Part No. 08162SL (Rev. A) Service Manual (Model 30413) GroundsmasterR 4100--D Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing and repair of major systems and components on the Groundsmaster 4100--D (Model 30413). REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. For reference, insert a copy of the Operator’s Manual and Parts Catalog for your machine into Chapter 2 of this service manual.
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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 General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 3 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 was tested and certified by TORO for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.
1. Before servicing or making adjustments, lower deck, stop engine, apply parking brake and remove key from the switch. 10.Do not overspeed the engine by changing governor setting. To assure safety and accuracy, check maximum engine speed. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 11. Shut engine off before checking or adding oil to the crankcase. 3.
Jacking Instructions CAUTION When changing attachments, tires or performing other service, use correct 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 Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 4100--D. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog.
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Chapter 2 Product Records and Maintenance Product Records and Maintenance Table of Contents 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 + 56 # 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
Thread Size Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in--lb 644 + 68 N--cm 78 + 8 in--lb 881 + 90 N--cm M6 X 1.0 96 + 10 in--lb 1085 + 113 N--cm 133 + 14 in--lb 1503 + 158 N--cm M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 28 + 3 ft--lb 38 + 4 N--m M10 X 1.5 38 + 4 ft--lb 52 + 5 N--m 54 + 6 ft--lb 73 + 8 N--m M12 X 1.
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 Page 3 -- 1 Kubota Diesel Engine GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Air Filter System . . . . . . . . . . . . . . . . . .
General Information This Chapter gives information about specifications and repair of the diesel engine used in the Groundsmaster 4100--D. General maintenance procedures are described in your Operator’s Manual. Information on engine troubleshooting, testing, disassembly and reassembly is identified in the Kubota Workshop Manual, Diesel Engine, V2403--M--T--E3B that is included at the end of this section. Most repairs and adjustments require tools which are commonly available in many service shops.
Specifications Item Description Make / Designation Kubota Model V2403--M--T--E3B: 4--Cycle, 4 Cylinder, Water Cooled, Turbocharged, Diesel Engine 3.43” (87.0 mm) Stroke 4.031” (102.4 mm) Total Displacement cc (cu. in.) 148.5 in3 (2434 cc) Firing Order 1 (closest to gear case end) -- 3 -- 4 (closest to flywheel end) -- 2 Combustion Chamber Spherical Type (E--TVCS) Compression Ratio 23.
Service and Repairs Air Filter System 7 RIGHT FRONT 1 9 12 to 15 in--lb (1.4 to 1.6 N--m) 11 6 12 13 14 4 15 8 2 10 5 11 16 17 VACUATOR DIRECTION 3 Figure 1 1. 2. 3. 4. 5. 6. Air cleaner hose Hose clamp Air cleaner assembly 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.
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 B 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 C 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. Raise and support hood. A 3. Remove exhaust system components from the engine as necessary using Figure 5 as a guide. Figure 6 Installation (Fig.
Fuel System 38 39 37 RIGHT 36 35 34 FRONT 23 24 29 26 27 28 25 41 2 30 31 22 33 1 21 14 3 4 5 40 6 32 20 7 19 18 17 1615 7 8 12 11 13 60 to 80 in--lb (7 to 9 N--m) 9 10 135 to 165 ft--lb (183 to 223 N--m) Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Fuel Tank Installation (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 hose to the standpipe and venting hoses to the elbow fittings. 4. Connect electrical wiring to the fuel sender. A. Connect white wire to the center terminal and black wire to any of the screws that secure the fuel sender to the fuel tank.
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 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Removal (Fig. 8) Installation (Fig. 8) 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 placed during the removal procedure. 2. Open and support hood. CAUTION 2. Carefully position radiator to the support frame. Secure radiator to the support frame with cap screws and flange nuts. 3. Position lower radiator shroud and fan motor bracket assembly to the radiator.
Engine 27 1 RIGHT FRONT 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 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 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) Kubota Diesel Engine 10. 11. 12. 13. 14. 15. 16. 17. 18.
Engine Removal (Fig. 9) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2 2. Remove battery cover and strap. Disconnect negative battery cable first and then positive battery cable. Remove battery from machine. 1 3. Open and support hood. CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Figure 10 1. Dual temperature switch 2.
9. Disconnect throttle cable from the speed control lever by removing the flat washer and lock nut (Fig. 14). Loosen jam nut and separate cable from cable support. Position cable away from engine. 1 10.Remove fasteners that secure the upper radiator shroud to the lower shroud and radiator (see Radiator Removal in this section). Position coolant reservoir and bracket away from the radiator. Remove upper radiator shroud from machine. 3 11. Remove fan hub and fan from hydraulic fan motor (Fig. 15). 2 A.
3. Slowly lower engine into the machine. 27 to 33 ft--lb (37 to 44 N--m) 11 5. Secure hydraulic pump assembly to engine (see Pump Assembly Installation in the Service and Repairs section of Chapter 4 -- Hydraulic System). 8 1 10 2 9 3 6. Thoroughly clean tapered surfaces of fan motor shaft and fan hub. Position fan hub (with fan attached) onto motor shaft and secure with washer and hex nut (Fig. 15). Torque nut from 27 to 33 ft--lb (37 to 44 N--m). 7.
Spring Coupler RIGHT FRONT 8 2 1 2 2 4 5 7 3 2 Loctite #242 29 to 33 ft--lb (40 to 44 N--m) 6 28 to 32 ft--lb (38 to 43 N--m) Figure 16 1. Spring coupler 2. Washer (14 used) 3. Cap screw (6 used) Kubota Diesel Engine 4. Flywheel plate 5. Cap screw (4 used) 6. LH engine mount Page 3 -- 16 7. Cap screw (2 used) 8.
Coupler Removal (Fig. 16) 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 while removing hydraulic pump assembly (see Piston (Traction) Pump Removal in the Service and Repairs section of Chapter 4 -- Hydraulic System), transport cylinder assembly, flywheel plate, engine mounts and spring coupler. 1 2.
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Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 3 Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic Hose and Tube Installation . . . . . . . . . .
Specifications Item Description Piston (Traction) Pump Eaton Variable Displacement Piston Pump (Model 72400) 4000 PSI (274 bar) 5000 PSI (343 bar) 250 PSI (17 bar) System Relief Pressure: Forward System Relief Pressure: Reverse Charge Pressure Front Wheel Motors Eaton Fixed Displacement Piston Motors (Model 74328) Rear Axle Motor Eaton Fixed Displacement Piston Motor (Model 74315) Gear Pump Section P1/P2 Displacement (per revolution) Section P3/P4 Displacement (per revolution) Casappa 4 section, po
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. Towing Traction Unit IMPORTANT: If towing limits are exceeded, severe damage to the piston pump may occur. If it becomes necessary to tow (or push) the machine, tow (or push) in a forward direction only and at a speed below 3 mph.
Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions or mishandling during operation and maintenance. These conditions can cause hose damage and deterioration. Some hoses are more susceptible to these conditions than others.
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) Non--Adjustable Fitting (Fig. 6) 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.
Hydraulic System RH WING DECK MANIFOLD LH WING DECK MANIFOLD CENTER DECK MANIFOLD NOTE: A larger hydraulic schematic is included in Chapter 9: Foldout Drawings FAN DRIVE MANIFOLD FILTER MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD Hydraulic Schematic Page 4 -- 8 Groundsmaster 4100--D
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Hydraulic System RV2 Page 4 -- 10 RV2 M2 M1 RV2 RH WING DECK MANIFOLD M2 M1 LH WING DECK MANIFOLD M2 M1 CENTER DECK MANIFOLD OR LC2 OR LC2 LC2 RV1 RV1 RV1 S S S LC1 LC1 LC1 P2 P1 P2 P1 P2 P1 Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100--D Traction Circuit (4WD Forward Shown) P1 M1 M2 T ST P2 L FAN DRIVE MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD Hydraulic Flow Diagrams Groundsmaster 4100--D
Traction Circuit: 4WD (Mow) Traction circuit pressure (forward and reverse) can be measured at test ports on the sides 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. This leakage results in the loss of hydraulic fluid from the closed loop traction circuit that must be replaced. The charge circuit is designed to replace this traction circuit leakage.
Hydraulic System Page 4 -- 12 Groundsmaster 4100--D RV2 RV2 M2 M1 RV2 RH WING DECK MANIFOLD M2 M1 LH WING DECK MANIFOLD M2 M1 CENTER DECK MANIFOLD OR LC2 OR LC2 LC2 RV1 RV1 RV1 S S S LC1 LC1 LC1 P2 P1 P2 P1 P2 P1 Working Pressure Low Pressure (Charge) Return or Suction Flow P1 M1 M2 Groundsmaster 4100--D Traction Circuit (Transport Forward Shown) T ST P2 L FAN DRIVE MANIFOLD 4WD MANIFOLD (energized) (shifted) (shifted) COUNTERBALANCE MANIFOLD
Traction Circuit: Transport (2WD) Traction circuit pressure (forward and reverse) can be measured at test ports on the sides 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. This leakage results in the loss of hydraulic fluid from the closed loop traction circuit that must be replaced.
Hydraulic System Page 4 -- 14 Groundsmaster 4100--D RV2 RV2 M2 M1 RV2 RH WING DECK MANIFOLD M2 M1 LH WING DECK MANIFOLD M2 M1 CENTER DECK MANIFOLD OR LC2 OR LC2 LC2 RV1 RV1 RV1 S S S LC1 LC1 LC1 P2 P1 P2 P1 P2 P1 Working Pressure Low Pressure (Charge) Return or Suction Flow P1 M1 Groundsmaster 4100--D Lower Cutting Deck (LH Deck Shown) M2 T ST P2 L FAN DRIVE MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD
Lower Cutting Deck When the cutting deck is in a stationary position, flow from the gear pump is by--passed through the lift/lower control valve, counterbalance manifold, oil filter and traction charge circuit. To lower the cutting deck, the center lift lever on the lift/ lower control valve is pushed to allow valve shift in the lift/lower control. This valve change allows a passage for oil flow from the rod end of the front deck lift cylinders.
Hydraulic System Page 4 -- 16 Groundsmaster 4100--D RV2 RV2 M2 M1 RV2 RH WING DECK MANIFOLD M2 M1 LH WING DECK MANIFOLD M2 M1 CENTER DECK MANIFOLD OR LC2 OR LC2 LC2 RV1 RV1 RV1 S S S LC1 LC1 LC1 P2 P1 P2 P1 P2 P1 Working Pressure Low Pressure (Charge) Return or Suction Flow M1 Groundsmaster 4100--D Raise Cutting Deck (LH Deck Shown) P1 M2 T ST P2 FAN DRIVE MANIFOLD L 4WD MANIFOLD COUNTERBALANCE MANIFOLD
Raise Cutting Deck When the cutting deck is in a stationary position, flow from the gear pump is by--passed through the lift/lower control valve, counterbalance manifold, oil filter and traction charge circuit. To raise the cutting deck, the center lift lever on the lift/ lower control valve is pulled to allow valve shift in the lift/ lower control valve. This valve change allows hydraulic pressure to the rod end of the front deck lift cylinders, causing the cylinders to retract.
Hydraulic System Page 4 -- 18 Groundsmaster 4100--D RV2 RV2 M2 M1 RV2 RH WING DECK MANIFOLD M2 M1 LH WING DECK MANIFOLD M2 M1 CENTER DECK MANIFOLD OR LC2 OR LC2 LC2 RV1 RV1 RV1 S S S LC1 LC1 LC1 P2 P1 P2 P1 P2 P1 Working Pressure Low Pressure (Charge) Return or Suction Flow P1 M1 Groundsmaster 4100--D Mow Circuit (All Deck Motors Rotating) M2 T ST P2 L FAN DRIVE MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD
Mow Circuit Hydraulic flow for the mow circuit is supplied by two sections of the gear pump. The gear pump section closest to the piston (traction) pump supplies hydraulic flow to the wing decks, while the next gear pump section supplies the center deck. Return oil from the deck motors is directed to the oil cooler and oil filter. Deck motor case drain leakage returns to the hydraulic reservoir. Maximum mow circuit pressure is limited at each deck by a relief valve (RV1) in the hydraulic manifold.
Mow Circuit Cutting Deck Blade Braking When the operator turns the PTO switch OFF or if a deck is raised with the PTO switch ON, deck control manifold solenoid valve (S) is de--energized causing logic cartridge (LC1) to shift (refer to information in PTO Mow Circuit in this section). This shifted cartridge allows oil return out manifold port P2.
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Hydraulic System Page 4 -- 22 Groundsmaster 4100--D M2 M1 M2 M1 M2 M1 LC2 OR LC2 RV2 OR LC2 RH PTO MANIFOLD RV2 LH PTO MANIFOLD RV2 FRONT PTO MANIFOLD RV1 RV1 RV1 S S S LC1 LC1 LC1 P2 P1 P2 P1 P2 P1 Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100--D Steering Circuit (Left Turn Shown) P1 M1 M2 T ST P2 L FAN DRIVE MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD
Steering Circuit A four section gear pump is coupled to the piston (traction) pump. The third gear pump section supplies hydraulic flow to the steering control valve and the lift/lower control valve. Pump hydraulic flow is delivered to the two circuits through a proportional flow divider located in the fan drive manifold. The gear pump takes its suction from the hydraulic reservoir. Steering circuit pressure is limited to 1350 PSI (93 bar) by a relief valve located in the steering control.
Hydraulic System Page 4 -- 24 Groundsmaster 4100--D M2 M1 M2 M1 M2 M1 LC2 OR LC2 RV2 OR LC2 RH PTO MANIFOLD RV2 LH PTO MANIFOLD RV2 FRONT PTO MANIFOLD RV1 RV1 RV1 S S S LC1 LC1 LC1 Working Pressure Low Pressure (Charge) Return or Suction Flow P2 P1 P2 P1 P2 P1 P1 M1 M2 T ST P2 L Groundsmaster 4100--D Engine Cooling Fan Circuit (Forward Direction Shown) FAN DRIVE MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD
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. runs in the reverse direction.
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 Testing section of this chapter.
Hydraulic Test Fitting Kit This kit includes a variety of O--ring Face Seal fittings to enable you to connect test gauges into the system. TORO TEST FITTING KIT (NO. TOR4079) The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Toro Part Number: TOR4079 Figure 18 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 to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the Testing section of this Chapter for precautions and specific test procedures. NOTE: When troubleshooting traction problems on the Groundsmaster 4100--D, if a problem exists in both 4WD and transport speeds, consider a faulty component that affects the entire traction circuit (e.g.
Problem Possible Causes Traction power is lost or unit will not operate in either direction. Hydraulic reservoir oil level is low. Piston pump by--pass valve is open or damaged. Charge pressure is low. Traction circuit pressure is low. Front wheel motor couplers are damaged. Four wheel drive will not engage. Electrical problem exists (see Chapter 5 -- Electrical System). Solenoid valve (SV) in 4WD hydraulic manifold is faulty. Cartridge valve(s) in 4WD manifold is faulty.
Problem Possible Causes Cutting deck (or wing decks) will not raise. Engine RPM is too low. Hydraulic oil level in reservoir is low. Lift arm pivots are binding. Relief valve in lift/lower control valve is stuck. Pilot valve in lift/lower control valve is damaged or sticking. Lift cylinder(s) is (are) damaged. Gear pump section for lift/lower control valve is inefficient. Cutting deck (or wing decks) raise, but will not stay up. NOTE: Lift cylinders cannot provide an absolutely perfect seal.
Testing Before Performing Hydraulic Tests IMPORTANT: All obvious areas such as oil supply, filter, binding linkages, loose fasteners or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem. Precautions for Hydraulic Testing CAUTION Failure to use gauges with recommended pressure (PSI) rating as listed in test procedures could result in damage to the gauge and possible personal injury from leaking hot oil.
Traction Circuit Charge Pressure (Using Pressure Gauge) FROM COUNTERBALANCE MANIFOLD 4WD MANIFOLD FROM FRONT DECK 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 -- 32 FROM DECK MANIFOLDS AND FAN MOTOR FROM DECK MANIFOLDS TO COOLING FAN CIRCUIT Groundsmaster 4100--D
Procedure for Traction Circuit Charge Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 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. 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 FROM COUNTERBALANCE MANIFOLD 4WD MANIFOLD FROM FRONT DECK 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 FROM DECK MANIFOLDS TO COOLING FAN CIRCUIT Hydraulic System Page 4 -- 34 FROM DECK MANIFOLDS AND FAN MOTOR TO STEERING & LIFT CIRCUITS Groundsmaster 4100--D
Procedure for Traction Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 9. When testing is completed, disconnect pressure gauge from test port. 2 CAUTION 1 Move machine to an open area, away from people and obstructions. 2. Drive machine to an open area, lower cutting deck, turn the engine off and engage the parking brake. Figure 22 1. Forward traction port 2.
Hydraulic System Page 4 -- 36 FROM FRONT DECK MANIFOLD FROM RH DECK CIRCUIT FROM RH DECK MANIFOLD P1 M1 M2 T ST TO MOW CIRCUIT TO MOW CIRCUIT P2 FROM DECK MANIFOLDS FAN DRIVE MANIFOLD L FILTER MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD Counterbalance Pressure (Using Pressure Gauge) PRESSURE GAUGE FROM DECK MOTORS Groundsmaster 4100--D
Procedure for Counterbalance Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting deck lowered and off. Make sure engine is off and the parking brake is engaged. Remove console cover. CAUTION C. To decrease pressure setting, turn the adjustment screw on the valve in a counterclockwise direction.
Rear Traction Circuit (RV) Relief Pressure (Using Pressure Gauge) FROM COUNTERBALANCE MANIFOLD PRESSURE GAUGE FROM FRONT DECK FILTER MANIFOLD 4WD 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 -- 38 FROM DECK MANIFOLDS AND FAN MOTOR FROM DECK MANIFOLDS TO COOLING FAN CIRCUIT Groundsmaster 4100--D
Procedure for Rear Traction Circuit (RV) Relief Pressure Test 8. When testing is completed, disconnect pressure gauge from test port. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 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 2 Prevent personal injury and/or damage to equipment.
Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge) FROM COUNTERBALANCE MANIFOLD PRESSURE GAUGE FROM FRONT DECK FILTER MANIFOLD 4WD 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 -- 40 FROM DECK MANIFOLDS AND FAN MOTOR FROM DECK MANIFOLDS TO COOLING FAN CIRCUIT Groundsmaster 4100--D
Procedure for Traction Circuit Reducing Valve (PR) Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. C. Recheck reducing valve (PR) pressure setting and readjust as needed. 9. Disconnect pressure gauge from test port. 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.
Hydraulic System Page 4 -- 42 M2 OR LC2 RV1 RV2 OR LC2 RV1 RH WING DECK MANIFOLD RV2 S S S LC1 LC1 LC1 P2 P1 P2 P1 P2 P1 FROM COOLING FAN CIRCUIT 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 M1 M2 M1 LC2 RV1 LH WING DECK MANIFOLD RV2 PRESSURE GAUGE M2 M1 CENTER DECK MANIFOLD Cutting
Procedure for Cutting Deck Circuit Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting deck lowered and off. Make sure engine is off and the parking brake is engaged. CAUTION 2 1 Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.
TESTER Hydraulic System Page 4 -- 44 M2 LC2 OR LC2 RV2 OR LC2 RH WING DECK MANIFOLD RV2 RV1 RV1 RV1 LH WING DECK MANIFOLD RV2 S S S LC1 LC1 LC1 P2 P1 P2 P1 P2 P1 FROM COOLING FAN CIRCUIT 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 CENTER DECK PTO RELIEF PRESSURE TEST SHOWN M1 M2 M1 M2 M1 CENTER DECK MANIFOLD PTO Relief
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting deck lowered and off. Make sure engine is off and the parking brake is engaged. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 3. Locate deck manifold to be tested (Fig. 34).
Hydraulic System Page 4 -- 46 M2 LC2 RV1 OR LC2 RV1 RV2 OR LC2 RV1 RH WING DECK MANIFOLD RV2 LH WING DECK MANIFOLD RV2 S S S LC1 LC1 LC1 P2 P1 P2 P1 P2 P1 FROM COOLING FAN CIRCUIT 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 GEAR PUMP SECTION FLOW TEST SHOWN M1 M2 M1 M2 M1 CENTER DECK MANIFOLD Cutting Deck Ge
Procedure for Cutting Deck Gear Pump Flow Test NOTE: Over a period of time, the gears and wear plates in the gear pump can wear. A worn pump will by--pass oil and make the pump less efficient. Eventually, enough oil loss will occur to cause the cutting deck motors to stall under heavy cutting conditions. Continued operation with a worn, inefficient pump can generate excessive heat and cause damage to the seals and other components in the hydraulic system. 1.
Hydraulic System Page 4 -- 48 OR LC2 RV2 OR LC2 RV1 RV1 RH WING DECK MANIFOLD RV2 LC2 RV1 S S S LC1 LC1 P2 P1 P2 P1 LC1 P2 P1 FROM COOLING FAN CIRCUIT 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 CENTER CUTTING DECK MOTOR CASE DRAIN LEAKAGE TEST SHOWN M2 M1 M2 M1 RV2 LH WING DECK MANIFOLD M2 M1 CENTER DECK MANIFOLD Cutting Deck Motor Case Drain
Procedure for Cutting Deck Motor Case Drain Leakage Test 6. Sit on seat and operate the engine at full speed (2870 RPM). Move PTO switch to ON. NOTE: Over a period of time, a deck motor can wear internally. A worn motor may by--pass oil to its case drain causing the motor to be less efficient. Eventually, enough oil loss will cause the deck motor to stall under heavy cutting conditions.
Steering Circuit Relief Pressure (Using Pressure Gauge) FROM COUNTERBALANCE MANIFOLD FILTER MANIFOLD 4WD MANIFOLD FROM FRONT DECK LIFT CYLINDERS TO LIFT/LOWER CONTROL VALVE FAN DRIVE MANIFOLD P2 P1 T ST M2 M1 TO MOW CIRCUIT TO MOW CIRCUIT FROM DECK MANIFOLDS L PRESSURE GAUGE Hydraulic System Page 4 -- 50 FROM RH DECK CIRCUIT FROM FRONT DECK MANIFOLD FROM RH DECK MANIFOLD FROM DECK MOTORS Groundsmaster 4100--D
Procedure for Steering Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting deck lowered and off. Make sure engine is off and the parking brake is engaged. 1 CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.
Hydraulic System Page 4 -- 52 FROM FRONT DECK MANIFOLD FROM RH DECK CIRCUIT FROM RH DECK MANIFOLD P1 M1 M2 T ST P2 TO MOW CIRCUIT TO MOW CIRCUIT FROM DECK MANIFOLDS FAN DRIVE MANIFOLD L FILTER MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) PRESSURE GAUGE FROM DECK MOTORS Groundsmaster 4100--D
Procedure for Lift/Lower Circuit Relief Pressure Test 3 NOTE: Before attempting to check or adjust lift pressure, make sure that counterbalance pressure is correctly adjusted. 2 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting deck lowered and off. Make sure engine is off and the parking brake is engaged. 4 1 Figure 41 1. Fan drive manifold 2.
FILTER MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD Steering and Lift/Lower Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter) T ST P1 M2 M1 TO MOW CIRCUIT TO MOW CIRCUIT FROM DECK MANIFOLDS L P2 FAN DRIVE MANIFOLD TESTER Hydraulic System Page 4 -- 54 FROM RH DECK CIRCUIT FROM FRONT DECK MANIFOLD FROM RH DECK MANIFOLD FROM DECK MOTORS Groundsmaster 4100--D
Procedure for Steering and Lift/Lower Gear Pump Flow Test 5. Start the engine and move throttle to full speed (2870 RPM). DO NOT engage the cutting deck. Output from the steering and lift/lower gear pump section is equally divided by a proportional valve to provide flow to the steering circuit and the lift circuit. To test gear pump flow, testing of both steering and lift/lower circuits is required. Total gear pump flow is the combined flow from the two circuits. 6.
Hydraulic System Page 4 -- 56 FROM RH PTO CIRCUIT FROM RH PTO MANIFOLD FROM FRONT PTO MANIFOLD P1 M1 M2 T ST TO MOW MANIFOLD TO MOW MANIFOLD FROM DECK MANIFOLDS P2 FAN DRIVE MANIFOLD L FILTER MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac) FROM DECK MOTORS Groundsmaster 4100--D
Procedure for Engine Cooling Fan Circuit Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2 2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is applied. Raise and support hood. 3 1 CAUTION Prevent personal injury and/or damage to equipment.
FILTER MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD Engine Cooling Fan Circuit Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter) P2 FAN DRIVE MANIFOLD T ST P1 M2 M1 TO MOW MANIFOLD TO MOW MANIFOLD FROM DECK MANIFOLDS L TESTER Hydraulic System Page 4 -- 58 FROM RH PTO CIRCUIT FROM FRONT PTO MANIFOLD FROM RH PTO MANIFOLD FROM DECK MOTORS Groundsmaster 4100--D
Procedure for Engine Cooling Fan Circuit Gear Pump Flow Test 2 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting deck lowered and off. Make sure engine is off and the parking brake is applied. 1 4 CAUTION Prevent personal injury and/or damage to equipment.
Adjustments Adjust Cutting Deck Flow Control Valve The cutting deck lift circuit is equipped with an adjustable flow control valve used to adjust the rate at which the cutting deck lowers. The control valve is located under the front platform. 2 Adjust flow control valve as follows: 1. Run machine to get hydraulic oil at operating temperatures. Park machine on a level surface, shut engine off and lower cutting deck to the ground. 2. Locate valve under front of machine (Fig. 46). 1 3.
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower cutting 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 (oil appears milky, black or contains metal particles). 7. Fill hydraulic reservoir with new hydraulic fluid. 1. Park machine on a level surface. Lower cutting deck to the ground, stop engine and engage parking brake. Remove key from the ignition switch. 9. Turn ignition key switch and engage starter for ten (10) seconds to prime hydraulic pumps. Repeat this step again.
Charge Hydraulic System IMPORTANT: Change hydraulic oil filter whenever hydraulic components are repaired or replaced. 11. After the hydraulic system starts to show signs of fill, actuate lift control lever until the lift cylinder rod moves in and out several times. If the cylinder rod does not move after 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 9 23 10 9 13 12 14 11 27 7 15 1 6 24 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 47 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. 19.
Removal (Fig. 47) 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 suction strainer with solvent. 2. Inspect for leaks, cracks or other damage. Installation (Fig. 47) 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 48 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 -- 66 13. 14. 15. 16. 17. 18.
Removal (Fig. 48) 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. 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 1 11 10 23 15 11 20 32 14 14 33 24 103 to 118 ft--lb (140 to 160 N--m) 4 34 3 2 24 22 21 31 22 30 19 8 17 27 6 7 18 RIGHT 5 16 13 12 79 to 84 ft--lb (108 to 113 N--m) 25 26 9 28 FRONT 79 to 84 ft--lb (108 to 113 N--m) 29 Figure 49 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Removal (Fig 49) Installation (Fig 49) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1. Lubricate new O--rings with clean hydraulic oil and position on pump. 3. Drain the hydraulic reservoir. 4. To prevent contamination of hydraulic system during pump removal, thoroughly clean exterior of pump and fittings. 5.
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 23 22 33 ft--lb (45 N--m) 22 20 Figure 50 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.
3. Secure the front cover of the pump in a vise with the drive shaft pointing down. 4. Loosen the four (4) cap screws that secure pump assembly. 5. Remove pump from vise and remove fasteners. 6. Support the pump assembly and gently tap the pump case with a soft face hammer to loosen the pump sections. Be careful to not drop parts or disengage gear mesh. IMPORTANT: Mark the relative positions of the gear teeth and the thrust plates so they can be reassembled in the same position.
Traction Circuit 9 4 RIGHT 6 FRONT 8 1 2 5 7 3 Figure 52 1. Piston (traction) pump 2. Gear pump 3. LH front wheel motor 4. Check valve 5. RH front wheel motor 6. 4WD manifold 7. Filter manifold 8. Rear axle motor 9. Cooling fan motor Figure 52 illustrates the components that are used in the Groundsmaster 4100--D traction circuit. Procedures for removal, installation and disassembly/assembly of these components are provided on the following pages of this section.
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Piston (Traction) Pump 1 11 10 23 15 11 20 32 14 14 33 24 103 to 118 ft--lb (140 to 160 N--m) 4 34 3 2 24 22 21 31 22 30 19 8 17 27 6 7 18 RIGHT 5 16 13 12 79 to 84 ft--lb (108 to 113 N--m) 25 26 9 28 FRONT 79 to 84 ft--lb (108 to 113 N--m) 29 Figure 53 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 3. Install gear pump to piston pump (see Gear Pump Installation). 4. Position traction rod to control arm on piston pump by installing cap screw, spacer and lock nut (Fig. 54). 2. To prevent contamination of hydraulic system during removal, thoroughly clean exterior of pump assembly. 5. Connect wire harness connector to neutral switch on traction pump. 3.
Piston (Traction) Pump Service 100 to 110 ft--lb (136 to 149 N--m) 27 to 31 ft--lb (37 to 42 N--m) 16 20 150 to 160 in--lb (17 to 18 N--m) 38 18 100 to 110 ft--lb (136 to 149 N--m) 15 14 1 29 40 to 48 in--lb (4.5 to 5.4 N--m) 26 4 22 45 10 33 28 27 23 17 8 30 7 5 4 to 6 ft--lb (5 to 8 N--m) 34 43 35 31 32 44 36 11 40 to 48 in--lb (4.5 to 5.4 N--m) 37 19 25 to 28 ft--lb (34 to 38 N--m) 42 41 40 6 31 5 39 37 21 12 40 to 48 in--lb (4.5 to 5.
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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 56 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. Pinion gear External snap ring (2 used) Gear Needle bearing O--ring O--ring O--ring Page 4 -- 78 15. 16. 17. 18. 19. 20. 21.
Removal (Fig. 56) Installation (Fig. 56) 1. Park machine on a level surface, lower cutting deck, stop engine, apply 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 10 15 12 11 13 7 11 13 14 Arrow on side of motor case points up 15 16 1 8 19 6 15 RIGHT 12 75 to 85 ft--lb (101 to 115 N--m) 2 16 17 5 13 9 FRONT 20 3 Figure 57 1. 2. 3. 4. 5. 6. 7. Front wheel motor Internal retaining ring Splined brake shaft RH brake assembly Planetary assembly Cap screw (2 used per motor) Flat washer (2 used per motor) Hydraulic System 8. 9. 10. 11.
Removal (Fig. 57) Installation (Fig. 57) 1. Park machine on a level surface, lower cutting deck, stop engine, apply 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).
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 58 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 19 13 4 5 3 11 9 6 8 7 9 10 10 17 16 11 7 4 13 12 14 15 11 RIGHT 1 FRONT 18 Figure 59 1. 2. 3. 4. 5. 6. 7. Frame assembly 4 wheel drive manifold 90o hydraulic fitting O--ring O--ring Quick fitting O--ring Hydraulic System 8. 9. 10. 11. 12. 13. Fitting cap Hydraulic fitting O--ring O--ring 90o hydraulic fitting O--ring Page 4 -- 84 14. 15. 16. 17. 18. 19.
Removal (Fig. 59) Installation (Fig. 59) 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 9 -Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port). 1. Install hydraulic manifold to the frame using Figure 59 as guide. 2. Remove caps and plugs from fittings and hoses.
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 60 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. 60) 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 handling the valve cartridge. Slight bending or distortion of the stem tube can cause binding and malfunction. 3. Remove cartridge valve with a deep socket wrench. Note correct location for O--rings, sealing rings and backup rings. Remove and discard seal kit. A.
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 61 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. 61) Installation (Fig. 61) 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 62 1. Filter manifold 2. Check valve (reservoir return) 3. Oil filter element 4. Check valve (filter bypass) 5. Plug (Zero Leak #6) 6. Charge relief valve 7. Plug (Zero Leak #8) NOTE: The ports on the manifold are marked for easy identification of components.
Filter Manifold Service (Fig. 62) Hydraulic System For cartridge valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 62 for filter manifold cartridge valve and plug installation torque.
Steering and Cooling Fan Circuits RIGHT 4 FRONT 3 2 1 5 Figure 63 1. Gear pump 2. Steering control valve 3. Fan drive manifold 4. Fan motor 5. Steering cylinder Figure 63 illustrates the components that are used in the Groundsmaster 4100--D steering and cooling fan circuit. Procedures for removal, installation and disassembly/ assembly of these components are provided on the following pages of this section.
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Steering Valve 24 23 1 3 2 22 29 4 28 27 25 5 21 12 26 6 8 20 16 to 20 ft--lb (22 to 27 N--m) 19 18 7 17 16 15 RIGHT 9 10 11 9 12 13 11 14 FRONT Figure 64 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Hex nut Flat washer Steering wheel Foam collar Steering seal External snap ring Steering shaft assembly Steering tower cover O--ring 90o hydraulic fitting Hydraulic System 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Removal (Fig. 64) Installation (Fig. 64) 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 steering valve, 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). 2.
Steering Valve Service 8 1 3 24 2 4 5 20 19 23 6 7 19 22 21 150 in--lb (17 N--m) 9 10 14 18 17 16 13 12 11 140 to 160 in--lb (16 to 18 N--m) 15 Figure 65 1. 2. 3. 4. 5. 6. 7. 8. Steering valve housing Dust seal O--ring Spool Spring retaining ring Pin Sleeve Centering springs/spacers 9. 10. 11. 12. 13. 14. 15. 16. Cap screw (7 used) End cap O--ring Seal ring O--ring Geroter O--ring Spacer Disassembly (Fig.
8. Put the thrust bearing and races into the housing. The thrust bearing goes between the two races (Fig. 66). The centering springs are under tension. Remove the retaining ring carefully. IMPORTANT: Do not damage the dust or quad seals when installing the spool and sleeve assembly. 10.Remove the spring retaining ring and centering springs from the spool. 9. Apply a light coating of clean hydraulic fluid to the spool and sleeve assembly and carefully slide the assembly into the housing.
Steering Cylinder 9 6 4 7 9 1 8 5 2 4 3 10 See text for tightening procedure 12 13 14 11 RIGHT See text for tightening procedure FRONT Figure 67 1. 2. 3. 4. 5. Steering cylinder Ball joint Ball joint Retaining ring Grease fitting Hydraulic System 6. 7. 8. 9. 10. Grease fitting 90o hydraulic fitting O--ring O--ring Drive axle assembly Page 4 -- 98 11. 12. 13. 14.
Removal (Fig. 67) Installation (Fig. 67) 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 68 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 -- 100 9. 10. 11. 12.
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. 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. Mount cylinder in a vise so rod end of cylinder is tilted up slightly. Do not close vise so firmly that cylinder tube could become distorted. 3. Loosen head from tube: A.
Engine Cooling Fan Motor 4 27 to 33 ft--lb (37 to 44 N--m) 3 2 1 5 21 6 20 7 8 2 9 4 10 5 19 18 13 14 15 16 17 12 11 12 to 14 ft--lb (17 to 18 N--m) RIGHT FRONT Figure 69 1. 2. 3. 4. 5. 6. 7. Hydraulic fan motor O--ring Bracket 45o hydraulic fitting O--ring Hydraulic hose Fan hub Hydraulic System 8. 9. 10. 11. 12. 13. 14. Washer Hex nut Engine Cap screw (4 used) Washer (4 used) Fan Lock nut (2 used) Page 4 -- 102 15. 16. 17. 18. 19. 20. 21.
1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3. Unlatch and raise hood. 4. Remove air cleaner hose and upper radiator shroud to allow easier access to hydraulic fan motor (Fig. 70). CAUTION The radiator and oil cooler may be hot.
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 71 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 (2 used) Drive gear Washer (4 used) Disassembly (Fig. 71) 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. 3 9. Turn front flange over, with seal side up. 2 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. 74). Discard seals. 1 Inspection 4 1. Remove any nicks and burrs from all parts with emery cloth. 1. 2. Gear shaft spline Gear shaft CAUTION 1 Figure 73 3. 4.
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 75 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. 75) Installation (Fig. 75) 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.
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 76 1. 2. 3. 4. Fan drive manifold #4 zero leak plug (3 used) Check valve #6 zero leak plug (2 used) 5. Flow divider valve 6. Nut 7. Solenoid coil (2 used) 8.
Fan Drive Manifold Service (Fig. 76) Hydraulic System For cartridge valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 76 for fan drive manifold cartridge valve and plug installation torque.
Mow Circuit 9 RIGHT FRONT 4 2 6 1 8 7 5 3 Figure 77 1. Gear pump 2. RH wing deck motor 3. LH wing deck motor 4. RH Wing Deck manifold 5. Front cutting deck motor 6. LH Wing Deck manifold 7. Front Deck manifold 8. Filter manifold 9. Oil cooler Figure 77 illustrates the components that are used in the Groundsmaster 4100--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. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of this section. 5. Remove caps or plugs from fittings and hoses. Connect hydraulic hoses to deck motor. 6.
Cutting Deck Motor Service 15 12 27 to 33 ft--lb (37 to 45 N--m) 9 10 10 14 15 13 9 1 8 7 6 15 5 11 8 4 33 to 40 ft--lb (45 to 55 N--m) 2 3 Figure 80 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. 80) 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. 82). 9. Carefully remove and discard O--rings, pressure seals and back--up rings (Fig. 83) from motor. Do not cause any damage to the machined grooves during the removal process.
Assembly (Fig. 80) 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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Deck Manifolds 16 4 6 10 25 8 16 20 2 11 14 13 12 14 21 22 19 18 6 17 4 4 16 6 2 4 16 6 17 13 10 23 7 6 4 18 24 6 11 13 12 4 14 8 9 8 10 1 2 5 8 11 15 14 12 25 6 3 RIGHT FRONT Figure 85 1. 2. 3. 4. 5. 6. 7. 8. 9. Center deck manifold O--ring Hydraulic adapter O--ring Straight hydraulic fitting O--ring 90o hydraulic fitting O--ring Hydraulic tee fitting Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17.
Removal (Fig. 85) Installation (Fig. 85) NOTE: The ports on the manifold are marked for easy identification of components. Example: SV1 is the deck solenoid valve and P1 is a gear pump connection port. (See Hydraulic Schematic in Chapter 9 -- 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.
Deck 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 86 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. Relief valve (port RV2) Solenoid valve (port S) Solenoid coil Nut 9. Relief valve (port RV1) 10.
PTO Manifold Service (Fig. 86) Hydraulic System For solenoid and control valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 86 for PTO manifold cartridge valve and plug installation torque.
Lift/Lower Circuit 1 RIGHT 5 FRONT 7 4 8 6 7 2 3 Figure 87 1. Counterbalance manifold 2. RH wing deck lift cylinder 3. LH wing deck lift cylinder 4. Fan drive manifold 5. Lift control valve 6. Front deck flow control valve 7. Front lift cylinder 8. Oil filter Figure 87 illustrates the components that are used in the Groundsmaster 4100--D cutting deck lift and lower circuits.
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Lift/Lower Control Valve 25 13 17 16 14 24 18 18 19 28 1 2 29 27 28 26 23 17 20 17 21 22 12 RIGHT FRONT 11 10 9 6 8 7 5 4 3 15 Figure 88 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Control valve assembly Valve bracket Isolator (6 used) Cap screw Lock nut (2 used) Pivot bracket LH lever assembly Lever link (3 used) Center lever assembly Cotter pin (6 used) Hydraulic System 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Removal (Fig. 88) Installation (Fig. 88) 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 control valve, 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.
Lift/Lower Control Valve Service 6 32 20 34 13 14 15 31 10 7 11 23 27 21 22 24 17 18 35 3 36 28 5 33 4 25 1 11 8 16 19 2 12 26 20 to 25 ft--lb (27 to 33 N--m) 9 30 29 Figure 89 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Poppet Spacer Wiper seal Seat O--ring Plug (3 used) O--ring Bushing Spool cap (3 used) Relief valve poppet O--ring Retaining ring Hydraulic System 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Disassembly (Fig. 89) Assembly (Fig. 89) 1. Plug all ports and clean outside of valve thoroughly. 1. Thoroughly clean and dry all parts. Apply a light coating of clean hydraulic oil to all control valve parts prior to assembly. NOTE: Spools and spool bores are matched sets. Be sure each spool is identified with the correct valve body spool bore. 3. Remove spools (item 35) from valve body (item 36). 4. Remove bushings (item 8) and O--rings (item 11) from spools. 5. Remove plugs (item 6).
Front Deck Lift Cylinder 10 9 7 8 RIGHT 11 9 12 7 FRONT 6 13 5 1 4 2 3 Figure 90 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 -- 128 10. 11. 12. 13.
Removal (Fig. 90) Installation (Fig. 90) 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 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.
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 91 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 -- 130 10. 11. 12. 13.
Removal (Fig. 91) Installation (Fig. 91) 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. 3. Remove deck covers as needed to allow access to lift cylinder hoses and fasteners. 4. To prevent contamination of hydraulic system during lift cylinder removal, thoroughly clean exterior of cylinder and fittings.
Deck Lift Cylinder Service 100 to 120 ft--lb (136 to 162 N--m) FRONT DECK LIFT CYLINDER 12 11 3 8 2 1 13 10 9 6 7 5 4 Figure 92 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 Locking nut Seal with loader WING DECK LIFT CYLINDER 11 8 2 4 3 1 10 9 6 7 5 Figure 93 1. 2. 3. 4.
Disassembly (Figs. 92 and 93) Assembly (Figs. 92 and 93) 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.
Counterbalance Manifold 12 16 15 10 13 9 5 14 1 RIGHT 2 FRONT 10 11 10 8 9 3 4 7 6 5 Figure 94 1. 2. 3. 4. 5. 6. Counterbalance hydraulic manifold Valve plate Flat washer (2 used) Cap screw (2 used) Isolator (4 used) Flat washer (2 used) 7. 8. 9. 10. 11. Lock nut (2 used) Hydraulic fitting (2 used) O--ring O--ring 90o hydraulic fitting (4 used) 12. 13. 14. 15. 16.
Removal (Fig. 94) Installation (Fig. 94) 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.
Counterbalance Manifold Service 35 to 40 ft--lb (47 to 54 N--m) 2 35 to 40 ft--lb (47 to 54 N--m) 4 35 to 40 ft--lb (47 to 54 N--m) 2 3 5 3 1 UP FRONT Figure 95 1. Manifold body 2. Pilot valve 3. Seal kit 4. Relief valve (counterbalance) NOTE: The ports on the manifold are marked for easy identification of components.
Chapter 5 Electrical System Table of Contents Groundsmaster 4100--D Audio Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow and Power Relays . . . . . . . . . . . . . . . . . . . . . Start, Engine Shutdown, Seat, Alarm, PTO, PTO Overtemp, Down Latching and Over Temperature Relays . . . . . . . . . . . . . . . . . . . . . . Hydraulic Valve Solenoids . . . . . . . . . . . . . . . . . . . TEC--5002 Controller . . . . . . . . . . . . . . . . . . . . . . . Fuel Sender . . . . . . . . .
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. Electrical Drawings The electrical schematic, circuit diagrams and wire harness drawings for the Groundsmaster 4100--D are located in Chapter 9 -- Foldout Drawings.
Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The meter can test electrical components and circuits for current, resistance or voltage. NOTE: Toro recommends the use of a DIGITAL Volt-Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter.
Dielectric Gel Dielectric gel should be used to prevent corrosion of connection terminals. To ensure complete coating of terminals, liberally apply gel to both component and wire harness connector, plug connector to component, unplug connector, reapply gel to both surfaces and reconnect harness connector to component. Connectors should be thoroughly packed with gel for effective results.
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 and circuit diagrams in Chapter 9 -- 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.
Problem Possible Causes Engine cranks, but does not start. Engine is not cranking fast enough. The engine run solenoid or circuit wiring is faulty. The fuel pump is faulty. An engine problem exists (see Chapter 3 -- Kubota Engine). Starter cranks, but should not when the traction pedal is depressed. The traction neutral switch is out of adjustment. The traction neutral switch or circuit wiring is faulty.
Cutting Deck Operating Problems The cutting deck remains engaged, but should not, with no operator in the seat. The seat switch or circuit wiring is faulty. Cutting deck runs, but should not, when raised. Deck shuts off with PTO switch. The deck position switch or circuit wiring is faulty. Cutting deck runs, but should not, when raised. Deck does not shut off with the PTO switch. The deck position switch or circuit wiring and PTO switch or circuit wiring are faulty.
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. 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. Connect the positive (+) meter lead to the positive battery post and the negative (--) meter lead to the negative battery post. Voltage Measured Battery Charge Level 12.
Adjustments Wing Deck Position Switches Adjustment 5 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove switch cover from deck to allow access to position switch that requires adjustment. NOTE: Use Deck Proximity Switch Adjustment Tool (TOR4095) to assist with switch adjustment (see Special Tools). 4 3. Loosen two (2) lock nuts that secure switch bracket to center cutting deck (Fig. 7). 3 2 4.
Cutting Deck Raise and Lower Switches Adjustment (Fig. 9) 1 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. Remove console housing. 2 3 5 4 6 2. The cutting deck raise and lower switches can be adjusted for correct operation by repositioning the switch(es). 7 A. The distance between switches should be from 0.595” to 0.655” (15.2 to 16.6 mm) (Fig. 10). B.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check). NOTE: For engine component testing information, see the Kubota Workshop Manual, Diesel Engine, V2403--M--T--E3B Series at the end of Chapter 3 -- Kubota Diesel Engine.
Fuses The fuse blocks are located under the operator’s control console. 10A 10A 15A OPT B 10A A 10A The fuses are held in three (3) fuse blocks. Use Figures 13 and 14 to identify each individual fuse and its correct amperage. Each fuse holder has the following functions and wire connected to it. 5A Identification, Function and Wiring Fuse F1 (5 amp) (fuseblock location A1): Supplies power to the seat switch and seat relay.
Warning Lights Engine Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON position with the engine not running. Also, it should light with the engine running if the engine oil pressure drops below 7 PSI (0.5 kg/cm2). 3 1. Disconnect green wire from the oil pressure switch on the engine (located near the starter motor). 4 2 2. Ground green wire to the engine block. 1 3.
PTO Switch The PTO switch is used to engage or disengage the cutting deck. The PTO switch is attached to the control console next to the operator seat (Fig. 17). 2 1 The switch terminals are marked as shown in Figure 18. The circuitry of the PTO switch is shown in the chart below. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each position. Verify continuity between switch terminals.
Transport / 4WD Switch The transport/4WD switch is used to set the machine traction speed for transport or mow. The transport/4WD rocker switch is located on the control console next to the operator seat (Fig. 21). 1 Testing The switch terminals are shown in Figure 22. The circuitry of the switches is shown in the chart below. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each position.
Cooling Fan Switch The cooling fan switch is used to control the operation of the hydraulic cooling fan and is located on the control console (Fig. 23). This switch has three (3) positions: Reverse, Auto and Forward. When the cooling fan switch is in the normal Auto position, cooling fan operation is controlled by the TEC--5002 controller.
Seat Switch The seat switch is normally open and closes when the operator is on the seat. 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 seat wire from the machine wiring harness (Fig. 25). 2 Testing 1 1. Make sure the engine is off. 2.
Parking Brake Switch The switch used for the parking brake is a normally open switch that is located under the steering tower cover (Fig. 26). 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. Make sure the engine is off. Locate parking brake switch for testing. 2.
Hour Meter The hour meter is located on the control console next to the operator seat. Testing 1. Disconnect wire harness connector from hour meter. 2. Connect the positive (+) terminal of a 12 VDC source to the positive (+) terminal of the hour meter. 1 3. Connect the negative (--) terminal of the voltage source to the other terminal of the hour meter. 4. The hour meter should move a 1/10 of an hour in six (6) minutes. 2 Figure 27 1. Positive (+) terminal 2. Negative (--) terminal 5.
Glow and Power Relays The Groundsmaster 4100--D uses two (2) identical relays to control electrical power circuits. The glow relay is attached to the the right side of the fuel tank support under the hood. The power relay is attached to the control panel under the console housing. The glow relay supplies electrical power for the engine glow plugs when energized. The start relay is energized by the glow plug controller.
Start, Engine Shutdown, Seat, Alarm, PTO, PTO Overtemp, Down Latching and Over Temperature Relays These eight (8) relays are located under the console housing cover (Fig. 30). The wiring harness is tagged to identify each relay. 1 Testing 1. Make sure that ignition switch is OFF. 2 2. Locate relay and disconnect the machine wire harness connector from the relay. Remove relay from machine if necessary.
Hydraulic Valve Solenoids 1 3 5 RIGHT FRONT 2 4 Figure 32 1. 4WD manifold 2. LH deck manifold 3. RH deck manifold 4. Front deck manifold There are several hydraulic valve solenoids on the Groundsmaster 4100--D (Fig. 32). Testing of these solenoids can be done with the solenoid on the hydraulic valve. Testing 5. Fan drive manifold 3. Install new solenoid if necessary. Torque solenoid nut to 5 ft--lb (6.7 N--m). Over--tightening may damage the solenoid or cause the cartridge valve to malfunction. 4.
TEC--5002 Controller Groundsmaster 4100--D machines use a Toro Electronic Controller (TEC) to control the operation of the hydraulic cooling fan. The controller is attached to the operator platform under the console housing cover (Fig. 34). 1 Logic power is provided to the controller as long as the battery cables are connected to the battery. A 2 amp fuse in a fuse holder near the battery provides circuit protection for this logic power to the controller.
Fuel Sender The fuel sender is located on top of the fuel tank. Testing 1. Remove white wire and black ground wire from the sender. CAUTION FULL POSITION EMPTY POSITION If testing circuit wiring and fuel gauge, make sure wire connections are secure before turning ignition switch ON to prevent an explosion or fire from sparks. Figure 35 2. To test the circuit wiring and fuel gauge, connect white and black wires and turn ignition switch to ON.
Fuel Gauge The fuel gauge can be tested using a new gauge as a substitute or with the use of a DC voltage source and a variable resistance box (see Fuel Sender Testing in this section for additional information). Testing CAUTION Make sure the voltage source is turned OFF before connecting it to the electrical circuit to avoid electrical shock and prevent damaging the gauge. VARIABLE RESISTANCE 14 VDC + 0.01 VDC -- 1. Connect fuel gauge to the variable resistance and DC voltage source (Fig. 36).
Fuel Pump The fuel pump is attached to the frame above the fuel water separator (Fig. 38). 3 2 Operational Test 1. Park machine on a level surface, lower cutting deck, stop engine and apply parking brake. 2. Disconnect wire harness electrical connector from the fuel stop solenoid to prevent the engine from firing. 3. Disconnect fuel hose (pump discharge) from the fuel water separator. 4. Make sure fuel hoses attached to the fuel pump are free of obstructions. 5.
Glow Controller The glow controller is located under the console cover (Fig. 39). 1 NOTE: Refer to electrical schematic and circuit drawings in Chapter 9 -- Foldout Drawings when troubleshooting the glow controller. 2 Glow Controller Operation 1. When the ignition switch is placed in the ON position, the controller energizes the glow plugs and lights up the glow lamp for approximately 10 seconds. 2.
Temperature Sender The temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 41). The resistance of the temperature sender reduces as the engine coolant temperature increases. There is a gray harness wire attached to the terminal of the switch. 1 Testing 1. Lower coolant level in the engine and remove the temperature sender from water flange. 2 2. Suspend sender in a container of oil with a thermometer and slowly heat the oil (Fig. 42).
Dual Temperature Switch The dual temperature switch is attached to the engine near the alternator on the water flange attached to the engine cylinder head (Fig. 43). Two (2) electrical harness wires (a blue wire and a yellow wire) are attached to the switch. The terminal on the switch is used to activate the engine over temperature warning. The warning illuminates the overtemp warning light and also causes the PTO to disengage. The wire harness blue wire attaches to the switch terminal. B.
Temperature Gauge The temperature gauge can be tested using a new gauge as a substitute or with the use of a DC voltage source and a variable resistance box. Testing CAUTION Make sure the voltage source is turned OFF before connecting variable resistance to the electrical circuit to avoid electrical shock and to prevent damaging the gauge. VARIABLE RESISTANCE 14 VDC + 0.01 VDC 1. Connect temperature gauge to the variable resistance and DC voltage source (Fig. 46).
Traction Neutral Switch The traction neutral switch is closed when the traction pedal is in the neutral position and opens when the pedal is depressed in either direction. The switch is located on the right side of the piston (traction) pump (Fig. 48). Testing Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester across the two switch terminals.
Diode Circuit Board The diode circuit board (Fig. 50) contains four (4) diodes and is located under the console housing. Diode D1--A provides logic for the interlock system. Diodes D1--B (right wing deck), D1--C (front deck) and D1--D (left wing deck) provide latching circuits for the PTO relay. H F D1--A D1--C D1--D D1--A The diodes can be individually tested using a digital multimeter (ohms setting) and the table to the right.
Fusible Links The Groundsmaster 4100--D uses five (5) fusible links for circuit protection. Three (3) of these fusible links are located in a harness that connects the starter B+ terminal to the wire harness (Fig. 51). An additional fusible link is used that connects the starter B+ terminal to the alternator B+ terminal (Fig. 52). The remaining fusible link is included in the wire harness and connects the starter terminal to the engine run solenoid pull coil.
Wing Deck Position Switches The wing deck position switches on the Groundsmaster 4100--D are attached to the center deck housing (Fig. 53) and are normally open. The wing deck position switch is a powered proximity switch that incorporates an internal reed switch and relay (see schematic in Figure 54). The actuator for the position switch is bolted to the wing deck link (Fig. 55).
Cutting Deck Raise and Lower Switches The deck raise and lower switches are normally open proximity switches that are located under the console housing (Fig. 56). These identical switches are mounted in opposite directions so their circuit logic differs. The actuator for the switches is on the center deck lift/lower lever. The raise and lower switches are used in conjunction with the down latching relay to provide current to the PTO switch.
Engine Coolant and Hydraulic Oil Temperature Senders The Groundsmaster 4100--D uses 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, see the Kubota Workshop Manual, Diesel Engine, V2403--M--T--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 CAUTION 1 When working with batteries, use extreme caution to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries. 3 Electrolyte Specific Gravity Fully charged: 1.
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 To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which is readily available locally. 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.
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 75 to 85 ft--lb (101 to 115 N--m) 3 11 4 5 16 5 7 8 RIGHT 17 18 15 3 FRONT 6 9 75 to 85 ft--lb (101 to 115 N--m) 1. 2. 3. 4. 5. 6. Planetary assembly Retaining ring Splined brake coupler Brake assembly (RH) O--ring Hydraulic wheel motor 1 10 7. 8. 9. 10. 11. 12.
3. Chock rear wheels and jack up front of machine (see Jacking Instructions in Chapter 1 -- Safety). Support machine with suitable jack stands. 4. Remove front wheel assembly. 5. Remove hydraulic wheel motor (see Front Wheel Motors in Service and Repairs section of Chapter 4 -Hydraulic System). 6. Disconnect brake cable from pull rod on brake assembly. 8. Make sure drain plug is installed in bottom of brake assembly (Fig. 3). Fill planetary wheel drive/brake assembly with SAE 85W--140 gear lube.
Brake Service 3 2 1 4 5 5 6 7 8 7 8 7 15 14 10 13 12 11 7 8 9 1. 2. 3. 4. 5. Brake housing (LH shown) Seal Pull rod Clevis pin (2 used) Link 6. 7. 8. 9. 10. Figure 5 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. 5) 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 6 1. 2. 3. 4. 5. Planetary assembly Retaining ring Splined brake coupler Brake assembly (RH) O--ring Axles, Planetaries and Brakes 6. 7. 8. 9. 10. Hydraulic wheel motor Flat washer Cap screw (2 used per side) Flange head screw (4 used per side) Brake assembly (LH) Page 6 -- 8 11. 12. 13. 14.
Removal (Fig. 6) 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 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 8 1. 2. 3. 4. 5. 6. 7. 8. Spindle Boot seal Bearing cone Bearing cup Wheel stud (8 used) Housing Bearing cup Bearing cone Axles, Planetaries and Brakes 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 Page 6 -- 10 17. 18. 19. 20. 21. 22. 23. 24.
NOTE: The planetary wheel drive assembly can be serviced with the planetary installed to machine. If the spindle (item 1) needs to be removed from machine, see Planetary Wheel Drive Assembly Removal in this section. 3 1 2 24 4 7 19 20 8 12 21 11 14 Disassembly (Figs. 8 and 9) 15 1. If planetary wheel drive assembly is installed on machine: 17 A. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch. 16 B.
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 10 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. 10) 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. 12). 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 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.
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. 15). 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. 18). 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. 20). 3 2 1 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. 21). Tighten cover screws from 17 to 20 ft-lb (23 to 27 N--m). 3. Shaft seal 7 8 3. Slide the bevel gear case over the bevel gear shaft and install the bevel gear and collar.
5. Determine necessary quantity of support shims. 4 A. Lubricate the axle case support bushing with a thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during disassembly between axle case support and axle case. Install mounting screws into axle case. Slowly tighten screws while frequently checking for clearance (vertical endplay) between axle case support and knuckle pin.
9. Remove the bevel gear case/axle case assembly from the axle support. Coat a new O-ring with grease and temporarily install the axle cover assembly. Position a dial indicator at the tooths center. Prevent the axle from turning and measure the lower bevel gear to axle gear backlash (Fig. 24). LOWER BEVEL GEAR BACKLASH: 0.004 to 0.016 in. (0.10 to 0.40 mm) 11. Tighten axle cover screws from 17 to 20 ft-lb (23 to 27 N--m). 12.
Differential Shafts The following procedures assume the rear axle assembly has been removed from the machine (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. 25). 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. 27). 2. Use a bearing puller to remove the bearing and bevel gear as shown (Fig. 28). 3. Remove the shims, spacer and retaining ring. Drive the axle out of the bearing and cover.
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 30 1. 2. 3. 4. 5. 6. Nut (2 used) Lockwasher (2 used) Stud (2 used) Locknut Stake washer Oil seal 7. 8. 9. 10. 11. 12. O-ring Seal collar Bearing O-ring Input shaft/pinion gear Bearing case 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. 32). 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. 37). 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 tighten the mounting screws from 22 to 25 ft-lb (30 to 34 N--m). 2 1 2. Apply molybdenum disulfide grease to the splines and bearing surfaces of the differential pinion gears, pinion washers and side gears. 3. Install the side gear shims and side gears in their original location in the differential case. 4.
Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using the gear contact pattern method as described in the following procedure. PROFILE TOP LAND GEAR TOOTH DEFINITIONS (Fig. 41): 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. 44): A. Install thicker or additional bearing case shim(s) to move pinion shaft toward ring gear. Figure 44 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 Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operator Seat Service . . . . . . . . . . . . . .
Service and Repairs Steering Tower 39 24 25 2 23 26 27 33 34 35 36 37 4 5 6 41 7 21 40 22 1 3 8 28 9 10 29 30 31 11 12 13 14 32 16 to 20 ft--lb (22 to 27 N--m) 41 15 16 17 18 19 38 20 21 RIGHT FRONT Figure 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Hex nut Flat washer Steering wheel Foam collar Steering seal External snap ring (2 used) Knob Steering tower cover Steering shaft Compression spring Cap Rod assembly Extension spring Tilt rod Chassis 15. 16. 17. 18. 19. 20. 21.
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 washer(s) (item 24) on steering column are used as needed to remove end play of steering shaft.
Cutting Deck Lift Arms 8 38 Loctite 242 on threads 60 to 70 ft--lb (81 to 94 N--m) 9 10 11 RIGHT 30 to 40 ft--lb (41 to 54 N--m) 12 14 15 16 17 18 19 20 21 22 FRONT 23 3 13 6 11 36 25 16 32 26 4 5 35 33 24 25 16 7 2 1 27 30 28 29 31 34 155 to 185 ft--lb (211 to 251 N--m) 16 37 75 to 85 ft--lb (102 to 115 N--m) Figure 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
E. Thoroughly clean tapered surfaces of stud and mounting boss of support hub. Secure support hub (position slotted hole in hub toward rear of deck) to tapered stud with flat washer and flange nut. Tighten flange nut from 155 to 185 ft--lb (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.
Operator Seat 1 7 9 17 8 10 14 2 5 11 6 3 13 15 2 18 12 8 16 21 22 23 20 24 4 RIGHT 19 FRONT Figure 5 1. 2. 3. 4. 5. 6. 7. 8. Seat assembly Flat washer (5 used) Seat belt Cap screw (4 used) Seat platform Flange nut (4 used) Seat belt buckle Cap screw (2 used) Chassis 9. 10. 11. 12. 13. 14. 15. 16. R--clamp (2 used) Manual tube Screw Lock nut Seat belt mount Lock washer (2 used) R--clamp (2 used) Wire harness seat switch lead Page 7 -- 6 17. 18. 19. 20. 21. 22. 23. 24.
Removal (Fig. 5) 1 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2 2. Remove seat from seat suspension: A. Disconnect seat electrical connectors from machine wire harness (Fig. 6). 3 B. Remove four (4) Torx head screws that secure seat to seat suspension (Fig. 7). Note that the screw near the seat adjustment handle is longer than the other three (3) screws. C. Lift seat from seat suspension and remove from machine.
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 8 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 -- 8 21. 22. 23.
Assembly (Fig. 8) 1. Disassemble operator seat as necessary using Figure 8 as a guide. 1. Assemble operator seat using Figure 8 as a guide. Chassis Disassembly (Fig.
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 9 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. 9) 1. Remove operator seat from seat suspension (see Operator Seat Removal in this section). 3 2.
Hood 5 35 RIGHT 33 36 FRONT 1 2 34 37 42 13 29 39 6 7 38 3 40 41 28 8 43 9 25 26 27 31 11 10 12 3 10 4 30 14 47 3 32 15 16 18 17 19 21 46 22 45 24 17 23 15 20 44 Figure 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
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 11 as a guide. Installation 2 1. Install hood using Figure 11 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. 12 and 13). 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 hydraulic lift levers. 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. 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 38 19 8 52 FRONT 42 29 9 11 18 52 53 54 10 28 23 39 36 24 5 32 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) 3 1. Position machine on a clean, level surface. Lower cutting deck and engage parking brake. 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 a hardened spacer (item 42) on each side of the front link. Use one or two thrust washers on rear side of assembly so that link is snug between deck brackets. B. Place a thrust washer (item 6) on each side of rear link. 6. Secure pins with carriage screw and flange head screw. 7.
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. 1 2. Install cutting blade, anti--scalp cup and blade bolt. Tighten blade bolt from 88 to 108 ft--lb (119 to 146 N--m). 3. Slowly rotate cutting blades to verify that blades do not contact any deck component(s). 2 1 4. Install drive belt and adjust belt tension (see Idler Assembly Installation in this section). Figure 14 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 Stop bolt Flange nut Cap screw Spacer Shoulder bolt 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 6 RIGHT 7 4 3 FRONT 2 1 Figure 23 1. 2. 3. 4. Roller Flange head screw Roller shaft Flange nut 5. 6. 7. Lock nut Roller Cap screw 8. Flange nut 9. Skid (RH shown) 10. Flange head screw Removal (Fig. 23) Installation (Fig. 23) 1. Remove skids and rollers from deck using Figure 23 as a guide. 1. Install skids to deck using Figure 23 as a guide. Make sure to install skids in the same mounting hole height position (lower or upper). 2.
Chapter 9 Foldout Drawings Table of Contents Foldout Drawings HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL SCHEMATIC Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CIRCUIT DIAGRAMS Glow Plug Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Crank Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Run (Transport) Circuits . . . . .
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CENTER DECK MANIFOLD COUNTERBALANCE MANIFOLD LH WING DECK MANIFOLD 4WD MANIFOLD RH WING DECK MANIFOLD FAN DRIVE MANIFOLD FILTER MANIFOLD Groundsmaster 4100--D Hydraulic Schematic Page 9 - 3
CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) 2WD SOLENOID PTO OVERTEMP SHUTDOWN RELAY CONTINUES TO SHEET 2 Groundsmaster 4100--D Electrical Schematic Sheet 1 of 2 All relays and solenoids are shown as de-- energized. All ground wires are black.
CONTINUES FROM SHEET 1 CONTINUES FROM SHEET 1 COOLING FAN SWITCH POWER RELAY CONTINUES FROM SHEET 1 CONTINUES FROM SHEET 1 Groundsmaster 4100--D Electrical Schematic Sheet 2 of 2 All relays and solenoids are shown as de-- energized. All ground wires are black.
CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (IGNITION SWITCH IN RUN) (OPTIONAL CRUISE CONTROL KIT) FRONT DECK PTO SOLENOID 2WD SOLENOID LEFT DECK PTO SOLENOID RIGHT DECK PTO SOLENOID (UNOCCUPIED) PTO OVERTEMP SHUTDOWN RELAY CONTINUES TO SHEET 2 Groundsmaster 4100--D Glow Plug Circuits Power Current Control Current Indication Current Page 9 - 6
CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (IGNITION SWITCH IN START) (OPTIONAL CRUISE CONTROL KIT) FRONT DECK PTO SOLENOID 2WD SOLENOID LEFT DECK PTO SOLENOID RIGHT DECK PTO SOLENOID (UNOCCUPIED) PTO OVERTEMP SHUTDOWN RELAY CONTINUES TO SHEET 2 Groundsmaster 4100--D Crank Circuits Power Current Control Current Indication Current Page 9 - 7
CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (IGNITION SWITCH IN RUN) FRONT DECK PTO SOLENOID (DISENGAGED) (NOT IN NEUTRAL) 2WD SOLENOID LEFT DECK PTO SOLENOID RIGHT DECK PTO SOLENOID (OCCUPIED) (IN TRANSPORT) PTO OVERTEMP SHUTDOWN RELAY CONTINUES TO SHEET 2 Groundsmaster 4100--D Run (Transport) Circuits Power Current Control
CONTINUES TO SHEET 2 WHEN THE PTO SWITCH IS MOVED TO THE ENGAGE POSITION, PTO SWITCH TERMINALS 4 & 5 ARE MOMENTARILY CONNECTED ALLOWING A CURRENT CONTINUES TO SHEET 2 PATH TO ENERGIZE THE PTO RELAY, THE DECK POSITION SWITCHES AND THE PTO SOLENOIDS. DIODES D1-- B, D1-- C AND D1-- D WILL THEN CREATE CONTINUES TO SHEET 2 A LATCHING CIRCUIT TO KEEP THE PTO RELAY ENERGIZED WHEN THE PTO SWITCH IS IN THE ON POSITION.
CONTINUES TO SHEET 2 o o IF THE ENGINE COOLANT TEMPERATURE RISES TO 220F (105 C), THE DUAL TEMPERATURE WARNING SWITCH CLOSES. THIS CLOSED SWITCH CAUSES CONTINUES TO SHEET 2 THE OVER TEMPERATURE WARNING LIGHT TO ILLUMINATE AND ALSO ENERGIZES THE PTO OVERTEMP SHUTDOWN RELAY. THIS ENERGIZED RELAY CONTINUES TO SHEET 2 CAUSES THE PTO RELAY TO DE-- ENERGIZE AND SHUT OFF ELECTRICAL TO THE DECK PTO SOLENOIDS.
o o IF THE ENGINE COOLANT TEMPERATURE RISES TO 240 F (115 C), THE DUAL TEMPERATURE SHUTDOWN SWITCH CLOSES. THIS CLOSED SWITCH CAUSES THE OVER TEMPERATURE SHUTDOWN RELAY TO ENERGIZE AND REMOVES ELECTRICAL POWER FROM THE ENGINE RUN SOLENOID AND FUEL PUMP CONTINUES TO SHEET 2 SHUTTING OFF THE ENGINE.
(ENGINE SHUTDOWN DELAY) COOLING FAN SWITCH FLOW DIVIDER SWITCH TRANSPORT/4WD SWITCH Groundsmaster 4100--D Console Wire Harness Page 9 - 12 (PTO SHUTDOWN DELAY)
TRANSPORT/4WD YELLOW/BLACK VIOLET WHITE TO SHEET 2 YELLOW TO SHEET 2 YELLOW TAN BLACK BLUE BLACK WHITE YELLOW/BLACK YELLOW YELLOW YELLOW BLUE TAN RED/BLACK YELLOW YELLOW YELLOW YELLOW GRAY YELLOW YELLOW ORANGE BLACK PINK PINK BLACK PINK PINK PINK BLACK PINK WHITE YELLOW GREEN BLUE PT0 SHUTDOWN ENGINE SHUTDOWN DELAY DELAY WHITE ORANGE FLOW DIVIDER SWITCH YELLOW YELLOW YELLOW TAN TAN GREEN TAN GRAY BLACK RED BLACK GRAY WHITE GRAY TAN BLACK YELLOW TAN TO SHEET 2 BLAC
Groundsmaster 4100--D Console Wire Harness Sheet 2 of 2 Page 9 - 14 YELLOW/WHITE WHITE/GREEN TO SHEET 1 TO SHEET 1 TO SHEET 1 TO SHEET 1 RED WHITE/BLACK TAN/BLACK BLACK ORANGE/BLACK BLACK BROWN/WHITE BLUE/BLACK BLACK YELLOW BLACK BLACK GREEN/BLACK VIOLET YELLOW TAN/BLACK RED YELLOW/GREEN TAN/BLACK BLACK VIOLET BLACK BLUE/BLACK BLACK TO SHEET 1 COOLING FAN SWITCH TO SHEET 1 TO SHEET 1 BLACK YELLOW/GREEN BLACK BLACK WHITE/GREEN RED TAN/BLACK RED RED RED GREEN/BLACK TAN/
FLOW DIVIDER SOLENOID Groundsmaster 4100--D Front Wire Harness Page 9 - 15
PINK BLACK WHITE FLOW DIVIDER SOLENOID PINK BROWN YELLOW PINK PINK GRAY PINK PINK PINK GREEN/BLACK TAN TAN BLACK BLACK GRAY TAN GREEN WHITE BLUE ORANGE VIOLET/BLACK BLACK Groundsmaster 4100--D Front Wire Harness Page 9 - 16 GREEN/BLACK GREEN/BLACK BLACK GREEN/BLACK BLACK YELLOW/BLACK ORANGE ORANGE BLUE ORANGE BLACK TAN BLACK
(STARTER) (STARTER) (STARTER) Groundsmaster 4000--D Engine Wire Harness Page 9 - 17
RED/BLACK FUSIBLE LINK RED BLACK BLACK RED RED WHITE RED/BLACK RED/BLACK PINK ORANGE BLUE WHITE GRAY GREEN YELLOW BLACK YELLOW BLACK WHITE/BLACK YELLOW BROWN BLUE ORANGE WHITE ORANGE VIOLET/BLACK YELLOW/BLACK GREEN BROWN/WHITE YELLOW/WHITE BLACK RED BLACK BLACK BLACK BLACK GREEN BLACK BLACK Page 9 - 18 YELLOW/BLACK YELLOW/BLACK BLACK YELLOW/BLACK VIOLET/BLACK BLACK VIOLET/BLACK BLACK BLACK ORANGE Groundsmaster 4000--D Engine Wire Harness VIOLET/BLACK ORANGE
VIOLET BLUE GRAY BLUE BLUE GRAY GRAY VIOLET VIOLET YELLOW BLACK Groundsmaster 4100--D Jumper Wire Harness Page 9 - 19
P15 ORANGE VIOLET/BLACK BLACK YELLOW/BLACK ORANGE Groundsmaster 4100--D Cutting Deck Wire Harness Page 9 - 20 ORANGE BLACK BLACK P1 P2 DECK LIFT SENSOR (LH) DECK LIFT SENSOR (RH)
