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4100-D service manual This page is intentionally blank
Models:
4100-D
1
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Troubleshooting
Specifications
Install
Error codes
Hydraulic Schematic
Maintenance
Console Wire Harness
Problem
Assembly Fig
Tightening Procedure
Page 107
Image 107
System
Hydraulic
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Groundsmaster
4100--D
Page 4
--
73
Hydraulic System
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Page 108
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Contents
Toro Company 2008
Preface
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Table Of Contents
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Chapter
Groundsmaster 4100--D Safety
While Operating
General Safety Instructions
Safety Groundsmaster 4100--D
Before Operating
Maintenance and Service
Jacking the Rear End Fig
Jacking Instructions
Safety and Instruction Decals
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Product Records
Maintenance
Equivalents and Conversions
Product Records and Maintenance Groundsmaster 4100--D
Fastener Identification
Torque Specifications
Using a Torque Wrench with an Offset Wrench
In-lb
Class 8.8 Bolts, Screws and Studs with
Groundsmaster 4100--D Product Records and Maintenance
Conversion Factors
Other Torque Specifications
Groundsmaster 4100--D Kubota Diesel Engine
Kubota Diesel Engine
Stopping the Engine
General Information
Operator’s Manual
Description
Specifications
Kubota Diesel Engine Groundsmaster 4100--D
Service and Repairs
Air Filter System
Removal Fig
Exhaust System
Groundsmaster 4100--D 3 -- 7 Rev. a Kubota Diesel Engine
Installation Fig
60 to 80 in-lb
Fuel System
Fuel Tank Removal Fig
Empty and Clean Fuel Tank
Fuel Tank Installation Fig
Radiator
Removal Fig
Engine
Engine Removal Fig
Engine Installation Fig
Cap screw 4 used
Spring Coupler
Coupler Removal Fig
Coupler Installation Fig
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Groundsmaster 4100--D Hydraulic System
Hydraulic System
Hydraulic System Groundsmaster 4100--D
Check Hydraulic Fluid
Towing Traction Unit
Hydraulic Hoses
18 to 22 ft Lb 25 to 29 N
Aluminum Port
Non--Adjustable Fitting Fig
Adjustable Fitting Fig
Hydraulic Schematic
Hydraulic
Traction Circuit 4WD Forward Shown
Hydraulic Flow
Reverse Direction
Traction Circuit 4WD Mow
Forward Direction
Traction Circuit Transport Forward Shown
Traction Circuit Transport 2WD
Working Pressure Low Pressure Charge Return Or Suction Flow
Lower Cutting Deck LH Deck Shown
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
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Steering Circuit Left Turn Shown
Right Turn
Steering Circuit
Left Turn
Engine Cooling Fan Circuit Forward Direction Shown
Reverse Direction Fan Operation Fig
Engine Cooling Fan Circuit
Forward Direction Fan Operation
Hydraulic System 4 -- 26 Rev. a Groundsmaster 4100--D
Special Tools
Hydraulic Pressure Test Kit
Hydraulic Tester Pressure and Flow
Measuring Container
Hydraulic Test Fitting Kit
Problem Possible Cause
Troubleshooting
Possible Causes
Problem
Problem Possible Causes
Before Performing Hydraulic Tests
Testing
Traction Circuit Charge Pressure Using Pressure Gauge
Gauge Reading to be 200 to 300 PSI 13.8 to 20.6 bar
Procedure for Traction Circuit Charge Pressure Test
Forward Traction Circuit Relief Pressure Test Shown
Traction Circuit Relief Pressure Using Pressure Gauge
Gauge Reading to be
Procedure for Traction Circuit Relief Pressure Test
Counterbalance Pressure Using Pressure Gauge
Procedure for Counterbalance Pressure Test
From Deck Manifolds From Deck Manifolds and FAN Motor
HydraulicSystem
Gauge Reading to be 750 PSI 52 bar approximate
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
Make sure the flow control valve on tester is fully open
Procedure for Cutting Deck Manifold Relief Pressure Test
Section Flow Test Shown
Make sure the flow control valve on the tester is fully open
Procedure for Cutting Deck Gear Pump Flow Test
Center Cutting Deck Motor
Test Results Flow less than 22.2 ounces 662 ml
Procedure for Cutting Deck Motor Case Drain Leakage Test
Steering Circuit Relief Pressure Using Pressure Gauge
Gauge Reading to be 1300 to 1400 PSI 90 to 96 bar
Procedure for Steering Circuit Relief Pressure Test
Lift/Lower Circuit Relief Pressure Using Pressure Gauge
Gauge Reading to be 2500 to 2550 PSI 173 to 175 bar
Procedure for Lift/Lower Circuit Relief Pressure Test
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
Adjust Cutting Deck Flow Control Valve
Adjustments
Check Hydraulic Lines and Hoses
Before Repair or Replacement of Components
After Repair or Replacement of Components
Flush Hydraulic System
Charge Hydraulic System
30 to 40 in-lb To 4.5 N--m Minimum
Hydraulic Reservoir
Inspection
Ft-lb
Hydraulic Oil Cooler
Use eye protection such as goggles when using compressed air
Gear Pump
Hydraulic System
Diagonal Line
Gear Pump Service
Assembly Fig
Traction Circuit
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108 to 113 N--m
Piston Traction Pump
Piston pump Lock nut Cap screw Jam nut Pump control arm
Piston Traction Pump Service
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Rear Axle Motor
Hydraulic System
Front Wheel Motors
Hydraulic System
20 to 24 N-m
Rear Axle and Front Wheel Motor Service
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4WD Manifold
Removal Fig
Ft--lb
4WD Manifold Service
4WD Manifold Service Fig
Filter Manifold
System
Filter Manifold Service
Filter Manifold Service Fig
Steering and Cooling Fan Circuits
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Steering Valve
Removal Fig
Disassembly Fig
Steering Valve Service
In-lb 17 N--m
Reassembly Fig
In-lb 16 to 18 N--m
Steering Cylinder
Tightening Procedure
Hydraulic System
62 to 74 N-m
Steering Cylinder Service
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
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Fan Drive Manifold
Removal Fig
Fan Drive Manifold Service
Fan Drive Manifold Service Fig
Gear pump RH Wing Deck manifold
Removal
Installation
Cutting Deck Motor
27 to 33 ft--lb 37 to 45 N-m 33 to 40 ft--lb 45 to 55 N-m
Cutting Deck Motor Service
Position front flange with seal side up. Remove shaft seal
Assembly Fig
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Deck Manifolds
Removal Fig
RH Wing Deck PTO Manifold Shown
Deck Manifold Service
PTO Manifold Service Fig
Lift/Lower Circuit
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Lift/Lower Control Valve
Hydraulic System
27 to 33 N-m
Lift/Lower Control Valve Service
Disassembly Fig
Front Deck Lift Cylinder
Removal Fig
Wing Deck Lift Cylinder
Hydraulic System
Front Deck Lift Cylinder
Deck Lift Cylinder Service
Assembly Figs
Disassembly Figs
Counterbalance Manifold
System
Counterbalance Manifold Service Fig
Counterbalance Manifold Service
Groundsmaster 4100--D Electrical System
Electrical System
Electrical System Groundsmaster 4100--D
Electrical Drawings
Skin-Over Grease
Deck Proximity Switch Adjustment Tool
Multimeter
Dielectric Gel
Battery Terminal Protector
Battery Hydrometer
Starting Problems
General Run and Transport Problems
Cutting Deck Operating Problems
Charging System Test
Battery Test Open Circuit Test
Check Operation of Interlock Switches
Electrical System Quick Checks
Adjustment
Wing Deck Position Switches
Adjustment Fig
Cutting Deck Raise and Lower Switches
Ignition Switch
Component Testing
Fuses
Identification, Function and Wiring
Testing Warning Lights
High Temperature Warning Light
Glow Plug Indicator Light
Charge Indicator Light
Testing
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
Control panel Relay location
Hydraulic Valve Solenoids
TEC-5002 Controller
Fuel Sender
Fuel Gauge
Operational Test
Fuel Pump
Glow Controller Checks
Glow Controller
Glow Controller Operation
Coolant Temp Temp Sender Resistance
Temperature Sender
Groundsmaster 4100--D 5 -- 29 Rev. a Electrical System
Dual Temperature Switch
Temperature Gauge
Continuity
Traction Neutral Switch
Diode Assemblies
Multimeter
Diode Circuit Board
Fusible Links
Switch cover Switch bracket Position switch
Cutting Deck Raise and Lower Switches
Electrical System 5 -- 36 Rev. a
Engine Coolant and Hydraulic Oil Temperature Senders
Battery Care
Battery Storage
Battery Inspection, Maintenance and Testing
Battery Service
Battery Removal and Installation Fig
Minimum Battery Electrolyte
81 to Hrs 10.5 hrs 15.8 hrs 21 hrs Amps
Battery Charging
Battery Charge Specific Open Circuit
Gravity
Groundsmaster 4100--D Axles, Planetaries and Brakes
Axles, Planetaries and Brakes
Axles, Planetaries and Brakes Groundsmaster 4100--D
Specification
General Information
Brake Assembly
PlanetariesAxles Brakesand
Brake Inspection and Repair Fig
Brake Service
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Planetary Wheel Drive Assembly
AndBrakes
Planetary Wheel Drive Service
Disassembly Figs
Axles, Planetaries and Brakes Groundsmaster 4100--D
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Rear Axle Assembly
Hydraulic hose Hydraulic tube
Steering stop bolt Bevel gear case LH
Bevel Gear Case and Axle Case Removal
Bevel Gear Case and Axle Case
Bevel Gear Case and Axle Case Inspection
Bevel Gear Case and Axle Case Installation
Vertical ENDPLAY6
Groundsmaster 4100--D Axles, Planetaries and Brakes
Differential Shafts
Differential Shaft Installation
Ft-lb 23 to 27 N--m
Axle Shaft Installation
Axle Shafts
Axle Shaft Removal
Input Shaft/Pinion Gear
040 in .0 mm Oil seal
Differential Gear Removal
Differential Gear
Differential Gear Inspection
Differential Gear Installation
Profile TOP Land TOE Lengthwise Bearing ARC Heel Root
Pinion Gear to Ring Gear Engagement
Gear Pattern Movement Summary
Groundsmaster 4100--D Chassis
Chassis
Chassis Groundsmaster 4100--D
Steering Tower
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
RIGHT16 Front
Operator Seat Suspension
Operator seat
Hood
Removal
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Groundsmaster 4100--D Cutting Deck
Cutting Deck
Cutting Deck Groundsmaster 4100--D
Blade Stopping Time
Castor Wheel Tire Pressure
Factors That Can Affect Quality of Cut
Factor Possible Problem/Correction
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75 to 85 ft--lb 102 to 115 N--m
Cutting Deck
Hairpin and clevis pin Height-of-cut chain Lift arm
Cutting deck wire harness connection
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Wing Deck Service
380 to 0.620 9.7 to 15.7 mm
Cutting Deck Groundsmaster 4100--D
5 6 7
Cutting Deck Link Service
Wing Deck Latch
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119 to 146 N--m
Blade Spindle
88 to 108 ft--lb
Driven spindle high pulley Drive spindle center deck
Drive Spindle
Blade Spindle Service
Press
Idler Assembly
250 to To 4.6 mm 82.6 to 95.2 mm
125 to
60 to 80 ft--lb 81 to 108 N--m
Castor Forks and Wheels
Disassembly Fig
Deck Rollers and Skids
Foldout Drawings
Foldout Drawings Groundsmaster 4100--D
Hydraulic Schematic
Continues to Sheet
Electrical Schematic
Sheet 2
Glow Plug Circuits
Power Current Control Current Indication Current
Crank Circuits
Run Transport Circuits
Run Mow Circuits
Switch is in the on Position
To the Deck PTO Solenoids
High Temperature Warning Circuits
Solenoid and Fuel Pump
Over Temperature Shutdown Circuits
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
