Page 1: Service Manual
The Toro Company reserves the right to change product IMPORTANT: The IMPORTANT notice will give im- specifications or this publication without notice. portant instructions which must be followed to pre- vent damage to systems or components on the machine.
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Page 3: Table Of Contents
Table Of Contents Chapter 1 - - Safety Chapter 5 - - Electrical System General Safety Instructions ....1 -- 2 General Information .
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Page 5 Table Of Contents (Continued) Chapter 9 - - Operator Cab General Information ......9 -- 2 Service and Repairs .
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Page 7: General Safety Instructions 1
Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS ... . Before Operating ......While Operating .
Page 8: General Safety Instructions
General Safety Instructions The Groundsmaster 4100-D and 4110--D have been tested and certified by TORO for compliance with exist- WARNING ing safety standards and specifications. Although haz- ard control and accident prevention partially are To reduce the potential for injury or death, dependent upon the design and configuration of the ma- comply with the following safety instructions.
Page 9 D. Stop engine and remove key from switch. C. After engine is started, release parking brake and E. Toro recommends that anytime the machine is keep foot off traction pedal. Machine must not move. parked (short or long term), the cutting deck should If movement is evident, the traction pedal linkage is be lowered to the ground.
Page 10: Jacking Instructions 1
5. Keep body and hands away from pin hole leaks in hy- timum performance and continued safety certification of draulic lines that eject high pressure hydraulic fluid. Use the machine, use genuine Toro replacement parts and cardboard or paper to find hydraulic leaks. Hydraulic accessories. Replacement parts and accessories made...
Page 11: Jacking Instructions
Jacking Instructions CAUTION When changing attachments, tires or perform- ing other service, use correct jacks and sup- ports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine.
Page 12: Safety And Instruction Decals
Safety and Instruction Decals Numerous safety and instruction decals are affixed to your Groundsmaster machine. If any decal becomes il- legible or damaged, install a new decal. Decal part num- bers are listed in your Parts Catalog. Safety Page 1 - - 6 Groundsmaster 4100--D/4110--D...
Page 13: Product Records
Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......MAINTENANCE ....... EQUIVALENTS AND CONVERSIONS .
Page 14: Equivalents And Conversions
Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 - - 2 Groundsmaster 4100--D/4110--D...
Page 15: Torque Specifications
For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
Page 16 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
Page 17 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series) Class 8.8 Bolts, Screws and Studs with Class 10.9 Bolts, Screws and Studs with Thread Size Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...
Page 18 Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Thread Size Square Head Hex Socket 7/16 -- 20 UNF 65 + 10 ft--lb 88 + 14 N--m Grade 5 1/4 -- 20 UNC 140 + 20 in--lb...
Page 19: Specifications
Chapter 3 Kubota Diesel Engine Table of Contents SPECIFICATIONS ......GENERAL INFORMATION .
Page 20: Specifications
Specifications Item Description Make / Designation Kubota Model V2403--M--T--E3B: 4--Cycle, 4 Cylinder, Water Cooled, Turbocharged, Diesel Engine Bore 3.43 in (87.0 mm) Stroke 4.031 in (102.4 mm) Total Displacement cc (cu. in.) 148.5 in (2434 cc) Firing Order 1 (closest to gear case end) -- 3 -- 4 (closest to flywheel end) -- 2 Combustion Chamber Spherical Type (E--TVCS) Compression Ratio...
Page 21: General Information
Authorized Toro Distributor. If no parts list is available, be prepared to provide your distrib- Most repairs and adjustments require tools which are utor with the Toro model and serial number of your ma- commonly available in many service shops. Special chine.
Page 22 Service and Repairs Air Filter System RIGHT FRONT 12 to 15 in- -lb (1.4 to 1.6 N- -m) 16 17 VACUATOR DIRECTION Figure 1 1. Air cleaner hose 7. Hose clamp 13. Flat washer (2 used) 2. Hose clamp 8. Air cleaner hose 14.
Page 23 Removal (Fig. 1) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. Raise and support hood. 3. Remove air cleaner components as needed using Figure 1 as a guide. Installation (Fig.
Page 24: Exhaust System
Exhaust System 16 to 22 ft- -lb 16 to 22 ft- -lb (21 to 29 N- -m) (21 to 29 N- -m) 16 to 22 ft- -lb (21 to 29 N- -m) 13 ft- -lb (17.6 N- -m) RIGHT FRONT 16 to 22 ft- -lb (21 to 29 N- -m) Figure 5...
Page 25 Removal (Fig. 5) CAUTION The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and ex- haust system to cool before working on the muf- fler. 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch.
Page 26: Fuel System
Fuel System RIGHT FRONT 135 to 165 ft- -lb 18 17 (183 to 223 N- -m) 60 to 80 in- -lb (7 to 9 N- -m) Figure 7 1. Fuel tank 15. Retaining ring (2 used) 29. Vent hose 2. Fuel tank bracket 16.
Page 27: Check Fuel Lines And Connections
Fuel Tank Installation (Fig. 7) DANGER 1. Install fuel tank using Figure 7 as a guide. A. Torque two (2) flange nuts that secure the fuel Because diesel fuel is highly flammable, use cau- tank to the frame from 60 to 80 in- -lb (7 to 9 N- -m). tion when storing or handling it.
Page 28: Radiator
Radiator RIGHT FRONT Figure 9 1. Radiator cap 22. Carriage screw (2 used) 43. Coolant reservoir 2. Foam strip (2 used) 23. 90 hydraulic fitting (2 used) 44. Tank bracket 3. Foam strip (2 used) 24. Cap screw (6 used) 45.
Page 29 Removal (Fig. 9) Installation (Fig. 9) 1. Park machine on a level surface, lower cutting deck, 1. Remove all plugs from radiator and hose openings stop engine, apply parking brake and remove key from that were placed during the removal procedure. the ignition switch.
Page 30: Engine
Engine RIGHT FRONT Loctite #242 29 to 33 ft- -lb 28 to 32 ft- -lb (40 to 44 N- -m) 28 to 32 ft- -lb (38 to 43 N- -m) (38 to 43 N- -m) Figure 10 1. Engine 11. Cap screw (8 used) 20.
Page 31: Engine Removal
Engine Removal (Fig. 10) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove battery cover and strap. Disconnect nega- tive battery cable first and then positive battery cable. Remove battery from machine.
Page 32 8. Disconnect fuel supply hose from injection pump 13.Support hydraulic pump assembly. Remove fasten- (Fig. 13). ers that secure pump assembly to engine (see Pump Assembly Removal in the Service and Repairs section 9. Remove throttle cable from engine (Figs. 13 and 14): of Chapter 4 -- Hydraulic System).
Page 33: Engine Installation
15.Connect hoist or lift to the lift tabs on engine. 16.Remove flange nuts, rebound washers and cap screws securing the engine mounts to the engine sup- ports. CAUTION One person should operate lift or hoist while another person guides the engine out of the ma- chine.
Page 34 9. Connect throttle cable to injector pump (Figs. 13 and 13.Install air cleaner assembly to the engine (see Air Fil- 14): ter System Installation in this section). A. Secure throttle cable swivel to speed control le- 14.Install exhaust system to machine (see Exhaust Sys- ver with lock nut.
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Page 36: Spring Coupler
Spring Coupler RIGHT FRONT Loctite #242 29 to 33 ft- -lb (40 to 44 N- -m) Loctite #242 28 to 32 ft- -lb (38 to 43 N- -m) Figure 17 1. Spring coupler 5. Cap screw (4 used) 8. RH engine mount 2.
Page 37 Coupler Removal (Fig. 17) NOTE: The hydraulic pump assembly needs to be re- moved from engine before coupler can be removed. Engine Side Hydraulic Pump Side 1. If engine is in machine, support engine from below to prevent it from shifting. Remove hydraulic pump assem- bly (see Piston (Traction) Pump Removal in the Service and Repairs section of Chapter 4 -- Hydraulic System).
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Page 39: General Information 7
Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......Check Hydraulic Lines and Hoses .
Page 40: Specifications 3
Specifications Item Description Piston (Traction) Pump Eaton Variable Displacement Piston Pump (Model 72400) Maximum Displacement (per revolution) 2.48 in (40.6 cc) System Relief Pressure: Forward 4000 PSI (274 bar) System Relief Pressure: Reverse 5000 PSI (343 bar) Charge Pressure 250 PSI (17 bar) Front Wheel Motors Eaton Fixed Displacement Piston Motors (Model 74328)
Page 41: General Information 3
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Check Hydraulic Fluid Your Groundsmaster hydraulic system is designed to operate on anti--wear hydraulic fluid.
Page 42: Service And Repairs 3
Traction Circuit Component Failure The traction circuit on Groundsmaster 4100--D and Once the Toro high flow hydraulic filter kit has been 4110--D machines is a closed loop system that includes placed in the circuit, raise and support the machine with the piston (traction) pump, two (2) front wheel motors all wheels off the ground.
Page 43 If the hose has an elbow at one end, tighten the swivel nut on that end before tightening the nut on the straight end of the hose. For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL).
Page 44 Hydraulic Hose and Tube Installation (O- -Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ C. Use a second wrench to tighten the nut to the cor- tube and the fitting are free of burrs, nicks, scratches or rect Flats From Wrench Resistance (F.F.W.R.).
Page 45 Hydraulic Fitting Installation (SAE Straight Thread O- -Ring Fitting into Component Port) Non- -Adjustable Fitting (Fig. 6) 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate meth- 1.
Page 46 Adjustable Fitting (Fig. 8) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is rec- ommended that the O--ring be replaced any time the connection is opened.
Page 47: Hydraulic Schematic
Hydraulic Schematic Groundsmaster 4100--D/4110--D Page 4 - - 9 Rev. A Hydraulic System...
Page 48: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams Hydraulic System Page 4 - - 10 Rev. A Groundsmaster 4100--D/4110--D...
Page 49 Traction Circuit: Low Speed (4WD) The traction circuit piston pump is a variable displace- Forward Direction ment pump that is directly coupled to the engine fly- When the Hi/Low switch is in the Low speed (4WD) posi- wheel. Pushing the traction pedal engages a hydraulic tion and the traction pedal is pushed in the forward direc- servo valve which controls the variable displacement tion, oil from the piston pump is directed to the front...
Page 50 Hydraulic System Page 4 - - 12 Rev. A Groundsmaster 4100--D/4110--D...
Page 51 Traction Circuit: Hi Speed (2WD) The traction circuit piston pump is a variable displace- Forward Direction ment pump that is directly coupled to the engine fly- With the Hi/Low speed switch in the Hi speed position, wheel. Pushing the traction pedal engages a hydraulic solenoid valve (SV) in the 4WD control manifold is ener- servo valve which controls the variable displacement gized.
Page 52 Hydraulic System Page 4 - - 14 Rev. A Groundsmaster 4100--D/4110--D...
Page 53: Lower Cutting Deck
Lower Cutting Deck A four section gear pump is coupled to the piston (trac- Lower Right Wing Cutting Deck tion) pump. The third gear pump section supplies hy- To lower the right wing deck, the front of the right console draulic flow to both the steering and lift/lower circuits.
Page 54 Hydraulic System Page 4 - - 16 Rev. A Groundsmaster 4100--D/4110--D...
Page 55 Raise Cutting Deck A four section gear pump is coupled to the piston (trac- Raise Right Wing Cutting Deck tion) pump. The third gear pump section supplies hy- To raise the right wing deck, the rear of the right console draulic flow to both the steering and lift/lower circuits.
Page 56 Hydraulic System Page 4 - - 18 Rev. A Groundsmaster 4100--D/4110--D...
Page 57 Mow Circuit A four section gear pump is coupled to the piston (trac- Deck motor case drain leakage returns to the hydraulic tion) pump. Hydraulic flow for the mow circuit is supplied reservoir. by two sections of the gear pump. The gear pump sec- PTO Circuit Relief tion closest to the piston (traction) pump supplies hy- draulic flow to the wing cutting decks, while the next gear...
Page 58 Mow Circuit Cutting Deck Blade Braking When the operator turns the PTO switch OFF or if a deck is raised with the PTO switch ON, PTO manifold sole- noid valve (S) is de--energized causing bypass cartridge (LC1) to shift (refer to information in Mow Circuit in this section).
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Page 60 Hydraulic System Page 4 - - 22 Rev. A Groundsmaster 4100--D/4110--D...
Page 61: Steering Circuit
Steering Circuit A four section gear pump is coupled to the piston (trac- (V1) and out the L port. Pressure contracts the steering tion) pump. The third gear pump section supplies hy- cylinder piston for a left turn. The rotary meter ensures draulic flow to both the steering and lift/lower circuits.
Page 62 Hydraulic System Page 4 - - 24 Rev. A Groundsmaster 4100--D/4110--D...
Page 63: Engine Cooling Fan Circuit
Engine Cooling Fan Circuit A four section gear pump is coupled to the piston (trac- tion. A lower PWM signal is sent to the PRV valve allow- tion) pump. The gear pump section farthest from the pis- ing oil flow to return to the fan motor but in the reverse ton pump supplies hydraulic flow for the engine cooling direction causing the motor and cooling fan to run in re- fan circuit (Fig.
Page 64: Special Tools
Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.
Page 65 3. FLOW METER: This meter measures actual oil flow in the operating circuit with a gauge rated from 4 to 40 GPM (20 to 150 LPM). Toro Part Number: AT40002 Figure 19 NOTE: This tester does not include hydraulic hoses (see Hydraulic Hose Kit TOR6007 below).
Page 66 Toro Part Number: TOR6011 NOTE: This kit does not include hydraulic hoses (see Hydraulic Hose Kit TOR6007 above). NOTE: Replacement filter element is Toro part number TOR6012. Filter element cannister tightening torque is 25 ft- -lb (34 N- -m). O- -Ring Kit The O--ring kit includes O--rings in a variety of sizes for face seal and port seal hydraulic connections.
Page 67: Measuring Container
Hydraulic Test Fitting Kit This kit includes a variety of O--ring face seal fittings to TORO TEST FITTING KIT (TOR4079) enable the connection of test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings.
Page 68: Troubleshooting
Troubleshooting The charts that follow contain suggestions that can be NOTE: When troubleshooting traction problems on used to assist in diagnosing hydraulic system perfor- your Groundsmaster, if a problem exists in both Low mance issues. The suggestions are not all--inclusive. (4WD) and Hi (2WD) speeds, consider a faulty compo- Also, consider that there may be more than one cause nent that affects the entire traction circuit (e.g.
Page 69 Traction Circuit Problems Problem Possible Cause Machine operates in one direction Traction control linkage is faulty. only. Traction relief valve is faulty. Traction pedal is sluggish. Traction control linkage is stuck or binding. Charge pressure is low. Piston (traction) pump servo control valve orifices are plugged or damaged.
Page 70: Mow Circuit Problems
Mow Circuit Problems Problem Possible Cause Cutting deck will not operate. Electrical problem exists (see Chapter 5 -- Electrical System). NOTE: To engage the mow circuit, Gear pump or its coupler is damaged (NOTE: other hydraulic circuits the seat must be occupied, the trac- impacted as well).
Page 71 Lift Circuit Problems Problem Possible Cause Cutting deck (or wing decks) will not Engine RPM is too low. raise. Hydraulic oil level in reservoir is low. NOTE: The seat must be occupied Solenoid valve (S1) in lift/lower manifold is faulty. in order to raise cutting deck.
Page 72: Steering Circuit Problems
Steering Circuit Problems Problem Possible Cause Steering is inoperative or sluggish. Steering components (e.g. tie rods, steering cylinder ends) are worn or binding. Steering cylinder is binding. Oil level in hydraulic reservoir is low (NOTE: other hydraulic sys- tems are affected as well). Steering relief valve in steering control valve is stuck or damaged.
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Page 74: Testing
Testing The most effective method for isolating problems in the 1. Clean machine thoroughly before disconnecting or hydraulic system is by using hydraulic test equipment disassembling any hydraulic components. Always keep such as pressure gauges and flow meters in the circuits in mind the need for cleanliness when working on hy- during various operational checks (see the Special draulic equipment.
Page 75 Which Hydraulic Tests Are Necessary? 2. If a cutting (mow) circuit problem exists, consider performing one or more of the following tests: Cutting Before beginning any hydraulic test, identify if the prob- Deck Circuit Pressure, PTO Relief Pressure, Cutting lem is related to the traction circuit, cutting (mow) circuit, Deck Motor Case Drain Leakage and/or Cutting Deck lift circuit, steering circuit or engine cooling fan circuit.
Page 76 Traction Circuit Charge Pressure (Using Pressure Gauge) FROM LIFT/LOWER MANIFOLD FROM DECK PRESSURE GAUGE LIFT CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO MOW CIRCUIT TO MOW CIRCUIT TO STEERING & LIFT CIRCUITS TO COOLING FAN CIRCUIT Hydraulic System Page 4 - - 38...
Page 77: Service And Repairs 8
Procedure for Traction Circuit Charge Pressure Test 8. Next, with the pressure gauge still connected to the charge pressure test port, take a gauge reading while 1. Make sure hydraulic oil is at normal operating tem- operating the machine in forward and reverse. Start the perature by operating the machine under load for engine and put throttle at high idle speed (2870 RPM).
Page 78 Traction Circuit Relief Pressure (Using Pressure Gauge) FORWARD TRACTION CIRCUIT RELIEF PRESSURE TEST SHOWN FROM LIFT/LOWER MANIFOLD PRESSURE GAUGE FROM FRONT DECK CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO MOW CIRCUIT TO MOW CIRCUIT TO STEERING &...
Page 79 Procedure for Traction Circuit Relief Pressure Test NOTE: Seal leakage across pilot directional valves PD1 and PD2 in 4WD manifold can cause low forward 1. Make sure hydraulic oil is at normal operating tem- traction pressure with reverse pressure meeting specifi- perature by operating the machine under load for cations.
Page 80 Counterbalance Pressure (Using Pressure Gauge) PRESSURE GAUGE FROM DECK MOTORS FROM FRONT PTO MANIFOLD Hydraulic System Page 4 - - 42 Rev. A Groundsmaster 4100--D/4110--D...
Page 81 Procedure for Counterbalance Pressure Test C. To decrease pressure setting, turn the adjust- ment screw on the valve in a counterclockwise direc- 1. Make sure hydraulic oil is at normal operating tem- tion. A 1/8 turn on the screw will make a measurable perature by operating the machine under load for change in counterbalance pressure.
Page 82 Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge) FROM LIFT/LOWER MANIFOLD PRESSURE GAUGE FROM DECK LIFT CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO MOW CIRCUIT TO MOW CIRCUIT TO STEERING & LIFT CIRCUITS TO COOLING FAN CIRCUIT Hydraulic System Page 4 - - 44...
Page 83 Procedure for Traction Circuit Reducing Valve (PR) Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine under load for approximately ten (10) minutes. Make sure the hydrau- lic tank is full. 2. Park machine on a level surface with the cutting deck lowered and off.
Page 84 Rear Traction Circuit (RV) Relief Pressure (Using Pressure Gauge) FROM LIFT/LOWER MANIFOLD PRESSURE GAUGE FROM DECK LIFT CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO MOW CIRCUIT TO MOW CIRCUIT TO STEERING & LIFT CIRCUITS TO COOLING FAN CIRCUIT Hydraulic System Page 4 - - 46...
Page 85 Procedure for Rear Traction Circuit (RV) Relief Pres- 10.If specification is not met, clean or adjust relief valve sure Test (RV) in 4WD control manifold. Relief valve (RV) is lo- cated on the lower, front side of the 4WD control man- 1.
Page 86 Piston (Traction) Pump Flow Test (Using Tester with Flow meter and Pressure Gauge) FROM LIFT/LOWER MANIFOLD FROM FRONT DECK CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO MOW CIRCUIT TO MOW CIRCUIT TO STEERING &...
Page 87 Procedure for Piston (Traction) Pump Flow Test 7. Start engine and run at idle speed. Check for any hy- draulic leakage from tester and hose connections. Cor- This test measures piston (traction) pump output (flow). rect any leaks before proceeding. During this test, pump load is created at the flow meter using the adjustable load valve on the tester.
Page 88 Cutting Deck Circuit Pressure (Using Pressure Gauge) NOTE: CENTER DECK PRESSURE TEST SHOWN FROM COOLING FAN MOTOR PRESSURE GAUGE Hydraulic System Page 4 - - 50 Groundsmaster 4100--D/4110--D...
Page 89 Procedure for Cutting Deck Circuit Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine under load for approximately ten (10) minutes. Make sure the hydrau- lic tank is full. 2. Park machine on a level surface with the cutting deck lowered and off.
Page 90 PTO Relief Pressure (Using Tester with Pressure Gauge and Flow Meter) CENTER DECK PTO RELIEF PRESSURE TEST SHOWN FROM COOLING FAN MOTOR Hydraulic System Page 4 - - 52 Groundsmaster 4100--D/4110--D...
Page 91 Procedure for Cutting Deck Manifold Relief 8. As the relief valve lifts, the pressure gauge needle Pressure Test will momentarily stop or hesitate. System pressure should be approximately: IMPORTANT: Mow circuit flow for the Groundsmas- ter 4100/4110 is approximately 16 GPM (61 LPM). 2900 to 3100 PSI (200 to 213 bar) for the center Use 40 GPM Hydraulic Tester #AT40002 (pressure deck and LH wing deck...
Page 92 Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauge and Flow Meter) CENTER CUTTING DECK MOTOR CASE DRAIN LEAKAGE TEST SHOWN FROM COOLING FAN MOTOR TESTER MEASURING CONTAINER Hydraulic System Page 4 - - 54 Groundsmaster 4100--D/4110--D...
Page 93 Procedure for Cutting Deck Motor Case Drain 6. After installing flow tester, start engine and run at idle Leakage Test speed. Check for hydraulic leakage and correct before proceeding with test. NOTE: Over a period of time, a deck motor can wear in- ternally.
Page 94 Cutting Deck Gear Pump Flow (Using Tester with Pressure Gauge and Flow Meter) NOTE: CENTER DECK GEAR PUMP SECTION FLOW TEST SHOWN FROM COOLING TESTER FAN MOTOR Hydraulic System Page 4 - - 56 Groundsmaster 4100--D/4110--D...
Page 95 Procedure for Cutting Deck Gear Pump Flow Test IMPORTANT: Do not fully restrict oil flow through tester. In this test, the flow tester is positioned be- NOTE: Over a period of time, the gears and wear plates fore the relief valve. Pump damage can occur if the in the gear pump can wear.
Page 96 Steering Circuit Relief Pressure (Using Pressure Gauge) FROM LIFT/LOWER MANIFOLD FROM FRONT DECK LIFT CYLINDERS TO LIFT/LOWER MANIFOLD PRESSURE GAUGE FROM DECK MOTORS FROM FRONT PTO MANIFOLD Hydraulic System Page 4 - - 58 Groundsmaster 4100--D/4110--D...
Page 97 Procedure for Steering Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine under load for approximately ten (10) minutes. Make sure the hydrau- lic tank is full. 2. Park machine on a level surface with the cutting deck lowered and off.
Page 98 Steering Cylinder Internal Leakage STEERING CYLINDER CYLINDER FULLY EXTENDED LOOK FOR LEAKAGE STEEL CAP STEERING WHEEL TURNED FOR RIGHT TURN 1350 STEERING CONTROL Hydraulic System Page 4 - - 60 Groundsmaster 4100--D/4110--D...
Page 99 Procedure for Steering Cylinder Internal Leakage 6. Remove all hydraulic oil from drain pan. Make sure Test that empty drain pan remains under the open fitting of the steering cylinder. NOTE: Steering circuit operation will be affected by rear tire pressure, binding of steering cylinder, extra 7.
Page 100 Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) PRESSURE GAUGE FROM DECK MOTORS FROM FRONT PTO MANIFOLD Hydraulic System Page 4 - - 62 Rev. A Groundsmaster 4100--D/4110--D...
Page 101 Procedure for Lift/Lower Circuit Relief Pressure 10.If relief valve adjustment does not change relief pres- Test sure, check for restriction in pump intake line, lift cylin- der(s) internal leakage or gear pump damage. NOTE: Before attempting to check or adjust lift/lower circuit relief pressure, make sure that counterbalance 11.
Page 102 Steering and Lift/Lower Gear Pump Flow (Using Tester with Pressure Gauge and Flow Meter) TESTER FROM DECK MOTORS FROM FRONT PTO MANIFOLD Hydraulic System Page 4 - - 64 Rev. A Groundsmaster 4100--D/4110--D...
Page 103 Procedure for Steering and Lift/Lower Gear Pump IMPORTANT: The gear pump is a positive displace- Flow Test ment type. If pump flow is completely restricted or stopped, damage to the pump, tester or other com- NOTE: Output from the steering and lift/lower gear ponents could occur.
Page 104 Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac) PRESSURE GAUGE FROM DECK MOTORS FROM FRONT PTO MANIFOLD Hydraulic System Page 4 - - 66 Rev. A Groundsmaster 4100--D/4110--D...
Page 105 Procedure for Engine Cooling Fan Circuit Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine under load for approximately ten (10) minutes. Make sure the hydrau- lic tank is full. 2. Park machine on a level surface with the cutting deck lowered and off.
Page 106 Engine Cooling Fan Circuit Gear Pump Flow (Using Tester with Pressure Gauge and Flow Meter) TESTER FROM DECK MOTORS FROM FRONT PTO MANIFOLD Hydraulic System Page 4 - - 68 Rev. A Groundsmaster 4100--D/4110--D...
Page 107 Procedure for Engine Cooling Fan Circuit Gear 7. Move throttle so engine is running at high idle speed Pump Flow Test (2870 RPM). DO NOT engage the cutting deck. 1. Make sure hydraulic oil is at normal operating tem- 8. While watching tester pressure gauge, slowly close perature by operating the machine under load for flow control valve until 1000 PSI (69 bar) is obtained on approximately ten (10) minutes.
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Page 109: Adjustments
Adjustments Adjust Control Manifold Relief Valves Several of the hydraulic control manifolds on the Groundsmaster include adjustable relief valves. The fol- lowing procedure can be used to adjust these relief valves. Refer to the Testing section of this chapter for in- formation on testing relief pressure.
Page 110 Traction Linkage Adjustment RIGHT FRONT Figure 52 1. Traction pedal 11. Flat washer 21. Traction lever 2. Cap screw (4 used) 12. Compression spring 22. Lock nut 3. Hex nut (2 used) 13. Spring retainer 23. Spacer 4. Pedal stop 14.
Page 111 Adjustment of the traction linkage should be checked C. When traction pedal is released from either for- whenever traction drive components are replaced or re- ward or reverse, pedal should return to the neutral moved. position and wheels should stop rotating. Assembly Adjustments D.
Page 112: Service And Repairs
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- 1. Check oil level in the hydraulic reservoir and add cor- tem, park machine on a level surface, engage parking rect oil if necessary.
Page 113 Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time 6. Connect all hydraulic hoses, lines and components there is a severe component failure or the system is that were disconnected while draining system. contaminated. Contaminated oil may appear milky NOTE: Use only hydraulic fluids specified in the Opera- or black or may contain metal particles.
Page 114: Special Tools 5
IMPORTANT: If using a filter that is not the bi- -direc- 2. Raise and support machine so all wheels are off the tional Toro high flow filter, do not press the traction ground (see Jacking Instructions in Chapter 1 -- Safety).
Page 115 Charge Hydraulic System NOTE: When initially starting the hydraulic system with 11. After the hydraulic system starts to show signs of fill, new or rebuilt components such as motors, pumps or lift actuate lift control switch so that the lift cylinder rod cylinders, it is important that the hydraulic system be moves in and out several times.
Page 116: Hydraulic Reservoir
Hydraulic Reservoir 30 to 40 in- -lb (3.4 to 4.5 N- -m) (minimum) RIGHT NOTE: HYDRAULIC COMPONENTS FRONT ATTACHED TO FRONT FRAME ARE NOT SHOWN IN ILLUSTRATION Figure 55 1. Hydraulic reservoir 12. Dipstick 22. Lock nut (3 used) 2. Petcock 13.
Page 117 NOTE: The front frame needs to be lowered from the Inspection main frame to allow clearance to remove the hydraulic 1. Clean hydraulic reservoir and tank strainer with sol- reservoir from the machine. vent. Removal (Fig. 55) 2. Inspect reservoir for leaks, cracks or other damage. 1.
Page 118: Hydraulic Oil Cooler
Hydraulic Oil Cooler RIGHT FRONT 12 ft- -lb (16 N- -m) Figure 56 1. Radiator 7. Carriage screw (2 used) 13. Oil cooler 2. RH radiator support 8. O- -ring 14. Flange nut (2 used) 3. Top radiator support 9. 90 hydraulic fitting (2 used) 15.
Page 119 Removal (Fig. 56) CAUTION CAUTION Use eye protection such as goggles when using compressed air. The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling 2. Dry inside of oil cooler using compressed air in the systems to cool before working on the oil cooler.
Page 120: Gear Pump
Gear Pump 103 to 118 ft- -lb (140 to 160 N- -m) Loctite #242 79 to 84 ft- -lb (108 to 113 N- -m) Loctite #242 79 to 84 ft- -lb (108 to 113 N- -m) RIGHT FRONT 30 to 40 in- -lb (3.4 to 4.5 N- -m) Figure 57 1.
Page 121 Removal (Fig 57) Installation (Fig 57) 1. Park machine on a level surface, lower cutting deck, 1. If fittings were removed from gear pump, lubricate stop engine, engage parking brake and remove key and place new O--rings onto fittings. Install fittings into from the ignition switch.
Page 122: Gear Pump Service
Gear Pump Service 33 ft- -lb (45 N- -m) Figure 58 1. Dust seal 10. Seal (8 used) 19. Body 2. Retaining ring 11. Idler gear 20. Body 3. Flange washer 12. Drive shaft 21. Drive gear 4. Shaft seal 13.
Page 123 IMPORTANT: Use caution when clamping gear NOTE: Pressure seals and back--up gaskets fit in pump in a vise to avoid distorting any pump compo- grooves machined into thrust plates. Body seals fit in nents. grooves machined in body faces. 3. Secure the front cover of the pump in a vise with the 2.
Page 124: Traction Circuit
Traction Circuit RIGHT NOTE: Arrow on check valve points toward rear of machine FRONT Figure 61 1. Piston (traction) pump 5. RH front wheel motor 9. Cooling fan motor 2. Gear pump 6. 4WD manifold 10. Reverse traction pressure port 3.
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Page 126 Piston (Traction) Pump 103 to 118 ft- -lb (140 to 160 N- -m) Loctite #242 79 to 84 ft- -lb Loctite #242 (108 to 113 N- -m) 79 to 84 ft- -lb (108 to 113 N- -m) RIGHT FRONT 30 to 40 in- -lb (3.4 to 4.5 N- -m) Figure 62 1.
Page 127 7. For installation purposes, label all hydraulic lines that 6. Remove plugs or caps from disconnected hydraulic connect to gear pump and piston pump. hoses and open ports of the pump assembly. Using la- bels placed during pump removal, install hydraulic fit- 8.
Page 128 Piston (Traction) Pump Service 40 to 48 in- -lb 4 to 6 ft- -lb (4.5 to 5.4 N- -m) (5 to 8 N- -m) 100 to 110 ft- -lb 40 to 48 in- -lb 25 to 28 ft- -lb (136 to 149 N- -m) (4.5 to 5.4 N- -m) (34 to 38 N- -m) 27 to 31 ft- -lb...
Page 129 Piston (Traction) Pump Service (Fig. 64) For service of the piston (traction) pump (including the servo control (item 35) assembly), see the Eaton Model 72400 Servo Controlled Piston Pump Repair Informa- tion at the end of this chapter. Groundsmaster 4100--D/4110--D Page 4 - - 91 Hydraulic System...
Page 130: Rear Axle Motor
Rear Axle Motor Arrow on side of motor case points up 59 to 73 ft- -lb (80 to 99 N- -m) RIGHT FRONT Figure 65 1. Axle motor 8. Gear (39T) 15. O- -ring 2. 90 hydraulic fitting (2 used) 9.
Page 131 Removal (Fig. 65) Installation (Fig. 65) 1. Park machine on a level surface, lower cutting deck, 1. If fittings were removed from motor, lubricate and stop engine, engage parking brake and remove key place new O--rings onto fittings. Install fittings into port from the ignition switch.
Page 132: Front Wheel Motors
Front Wheel Motors Arrow on side of motor case points up Arrow on side of motor case points up RIGHT 75 to 85 ft- -lb (101 to 115 N- -m) FRONT Figure 66 1. Front wheel motor 8. O- -ring 15.
Page 133 Removal (Fig. 66) Installation (Fig. 66) 1. Park machine on a level surface, lower cutting deck, IMPORTANT: If 90 fitting (item 10) was removed stop engine, engage parking brake and remove key from backplate of right side wheel motor, make sure from the ignition switch.
Page 134: Rear Axle And Front Wheel Motor Service
Rear Axle and Front Wheel Motor Service 15 to 18 ft- -lb (20 to 24 N- -m) Figure 67 1. Drive shaft 7. Cap screw (6 used) 13. Thrust bearing 2. Backplate (front motor shown) 8. Shaft seal 14. Roll pin (3 used) 3.
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Page 136 4WD Manifold RIGHT FRONT Figure 68 1. Frame assembly 8. Fitting cap 14. O- -ring 2. 4WD manifold 9. Hydraulic fitting 15. Hydraulic fitting 3. 90 hydraulic fitting 10. O- -ring 16. Adapter 4. O- -ring 11. O- -ring 17. Plug (SAE #4) 5.
Page 137 Removal (Fig. 68) Installation (Fig. 68) NOTE: The ports on the manifold are marked for easy 1. If fittings were removed from manifold, lubricate and identification of components. Example: P1 is a piston place new O--rings onto fittings. Install fittings into man- pump connection port and SV is the location for the sole- ifold openings using marks made during the removal noid valve (see Hydraulic Schematic in Chapter 10 --...
Page 138: Wd Manifold Service
4WD Manifold Service 35 ft- -lb REAR 50 ft- -lb (47 N- -m) (67 N- -m) DOWN 25 ft- -lb (34 N- -m) FRONT 20 ft- -lb (27 N- -m) PLUG TORQUE #4 Zero Leak: 20 ft- -lb (27 N- -m) 5 ft- -lb #6 Zero Leak: 25 ft- -lb (34 N- -m) (6.7 N- -m)
Page 139 4WD Manifold Service (Fig. 69) 8. Reinstall the cartridge valve: 1. Make sure the manifold is clean before removing a A. Lubricate new seal kit components with clean hy- cartridge valve. draulic oil and install on valve. The O--rings, sealing rings and backup rings must be arranged properly on 2.
Page 140: Filter Manifold
Filter Manifold RIGHT FRONT Figure 70 1. Filter manifold 10. Hydraulic fitting 18. Hydraulic hose 2. 45 hydraulic fitting 11. O- -ring 19. Hydraulic tee fitting 3. Test nipple 12. O- -ring 20. 90 hydraulic fitting 4. Dust cap 13. 90 hydraulic fitting 21.
Page 141 Removal (Fig. 70) Installation (Fig. 70) 1. Read the General Precautions for Removing and 1. If fittings were removed from manifold, lubricate and Installing Hydraulic System Components at the begin- place new O--rings onto fittings. Install fittings into man- ning of the Service and Repairs section of this chapter. ifold openings using marks made during the removal process to properly orientate fittings.
Page 142: Filter Manifold Service
Filter Manifold Service 25 ft- -lb (34 N- -m) FRONT 25 ft- -lb (34 N- -m) 25 ft- -lb (34 N- -m) 30 ft- -lb (41 N- -m) 50 ft- -lb (67 N- -m) 30 ft- -lb (41 N- -m) FRONT Figure 71 1.
Page 143 Filter Manifold Service (Fig. 71) For filter manifold cartridge valve service procedures, see 4WD Manifold Service in this section. Refer to Fig- ure 71 for filter manifold cartridge valve and plug instal- lation torque. Groundsmaster 4100--D/4110--D Page 4 - - 105 Hydraulic System...
Page 144 Steering and Engine Cooling Fan Circuits RIGHT FRONT Figure 72 1. Gear pump 3. Fan drive manifold 5. Steering cylinder 2. Steering control valve 4. Fan motor Figure 72 illustrates the components that are used in the Groundsmaster 4100--D and 4110--D steering and en- gine cooling fan circuits.
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Page 146: Steering Control Valve
Steering Control Valve 16 to 20 ft- -lb (22 to 27 N- -m) RIGHT FRONT Figure 73 1. Hex nut 16. Parking brake switch 31. Flange head screw (4 used) 2. Flat washer 17. Cotter pin 32. Switch bracket 3. Steering wheel 18.
Page 147 Removal (Fig. 73) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of this section.
Page 148: Steering Control Valve Service
Steering Control Valve Service 150 in- -lb (17 N- -m) 140 to 160 in- -lb (16 to 18 N- -m) Figure 75 1. Steering control valve housing 9. Cap screw (7 used) 17. Geroter drive 2. Dust seal 10. End cap 18.
Page 149 6. Install the pin. CAUTION 7. Apply a light coating of petroleum jelly to the inner edge of the dust and quad seals. The centering springs are under tension. Re- 8. Put the thrust bearing and races into the housing. move the retaining ring carefully.
Page 150: Steering Cylinder
Steering Cylinder See text for tightening procedure RIGHT See text for tightening FRONT procedure Figure 77 1. Steering cylinder 7. 90 hydraulic fitting 12. Axle washer 2. Ball joint 8. O- -ring 13. Hex slotted nut 3. Ball joint 9. O- -ring 14.
Page 151 Removal (Fig. 77) Installation (Fig. 77) 1. Park machine on a level surface, lower cutting deck, 1. If removed, install ball joints into steering cylinder. stop engine, engage parking brake and remove key 2. If fittings were removed from steering cylinder, lubri- from the ignition switch.
Page 152: Steering Cylinder Service
Steering Cylinder Service 45 to 55 ft- -lb (62 to 74 N- -m) Figure 78 1. Tube assembly 5. Retaining ring 9. Rod seal 2. Rod 6. Backup ring 10. O- -ring 3. Piston assembly 7. O- -ring 11. O- -ring 4.
Page 153 Disassembly (Fig. 78) Assembly (Fig. 78) 1. Pump oil out of cylinder into a drain pan by SLOWLY 1. Use a complete repair kit when rebuilding the cylin- moving rod and piston in and out of cylinder bore. Plug der. Put a coating of clean hydraulic oil on all new seals ports and clean outside of cylinder.
Page 154: Engine Cooling Fan Motor
Engine Cooling Fan Motor 27 to 33 ft- -lb (37 to 44 N- -m) 16 17 Loctite #242 12 to 14 ft- -lb (17 to 18 N- -m) RIGHT FRONT Figure 79 1. Hydraulic fan motor 8. Washer 15. Hydraulic hose 2.
Page 155 5. Remove four (4) cap screws and washers used to se- IMPORTANT: Make sure to not damage the radiator cure fan (item 13) to fan hub. Remove fan. or other machine components while installing the fan motor and bracket assembly. IMPORTANT: Make sure to not damage the radiator, fan or other machine components while loosening 5.
Page 156: Engine Cooling Fan Motor Service
Engine Cooling Fan Motor Service 33 ft- -lb (45 N- -m) Figure 81 1. Flange washer 7. Shaft seal 12. Idler gear 2. O- -ring 8. Backup gasket 13. Cap screw (4 used) 3. Front flange 9. Pressure seal 14. Dowel pins (2 used) 4.
Page 157 8. Remove and discard back--up gaskets and pressure seals from wear plates. 9. Turn front flange over, with seal side up. IMPORTANT: Make sure not to damage the front flange counter bore when removing the seals from the front flange. 10.Carefully remove dust seal, retaining ring, flange washer and shaft seal from the front flange (Fig.
Page 158 3. Place front flange, seal side down, on a flat surface. 10.Install locating dowel pins in front flange. Align mark- er line on the body and front flange. 4. Install the pressure seals, flat side outward, into the grooves in the wear plates. Follow by carefully placing IMPORTANT: Do not dislodge seals during installa- the backup gaskets, flat side outward, between the tion.
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Page 160: Fan Drive Manifold
Fan Drive Manifold RIGHT FRONT Figure 85 1. Fan drive manifold 10. Hydraulic fitting 19. 90 hydraulic fitting 2. O- -ring 11. Hydraulic hose 20. Hydraulic hose 3. Test fitting 12. Hydraulic hose 21. Hydraulic hose 4. Dust cap (2 used) 13.
Page 161 Removal (Fig. 85) Installation (Fig. 85) 1. Park machine on a level surface, lower cutting deck, 1. If fittings were removed from manifold, lubricate and stop engine, engage parking brake and remove key place new O--rings onto fittings. Install fittings into man- from the ignition switch.
Page 162: Fan Drive Manifold Service
Fan Drive Manifold Service 5 ft- -lb (6.7 N- -m) 5 ft- -lb (6.7 N- -m) FRONT 25 ft- -lb 50 ft- -lb (34 N- -m) (67 N- -m) 20 ft- -lb (27 N- -m) 25 ft- -lb (34 N- -m) 25 ft- -lb 25 ft- -lb (34 N- -m)
Page 163 Fan Drive Manifold Service (Fig. 87) For fan drive manifold cartridge valve service proce- dures, see 4WD Manifold Service in this section. Refer to Figure 87 for fan drive manifold cartridge valve and plug installation torque. Groundsmaster 4100--D/4110--D Page 4 - - 125 Hydraulic System...
Page 164 Mow Circuit RIGHT FRONT Figure 88 1. Gear pump 4. RH PTO manifold 7. Front PTO manifold 2. RH wing deck motor 5. Front cutting deck motor 8. Filter manifold 3. LH wing deck motor 6. LH PTO manifold 9. Oil cooler Figure 88 illustrates the components that are used in the Groundsmaster 4100--D and 4110--D mow circuits.
Page 165 Cutting Deck Motor Removal 5. Remove caps or plugs from fittings and hoses. Using labels placed during motor removal, properly connect 1. Park machine on a level surface, lower cutting deck, hydraulic hoses to deck motor (see Hydraulic Hose and stop engine, engage parking brake and remove key Tube Installation in the General Information section of from the ignition switch.
Page 166: Cutting Deck Motor Service
Cutting Deck Motor Service 27 to 33 ft- -lb (37 to 45 N- -m) 33 to 40 ft- -lb (45 to 55 N- -m) Figure 91 1. Rear cover 6. Tab washer 11. Body 2. Drive gear 7. Spider hub 12.
Page 167 IMPORTANT: Mark the relative positions of the gear teeth and the bearing blocks so they can be re- assembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. 8. Place the motor on its side and push on the rear bear- ing block to remove the bearing block and gear set (Fig.
Page 168 Assembly (Fig. 91) 9. Gently slide the rear cover onto the assembly using marker or scribe mark for proper location. Firm hand NOTE: When assembling the motor, check the identifi- pressure should be sufficient to engage the dowel pins. cation marks made during disassembly to make sure the parts are properly aligned during assembly.
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Page 170 PTO Manifolds RIGHT FRONT Figure 96 1. Front PTO manifold 11. O- -ring 21. R- -clamp 2. O- -ring 12. Dust cap 22. 90 hydraulic fitting 3. Hydraulic adapter 13. Quick fitting 23. Hydraulic fitting 4. O- -ring 14. Flange nut 24.
Page 171 NOTE: The ports on the PTO manifolds are marked for Installation (Fig. 96) easy identification of components. Example: SV1 is the 1. If fittings were removed from manifold, lubricate and deck solenoid valve and P1 is a gear pump connection place new O--rings onto fittings.
Page 172: Pto Manifold Service
PTO Manifold Service 20 ft- -lb 5 ft- -lb (27 N- -m) (6.7 N- -m) 25 ft- -lb 20 ft- -lb (34 N- -m) (27 N- -m) 25 ft- -lb (34 N- -m) 20 ft- -lb (27 N- -m) 50 ft- -lb (67 N- -m) 20 ft- -lb (27 N- -m)
Page 173 PTO Manifold Service (Fig. 97) For PTO manifold solenoid and control valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 97 for PTO manifold cartridge valve and plug installation torque. Groundsmaster 4100--D/4110--D Page 4 - - 135 Hydraulic System...
Page 174 Cutting Deck Lift/Lower Circuit RIGHT FRONT Figure 98 1. Lift/lower manifold 3. LH wing deck lift cylinder 5. Oil filter 2. RH wing deck lift cylinder 4. Fan drive manifold 6. Front deck lift cylinder Figure 98 illustrates the components that are used in the Groundsmaster 4100--D and 4110--D cutting deck lift and lower circuits.
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Page 176 Lift/Lower Manifold RIGHT FRONT Figure 99 1. Lift/lower manifold 3. Washer head screw (2 used) 4. Splash shield 2. Flange head screw (2 used) Removal (Fig. 99) WARNING 1. Park machine on a level surface, lower cutting deck (including wing decks), stop engine, engage parking brake and remove key from the ignition switch.
Page 177 6. Disconnect hydraulic lines from manifold and put caps or plugs on open hydraulic lines and fittings. Label RIGHT disconnected hydraulic lines for proper installation. FRONT 7. Remove lift/lower manifold using Figure 99 as a guide. IMPORTANT: A flow control orifice is placed be- neath the hydraulic fittings in lift/lower manifold ports C2, C4 and C6.
Page 178 Lift/Lower Manifold Service 25 ft- -lb (34 N- -m) 5 ft- -lb (6.7 N- -m) 20 ft- -lb 5 ft- -lb (27 N- -m) (6.7 N- -m) 20 ft- -lb (27 N- -m) 20 ft- -lb 25 ft- -lb (27 N- -m) (34 N- -m) 20 ft- -lb (27 N- -m)
Page 179 Lift/Lower Manifold Service (Fig. 102) WARNING If lift/lower manifold is attached to machine, make sure that cutting deck (including wing decks) is fully lowered before loosening hydrau- lic lines, cartridge valves or plugs from lift/lower manifold. If decks are not fully lowered when manifold components are loosened, decks may drop unexpectedly.
Page 180 Front Deck Lift Cylinder RIGHT FRONT Figure 103 1. Lift cylinder (2 used) 6. Grease fitting 10. Hydraulic fitting 2. Lift arm (LH shown) 7. O- -ring 11. Pivot pin 3. Lock nut 8. 90 hydraulic fitting 12. Cotter pin (2 used per pin) 4.
Page 181 Removal (Fig. 103) Installation (Fig. 103) 1. Park machine on a level surface, lower cutting deck, 1. If fittings were removed from lift cylinder, lubricate stop engine, engage parking brake and remove key and place new O--rings onto fittings. Install fittings into from the ignition switch.
Page 182 Wing Deck Lift Cylinder 160 to 180 ft- -lb (217 to 244 N- -m) 30 to 40 ft- -lb (41 to 54 N- -m) 160 to 180 ft- -lb (217 to 244 N- -m) RIGHT FRONT Figure 104 1. Center deck 6.
Page 183 Removal (Fig. 104) Installation (Fig. 104) 1. Park machine on a level surface, lower cutting deck, 1. If removed, install spherical bearings into lift cylinder stop engine, engage parking brake and remove key clevis ends. from the ignition switch. A. On shaft clevis, press spherical bearing into cle- 2.
Page 184: Lift Cylinder Service
Lift Cylinder Service FRONT DECK LIFT CYLINDER 100 to 120 ft- -lb (136 to 162 N- -m) Figure 105 1. Barrel with clevis 6. O- -ring 10. Wear ring 2. Retaining ring 7. Back- -up ring 11. Piston 3. Shaft with clevis 8.
Page 185 Disassembly (Figs. 105 and 106) Assembly (Figs. 105 and 106) 1. Remove oil from lift cylinder into a drain pan by slowly 1. Make sure all cylinder components are clean before pumping the cylinder shaft. Plug both ports and clean assembly.
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Page 187: Electrical System Quick Checks 5
....... Toro Electronic Controllers (TEC) ....
Page 188: General Information
Groundsmaster 4100--D and 4110--D machines use two The controllers appear identical but they are different in (2) Toro Electronic Controllers (TEC) to manage ma- terms of the connectors and internal hardware. They are chine electrical functions. The controllers are micropro- arranged in ”master / slave”...
Page 189: Special Tools
Multimeter The multimeter can test electrical components and cir- cuits for current, resistance or voltage. NOTE: Toro recommends the use of a DIGITAL Volt-- Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
Page 190: Diagnostic Display
The Diagnostic Display (Fig. 4) can be connected to the wiring harness communication connector located under the controller cover to verify correct electrical functions of the machine. Toro Electronic Controller (TEC) inputs and outputs can be checked using the Diagnostic Dis- play.
Page 191 Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally. Figure 7 Groundsmaster 4100--D/4110--D Page 5 - - 5 Electrical System...
Page 192: Troubleshooting
NOTE: Use the Diagnostic Display (see Special Tools in this chapter) to test Toro Electronic Controller inputs and outputs when troubleshooting an electrical problem on your Groundsmaster. Diagnostic Display...
Page 193 4. Turn the ignition switch to the ON position, but do not start machine. TEC- -5002 MASTER NOTE: The red text on the Diagnostic Display overlay OVERLAY decal refers to input switches and the green text refers to TEC outputs. 5.
Page 194 Diagnostic Display Diagnostic Display TEC- -5002 Master Inputs LED Operation P BRAKE Parking brake released: LED ON Parking brake applied: LED OFF NEUTRAL Traction pedal in neutral: LED ON Traction pedal in forward or reverse: LED OFF SEAT Operator seat occupied: LED ON SWITCH Operator seat empty: LED OFF Hi/Lo speed switch in HI range: LED ON...
Page 195 Diagnostic Display Diagnostic Display TEC- -5001 Slave Inputs LED Operation C DECK Cutting deck lift switch for center deck in RAISE position: LED ON RAISE Lift switch for center deck NOT in RAISE position: LED OFF C DECK Cutting deck lift switch for center deck in LOWER position: LED ON LOWER Lift switch for center deck NOT in LOWER position: LED OFF L DECK...
Page 196 The Diagnostic Display also has the ability to detect correctly illuminated, this indicates a TEC controller which output solenoids or relays are energized by the problem. If this occurs, contact your Toro Distributor TEC controllers. This is a quick way to determine if a ma- for assistance.
Page 197: Starting Problems
Starting Problems Problem Possible Causes No electrical power to machine (including gauges). The battery is discharged. The battery cables are loose or corroded. Fuse F3--1 (2 amp) to the ignition switch is faulty. A faulty ground connection exists on machine. The ignition switch or circuit wiring is faulty.
Page 198 Starting Problems (Continued) Problem Possible Causes Engine cranks, but does not start. The fuel tank is empty. The engine is not cranking fast enough. Fuse F5--1 (40 amp) is faulty preventing the engine run solenoid pull coil from being energized. Fuse M1 (60 amp) is faulty preventing glow plug operation.
Page 199: General Run & Transport Problems
General Run and Transport Problems Problem Possible Causes The engine continues to run, but should not, when the The engine run solenoid is stuck or is faulty. ignition switch is turned off. The ignition switch or circuit wiring is faulty. The engine continues to run, but should not, when the The seat switch or circuit wiring is faulty.
Page 200: Cutting Deck Operating Problems
Cutting Deck Operating Problems Problem Possible Causes The cutting deck remains engaged, but should not, The seat switch or circuit wiring is faulty. with no operator in the seat. TEC--5001 controller is faulty. The cutting deck runs, but should not, with PTO switch The PTO switch or circuit wiring is faulty.
Page 201: Cutting Deck Lift/Lower Problems
Cutting Deck Lift/Lower Problems Problem Possible Causes Neither the cutting deck or wing decks will lower. Hi/Low speed switch is in the Hi speed position. Operator is not fully depressing the seat switch. TEC--5001 fuse(s) (F4--1, F4--2, F4--3, F4--4) are faulty.
Page 202 Cutting Deck Lift/Lower Problems (Continued) Problem Possible Causes LH wing cutting deck will not raise or lower, but the LH deck lift switch or circuit wiring is faulty. front and RH wing cutting decks will raise and lower. Lift control manifold solenoid coils S2, S3 or S4 or circuit wiring is faulty.
Page 203: Electrical System Quick Checks
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level battery terminals. 12.68 V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery 12.45 V 75% charged should be at a temperature of 60...
Page 204: Check Operation Of Interlock Switches
Replace any malfunctioning switches before op- NOTE: Use the Diagnostic Display (see Special Tools erating the machine. in this chapter) to test Toro Electronic Controller inputs and outputs before further troubleshooting of an electri- cal problem on your Groundsmaster. Electrical System...
Page 205: Adjustments
Adjustments Wing Deck Position Switches Adjustment 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove switch cover from deck to allow access to position switch that requires adjustment. 3.
Page 206: Component Testing
Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the CAUTION circuit (e.g. unplug the ignition switch connector before doing a continuity check). When testing electrical components for continu- NOTE: For engine component testing information, see ity with a multimeter (ohms setting), make sure the Kubota Workshop Manual, Diesel Engine, 03--M-- that power to the circuit has been disconnected.
Page 207: Fuses
Fuses The fuse blocks are located in the power center under Fuse Testing the hood on the right side of the machine (Fig. 17). Turn ignition switch to the ON position (do not start en- In addition to the fuses in the fuse blocks, a 40 amp fuse gine).
Page 208: Operator Cab Fuses (Groundsmaster 4110--D)
Operator Cab Fuses (Groundsmaster 4110- -D) The cab fuse blocks are located in the cab headliner (Fig. 19). Identification and Function (Figs. 19 and 21) Fuse F1--1 (20 Amp) protects the air conditioner circuit. Fuse F1--2 (20 Amp) protects the cab lighting circuit. Fuse F1--3 (20 Amp) protects the cab fan and dome light circuits.
Page 209: Chapter 7 - - Chassis
Warning Lights Charge Indicator Light 3. Apply 12 VDC to terminals 1A and 2A (Fig. 23). The charge indicator light should come on when the igni- 4. Ground terminals 1B and 2B (Fig. 23). tion switch is in ON with the engine not running or with 5.
Page 210: Pto Switch
PTO Switch The PTO switch is located on the console arm (Fig. 24). 6. If PTO switch tests correctly and circuit problem still The PTO switch is pulled up to engage the PTO and exists, check wire harness (see Electrical Schematics pushed in to disengage the PTO.
Page 211: Cutting Deck Lift Switches
Cutting Deck Lift Switches The cutting deck lift switches are used as inputs for the 7. After testing is completed, connect wire harness TEC--5001 controller to raise or lower the cutting deck connector to the lift switch. sections. When the front of a lift switch is depressed and 8.
Page 212: Hi/Low Speed And Headlight (Groundsmaster 4110--D) Switches
Hi/Low Speed and Headlight (Groundsmaster 4110- -D) Switches The Hi/Low speed and headlight switches (Ground- 6. After testing is completed, connect wire harness smaster 4110--D) are identical, two (2) position rocker connector to the switch. switches that are located on the control console. 7.
Page 213: Engine Cooling Fan Switch
Engine Cooling Fan Switch The engine cooling fan switch is a two (2) position rocker 6. If switch tests correctly and circuit problem still ex- switch that is located on the outside of the control con- ists, check wire harness (see Electrical Schematics and sole (Fig.
Page 214: Seat Switch
Seat Switch The seat switch is normally open and closes when the operator is occupying the seat. This switch is used as an input for the TEC--5002 controller. The seat switch and its electrical connector are located in the seat assembly. If the traction system or PTO switch is engaged when the operator raises out of the seat, the engine will stop.
Page 215: Parking Brake Switch
Parking Brake Switch The switch used for the parking brake is a normally open switch that is located under the steering tower cover (Fig. 33). The brake switch is used as an input for the TEC--5002 controller. When the parking brake is not ap- plied, the parking brake pawl depresses the switch plunger to close the switch.
Page 216: Main Power, Glow And Cab Power
Main Power, Glow and Cab Power (Groundsmaster 4110- -D) Relays The main power, glow and cab power relays are located 7. Disconnect voltage and test leads from the relay ter- at the power center behind the operator seat (Fig. 34). minals.
Page 217: Start And Air Conditioning (Groundsmaster 4110--D) Relays
Start and Air Conditioning (Groundsmaster 4110- -D) Relays When energized by the TEC--5002 controller, the start minal 85. The relay terminals 30 and 87A should have relay is used to provide current to the engine starter mo- continuity as +12 VDC is removed from terminal 85. tor solenoid.
Page 218: Hydraulic Valve Solenoid Coils
Hydraulic Valve Solenoid Coils RIGHT FRONT Figure 38 1. 4WD manifold 3. RH wing deck manifold 5. Fan drive manifold 2. LH wing deck manifold 4. Front deck manifold 6. Lift/lower manifold Several hydraulic solenoid valve coils are used on the NOTE: To assist in troubleshooting, identical solenoid hydraulic control manifolds of Groundsmaster 4100--D coils can be exchanged.
Page 219 Testing 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Locate hydraulic valve solenoid coil to be tested (Fig. 38). Disconnect wire harness connector from coil. 3.
Page 220: Toro Electronic Controllers (Tec)
Toro Electronic Controllers (TEC) Groundsmaster 4100--D and 4110--D machines use two Toro Electronic Controllers (TEC) to control electrical RIGHT system operation. The controllers are attached to the operator platform under the controller cover (Fig. 41). FRONT Logic power is provided to the controllers as long as the battery cables are connected to the battery.
Page 221: Hour Meter
Hour Meter The hour meter is located on the outside of the console 7. Assemble console arm (see Console Arm Assembly arm. in the Service and Repairs section of Chapter 7 -- Chas- sis). Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch.
Page 222: Fuel Sender
Fuel Sender The fuel sender is located on top of the fuel tank (Fig. 7. Replace sender as necessary. Reinstall sender into 44). fuel tank. Testing 8. Connect wires to fuel sender. Apply skin--over grease (see Special Tools in this chapter) to sender ter- 1.
Page 223: Fuel Gauge
Fuel Gauge The fuel gauge can be tested using a new gauge as a substitute or with the use of a DC voltage source and a variable resistance box (see Fuel Sender Testing in this section for additional information). Testing 1.
Page 224: Fuel Pump
Fuel Pump The fuel pump is attached to the frame above the fuel water separator (Fig. 48). Operational Test 1. Park machine on a level surface, lower cutting deck, stop engine and apply parking brake. Raise and support hood. 2. Remove fuse F1--1 (20A) (Fig. 49) from fuse block to prevent the engine from cranking.
Page 225: Temperature Sender
B. Screw sender into the water flange. Torque send- er from 16 to 20 ft- -lb (22 to 27 N- -m). C. Reconnect gray harness wire to sender. Apply skin--over grease (Toro Part No. 505--165) to sender terminal. 5. Fill engine cooling system.
Page 226: Temperature Gauge
Temperature Gauge The temperature gauge on the control panel indicates engine coolant temperature level during machine op- eration (Fig. 52). The changing resistance of the engine temperature sender signals the temperature gauge. The temperature gauge should display the first green segment when the ignition switch is turned to ON.
Page 227: Traction Neutral Switch
Traction Neutral Switch The traction neutral switch is closed when the traction See the Eaton Model 72400 Servo Controlled Piston pedal is in the neutral position and opens when the pedal Pump Repair Information at the end of Chapter 4 -- Hy- is depressed in either direction (forward or reverse).
Page 228: Wing Deck Position Switches
Wing Deck Position Switches Two (2) wing deck position switches are used on the B. Using a multimeter, verify that wire harness con- Groundsmaster 4100--D and 4110--D as inputs for the nector terminal for pink wire has 12 VDC when the TEC--5001 controller.
Page 229: Engine Coolant And Hydraulic Oil Temperature Senders
Engine Coolant and Hydraulic Oil Temperature Senders The Groundsmaster 4100--D and 4110--D use two (2) 6. Check and fill system (coolant or hydraulic) to proper temperature senders as inputs for the TEC--5002 to level. identify if either the engine coolant or hydraulic oil tem- perature has reached an excessive level.
Page 230: Service And Repairs
A. Clean battery by washing entire case with a solu- tion of baking soda and water. Rinse with clear water. B. Coat battery posts and cable connectors with ter- minal protector (Toro Part No. 107--0392) or petro- leum jelly to prevent corrosion. Electrical System...
Page 231: Battery Service
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes.
Page 232 2. Conduct a hydrometer test of the battery electrolyte. B. If the battery has recently been charged, apply a 150 amp load for 15 seconds to remove the surface IMPORTANT: Make sure the area around the cells is charge. Use a battery load tester following the clean before opening the battery caps.
Page 233 Battery Charging CAUTION To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging meth- od is presented here. This charging method can be ac- Do not charge a frozen battery because it can ex- complished with a constant current battery charger plode and cause injury.
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Page 235 Chapter 6 Axles, Planetaries and Brakes Table of Contents SPECIFICATIONS ......GENERAL INFORMATION .
Page 236 Specifications Item Specification Tire pressure (front and rear) 25 to 30 PSI (172 to 207 kPa) Rear wheel toe--in 0.125 in (3.18 mm) Planetary gear drive oil SAE 85W--140 wt. gear lube System gear lube capacity (each wheel) 16 fl. oz. (0.47 liters) Rear axle lubricant SAE 85W--140 wt.
Page 237: General Information
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Groundsmaster 4100--D/4110--D Page 6 - - 3 Axles, Planetaries and Brakes...
Page 238: Service And Repairs
Service and Repairs Brake Assembly 85 to 100 ft- -lb (115 to 135 N- -m) 75 to 85 ft- -lb (101 to 115 N- -m) RIGHT FRONT 75 to 85 ft- -lb (101 to 115 N- -m) Figure 1 1. Planetary assembly 7.
Page 239 Removal (Fig. 1) 1. Park machine on a level surface, lower cutting deck, stop engine and remove key from the ignition switch. 2. Drain oil from planetary wheel drive/brake assembly. CAUTION When removing front wheel, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor.
Page 240 Installation (Fig. 1) 1. Install splined brake shaft (item 3) into brake assem- bly. NOTE: The stepped end of the splined brake shaft must be aligned toward the hydraulic wheel motor (Fig. 2. Apply gasket sealant to sealing surfaces of new gas- ket (item 11).
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Page 242: Brake Service
Brake Service Figure 6 1. Brake housing (LH shown) 6. Hitch pin (2 used) 11. Rotating actuator 2. Seal 7. Stationary disc (4 used) 12. Extension spring (3 used) 3. Pull rod 8. Rotating disc (3 used) 13. Ball (3 used) 4.
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Page 244: Planetary Wheel Drive Assembly
Planetary Wheel Drive Assembly 85 to 100 ft- -lb (115 to 135 N- -m) 75 to 85 ft- -lb (101 to 115 N- -m) RIGHT FRONT 75 to 85 ft- -lb (101 to 115 N- -m) Figure 7 1. Planetary assembly 6.
Page 245 Removal (Fig. 7) 4. Secure hydraulic wheel motor to planetary assembly with two (2) cap screws. Torque screws from 75 to 85 ft- - 1. Park machine on a level surface, lower cutting deck, lb (101 to 115 N- -m). stop engine, engage parking brake and remove key from the ignition switch.
Page 246: Planetary Wheel Drive Service
Planetary Wheel Drive Service 9 ft- -lb (12 N- -m) Figure 9 1. Spindle 9. Thrust washer 17. Drive shaft 2. Boot seal 10. Retaining ring (external) 18. Carrier assembly 3. Bearing cone 11. Ring gear 19. Socket head screw (16 used) 4.
Page 247 Disassembly (Figs. 9 and 10) 1. If planetary wheel drive assembly is installed on ma- chine: A. Park machine on a level surface, lower cutting deck, stop engine and remove key from the ignition switch. B. Drain oil from planetary wheel drive/brake as- sembly.
Page 248 F. Lightly oil bearing journals on spindle shaft. Slide 3. Install carrier assembly (item 18) making sure that housing onto spindle (item 1) taking care to not dam- carrier gear teeth align with ring gear and spline on age seal or spindle. Make sure that bearing in hous- spindle shaft.
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Page 250: Rear Axle Assembly
Rear Axle Assembly See text for RIGHT tightening procedure FRONT Figure 11 1. Frame 8. Rear axle assembly 14. Lock nut 2. Cap screw (6 used) 9. Thrust washer (thin) 15. Flange nut 3. Flat washer 10. Washer head screw 16.
Page 251 8. Remove cap screw and flange nut that secures front corner of 4WD hydraulic manifold to rear frame mount. 9. If required, remove tie rod ends from steering arms on rear axle (Fig. 13). Remove the cotter pins and castle nuts from the tie rod ball joints.
Page 252 8. Install steering cylinder to axle assembly (see Steer- ing Cylinder Installation in the Service and Repairs sec- tion of Chapter 4 -- Hydraulic System). 9. Install hydraulic motor to axle assembly (see Rear Axle Motor Installation in the Service and Repairs sec- tion of Chapter 4 -- Hydraulic System).
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Page 254: Rear Axle Service
Rear Axle Service Figure 16 Axles, Planetaries and Brakes Page 6 - - 20 Groundsmaster 4100--D/4110--D...
Page 255 Figure 16 (Continued) 1. LH axle support 22. O- -ring 43. Collar 2. Flange bushing (2 used) 23. RH axle support 44. Bevel gear (17 tooth) 3. Axle vent 24. Input shaft assembly 45. Bevel gear shaft 4. O- -ring 25.
Page 256: Bevel Gear Case And Axle Case
Bevel Gear Case and Axle Case The following procedures assume the rear axle assem- 35 to 41 ft- -lb bly has been removed from the machine (see Rear Axle (47 to 56 N- -m) Assembly Removal in this section). Bevel Gear Case and Axle Case Removal 1.
Page 257 5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gas- ket material from either mating surface (Fig. 20). 6. While holding the bevel gear case, tap the upper end 17 to 20 ft- -lb (23 to 27 N- -m) of the bevel gear shaft out of the upper bearing and up- per bevel gear.
Page 258 Bevel Gear Case and Axle Case Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 22). Figure 22 1. Axle case 3. Shaft seal 2. Bevel gear case 2. Install the lower bevel gear and bevel gear shaft in the axle case cover.
Page 259 5. Determine necessary quantity of support shims. 57 to 67 ft- -lb A. Lubricate the axle case support bushing with a (77 to 91 N- -m) thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during VERTICAL disassembly between axle case support and axle ENDPLAY...
Page 260 9. Remove the bevel gear case/axle case assembly NOTE: Axle bearing shims are available in 0.008 in. from the axle support. Coat a new O-ring with grease (0.2 mm), 0.012 in. (0.3 mm) and 0.020 in. (0.5 mm) and temporarily install the axle cover assembly. Position thickness.
Page 261: Differential Shafts
Differential Shafts The following procedures assume the rear axle assem- 35 to 41 ft- -lb bly has been removed from the machine (see Rear Axle (47 to 56 N- -m) Assembly Removal in this section). Differential Shaft Removal IMPORTANT: Do not interchange right and left dif- ferential shaft assemblies.
Page 262: Axle Shafts
Axle Shafts The following procedures assume the rear axle assem- 17 to 20 ft- -lb bly has been removed from the machine (see Rear Axle (23 to 27 N- -m) Assembly Removal in this section). Axle Shaft Removal 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig.
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Page 264: Input Shaft/Pinion Gear
Input Shaft/Pinion Gear 35 to 41 ft- -lb (47 to 56 N- -m) 35 to 41 ft- -lb (47 to 56 N- -m) Figure 32 1. Nut (2 used) 7. O-ring 13. Shim 2. Lock washer (2 used) 8. Seal collar 14.
Page 265 7. Secure the lock nut with the stake washer. 8. Use a depth gauge to measure the distance from the end face of the input shaft/pinion gear to the mating sur- face of the bearing case. Subtract the “Design Cone Center Distance”...
Page 266: Differential Gear
Differential Gear The following procedures assume the rear axle assem- 35 to 41 ft- -lb bly has been removed from the machine (see Rear Axle (47 to 56 N- -m) Assembly Removal in this section). Differential Gear Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual).
Page 267 Differential Gear Inspection 1. Measure the differential side gear O.D. and the dif- ferential case I.D. to determine the side gear to case clearance (Fig. 39). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 in. (0.05 to 0.30 mm) SIDE GEAR O.D.
Page 268 Differential Gear Installation 1. If the ring gear was removed, use medium strength thread locking compound and torque the mounting screws from 22 to 25 ft-lb (30 to 34 N- -m). 2. Apply molybdenum disulfide grease to the splines and bearing surfaces of the differential pinion gears, pin- ion washers and side gears.
Page 269: Pinion Gear To Ring Gear Engagement
Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using PROFILE the gear contact pattern method as described in the fol- TOP LAND lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 43): Toe -- the portion of the tooth surface at the end to- LENGTHWISE wards the center.
Page 270 Gear Pattern Movement Summary Heel Contact Base Contact Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as gear location is changed. 1. If contact is toward the heel or base of the gear (Fig. 46): A.
Page 271 Chapter 7 Chassis Table of Contents GENERAL INFORMATION ..... Operator’s Manual ......SERVICE AND REPAIRS .
Page 272: Service And Repairs
Service and Repairs Steering Tower RIGHT FRONT 16 to 20 ft- -lb (22 to 27 N- -m) Figure 1 1. Hex nut 15. Lock nut (2 used) 28. Steering column 2. Flat washer 16. Parking brake switch 29. Cap screw (2 used) 3.
Page 273 Disassembly (Fig. 1) Assembly (Fig. 1) 1. Park machine on a level surface, lower cutting deck, 1. Assemble steering tower using Figure 1 as a guide. stop engine, engage parking brake and remove key A. Thrust washers (item 24) on steering column are from the ignition switch.
Page 274: Cutting Deck Lift Arms
Cutting Deck Lift Arms 60 to 70 ft- -lb (81 to 94 N- -m) RIGHT Loctite #271 on threads FRONT 30 to 40 ft- -lb (41 to 54 N- -m) 20 21 155 to 185 ft- -lb (211 to 251 N- -m) 25 16 75 to 85 ft- -lb (102 to 115 N- -m)
Page 275 E. Thoroughly clean tapered surfaces of stud and CAUTION mounting boss of support hub. Secure support hub (position slotted hole in hub toward rear of deck) to tapered stud with flat washer and flange nut. Torque When changing attachments, tires or perform- flange nut from 155 to 185 ft- -lb (211 to 251 N- -m).
Page 276: Console Arm
Console Arm RIGHT FRONT Figure 5 1. Flange nut (3 used) 16. Warning lamp (glow plug/temp) 31. Cap 2. Flange head screw (2 used) 17. PTO switch 32. Engine cooling fan control switch 3. Foam seal 18. Hole plug 33. Nut 4.
Page 277 Disassembly (Fig. 5) 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 2. Remove two (2) flange head screws (item 40) and then cover plate (item 39) from outside of console arm. Locate and retrieve two (2) spacers (item 38).
Page 278: Operator Seat
Operator Seat RIGHT FRONT Figure 7 1. Platform 14. Flat washer (2 used) 27. Seat and suspension assembly 2. Clevis pin (2 used) 15. Flat washer (4 used) 28. Cap screw 3. Hair pin (2 used) 16. R- -clamp (2 used) 29.
Page 279 Removal (Fig. 7) B. Secure console arm support (item 35) to coupler nut (item 38) with cap screw (item 37). 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from C. Place flat washer (item 20), seat belt latch (item the ignition switch.
Page 280: Operator Seat Service
Operator Seat Service Figure 10 Backrest cushion 11. Washer 21. Torx screw (5 used) Seat cushion 12. Cap screw (2 used) 22. RH adjustment rail Armrest cover 13. Seat 23. Rail stop LH armrest 14. Nut 24. Torx screw Bushing (2 used) 15.
Page 281 Disassembly (Fig. 10) 1. Disassemble operator seat as necessary using Fig- ures 10 and 11 as guides. Assembly (Fig. 10) 1. Assemble operator seat using Figures 10 and 11 as guides. 7 11 Figure 11 1. Operator seat 7. Flat washer 2.
Page 282: Operator Seat Suspension
Operator Seat Suspension RIGHT FRONT Figure 12 Cover 14. Washer (2 used) 27. Clamp (2 used) Cover 15. Tether 28. Hose nipple Level control 16. Rivet (2 used) 29. Screw Air control valve 17. Washer (4 used) 30. Handle Shock absorber 18.
Page 283 NOTE: Most of the seat suspension components can be serviced with the seat suspension base mounted to the frame platform. If the air spring assembly (item 6) re- quires removal, the seat suspension base will have to be removed from the seat platform. Disassembly (Fig.
Page 284: Hood
Hood RIGHT FRONT Figure 15 Rear screen 18. Latch cover 34. LH screen mount Top screen 19. Latch 35. Carriage bolt (2 used) Cap screw (22 used) 20. Hood latch bracket 36. Flange nut (2 used) Screen assembly 21. Washer head screw (2 used) 37.
Page 285 Removal 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove hood using Figure 15 as a guide. Installation 1. Install hood using Figure 15 as a guide. 2.
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Page 287 Chapter 8 Cutting Deck Table of Contents SPECIFICATIONS ......GENERAL INFORMATION ..... Operator’s Manual .
Page 288: Specifications
Specifications MOUNTING: Cutting deck is supported by lift arms con- CUTTING BLADE: Cutting blade dimensions are 19” trolled with individual lift switches. (483 mm) long, 2.5” (64 mm) wide and 0.250” (6.4 mm) thick. Anti--scalp cup installed on each cutting blade. CONSTRUCTION: Deck chamber is welded 12 gauge Center deck includes three (3) blades and each wing steel construction reinforced with channels and plates.
Page 289: General Information
General Information CAUTION Never install or work on the cutting deck or lift arms with the engine running. Always stop en- gine and remove ignition key first. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance, adjustments and maintenance intervals for your Groundsmaster cutting deck.
Page 290: Troubleshooting
Troubleshooting There are a number of factors that can contribute to un- Remember that the “effective” or actual height--of--cut satisfactory quality of cut, some of which may be turf depends on cutting deck weight, tire pressures, hydrau- conditions. Turf conditions such as excessive thatch, lic counterbalance settings and turf conditions.
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Page 292: Service And Repairs
Service and Repairs CAUTION Never install or work on the cutting deck or lift arms with the engine running. Always stop en- gine and remove ignition key first. Cutting Deck RIGHT FRONT 75 to 85 ft- -lb (102 to 115 N- -m) Figure 1 1.
Page 293 Removal (Fig. 1) 1. Position machine on a clean, level surface. Lower cutting deck, stop engine, engage parking brake and re- move key from the ignition switch. NOTE: Removal of clevis pins from deck and height-- of--cut chains is easier if deck is lifted slightly. 2.
Page 294 NOTE: Installation of clevis pins to deck and height--of-- cut chains is easier if deck is lifted slightly. 4. Install clevis pins and hairpins that secure the height--of--cut chains to the rear of the cutting deck (Fig. 5. Remove plugs from hydraulic hoses and fittings on wing deck lift cylinders.
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Page 296: Wing Deck Service
Wing Deck Service 30 to 40 ft- -lb 160 to 180 ft- -lb (41 to 54 N- -m) (217 to 244 N- -m) RIGHT FRONT Figure 6 1. Wing deck (RH shown) 19. Flange nut (front links) 37. Tapered stud 2.
Page 297 Removal (Fig. 6) 1. Position machine on a clean, level surface. Lower cutting deck and engage parking brake. 2. Fully raise wing deck, stop engine and remove key from the ignition switch. Remove three (3) washer head screws and shield strap that secure flex shield to wing deck.
Page 298 4. Position upper end of links to center cutting deck 10.Fully raise wing deck, stop engine and remove key brackets. from the ignition switch. Secure flex shield to wing deck with shield strap and three (3) washer head screws. 5. Align upper end of links with mounting holes in center Lower wing deck.
Page 299: Cutting Deck Link Service
Cutting Deck Link Service Disassembly (Fig. 10) 30 to 40 ft- -lb (41 to 54 N- -m) 1. Press bushings from top of link. 2. Remove dust cap and retaining ring from link. 3. Press tapered stud with spherical bearing, flat wash- ers and flange nut from link.
Page 300: Wing Deck Latch
Wing Deck Latch Disassembly (Fig. 12) 1. Raise wing deck to transport position. Carefully ro- tate latch to closed position. 2. Loosen lug nut to release compression spring ten- sion. 3. Remove retaining ring and flat washer from bottom of latch pin. Rotate lug nut enough to allow latch pin to be removed from latch.
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Page 302: Blade Spindle
Blade Spindle RIGHT 88 to 108 ft- -lb FRONT (119 to 146 N- -m) Figure 13 1. Cutting deck 5. Flange head screw 9. Anti- -scalp cup 2. Drive spindle: single pulley (2 used) 6. Flange nut 10. High driven spindle (1 used) 3.
Page 303 Installation (Fig. 13) 1. Position spindle on cutting deck noting orientation of grease fitting (Fig. 15). Secure spindle assembly to deck with removed fasteners. 2. Install cutting blade, anti--scalp cup and blade bolt. Tighten blade bolt from 88 to 108 ft- -lb (119 to 146 N- -m).
Page 304: Blade Spindle Service
Blade Spindle Service DRIVEN SPINDLE 130 to 150 ft- -lb (176 to 203 N- -m) DRIVE SPINDLE Figure 16 1. Lock nut 7. O- -ring 13. Snap ring 2. Flat washer 8. Oil seal 14. Grease fitting 3. Driven pulley 9.
Page 305 2. Install outer bearing spacer into top of spindle hous- ing. The spacer should fit against the snap ring. 3. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the outer bearing spacer previously installed, and the bottom bearing cup must contact the snap ring.
Page 306: Idler Assembly
Idler Assembly RIGHT FRONT Figure 20 1. Center deck 9. Socket head screw 17. Idler arm 2. Flange nut 10. Idler stop bolt 18. Retaining ring 3. Flange nut 11. Flange nut 19. Thrust washer (4 used per idler) 4. Adjusting screw 12.
Page 307 Removal (Fig. 20) CAUTION 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. Be careful when installing the idler spring. The spring is under heavy load and may cause per- 2.
Page 308: Chapter 8 - - Cutting Deck
Castor Forks and Wheels DECK CASTOR ARM WING DECK CASTOR FORK 60 to 80 ft- -lb (81 to 108 N- -m) CASTOR WHEEL 60 to 80 ft- -lb (81 to 108 N- -m) Figure 22 1. Castor arm (wing deck shown) 13.
Page 309 Disassembly (Fig. 22) Assembly (Fig. 22) 1. Park machine on a level surface, lower cutting deck, 1. Assemble castor forks and wheels using Figure 22 stop engine, engage parking brake and remove key as a guide. from the ignition switch. 2.
Page 310: Deck Rollers And Skids
Deck Rollers and Skids RIGHT FRONT Figure 23 1. Roller 5. Lock nut 8. Flange nut 2. Flange head screw 6. Roller 9. Skid (RH shown) 3. Roller shaft 7. Cap screw 10. Flange head screw 4. Flange nut Removal (Fig. 23) Installation (Fig.
Page 311 Chapter 9 Operator Cab Table of Contents GENERAL INFORMATION ..... Operator’s Manual ......Electrical Components and Schematic .
Page 312: General Information
General Information The information in this chapter pertains to the operator cab on the Groundsmaster 4110--D. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster. Refer to the Opera- tor’s Manual for additional information when servicing the machine.
Page 313: Service And Repairs
Service and Repairs General Precautions for Removing and Installing Air Conditioning System Components 4. Put labels on disconnected lines and hoses for prop- CAUTION er installation after repairs are completed. 5. Put caps or plugs on any lines, fittings or components left open or exposed to prevent system contamination.
Page 314 Air Conditioning Compressor FRONT RIGHT Figure 1 1. Cap screw (3 used) 13. Idler plate bracket 25. Hex nut (2 used) 2. Lock washer (8 used) 14. Lock nut 26. Cap screw 3. Pulley 15. Cap screw 27. Flat washer 4.
Page 315 5. Disconnect compressor electrical connector from 2. The clearance between the compressor mounting machine wire harness. flanges and mounting brackets must be less than 0.004” (0.10 mm). If necessary, install shims between com- 6. Read the General Precautions for Removing and pressor flanges and brackets to adjust clearance.
Page 316 Roof Assembly RIGHT FRONT Figure 3 1. Flange head screw (8 used) 5. Panel nut (4 used) 9. Headliner spacer 2. Flat washer (4 used) 6. Rear coupling plate (2 used) 10. Front coupling plate (2 used) 3. Bushing (4 used) 7.
Page 317 To gain access to the heater core and air conditioning components that are located above the cab headliner, the roof panel can be loosened, raised and supported. Removal (Fig. 3) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch.
Page 318 Cab Hose Identification RIGHT FRONT Figure 5 1. Grommet 8. AC hose (evaporator to compressor) 15. Heater evaporator assembly 2. AC hose (compressor to condenser) 9. AC hose (drier to evaporator) 16. O- -ring 3. AC hose (condenser coil to drier) 10.
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Page 320 Air Conditioning Condenser Assembly Figure 6 1. Condenser cover 6. Flat washer (4 used) 11. Coupler nut (4 used) 2. Flange nut (4 used) 7. Roof 12. Condenser fan mount 3. Condenser fan 8. Bushing (4 used) 13. AC hose (compressor to coil) 4.
Page 321 Removal (Fig. 6) Installation (Fig. 6) 1. Park machine on a level surface, lower cutting 1. Position condenser coil to roof. decks, stop engine, engage parking brake and remove 2. Remove caps that were placed on A/C hoses and fit- key from the ignition switch.
Page 322 Heater/Evaporator Assembly Figure 7 1. Heater/evaporator assembly 6. Hose clamp (2 used) 10. Screw (8 used) 2. Top cover 7. Speed nut (8 used) 11. Screw (5 used) 3. Flange head screw (2 used) 8. Panel nut (4 used) 12. Binary switch 4.
Page 323 Removal (Fig. 7) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove fasteners that secure roof in place. Raise and support roof to allow access to heater/evaporator assembly (see Roof Assembly Removal in this section).
Page 324 3. Slide air duct hose onto heater/evaporator assembly 7. Make sure that all machine air conditioning compo- covers and secure with cable tie. nents are installed and secure. 4. Remove caps that were placed on hoses and fittings 8. Have a certified air conditioning service technician during the removal process.
Page 325 Chapter 10 Foldout Drawings Table of Contents HYDRAULIC SCHEMATIC ..... ELECTRICAL SCHEMATIC Sheet 1 of 3 ....... . Sheet 2 of 3 .
Page 326 This page is intentionally blank. Page 10 - -2 Foldout Drawings Groundsmaster 4100--D/4110--D...
Page 327 2.000 BORE 7.875 STROKE .070 0.750 ROD .063 .035 .063 2.125 BORE 3.500 STROKE 1.000 ROD FRONT PTO MANIFOLD 2500 PSI 2.000 BORE 7.875 STROKE LIFT/LOWER 0.750 ROD MANIFOLD MANIFOLD LH PTO MANIFOLD BYPASS VALVE FAN DRIVE MANIFOLD FILTER MANIFOLD RH PTO MANIFOLD Groundsmaster 4100--D/4110--D...
Page 328 Groundsmaster 4100--D/4110--D Electrical Schematic Sheet 1 of 3 All relays and solenoids are shown as de- - energized. All ground wires are black. NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON THREE (3) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER WILL BE IDENTIFIED.
Page 329 (BRAKE APPLIED) (NOT IN NEUTRAL) (SEAT UNOCCUPIED) ENGINE OIL PRESSURE (OPTIONAL KIT) (OPTIONAL KIT) ALTERNATOR (OPTIONAL KIT) Groundsmaster 4100--D/4110--D Electrical Schematic Sheet 2 of 3 All relays and solenoids are shown as de- - energized. All ground wires are black. NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON THREE (3) SHEETS.
Page 330 (NOT USED) (NOT USED) Groundsmaster 4100--D/4110--D Electrical Schematic Sheet 3 of 3 All relays and solenoids are shown as de- - energized. All ground wires are black. NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON THREE (3) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER WILL BE IDENTIFIED.
Page 331 Groundsmaster 4110--D Operator Cab Electrical Schematic Sheet 1 of 3 All relays and solenoids are shown as de- - energized. All ground wires are black. Page 10 - - 7...
Page 332 Groundsmaster 4110--D Operator Cab Electrical Schematic Sheet 2 of 3 All relays and solenoids are shown as de- - energized. All ground wires are black. Page 10 - - 8...
Page 333 Groundsmaster 4110--D Operator Cab Electrical Schematic Sheet 3 of 3 All relays and solenoids are shown as de- - energized. All ground wires are black. Page 10 - - 9...
Page 334 This page is intentionally blank. Page 10 - - 10...
Page 335 (OPTIONAL KIT) TO REAR HARNESS (OPTIONAL KIT) (OPTIONAL KIT) A/C CLUTCH & (OPTIONAL KIT) WS WASHER PUMP (OPTIONAL KIT) NOTE CLOCK POSITION NOTE CLOCK POSITION (OPTIONAL KIT) TO REAR HARNESS (NOT USED) TO REAR TO REAR HARNESS HARNESS (OPTIONAL KIT) Groundsmaster 4100--D/4110--D Platform Wire Harness Drawing Page 10 - - 11...
Page 336 TO REAR HARNESS TO REAR HARNESS VIOLET WHITE/YELLOW BLACK BLACK WHITE PINK GRAY PINK RED/WHITE BLACK/WHITE RED/WHITE RED/WHITE BLACK/WHITE BLACK/WHITE BLACK BLACK BLACK BLACK BLACK BROWN BLACK PINK/BLACK VIOLET BLACK BLACK PINK/BLACK BLACK RED/GREEN BLACK GREEN (OPTIONAL KIT) (OPTIONAL KIT) (OPTIONAL KIT) (OPTIONAL KIT) (OPTIONAL KIT)
Page 337 TO REAR HARNESS TO REAR HARNESS (NOT USED) GRAY/BLACK VIOLET/BLACK YELLOW/BLACK WHITE/YELLOW VIOLET PINK BLACK RED/GREEN BROWN/BLACK VIOLET PINK/GREEN BROWN/YELLOW TAN/WHITE BLUE/BLACK YELLOW/BLUE YELLOW/BLUE PINK GREEN/BLACK ORANGE/BLACK BLACK VIOLET/BLACK BLACK BLACK ORANGE/WHITE WHITE/BLUE WHITE/BLUE PINK/BLACK BLACK BLACK BLACK BLACK TAN/BLACK VIOLET/WHITE PINK/WHITE TAN/WHITE...
Page 338 PLUG FUSEBLOCKS MAXI FUSES PLUG TO PLATFORM HARNESS TO PLATFORM HARNESS TO PLATFORM HARNESS TO PLATFORM HARNESS Groundsmaster 4100--D/4110--D Rear Wire Harness Drawing Page 10 - - 14...
Page 339 BLACK VIOLET BLACK BLUE BLACK WHITE/BLACK BROWN/BLACK TAN/BLACK TO PLATFORM GRAY/BLACK HARNESS BLUE PINK/BLACK WHITE WHITE/ORANGE BLACK YELLOW PINK VIOLET ORANGE BLACK BLACK WHITE/YELLOW RED/BLACK BLACK BROWN PINK RED/BLUE TO PLATFORM HARNESS RED/GREEN WHITE/BLACK BLACK BROWN/BLACK TAN/BLACK GRAY/BLACK PINK BLACK BLACK PINK YELLOW/BLUE...
Page 340 PLATFORM HARNESS PLATFORM HARNESS Groundsmaster 4100--D/4110--D Cutting Deck Wire Harness Page 10 - - 16...

This manual is also suitable for:

30449 Groundsmaster 4110-d 30447

Toro Groundsmaster 4100-D Service Manual

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Chapter 1 -- Safety

Chapter 2 -- Product Records and Maintenance

Chapter 3 Kubota Diesel Engine

Chapter 6 -- Axles, Planetaries and Brakes

Chapter 5 Electrical System

Chapter 7 - - Chassis

Chapter 6 Axles, Planetaries and Brakes

Chapter 7 Chassis

Chapter 8 Cutting Deck

Chapter 4 -- Hydraulic System

Quick Links

Service Manual

Chapters

Troubleshooting

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Summary of Contents for Toro Groundsmaster 4100-D