service repair manual

1. 

 4100−D




Groundsmaster 4100−D.

   









Bloomington, MN 55420−1196



    
 


  


 

       

The Toro Company − 2003, 2004, 2005, 2007

2. Groundsmaster 4100−D

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 2 − 1

Equivalents and Conversions 2 − 2

Torque Specifications 2 − 3

Maintenance 2 − 7

Chapter 3 − Kubota Diesel Engine
General Information 3 − 2

Specifications 3 − 3

Adjustments 3 − 4

Service and Repairs 3 − 6

    
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

Chapter 5 − Electrical System

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
Specifications 8 − 2

Troubleshooting 8 − 3

Adjustments 8 − 4

Service and Repairs 8 − 6

Chapter 9 − Electrical Diagrams
Electrical Schematic 9 − 3

Circuit Diagrams 9 − 4

Wire Harness Drawings 9 − 8


3. Groundsmaster 4100−D Page 1 − 1 
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
 

 

 

 

 

 

 

 
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4. Groundsmaster 4100−D
Page 1 − 2














       


 








Bloomington, Minnesota 55420−1196
 




 
        

 

 
 

 
 

 

 

 
 
     

 





 
  

 


 
 
 
        

 
 




 


5. Groundsmaster 4100−D Page 1 − 3 

 


 

        


 


 



       



 



 

 


 
       







     




       






  



        

     
       



        






6. Groundsmaster 4100−D
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



      

       
      




      
   


 

 

 



 
 

 

   


 
   

 


7. Groundsmaster 4100−D Page 1 − 5 


4100−D. If 



8. Groundsmaster 4100−D Page 2 − 1 Product Records and Maintenance



 

 

 

 

 

 


 


 

 

 

 


    

    
    




9. Groundsmaster 4100−D
Page 2 − 2



10. Groundsmaster 4100−D Page 2 − 3 Product Records and Maintenance


 



      
 











       

      








  


 


11. Groundsmaster 4100−D
Page 2 − 4















in−lb in−lb N−cm in−lb N−cm in−lb N−cm
# 6 − 32 UNC
  
   
# 6 − 40 UNF
  
   
# 8 − 32 UNC
  
   
# 8 − 36 UNF
  
   
# 10 − 24 UNC
  
   
# 10 − 32 UNF
  
   
1/4 − 20 UNC       
1/4 − 28 UNF       
5/16 − 18 UNC       
5/16 − 24 UNF       
ft−lb ft−lb N−m ft−lb N−m ft−lb N−m
3/8 − 16 UNC       
3/8 − 24 UNF       
7/16 − 14 UNC       
7/16 − 20 UNF       
1/2 − 13 UNC       
1/2 − 20 UNF       
5/8 − 11 UNC       
5/8 − 18 UNF       
3/4 − 10 UNC       
3/4 − 16 UNF       
7/8 − 9 UNC       
7/8 − 14 UNF       
 



 


       

       





12. Groundsmaster 4100−D Page 2 − 5 Product Records and Maintenance






 



  5 in−lb  60 N−cm  7 in−lb  80 N−cm
  9 in−lb  100 N−cm  13 in−lb  150 N−cm
  2 ft−lb  3 N−m  2 ft−lb  3 N−m
  4 ft−lb  5 N−m  5 ft−lb  7 N−m
  7 ft−lb  10 N−m   9 ft−lb   12 N−m
   15 ft−lb  20 N−m  22 ft−lb  30 N−m
  33 ft−lb  45 N−m  37 ft−lb  50 N−m
 



 


       

       




13. Groundsmaster 4100−D
Page 2 − 6






 
1/4 − 20 UNC  20 in−lb  12 in−lb
5/16 − 18 UNC  35 in−lb  20 in−lb
3/8 − 16 UNC  10 ft−lb  3 ft−lb
1/2 − 13 UNC  15 ft−lb  10 ft−lb



 
No. 6 − 32 UNC  5 in−lb
No. 8 − 32 UNC  5 in−lb
No. 10 − 24 UNC  7 in−lb
1/4 − 20 UNC  15 in−lb
5/16 − 18 UNC  20 in−lb
3/8 − 16 UNC  100 in−lb

 
7/16 − 20 UNF

 10 ft−lb  14 N−m
1/2 − 20 UNF

 10 ft−lb  14 N−m


 10 ft−lb  14 N−m


 10 ft−lb  14 N−m
** For steel wheels and non−lubricated fasteners.







 

    5 in−lb
    5 in−lb
    7 in−lb
    15 in−lb

  
torque values are based on non−lubri-


in−lb X 11.2985 = N−cm N−cm X 0.0885 = in−lb
ft−lb X 1.3558 = N−m N−m X 0.7376 = ft−lb

14. Groundsmaster 4100−D Page 2 − 7 Product Records and Maintenance


tervals for the Groundsmaster 4100−D are covered in

    
procedures have break−in intervals identi-

     


15. Groundsmaster 4100−D Page 3 − 1 Kubota Diesel Engine (Rev. A)



 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 


V2003−T SERIES

16. Groundsmaster 4100−D
Page 3 − 2




4100−D.
 


Workshop Manual, Diesel Engine, V2003−T


      

 V2003−T. The use of some specialized





       




     





17. Groundsmaster 4100−D Page 3 − 3 Kubota Diesel Engine (Rev. A)

 
 Kubota, 4−Cycle, 4 Cylinder,

 
 
 
 
 1−3−4−2
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

18. Groundsmaster 4100−D
Page 3 − 4



 


 


 
 
 
 
 






 
 
 




19. Groundsmaster 4100−D
Page 3 − 6




 
 
 
 
 
 
 
 
 

 

















20. Groundsmaster 4100−D Page 3 − 7 Kubota Diesel Engine (Rev. A)

 


 
 


 

        
cleaner and turbo−charger (Fig. 4):
        



 


 
 
 
 
 






21. Groundsmaster 4100−D
Page 3 − 8



 
 
 
 
 
 
 
 
 

 




















16 to 22 ft−lb
(21 to 29 N−m)
16 to 22 ft−lb
(21 to 29 N−m)
16 to 22 ft−lb
(21 to 29 N−m)




22. Groundsmaster 4100−D Page 3 − 9 Kubota Diesel Engine (Rev. A)


        



 


 


 
 

 

 


 

the following fasteners from 16 to 22 ft−lb (21 to 29 N−m)

 
 

 

 

 







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24. Groundsmaster 4100−D
Page 3 − 10



 
 
 
 
 
 
 
 
 

 




































  






















 

 






60 to 80 in−lb
(7 to 9 N−m)
135 to 165 ft−lb
(183 to 223 N−m)



25. 
Groundsmaster 4100−D Page 3 − 11 Kubota Diesel Engine (Rev. A)



       



ing the engine. Store fuel in a clean, safety−ap-

     







      






 


 
 


 

 

 

      

 

 
 
tank to the frame from 60 to 80 in−lb (7 to 9 N−m).
 
        

 
     


B. Apply skin−over 





 


 
 