caution - Toro

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Problem Cutting deck (or wing decks) will not raise. Possible Causes Engine RPM is too low. Hydraulic oil level in reservoir is low. Lift arm pivots are binding. Relief valve in lift/lower control valve is stuck. Pilot valve in lift/lower control valve is damaged or sticking. Lift cylinder(s) is (are) damaged. Gear pump section for lift/lower control valve is inefficient. Cutting deck (or wing decks) raise, but will not stay up. NOTE: Lift cylinders cannot provide an absolutely perfect seal. The cutting deck will eventually lower if left in the raised position during storage. Front cutting deck drops too fast or too slow. Cutting deck (or wing decks) will not lower. Lift circuit lines or fittings are leaking. Lift cylinder is damaged. Detents in lift/lower control valve are worn. Flow control valve is not adjusted properly. Lift arm pivots are binding. Counterbalance pressure is excessive. Pilot valve in lift/lower control valve is damaged or sticking. Lift cylinder is damaged. Lift/lower control valve is worn or damaged. Hydraulic System Page 4 - 30 Groundsmaster 4100--D
Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (See the Special Tools section in this Chapter). Before Performing Hydraulic Tests IMPORTANT: All obvious areas such as oil supply, filter, binding linkages, loose fasteners or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem. Pre<strong>caution</strong>s for Hydraulic Testing CAUTION Failure to use gauges with recommended pressure (PSI) rating as listed in test procedures could result in damage to the gauge and possible personal injury from leaking hot oil. CAUTION All testing should be performed by two (2) people. One person should be in the seat to operate the machine and the other should read and record test results. CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the ignition switch in OFF. Remove key from the ignition switch. WARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Do not use hands to search for leaks; use paper or cardboard. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury. WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved and all rotating machine parts must be stopped. Stop engine; lower or support attachments. 1. Clean machine thoroughly before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. Contamination will cause excessive wear of hydraulic components. 2. Put metal caps or plugs on any hydraulic lines left open or exposed during testing or removal of components. 3. The engine must be in good operating condition. Use a phototac when performing a hydraulic test. Engine speed can affect the accuracy of the tester readings. Check actual speed of the pump when performing flow testing. 4. The inlet and the outlet hoses for tester with pressure and flow capabilities must be properly connected and not reversed to prevent damage to the hydraulic tester or components. 5. When using hydraulic tester with pressure and flow capabilities, open load valve completely in the tester to minimize the possibility of damaging components. 6. Install fittings finger tight and far enough to make sure that they are not cross--threaded before tightening them with a wrench. 7. Position tester hoses to prevent rotating machine parts from contacting and damaging the hoses or tester. 8. Check oil level in the hydraulic reservoir. After connecting test equipment, make sure tank is full. 9. Check control linkages for improper adjustment, binding or broken parts. 10.After installing test gauges, run engine at low speed and check for any hydraulic oil leaks. 11.All hydraulic tests should be made with the hydraulic oil at normal operating temperature. 12.Before returning machine to use, make sure that hydraulic reservoir has correct fluid level. Also, check for hydraulic leaks after test equipment has been removed from hydraulic system. Hydraulic System Groundsmaster 4100--D Page 4 - 31 Hydraulic System
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Part No. 08162SL (Rev. A) Service M
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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
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Safety and Instruction Decals Numer
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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 and 62: Hydraulic Test Fitting Kit This kit
Page 63: Problem Traction power is lost or u
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
Page 113 and 114: Removal (Fig. 56) 1. Park machine o
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Removal (Fig. 57) 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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