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4100-D service manual This page is intentionally blank
Models:
4100-D
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4
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298 pages
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Troubleshooting
Specs
Install
Error codes
Hydraulic Schematic
Maintenance
Console Wire Harness
Problem
Assembly Fig
Tightening Procedure
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Groundsmaster
4100--D
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Page 5
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Page 5
Contents
Preface
Toro Company 2008
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Table Of Contents
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Groundsmaster 4100--D Safety
Chapter
General Safety Instructions
Safety Groundsmaster 4100--D
Before Operating
While Operating
Maintenance and Service
Jacking Instructions
Jacking the Rear End Fig
Safety and Instruction Decals
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Maintenance
Product Records
Product Records and Maintenance Groundsmaster 4100--D
Equivalents and Conversions
Using a Torque Wrench with an Offset Wrench
Torque Specifications
Fastener 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 Information
Stopping the Engine
Specifications
Description
Air Filter System
Service and Repairs
Kubota 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 Tank
Fuel 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
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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 Mow
Reverse 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
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Steering Circuit Left Turn Shown
Left Turn
Steering Circuit
Right Turn
Engine Cooling Fan Circuit Forward Direction Shown
Forward Direction Fan Operation
Engine Cooling Fan Circuit
Reverse Direction Fan Operation Fig
Special Tools
Hydraulic Pressure Test Kit
Hydraulic Tester Pressure and Flow
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 Components
Check 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
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Piston Traction Pump
108 to 113 N--m
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
Rear Axle and Front Wheel Motor Service
20 to 24 N-m
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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
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Steering Valve
Removal Fig
Steering Valve Service
Disassembly Fig
In-lb 16 to 18 N--m
Reassembly Fig
In-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
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Fan Drive Manifold
Removal Fig
Fan Drive Manifold Service
Fan Drive Manifold Service Fig
Gear pump RH Wing Deck manifold
Cutting Deck Motor
Installation
Removal
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
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Deck Manifolds
Removal Fig
Deck Manifold Service
RH Wing Deck PTO Manifold Shown
PTO Manifold Service Fig
Lift/Lower Circuit
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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 Tool
Skin-Over Grease
Battery Hydrometer
Battery Terminal Protector
Dielectric Gel
Starting Problems
General Run and Transport Problems
Cutting Deck Operating Problems
Battery Test Open Circuit Test
Check Operation of Interlock Switches
Electrical System Quick Checks
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
High Temperature Warning Light
Glow Plug Indicator Light
Charge Indicator Light
Testing Warning Lights
Alarm Silence and Temperature Override Switches
PTO Switch
Testing
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 Controller
Glow Controller Checks
Temperature Sender
Coolant Temp Temp Sender Resistance
Dual Temperature Switch
Groundsmaster 4100--D 5 -- 29 Rev. a Electrical System
Temperature Gauge
Traction Neutral Switch
Diode Assemblies
Multimeter
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 Service
Battery Inspection, Maintenance and Testing
Minimum Battery Electrolyte
Battery Charging
Battery Charge Specific Open Circuit
Gravity
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
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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
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 Installation
Axle Shafts
Axle Shaft Removal
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
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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
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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
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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
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88 to 108 ft--lb
Blade Spindle
119 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
