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This service manual provides information for technicians to troubleshoot, test, and repair major systems and components of the Toro Groundsmaster 4100-D and 4110-D riding mowers. It contains chapters covering safety procedures, product records, maintenance, the Kubota diesel engine, hydraulic system, electrical system, axles/planetary gears/brakes, chassis, cutting deck, operator cab, and foldout drawings. Technicians are instructed to follow safety procedures when servicing the equipment.
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Caterpillar cat 336 f excavator (prefix tje) service repair manual (tje00001 ...fhsjekdmme
The document provides instructions for disassembling the travel motor of an excavator model 336F. It lists 27 steps to fully disassemble the travel motor, removing components like the motor head assembly, piston assemblies, barrel assembly, springs, seals, and other internal parts. Detailed illustrations accompany each step to show how to properly remove each component. Safety precautions are provided to warn of potential spring forces and ensure protective equipment is worn during disassembly.
Caterpillar cat 336 f excavator (prefix ljy) service repair manual (ljy00001 ...fhsjekdmme
1. The document provides step-by-step instructions for disassembling and assembling the diesel exhaust fluid module of Caterpillar 336F excavators.
2. The disassembly procedure involves draining the fluid, removing hoses and connectors, and taking apart the various module components like the pump, tank, and control electronics.
3. The assembly procedure lists the parts and tools needed and describes reinstalling the components in reverse order and ensuring proper tightening of connections.
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This document provides instructions for removing and installing various components of a Caterpillar C9.3 engine, including the combustion head, ARD nozzle heater relay, ARD fuel solenoid valve, exhaust manifold, and exhaust elbow. The procedures describe disconnecting electrical connections and fluid lines, removing mounting hardware, and installing replacement parts in the reverse order of removal, taking care to clean parts and apply thread sealant or anti-seize as specified. Safety precautions are provided regarding working on hot or high-voltage components and using isopropyl alcohol.
Caterpillar cat 336 e lnh excavator (prefix ssl) service repair manual (ssl00...fhsjekdmme
The document provides instructions for disassembling and assembling components of a 336E excavator final drive and travel motor. It describes in detail how to remove and install the travel motor and final drive assembly, including removing hoses, bolts, seals and other parts. Precautions are given regarding weight of components and proper torque specifications for reinstallation. Detailed illustrations accompany each step of disassembly and assembly.
Caterpillar cat 336 e lnh excavator (prefix rza) service repair manual (rza00...fhsjekdmme
This document provides instructions for disassembling and assembling the travel motor on 336E LH and 336E LNH excavator models. The disassembly process involves removing 27 components of the travel motor including the head, springs, plates, seals, and housing cover. The assembly process describes installing these 27 components in reverse order and provides notes to ensure proper installation of parts. Tools required include an adapter, nuts, washers, eyebolt, retaining ring pliers, driver group, and bearing puller group.
Caterpillar cat 336 e lnh excavator (prefix gny) service repair manual (gny00...fhsjekdmme
The document provides assembly instructions for a travel motor in 28 steps. It details installing various components like seals, springs, pistons, and plates in the proper sequence. It also describes attaching the travel motor to the excavator and tightening bolts to the specified torques. The removal and installation procedures for a final drive and travel motor are also outlined in 13 steps, including draining oil first and marking components for reinstallation.
Caterpillar cat 336 e lh excavator (prefix ssl) service repair manual (ssl000...fhsjekdmme
The document provides instructions for disassembling and assembling components of a 336E excavator final drive and travel motor. It describes in detail how to remove and install the travel motor, including disconnecting hoses and removing mounting bolts. It also explains how to disassemble the final drive by removing the cover, planetary gears, and other internal components. Precise steps and required tools are listed to correctly take apart and rebuild the final drive and travel motor.
Caterpillar cat 336 e lh excavator (prefix rza) service repair manual (rza000...fhsjekdmme
This document provides instructions for disassembling and assembling the travel motor on 336E LH and 336E LNH excavator models. The disassembly process involves removing 27 components of the travel motor including the head, springs, plates, seals, and housing cover. The assembly process describes installing these 27 components in reverse order and provides notes to ensure proper installation of parts. Tools required include an adapter, nuts, washers, eyebolt, retaining ring pliers, driver group, and bearing puller group.
Caterpillar cat 336 e lh excavator (prefix jea) service repair manual (jea000...fhsjekdmme
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Caterpillar cat 336 e lh excavator (prefix gny) service repair manual (gny000...fhsjekdmme
The document provides assembly instructions for a travel motor in 28 steps. It details installing various components like seals, springs, pistons, and plates in the proper order. It also provides disassembly instructions for a final drive in 13 steps, removing components like bolts, gears, and covers. Installation requires cleaning, applying sealant, and torquing bolts to specified values.
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The document provides instructions for disassembling and assembling the travel motor of a 336E excavator. It describes 27 steps to disassemble the motor by removing components like the motor head, springs, brake piston, rotating assembly, bearings and seals. It then describes 28 steps for reassembling the motor components in reverse order, making sure to align parts properly, apply lubricants to seals and mating surfaces, and torque bolts to the specified values. The proper procedure is important to safely release spring forces and prevent damage during removal and installation of parts.
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This document provides the disassembly and assembly procedures for a travel motor on 336D2 XE and 336D2 LXE excavator models. It outlines 30 steps to disassemble the travel motor down to its core components. It then provides 19 steps to reassemble the travel motor. The document includes illustrations and notes on proper assembly order and tooling required. Safety precautions are provided throughout for tasks involving spring tension or component installation.
This document provides disassembly instructions for a 336D2 excavator travel motor. It outlines 27 steps to fully disassemble the travel motor. These include removing the motor head assembly, piston assemblies, barrel assembly, springs, seals, plates, and other internal components. Tools required include bolting fixtures, pry bars, pullers, and seal removal tools. Precautions are provided to retain component positioning for reassembly and to safely release spring forces during disassembly.
This document provides the disassembly and assembly procedures for a travel motor on 336D2 XE and 336D2 LXE excavator models. It outlines 30 steps to disassemble the travel motor down to its core components. It then provides 19 steps to reassemble the travel motor. The document includes illustrations and notes on proper assembly order and tooling required. Safety precautions are provided throughout for tasks involving spring forces or pressurized components.
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5) The water temperature regulator.
Detailed step-by-step instructions are provided for each component, along with illustrations to aid in the process. Safety notices are also included.
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This document provides disassembly instructions for a travel motor on a 336D2 excavator. It lists 27 steps to fully disassemble the travel motor, including removing components like the motor head assembly, piston assemblies, springs, seals, and plates. Special care must be taken when removing or handling components with stored spring energy to avoid personal injury. Tools required include bolting fixtures, pullers, pry bars, and seal removal tools.
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Caterpillar cat 336 f excavator (prefix tje) service repair manual (tje00001 ...fhsjekdmme
The document provides instructions for disassembling the travel motor of an excavator model 336F. It lists 27 steps to fully disassemble the travel motor, removing components like the motor head assembly, piston assemblies, barrel assembly, springs, seals, and other internal parts. Detailed illustrations accompany each step to show how to properly remove each component. Safety precautions are provided to warn of potential spring forces and ensure protective equipment is worn during disassembly.
Caterpillar cat 336 f excavator (prefix ljy) service repair manual (ljy00001 ...fhsjekdmme
1. The document provides step-by-step instructions for disassembling and assembling the diesel exhaust fluid module of Caterpillar 336F excavators.
2. The disassembly procedure involves draining the fluid, removing hoses and connectors, and taking apart the various module components like the pump, tank, and control electronics.
3. The assembly procedure lists the parts and tools needed and describes reinstalling the components in reverse order and ensuring proper tightening of connections.
Caterpillar cat 336 f excavator (prefix kcs) service repair manual (kcs00001 ...fhsjekdmme
This document provides instructions for removing and installing various components of a Caterpillar C9.3 engine, including the combustion head, ARD nozzle heater relay, ARD fuel solenoid valve, exhaust manifold, and exhaust elbow. The procedures describe disconnecting electrical connections and fluid lines, removing mounting hardware, and installing replacement parts in the reverse order of removal, taking care to clean parts and apply thread sealant or anti-seize as specified. Safety precautions are provided regarding working on hot or high-voltage components and using isopropyl alcohol.
Caterpillar cat 336 e lnh excavator (prefix ssl) service repair manual (ssl00...fhsjekdmme
The document provides instructions for disassembling and assembling components of a 336E excavator final drive and travel motor. It describes in detail how to remove and install the travel motor and final drive assembly, including removing hoses, bolts, seals and other parts. Precautions are given regarding weight of components and proper torque specifications for reinstallation. Detailed illustrations accompany each step of disassembly and assembly.
Caterpillar cat 336 e lnh excavator (prefix rza) service repair manual (rza00...fhsjekdmme
This document provides instructions for disassembling and assembling the travel motor on 336E LH and 336E LNH excavator models. The disassembly process involves removing 27 components of the travel motor including the head, springs, plates, seals, and housing cover. The assembly process describes installing these 27 components in reverse order and provides notes to ensure proper installation of parts. Tools required include an adapter, nuts, washers, eyebolt, retaining ring pliers, driver group, and bearing puller group.
Caterpillar cat 336 e lnh excavator (prefix gny) service repair manual (gny00...fhsjekdmme
The document provides assembly instructions for a travel motor in 28 steps. It details installing various components like seals, springs, pistons, and plates in the proper sequence. It also describes attaching the travel motor to the excavator and tightening bolts to the specified torques. The removal and installation procedures for a final drive and travel motor are also outlined in 13 steps, including draining oil first and marking components for reinstallation.
Caterpillar cat 336 e lh excavator (prefix ssl) service repair manual (ssl000...fhsjekdmme
The document provides instructions for disassembling and assembling components of a 336E excavator final drive and travel motor. It describes in detail how to remove and install the travel motor, including disconnecting hoses and removing mounting bolts. It also explains how to disassemble the final drive by removing the cover, planetary gears, and other internal components. Precise steps and required tools are listed to correctly take apart and rebuild the final drive and travel motor.
Caterpillar cat 336 e lh excavator (prefix rza) service repair manual (rza000...fhsjekdmme
This document provides instructions for disassembling and assembling the travel motor on 336E LH and 336E LNH excavator models. The disassembly process involves removing 27 components of the travel motor including the head, springs, plates, seals, and housing cover. The assembly process describes installing these 27 components in reverse order and provides notes to ensure proper installation of parts. Tools required include an adapter, nuts, washers, eyebolt, retaining ring pliers, driver group, and bearing puller group.
Caterpillar cat 336 e lh excavator (prefix jea) service repair manual (jea000...fhsjekdmme
The document provides instructions for disassembling and assembling the travel motor of a 336E excavator. It outlines 27 steps for disassembly, including removing the head, springs, brake piston, rotating assembly, and seals. It then outlines 28 steps for assembly, installing components in reverse order and noting proper lubrication and torque specifications. The proper procedure aims to prevent injury from spring forces and ensure correct alignment of parts.
Caterpillar cat 336 e lh excavator (prefix hdw) service repair manual (hdw000...fhsjekdmme
The document provides instructions for disassembling and assembling the travel motor on a 336E excavator model. It outlines 27 steps for disassembly, which includes removing the head, seals, springs, brake piston, plates, and seals from various components. It then outlines 28 steps for assembly, which reverses the disassembly process and includes lubricating parts and ensuring proper alignment of components. Special safety notes are included throughout to warn of spring loads and to wear protective equipment when specified.
Caterpillar cat 336 e lh excavator (prefix gny) service repair manual (gny000...fhsjekdmme
The document provides assembly instructions for a travel motor in 28 steps. It details installing various components like seals, springs, pistons, and plates in the proper order. It also provides disassembly instructions for a final drive in 13 steps, removing components like bolts, gears, and covers. Installation requires cleaning, applying sealant, and torquing bolts to specified values.
Caterpillar cat 336 e h excavator (prefix jea) service repair manual (jea0000...fhsjekdmme
The document provides instructions for disassembling and assembling the travel motor of a 336E excavator. It describes 27 steps to disassemble the motor by removing components like the motor head, springs, brake piston, rotating assembly, bearings and seals. It then describes 28 steps for reassembling the motor components in reverse order, making sure to align parts properly, apply lubricants to seals and mating surfaces, and torque bolts to the specified values. The proper procedure is important to safely release spring forces and prevent damage during removal and installation of parts.
Caterpillar cat 336 e h excavator (prefix hdw) service repair manual (hdw0000...fhsjekdmme
The document provides instructions for disassembling and assembling the travel motor on a 336E excavator model. It outlines 27 steps for disassembly, which includes removing the head, seals, springs, brake piston, plates, and seals from various components. It then outlines 28 steps for assembly, which reverses the disassembly process and includes lubricating parts and ensuring proper alignment of components. Special safety notes are included throughout to warn of spring loads and to wear protective equipment when specified.
This document provides the disassembly and assembly procedures for a travel motor on 336D2 XE and 336D2 LXE excavator models. It outlines 30 steps to disassemble the travel motor down to its core components. It then provides 19 steps to reassemble the travel motor. The document includes illustrations and notes on proper assembly order and tooling required. Safety precautions are provided throughout for tasks involving spring tension or component installation.
This document provides disassembly instructions for a 336D2 excavator travel motor. It outlines 27 steps to fully disassemble the travel motor. These include removing the motor head assembly, piston assemblies, barrel assembly, springs, seals, plates, and other internal components. Tools required include bolting fixtures, pry bars, pullers, and seal removal tools. Precautions are provided to retain component positioning for reassembly and to safely release spring forces during disassembly.
This document provides the disassembly and assembly procedures for a travel motor on 336D2 XE and 336D2 LXE excavator models. It outlines 30 steps to disassemble the travel motor down to its core components. It then provides 19 steps to reassemble the travel motor. The document includes illustrations and notes on proper assembly order and tooling required. Safety precautions are provided throughout for tasks involving spring forces or pressurized components.
Caterpillar cat 336 d2 l excavator (prefix hbk) service repair manual (hbk000...fhsjekdmme
This document provides disassembly instructions for a travel motor on 336D2, 336D2 L, and 336D2 GC excavators. The procedure involves 27 steps to disassemble the various components of the travel motor, including removing the head assembly, piston assemblies, barrel assembly, springs, seals, and other internal parts. Tools and safety precautions are listed. Alignment marks and noting component locations are emphasized to ensure correct reassembly.
Caterpillar cat 336 d2 l excavator (prefix fbt) service repair manual (fbt000...fhsjekdmme
This document provides instructions for removing and installing various engine components on a Caterpillar 336D2 excavator, including:
1) The engine oil filter and oil filter base.
2) The engine oil cooler.
3) The air cleaner assembly.
4) The turbocharger.
5) The water temperature regulator.
Detailed step-by-step instructions are provided for each component, along with illustrations to aid in the process. Safety notices are also included.
Caterpillar cat 336 d2 l excavator (prefix faj) service repair manual (faj000...fhsjekdmme
This document provides disassembly instructions for a travel motor on a 336D2 excavator. It lists 27 steps to fully disassemble the travel motor, including removing components like the motor head assembly, piston assemblies, springs, seals, and plates. Special care must be taken when removing or handling components with stored spring energy to avoid personal injury. Tools required include bolting fixtures, pullers, pry bars, and seal removal tools.
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Toro groundsmaster 4110 d (model 30447) service repair manual
1. (Models 30449 and 30447)
Part No. 10177SL
Service Manual
GroundsmasterR 4100-
-D & 4110-
-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 (Model 30449) and 4110--D
(Model 30447).
REFER TO THE OPERATOR’S MANUAL FOR OPER-
ATING, MAINTENANCE AND ADJUSTMENT
INSTRUCTIONS. For reference, insert a copy of the
Operator’s Manual and Parts Catalog for your machine
into Chapter 2 of this service manual. Additional copies
of the Operator’s Manual and Parts Catalog are avail-
able on the internet at www.Toro.com.
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 INSTRUC-
TION. 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 re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
E The Toro Company -
- 2010
Groundsmaster 4110-
-D
Groundsmaster 4100-
-D
5. Groundsmaster 4100--D/4110--D
Page 1 -
- 2
Safety
General Safety Instructions
The Groundsmaster 4100-D and 4110--D have been
tested and certified by TORO for compliance with exist-
ing safety standards and specifications. Although haz-
ard control and accident prevention partially are
dependent upon the design and configuration of the ma-
chine, these factors are also dependent upon the
awareness, concern and proper training of the person-
nel involved in the operation, transport, maintenance
and storage of the machine. Improper use or mainte-
nance of the machine can result in injury or death. To re-
duce 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. Review and understand the contents of the Opera-
tor’s Manual and Operator’s DVD before starting and
operating the vehicle. Become familiar with the controls
and know how to stop the vehicle and engine quickly.
Additional copies ofthe Operator’s Manual are available
on the internet at www.Toro.com.
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 ma-
chine.
3. Tighten any loose nuts, bolts or screws to ensure
machine is in safe operating condition.
4. Assure interlock switches are adjusted correctly so
engine cannot be started unless traction pedal is in
NEUTRAL and cutting deck is DISENGAGED.
5. Since diesel fuel is highly flammable, handle it care-
fully:
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.
6. Groundsmaster 4100--D/4110--D Page 1 -
- 3 Safety
While Operating
1. Sit on the seat when starting and operating the ma-
chine.
2. Before starting the engine:
A. Apply 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 ade-
quate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
4. Do not touch engine, muffler or exhaust pipe while
engine isrunning orsoon afteritisstopped.Theseareas
could be hot enough to cause burns.
5. Before getting off the seat:
A. Ensure that traction pedal is in neutral.
B. Apply parking brake.
C. Disengage cutting deck 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 deck should
be lowered to the ground. This relieves pressure
from the lift circuit and eliminates the risk of the cut-
ting deck unexpectedly lowering to the ground.
F. Do not park on slopes unless wheels are chocked
or blocked.
Safety
7. Groundsmaster 4100--D/4110--D
Page 1 -
- 4
Safety
Maintenance and Service
1. Before servicing or making adjustments, lower deck,
stop engine, apply 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.
3. Never store the machine or fuel container inside
where there is an open flame, such as near a water heat-
er or furnace.
4. Make sure all hydraulic line connectors are tight and
all hydraulic hoses and lines are in good condition be-
fore applying pressure to the system.
5. Keep body and hands away frompin hole leaks in hy-
draulic lines that eject high pressure hydraulic fluid. Use
cardboard or paper to find hydraulic leaks. Hydraulic
fluid escaping under pressure can penetrate skin and
cause injury. Fluid accidentally injected into the skin
must be surgically removed within a few hours by a doc-
tor familiar with this form of injury or gangrene may re-
sult.
6. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be re-
lieved by lowering cutting deck to the ground and stop-
ping engine.
7. If major repairs are ever needed or assistance is de-
sired, contact an Authorized Toro Distributor.
8. To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt. Clean
protective screen on machine frequently.
9. If engine must be running to perform maintenance or
an adjustment, keep hands, feet, clothing and other
parts of the body away from cutting deck and other mov-
ing parts. Keep bystanders away.
10.Do not overspeed the engine by changing governor
setting. To assure safety and accuracy, check maximum
engine speed.
11.Shut engine off before checking or adding oil to the
crankcase.
12.Disconnect battery before servicing the machine.
Disconnect negative cable first and positive cable last.
If battery voltage is required for troubleshooting or test
procedures,temporarily connectthe battery.Reconnect
positive cable first and negative cable last.
13.Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes and clothing. Protect your
face, eyes and clothing when working with a battery.
14.Battery gases can explode. Keep cigarettes, sparks
and flames away from the battery.
15.At the time of manufacture, the machine conformed
to the safety standards for riding mowers. To assure op-
timum performance and continued safety certification of
the machine, use genuine Toro replacement parts and
accessories. Replacement parts and accessories made
by other manufacturers may result in non-conformance
with the safety standards and the warranty may be
voided.
16.When changing attachments, tires or performing
other service, use correct jacks and supports. Make
sure machine is parked on a solid level surface such as
a concrete floor. Prior to raising the machine, remove
any attachments that may interfere with the safe and
proper raising of the machine. Always chock or block
wheels. Use appropriate jack stands to support the
raised machine. If the machine is not properly supported
by jack stands,themachine maymove orfall,whichmay
result in personal injury (see Jacking Instructions in this
chapter).
17.When welding on machine, disconnect battery
cables to prevent damage to machine electronic equip-
ment. Disconnect negative battery cable first and posi-
tive cable last. Also, disconnect wire harness connector
from both of the TEC controllers and disconnect the ter-
minal connector from the alternator. Attach welder
ground cable no more than two (2) feet (0.61 meters)
from the welding location.
8. Groundsmaster 4100--D/4110--D Page 1 -
- 5 Safety
Jacking Instructions
CAUTION
When changing attachments, tires or perform-
ing other service, use correct jacks and sup-
ports. Make sure machine is parked on a solid,
level surface such as a concrete floor. Prior to
raising machine, remove any attachments that
may interfere with the safe and proper raising of
the machine. Always chock orblock wheels.Use
jack stands to support the raised machine. If the
machine is not properly supported by jack
stands, the machine may move or fall, which
may result in personal injury.
Jacking the Front End (Fig. 1)
1. Set parking brake and chock both rear tires to pre-
vent the machine from moving.
2. Position jack securely under the frame, just to the in-
side of the front tire. Jack front wheel off the ground.
3. Once the machine is raised, position suitable jack
stand under the frame as close to the wheel as possible
to support the machine.
Jacking the Rear End (Fig. 2)
1. Place jack securely under the center of rear axle.
2. Chock both front tires. Jack rear of machine off the
ground.
3. Once the machine is raised, use suitable jack stands
under the rear axle to support the machine.
1. Frame jacking point 2. Front tire
Figure 1
1
2
2
1
1. Rear axle jacking point 2. Rear tire
Figure 2
1
2
2
Safety
9. Groundsmaster 4100--D/4110--D
Page 1 -
- 6
Safety
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
your Groundsmaster machine. If any decal becomes il-
legible or damaged, install a new decal. Decal part num-
bers are listed in your Parts Catalog.
10. Groundsmaster 4100--D/4110--D Page 2 -
- 1 Product Records and Maintenance
Chapter 2
Product Records and Maintenance
Table of Contents
PRODUCT RECORDS 1
. . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIVALENTS AND CONVERSIONS 2
. . . . . . . . . . .
Decimal and Millimeter Equivalents 2
. . . . . . . . . . . .
U.S. to Metric Conversions 2
. . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS 3
. . . . . . . . . . . . . . . . . . . .
Fastener Identification 3
. . . . . . . . . . . . . . . . . . . . . . .
Using a Torque Wrench with an Offset Wrench 3
. .
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Inch Series) 4
. . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Metric) 5
. . . . . . . . . . . . . . . . . . . .
Other Torque Specifications 6
. . . . . . . . . . . . . . . . . .
Conversion Factors 6
. . . . . . . . . . . . . . . . . . . . . . . . . .
Product Records
Insert Operator’s Manual and Parts Catalog for your
Groundsmaster atthe end ofthis chapter.Refer to Oper-
ator’s Manual for recommended maintenance intervals.
Additionally, insert Installation Instructions, Operator’s
Manuals and Parts Catalogs for any accessories that
have been installed on your Groundsmaster at the end
of this section.
Maintenance
Maintenance procedures and recommended service in-
tervals for your Groundsmaster are covered in the Oper-
ator’sManual.Referto thatpublication whenperforming
regular equipment maintenance. Several maintenance
procedures have break--in intervals identified in the Op-
erator’s Manual. Refer to the Engine Operator’s Manual
for additional engine specific maintenance procedures.
Product
Records
and
Maintenance
12. Groundsmaster 4100--D/4110--D Page 2 -
- 3 Product Records and Maintenance
Torque Specifications
Recommended fastener torque values are listed in the
following tables. For critical applications, as determined
by Toro, either the recommended torque or a torque that
is unique to the application is clearly identified and spe-
cified in this Service Manual.
These Torque Specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in this Ser-
vice Manual. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (e.g. Loctite), degree of lubrication
on the fastener, presence of a prevailing torque feature
(e.g. Nylock nut), hardness of the surface underneath
the fastener’s head or similar condition which affects the
installation.
As noted in the following tables, torque values should be
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread en-
gagement, etc.
The standard method of verifying torque shall be per-
formed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
Fastener Identification
Figure 1
Grade 1 Grade 5 Grade 8
Inch Series Bolts and Screws
Figure 2
Class 8.8 Class 10.9
Metric Bolts and Screws
Using a Torque Wrench with an Offset Wrench
Use of an offset wrench (e.g. crowfoot wrench) will affect
torque wrench calibration due to the effective change of
torque wrench length. When using a torque wrench with
an offset wrench, multiply the listed torque recommen-
dation by the calculated torque conversion factor (Fig.
3) to determine proper tightening torque. Tightening
torque when using a torque wrench with an offset
wrench will be lower than the listed torque recommen-
dation.
Example: The measured effective length of the torque
wrench (distance from the center of the handle to the
center of the square drive) is 18”.
The measured effective length of the torque wrench with
the offset wrench installed (distance from the center of
the handle to the center of the offset wrench) is 19”.
The calculated torque conversion factor for this torque
wrench with this offset wrench would be 18 / 19 = 0.947.
If the listed torque recommendation for a fastener is
from 76 to 94 ft--lb, the proper torque when using this
torque wrench with an offset wrench would be from 72
to 89 ft--lb.
Figure 3
(effective length of
torque wrench)
TORQUE CONVERSION FACTOR = A / B
A
B
(effective length of torque
Torque wrench
Offset wrench
wrench + offset wrench)
Product
Records
and
Maintenance
14. Groundsmaster 4100--D/4110--D Page 2 -
- 5 Product Records and Maintenance
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)
Thread Size
Class 8.8 Bolts, Screws and Studs with
Regular Height Nuts
Class 10.9 Bolts, Screws and Studs with
Regular Height Nuts
Thread Size Regular Height Nuts
(Class 8 or Stronger Nuts)
Regular Height Nuts
(Class 10 or Stronger Nuts)
M5 X 0.8 57 + 6 in--lb 644 + 68 N--cm 78 + 8 in--lb 881 + 90 N--cm
M6 X 1.0 96 + 10 in--lb 1085 + 113 N--cm 133 + 14 in--lb 1503 + 158 N--cm
M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 28 + 3 ft--lb 38 + 4 N--m
M10 X 1.5 38 + 4 ft--lb 52 + 5 N--m 54 + 6 ft--lb 73 + 8 N--m
M12 X 1.75 66 + 7 ft--lb 90 + 10 N--m 93 + 10 ft--lb 126 + 14 N--m
M16 X 2.0 166 + 17 ft--lb 225 + 23 N--m 229 + 23 ft--lb 310 + 31 N--m
M20 X 2.5 325 + 33 ft--lb 440 + 45 N--m 450 + 46 ft--lb 610 + 62 N--m
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
engine oil or thread sealant such as Loctite.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately + 10% of the
nominal torque value.
Product
Records
and
Maintenance
15. Groundsmaster 4100--D/4110--D
Page 2 -
- 6
Product Records and Maintenance
Other Torque Specifications
SAE Grade 8 Steel Set Screws
Thread Size
Recommended Torque
Thread Size
Square Head Hex Socket
1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb
5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb
3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3 ft--lb
1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Size Baseline Torque*
No. 6 -- 32 UNC 20 + 5 in--lb
No. 8 -- 32 UNC 30 + 5 in--lb
No. 10 -- 24 UNC 38 + 7 in--lb
1/4 -- 20 UNC 85 + 15 in--lb
5/16 -- 18 UNC 110 + 20 in--lb
3/8 -- 16 UNC 200 + 100 in--lb
Wheel Bolts and Lug Nuts
Thread Size Recommended Torque**
7/16 -- 20 UNF
Grade 5
65 + 10 ft--lb 88 + 14 N--m
1/2 -- 20 UNF
Grade 5
80 + 10 ft--lb 108 + 14 N--m
M12 X 1.25
Class 8.8
80 + 10 ft--lb 108 + 14 N--m
M12 X 1.5
Class 8.8
80 + 10 ft--lb 108 + 14 N--m
** For steel wheels and non--lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
Threads per Inch
Baseline Torque*
Size
Type A Type B
Baseline Torque*
No. 6 18 20 20 + 5 in--lb
No. 8 15 18 30 + 5 in--lb
No. 10 12 16 38 + 7 in--lb
No. 12 11 14 85 + 15 in--lb
*Hole size,materialstrength,materialthickness and fin-
ish must be considered when determining specific
torque values. All torque values are based on non--lubri-
cated fasteners.
Conversion Factors
in-
-lb X 11.2985 = N-
-cm N-
-cm X 0.08851 = in-
-lb
ft-
-lb X 1.3558 = N-
-m N-
-m X 0.7376 = ft-
-lb
17. Groundsmaster 4100--D/4110--D
Page 3 -
- 2
Kubota Diesel Engine
Specifications
Item Description
Make / Designation Kubota Model V2403--M--T--E3B: 4--Cycle, 4 Cylinder,
Water Cooled, Turbocharged, Diesel Engine
Bore 3.43 in (87.0 mm)
Stroke 4.031 in (102.4 mm)
Total Displacement cc (cu. in.) 148.5 in3 (2434 cc)
Firing Order 1 (closest to gear case end) -- 3 -- 4 (closest to flywheel end) -- 2
Combustion Chamber Spherical Type (E--TVCS)
Compression Ratio 23.0:1
Direction of Rotation Counterclockwise (viewed from flywheel)
Fuel Diesel or Biodiesel (up to B20) Fuel with
Low or Ultra Low Sulfur Content
Fuel Capacity 19.0 U.S. gallons (72 liters)
Fuel Injection Pump Denso PFR 4M Type Mini Pump
Injection Nozzle Denso OPD Mini Nozzle
Governor Centrifugal Mechanical
Low Idle (no load) 1450 + 50 RPM
High Idle (no load) 2870 +50/--120 RPM
Engine Oil API CH--4, CI--4 or higher
Engine Oil Viscosity See Operator’s Manual
Crankcase Oil Capacity 10.0 U.S. quarts (9.5 liters) with Filter
Oil Pump Trochoid Type
Coolant Capacity
Groundsmaster 4100--D 13 U.S. quarts (12.3 liters)
Groundsmaster 4110--D 17 U.S. quarts (16.1 liters)
Starter 12 VDC, 2.0 kW
Alternator/Regulator 12 VDC
Groundsmaster 4100--D 40 amp
Groundsmaster 4110--D 90 amp
Engine Dry Weight 419 U.S. pounds (190 kg)
18. Thank you very much for
your reading. Please Click
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19. Groundsmaster 4100--D/4110--D Page 3 -
- 3 Kubota Diesel Engine
General Information
This Chapter gives information about specifications and
repair of the diesel engine used in the Groundsmaster
4100--D and 4110--D.
General maintenance procedures are described in your
Operator’s Manual.Information on enginetroubleshoot-
ing, testing, disassembly and reassembly is identified in
the Kubota Workshop Manual, Diesel Engine, 03--M--
E3B Series that is included at the end of this section.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
tools are described in the Kubota Workshop Manual,
Diesel Engine, 03--M--E3B Series. The use of some
specialized test equipment is explained. However, the
cost of the test equipment and the specialized nature of
some repairs may dictate that the work be done at an en-
gine repair facility.
Service and repair parts for Kubota engines are sup-
plied through your Authorized Toro Distributor. If no
parts listis available,be prepared to provide your distrib-
utor with the Toro model and serial number of your ma-
chine.
Operator’s Manual
The Operator’s Manual provides information regarding
the operation, general maintenance and maintenance
intervals for your Groundsmaster machine. Refer to that
publication for additional information when servicing the
machine.
Stopping the Engine
IMPORTANT: Before stopping the engine after
mowing or full load operation, cool the turbo-char-
ger by allowing the engine to run at low idle speed
for five (5) minutes. Failure to do so may lead to tur-
bo-charger trouble.
Kubota
Diesel
Engine
20. Groundsmaster 4100--D/4110--D
Page 3 -
- 4
Kubota Diesel Engine
Service and Repairs
Air Filter System
Figure 1
1. Air cleaner hose
2. Hose clamp
3. Air cleaner assembly
4. Service indicator
5. Air cleaner strap
6. Lock nut (2 used)
7. Hose clamp
8. Air cleaner hose
9. Hose clamp
10. Cap screw (2 used)
11. Flat washer (4 used)
12. Spring (2 used)
13. Flat washer (2 used)
14. Cap screw (2 used)
15. Adapter
16. Lock nut (2 used)
17. Flat washer (2 used)
18. Overflow bracket
VACUATOR
DIRECTION
FRONT
RIGHT
8
1
3
4
5
6
9
7
10
2
11
11
12
13
14
15
16 17
18
12 to 15 in-
-lb
(1.4 to 1.6 N-
-m)
21. Groundsmaster 4100--D/4110--D Page 3 -
- 5 Kubota Diesel Engine
Removal (Fig. 1)
1. Park machine on a level surface, lower cutting deck,
stop engine, apply parking brake and remove key from
the ignition switch.
2. Raise and support hood.
3. Remove air cleaner components as needed using
Figure 1 as a guide.
Installation (Fig. 1)
IMPORTANT: Any leaks in the air filter system will
cause serious engine damage. Make sure that all air
cleaner components are in good condition and are
properly secured during assembly.
1. Assemble air cleaner system using Figure 1 as a
guide.
A. If service indicator (item 4) and adapter (item 15)
were removed fromair cleanerhousing,applythread
sealant to adapter threads before installing adapter
and indicator to housing. Install adapter so that
grooves in adapter hex and adapter filter elementare
installed toward service indicator (Fig. 3). Torque in-
dicator from 12 to 15 in-
-lb (1.4 to 1.6 N-
-m).
B. When securing air cleaner in air cleaner strap,
tighten cap screws (item 14) only enough to prevent
air cleaner from rotating in strap.
2. When installing air cleaner hose (item 1) between air
cleaner and turbo--charger (Fig. 4):
A. Make sure that hose does not contact engine
valve cover. To ensure clearance, move and/or ro-
tate air cleaner body in air cleaner strap.
B. Position hose to allow maximum clearance be-
tween air cleaner hose and muffler bracket.
3. Lower and secure hood.
Figure 2
1. Air cleaner housing
2. Safety filter element
3. Air filter element
4. Air cleaner cover
5. Vacuator valve
1
3
2
4
5
Figure 3
1. Air cleaner assembly
2. Service indicator
3. Adapter
1
3
2
1
2
3
4
Figure 4
1. Air cleaner hose
2. Muffler bracket
3. Air cleaner strap
4. Air cleaner slots
Kubota
Diesel
Engine