Form No.
Revision History Revision Date Description -- 2003 Initial Issue. A 2004 Updated Engine chapter. B 2005 Updated Electrical chapter. C 2007 Updated Engine chapter. D 2007 Updated Hydraulic chapter. E 2012 Updated Electrical chapter. F 2012 Updated Hydraulic chapter. G 03/2018 Added revision history. © THE TORO COMPANY 2018 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies).
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
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PART NO. 03116SL (Rev. G) Service Manual (Model 30411) GroundsmasterR 4100--D Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Groundsmaster 4100--D. REFER TO THE OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE, AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine.
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Chapter 2 − Product Records and Maintenance Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−1 2−2 2−3 2−7 Chapter 3 − Kubota Diesel Engine General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 − 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . Groundsmaster 4100−D 2 2 2 3 JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . Jacking the Front End . . . . . . . . . . . . . . . . . . . . . . . Jacking the Rear End . . . . . . . . . . . . . . . . . . . . .
General Safety Instructions The GROUNDSMASTER 4100-D was tested and certified by TORO for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
1. Before servicing or making adjustments, lower deck, stop engine, set parking brake, and remove key from the switch. 10.Do not overspeed the engine by changing governor setting. To assure safety and accuracy, check maximum engine speed. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 11. Shut engine off before checking or adding oil to the crankcase. 3.
Jacking Instructions CAUTION When changing attachments, tires, or performing other service, use correct blocks, hoists, and jacks. 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 or block wheels. Use jack stands or solid wood blocks to support the raised machine.
Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 4100−D. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog.
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Chapter 2 Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . . Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) . . . . . . . . . . . . . . .
Equivalents and Conversions Product Records and Maintenance Page 2 − 2 Groundsmaster 4100−D
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 specified 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 Service Manual.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in−lb in−lb N−cm 10 + 2 13 + 2 147 + 23 # 6 − 32 UNC # 6 − 40 UNF # 8 − 32 UNC 13 + 2 25 + 5 # 10 − 24 UNC 30 + 5 SAE Grade 8 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 5 or Stronger Nuts) in−lb N−cm in−lb N−cm 15 + 2 170 + 20 23 + 2 260 +
Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 5 in−lb 640 + 60 N−cm 78 + 7 in−lb 885 + 80 N−cm M6 X 1.0 96 + 9 in−lb 1018 + 100 N−cm 133 + 13 in−lb 1500 + 150 N−cm M8 X 1.25 19 + 2 ft−lb 26 + 3 N−m 27 + 2 ft−lb 36 + 3 N−m M10 X 1.5 38 + 4 ft−lb 52 + 5 N−m 53 + 5 ft−lb 72 + 7 N−m M12 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque 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 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.
Maintenance Groundsmaster 4100−D Page 2 − 7 Product Records and Maintenance Maintenance procedures and recommended service intervals for the Groundsmaster 4100−D are covered in the Operator’s Manual. Refer to that publication when performing regular equipment maintenance. Several maintenance procedures have break−in intervals identified in the Operator’s Manual. Refer to the Engine Operator’s Manual for additional engine specific maintenance procedures.
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Chapter 3 Kubota Diesel Engine GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Run Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 6 Air Filter System . . . . . . . . . . . . . . . . . .
General Information This Chapter gives information about specifications and repair of the diesel engine used in the Groundsmaster 4100−D. General maintenance procedures are described in your Operator’s Manual. Information on engine troubleshooting, testing, disassembly, and reassembly is identified in the Kubota Workshop Manual, Diesel Engine, V2003−T that is included at the end of this section. Most repairs and adjustments require tools which are commonly available in many service shops.
Specifications Item Description Make / Designation Kubota, 4−Cycle, 4 Cylinder, Water Cooled, Turbocharged, Diesel Engine 58 HP (43.3 kW) @ 2600 RPM Bore mm (in.) 83.0 (3.27) Stroke mm (in.) 92.4 (3.64) Total Displacement cc (cu. in.) 1999 (121.99) Firing Order 1−3−4−2 Combustion Chamber Spherical Type Fuel No. 2 Diesel Fuel (ASTM D975) Fuel Capacity liters (U.S. gallons) 72 (19.
Adjustments Run Solenoid 1. When ignition switch is in the RUN position, the run solenoid should energize and position the fuel stop lever to within 1/16” (1.6 mm) of stop on the injection pump. 4 2 3 2. If adjustment is needed, loosen lock nut and rotate the threaded end of the swivel until the lever is properly positioned. 3. Tighten lock nut. Recheck adjustment. 1 Figure 1 1. Run solenoid 2. Fuel stop lever (run) 3. Swivel 4. Lock nut 2 1 3 Figure 2 1. Run solenoid 2.
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Service and Repairs Air Filter System 9 8 7 RIGHT FRONT 1 11 6 5 4 2 11 10 3 EVACUATOR DIRECTION Figure 3 1. 2. 3. 4. Air cleaner hose Hose clamp Air cleaner assembly Indicator Kubota Diesel Engine (Rev. A) 5. 6. 7. 8. Air cleaner strap Lock nut (2 used) Hose clamp Air cleaner hose Page 3 − 6 9. Hose clamp 10. Cap screw (2 used) 11.
Removal 4 1. Remove air cleaner components as needed using Figure 3 as a guide. 1 Installation IMPORTANT: Any leaks in the air filter system will cause serious engine damage. Make sure daily that all air cleaner components are in good condition and are properly secured during reassembly. 3 5 2 2. When installing air cleaner hose (8) between air cleaner and turbo−charger (Fig. 4): A. Make sure that hose does not contact engine valve cover.
Exhaust System 1 14 3 11 2 4 5 16 to 22 ft−lb (21 to 29 N−m) 12 7 9 7 16 to 22 ft−lb (21 to 29 N−m) 11 8 8 6 RIGHT 10 6 FRONT 13 16 to 22 ft−lb (21 to 29 N−m) Figure 5 1. 2. 3. 4. 5. Muffler Muffler bracket Exhaust pipe Flange head screw (4 used) Exhaust gasket Kubota Diesel Engine (Rev. A) 6. 7. 8. 9. 10. Lock nut Cap screw Flat washer Spacer Rubber hanger Page 3 − 8 11. 12. 13. 14.
Removal 3 CAUTION The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the muffler. 2 4 2. Remove muffler and/or muffler bracket from the engine as necessary using Figure 5 as a guide. Installation IMPORTANT: If exhaust studs were removed from engine cylinder head, thoroughly clean threads in head and apply Loctite #277 (or equivalent) to stud threads before installing studs into head.
Fuel System 38 39 37 RIGHT 36 35 34 FRONT 24 41 2 29 26 27 28 25 22 30 31 23 33 1 21 14 3 4 5 40 6 32 20 7 19 7 8 12 18 17 1615 11 13 9 60 to 80 in−lb (7 to 9 N−m) 10 135 to 165 ft−lb (183 to 223 N−m) Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Fuel Tank Installation DANGER 1. Install fuel tank using Figure 7 as a guide. Check Fuel Lines and Connections Check fuel lines and connections periodically as recommended in the Operator’s Manual. Check lines for deterioration, damage, leaks, or loose connections. Replace hoses, clamps, and connections as necessary. A. Torque two locking flange nuts that secure the fuel tank to the frame from 60 to 80 in−lb (7 to 9 N−m). 2. Install two (2) tank covers to ROPS assembly. 3.
Radiator 21 20 18 23 46 22 RIGHT 45 17 16 FRONT 19 47 24 1 10 15 11 13 9 6 25 12 14 26 12 7 25 28 5 8 35 38 4 30 37 48 41 8 32 34 29 31 2 3 33 10 6 27 39 40 42 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Radiator cap Foam strip Foam strip Lower radiator hose Upper radiator hose Hose clamp Radiator shroud Lock nut Radiator Hose clamp Reservoir hose Flange head screw Grommet Flange nut Retaining ring Knob (2 used) Kubota Diesel Engine (Rev.
Removal Installation 1. Park machine on a level surface, lower cutting unit, stop engine, engage parking brake, and remove key from the ignition switch. 1. Remove plugs from radiator and hoses placed during the removal procedure. 2. Position radiator to the support frame. Secure radiator to the support frame with lock nuts, flat washers, and flange head screws. CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.
Engine 12 10 5 6 7 8 9 10 11 25 6 26 15 10 19 20 12 10 13 16 14 17 18 21 22 2 RIGHT 3 4 1 FRONT 23 24 23 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. Engine Engine mount bracket (RH shown) Lock washer Cap screw Barb fitting Hose clamp Hose Fuel line Fuel filter Kubota Diesel Engine (Rev. A) 10. 11. 12. 13. 14. 15. 16. 17. 18.
Engine Removal 1. Park machine on a level surface, lower cutting unit, stop engine, engage parking brake, and remove key from the ignition switch. 1 3 2. Remove battery cover and strap. Disconnect negative battery cable first and then positive battery cable. Remove battery from machine. 3. Open engine hood. 2 3 Kubota Diesel Engine CAUTION Figure 11 Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. 1. Temperature sender 2.
8. Disconnect fuel line from injection pump (Fig. 12). Cap fuel line and injector pump fuel inlet to prevent contamination. 1 9. Disconnect throttle cable from the speed control lever by removing the washer and lock nut. Loosen jam nut and take cable from mounting bracket (Fig. 12). 3 10.Remove coolant reservoir and bracket from fan shroud. 2 11. Remove four flange head screws and flat washers securing the fan shroud to the radiator. 12.
12.Connect wires and/or electrical connections to the following electrical components: Engine Installation 1. If removed, install engine mount brackets to the engine using Figure 10 as a guide. 2. Connect hoist or lift to the front and rear lift tabs on engine. A. The temperature sender and alternator (Fig 11). B. The engine run solenoid and fuel pump (Fig. 13). C. The high temperature shutdown switch and glow plug (Fig. 14). 3. Position fan shroud around the engine fan.
Pump Adapter Plate 1 2 17 to 21 ft−lb (23 to 28 N−m) 3 4 6 7 5 2 8 9 17 to 21 ft−lb (23 to 28 N−m) RIGHT 11 FRONT 10 10 35 to 43 ft−lb (48 to 58 N−m) 12 Figure 16 1. 2. 3. 4. Engine Lock washer Cap screw (4 used) Pump adapter plate Kubota Diesel Engine (Rev. A) 5. 6. 7. 8. Plate pin (2 used) Dowel (2 used) Coupling spacer Shoulder bolt (2 used) Page 3 − 18 9. 10. 11. 12.
Disassembly 1. If engine is in machine, hydraulic pump assembly needs to be removed from engine before coupling can be serviced (see Pump Assembly in Chapter 4 − Hydraulic Systems). 4 3 2. Remove pump adapter plate, spring center coupling, and coupling spacer from engine using Figure 16 as a guide. Assembly 2 UP 2 3 2. Install four cap screws and lockwashers to coupling spacer and flywheel. Torque cap screws from 17 to 21 ft−lb (23 to 28 N−m). 4 1 Figure 17 1. Coupling spacer 2.
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Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 3 Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 5 Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 5 HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . .
Specifications Item Description Piston (Traction) Pump System Relief Pressure: Forward System Relief Pressure: Reverse Charge Pressure Variable displacement piston pump 4000 PSI (274 bar) 5000 PSI (343 bar) 250 PSI (17 bar) Gear Pump Steering Relief Pressure Lift/Lower Relief Pressure 3 section, positive displacement gear type pump 1350 PSI (93 bar) 2525 PSI (174 bar) Front Wheel Motors Fixed displacement piston motors Rear Axle Motor Fixed displacement piston motor Cutting Deck Motors Relief Pres
General Information Hydraulic Hoses When replacing a hydraulic hose, be sure that the hose is straight (not twisted) before tightening the fittings. This can be done by observing the imprint on the hose. Use two wrenches; hold the hose straight with one and tighten the hose swivel nut onto the fitting with the other. WARNING Before disconnecting or performing any work on hydraulic system, relieve all pressure in system. Stop engine; lower or support box and/or other attachment(s).
SAE Straight Thread O--Ring Port -- Non--adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O--ring seal when this type of fitting shows signs of leakage. 3. Lubricate the O--ring with a light coating of oil. O--Ring 4. Install the fitting into the port and tighten it down full length until finger tight. 5. Tighten the fitting to the correct Flats From Finger Tight (F.F.F.T.). Size 4 (1/4 in.
Towing Traction Unit IMPORTANT: If towing limits are exceeded, severe damage to the piston pump may occur. If it becomes necessary to tow (or push) the machine, tow (or push) in a forward direction only and at a speed below 3 mph. The piston (traction) pump is equipped with a by--pass valve that needs to be turned 90o for towing. See Operator’s Manual for Towing Procedures. 1 Figure 7 1.
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Groundsmaster 4100--D Page 4 -- 7 Hydraulic System Hydraulic System All solenoids are shown as de--energized Groundsmaster 4100--D Hydraulic Schematic Hydraulic Schematic
Hydraulic System Page 4 -- 8 Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100--D Traction Circuit (Forward/Mow Shown) Hydraulic Flow Diagrams Groundsmaster 4100--D
Traction Circuit Traction circuit pressure (forward and reverse) can be measured at test ports on the sides of the machine. The traction pump and wheel motors use a small amount of hydraulic oil for internal lubrication. Oil is designed to leak across pump and motor parts into the case drain. This leakage results in the loss of hydraulic oil from the closed loop traction circuit that must be replaced.
Hydraulic System Page 4 -- 10 Rev.
Lower Cutting Deck When the cutting deck is in a stationary position, flow from the gear pump is by--passed through the lift/lower control valve, counterbalance manifold, oil filter, and traction charge circuit. To lower the cutting deck, the center lift lever on the lift/ lower control valve is pushed to allow valve shift in the lift/lower control. This valve change allows a passage for oil flow from the rod end of the deck lift cylinders.
Hydraulic System Page 4 -- 12 Rev.
Raise Cutting Deck When the cutting deck is in a stationary position, flow from the gear pump is by--passed through the lift/lower control valve, counterbalance manifold, oil filter, and traction charge circuit. To raise the cutting deck, the center lift lever on the lift/ lower control valve is pulled to allow valve shift in the lift/ lower control. This valve change allows hydraulic pressure to the rod end of the deck lift cylinders, causing the cylinders to retract.
Hydraulic System Page 4 -- 14 Groundsmaster 4100--D Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100--D Mow Circuit (All Deck Motors Rotating)
Mow Circuit Each cutting deck is controlled by a hydraulic manifold equipped with a solenoid control valve (SV1), bypass cartridge (BY1), brake cartridge (BR1), and relief cartridge (R1BR). When the the deck solenoid valve (SV1) is not energized (PTO switch OFF), hydraulic flow by-passes the deck motor through the bypass cartridge (BY1). When the PTO switch is turned ON, the solenoid valve (SV1) energizes, causing a shift of the by--pass cartridge (BY1) and allowing hydraulic flow to the deck motor.
Hydraulic System Page 4 -- 16 Groundsmaster 4100--D Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100--D Steering Circuit (Left Turn Shown)
Steering Circuit A three section gear pump is coupled to the piston (traction) pump. The gear pump section farthest from the piston pump supplies hydraulic flow to the steering control valve and the lift/lower control valve. Pump hydraulic flow is delivered to the two circuits through a proportional flow divider. The gear pump takes its suction from the hydraulic reservoir. Steering circuit pressure is limited by a relief valve located in the steering control valve.
Special Tools Order these tools from your Toro Distributor. Hydraulic Pressure Test Kit -- TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges. Use gauges as recommended in Testing section of this chapter.
Hydraulic Test Fitting Kit -- TOR4079 This kit includes a variety of O--ring Face Seal fittings to enable you to connect test gauges into the system. TORO TEST FITTING KIT (NO. TOR4079) The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings. Figure 15 Measuring Container -- TOR4077 Hydraulic System Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only).
Troubleshooting The charts that follow contain information 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 precautions and specific test procedures. Problem Possible Cause Hydraulic system operates hot. Engine RPM is too low. Hydraulic reservoir oil level is low. Hydraulic oil is contaminated or the wrong type. Brakes are engaged or sticking. Piston pump by--pass valve is open or damaged.
Problem Possible Causes Four wheel drive will not engage. Electrical problem exists (see Chapter 5 -- Electrical System). Solenoid valve on 4WD hydraulic manifold is faulty. Cartridge valve in 4WD manifold is damaged or sticking. Rear axle motor is damaged. Four wheel drive will not disengage. Electrical problem exists (see Chapter 5 -- Electrical System). Solenoid valve on 4WD hydraulic manifold is faulty. Cartridge valve in 4WD manifold is damaged or sticking. Cutting decks will not operate.
Problem Possible Causes Cutting decks drop too fast or too slow. Flow control valve is not adjusted properly. Cutting deck will not lower. Lift arm pivots are binding. Lift cylinder is damaged. Counterbalance pressure is excessive. Lift/lower control valve is worn or damaged. Pilot valve in lift/lower manifold is damaged or sticking.
Testing 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. Precautions 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.
TEST NO.
Procedure for Traction Circuit Charge Pressure Test 2 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is engaged. 1 CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning of this section.
TEST NO.
Procedure for Traction Circuit Relief Pressure Test 2 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. CAUTION 1 Move machine to an open area, away from people and obstructions. Figure 19 1. Forward traction port 2. LH front tire 2. Drive machine to an open area, lower cutting decks, turn the engine off, and engage the parking brake. 2 CAUTION 1 3.
NOTE: CENTER DECK TEST SHOWN TRACTION CIRCUIT CASE DRAIN/RETURN CHARGE CIRCUIT TEST NO.
Procedure for Cutting Deck Circuit Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is engaged. CAUTION 2 Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning of this section.
NOTE: CENTER GEAR PUMP SECTION FLOW TEST SHOWN TRACTION CIRCUIT CASE DRAIN/RETURN CHARGE CIRCUIT TEST NO.
Procedure for Cutting Deck Gear Pump Flow Test NOTE: Over a period of time, the gears and wear plates in the gear pump can wear. A worn pump will by--pass oil and make the pump less efficient. Eventually, enough oil loss will occur to cause the cutting deck motors to stall under heavy cutting conditions. Continued operation with a worn, inefficient pump can generate excessive heat and cause damage to the seals and other components in the hydraulic system. 1.
NOTE: CENTER DECK TEST SHOWN TRACTION CIRCUIT CASE DRAIN/RETURN CHARGE CIRCUIT TEST NO.
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is engaged. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning of this section. 3. Locate deck manifold to be tested (Fig. 26).
TEST NO.
Procedure for Cutting Deck Motor Case Drain Leakage Test 6. Sit on seat and operate the engine at full speed (2730 + 30 RPM). Move PTO switch to ON. NOTE: Over a period of time, a deck motor can wear internally. A worn motor may by--pass oil to its case drain causing the motor to be less efficient. Eventually, enough oil loss will cause the deck motor to stall under heavy cutting conditions.
TEST NO. 7: Steering Circuit Relief Pressure (Using Pressure Gauge) STEERING CYLINDER PISTON MOVEMENT NOTE: LEFT TURN SHOWN L R 1350 PSI STEERING CONTROL T PB P G TO LIFT/LOWER CIRCUIT CHARGE CIRCUIT TO RESERVOIR TO PTO (MOW) CIRCUIT .58 1.37 1.37 2.
Procedure for Steering Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is engaged. 1 CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning of this section.
TEST NO.
Procedure for Lift/Lower Circuit Relief Pressure Test 2 1 NOTE: Before attempting to check or adjust lift pressure, make sure that counterbalance pressure is correctly adjusted. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is engaged. Raise seat. 1.
TEST NO. 9: Steering and Lift/Lower Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter) NOTE: LIFT/LOWER CIRCUIT FLOW TEST SHOWN TO STEERING CIRCUIT .58 1.37 TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT TO LIFT/LOWER CIRCUIT 1.37 2.
Procedure for Steering and Lift/Lower Gear Pump Flow Test Output from the steering and lift/lower gear pump section is equally divided by a proportional valve to provide flow to the steering circuit and the lift circuit. To test gear pump flow, testing of both steering and lift/lower circuits is required. Total gear pump flow is the combined flow from the two circuits. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes.
FROM PTO (MOW) CIRCUIT PTO (MOW) CIRCUIT CASE DRAIN TO PTO (MOW) CIRCUIT TEST NO.
Procedure for Counterbalance Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is engaged. Remove console cover. C. To decrease pressure setting, turn the adjustment screw on the valve in a counterclockwise direction.
TEST NO.
Procedure for Rear Traction Circuit (RV5) Relief Pressure Test 1 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is engaged. 2 CAUTION Figure 37 1. 2WD/4WD control manifold 2. Relief valve test port Prevent personal injury and/or damage to equipment.
TEST NO.
Procedure for Traction Circuit Reducing Valve (PR) Pressure Test 1 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is engaged. 2 CAUTION Figure 40 1. 2WD/4WD control manifold 2. Pressure test port Prevent personal injury and/or damage to equipment.
Adjustments Adjust Cutting Deck Flow Control Valve The cutting deck lift circuit is equipped with an adjustable flow control valve used to adjust the rate at which the cutting decks lower. The control valve is located under the front platform. Adjust flow control valve as follows: 2 1. Run machine to get hydraulic oil at operating temperatures. Park machine on a level surface, shut engine off and lower cutting decks to the ground. 1 2. Locate valve under front of machine (Fig. 42). 3.
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower cutting decks or attachments, and stop engine. Remove key from the ignition switch. 1. Check oil level in the hydraulic reservoir and add correct oil if necessary.
Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky, black, or contains metal particles). IMPORTANT: Flush hydraulic system when changIng from petroleum base hydraulic fluid to a biodegradable fluid such as Mobil EAL 224H. Operate machine under normal operating conditions for at least four (4) hours before draining. 1. Park machine on a level surface.
Charge Hydraulic System IMPORTANT: Change hydraulic oil filter whenever hydraulic components are repaired or replaced. 11. After the hydraulic system starts to show signs of fill, actuate lift control lever until the lift cylinder rod moves in and out several times. If the cylinder rod does not move after 15 seconds, or the pump emits abnormal sounds, shut the engine off immediately and determine cause or problem. Inspect for the following: A. Loose filter or suction lines. 1.
Gear Pump 20 15 16 17 3 12 13 4 14 1 2 6 3 5 8 10 7 18 9 19 25 27 11 11 21 26 RIGHT 22 FRONT 23 24 1. 2. 3. 4. 5. 6. 7. 8. 9. 90o hydraulic fitting O--ring O--ring 90o hydraulic fitting O--ring O--ring Hydraulic fitting O--ring Hydraulic fitting Hydraulic System Figure 43 10. 11. 12. 13. 14. 15. 16. 17. 18. O--ring Clamp Hydraulic T fitting O--ring Hydraulic fitting Fitting cap Hydraulic fitting O--ring Cap screw (2 used) Page 4 -- 52 19. 20. 21. 22. 23. 24. 25. 26. 27.
Removal (Fig 43) Installation (Fig 43) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake, and remove key from the ignition switch. 1. Lubricate new o--rings with clean hydraulic oil and position on pump. 3. Drain the hydraulic reservoir (see Operator’s Manual). 4. To prevent contamination of hydraulic system during pump removal, thoroughly clean exterior of pump and fittings. 5.
Gear Pump Service 5 13 11 4 8 14 3 1 12 15 10 4 4 19 18 17 23 16 4 20 21 21 to 24 ft--lb (29 to 33 N--m) 25 to 28 ft--lb (34 to 38 N--m) 2 22 12 13 24 14 9 7 28 4 29 27 25 26 4 21 to 24 ft--lb (29 to 33 N--m) 6 Figure 44 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Shaft seal Washer Cap screw (8 used) O--ring Washer (8 used) Proportional valve Plug Plug O--ring Front body 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
3. Remove pump from vise, hold pump in hands and bump shaft against wooden block to separate front pump sections. Front body (10) will remain with either front plate (15) or front adapter plate (23). Inspection 4. Place front idler gear (16) into gear pocket and tap with soft face hammer until the front body separates. Remove idler gear from front plate or adapter plate. 2. Check spline drive shaft for damaged teeth.
Reassembly (Fig. 44) It is important that the relationship of the backplate, adapter plates, bodies, wear plates and front plate is correct. The two half moon cavities in the bodies must face away from the front plate or adapter plate. The smaller half moon port cavity must be on the pressure side of the pump. The side of the wear plate with mid section cut out must be on suction side of pump. Suction side of backplate or adapter plate is always the side with larger port boss. 1.
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Piston (Traction) Pump 32 33 31 34 17 30 16 3 3 13 1 85 to 95 ft--lb (115 to 128 N--m) 2 4 6 15 3 5 18 2 5 22 20 14 11 8 8 7 12 RIGHT 19 10 21 21 27 29 9 23 28 FRONT 26 25 24 Figure 45 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Hydraulic T fitting O--ring O--ring 90o hydraulic fitting O--ring O--ring Hydraulic fitting (2 used) O--ring O--ring Hydraulic fitting O--ring Hose connector Hydraulic System 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Installation (Fig. 45) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake, and remove key from the ignition switch. 1. Carefully lower piston pump into the machine and position it to the engine adapter plate. Support pump to prevent it from falling while installing two (2) cap screws and washers securing piston pump to engine adapter plate. Torque screws from 85 to 95 ft--lb (115 to 128 N--m). 2.
Piston (Traction) Pump Service 100 to 110 ft--lb (136 to 149 N--m) 27 to 31 ft--lb (37 to 42 N--m) 16 20 150 to 160 in--lb (17 to 18 N--m) 38 18 100 to 110 ft--lb (136 to 149 N--m) 15 4 to 6 ft--lb (5 to 8 N--m) 14 1 29 26 4 22 45 10 33 28 23 17 8 30 7 5 27 40 to 48 in--lb (4.5 to 5.4 N--m) 34 43 35 31 36 32 44 11 40 to 48 in--lb (4.5 to 5.4 N--m) 37 19 25 to 28 ft--lb (34 to 38 N--m) 42 41 40 6 Loctite #277 31 5 39 37 21 12 40 to 48 in--lb (4.5 to 5.
1. Position the pump into a protected jaw vise, clamping onto the outer portion of the flange, with the cap screws up. Mark the relationship of the working ports (for reassembly identification) to the servo control assembly with a scribe. Remove the four cap screws (15) retaining backplate (20). 2. Lift backplate (20) straight up off drive shaft (21) and housing (19). Remove valve plate (18) from backplate (20) or from rotating kit assembly (6), still in housing (19). 3.
3. Inspect camplate assembly: A. The finish on the piston shoe surfaces of the camplate (11) should show no signs of scoring. 3 2 1 B. Inspect camplate (11) bushing surface for wear. Also inspect surface for coating transfer from bushing. 5 4. Inspect bushing (44) for contamination embedment within coating of bushing surface coming in contact with camplate (11). 4 Figure 49 5. Inspect rotating kit (Fig. 49): A. The pistons should move freely in the rotating kit piston block bore.
9. Install shaft assembly into front of housing. Seat seal (25) into position with seal driver and retain with interior retaining ring (2). 10.Install servo piston follower (8) onto camplate dowel pin. Install camplate (11) carefully onto bushing (44) (coat bushing surface with hydraulic oil), aligning servo piston follower (8) with slot in servo piston assembly (7). 11. Position housing in a horizontal position.
Piston Pump Control Assembly 44 to 52 ft--lb (60 to 70 N--m) 15 10 1 2 14 3 4 9 7 5 13 12 4 8 6 16 24 17 to 26 in--lb (2 to 3 N--m) 17 23 Loctite #222 11 22 28 to 34 in--lb (3.2 to 3.8 N--m) 21 18 20 Loctite #242 19 Figure 51 1. 2. 3. 4. 5. 6. 7. 8. Plug O--ring Retaining ring Spring retainer Spring Spool valve Control housing Input shaft 9. 10. 11. 12. 13. 14. 15. 16. O--ring Wiper seal O--ring Adaptor Ball Pin Neutral switch O--ring 17. 18. 19. 20. 21. 22. 23. 24.
6. Install wiper seal on input shaft. 7. Install new o--ring (2) onto plug and install plug. Adjust plug until there is no end play in the valve spool with input shaft held stationary. Secure plug in place with set screw (24). Torque set screw from 17 to 26 in--lb (2 to 3 N--m). Disassembly -- Neutral Switch 1. Loosen set screw (17) in adapter and remove neutral switch from adapter. 5. Test the switch by moving the control arm to the detent position, the light should be on.
Hydraulic Control Manifold: 4 Wheel Drive 2 12 19 13 4 5 3 11 9 6 8 7 9 10 10 17 16 11 7 4 13 12 14 15 11 RIGHT 1 FRONT 18 Figure 53 1. 2. 3. 4. 5. 6. 7. Frame assembly 4 wheel drive manifold 90o hydraulic fitting O--ring O--ring Quick fitting O--ring Hydraulic System 8. 9. 10. 11. 12. 13. Fitting cap Hydraulic fitting O--ring O--ring 90o hydraulic fitting O--ring Page 4 -- 66 14. 15. 16. 17. 18. 19.
Removal Installation NOTE: The ports on the manifold are marked for easy identification of components. Example: P1 is a piston pump connection port and 2 is the location for the solenoid valve (See Hydraulic Schematic to identify the function of the hydraulic lines and cartridge valves at each port). 1. Install hydraulic manifold to the frame using Figure 53 as guide. 2. Remove caps and plugs from fittings and hoses. Properly connect hydraulic lines to manifold. 3.
Hydraulic Control Manifold Service: 4 Wheel Drive 19 EATON/VICKERS MANIFOLD 18 16 14 15 24 18 19 12 17 1 80 to 90 ft--lb (108 to 122 N--m) 7 80 to 90 ft--lb (108 to 122 N--m) 16 17 18 13 19 18 19 21 18 16 17 17 5 6 19 20 7 16 13 4 12 16 13 17 15 9 11 17 16 14 3 60 to 70 ft--lb (81 to 95 N--m) 10 20 21 8 35 to 40 ft--lb (47 to 54 N--m) 13 12 21 13 12 15 14 PLUG TORQUE 2 #2: 41 to 49 in--lb (4.6 to 5.
tridge design allows, use a wood or plastic probe to push the internal spool in and out 20 to 30 times to flush out contamination. Be extremely careful not to damage cartridge. Use compressed air for cleaning. IMPORTANT: Use care when handling the valve cartridge. Slight bending or distortion of the stem tube can cause binding and malfunction. 3. Remove cartridge valve with a deep socket wrench. Note correct location for o--rings, sealing rings, and backup rings. Remove and discard seal kit. 6.
Hydraulic Control Manifold: Deck Drive 16 4 6 10 25 8 16 20 2 11 14 13 12 14 21 22 19 18 6 17 4 4 16 6 2 4 16 6 17 13 10 23 7 6 4 18 24 6 11 13 12 4 14 8 9 8 10 1 2 5 8 11 15 14 12 25 6 3 RIGHT FRONT Figure 56 1. 2. 3. 4. 5. 6. 7. 8. 9. Hydraulic manifold (center deck) O--ring Hydraulic adapter O--ring Straight hydraulic fitting O--ring 90o hydraulic fitting O--ring Hydraulic tee fitting Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17.
Removal Installation NOTE: The ports on the manifold are marked for easy identification of components. Example: SV1 is the deck solenoid valve and P1 is a gear pump connection port. (See Hydraulic Schematic to identify the function of the hydraulic lines and cartridge valves at each port). 1. Install hydraulic manifold to the frame using Figure 56 as guide. The control manifolds for the three cutting deck sections are very similar.
Hydraulic Control Manifold Service: Deck Drive 12 6 30 to 35 ft--lb (41 to 47 N--m) 20 30 to 35 ft--lb (41 to 47 N--m) 13 7 18 19 15 14 15 17 9 14 9 12 to 15 ft--lb (16 to 20 N--m) 16 9 3 Loctite #242 8 1 50 to 55 in--lb (5.6 to 6.2 N--m) 15 14 10 5 11 2 4 PLUG TORQUE SAE #2: 60 to 65 in--lb (6.8 to 9.5 N--m) SAE #4: 9 to 11 ft--lb (12 to 15 N--m) SAE #8: 43 to 46 ft--lb (58 to 62 N--m) 80 ft--lb (108 N--m) Figure 57 1. 2. 3. 4. 5. 6. 7.
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Hydraulic Control Manifold: Cutting Deck Lift/Lower 12 16 15 10 13 9 5 14 1 RIGHT 2 FRONT 10 11 10 8 9 3 4 7 6 5 Figure 58 1. 2. 3. 4. 5. 6. Lift/lower hydraulic manifold Valve plate Flat washer (2 used) Cap screw (2 used) Grommet (4 used) Flat washer (2 used) 7. 8. 9. 10. 11. Lock nut Hydraulic fitting (2 used) O--ring O--ring 90o hydraulic fitting (4 used) Removal NOTE: The ports on the manifold are marked for easy identification of components.
Hydraulic Control Manifold Service: Cutting Deck Lift/Lower 35 to 40 ft--lb (47 to 54 N--m) 2 35 to 40 ft--lb (47 to 54 N--m) 4 35 to 40 ft--lb (47 to 54 N--m) 2 3 41 to 49 in--lb (4.6 to 5.6 N--m) 5 6 3 Hydraulic System 7 1 Figure 59 1. Manifold body 2. Pilot valve 3. Seal kit 4. Relief valve (Counterbalance) 5. Seal kit 6. Plug (SAE #2) 7. O--ring NOTE: The ports on the manifold are marked for easy identification of components.
Hydraulic Control Manifold: Filter Manifold 8 4 9 3 2 5 1 6 10 7 11 12 14 13 15 16 23 22 17 21 20 12 19 15 18 RIGHT FRONT Figure 60 1. 2. 3. 4. 5. 6. 7. 8. Filter manifold 45o hydraulic elbow Test nipple Fitting cap O--ring O--ring O--ring Cap screw (3 used) 9. 10. 11. 12. 13. 14. 15. 16. Flat washer (3 used) Hydraulic fitting O--ring O--ring Hydraulic fitting Hydraulic hose O--ring O--ring Removal NOTE: The ports on the manifold are marked for easy identification of components.
Hydraulic Control Manifold Service: Filter Manifold 4 60 to 70 ft--lb (81 to 95 N--m) 35 to 40 ft--lb (47 to 54 N--m) 7 6 2 10 12 11 5 10 10 11 13 11 13 12 9 8 9 1 12 13 15 9 14 9 8 8 16 PLUG TORQUE SAE #4: 6 to 10 ft--lb (8 to 13 N--m) SAE #5: 10 to 15 ft--lb (13 to 20 N--m) SAE #6: 15 to 20 ft--lb (20 to 27 N--m) SAE #10: 35 to 40 ft--lb (48 to 54 N--m) Figure 61 1. 2. 3. 4. 5. 6.
Rear Axle Motor 9 Arrow on side of motor case points up 12 2 10 11 1 9 7 8 13 10 7 3 2 4 5 6 59 to 73 ft--lb (80 to 99 N--m) RIGHT FRONT Figure 62 1. 2. 3. 4. 5. Rear axle motor 90o hydraulic fitting Hydraulic fitting Cap screw (2 used) Flat washer (2 used) Hydraulic System 6. 7. 8. 9. O--ring External snap ring Pinion gear O--ring Page 4 -- 78 10. 11. 12. 13.
Removal Installation 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake, and remove key from the ignition switch. 1. If removed, install pinion gear to axle motor. 3. To prevent contamination of hydraulic system during motor removal, thoroughly clean exterior of motor and fittings. NOTE: To ease reassembly, tag the hydraulic hoses to show their correct position on the axle motor. 4. Disconnect hydraulic hoses from rear axle motor.
Front Wheel Motors 2 5 12 16 11 13 14 3 15 19 4 8 1 18 16 14 Arrow on side of motor case points up 10 15 12 11 13 7 11 13 14 Arrow on side of motor case points up 15 16 1 8 19 6 15 RIGHT 12 75 to 85 ft--lb (101 to 115 N--m) 2 16 17 5 13 9 FRONT 20 3 Figure 63 1. 2. 3. 4. 5. 6. 7. Front wheel motor Internal retaining ring Splined brake shaft RH brake assembly Planetary assembly Cap screw (2 used per motor) Flat washer (2 used per motor) Hydraulic System 8. 9. 10. 11.
Removal Installation 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake, and remove key from the ignition switch. 1. Position wheel motor to brake assembly making sure that arrows on the side of motor case point upward. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3.
Rear Axle/Front Wheel Motor Service 15 to 18 ft--lb (20 to 24 N--m) 9 9 10 13 10 7 2 1 11 18 8 6 14 15 16 12 4 5 3 17 Figure 64 1. 2. 3. 4. 5. 6. Drive shaft Backplate (front motor shown) Housing assembly Rotating assembly Cam plate insert Retaining ring 7. 8. 9. 10. 11. 12. Cap screw (6 used) Shaft seal Retaining ring Thrust race O--ring Valve plate NOTE: The front wheel motors are identical. The rear axle motor has some differences from the front motors.
2. If necessary, install new needle bearing (17) in housing (3) with numbered end of the bearing outward. 5. Remove the camplate insert (5) from housing. Use caution not to mar the finish that makes contact with pistons. 3. Install retaining ring (9) on shaft. Install thrust race (10), thrust bearing (13), and second thrust race (10). Secure with second retaining ring (9). 6. Remove retaining ring (6) from housing. Press shaft from housing and remove shaft seal (8) and washer (18). 4.
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Cutting Deck Motor Removal 1 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake, and remove key from the ignition switch. 5 4 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3. Disconnect hydraulic lines from deck motor. Put caps or plugs on fittings and hoses to prevent contamination. Tag hydraulic lines for proper reassembly. 2 3 4.
Cutting Deck Motor Service 15 12 27 to 33 ft--lb (37 to 45 N--m) 9 10 10 14 15 13 9 1 8 7 6 15 5 11 8 4 33 to 40 ft--lb (45 to 55 N--m) 2 3 Figure 68 1. 2. 3. 4. 5. Rear cover Drive gear Seal Woodruff key Nut 6. 7. 8. 9. 10. Tab washer Spider hub Pressure seal Back--up ring O--ring 11. 12. 13. 14. 15. Body Idler gear Cap screw (4 used) Front flange Dowel pin Disassembly (Fig. 68) 6. Take motor from the vise and remove cap screws. 1.
IMPORTANT: Mark the relative positions of the gear teeth and the bearing blocks so they can be reassembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. 1 8. Place the motor on its side and push on the rear bearing block to remove the bearing block and gear set (Fig. 70). 9. Carefully remove and discard o--rings, pressure seals, and back--up rings (Fig. 71) from motor. Do not cause any damage to the machined grooves during the removal process.
Reassembly (Fig. 68) NOTE: When reassembling the motor, check the identification marks made during disassembly to make sure the parts are properly aligned during reassembly. 1. Lubricate o--rings, pressure seals, back--up gaskets, and seal grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic oil. IMPORTANT: Do not dislodge o--rings, pressure seals, or back--up rings during final assembly. 9.
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Lift/Lower Control Valve 13 25 17 16 14 24 18 18 19 15 1 2 27 23 17 20 17 21 22 26 12 RIGHT FRONT 11 10 9 6 8 7 5 4 3 15 Figure 73 1. 2. 3. 4. 5. 6. 7. 8. 9. Control valve assembly Valve bracket Grommet Cap screw Lock nut Pivot bracket LH lever assembly Lever link (3 used) Center lever assembly Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal Installation 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake, and remove key from the ignition switch. 1. Install lift/lower control valve using Figure 73 as a guide. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3.
Lift/Lower Control Valve Service 6 32 20 34 13 14 15 31 10 7 11 23 27 21 22 24 17 18 35 3 36 28 5 33 4 25 1 11 8 16 19 2 12 26 20 to 25 ft--lb (27 to 33 N--m) 9 30 29 Figure 74 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Poppet Spacer Wiper seal Seat O--ring Plug (3 used) O--ring Bushing Spool cap (3 used) Relief valve poppet O--ring Retaining ring Hydraulic System 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Disassembly (Fig. 74) Assembly (Fig. 74) 1. Plug all ports and clean outside of valve thoroughly. 1. Thoroughly clean and dry all parts. Apply a light coating of clean hydraulic oil to parts prior to assembly. NOTE: Spools and spool bores are matched sets. Be sure each spool is identified with the correct valve body spool bore. 3. Remove spools (35) from valve body (36). 4. Remove bushings (8) and O--rings (11) from spools. 5. Remove plugs (6).
Steering Valve 24 23 1 3 2 22 29 4 28 27 25 5 21 12 26 6 8 20 18 to 22 ft--lb (25 to 29 N--m) 19 18 7 17 16 15 RIGHT 9 10 11 9 12 13 11 14 FRONT Figure 75 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Hex nut Flat washer Steering wheel Foam collar Steering seal External snap ring Steering shaft assembly Steering tower cover O--ring 90o hydraulic fitting Hydraulic System 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Removal Installation 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake, and remove key from the ignition switch. 1. Install steering valve using Figure 75 as a guide. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 2. Make sure hydraulic tank is full. Add correct oil if necessary before returning machine to service (see Operator’s Manual). 3.
Steering Valve Service 8 1 3 24 2 4 5 20 19 23 6 7 19 22 21 150 in--lb (17 N--m) 9 10 14 18 17 16 13 12 11 140 to 160 in--lb (16 to 18 N--m) 15 Figure 76 1. 2. 3. 4. 5. 6. 7. 8. Steering valve housing Dust seal O--ring Spool Spring retaining ring Pin Sleeve Centering springs/spacers 9. 10. 11. 12. 13. 14. 15. 16. Cap screw (7 used) End cap O--ring Seal ring O--ring Geroter O--ring Spacer Disassembly (Fig.
8. Put the thrust bearing and races into the housing. The thrust bearing goes between the two races (Fig. 77). The centering springs are under tension. Remove the retaining ring carefully. IMPORTANT: Do not damage the dust or quad seals when installing the spool and sleeve assembly. 10.Remove the spring retaining ring and centering springs from the spool. 9. Apply a light coating of clean hydraulic fluid to the spool and sleeve assembly and carefully slide the assembly into the housing.
Front Deck Lift Cylinder 10 9 7 8 11 9 12 7 RIGHT FRONT 6 13 5 1 4 2 3 Figure 78 1. 2. 3. 4. 5. Lift cylinder Lift arm (LH shown) Lock nut Pin Flange head screw Hydraulic System 6. 7. 8. 9. Grease fitting O--ring 90o hydraulic fitting O--ring Page 4 -- 98 10. 11. 12. 13.
Removal (Fig. 78) Installation (Fig. 78) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake, and remove key from the ignition switch. 1. Position cylinder barrel clevis to frame and insert upper lift pin into frame and clevis. Secure lift pin with cotter pin. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 2.
Front Deck Lift Cylinder Service 1 12 11 8 2 3 10 9 6 7 1 9 5 4 3 12 11 8 10 6 7 5 2 4 Figure 79 1. 2. 3. 4. Barrel with clevis Retaining ring Shaft with clevis Dust seal Hydraulic System 5. 6. 7. 8. Rod seal O--ring Back--up ring Head Page 4 -- 100 9. 10. 11. 12.
Disassembly (Fig. 79) Assembly (Fig. 79) 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 1. Make sure all parts are clean before reassembly. 2. Mount lift cylinder into a vise. Use of a vise with soft jaws is recommended. 3. Remove retaining ring that secures head in barrel. A. Use a spanner wrench to rotate head clockwise until the edge of the retaining ring appears in the barrel opening. B.
Wing Deck Lift Cylinder 11 6 2 10 4 9 8 100 to 140 in--lb (11.3 to 15.8 N--m) 7 6 12 5 16 2 4 3 160 to 180 ft--lb (217 to 244 N--m) 15 14 1 13 RIGHT FRONT Figure 80 1. 2. 3. 4. 5. 6. Center deck Grease fitting Tapered stud Spherical bearing Flange nut Retaining ring Hydraulic System 7. 8. 9. 10. 11. Wing deck lift cylinder O--ring (2 used per cylinder) Hydraulic fitting (2 used per cylinder) O--ring (2 used per cylinder) Pilot spacer Page 4 -- 102 12. 13. 14. 15. 16.
Removal (Fig. 80) Installation (Fig. 80) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake, and remove key from the ignition switch. 1. If removed, install spherical bearings into lift cylinder clevis ends. 3. Remove deck covers as needed to allow access to lift cylinder hoses and fasteners. 4. To prevent contamination of hydraulic system during lift cylinder removal, thoroughly clean exterior of cylinder and fittings.
Wing Deck Lift Cylinder Service 13 11 8 2 3 1 12 12 13 11 10 9 6 7 5 1 9 5 8 10 4 6 7 4 3 2 Figure 81 1. 2. 3. 4. 5. Barrel with clevis Internal collar Shaft with clevis Dust seal Rod seal Hydraulic System 6. 7. 8. 9. O--ring Back--up ring Head O--ring Page 4 -- 104 10. 11. 12. 13.
1. Remove oil from lift cylinder by slowly pumping the cylinder shaft. After removing oil from cylinder, plug both ports and clean the outside of the cylinder. IMPORTANT: Prevent damage when clamping the cylinder’s barrel into a vise; clamp on the clevis only. Do not close vise enough to distort the barrel. 2. Mount lift cylinder into a vise. Use of a vise with soft jaws is recommended. Remove internal collar with a spanner wrench. 3. Loosen head from barrel: A.
Steering Cylinder 9 6 4 7 9 1 8 5 2 4 3 10 12 100 to 125 ft--lb (135 to 169 N--m) 13 14 11 RIGHT 100 to 125 ft--lb (135 to 169 N--m) FRONT Figure 83 1. 2. 3. 4. 5. Steering cylinder Ball joint Ball joint Retaining ring Grease fitting Hydraulic System 6. 7. 8. 9. 10. Grease fitting 90o hydraulic fitting O--ring O--ring Drive axle assembly Page 4 -- 106 11. 12. 13. 14.
Removal (Fig. 83) Installation (Fig. 83) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake, and remove key from the ignition switch. 1. If removed, install ball joints into steering cylinder. 3. To prevent contamination of hydraulic system during steering cylinder removal, thoroughly clean exterior of cylinder and fittings. NOTE: To ease reassembly, tag the hydraulic hoses to show their correct position on the steering cylinder. 4.
Steering Cylinder Service 11 4 10 8 7 2 5 9 3 6 1 Figure 84 1. 2. 3. 4. Butt and tube assembly Shaft Piston rod assembly Gland Hydraulic System 5. 6. 7. 8. Locking nut O--ring PTFE seal O--ring Page 4 -- 108 Rev. D 9. O--ring 10. U--cup 11.
Disassembly (Fig. 84) Assembly (Fig. 84) 1. Remove oil from lift cylinder by slowly pumping the cylinder shaft. After removing oil from cylinder, plug both ports and clean the outside of the cylinder. 1. Use a complete repair kit when rebuilding the cylinder. Put a coating of clean hydraulic oil on all new seals, and O--rings. IMPORTANT: To prevent damage when clamping cylinder barrel or rod in a vise, clamp only on pivotal ends. Use of a vise with soft jaws is recommended. 2.
Hydraulic Reservoir 8 19 23 14 13 10 18 9 12 15 11 7 24 6 4 1 5 16 17 3 2 20 4 25 22 RIGHT FRONT 4 21 1. 2. 3. 4. 5. 6. 7. 8. 9. Hydraulic reservoir Petcock O--ring Strap (2 used) Felt strap (2 used) Bushing Bushing Hydraulic fitting Stand pipe Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17. Figure 86 Hose clamp Screen filter Dipstick O--ring Reservoir cap Suction hose Tank strainer w/o--ring Hose clamp Page 4 -- 110 18. 19. 20. 21. 22. 23. 24. 25.
Removal Inspection 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake, and remove key from the ignition switch. 1. Clean hydraulic reservoir and suction strainer with solvent. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3. Drain reservoir into a suitable container (see Operator’s Manual). 4. Disconnect hydraulic hoses from reservoir. 2.
Hydraulic Oil Cooler Removal CAUTION The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool before working on the oil cooler. 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake, and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. Figure 87 1. Oil cooler 3.
Chapter 5 Electrical System Table of Contents Groundsmaster 4100−D Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start, Engine Shutdown, Seat, PTO, Alarm, Down Latching, and Over Temperature Relays Hydraulic Valve Solenoids . . . . . . . . . . . . . . . . . . . Engine Run Solenoid . . . . . . . . . . . . . . . . . . . . . . . Fuel Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic, Circuit Diagrams, and Wire Harness Drawings The electrical schematic, circuit diagrams, and wire harness drawings for the Groundsmaster 4100−D are located in Chapter 9 − Electrical Diagrams.
Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: Toro recommends the use of a DIGITAL Volt− Ohm−Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter.
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Chapter 9 − Electrical Diagrams). CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. If the machine has any interlock switches by−passed, reconnect the switches for proper troubleshooting and safety.
Problem Possible Causes Engine cranks, but does not start. Engine is not cranking fast enough. Engine run solenoid, circuit wiring, or fuel pump is faulty. The problem is not electrical (see Chapter 3 − Kubota Engine). Starter cranks, but should not when the traction pedal is depressed. The traction neutral switch is out of adjustment. The traction neutral switch or circuit wiring is faulty.
Cutting Deck Operating Problems The cutting deck remains engaged, but should not, with no operator in the seat. The seat switch or circuit wiring is faulty. Cutting decks run, but should not, when raised. Decks shut off with PTO switch. The deck position switch or circuit wiring is faulty. Cutting decks run, but should not, when raised. Units do not shut off with the PTO switch. The deck position switch or circuit wiring, and PTO switch or circuit wiring are faulty.
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Voltage Measured Battery Charge Level 12.68 V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery should be at a temperature of 60oF to 100oF (16oC to 38oC). The ignition key should be off and all accessories turned off.
Adjustments Wing Deck Position Switches Adjustment 5 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove switch cover from deck to allow access to position switch that requires adjustment. NOTE: Use Deck Proximity Switch Adjustment Tool (TOR4095) to assist with switch adjustment (see Special Tools). 4 3. Loosen two (2) lock nuts that secure switch bracket to center cutting deck (Fig. 4). 3 2 4.
Cutting Deck Raise and Lower Switches Adjustment (Fig. 6) 1 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake, and remove key from the ignition switch. Remove console housing. 2 3 5 4 6 2. The cutting deck raise and lower switches can be adjusted for correct operation by repositioning the switch(es). 7 A. The distance between switches should be approximately .625” (15.9 mm) (Fig. 7). B.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check). NOTE: For engine component testing information, see the Kubota Workshop Manual, Diesel Engine, V2003−T Series at the end of Chapter 3 − Kubota Diesel Engine.
Fuses 1 2 3 A 5A 10A 10A B 10A The fuse blocks are located under the operator’s control console. 2 3 4 OPT. The fuses are held in two fuse blocks. Use Figure 11 to identify each individual fuse and its correct amperage. Each fuse holder has the following functions and wires connected to it. 10A Identification, Function, and Wiring Fuse A1 (5 amp) 1 A. Supplies power to the seat switch. B. Has green wire and red wire (battery). 4 Figure 11 Fuse A2 (10 amp) SEAT 5A B.
Warning Lights Testing Warning Lights 1. Apply 12 VDC to terminals 1A and 2A. 2. Ground terminals 1B and 2B. 3 3. Both indicator lights should light. 4 2 Engine Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON position with the engine not running. Also, it should light with the engine running if the engine oil pressure drops below 7 PSI (0.5 kg/cm2). 1 1. Disconnect green wire from the oil pressure switch on the engine (located near the starter motor). 2.
PTO Switch The PTO switch is attached to the control console next to the operator seat (Fig. 15). The switch terminals are marked as shown in Figure 16. The circuitry of the PTO switch is shown in the chart below. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each position. Verify continuity between switch terminals.
Transport, Alarm Silence, and Temperature Override Switches The transport, alarm silence, and temperature override rocker switches are located on the control console (Fig. 18). These switches have common switching logic. 3 The switch terminals are marked as shown in Figure 19 and Figure 20. The circuitry of these switches is shown in the chart below.
Seat Switch The seat switch is normally open and closes when the operator is on the seat. If the traction system or PTO switch is engaged when the operator raises out of the seat, the engine will stop. The seat switch and its electrical connector are located directly under the seat (Fig. 21). Testing of the switch can be done without seat removal by disconnecting the seat wire from the machine wiring harness. 1 2 Testing 1. Make sure the engine is off. 2.
Hour Meter The hour meter is located on the control console next to the operator seat. 1. Disconnect harness connector from hour meter. 2. Connect the positive (+) terminal of a 12 VDC source to the positive (+) terminal of the hour meter. 3. Connect the negative (−) terminal of the voltage source to the other terminal of the hour meter. 4. The hour meter should move a 1/10 of an hour in six minutes. Figure 23 5. Disconnect voltage source from the hour meter. Reconnect harness connector to hour meter.
Start, Engine Shutdown, Seat, PTO, Alarm, Down Latching, and Over Temperature Relays These seven relays are located under the console housing cover. The wiring harness is tagged to identify each relay. Testing NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads.
Hydraulic Valve Solenoids There are four hydraulic valve solenoids on the Groundsmaster 4100−D (Fig. 28). Testing of these solenoids can be done with the solenoid on the hydraulic valve. 4. Measure resistance between the two connector terminals. The resistance for the solenoid coil should be approximately 7.2 ohms. Testing 5. Reconnect electrical connector to the solenoid. NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together.
Engine Run Solenoid The engine run solenoid must be energized for the engine to run. It is mounted on the engine block near the injection pump (Fig. 29). In Place Testing NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads.
Fuel Sender The fuel sender is located on top of the fuel tank. Testing 1. Remove white wire and black ground wire from the sender. FULL POSITION EMPTY POSITION CAUTION If testing circuit wiring and fuel gauge, make sure wire connections are secure before turning ignition switch ON to prevent an explosion or fire from sparks. Figure 31 2. To test the circuit wiring and fuel gauge, connect white and black wires and turn ignition switch to ON.
Fuel Gauge The fuel gauge can be tested using a new gauge as a substitute or with the use of a DC voltage source and a variable resistance box (see Fuel Sender Testing in this section for additional information). Testing CAUTION VARIABLE RESISTANCE Make sure the voltage source is turned OFF before connecting it to the electrical circuit to avoid electrical shock and prevent damaging the gauge. 14 VDC + 0.01 VDC − 1. Connect fuel gauge to the variable resistance and DC voltage source (Fig. 32).
Fuel Pump The fuel pump is attached to the fuel tank support above the fuel/water separator (Fig. 34). IMPORTANT: When testing fuel pump, make sure that pump is not operated dry. 1 Operational Test 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake. 2 3 2. Disconnect electrical connector from the fuel stop solenoid to prevent the engine from firing. DANGER Figure 34 Because diesel fuel is highly flammable, use caution when testing.
Glow Controller The glow controller is located under the console cover. 2 NOTE: Refer to Chapter 9 − Electrical Schematics and Diagrams when troubleshooting the controller. Controller Operation 1. When the ignition switch is placed in the ON position, the controller energizes the glow plugs and illuminates the glow indicator light for approximately 7 seconds. 2. When the ignition switch is held in the START position, the glow plugs will energize and the glow indicator light will not light. 3.
Temperature Sender The temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 36). There is a gray wire attached to the terminal of the switch. 1 Testing 1. Lower coolant level in the engine and remove the temperature sender from water flange. 2. Put switch in a container of oil with a thermometer and slowly heat the oil (Fig. 37). 2 CAUTION Handle the hot oil with extreme care to prevent personal injury or fire. Figure 36 1.
High Temperature Shutdown Switch The high temperature shutdown switch is located near the glow plug connection on the engine cylinder head (Fig. 38). There is a blue wire attached to the switch. Testing CAUTION 2 Make sure engine is cool before removing the temperature switch. 1. Lower coolant level in the engine and remove the temperature shutdown switch. 2. Put switch in a container of oil with a thermometer and slowly heat the oil (Fig. 39). 1 Figure 38 1. Temp. shutdown switch 2.
Temperature Gauge The temperature gauge can be tested using a new gauge as a substitute or with the use of a DC voltage source and a variable resistance box. Testing CAUTION Make sure the voltage source is turned OFF before connecting variable resistance to the electrical circuit to avoid electrical shock and to prevent damaging the gauge. VARIABLE RESISTANCE 14 VDC + 0.01 VDC 1. Connect temperature gauge to the variable resistance and DC voltage source (Fig. 40).
Traction Neutral Switch The traction neutral switch is closed when the traction pedal is in the neutral position and opens when the pedal is depressed in either direction. The switch is located on the right side of the piston (traction) pump (Fig. 42). 2 Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester across the two switch terminals.
Diode Circuit Board (Fig. 44) The diode circuit board contains four diodes and is located under the console housing. Diode D1−A provides logic for the interlock system. Diodes D1−B (right wing deck), D1−C (front deck), and D1−D (left wing deck) provide latching circuits for the PTO relay. H G D1−D F D1−A D1−C D1−D D C B A CIRCUIT BOARD DIODE DIAGRAM Apply dielectric grease to circuit board contacts whenever the circuit board is installed into the wire harness.
Wing Deck Position Switches The wing deck position switches on the Groundsmaster 4100−D are attached to the center deck housing (Fig. 45) and are normally open. The wing deck position switch is a powered proximity switch that incorporates an internal reed switch and relay (see schematic in Figure 46). The actuator for the position switch is bolted to the wing deck link (Fig. 47).
Cutting Deck Raise and Lower Switches The deck raise and lower switches are normally open proximity switches that are located under the console housing (Fig. 48). These identical switches are mounted in opposite directions so their circuit logic differs. The actuator for the switches is on the center deck lift/lower lever. The raise and lower switches are used in conjunction with the down latching relay to provide current to the PTO switch.
Service and Repairs NOTE: For more component repair information, see the Kubota Workshop Manual, Diesel Engine, V2003−T Series at the end of Chapter 3 − Kubota Diesel Engine. Hydraulic Valve Solenoids The hydraulic valve solenoids can be replaced without opening the hydraulic system. 1. Make sure ignition switch is off. Disconnect hydraulic valve solenoid electrical connector from wiring harness (Fig. 49). 1 2 2. Remove nut that secures solenoid coil to valve. Carefully slide coil from valve stem. 3.
Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery and charge it fully (see Battery Service). 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5. To help prevent the battery from freezing, make sure it is fully charged (see Battery Service). 2. Either store battery on a shelf or on the machine. 3. Leave cables disconnected if the battery is stored on the machine. Battery Care 1.
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. 2 CAUTION When working with batteries, use extreme caution to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries. 3 Electrolyte Specific Gravity Fully charged: 1.
C. If the difference between the highest and lowest cell specific gravity is 0.050 or greater or the lowest cell specific gravity is less than 1.225, charge the battery. Charge at the recommended rate and time given in Charging or until all cells specific gravity is 1.225 or greater with the difference in specific gravity between the highest and lowest cell less than 0.050. If these charging conditions can not be met, replace the battery. H.
Charging To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which is available in most shops. CAUTION Follow the manufacturer’s instructions when using a battery charger. NOTE: Using specific gravity of the battery cells is the most accurate method of determining battery condition. 1.
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Chapter 6 Axles, Planetaries, and Brakes Table of Contents Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . Bevel Gear Case and Axle Case . . . . . . . . . . . . . Differential Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Shaft/Pinion Gear . . . . . . . . . . . . . . . . . . . . . Differential Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion Gear to Ring Gear Engagement . . . .
Specifications Item Specification Wheel lug nut torque 85 to 100 ft−lb (115 to 135 N−m), front and rear Steering cylinder bolt torque 100 to 125 ft−lb (139 to 169 N−m) Rear wheel toe−in .125 in (3.18 mm) Tire pressure 25 to 30 psi (1.7 to 2.1 bar), front and rear Planetary, brake housing, and front wheel motor mounting screw torque 75 to 85 ft−lb (101 to 115 N−m) Planetary gear drive oil System gear lube capacity (each wheel) SAE 85W−140 wt. gear lube 16 fl oz (.
Adjustments Axles, Planetaries, and Brakes See Operator’s Manual for adjustment procedures for Groundsmaster 4100−D axles, planetaries, and brakes.
Service and Repairs Brake Assembly 85 to 100 ft−lb (115 to 135 N−m) 13 14 2 12 6 1 75 to 85 ft−lb (101 to 115 N−m) 3 11 4 17 5 16 5 7 8 18 15 3 6 RIGHT 9 10 FRONT 75 to 85 ft−lb (101 to 115 N−m) 11 2 1 Figure 1 1. 2. 3. 4. 5. 6. Planetary assembly Retaining ring Splined brake coupler Brake assembly (RH) O−ring Hydraulic wheel motor 7. 8. 9. 10. 11. 12.
CAUTION WARNING When changing attachments, tires, or performing other service, use correct blocks, hoists, and jacks. 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 or block wheels. Use jack stands or solid wood blocks to support the raised machine.
Brake Inspection and Repair 3 2 1 4 5 5 6 7 8 7 8 7 15 10 14 13 12 11 7 8 9 Figure 4 1. 2. 3. 4. 5. Brake housing (LH shown) Seal Pull rod Clevis pin (2 used) Link 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Hitch pin (2 used) Stationary disc Rotating disc Retaining ring Gasket Rotating actuator Extension spring (3 used) Ball (3 used) Plug O−ring Brake Inspection and Repair (Fig. 4) 6. Remove seal (2) from brake housing. 1.
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Planetary Wheel Drive Assembly 85 to 100 ft−lb (115 to 135 N−m) 13 14 2 12 6 1 75 to 85 ft−lb (101 to 115 N−m) 3 11 4 5 5 7 8 3 6 RIGHT 9 10 FRONT 75 to 85 ft−lb (101 to 115 N−m) 11 2 1 Figure 5 1. 2. 3. 4. 5. Planetary assembly Retaining ring Splined brake coupler Brake assembly (RH) O−ring Axles, Planetaries, and Brakes 6. 7. 8. 9. 10. Hydraulic wheel motor Flat washer Cap screw (2 used per side) Flange head screw (4 used per side) Brake assembly (LH) Page 6 − 8 11. 12. 13. 14.
Planetary Wheel Drive Removal (Fig. 5) 1. Park machine on a level surface, lower cutting unit, stop engine, engage parking brake, and remove key from the ignition switch. 4. Secure hydraulic wheel motor to planetary assembly with two (2) cap screws. Torque screws from 75 to 85 ft− lb (101 to 115 N−m). WARNING 2. Drain oil from planetary wheel drive/brake assembly (see Operator’s Manual).
Planetary Wheel Drive Service 2 24 9 ft−lb (12 N−m) 3 19 20 6 7 1 8 21 9 10 4 11 5 23 18 17 12 16 15 22 14 25 13 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. Spindle Boot seal Bearing cone Bearing cup Wheel stud (8 used) Housing Bearing cup Bearing cone Thrust washer Axles, Planetaries, and Brakes 10. 11. 12. 13. 14. 15. 16. 17. Retaining ring (external) Ring gear Retaining ring (internal) Plug (2 used) End cap Thrust plug Thrust washer Drive shaft Page 6 − 10 18. 19. 20. 21. 22. 23. 24. 25.
Planetary Wheel Drive Disassembly (Figure 7) Planetary Wheel Drive Assembly (Figure 7) 1. Remove retaining ring (12). NOTE: Use new seal kit when assembling planetary wheel drive. 2. Remove end cap (14). Thrust plug (15) and thrust washer (16) are captive on inside of end cap. 1. Clean parts in solvent. Inspect parts for damage or excessive wear and replace as necessary. 3. Remove drive shaft (17). 2. If spindle and housing were separated: 4. Remove carrier assembly (18). A.
Rear Axle Assembly 18 17 16 2 3 RIGHT 70 ft−lb maximum (94 N−m maximum) FRONT 19 7 15 14 13 12 5 11 10 4 9 8 6 1 Figure 8 1. 2. 3. 4. 5. 6. 7. Frame Cap screw (6 used) Flat washer Bulkhead lock nut (2 used) Washer Thrust washer (thick) Grease fitting (2 used) 8. 9. 10. 11. 12. 13. Rear axle assembly Thrust washer (thin) Washer head screw Pivot pin Rear frame mount Washer Remove Rear Axle 1.
8. Remove cap screw and flange nut that secures front corner of 4WD hydraulic manifold to rear frame mount. 1 2 3 9. If required, remove tie rod ends from steering arms on rear axle (Fig. 10). Remove the cotter pins and castle nuts from the tie rod ball joints. Use a ball joint fork and remove the tie rod ends from the axle steering arms. 10.Support rear axle to prevent it from falling. Remove six cap screws, flat washers, and flange nuts that secure rear frame mount to equipment frame.
9. Install steering cylinder to axle assembly (see Steering Cylinder in Service and Repairs section of Chapter 4 − Hydraulic System). 10.Install hydraulic motor to axle assembly (see Rear Axle Motor in Service and Repairs section of Chapter 4 − Hydraulic System). 1 2 WARNING Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury. 11. Install wheels to axle. Torque wheel lug nuts from 85 to 100 ft−lb (115 to 135 N−m). Figure 12 1.
Bevel Gear Case and Axle Case The following procedures assume the rear axle assembly has been removed from the machine. 35 to 41 ft−lb (47 to 56 N−m) Removal 1 6 5 1. Remove the mounting screws, nuts, and lock washers. Remove the bevel gear case/axle case assembly and O-ring from the axle support (Fig. 13). 4 2 2. Mark both right and left bevel gear case/axle case assemblies. 3 35 to 41 ft−lb (47 to 56 N−m) IMPORTANT: Do not interchange right and left bevel gear case/axle case assemblies.
5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gasket material from either mating surface (Fig. 16). 6. While holding the bevel gear case, tap the upper end of the bevel gear shaft out of the upper bearing and upper bevel gear. 2 1 17 to 20 ft−lb (23 to 27 N−m) 3 4 Threadlocking Compound 7. Pull the bevel gear case from the axle case and remove the upper bevel gear, and collar from the gear case. 5 14 8.
Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 18). 3 2 1 Figure 18 1. Axle case 2. Bevel gear case 2. Install the lower bevel gear, and bevel gear shaft in the axle case cover. Coat a new O-ring with grease and install the axle case cover (Fig. 19). Tighten cover screws from 17 to 20 ft-lb (23 to 27 N−m). 3. Shaft seal 7 8 3. Slide the bevel gear case over the bevel gear shaft and install the bevel gear and collar.
5. Determine necessary quantity of support shims. 4 A. Lubricate the axle case support bushing with a thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during disassembly between axle case support and axle case. Install mounting screws into axle case. Slowly tighten screws while frequently checking for clearance (vertical endplay) between axle case support and knuckle pin.
9. Remove the bevel gear case/axle case assembly from the axle support. Coat a new O-ring with grease and temporarily install the axle cover assembly. Position a dial indicator at the tooths center. Prevent the axle from turning and measure the lower bevel gear to axle gear backlash (Fig. 22). LOWER BEVEL GEAR BACKLASH: 0.004 to 0.016 in. (0.10 to 0.40 mm) 11. Tighten axle cover screws from 17 to 20 ft-lb (23 to 27 N−m). 12.
Differential Shafts The following procedures assume the rear axle assembly has been removed from the machine. 35 to 41 ft−lb (47 to 56 N−m) Removal 1 6 IMPORTANT: Do not interchange right and left differential shaft assemblies. 1. Remove the mounting screws, nuts, and lock washers. Remove the bevel gear case/axle case assembly and O-ring from the axle support (Fig. 23). 4 2 3 4. Drive the differential shaft out of the bearings. Remove the bearings and bearing shims.
Axle Shafts The following procedures assume the rear axle assembly has been removed from the machine. 17 to 20 ft−lb (23 to 27 N−m) 1 Removal 4 3 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig. 25). 2. Use a bearing puller to remove the bearing and bevel gear as shown (Fig. 26). 2 3. Remove the shims, spacer, and retaining ring. Drive the axle out of the bearing and cover. Remove and discard the axle shaft seal. Figure 25 1. Axle case 2.
Input Shaft/Pinion Gear 1 35 to 41 ft−lb (47 to 56 N−m) 3 2 18 17 4 5 7 8 6 16 18 9 15 10 14 10 9 13 35 to 41 ft−lb (47 to 56 N−m) 11 12 Figure 28 1. 2. 3. 4. 5. 6. Nut (2 used) Lockwasher (2 used) Stud (2 used) Locknut Stake washer Oil seal 7. 8. 9. 10. 11. 12. O-ring Seal collar Bearing O-ring Input shaft/pinion gear Bearing case 13. 14. 15. 16. 17. 18.
6. Set the bearing preload by securing the bearing case in a vise. Thread a M12 x 1.5 hex head cap screw into the splined end of the input shaft/pinion gear and slowly tighten the locknut until 4 to 6 in-lb (0.4 to 0.7 N−m) of force is required to rotate the input shaft/pinion gear in the bearing case. 0.040 in. (1.0 mm) 7. Secure the lock nut with the stake washer. 2 1 8.
Differential Gear The following procedures assume the rear axle assembly has been removed from the machine. 35 to 41 ft−lb (47 to 56 N−m) 5 Removal 1 2 6 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual). IMPORTANT: Do not interchange right and left differential shafts assemblies. 7 4 2. Mark and pull the differential shaft assemblies from the axle support. 3 35 to 41 ft−lb (47 to 56 N−m) 3.
Inspection 1. Measure the differential side gear O.D. and the differential case I.D. to determine the side gear to case clearance (Fig. 35). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 in. (0.05 to 0.30 mm) 1 SIDE GEAR O.D. (Factory Spec.): 1.335 to 1.337 in. (33.91 to 33.95 mm) DIFFERENTIAL CASE I.D. (Factory Spec.): 1.339 to 1.341 in. (34.00 to 34.06 mm) 2 2. Measure the differential pinion shaft O.D. and the pinion gear I.D.
Installation 3 1. If the ring gear was removed, use medium strength thread locking compound and tighten the mounting screws from 22 to 25 ft-lb (30 to 34 N−m). 2 1 2. Apply molybdenum disulfide grease to the splines and bearing surfaces of the differential pinion gears, pinion washers, and side gears. 3. Install the side gear shims and side gears in their original location in the differential case. 4.
Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using the gear contact pattern method as described in the following procedure. PROFILE TOP LAND GEAR TOOTH DEFINITIONS (Fig. 39): TOE Toe − the portion of the tooth surface at the end towards the center. LENGTHWISE BEARING ARC HEEL Heel − the portion of the gear tooth at the outer end. Top Land − top surface of tooth. 1.
Gear Pattern Movement Summary Heel Contact Base Contact Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as gear location is changed. 1. If contact is toward the heel or base of the gear (Fig. 42): A. Install thicker or additional bearing case shim(s) to move pinion shaft toward ring gear. Figure 42 B. Install thinner or remove differential bearing shim(s) to move ring gear backward. Toe Contact Tip Contact C.
Chapter 7 Chassis Table of Contents 2 2 4 6 Chassis SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . Steering Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Deck Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs Steering Tower 39 24 1 3 2 23 25 26 27 4 5 6 41 7 21 40 8 28 22 33 34 35 36 37 9 10 29 30 31 11 12 13 14 32 18 to 22 ft−lb (25 to 29 N−m) 41 15 16 17 18 19 38 20 21 RIGHT FRONT Figure 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Hex nut Flat washer Steering wheel Foam collar Steering seal External snap ring (2 used) Knob Steering tower cover Steering shaft Compression spring Cap Rod assembly Extension spring Tilt rod Chassis 15. 16. 17. 18. 19. 20. 21. 22. 23.
Disassembly Assembly 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. Assemble steering tower using Figure 1 as a guide. Note: Thrust washer(s) (24) on steering column are used as needed to remove end play of steering shaft. Chassis 2. Disassemble steering tower as needed using Figure 1 as a guide.
Front Deck Lift Arms 8 60 to 70 ft−lb (81 to 94 N−m) 9 38 Loctite 242 on threads 10 11 RIGHT 100 to 140 in−lb (11.3 to 15.8 N−m) 12 14 15 16 17 18 19 20 21 22 FRONT 23 3 13 7 2 1 6 11 36 34 25 16 32 26 5 35 33 24 25 16 4 27 30 28 29 155 to 185 ft−lb (210 to 321 N−m) 31 16 37 75 to 85 ft−lb (102 to 115 N−m) Figure 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
E. Thoroughly clean tapered surfaces of stud and mounting boss of support hub. Secure support hub (position slotted hole in hub toward rear of deck) to tapered stud with flat washer and flange nut. Tighten flange nut from 155 to 185 ft−lb (210 to 321 N−m). CAUTION When raising machine, use correct blocks, hoists, and jacks. Make sure machine is parked on a solid, level surface such as a concrete floor.
Hood 28 29 RIGHT 27 30 1 FRONT 3 2 31 3 26 32 4 25 22 24 23 32 5 22 34 33 20 21 14 6 19 35 8 18 7 17 15 13 9 8 10 11 16 14 12 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Hood R−clamp (2 used) Cap screw Hood support Latch bracket (RH) Fuel tank support Flange nut Lock nut Latch bracket (LH) Screw (2 used per handle) Latch bracket (2 used) Latch handle (2 used) Chassis 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Removal 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake, and remove key from the ignition switch. 3 2. Remove hood using Figure 5 as a guide. Installation 2 1. Install hood using Figure 5 as a guide. 2. Align hood to machine to allow correct operation of hood latches and dust seals: A. Place shim that is 3/8” to 7/16” (9.5 to 11.1 mm) thick on top of frame (both RH and LH sides) near the sides of oil cooler (Figs. 6 and 7). 1 Figure 6 1. LH shim location 2.
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Chapter 8 Cutting Deck Table of Contents 2 3 3 4 4 4 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 6 Cutting Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Wing Deck Service . . . . . . . . . . . . . . . . . . . . . . . . . 10 Cutting Deck Link Service . . . . . . . . . . . . . . . . . . . 12 Wing Deck Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Blade Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Blade Spindle Service . . .
Specifications MOUNTING: Cutting deck is supported by lift arms controlled with hydraulic lift levers. CONSTRUCTION: Deck chamber is welded 12 gauge steel construction reinforced with channels and plates. HEIGHT−OF−CUT RANGE: 1” to 5” (2.54 cm to 12.7 cm) adjustable in 1/2” (1.27 cm) increments. Center deck height−of−cut adjustment is achieved by changing spacers on castor wheels and adjusting length of deck support chains.
Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, uneven ground conditions, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the machine. Remember that the “effective” or actual height−of−cut depends on cutting unit weight, tire pressures, hydraulic counterbalance settings, and turf conditions.
Adjustments CAUTION Never install or work on the cutting deck or lift arms with the engine running. Always stop engine and remove ignition key first. See Operator’s Manual for adjustment procedures for the cutting deck on the Groundsmaster 4100−D. Castor Wheel Tire Pressure Castor tires on the cutting deck should be inflated to 50 psi (3.5 bar).
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Service and Repairs CAUTION Never install or work on the cutting deck or lift arms with the engine running. Always stop engine and remove ignition key first. Cutting Deck 8 RIGHT FRONT 9 7 6 5 10 11 4 1 12 3 2 13 12 14 15 12 16 17 18 12 11 Figure 1 1. 2. 3. 4. 5. 6. Cutting deck Cap screw Lift arm (LH shown) Flange nut Spacer Damper Cutting Deck 7. 8. 9. 10. 11. 12. Damper rod end (2 per damper) Hair pin Clevis pin Cap screw Lock nut Flat washer Page 8 − 6 13. 14. 15. 16. 17. 18.
Removal (Fig. 1) 1. Position machine on a clean, level surface. Lower cutting deck, stop engine, engage parking brake, and remove key from the ignition switch. 2 NOTE: Removal of clevis pins from deck and height− of−cut chains is easier if deck is lifted slightly. 1 2. Remove hairpins and clevis pins that secure the height−of−cut chains to the rear of the cutting deck (Fig. 2). 3.
NOTE: Installation of clevis pins to deck and height−of− cut chains is easier if deck is lifted slightly. 4. Install clevis pins and hairpins that secure the height−of−cut chains to the rear of the cutting deck (Fig. 2). 5. Install wing deck lift cylinders to cutting deck (Fig. 4): A. Thoroughly clean tapered surfaces of lift cylinder studs and mounting bosses on deck. 1 B. Position lift cylinders to the deck. C.
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Wing Deck Service 16 1 15 2 6 7 32 10 160 to 180 ft−lb (217 to 244 N−m) 31 40 33 34 14 41 37 9 8 6 13 3 11 35 39 42 12 36 38 5 29 4 42 7 21 23 18 17 28 18 RIGHT FRONT 27 19 17 20 30 37 23 22 24 25 26 Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Wing deck (RH shown) Flex shield Cap screw Switch actuator Lock nut Thrust washer (.030” thick) Link assembly Flat washer Flange nut Screw (6 used per flex shield) Lock nut Anti−scalp roller Cap screw Flange nut 15.
6. Support wing deck to prevent it from falling as links are removed. 3 7. Remove cap screw and washer from pivot pin on upper end of both links. Remove flange nut from carriage bolt and pull pivot pins from deck. Locate and retrieve two thrust washers (item 6) from upper end of both links and two hardened spacers (item 42) from front link. 2 8. Slide the wing deck away from the center deck. 9.
Cutting Deck Link Service Disassembly (Fig. 9) 2 1. Press flange bushings from top of link. 7 1 5 2. Remove retaining ring and press tapered stud with spherical bearing and flange nut from link. 2 3. Remove flange nut and press spherical bearing from tapered stud. 6 Reassembly (Fig. 9) 4 1. Install new spherical bearing onto tapered stud. Secure bearing with flange nut. Torque nut from 30 to 40 ft−lb (41 to 54 N−m). 2. Press tapered stud with spherical bearing and flange nut into link.
Wing Deck Latch Disassembly (Fig. 11) 9 1. Raise wing deck to transport position. Carefully rotate latch to closed position. 13 2. Loosen lug nut to release compression spring tension. 3. Remove retaining ring and flat washer from bottom of latch pin. Rotate lug nut enough to allow latch pin to be removed from latch. 14 5 4. Remove lug nut from spring support. Remove latch assembly from deck. 4 6 3 5. Disassemble latch (items 1 through 8) using Figure 11 as a guide. 4 12 3 2 1 Assembly (Fig.
Blade Spindle 4 2 5 6 3 7 18 8 9 10 1 11 17 12 13 RIGHT 88 to 108 ft−lb (119 to 146 N−m) FRONT 14 15 16 Figure 12 1. 2. 3. 4. 5. 6. Cutting deck Drive spindle: single pulley (2 used) Low driven spindle (3 used) Drive spindle: double pulley (1 used) Lock nut Flat washer 7. 8. 9. 10. 11. 12. Idler pulley (4 used) Flat washer Idler spacer High driven spindle (1 used) Flat washer Cap screw Removal (Fig. 12) 1.
Installation (Fig. 12) 1. Position spindle on cutting deck noting orientation of grease fitting (Fig. 14). Secure spindle assembly to deck with correct fasteners. 1 2. Install cutting blade, anti−scalp cup, and blade bolt (see Operator’s Manual). Tighten blade bolt from 88 to 108 ft−lb (119 to 146 N−m). 3. Slowly rotate cutting blades to verify that blades do not contact any deck component(s). 1 2 4. Install drive belt and adjust belt tension (see Operator’s Manual). Figure 13 1. Flange head screw 5.
Blade Spindle Service DRIVEN SPINDLE 7 1 8 2 9 3 10 11 12 13 14 4 130 to 150 ft−lb (176 to 203 N−m) 17 DRIVE SPINDLE 15 1 2 9 5 16 8 4 17 6 17 Figure 15 1. 2. 3. 4. 5. 6. Lock nut Flat washer Driven pulley V−ring seal (if equipped) Drive pulley (single shown) Hydraulic motor mount 7. 8. 9. 10. 11. 12. O−ring Oil seal Bearing cup and cone Outer bearing spacer Inner bearing spacer Spacer ring Disassembly (Fig.
3. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the spacer previously installed, and the bottom bearing cup must contact the snap ring. Make sure that the assembly is correct by supporting the first bearing cup and pressing the second against it (Fig 16). 4. Pack the bearing cones with grease. Apply a film of grease on lips of oil seals. PRESS 4 3 1 5. Install lower bearing cone and oil seal into bottom of spindle housing.
Castor Forks and Wheels DECK CASTOR ARM WING DECK CASTOR FORK 14 13 17 20 24 12 21 11 25 6 20 60 to 80 ft−lb (81 to 108 N−m) 26 19 8 7 1 5 10 4 9 7 18 22 16 23 CASTOR WHEEL 32 8 33 27 15 4 3 34 28 2 29 5 27 30 60 to 80 ft−lb (81 to 108 N−m) 31 Figure 19 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Deck Rollers and Skids 9 7 10 6 5 8 7 6 5 5 7 6 RIGHT 4 FRONT 3 2 1 Figure 20 1. 2. 3. 4. Roller Flange head screw Roller shaft Flange nut 5. 6. 7. Lock nut Roller Cap screw 8. Flange nut 9. Skid (RH shown) 10. Flange head screw Removal 1. Remove skids and rollers from deck using Figure 20 as a guide. Installation Cutting Deck 1. Install skids to deck using Figure 20 as a guide. Make sure to install skids in the same mounting hole height position (lower or upper). 2.
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Chapter 9 Electrical Diagrams Table of Contents Electrical Diagrams ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . 3 CIRCUIT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Glow Plug Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Crank Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Run (Transport) Circuit . . . . . . . . . . . . . . . . . . . . . . . 6 Run (Mow) Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Groundsmaster 4100−D Electrical Schematic All relays and solenoids are shown as de−energized. All ground wires are black.
Groundsmaster 4100−D Glow Plug Circuit Power Current Control Current Indication Current Logic Direction Page 9 - 4
Groundsmaster 4100−D Crank Circuit Power Current Control Current Indication Current Logic Direction Page 9 - 5
Groundsmaster 4100−D Run (Transport) Circuit Power Current Control Current Indication Current Logic Direction Page 9 - 6
NOTE: The drawing on this page shows the center deck and the left wing deck lowered and the right wing deck raised.
P22 BLUE WHITE YELLOW YELLOW YELLOW TAN J4 ORANGE P34 BLUE YELLOW J3 J1 J2 P21 YELLOW YELLOW BLUE PINK P20 YELLOW/BLACK P19 P18 ORANGE P17 PINK PINK P16 BLACK J6 PINK P15 BLACK GREEN WHITE P14 TAN YELLOW WHITE WHITE YELLOW YELLOW YELLOW P13 BLUE TAN TAN BLACK BLACK BLACK P11 P23 TAN VIOLET/BLACK YELLOW/BLACK RED BLACK GRAY P10 GREEN GRAY GRAY GREEN/BLACK WHITE BLACK WHITE YELLOW GREEN GRAY P24 TAN P8 RED/BLACK BLUE BLACK YELLOW TAN P25 VIOLET
Groundsmaster 4100−D Main Wire Harness Page 9 - 9
P1 P1 P2 J1 J2 J4 J3 P17 RED/BLACK FUSIBLE LINK (14 GA.) FUSIBLE LINK (16 GA.) FUSIBLE LINK (14 GA.) FUSIBLE LINK (16 GA.
(D4) (D2) (D6) Groundsmaster 4100−D Engine Wire Harness Page 9 - 11
P3 J1 PINK BLACK YELLOW P14 P4 PINK BROWN YELLOW P5 PINK GRAY P6 (D8) PINK P2 BLACK TAN PINK BLACK P7 PINK PINK TAN GREEN/BLACK GRAY TAN GREEN WHITE P1 P8 BLUE ORANGE VIOLET/BLACK J2 BLACK P13 P15 P12 P11 BLACK P9 (D7) GREEN/BLACK GREEN/BLACK BLACK GREEN/BLACK BLACK YELLOW/BLACK ORANGE ORANGE BLUE ORANGE BLACK TAN P10 Groundsmaster 4100−D Front Wire Harness (D5) Page 9 - 12
(D8) (D7) (D5) Groundsmaster 4100−D Front Wire Harness Page 9 - 13
P15 BLUE GRAY VIOLET P35 P2 BLUE GRAY GRAY P1 VIOLET VIOLET/BLACK BLACK BLUE VIOLET BLACK ORANGE BLACK ORANGE P4 BLACK YELLOW P3 ORANGE YELLOW/BLACK P1 P2 DECK LIFT SENSOR (LH) DECK LIFT SENSOR (RH) Groundsmaster 4100−D Cutting Deck Wire Harnesses Page 9 - 14
Groundsmaster 4100−D Cutting Deck Wire Harnesses Page 9 - 15
