Part No. 13203SL Service Manual (Models 30602, 30604, 30606 and 30608) GroundsmasterR 4100--D & 4110--D Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing and repair of major systems and components on the Groundsmaster 4100--D (Model 30604 and 30608) and 4110--D (Model 30602 and 30606). REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.
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Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 -2 -2 -2 -- 1 1 2 3 Chapter 3 -- Yanmar Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 5 Service and Repairs . .
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Table Of Contents (Continued) Chapter 10 -- Foldout Drawings Electrical Drawing Designations . . . . . . . . . . . . . 10 -Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . 10 -Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 10 -Wire Harness Drawings . . . . . . . . . . . . . . . . . . . . 10 -- Groundsmaster 4100--D/4110--D 2 3 4 9 Foldout Drawings General Information . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 2 Service and Repairs . . . . . . . . . . . . .
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Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . Jacking the Front End . . . . . . . . . . . . . . . . . . . . . . . Jacking the Rear End . . . . . . . . . . . . . . . . . . . . . . . .
General Safety Instructions The Groundsmaster 4100-D and 4110--D are tested and certified by Toro for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.
While Operating 6. Before getting off the seat: A. Ensure that traction pedal is in neutral. 2. Before starting the engine: B. Fully lower and disengage cutting deck. Wait for blades to stop. A. Apply the parking brake. B. Make sure traction pedal is in neutral and the PTO switch is OFF (disengaged). 3. After engine is started, release parking brake and keep foot off traction pedal. Machine must not move.
Maintenance and Service 1. Before servicing or making adjustments, lower deck, stop engine, apply parking brake and remove key from the switch. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 3. Never store the machine or fuel container inside where there is an open flame, such as near a water heater or furnace. 4. Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system.
Jacking Instructions CAUTION 1. Set parking brake and chock both front tires to prevent the machine from moving. When changing attachments, tires or performing other service, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands to support the raised machine.
Safety and Instruction Decals Numerous safety and instruction decals are affixed to your Groundsmaster machine. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog.
Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 0.
Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size # 6 -- 32 UNC Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in--lb in--lb N--cm 10 + 2 13 + 2 147 + 23 # 6 -- 40 UNF # 8 -- 32 UNC 13 + 2 25 + 5 282 + 30 # 8 -- 36 UNF # 10 -- 24 UNC 18 + 2 30 + 5 339 + 56 # 10 -- 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger N
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series) Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in--lb 644 + 68 N--cm 78 + 8 in--lb 881 + 90 N--cm M6 X 1.0 96 + 10 in--lb 1085 + 113 N--cm 133 + 14 in--lb 1503 + 158 N--cm M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 28 + 3 ft--lb 38 + 4 N--m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3 ft--lb 1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb Recommended Torque** 7/16 -- 20 UNF Grade 5 65 + 10 ft--lb 88 + 14 N--m 1/2 -- 20 UNF Grade 5 80 + 10 ft--lb 108 + 14 N--m M12 X 1.25 Class 8.
Chapter 3 Yanmar Diesel Engine Table of Contents Groundsmaster 4100--D/4110--D Page 3 -- 1 Yanmar Diesel Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Models 30602 and 30604 . . . . . . . . . . . . . . . . . . . . 2 Models 30606 and 30608 . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 5 Operator’s Manuals . . . . . . . . . . . . . . . . . . . . . . . . . 5 Yanmar Service and Troubleshooting Manuals . .
Specifications (Models 30602 and 30604) Item Description Make / Designation Yanmar Model 4TNV84T--ZMTR: 4--Cycle, 4 Cylinder, Water Cooled, Turbocharged, Tier 4i Diesel Engine Bore 3.307 in (84 mm) Stroke 3.543 in (90 mm) 121.
Specifications (Models 30606 and 30608) Item Description Make / Designation Yanmar Model 4TNV86CT--DTR: 4--Cycle, 4 Cylinder, Water Cooled, Tier 4 Diesel Engine Bore 3.386 in (86 mm) Stroke 3.543 in (90 mm) 127.5 in3 (2090 cc) Total Displacement Firing Order 1 (closest to flywheel end) -- 3 -- 4 (farthest from flywheel) -- 2 Counterclockwise (viewed from flywheel) Fuel Diesel or Biodiesel (up to B7) Fuel with Ultra Low Sulfur Content Fuel Capacity 21 U.S. gallons (79.
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General Information This Chapter gives information about specifications and repair of the diesel engine used in the Groundsmaster 4100--D and 4110--D. General maintenance procedures are described in your Operator’s Manual. Information on engine troubleshooting, testing, disassembly and reassembly is identified in the Yanmar Service Manual. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Yanmar Service Manual.
Engine Electronic Control Unit (ECU) The Yanmar engine that powers your Groundsmaster uses an electronic control unit (ECU) for engine management and also to communicate with the machine TEC controllers and the operator Info Center display on the machine. All wire harness electrical connectors should be plugged into the ECU before the machine ignition switch is moved from the OFF position to either the ON or START position.
Yanmar Engine: Models 30602 and 30604 The engine used on Groundsmaster models 30602 and 30604 is a Yanmar TNV Series, turbocharged, diesel engine that complies with EPA interim Tier 4 emission regulations. Engine features include an electronic control unit (ECU) controlled direct fuel injection and electronic governor. An air heater in the intake system is used to assist starting the engine.
Yanmar Engine: Models 30606 and 30608 The engine used on Groundsmaster models 30606 and 30608 is a Yanmar TNV Series, turbocharged, diesel engine that complies with EPA Tier 4 emission regulations.
Groundsmaster 4100--D/4110--D When the regeneration process is completed, the InfoCenter will remove the stationary regeneration icon and cease periodic regeneration messages. The engine will return to low idle speed with operator controls returned to normal. IMPORTANT: A stationary regeneration should ONLY be initiated if an InfoCenter display advisory requests that this be done.
Service and Repairs Air Filter System RIGHT 8 9 6 10 14 11 13 12 FRONT 15 3 4 2 7 6 5 1 VACUATOR DIRECTION 14 16 16 14 18 17 MODELS 30606 and 30608 MODELS 30602 and 30604 Figure 6 1. 2. 3. 4. 5. 6. Air cleaner assembly Tank support Indicator Adapter Air cleaner strap Flat washer (4 used) Yanmar Diesel Engine 7. 8. 9. 10. 11. 12. Cap screw (2 used) Lock nut (2 used) Flat washer (2 used) Lock nut (2 used) Spring (2 used) Flat washer (2 used) Page 3 -- 10 13. 14. 15. 16. 17. 18.
Removal (Fig. 6) 2 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 4 2. Raise and support hood. 1 3. Remove air cleaner components as needed using Figure 6 as a guide. 3 Installation (Fig. 6) 1. Assemble air cleaner system using Figure 6 as a guide. 5 Figure 7 1. Air cleaner housing 2. Safety filter element 3. Air filter element A. If service indicator (item 4 in Fig. 6) and adapter (item 15 in Fig.
Fuel System 24 25 22 9 RIGHT FRONT 11 17 10 6 5 7 20 21 23 26 27 28 29 30 31 19 8 7 32 18 13 34 35 26 16 12 14 36 33 15 60 to 80 in--lb (7 to 9 N--m) 4 4 38 37 3 2 1 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
4. Disconnect wire harness connections from the fuel sender (item 14). Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety--approved container and keep cap in place. Use diesel fuel for the engine only; not for any other purpose.
Radiator and Oil Cooler Assembly 31 30 27 RIGHT 28 26 FRONT 3 25 32 33 2 24 4 23 6 1 29 3 21 5 34 9 8 22 10 3 16 20 19 11 35 7 Thread Sealant 12 18 17 13 36 9 4 14 15 12 3 Figure 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. LH radiator support Cap screw (2 used) Flange nut (12 used) Hose clamp (3 used) Hose Flange nut (6 used) Foam plug (2 used) Flange head screw (6 used) Flange head screw (9 used) Foam strip Hose bracket R--clamp (2 used) Yanmar Diesel Engine 13. 14. 15.
1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. Open and support hood. MODEL 30606 (WITH TIER 4 ENGINE) 1 CAUTION RIGHT Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Ethylene--glycol antifreeze is poisonous. Dispose of coolant properly or store it in a properly labeled container away from children and pets. FRONT 5 2 2.
Installation (Fig. 11) 4 1. Inspect seals (items 7, 10, 27 and 34) around radiator location for wear or damage. Replace seals if necessary. 1 2. Remove all plugs placed during the removal procedure. 5 3. If hydraulic fittings (items 29 and 31) were removed from oil cooler, lubricate and place new O--rings onto fittings. Install fittings into port openings and tighten fittings (see Hydraulic Fitting Installation in the General Information section of Chapter 4 -- Hydraulic System). 2 4.
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Engine 16 22 14 MODEL 30604 SHOWN 15 13 1 12 11 7 18 11 19 9 2 7 5 17 20 11 6 10 21 RIGHT 9 5 FRONT 3 4 8 4 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. Engine (model 30604 shown) Cap screw (4 used) Rebound washer (4 used) Flange nut (12 used) Engine mount (4 used) Cap screw (2 used per mount) Engine mount bracket (2 used) Lock washer Yanmar Diesel Engine 9. 10. 11. 12. 13. 14. 15.
Engine Removal (Fig. 15) 1 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. Disconnect negative battery cable from battery terminal and then disconnect positive cable from battery (see Battery Service in the Service and Repairs section of Chapter 5 -- Electrical System). 2 3. Raise and support hood. 3 Do not open radiator cap or drain coolant if the radiator or engine is hot.
11. On machines with a Tier 4 compliant engine (models 30606 and 30608): RIGHT FRONT A. Remove fuel tank to allow engine to be raised from machine (see Fuel System in this section). 1 B. Install lift bracket to front of engine cylinder head (item 6 in Fig. 17). Front lift bracket was included with new machine or is available as a service part (refer to parts catalog for part number). 12.On Groundsmaster 4110--D machines: A.
7. On machines with a Tier 4 compliant engine (models 30606 and 30608): A. Remove lift bracket from front of engine cylinder head (item 6 in Fig. 17). The bracket must be removed before fuel tank installation. Retain lift bracket and fasteners for future use. One person should operate lift or hoist while a second person guides the engine out of the machine.
17.Check position of electrical wires, fuel lines and hydraulic lines for proper clearance with rotating, high temperature and moving components. 18.Connect positive battery cable to positive battery terminal first and then connect negative cable to battery (see Battery Service in the Service and Repairs section of Chapter 5 -- Electrical System). 19.Check and adjust engine oil as needed. 21.Prime the fuel system (see Fuel System in this section). 22.
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Spring Coupler RIGHT FRONT 7 28 to 32 ft--lb (38 to 43 N--m) 3 2 1 6 5 4 29 to 33 ft--lb (40 to 44 N--m) Figure 21 1. Cap screw (8 used) 2. Washer (8 used) 3. Flywheel plate Yanmar Diesel Engine 4. Cap screw (8 used) 5. Washer (8 used) Page 3 -- 24 6. Spring coupler 7.
Coupler Removal (Fig. 21) 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, remove hydraulic pump assembly from machine (see Piston (Traction) Pump Removal in the Service and Repairs section of Chapter 4 -- Hydraulic System). 1 2. Remove flywheel plate and spring coupler from engine using Figure 21 as a guide. Coupler Installation (Fig. 21) 2 2.
Exhaust System (Models 30606 and 30608) 7 40 41 19 to 29 ft--lb (25 to 40 N--m) 39 37 8 35 16 31 18 22 11 31 29 36 38 26 17 34 25 32 10 5 28 27 30 16 20 15 27 25 12 34 33 18 4 9 16 23 18 1 18 3 14 18 23 15 44 21 23 16 13 RIGHT 42 FRONT 19 6 24 2 43 Figure 23 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
The diesel particulate filter (DPF) is cleaned periodically through a regenerative process that is controlled by the engine ECU (see Yanmar Engine: Models 30606 and 30608 in the General Information section of this chapter). The InfoCenter display will identify the status of DPF regeneration. At recommended intervals, DPF reconditioning is necessary which will require exhaust system disassembly, DPF removal and DPF reconditioning by a company that has the necessary equipment.
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Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 3 Relieving Hydraulic System Pressure . . . . . . . . . . 3 Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 4 Traction Circuit Component Failure . . . . . . . . . . . .
Specifications Item Description Piston (Traction) Pump Maximum Displacement (per revolution) System Relief Pressure: Forward System Relief Pressure: Reverse Charge Pressure Sauer--Danfoss Variable Displacement Axial Piston Pump 2.75 in3 (45 cc) 4350 PSI (300 bar) 5000 PSI (345 bar) 250 PSI (17 bar) Front Wheel Motors Displacement (per revolution) Sauer--Danfoss 2--Position Axial Piston Motors 1.40 in3 (23 cc) Maximum / 0.
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Check Hydraulic Fluid Your Groundsmaster hydraulic system is designed to operate on anti--wear hydraulic fluid. The reservoir holds approximately 7.75 U.S. gallons (29.3 liters) of hydraulic fluid. Check level of hydraulic fluid daily.
Towing Traction Unit IMPORTANT: If towing limits are exceeded, severe damage to the piston (traction) 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 (5 kph). The piston (traction) pump relief valves (both forward and reverse) need to be loosened three (3) revolutions to allow the machine to be moved (Fig. 2). To prevent leakage from relief valves, do not loosen them more than three (3) revolutions.
Hydraulic Hoses Hard, cracked, cut, abraded, charred, leaking or otherwise damaged hose. Kinked, crushed, flattened or twisted hose. Blistered, soft, degraded or loose hose cover. Cracked, damaged or badly corroded hose fittings. When replacing a hydraulic hose, be sure that the hose is straight (not twisted) before tightening the fittings. This can be done by observing the imprint (layline) on the hose.
Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The markings on the nut and fitting body will verify that the connection has been properly tightened. 2.
Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.) method. 2.
Adjustable Fitting (Fig. 8) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is recommended that the O--ring be replaced any time the connection is opened. Lock Nut 3. Lightly lubricate the O--ring with clean hydraulic oil. Fitting threads should be clean with no lubricant applied. Back--up Washer 4. Turn back the lock nut as far as possible.
Groundsmaster 4100--D/4110--D Page 4 -- 9 M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 50 PSI RIGHT DECK LC1 LEFT DECK LC1 G P2 G P2 G P1 P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 P1 P T STEERING CYLINDER 1.37 1.37 CID CID 2.75 CID 15.2 GPM 15.2 GPM 4.4 GPM 3.3 GPM 6.1 CID E L 0.3 0.4 CID CID R 2.00” BORE 4.20” STROKE 0.
Hydraulic System Page 4 -- 10 M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow STEERING CONTROL VALVE P G T G 1.37 CID 2.75 CID 15.2 GPM 15.2 GPM 4.4 GPM 3.3 GPM E 6.1 CID L STEERING CYLINDER 0.3 0.4 1.
Traction Circuit: LOW Speed (Mow) Front wheel and rear axle motors are positive displacement, two speed variable motors that allow operation in either LOW (mow) or HI (transport) speed. The motors are spring biased to maximum displacement for LOW speed and are hydraulically shifted to minimum displacement for HI speed. The rear axle motor includes a flushing valve that bleeds off a small amount of hydraulic oil for cooling of the closed loop traction circuit.
Hydraulic System Page 4 -- 12 Groundsmaster 4100--D/4110--D M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P1 G P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow STEERING CONTROL VALVE P G T G 1.37 CID 2.75 CID 15.2 GPM 15.2 GPM 4.4 GPM 3.3 GPM E 6.
Traction Circuit: HI Speed (Transport) Front wheel and rear axle motors are positive displacement, two speed variable motors that allow operation in either LOW (mow) or HI (transport) speed. The motors are spring biased to maximum displacement for LOW speed and are hydraulically shifted to minimum displacement for HI speed. The rear axle motor includes a flushing valve that bleeds off a small amount of hydraulic oil for cooling of the closed loop traction circuit.
Hydraulic System Page 4 -- 14 Groundsmaster 4100--D/4110--D M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow STEERING CONTROL VALVE P L 4.4 GPM G 1.37 CID 2.75 CID 15.2 GPM 15.2 GPM 0.4 1.
Lower Cutting Deck Each of the cutting deck sections (main, right wing and left wing) can be lowered independently with the use of three (3) switches on the armrest console. Pressing the front of a lift switch provides an input for the TEC controller to lower the cutting deck or wing deck. The controller provides electrical outputs to solenoids in the combination control manifold to allow appropriate manifold valve shift that causes a cutting deck to lower.
Hydraulic System Page 4 -- 16 Groundsmaster 4100--D/4110--D M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow STEERING CONTROL VALVE P L 4.4 GPM G 1.37 CID 2.75 CID 15.2 GPM 15.2 GPM 0.4 1.
Raise Cutting Deck Each of the cutting deck sections (main, right wing and left wing) can be raised independently with the use of three (3) switches on the armrest console. Pressing the rear of a lift switch provides an input for the TEC controller to raise the cutting deck or wing deck. The controller provides electrical outputs to solenoids in the combination control manifold to allow appropriate manifold valve shift that causes a cutting deck to raise.
Hydraulic System Page 4 -- 18 Groundsmaster 4100--D/4110--D M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow STEERING CONTROL VALVE P L 0.4 CID G T STEERING CYLINDER 1.37 1.37 CID CID G 2.75 CID 15.2 GPM 15.
Mow Circuit A four section gear pump is coupled to the piston (traction) pump. 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 wings of the cutting deck, while the next gear pump section supplies the center section of the cutting deck. direction valve PD shifts to provide a return path for circuit flow.
Mow Circuit Cutting Deck Blade Braking When the operator turns the PTO switch OFF or if a wing deck is raised with the PTO switch ON, PTO manifold proportional relief valve (PRV) is de--energized causing logic valve (LC1) to shift (refer to information in Mow Circuit in this section). This shifted cartridge directs oil return out of manifold port P2.
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Hydraulic System Page 4 -- 22 Groundsmaster 4100--D/4110--D M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow P G 1.37 CID 2.75 CID 15.2 GPM 15.2 GPM 4.4 GPM 3.3 GPM T 0.3 0.4 1.
Steering Circuit NOTE: The hydraulic schematic symbol for the pressure compensator valve (EC) appears to be a two (2) position valve. In operation, this valve will direct the gear pump section flow to the steering circuit as priority depending on steering input. The remainder of the gear pump section flow will be directed to the charge and engine cooling fan circuits. If there is no steering input, the compensator valve (EC) directs all gear pump section flow to the charge and engine cooling fan circuits.
Hydraulic System Page 4 -- 24 Groundsmaster 4100--D/4110--D M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow STEERING CONTROL VALVE P G T G 1.37 CID 2.75 CID 15.2 GPM 15.2 GPM 4.4 GPM 3.3 GPM E 6.
Engine Cooling Fan Circuit A four section gear pump is coupled to the piston (traction) pump (Fig. 14). The fourth gear pump section (farthest from the piston pump) supplies hydraulic flow to the steering circuit, the engine cooling fan circuit and the traction charge circuit. The third gear pump section supplies hydraulic flow to the engine cooling fan circuit, the lift/lower circuit and the traction charge circuit.
Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 bar), 5000 PSI (350 bar) and 10000 PSI (700 bar) gauges. Use gauges as recommended in the Testing section of this chapter.
40 GPM Hydraulic Tester (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter. This tester includes the following: 1. LOAD VALVE: A simulated working load is created in the circuit by turning the valve to restrict flow. 2. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure. 3.
High Flow Hydraulic Filter Kit The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi--directional filtration which prevents filtered debris from being allowed back into the circuit regardless of flow direction. If a component failure occurs in the closed loop traction circuit, contamination from the failed part will remain in the circuit until removed.
Hydraulic Test Fitting Kit This kit includes a variety of O--ring face seal fittings to enable the connection of test gauges into the system. TORO TEST FITTING KIT (TOR4079) The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Toro Part Number: TOR4079 Figure 21 Measuring Container Hydraulic System Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only).
Remote Starter Switch After flushing the hydraulic system or replacing a hydraulic component (e.g. gear pump, piston pump, wheel motor), it is necessary to prime the hydraulic pumps. A remote starter switch (Fig. 24) can be used for this purpose. Obtain a remote starter switch locally. IMPORTANT: When using a remote starter switch, it is highly recommended to include a 20 amp inline fuse between the battery and switch connector for circuit protection.
Troubleshooting The charts that follow contain suggestions that can be used to assist in diagnosing hydraulic system performance issues. The suggestions are not all--inclusive. Also, consider that there may be more than one cause for a machine problem. Review the hydraulic schematic and information on hydraulic system operation in the Hydraulic Flow Diagrams section of this Chapter. This information will be useful during the hydraulic troubleshooting process.
Traction Circuit Problems Problem Possible Cause Machine operates in one direction only. Piston (traction) pump by--pass valve is open or damaged. Traction relief valve is leaking or faulty. Piston (traction) pump servo control valve orifices or screens are plugged or damaged. Problem with TEC output to piston (traction) pump servo control exists (see Chapter 5 -- Electrical System). Traction pedal response is sluggish. Traction pedal components are stuck or binding. Traction charge pressure is low.
Mow Circuit Problems Problem Possible Cause None of the cutting deck sections will operate. Electrical problem exists that prevents PRV solenoid valve in PTO manifolds from being energized (see Chapter 5 -- Electrical System). NOTE: To engage the mow circuit, the seat must be occupied, the cutting deck(s) must be fully lowered, the traction speed must be in the LOW (mow) position and the PTO switch must be ON. One cutting deck section will not operate.
Lift Circuit Problems Problem Possible Cause Cutting deck (or wing decks) will not raise. Engine RPM is too low. NOTE: The seat must be occupied in order to raise cutting deck. Hydraulic oil level in reservoir is low (NOTE: Other hydraulic systems are affected as well). Solenoid valve (S1) in combination manifold is faulty. Electrical problem exists (see Chapter 5 -- Electrical System). Lift arm pivots are binding. Relief valve in combination manifold is stuck. Lift cylinder(s) is (are) damaged.
Steering Circuit Problems Problem Possible Cause Steering is inoperative or sluggish. Steering components (e.g. tie rods, steering cylinder ends) are worn or binding. Steering cylinder is binding. Oil level in hydraulic reservoir is low (NOTE: other hydraulic systems are affected as well). Steering relief valve (RV1) in combination manifold is stuck or damaged. The pressure compensator valve (EC) in combination manifold is stuck or damaged. Steering cylinder leaks internally.
Engine Cooling Fan Circuit Problems Problem Possible Cause Cooling fan runs only in forward direction (fan does not run in reverse direction). Solenoid cartridge valve (S10) in combination control manifold is faulty. Cooling fan does not rotate. Cooling fan motor is worn or damaged. Electrical problem exists that prevents combination control manifold solenoid valve (S10) operation (see Chapter 5 -- Electrical System). Proportional relief valve (PRV) in combination manifold is stuck or damaged.
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Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (see the Special Tools section in this Chapter). IMPORTANT: All obvious areas such as hydraulic oil supply, oil filters, binding components, loose fasteners or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem.
Which Hydraulic Tests Are Necessary? Before beginning any hydraulic test, identify if the problem is related to the traction circuit, cutting (mow) circuit, lift/lower circuit, steering circuit or engine cooling fan circuit. Once the faulty system has been identified, perform tests that relate to that circuit. 1.
Hydraulic System TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD PRESSURE GAUGE Page 4 -- 40 FROM OIL FILTER 0.3 CID FROM CENTER DECK PTO MANIFOLD 0.4 CID G 1.29 CID G 1.29 CID 14.3 GPM 14.3 GPM 4.4 GPM 2.75 CID .0315 TO COMBINATION MANIFOLD 3.3 GPM 250 PSI .0315 FROM COMBINATION MANIFOLD G G 5000 PSI 4350 PSI 30.5 GPM P2 650 PSI PR 380 PSI CV TO COMBINATION MANIFOLD REAR OR1 TRACTION .050 MANIFOLD T ENGINE TO COMBINATION MANIFOLD M8 RV CH 200 PSI 2.14 CID / 1.
Procedure for Traction Circuit Charge Pressure Test CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting deck lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied.
Hydraulic System 0.3 CID G 0.4 CID 1.29 CID G 1.29 CID 14.3 GPM 14.3 GPM 4.4 GPM 2.75 CID .0315 TO COMBINATION MANIFOLD 3.3 GPM 250 PSI .0315 FROM COMBINATION MANIFOLD G G 5000 PSI 4350 PSI Page 4 -- 42 REAR TRACTION MANIFOLD ENGINE 30.5 GPM TO COMBINATION MANIFOLD PRESSURE GAUGE FROM OIL FILTER TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD FROM CENTER DECK PTO MANIFOLD .050 T OR1 P2 380 PSI CV TO COMBINATION MANIFOLD PR 650 PSI M8 RV CH 200 PSI 1.16 CID 2.
Procedure for Traction Circuit Relief Pressure Test CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 7. If traction pressure is too low, inspect traction pump relief valves (Fig. 28 or 29). Clean or replace relief valves as necessary. These cartridge type valves are factory set, and are not adjustable.
Hydraulic System TO RESERVOIR TO STEERING CONTROL VALVE Page 4 -- 44 EC CV2 4 PSI FROM GEAR PUMP FROM GEAR PUMP G4 CF LS G2 CH4 S10 M1 G P4 80 PSI OR1 .030” 0.51 CID S11 3250 PSI CH2 RV1 1350 PSI CV1 4 PSI PRV M2 G 60 PSI CV3 TO FRONT TRACTION VALVE CH1 OR3 .070 C3 S4 S2 C4 S3 S1 PR 310 PSI P3 RV3 OR2 .063 G3 3300 PSI TO RESERVOIR CH3 CV4 4 PSI OR5 .070 T OR9 .030 OR4 .040 S5 C2 3.08” STROKE 6.50” STROKE 1.125” ROD 1.50” BORE 2.
Procedure for Counterbalance Pressure Test C. To increase pressure setting, turn the adjustment screw on the valve in a clockwise direction. A 1/8 turn on the screw will make a measurable change in counterbalance pressure. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting deck lowered and off.
Hydraulic System Page 4 -- 46 FROM OIL FILTER TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD FROM CENTER DECK PTO MANIFOLD 0.3 CID G 0.4 CID 1.29 CID G 1.29 CID 14.3 GPM 14.3 GPM 4.4 GPM 2.75 CID .0315 TO COMBINATION MANIFOLD 3.3 GPM 250 PSI .0315 FROM COMBINATION MANIFOLD G G 5000 PSI 4350 PSI REAR TRACTION MANIFOLD ENGINE 30.5 GPM TO COMBINATION MANIFOLD T OR1 .050 P2 380 PSI CV TO COMBINATION MANIFOLD PR M8 RV 200 PSI PRESSURE GAUGE 650 PSI CH 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. NOTE: The rear traction circuit relief valve (RV) pressure test uses the same pressure gauge position as used to measure reverse traction circuit reducing valve (PR) pressure. If necessary, conduct the rear traction circuit relief valve (RV) pressure test before removing pressure gauge from rear traction manifold. 8.
Hydraulic System Page 4 -- 48 FROM OIL FILTER TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD FROM CENTER DECK PTO MANIFOLD 0.3 CID G 0.4 CID 1.29 CID G 1.29 CID 14.3 GPM 14.3 GPM 4.4 GPM 2.75 CID .0315 TO COMBINATION MANIFOLD 3.3 GPM 250 PSI .0315 FROM COMBINATION MANIFOLD G G 5000 PSI 4350 PSI REAR TRACTION MANIFOLD ENGINE 30.5 GPM TO COMBINATION MANIFOLD T OR1 .050 P2 380 PSI CV TO COMBINATION MANIFOLD PR M8 RV 200 PSI PRESSURE GAUGE 650 PSI CH 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. 1. Park machine on a level surface with the cutting deck lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. NOTE: This test uses the same pressure gauge position as used to measure reverse traction circuit reducing valve (PR) pressure. 6. Stop engine and record test results.
Hydraulic System FROM OIL FILTER TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD FROM CENTER DECK PTO MANIFOLD 0.3 CID G 0.4 CID 1.29 CID G 1.29 CID 14.3 GPM 14.3 GPM 4.4 GPM 2.75 CID .0315 TO COMBINATION MANIFOLD 3.3 GPM 250 PSI .0315 FROM COMBINATION MANIFOLD G G 5000 PSI 4350 PSI Page 4 -- 50 .050 T OR1 P2 380 PSI CV TO COMBINATION MANIFOLD TESTER REAR TRACTION MANIFOLD ENGINE 30.5 GPM TO COMBINATION MANIFOLD PR 650 PSI M8 RV CH 200 PSI 1.16 CID 2.
Procedure for Piston (Traction) Pump Flow Test This test measures piston (traction) pump output (flow). During this test, pump load is created at the flow meter using the adjustable load valve on the tester. NOTE: Before performing piston pump flow test, make sure that traction speed is set to 100% using the InfoCenter settings menu. IMPORTANT: Traction circuit flow for the Groundsmaster 4100--D/4110--D is approximately 30 GPM (113.5 LPM).
Hydraulic System Page 4 -- 52 M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 600 PSI .025 CD PRV 2000 PSI CD PRV 3000 PSI CD PRV 3000 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 P2 G P1 P2 G P1 50 PSI CENTER DECK LC1 G P1 0.3 CID 0.4 CID G TO COMBINATION MANIFOLD 1.29 CID G 1.29 CID 2.75 CID 14.3 GPM 14.3 GPM .0315 250 PSI .0315 TO COMBINATION MANIFOLD 3.3 GPM FROM STEERING CONTROL VALVE 5000 PSI 4350 PSI 30.
Procedure for Cutting Deck Circuit Pressure Test 2 CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1 1. Park machine on a level surface with the cutting deck lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. 2.
Hydraulic System 1.17 CID 1.17 CID 1.17 CID M2 M1 M2 M1 M2 M1 Page 4 -- 54 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 600 PSI .025 CD PRV 2000 PSI CD PRV 3000 PSI CD PRV 3000 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 P2 G P1 P2 0.3 CID 0.4 CID G TO COMBINATION MANIFOLD 1.29 CID G 1.29 CID 2.75 CID 14.3 GPM 14.3 GPM .0315 250 PSI .0315 TO COMBINATION MANIFOLD 3.
The PTO circuit relief pressure test should be performed to make sure that the PTO circuit relief pressures are correct. Procedure for PTO Relief Pressure Test CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting deck lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. 7.
Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauge and Flow Meter) CENTER CUTTING DECK MOTOR CASE DRAIN LEAKAGE TEST SHOWN M1 P1 1.17 CID .025 3000 PSI G PD PRV TESTER LC1 RV P2 600 PSI M2 CD CENTER DECK FROM STEERING CONTROL VALVE CAP P1 M1 G 3000 PSI .025 1.17 CID PD TO RESERVOIR PRV LC1 MEASURING CONTAINER RV P2 600 PSI M2 CD LEFT DECK M1 FROM SECOND GEAR PUMP SECTION .025 1.
Procedure for Cutting Deck Motor Case Drain Leakage Test NOTE: Over a period of time, a deck motor can wear internally. A worn motor may by--pass oil to its case drain causing the motor to be less efficient. Eventually, enough oil loss will cause the deck motor to stall under heavy cutting conditions. Continued operation with a worn, inefficient motor can generate excessive heat, cause damage to seals and other components in the hydraulic system and affect quality of cut.
Hydraulic System Page 4 -- 58 FROM LEFT AND RIGHT DECK PTO MANIFOLDS 0.3 CID P 0.4 CID 6.1 CID G R T G 1.29 CID 1.29 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM E L STEERING CYLINDER 2.75 CID G4 CF LS G2 CH4 G EC CV2 4 PSI S10 M1 .0315 P4 250 PSI G G CH2 CH1 5000 PSI S1 OR3 .070 P3 P2 RV3 OR2 .063 S2 S4 C3 S3 PR M8 CV 650 PSI RV CH CV4 T S5 OR9 .030 OR4 .040 C2 200 PSI OR5 .070 CENTER DECK RAM CYLINDERS 1.50” BORE 3.
The lift/lower circuit relief pressure test should be performed to make sure that the cutting unit lift and lower circuit relief pressure is correct. Procedure for Lift/Lower Circuit Relief Pressure Test NOTE: Before attempting to check or adjust lift/lower circuit relief pressure, make sure that counterbalance pressure is correctly adjusted (see Counterbalance Pressure Test in this section). B. If relief pressure is too low, check for restriction in gear pump intake line.
Hydraulic System Page 4 -- 60 M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 P1 STEERING CONTROL VALVE P 0.3 CID G E L 0.4 CID 6.1 CID R 2.00” BORE 4.20” STROKE 0.625” ROD T STEERING CYLINDER 1.29 1.29 CID CID G 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.
The steering circuit relief pressure test should be performed to make sure that the steering circuit relief pressure is correct. Procedure for Steering Circuit Relief Pressure Test CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 7. If pressure is incorrect, inspect steering relief valve in steering control valve (see Steering Control Valve in the Service and Repairs section of this chapter).
Steering Cylinder Internal Leakage STEERING CYLINDER CYLINDER FULLY EXTENDED 2.00” BORE 4.20” STROKE 0.625” ROD LOOK FOR LEAKAGE STEEL CAP R L STEERING CONTROL VALVE STEERING WHEEL TURNED FOR RIGHT TURN 6.
Procedure for Steering Cylinder Internal Leakage Test NOTE: Steering circuit operation will be affected by rear tire pressure, binding of steering cylinder, extra weight on the vehicle and/or binding of rear axle steering components. Make sure that these items are checked before proceeding with steering cylinder internal leakage test. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1.
Hydraulic System Page 4 -- 64 FROM LEFT AND RIGHT DECK PTO MANIFOLDS FROM OIL FILTER P R 0.3 CID 6.1 CID E L 0.4 CID G 1.29 CID G 1.29 CID 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM T STEERING CYLINDER .0315 G4 CF LS G2 CH4 PRESSURE GAUGE TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD FROM CENTER DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD STEERING CONTROL VALVE 2.00” BORE 4.20” STROKE 0.625” ROD 250 PSI 80 PSI OR1 .030” P4 .
The cooling fan circuit test should be performed to make sure that the engine cooling fan circuit has the correct system pressure and fan speed. Procedure for Engine Cooling Fan Circuit Test CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting deck lowered and off.
Gear Pump Flow (Using Tester with Pressure Gauge and Flow Meter) Hydraulic System FROM REAR AXLE MOTOR G CID CID FROM OIL FILTER FROM MANIFOLD AND FAN MOTOR FROM MOW CIRCUIT 1.29 0.4 CID 1.29 CID 2.75 The gear pump flow test should be performed to make sure that the mow, steering, lift/lower, cooling fan and traction charge circuits have adequate hydraulic flow. The front gear pump section provides hydraulic flow for the cutting wing decks (Fig. 47).
Procedure for Gear Pump Flow Test 10.If a pressure of 1000 PSI (69 bar) cannot be obtained or flow was less than the minimum flow listed in Figure 48, check for restriction in the pump intake line. If line is not restricted, consider that the tested gear pump section is worn or damaged. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 11.
Adjustments Adjust Control Manifold Relief Valves Several of the hydraulic control manifolds on the Groundsmaster include adjustable relief valves. The following procedure can be used to adjust these relief valves. Refer to the Testing section of this chapter for information on testing relief pressure. NOTE: Do not remove relief valve from the hydraulic manifold for adjustment. 1 1. Locate relief valve and remove cap from valve. 2. Remove cap on relief valve with an allen wrench. 3.
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.
Check Hydraulic Lines and Hoses WARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury.
Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated. Contaminated oil may appear milky or black or may contain metal particles. IMPORTANT: If a component failure occurred in the closed loop traction circuit (e.g. piston pump or wheel motor), filtering the traction circuit is recommended. See Filtering Closed--Loop Traction Circuit in this section. 1. Park machine on a level surface.
Filtering Closed--Loop Traction Circuit Filtering of a closed--loop hydraulic system after a major component failure (e.g. traction (piston) pump or front wheel motor) is a requirement to prevent debris from transmitting throughout the system. If a closed--loop hydraulic system filtering tool is not used to ensure system cleanliness, repeat failures, as well as subsequent damage to other hydraulic components in the affected system, will occur.
Charge Hydraulic System IMPORTANT: Change hydraulic oil filters whenever hydraulic components are repaired or replaced. 8. After the hydraulic system starts to show signs of fill, actuate a lift switch until the lift cylinder rod moves in and out several times. If the lift cylinder does not move after 10 to 15 seconds, or if 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 26 27 RIGHT 8 FRONT 80 to 88 ft--lb (109 to 119 N--m) 30 9 28 10 7 12 6 11 31 14 3 1 15 23 29 4 3 25 24 13 18 19 16 17 20 2 5 21 22 Figure 52 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Hydraulic reservoir Cap screw Recess bumper (2 used) Thin spacer Flange nut Breather Bushing (3 used) Stand pipe (3 used) Hose clamp Reservoir cap O--ring Hydraulic System 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Removal (Fig. 52) 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. Drain reservoir into a suitable container. IMPORTANT: Follow all local codes and regulations when recycling or disposing hydraulic fluid. 2.
Radiator and Oil Cooler Assembly 31 30 27 28 26 3 25 32 33 2 24 23 4 6 1 29 3 21 5 34 9 8 22 3 20 10 16 11 19 Thread Sealant 12 18 17 RIGHT FRONT 35 7 13 36 4 14 15 9 12 3 Figure 54 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. LH radiator support Cap screw (2 used) Flange nut (12 used) Hose clamp (3 used) Hose Flange nut (6 used) Foam plug (2 used) Flange head screw (6 used) Flange head screw (9 used) Foam strip Hose bracket R--clamp (2 used) 13. 14. 15. 16. 17. 18. 19. 20. 21.
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Gear Pump RIGHT FRONT 24 26 19 1 16 13 18 20 9 6 11 14 22 10 9 17 8 23 15 25 27 21 15 20 12 2 4 5 1 3 1 2 7 Figure 55 1. 2. 3. 4. 5. 6. 7. 8. 9. Hose clamp (3 used) Hose clamp (2 used) Hydraulic hose Suction hose Tee fitting Straight hydraulic fitting Plug Cap screw (2 used) Flat washer (4 used) Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 55) Remove plugs before installing gear pump to piston pump 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 1 2. Raise and support machine to gain access to gear pump from the underside of the machine. 3. Drain the hydraulic reservoir. IMPORTANT: Follow all local codes and regulations when recycling or disposing hydraulic fluid. 2 4.
10.Replace hydraulic filters and fill hydraulic reservoir with new hydraulic oil. 2 1 11. Prime hydraulic pumps (see Priming Hydraulic Pumps in this section). 3 12.Properly fill hydraulic system (see Charge Hydraulic System in this section). 13.Stop engine and check for hydraulic oil leaks. Check hydraulic reservoir oil level. Figure 57 1. Piston (traction) pump 2. Gear pump Hydraulic System Page 4 -- 80 3.
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Gear Pump Service 11 15 13 16 9 7 3 2 5 18 10 12 14 17 21 8 4 6 24 1 25 23 22 20 33 ft--lb (45 N--m) 19 Figure 58 1. 2. 3. 4. 5. 6. 7. 8. 9. Front cover Dowel pin (4 used) Pressure seal Back--up gasket Front thrust plate Seal (8 used) Front body Idler gear Drive shaft 10. 11. 12. 13. 14. 15. 16. 17. Thrust plate (7 used) Dowel pin (6 used) Splined connecting shaft (3 used) Flange (3 used) Back--up gasket Pressure seal Drive gear Idler gear Disassembly (Fig.
IMPORTANT: Use caution when clamping gear pump in a vise to avoid distorting any pump components. 1 2 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. 3 4 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. 7.
Piston (Traction) Pump RIGHT FRONT 24 26 19 1 16 13 18 20 9 6 11 14 22 10 9 17 8 23 15 25 27 21 15 20 12 2 4 5 1 3 1 2 7 Figure 61 1. 2. 3. 4. 5. 6. 7. 8. 9. Hose clamp (2 used) Hose clamp (2 used) Hose Suction hose Tee fitting Straight hydraulic fitting Plug Cap screw (2 used) Flat washer (4 used) Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 61) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2 2. To prevent contamination of hydraulic system during removal, thoroughly clean exterior of pump assembly. 3. Raise and support machine to gain access to pump assembly from the underside of machine. 4. Label wire harness connectors that attach to the two (2) solenoid coils on left side of piston pump (Fig. 62).
Installation (Fig. 61) 1. If fittings were removed from piston pump, lubricate and place new O--rings onto fittings. Install fittings into pump 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). IMPORTANT: To prevent spring coupler damage, make sure that piston pump is properly supported and does not put side load into coupler during pump installation. 2.
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Piston (Traction) Pump Service 43 41 51 42 52 45 53 42 46 44 45 46 47 48 42 55 42 41 39 49 37 50 34 33 35 3 2 8 30 44 36 7 15 13 40 38 1 14 25 3 34 7 29 2 31 6 33 32 29 25 10 54 10 10 24 28 4 23 11 16 5 18 17 27 26 20 12 21 22 19 9 10 Figure 65 Hydraulic System Page 4 -- 88 Groundsmaster 4100--D/4110--D
Figure 65 (Continued) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Screen (2 used) Plug with O--ring (2 used) Plug with O--ring (2 used) Cylinder block assembly Valve plate Servo piston Screw (4 used) Orifice (2 used) Screw (4 used) Plug with O--ring (4 used) Screw (2 used) Plug Shaft Bearing assembly Retaining ring Gasket Adapter Adapter seal Coupling 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.
Rear Axle Motor 2 1 9 12 11 13 4 3 7 18 8 19 6 10 14 5 15 16 17 9 to 11 ft--lb (12.3 to 14.9 N--m) 20 21 RIGHT FRONT Figure 66 1. 2. 3. 4. 5. 6. 7. Rear axle motor 90o hydraulic fitting (2 used) 90o hydraulic fitting Straight hydraulic fitting 90o hydraulic fitting Temperature sender Cap screw (2 used) Hydraulic System 8. 9. 10. 11. 12. 13. 14. Flat washer (2 used) O--ring External snap ring (2 used) Pinion gear (27T) Cap screw (6 used) Lock washer (6 used) Cover plate Page 4 -- 90 15.
Removal (Fig. 66) Installation (Fig. 66) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. IMPORTANT: Refer to Traction Circuit Component Failure in the General Information section of this chapter for information regarding the importance of removing contamination from the traction circuit. 3.
Front Wheel Motors 4 1 15 13 3 8 11 7 6 14 5 12 1 13 8 10 RIGHT 2 6 7 FRONT 9 Figure 67 1. 2. 3. 4. 5. Front wheel motor Internal retaining ring Splined brake shaft RH brake assembly Planetary assembly (2 used) Hydraulic System 6. 7. 8. 9. 10. Cap screw (2 used per motor) Flat washer (2 used per motor) O--ring LH brake assembly Hydraulic tee fitting Page 4 -- 92 11. 12. 13. 14. 15.
Removal (Fig. 67) Installation (Fig. 67) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. IMPORTANT: Refer to Traction Circuit Component Failure in the General Information section of this chapter for information regarding the importance of removing contamination from the traction circuit. 3. To prevent contamination of hydraulic system during wheel motor removal, thoroughly clean exterior of motor and fittings.
Rear Axle and Front Wheel Motor Service 1 2 3 4 5 6 8 7 9 10 12 13 11 14 16 24 15 25 17 16 20 21 22 23 21 18 19 Figure 68 1. 2. 3. 4. 5. 6. 7. 8. 9. Plug with O--ring Minimum angle stop Bias spring Servo piston O--ring O--ring Socket head screw (5 used) Endcap Dowel Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17. Dowel pin Bearing Gasket Valve plate Cylinder block kit Swashplate Swash plate bearing assembly Output shaft Page 4 -- 94 18. 19. 20. 21. 22. 23. 24. 25.
NOTE: The front wheel motors on your Groundsmaster are identical (Fig. 68). The rear axle motor includes a flushing valve for cooling of the closed loop traction circuit and therefore has some differences from the front motors (Fig. 69). Service of the wheel and axle motors uses the same procedure. REAR AXLE MOTOR FLUSHING VALVE 3 10 NOTE: For service of the front wheel and rear axle motors, see the Sauer--Danfoss K and L Frame Variable Motors Service Manual at the end of this chapter.
Rear Traction Manifold 2 1 8 6 7 10 13 11 9 12 4 14 15 17 16 3 RIGHT FRONT 5 Figure 70 1. 2. 3. 4. 5. 6. Front frame PTO manifold (center deck section) Rear traction manifold Cap screw (2 used) Flange nut (2 used) 90o hydraulic fitting 7. 8. 9. 10. 11. 12. O--ring 45o hydraulic fitting O--ring O--ring Straight fitting O--ring 13. 14. 15. 16. 17.
Removal (Fig. 70) Installation (Fig. 70) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 1. If fittings were removed from manifold, lubricate and place new O--rings onto fittings. Install fittings into manifold openings using marks made during the removal process to properly orientate fittings.
Rear Traction Manifold Service 3 25 ft--lb (34 N--m) 2 50 ft--lb (67 N--m) 20 ft--lb (27 N--m) 4 1 7 35 ft--lb (47 N--m) 25 ft--lb (34 N--m) 5 6 Figure 71 1. Rear traction manifold body 2. Relief valve (port RV) 3. Pressure reducing valve (port PR) 4. #4 zero leak plug with O--ring 5. #6 zero leak plug with O--ring NOTE: The ports on the rear traction manifold are marked for easy identification of components.
Control Manifold Cartridge Valve Service 2. If cartridge valve is solenoid operated, remove nut securing solenoid coil to the cartridge valve. Carefully slide coil off the valve. IMPORTANT: Use care when handling the cartridge valve. Slight bending or distortion of the stem tube can cause binding and malfunction. When removing cartridge valve from manifold, make sure that deep well socket fully engages the valve base. 3. Remove cartridge valve from manifold using a deep socket wrench.
Combination Manifold 5 1 RIGHT 4 FRONT 3 2 Figure 72 1. Combination manifold 2. Flange nut (3 used) 3. Flat washer (3 used) 4. Mount (3 used) 5. Spacer (3 used) NOTE: The ports on the combination manifold are marked for easy identification of components.
Removal (Fig. 72) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 14 2 2. To prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of combination manifold and fittings. 1 3. Label all wire harness connectors that attach to solenoid coils on combination manifold. Disconnect wire harness connectors from solenoid coils on the combination manifold.
Combination Manifold Service UP FRONT 20 ft--lb (27 N--m) 25 ft--lb (34 N--m) 20 ft--lb (27 N--m) 25 ft--lb (34 N--m) 25 ft--lb (34 N--m) 20 ft--lb (27 N--m) 12 13 20 ft--lb (27 N--m) 11 25 ft--lb (34 N--m) 10 9 14 8 15 8 20 ft--lb (27 N--m) 20 ft--lb (27 N--m) 16 20 ft--lb (27 N--m) 5 25 ft--lb (34 N--m) 7 17 18 2 6 19 5 20 ft--lb (27 N--m) 18 4 2 20 21 25 ft--lb (34 N--m) 17 2 17 22 2 3 4 5 25 ft--lb (34 N--m) 1 20 ft--lb (27 N--m) 2 20 ft--lb (27 N--m) Figure 74 1. 2.
NOTE: The ports on the combination manifold are marked for easy identification of components. Example: P4 is the gear pump connection port, S1 is the lift/lower solenoid valve and SV10 is the engine cooling fan solenoid valve (see Hydraulic Schematic in Chapter 10 -Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port). 3 For combination manifold cartridge valve service procedures, see Control Manifold Cartridge Valve Service in this section.
Steering Control Valve 2 1 3 6 20 to 26 ft--lb (28 to 35 N--m) 4 7 27 to 33 ft--lb (37 to 44 N--m) 5 8 10 9 17 19 10 11 18 7 20 12 13 14 15 RIGHT FRONT 16 Figure 77 1. 2. 3. 4. 5. 6. 7. Steering wheel cover Hex nut Flat washer Steering wheel Foam collar Steering seal External snap ring (2 used) Hydraulic System 8. 9. 10. 11. 12. 13. 14. Steering shaft Flange bushing Thrust washer (as needed) Cap screw (4 used) Washer (4 used) Washer (4 used) Mount (4 used) Page 4 -- 104 15. 16. 17.
Removal (Fig. 77) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 1 5 2. Remove steering tower cover to allow access to steering control valve. 3 2 3. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 4 3 4.
Steering Control Valve Service 8 7 17 11 18 5 3 16 19 1 6 9 4 2 20 10 15 21 14 23 13 12 150 in--lb (17 N--m) 22 140 to 160 in--lb (16 to 18 N--m) Figure 80 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 Quad seal 17. 18. 19. 20. 21. 22. 23.
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Steering Cylinder 7 6 4 5 3 4 8 1 2 10 13 RIGHT 9 FRONT 12 11 79 to 84 ft--lb (108 to 113 N--m) Figure 81 1. 2. 3. 4. 5. Steering cylinder Ball joint Ball joint Retaining ring (2 used) Grease fitting Hydraulic System 6. 7. 8. 9. Grease fitting 90o hydraulic fitting (2 used) Drive axle assembly Ball joint spacer Page 4 -- 108 10. 11. 12. 13.
Removal (Fig. 81) 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. To prevent contamination of hydraulic system during cylinder removal, thoroughly clean exterior of cylinder and fittings. 4.
Steering Cylinder Service 6 9 8 7 3 1 2 5 4 12 10 11 40 ft--lb (54 N--m) 1 8 9 2 10 12 11 3 4 7 6 5 Figure 83 1. 2. 3. 4. Barrel Rod Piston Head Hydraulic System 5. 6. 7. 8. Internal collar Backup ring O--ring Dust seal Page 4 -- 110 9. 10. 11. 12.
Disassembly (Fig. 83) Assembly (Fig. 83) 1. Pump oil out of steering cylinder into a drain pan by slowly moving rod in and out of cylinder bore. After oil has been removed from cylinder, plug ports and clean outside of cylinder. 1. Use a complete repair kit when rebuilding the steering cylinder. Put a coating of clean hydraulic oil on all new seals and O--rings. 2. Mount steering cylinder securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft jaws is recommended. 2.
Engine Cooling Fan Motor 26 6 RIGHT FRONT 16 1 15 27 12 to 14 ft--lb (17 to 18 N--m) 9 20 8 14 17 4 12 11 18 5 2 19 10 7 5 3 19 13 21 24 25 22 5 24 23 Figure 84 1. 2. 3. 4. 5. 6. 7. 8. 9. Hydraulic fan motor O--ring Fan bracket Hydraulic fitting (2 used) O--ring Radiator/oil cooler assembly Fan hub Washer Hex nut Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 84) 10 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. RIGHT 1 FRONT 2 2. Unlatch and raise hood. CAUTION The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool before removing fan motor. 3 12 3. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
4. Position fan hub onto motor shaft and secure with washer (item 8) and hex nut (item 9). IMPORTANT: Make sure to not damage the radiator or other machine components while installing the fan motor and bracket assembly. 5. Carefully position fan motor and bracket assembly to radiator and secure with six (6) cap screws and flange nuts. 6. Secure radiator assembly to frame with removed fasteners (Fig. 85). 7.
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Engine Cooling Fan Motor Service 11 10 15 6 3 1 14 7 16 9 8 12 8 4 5 14 33 ft--lb (45 N--m) 9 2 13 Figure 86 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 NOTE: Internal components for a cooling fan motor are not available separately. Disassemble motor for cleaning, inspection and seal replacement only. 12. 13. 14. 15. 16.
9. Turn front flange over, with seal side up. 1 4 3 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. 88). Note orientation of seal lips during removal. Discard removed seals. Inspection 1. Remove any nicks and burrs from all parts with emery cloth. Figure 88 1. Dust seal 2. Retaining ring CAUTION 3. Flange washer 4.
3. Place front flange, seal side down, on a flat surface. 4. Install the pressure seals, flat side outward, into the grooves in the wear plates. Follow by carefully placing the backup gaskets, flat side outward, between the pressure seals and the grooves in the wear plate. 5. Apply a light coating of petroleum jelly to the exposed side of the front flange. 6. Lubricate the drive gear shaft with clean hydraulic oil.
Cutting Deck Motor 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. 3. To prevent contamination of hydraulic system during motor removal, thoroughly clean exterior of motor and fittings. 4. Disconnect hydraulic lines from deck motor. Put caps or plugs on fittings and hoses to prevent contamination.
Cutting Deck Motor Service (Sauer--Danfoss) 15 12 27 to 33 ft--lb (37 to 45 N--m) 9 10 10 14 15 13 9 1 8 7 6 15 33 to 40 ft--lb (45 to 55 N--m) 2 11 5 8 4 3 Figure 91 1. 2. 3. 4. 5. Rear cover Drive gear Seal Woodruff key Nut 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Tab washer Spider hub Pressure seal Back--up ring O--ring NOTE: Internal components for a cutting deck motor are not available separately. Disassemble motor for cleaning, inspection and seal replacement only. Disassembly (Fig.
IMPORTANT: Mark the relative positions of the gear teeth and the bearing blocks so they can be reassembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. 1 8. Place the motor on its side and push on the rear bearing block to remove the bearing block and gear set (Fig. 93). 9. Carefully remove and discard O--rings, pressure seals and back--up rings (Fig. 94) from motor. Do not cause any damage to the machined grooves during the removal process.
Assembly (Fig. 91) NOTE: When assembling the motor, check the identification marks made during disassembly to make sure the parts are properly aligned during assembly. 1. Lubricate O--rings, pressure seals, back--up gaskets and seal grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic oil. 2. Install new shaft seal into front flange. 3. Install lubricated pressure seals into the grooves in the front flange and rear cover.
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Cutting Deck Motor Service (Casappa) 17 2 14 11 9 15 6 3 1 10 7 16 13 14 8 2 33 to 40 ft--lb (45 to 55 N--m) 12 8 5 9 4 Figure 96 1. 2. 3. 4. 5. 6. Flange washer O--ring Front flange Dust seal Retaining ring Front wear plate 7. 8. 9. 10. 11. 12. Shaft seal Backup gasket Pressure seal Rear wear plate Body Idler gear 13. 14. 15. 16. 17. The Casappa cutting deck motors have similar construction as the cooling fan motor (also a Casappa brand) used on the Groundsmaster 4100--D and 4110--D.
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PTO Manifolds 8 18 4 18 20 6 1 10 2 4 12 2 13 16 7 17 4 9 7 18 13 5 11 4 12 4 19 6 8 7 10 18 8 7 14 6 7 13 RIGHT FRONT 4 8 9 2 3 12 8 15 7 Figure 98 1. 2. 3. 4. 5. 6. 7. Hydraulic PTO manifold (center deck) Quick fitting (1 used per manifold) Flange screw (2 used per manifold) O--ring Hydraulic tee fitting O--ring O--ring 8. 9. 10. 11. 12. 13. 14.
Removal (Fig. 98) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 2 2. To prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of PTO manifold and fittings. 3. Disconnect wire harness connector from the proportional relief valve coil on the PTO manifold. 1 4. Disconnect hydraulic lines from manifold and put caps or plugs on open hydraulic lines and fittings.
PTO Manifold Service 20 ft--lb (27 N--m) 5 10 25 ft--lb (34 N--m) 35 ft--lb (47 N--m) 9 20 ft--lb (27 N--m) 1 6 7 3 8 20 ft--lb (27 N--m) 5 ft--lb (6.7 N--m) 2 25 ft--lb (34 N--m) 4 Figure 100 1. 2. 3. 4. PTO manifold body NWD SAE #4 plug with O--ring Orifice (0.025) (port OR) #6 zero leak plug with O--ring 5. Relief valve (port RV1) 6. Proportional relief valve (port PRV) 7. Solenoid coil 8. Nut 9. Logic cartridge valve (port LC1) 10.
The manifolds for the three (3) cutting deck sections are very similar. The front and right side PTO manifolds are identical. The left side PTO manifold uses the same cartridges and plugs as the front and right side manifolds but also includes an additional orifice that threads into the manifold OR2 port (Fig. 101). NOTE: When servicing the PTO manifolds, DO NOT interchange parts from one manifold to another. 1 NOTE: The PTO manifold assembly includes zero leak plugs.
Cutting Deck Lift Cylinders 10 RIGHT 9 10 11 11 4 2 FRONT 12 6 7 5 3 8 1 Figure 102 1. 2. 3. 4. Cutting deck RH lift arm LH lift arm Lift cylinder (2 used) Hydraulic System 5. 6. 7. 8. Pin (1 used per cylinder) Flange nut (1 used per pin) Cap screw (1 used per pin) Grease fitting (1 used per pin) Page 4 -- 130 9. 10. 11. 12.
Removal (Fig. 102) Installation (Fig. 102) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1. If fittings were removed from lift cylinder, lubricate and place new O--rings onto fittings. Install fittings into cylinder port openings using marks made during the removal process to properly orientate fittings (Fig. 103). Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter).
Wing Deck Lift Cylinders 2 160 to 180 ft--lb (217 to 244 N--m) 8 6 4 11 11 7 30 to 40 ft--lb (41 to 54 N--m) 12 6 13 5 4 2 160 to 180 ft--lb (217 to 244 N--m) 3 9 10 RIGHT FRONT 1 Figure 104 1. 2. 3. 4. 5. Center deck Grease fitting Tapered stud Spherical bearing Flange nut Hydraulic System 6. 7. 8. 9. Retaining ring Wing deck lift cylinder Lock nut Flat washer Page 4 -- 132 10. 11. 12. 13.
Removal (Fig. 104) Installation (Fig. 104) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1. If removed, install spherical bearings into lift cylinder clevis ends. WARNING Make sure that cutting deck (including wing decks) is fully lowered before loosening hydraulic lines from wing deck lift cylinders. If deck sections are not fully lowered as hydraulic lines are loosened, deck may drop unexpectedly. 3.
Lift Cylinder Service FRONT DECK LIFT CYLINDER 40 ft--lb (54 N--m) 7 6 12 5 4 2 3 14 1 11 10 9 8 13 Figure 105 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Barrel with clevis Internal collar Shaft with clevis Dust seal Rod seal 11. 12. 13. 14. O--ring Back--up ring Head O--ring Wear ring Piston Lock nut Piston seal Grease fitting WING DECK LIFT CYLINDER 60 to 75 ft--lb (82 to 101 N--m) 12 11 8 2 4 3 1 10 9 6 7 5 Figure 106 1. 2. 3. 4.
Disassembly (Figs. 105 and 106) Assembly (Figs. 105 and 106) 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 1. Make sure all lift 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.
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Chapter 5 Electrical System Table of Contents Groundsmaster 4100--D/4110--D Cruise Control Switch . . . . . . . . . . . . . . . . . . . . . . . Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . Service Brake Switches . . . . . . . . . . . . . . . . . . . . . Headlight Switch (Groundsmaster 4110--D) . . . . Windshield Wiper/Washer Switch (Grounds-master 4110--D) . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Toro Electronic Controllers (TEC) Groundsmaster 4100--D and 4110--D machines use two (2) Toro Electronic Controllers (TEC) to manage machine electrical functions.
Yanmar Engine Electronic Control Unit (ECU) The Yanmar engine that powers the Groundsmaster 4100--D and 4110--D uses an electronic control unit (ECU) for engine management and also to communicate with the TEC controllers and the InfoCenter Display on the machine. All engine ECU electrical connectors should be plugged into the controller before the machine ignition switch is moved from the OFF position to either the RUN or START position.
CAN--bus Communications The two (2) TEC controllers, the Yanmar engine electronic control unit and the InfoCenter Display used on the Groundsmaster 4100--D and 4110--D communicate with each other on a CAN--bus system. Using this system allows the traction unit to fully integrate all the different electrical components of the tractor and bring them together as one.
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Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The multimeter can test electrical components and circuits for current, resistance or voltage. NOTE: Toro recommends the use of a DIGITAL Volt-Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter.
Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally.
InfoCenter Display The InfoCenter Display used on your Groundsmaster is a LCD device that is located on the console. The InfoCenter provides information for the machine operator during machine operation, provides electrical system diagnostic assistance for technicians and allows inputs for adjustable machine settings. Power for the InfoCenter is available when energized by the main power relay (ignition switch in the RUN or START position).
Main Information Screen The two (2) InfoCenter main information screens (Figs. 10 and 11) are displayed after the initial splash screen has been displayed for several seconds. During normal machine operation, the main information screens provide machine information for the operator. Toggling between the main information screens is done by pressing the right button on the InfoCenter.
Main Menu Screen The main menu screen can be accessed from the InfoCenter main information or splash screen by pressing and releasing the menu/back button (left button) on the display. Once to the main menu screen (Fig. 12), navigation to the five (5) different menu items can occur. Pressing the move to menu item button (center button) allows a different menu item to be highlighted. Selection of the highlighted item is completed by pressing the choose item button (right button).
Service Screen NOTE: If the protected menu items are available, PIN will be shown in the upper right corner of the InfoCenter display. The options listed for hours include the following: D Key On identifies the number of hours that the ignition switch has been in the RUN position. D Machine Run identifies the number of hours that the engine has been running. D PTO On identifies the number of hours that the machine has been operated with the cutting deck engaged.
Diagnostics Screen The diagnostics screen (Fig. 16) lists the various states of machine electrical components. The diagnostics screen should be used to check operation of machine controls and to verify that switches and circuit wiring are functioning correctly. For each of the diagnostics screen items, inputs, qualifiers and outputs are identified. The diagnostics screen includes the following: D Left Deck identifies machine requirements to allow the left wing deck to raise and lower.
Settings Screen If either the backlight (brightness) or contrast items are selected, the center button (--) or right button (+) can be used to change the display settings. Protected menus allows the machine PIN to be entered so that hidden machine service screen items can be viewed and modified. The protected service items include traction pedal sensor calibration, cooling fan reversal demonstration, Smart PowerTM ON/OFF and exhaust system DPF regeneration (Tier4 engines).
About Screen The about screen (Fig. 19) identifies the machine model number, serial number and software revisions for the TEC controllers, InfoCenter and engine electronic control unit (if available). The about screen also lists the CAN--bus status. Additional information is identified if the about screen is accessed after the protected menus have been accessed by entering the PIN.
Troubleshooting If the machine has any interlock switches by--passed, reconnect the switches for safety and efficient troubleshooting. CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Also, disconnect the battery cables unless the test requires battery voltage. NOTE: Check the InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems.
Fault Codes The list below identifies the fault codes that are generated by the TEC controller to identify an electrical system malfunction (fault) that occurred during machine operation. Use the InfoCenter Display for fault retrieval. NOTE: The following list of fault codes identifies electrical problems that typically will prevent normal machine operation. The InfoCenter Display will identify existing faults if they should occur. Fault codes 13 through 25 identify problems with inputs (e.g.
Fault Description 31 Brake/RH turn light output has open or short to ground 32 Brake/LH turn light output has open or short to ground 33 Forward piston (traction) pump output has open or short to ground 34 Reverse piston (traction) pump output has open or short to ground 35 Reverse engine cooling fan output (solenoid valve S10) has open or short to ground 36 Disable dual engine cooling fan output (solenoid valve S11) has open or short to ground 38 Center PTO output has open or short to ground
Starting Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. Problem Possible Causes No electrical power to machine. The battery is discharged. The battery cables are loose or corroded. Fuse F--D1 (2 Amp) is faulty. Fuse F--D2 (2 Amp) is faulty. Fuse M1 (60 Amp) is faulty. A faulty ground connection exists on machine. The ignition switch or circuit wiring is faulty. Starter solenoid clicks, but starter will not crank.
Starting Problems (Continued) Problem Possible Causes Starter cranks, but should not, when the traction pedal is depressed. Traction pedal position sensor is out of adjustment. Engine cranks, but does not start. The fuel tank is empty. Traction pedal position sensor or circuit wiring is faulty. The engine is not cranking fast enough. The fuel pump or circuit wiring is faulty. Electrical System The engine or fuel system is malfunctioning (see Yanmar Service Manual).
General Run and Transport Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. Problem Possible Causes Engine continues to run, but should not, when the ignition switch is turned off. The ignition switch or circuit wiring is faulty. The alternator circuit is faulty (machines with 80 Amp alternator) The engine or fuel system is malfunctioning (see Yanmar Service Manual).
Cutting Deck Operating Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. NOTE: To engage the mow circuit, the operator must be in the operator seat, the traction speed must be in the LOW speed (mow) position, the PTO switch must be ON and the cutting deck(s) must be fully lowered and in float. Problem Possible Causes The cutting deck remains engaged, but should not, with no operator in the seat.
Cutting Deck Operating Problems (Continued) Problem Possible Causes Wing cutting deck does not operate. The wing cutting deck is not fully lowered. The wing deck position switch or circuit wiring is faulty. Hydraulic valve solenoid(s) or circuit wiring to the affected wing deck manifold is faulty. A hydraulic problem in the mow circuit exists (see Troubleshooting section of Chapter 4 -- Hydraulic System). The TEC controller is faulty. Cutting deck does not operate.
Cutting Deck Lift/Lower Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. NOTE: To lower a cutting deck, the operator must be in the operator seat and the traction speed must be in the LOW speed (mow) position. To raise a cutting deck, the operator must be in the operator seat. Problem Possible Causes Neither the cutting deck or wing decks will lower. The HI/LOW speed switch is in the HI speed position.
Cutting Deck Lift/Lower Problems (Continued) Problem Possible Causes RH wing cutting deck will not raise or lower, but the front and LH wing cutting decks will raise and lower. The RH deck lift switch or circuit wiring is faulty. Fuse is faulty. Combination control manifold solenoid coils S7, S8 or S9 or circuit wiring is faulty. A hydraulic problem in the lift/lower circuit exists (see Troubleshooting section of Chapter 4 - Hydraulic System). The TEC controller is faulty.
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Electrical System Quick Checks Battery Test (Open Circuit) 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 60o to 100oF (16o to 38oC). The ignition key should be off and all accessories turned off. Connect the positive (+) multimeter lead to the positive battery post and the negative (--) multimeter lead to the negative battery post. The multimeter will display battery voltage.
Adjustments Wing Deck Position Switch Adjustment 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove switch cover from deck to allow access to position switch that requires adjustment. 3. Raise and lower wing deck while monitoring the wing deck latch and the position switch LED on cable end of switch: 3 4 A.
Traction Pedal Adjustment The traction pedal includes a neutral assembly that is used to adjust the traction neutral position (Fig. 22). Traction pedal adjustment may be necessary to make sure that traction pedal movement provides the correct full reverse and full forward positions for the traction pedal position sensor. The InfoCenter display can be used to check traction pedal adjustment using the following procedure. 1 1.
6. After any adjustment of the spring shaft and rod end bearing, use the InfoCenter Display Diagnostics menu (see InfoCenter Display in this chapter) to obtain and select the Traction Pedal menu item. Choose Outputs and the InfoCenter display will identify the traction pedal position (Fig. 24). Traction Pedal Forward Range: Neutral Reverse Range: OFF ON OFF A. When the traction pedal is in the neutral position, the InfoCenter should display Neutral as ON and both Forward Range and Reverse Range as OFF.
Traction Pedal Position Sensor Calibration IMPORTANT: A properly installed and calibrated traction pedal position sensor is critical to accurate traction system response and for reliable sensor life. Use care when removing, installing and calibrating the traction pedal position sensor. 1 Calibration of the traction pedal position sensor ensures that the TEC controller can identify the traction neutral, forward and reverse positions. 2 1.
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 Yanmar Service Manual and Yanmar Troubleshooting Manual. CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected.
Fuses The fuse block is located under the controller cover next to the operator seat (Fig. 30). In addition to the fuses in the fuse block, a 60 Amp fuse is included in the wire harness to protect the power circuit for the operator cab. This fuse resides in a fuse holder near the fuse block (Fig. 30). Fuse Identification and Function Use Figure 31 to identify each individual fuse and its correct amperage in the fuse block. The fuses have the following functions.
Operator Cab Fuses (Groundsmaster 4110--D) The operator cab fuse blocks are located in the cab headliner (Fig. 32). Identification and Function (Figs. 33 and 34) Fuse F1--2 (15 Amp) protects the cab fan circuit. Fuse F1--3 (30 Amp) protects the air conditioner circuit. Fuse F2--1 (15 Amp) protects the windshield wiper/ washer circuit. 2 Fuse F2--2 (15 Amp) protects the cab dome light circuit. Fuses F1--1, F1--4, F2--3 and F2--4 are available for optional equipment. 1 Figure 32 Testing 1.
Fusible Link Harness Your Groundsmaster uses two (2) fusible links for circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the wire harness (Fig. 35). If either of these links should fail, current to the protected circuits will cease. Refer to wire harness drawings in Chapter 10 -- Foldout Drawings for additional fusible link information. 1 2 Testing Make sure that ignition switch is OFF.
PTO Switch The PTO switch is located on the control arm (Fig. 37). The PTO switch is pulled up to engage the PTO and pushed in to disengage the PTO. The TEC controller monitors the position of the PTO switch (up or down). Using inputs from the PTO switch and other switches in the interlock system, the TEC controller controls the energizing of the hydraulic solenoid valves used to drive the cutting deck motors.
HI/LOW Speed, Engine Speed and Cutting Deck Lift Switches The HI/LOW, engine speed and cutting deck lift switches are all identical momentary switches. These switches are located on the control arm (Fig. 39). The HI/LOW speed switch is used as an input for the TEC controller to select either the HI (transport) or LOW (mow) traction speed. The engine speed switch is used as an input for the engine electronic control unit to raise or lower the engine speed.
Cruise Control Switch The cruise control switch is used as an input for the TEC controller to maintain ground speed when engaged. The cruise control function is enabled when the switch is in the ON (center) position. Pressing the front of the switch to the momentary position sets the desired ground speed. The cruise control function is disengaged when the rear of the cruise control switch is depressed.
Seat Switch The seat switch is normally open and closes when the operator is on the seat. This switch is used as an input for the TEC controller. The seat switch and its electrical connector are located in the seat assembly. If the traction system or PTO switch is engaged when the operator raises out of the seat, an operator advisory will be displayed on the InfoCenter. Testing of the switch can be done without seat removal by disconnecting the switch wire from the machine wire harness (Fig. 43).
Parking Brake Switch The switch used for the parking brake is a normally open proximity switch that is located under the steering tower cover (Fig. 44). The parking brake switch is an input for the TEC controller. When the parking brake is not applied, a tab on the brake rod is positioned near the switch sense zone which causes the switch to close (continuity).
Service Brake Switches The two (2) switches used for the service brakes are normally open switches that are located under the footrest panel (Fig. 45). The service brake switches provide inputs for the TEC controller. When a brake pedal is not depressed, the brake pedal assembly contacts the switch plunger to close the switch. When a brake is applied, the brake pedal assembly moves away from the switch plunger, allowing the switch plunger to extend and the switch to open. 13 to 17 in--lb (1.5 to 1.
Headlight Switch (Groundsmaster 4110--D) The Groundsmaster 4110--D headlight switch is a two (2) position rocker switch that is located on the inside of the control arm (Fig. 46). The headlight switch allows the headlights and taillights to be turned on and off. 2 Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 1 2. Disassemble control arm to gain access to headlight switch (see Control Arm in the Service and Repairs section of Chapter 7 -- Chassis). 3.
Windshield Wiper/Washer Switch (Groundsmaster 4110--D) The windshield wiper/washer switch is used to control operation of the windshield wiper and washer pump on the Groundsmaster 4110--D. The windshield wiper/washer switch is located in the cab headliner (Fig. 48). 2 Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 2. Remove switch plate from cab headliner. 3. Locate windshield wiper/washer switch and unplug wire harness connector from switch. 4.
Air Conditioning Switch (Groundsmaster 4110--D) The air conditioning switch is used to control operation of the air conditioning system on the Groundsmaster 4110--D. The switch is located in the cab headliner (Fig. 50). Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 2 2. Remove switch plate from cab headliner. 3. Locate air conditioning switch and unplug wire harness connector from switch.
Turn Signal Switch (Groundsmaster 4110--D) On Groundsmaster 4110--D machines, the turn signal switch is used as an input for the TEC controller to provide power for the turn signals. The switch is located on the steering tower (Fig. 52). Testing 1. Before disconnecting the turn signal switch for testing, the switch and its circuit wiring should be tested as a TEC input with the InfoCenter Display (see InfoCenter Display in this chapter).
Flasher Switch (Groundsmaster 4110--D) On Groundsmaster 4110--D machines, the flasher switch is used as an input for the TEC controller to provide power for the four way flashers. The switch is located on the steering tower (Fig. 54). 2 Testing 1. Before disconnecting the flasher switch for testing, the switch and its circuit wiring should be tested as a TEC input with the InfoCenter Display (see InfoCenter Display in this chapter).
Relays with Four (4) Terminals Your Groundsmaster uses a number of electrical relays that have four (4) terminals. A tag near the wire harness relay connector can be used to identify each relay. The main power relay is used to provide current to most of the fuse protected circuits (operator seat, InfoCenter display, power point and optional electric equipment). The main power relay is energized when the ignition switch is in the RUN or START position.
5. Using a multimeter, verify that coil resistance between terminals 86 and 85 is approximately 72 ohms. 6. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as +12 VDC is applied and removed from terminal 85. 86 87 30 85 85 30 86 87 7. Disconnect voltage and test leads from the relay terminals. 8.
Relays with Five (5) Terminals Your Groundsmaster uses a number of electrical relays that have five (5) terminals. A tag near the wire harness relay connector can be used to identify each relay. The air conditioning relay is used to control the air conditioning electrical power circuit on the Groundsmaster 4110--D. When energized by the air conditioning switch, the relay provides current for the air conditioning components.
8. Connect multimeter (ohms setting) leads to relay terminals 30 and 87A. Apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87A as +12 VDC is applied and removed from terminal 85. 10.Secure all removed components to machine. 11. Connect positive (+) cable first to battery and then connect negative (--) cable to battery (see Battery Service in the Service and Repairs section of this chapter). Electrical System 9.
Toro Electronic Controllers (TEC) Groundsmaster 4100--D and 4110--D machines use two (2) Toro Electronic Controllers (TEC) to control electrical system operation. The controllers are attached to the operator platform under the controller cover (Figs. 63 and 64). 2 3 1 8 Logic power is provided to the controllers as long as the battery cables are connected to the battery.
12V POWER (7.5A FUSES) 12V LOGIC POWER (2 AMP FUSE) VOLTAGE OUT The machine electrical schematic and wire harness drawings in Chapter 10 -- Foldout Drawings can be used to identify possible circuit problems between the controllers and the input/output devices (e.g. switches and solenoid coils). IGNITION SWITCH INPUTS Because of the solid state circuitry built into the TEC controllers, there is no method to test a controller directly.
Traction Pedal Position Sensor The traction pedal position sensor is connected to the traction pedal assembly (Fig. 67). This position sensor determines the neutral band for the traction pedal, the direction of travel desired by the operator and the traction speed. The position sensor is a single analog, dual digital signal electronic device.
Audio Alarm The audio alarm sounds to notify the operator when a machine problem exists. Electrical current for the alarm is provided as an output from the TEC controller. The alarm is attached to the console arm next to the operator seat. Testing 6. Disconnect voltage source from the alarm. Reconnect harness connector to alarm. 7. Assemble console arm (see Console Arm Assembly in the Service and Repairs section of Chapter 7 -- Chassis). 1. Make sure ignition switch is OFF.
Hydraulic Valve Solenoid Coils 2 4 1 RIGHT FRONT 3 Figure 69 1. Front PTO manifold 2. RH PTO manifold 3. LH PTO manifold Several hydraulic solenoid valve coils are used on the hydraulic control manifolds of Groundsmaster 4100--D and 4110--D machines. When energized by the TEC controller, these coils provide hydraulic circuit control. Solenoid valve coils with two (2) different resistance specifications are used on the 4100--D and 4110--D.
Testing 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Locate hydraulic solenoid valve coil to be tested (Fig. 69). Disconnect wire harness connector from coil. 3. Identify coil resistance specification by measuring the coil diameter and coil height (Fig. 70). COIL DIAMETER NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together.
Piston (Traction) Pump Control Solenoid Coils The piston (traction) pump uses an electronic control assembly for swash plate rotation. Electrical outputs from the machine TEC controller are provided to two (2) solenoid coils for pump control. The piston pump control assembly is attached to the left side of the piston pump (Fig. 72). C. Slide new coil with O--rings onto the solenoid stem. NOTE: To assist in troubleshooting, the piston pump solenoid coils can be exchanged because they are identical.
CAN--bus Termination Resistor System communication between electrical components on Groundsmaster 4100--D and 4110--D machines is accomplished on a CAN--bus communication system. Two (2) specially designed, twisted wires form the bus for the network used on the machine. These wires provide the data pathways between machine components. At the end of the twisted pair of bus wires near the InfoCenter display is a 120 ohm termination resistor.
Diode Assemblies The Groundsmaster engine wire harness contains a diode assembly that is used for circuit protection from voltage spikes when the engine starter solenoid is de-energized. 1 4 2 Groundsmaster models 30606 and 30608 use an additional diode assembly in the engine wire harness that protects the engine EGR circuit from reverse polarity. The diode assemblies plug into the wiring harness near the engine starter motor (see engine wire harness drawing in Chapter 10 -- Foldout Drawings).
Fuel Sender The fuel sender is attached to the top of the fuel tank. The resistance of the fuel sender increases as the fuel level in the fuel tank decreases. The TEC controller uses the fuel sender as an input to generate an output for the InfoCenter fuel gauge. Two (2) styles of fuel senders have been used on Groundsmaster 4100--D and 4110--D machines. Early production machines are equipped with a pivoting float design that has two (2) wire harness terminals (shown in Fig. 77).
Fuel Pump (Models 30602 and 30604) The fuel pump is attached to the fuel tank support above the fuel water separator (Fig. 79). 2 Operational Test 4 1. Park machine on a level surface, lower cutting deck, stop engine and apply parking brake. Raise hood to access fuel pump. 3 2. Disconnect fuel pump discharge hose from the fuel injection pump fitting on the engine (Fig. 80). 3. Make sure fuel hoses attached to the fuel pump are free of obstructions. 4.
Fuel Pump (Models 30606 and 30608) The fuel pump is attached to the fuel tank support above the fuel water separator (Fig. 81). Operational Test 2 1. Park machine on a level surface, lower cutting deck, stop engine and apply parking brake. Raise hood to access fuel pump. 2. Disconnect fuel pump discharge hose from the fuel filter attached to the engine (Fig. 82). 3 3. Make sure fuel hoses attached to the fuel pump are free of obstructions. 4.
Wing Deck Position Switches Two (2) wing deck position switches are used on the Groundsmaster 4100--D and 4110--D as inputs for the TEC controller. The position switches are powered proximity switches that are normally open. The switches incorporate an internal reed switch and a LED. These switches are secured to the center section of the cutting deck (Fig. 83). A bolt head on the wing deck link is the sensing plate for the position switch (Fig. 84). B.
Hydraulic Oil Temperature Sender The Groundsmaster 4100--D and 4110--D use a temperature sender as an input for the TEC controller to identify if the hydraulic oil temperature has reached an excessive level. The hydraulic oil temperature sender is attached to the bottom of the rear axle motor (Fig. 85). The InfoCenter will display fault code 18 if the hydraulic oil temperature sender inputs to the TEC controller are not in the normal range. 5. After allowing the sender to cool, install sender: A.
Service and Repairs NOTE: For engine component repair information (e.g. starter motor), refer to the Yanmar Service Manual that is correct for your Groundsmaster model. Battery Care 1. The top of the battery must be kept clean. lf the machine is stored in a location where temperatures are extremely high, the battery will discharge more rapidly than if the machine is stored in a location where temperatures are cool. B. Coat battery posts and cable connectors with battery terminal protector (Toro Part No.
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. Electrolyte Specific Gravity Fully charged: 1.
Battery Testing 1. Perform a high--discharge test with an adjustable load tester. This is one of the most reliable means of testing a battery as it simulates the cold--cranking test. A commercial battery load tester is required to perform this test. CAUTION Follow the manufacturer’s instructions when using a battery load tester. A. Check the voltage across the battery terminals prior to testing the battery. If the voltage is less than 12.4 VDC, charge the battery before performing a load test. B.
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. CAUTION Follow the manufacturer’s instructions when using a battery charger. NOTE: Using specific gravity of the battery electrolyte is the most accurate method of determining battery condition. 1.
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Chapter 6 Axles, Planetaries and Brakes Table of Contents Axles, Planetaries and Brakes SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Planetary Wheel Drive Assembly Endplay . . . . . . 4 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 6 Brake Assembly . .
Specifications Item Specification Tire pressure (front and rear) 25 to 30 PSI (172 to 207 kPa) Rear wheel toe--in 0.250 in (6 mm) Planetary gear drive oil System gear lube capacity (each wheel) SAE 85W--140 wt. gear lube 22 fl. oz. (0.65 liters) Rear axle lubricant System gear lube capacity SAE 85W--140 wt. gear lube 80 fl. oz. (2.4 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.
Adjustments Planetary Wheel Drive Assembly Endplay A front planetary wheel drive assembly that is properly operating should have no endplay. Any endplay in a planetary assembly indicates that there are potential problems with the planetary. Check planetary endplay at intervals specified in your Operator’s Manual. Endplay Checking Procedure 1. Park machine on a level surface, lower cutting deck, stop engine and remove key from the ignition switch. 3.
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Service and Repairs Brake Assembly 75 to 85 ft--lb (101 to 115 N--m) 19 4 1 15 13 3 8 11 7 6 14 20 12 1 13 8 10 2 22 6 RIGHT FRONT 5 17 7 16 75 to 85 ft--lb (101 to 115 N--m) 9 18 85 to 100 ft--lb (115 to 135 N--m) 21 Figure 1 1. 2. 3. 4. 5. 6. 7. 8. Front wheel motor Internal retaining ring Splined brake shaft RH brake assembly Planetary assembly (2 used) Cap screw (2 used per motor) Flat washer (2 used per motor) O--ring Axles, Planetaries and Brakes 9. 10. 11. 12. 13. 14. 15.
Removal (Fig. 1) 1. Park machine on a level surface, lower cutting deck, stop engine and remove key from the ignition switch. 2. Drain oil from planetary wheel drive/brake assembly (Fig. 2). 2 CAUTION 1 When removing front wheel, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels.
2. Apply gasket sealant to sealing surfaces of new gasket (item 18). Apply gasket to brake assembly. 9. Make sure drain plugs are installed in brake and planetary drive assemblies (Fig. 2). 3. Install brake assembly onto machine, aligning splined brake shaft with input shaft on planetary wheel drive. Make sure that brake pull rod is orientated toward rear of machine. 10.Fill planetary wheel drive/brake assembly with SAE 85W--140 gear lube (Fig. 5). Capacity is approximately 22 fl. oz. (0.
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Brake Inspection and Repair 2 1 3 4 5 6 7 8 9 15 10 14 13 12 11 Figure 6 1. 2. 3. 4. 5. Brake housing (LH shown) Seal Pull rod Clevis pin (2 used) Link (2 used) 6. 7. 8. 9. 10. Hitch pin (2 used) Stationary disc (4 used) Rotating disc (3 used) Retaining ring Gasket Brake Inspection and Repair (Fig. 6) 1. Carefully scrape gasket material (item 10) from brake housing and planetary wheel drive mounting surfaces. 2. Remove retaining ring (item 9) from brake housing groove. 3.
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Planetary Wheel Drive Assembly 75 to 85 ft--lb (101 to 115 N--m) 19 4 1 15 13 3 8 11 7 6 14 1 13 8 2 22 6 17 7 FRONT 20 12 10 RIGHT 5 16 75 to 85 ft--lb (101 to 115 N--m) 9 18 85 to 100 ft--lb (115 to 135 N--m) 21 Figure 7 1. 2. 3. 4. 5. 6. 7. Front wheel motor Internal retaining ring Splined brake shaft RH brake assembly Planetary assembly (2 used) Cap screw (2 used per motor) Flat washer (2 used per motor) 8. 9. 10. 11. 12. 13. 14.
Removal (Fig. 7) WARNING 1. Park machine on a level surface, lower cutting deck, stop engine and remove key from the ignition switch. 2. Drain oil from planetary wheel drive/brake assembly (Fig. 8). Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury. 5. Lower machine from jack stands. Torque lug nuts from 85 to 100 ft--lb (115 to 135 N--m). CAUTION When removing front wheel, use correct jacks and supports.
Planetary Wheel Drive Service 2 118 to 144 in--lb (13.3 to 16.3 N--m) 3 4 7 8 9 11 1 12 13 14 5 15 16 6 10 28 21 13 27 26 17 25 24 23 22 20 19 18 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Spindle Boot seal Oil seal Inner bearing cone Inner bearing cup Wheel stud (8 used) Socket head screw (16 used) Lock washer (16 used) Housing Dowel pin (2 used) Axles, Planetaries and Brakes 11. 12. 13. 14. 15. 16. 17. 18. 19.
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 in this section. Disassembly (Figs. 10 and 11) 1. If planetary wheel drive assembly is installed on machine: A. Park machine on a level surface, lower cutting units, stop engine and remove key from the ignition switch. B. Drain oil from planetary wheel drive/brake assembly. C.
F. Lightly oil bearing journals on spindle shaft. Slide housing assembly onto spindle (item 1) taking care to not damage seal or spindle. Make sure that inner bearing in housing fully seats against spindle shaft shoulder. G. Install outer bearing cone (item 12) onto spindle. NOTE: The planetary shim kit includes the retaining ring and several thrust washers with thickness in incremental steps of 0.004 inch (0.10 mm). Refer to your Parts Catalog to identify the correct part number for the planetary shim kit.
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Rear Axle Assembly 18 19 5 8 6 7 22 28 4 16 5 15 27 17 1 24 20 3 12 29 14 25 27 23 RIGHT 26 21 FRONT 9 10 13 1 11 85 to 100 ft--lb (115 to 135 N--m) 2 Figure 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Plug with O--ring Lug nut (5 used per wheel) Rear wheel assembly (2 used) Cap screw (2 used) Flat washer (8 used) Rear axle motor O--ring Steering cylinder Spacer Cotter pin (2 used) 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Removal (Fig. 12) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. Drain oil from rear axle and axle gearbox (Figs. 13 and 14). 3. Chock front wheels and jack up rear of machine (see Jacking Instructions in Chapter 1 -- Safety). Support machine with appropriate jack stands. 1 2 4. Remove both wheels from rear axle. 5.
2. Secure rear axle to rear axle mount. A. Slide rear axle pin through rear axle mount and rear axle. Install washer and lock nut onto rear axle pin. 2 1 B. Secure pivot pin to axle mount with washer head screw (Fig. 16). C. Torque lock nut from 135 to 165 ft--lb (184 to 223 N--m). After tightening the lock nut, makes sure that the rear axle pivots freely. 3. Position rear axle with attached mount under machine.
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Rear Axle Service 10 11 21 20 19 17 18 24 22 2 23 16 1 25 4 13 15 12 5 26 43 6 7 8 44 45 27 46 61 62 14 3 8 9 47 33 28 29 32 30 31 10 11 48 37 50 63 64 42 22 60 51 38 41 52 8 9 35 36 49 13 34 40 53 59 54 58 39 57 56 55 Figure 19 Axles, Planetaries and Brakes Page 6 -- 22 Groundsmaster 4100--D/4110--D
Figure 19 (Continued) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. LH axle support Flange bushing (2 used) Axle vent Filter Vent extension Cap screw (4 used per gear case) Shim set Seal washer Plug Lock nut Lock washer Grease fitting Ball bearing Screw (2 used per steering arm) Axle case support (LH shown) Bolt (2 used) Stud (2 used) Shim set Differential assembly O--ring Plug O--ring 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43.
Bevel Gear Case and Axle Case The following procedures assume the rear axle assembly has been removed from the machine. 35 to 41 ft--lb (47 to 56 N--m) Removal 1 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. 20). 4 5 6 2 2. Mark both right and left bevel gear case/axle case assemblies. 3 35 to 41 ft--lb (47 to 56 N--m) IMPORTANT: Do not interchange right and left bevel gear case/axle case assemblies.
5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gasket material from either mating surface (Fig. 23). 6. While holding the bevel gear case, tap the upper end of the bevel gear shaft out of the upper bearing and upper bevel gear. 2 1 17 to 20 ft--lb (23 to 27 N--m) 3 4 Threadlocking Compound 7. Pull the bevel gear case from the axle case and remove the upper bevel gear and collar from the gear case. 5 14 8.
Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 25). 3 2 1 Figure 25 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. 26). 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. 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. If binding of components is noted before screws are fully tightened, add additional support shims. Torque screws from 57 to 67 ft--lb (77 to 91 N--m). C.
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. 29). LOWER BEVEL GEAR BACKLASH: 0.004 to 0.016 inch (0.10 to 0.40 mm) 10.Adjust backlash by increasing or reducing axle bearing shim thickness (see Axle Shafts in this section of this manual).
Axle Shafts The following procedures assume the rear axle assembly has been removed from the machine. 1 Removal 4 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig. 32). 17 to 20 ft--lb (23 to 27 N--m) 3 2. Use a bearing puller to remove the bearing and bevel gear as shown (Fig. 33). 3. Remove the shims, spacer and retaining ring. Drive the axle out of the bearing and cover. Remove and discard the axle shaft seal. 4.
Input Shaft/Pinion Gear 20 35 to 41 ft--lb (47 to 56 N--m) 22 1 3 19 2 17 18 16 4 10 9 8 6 21 5 23 15 10 14 9 13 7 11 35 to 41 ft--lb (47 to 56 N--m) 12 Figure 35 1. 2. 3. 4. 5. 6. 7. 8. Nut (2 used) Lock washer (2 used) Stud (2 used) Lock nut Stake washer Oil seal O-ring Seal collar 9. 10. 11. 12. 13. 14. 15. 16.
5. Install a new stake washer. Install the lock nut finger tight. 6. Set the bearing preload by securing the bearing case in a vise. Thread a M12 x 1.5 hex head cap screw into the splined end of the input shaft/pinion gear and slowly tighten the lock nut until 4 to 6 in-lb (0.4 to 0.7 N--m) of force is required to rotate the input shaft/pinion gear in the bearing case. 0.040 in. (1.0 mm) 2 1 7. Secure the lock nut with the stake washer. 8.
Differential Gear The following procedures assume the rear axle assembly has been removed from the machine. 35 to 41 ft--lb (47 to 56 N--m) 1 Removal 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. 2. Mark and pull the differential shaft assemblies from the axle support. 3. Remove input shaft/pinion gear assembly, shims and O-ring from the axle support (Fig.
Inspection 1. Measure the differential side gear O.D. and the differential case I.D. to determine the side gear to case clearance (Fig. 42). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 inch (0.05 to 0.30 mm) 1 SIDE GEAR O.D. (Factory Spec.): 1.335 to 1.337 inch (33.91 to 33.95 mm) DIFFERENTIAL CASE I.D. (Factory Spec.): 1.339 to 1.341 inch (34.00 to 34.06 mm) 2 2. Measure the differential pinion shaft O.D. and the pinion gear I.D.
Installation 3 1. If the ring gear was removed from the differential case, use medium strength Loctite thread locker and tighten the mounting screws from 22 to 25 ft-lb (30 to 34 N--m). 2 1 2. Apply molybdenum disulfide lubricant (Three Bond 1901 or equivalent) 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. 46): 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. 49): A. Install thicker or additional bearing case shim(s) to move pinion shaft toward ring gear. Figure 49 B. Install thinner or remove differential bearing shim(s) to move ring gear backward. C.
Chapter 7 Chassis Table of Contents GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 1 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 2 Steering Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cutting Deck Lift Arms . . . . . . . . . . . . . . . . . . . . . . . 4 Console Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Traction Pedal Assembly . . . . . . . . . . . . . .
Service and Repairs Steering Tower 2 1 3 6 20 to 26 ft--lb (28 to 35 N--m) 4 7 27 to 33 ft--lb (37 to 44 N--m) 5 8 10 9 17 19 10 11 18 7 20 12 13 14 20 15 16 RIGHT FRONT 22 21 23 19 24 Figure 1 1. 2. 3. 4. 5. 6. 7. 8. Steering wheel cover Hex nut Flat washer Steering wheel Foam collar Steering seal External snap ring (2 used) Steering shaft Chassis 9. 10. 11. 12. 13. 14. 15. 16.
Disassembly (Fig. 1) 3 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 5 2. Remove steering tower covers to access steering tower components (Fig. 2). 2 3. Disassemble steering tower as needed using Figure 1 as a guide. Assembly (Fig. 1) 2 1. Assemble steering tower using Figures 1 and 2 as guides. 4 A.
Cutting Deck Lift Arms 2 26 75 to 85 ft--lb (102 to 115 N--m) 27 to 33 ft--lb (37 to 44 N--m) 37 27 16 18 3 40 Loctite #271 on threads (both ends) 29 38 4 1 24 7 23 25 22 28 9 17 21 15 11 5 20 12 32 6 10 8 34 35 19 36 33 39 14 13 60 to 70 ft--lb (82 to 94 N--m) FRONT 31 30 RIGHT 41 43 155 to 185 ft--lb (211 to 251 N--m) 42 Figure 3 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Removal (Fig. 3) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2 2. Remove front cutting deck (see Cutting Deck Removal in Chapter 8 -- Cutting Deck). 3 CAUTION 4 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.
Installation (Fig. 3) 1. If removed, install components to lift arm. A. Press flange bushings into lift arm. B. Install spherical bearing on tapered stud and secure with flange nut. Torque flange nut from 30 to 40 ft--lb (41 to 54 N--m). Install stud with spherical bearing into lift arm and secure with retaining ring. 2 C. If rod and clevis ends were removed from damper, apply Loctite #271 (or equivalent) to threads on damper shaft and stud. Install ends on damper.
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Console Arm 27 26 28 18 25 23 21 22 20 34 1 19 31 14 13 11 29 36 30 33 32 37 40 35 41 10 9 38 15 24 39 2 16 17 7 3 12 6 RIGHT 4 8 42 FRONT 5 43 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Flange nut (3 used) Flange head screw (2 used) Washer head screw (10 used) LH cover Lock nut Control arm panel Ignition switch InfoCenter display R--clamp Audio alarm PTO switch Nut Bracket U--nut (5 used) Clip (2 used) Chassis 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.
Disassembly (Fig. 8) 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 2. Remove two (2) flange head screws (item 27) and then cover plate (item 26) from outside of control arm. Locate and retrieve two (2) spacers (item 25). 3. At front of control arm, remove screw (item 29) and lock nut (item 5) that secure control arm covers to each other. 8 6 6.
Traction Pedal Assembly 5 6 7 13 to 17 in--lb (1.5 to 1.9 N--m) 10 11 8 37 13 36 14 2 16 24 18 8 22 19 35 38 34 25 9 32 12 15 30 29 17 20 33 21 31 1 23 26 27 3 28 RIGHT 4 FRONT 8 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Carriage bolt (6 used) Traction pedal Bushing Operator platform Cap screw Rod end bearing Hex nut Flange nut (10 used) Traction pedal shaft Roll pin Cap screw (2 used) Clamp block (2 used) Lock nut Chassis 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
IMPORTANT: A properly installed and calibrated traction pedal position sensor is critical to accurate traction system response and for reliable sensor life. Use care when removing, installing and calibrating the traction pedal position sensor. F. To install the traction pedal position sensor (item 28 in Fig. 10), press and hold the traction pedal in the reverse direction slightly. Align the slot on the end of the pedal shaft with the slot in the position sensor.
Operator Platform 1 2 3 7 3 4 4 95 to 115 ft--lb (129 to 155 N--m) 6 5 5 6 RIGHT FRONT Figure 12 1. 2. 3. Operator platform Cap screw (2 used) Flat washer (4 used) Chassis 4. 5. Center mount (4 used) Plain washer (4 used) Page 7 -- 12 6. 7.
Some service procedures (e.g. removing the hydraulic reservoir) require the operator platform to be raised. The following steps can be used to raise the platform. 5 2 Disassembly (Fig. 12) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 3 2 2.
Assembly (Fig. 12) 2 13 to 17 in--lb (1.5 to 1.9 N--m) 3 1. Make sure that all machine components are installed below operator platform before platform is lowered to frame. 1 IMPORTANT: Make sure to not damage the electrical wire harness or other components while lowering the operator platform. 5 4 6 2. Carefully lower operator platform and position over center mounts (item 4) that are installed in the frame. 7 3.
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Operator Seat 8 7 38 9 37 25 31 21 5 6 1 2 12 4 10 3 6 13 32 28 11 15 35 16 33 27 14 17 34 19 36 23 20 22 27 30 18 4 26 28 RIGHT 27 FRONT 29 24 Figure 17 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Carriage screw (5 used) Support channel Support bracket Flange nut (6 used) Cap screw Flat washer (4 used) Arm support Screw Coupler nut Spacer Flange nut (4 used) Seat belt Cap screw Chassis 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Removal (Fig. 17) B. Secure control arm support (item 7) to coupler nut (item 9) with screw (item 8). 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. C. Place flat washer (item 6), seat belt latch (item 21) and spacer (item 10) between seat and control arm support (item 7). Secure with cap screw (item 5) and second flat washer (item 6). 2. Disconnect seat electrical connector from machine wire harness (Fig. 18). D.
Operator Seat Service 7 6 21 1 2 13 5 28 12 21 22 26 25 30 29 16 18 19 20 11 4 24 14 17 3 23 9 8 27 10 15 Figure 20 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 -- 18 21. 22. 23.
Disassembly (Fig. 20) 2 1. Disassemble operator seat as necessary using Figures 20 and 21 as guides. 3 Assembly (Fig. 20) 1. Assemble operator seat using Figures 20 and 21 as guides. 1 4 6 7 5 Figure 21 Operator seat R--clamp (2 used) Screw (2 used) Manual tube 5. Flat washer 6. Seat belt 7. Cap screw Chassis 1. 2. 3. 4.
Operator Seat Suspension RIGHT 16 17 FRONT 24 22 25 23 5 18 2 19 21 33 1 20 3 39 14 12 7 13 35 28 30 6 15 38 27 31 4 36 8 29 9 10 26 33 11 34 37 32 Figure 22 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. 22) 1. Remove operator seat from seat suspension (see Operator Seat Removal in this section). 3 2. Disconnect seat suspension connector from machine wire harness (Fig. 23). 3.
Hood 21 4 1 20 24 29 18 26 28 25 31 7 23 30 27 12 9 22 6 8 5 15 RIGHT 11 10 FRONT 14 2 3 17 16 19 13 Figure 25 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Hood Screen assembly Bulb seal Flange nut (2 used) Screen pivot (2 used) Hair pin (2 used) Hood support Plastite screw (4 used) Door handle (2 used) Bulb seal Hood pivot (2 used) Chassis 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Removal 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 1 3 2. Remove hood assembly from machine: A. Remove hair pins (item 6) that retain screen pivots to hood pivots. 2 B. Slide hood assembly to disengage screen pivots from hood pivots and lift hood from machine. 3. Disassemble hood as needed using Figure 25 as a guide. Figure 26 Installation 1. LH shim location 2. LH hood pivot 1.
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Chapter 8 Cutting Deck Table of Contents Cutting Deck SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Castor Wheel Tire Pressure . . . . . . . . . . . . . . . . . . 3 Blade Stopping Time . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4 Factors That Can Affect Quality of Cut . .
Specifications MOUNTING: Cutting deck is supported by lift arms controlled with individual lift switches for complete deck, right wing deck and left wing deck. 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 23 75 to 85 ft--lb (102 to 115 N--m) 22 19 9 7 6 3 8 10 5 4 11 18 13 14 17 15 16 12 20 21 2 1 RIGHT FRONT Figure 1 1. 2. 3. 4. 5. 6. 7. 8. Cutting deck Cap screw (4 used) LH lift arm Flange nut (4 used) Spacer Damper Damper rod end Damper clevis end Cutting Deck 9. 10. 11. 12. 13. 14. 15. 16.
Removal (Fig. 1) 1. Position machine on a clean, level surface. Lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2 NOTE: Removal of clevis pins from deck and height-of--cut chains is easier if deck is lifted slightly. 1 2. Note location of clevis pins that secure height of cut chains to the rear of the cutting deck. Remove hairpins and clevis pins that secure the height--of--cut chains to 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. 2 4. Install clevis pins and hairpins that secure the height--of--cut chains to the rear of the cutting deck (Fig. 2). 3 5. Remove plugs from hydraulic hoses and fittings on wing deck lift cylinders. Using labels placed during removal, correctly attach hydraulic hoses to lift cylinders. 6. Connect cutting deck wire harness to machine wire harness. 7. Position damper to cutting deck bracket.
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Wing Deck Service 25 2 100 to 140 in--lb (12 to 15 N--m) 160 to 180 ft--lb (217 to 244 N--m) 43 23 3 46 45 47 40 34 48 49 37 1 31 30 41 24 4 6 44 7 33 19 50 RIGHT 39 21 22 20 42 38 19 8 52 FRONT 10 29 18 52 53 36 32 28 23 39 24 5 35 27 26 51 9 11 17 14 16 10 12 15 17 13 Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 6) 1. Position machine on a clean, level surface. Lower cutting deck and engage parking brake. 1 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 in the Service and Repairs Section of Chapter 4 -- Hydraulic System). 3 4.
4. Position upper end of link assemblies to center cutting deck brackets. 5. Align upper end of link assemblies with mounting holes in center deck. While installing pivot pins to center deck and links, insert spacers and washers as follows: A. Place one (1) hardened spacer (item 42) on each side of the front link. Use two (2) thrust washers on rear side of assembly so that link is snug between deck brackets. Additional thrust washers should be installed, if necessary, to remove excess clearance. B.
Cutting Deck Link Service Disassembly (Fig. 10) 100 to 140 in--lb (12 to 15 N--m) 1. Press bushings from top of link. 1 2. Remove dust cap and retaining ring from link. 2 3. Press tapered stud with spherical bearing, flat washers and flange nut from link. 3 4. Remove flange nut and press spherical bearing from tapered stud. 4 5 5 6 7 8 Assembly (Fig. 10) 1. Install new spherical bearing onto tapered stud. Secure bearing with flange nut. Torque nut from 100 to 140 in--lb (12 to 15 N--m). 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 2 4 3 10 11 5 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. High driven spindle (1 used) 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) 7. Attach a hand pump grease gun to grease fitting on spindle housing and fill housing cavity with grease until grease starts to come out of lower seal. 1. If screws were removed from spindle housing, press new screws into housing. Make sure that screw head is squarely seated against housing after installation. 8. Install belt covers to cutting deck. 2. Position spindle on cutting deck noting orientation of grease fitting (Fig. 15).
Blade Spindle Service 7 DRIVEN SPINDLE 8 2 1 9 3 10 11 12 130 to 150 ft--lb (176 to 203 N--m) 4 13 14 DRIVE SPINDLE 15 1 2 9 5 8 16 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 23 18 16 19 15 20 21 14 19 5 9 8 22 7 7 8 13 12 6 11 10 1 5 RIGHT FRONT 4 2 3 Figure 20 1. 2. 3. 4. 5. 6. 7. 8. Center deck Flange nut Flange nut Adjusting screw Idler pulley High driven pulley Flat washer Lock washer 9. 10. 11. 12. 13. 14. 15. 16. Socket head screw Idler stop bolt Flange nut Cap screw Spacer Shoulder bolt Idler spring Lock nut 17. 18. 19. 20. 21. 22. 23. 24.
Removal (Fig. 20) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove deck covers from top of cutting deck. CAUTION Be careful when removing idler spring. The spring is under heavy load and may cause personal injury. 3. Use spring hook tool to unhook the idler spring (item 15) from the adjusting screw (item 4). 4. Remove drive belt(s) from deck pulleys. 5.
Castor Forks and Wheels DECK CASTOR ARM WING DECK CASTOR FORK 14 13 17 20 24 12 21 11 25 6 60 to 80 ft--lb (81 to 108 N--m) 7 5 9 7 19 8 1 10 20 26 4 18 22 16 23 CASTOR WHEEL 8 15 4 32 2 34 28 5 3 33 27 29 27 30 60 to 80 ft--lb (81 to 108 N--m) 31 Figure 22 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Disassembly (Fig. 22) Assembly (Fig. 22) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1. Assemble castor forks and wheels using Figure 22 as a guide. 2. Disassemble castor forks and wheels using Figure 22 as a guide. 2. Torque castor wheel lock nut from 60 to 80 ft--lb (81 to 108 N--m). 3. If castor fork was removed, lubricate grease fitting. Cutting Deck 4. See Operator’s Manual for castor wheel adjustment.
Deck Rollers and Skids 9 7 10 6 5 8 7 6 5 5 RIGHT 6 7 4 3 FRONT 2 1 Figure 23 1. 2. 3. 4. Roller Flange head screw Roller shaft Flange nut 5. Lock nut 6. Roller 7. Cap screw 8. Flange nut 9. Skid (RH shown) 10. Flange head screw Removal (Fig. 23) Installation (Fig. 23) 1. Remove skids and rollers from deck using Figure 23 as a guide. 1. Install skids (item 9) to deck using Figure 23 as a guide. Make sure to install skids in the same mounting hole height position (lower or upper). 2.
Operator Cab Table of Contents GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical Components and Schematic . . . . . . . . . 2 Air Conditioning System . . . . . . . . . . . . . . . . . . . . . 2 Cab Heater System . . . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 3 General Precautions for Removing and Installing Air Conditioning System Components .
General Information The information in this chapter pertains to the operator cab on the Groundsmaster 4110--D. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster. Refer to the Operator’s Manual for additional information when servicing the machine.
Service and Repairs 5. Put labels on disconnected lines and hoses for proper installation after repairs are completed. CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. WARNING Always wear safety goggles or a face shield when working with air conditioning system components.
Air Conditioning Compressor 21 7 8 1 2 15 5 6 13 14 16 4 3 9 2 18 10 19 20 3 17 11 12 RIGHT FRONT Figure 1 1. 2. 3. 4. 5. 6. 7. Cap screw (2 used) Flat washer (4 used) Lock washer (6 used) Hex nut (2 used) Conduit O--ring (2 used) 90o fitting 8. 9. 10. 11. 12. 13. 14. O--ring A/C compressor Cap screw (4 used) Cap screw (2 used) A/C compressor mount Flange head screw (2 used) Exhaust bracket Removal (Fig. 1) 1.
CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. 8. Have refrigerant evacuated from air conditioning system by a certified A/C service technician. 9. Label and remove hoses from compressor. Immediately cap hoses and fittings to prevent moisture and contaminants from entering the system. 10.Support compressor to prevent it from shifting or falling.
Roof Assembly 16 3 4 1 15 14 2 3 FRONT 7 5 4 8 13 6 4 12 2 9 3 4 11 10 10 9 Figure 3 1. 2. 3. 4. 5. 6. Roof Screw (2 used) Flat washer (6 used) Bushing (10 used) Rear fastener (2 used) Rear spacer (2 used) Operator Cab 7. 8. 9. 10. 11. Panel nut Roof mount Flange nut (2 used) Flange nut (4 used) Headliner Page 9 -- 6 12. 13. 14. 15. 16.
To gain access to the heater core and air conditioning components that are located under the cab roof, the roof panel can be loosened, raised and supported. 5 3 6 Removal (Fig. 3) 1 8 2. Remove screw (item 2), flat washer (item 3) and bushing (item 4) that secure the rear of the roof to the roof mount. 3. Remove the cap screw (item 15) and rubber washer (item 14) that secure the front of the roof. 4.
Air Conditioning Condenser Assembly 10 1 2 6 8 3 6 4 2 6 8 7 6 9 5 Figure 5 1. 2. 3. 4. Condenser cover Lock nut (4 used) Condenser fan Condenser coil assembly 5. Carriage screw (2 used) 6. Flat washer (8 used) 7. Roof Removal (Fig. 5) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 6.
8. Label and remove hoses from condenser coil. Immediately cap hoses and fittings to prevent moisture and contaminants from entering the system. 7 3 11 NOTE: The replacement of the drier--receiver is recommended whenever the air conditioning system is opened (see Heater/Evaporator in this section). 21 20 Installation (Fig. 5) 19 2 17 1. Install condenser coil to roof using Figure 6 as a guide. 18 9 2. Remove caps that were placed on hoses and fittings during the removal process.
Heater/Evaporator Assembly 2 16 10 12 1 9 15 13 14 13 11 7 6 4 8 12 3 5 Figure 7 1. 2. 3. 4. 5. 6. Heater/evaporator assembly Top cover Flange head screw (2 used) Drier--receiver mount Bottom cover Hose clamp (2 used) 7. 8. 9. 10. 11. Speed nut (8 used) Panel nut (4 used) Drier--receiver assembly Screw (8 used) Screw (4 used) Removal (Fig. 7) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2.
7. Loosen hose clamp that secures air duct hose to heater/evaporator assembly covers. Slide hose from covers. 5 3 6 8. Remove screws that secure top cover to bottom cover. Remove top cover to access heater/evaporator assembly. 9. Disassemble heater/evaporator assembly using Fig. 7 as a guide. 8 10.If necessary, remove fan resistor from blower fan assembly (Fig. 9). 7 NOTE: The replacement of the drier--receiver is recommended whenever the air conditioning system is opened.
Windshield Wiper 8 1 7 9 2 3 4 10 6 5 11 12 13 Figure 10 1. 2. 3. 4. 5. Wiper motor Gasket Linkage bracket Lock washer Cap screw Operator Cab 6. 7. 8. 9. Cap (2 used) Washer Nut Flange nut (2 used) Page 9 -- 12 10. 11. 12. 13.
Assembly (Fig. 10) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1. Assemble windshield wiper components using Figure 10 as a guide. 2. If access to wiper motor is necessary, remove fasteners that secure roof in place. Raise and support roof to allow access to condenser assembly (see Roof Assembly in this section). 2. If roof was raised, lower and secure roof assembly (see Roof Assembly in this section). 3.
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Chapter 10 Foldout Drawings Table of Contents Groundsmaster 4100--D/4110--D Page 10 -- 1 Foldout Drawings ELECTRICAL DRAWING DESIGNATIONS . . . . . . . 2 HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL SCHEMATICS Models 30602 and 30604 . . . . . . . . . . . . . . . . . . . . 4 Models 30606 and 30608 . . . . . . . . . . . . . . . . . . . . 5 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 International Light Kits . . . . . . . . . . . . . . . . . .
Electrical Drawing Designations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. ABBREVIATION COLOR BK BLACK BR or BN BROWN BU BLUE GN GREEN GY GRAY OR ORANGE PK PINK R or RD RED T TAN VIO VIOLET W or WH WHITE Y or YE YELLOW Numerous harness wires used on Groundsmaster 4100--D and 4110--D machines include a line with an alternate color.
STEERING CYLINDER 2.00” BORE 4.20” STROKE 0.625” ROD R M1 L STEERING CONTROL VALVE M1 PRV C3 C4 C2 OR5 .070 C6 C5 OR7 .070 CH4 PRV 3250 PSI 6.1 CID P PD RIGHT WING DECK 2.50” BORE 6.50” STROKE 1.125” ROD CENTER DECK RAM CYLINDERS 1.50” BORE 3.08” STROKE OR3 .070 G 3000 PSI .025 M2 S10 P1 1.17 CID LEFT WING DECK 2.50” BORE 6.50” STROKE 1.125” ROD 0.51 CID E S4 S9 S5 T S2 PR CV1 4 PSI LC1 S3 S7 S6 S8 310 PSI G1 RV M2 CV2 4 PSI P2 600 PSI CD CENTER DECK RV2 OR2 .
Groundsmaster 4100--D/4110--D Models 30602 and 30604 Electrical Schematic NOTE: WHEN A WIRE FROM THIS SCHEMATIC CONTINUES TO THE OPERATOR CAB, A REFERENCE NUMBER WILL BE LISTED. THE CAB SCHEMATIC WILL ALSO INCLUDE THE REFERENCE NUMBER. All relays and solenoids are shown as de-- energized. All ground wires are black.
Groundsmaster 4100--D/4110--D Models 30606 and 30608 Electrical Schematic NOTE: WHEN A WIRE FROM THIS SCHEMATIC CONTINUES TO THE OPERATOR CAB, A REFERENCE NUMBER WILL BE LISTED. THE CAB SCHEMATIC WILL ALSO INCLUDE THE REFERENCE NUMBER. All relays and solenoids are shown as de-- energized. All ground wires are black.
NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. 1 2 TO GROUND BLOCK 4 FROM OPERATOR PLATFORM WIRE HARNESS 3 Groundsmaster 4110--D Operator Cab (shown with lights for US model) Electrical Schematic All relays and solenoids are shown as de-- energized. All ground wires are black. NOTE: THE OPERATOR CAB SCHEMATIC SHOULD BE USED WITH THE ELECTRICAL SCHEMATIC FOR THE APPROPRIATE MODEL NUMBER WHICH IS ON A SEPARATE PAGE.
NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. 4 2 FROM OPERATOR PLATFORM WIRE HARNESS 3 5 TO OPERATOR PLATFORM WIRE HARNESS TO OPERATOR PLATFORM WIRE HARNESS TO CAB WIRE HARNESS Groundsmaster 4110--D International Light Kits Electrical Schematic All relays and solenoids are shown as de-- energized. All ground wires are black.
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A B C D 1 2 3 4 5 Groundsmaster 4100--D/4110--D Platform Wire Harness Drawing Page 10 -- 9
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4100--D/4110--D Platform Wire Harness Diagram Sheet 1 of 2 NOTE: THE PLATFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, A REFERENCE NUMBER WILL BE IDENTIFIED.
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4100--D/4110--D Platform Wire Harness Diagram Sheet 2 of 2 NOTE: THE PLATFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, A REFERENCE NUMBER WILL BE IDENTIFIED.
Groundsmaster 4100--D/4110--D Rear Wire Harness Drawing Page 10 -- 12
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
Groundsmaster 4100--D/4110--D Models 30606 and 30608 Engine Wire Harness Drawing Page 10 -- 14
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
Groundsmaster 4100--D/4110--D Models 30602 and 30604 Engine Wire Harness Drawing Page 10 -- 16
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
Groundsmaster 4110--D Operator Cab Wire Harness Drawing Page 10 -- 20
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.