Toro 03116SL Rev E Service Manual Groundsmaster 4100 D Preface Publication - 1 of 258
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From inside (document excerpt):
PART NO. 03116SL (Rev. E) Service Manual GroundsmasterR 4100-D Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Groundsmaster 4100-D. REFER TO THE OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE, AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine.
Replacement Operator’s Manuals and Parts Catalogs are available on the internet at www.Toro.com or by sending complete Model and Serial Number to: The Toro Company Attn. Technical Publications 8111 Lyndale Avenue South Bloomington, MN 55420-1196 The Toro Company reserves the right to change product specifications or this publication without notice. This safety symbol means DANGER, WARNING, or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions may result in personal injury. NOTE: A NOTE will give general information about the correct operation, maintenance, service, testing, or repair of the machine. IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the machine. E The Toro Company – 2003, 2004, 2005, 2007 This page is intentionally blank. Groundsmaster 4100-D Table Of Contents Chapter 1 – Safety General Safety Instructions 1 – 2 Jacking Instructions . 1 – 4 Safety and Instruction Decals 1 – 5 Chapter 2 – Product Records and Maintenance Product Records . Equivalents and Conversions Torque Specifications . Maintenance . Chapter 3 – Kubota Diesel Engine General Information 3 – 2 Specifications 3 – 3 Adjustments . 3 – 4 Service and Repairs 3 – 6 KUBOTA WORKSHOP MANUAL, DIESEL ENGINE, V2003-T SERIES Chapter 4 – Hydraulic System Specifications 4 – 2 General Information 4 – 3 Hydraulic Schematic 4 – 7 Hydraulic Flow Diagrams 4 – 8 Special Tools . 4 – 18 Troubleshooting . 4 – 20 Testing . 4 – 23 Adjustments 4 – 48 Service and Repairs . 4 – 49 Specifications Troubleshooting Adjustments . Service and Repairs Chapter 9 – Electrical Diagrams Electrical Schematic 9 – 3 Circuit Diagrams . 9 – 4 Wire Harness Drawings . 9 – 8 8-2 8-3 8-4 8-6 2-1 2-2 2-3 2-7 Chapter 5 – Electrical System Electrical Schematic, Circuit Diagrams, and Wire Harness Drawings 5 – 2 Special Tools 5 – 3 Troubleshooting 5 – 4 Electrical System Quick Checks 5 – 7 Adjustments . 5 – 8 Component Testing 5 – 10 Service and Repairs . 5 – 31 Chapter 6 – Axles, Planetaries, and Brakes Specifications 6 – 2 Adjustments . 6 – 3 Service and Repairs 6 – 4 Chapter 7 – Chassis Service and Repairs 7 – 2 Chapter 8 – Cutting Deck Safety Electrical Diagrams Groundsmaster 4100-D Cutting Deck Chassis Axles, Planetaries, and Brakes Electrical System Hydraulic System Kubota Diesel Engine Product Records and Maintenance This page is intentionally blank. Groundsmaster 4100-D Safety Table of Contents GENERAL SAFETY INSTRUCTIONS Before Operating While Operating Maintenance and Service 2 2 2 3 JACKING INSTRUCTIONS . Jacking the Front End . Jacking the Rear End SAFETY AND INSTRUCTION DECALS 4 4 4 5 Groundsmaster 4100-D Page 1 – 1 Safety Safety Chapter 1 General Safety Instructions The GROUNDSMASTER 4100-D was tested and certified by TORO for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine. Improper use or maintenance of the machine can result in injury or death. To reduce the potential for injury or death, comply with the following safety instructions. WARNING To reduce the potential for injury or death, comply with the following safety instructions. Before Operating 1. Read and understand the contents of the Operator’s Manual before starting and operating the machine. Become familiar with the controls and know how to stop the machine and engine quickly. A replacement Operator’s Manual is available on the Internet at www.Toro.com or by sending the complete model and serial number to: The Toro Company Attn. Technical Publications 8111 Lyndale Avenue South Bloomington, Minnesota 55420-1196 2. Keep all shields, safety devices, and decals in place. If a shield, safety device, or decal is defective, illegible or damaged, repair or replace it before operating the machine. Also tighten any loose nuts, bolts or screws to ensure machine is in safe operating condition. 3. Assure interlock switches are adjusted correctly so engine cannot be started unless traction pedal is in NEUTRAL and cutting unit is DISENGAGED. 4. Since diesel fuel is highly flammable, handle it carefully: A. Use an approved fuel container. B. Do not remove fuel tank cap while engine is hot or running. C. Do not smoke while handling fuel. D. Fill fuel tank outdoors and only to within an inch of the top of the tank, not the filler neck. Do not overfill. E. Wipe up any spilled fuel. While Operating 1. Sit on the seat when starting and operating the machine. 2. Before starting the engine: B. Set parking brake. A. Engage the parking brake. B. Make sure traction pedal is in neutral and the PTO switch is OFF (disengaged). C. After engine is started, release parking brake and keep foot off traction pedal. Machine must not move. If movement is evident, the traction pedal linkage is adjusted incorrectly; therefore, shut engine off and adjust linkage until machine does not move when traction pedal is released. 3. Do not run engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could possibly be deadly. 4. Do not touch engine, muffler or exhaust pipe while engine is running or soon after it is stopped. These areas could be hot enough to cause burns. Safety Page 1 – 2 Groundsmaster 4100-D C. Disengage cutting unit and wait for blades to stop. D. Stop engine and remove key from switch. E. Toro recommends that anytime the machine is parked (short or long term), the cutting unit should be lowered to the ground. This relieves pressure from the lift circuit and eliminates the risk of the cutting unit accidentally lowering to the ground. F. Do not park on slopes unless wheels are chocked or blocked. 5. Before getting off the seat: A. Ensure that traction pedal is in neutral. 1. Before servicing or making adjustments, lower deck, stop engine, set parking brake, and remove key from the switch. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight.
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