Toro Groundsmaster 4100-D, 4110-D (Model 30449, 30447) Service Repair Manual

Table of Content – Groundsmaster 4100-D, 4110-D (Model 30449, 30447)

Title Page
Revision History
Reader Comments
Preface
1 – Safety
General Safety Instructions
Before Operating
While Operating
Maintenance and Service
Jacking Instructions
Safety and Instruction Decals
2 – Product Records and Maintenance
Product Records
Maintenance
Equivalents and Conversions
Decimal and Millimeter Equivalents
US to Metric Conversions
Torque Specifications
Fastener Identification
Using a Torque Wrench with an Offset Wrench
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)
Other Torque Specifications
Conversion Factors
3 – Kubota Diesel Engine
Specifications
General Information
Operator’s Manual
Stopping the Engine
Service and Repairs
Air Filter System
Exhaust System
Fuel System
Radiator
Engine
Engine Removal
Engine Installation
Spring Coupler
Kubota Diesel Engine Workshop Manual
4 – Hydraulic System
Specifications
General Information
Operator’s Manual
Check Hydraulic Fluid
Towing Traction Unit
Relieving Hydraulic System Pressure
Traction Circuit Component Failure
Hydraulic Hoses
Hydraulic Hose and Tube Installation
Hydraulic Fitting Installation
Hydraulic Schematic
Hydraulic Flow Diagrams
Traction Circuit: Low Speed (4WD)
Traction Circuit: Hi Speed (2WD)
Lower Cutting Deck
Raise Cutting Deck
Mow Circuit
Mow Circuit Cutting Deck Blade Braking
Steering Circuit
Engine Cooling Fan Circuit
Special Tools
Hydraulic Pressure Test Kit
15 GPM Hydraulic Tester Kit (Pressure and Flow)
40 GPM Hydraulic Tester (Pressure and Flow)
Hydraulic Hose Kit
High Flow Hydraulic Filter Kit
O–Ring Kit
Hydraulic Test Fitting Kit
Measuring Container
Troubleshooting
General Hydraulic System Problems
Traction Circuit Problems
Mow Circuit Problems
Lift Circuit Problems
Steering Circuit Problems
Engine Cooling Fan Circuit Problems
Testing
Traction Circuit Charge Pressure
Traction Circuit Relief Pressure
Counterbalance Pressure
Traction Circuit Reducing Valve (PR) Pressure
Rear Traction Circuit (RV) Relief Pressure
Piston (Traction) Pump Flow Test
Cutting Deck Circuit Pressure
PTO Relief Pressure
Cutting Deck Motor Case Drain Leakage
Cutting Deck Gear Pump Flow
Steering Circuit Relief Pressure
Steering Cylinder Internal Leakage
Lift, Lower Circuit Relief Pressure
Steering and Lift, Lower Gear Pump Flow
Engine Cooling Fan Circuit
Engine Cooling Fan Circuit Gear Pump Flow
Adjustments
Adjust Control Manifold Relief Valves
Traction Linkage Adjustment
Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Check Hydraulic Lines and Hoses
Flush Hydraulic System
Filtering Closed–Loop Traction Circuit
Charge Hydraulic System
Hydraulic Reservoir
Hydraulic Oil Cooler
Gear Pump
Gear Pump Service
Traction Circuit
Piston (Traction) Pump
Piston (Traction) Pump Service
Rear Axle Motor
Front Wheel Motors
Rear Axle and Front Wheel Motor Service
4WD Manifold
4WD Manifold Service
Filter Manifold
Filter Manifold Service
Steering and Engine Cooling Fan Circuits
Steering Control Valve
Steering Control Valve Service
Steering Cylinder
Steering Cylinder Service
Engine Cooling Fan Motor
Engine Cooling Fan Motor Service
Fan Drive Manifold
Fan Drive Manifold Service
Mow Circuit
Cutting Deck Motor
Cutting Deck Motor Service
PTO Manifolds
PTO Manifold Service
Cutting Deck Lift, Lower Circuit
Lift, Lower Manifold
Lift, Lower Manifold Service
Front Deck Lift Cylinder
Wing Deck Lift Cylinder
Lift Cylinder Service
Eaton Piston Pump Repair Information
Eaton Piston Motor Repair Manual
5 – Electrical System
General Information
Operator’s Manual
Toro Electronic Controllers (TEC)
CAN–bus Communications
Electrical Drawings
Special Tools
Troubleshooting
Diagnostic Display
Verify Diagnostic Display Input Functions
Verify Diagnostic Display Output Functions
Starting Problems
General Run and Transport Problems
Cutting Deck Operating Problems
Cutting Deck Lift, Lower Problems
Electrical System Quick Checks
Battery Test (Open Circuit Test)
Charging System Test
Glow Plug System Test
Check Operation of Interlock Switches
Adjustments
Wing Deck Position Switches
Component Testing
Ignition Switch
Fuses
Operator Cab Fuses (Groundsmaster 4110–D)
Warning Lights
PTO Switch
Cutting Deck Lift Switches
Hi, Low Speed and Headlight (Groundsmaster 4110–D) Switches
Engine Cooling Fan Switch
Seat Switch
Parking Brake Switch
Main Power, Glow and Cab Power (Groundsmaster 4110–D) Relays
Start and Air Conditioning (Groundsmaster 4110–D) Relays
Hydraulic Valve Solenoid Coils
Toro Electronic Controllers (TEC)
Hour Meter
Audio Alarm
Fuel Sender
Fuel Gauge
Fuel Pump
Temperature Sender
Temperature Gauge
Traction Neutral Switch
Diode Assembly
Wing Deck Position Switches
Engine Coolant and Hydraulic Oil Temperature Senders
Service and Repairs
Battery Storage
Battery Care
Battery Service
6 – Axles, Planetaries and Brakes
Specifications
General Information
Operator’s Manual
Service and Repairs
Brake Assembly
Brake Service
Planetary Wheel Drive Assembly
Planetary Wheel Drive Service
Rear Axle Assembly
Rear Axle Service
Bevel Gear Case and Axle Case
Differential Shafts
Axle Shafts
Input Shaft, Pinion Gear
Differential Gear
Pinion Gear to Ring Gear Engagement
7 – Chassis
General Information
Operator’s Manual
Service and Repairs
Steering Tower
Cutting Deck Lift Arms
Console Arm
Operator Seat
Operator Seat Service
Operator Seat Suspension
Hood
8 – Cutting Deck
Specifications
General Information
Operator’s Manual
Castor Wheel Tire Pressure
Blade Stopping Time
Troubleshooting
Factors That Can Affect Quality of Cut
Service and Repairs
Cutting Deck
Wing Deck Service
Cutting Deck Link Service
Wing Deck Latch
Blade Spindle
Blade Spindle Service
Idler Assembly
Castor Forks and Wheels
Deck Rollers and Skids
9 – Operator Cab
General Information
Operator’s Manual
Electrical Components and Schematic
Air Conditioning System
Cab Heater System
Service and Repairs
General Precautions for Removing and Installing Air Conditioning System Components
Air Conditioning Compressor
Roof Assembly
Cab Hose Identification
Air Conditioning Condenser Assembly
Heater, Evaporator Assembly
Sanden Compressor Service Guide
10 – Foldout Drawings
Hydraulic Schematic
Electrical Schematic
Sheet 1 of 3
Sheet 2 of 3
Sheet 3 of 3
Operator Cab Electrical Schematic
Sheet 1 of 3
Sheet 2 of 3
Sheet 3 of 3
Platform Wire Harness Drawing
Platform Wire Harness Diagram
Sheet 1 of 2
Sheet 2 of 2
Rear Wire Harness Drawing
Rear Wire Harness Diagram
Cutting Deck Wire Harness