caution - Toro

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Troubleshooting The charts that follow contain suggestions to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the Testing section of this Chapter for pre<strong>caution</strong>s and specific test procedures. NOTE: When troubleshooting traction problems on the Groundsmaster 4100--D, if a problem exists in both 4WD and transport speeds, consider a faulty component that affects the entire traction circuit (e.g. charge circuit, relief valves, piston pump, front wheel motors). If the problem exists in 4WD but not in transport, consider a problem in the 4WD traction system (e.g. rear axle motor, 4WD manifold). Problem Hydraulic system operates hot. NOTE: An indication that the hydraulic system is operating at excessive temperatures would be frequent reversing of the cooling fan and a normal engine coolant temperature. Possible Cause Engine RPM is too low. Brakes are applied or sticking. Hydraulic reservoir oil level is low. Hydraulic oil is contaminated or the wrong type. Piston pump by--pass valve is open or damaged. Cooling system is not operating properly. Charge pressure is low. Traction circuit pressure is incorrect. Pump(s) or motor(s) are damaged. Hydraulic oil in reservoir foams. Hydraulic reservoir oil level is low. Wrong type of oil is in the hydraulic system. Air is leaking into a pump suction line. Machine operates in one direction only. Traction pedal is sluggish. Traction control linkage is faulty. Traction relief valve is defective. Traction control linkage is stuck or binding. Charge pressure is low. Piston (traction) pump servo control valve orifices are plugged or damaged. 4WD manifold PD1 and PD2 pilot directional valves seals are leaking or damaged. Machine travels too far before stopping when the traction pedal is released. Traction linkage is out of adjustment. Charge pressure is low. Piston (traction) pump servo control valve orifices are plugged or damaged. Traction pedal does not return to neutral. Hydraulic System Page 4 - 28 Groundsmaster 4100--D
Problem Traction power is lost or unit will not operate in either direction. Possible Causes Hydraulic reservoir oil level is low. Piston pump by--pass valve is open or damaged. Charge pressure is low. Traction circuit pressure is low. Front wheel motor couplers are damaged. Four wheel drive will not engage. Electrical problem exists (see Chapter 5 -- Electrical System). Four wheel drive will not disengage. No cutting decks will operate. One cutting deck will not operate. All cutting decks operate slowly. Cutting deck stops under load. Solenoid valve (SV) in 4WD hydraulic manifold is faulty. Cartridge valve(s) in 4WD manifold is faulty. Drive gear on rear axle motor or driven gear for rear axle is loose or damaged. Rear axle motor is damaged. Electrical problem exists (see Chapter 5 -- Electrical System). Solenoid valve (SV) in 4WD hydraulic manifold is faulty. Cartridge valve in 4WD manifold is damaged or sticking. Electrical problem exists (see Chapter 5 -- Electrical System). Gear pump or its coupler is damaged (Note: other hydraulic circuits impacted as well). Electrical problem exists (see Chapter 5 -- Electrical System). System pressure to the affected deck is low. Woodruff key on affected deck motor is damaged. Solenoid valve (S) in deck manifold is faulty. Cartridge valve in deck manifold is damaged or sticking. Deck motor or gear pump section is damaged. Engine RPM is low. Deck motor or gear pump sections are damaged. Relief valve in deck manifold is by--passing. Deck motor has internal leakage (by--passing oil). Cutting deck gear pump section is inefficient. Hydraulic System Groundsmaster 4100--D Page 4 - 29 Hydraulic System
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Part No. 08162SL (Rev. A) Service M
Page 3 and 4:
Table Of Contents Chapter 1 - Safet
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Table of Contents GENERAL SAFETY IN
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Maintenance and Service 1. Before s
Page 9 and 10:
Safety and Instruction Decals Numer
Page 11 and 12: Chapter 2 Table of Contents Product
Page 13 and 14: Torque Specifications Recommended f
Page 15 and 16: Standard Torque for Dry, Zinc Plate
Page 17 and 18: Chapter 3 Kubota Diesel Engine Tabl
Page 19 and 20: Specifications Item Make / Designat
Page 21 and 22: Removal (Fig. 1) 1. Park machine on
Page 23 and 24: Removal (Fig. 5) CAUTION B The muff
Page 25 and 26: DANGER Because diesel fuel is highl
Page 27 and 28: Removal (Fig. 8) 1. Park machine on
Page 29 and 30: Engine Removal (Fig. 9) 1. Park mac
Page 31 and 32: 3. Slowly lower engine into the mac
Page 33 and 34: Coupler Removal (Fig. 16) NOTE: The
Page 35 and 36: Chapter 4 Hydraulic System Table of
Page 37 and 38: General Information Operator’s Ma
Page 39 and 40: Hydraulic Hose and Tube Installatio
Page 41 and 42: Adjustable Fitting (Fig. 8) 1. Make
Page 43 and 44: Hydraulic System This page is inten
Page 45 and 46: Traction Circuit: 4WD (Mow) The tra
Page 47 and 48: Traction Circuit: Transport (2WD) T
Page 49 and 50: Lower Cutting Deck A four section g
Page 51 and 52: Raise Cutting Deck A four section g
Page 53 and 54: Mow Circuit Hydraulic flow for the
Page 57 and 58: Steering Circuit A four section gea
Page 59 and 60: Engine Cooling Fan Circuit A four s
Page 61: Hydraulic Test Fitting Kit This kit
Page 65 and 66: Testing The most effective method f
Page 67 and 68: Procedure for Traction Circuit Char
Page 69 and 70: Procedure for Traction Circuit Reli
Page 71 and 72: Procedure for Counterbalance Pressu
Page 73 and 74: Procedure for Rear Traction Circuit
Page 75 and 76: Procedure for Traction Circuit Redu
Page 77 and 78: Procedure for Cutting Deck Circuit
Page 79 and 80: Procedure for Cutting Deck Manifold
Page 81 and 82: Procedure for Cutting Deck Gear Pum
Page 83 and 84: Procedure for Cutting Deck Motor Ca
Page 85 and 86: Procedure for Steering Circuit Reli
Page 87 and 88: Procedure for Lift/Lower Circuit Re
Page 89 and 90: Procedure for Steering and Lift/Low
Page 91 and 92: Procedure for Engine Cooling Fan Ci
Page 93 and 94: Procedure for Engine Cooling Fan Ci
Page 95 and 96: Service and Repairs General Precaut
Page 97 and 98: Charge Hydraulic System NOTE: When
Page 99 and 100: NOTE: The front frame needs to be l
Page 101 and 102: Removal (Fig. 48) CAUTION The radia
Page 103 and 104: Removal (Fig 49) 1. Park machine on
Page 105 and 106: IMPORTANT: Use caution when clampin
Page 109 and 110: Removal (Fig. 53) 1. Park machine o
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Removal (Fig. 56) 1. Park machine o
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Hydraulic System This page is inten
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Removal (Fig. 59) NOTE: The ports o
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4WD Manifold Service (Fig. 60) 1. M
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Removal (Fig. 61) 1. Read the Gener
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Filter Manifold Service (Fig. 62) F
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CAUTION The centering springs are u
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Disassembly (Fig. 68) 1. Pump oil o
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8. Remove and discard back--up gask
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Fan Drive Manifold Service (Fig. 76
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Cutting Deck Motor Removal 1. Park
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IMPORTANT: Mark the relative positi
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Removal (Fig. 85) NOTE: The ports o
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PTO Manifold Service (Fig. 86) For
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Disassembly (Fig. 89) 1. Plug all p
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Disassembly (Figs. 92 and 93) 1. Re
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Chapter 5 Electrical System Table o
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Special Tools Order special tools f
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Troubleshooting CAUTION Remove all
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Cutting Deck Operating Problems The
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Adjustments Wing Deck Position Swit
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Component Testing For accurate resi
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Warning Lights Engine Oil Pressure
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Transport / 4WD Switch The transpor
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Seat Switch The seat switch is norm
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Hour Meter The hour meter is locate
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Start, Engine Shutdown, Seat, Alarm
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TEC -5002 Controller Groundsmaster
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Fuel Gauge The fuel gauge can be te
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Glow Controller The glow controller
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Dual Temperature Switch The dual te
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Traction Neutral Switch The tractio
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Fusible Links The Groundsmaster 410
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Cutting Deck Raise and Lower Switch
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Service and Repairs NOTE: For engin
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2. Conduct a hydrometer test of the
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Chapter 6 Axles, Planetaries and Br
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General Information Operator’s Ma
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3. Chock rear wheels and jack up fr
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This page is intentionally blank. A
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Removal (Fig. 6) 1. Park machine on
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NOTE: The planetary wheel drive ass
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This page is intentionally blank. A
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8. Remove cap screw and flange nut
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Bevel Gear Case and Axle Case The f
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Bevel Gear Case and Axle Case Insta
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9. Remove the bevel gear case/axle
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Axle Shafts The following procedure
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7. Secure the lock nut with the sta
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Differential Gear Inspection 1. Mea
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Pinion Gear to Ring Gear Engagement
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Chapter 7 Chassis Table of Contents
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Disassembly (Fig. 1) 1. Park machin
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CAUTION When changing attachments,
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Removal (Fig. 5) 1. Park machine on
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Disassembly (Fig. 8) 1. Disassemble
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NOTE: Most of the seat suspension c
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Removal 1. Park machine on a level
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Chapter 8 Cutting Deck Table of Con
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General Information CAUTION Never i
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This page is intentionally blank. C
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Removal (Fig. 1) 1. Position machin
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Removal (Fig. 6) 1. Position machin
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Cutting Deck Link Service Disassemb
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Installation (Fig. 13) 1. Position
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2. Install outer bearing spacer int
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Disassembly (Fig. 22) 1. Park machi
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Chapter 9 Foldout Drawings Table of
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CENTER DECK MANIFOLD COUNTERBALANCE
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CONTINUES FROM SHEET 1 CONTINUES FR
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CONTINUES TO SHEET 2 CONTINUES TO S
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CONTINUES TO SHEET 2 WHEN THE PTO S
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CONTINUES TO SHEET 2 CONTINUES TO S
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YELLOW GRAY YELLOW/BLACK VIOLET WHI
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FLOW DIVIDER SOLENOID Groundsmaster
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(STARTER) (STARTER) (STARTER) Groun
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BLUE GRAY VIOLET BLACK YELLOW GRAY
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caution - Toro

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