Manuals / Toro / Lawn and Garden / Lawn Mower

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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System

Hydraulic

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Groundsmaster 4100--D

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Hydraulic System

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Toro 4100-D service manual This page is intentionally blank

Page 54 Page 56

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Contents

Toro Company 2008 Preface This page is intentionally blank Table Of Contents This page is intentionally blank Chapter Groundsmaster 4100--D Safety While Operating General Safety InstructionsSafety Groundsmaster 4100--D Before Operating Maintenance and Service Jacking the Rear End Fig Jacking Instructions Safety and Instruction Decals This page is intentionally blank Product Records Maintenance Equivalents and Conversions Product Records and Maintenance Groundsmaster 4100--D Using a Torque Wrench with an Offset Wrench Torque SpecificationsFastener Identification 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 Operator’s Manual General InformationStopping the Engine Description Specifications Air Filter System Service and RepairsKubota Diesel Engine Groundsmaster 4100--D 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 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 Removal Fig Coupler Installation Fig This page is intentionally blank 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 Forward Direction Traction Circuit 4WD MowReverse 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 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 System 4 -- 26 Rev. a Groundsmaster 4100--D Special ToolsHydraulic 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 After Repair or Replacement of Components Before Repair or Replacement of ComponentsCheck Hydraulic Lines and Hoses 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 This page is intentionally blank 108 to 113 N--m Piston Traction Pump 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 20 to 24 N-m Rear Axle and Front Wheel Motor Service This page is intentionally blank 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 This page is intentionally blank Steering Valve Removal Fig Disassembly Fig Steering Valve Service In-lb 16 to 18 N--m Reassembly FigIn-lb 17 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 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 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 This page is intentionally blank Deck Manifolds Removal Fig RH Wing Deck PTO Manifold Shown Deck Manifold Service PTO Manifold Service Fig Lift/Lower Circuit This page is intentionally blank 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 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 Charging System Test Battery Test Open Circuit TestCheck 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 LightGlow Plug Indicator Light Charge Indicator Light Alarm Silence and Temperature Override Switches PTO SwitchTesting 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 Operation Glow ControllerGlow Controller Checks Coolant Temp Temp Sender Resistance Temperature Sender Groundsmaster 4100--D 5 -- 29 Rev. a Electrical System Dual Temperature Switch Temperature Gauge Continuity Traction Neutral SwitchDiode 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 Removal and Installation Fig Battery ServiceBattery Inspection, Maintenance and Testing Minimum Battery Electrolyte 81 to Hrs 10.5 hrs 15.8 hrs 21 hrs Amps Battery ChargingBattery 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 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 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 InstallationAxle 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 This page is intentionally blank 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 This page is intentionally blank 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 This page is intentionally blank 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 This page is intentionally blank 88 to 108 ft--lb Blade Spindle119 to 146 N--m 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

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