pressure Test Shown Procedure for Cutting Deck Manifold Relief Pressure Test Make sure the flow control valve on tester is fully open Section Flow Test Shown Procedure for Cutting Deck Gear Pump Flow Test Make sure the flow control valve on the tester is fully open Center Cutting Deck Motor Procedure for Cutting Deck Motor Case Drain Leakage Test Test Results Flow less than 22.2 ounces 662 ml Steering Circuit Relief Pressure Using Pressure Gauge Procedure for Steering Circuit Relief Pressure Test Gauge Reading to be 1300 to 1400 PSI 90 to 96 bar Lift/Lower Circuit Relief Pressure Using Pressure Gauge Procedure for Lift/Lower Circuit Relief Pressure Test Gauge Reading to be 2500 to 2550 PSI 173 to 175 bar From Procedure for Steering and Lift/Lower Gear Pump Flow Test Engine Cooling Fan Circuit Using Pressure Gauge and Phototac Procedure for Engine Cooling Fan Circuit Test Tester Deck Manifolds Procedure for Engine Cooling Fan Circuit Gear Pump Flow Test Adjustments Adjust Cutting Deck Flow Control Valve After Repair or Replacement of Components Before Repair or Replacement of ComponentsCheck Hydraulic Lines and Hoses Flush Hydraulic System Charge Hydraulic System Hydraulic Reservoir 30 to 40 in-lb To 4.5 N--m Minimum Inspection Hydraulic Oil Cooler Ft-lb Use eye protection such as goggles when using compressed air Gear Pump Hydraulic System Gear Pump Service Diagonal Line Assembly Fig Traction Circuit This page is intentionally blank Piston Traction Pump 108 to 113 N--m Piston pump Lock nut Cap screw Jam nut Pump control arm Piston Traction Pump Service This page is intentionally blank Rear Axle Motor Hydraulic System Front Wheel Motors Hydraulic System Rear Axle and Front Wheel Motor Service 20 to 24 N-m This page is intentionally blank 4WD Manifold Removal Fig 4WD Manifold Service Ft--lb 4WD Manifold Service Fig Filter Manifold System Filter Manifold Service Filter Manifold Service Fig Steering and Cooling Fan Circuits This page is intentionally blank Steering Valve Removal Fig Steering Valve Service Disassembly Fig In-lb 16 to 18 N--m Reassembly FigIn-lb 17 N--m Tightening Procedure Steering Cylinder Hydraulic System Steering Cylinder Service 62 to 74 N-m Disassembly Fig Engine Cooling Fan Motor Radiator Air cleaner hose Upper radiator shroud Engine Cooling Fan Motor Service Remove any nicks and burrs from all parts with emery cloth Important Do not dislodge seals during installa- tion This page is intentionally blank Fan Drive Manifold Removal Fig Fan Drive Manifold Service Fan Drive Manifold Service Fig Gear pump RH Wing Deck manifold Cutting Deck Motor InstallationRemoval Cutting Deck Motor Service 27 to 33 ft--lb 37 to 45 N-m 33 to 40 ft--lb 45 to 55 N-m Position front flange with seal side up. Remove shaft seal Assembly Fig This page is intentionally blank Deck Manifolds Removal Fig Deck Manifold Service RH Wing Deck PTO Manifold Shown PTO Manifold Service Fig Lift/Lower Circuit This page is intentionally blank Lift/Lower Control Valve Hydraulic System Lift/Lower Control Valve Service 27 to 33 N-m Disassembly Fig Front Deck Lift Cylinder Removal Fig Wing Deck Lift Cylinder Hydraulic System Deck Lift Cylinder Service Front Deck Lift Cylinder Disassembly Figs Assembly Figs Counterbalance Manifold System Counterbalance Manifold Service Counterbalance Manifold Service Fig Electrical System Groundsmaster 4100--D Electrical System Electrical Drawings Electrical System Groundsmaster 4100--D Multimeter Deck Proximity Switch Adjustment ToolSkin-Over Grease Battery Hydrometer Battery Terminal ProtectorDielectric Gel Starting Problems General Run and Transport Problems Cutting Deck Operating Problems Electrical System Quick Checks Battery Test Open Circuit TestCheck Operation of Interlock Switches Charging System Test Wing Deck Position Switches Adjustment Cutting Deck Raise and Lower Switches Adjustment Fig Component Testing Ignition Switch Identification, Function and Wiring Fuses Charge Indicator Light High Temperature Warning LightGlow Plug Indicator Light Testing Warning Lights Alarm Silence and Temperature Override Switches PTO SwitchTesting Transport / 4WD Switch Cooling Fan Switch Seat Switch Parking Brake Switch Audio Alarm Hour Meter Glow and Power Relays Control panel Relay location Hydraulic Valve Solenoids TEC-5002 Controller Fuel Sender Fuel Gauge Fuel Pump Operational Test Glow Controller Operation Glow ControllerGlow Controller Checks Temperature Sender Coolant Temp Temp Sender Resistance Dual Temperature Switch Groundsmaster 4100--D 5 -- 29 Rev. a Electrical System Temperature Gauge Multimeter Traction Neutral SwitchDiode Assemblies Continuity Diode Circuit Board Fusible Links Switch cover Switch bracket Position switch Cutting Deck Raise and Lower Switches Engine Coolant and Hydraulic Oil Temperature Senders Electrical System 5 -- 36 Rev. a Battery Storage Battery Care Battery Removal and Installation Fig Battery ServiceBattery Inspection, Maintenance and Testing Minimum Battery Electrolyte Gravity Battery ChargingBattery Charge Specific Open Circuit 81 to Hrs 10.5 hrs 15.8 hrs 21 hrs Amps Axles, Planetaries and Brakes Groundsmaster 4100--D Axles, Planetaries and Brakes Specification Axles, Planetaries and Brakes Groundsmaster 4100--D General Information Brake Assembly PlanetariesAxles Brakesand Brake Service Brake Inspection and Repair Fig This page is intentionally blank Planetary Wheel Drive Assembly AndBrakes Planetary Wheel Drive Service Disassembly Figs Axles, Planetaries and Brakes Groundsmaster 4100--D This page is intentionally blank Rear Axle Assembly Hydraulic hose Hydraulic tube Steering stop bolt Bevel gear case LH Bevel Gear Case and Axle Case Bevel Gear Case and Axle Case Removal Bevel Gear Case and Axle Case Inspection Bevel Gear Case and Axle Case Installation Vertical ENDPLAY6 Groundsmaster 4100--D Axles, Planetaries and Brakes Differential Shaft Installation Differential Shafts Axle Shaft Removal Axle Shaft InstallationAxle Shafts Ft-lb 23 to 27 N--m Input Shaft/Pinion Gear 040 in .0 mm Oil seal Differential Gear Differential Gear Removal Differential Gear Inspection Differential Gear Installation Pinion Gear to Ring Gear Engagement Profile TOP Land TOE Lengthwise Bearing ARC Heel Root Gear Pattern Movement Summary Chassis Groundsmaster 4100--D Chassis Steering Tower Chassis Groundsmaster 4100--D Disassembly Fig Cutting Deck Lift Arms Cal bearing from lift arm after removing retaining ring Operator Seat Torque screws 18 ft--lb 25 N--m Operator Seat Service Assemble operator seat using as a guide Operator Seat Suspension RIGHT16 Front Operator seat Hood Removal This page is intentionally blank Cutting Deck Groundsmaster 4100--D Cutting Deck Cutting Deck Groundsmaster 4100--D Castor Wheel Tire Pressure Blade Stopping Time Factor Possible Problem/Correction Factors That Can Affect Quality of Cut This page is intentionally blank Cutting Deck 75 to 85 ft--lb 102 to 115 N--m Hairpin and clevis pin Height-of-cut chain Lift arm Cutting deck wire harness connection This page is intentionally blank Wing Deck Service 380 to 0.620 9.7 to 15.7 mm Cutting Deck Groundsmaster 4100--D Cutting Deck Link Service 5 6 7 Wing Deck Latch This page is intentionally blank 88 to 108 ft--lb Blade Spindle119 to 146 N--m Driven spindle high pulley Drive spindle center deck Blade Spindle Service Drive Spindle Press Idler Assembly 125 to 250 to To 4.6 mm 82.6 to 95.2 mm Castor Forks and Wheels 60 to 80 ft--lb 81 to 108 N--m Disassembly Fig Deck Rollers and Skids Foldout Drawings Foldout Drawings Groundsmaster 4100--D Hydraulic Schematic Electrical Schematic Continues to Sheet Sheet 2 Power Current Control Current Indication Current Glow Plug Circuits Crank Circuits Run Transport Circuits Switch is in the on Position Run Mow Circuits High Temperature Warning Circuits To the Deck PTO Solenoids Over Temperature Shutdown Circuits Solenoid and Fuel Pump Console Wire Harness Sheet 1 Sheet 2 Front Wire Harness GREEN/BLACK TAN Pink White Orange Black Blue YELLOW/BLACK Engine Wire Harness Engine Wire Harness Jumper Wire Harness Cutting Deck Wire Harness

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