Form No.
Revision History Revision Date Description -- 2010 Initial Issue. A 2012 Updated Hydraulic chapter. B 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). No intellectual property rights are granted by the delivery of this document or the disclosure of its content.
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. 10177SL (Rev. B) Service Manual (Models 30449 and 30447) GroundsmasterR 4100--D & 4110--D Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing and repair of major systems and components on the Groundsmaster 4100--D (Model 30449) and 4110--D (Model 30447). REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.
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Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 -2 -2 -2 -- 1 1 2 3 Chapter 3 -- Kubota Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 3 Service and Repairs . .
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Table Of Contents (Continued) Chapter 10 -- Foldout Drawings Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . 10 -- 3 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . 10 -- 4 Operator Cab Electrical Schematic . . . . . . . . . . 10 -- 7 Wire Harness Drawings . . . . . . . . . . . . . . . . . . . 10 -- 11 Groundsmaster 4100--D/4110--D Foldout Drawings General Information . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 2 Service and Repairs . . . . . . . . . . . . .
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Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . Jacking the Front End . . . . . . . . . . . . . . . . . . . . . . . . Jacking the Rear End . . . . . . . . . . . . . . . . . . . . . . . .
General Safety Instructions The Groundsmaster 4100-D and 4110--D have been 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.
While Operating 5. Before getting off the seat: 2. Before starting the engine: Safety 1. Sit on the seat when starting and operating the machine. A. Ensure that traction pedal is in neutral. B. Apply parking brake. A. Apply the parking brake. B. Make sure traction pedal is in neutral and the PTO switch is OFF (disengaged). C. After engine is started, release parking brake and keep foot off traction pedal. Machine must not move.
Maintenance and Service 1. Before servicing or making adjustments, lower deck, stop engine, apply parking brake and remove key from the switch. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 3. Never store the machine or fuel container inside where there is an open flame, such as near a water heater or furnace. 4. Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system.
Jacking Instructions When changing attachments, tires or performing other service, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands to support the raised machine.
Safety and Instruction Decals Numerous safety and instruction decals are affixed to your Groundsmaster machine. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog.
Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 0.
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 # 6 -- 32 UNC 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 -- 40 UNF # 8 -- 32 UNC 13 + 2 25 + 5 282 + 30 # 8 -- 36 UNF # 10 -- 24 UNC 18 + 2 30 + 5 339 + 56 # 10 -- 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger N
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series) 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 + 6 in--lb 644 + 68 N--cm 78 + 8 in--lb 881 + 90 N--cm M6 X 1.0 96 + 10 in--lb 1085 + 113 N--cm 133 + 14 in--lb 1503 + 158 N--cm M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 28 + 3 ft--lb 38 + 4 N--m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size 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 Recommended Torque** 7/16 -- 20 UNF Grade 5 65 + 10 ft--lb 88 + 14 N--m 1/2 -- 20 UNF Grade 5 80 + 10 ft--lb 108 + 14 N--m M12 X 1.25 Class 8.
Chapter 3 Kubota Diesel Engine Table of Contents Groundsmaster 4100--D/4110--D Page 3 -- 1 Kubota Diesel Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Air Filter System . . . . . . . . . . . . . .
Specifications Item Description Make / Designation Kubota Model V2403--M--T--E3B: 4--Cycle, 4 Cylinder, Water Cooled, Turbocharged, Diesel Engine Bore 3.43 in (87.0 mm) Stroke 4.031 in (102.4 mm) 148.5 in3 (2434 cc) Total Displacement cc (cu. in.) Firing Order 1 (closest to gear case end) -- 3 -- 4 (closest to flywheel end) -- 2 Combustion Chamber Spherical Type (E--TVCS) Compression Ratio 23.
General Information This Chapter gives information about specifications and repair of the diesel engine used in the Groundsmaster 4100--D and 4110--D. General maintenance procedures are described in your Operator’s Manual. Information on engine troubleshooting, testing, disassembly and reassembly is identified in the Kubota Workshop Manual, Diesel Engine, 03--M-E3B Series that is included at the end of this section.
Service and Repairs Air Filter System 7 RIGHT 1 FRONT 9 12 to 15 in--lb (1.4 to 1.6 N--m) 11 6 12 14 13 4 15 8 11 2 5 16 17 10 18 VACUATOR DIRECTION 3 Figure 1 1. 2. 3. 4. 5. 6. Air cleaner hose Hose clamp Air cleaner assembly Service indicator Air cleaner strap Lock nut (2 used) Kubota Diesel Engine 7. 8. 9. 10. 11. 12. Hose clamp Air cleaner hose Hose clamp Cap screw (2 used) Flat washer (4 used) Spring (2 used) Page 3 -- 4 13. 14. 15. 16. 17. 18.
Removal (Fig. 1) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2 4 2. Raise and support hood. 1 3. Remove air cleaner components as needed using Figure 1 as a guide. 3 Installation (Fig. 1) 1. Assemble air cleaner system using Figure 1 as a guide. 5 Figure 2 1. Air cleaner housing 2. Safety filter element 3. Air filter element 4. Air cleaner cover 5. Vacuator valve A.
Exhaust System 16 to 22 ft--lb (21 to 29 N--m) 11 12 1 16 to 22 ft--lb (21 to 29 N--m) 11 14 3 2 15 16 4 16 to 22 ft--lb (21 to 29 N--m) 7 5 8 13 ft--lb (17.6 N--m) 9 8 7 6 8 13 6 8 RIGHT 10 FRONT 16 to 22 ft--lb (21 to 29 N--m) Figure 5 1. 2. 3. 4. 5. 6. Muffler Muffler bracket Exhaust pipe Flange head screw (4 used) Exhaust gasket Lock nut (2 used) Kubota Diesel Engine 7. 8. 9. 10. 11.
Removal (Fig. 5) CAUTION C 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. E B 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. D 2. Raise and support hood. Installation (Fig.
Fuel System 38 37 39 RIGHT 36 3 FRONT 35 2 29 30 30 25 31 40 4 24 33 34 6 28 26 27 23 41 1 22 32 21 7 20 5 14 16 19 18 17 8 7 15 13 11 12 9 60 to 80 in--lb (7 to 9 N--m) 135 to 165 ft--lb (183 to 223 N--m) 10 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Fuel Tank Installation (Fig. 7) DANGER 1. Install fuel tank using Figure 7 as a guide. A. Torque two (2) 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. Connect fuel supply hose to the standpipe and vent and overflow hoses to the elbow fittings (Fig. 8). 4. Connect wire harness connections to the fuel sender. A.
Radiator RIGHT 20 16 18 22 19 28 51 23 53 FRONT 17 62 24 25 1 27 52 46 12 9 45 50 8 54 6 61 21 49 41 25 7 30 28 26 59 4 38 29 5 11 55 37 49 10 60 57 56 32 13 41 15 14 42 44 35 2 34 48 39 47 33 3 45 58 28 31 43 58 36 40 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Removal (Fig. 9) Installation (Fig. 9) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 1. Remove all plugs from radiator and hose openings that were placed during the removal procedure. CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Ethylene--glycol antifreeze is poisonous.
Engine 27 1 RIGHT FRONT 28 26 25 24 2 3 4 23 5 22 6 21 11 13 12 7 14 20 13 13 8 9 15 10 16 19 28 to 32 ft--lb (38 to 43 N--m) 18 9 17 Loctite #242 28 to 32 ft--lb (38 to 43 N--m) 29 to 33 ft--lb (40 to 44 N--m) Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Engine Cap screw (4 used) LH engine mount Lock washer Cap screw Lock washer (5 used) Cap screw (5 used) Engine support (4 used) Flange nut (12 used) Rebound washer (4 used) Kubota Diesel Engine 11. 12. 13. 14. 15. 16. 17. 18.
Engine Removal (Fig. 10) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 1 2. Remove battery cover and strap. Disconnect negative battery cable first and then positive battery cable. Remove battery from machine. 2 3. Open and support hood. CAUTION Figure 11 1. Temperature sender 2. Alternator Kubota Diesel Engine Do not open radiator cap or drain coolant if the radiator or engine is hot.
8. Disconnect fuel supply hose from injection pump (Fig. 13). 9. Remove throttle cable from engine (Figs. 13 and 14): 13.Support hydraulic pump assembly. Remove fasteners that secure pump assembly to engine (see Pump Assembly Removal in the Service and Repairs section of Chapter 4 -- Hydraulic System). A. Remove lock nut that secures throttle cable swivel to speed control lever. 14.Make sure all cable ties securing the wiring harness, fuel lines or hydraulic hoses to the engine are removed. B.
15.Connect hoist or lift to the lift tabs on engine. 2 6 16.Remove flange nuts, rebound washers and cap screws securing the engine mounts to the engine supports. 1 3 7 CAUTION One person should operate lift or hoist while another person guides the engine out of the machine. 4 5 IMPORTANT: Make sure to not damage the engine, fuel hoses, hydraulic lines, electrical harness or other components while removing the engine. Kubota Diesel Engine 17.Slowly remove engine assembly from the machine. 18.
9. Connect throttle cable to injector pump (Figs. 13 and 14): 13.Install air cleaner assembly to the engine (see Air Filter System Installation in this section). A. Secure throttle cable swivel to speed control lever with lock nut. 14.Install exhaust system to machine (see Exhaust System Installation in this section). B. Place throttle cable under cable clamp. 15.Connect coolant hoses to the radiator. Make sure radiator drain is shut. Fill radiator and reservoir with coolant. C.
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Spring Coupler RIGHT FRONT 8 2 1 2 2 4 5 6 9 3 2 Loctite #242 29 to 33 ft--lb (40 to 44 N--m) 10 Loctite #242 28 to 32 ft--lb (38 to 43 N--m) 7 Figure 17 1. 2. 3. 4. Spring coupler Washer (14 used) Cap screw (6 used) Flywheel plate Kubota Diesel Engine 5. Cap screw (4 used) 6. LH engine mount 7. Cap screw (2 used) Page 3 -- 18 8. RH engine mount 9. Lock washer (2 used) 10.
Coupler Removal (Fig. 17) NOTE: The hydraulic pump assembly needs to be removed from engine before coupler can be removed. Engine Side Hydraulic Pump Side 1. If engine is in machine, support engine from below to prevent it from shifting. Remove hydraulic pump assembly (see Piston (Traction) Pump Removal in the Service and Repairs section of Chapter 4 -- Hydraulic System). 1 2. Remove flywheel plate and spring coupler from engine using Figure 17 as a guide. Coupler Installation (Fig. 17) 3 2.
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Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 3 Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 3 Relieving Hydraulic System Pressure . . . . . . . . . . 4 Traction Circuit Component Failure . . . . . . . . . . . .
Specifications Item Description Piston (Traction) Pump Eaton Variable Displacement Piston Pump (Model 72400) 2.48 in3 (40.6 cc) 4000 PSI (274 bar) 5000 PSI (343 bar) 250 PSI (17 bar) Maximum Displacement (per revolution) System Relief Pressure: Forward System Relief Pressure: Reverse Charge Pressure Front Wheel Motors Eaton Fixed Displacement Piston Motors (Model 74328) 3.02 in3 (49.4 cc) Displacement (per revolution) Rear Axle Motor Eaton Fixed Displacement Piston Motor (Model 74315) 2.01 in3 (32.
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Check Hydraulic Fluid Your Groundsmaster hydraulic system is designed to operate on anti--wear hydraulic fluid. The reservoir holds approximately 8 U.S. gallons (30.3 liters) of hydraulic fluid. Check level of hydraulic fluid daily.
Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hydraulic system, all pressure in the hydraulic system must be relieved. Park machine on a level surface, lower cutting deck fully, stop engine and engage parking brake. Wait for all moving parts to come to a complete stop. To relieve hydraulic pressure in traction circuit, move traction pedal to both forward and reverse directions.
Hydraulic Hoses Hard, cracked, cut, abraded, charred, leaking or otherwise damaged hose. Kinked, crushed, flattened or twisted hose. Blistered, soft, degraded or loose hose cover. Cracked, damaged or badly corroded hose fittings. 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 (layline) on the hose.
Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The markings on the nut and fitting body will verify that the connection has been properly tightened. 2.
Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.) method. 2.
Adjustable Fitting (Fig. 8) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is recommended that the O--ring be replaced any time the connection is opened. Lock Nut 3. Lightly lubricate the O--ring with clean hydraulic oil. Fitting threads should be clean with no lubricant applied. Back--up Washer 4. Turn back the lock nut as far as possible.
Groundsmaster 4100--D/4110--D Page 4 -- 9 Rev. A RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD P1 M1 NOTE: A larger hydraulic schematic is included in Chapter 10 -- Foldout Drawings M2 T ST P2 FAN DRIVE MANIFOLD L RV1 LIFT/LOWER MANIFOLD 2500 PSI S1 S6 S5 S3 S4 S2 .035 .
Hydraulic System Page 4 -- 10 Rev. A RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow P1 M1 M2 T ST P2 Groundsmaster 4100--D/4110--D Traction Circuit: Low Speed (4WD) (Forward Shown) FAN DRIVE MANIFOLD L RV1 LIFT/LOWER MANIFOLD 2500 PSI S1 S5 S2 S3 S6 S4 .035 .
Traction Circuit: Low Speed (4WD) Traction circuit pressure (forward and reverse) can be measured at test ports in hydraulic tubes. The forward traction port is on the left side of the machine and the reverse traction port is on the right side of the machine. The traction circuit pump and motors use a small amount of hydraulic fluid for internal lubrication. Fluid is designed to leak across traction pump and motor components into the case drain.
Hydraulic System Page 4 -- 12 Rev. A Groundsmaster 4100--D/4110--D RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow P1 M1 M2 T ST Groundsmaster 4100--D/4110--D Traction Circuit: Hi Speed (2WD) (Forward Shown) P2 FAN DRIVE MANIFOLD L RV1 LIFT/LOWER MANIFOLD 2500 PSI S1 S5 S2 S3 S6 S4 .035 .
Traction Circuit: Hi Speed (2WD) Traction circuit pressure (forward and reverse) can be measured at test ports in hydraulic tubes. The forward traction port is on the left side of the machine and the reverse traction port is on the right side of the machine. The traction circuit pump and motors use a small amount of hydraulic fluid for internal lubrication. Fluid is designed to leak across traction pump and motor components into the case drain.
Hydraulic System Page 4 -- 14 Rev. A Groundsmaster 4100--D/4110--D RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow P1 M1 M2 Groundsmaster 4100--D/4110--D Lower Cutting Deck (LH Wing Deck Shown) T ST P2 FAN DRIVE MANIFOLD L RV1 S7 S9 RV2 S8 SOLENIDS S1, S3 AND S4 ENERGIZED LIFT/LOWER MANIFOLD 2500 PSI S1 S5 S2 S3 S6 S4 .035 .
Lower Cutting Deck A relief valve (RV1) located in the lift/lower manifold limits lift/lower circuit pressure to 1600 PSI (110 bar). An adjustable valve (RV2) in the lift/lower manifold maintains back pressure (counterbalance) on the deck lift cylinders to allow some of the cutting deck weight to be transferred to the traction unit to improve traction. The cutting deck and wing decks can be lowered independently with the use of three (3) switches on the armrest console.
Hydraulic System Page 4 -- 16 Rev. A Groundsmaster 4100--D/4110--D RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow P1 M1 M2 Groundsmaster 4100--D/4110--D Raise Cutting Deck (LH Wing Deck Shown) T ST P2 FAN DRIVE MANIFOLD L S4 S2 S1 2500 PSI RV1 S6 S5 S9 S7 S8 RV2 LIFT/LOWER MANIFOLD SOLENIDS S1 AND S2 ENERGIZED S3 .035 .
Raise Cutting Deck A relief valve (RV1) located in the lift/lower manifold limits lift/lower circuit pressure to 1600 PSI (110 bar). An adjustable valve (RV2) in the lift/lower manifold maintains back pressure (counterbalance) on the deck lift cylinders to allow some of the cutting deck weight to be transferred to the traction unit to improve traction. The cutting deck and wing decks can be raised independently with the use of three (3) switches on the armrest console.
Hydraulic System Page 4 -- 18 Rev. A Groundsmaster 4100--D/4110--D RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100--D/4110--D Mow Circuit (All Deck Motors Rotating) P1 M1 M2 T ST P2 FAN DRIVE MANIFOLD L RV1 LIFT/LOWER MANIFOLD 2500 PSI S1 S6 S5 S3 S4 S2 .035 .
Mow Circuit NOTE: To engage the mow circuit, the operator must be in the operator seat, the cutting deck(s) must be fully lowered and the traction speed must be in the Low speed (4WD) position. PTO Not Engaged When the PTO switch is OFF or if the deck or wing deck is raised with the PTO switch ON, the PTO manifold solenoid valve (S) is not energized and the solenoid spool is in the neutral position.
Mow Circuit Cutting Deck Blade Braking RETURN PTO MANIFOLD PUMP FLOW Figure 11 RETURN The inertia of the rotating cutting blades, however, effectively turns the deck motor into a pump causing an increase in pressure as the flow from the motor comes up against the closed brake cartridge (LC2). When this pressure builds to approximately 600 PSI (41 bar), relief valve (RV2) opens which allows a small amount of hydraulic flow to return to tank through a manifold sensing line (Fig. 12).
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Hydraulic System Page 4 -- 22 Rev. A Groundsmaster 4100--D/4110--D RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100--D/4110--D Steering Circuit (Left Turn Shown) P1 M1 M2 T ST P2 RETRACTING FAN DRIVE MANIFOLD L RV1 LIFT/LOWER MANIFOLD 2500 PSI S1 S6 S5 S3 S4 S2 .035 .
Steering Circuit A four section gear pump is coupled to the piston (traction) pump. The third gear pump section supplies hydraulic flow to both the steering and lift/lower circuits. Hydraulic flow from this pump section is delivered to the two circuits through a proportional flow divider that is located in the fan drive manifold. This flow divider splits pump flow approximately 50% for the steering circuit and 50% for the lift/lower circuit. (V1) and out the L port.
Hydraulic System Page 4 -- 24 Rev. A Groundsmaster 4100--D/4110--D RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow P1 M1 M2 T ST P2 Groundsmaster 4100--D/4110--D Engine Cooling Fan Circuit (Forward Direction Shown) FAN DRIVE MANIFOLD L RV1 LIFT/LOWER MANIFOLD 2500 PSI S1 S6 S5 S3 S4 S2 .035 .
Engine Cooling Fan Circuit The fan drive manifold controls the operation of the hydraulic motor that drives the engine cooling fan in addition to including the flow divider for the steering and lift circuits. The electronically controlled proportional relief valve (PRV) in the manifold controls the oil flow to the fan motor. The fan drive manifold controls the speed and direction of the fan motor based on electrical output from the TEC--5002 controller. tion.
Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit 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 the Testing section of this chapter.
40 GPM Hydraulic Tester (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter. This tester includes the following: 1. LOAD VALVE: A simulated working load is created in the circuit by turning the valve to restrict flow. 2. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure. 3.
High Flow Hydraulic Filter Kit The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi--directional filtration which prevents filtered debris from being allowed back into the circuit regardless of flow direction. If a component failure occurs in the closed loop traction circuit, contamination from the failed part will remain in the circuit until removed.
Hydraulic Test Fitting Kit This kit includes a variety of O--ring face seal fittings to enable the connection of test gauges into the system. TORO TEST FITTING KIT (TOR4079) The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Toro Part Number: TOR4079 Figure 23 Measuring Container Hydraulic System Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only).
Troubleshooting The charts that follow contain suggestions that can be used to assist in diagnosing hydraulic system performance issues. The suggestions are not all--inclusive. Also, consider that there may be more than one cause for a machine problem. Review the hydraulic schematic and information on hydraulic system operation in the Hydraulic Flow Diagrams section of this Chapter. This information will be useful during the hydraulic troubleshooting process.
Traction Circuit Problems Problem Possible Cause Machine operates in one direction only. Traction control linkage is faulty. Traction pedal is sluggish. Traction control linkage is stuck or binding. Traction relief valve is faulty. Charge pressure is low. Piston (traction) pump servo control valve orifices are plugged or damaged. 4WD manifold PD1 and PD2 pilot directional valves seals are leaking or damaged. Machine travels too far before stopping when the traction pedal is released.
Mow Circuit Problems Problem Possible Cause Cutting deck will not operate. Electrical problem exists (see Chapter 5 -- Electrical System). NOTE: To engage the mow circuit, the seat must be occupied, the traction speed must be in the Low (4WD) position and the PTO switch needs to be ON. Gear pump or its coupler is damaged (NOTE: other hydraulic circuits impacted as well). One cutting deck section will not operate. Electrical problem exists (see Chapter 5 -- Electrical System).
Lift Circuit Problems Problem Possible Cause Cutting deck (or wing decks) will not raise. Engine RPM is too low. NOTE: The seat must be occupied in order to raise cutting deck. Hydraulic oil level in reservoir is low. Solenoid valve (S1) in lift/lower manifold is faulty. Electrical problem exists (see Chapter 5 -- Electrical System). Lift arm pivots are binding. Relief valve in lift/lower manifold is stuck. Lift cylinder(s) is (are) damaged.
Steering Circuit Problems Problem Possible Cause Steering is inoperative or sluggish. Steering components (e.g. tie rods, steering cylinder ends) are worn or binding. Steering cylinder is binding. Oil level in hydraulic reservoir is low (NOTE: other hydraulic systems are affected as well). Steering relief valve in steering control valve is stuck or damaged. Steering cylinder leaks internally. Steering control valve is worn or damaged.
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Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (see the Special Tools section in this Chapter). 1. Clean machine thoroughly before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. Contamination will cause excessive wear of hydraulic components.
Which Hydraulic Tests Are Necessary? Before beginning any hydraulic test, identify if the problem is related to the traction circuit, cutting (mow) circuit, lift circuit, steering circuit or engine cooling fan circuit. Once the faulty system has been identified, perform tests that relate to that circuit. 1.
Traction Circuit Charge Pressure (Using Pressure Gauge) 4WD MANIFOLD FROM LIFT/LOWER MANIFOLD FROM DECK LIFT CYLINDERS FILTER MANIFOLD PRESSURE GAUGE FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO MOW CIRCUIT TO MOW CIRCUIT TO STEERING & LIFT CIRCUITS Hydraulic System Page 4 -- 38 FROM PTO MANIFOLDS AND FAN MOTOR FROM PTO MANIFOLD TO COOLING FAN CIRCUIT Groundsmaster 4100--D/4110--D
Procedure for Traction Circuit Charge Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting deck lowered and off. Make sure engine is off and the parking brake is engaged. Raise and support operator seat. CAUTION Prevent personal injury and/or damage to equipment.
Traction Circuit Relief Pressure (Using Pressure Gauge) FORWARD TRACTION CIRCUIT RELIEF PRESSURE TEST SHOWN 4WD MANIFOLD FROM LIFT/LOWER MANIFOLD PRESSURE GAUGE FILTER MANIFOLD FROM FRONT DECK CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO MOW CIRCUIT TO MOW CIRCUIT TO STEERING & LIFT CIRCUITS Hydraulic System Page 4 -- 40 FROM PTO MANIFOLDS AND FAN MOTOR FROM PTO MANIFOLDS TO COOLING FAN CIRCUIT Groundsmaster 4100--D/4110--D
Procedure for Traction Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full. NOTE: Seal leakage across pilot directional valves PD1 and PD2 in 4WD manifold can cause low forward traction pressure with reverse pressure meeting specifications. 9. When testing is completed, disconnect pressure gauge from test port.
Hydraulic System Page 4 -- 42 Rev. A FROM RH PTO CIRCUIT FROM RH PTO MANIFOLD TO MOW CIRCUIT TO MOW CIRCUIT P1 M1 FROM FRONT PTO MANIFOLD M2 T ST P2 FAN DRIVE MANIFOLD L RV1 LIFT/LOWER MANIFOLD 2500 PSI S1 S5 S2 S3 S6 S4 .035 .
Procedure for Counterbalance Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting deck lowered and off. Make sure engine is off and the parking brake is engaged. 3. Remove controller cover to gain access to lift/lower manifold (Fig. 30). C.
Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge) FROM LIFT/LOWER MANIFOLD PRESSURE GAUGE FROM DECK FILTER MANIFOLD 4WD MANIFOLD LIFT CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO MOW CIRCUIT TO MOW CIRCUIT TO STEERING & LIFT CIRCUITS Hydraulic System Page 4 -- 44 Rev.
Procedure for Traction Circuit Reducing Valve (PR) Pressure Test 1 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting deck lowered and off. Make sure engine is off and the parking brake is engaged. 2 Figure 32 CAUTION 1. 4WD control manifold 2. Pressure test port Prevent personal injury and/or damage to equipment.
Rear Traction Circuit (RV) Relief Pressure (Using Pressure Gauge) FROM LIFT/LOWER MANIFOLD 4WD MANIFOLD PRESSURE GAUGE FROM DECK LIFT FILTER MANIFOLD CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO MOW CIRCUIT TO MOW CIRCUIT TO STEERING & LIFT CIRCUITS Hydraulic System Page 4 -- 46 Rev.
Procedure for Rear Traction Circuit (RV) Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting deck lowered and off. Make sure engine is off and the parking brake is engaged. 10.If specification is not met, clean or adjust relief valve (RV) in 4WD control manifold.
Piston (Traction) Pump Flow Test (Using Tester with Flow meter and Pressure Gauge) TESTER 4WD MANIFOLD FROM LIFT/LOWER MANIFOLD FILTER MANIFOLD FROM FRONT DECK CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO MOW CIRCUIT TO MOW CIRCUIT TO STEERING & LIFT CIRCUITS Hydraulic System Page 4 -- 48 FROM PTO MANIFOLDS AND FAN MOTOR FROM PTO MANIFOLDS TO COOLING FAN CIRCUIT Groundsmaster 4100--D/4110--D
This test measures piston (traction) pump output (flow). During this test, pump load is created at the flow meter using the adjustable load valve on the tester. IMPORTANT: Traction circuit flow for the Groundsmaster 4100/4110 is approximately 30 GPM (113.5 LPM). Use 40 GPM Hydraulic Tester #AT40002 (pressure and flow) for this test (see Special Tools in this chapter). 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes.
Hydraulic System Page 4 -- 50 FAN CIRCUIT FROM COOLING TO COOLING FAN CIRCUIT TO STEERING & LIFT CIRCUITS FILTER MANIFOLD FROM REAR AXLE MOTOR CHARGE CIRCUIT FROM FRONT WHEEL MOTORS FROM 4WD MANIFOLD TRACTION CIRCUIT FLOW TRACTION CIRCUIT FLOW NOTE: CENTER DECK PRESSURE TEST SHOWN RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD Cutting Deck Circuit Pressure (Using Pressure Gauge) FROM COOLING FAN MOTOR PRESSURE GAUGE Groundsmaster 4100--D/4110--D
Procedure for Cutting Deck Circuit Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2 2. Park machine on a level surface with the cutting deck lowered and off. Make sure engine is off and the parking brake is engaged. CAUTION 1 Prevent personal injury and/or damage to equipment.
TESTER Hydraulic System Page 4 -- 52 FAN CIRCUIT FROM COOLING TO STEERING & LIFT CIRCUITS TO COOLING FAN CIRCUIT FILTER MANIFOLD FROM REAR AXLE MOTOR CHARGE CIRCUIT FROM FRONT WHEEL MOTORS FROM 4WD MANIFOLD TRACTION CIRCUIT FLOW TRACTION CIRCUIT FLOW CENTER DECK PTO RELIEF PRESSURE TEST SHOWN RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD PTO Relief Pressure (Using Tester with Pressure Gauge and Flow Meter) FROM COOLING FAN MOTOR Groundsmaster 4100--D/4110--D
IMPORTANT: Mow circuit flow for the Groundsmaster 4100/4110 is approximately 16 GPM (61 LPM). Use 40 GPM Hydraulic Tester #AT40002 (pressure and flow) for this test (see Special Tools in this chapter). 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting deck lowered and off. Make sure engine is off and the parking brake is engaged.
Hydraulic System Page 4 -- 54 FROM COOLING FAN CIRCUIT TO STEERING & LIFT CIRCUITS TO COOLING FAN CIRCUIT FILTER MANIFOLD FROM REAR AXLE MOTOR CHARGE CIRCUIT FROM FRONT WHEEL MOTORS FROM 4WD MANIFOLD TRACTION CIRCUIT FLOW TRACTION CIRCUIT FLOW CENTER CUTTING DECK MOTOR CASE DRAIN LEAKAGE TEST SHOWN RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauge and Flow Meter) FROM COOLING FAN MOTOR TESTER CAP MEASURING CONTAINER
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. Continued operation with a worn motor can generate excessive heat and cause damage to hydraulic system components. NOTE: One method to find a failing or malfunctioning deck motor is to have another person observe the machine while mowing in dense turf.
Hydraulic System TESTER Page 4 -- 56 FROM COOLING FAN CIRCUIT TO STEERING & LIFT CIRCUITS TO COOLING FAN CIRCUIT FILTER MANIFOLD FROM REAR AXLE MOTOR CHARGE CIRCUIT FROM FRONT WHEEL MOTORS FROM 4WD MANIFOLD TRACTION CIRCUIT FLOW TRACTION CIRCUIT FLOW NOTE: CENTER DECK GEAR PUMP SECTION FLOW TEST SHOWN RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD Cutting Deck Gear Pump Flow (Using Tester with Pressure Gauge and Flow Meter) FROM COOLING FAN MOTOR Groundsmaster 4100--D/4110--D
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. IMPORTANT: Mow circuit flow for the Groundsmaster 4100/4110 is approximately 16 GPM (61 LPM).
Steering Circuit Relief Pressure (Using Pressure Gauge) 4WD MANIFOLD FROM LIFT/LOWER MANIFOLD FILTER MANIFOLD FROM FRONT DECK LIFT CYLINDERS TO LIFT/LOWER MANIFOLD P2 T ST P1 M2 M1 TO MOW CIRCUIT TO MOW CIRCUIT FROM FRONT PTO MANIFOLD L FAN DRIVE MANIFOLD PRESSURE GAUGE Hydraulic System Page 4 -- 58 FROM RH DECK CIRCUIT FROM FRONT PTO MANIFOLD FROM RH PTO MANIFOLD FROM DECK MOTORS Groundsmaster 4100--D/4110--D
Procedure for Steering Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full. 1 2. Park machine on a level surface with the cutting deck lowered and off. Make sure engine is off and the parking brake is engaged. CAUTION Figure 44 1. Steering circuit pressure test port Prevent personal injury and/or damage to equipment.
Steering Cylinder Internal Leakage STEERING CYLINDER CYLINDER FULLY EXTENDED L R LOOK FOR LEAKAGE STEEL CAP STEERING WHEEL TURNED FOR RIGHT TURN 1350 PSI T Hydraulic System PB P STEERING CONTROL Page 4 -- 60 Groundsmaster 4100--D/4110--D
NOTE: Steering circuit operation will be affected by rear tire pressure, binding of steering cylinder, extra weight on the vehicle and/or binding of rear axle steering components. Make sure that these items are checked before proceeding with steering cylinder internal leakage test. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2.
Hydraulic System TO MOW CIRCUIT TO MOW CIRCUIT Page 4 -- 62 FROM FRONT PTO MANIFOLD Rev. A FROM RH DECK CIRCUIT FROM RH PTO MANIFOLD M2 T ST P2 FAN DRIVE MANIFOLD L PRESSURE GAUGE P1 M1 FROM FRONT PTO MANIFOLD RV1 LIFT/LOWER MANIFOLD 2500 PSI S1 S5 S2 S3 S6 S4 .035 .
Procedure for Lift/Lower Circuit Relief Pressure Test NOTE: Before attempting to check or adjust lift/lower circuit relief pressure, make sure that counterbalance pressure is correctly adjusted (see Counterbalance Pressure Test in this section). 10.If relief valve adjustment does not change relief pressure, check for restriction in pump intake line, lift cylinder(s) internal leakage or gear pump damage. 11. When testing is completed, disconnect pressure gauge from test port. Install controller cover. 1.
Hydraulic System TO MOW CIRCUIT TO MOW CIRCUIT Page 4 -- 64 Rev. A FROM RH DECK CIRCUIT FROM RH PTO MANIFOLD FROM FRONT PTO MANIFOLD P1 M1 FROM FRONT PTO MANIFOLD M2 T ST P2 FAN DRIVE MANIFOLD L RV1 LIFT/LOWER MANIFOLD 2500 PSI S1 S5 S2 S3 S6 S4 .035 .
NOTE: 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. The proportional valve is in the fan drive manifold. NOTE: If steering and lift/lower gear pump section is worn or damaged, charge, steering and lift circuits will all be affected.
Hydraulic System TO MOW CIRCUIT TO MOW CIRCUIT Page 4 -- 66 FROM FRONT PTO MANIFOLD Rev. A FROM RH DECK CIRCUIT FROM RH PTO MANIFOLD P1 M1 FROM FRONT PTO MANIFOLD M2 T ST P2 FAN DRIVE MANIFOLD L RV1 LIFT/LOWER MANIFOLD 2500 PSI S1 S5 S2 S3 S6 S4 .035 .
Procedure for Engine Cooling Fan Circuit Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2 2. Park machine on a level surface with the cutting deck lowered and off. Make sure engine is off and the parking brake is applied. Raise and support hood. 1 CAUTION Prevent personal injury and/or damage to equipment.
Hydraulic System TO MOW CIRCUIT TO MOW CIRCUIT Page 4 -- 68 Rev. A FROM RH DECK CIRCUIT FROM RH PTO MANIFOLD FROM FRONT PTO MANIFOLD P1 M1 FROM FRONT PTO MANIFOLD M2 T ST P2 FAN DRIVE MANIFOLD L S2 S4 RV1 2500 PSI S1 S5 LIFT/LOWER MANIFOLD S3 S6 .035 .
Procedure for Engine Cooling Fan Circuit Gear Pump Flow Test 7. Move throttle so engine is running at high idle speed (2870 RPM). DO NOT engage the cutting deck. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full. 8. While watching tester pressure gauge, slowly close flow control valve until 1000 PSI (69 bar) is obtained on pressure gauge. Verify engine speed continues to be 2870 RPM.
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Adjustments Adjust Control Manifold Relief Valves Several of the hydraulic control manifolds on the Groundsmaster include adjustable relief valves. The following procedure can be used to adjust these relief valves. Refer to the Testing section of this chapter for information on testing relief pressure. NOTE: Do not remove relief valve from the hydraulic manifold for adjustment. 1 1. Locate relief valve and remove cap from valve. 2. Remove cap on relief valve with an allen wrench. 3.
Traction Linkage Adjustment 22 15 16 28 18 19 23 17 19 25 8 20 14 27 21 10 24 19 10 29 6 9 24 20 12 13 5 11 17 18 7 26 1 4 3 RIGHT 2 FRONT Figure 52 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Traction pedal Cap screw (4 used) Hex nut (2 used) Pedal stop Washer head screw (2 used) Pedal bracket Lock nut (4 used) Traction rod Slotted roll pin Lock nut Hydraulic System 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Adjustment of the traction linkage should be checked whenever traction drive components are replaced or removed. C. When traction pedal is released from either forward or reverse, pedal should return to the neutral position and wheels should stop rotating. Assembly Adjustments D. If necessary, adjust spring shaft (item 5 in Fig. 53) until neutral operation is correct. 2. On traction pump end of traction rod, rod end should be installed so that distance from end of traction rod to center of rod end is 1.
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 deck 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. Contaminated oil may appear milky or black or may contain metal particles. IMPORTANT: If a component failure occurred in the closed loop traction circuit (e.g. piston pump or wheel motor), filtering the traction circuit is recommended. See Filtering Closed--Loop Traction Circuit in this section. 1. Park machine on a level surface.
Filtering Closed--Loop Traction Circuit Filtering of a closed--loop hydraulic system after a major component failure (e.g. traction (piston) pump or front wheel motor) is a requirement to prevent debris from transmitting throughout the system. If a closed--loop hydraulic system filtering tool is not used to ensure system cleanliness, repeat failures, as well as subsequent damage to other hydraulic components in the affected system, will occur.
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 switch so that the lift cylinder rod moves in and out several times. If the cylinder rod does not move after fifteen (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.
Hydraulic Reservoir 25 19 18 10 23 9 24 10 13 14 12 11 27 7 15 1 9 6 17 5 16 3 2 30 to 40 in--lb (3.4 to 4.5 N--m) (minimum) 21 4 8 20 31 28 30 22 26 RIGHT NOTE: HYDRAULIC COMPONENTS ATTACHED TO FRONT FRAME ARE NOT SHOWN IN ILLUSTRATION FRONT 29 Figure 55 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Hydraulic reservoir Petcock O--ring Strap Felt strap (2 used) Bushing (2 used) Bushing Strap Stand pipe (2 used) Hose clamp (2 used) Screen filter Hydraulic System 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 55) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove front cutting deck (see Cutting Deck Removal in the Service and Repairs section of Chapter 8 -- Cutting Deck). Inspection 1. Clean hydraulic reservoir and tank strainer with solvent. 2. Inspect reservoir for leaks, cracks or other damage. Installation (Fig. 55) 1.
Hydraulic Oil Cooler 8 5 9 4 RIGHT 6 7 8 10 3 FRONT 9 10 2 11 12 1 13 14 15 16 12 17 18 12 ft--lb (16 N--m) Figure 56 1. 2. 3. 4. 5. 6. Radiator RH radiator support Top radiator support Knob (2 used) Oil cooler bracket Retaining ring (2 used) Hydraulic System 7. 8. 9. 10. 11. 12. Carriage screw (2 used) O--ring 90o hydraulic fitting (2 used) O--ring Cap screw (2 used) Lock washer (6 used) Page 4 -- 80 13. 14. 15. 16. 17. 18.
Removal (Fig. 56) CAUTION 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 deck, stop engine, apply parking brake and remove key from the ignition switch. Raise and support hood. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
Gear Pump 10 11 1 23 15 11 14 14 33 15 103 to 118 ft--lb (140 to 160 N--m) 20 32 24 4 34 3 2 24 22 21 19 8 6 31 22 7 18 13 12 30 17 27 25 RIGHT 5 16 9 26 35 Loctite #242 79 to 84 ft--lb (108 to 113 N--m) Loctite #242 79 to 84 ft--lb (108 to 113 N--m) 28 30 to 40 in--lb (3.4 to 4.5 N--m) FRONT 29 Figure 57 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Removal (Fig 57) Installation (Fig 57) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1. If fittings were removed from gear pump, lubricate and place new O--rings onto fittings. Install fittings into port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 3.
Gear Pump Service 18 6 9 12 10 13 14 15 17 16 5 3 19 4 11 24 21 9 11 1 2 7 8 21 26 25 22 23 33 ft--lb (45 N--m) 22 20 Figure 58 1. 2. 3. 4. 5. 6. 7. 8. 9. Dust seal Retaining ring Flange washer Shaft seal Front cover Dowel pin (16 used) Pressure seal Back--up gasket Thrust plate (8 used) 10. 11. 12. 13. 14. 15. 16. 17. 18. Seal (8 used) Idler gear Drive shaft Back--up gasket Pressure seal Front body Splined connecting shaft (3 used) Flange Drive gear 19. 20. 21. 22. 23. 24. 25.
IMPORTANT: Use caution when clamping gear pump in a vise to avoid distorting any pump components. NOTE: Pressure seals and back--up gaskets fit in grooves machined into thrust plates. Body seals fit in grooves machined in body faces. 3. Secure the front cover of the pump in a vise with the drive shaft pointing down. 2. Assemble pump sections starting at front cover end. Apply grease or petroleum jelly to new section seals to hold them in position during gear pump assembly. 4.
Traction Circuit RIGHT NOTE: Arrow on check valve points toward rear of machine 9 FRONT 4 6 8 1 2 10 5 7 11 12 3 Figure 61 1. 2. 3. 4. Piston (traction) pump Gear pump LH front wheel motor Check valve 5. 6. 7. 8. RH front wheel motor 4WD manifold Filter manifold Rear axle motor 9. 10. 11. 12.
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Piston (Traction) Pump 10 1 11 23 15 11 14 14 33 15 103 to 118 ft--lb (140 to 160 N--m) 20 32 24 4 34 3 2 24 22 21 19 8 7 13 12 17 27 9 6 31 22 18 RIGHT 5 16 30 Loctite #242 79 to 84 ft--lb (108 to 113 N--m) 25 Loctite #242 79 to 84 ft--lb (108 to 113 N--m) 26 35 28 FRONT 30 to 40 in--lb (3.4 to 4.5 N--m) 29 Figure 62 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
8. Put a drain pan below the pump assembly. Remove hydraulic hoses and fittings connected to piston and gear pumps. Put plugs or caps on disconnected hydraulic hoses to prevent contamination of the system. Put plugs in open ports of pumps. NOTE: If fuel tank is removed from the machine, the gear pump and piston pump can be removed as a complete assembly. 9. Remove gear pump from machine (see Gear Pump Removal in this section). 10.
Piston (Traction) Pump Service 40 to 48 in--lb (4.5 to 5.4 N--m) 4 to 6 ft--lb (5 to 8 N--m) 40 to 48 in--lb (4.5 to 5.
Piston (Traction) Pump Service (Fig. 64) Hydraulic System For service of the piston (traction) pump (including the servo control (item 35) assembly), see the Eaton Model 72400 Servo Controlled Piston Pump Repair Information at the end of this chapter.
Rear Axle Motor 2 Arrow on side of motor case points up 15 3 12 1 2 17 18 13 14 11 16 10 5 9 4 6 19 20 7 59 to 73 ft--lb (80 to 99 N--m) 21 8 RIGHT FRONT Figure 65 1. 2. 3. 4. 5. 6. 7. Axle motor 90o hydraulic fitting (2 used) Hydraulic fitting Cap screw (2 used) Flat washer (2 used) O--ring External snap ring (2 used) Hydraulic System 8. 9. 10. 11. 12. 13. 14. Gear (39T) External snap ring (2 used) Pinion gear (33T) Needle bearing O--ring O--ring O--ring Page 4 -- 92 15. 16. 17. 18.
Removal (Fig. 65) Installation (Fig. 65) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1. If fittings were removed from motor, lubricate and place new O--rings onto fittings. Install fittings into port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter).
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 11 14 10 15 12 11 13 7 Arrow on side of motor case points up 15 16 1 8 19 6 15 RIGHT 12 13 75 to 85 ft--lb (101 to 115 N--m) 2 16 17 5 13 9 FRONT 20 3 Figure 66 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. 12.
Removal (Fig. 66) Installation (Fig. 66) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. IMPORTANT: If 90o fitting (item 10) was removed from backplate of right side wheel motor, make sure that straight fittings (item 14) are installed and correctly torqued before installing 90o fitting. NOTE: To ease installation, label the hydraulic lines to show their correct position on the wheel motor. 3.
Rear Axle and Front Wheel Motor Service 15 to 18 ft--lb (20 to 24 N--m) 9 10 13 10 9 7 2 1 11 18 8 6 14 15 16 12 4 5 3 17 Figure 67 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.
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4WD Manifold 2 12 RIGHT 19 13 4 5 3 6 11 9 FRONT 8 7 9 10 10 17 16 11 7 4 13 12 14 15 11 1 18 Figure 68 1. 2. 3. 4. 5. 6. 7. Frame assembly 4WD 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 -- 98 14. 15. 16. 17. 18. 19.
Removal (Fig. 68) Installation (Fig. 68) NOTE: The ports on the manifold are marked for easy identification of components. Example: P1 is a piston pump connection port and SV is the location for the solenoid valve (see Hydraulic Schematic in Chapter 10 -Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port). 1. If fittings were removed from manifold, lubricate and place new O--rings onto fittings.
4WD Manifold Service 13 35 ft--lb (47 N--m) 25 ft--lb (34 N--m) 10 13 REAR DOWN 11 10 6 50 ft--lb (67 N--m) 1 4 10 11 8 7 1 13 2 5 9 13 10 UP FRONT 3 20 ft--lb (27 N--m) 11 PLUG TORQUE #4 Zero Leak: 20 ft--lb (27 N--m) #6 Zero Leak: 25 ft--lb (34 N--m) #8 Zero Leak: 50 ft--lb (67 N--m) 5 ft--lb (6.7 N--m) 10 11 12 Figure 69 1. 2. 3. 4. 5. Manifold body Solenoid valve (port SV) Solenoid coil Check valve (port CV) Nut 6. 7. 8. 9.
4WD Manifold Service (Fig. 69) 8. Reinstall the cartridge valve: 2. If cartridge is solenoid operated, remove nut securing solenoid to the cartridge valve. Carefully slide solenoid off the valve. IMPORTANT: Use care when removing cartridge valves. Slight bending or distortion of the stem tube can cause binding and malfunction. Make sure that deep well socket fully engages the valve base. A. Lubricate new seal kit components with clean hydraulic oil and install on valve.
Filter Manifold 8 9 18 20 6 10 11 2 21 4 11 12 19 6 5 22 1 23 14 17 6 3 7 11 13 RIGHT 15 FRONT 24 16 25 Figure 70 1. 2. 3. 4. 5. 6. 7. 8. 9. Filter manifold 45o hydraulic fitting Test nipple Dust cap O--ring O--ring O--ring Cap screw (3 used) Flat washer (3 used) 10. 11. 12. 13. 14. 15. 16. 17. Hydraulic fitting O--ring O--ring 90o hydraulic fitting Hydraulic hose O--ring O--ring 90o hydraulic fitting 18. 19. 20. 21. 22. 23. 24. 25.
Removal (Fig. 70) Installation (Fig. 70) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 1. If fittings were removed from manifold, lubricate and place new O--rings onto fittings. Install fittings into manifold openings using marks made during the removal process to properly orientate fittings.
Filter Manifold Service 5 25 ft--lb (34 N--m) UP FRONT 25 ft--lb (34 N--m) 1 6 25 ft--lb (34 N--m) 30 ft--lb (41 N--m) 5 7 4 3 2 50 ft--lb (67 N--m) 30 ft--lb (41 N--m) UP FRONT 3 Figure 71 1. Filter manifold 2. Check valve (reservoir return) 3. Oil filter element 4. Check valve (filter bypass) 5. #6 zero leak plug with O--ring NOTE: The ports on the manifold are marked for easy identification of components.
Filter Manifold Service (Fig. 71) Hydraulic System For filter manifold cartridge valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 71 for filter manifold cartridge valve and plug installation torque.
Steering and Engine Cooling Fan Circuits 4 RIGHT FRONT 3 2 1 5 Figure 72 1. Gear pump 2. Steering control valve 3. Fan drive manifold 4. Fan motor 5. Steering cylinder Figure 72 illustrates the components that are used in the Groundsmaster 4100--D and 4110--D steering and engine cooling fan circuits. Procedures for removal, installation and disassembly/assembly of these components are provided on the following pages of this section.
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Steering Control Valve 39 45 25 2 23 7 44 26 4 5 6 21 40 43 41 1 3 24 42 22 8 28 9 10 29 30 31 33 34 35 36 37 11 12 13 14 32 38 27 16 to 20 ft--lb (22 to 27 N--m) 27 15 16 17 18 19 20 21 RIGHT FRONT Figure 73 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Removal (Fig. 73) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1 3 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of this section. 3. To prevent contamination of hydraulic system during steering control valve removal, thoroughly clean exterior of control valve and fittings.
Steering Control 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 13 11 12 140 to 160 in--lb (16 to 18 N--m) 14 18 17 16 15 Figure 75 1. 2. 3. 4. 5. 6. 7. 8. Steering control 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 assembly O--ring Spacer Disassembly (Fig.
6. Install the pin. CAUTION 7. Apply a light coating of petroleum jelly to the inner edge of the dust and quad seals. The centering springs are under tension. Remove the retaining ring carefully. 10.Remove the spring retaining ring and centering springs from the spool. Assembly (Fig. 75) 8. Put the thrust bearing and races into the housing. The thrust bearing goes between the two races (Fig. 76). IMPORTANT: Do not damage the dust or quad seals when installing the spool and sleeve assembly. 9.
Steering Cylinder 15 9 7 6 7 9 16 4 1 8 5 2 4 3 10 12 See text for tightening procedure 13 14 11 RIGHT See text for tightening procedure FRONT Figure 77 1. 2. 3. 4. 5. 6. Steering cylinder Ball joint Ball joint Retaining ring Grease fitting Grease fitting Hydraulic System 7. 8. 9. 10. 11. 90o hydraulic fitting O--ring O--ring Drive axle assembly Ball joint spacer Page 4 -- 112 12. 13. 14. 15. 16.
Removal (Fig. 77) Installation (Fig. 77) 1. Park machine on a level surface, lower cutting deck, 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 installation, label the hydraulic hoses to show their correct position on the steering cylinder. 4.
Steering Cylinder Service 12 9 11 10 2 7 8 5 4 1 6 3 45 to 55 ft--lb (62 to 74 N--m) Figure 78 1. 2. 3. 4. Tube assembly Rod Piston assembly Head Hydraulic System 5. 6. 7. 8. Retaining ring Backup ring O--ring Cap seal Page 4 -- 114 9. 10. 11. 12.
Disassembly (Fig. 78) Assembly (Fig. 78) 1. Pump oil out of cylinder into a drain pan by SLOWLY moving rod and piston in and out of cylinder bore. Plug ports and clean outside of 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 in a vise, clamp only on pivotal ends. Use of a vise with soft jaws is recommended. 2.
Engine Cooling Fan Motor 4 27 to 33 ft--lb (37 to 44 N--m) 3 2 1 5 7 21 6 20 8 2 9 4 10 5 19 18 13 14 15 16 17 12 11 Loctite #242 12 to 14 ft--lb (17 to 18 N--m) RIGHT FRONT Figure 79 1. 2. 3. 4. 5. 6. 7. Hydraulic fan motor O--ring Fan motor bracket 45o hydraulic fitting O--ring Hydraulic hose Fan hub 8. 9. 10. 11. 12. 13. 14. Washer Hex nut Engine Cap screw (4 used) Washer (4 used) Fan Lock nut (2 used) 15. 16. 17. 18. 19. 20. 21. Removal (Fig. 79) 1.
IMPORTANT: Make sure to not damage the radiator, fan or other machine components while loosening and removing the fan motor. 6. Remove cooling fan motor and bracket assembly. A. To prevent contamination of hydraulic system, thoroughly clean exterior of fan motor and fittings. B. Disconnect hydraulic hoses from fan motor. Put caps or plugs on fittings and hoses to prevent contamination. Label hydraulic lines for proper assembly. C.
Engine Cooling Fan Motor Service 11 10 15 6 3 1 14 7 16 9 8 12 8 5 4 14 33 ft--lb (45 N--m) 9 2 13 Figure 81 1. 2. 3. 4. 5. 6. Flange washer O--ring Front flange Dust seal Retaining ring Front wear plate 7. 8. 9. 10. 11. Shaft seal Backup gasket Pressure seal Rear wear plate Body 12. 13. 14. 15. 16. Idler gear Cap screw (4 used) Dowel pins (2 used) Drive gear Washer (4 used) Disassembly (Fig. 81) MARKER LINE 1. Plug motor ports and clean the outside of the motor thoroughly.
8. Remove and discard back--up gaskets and pressure seals from wear plates. 1 4 3 2 9. Turn front flange over, with seal side up. IMPORTANT: Make sure not to damage the front flange counter bore when removing the seals from the front flange. 10.Carefully remove dust seal, retaining ring, flange washer and shaft seal from the front flange (Fig. 83). Note orientation of seal lips during removal. Discard removed seals. Inspection 1. Remove any nicks and burrs from all parts with emery cloth. Figure 83 1.
3. Place front flange, seal side down, on a flat surface. 4. Install the pressure seals, flat side outward, into the grooves in the wear plates. Follow by carefully placing the backup gaskets, flat side outward, between the pressure seals and the grooves in the wear plate. 5. Apply a light coating of petroleum jelly to the exposed side of the front flange. 6. Lubricate the drive gear shaft with clean hydraulic oil.
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Fan Drive Manifold 4 3 6 7 5 2 8 1 9 25 4 5 10 10 5 26 7 27 7 11 23 7 22 7 21 7 5 14 20 19 7 18 17 16 15 5 12 13 14 RIGHT FRONT 24 Figure 85 1. 2. 3. 4. 5. 6. 7. 8. 9. Fan drive manifold O--ring Test fitting Dust cap (2 used) O--ring 45o hydraulic fitting (2 used) O--ring Hydraulic hose Hydraulic hose 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 85) Installation (Fig. 85) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1. If fittings were removed from manifold, lubricate and place new O--rings onto fittings. Install fittings into manifold openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 3.
Fan Drive Manifold Service 5 ft--lb (6.7 N--m) 5 ft--lb (6.7 N--m) UP FRONT 6 25 ft--lb (34 N--m) 50 ft--lb (67 N--m) 10 7 7 2 5 20 ft--lb (27 N--m) 1 25 ft--lb (34 N--m) 8 9 4 2 25 ft--lb (34 N--m) 25 ft--lb (34 N--m) B 2 4 3 25 ft--lb (34 N--m) 20 ft--lb (27 N--m) FRONT 20 ft--lb (27 N--m) UP Figure 87 1. 2. 3. 4. Fan drive manifold #4 zero leak plug with O--ring (3 used) Check valve #6 zero leak plug with O--ring (2 used) 5. Flow divider valve 6. Nut 7.
Fan Drive Manifold Service (Fig. 87) Hydraulic System For fan drive manifold cartridge valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 87 for fan drive manifold cartridge valve and plug installation torque.
Mow Circuit 9 RIGHT FRONT 4 2 6 1 8 7 5 3 Figure 88 1. Gear pump 2. RH wing deck motor 3. LH wing deck motor 4. RH PTO manifold 5. Front cutting deck motor 6. LH PTO manifold 7. Front PTO manifold 8. Filter manifold 9. Oil cooler Figure 88 illustrates the components that are used in the Groundsmaster 4100--D and 4110--D mow circuits. Procedures for removal, installation and disassembly/assembly of these components are provided on the following pages of this section.
Cutting Deck Motor Removal 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 5. Remove caps or plugs from fittings and hoses. Using labels placed during motor removal, properly connect hydraulic hoses to deck motor (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 2.
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 33 to 40 ft--lb (45 to 55 N--m) 2 11 5 8 4 3 Figure 91 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. 91) 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. 93). 9. Carefully remove and discard O--rings, pressure seals and back--up rings (Fig. 94) from motor. Do not cause any damage to the machined grooves during the removal process.
Assembly (Fig. 91) NOTE: When assembling the motor, check the identification marks made during disassembly to make sure the parts are properly aligned during assembly. 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. 2. Install new shaft seal into front flange. 3. Install lubricated pressure seals into the grooves in the front flange and rear cover.
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PTO Manifolds 4 16 6 10 8 14 21 12 25 13 11 19 2 20 30 14 18 26 6 4 22 29 28 27 17 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 96 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Front PTO manifold O--ring Hydraulic adapter O--ring Straight hydraulic fitting O--ring 90o hydraulic fitting O--ring Hydraulic tee fitting O--ring Hydraulic System 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
The PTO control manifolds for the three (3) cutting deck sections are very similar. IMPORTANT: When servicing the PTO manifolds, DO NOT interchange parts from one control manifold to another. Removal (Fig. 96) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of this section. 2. To prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of manifold and fittings. 3.
PTO Manifold Service 20 ft--lb (27 N--m) 8 5 ft--lb (6.7 N--m) 7 9 25 ft--lb (34 N--m) 20 ft--lb (27 N--m) 10 6 11 5 25 ft--lb (34 N--m) 20 ft--lb (27 N--m) 1 50 ft--lb (67 N--m) 20 ft--lb (27 N--m) 4 2 RH WING DECK PTO MANIFOLD SHOWN 3 Figure 97 1. 2. 3. 4. Manifold body NWD SAE #4 plug with O--ring Orifice (0.063) (port OR) #8 zero leak plug with O--ring 5. 6. 7. 8.
PTO Manifold Service (Fig. 97) Hydraulic System For PTO manifold solenoid and control valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 97 for PTO manifold cartridge valve and plug installation torque.
Cutting Deck Lift/Lower Circuit 1 4 RIGHT 6 FRONT 5 6 2 3 Figure 98 1. Lift/lower manifold 2. RH wing deck lift cylinder 3. LH wing deck lift cylinder 4. Fan drive manifold 5. Oil filter 6. Front deck lift cylinder Figure 98 illustrates the components that are used in the Groundsmaster 4100--D and 4110--D cutting deck lift and lower circuits. Procedures for removal, installation and disassembly/assembly of these components are provided on the following pages of this section.
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Lift/Lower Manifold 1 4 3 2 RIGHT FRONT Figure 99 1. Lift/lower manifold 2. Flange head screw (2 used) 3. Washer head screw (2 used) 4. Splash shield Removal (Fig. 99) 1. Park machine on a level surface, lower cutting deck (including wing decks), stop engine, engage parking brake and remove key from the ignition switch. Raise and support operator seat. 2. Remove controller cover and then support bracket from the right side of the operator seat (Fig. 100). 3.
6. Disconnect hydraulic lines from manifold and put caps or plugs on open hydraulic lines and fittings. Label disconnected hydraulic lines for proper installation. RIGHT 1 FRONT 7. Remove lift/lower manifold using Figure 99 as a guide. 2 3 IMPORTANT: A flow control orifice is placed beneath the hydraulic fittings in lift/lower manifold ports C2, C4 and C6. If any of these fittings is removed from the manifold, make sure to remove orifice and label its position for assembly purposes.
Lift/Lower Manifold Service 25 ft--lb (34 N--m) 5 ft--lb (6.7 N--m) 20 ft--lb (27 N--m) 4 5 5 ft--lb (6.7 N--m) 8 4 3 7 6 3 9 3 UP 10 2 12 10 20 ft--lb (27 N--m) 20 ft--lb (27 N--m) 25 ft--lb (34 N--m) 1 20 ft--lb (27 N--m) 2 11 11 20 ft--lb (27 N--m) Figure 102 1. 2. 3. 4. Lift/lower manifold body Solenoid valve (S4, S6 & S9) Solenoid coil (5 used) Nut (8 used) 5. 6. 7. 8.
Lift/Lower Manifold Service (Fig. 102) WARNING If lift/lower manifold is attached to machine, make sure that cutting deck (including wing decks) is fully lowered before loosening hydraulic lines, cartridge valves or plugs from lift/lower manifold. If decks are not fully lowered when manifold components are loosened, decks may drop unexpectedly. Hydraulic System For lift/lower manifold solenoid and control valve service procedures, see 4WD Manifold Service in this section.
Front Deck Lift Cylinder 10 9 7 8 RIGHT 11 9 12 7 FRONT 6 13 5 1 4 2 3 Figure 103 1. 2. 3. 4. 5. Lift cylinder (2 used) 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 -- 142 10. 11. 12. 13.
Removal (Fig. 103) Installation (Fig. 103) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1. If fittings were removed from lift cylinder, lubricate and place new O--rings onto fittings. Install fittings into cylinder port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 2.
Wing Deck Lift Cylinder 2 160 to 180 ft--lb (217 to 244 N--m) 8 6 4 11 11 7 30 to 40 ft--lb (41 to 54 N--m) 12 6 13 5 4 2 160 to 180 ft--lb (217 to 244 N--m) 3 9 10 RIGHT FRONT 1 Figure 104 1. 2. 3. 4. 5. Center deck Grease fitting Tapered stud Spherical bearing Flange nut Hydraulic System 6. 7. 8. 9. Retaining ring Wing deck lift cylinder Lock nut Flat washer Page 4 -- 144 10. 11. 12. 13.
Removal (Fig. 104) Installation (Fig. 104) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1. If removed, install spherical bearings into lift cylinder clevis ends. WARNING Make sure that cutting deck (including wing decks) is fully lowered before loosening hydraulic lines from wing deck lift cylinders. If decks are not fully lowered as hydraulic lines are loosened, deck may drop unexpectedly. 3.
Lift Cylinder Service FRONT DECK LIFT CYLINDER 100 to 120 ft--lb (136 to 162 N--m) 12 11 3 8 2 1 13 10 9 6 7 5 4 Figure 105 1. 2. 3. 4. 5. Barrel with clevis Retaining ring Shaft with clevis Dust seal Rod seal 6. 7. 8. 9. O--ring Back--up ring Head O--ring 10. 11. 12. 13. 60 to 75 ft--lb (82 to 101 N--m) 12 Wear ring Piston Lock nut Seal with loader WING DECK LIFT CYLINDER 11 8 2 4 3 1 10 9 6 7 5 Figure 106 1. 2. 3. 4.
Disassembly (Figs. 105 and 106) Assembly (Figs. 105 and 106) 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 cylinder components are clean before assembly. 2. Mount lift cylinder securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft jaws is recommended. 3. Loosen head from barrel: A.
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Chapter 5 Electrical System Table of Contents Groundsmaster 4100--D/4110--D Engine Cooling Fan Switch . . . . . . . . . . . . . . . . . . Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . Main Power, Glow and Cab Power (Groundsmaster 4110--D) Relays . . . . . . . . . . . Start and Air Conditioning (Groundsmaster 4110--D) Relays . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Valve Solenoid Coils . . .
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Toro Electronic Controllers (TEC) Groundsmaster 4100--D and 4110--D machines use two (2) Toro Electronic Controllers (TEC) to manage machine electrical functions.
Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The multimeter 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.
Diagnostic Display The Diagnostic Display (Fig. 4) can be connected to the wiring harness communication connector located under the controller cover to verify correct electrical functions of the machine. Toro Electronic Controller (TEC) inputs and outputs can be checked using the Diagnostic Display.
Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally.
Troubleshooting For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and components used on this machine (see electrical schematic in Chapter 10 -- Foldout Drawings). 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.
4. Turn the ignition switch to the ON position, but do not start machine. NOTE: The red text on the Diagnostic Display overlay decal refers to input switches and the green text refers to TEC outputs. TEC--5002 MASTER OVERLAY 5. Make sure that the “INPUTS DISPLAYED” LED, on lower right column of the Diagnostic Display, is illuminated. If “OUTPUTS DISPLAYED” LED is illuminated, press the toggle button on the Diagnostic Display to change to “INPUTS DISPLAYED” LED. 6.
Diagnostic Display TEC--5002 Master Inputs Diagnostic Display LED Operation P BRAKE OFF Parking brake released: LED ON Parking brake applied: LED OFF NEUTRAL Traction pedal in neutral: LED ON Traction pedal in forward or reverse: LED OFF SEAT SWITCH Operator seat occupied: LED ON Operator seat empty: LED OFF HI RANGE Hi/Lo speed switch in HI range: LED ON Hi/Lo speed switch in LO range: LED OFF OIL PRESSURE LOW Engine not running OR low engine oil pressure: LED ON Engine oil pressure OK: LED OFF
Diagnostic Display LED Operation C DECK RAISE Cutting deck lift switch for center deck in RAISE position: LED ON Lift switch for center deck NOT in RAISE position: LED OFF C DECK LOWER Cutting deck lift switch for center deck in LOWER position: LED ON Lift switch for center deck NOT in LOWER position: LED OFF L DECK RAISE Cutting deck lift switch for left deck in RAISE position: LED ON Lift switch for left deck NOT in RAISE position: LED OFF L DECK LOWER Cutting deck lift switch for left deck in LOW
Verify Diagnostic Display Output Functions The Diagnostic Display also has the ability to detect which output solenoids or relays are energized by the TEC controllers. This is a quick way to determine if a machine malfunction is electrical or hydraulic. NOTE: An open output (e.g. an unplugged connector or a broken wire) cannot be detected with the Diagnostic Display. C.
Starting Problems Problem Possible Causes No electrical power to machine (including gauges). The battery is discharged. The battery cables are loose or corroded. Fuse F3--1 (2 amp) to the ignition switch is faulty. A faulty ground connection exists on machine. The ignition switch or circuit wiring is faulty. Starter solenoid clicks, but starter will not crank. The battery is discharged. NOTE: If the solenoid clicks, the problem is not in the interlock circuit.
Starting Problems (Continued) Problem Possible Causes Engine cranks, but does not start. The fuel tank is empty. The engine is not cranking fast enough. Fuse F5--1 (40 amp) is faulty preventing the engine run solenoid pull coil from being energized. Fuse M1 (60 amp) is faulty preventing glow plug operation. The glow relay or circuit wiring is faulty preventing glow plug operation. Glow plug(s) is faulty. The engine run solenoid or circuit wiring is faulty. The fuel pump or circuit wiring is faulty.
General Run and Transport Problems Problem Possible Causes The engine continues to run, but should not, when the ignition switch is turned off. The engine run solenoid is stuck or is faulty. The engine continues to run, but should not, when the traction pedal is engaged with no operator in the seat. The seat switch or circuit wiring is faulty. The engine stops during operation, but is able to restart. The operator is lifting off the seat switch.
Cutting Deck Operating Problems Problem Possible Causes The cutting deck remains engaged, but should not, with no operator in the seat. The seat switch or circuit wiring is faulty. The cutting deck runs, but should not, with PTO switch in the OFF (disengage) position. The PTO switch or circuit wiring is faulty. TEC--5001 controller is faulty. A hydraulic problem exists (see Troubleshooting section of Chapter 4 -- Hydraulic System). TEC--5001 controller is faulty.
Cutting Deck Lift/Lower Problems Problem Possible Causes Neither the cutting deck or wing decks will lower. Hi/Low speed switch is in the Hi speed position. Operator is not fully depressing the seat switch. TEC--5001 fuse(s) (F4--1, F4--2, F4--3, F4--4) are faulty. Seat switch or circuit wiring is faulty. Hi/Low speed switch or circuit wiring is faulty. Lift control manifold solenoid coil S1 or circuit wiring is faulty.
Cutting Deck Lift/Lower Problems (Continued) Problem Possible Causes LH wing cutting deck will not raise or lower, but the front and RH wing cutting decks will raise and lower. LH deck lift switch or circuit wiring is faulty. Lift control manifold solenoid coils S2, S3 or S4 or circuit wiring is faulty. A hydraulic problem exists (see Troubleshooting section of Chapter 4 - Hydraulic System). TEC--5001 controller is 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.
Check Operation of Interlock Switches CAUTION Do not disconnect safety switches. They are for the operator’s protection. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before operating the machine. Electrical System Interlock switch operation is described in the Operator’s Manual. Your Groundsmaster is equipped with two (2) Toro Electronic Controllers (TEC) which monitor interlock switch operation.
Adjustments Wing Deck Position Switches Adjustment 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. 3. Raise and lower wing deck while monitoring the wing deck latch and the position switch LED on cable end of switch: 3 4 A.
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, 03--M-E3B Series at the end of Chapter 3 -- Kubota Diesel Engine.
Fuses The fuse blocks are located in the power center under the hood on the right side of the machine (Fig. 17). In addition to the fuses in the fuse blocks, a 40 amp fuse (F5--1) is included in the wire harness to protect the pull coil circuit for the engine run solenoid. This fuse resides in a fuse holder near the starter motor (Fig. 17). Fuse Identification and Function Use Figure 18 to identify each individual fuse and its correct amperage. The fuses have the following functions.
Operator Cab Fuses (Groundsmaster 4110--D) The cab fuse blocks are located in the cab headliner (Fig. 19). Identification and Function (Figs. 19 and 21) Fuse F1--1 (20 Amp) protects the air conditioner circuit. Fuse F1--2 (20 Amp) protects the cab lighting circuit. 1 Fuse F1--3 (20 Amp) protects the cab fan and dome light circuits. Fuse F2--1 (20 Amp) protects the heater circuit. Fuse F2--3 (20 Amp) protects the windshield wiper/ washer circuit.
Warning Lights Charge Indicator Light 3. Apply 12 VDC to terminals 1A and 2A (Fig. 23). The charge indicator light should come on when the ignition switch is in ON with the engine not running or with an improperly operating charging circuit while the engine is running. 4. Ground terminals 1B and 2B (Fig. 23). To test the charge indicator light and circuit wiring, ground the white wire attached to alternator.
PTO Switch The PTO switch is located on the console arm (Fig. 24). The PTO switch is pulled up to engage the PTO and pushed in to disengage the PTO. The TEC--5001 controller monitors the position of the PTO switch (up or down). Using inputs from the PTO switch and other switches in the interlock system, the TEC--5001 controller controls the energizing of the hydraulic solenoid valves used to drive the cutting deck motors.
Cutting Deck Lift Switches The cutting deck lift switches are used as inputs for the TEC--5001 controller to raise or lower the cutting deck sections. When the front of a lift switch is depressed and held, the controlled deck will lower. When the rear of a lift switch is depressed and held, the controlled deck will raise. The deck section will remain in position when the switch is released. The lift switches are located on the console arm (Fig. 26). 7.
Hi/Low Speed and Headlight (Groundsmaster 4110--D) Switches The Hi/Low speed and headlight switches (Groundsmaster 4110--D) are identical, two (2) position rocker switches that are located on the control console. The Hi/Low speed switch (Fig. 28) is used as an input for the TEC--5002 controller to set the machine traction speed for Hi speed (2WD) or Low speed (4WD). 6. After testing is completed, connect wire harness connector to the switch. 7.
Engine Cooling Fan Switch The engine cooling fan switch is a two (2) position rocker switch that is located on the outside of the control console (Fig. 30). The switch has a normal and a momentary position. 6. If switch tests correctly and circuit problem still exists, check wire harness (see Electrical Schematics and Wire Harness Drawings in Chapter 10 -- Foldout Drawings).
Seat Switch The seat switch is normally open and closes when the operator is occupying the seat. This switch is used as an input for the TEC--5002 controller. The seat switch and its electrical connector are located in the seat assembly. If the traction system or PTO switch is engaged when the operator raises out of the seat, the engine will stop. Testing of the switch can be done without seat removal by disconnecting the switch wire from the machine wire harness (Fig. 32). 2 1 Testing 1.
Parking Brake Switch The switch used for the parking brake is a normally open switch that is located under the steering tower cover (Fig. 33). The brake switch is used as an input for the TEC--5002 controller. When the parking brake is not applied, the parking brake pawl depresses the switch plunger to close the switch. When the parking brake is applied, the parking brake pawl is positioned away from the switch plunger so the switch is in its normal, open state. Testing 1.
Main Power, Glow and Cab Power (Groundsmaster 4110--D) Relays The main power, glow and cab power relays are located at the power center behind the operator seat (Fig. 34). The wire harness is attached to these relays with a four (4) wire connector (Fig. 35). The main power relay is used to provide current to the TEC controllers and most of the fuse protected circuits (operator seat, power point and optional electric equipment).
Start and Air Conditioning (Groundsmaster 4110--D) Relays When energized by the TEC--5002 controller, the start relay is used to provide current to the engine starter motor solenoid. The TEC--5002 controls and monitors the operation of the start relay. The start relay is located at the power center behind the operator seat (Fig. 36). minal 85. The relay terminals 30 and 87A should have continuity as +12 VDC is removed from terminal 85.
Hydraulic Valve Solenoid Coils 1 3 RIGHT 5 FRONT 6 2 4 Figure 38 1. 4WD manifold 2. LH wing deck manifold 3. RH wing deck manifold 4. Front deck manifold Several hydraulic solenoid valve coils are used on the hydraulic control manifolds of Groundsmaster 4100--D and 4110--D machines. When energized by the TEC controller, these coils provide hydraulic circuit control. Solenoid valve coils with two (2) different resistance specifications are used on the 4100--D and 4110--D.
Testing 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Locate hydraulic valve solenoid coil to be tested (Fig. 38). Disconnect wire harness connector from coil. 3. Identify coil resistance specification by measuring the coil diameter and coil height (Fig. 39). COIL DIAMETER NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together.
Toro Electronic Controllers (TEC) Groundsmaster 4100--D and 4110--D machines use two Toro Electronic Controllers (TEC) to control electrical system operation. The controllers are attached to the operator platform under the controller cover (Fig. 41). RIGHT FRONT Logic power is provided to the controllers as long as the battery cables are connected to the battery. A pair of 2 amp fuses (F3--1 and F4--1) provide circuit protection for this logic power to the controllers.
Hour Meter The hour meter is located on the outside of the console arm. Testing 7. Assemble console arm (see Console Arm Assembly in the Service and Repairs section of Chapter 7 -- Chassis). 1. Make sure ignition switch is OFF. Remove key from ignition switch. Hobbs QUARTZ 2. Disassemble console arm to gain access to the hour meter (see Console Arm Disassembly in the Service and Repairs section of Chapter 7 -- Chassis). 00001 HOURS 3.
Fuel Sender The fuel sender is located on top of the fuel tank (Fig. 44). 7. Replace sender as necessary. Reinstall sender into fuel tank. Testing 8. Connect wires to fuel sender. Apply skin--over grease (see Special Tools in this chapter) to sender terminals. 1. Make sure ignition switch is OFF. Remove key from ignition switch. 2. Remove white (+) wire and black (--) wire from the fuel sender.
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 1. Make sure ignition switch is OFF. Remove key from ignition switch. 2. Locate fuel gauge for testing (see Steering Tower Disassembly in the Service and Repairs section of Chapter 7 -- Chassis). VARIABLE RESISTANCE 14 VDC + 0.
Fuel Pump The fuel pump is attached to the frame above the fuel water separator (Fig. 48). Operational Test 3 1. Park machine on a level surface, lower cutting deck, stop engine and apply parking brake. Raise and support hood. 2 2. Remove fuse F1--1 (20A) (Fig. 49) from fuse block to prevent the engine from cranking. 4 3. Disconnect fuel hose (pump discharge) from the fuel water separator. 1 4. Make sure fuel hoses attached to the fuel pump are free of obstructions. Figure 48 5.
Temperature Sender The temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 50). The resistance of the temperature sender reduces as the engine coolant temperature increases. There is a gray harness wire attached to the switch. 1 Testing 1. Lower coolant level in the engine, disconnect gray harness wire from temperature sender and remove the temperature sender from water flange. 2 2.
Temperature Gauge The temperature gauge on the control panel indicates engine coolant temperature level during machine operation (Fig. 52). The changing resistance of the engine temperature sender signals the temperature gauge. The temperature gauge should display the first green segment when the ignition switch is turned to ON. The first yellow segment on the gauge should display when engine coolant temperature is approximately 212oF (100oC).
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 (forward or reverse). The neutral switch is used as an input to the TEC--5002 controller. The switch is located on the right side of the piston (traction) pump (Fig. 53).
Wing Deck Position Switches Two (2) wing deck position switches are used on the Groundsmaster 4100--D and 4110--D as inputs for the TEC--5001 controller. The position switches are powered proximity switches that are normally open. The switches incorporate an internal reed switch and a LED. These switches are secured to the center section of the cutting deck (Fig. 55). A bolt head on the wing deck link is the sensing plate for the position switch (Fig. 56). B.
Engine Coolant and Hydraulic Oil Temperature Senders The Groundsmaster 4100--D and 4110--D use two (2) temperature senders as inputs for the TEC--5002 to identify if either the engine coolant or hydraulic oil temperature has reached an excessive level. These senders are identical. The coolant temperature sender threads into the radiator (Fig. 57). The hydraulic oil temperature sender is attached to the hydraulic hydraulic tube on the left side of the machine (Fig. 58). 6.
Service and Repairs NOTE: For engine component repair information (e.g. starter motor), see the Kubota Workshop Manual, Diesel Engine, 03--M--E3B Series at the end of Chapter 3 -- Kubota Diesel Engine. Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery and charge it fully (see Battery Service in this section). 2. Either store battery on a shelf or on the machine. 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5.
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 1 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. Electrolyte Specific Gravity Fully charged: 1.
2. Conduct a hydrometer test of the battery electrolyte. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. A. Measure the specific gravity of each cell with a hydrometer. Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm-up the hydrometer. At the same time take the temperature of the cell. B. Temperature correct each cell reading. For each 10oF (5.5oC) above 80oF (26.7oC) add 0.004 to the specific gravity reading. For each 10oF (5.
Battery Charging 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. Determine the battery charge level from either its specific gravity or open circuit voltage. Battery Charge Level Specific Gravity Open Circuit Voltage 100% 1.265 12.68 75% 1.225 12.45 50% 1.190 12.24 25% 1.155 12.06 0% 1.120 11.89 2.
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Chapter 6 Axles, Planetaries and Brakes Table of Contents Axles, Planetaries and Brakes SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Brake Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Specification Tire pressure (front and rear) 25 to 30 PSI (172 to 207 kPa) Rear wheel toe--in 0.125 in (3.18 mm) Planetary gear drive oil System gear lube capacity (each wheel) SAE 85W--140 wt. gear lube 16 fl. oz. (0.47 liters) Rear axle lubricant System gear lube capacity SAE 85W--140 wt. gear lube 80 fl. oz. (2.37 liters) Rear axle gear box lubricant System gear lube capacity SAE 85W--140 wt. gear lube 16 fl. oz. (0.
General Information Operator’s Manual Axles, Planetaries and Brakes The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine.
Service and Repairs Brake Assembly 85 to 100 ft--lb (115 to 135 N--m) 13 14 2 12 6 1 3 11 4 75 to 85 ft--lb (101 to 115 N--m) 17 5 5 7 15 16 8 18 3 RIGHT FRONT 6 75 to 85 ft--lb (101 to 115 N--m) 1 9 10 11 2 Figure 1 1. 2. 3. 4. 5. 6. Planetary assembly Retaining ring Splined brake coupler Brake assembly (RH) O--ring Hydraulic wheel motor Axles, Planetaries and Brakes 7. 8. 9. 10. 11. 12.
Removal (Fig. 1) 24 25 1. Park machine on a level surface, lower cutting deck, stop engine and remove key from the ignition switch. 6 23 21 22 2. Drain oil from planetary wheel drive/brake assembly. 5 CAUTION 20 When removing front wheel, use correct jacks and supports. 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.
Installation (Fig. 1) 1. Install splined brake shaft (item 3) into brake assembly. NOTE: The stepped end of the splined brake shaft must be aligned toward the hydraulic wheel motor (Fig. 4). 2. Apply gasket sealant to sealing surfaces of new gasket (item 11). Apply gasket to brake assembly. 2 3 3. Install brake assembly to machine, aligning splined brake shaft with input shaft on planetary wheel drive. 4. Secure brake assembly to planetary assembly with four (4) flange head screws (item 9).
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Brake Service 3 2 1 4 5 5 6 7 8 7 8 7 15 14 10 13 12 11 7 8 9 Figure 6 1. 2. 3. 4. 5. Brake housing (LH shown) Seal Pull rod Clevis pin (2 used) Link 6. 7. 8. 9. 10. Hitch pin (2 used) Stationary disc (4 used) Rotating disc (3 used) Retaining ring Gasket 11. 12. 13. 14. 15. Rotating actuator Extension spring (3 used) Ball (3 used) Plug O--ring Brake Inspection and Repair (Fig. 6) 6. Remove seal (item 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 FRONT 9 10 75 to 85 ft--lb (101 to 115 N--m) 11 2 1 Figure 7 1. 2. 3. 4. 5. Planetary assembly Retaining ring Splined brake coupler Brake assembly (RH) O--ring 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) 11. 12. 13. 14.
Removal (Fig. 7) 1. Park machine on a level surface, lower cutting deck, 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). 5. Install front wheel assembly. 2. Drain oil from planetary wheel drive/brake assembly. WARNING CAUTION When removing front wheel, use correct jacks and supports.
Planetary Wheel Drive Service 2 24 3 9 ft--lb (12 N--m) 19 20 6 7 1 8 21 9 4 10 11 5 23 18 17 12 16 15 21 14 22 13 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. Spindle Boot seal Bearing cone Bearing cup Wheel stud (8 used) Housing Bearing cup Bearing cone 9. 10. 11. 12. 13. 14. 15. 16. Thrust washer Retaining ring (external) Ring gear Retaining ring (internal) Plug (2 used) End cap Thrust plug Thrust washer 17. 18. 19. 20. 21. 22. 23. 24.
Disassembly (Figs. 9 and 10) 3 1. If planetary wheel drive assembly is installed on machine: 1 2 24 4 7 19 20 8 12 21 11 A. Park machine on a level surface, lower cutting deck, stop engine and remove key from the ignition switch. 14 15 B. Drain oil from planetary wheel drive/brake assembly. 17 C. Chock rear wheels and jack up front of machine (see Jacking Instructions in Chapter 1 -- Safety). Support machine with jack stands. 16 D.
F. Lightly oil bearing journals on spindle shaft. Slide housing onto spindle (item 1) taking care to not damage seal or spindle. Make sure that bearing in housing fully seats against spindle shaft shoulder. 3. Install carrier assembly (item 18) making sure that carrier gear teeth align with ring gear and spline on spindle shaft. G. Install outer bearing cone (item 8) onto spindle. 4. Install drive shaft (item 17) making sure that drive shaft spline aligns with carrier gears.
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Rear Axle Assembly 18 17 16 2 3 See text for tightening procedure RIGHT FRONT 19 7 15 14 13 12 5 11 10 4 9 8 6 1 Figure 11 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 Removal (Fig. 11) 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. 13). 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 (6) cap screws, flat washers and flange nuts that secure rear frame mount to equipment frame.
8. Install steering cylinder to axle assembly (see Steering Cylinder Installation in the Service and Repairs section of Chapter 4 -- Hydraulic System). 9. Install hydraulic motor to axle assembly (see Rear Axle Motor Installation in the Service and Repairs section of Chapter 4 -- Hydraulic System). 2 1 10.Install wheels to rear axle. WARNING Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury. 11. Lower machine to ground.
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Rear Axle Service 10 11 22 21 20 24 17 23 18 19 8 2 9 25 15 3 13 12 5 26 43 14 16 1 6 33 7 27 44 45 28 29 8 61 62 9 46 47 10 37 22 50 41 60 52 4 42 36 11 48 63 39 59 9 38 40 53 8 35 30 31 49 13 34 32 58 57 54 51 56 55 Figure 16 Axles, Planetaries and Brakes Page 6 -- 20 Groundsmaster 4100--D/4110--D
Figure 16 (Continued) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. LH axle support Flange bushing (2 used) Axle vent O--ring Vent extension Cap screw (4 used per gear case) Shim set Seal washer Plug Lock nut Lock washer Grease fitting Ball bearing Screw (2 used per steering arm) Axle case support (LH shown) Bolt (2 used) Stud (2 used) Shim set Differential assembly O--ring Plug 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42.
Bevel Gear Case and Axle Case The following procedures assume the rear axle assembly has been removed from the machine (see Rear Axle Assembly Removal in this section). 35 to 41 ft--lb (47 to 56 N--m) 1 Bevel Gear Case and Axle Case Removal 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. 17). 4 6 5 2 3 2. Mark both 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. 20). 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 8.
Bevel Gear Case and Axle Case Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 22). 3 2 1 Figure 22 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. 23). Torque cover screws from 17 to 20 ft-lb (23 to 27 N--m). 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. 26). LOWER BEVEL GEAR BACKLASH: 0.004 to 0.016 in. (0.10 to 0.40 mm) 10.Adjust backlash by increasing or reducing axle bearing shim thickness (see Axle Shafts in this section of this manual).
Differential Shafts The following procedures assume the rear axle assembly has been removed from the machine (see Rear Axle Assembly Removal in this section). 35 to 41 ft--lb (47 to 56 N--m) 1 Differential Shaft Removal 6 5 IMPORTANT: Do not interchange right and left differential shaft assemblies. 4 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. 27). 3 4. Drive the differential shaft out of the bearings.
Axle Shafts The following procedures assume the rear axle assembly has been removed from the machine (see Rear Axle Assembly Removal in this section). 17 to 20 ft--lb (23 to 27 N--m) 1 4 Axle Shaft Removal 3 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig. 29). 2. Use a bearing puller to remove the bearing and bevel gear as shown (Fig. 30). 3. Remove the shims, spacer and retaining ring. Drive the axle out of the bearing and cover.
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Input Shaft/Pinion Gear 1 35 to 41 ft--lb (47 to 56 N--m) 9 7 8 6 5 3 2 18 17 4 18 15 10 9 16 14 10 13 35 to 41 ft--lb (47 to 56 N--m) 11 12 Figure 32 1. 2. 3. 4. 5. 6. Nut (2 used) Lock washer (2 used) Stud (2 used) Lock nut Stake washer Oil seal 7. 8. 9. 10. 11. 12. O-ring Seal collar Bearing O-ring Input shaft/pinion gear Bearing case The following procedures assume the rear axle assembly has been removed from the machine (see Rear Axle Assembly Removal in this section).
7. Secure the lock nut with the stake washer. 8. Use a depth gauge to measure the distance from the end face of the input shaft/pinion gear to the mating surface of the bearing case. Subtract the “Design Cone Center Distance” from this distance to determine initial shim thickness (Fig. 34). 0.040 in. (1.0 mm) 2 DESIGN CONE CENTER DISTANCE (distance from mating surface of axle support to end face of pinion gear): 1.870 + 0.002 in. (47.5 + 0.05 mm) 1 NOTE: Bearing case shims are available in 0.004 in. (0.
Differential Gear The following procedures assume the rear axle assembly has been removed from the machine (see Rear Axle Assembly Removal in this section). 35 to 41 ft--lb (47 to 56 N--m) 5 2 6 Differential Gear Removal 1 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 3 2. Mark and pull the differential shaft assemblies from the axle support. 3.
Differential Gear Inspection 1. Measure the differential side gear O.D. and the differential case I.D. to determine the side gear to case clearance (Fig. 39). 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.
Differential Gear Installation 3 1. If the ring gear was removed, use medium strength thread locking compound and torque 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. 43): Toe -- the portion of the tooth surface at the end towards the center. TOE HEEL Heel -- the portion of the gear tooth at the outer end. LENGTHWISE BEARING ARC 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. 46): A. Install thicker or additional bearing case shim(s) to move pinion shaft toward ring gear. Figure 46 B. Install thinner or remove differential bearing shim(s) to move ring gear backward. C.
Chapter 7 Chassis Table of Contents GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 1 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 2 Steering Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cutting Deck Lift Arms . . . . . . . . . . . . . . . . . . . . . . . 4 Console Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operator Seat . . . . . . . . . . . . . . . . . .
Service and Repairs Steering Tower 39 RIGHT FRONT 25 1 3 24 2 23 7 26 4 5 6 21 40 22 33 34 35 36 37 8 28 28 9 10 29 30 31 11 12 13 14 32 16 to 20 ft--lb (22 to 27 N--m) 27 15 16 17 18 19 38 20 21 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 (Fig. 1) Assembly (Fig. 1) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1. Assemble steering tower using Figure 1 as a guide. B. If steering wheel was removed, torque hex nut (item 1) from 16 to 20 ft lb (22 to 27 N--m). Chassis 2. Disassemble steering tower as needed using Figure 1 as a guide. A. Thrust washers (item 24) on steering column are used as needed to remove end play of steering shaft.
Cutting Deck Lift Arms 8 38 RIGHT FRONT Loctite #271 on threads 60 to 70 ft--lb (81 to 94 N--m) 9 10 11 30 to 40 ft--lb (41 to 54 N--m) 12 14 15 16 17 18 19 20 21 22 23 3 13 6 11 36 25 16 32 26 4 5 35 33 24 25 16 7 2 1 27 30 28 29 34 155 to 185 ft--lb (211 to 251 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. Torque flange nut from 155 to 185 ft--lb (211 to 251 N--m). CAUTION When changing attachments, tires or performing other service, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor.
Console Arm 40 32 39 38 37 31 30 29 34 1 28 27 35 1 18 19 25 17 43 6 13 12 36 14 33 15 23 24 16 22 2 21 26 11 10 9 RIGHT 42 8 7 FRONT 20 41 5 4 3 44 7 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Disassembly (Fig. 5) 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 2. Remove two (2) flange head screws (item 40) and then cover plate (item 39) from outside of console arm. Locate and retrieve two (2) spacers (item 38). 3. At front of console arm, remove screw (item 43) and lock nut (item 7) that secure console arm covers to each other. 9 3 1 1 5 12 5 13 11 10 5. Remove console arm covers from machine.
Operator Seat 37 36 RIGHT 39 35 FRONT 33 27 38 20 34 26 20 25 32 5 18 19 32 31 30 20 29 29 28 24 4 21 22 6 23 3 7 17 1 9 10 12 11 13 14 16 2 8 15 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Platform Clevis pin (2 used) Hair pin (2 used) Seat plate Grommet Cotter pin (2 used) Latch shaft Cap screws (4 used) Latch Torsion spring Prop rod Flange nut (4 used) Cotter pin (2 used) Chassis 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Removal (Fig. 7) B. Secure console arm support (item 35) to coupler nut (item 38) with cap screw (item 37). 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. C. Place flat washer (item 20), seat belt latch (item 39) and spacer (item 36) between seat and console arm support (item 35). Secure with cap screw (item 33) and second flat washer (item 20). 2. Disconnect seat electrical connector from machine wire harness (Fig. 8).
Operator Seat Service 7 6 21 1 2 13 5 28 12 21 22 26 25 30 29 16 18 19 20 11 4 14 17 3 24 23 9 8 27 10 15 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Backrest cushion Seat cushion Armrest cover LH armrest Bushing (2 used) Backrest Plug (2 used) Cable tie (3 used) LH adjustment rail Bumper (2 used) Chassis 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Washer Cap screw (2 used) Seat Nut Spring (2 used) Magnet Seat switch Rivet (4 used) Mounting plate Return spring Page 7 -- 10 21. 22. 23.
Disassembly (Fig. 10) 2 1. Disassemble operator seat as necessary using Figures 10 and 11 as guides. 3 Assembly (Fig. 10) 1. Assemble operator seat using Figures 10 and 11 as guides. 1 4 5 7 11 6 7 10 8 9 Figure 11 Operator seat R--clamp Screw Manual tube Button head screw Seat belt 7. 8. 9. 10. 11. Flat washer Lock nut Cap screw Lock washer Seat belt mount Chassis 1. 2. 3. 4. 5. 6.
Operator Seat Suspension 16 RIGHT 17 FRONT 24 22 25 23 5 18 2 19 21 33 1 20 3 39 14 12 7 35 28 31 4 30 6 15 38 27 13 36 8 29 9 10 26 33 11 34 32 37 Figure 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Cover Cover Level control Air control valve Shock absorber Air spring Air tube assembly Wire harness Compressor Bellows Stop Bumper set (2 used) Roller (4 used) Chassis 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
NOTE: Most of the seat suspension components can be serviced with the seat suspension base mounted to the frame platform. If the air spring assembly (item 6) requires removal, the seat suspension base will have to be removed from the seat platform. 1 2 Disassembly (Fig. 12) 1. Remove operator seat from seat suspension (see Operator Seat Removal in this section). 2. Disconnect seat suspension connector from machine wire harness (Fig. 13). 3 3.
Hood 49 1 35 RIGHT 33 36 34 2 FRONT 37 5 42 13 39 38 3 40 7 28 41 43 6 29 4 27 12 26 46 14 15 16 18 17 47 45 9 10 48 11 10 8 3 31 30 3 32 19 21 17 22 24 23 44 25 20 15 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
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 15 as a guide. Installation 1 1. Install hood using Figure 15 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. 16 and 17). B.
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Chapter 8 Cutting Deck Table of Contents Cutting Deck SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Castor Wheel Tire Pressure . . . . . . . . . . . . . . . . . . 3 Blade Stopping Time . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4 Factors That Can Affect Quality of Cut .
Specifications MOUNTING: Cutting deck is supported by lift arms controlled with individual lift switches. CONSTRUCTION: Deck chamber is welded 12 gauge steel construction reinforced with channels and plates. HEIGHT--OF--CUT RANGE: 1” to 5” (25.4 mm to 127 mm) adjustable in 1/2” (12.7 mm) increments. Center deck height--of--cut adjustment is achieved by changing spacers on castor wheels and adjusting length of deck support chains.
General Information CAUTION Never install or work on the cutting deck or lift arms with the engine running. Always stop engine and remove ignition key first. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance, adjustments and maintenance intervals for your Groundsmaster cutting deck. Refer to that publication for additional information when servicing the machine.
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 deck weight, tire pressures, hydraulic counterbalance settings and turf conditions.
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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 RIGHT 8 FRONT 9 7 6 5 10 11 4 1 18 3 2 13 18 14 18 16 17 15 12 75 to 85 ft--lb (102 to 115 N--m) 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.
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 1 NOTE: Removal of clevis pins from deck and height-of--cut chains is easier if deck is lifted slightly. 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. Remove plugs from hydraulic hoses and fittings on wing deck lift cylinders. Using labels placed during removal, correctly attach hydraulic hoses to lift cylinders. 1 6. Connect cutting deck wire harness to main machine wire harness (Fig. 5). 7. Position dampers to lift arms.
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Wing Deck Service 25 2 30 to 40 ft--lb (41 to 54 N--m) 160 to 180 ft--lb (217 to 244 N--m) 43 23 3 46 45 47 40 34 48 49 37 1 31 30 41 24 4 6 44 7 33 19 50 RIGHT 39 21 22 20 42 38 19 8 52 FRONT 10 29 9 11 18 52 53 36 32 28 23 39 24 5 35 27 26 51 17 14 16 10 12 15 17 13 Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 6) 1 1. Position machine on a clean, level surface. Lower cutting deck and engage parking brake. 3 2. Fully raise wing deck, stop engine and remove key from the ignition switch. Remove three (3) washer head screws and shield strap that secure flex shield to wing deck. Lower wing deck. 2 3. Remove hydraulic motor from wing deck (see Cutting Deck Motor Removal in the Service and Repairs Section of Chapter 4 -- Hydraulic System). 4.
4. Position upper end of links to center cutting deck brackets. 5. Align upper end of links with mounting holes in center deck. While installing pivot pins to center deck and links, insert spacers and washers as follows: A. Place one (1) hardened spacer (item 42) on each side of the front link. Use two (2) thrust washers on rear side of assembly so that link is snug between deck brackets. Additional thrust washers should be installed, if necessary, to remove excess clearance. B.
Cutting Deck Link Service Disassembly (Fig. 10) 1. Press bushings from top of link. 1 30 to 40 ft--lb (41 to 54 N--m) 2 2. Remove dust cap and retaining ring from link. 3. Press tapered stud with spherical bearing, flat washers and flange nut from link. 3 4 5 6 7 8 4. Remove flange nut and press spherical bearing from tapered stud. Assembly (Fig. 10) 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). Figure 10 1. 2.
Wing Deck Latch Disassembly (Fig. 12) 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. 5. Disassemble latch (items 1 through 8) using Figure 12 as a guide. 4 6 3 4 3 2 12 1 Assembly (Fig.
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Blade Spindle 4 2 3 5 11 12 10 1 6 8 RIGHT FRONT 9 88 to 108 ft--lb (119 to 146 N--m) 7 Figure 13 1. 2. 3. 4. Cutting deck Drive spindle: single pulley (2 used) Low driven spindle (3 used) Drive spindle: double pulley (1 used) 5. 6. 7. 8. Flange head screw Flange nut Blade bolt Cutting blade (7 used) Removal (Fig. 13) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2.
Installation (Fig. 13) 1. Position spindle on cutting deck noting orientation of grease fitting (Fig. 15). Secure spindle assembly to deck with removed fasteners. 2 2. Install cutting blade, anti--scalp cup and blade bolt. Tighten blade bolt from 88 to 108 ft--lb (119 to 146 N--m). 1 3. Slowly rotate cutting blades to verify that blades do not contact any deck component(s). 1 Figure 14 4. Install drive belt and adjust belt tension (see Idler Assembly Installation in this section). 1.
Blade Spindle Service DRIVEN SPINDLE 7 1 8 2 9 3 10 11 130 to 150 ft--lb (176 to 203 N--m) 12 4 13 14 DRIVE SPINDLE 15 1 2 9 5 16 8 17 6 4 Figure 16 1. 2. 3. 4. 5. 6. Lock nut Flat washer Driven pulley Spindle shaft 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 13. 14. 15. 16. 17.
2. Install outer bearing spacer into top of spindle housing. The spacer should fit against the snap ring. 1 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 outer bearing 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 cup against it (Fig 18). 2 1 Figure 17 1. Bearing 2. Spacer ring 3.
Idler Assembly 24 17 15 19 5 8 7 7 22 20 21 14 9 23 18 19 16 13 8 12 11 6 10 1 5 RIGHT 4 FRONT 2 3 Figure 20 1. 2. 3. 4. 5. 6. 7. 8. Center deck Flange nut Flange nut Adjusting screw Idler pulley High driven pulley Flat washer Lock washer 9. 10. 11. 12. 13. 14. 15. 16. Socket head screw Idler stop bolt Flange nut Cap screw Spacer Shoulder bolt Idler spring Lock nut 17. 18. 19. 20. 21. 22. 23. 24.
Removal (Fig. 20) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove deck covers from top of cutting deck. CAUTION Be careful when removing idler spring. The spring is under heavy load and may cause personal injury. 3. Use spring hook tool to unhook the idler spring (item 15) from the adjusting screw (item 4). 4. Remove drive belt(s) from deck pulleys. 5.
Castor Forks and Wheels DECK CASTOR ARM WING DECK CASTOR FORK 14 13 17 20 24 12 21 11 25 6 60 to 80 ft--lb (81 to 108 N--m) 7 5 9 7 19 8 1 10 20 26 4 18 22 16 23 CASTOR WHEEL 8 15 4 32 2 27 5 3 33 28 29 27 30 60 to 80 ft--lb (81 to 108 N--m) 34 31 Figure 22 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Disassembly (Fig. 22) Assembly (Fig. 22) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1. Assemble castor forks and wheels using Figure 22 as a guide. 2. Disassemble castor forks and wheels using Figure 22 as a guide. 2. Torque castor wheel lock nut from 60 to 80 ft--lb (81 to 108 N--m). 3. If castor fork was removed, lubricate grease fitting. Cutting Deck 4. See Operator’s Manual for castor wheel adjustment.
Deck Rollers and Skids 9 7 10 6 5 8 7 6 5 5 RIGHT 6 7 4 3 FRONT 2 1 Figure 23 1. 2. 3. 4. Roller Flange head screw Roller shaft Flange nut 5. Lock nut 6. Roller 7. Cap screw 8. Flange nut 9. Skid (RH shown) 10. Flange head screw Removal (Fig. 23) Installation (Fig. 23) 1. Remove skids and rollers from deck using Figure 23 as a guide. 1. Install skids (item 9) to deck using Figure 23 as a guide. Make sure to install skids in the same mounting hole height position (lower or upper). 2.
Operator Cab Table of Contents GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical Components and Schematic . . . . . . . . . 2 Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . 2 Cab Heater System . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
General Information The information in this chapter pertains to the operator cab on the Groundsmaster 4110--D. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster. Refer to the Operator’s Manual for additional information when servicing the machine.
Service and Repairs 4. Put labels on disconnected lines and hoses for proper installation after repairs are completed. CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. WARNING Always wear safety goggles or a face shield when working with air conditioning system components.
Air Conditioning Compressor FRONT RIGHT 31 29 27 4 34 23 22 9 3 22 23 26 28 2 17 8 5 2 24 35 15 16 17 6 1 17 7 14 32 8 11 12 2 13 10 25 30 33 2 18 15 19 20 21 22 23 22 Figure 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Cap screw (3 used) Lock washer (8 used) Pulley V--belt Lower radiator hose Hose clamp (2 used) Lower radiator hose Cap screw Alternator plate Carriage screw Flat washer Idler pulley 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
6. Read the General Precautions for Removing and Installing Air Conditioning System Components at the beginning of the Service and Repairs section of this chapter. CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. 7. Have refrigerant evacuated from air conditioning system by a certified A/C service technician. 8. Label and remove hoses from compressor.
Roof Assembly 11 1 2 1 3 2 3 5 6 5 7 10 8 7 9 4 1 RIGHT FRONT 1 Figure 3 1. 2. 3. 4. Flange head screw (8 used) Flat washer (4 used) Bushing (4 used) Headliner Operator Cab 5. 6. 7. 8. Panel nut (4 used) Rear coupling plate (2 used) Flange nut (4 used) Foam spacer (3 used) Page 9 -- 6 9. Headliner spacer 10. Front coupling plate (2 used) 11.
To gain access to the heater core and air conditioning components that are located above the cab headliner, the roof panel can be loosened, raised and supported. 4 Removal (Fig. 3) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 6 1 7 11 3. Carefully lift front of roof while leaving rear of roof against headliner. Support front of roof in the raised position to allow access to heater and air conditioning components.
Cab Hose Identification 13 2 14 1 17 3 18 11 16 10 6 12 4 20 5 19 7 6 10 2 16 15 12 8 9 16 RIGHT FRONT Figure 5 1. 2. 3. 4. 5. 6. 7. Grommet AC hose (compressor to condenser) AC hose (condenser coil to drier) Heater hose (valve to heater) Heater valve Heater hose (thermostat to valve) Heater hose (heater to pump) 8. 9. 10. 11. 12. 13. 14. AC hose (evaporator to compressor) AC hose (drier to evaporator) Cable tie (2 used) Air duct hose Hose clamp (6 used) O--ring Headliner 15. 16.
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Air Conditioning Condenser Assembly 2 1 3 13 5 14 12 4 11 9 8 7 6 10 Figure 6 1. 2. 3. 4. 5. Condenser cover Flange nut (4 used) Condenser fan Condenser coil Button head screw (4 used) Operator Cab 6. 7. 8. 9. 10. Flat washer (4 used) Roof Bushing (4 used) Isolator mount (4 used) Flange head screw (4 used) Page 9 -- 10 11. 12. 13. 14.
Installation (Fig. 6) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1. Position condenser coil to roof. 2. Remove fasteners that secure roof in place. Raise and support roof to allow access to condenser assembly (see Roof Assembly Removal in this section). 3. Disconnect wire harness connector from condenser fan motor. 4. Remove four (4) flange nuts (item 2) that secure condenser fan and cover to condenser fan mount.
Heater/Evaporator Assembly 10 10 2 10 1 9 12 13 8 4 11 7 5 8 11 11 8 6 3 Figure 7 1. 2. 3. 4. 5. Heater/evaporator assembly Top cover Flange head screw (2 used) Drier--receiver mount Bottom cover Operator Cab 6. 7. 8. 9. Hose clamp (2 used) Speed nut (8 used) Panel nut (4 used) Drier--receiver assembly Page 9 -- 12 10. 11. 12. 13.
Removal (Fig. 7) 4 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove fasteners that secure roof in place. Raise and support roof to allow access to heater/evaporator assembly (see Roof Assembly Removal in this section). 6 3. Disconnect wire harness connectors from fan motor and binary switch on drier--receiver. 1 7 11 4.
3. Slide air duct hose onto heater/evaporator assembly covers and secure with cable tie. 7. Make sure that all machine air conditioning components are installed and secure. 4. Remove caps that were placed on hoses and fittings during the removal process. Using labels placed during removal, properly secure hoses to heater core, evaporator and drier--receiver. 8.
Chapter 10 Foldout Drawings Table of Contents Groundsmaster 4100--D/4110--D Page 10 -- 1 Foldout Drawings HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL SCHEMATIC Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 OPERATOR CAB ELECTRICAL SCHEMATIC Sheet 1 of 3 . . . . . . . . . . . . . . . .
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2.000 BORE 7.875 STROKE 0.750 ROD .070 .063 .035 .063 S9 S4 S6 S2 S3 S5 S7 2.125 BORE 3.500 STROKE 1.000 ROD S8 FRONT PTO MANIFOLD S1 RV1 RV2 2500 PSI 2.000 BORE 7.875 STROKE 0.750 ROD LIFT/LOWER MANIFOLD 4WD MANIFOLD LH PTO MANIFOLD M1 M2 ST L BYPASS VALVE P1 RH PTO MANIFOLD T P2 FAN DRIVE MANIFOLD FILTER MANIFOLD Groundsmaster 4100--D/4110--D Hydraulic Schematic Page 10 -- 3 Rev.
Groundsmaster 4100--D/4110--D Electrical Schematic Sheet 1 of 3 All relays and solenoids are shown as de-- energized. All ground wires are black. NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON THREE (3) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER WILL BE IDENTIFIED.
(BRAKE APPLIED) (NOT IN NEUTRAL) (SEAT UNOCCUPIED) ENGINE OIL PRESSURE (OPTIONAL KIT) ALTERNATOR (OPTIONAL KIT) (OPTIONAL KIT) Groundsmaster 4100--D/4110--D Electrical Schematic Sheet 2 of 3 All relays and solenoids are shown as de-- energized. All ground wires are black. NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON THREE (3) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER WILL BE IDENTIFIED.
A B C (NOT USED) A A B B C C (NOT USED) Groundsmaster 4100--D/4110--D Electrical Schematic Sheet 3 of 3 All relays and solenoids are shown as de-- energized. All ground wires are black. NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON THREE (3) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER WILL BE IDENTIFIED.
Groundsmaster 4110--D Operator Cab Electrical Schematic Sheet 1 of 3 All relays and solenoids are shown as de-- energized. All ground wires are black.
Groundsmaster 4110--D Operator Cab Electrical Schematic Sheet 2 of 3 All relays and solenoids are shown as de-- energized. All ground wires are black.
Groundsmaster 4110--D Operator Cab Electrical Schematic Sheet 3 of 3 All relays and solenoids are shown as de-- energized. All ground wires are black.
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(OPTIONAL KIT) TO REAR HARNESS (OPTIONAL KIT) A/C CLUTCH & WS WASHER PUMP (OPTIONAL KIT) (OPTIONAL KIT) (OPTIONAL KIT) NOTE CLOCK POSITION NOTE CLOCK POSITION (OPTIONAL KIT) TO REAR HARNESS (NOT USED) TO REAR HARNESS TO REAR HARNESS (OPTIONAL KIT) Groundsmaster 4100--D/4110--D Platform Wire Harness Drawing Page 10 -- 11
Page 10 -- 12 Groundsmaster 4100--D/4110--D Platform Wire Harness Diagram Sheet 1 of 2 (OPTIONAL KIT) (OPTIONAL KIT) (OPTIONAL KIT) (OPTIONAL KIT) (OPTIONAL KIT) BLACK PINK/BLACK PINK/BLACK RED 659 BLACK BLACK PINK GRAY/BLACK BLACK 258 636 BLACK RED/YELLOW WHITE/BLACK PINK/BLACK BLUE BROWN/YELLOW BLACK BLACK BLACK WHITE/BLACK 154 BROWN/WHITE 165 BLACK/WHITE RED/WHITE 635 728 167 WHITE/GREEN 246 WHITE/BLACK TAN/WHITE WHITE/BLUE GRAY/BLUE 245 BLACK TAN/BLACK GREEN/YELLOW YELLOW VIOLE
TO REAR HARNESS TO REAR HARNESS BLACK BLACK BLACK BLACK BLACK WHITE/ORANGE BLUE PINK/BLACK PINK PINK BLACK WHITE YELLOW YELLOW BLUE BROWN ORANGE GRAY YELLOW RED GREEN BLACK YELLOW BLACK 265 728 BLACK BLUE/WHITE BLACK BROWN WHITE PINK PINK WHITE PINK GREEN PINK 175 VIOLET YELLOW PINK BLACK GRAY/BLUE PINK BLACK GRAY (NOT USED) 197 747 641 166 BLACK 635 165 167 636 PINK/GREEN 270 172 YELLOW/BLUE 154 269 GREEN/BLACK ORANGE/BLACK BLACK WHITE/BLUE 242 246 BLACK
PLUG FUSEBLOCKS MAXI FUSES TO PLATFORM HARNESS TO PLATFORM HARNESS TO PLATFORM HARNESS TO PLATFORM HARNESS Groundsmaster 4100--D/4110--D Rear Wire Harness Drawing Page 10 -- 14 PLUG
BLACK RED/BLACK BLUE BLACK PINK WHITE RED RED PINK RED RED RED BLACK RED VIOLET RED BLACK BLUE BLACK WHITE/BLACK BROWN/BLACK TAN/BLACK TO PLATFORM HARNESS GRAY/BLACK BLUE PINK/BLACK RED BLACK WHITE WHITE/ORANGE RED YELLOW PINK VIOLET ORANGE BLACK BLACK RED/BLACK BLACK WHITE/YELLOW BROWN PINK RED/BLUE RED/GREEN BLACK BROWN/BLACK BLACK WHITE/BLACK TAN/BLACK GRAY/BLACK BLACK PINK BLACK PINK YELLOW/BLUE BLACK BLACK BLACK BLACK BLACK RED RED RED RED RED RED BLACK PINK/BLACK
PLATFORM HARNESS Groundsmaster 4100--D/4110--D Cutting Deck Wire Harness Page 10 -- 16 BLACK PINK YELLOW/BLACK BLACK PINK VIOLET/BLACK PINK BLACK PLATFORM HARNESS
