caution

caution
PART NO. 03116SL (Rev. F)
Service Manual
(Model 30411)
GroundsmasterR 4100--D
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing,
and repair of major systems and components on the
Groundsmaster 4100--D.
REFER TO THE OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE, AND ADJUSTMENT
INSTRUCTIONS. Space is provided in Chapter 2 of this
book to insert the Operator’s Manuals and Parts Catalogs for your machine. Replacement Operator’s Manuals and Parts Catalogs are available on the internet at
www.Toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing, or repair of the machine.
IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the
machine.
E The Toro Company - 2003, 2004, 2005, 2007, 2012
This page is intentionally blank.
Groundsmaster 4100−D
Chapter 2 − Product Records and Maintenance
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions . . . . . . . . . . . . . . . .
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−1
2−2
2−3
2−7
Chapter 3 − Kubota Diesel Engine
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 − 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 − 3
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 − 4
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 − 6
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
V2003−T SERIES
Chapter 6 − Axles, Planetaries, and Brakes
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 − 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 − 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 − 4
Chapter 7 − Chassis
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 7 − 2
Chapter 8 − Cutting Deck
Chapter 4 − Hydraulic System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . .
8−2
8−3
8−4
8−6
Chapter 9 − Electrical Diagrams
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . 9 − 3
Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 − 4
Wire Harness Drawings . . . . . . . . . . . . . . . . . . . . . 9 − 8
Electrical
Diagrams
Cutting Deck
Chassis
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 − 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 − 3
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . 4 − 7
Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . . 4 − 8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 − 18
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 − 20
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 − 23
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 − 48
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 − 49
Kubota
Diesel Engine
Electrical Schematic, Circuit Diagrams, and
Wire Harness Drawings . . . . . . . . . . . . . . . . . . . . 5 − 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 − 3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 − 4
Electrical System Quick Checks . . . . . . . . . . . . . . 5 − 7
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 − 8
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 5 − 10
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 − 31
Hydraulic
System
General Safety Instructions . . . . . . . . . . . . . . . . . . 1 − 2
Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 − 4
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 − 5
Electrical
System
Chapter 5 − Electrical System
Axles, Planetaries,
and Brakes
Chapter 1 − Safety
Product Records
and Maintenance
Safety
Table Of Contents
Groundsmaster 4100−D
This page is intentionally blank.
Groundsmaster 4100−D
Safety
Table of Contents
GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . .
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . .
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Service . . . . . . . . . . . . . . . . . . . .
Groundsmaster 4100−D
2
2
2
3
JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . .
Jacking the Front End . . . . . . . . . . . . . . . . . . . . . . .
Jacking the Rear End . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
Page 1 − 1
4
4
4
5
Safety
Safety
Chapter 1
General Safety Instructions
The GROUNDSMASTER 4100-D was tested and certified by TORO for compliance with existing safety standards and specifications. Although hazard control and
accident prevention partially are dependent upon the
design and configuration of the machine, these factors
are also dependent upon the awareness, concern, and
proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine. Improper use or maintenance of the machine can
result in injury or death. To reduce the potential for injury
or death, comply with the following safety instructions.
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
Before Operating
1. Read and understand the contents of the Operator’s
Manual before starting and operating the machine. Become familiar with the controls and know how to stop the
machine and engine quickly. A replacement Operator’s
Manual is available on the Internet at www.Toro.com or
by sending the complete model and serial number to:
3. Assure interlock switches are adjusted correctly so
engine cannot be started unless traction pedal is in
NEUTRAL and cutting unit is DISENGAGED.
4. Since diesel fuel is highly flammable, handle it carefully:
A. Use an approved fuel container.
The Toro Company
Attn. Technical Publications
8111 Lyndale Avenue South
Bloomington, Minnesota 55420−1196
B. Do not remove fuel tank cap while engine is hot or
running.
C. Do not smoke while handling fuel.
2. Keep all shields, safety devices, and decals in place.
If a shield, safety device, or decal is defective, illegible
or damaged, repair or replace it before operating the
machine. Also tighten any loose nuts, bolts or screws to
ensure machine is in safe operating condition.
D. Fill fuel tank outdoors and only to within an inch of
the top of the tank, not the filler neck. Do not overfill.
E. Wipe up any spilled fuel.
While Operating
1. Sit on the seat when starting and operating the machine.
5. Before getting off the seat:
A. Ensure that traction pedal is in neutral.
2. Before starting the engine:
B. Set parking brake.
A. Engage the parking brake.
B. Make sure traction pedal is in neutral and the
PTO switch is OFF (disengaged).
C. Disengage cutting unit and wait for blades to
stop.
D. Stop engine and remove key from switch.
C. After engine is started, release parking brake and
keep foot off traction pedal. Machine must not move.
If movement is evident, the traction pedal linkage is
adjusted incorrectly; therefore, shut engine off and
adjust linkage until machine does not move when
traction pedal is released.
3. Do not run engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
E. Toro recommends that anytime the machine is
parked (short or long term), the cutting unit should be
lowered to the ground. This relieves pressure from
the lift circuit and eliminates the risk of the cutting unit
accidentally lowering to the ground.
F. Do not park on slopes unless wheels are chocked
or blocked.
4. Do not touch engine, muffler or exhaust pipe while
engine is running or soon after it is stopped. These areas
could be hot enough to cause burns.
Safety
Page 1 − 2
Groundsmaster 4100−D
1. Before servicing or making adjustments, lower deck,
stop engine, set parking brake, and remove key from the
switch.
10.Do not overspeed the engine by changing governor
setting. To assure safety and accuracy, check maximum
engine speed.
2. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
11. Shut engine off before checking or adding oil to the
crankcase.
3. Never store the machine or fuel container inside
where there is an open flame, such as near a water heater or furnace.
12.Disconnect battery before servicing the machine.
Disconnect negative cable first and positive cable last.
If battery voltage is required for troubleshooting or test
procedures, temporarily connect the battery. Reconnect
positive cable first and negative cable last.
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.
5. Keep body and hands away from pin hole leaks in hydraulic lines that eject high pressure hydraulic fluid. Use
cardboard or paper to find hydraulic leaks. Hydraulic
fluid escaping under pressure can penetrate skin and
cause injury. Fluid accidentally injected into the skin
must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.
6. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be relieved by stopping engine and lowering the cutting unit
to the ground.
7. If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor.
8. To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt. Clean
protective screen on machine frequently.
9. If engine must be running to perform maintenance or
an adjustment, keep hands, feet, clothing and other
parts of the body away from cutting units and other moving parts. Keep bystanders away.
Groundsmaster 4100−D
13.Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes, and clothing. Protect your
face, eyes, and clothing when working with a battery.
14.Battery gases can explode. Keep cigarettes, sparks,
and flames away from the battery.
15.At the time of manufacture, the machine conformed
to the safety standards for riding mowers. To assure optimum performance and continued safety certification of
the machine, use genuine Toro replacement parts and
accessories. Replacement parts and accessories made
by other manufacturers may result in non-conformance
with the safety standards, and the warranty may be
voided.
16.When changing attachments, tires, or performing
other service, use correct blocks, hoists, and jacks.
Make sure machine is parked on a solid level surface
such as a concrete floor. Prior to raising the machine, remove any attachments that may interfere with the safe
and proper raising of the machine. Always chock or
block wheels. Use jack stands or solid wood blocks to
support the raised machine. If the machine is not properly supported by blocks or jack stands, the machine may
move or fall, which may result in personal injury (see
Jacking Instructions).
Page 1 − 3
Safety
Safety
Maintenance and Service
Jacking Instructions
CAUTION
When changing attachments, tires, or performing other service, use correct blocks, hoists,
and jacks. Make sure machine is parked on a
solid level surface such as a concrete floor.
Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block
wheels. Use jack stands or solid wood blocks to
support the raised machine. If the machine is
not properly supported by blocks or jack
stands, the machine may move or fall, which
may result in personal injury.
1
2
2
Figure 1
1. Frame jacking point
2. Front tire
Jacking the Front End (Fig. 1)
1. Set parking brake and chock both rear tires to prevent the machine from moving.
2. Position jack securely under the frame, just to the inside of the front tire.
3. Position jack stands or hardwood blocks under the
frame as close to the wheels as possible to support the
machine.
2
Jacking the Rear End (Fig. 2)
2
1
Figure 2
1. Place jack securely under the center of rear axle.
1. Rear axle jacking point
2. Rear tire
2. Chock both front tires. Jack rear of machine off the
ground.
3. Use jack stands or blocks under the rear axle to support the machine.
Safety
Page 1 − 4
Groundsmaster 4100−D
Safety
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
the Groundsmaster 4100−D. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog.
Groundsmaster 4100−D
Page 1 − 5
Safety
This page is intentionally blank.
Safety
Page 1 − 6
Groundsmaster 4100−D
Chapter 2
Table of Contents
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . .
Decimal and Millimeter Equivalents . . . . . . . . . . . .
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . .
Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated, and
Steel Fasteners (Inch Series) . . . . . . . . . . . . . . .
1
2
2
2
3
3
Standard Torque for Dry, Zinc Plated, and
Steel Fasteners (Metric) . . . . . . . . . . . . . . . . . . . .
Other Torque Specifications . . . . . . . . . . . . . . . . . .
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
6
6
7
4
Product Records
Insert Operator’s Manual and Parts Catalog for your
Groundsmaster 4100 at the end of this chapter. Refer to
Operator’s Manual for recommended maintenance
intervals. Additionally, insert Installation Instructions,
Operator’s Manuals, and Parts Catalogs for any accessories that have been installed on your Groundsmaster
at the end of this section.
Groundsmaster 4100−D
Page 2 − 1
Product Records and Maintenance
Product Records
and Maintenance
Product Records and Maintenance
Equivalents and Conversions
Product Records and Maintenance
Page 2 − 2
Groundsmaster 4100−D
Recommended fastener torque values are listed in the
following tables. For critical applications, as determined
by Toro, either the recommended torque or a torque that
is unique to the application is clearly identified and specified in this Service Manual.
These Torque Specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in this Service Manual. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (e.g. Loctite), degree of lubrication
on the fastener, presence of a prevailing torque feature,
hardness of the surface underneath the fastener’s head,
or similar condition which affects the installation.
As noted in the following tables, torque values should be
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread engagement, etc.
The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
Fastener Identification
Grade 1
Grade 5
Grade 8
Class 8.8
Inch Series Bolts and Screws
Metric Bolts and Screws
Figure 1
Groundsmaster 4100−D
Class 10.9
Figure 2
Page 2 − 3
Product Records and Maintenance
Product Records
and Maintenance
Torque Specifications
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Thread Size
Grade 1, 5, &
8 with Thin
Height Nuts
SAE Grade 1 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
in−lb
in−lb
N−cm
10 + 2
13 + 2
147 + 23
# 6 − 32 UNC
# 6 − 40 UNF
# 8 − 32 UNC
13 + 2
25 + 5
# 10 − 24 UNC
30 + 5
SAE Grade 8 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
in−lb
N−cm
in−lb
N−cm
15 + 2
170 + 20
23 + 2
260 + 20
17 + 2
190 + 20
25 + 2
280 + 20
29 + 3
330 + 30
41 + 4
460 + 45
31 + 3
350 + 30
43 + 4
485 + 45
42 + 4
475 + 45
60 + 6
675 + 70
48 + 4
540 + 45
68 + 6
765 + 70
282 + 30
# 8 − 36 UNF
18 + 2
SAE Grade 5 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
339 + 56
# 10 − 32 UNF
1/4 − 20 UNC
48 + 7
53 + 7
599 + 79
100 + 10
1125 + 100
140 + 15
1580 + 170
1/4 − 28 UNF
53 + 7
65 + 10
734 + 113
115 + 10
1300 + 100
160 + 15
1800 + 170
5/16 − 18 UNC
115 + 15
105 + 17
1186 + 169
200 + 25
2250 + 280
300 + 30
3390 + 340
5/16 − 24 UNF
138 + 17
128 + 17
1446 + 192
225 + 25
2540 + 280
325 + 30
3670 + 340
ft−lb
ft−lb
N−m
ft−lb
N−m
ft−lb
N−m
3/8 − 16 UNC
16 + 2
16 + 2
22 + 3
30 + 3
41 + 4
43 + 4
58 + 5
3/8 − 24 UNF
17 + 2
18 + 2
24 + 3
35 + 3
47 + 4
50 + 4
68 + 5
7/16 − 14 UNC
27 + 3
27 + 3
37 + 4
50 + 5
68 + 7
70 + 7
95 + 9
7/16 − 20 UNF
29 + 3
29 + 3
39 + 4
55 + 5
75 + 7
77 + 7
104 + 9
1/2 − 13 UNC
30 + 3
48 + 7
65 + 9
75 + 8
102 + 11
105 + 10
142 + 14
1/2 − 20 UNF
32 + 3
53 + 7
72 + 9
85 + 8
115 + 11
120 + 10
163 + 14
5/8 − 11 UNC
65 + 10
88 + 12
119 + 16
150 + 15
203 + 20
210 + 20
285 + 27
5/8 − 18 UNF
75 + 10
95 + 15
129 + 20
170 + 15
230 + 20
240 + 20
325 + 27
3/4 − 10 UNC
93 + 12
140 + 20
190 + 27
265 + 25
359 + 34
375 + 35
508 + 47
3/4 − 16 UNF
115 + 15
165 + 25
224 + 34
300 + 25
407 + 34
420 + 35
569 + 47
7/8 − 9 UNC
140 + 20
225 + 25
305 + 34
430 + 45
583 + 61
600 + 60
813 + 81
7/8 − 14 UNF
155 + 25
260 + 30
353 + 41
475 + 45
644 + 61
660 + 60
895 + 81
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Product Records and Maintenance
Page 2 − 4
Groundsmaster 4100−D
Thread Size
Class 8.8 Bolts, Screws, and Studs with
Regular Height Nuts
(Class 8 or Stronger Nuts)
Class 10.9 Bolts, Screws, and Studs with
Regular Height Nuts
(Class 10 or Stronger Nuts)
M5 X 0.8
57 + 5 in−lb
640 + 60 N−cm
78 + 7 in−lb
885 + 80 N−cm
M6 X 1.0
96 + 9 in−lb
1018 + 100 N−cm
133 + 13 in−lb
1500 + 150 N−cm
M8 X 1.25
19 + 2 ft−lb
26 + 3 N−m
27 + 2 ft−lb
36 + 3 N−m
M10 X 1.5
38 + 4 ft−lb
52 + 5 N−m
53 + 5 ft−lb
72 + 7 N−m
M12 X 1.75
66 + 7 ft−lb
90 + 10 N−m
92 + 9 ft−lb
125 + 12 N−m
M16 X 2.0
166 + 15 ft−lb
225 + 20 N−m
229 + 22 ft−lb
310 + 30 N−m
M20 X 2.5
325 + 33 ft−lb
440 + 45 N−m
450 + 37 ft−lb
610 + 50 N−m
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately + 10% of the
nominal torque value.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Groundsmaster 4100−D
Page 2 − 5
Product Records and Maintenance
Product Records
and Maintenance
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric)
Other Torque Specifications
SAE Grade 8 Steel Set Screws
Wheel Bolts and Lug Nuts
Recommended Torque
Thread Size
Recommended Torque**
Thread Size
Square Head
Hex Socket
1/4 − 20 UNC
140 + 20 in−lb
73 + 12 in−lb
5/16 − 18 UNC
215 + 35 in−lb
145 + 20 in−lb
3/8 − 16 UNC
35 + 10 ft−lb
18 + 3 ft−lb
1/2 − 13 UNC
75 + 15 ft−lb
50 + 10 ft−lb
7/16 − 20 UNF
Grade 5
65 + 10 ft−lb
88 + 14 N−m
1/2 − 20 UNF
Grade 5
80 + 10 ft−lb
108 + 14 N−m
M12 X 1.25
Class 8.8
80 + 10 ft−lb
108 + 14 N−m
M12 X 1.5
Class 8.8
80 + 10 ft−lb
108 + 14 N−m
** For steel wheels and non−lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23, or Type F
Thread Size
Baseline Torque*
No. 6 − 32 UNC
20 + 5 in−lb
No. 8 − 32 UNC
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
Threads per Inch
Baseline Torque*
Type A
Type B
No. 6
18
20
20 + 5 in−lb
30 + 5 in−lb
No. 8
15
18
30 + 5 in−lb
No. 10 − 24 UNC
38 + 7 in−lb
No. 10
12
16
38 + 7 in−lb
1/4 − 20 UNC
85 + 15 in−lb
No. 12
11
14
85 + 15 in−lb
5/16 − 18 UNC
110 + 20 in−lb
3/8 − 16 UNC
200 + 100 in−lb
* Hole size, material strength, material thickness, and
finish must be considered when determining specific
torque values. All torque values are based on non−lubricated fasteners.
Conversion Factors
in−lb X 11.2985 = N−cm
ft−lb X 1.3558 = N−m
Product Records and Maintenance
N−cm X 0.0885 = in−lb
N−m X 0.7376 = ft−lb
Page 2 − 6
Groundsmaster 4100−D
Maintenance
Groundsmaster 4100−D
Page 2 − 7
Product Records
and Maintenance
Maintenance procedures and recommended service intervals for the Groundsmaster 4100−D are covered in
the Operator’s Manual. Refer to that publication when
performing regular equipment maintenance. Several
maintenance procedures have break−in intervals identified in the Operator’s Manual. Refer to the Engine Operator’s Manual for additional engine specific
maintenance procedures.
Product Records and Maintenance
This page is intentionally blank.
Product Records and Maintenance
Page 2 − 8
Groundsmaster 4100−D
Chapter 3
Kubota Diesel Engine
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Run Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 6
Air Filter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Check Fuel Lines and Connections . . . . . . . . . . 11
Drain and Clean Fuel Tank . . . . . . . . . . . . . . . . . . 11
Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . 11
Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . 11
Groundsmaster 4100−D
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . 17
Pump Adapter Plate . . . . . . . . . . . . . . . . . . . . . . . . 18
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
V2003−T SERIES
Page 3 − 1
Kubota Diesel Engine (Rev. A)
Kubota
Diesel Engine
Table of Contents
General Information
This Chapter gives information about specifications and
repair of the diesel engine used in the Groundsmaster
4100−D.
General maintenance procedures are described in your
Operator’s Manual. Information on engine troubleshooting, testing, disassembly, and reassembly is identified in
the Kubota Workshop Manual, Diesel Engine, V2003−T
that is included at the end of this section.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
tools are described in the Kubota Workshop Manual,
Diesel Engine, V2003−T. The use of some specialized
test equipment is explained. However, the cost of the
test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility.
Service and repair parts for Kubota engines are supplied through your Authorized Toro Distributor. If no
parts list is available, be prepared to provide your distributor with the Toro model and serial number of your machine.
Stopping the Engine
IMPORTANT: Before stopping the engine after
mowing or full load operation, cool the turbo-charger by allowing the engine to idle at low speed for 5
minutes. Failure to do so may lead to turbo-charger
trouble.
Kubota Diesel Engine (Rev. A)
Page 3 − 2
Groundsmaster 4100−D
Specifications
Item
Description
Make / Designation
Kubota, 4−Cycle, 4 Cylinder,
Water Cooled, Turbocharged, Diesel Engine
58 HP (43.3 kW) @ 2600 RPM
Bore mm (in.)
83.0 (3.27)
Stroke mm (in.)
92.4 (3.64)
Total Displacement cc (cu. in.)
1999 (121.99)
Firing Order
1−3−4−2
Combustion Chamber
Spherical Type
Fuel
No. 2 Diesel Fuel (ASTM D975)
Fuel Capacity liters (U.S. gallons)
72 (19.0)
Fuel Injection Pump
Bosch Type Mini Pump (PFR)
Governor
Centrifugal Mechanical
Low Idle (no load)
1375 + 50 RPM
High Idle (no load)
2730 + 30 RPM
Direction of Rotation
Counterclockwise (Viewed from Flywheel)
Compression Ratio
22.0:1
Injection Nozzle
Bosch Throttle Type
Engine Oil
SAE 10W30 or 10W40 Detergent (API CD, or higher)
Oil Pump
Trochoid Type
Crankcase Oil Capacity liters (U.S. quarts)
7.6 (8.0) with Filter
Starter
12 VDC, 1.4 kW
Alternator/Regulator
12 VDC, 40 AMP
Coolant Capacity liters (U.S. quarts)
10.4 (11) with 0.9 (1.0) Reservoir
Engine Dry Weight kilograms (U.S. pounds)
Groundsmaster 4100−D
184 (406)
Page 3 − 3
Kubota Diesel Engine (Rev. A)
Kubota
Diesel Engine
Horse Power
Adjustments
Run Solenoid
1. When ignition switch is in the RUN position, the run
solenoid should energize and position the fuel stop lever
to within 1/16” (1.6 mm) of stop on the injection pump.
4
2
3
2. If adjustment is needed, loosen lock nut and rotate
the threaded end of the swivel until the lever is properly
positioned.
3. Tighten lock nut. Recheck adjustment.
1
Figure 1
1. Run solenoid
2. Fuel stop lever (run)
3. Swivel
4. Lock nut
2
1
3
Figure 2
1. Run solenoid
2. Fuel stop lever (off)
Kubota Diesel Engine (Rev. A)
Page 3 − 4
3. Injection pump stop
Groundsmaster 4100−D
Kubota
Diesel Engine
This page is intentionally blank.
Groundsmaster 4100−D
Page 3 − 5
Kubota Diesel Engine (Rev. A)
Service and Repairs
Air Filter System
9
8
7
RIGHT
FRONT
1
11 6
5 4
2
11
10
3
EVACUATOR
DIRECTION
Figure 3
1.
2.
3.
4.
Air cleaner hose
Hose clamp
Air cleaner assembly
Indicator
Kubota Diesel Engine (Rev. A)
5.
6.
7.
8.
Air cleaner strap
Lock nut (2 used)
Hose clamp
Air cleaner hose
Page 3 − 6
9. Hose clamp
10. Cap screw (2 used)
11. Flat washer (4 used)
Groundsmaster 4100−D
Removal
4
1. Remove air cleaner components as needed using
Figure 3 as a guide.
1
Installation
IMPORTANT: Any leaks in the air filter system will
cause serious engine damage. Make sure daily that
all air cleaner components are in good condition
and are properly secured during reassembly.
3
5
2
2. When installing air cleaner hose (8) between air
cleaner and turbo−charger (Fig. 4):
A. Make sure that hose does not contact engine
valve cover. To modify clearance, move and/or rotate
air cleaner body in air cleaner strap. Verify that tabs
in strap mesh fully with slots in air cleaner body.
Figure 4
1. Air cleaner hose
2. Engine valve cover
3. Air cleaner strap
4. Air cleaner body
5. Muffler bracket
B. Position hose to allow maximum clearance between air cleaner hose and muffler bracket.
Groundsmaster 4100−D
Page 3 − 7
Kubota Diesel Engine (Rev. A)
Kubota
Diesel Engine
1. Reassemble air cleaner system using Figure 3 as a
guide.
Exhaust System
1
14
3
11
2
4
5
16 to 22 ft−lb
(21 to 29 N−m)
12
7
9
7
16 to 22 ft−lb
(21 to 29 N−m)
11
8
8
6
RIGHT
10
6
FRONT
13
16 to 22 ft−lb
(21 to 29 N−m)
Figure 5
1.
2.
3.
4.
5.
Muffler
Muffler bracket
Exhaust pipe
Flange head screw (4 used)
Exhaust gasket
Kubota Diesel Engine (Rev. A)
6.
7.
8.
9.
10.
Lock nut
Cap screw
Flat washer
Spacer
Rubber hanger
Page 3 − 8
11.
12.
13.
14.
Flange nut (2 used)
Flange head screw (2 used)
Engine mount
Muffler clamp
Groundsmaster 4100−D
Removal
3
CAUTION
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the engine and exhaust system to cool before working on the muffler.
2
4
2. Remove muffler and/or muffler bracket from the engine as necessary using Figure 5 as a guide.
Installation
IMPORTANT: If exhaust studs were removed from
engine cylinder head, thoroughly clean threads in
head and apply Loctite #277 (or equivalent) to stud
threads before installing studs into head.
1
Figure 6
NOTE: Make sure muffler flange and exhaust manifold
sealing surfaces are free of debris or damage that may
prevent a tight seal.
1. Install new gasket if original gasket is damaged or
torn.
IMPORTANT: Failure to follow the suggested muffler fastener sequence may result in premature muffler failure.
2. Install muffler and/or muffler bracket to the engine
using Figure 5 as a guide. Hand tighten and then torque
the following fasteners from 16 to 22 ft--lb (21 to 29 N--m)
in the sequence listed (Fig. 6):
A. Locknuts used on rubber hanger cap screws.
B. Flange nuts that secure muffler to muffler bracket.
C. Flange head screws that secure muffler flange to
engine.
D. Flange nuts that secure muffler bracket to engine.
3. Tailpipe should have equal clearance between frame
and engine after installation.
Groundsmaster 4100--D
Page 3 -- 9 Rev. F
Kubota Diesel Engine (Rev. A)
Kubota
Diesel Engine
1. Park machine on a level surface, lower cutting unit,
stop engine, engage parking brake, and remove key
from the ignition switch.
Fuel System
38
39
37
RIGHT
36 35
34
FRONT
24
41
2
29
26 27 28
25
22
30 31
23
33
1
21
14
3
4
5
40
6
32
20
7
19
7
8
12
18 17 1615
11
13
9
60 to 80 in−lb
(7 to 9 N−m)
10
135 to 165 ft−lb
(183 to 223 N−m)
Figure 7
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Fuel tank
Fuel tank bracket
Air breather
Female hose barb
Tank support assembly
Fuel hose
Locking flange nut
Cap screw (4 used)
Flat washer
Cap screw (4 used)
Carriage screw (2 used)
Washer
Battery strap
Battery
Kubota Diesel Engine (Rev. A)
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Retaining ring (2 used)
Battery cover
Flat washer (2 used)
Knob (2 used)
Battery plate
Negative battery cable
Positive battery cable
Carriage screw (2 used)
Gasket
Bushing (3 used)
Stand pipe
Fuel sender
Lock washer (5 used)
Phillips head screw (5 used)
Page 3 − 10
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
Fuel hose
Hose clamp
Elbow fitting
Fuel cap
Locking flange nut
Speed nut
Tank cover (2 used)
Phillips head screw
Vent tube
Insulated clip (3 used)
Washer head screw (3 used)
Hose clamp
ROPS assembly
Groundsmaster 4100−D
Fuel Tank Installation
DANGER
1. Install fuel tank using Figure 7 as a guide.
Check Fuel Lines and Connections
Check fuel lines and connections periodically as recommended in the Operator’s Manual. Check lines for deterioration, damage, leaks, or loose connections. Replace
hoses, clamps, and connections as necessary.
A. Torque two locking flange nuts that secure the
fuel tank to the frame from 60 to 80 in−lb (7 to 9 N−m).
2. Install two (2) tank covers to ROPS assembly.
3. Connect fuel hose to the standpipe and venting
hoses to the elbow fittings.
4. Connect electrical wiring to the fuel sender.
A. Connect white wire to the center terminal and
black wire to any of the screws that secure the fuel
sender to the fuel tank.
B. Apply skin−over grease to the wire terminal connections.
CAUTION
Drain and Clean Fuel Tank
Drain and clean the fuel tank periodically as recommended in the Operator’s Manual. Also, drain and clean
the fuel tank if the fuel system becomes contaminated
or if the machine is to be stored for an extended period.
Connecting battery cables to the wrong battery
post could result in personal injury and/or damage to the electrical system.
To clean fuel tank, flush tank out with clean diesel fuel.
Make sure tank is free of contaminates and debris.
5. Position battery in machine. Connect positive battery
cable first and then negative battery cable. Install battery strap and cover.
Fuel Tank Removal (Fig. 7)
6. Lower seat and hood.
1. Park machine on a level surface, lower cutting unit,
stop engine, engage parking brake, and remove key
from the ignition switch.
7. Fill fuel tank (see Operator’s Manual).
2. Raise seat and hood.
3. Remove battery cover and strap. Disconnect negative battery cable first and then positive battery cable.
Remove battery from machine.
4. Use a fuel transfer pump to remove fuel from the fuel
tank and into a suitable container.
5. Disconnect electrical wiring from the fuel sender on
the fuel tank.
6. Disconnect fuel hose from the standpipe and venting
hoses from elbow fittings in top of tank.
7. Remove phillips head screws that secure two (2)
tank covers to ROPS assembly. Remove tank covers.
8. Remove fuel tank using Figure 7 as a guide.
Groundsmaster 4100−D
Page 3 − 11 Rev. E
Kubota Diesel Engine (Rev. A)
Kubota
Diesel Engine
Because diesel fuel is highly 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
21
20
18
23
46
22
RIGHT
45
17
16
FRONT
19
47
24
1
10
15
11
13
9
6
25
12
14
26
12
7
25
28
5
8
35
38
4
30
37
48
41
8
32
34
29
31
2
3
33
10
6
27
39
40
42
12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Radiator cap
Foam strip
Foam strip
Lower radiator hose
Upper radiator hose
Hose clamp
Radiator shroud
Lock nut
Radiator
Hose clamp
Reservoir hose
Flange head screw
Grommet
Flange nut
Retaining ring
Knob (2 used)
Kubota Diesel Engine (Rev. A)
44 12
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
36
43
Figure 8
Bulb seal
Radiator support assembly
Retaining ring
Oil cooler bracket
Oil cooler
Carriage screw
Oil cooler hydraulic fitting (2 used)
Flange head screw
Clamp (6 used)
Flange nut
Oil cooler bracket (RH shown)
Flat washer
Foam plug
Lock nut
Foam strip
Lower radiator support
Page 3 − 12
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
Flange head screw (4 used)
Bulb seal
Grommet (2 used)
Frame cover
Flange head screw
Plate
Flat washer
Knob
Shoulder bolt (2 used)
Flat washer
Coolant reservoir
Coolant reservoir bracket
O−ring
O−ring
Air cleaner hose
Reservoir hose
Groundsmaster 4100−D
Removal
Installation
1. Park machine on a level surface, lower cutting unit,
stop engine, engage parking brake, and remove key
from the ignition switch.
1. Remove plugs from radiator and hoses placed during the removal procedure.
2. Position radiator to the support frame. Secure radiator to the support frame with lock nuts, flat washers, and
flange head screws.
CAUTION
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.
Ethylene−glycol antifreeze is poisonous. Dispose of coolant properly, or store it in a properly
labeled container away from children and pets.
3. Attach radiator shroud to the radiator with flange
screws and flat washers. Make sure that clearance between shroud and fan is at least .180” (4.6 mm) at all
points.
4. Connect reservoir hose (item 11) to the radiator vent
tube.
5. Connect hoses (upper and lower) to the radiator.
6. Reinstall air cleaner hose (item 47).
3. Drain radiator into a suitable container using the radiator drain. The radiator drain is located near the left
hand wing deck manifold (Fig. 9).
4. Disconnect hoses (upper and lower) from the radiator.
7. Make sure radiator drain is closed. Fill radiator with
coolant (see Operator’s Manual).
8. Close and secure engine hood on the machine.
2
5. Remove air cleaner hose (item 47).
6. Disconnect reservoir hose (item 11) from the radiator
vent tube.
1
7. Detach radiator shroud from the radiator by removing four flange head screws and flat washers. Position
shroud away from radiator.
8. Remove flange head screws, flat washers, and lock
nuts that secure the radiator to the support frame. Pull
radiator from the machine.
9. Plug all radiator and hose openings to prevent contamination.
Groundsmaster 4100−D
Figure 9
1. Radiator drain
Page 3 − 13
2. LH wing deck manifold
Kubota Diesel Engine (Rev. A)
Kubota
Diesel Engine
2. Open engine hood on the machine.
Engine
12
10
5
6
7
8
9
10
11
25
6
26
15
10
19
20
12
10
13
16
14
17
18
21
22
2
RIGHT
3 4
1
FRONT
23
24
23
Figure 10
1.
2.
3.
4.
5.
6.
7.
8.
9.
Engine
Engine mount bracket (RH shown)
Lock washer
Cap screw
Barb fitting
Hose clamp
Hose
Fuel line
Fuel filter
Kubota Diesel Engine (Rev. A)
10.
11.
12.
13.
14.
15.
16.
17.
18.
Fuel line
Coolant drain hose
Hose clamp
Cap screw (4 used)
Barb fitting (female)
Coolant drain cock fitting
Engine mount bracket (RH shown)
Lock washer
Cap screw
Page 3 − 14
19.
20.
21.
22.
23.
24.
25.
26.
Lock washer
Cap screw
Cap screw (8 used)
Rubber engine mount (4 used)
Flange head locking nut
Rebound washer
Hose clamp
Fuel line
Groundsmaster 4100−D
Engine Removal
1. Park machine on a level surface, lower cutting unit,
stop engine, engage parking brake, and remove key
from the ignition switch.
1
3
2. Remove battery cover and strap. Disconnect negative battery cable first and then positive battery cable.
Remove battery from machine.
3. Open engine hood.
2
3
Kubota
Diesel Engine
CAUTION
Figure 11
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.
1. Temperature sender
2. Alternator
Ethylene−glycol antifreeze is poisonous. Dispose of coolant properly, or store it in a properly
labeled container away from children and pets.
3
4. Drain coolant from the radiator into a suitable container (see Radiator Removal). Disconnect coolant
hoses from the radiator.
3. Coolant hose
4
5
2
1
CAUTION
Figure 12
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the exhaust system
to cool before working on or near the muffler.
1. Run solenoid
2. Fuel line
3. Throttle cable
4. Cable jam nut
5. Cable washer/lock nut
5. Remove exhaust system from engine (see Muffler
Removal).
6. Remove air cleaner system from engine (see Air
Cleaner Removal).
3
7. Note location of cable ties used to secure wires. Disconnect wires and/or electrical connections from the following electrical components:
A. The temperature sender and alternator (Fig 11).
Note: red wire attached to alternator with washer,
nut, and boot does not have to be removed.
1
2
B. The engine run solenoid and fuel pump (Fig. 13).
C. The high temperature shutdown switch and glow
plug (Fig. 14).
D. Battery, frame, and wire harness ground at the
engine block (Fig. 15).
E. The electric starter (Fig. 15) and low oil pressure
switch (near electric starter).
Groundsmaster 4100−D
Figure 13
1. Run solenoid
2. Fuel pump
Page 3 − 15
3. Fuel filter
Kubota Diesel Engine (Rev. A)
8. Disconnect fuel line from injection pump (Fig. 12).
Cap fuel line and injector pump fuel inlet to prevent contamination.
1
9. Disconnect throttle cable from the speed control lever by removing the washer and lock nut. Loosen jam
nut and take cable from mounting bracket (Fig. 12).
3
10.Remove coolant reservoir and bracket from fan
shroud.
2
11. Remove four flange head screws and flat washers
securing the fan shroud to the radiator.
12.Disconnect two wires from neutral switch on hydraulic traction pump.
Figure 14
1. Glow plug wire
2. High temp shutdown
3. Rear engine lift tab
IMPORTANT: Support hydraulic pump assembly to
prevent it from falling and being damaged.
7
13.Remove hydraulic pump assembly from engine (see
Pump Assembly in Chapter 4 − Hydraulic Systems).
4
14.Make sure all cable ties securing the wiring harness,
fuel lines, or hydraulic hoses to the engine are removed.
5
6
7
15.Connect hoist or lift to the front and rear lift tabs on
engine.
1
16.Remove flange head locking nuts, rebound washers,
and cap screws securing the engine brackets to the engine mounts.
2
3
Figure 15
CAUTION
One person should operate lift or hoist while the
other person guides the engine out of the machine.
1.
2.
3.
4.
Battery cable (+)
Battery cable (−)
Engine to frame ground
Engine wire harness
5. Alternator wire
6. Fusible link harness
7. Cable tie
IMPORTANT: Make sure not to damage the engine,
fuel and hydraulic lines, electrical harness, or other
parts while removing the engine.
17.Slowly remove engine from the machine.
18.If necessary, remove engine mount brackets from
the engine using Figure 10 as a guide. Note cap screw
length and position during removal.
Kubota Diesel Engine (Rev. A)
Page 3 − 16
Groundsmaster 4100−D
12.Connect wires and/or electrical connections to the
following electrical components:
Engine Installation
1. If removed, install engine mount brackets to the engine using Figure 10 as a guide.
2. Connect hoist or lift to the front and rear lift tabs on
engine.
A. The temperature sender and alternator (Fig 11).
B. The engine run solenoid and fuel pump (Fig. 13).
C. The high temperature shutdown switch and glow
plug (Fig. 14).
3. Position fan shroud around the engine fan.
CAUTION
One person should operate lift or hoist while the
other person guides the engine into the machine.
IMPORTANT: Make sure not to damage the engine,
fuel and hydraulic lines, electrical harness, or other
parts while installing the engine.
4. Slowly lower engine into the machine.
5. Align engine to the rubber engine mounts and secure
with cap screws, rebound washers, and flange head
locking nuts.
6. Secure fan shroud to the radiator with four cap
screws, flat washers, and locknuts. Make sure that
clearance between shroud and fan is at least .180” (4.6
mm) at all points.
7. Install coolant reservoir bracket and reservoir to fan
shroud.
8. Connect throttle cable to the speed control lever with
washer and lock nut. Install cable to mounting bracket
(Fig. 12). Adjust throttle cable (see Operator’s Manual).
E. The starter (Fig. 15) and low oil pressure switch
(near starter).
13.Install air cleaner assembly to the engine (see Air
Cleaner Installation).
14.Install exhaust system to machine (see Muffler
Installation).
15.Connect coolant hoses to the radiator. Make sure radiator drain is shut. Fill radiator and reservoir with coolant (see Operator’s Manual).
16.Check position of wires, fuel lines, hydraulic hoses,
and cables for proper clearance with rotating, high temperature, and moving components.
17.Position battery to machine. Connect positive battery cable first and then negative battery cable. Secure
battery to machine with strap and cover.
18.Check and adjust engine oil as needed (see Operator’s Manual).
19.Check and adjust hydraulic oil as needed (see Operator’s Manual).
9. Connect fuel line to the injection pump fitting (Fig.
12).
20.Bleed fuel system (see Operator’s Manual).
IMPORTANT: Support hydraulic pump assembly to
prevent it from falling and being damaged.
21.Operate hydraulic controls to properly fill hydraulic
system (see Charge Hydraulic System in Chapter 4 −
Hydraulic Systems).
10.Install hydraulic pump assembly to engine (see
Pump Assembly in Chapter 4 − Hydraulic Systems).
11. Connect two wires to neutral switch on traction
pump.
Groundsmaster 4100−D
Page 3 − 17
Kubota Diesel Engine (Rev. A)
Kubota
Diesel Engine
D. Battery, frame, and wire harness ground to the
engine block (Fig. 15).
Pump Adapter Plate
1
2
17 to 21 ft−lb
(23 to 28 N−m)
3
4
6
7
5
2
8
9
17 to 21 ft−lb
(23 to 28 N−m)
RIGHT
11
FRONT
10
10
35 to 43 ft−lb
(48 to 58 N−m)
12
Figure 16
1.
2.
3.
4.
Engine
Lock washer
Cap screw (4 used)
Pump adapter plate
Kubota Diesel Engine (Rev. A)
5.
6.
7.
8.
Plate pin (2 used)
Dowel (2 used)
Coupling spacer
Shoulder bolt (2 used)
Page 3 − 18
9.
10.
11.
12.
Spring center coupling
Lock washer
Cap screw (6 used)
Cap screw (8 used)
Groundsmaster 4100−D
Disassembly
1. If engine is in machine, hydraulic pump assembly
needs to be removed from engine before coupling can
be serviced (see Pump Assembly in Chapter 4 − Hydraulic Systems).
4
3
2. Remove pump adapter plate, spring center coupling,
and coupling spacer from engine using Figure 16 as a
guide.
Assembly
2
UP
2
3
2. Install four cap screws and lockwashers to coupling
spacer and flywheel. Torque cap screws from 17 to 21
ft−lb (23 to 28 N−m).
4
1
Figure 17
1. Coupling spacer
2. Shoulder bolt position
3. Cap screw position
4. Dowel position
3. Place dowels in locating holes of coupling spacer
(Fig. 17).
4. Position spring center coupling (coil springs toward
engine (Fig. 18)) over dowels. Secure coupling to coupling spacer with cap screws and lockwashers. Torque
cap screws from 35 to 43 ft−lb (48 to 58 N−m).
5. Install plate pins into engine casting. Position pump
adapter plate to engine using plate pins as alignment
points. Secure adaptor plate with cap screws and lock
washers using a star pattern tightening procedure.
Hydraulic
Pump Side
Engine Side
Spring Center
Coupling
6. If engine is in machine, install hydraulic pump assembly (see Pump Assembly in Chapter 4 − Hydraulic
Systems).
Figure 18
Groundsmaster 4100−D
Kubota Diesel Engine (Rev. A)
Page 3 − 19
Kubota
Diesel Engine
1. Position coupling spacer to engine and align mounting holes. Use two shoulder bolts and lockwashers in the
positions shown in Figure 17 to secure the spacer to the
half threaded holes in engine flywheel. Torque shoulder
bolts from 17 to 21 ft−lb (23 to 28 N−m).
This page is intentionally blank.
Kubota Diesel Engine (Rev. A)
Page 3 − 20
Groundsmaster 4100−D
Chapter 4
Hydraulic System
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 3
Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 5
Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 5
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 7
HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . . 8
Traction Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Lower Cutting Deck . . . . . . . . . . . . . . . . . . . . . . . . 10
Raise Cutting Deck . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mow Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Hydraulic Pressure Test Kit . . . . . . . . . . . . . . . . . . 18
Hydraulic Tester (Pressure and Flow) . . . . . . . . . 18
Hydraulic Test Fitting Kit . . . . . . . . . . . . . . . . . . . . . 19
Measuring Container . . . . . . . . . . . . . . . . . . . . . . . 19
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 20
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Test No. 1: Traction Circuit Charge Pressure . . . 24
Test No. 2: Traction Circuit Relief Pressure . . . . 26
Test No. 3: Cutting Deck Circuit Pressure . . . . . . 28
Test No. 4: Cutting Deck Gear Pump Flow . . . . . 30
Test No. 5: Cutting Deck Manifold
Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Test No. 6: Cutting Deck Motor Case
Drain Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Test No. 7: Steering Circuit Relief Pressure . . . . 36
Test No. 8: Lift/Lower Circuit Relief Pressure . . . 38
Test No. 9: Steering and Lift/Lower
Gear Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . 40
Test No. 10: Counterbalance Pressure . . . . . . . . 42
Test No. 11: Rear Traction Circuit (RV5)
Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Test No. 12: Traction Circuit Reducing
Valve (PR) Pressure . . . . . . . . . . . . . . . . . . . . . . 46
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Adjust Cutting Deck Flow Control Valve . . . . . . . 48
Groundsmaster 4100--D
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 49
General Precautions for Removing and
Installing Hydraulic System Components . . . . 49
Check Hydraulic Lines and Hoses . . . . . . . . . . . . 49
Flush Hydraulic System . . . . . . . . . . . . . . . . . . . . . 50
Charge Hydraulic System . . . . . . . . . . . . . . . . . . . 51
Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Gear Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . 54
Piston (Traction) Pump . . . . . . . . . . . . . . . . . . . . . . 58
Piston (Traction) Pump Service . . . . . . . . . . . . . . 60
Piston Pump Control Assembly . . . . . . . . . . . . . . 64
Hydraulic Control Manifold: 4 Wheel Drive . . . . . 66
Hydraulic Control Manifold Service:
4 Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Hydraulic Control Manifold: Deck Drive . . . . . . . . 70
Hydraulic Control Manifold Service: Deck Drive 72
Hydraulic Control Manifold: Cutting Deck
Lift/Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Hydraulic Control Manifold Service: Cutting
Deck Lift/Lower . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Hydraulic Control Manifold: Filter Manifold . . . . . 76
Hydraulic Control Manifold Service:
Filter Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Rear Axle Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Front Wheel Motors . . . . . . . . . . . . . . . . . . . . . . . . 80
Rear Axle/Front Wheel Motor Service . . . . . . . . . 82
Cutting Deck Motor . . . . . . . . . . . . . . . . . . . . . . . . . 85
Cutting Deck Motor Service . . . . . . . . . . . . . . . . . . 86
Lift/Lower Control Valve . . . . . . . . . . . . . . . . . . . . . 90
Lift/Lower Control Valve Service . . . . . . . . . . . . . . 92
Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Steering Valve Service . . . . . . . . . . . . . . . . . . . . . . 96
Front Deck Lift Cylinder . . . . . . . . . . . . . . . . . . . . . 98
Front Deck Lift Cylinder Service . . . . . . . . . . . . . 100
Wing Deck Lift Cylinder . . . . . . . . . . . . . . . . . . . . 102
Wing Deck Lift Cylinder Service . . . . . . . . . . . . . 104
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Steering Cylinder Service . . . . . . . . . . . . . . . . . . 108
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . 110
Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . 112
Page 4 -- 1 Rev. E
Hydraulic System
Hydraulic
System
Table of Contents
Specifications
Item
Description
Piston (Traction) Pump
System Relief Pressure: Forward
System Relief Pressure: Reverse
Charge Pressure
Variable displacement piston pump
4000 PSI (274 bar)
5000 PSI (343 bar)
250 PSI (17 bar)
Gear Pump
Steering Relief Pressure
Lift/Lower Relief Pressure
3 section, positive displacement gear type pump
1350 PSI (93 bar)
2525 PSI (174 bar)
Front Wheel Motors
Fixed displacement piston motors
Rear Axle Motor
Fixed displacement piston motor
Cutting Deck Motors
Relief Pressure (front and left side)
Relief Pressure (right side)
Gear motor
3000 PSI (207 bar)
2000 PSI (137 bar)
Hydraulic Filters
In--line Suction Strainer
10 Micron spin--on cartridge type
100 mesh (in reservoir)
Hydraulic Reservoir
8 gal. (30.3 l)
Hydraulic Oil
Hydraulic System
See Operator’s Manual
Page 4 -- 2
Groundsmaster 4100--D
General Information
Hydraulic Hoses
When replacing a hydraulic hose, be sure that the hose
is straight (not twisted) before tightening the fittings.
This can be done by observing the imprint on the hose.
Use two wrenches; hold the hose straight with one and
tighten the hose swivel nut onto the fitting with the other.
WARNING
Before disconnecting or performing any work
on hydraulic system, relieve all pressure in
system. Stop engine; lower or support box
and/or other attachment(s).
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.
Hydraulic Fitting Installation
O--Ring Face Seal
Nut
1. Make sure both threads and sealing surfaces are
free of burrs, nicks, scratches, or any foreign material.
Body
Sleeve
2. Make sure the O--ring is installed and properly
seated in the groove. It is recommended that the O--ring
be replaced any time the connection is opened.
Seal
3. Lubricate the O--ring with a light coating of oil.
4. Put the tube and nut squarely into position on the
face seal end of the fitting and tighten the nut until finger
tight.
Figure 1
5. Mark the nut and fitting body. Hold the body with a
wrench. Use another wrench to tighten the nut to the correct Flats From Finger Tight (F.F.F.T.). The markings on
the nut and fitting body will verify that the connection has
been tightened.
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
Groundsmaster 4100--D
Final
Position
Mark Nut
and Body
F.F.F.T.
0.75 + 0.25
0.75 + 0.25
0.75 + 0.25
1.00 + 0.25
0.75 + 0.25
0.75 + 0.25
Extend Line
Finger Tight
Initial
Position
After Proper Tightening
Figure 2
Page 4 -- 3
Hydraulic System
Hydraulic
System
Hydraulic hoses are subject to extreme conditions such
as pressure differentials during operation and exposure
to weather, sun, chemicals, very warm storage conditions, or mishandling during operation or maintenance.
These conditions can cause damage or premature deterioration. Some hoses are more susceptible to these
conditions than others. Inspect the hoses frequently for
signs of deterioration or damage.
SAE Straight Thread O--Ring Port -- Non--adjustable
1. Make sure both threads and sealing surfaces are
free of burrs, nicks, scratches, or any foreign material.
2. Always replace the O--ring seal when this type of fitting shows signs of leakage.
3. Lubricate the O--ring with a light coating of oil.
O--Ring
4. Install the fitting into the port and tighten it down full
length until finger tight.
5. Tighten the fitting to the correct Flats From Finger
Tight (F.F.F.T.).
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
F.F.F.T.
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
NOTE: Installation torque values for non--adjustable fittings are listed in Figure 4. These torque values should
only be used when a fitting can be accessed with a
socket. Use of an offset wrench (e.g. crowfoot wrench)
will affect torque wrench accuracy and should not be
used.
Figure 3
Fitting Size
Installation Torque
4
9--10 ft--lb (12--13 N--m)
6
20--21 ft--lb (27--28 N--m)
8
35--37 ft--lb (47--50 N--m)
10
60--66 ft--lb (81--89 N--m)
12
81--87 ft--lb (110--117 N--m)
16
121--131 ft--lb (164--177 N--m)
Figure 4
SAE Straight Thread O--Ring Port -- Adjustable
1. Make sure both threads and sealing surfaces are
free of burrs, nicks, scratches, or any foreign material.
2. Always replace the O--ring seal when this type of fitting shows signs of leakage.
Lock Nut
3. Lubricate the O--ring with a light coating of oil.
4. Turn back the jam nut as far as possible. Make sure
the back up washer is not loose and is pushed up as far
as possible (Step 1).
Back--up Washer
O--Ring
Figure 5
5. Install the fitting into the port and tighten finger tight
until the washer contacts the face of the port (Step 2).
6. To put the fitting in the desired position, unscrew it by
the required amount, but no more than one full turn
(Step 3).
7. Hold the fitting in the desired position with a wrench
and turn the jam nut with another wrench to the correct
Flats From Finger Tight (F.F.F.T.) (Step 4).
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
Hydraulic System
Step 1
Step 3
Step 2
Step 4
F.F.F.T.
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
Figure 6
Page 4 -- 4
Groundsmaster 4100--D
Towing Traction Unit
IMPORTANT: If towing limits are exceeded, severe
damage to the piston pump may occur.
If it becomes necessary to tow (or push) the machine,
tow (or push) in a forward direction only and at a
speed below 3 mph. The piston (traction) pump is
equipped with a by--pass valve that needs to be turned
90o for towing. See Operator’s Manual for Towing Procedures.
1
Figure 7
1. By--pass valve location
The Groundsmaster 4100--D hydraulic system is designed to operate on anti--wear hydraulic fluid. The reservoir holds approximately 8 gallons (30.3 liters) of
hydraulic fluid. Check level of hydraulic fluid daily.
See Operator’s Manual for fluid level checking procedure and hydraulic oil recommendations.
Hydraulic
System
Check Hydraulic Fluid
1
Figure 8
1. Hydraulic reservoir cap
Groundsmaster 4100--D
Page 4 -- 5
Hydraulic System
This page is intentionally blank.
Hydraulic System
Page 4 -- 6
Groundsmaster 4100--D
Groundsmaster 4100--D
Page 4 -- 7
Hydraulic System
Hydraulic
System
All solenoids are shown as
de--energized
Groundsmaster 4100--D
Hydraulic Schematic
Hydraulic Schematic
Hydraulic System
Page 4 -- 8
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundsmaster 4100--D
Traction Circuit (Forward/Mow Shown)
Hydraulic Flow Diagrams
Groundsmaster 4100--D
Traction Circuit
Traction circuit pressure (forward and reverse) can be
measured at test ports on the sides of the machine.
The traction pump and wheel motors use a small
amount of hydraulic oil for internal lubrication. Oil is designed to leak across pump and motor parts into the
case drain. This leakage results in the loss of hydraulic
oil from the closed loop traction circuit that must be replaced.
The gear pump that supplies oil to the steering and lift/
lower circuits also provides charge oil for the traction circuit. This gear pump is driven directly off the traction
pump. It provides a constant supply of charge oil to the
traction circuit to make up for oil that is lost due to internal leakage in the traction pump and motors.
Groundsmaster 4100--D
Charge pump flow is directed through the oil filter and to
the low pressure side of the closed loop traction circuit.
A filter bypass valve allows charge oil flow to the closed
loop if the filter becomes plugged. Charge pressure is
limited by a relief valve located in the oil filter manifold.
Charge pressure can be measured at the charge circuit
pressure test port on the oil filter manifold.
The 4WD/2WD control manifold provides hydraulic flow
management in a variety of situations. Pressure testing
of this control manifold can be performed at a test port
on the manifold.
1. Four wheel drive (mow) and two wheel drive (transport) operation is controlled by a solenoid valve (SV) located in the 4WD/2WD control manifold. When in
transport (2WD), the solenoid valve (SV) is energized
and directs charge pressure to shift the control valves
(PD1 and PD2). These shifted valves block hydraulic
flow to the rear axle motor in both forward and reverse
directions when in transport (2WD).
2. A pressure reducing valve (PR) in the 4WD/2WD
control manifold lowers pressure to the rear axle motor
when the machine is operated in reverse. The lower
pressure prevents rear tire scuffing and provides added
pressure to the front wheels during reverse operation.
3. An adjustable relief valve (RV5) in the 4WD/2WD
control manifold reduces rear axle motor pressure
created in down--hill, dynamic braking conditions.
To enhance traction control, the lift/lower circuit is
equipped with a counterbalance system. An adjustable
counterbalance valve located in the counterbalance
control manifold (in CB port) transfers cutting deck
weight to the machine to improve traction.
Page 4 -- 9
Rev. E
Hydraulic System
Hydraulic
System
The traction circuit piston pump is a variable displacement pump that is directly coupled to the engine flywheel. Pushing the top of the traction pedal engages a
hydraulic servo valve which controls the variable displacement piston pump swash plate to create a flow of
oil. This oil is directed to the front wheel and rear axle
motors. Operating pressure on the high pressure side of
the closed traction circuit loop is determined by the
amount of load developed at the fixed displacement
wheel and axle motors. As the load increases, circuit
pressure can increase to relief valve settings: 4000 PSI
in forward and 5000 PSI in reverse. If pressure exceeds
the relief setting, oil flows through the relief valve to the
low pressure side of the closed loop circuit. The traction
circuit provides operation in either four wheel drive
(mow) or two wheel drive (transport).
Hydraulic System
Page 4 -- 10
Rev. E
Groundsmaster 4100--D
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundsmaster 4100--D
Lower Cutting Deck
Lower Cutting Deck
When the cutting deck is in a stationary position, flow
from the gear pump is by--passed through the lift/lower
control valve, counterbalance manifold, oil filter, and
traction charge circuit.
To lower the cutting deck, the center lift lever on the lift/
lower control valve is pushed to allow valve shift in the
lift/lower control. This valve change allows a passage for
oil flow from the rod end of the deck lift cylinders. The
weight of the cutting deck causes the lift cylinder shafts
to extend, and lowers the deck. Oil from the rod end of
the cylinders is allowed to return to the traction charge
circuit. When the lift lever is released, the lift cylinders,
and cutting deck, are held in position.
Groundsmaster 4100--D
The drop speed of the cutting deck is regulated by an adjustable flow control valve that is located in the hydraulic
lines between the lift/lower control valve and the deck lift
cylinders.
To lower a wing deck, the appropriate lift lever (right side
or left side) on the lift/lower control valve is pushed to allow valve shift in the lift/lower control valve. This valve
change causes a valve shift in the counterbalance manifold and oil flow to the piston end of the lift cylinder. Higher hydraulic pressure against the piston end of the
cylinder causes the shaft to extend, and lowers the wing
deck. Oil from the rod end of the cylinder returns to the
traction charge circuit. When the lift lever is released, the
lift cylinder, and wing deck, is held in position.
An adjustable counterbalance valve maintains back
pressure on the deck lift cylinders. A relief valve located
in the lift/lower control valve limits circuit pressure. Excess circuit flow is routed to the oil filter and then to the
traction charge circuit.
Page 4 -- 11 Rev. E
Hydraulic System
Hydraulic
System
A three section gear pump is coupled to the piston (traction) pump. The gear pump section farthest from the piston pump supplies hydraulic flow to both the lift/lower
control valve and the steering control valve. Hydraulic
flow from this pump section is delivered to the circuits
through a proportional flow divider. This pump section
takes its suction from the hydraulic reservoir.
Hydraulic System
Page 4 -- 12
Rev. E
Groundsmaster 4100--D
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundsmaster 4100--D
Raise Cutting Deck
Raise Cutting Deck
When the cutting deck is in a stationary position, flow
from the gear pump is by--passed through the lift/lower
control valve, counterbalance manifold, oil filter, and
traction charge circuit.
To raise the cutting deck, the center lift lever on the lift/
lower control valve is pulled to allow valve shift in the lift/
lower control. This valve change allows hydraulic
pressure to the rod end of the deck lift cylinders, causing
the cylinders to retract. As the cylinders retract, the cutting deck raises. Oil from the piston end of the cylinders
returns to the hydraulic reservoir. When the lift lever is
released, the lift cylinders, and cutting deck, are held in
position.
Groundsmaster 4100--D
To raise a wing deck, the appropriate lift lever (right side
or left side) on the lift/lower control valve is pulled to allow valve shift in the lift/lower control. This valve change
allows hydraulic pressure to the piston end of the lift cylinder and causes the shaft to retract, raising the wing
deck. Oil from the rod end of the cylinder flows to the
traction charge circuit. When the lift lever is released, the
lift cylinder, and wing deck, is held in position.
An adjustable counterbalance valve maintains back
pressure on the lift cylinders. A relief valve located in the
lift/lower control valve limits circuit pressure. Excess circuit flow is routed to the oil filter and then to the traction
charge circuit.
Page 4 -- 13 Rev. E
Hydraulic
System
A three section gear pump is coupled to the piston (traction) pump. The gear pump section farthest from the piston pump supplies hydraulic flow to the lift/lower control
valve and the steering control valve. Hydraulic flow from
this pump section is delivered to the two circuits through
a proportional flow divider. The gear pump takes its suction from the hydraulic reservoir.
Hydraulic System
Hydraulic System
Page 4 -- 14
Groundsmaster 4100--D
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundsmaster 4100--D
Mow Circuit (All Deck Motors Rotating)
Mow Circuit
Each cutting deck is controlled by a hydraulic manifold
equipped with a solenoid control valve (SV1), bypass
cartridge (BY1), brake cartridge (BR1), and relief cartridge (R1BR). When the the deck solenoid valve (SV1)
is not energized (PTO switch OFF), hydraulic flow by-passes the deck motor through the bypass cartridge
(BY1). When the PTO switch is turned ON, the solenoid
valve (SV1) energizes, causing a shift of the by--pass
cartridge (BY1) and allowing hydraulic flow to the deck
motor. Brake cartridge (BR1) and relief cartridge
(R1BR) control the stopping rate of the blade when the
solenoid control valve is de--energized as the PTO
switch is turned OFF.
The solenoid valve (SV1) for each wing deck is de--energized any time the wing deck is raised.
TO DECK
MOTOR
PUMP FLOW
FROM DECK
MOTOR
RETURN
Figure 9
TO DECK
MOTOR
PUMP FLOW
Return oil from the deck motors is directed to the oil cooler and oil filter. Deck motor case drain leakage returns
to the hydraulic reservoir.
Maximum mow circuit pressure is limited at each deck
by a relief valve (R1BY) in the hydraulic manifold. The
center and left wing deck relief valves are set at 3000
PSI and the right wing deck relief valve is set at 2000
PSI.
FROM DECK
MOTOR
Circuit pressure can be measured at port (G) of the hydraulic manifold for each cutting deck.
RETURN
Figure 10
Cutting Deck Blade Braking
When the operator turns the cutting deck OFF, solenoid
valve (SV1) is de--energized causing logic cartridge
(BY1) to shift (Fig. 9). This shifted valve allows oil return
to the oil cooler and gear pump. Hydraulic pressure is reduced to the cutting deck motor which begins to slow the
cutting blades and also causes logic cartridge (BR1) to
shift (Fig. 10).
The inertia of the rotating cutting blades increases pressure of the oil return to the deck control manifold. This
pressure increase, along with the shifted logic cartridge
(BR1), causes relief valve (R1BR) to shift, which bleeds
the residual pressure in the circuit and allows the blades
to stop in a controlled manner (Fig. 11).
Groundsmaster 4100--D
TO DECK
MOTOR
PUMP FLOW
FROM DECK
MOTOR
Page 4 -- 15 Rev. E
RETURN
Figure 11
Hydraulic System
Hydraulic
System
Hydraulic flow for the mow circuit is supplied by two sections of the gear pump. The gear pump section closest
to the piston (traction) pump supplies hydraulic flow to
the wing decks, while the next gear pump section supplies the center deck.
Hydraulic System
Page 4 -- 16
Groundsmaster 4100--D
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundsmaster 4100--D
Steering Circuit (Left Turn Shown)
Steering Circuit
A three section gear pump is coupled to the piston (traction) pump. The gear pump section farthest from the piston pump supplies hydraulic flow to the steering control
valve and the lift/lower control valve. Pump hydraulic
flow is delivered to the two circuits through a proportional flow divider. The gear pump takes its suction from the
hydraulic reservoir. Steering circuit pressure is limited
by a relief valve located in the steering control valve.
ensures that the oil flow to the cylinder is proportional to
the amount of the turning on the steering wheel. Fluid
leaving the cylinder flows back through the spool valve
then through the T port and to the hydraulic reservoir.
With the steering wheel in the neutral position (rear
wheels positioned straight ahead) and the engine running, flow enters the steering control valve at the P port
and goes through the steering control spool valve, by-passing the rotary meter (V1) and steering cylinder.
Flow leaves the control valve through the PB port to the
oil filter and traction charge circuit.
Right Turn
When a right turn is made with the engine running, the
turning of the steering wheel positions the spool valve so
that flow goes through the bottom of the spool. Flow entering the steering control valve at the P port passes
through rotary meter (V1) is directed out port R. Pressure extends the piston for a right turn. The rotary meter
ensures that the oil flow to the cylinder is proportional to
the amount of the turning on the steering wheel. Fluid
leaving the cylinder flows back through the spool valve
then through the T port and to the hydraulic reservoir.
Left Turn
When a left turn is made with the engine running, the
turning of the steering wheel positions the spool valve so
that flow goes through the top of the spool. Flow entering
the steering control valve at the P port passes through
the rotary meter (V1) and is directed out the L port. Pressure contracts the piston for a left turn. The rotary meter
The steering wheel and steering control valve return to
the neutral position when turning is completed.
STEERING CYLINDER
STEERING CYLINDER
STEERING CYLINDER
NO PISTON MOVEMENT
PISTON MOVEMENT
PISTON MOVEMENT
L
R
L
R
1350
PSI
T
PB
P
L
R
1350
PSI
STEERING
CONTROL
NEUTRAL POSITION
T
PB
P
1350
PSI
STEERING
CONTROL
LEFT TURN
T
PB
P
STEERING
CONTROL
RIGHT TURN
Figure 12
Groundsmaster 4100--D
Page 4 -- 17
Hydraulic System
Hydraulic
System
The steering wheel and steering control valve return to
the neutral position when turning is completed.
Special Tools
Order these tools from your Toro Distributor.
Hydraulic Pressure Test Kit -- TOR47009
Use to take various pressure readings for diagnostic
tests. Quick disconnect fittings provided attach directly
to mating fittings on machine test ports without tools. A
high pressure hose is provided for remote readings.
Contains one each: 1000 PSI (70 Bar), 5000 PSI (350
Bar) and 10000 PSI (700 Bar) gauges. Use gauges as
recommended in Testing section of this chapter.
Figure 13
Hydraulic Tester (Pressure and Flow) -- TOR214678
Figure 14
This tester requires O--ring Face Seal (ORFS) adapter
fittings for use on this machine (see Hydraulic Test Fitting Kit -- TOR4079 in this section).
4. HIGH PRESSURE GAUGE: High range gauge
which accommodates pressures beyond the capacity of
the low pressure gauge: 0 to 5,000 PSI.
1. INLET HOSE: Hose connected from the system circuit to the inlet side of the hydraulic tester.
5. FLOW METER: This meter measures actual oil flow
in the operating circuit with a gauge rated at 15 GPM.
2. LOAD VALVE: A simulated working load is created
in the circuit by turning the valve to restrict flow.
6. OUTLET HOSE: A hose from the outlet side of the
hydraulic tester connects to the hydraulic system circuit.
3. LOW PRESSURE GAUGE: Low range gauge to provide accurate reading at low pressure: 0 to 1000 PSI.
A protector valve cuts out when pressure is about to
exceed the normal range for the gauge. The cutout
pressure is adjustable.
Hydraulic System
Page 4 -- 18 Rev. E
Groundsmaster 4100--D
Hydraulic Test Fitting Kit -- TOR4079
This kit includes a variety of O--ring Face Seal fittings to
enable you to connect test gauges into the system.
TORO TEST FITTING KIT (NO. TOR4079)
The kit includes: tee’s, unions, reducers, plugs, caps,
and male test fittings.
Figure 15
Measuring Container -- TOR4077
Hydraulic
System
Use this container for doing hydraulic motor efficiency
testing (motors with case drain lines only). Measure efficiency of a hydraulic motor by restricting the outlet flow
from the motor and measuring leakage from the case
drain line while the motor is pressurized by the hydraulic
system.
The table in Figure 17 provides gallons per minute
(GPM) conversion for measured milliliter or ounce motor
case drain leakage.
Figure 16
Figure 17
Groundsmaster 4100--D
Page 4 -- 19
Hydraulic System
Troubleshooting
The charts that follow contain information to assist in
troubleshooting. There may possibly be more than one
cause for a machine malfunction.
Refer to the Testing section of this Chapter for precautions and specific test procedures.
Problem
Possible Cause
Hydraulic system operates hot.
Engine RPM is too low.
Hydraulic reservoir oil level is low.
Hydraulic oil is contaminated or the wrong type.
Brakes are engaged or sticking.
Piston pump by--pass valve is open or damaged.
Cooling system is not operating properly.
Charge pressure is low.
Traction circuit pressure is incorrect.
Pump(s) or motor(s) are damaged.
Hydraulic oil in reservoir foams.
Hydraulic reservoir oil level is low.
Wrong type of oil is in the hydraulic system.
Air is leaking in suction line.
Machine operates in one direction
only.
Traction control linkage is faulty.
System charge check valve and/or system relief valve is defective.
Pilot direction valve in 4WD manifold is damaged or sticking.
Traction pedal is sluggish.
Traction control linkage is stuck or binding.
Piston pump servo control valve is damaged.
Charge pressure is low.
Machine travels too far before stopping when the traction pedal is released.
Traction linkage is binding or out of adjustment.
Piston pump servo control valve is damaged.
Traction pedal does not return to neutral.
Traction power is lost or unit will not
operate in either direction.
Brakes are engaged or sticking.
Traction control linkage is damaged or disconnected.
Hydraulic reservoir oil level is low.
Piston pump by--pass valve is open or damaged.
Charge pressure is low.
Traction circuit pressure is low.
Front wheel motor couplers are damaged.
Hydraulic System
Page 4 -- 20
Groundsmaster 4100--D
Problem
Possible Causes
Four wheel drive will not engage.
Electrical problem exists (see Chapter 5 -- Electrical System).
Solenoid valve on 4WD hydraulic manifold is faulty.
Cartridge valve in 4WD manifold is damaged or sticking.
Rear axle motor is damaged.
Four wheel drive will not disengage.
Electrical problem exists (see Chapter 5 -- Electrical System).
Solenoid valve on 4WD hydraulic manifold is faulty.
Cartridge valve in 4WD manifold is damaged or sticking.
Cutting decks will not operate.
Electrical problem exists (see Chapter 5 -- Electrical System).
Gear pump or it’s coupler is damaged.
Electrical problem exists (see Chapter 5 -- Electrical System).
System pressure to the affected motor is low.
Key on affected deck motor is damaged (motor rotates but deck
blades don’t rotate).
Solenoid valve in deck manifold is faulty.
Cartridge valve in deck manifold is damaged or sticking.
Deck motor or gear pump section is damaged.
All cutting deck motors operate
slowly.
Engine RPM is low.
Cutting deck stops under load.
Relief valve in deck manifold is by--passing.
Deck motor or gear pump section is damaged.
Deck motor has internal leakage (by--passing oil).
Cutting deck gear pump section is inefficient.
Cutting deck will not raise.
Engine RPM is too low.
Hydraulic oil level in reservoir is low.
Lift arm pivots are binding.
Lift cylinder is damaged.
Relief valve in lift/lower control valve is stuck.
Pilot valve in lift/lower manifold is damaged or sticking.
Proportional flow divider in gear pump is faulty.
Gear pump section for lift/lower control valve is inefficient.
Cutting deck raises, but will not stay
up.
Lift circuit lines or fittings are leaking.
Lift cylinder is damaged.
Detents in lift/lower control valve are worn.
Groundsmaster 4100--D
Page 4 -- 21 Rev. E
Hydraulic System
Hydraulic
System
One cutting deck motor will not operate.
Problem
Possible Causes
Cutting decks drop too fast or too
slow.
Flow control valve is not adjusted properly.
Cutting deck will not lower.
Lift arm pivots are binding.
Lift cylinder is damaged.
Counterbalance pressure is excessive.
Lift/lower control valve is worn or damaged.
Pilot valve in lift/lower manifold is damaged or sticking.
Hydraulic System
Page 4 -- 22
Groundsmaster 4100--D
Testing
Before Performing Hydraulic Tests
IMPORTANT: All obvious areas such as oil supply,
filter, binding linkages, loose fasteners, or improper
adjustments must be checked before assuming that
a hydraulic component is the source of the problem.
Precautions for Hydraulic Testing
CAUTION
Failure to use gauges with recommended pressure (PSI) rating as listed in test procedures
could result in damage to the gauge and possible
personal injury from leaking hot oil.
CAUTION
All testing should be performed by two (2)
people. One person should be in the seat to operate the machine, and the other should read and
record test results.
CAUTION
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the
ignition switch in OFF. Remove key from the ignition switch.
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved and all rotating machine parts must be stopped. Stop engine;
lower or support attachments.
1. Clean machine thoroughly before disconnecting or
disassembling any hydraulic components. Always keep
in mind the need for cleanliness when working on hydraulic equipment. Contamination will cause excessive
wear of hydraulic components.
2. Put metal caps or plugs on any hydraulic lines left
open or exposed during testing or removal of components.
3. The engine must be in good operating condition. Use
a phototac when performing a hydraulic test. Engine
speed can affect the accuracy of the tester readings.
Check actual speed of the pump when performing flow
testing.
4. The inlet and the outlet hoses for tester with pressure
and flow capabilities must be properly connected and
not reversed to prevent damage to the hydraulic tester
or components.
5. When using hydraulic tester with pressure and flow
capabilities, open load valve completely in the tester to
minimize the possibility of damaging components.
6. Install fittings finger tight and far enough to make
sure that they are not cross--threaded before tightening
them with a wrench.
7. Position tester hoses to prevent rotating machine
parts from contacting and damaging the hoses or tester.
8. Check oil level in the hydraulic reservoir. After connecting test equipment, make sure tank is full.
WARNING
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Do not use hands to search for
leaks; use paper or cardboard. 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.
Groundsmaster 4100--D
9. Check control linkages for improper adjustment,
binding, or broken parts.
10.After installing test gauges, run engine at low speed
and check for any hydraulic oil leaks.
11. All hydraulic tests should be made with the hydraulic
oil at normal operating temperature.
12.Before returning machine to use, make sure that hydraulic reservoir has correct fluid level. Also, check for
hydraulic leaks after test equipment has been removed
from hydraulic system.
Page 4 -- 23
Hydraulic System
Hydraulic
System
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).
TEST NO. 1: Traction Circuit Charge Pressure (Using Pressure Gauge)
CHARGE OIL FROM
LIFT AND STEERING
CIRCUITS
RETURN FROM LIFT
AND STEERING CYLINDERS
TO CUTTING DECK
TO LIFT/LOWER CONTROL VALVE
TO STEERING CONTROL
CASE DRAIN FROM
PTO (MOW) CIRCUIT
RETURN FROM CUTTING DECKS
Working Pressure
Low (Charge) Pressure
Return or Suction
Flow
Hydraulic System
Page 4 -- 24
Groundsmaster 4100--D
Procedure for Traction Circuit Charge Pressure Test
2
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
2. Park machine on a level surface with the cutting
decks lowered and off. Make sure engine is off and the
parking brake is engaged.
1
CAUTION
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
Figure 18
1. Charge pressure port
2. Hydraulic reservoir cap
3. Connect a 1000 PSI gauge onto charge pressure
test port (Fig. 18) under operator seat.
Hydraulic
System
4. After installing pressure gauge, start engine and run
at idle speed. Check for hydraulic leakage and correct
before proceeding with test.
5. Operate the engine at full engine speed (2730 + 30
RPM) with no load on the hydraulic system.
GAUGE READING TO BE 200 to 300 PSI.
6. Stop engine and record test results.
7. If there is no pressure, or pressure is low, check for
restriction in pump intake line. Also, inspect charge relief
valve located in filter manifold (see Hydraulic Manifold
Service: Filter Manifold in this chapter). If necessary,
check for internal damage or worn parts in gear pump.
8. Also, with the pressure gauge still connected to the
charge pressure test port, take a gauge reading while
operating the machine in forward and reverse. Start the
engine and put throttle at full engine speed (2730 + 30
RPM). Apply the brakes and push the traction pedal forward, then reverse.
GAUGE READING TO BE 200 to 300 PSI.
9. If charge pressure is good under no load, but drops
below specification when under traction load, the piston
(traction) pump and/or traction motor(s) should be suspected of wear and inefficiency. When the pump and/or
traction motor(s) are worn or damaged, the charge
pump is not able to keep up with internal leakage in traction circuit components.
10.Disconnect pressure gauge from test port.
Groundsmaster 4100--D
Page 4 -- 25
Hydraulic System
TEST NO. 2: Traction Circuit Relief Pressure (Using Pressure Gauge)
CHARGE OIL FROM
LIFT AND STEERING
CIRCUITS
NOTE: FORWARD
DIRECTION
TEST SHOWN
RETURN FROM LIFT
AND STEERING CYLINDERS
TO CUTTING DECK
TO LIFT/LOWER CONTROL VALVE
TO STEERING CONTROL
CASE DRAIN FROM
PTO (MOW) CIRCUIT
RETURN FROM CUTTING DECK
Working Pressure
Low (Charge) Pressure
Return or Suction
Flow
Hydraulic System
Page 4 -- 26
Groundsmaster 4100--D
Procedure for Traction Circuit Relief Pressure Test
2
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
CAUTION
1
Move machine to an open area, away from people
and obstructions.
Figure 19
1. Forward traction port
2. LH front tire
2. Drive machine to an open area, lower cutting decks,
turn the engine off, and engage the parking brake.
2
CAUTION
1
3. Connect a 10,000 PSI gauge to traction circuit test
port for function to be checked (Forward or Reverse:
Fig. 19 or 20).
Hydraulic
System
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
Figure 20
1. Reverse traction port
4. After installing pressure gauge, start engine and run
at idle speed. Check for hydraulic leakage and correct
before proceeding with test.
2. RH front tire
RIGHT
5. Operate the engine at full speed (2730 + 30 RPM).
FRONT
6. Sit on seat, apply brakes fully, and slowly depress the
traction pedal in the appropriate direction. While pushing traction pedal, look at pressure reading on gauge:
2
GAUGE READING TO BE:
Forward: maximum of 4000 PSI
Reverse: maximum of 5000 PSI
7. Release traction pedal and stop engine. Record test
results.
8. If traction pressure is too low, inspect traction pump
relief valves (Fig. 21). Clean or replace valves as necessary. These cartridge type valves are factory set, and
are not adjustable. If relief valves are in good condition,
traction pump or wheel motors should be suspected of
wear and inefficiency.
3
1
Figure 21
1. Forward relief valve
2. Reverse relief valve
3. Traction pump
9. Disconnect pressure gauge from test port.
Groundsmaster 4100--D
Page 4 -- 27
Hydraulic System
NOTE: CENTER DECK TEST SHOWN
TRACTION
CIRCUIT
CASE DRAIN/RETURN
CHARGE CIRCUIT
TEST NO. 3: Cutting Deck Circuit Pressure (Using Pressure Gauge)
TO LIFT/LOWER CONTROL VALVE
TO STEERING CONTROL VALVE
Working Pressure
Low (Charge) Pressure
Return or Suction
Flow
Hydraulic System
Page 4 -- 28
Groundsmaster 4100--D
Procedure for Cutting Deck Circuit Pressure Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
2. Park machine on a level surface with the cutting
decks lowered and off. Make sure engine is off and the
parking brake is engaged.
CAUTION
2
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
1
Figure 22
1. Center deck hydraulic manifold
2. Center deck circuit pressure test port
Hydraulic
System
3. Install test pressure gauge with hydraulic hose attached to deck manifold test port for the deck to be
tested (Fig. 22, 23, and 24).
4. After installing pressure gauge, start engine and run
at idle speed. Check for hydraulic leakage and correct
before proceeding with test.
1
CAUTION
Keep away from decks during test to prevent personal injury from the cutting blades.
5. Operate engine at full speed (2730 + 30 RPM). Engage the cutting decks.
Figure 23
1. Right wing deck circuit pressure test port
6. Watch pressure gauge carefully while mowing with
the machine.
7. Cutting deck circuit pressure should be from 1000 to
3000 PSI (1000 to 2000 PSI for RH wing deck) and will
vary depending on mowing conditions.
8. Disengage cutting decks and shut off engine. Record
test results.
9. Disconnect test gauge with hose from manifold test
port.
1
Figure 24
1. Left wing deck circuit pressure test port
Groundsmaster 4100--D
Page 4 -- 29
Hydraulic System
NOTE: CENTER GEAR PUMP
SECTION FLOW TEST SHOWN
TRACTION
CIRCUIT
CASE DRAIN/RETURN
CHARGE CIRCUIT
TEST NO. 4: Cutting Deck Gear Pump Flow (Using Tester with Pressure Gauges and
Flow Meter)
TO LIFT/LOWER CONTROL VALVE
TO STEERING CONTROL VALVE
Working Pressure
Low (Charge) Pressure
Return or Suction
Flow
Hydraulic System
Page 4 -- 30
Groundsmaster 4100--D
Procedure for Cutting Deck Gear Pump Flow Test
NOTE: Over a period of time, the gears and wear plates
in the gear pump can wear. A worn pump will by--pass
oil and make the pump less efficient. Eventually, enough
oil loss will occur to cause the cutting deck motors to stall
under heavy cutting conditions. Continued operation
with a worn, inefficient pump can generate excessive
heat and cause damage to the seals and other components in the hydraulic system.
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
2. Park machine on a level surface with the cutting
decks lowered and off. Make sure engine is off and the
parking brake is engaged.
CAUTION
IMPORTANT: Do not fully restrict oil flow through
tester. In this test, the flow tester is positioned before the relief valve. Pump damage can occur if the
oil flow is fully restricted.
8. Watch pressure gauge carefully while slowly closing
the flow control valve until 2000 PSI is obtained. Verify
with a phototac that the engine speed is 2400 RPM.
9. For a normal pump, gear pump flow should be
approximately 14 GPM. Shut off engine. Record test results.
10.If measured flow is less than 12 GPM or if a pressure
of 2000 PSI cannot be obtained, check for restriction in
the pump intake line. If line is not restricted, remove gear
pump and repair or replace as necessary.
11. Disconnect flow tester from hydraulic hose and manifold port. Reconnect hose to the manifold.
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
TO OIL COOLER
RIGHT
FRONT
4
3. Locate deck manifold for gear pump section to be
tested. Disconnect hydraulic hose at deck manifold port
(P1) (Fig. 25).
1
2
3
4. Install tester with pressure gauges and flow meter in
series with the the disconnected hose and hydraulic
manifold port (P1).
5. Make sure the flow control valve on the tester is
fully open.
6. After installing tester, start engine and run at idle
speed. Check for hydraulic leakage and correct before
proceeding with test.
Figure 25
1. Center deck manifold
2. Hyd. hose to front P1
3. Wing deck manifold
4. Hyd. hose to side P1
IMPORTANT: Do not run engine at full speed during
testing. At full engine speed, cutting deck gear
pump output can exceed 15 GPM and cause tester
damage.
7. Using a phototac, adjust engine speed to 2400 RPM.
Do not engage the cutting decks.
Groundsmaster 4100--D
Page 4 -- 31
Hydraulic System
Hydraulic
System
12.Repeat test for second pump section if required.
NOTE: CENTER DECK TEST SHOWN
TRACTION
CIRCUIT
CASE DRAIN/RETURN
CHARGE CIRCUIT
TEST NO. 5: Cutting Deck Manifold Relief Pressure (Using Tester with Pressure Gauges
and Flow Meter)
TO LIFT/LOWER CONTROL VALVE
TO STEERING CONTROL VALVE
Working Pressure
Low (Charge) Pressure
Return or Suction
Flow
Hydraulic System
Page 4 -- 32
Groundsmaster 4100--D
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
2. Park machine on a level surface with the cutting
decks lowered and off. Make sure engine is off and the
parking brake is engaged.
CAUTION
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
3. Locate deck manifold to be tested (Fig. 26). Disconnect hydraulic hose at deck manifold port (MP).
NOTE: An alternative to using manifold port (MP)
would be to disconnect the inlet hydraulic hose at the
deck motor.
11. If specification is not met, adjust or clean relief valve
in deck manifold port (R1BY). Adjust relief valve as follows:
NOTE: Do not remove valve from the hydraulic manifold for adjustment.
A. Remove cap on relief valve with an allen wrench.
B. 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 relief pressure.
C. To decrease pressure setting, turn the adjustment screw on the valve in a counterclockwise direction. A 1/8 turn on the screw will make a measurable
change in relief pressure.
D. Reinstall and tighten cap to secure adjustment.
Recheck relief pressure and readjust as needed.
12.Disconnect tester from manifold and hose. Reconnect hydraulic hose that was disconnected for test procedure.
3
4. Install tester with pressure gauges and flow meter in
series with the the disconnected hose and hydraulic
manifold port (MP) (or motor inlet if hose was disconnected at deck motor).
RIGHT
FRONT
TO OIL COOLER
1
5. Make sure the flow control valve on tester is fully
open.
2
6. After installing tester, start engine and run at idle
speed. Check for hydraulic leakage and correct before
proceeding with test.
CAUTION
Figure 26
Keep away from decks during test to prevent personal injury from the cutting blades.
1. Center deck manifold
2. LH wing deck manifold
3. RH wing deck manifold
3
7. Operate engine at full speed (2730 + 30 RPM). Engage the cutting decks.
1
8. Watch pressure gauge carefully while slowly closing
the flow control valve to fully closed.
2
9. As the relief valve lifts, system pressure should be
approximately:
3000 PSI for the center deck and left wing deck
2000 PSI for the right wing deck
10.Disengage cutting decks. Shut off engine. Record
test results.
Groundsmaster 4100--D
1. Deck manifold
2. Relief valve
Page 4 -- 33
Figure 27
3. Relief valve cap
Hydraulic System
Hydraulic
System
Procedure for Cutting Deck Manifold Relief
Pressure Test
TEST NO. 6: Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure
Gauges and Flow Meter)
TRACTION
CIRCUIT
CASE DRAIN/RETURN
CHARGE CIRCUIT
NOTE: CENTER DECK MOTOR TEST SHOWN
TO LIFT/LOWER CONTROL VALVE
TO STEERING CONTROL VALVE
Working Pressure
Low (Charge) Pressure
MEASURING
CONTAINER
Hydraulic System
Page 4 -- 34
Return or Suction
Flow
Groundsmaster 4100--D
Procedure for Cutting Deck Motor Case Drain
Leakage Test
6. Sit on seat and operate the engine at full speed (2730
+ 30 RPM). Move PTO switch to ON.
NOTE: Over a period of time, a deck motor can wear internally. A worn motor may by--pass oil to its case drain
causing the motor to be less efficient. Eventually,
enough oil loss will cause the deck motor to stall under
heavy cutting conditions. 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.
7. While watching pressure gauge, slowly close flow
control valve on tester until a pressure of 1200 PSI is obtained.
8. Have another person measure flow from the case
drain line for 15 seconds, then move the PTO switch to
OFF. Open the tester flow control valve and stop the engine. Record test results.
TEST RESULTS: Flow less than 0.7 GPM (less than
22.4 ounces (662 ml) of hydraulic fluid in 15 seconds).
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
9. If flow is more than 0.7 GPM, the motor is worn or
damaged and should be repaired or replaced.
2. Park machine on a level surface with the cutting
decks lowered and off. Make sure engine is off and the
parking brake is engaged.
10.Disconnect tester from motor and hose. Reconnect
hose to the deck motor. Remove cap from machine fitting and reconnect case drain hose.
11. If required, repeat test procedure for other deck motors.
CAUTION
1
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 wing deck motors are connected in series.
To isolate a faulty motor, both motors in the circuit may
have to be tested by starting with the left side motor first.
3
2
3. Disconnect return hose from the motor to be tested
(Fig. 28). Install flow tester in series with the motor and
the disconnected return hose. Make sure the flow control valve on tester is fully open.
4. Disconnect the motor case drain hose (small diameter hose) where it connects to the machine (not at the
motor). Put a steel cap on the fitting; leave the case drain
hose open (Fig. 29).
Figure 28
1. Deck motor (RH shown)
2. Return hose
3. Case drain hose
5. After installing flow tester, start engine and run at idle
speed. Check for hydraulic leakage and correct before
proceeding with test.
CAUTION
Cutting deck blades will rotate with PTO switch
in ON position. Keep away from cutting decks
during test to prevent personal injury from rotating blades. Do not stand in front of the machine.
Groundsmaster 4100--D
Page 4 -- 35 Rev. F
Figure 29
Hydraulic System
Hydraulic
System
NOTE: One method to find a failing or malfunctioning
deck motor is to have another person observe the machine while mowing in dense turf. A bad deck motor will
run slower, produce fewer clippings, and may cause a
different appearance on the turf.
NOTE: Use a graduated container, special tool
TOR4077, to measure case drain leakage (Fig. 29).
TEST NO. 7: Steering Circuit Relief Pressure (Using Pressure Gauge)
STEERING CYLINDER
PISTON MOVEMENT
NOTE: LEFT TURN SHOWN
L
R
1350
PSI
STEERING CONTROL T
PB
P
G
TO LIFT/LOWER CIRCUIT
CHARGE CIRCUIT
TO
RESERVOIR
TO PTO (MOW) CIRCUIT
.58
1.37
1.37
2.48
TRACTION
CIRCUIT
FROM
RESERVOIR
FROM OIL
FILTER
High Pressure
Low (Charge) Pressure
Return or Suction
Flow
Hydraulic System
Page 4 -- 36
Groundsmaster 4100--D
Procedure for Steering Circuit Relief Pressure Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
2. Park machine on a level surface with the cutting
decks lowered and off. Make sure engine is off and the
parking brake is engaged.
1
CAUTION
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
Figure 30
1. Steering circuit pressure test port
4. After installing pressure gauge, start engine and run
at idle speed. Check for hydraulic leakage and correct
before proceeding with test.
Hydraulic
System
3. Connect a 5000 PSI gauge onto steering circuit pressure test port (Fig. 30).
1
5. Operate the engine at full engine speed (2730 + 30
RPM).
IMPORTANT: Hold steering wheel at full lock only
long enough to get a system pressure reading.
Holding the steering wheel against the stop for an
extended period will damage the steering motor.
2
6. Turn steering all the way in one direction and momentarily hold the steering wheel against resistance.
GAUGE READING TO BE 1350 + 50 PSI.
Figure 31
7. Stop the engine. Record test results.
1. Steering tower
2. Steering relief valve
8. If pressure is incorrect, inspect steering relief valve
(Fig. 31). If steering relief valve is operating properly and
if lift/lower problems also exist, gear pump should be
suspected of wear and inefficiency. If steering wheel
continues to turn at end of cylinder travel (with lower
than normal effort), steering cylinder or steering valve
should be suspected of wear or damage.
9. Disconnect pressure gauge from test port.
Groundsmaster 4100--D
Page 4 -- 37
Hydraulic System
TEST NO. 8: Lift/Lower Circuit Relief Pressure (Using Pressure Gauge)
FROM PTO (MOW) CIRCUIT
PTO (MOW) CIRCUIT CASE DRAIN
TO PTO (MOW) CIRCUIT
NOTE: CENTER LIFT LEVER
SHOWN IN RAISE POSITION
High Pressure
Low (Charge) Pressure
Return or Suction
Flow
Hydraulic System
Page 4 -- 38
Groundsmaster 4100--D
Procedure for Lift/Lower Circuit Relief Pressure
Test
2
1
NOTE: Before attempting to check or adjust lift pressure, make sure that counterbalance pressure is correctly adjusted.
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
2. Park machine on a level surface with the cutting
decks lowered and off. Make sure engine is off and the
parking brake is engaged. Raise seat.
1. Lift circuit port
Figure 32
2. Hydraulic reservoir cap
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
2
Hydraulic
System
CAUTION
3
4
3. Raise seat to gain access to hydraulic test fitting.
Connect a 5,000 PSI gauge to lift circuit test port (Fig.
32). Route gauge hose to allow seat to be safely lowered.
5
1
4. After installing pressure gauge, start engine and run
at idle speed. Check for hydraulic leakage and correct
before proceeding with test.
5. Sit on the seat and operate the engine at full speed
(2730 + 30 RPM).
6. While sitting on the seat, pull lift lever back to raise
the cutting decks. Momentarily hold the lever with the lift
cylinder fully retracted (decks fully raised) while looking
at the gauge.
GAUGE READING TO BE 2500 to 2550 PSI.
Figure 33
1. Control valve assembly
2. Relief valve assembly
3. Washers
4. Spring
5. Poppet
7. Record test results.
8. Stop the engine. If pressure is too high, adjust relief
valve in lift control valve by rotating counterclockwise
(Figure 33). If pressure is too low, check for restriction
in pump intake line. Check the lift cylinder for internal
leakage. If cylinder is not leaking, adjust the relief valve
by rotating clockwise. If pressure is still too low, pump or
lift cylinder(s) should be suspected of wear, damage or
inefficiency.
9. Disconnect pressure gauge from test port.
Groundsmaster 4100--D
Page 4 -- 39
Hydraulic System
TEST NO. 9: Steering and Lift/Lower Gear Pump Flow (Using Tester with Pressure
Gauges and Flow Meter)
NOTE: LIFT/LOWER CIRCUIT FLOW TEST SHOWN
TO STEERING CIRCUIT
.58
1.37
TO PTO (MOW) CIRCUIT
TO PTO (MOW) CIRCUIT
TO LIFT/LOWER CIRCUIT
1.37
2.48
TRACTION
CIRCUIT
FROM
RESERVOIR
FROM OIL
FILTER
High Pressure
Low (Charge) Pressure
Return or Suction
Flow
Hydraulic System
Page 4 -- 40
Groundsmaster 4100--D
Procedure for Steering and Lift/Lower Gear Pump
Flow Test
Output from the steering and lift/lower gear pump section is equally divided by a proportional valve to provide
flow to the steering circuit and the lift circuit. To test gear
pump flow, testing of both steering and lift/lower circuits
is required. Total gear pump flow is the combined flow
from the two circuits.
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
8. If the total of the two flows is lower than 7 GPM or a
pressure of 1000 PSI could not be obtained, check for
restriction in pump intake line. If intake line is not restricted, remove gear pump and repair or replace as
necessary.
If the total of the two flows is 7 GPM but individual circuit
flow is less than 3.5 GPM (e.g. steering circuit has 2
GPM and lift circuit has 5 GPM), suspect a problem with
the proportional valve in the gear pump.
2. Park machine on a level surface with the cutting
decks lowered and off. Make sure engine is off and the
parking brake is engaged. Raise seat.
2
1
3
CAUTION
Hydraulic
System
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
IMPORTANT: Make sure that the oil flow indicator
arrow on the flow gauge is showing that the oil will
flow from the pump, through the tester, and into the
hydraulic hose.
1. Hydraulic tank cap
2. Lift circuit hose
3. With the engine off and cutting decks lowered, install
tester with pressure gauges and flow meter in series between the last gear pump section and one of the circuit
hoses (Fig. 34). Make sure the tester flow control
valve is open.
1
3. Steering circuit hose
2
3
4. After installing tester, start engine and run at idle
speed. Check for hydraulic leakage and correct before
proceeding with test.
IMPORTANT: The pump is a positive displacement
type. If pump flow is completely restricted or
stopped, damage to the pump, tester, or other components could occur.
Figure 34
4
Figure 35
1. Gear pump backplate
2. Lift circuit
3. Steering circuit
4. Proportional valve
5. Operate the engine at full speed (2730 + 30 RPM).
DO NOT engage the cutting decks.
6. While watching tester pressure gauges, slowly close
flow control valve on the tester until 1000 PSI is obtained
on gauge. Verify engine speed continues to be correct
(2730 + 30 RPM). Record test results.
GAUGE READING TO BE: Flow approximately 3.5
GPM at 1000 PSI.
7. Open tester flow control valve and stop engine. Remove tester and reinstall disconnected hose. Complete
steps 3 through 6 for other circuit hose.
Groundsmaster 4100--D
Page 4 -- 41
Hydraulic System
FROM PTO (MOW) CIRCUIT
PTO (MOW) CIRCUIT CASE DRAIN
TO PTO (MOW) CIRCUIT
TEST NO. 10: Counterbalance Pressure (Using Pressure Gauge)
High Pressure
Low (Charge) Pressure
Return or Suction
Flow
Hydraulic System
Page 4 -- 42
Groundsmaster 4100--D
Procedure for Counterbalance Pressure Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
2. Park machine on a level surface with the cutting
decks lowered and off. Make sure engine is off and the
parking brake is engaged. Remove console cover.
C. To decrease pressure setting, turn the adjustment screw on the valve in a counterclockwise direction. A 1/8 turn on the screw will make a measurable
change in counterbalance pressure.
D. Tighten locknut to secure adjustment. After adjustment, recheck counterbalance pressure. Readjust as needed.
9. Disconnect pressure gauge from test port.
CAUTION
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
4
3
3. Determine system charge pressure (see TEST NO.
1: Traction Circuit Charge Pressure in this chapter).
2
Hydraulic
System
1
4. Connect a 1000 PSI gauge to counterbalance test
port on manifold under console (Fig. 36).
5. After installing pressure gauge, start engine and run
at idle speed. Check for hydraulic leakage and correct
before proceeding with test.
6. Operate the engine at full engine speed (2730 + 30
RPM) with no load on the system. Do not engage the
cutting decks.
Figure 36
1. Counterbalance test port
2. Counterbalance valve
3. Locknut
4. Adjusting screw
GAUGE READING TO BE 225 PSI (17.3 bar) over
system charge pressure (e.g. if charge pressure is
250 PSI, counterbalance pressure should be 475
PSI).
7. Stop the engine. Record test results.
8. Adjustment of the counterbalance valve can be performed as follows:
NOTE: Do not remove the valve from the hydraulic
manifold for adjustment.
A. Loosen locknut on counterbalance valve (Fig.
36).
B. 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.
Groundsmaster 4100--D
Page 4 -- 43
Hydraulic System
TEST NO. 11: Rear Traction Circuit (RV5) Relief Pressure (Using Pressure Gauge)
CHARGE OIL FROM
LIFT AND STEERING
CIRCUITS
RETURN FROM LIFT
AND STEERING CYLINDERS
TO LIFT/LOWER CIRCUIT
TO STEERING CIRCUIT
FROM PTO (MOW) CIRCUIT
PTO (MOW) CIRCUIT CASE DRAIN
TO PTO (MOW) CIRCUIT
Working Pressure
Low (Charge) Pressure
Return or Suction
Flow
Hydraulic System
Page 4 -- 44
Groundsmaster 4100--D
Procedure for Rear Traction Circuit (RV5) Relief
Pressure Test
1
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
2. Park machine on a level surface with the cutting
decks lowered and off. Make sure engine is off and the
parking brake is engaged.
2
CAUTION
Figure 37
1. 2WD/4WD control manifold
2. Relief valve test port
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
2
Hydraulic
System
3. Connect a 1000 PSI gauge to test port on 2WD/4WD
control manifold under radiator (Fig. 37).
4. After installing pressure gauge, start engine and run
at idle speed. Check for hydraulic leakage and correct
before proceeding with test.
5. Operate the engine at full engine speed (2730 + 30
RPM).
6. Operate the machine in 4WD with the cutting decks
lowered. Drive down a slope in a forward direction, decrease pressure on the traction pedal, and monitor the
pressure gauge. Pressure should increase until the relief valve (RV5) lifts. Record test results.
1
Figure 38
1. Manifold: lower side
2. Relief valve (RV5)
GAUGE READING TO BE 750 PSI (approximate).
7. Relief valve (RV5) is located on the lower, front side
of the 2WD/4WD control manifold (Fig. 38). Adjustment
of the relief valve can be performed as follows:
1
NOTE: Do not remove the relief valve from the hydraulic manifold for adjustment.
A. To increase relief pressure setting, remove cap
on relief valve and turn the adjustment socket on the
relief valve in a clockwise direction. A 1/8 turn on the
socket will make a measurable change in relief pressure (Fig. 39).
2
B. To decrease pressure setting, remove cap on relief valve and turn the adjustment socket on the relief
valve in a counterclockwise direction. A 1/8 turn on
the socket will make a measurable change in relief
pressure (Fig. 39).
C. Recheck relief pressure and readjust as needed.
Figure 39
1.
Relief valve cap
2.
Adjustment socket
8. Disconnect pressure gauge from test port.
Groundsmaster 4100--D
Page 4 -- 45
Hydraulic System
TEST NO. 12: Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge)
CHARGE OIL FROM
LIFT AND STEERING
CIRCUITS
RETURN FROM LIFT
AND STEERING CYLINDERS
PTO (MOW) CIRCUIT CASE DRAIN
TO PTO (MOW) CIRCUIT
TO LIFT/LOWER CIRCUIT
TO STEERING CIRCUIT
FROM PTO (MOW) CIRCUIT
Working Pressure
Low (Charge) Pressure
Return or Suction
Flow
Hydraulic System
Page 4 -- 46
Groundsmaster 4100--D
Procedure for Traction Circuit Reducing Valve (PR)
Pressure Test
1
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
2. Park machine on a level surface with the cutting
decks lowered and off. Make sure engine is off and the
parking brake is engaged.
2
CAUTION
Figure 40
1. 2WD/4WD control manifold
2. Pressure test port
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
Hydraulic
System
3. Connect a 1000 PSI gauge to test port on 2WD/4WD
control manifold under radiator (Fig. 40).
4. After installing pressure gauge, start engine and run
at idle speed. Check for hydraulic leakage and correct
before proceeding with test.
5. Operate the engine at full engine speed (2730 + 30
RPM).
6. Sit on seat, apply brakes fully, and slowly depress the
traction pedal in the reverse direction. While pushing
traction pedal, look at pressure reading on gauge:
1
2
Figure 41
1. Manifold: lower side
2. Reducing valve (PR)
GAUGE READING TO BE 650 PSI (approximate).
7. Stop engine and record test results.
8. Pressure reducing valve (PR) is located on the lower,
front side of the 2WD/4WD control manifold (Fig. 41).
Adjustment of this valve can be performed as follows:
NOTE: Do not remove the valve from the hydraulic
manifold for adjustment.
A. To increase pressure setting, remove cap on reducing valve and turn the adjustment socket on the
valve in a clockwise direction. A 1/8 turn on the socket will make a measurable change in pressure setting.
B. To decrease pressure setting, remove cap on reducing valve and turn the adjustment socket on the
valve in a counterclockwise direction. A 1/8 turn on
the socket will make a measurable change in pressure setting.
C. Recheck reducing valve (PR) pressure setting
and readjust as needed.
9. Disconnect pressure gauge from test port.
Groundsmaster 4100--D
Page 4 -- 47
Hydraulic System
Adjustments
Adjust Cutting Deck Flow Control Valve
The cutting deck lift circuit is equipped with an adjustable flow control valve used to adjust the rate at which
the cutting decks lower. The control valve is located under the front platform. Adjust flow control valve as follows:
2
1. Run machine to get hydraulic oil at operating temperatures. Park machine on a level surface, shut engine off
and lower cutting decks to the ground.
1
2. Locate valve under front of machine (Fig. 42).
3. Loosen setscrew on valve and rotate valve clockwise to slow down drop rate of cutting decks.
4. Verify adjustment by raising and lowering cutting
decks several times. Readjust as required.
5. After desired drop rate is attained, tighten setscrew
on valve to lock adjustment.
Hydraulic System
Page 4 -- 48
Figure 42
1. Cutting deck lift flow control valve
2. Front deck hydraulic manifold
Groundsmaster 4100--D
Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Before Repair or Replacement of Components
After Repair or Replacement of Components
1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking
brake, lower cutting decks or attachments, and stop engine. Remove key from the ignition switch.
1. Check oil level in the hydraulic reservoir and add correct oil if necessary. Drain and refill hydraulic system
reservoir, and change oil filter if component failure was
severe or system is contaminated (see Flush Hydraulic
System).
CAUTION
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the
ignition switch in RUN and the engine OFF. Make
sure all electrically operated control valves are
actuated. Return ignition switch to OFF when
pressure has been relieved. Remove key from
the ignition switch.
3. Put caps or plugs on any hydraulic lines, hydraulic fittings, and components left open or exposed to prevent
contamination.
2. Lubricate o--rings and seals with clean hydraulic oil
before installing hydraulic components.
3. Make sure all caps or plugs are removed from hydraulic tubes, hydraulic fittings, and components before
reconnecting.
4. Use proper tightening methods when installing hydraulic hoses and fittings (see Hydraulic Fitting Installation).
5. After repairs, check control linkages or cables for
proper adjustment, binding, or broken parts.
6. After disconnecting or replacing any hydraulic components, operate machine functions slowly until air is
out of system (see Charge Hydraulic System).
7. Check for hydraulic oil leaks. Shut off engine and correct leaks if necessary. Check oil level in hydraulic reservoir and add correct oil if necessary.
4. Put labels on disconnected hydraulic lines and
hoses for proper installation after repairs are completed.
5. Note the position of hydraulic fittings (especially elbow fittings) on hydraulic components before removal.
Mark parts if necessary to make sure they will be aligned
properly when reinstalling hydraulic hoses and tubes.
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.
Groundsmaster 4100--D
IMPORTANT: Check hydraulic lines and hoses daily
for leaks, kinked lines, loose mounting supports,
wear, loose fittings, weather deterioration, or chemical deterioration. Make all necessary repairs before
operating.
Page 4 -- 49
Hydraulic System
Hydraulic
System
2. Clean machine before disconnecting, removing, or
disassembling any hydraulic components. Make sure
hydraulic components, hoses connections, and fittings
are cleaned thoroughly. Always keep in mind the need
for cleanliness when working on hydraulic equipment.
Flush Hydraulic System
IMPORTANT: Flush the hydraulic system any time
there is a severe component failure or the system is
contaminated (oil appears milky, black, or contains
metal particles).
IMPORTANT: Flush hydraulic system when changIng from petroleum base hydraulic fluid to a biodegradable fluid such as Mobil EAL 224H. Operate
machine under normal operating conditions for at
least four (4) hours before draining.
1. Park machine on a level surface. Lower cutting
decks, stop engine, and engage parking brake. Remove
key from the ignition switch.
6. Reconnect all hydraulic hoses, tubes, and components that were disconnected while draining system.
NOTE: Use only hydraulic fluids specified in the Operator’s Manual. Other fluids may cause system damage.
7. Fill hydraulic reservoir with new hydraulic fluid (see
Operator’s Manual).
8. Disconnect electrical connector from engine run solenoid.
9. Turn ignition key switch; engage starter for 15 seconds to prime hydraulic pumps. Wait 15 seconds to allow the starter to cool and then repeat this step again.
10.Connect electrical connector to engine run solenoid.
CAUTION
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the
ignition switch in OFF. Remove key from the ignition switch.
11. Start engine and let it run at low idle (1375 + 50 RPM)
for a minimum of 2 minutes. Increase engine speed to
high idle (2730 + 30 RPM) for a minimum of 1 minute under no load.
12.Raise and lower cutting decks several times. Turn
steering wheel fully left and right several times.
IMPORTANT: Make sure to clean around any hydraulic connections that will be disconnected for
draining.
13.Shut off engine and check for hydraulic oil leaks.
Check oil level in hydraulic reservoir and add correct
amount of oil if necessary.
2. Drain hydraulic reservoir (see Operator’s Manual).
14.Operate machine for 2 hours under normal operating
conditions.
3. Drain hydraulic system. Drain all hoses, tubes, and
components while the system is warm.
4. Change and replace both hydraulic oil filters (see
Operator’s Manual).
5. Inspect and clean hydraulic reservoir (see Hydraulic
Reservoir Inspection in the Service and Repairs section
of this chapter).
Hydraulic System
15.Check condition of hydraulic oil. If the new fluid
shows any signs of contamination, repeat steps 1
through 14 again until oil is clean. If changing to biodegradable fluid, repeat steps 1 through 14 again at least
once and until the oil is clean.
16.Assume normal operation and follow recommended
maintenance intervals.
Page 4 -- 50
Groundsmaster 4100--D
Charge Hydraulic System
IMPORTANT: Change hydraulic oil filter whenever
hydraulic components are repaired or replaced.
11. After the hydraulic system starts to show signs of fill,
actuate lift control lever until the lift cylinder rod moves
in and out several times. If the cylinder rod does not
move after 15 seconds, or the pump emits abnormal
sounds, shut the engine off immediately and determine
cause or problem. Inspect for the following:
A. Loose filter or suction lines.
1. Park machine on a level surface. Lower cutting
decks, stop engine, and engage parking brake. Remove
key from the ignition switch.
B. Blocked suction line.
2. Make sure all hydraulic connections, lines, and components are tight.
D. Faulty gear pump.
3. If component failure was severe or the system is contaminated, flush and refill hydraulic system and reservoir (see Flush Hydraulic System in the Service and
Repairs section of this chapter).
4. Make sure hydraulic reservoir is full. Add correct hydraulic oil if necessary (see Operator’s Manual).
5. Disconnect engine run solenoid lead to prevent the
engine from starting.
6. Check control rod to the piston (traction) pump for
proper adjustment, binding, or broken parts.
7. Make sure traction pedal and lift control lever are in
the neutral position. Turn ignition key switch; engage
starter for fifteen (15) seconds to prime the traction and
gear pumps.
C. Faulty charge relief valve.
12.If cylinder does move in 15 seconds, proceed to
step 13.
13.Operate the traction pedal in the forward and reverse
directions. The wheels off the ground should rotate in
the proper direction.
A. If the wheels rotate in the wrong direction, stop
engine, remove lines from bottom of piston (traction)
pump, and reverse the connections.
B. If the wheels rotate in the proper direction, stop
engine.
14.Adjust traction pedal to the neutral position (see Operator’s Manual).
15.Check operation of the traction interlock switch (see
Operator’s Manual).
16.Remove blocks from frame and lower machine to the
ground. Remove chocks from remaining wheels.
8. Reconnect engine run solenoid lead.
17.If the piston (traction) pump or a wheel or axle motor
was replaced or rebuilt, run the machine so all wheels
turn slowly for 10 minutes.
WARNING
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 -- Safety.
9. Raise one front and one rear wheel off the ground,
and place support blocks under the frame. Chock remaining wheels to prevent movement of the machine.
18.Operate machine by gradually increasing it’s work
load to full over a 10 minute period.
19.Stop the machine. Check hydraulic reservoir and fill
if necessary. Check hydraulic components for leaks and
tighten any loose connections.
10.Make sure traction pedal and lift control lever are in
neutral. Start engine and run it at low idle (1375 + 50
RPM). The charge pump should pick up oil and fill the
hydraulic system. If there is no indication of fill in 30 seconds, stop the engine and determine the cause.
Groundsmaster 4100--D
Page 4 -- 51
Hydraulic System
Hydraulic
System
NOTE: When initially starting the hydraulic system with
new or rebuilt components such as motors, pumps, or
lift cylinders, it is important that the hydraulic system be
charged properly. Air must be purged from the system
and its components to reduce the chance of damage.
Gear Pump
20
15
16
17
3
12
13
4
14
1
2
6
3
5
8
10
7
18
9
19
25
27
11
11
21
26
RIGHT
22
FRONT
23
24
1.
2.
3.
4.
5.
6.
7.
8.
9.
90o hydraulic fitting
O--ring
O--ring
90o hydraulic fitting
O--ring
O--ring
Hydraulic fitting
O--ring
Hydraulic fitting
Hydraulic System
Figure 43
10.
11.
12.
13.
14.
15.
16.
17.
18.
O--ring
Clamp
Hydraulic T fitting
O--ring
Hydraulic fitting
Fitting cap
Hydraulic fitting
O--ring
Cap screw (2 used)
Page 4 -- 52
19.
20.
21.
22.
23.
24.
25.
26.
27.
Flat washer (2 used)
Engine
Piston pump
O--ring
Coupler
Gear pump
Spacer
Cap screw (2 used)
Washer (2 used)
Groundsmaster 4100--D
Removal (Fig 43)
Installation (Fig 43)
1. Park machine on a level surface, lower cutting
decks, stop engine, engage parking brake, and remove
key from the ignition switch.
1. Lubricate new o--rings with clean hydraulic oil and
position on pump.
3. Drain the hydraulic reservoir (see Operator’s Manual).
4. To prevent contamination of hydraulic system during
pump removal, thoroughly clean exterior of pump and
fittings.
5. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
2. Slide coupler onto the piston pump output shaft.
3. Position o--rings and spacer to gear pump. Align
gear teeth and slide gear pump input shaft into coupler.
Secure gear pump to piston pump with two (2) cap
screws and washers.
4. Remove caps or plugs from hydraulic lines and fittings. Install hydraulic lines to gear pump.
5. Replace hydraulic filter and fill hydraulic reservoir
with new hydraulic oil.
6. Disconnect hydraulic lines from gear pump and put
caps or plugs on open hydraulic lines and fittings. Label
disconnected hydraulic lines for proper reassembly.
6. Disconnect engine run solenoid electrical connector
to prevent engine from starting. Prime the hydraulic
pump by turning the ignition key switch to start and crank
the engine for 15 seconds. Wait 15 seconds and repeat
cranking procedure again.
7. Support gear pump assembly to prevent it from falling.
7. Connect engine run solenoid electrical connector,
start the engine, and check for proper operation.
8. Remove two (2) cap screws and washers that secure
gear pump to piston pump. Remove gear pump, coupler, spacer, and o--rings from machine through the seat
opening.
8. Properly fill hydraulic system (see Charge Hydraulic
System in the Service and Repairs section of this chapter).
Groundsmaster 4100--D
9. Stop engine and check for hydraulic oil leaks. Check
hydraulic reservoir oil level.
Page 4 -- 53
Hydraulic System
Hydraulic
System
2. Raise seat and secure it with prop rod to gain access
to gear pump.
Gear Pump Service
5
13
11
4
8
14
3
1
12
15
10
4
4
19
18
17
23
16
4
20 21
21 to 24 ft--lb
(29 to 33 N--m)
25 to 28 ft--lb
(34 to 38 N--m)
2
22
12
13
24
14
9
7
28
4
29
27
25
26
4
21 to 24 ft--lb
(29 to 33 N--m)
6
Figure 44
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Shaft seal
Washer
Cap screw (8 used)
O--ring
Washer (8 used)
Proportional valve
Plug
Plug
O--ring
Front body
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Drive gear assembly
Wear plate
Pressure seal
Backup gasket
Front plate assembly
Idler gear
Key
Drive gear
Middle body
Drive gear
Disassembly (Fig. 44)
Work in a clean area as cleanliness is extremely important when repairing hydraulic pumps. Thoroughly clean
the outside of pump. After cleaning, remove port plugs
and drain oil from pump.
1. Scribe a line, at an angle, across front plate (15), bodies (10, 19, 26), adapter plates (23, 24) and backplate
(27). This will assure proper reassembly.
Hydraulic System
21.
22.
23.
24.
25.
26.
27.
28.
29.
Idler gear
Key
Front adapter plate
Rear adapter plate
Idler gear
Rear body
Backplate assembly
Plug
O--ring
NOTE: To maintain maximum pump efficiency, keep
body, gears and wear plates for each section together.
DO NOT mix parts between different sections.
IMPORTANT: Avoid using excessive clamping
pressure on the pump housing to prevent distorting
the housing.
2. Clamp pump in vise, shaft end up and remove the
eight cap screws (3).
Page 4 -- 54
Groundsmaster 4100--D
3. Remove pump from vise, hold pump in hands and
bump shaft against wooden block to separate front
pump sections. Front body (10) will remain with either
front plate (15) or front adapter plate (23).
Inspection
4. Place front idler gear (16) into gear pocket and tap
with soft face hammer until the front body separates.
Remove idler gear from front plate or adapter plate.
2. Check spline drive shaft for damaged teeth. Also
check for damaged keyway, on drive shaft, that drives
the slip fit gears of the pump.
5. Remove plug (8) from front plate (15).
3. Inspect both the drive gear and idler gear shafts at
bushing points and seal area for rough surfaces and excessive wear.
7. Remove idler gear (21), slip fit gear (18), and key
(17).
8. Remove backplate (27) from rear body (26) by tapping on backplate with soft face hammer.
9. Remove rear idler gear (25), slip fit gear (20) and key
(22).
10.Remove drive gear assembly (11) from rear adapter
plate (24).
11. Place rear idler gear assembly (25) back into gear
pocket and tap protruding end with soft face hammer to
remove rear body (26) from the backplate assembly (27)
or the rear adapter plate (24).
IMPORTANT: Note position of the open and closed
side of the wear plates before removing.
12.Remove the wear plates (12) and o--rings (4) from
front plate (15), front adapter plate (23), and rear adapter plate (24).
13.Remove backup gaskets (14) and pressure seals
(13) from wear plates (15) by carefully prying out with a
sharp tool.
4. Replace gear assembly if shaft measures less than
.873” (22.17mm) in bushing area. (One gear assembly
may be replaced separately; shafts and gears are available as assemblies only. The slip fit gear is available
separately).
5. Inspect gear faces for scoring or excessive wear.
6. Replace gear assembly if gear width is below
1.181 inch (30.00 mm).
7. Assure that snap rings are in grooves on either side
of drive and idler gears.
8. If any edge of gear teeth is sharp, break edge with
emery cloth.
9. Oil groove in bushings in front plate, backplate and
adapter plates should be in line with dowel pin holes and
180o apart. This positions the oil grooves closest to respective dowel pin holes.
10.Replace the backplate, front plate or adapter plates
if l.D. of bushings exceed .879” (22.33mm) (Bushings
are not available as separate items).
11. Bushings in front plate and backup gasket side of
adapter plates should be flush with face of plate.
IMPORTANT: Do not damage the seal bore in the
front plate during seal removal.
12.Check for scoring on face of backplate and adapter
plates. Replace if wear exceeds .0015” (.038mm).
14.Remove shaft seal (1) and washer (2) from front
plate (15).
13.Check bodies inside gear pockets for excessive
scoring or wear.
15.Remove plug (7) and washer (9) from rear adapter
plate (24).
14.Replace bodies if l.D. of gear pockets exceeds
2.100 inch (53.34mm).
16.Remove proportional valve (6) from backplate assembly (27).
Groundsmaster 4100--D
Page 4 -- 55
Hydraulic System
Hydraulic
System
6. Remove front adapter plate (23) from front body (10)
by tapping on the adapter plate with a soft face hammer.
1. Clean and dry all pump components. Remove nicks
and burrs from all parts with emery cloth.
Reassembly (Fig. 44)
It is important that the relationship of the backplate,
adapter plates, bodies, wear plates and front plate is
correct. The two half moon cavities in the bodies must
face away from the front plate or adapter plate. The
smaller half moon port cavity must be on the pressure
side of the pump. The side of the wear plate with mid
section cut out must be on suction side of pump. Suction
side of backplate or adapter plate is always the side with
larger port boss.
1. Replace the wear plates, pressure seals, backup
gaskets, shaft seal and o--rings as new parts. During reassembly, check the scribe mark on each part to make
sure the parts are properly aligned.
2. Install o--rings (4) in groove of front plate (15), adapter plates (23, 24), and backplate (27) with a small
amount of petroleum jelly to hold in place.
3. Install new pressure seals (13) and backup gaskets
(14) into new wear plates (12). The flat section in the
middle of the backup gasket must face away from the
wear plate inside the seal.
4. Place plug (8) into pocket of front plate (15).
5. Apply a thin coat of petroleum jelly to both milled gear
pockets of front body (10). Position body onto front plate
(15) with half moon port cavities in body facing away
from front plate.
NOTE: The small half moon port cavity must be on the
pressure side of pump.
6. Place wear plate (12) into the gear pocket with the
pressure seal and backup gasket against the front plate.
The side with the mid section cut away must be on suction side of pump.
7. Dip drive gear assembly (11) and idler gear assembly (16) into clean hydraulic oil. Slip both gear assemblies into gear pocket of front body (10) and into front
plate bushings.
10.Install key (17) in slot of drive gear shaft. Dip slip fit
gear (18) in clean hydraulic oil and slide on shaft and into
gear pocket of middle body (19). Check key for proper
alignment.
11. Dip idler gear (21) in clean hydraulic oil and install in
gear pocket of middle body.
12.Install rear adapter plate (24) in place on middle body
(19). Check positioning mark on all sections of pump.
13.Position rear body (26) onto rear adapter plate (24).
Place wear plate (12) into the gear pocket with the pressure seal and backup gasket against the rear adapter
plate.
14.Install key (22) in slot of drive gear shaft. Dip slip fit
gear (20) in clean hydraulic oil and slide on shaft and into
gear pocket of rear body (26). Check key for proper
alignment.
15.Dip rear idler gear (25) in clean hydraulic oil and
install in gear pocket of rear body.
16.Position backplate (27) over shafts until dowel pins
in body are engaged.
17.Secure pump components with cap screws (3).
Torque cap screws evenly in a crisscross pattern from
25 to 28 ft--Ib (34 to 38 N--m).
18.Place washer (2) over drive shaft into housing. Liberally oil shaft seal (1) and install over drive shaft carefully
so that rubber sealing lips are not cut.
19.Place 1--3/8” O.D. sleeve over shaft and press in
shaft seal .200 in. (5.08mm) below surface of front plate.
20.Install plug (7) and washer (9) into rear adapter plate.
21.If removed, install plug (28) with o--ring into backplate and torque from 21 to 24 ft--lb (29 to 33 N--m).
22.Install proportional valve (6) into backplate. Torque
plug from 21 to 24 ft--lb (29 to 33 N--m).
8. Install front adapter plate (23) in place on front body
(10). Check positioning marks for correct orientation.
9. Install middle body (19) onto front adapter plate (23).
Place wear plate (12) into the gear pocket with the pressure seal and backup gasket against the front adapter
plate.
Hydraulic System
Page 4 -- 56
Groundsmaster 4100--D
Hydraulic
System
This page is intentionally blank.
Groundsmaster 4100--D
Page 4 -- 57
Hydraulic System
Piston (Traction) Pump
32
33
31
34
17
30
16
3
3
13
1
85 to 95 ft--lb
(115 to 128 N--m)
2
4
6
15
3
5
18
2
5
22
20
14
11
8
8
7
12
RIGHT
19
10
21
21
27
29
9
23
28
FRONT
26
25
24
Figure 45
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Hydraulic T fitting
O--ring
O--ring
90o hydraulic fitting
O--ring
O--ring
Hydraulic fitting (2 used)
O--ring
O--ring
Hydraulic fitting
O--ring
Hose connector
Hydraulic System
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
90o hydraulic fitting
O--ring
Hydraulic T fitting
Hydraulic fitting
Fitting cap
Hydraulic fitting
Cap screw (2 used)
Flat washer (2 used)
Clamp
Roll pin
Piston pump
Page 4 -- 58
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
Gear pump
Coupler
O--ring
Spacer
Cap screw (2 used)
Washer (2 used)
Cap screw
Control arm (on piston pump)
Spacer
Lock nut
Traction rod
Groundsmaster 4100--D
Installation (Fig. 45)
1. Park machine on a level surface, lower cutting
decks, stop engine, engage parking brake, and remove
key from the ignition switch.
1. Carefully lower piston pump into the machine and
position it to the engine adapter plate. Support pump to
prevent it from falling while installing two (2) cap screws
and washers securing piston pump to engine adapter
plate. Torque screws from 85 to 95 ft--lb (115 to 128
N--m).
2. To prevent contamination of hydraulic system during
pump removal, thoroughly clean exterior of pump assembly.
3. Remove traction rod from control arm on piston
pump by removing lock nut, spacer, and cap screw.
2. Install gear pump to piston pump (see Gear Pump
Installation in the Service and Repairs section of this
chapter).
4. Disconnect two wires from neutral switch on traction
pump.
3. Position traction rod to control arm on piston pump
by installing cap screw, spacer, and lock nut.
5. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
4. Connect two wires to neutral switch on traction
pump.
6. Put a drain pan below the pump assembly. Remove
hydraulic hoses and fittings connected to piston and
gear pumps. Put plugs or caps on disconnected hydraulic hoses to prevent contamination of the system. Put
plugs in open ports of pumps.
7. Remove gear pump from machine (see Gear Pump
Removal). Note: If fuel tank is loosened and raised
approximately 4” (102 mm) from the machine, the gear
pump and piston pump can be removed as a complete
assembly.
8. Support the piston pump to prevent it from falling
while removing two (2) cap screws and washers retaining pump assembly to engine adapter plate. Carefully
pull pump assembly from adapter plate and raise it out
of the machine.
5. Remove plugs or caps from disconnected hydraulic
hoses and open ports of the pump assembly. Install fittings and hoses to correct location on gear and piston
pumps.
6. Install new hydraulic oil filter and fill hydraulic reservoir with correct oil.
7. Disconnect engine run solenoid electrical connector
to prevent engine from starting. Prime hydraulic pumps
by turning ignition key switch to start and crank engine
for 15 seconds. Wait 15 seconds and repeat cranking
procedure again.
8. Connect engine run solenoid electrical connector,
start the engine, and check for proper operation.
9. Properly fill hydraulic system (see Charge Hydraulic
System in the Service and Repairs section of this chapter).
10.Stop engine and check for hydraulic oil leaks. Check
hydraulic reservoir oil level.
Groundsmaster 4100--D
Page 4 -- 59
Hydraulic System
Hydraulic
System
Removal (Fig. 45)
Piston (Traction) Pump Service
100 to 110 ft--lb
(136 to 149 N--m)
27 to 31 ft--lb
(37 to 42 N--m)
16
20
150 to 160 in--lb
(17 to 18 N--m)
38
18
100 to 110 ft--lb
(136 to 149 N--m)
15
4 to 6 ft--lb
(5 to 8 N--m)
14
1
29
26
4
22
45
10
33
28
23
17
8
30
7
5
27
40 to 48 in--lb
(4.5 to 5.4 N--m)
34
43
35
31
36
32
44
11
40 to 48 in--lb
(4.5 to 5.4 N--m)
37
19
25 to 28 ft--lb
(34 to 38 N--m)
42
41
40
6
Loctite #277
31
5
39
37
21
12
40 to 48 in--lb
(4.5 to 5.4 N--m)
33
3
3
9
13
24
2
25
Figure 46
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Jam nut
Retaining ring
Retaining ring
Seal washer
Socket head screw (4 used per cover)
Rotating kit assembly
Servo piston assembly
Piston follower
Cover plate
Cover plate
Camplate assembly
Thrust race
Thrust bearing
Bypass valve
Cap screw (4 used)
Hydraulic System
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Relief valve (Reverse)
Socket head screw (6 used)
Valve plate
Pump housing
Backplate assembly
Drive shaft
Nut
Lock washer
Washer
Shaft seal
Relief valve (Forward)
Control arm
Servo control assembly
Washer
Orifice plate (3 used)
Page 4 -- 60
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
Flat washer
Housing gasket
Cover plate gasket
Control assembly gasket
Plug
O--ring
Seal sub--assembly
Roll pin
Bearing
Dowel bushing (2 used)
Cradle sub--assembly
Cap screw (2 used)
Button head cap screw
Bushing
Bearing
Groundsmaster 4100--D
1. Position the pump into a protected jaw vise, clamping onto the outer portion of the flange, with the cap
screws up. Mark the relationship of the working ports
(for reassembly identification) to the servo control assembly with a scribe. Remove the four cap screws (15)
retaining backplate (20).
2. Lift backplate (20) straight up off drive shaft (21) and
housing (19). Remove valve plate (18) from backplate
(20) or from rotating kit assembly (6), still in housing
(19).
3. From backplate (20), remove bypass valve (14), forward relief valve (26), and reverse relief valve (16).
Note: Mark the valves in relationship to the cavity it was
removed, for reassembly purposes.
4. Remove housing gasket (32) from housing (19) or
backplate (20).
5. With pump still in vise, remove the six socket head
screws (17) retaining the servo control assembly (28).
Remove the control assembly and control housing gasket (34) from the housing. Remove orifice plates (30),
noting location for reassembly. Remove nut (22), lock
washer (23), and control arm (27) from servo control input shaft. Note position of control arm for reassembly.
12.Remove the two cap screws (42) that secure cradle
sub--assembly inside housing. Move the cradle sub--assembly back--and--forth to release dowel bushings (40)
and remove cradle sub--assembly from housing.
13.Remove button head cap screw (43) to remove
bushing (44) from cradle.
14.Remove remaining plugs from housing.
15.Discard the shaft seal (25), gaskets (32, 33, 34), and
o--rings from all assemblies. Replace with new seals
upon reassembly.
Inspection
1. Inspect backplate assembly:
A. Check the bearing (45) (press fit) in backplate
(20). If needles remain in cage, move freely, and setting is at the dimension shown in Figure 47, bearing
removal is not required.
B. Check roll pin (38) in backplate (20). If tight and
set to the dimension shown in Figure 47, removal not
required.
Numbered end
6. To remove rotating kit assembly (6) from housing,
first remove pump from vise holding the rotating kit assembly in position. Lower pump so that the shaft end
(flange end) is up. Set the rear of housing onto table with
housing flat and rotating kit assembly at rest on table.
(Hole in table, for protruding shaft, is required.) Lift and
remove the housing (19) and drive shaft (21) from rotating kit assembly (6) and camplate assembly(11).
7. Remove camplate (11) from rotating kit assembly (6)
and servo piston follower (8) from camplate (11).
8. Remove the four socket head screws (5) and washers (31) retaining each cover plate (9 & 10).
Figure 47
2. Check the bearing (39) (press fit) in pump housing
(19). If needles remain in cage, move freely, and setting
at the dimension shown in Figure 48, bearing removal
is not required.
Flange end of housing
9. Remove jam nut (1), washer (29), and seal washer
(4). Hold the servo piston bolt with hex key and unscrew
cover plate (10) from bolt.
10.Remove servo piston assembly (7) and seal sub--assemblies (two sets) (37) from housing. Note: Disassembly of servo piston assembly is not required.
Numbered end
.070 inch
(1.78 mm)
11. Remove retaining ring (2) from the front of pump
housing (19). Press the drive shaft (21), shaft seal (25),
and washer (24) from housing. Remove retaining ring
(3), thrust race (12), thrust bearing (13), second thrust
race (12), and second retaining ring (3) from drive shaft
(21).
Groundsmaster 4100--D
.173 inch
(4.39 mm)
.090 inch
(2.29 mm)
Page 4 -- 61
Figure 48
Hydraulic System
Hydraulic
System
Disassembly (Fig. 46)
3. Inspect camplate assembly:
A. The finish on the piston shoe surfaces of the camplate (11) should show no signs of scoring.
3
2
1
B. Inspect camplate (11) bushing surface for wear.
Also inspect surface for coating transfer from bushing.
5
4. Inspect bushing (44) for contamination embedment
within coating of bushing surface coming in contact with
camplate (11).
4
Figure 49
5. Inspect rotating kit (Fig. 49):
A. The pistons should move freely in the rotating kit
piston block bore. If they are sticky in the bore, examine the bore for scoring or contamination.
B. Examine the O.D. of the pistons for finish condition. They should not show wear or deep scratches.
Inspect the shoes for a snug fit on the ball end of the
pistons and a flat smooth surface that comes in contact with the camplate. Do not lap piston shoes.
1. Piston assemblies
2. Spider
3. Spider pivot
4. Piston block
5. Retainer
.500 inch
(12.7 mm)
Left Side
Right Side
C. Examine the spider for wear in the pivot area.
D. Examine the spider pivot to insure smoothness
and no signs of wear.
Front flange -- Drive shaft end of pump
Adjust to center piston
Reassembly (Fig. 46)
1. All parts should be cleaned and internal pump parts
lubricated with clean hydraulic oil before reassembly.
2. If necessary, press new bearing into pump housing
to dimension shown in Figure 48 with the numbered end
of bearing outward.
3. Install the two new seal sub--assemblies (37) into the
servo piston cavity of pump housing (19).
4. Screw the cover plate (10) onto the servo piston assembly (7). Install new cover plate gasket (33) in place
on pump housing. Install servo piston assembly (7) and
cover plate (10) into servo piston bore in right side of
housing (Fig. 50). Retain cover plate with four washers
(31) and socket head screws (5). Torque screws from 40
to 48 in--lb (4.5 to 5.4 N--m). To obtain neutral, centering
the servo piston assembly is required. Measure in from
the left side and set servo piston .500 in. (12.7 mm) from
surface of servo housing bore as shown in Figure 50.
NOTE: Re--adjustment may be required for neutral at
machine start--up.
Hydraulic System
Install servo piston
in this direction
Figure 50
5. Install new seal washer (4), washer (29), and jam nut
(1) to servo piston bolt. Holding servo piston bolt with
hex key wrench, torque jam nut from 150 to 160 in--lb (17
to 18 N--m). Check the centering of servo piston assembly (7). Install new cover plate gasket (33) and cover
plate (9) to open side of servo piston and retain with four
washers (31) and socket head screws (5). Torque
screws from 40 to 48 in--lb (4.5 to 5.4 N--m).
6. Press dowel bushings (40) into cradle and secure
bushing (44) onto cradle with button head cap screw
(43). Torque button head cap screw from 14 to 16 in--lb
(1.6 to 1.8 N--m).
7. Place cradle sub--assembly (41) into housing (19)
making sure dowel bushings (40) and cradle (41) are
completely seated into housing. Retain cradle sub--assembly with two cap screws (42) after applying Loctite
#277 (or equivalent) to the end of threads. Torque cap
screws from 25 to 28 ft--lb (34 to 38 N--m).
Page 4 -- 62
Groundsmaster 4100--D
9. Install shaft assembly into front of housing. Seat seal
(25) into position with seal driver and retain with interior
retaining ring (2).
10.Install servo piston follower (8) onto camplate dowel
pin. Install camplate (11) carefully onto bushing (44)
(coat bushing surface with hydraulic oil), aligning servo
piston follower (8) with slot in servo piston assembly (7).
11. Position housing in a horizontal position. Holding
camplate (11) in position with screw driver through controller linkage passageway at the top of housing, place
rotating kit assembly (6) over shaft and into housing until
pistons are against camplate (11). Make sure all parts
are in housing completely and are properly positioned.
Return the pump to the vise with open end of housing up,
clamping housing on the outer portion of the flange.
12.Install gasket (32) onto housing.
13.If necessary, press new bearing (45) and roll pin (38)
in backplate (20) to dimension shown in Figure 47. Note:
Bearing should be installed with the numbered end outward. Roll pin should be installed with split oriented
away from bearing.
14.Install new o--ring on relief valves (16 & 26). Install
relief valve in the cavity in backplate that it was removed
and torque from 100 to 110 ft--lb (136 to 149 N--m).
16.Apply a small amount of petroleum jelly to the steel
side of valve plate (18) to hold in place for installation.
Aligning the index pin, place the valve plate (18) in position onto the backplate (20), with steel side against
backplate.
17.Install backplate assembly (20) onto housing assembly (19). Make sure ports are positioned correctly, and
that valve plate (18) and gasket (32) stay in place.
18.Retain backplate (20) with four cap screws (15).
Torque cap screws from 27 to 31 ft--lb (37 to 42 N--m).
19.Install control housing gasket (34) onto housing.
Install orifices (30) into servo control assembly (28) and
retain in position with petroleum jelly. Position the feedback link at 90 degrees from control housing. Install
manual servo control assembly (28) onto housing making sure feedback link entered small groove in servo piston assembly (7).
20.Secure control assembly with six socket head
screws (17). Torque screws from 40 to 48 in--lb (4.5 to
5.4 N--m).
21.Install control arm (27) onto control assembly input
shaft. Retain with lock washer (23) and nut (22). Torque
nut from 4 to 6 ft--lb (5 to 8 N--m).
22.Install remaining plugs that were removed from
pump. Torque 3/4 in. plug from 21 to 24 ft--lb (28 to 32
N--m). Torque 1--1/4 in. plug from 40 to 45 ft--lb (54 to 61
N--m).
15.Install new o--ring on bypass valve (14). Install bypass valve (14) into backplate (20). Note: Make sure
paddle of bypass valve is perpendicular to relief valve
axis prior to installing or damage could result.
Groundsmaster 4100--D
Page 4 -- 63
Hydraulic System
Hydraulic
System
8. Place exterior retaining ring (3), thrust race (12),
thrust bearing (13), second thrust race (12), and second
retaining ring (3) onto drive shaft (21). Position washer
(24) and shaft seal (25) onto shaft.
Piston Pump Control Assembly
44 to 52 ft--lb
(60 to 70 N--m)
15
10
1
2
14
3
4
9
7
5
13
12
4
8
6
16
24
17 to 26 in--lb
(2 to 3 N--m)
17
23
Loctite #222
11
22
28 to 34 in--lb
(3.2 to 3.8 N--m)
21
18
20
Loctite #242
19
Figure 51
1.
2.
3.
4.
5.
6.
7.
8.
Plug
O--ring
Retaining ring
Spring retainer
Spring
Spool valve
Control housing
Input shaft
9.
10.
11.
12.
13.
14.
15.
16.
O--ring
Wiper seal
O--ring
Adaptor
Ball
Pin
Neutral switch
O--ring
17.
18.
19.
20.
21.
22.
23.
24.
Set screw
Set screw
Pin
Retaining ring
Feedback link
Dowel pin
Bell crank
Set screw
Disassembly -- Manual Servo Control Assembly
Reassembly -- Manual Servo Control Assembly
1. Remove wiper seal with screw driver. Remove set
screw (18) that retains input shaft and remove input
shaft from control housing. Remove o--ring from shaft.
1. Install spring retainer, spring, and second spring retainer onto spool valve. Compress spring to allow retaining ring (3) to be installed onto spool valve.
2. Remove set screw (24) from plug that retains valve
spool. Remove plug from control housing and o--ring
from plug.
2. Install spool valve into control housing making sure
that metering notches on spool valve can be seen in the
metering ports.
3. Remove retaining ring (20) from pin that retains feedback link and spool valve. Remove pin, feedback link,
spool valve, and bell crank from control housing.
3. Position bell crank in housing. Slide feedback link
into position between clevis on valve spool, aligning
holes, and install dowel pin and retaining ring (20).
4. Compress spring and remove retaining ring (3). Remove spring retainer, spring, and second spring retainer
from spool valve.
4. Install new o--ring (9) onto input shaft. Hold bell crank
in position with feedback link slot and align splined hole
of bell crank with input shaft cavity. Install input shaft into
control housing and bell crank.
5. Clean all parts and lubricate in clean hydraulic oil for
reassembly.
Hydraulic System
5. Apply Loctite #242 or equivalent to set screw (18)
and install into control housing. Adjust set screw until it
bottoms out on input shaft and back out one--quarter
turn.
Page 4 -- 64
Groundsmaster 4100--D
6. Install wiper seal on input shaft.
7. Install new o--ring (2) onto plug and install plug. Adjust plug until there is no end play in the valve spool with
input shaft held stationary. Secure plug in place with set
screw (24). Torque set screw from 17 to 26 in--lb (2 to 3
N--m).
Disassembly -- Neutral Switch
1. Loosen set screw (17) in adapter and remove neutral
switch from adapter.
5. Test the switch by moving the control arm to the detent position, the light should be on. Move the control arm
out of detent, the light should go off.
6. Remove test light and put servo control assembly
into operation.
Reassembly
Step 4--C
“A”
Reassembly
Step 4--D
“B”
Reassembly
Step 4--E
“B”
2. Remove adapter from control housing.
3. Remove pin, ball, and o--rings (11 & 16) from adapter.
1. Install new o--ring (11) onto adapter and new o--ring
(16) onto pin.
Hydraulic
System
Reassembly -- Neutral Switch
2. Install ball and pin into adapter. Lubricate with petroleum jelly to hold in place during installation.
3. Install adapter into control housing. Torque from 44
to 52 ft--lb (60 to 70 N--m).
4. Apply Loctite #222 or equivalent to threads of neutral
switch and install switch into adapter. The adjustment
procedure for the switch are as follows.
A. Install switch, while moving link back and forth,
until “detent” action is detected. Back out the switch
until the “detent” action is very slight.
B. Attach the leads from a test light to the switch terminals. Note: A multimeter could be used instead of
a test light.
C. Move the link out of the detent position. The test
light will go on (continuity). Screw in the switch until
the light goes off (no continuity). Mark this as position
“A” (Fig. 52). Move the link to the detent position and
the test light should come back on.
“A”
Figure 52
D. Leaving the link in the detent position, the light will
remain on. Screw in the switch until the light goes off.
Mark this position “B”.
E. Unscrew the switch one third of the distance between “B” and “A”. Install and tighten the set screw
(17) in one of the upper quadrants of the hex of the
switch adapter (Fig. 52). Torque set screw from 28 to
34 in--lb (3.2 to 3.8 N--m).
Groundsmaster 4100--D
Page 4 -- 65
Hydraulic System
Hydraulic Control Manifold: 4 Wheel Drive
2
12
19
13
4
5
3
11
9
6
8
7
9
10
10
17
16
11
7
4
13
12
14
15
11
RIGHT
1
FRONT
18
Figure 53
1.
2.
3.
4.
5.
6.
7.
Frame assembly
4 wheel drive manifold
90o hydraulic fitting
O--ring
O--ring
Quick fitting
O--ring
Hydraulic System
8.
9.
10.
11.
12.
13.
Fitting cap
Hydraulic fitting
O--ring
O--ring
90o hydraulic fitting
O--ring
Page 4 -- 66
14.
15.
16.
17.
18.
19.
O--ring
Hydraulic fitting
Adapter
Plug (SAE #4)
Flange nut (2 used)
Cap screw (2 used)
Groundsmaster 4100--D
Removal
Installation
NOTE: The ports on the manifold are marked for easy
identification of components. Example: P1 is a piston
pump connection port and 2 is the location for the solenoid valve (See Hydraulic Schematic to identify the
function of the hydraulic lines and cartridge valves at
each port).
1. Install hydraulic manifold to the frame using Figure
53 as guide.
2. Remove caps and plugs from fittings and hoses.
Properly connect hydraulic lines to manifold.
3. Connect electrical connector to the solenoid valve.
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. To prevent contamination of hydraulic system during
manifold removal, thoroughly clean exterior of manifold
and fittings.
3. Disconnect electrical connector from the solenoid
valve.
Hydraulic
System
4. Disconnect hydraulic lines from manifold and put
caps or plugs on open hydraulic lines and fittings. Label
disconnected hydraulic lines for proper reassembly.
5. Remove hydraulic manifold from the frame using
Figure 53 as guide.
Groundsmaster 4100--D
Page 4 -- 67
Hydraulic System
Hydraulic Control Manifold Service: 4 Wheel Drive
19
EATON/VICKERS MANIFOLD
18 16
14
15
24
18
19
12
17
1
80 to 90 ft--lb
(108 to 122 N--m)
7
80 to 90 ft--lb
(108 to 122 N--m)
16
17 18
13
19
18
19
21
18
16
17
17
5
6
19
20
7
16
13
4
12
16
13
17
15
9
11
17
16
14
3
60 to 70 ft--lb
(81 to 95 N--m)
10
20
21
8
35 to 40 ft--lb
(47 to 54 N--m)
13
12
21
13
12
15
14
PLUG TORQUE
2
#2: 41 to 49 in--lb (4.6 to 5.6 N--m)
25 to 30 ft--lb
(34 to 41 N--m)
#4: 6 to 10 ft--lb (8 to 13 N--m)
#5: 10 to 15 ft--lb (13 to 20 N--m)
#6: 15 to 20 ft--lb (20 to 27 N--m)
#10: 35 to 40 ft--lb (48 to 54 N--m)
22
23
Loctite #242
4 to 6 ft--lb
(5 to 8 N--m)
Figure 54
1.
2.
3.
4.
5.
6.
7.
8.
Manifold body (4WD)
Solenoid valve (port 2)
Seal kit
Check valve (port 3)
Seal kit
Control valve (ports 5A & 5B)
Seal kit
Relief valve (port 7)
9.
10.
11.
12.
13.
14.
15.
16.
Seal kit
Reducing valve (port 8)
Seal kit
Zero leak plug (#2)
O--ring
Zero leak plug (#4)
O--ring
Zero leak plug (#5)
17.
18.
19.
20.
21.
22.
23.
24.
O--ring
Zero leak plug (#6)
O--ring
Zero leak plug (#10)
O--ring
Solenoid coil
Nut
Orifice plug
NOTE: The ports on the manifold are marked for easy
identification of components. Example: P1 is a piston
pump connection port and 2 is the location for the solenoid valve (See Hydraulic Schematic to identify the
function of the hydraulic lines and cartridge valves at
each port).
head of the plug. When installing plugs, refer to manifold
illustration for plug installation torque.
NOTE: The Groundsmaster 4100--D four wheel drive
manifold uses several zero leak plugs. These plugs
have a tapered sealing surface on the plug head that is
designed to resist vibration induced plug loosening. The
zero leak plugs also have an o--ring as a secondary seal.
If zero leak plug removal is necessary, lightly rap the
plug head using a punch and hammer before using an
allen wrench to remove the plug: the impact will allow
plug removal with less chance of damage to the socket
Valve Cartridge Service
Hydraulic System
NOTE: 4WD manifolds used on Groundsmaster
4000--D machines are either Eaton/Vickers (Fig. 54) or
JEM (Fig. 55).
1. Make sure the entire outer surface of the manifold is
clean before removing the valve.
2. If cartridge is solenoid operated, remove nut securing solenoid to the cartridge valve. Carefully slide solenoid off the valve.
Page 4 -- 68 Rev. E
Groundsmaster 4100--D
tridge design allows, use a wood or plastic probe to push
the internal spool in and out 20 to 30 times to flush out
contamination. Be extremely careful not to damage cartridge. Use compressed air for cleaning.
IMPORTANT: Use care when handling the valve cartridge. Slight bending or distortion of the stem tube
can cause binding and malfunction.
3. Remove cartridge valve with a deep socket wrench.
Note correct location for o--rings, sealing rings, and
backup rings. Remove and discard seal kit.
6. Reinstall the cartridge valve:
4. Visually inspect the port in the manifold for damage
to the sealing surfaces, damaged threads, and contamination. Also, inspect cartridge valve for damaged sealing surfaces and contamination.
A. Lubricate new seal kit components with clean hydraulic oil and install on valve. The o--rings, sealing
rings, and backup rings must be arranged properly
on the cartridge valve for proper operation and sealing.
A. Contamination may cause valves to stick or hang
up. Contamination can become lodged in small valve
orifices or seal areas causing malfunction.
IMPORTANT: Use care when handling the valve cartridge. Slight bending or distortion of the stem tube
can cause binding and malfunction.
B. If valve sealing surfaces appear pitted or damaged, the hydraulic system may be overheating or
there may be water in the system.
B. Thread cartridge valve carefully into manifold
port. The valve should go in easily without binding.
CAUTION
D. If cartridge is solenoid operated, carefully install
solenoid coil to the cartridge valve. Apply Loctite
#242 or equivalent to the threads of the valve. Torque
nut to value identified in manifold illustration. Over-tightening may damage the solenoid or cause the
valve to malfunction.
Use eye protection such as goggles when using
compressed air.
5. Clean cartridge valve using clean mineral spirits.
Submerge valve in clean mineral spirits to flush out contamination. Particles as fine as talcum powder can affect
the operation of high pressure hydraulic valves. If car-
7. If problems still exist, remove valve and clean again
or replace valve.
JEM MANIFOLD
35 ft--lb
(47 N--m)
13
6
10
13
50 ft--lb
(67 N--m)
11
25 ft--lb
(34 N--m)
10
REAR
DOWN
1
4
10
11
8
1
7
13
13
2
5
3
9
UP
FRONT
11
10
20 ft--lb
(27 N--m)
PLUG TORQUE
#4 Zero Leak: 20 ft--lb (27 N--m)
#6 Zero Leak: 25 ft--lb (34 N--m)
#8 Zero Leak: 50 ft--lb (67 N--m)
5 ft--lb
(6.7 N--m)
10
11
12
Figure 55
1.
2.
3.
4.
5.
Manifold body
Solenoid valve (port SV)
Solenoid coil
Check valve (port CV)
Nut
Groundsmaster 4100--D
6.
7.
8.
9.
Directional valve (ports PD1 & PD2)
Pressure reducing valve (port PR)
Relief valve (port RV)
Orifice (.030)
Page 4 -- 69 Rev. E
10.
11.
12.
13.
#4 zero leak plug with O--ring
#6 zero leak plug with O--ring
Orifice (.050)
#8 zero leak plug with O--ring
Hydraulic System
Hydraulic
System
C. Torque cartridge valve using a deep socket to value identified in manifold illustration.
Hydraulic Control Manifold: Deck Drive
16
4
6
10
25
8
16
20
2
11 14
13
12
14
21
22
19
18
6
17
4
4
16
6 2
4
16
6
17
13
10
23
7
6
4
18
24
6 11
13
12
4
14
8
9 8
10 1
2
5
8
11
15
14
12
25
6
3
RIGHT
FRONT
Figure 56
1.
2.
3.
4.
5.
6.
7.
8.
9.
Hydraulic manifold (center deck)
O--ring
Hydraulic adapter
O--ring
Straight hydraulic fitting
O--ring
90o hydraulic fitting
O--ring
Hydraulic tee fitting
Hydraulic System
10.
11.
12.
13.
14.
15.
16.
17.
O--ring
O--ring
Dust cap
Quick fitting
Flange nut
Hydraulic manifold (LH wing deck)
45o hydraulic fitting
Cap screw (2 used per manifold)
Page 4 -- 70
18.
19.
20.
21.
22.
23.
24.
25.
O--ring
Hydraulic tee fitting
Hydraulic manifold (RH wing deck)
Hose
90o hydraulic fitting
Hydraulic fitting
Hydraulic adapter
90o hydraulic fitting
Groundsmaster 4100--D
Removal
Installation
NOTE: The ports on the manifold are marked for easy
identification of components. Example: SV1 is the deck
solenoid valve and P1 is a gear pump connection port.
(See Hydraulic Schematic to identify the function of the
hydraulic lines and cartridge valves at each port).
1. Install hydraulic manifold to the frame using Figure
56 as guide.
The control manifolds for the three cutting deck sections
are very similar. Note: When servicing the deck control
manifolds, DO NOT interchange parts from one control
manifold to another.
3. Connect electrical connector to the solenoid valve.
2. Remove caps and plugs from fittings and hoses.
Properly connect hydraulic lines to manifold.
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. To prevent contamination of hydraulic system during
manifold removal, thoroughly clean exterior of manifold
and fittings.
Hydraulic
System
3. Disconnect electrical connector from the solenoid
valve.
4. Disconnect hydraulic lines from manifold and put
caps or plugs on open hydraulic lines and fittings. Label
disconnected hydraulic lines for proper reassembly.
5. Remove hydraulic manifold from the frame using
Figure 56 as guide.
Groundsmaster 4100--D
Page 4 -- 71
Hydraulic System
Hydraulic Control Manifold Service: Deck Drive
12
6
30 to 35 ft--lb
(41 to 47 N--m)
20
30 to 35 ft--lb
(41 to 47 N--m)
13
7
18
19
15
14
15
17
9
14
9
12 to 15 ft--lb
(16 to 20 N--m)
16
9
3
Loctite #242
8
1
50 to 55 in--lb
(5.6 to 6.2 N--m)
15
14
10
5
11
2
4
PLUG TORQUE
SAE #2: 60 to 65 in--lb (6.8 to 9.5 N--m)
SAE #4: 9 to 11 ft--lb (12 to 15 N--m)
SAE #8: 43 to 46 ft--lb (58 to 62 N--m)
80 ft--lb
(108 N--m)
Figure 57
1.
2.
3.
4.
5.
6.
7.
Manifold body
Spool logic cartridge (port BY1)
Seal kit
Spool logic cartridge (port BR1)
Seal kit
Relief valve (port R1BY)
Seal kit
8.
9.
10.
11.
12.
13.
14.
Solenoid valve (port SV1)
Seal kit
Solenoid coil
Nut
Relief pilot cartridge (port R1BR)
Seal kit
Plug (SAE #2)
NOTE: The ports on the manifold are marked for easy
identification of components. Example: SV1 is the deck
solenoid valve and P1 is the gear pump connection port.
(See Hydraulic Schematic to identify the function of the
hydraulic lines and cartridge valves at each port location).
15.
16.
17.
18.
19.
20.
O--ring
Plug (SAE #4)
O--ring
Plug (SAE #8)
O--ring
Orifice plug (port MR)
For solenoid and control valve service procedures, see
Hydraulic Control Manifold Service: 4 Wheel Drive in
this section. Refer to Figure 57 for cartridge valve and
plug installation torque.
The control manifolds for the three cutting deck sections
are very similar. Note: When servicing the deck control
manifolds, DO NOT interchange parts from one control
manifold to another.
Hydraulic System
Page 4 -- 72 Rev. F
Groundsmaster 4100--D
Hydraulic
System
This page is intentionally blank.
Groundsmaster 4100--D
Page 4 -- 73
Hydraulic System
Hydraulic Control Manifold: Cutting Deck Lift/Lower
12
16
15
10
13
9
5
14
1
RIGHT
2
FRONT
10
11
10
8
9
3
4
7 6
5
Figure 58
1.
2.
3.
4.
5.
6.
Lift/lower hydraulic manifold
Valve plate
Flat washer (2 used)
Cap screw (2 used)
Grommet (4 used)
Flat washer (2 used)
7.
8.
9.
10.
11.
Lock nut
Hydraulic fitting (2 used)
O--ring
O--ring
90o hydraulic fitting (4 used)
Removal
NOTE: The ports on the manifold are marked for easy
identification of components. Example: C1 is the connection port from the LH wing deck lift cylinder and CHG
is the charge circuit connection (See Hydraulic Schematic to identify the function of the hydraulic lines and
cartridge valves at each port).
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. To prevent contamination of hydraulic system during
manifold removal, thoroughly clean exterior of manifold
and fittings.
Hydraulic System
12.
13.
14.
15.
16.
Cap screw (2 used)
90o hydraulic fitting
O--ring
Test nipple
Fitting cap
3. Disconnect hydraulic lines from manifold and put
caps or plugs on open hydraulic lines and fittings. Label
disconnected hydraulic lines for proper reassembly.
4. Remove hydraulic manifold from the frame using
Figure 58 as guide.
Installation
1. Install hydraulic manifold to the frame using Figure
58 as guide.
2. Remove caps and plugs from fittings and hoses.
Properly connect hydraulic lines to manifold.
Page 4 -- 74
Groundsmaster 4100--D
Hydraulic Control Manifold Service: Cutting Deck Lift/Lower
35 to 40 ft--lb
(47 to 54 N--m)
2
35 to 40 ft--lb
(47 to 54 N--m)
4
35 to 40 ft--lb
(47 to 54 N--m)
2
3
41 to 49 in--lb
(4.6 to 5.6 N--m)
5
6
3
Hydraulic
System
7
1
Figure 59
1. Manifold body
2. Pilot valve
3. Seal kit
4. Relief valve (Counterbalance)
5. Seal kit
6. Plug (SAE #2)
7. O--ring
NOTE: The ports on the manifold are marked for easy
identification of components. Example: C1 is the connection port from the LH wing deck lift cylinder and CHG
is the charge circuit connection (See Hydraulic Schematic to identify the function of the hydraulic lines and
cartridge valves at each port).
For cartridge valve service procedures, see Hydraulic
Control Manifold Service: 4 Wheel Drive in this section.
Refer to Figure 59 for cartridge valve and plug installation torque.
Groundsmaster 4100--D
Page 4 -- 75
Hydraulic System
Hydraulic Control Manifold: Filter Manifold
8
4
9
3
2
5
1
6
10
7
11
12
14
13
15
16
23
22
17
21
20
12
19
15
18
RIGHT
FRONT
Figure 60
1.
2.
3.
4.
5.
6.
7.
8.
Filter manifold
45o hydraulic elbow
Test nipple
Fitting cap
O--ring
O--ring
O--ring
Cap screw (3 used)
9.
10.
11.
12.
13.
14.
15.
16.
Flat washer (3 used)
Hydraulic fitting
O--ring
O--ring
Hydraulic fitting
Hydraulic hose
O--ring
O--ring
Removal
NOTE: The ports on the manifold are marked for easy
identification of components. Example: P2 is the gear
pump connection port and T is the connection for the
reservoir return (See Hydraulic Schematic to identify the
function of the hydraulic lines and cartridge valves at
each port).
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. To prevent contamination of hydraulic system during
manifold removal, thoroughly clean exterior of manifold
and fittings.
Hydraulic System
17.
18.
19.
20.
21.
22.
23.
90o hydraulic elbow
Hydraulic hose
Hydraulic fitting (2 used)
90o hydraulic fitting
O--ring
Hose clamp
Filter hose
3. Disconnect hydraulic lines from manifold and put
caps or plugs on open hydraulic lines and fittings. Label
disconnected hydraulic lines for proper reassembly.
4. Remove hydraulic manifold from the frame using
Figure 60 as guide.
Installation
1. Install hydraulic manifold to the frame using Figure
60 as guide.
2. Remove caps and plugs from fittings and hoses.
Properly connect hydraulic lines to manifold.
Page 4 -- 76
Groundsmaster 4100--D
Hydraulic Control Manifold Service: Filter Manifold
4
60 to 70 ft--lb
(81 to 95 N--m)
35 to 40 ft--lb
(47 to 54 N--m)
7
6
2
10
12
11
5
10
10
11
13
11
13 12
9
8
9
1
12
13
15
9
14
9
8
8
16
PLUG TORQUE
SAE #4: 6 to 10 ft--lb (8 to 13 N--m)
SAE #5: 10 to 15 ft--lb (13 to 20 N--m)
SAE #6: 15 to 20 ft--lb (20 to 27 N--m)
SAE #10: 35 to 40 ft--lb (48 to 54 N--m)
Figure 61
1.
2.
3.
4.
5.
6.
Filter manifold assembly
Check valve (Reservoir return)
Seal kit
Check valve (Filter bypass)
Seal kit
Check valve (Charge pressure)
7.
8.
9.
10.
11.
Seal kit
Plug (SAE #4)
O--ring
Plug (SAE #6)
O--ring
12.
13.
14.
15.
16.
Plug (SAE #5)
O--ring
Plug (SAE #10)
O--ring
Oil filter element
NOTE: The ports on the manifold are marked for easy
identification of components. Example: P2 is the gear
pump connection port and T is the connection for the
reservoir return (See Hydraulic Schematic to identify the
function of the hydraulic lines and cartridge valves at
each port).
For cartridge valve service procedures, see Hydraulic
Control Manifold Service: 4 Wheel Drive in this section.
Refer to Figure 61 for cartridge valve and plug installation torque.
Groundsmaster 4100--D
Page 4 -- 77
Hydraulic System
Hydraulic
System
3
Rear Axle Motor
9
Arrow on side of
motor case points up
12
2
10
11
1
9
7
8
13
10
7
3
2
4
5
6
59 to 73 ft--lb
(80 to 99 N--m)
RIGHT
FRONT
Figure 62
1.
2.
3.
4.
5.
Rear axle motor
90o hydraulic fitting
Hydraulic fitting
Cap screw (2 used)
Flat washer (2 used)
Hydraulic System
6.
7.
8.
9.
O--ring
External snap ring
Pinion gear
O--ring
Page 4 -- 78
10.
11.
12.
13.
O--ring
O--ring
O--ring
Drive axle assembly
Groundsmaster 4100--D
Removal
Installation
1. Park machine on a level surface, lower cutting
decks, stop engine, engage parking brake, and remove
key from the ignition switch.
1. If removed, install pinion gear to axle motor.
3. To prevent contamination of hydraulic system during
motor removal, thoroughly clean exterior of motor and
fittings.
NOTE: To ease reassembly, tag the hydraulic hoses to
show their correct position on the axle motor.
4. Disconnect hydraulic hoses from rear axle motor.
Put caps or plugs on open hydraulic lines, fittings, and
ports to prevent contamination.
IMPORTANT: Support axle motor to prevent motor
from falling during removal.
3. Secure motor to axle with cap screws and flat washers. Torque screws from 59 to 73 ft--lb (80 to 99 N--m).
4. Remove plugs from hydraulic lines, fittings, and
ports. Attach hydraulic hoses to axle motor.
5. Fill reservoir with hydraulic fluid as required (see Operator’s Manual).
6. After assembly is completed, verify that hydraulic
hoses and fittings do not contact anything through full
range of axle pivot motion. Also, check for any leaks.
Hydraulic
System
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
2. Install o--ring onto motor. Position motor to rear axle
assembly making sure that arrows on the side of motor
case point upward. Align gear teeth and slide motor into
place.
5. Remove motor using Figure 62 as a guide.
Groundsmaster 4100--D
Page 4 -- 79
Hydraulic System
Front Wheel Motors
2
5
12 16
11
13
14
3
15
19
4
8
1
18
16
14
Arrow on side of
motor case points up
10
15
12
11
13
7
11
13
14
Arrow on side of
motor case points up
15
16
1
8
19
6
15
RIGHT
12
75 to 85 ft--lb
(101 to 115 N--m)
2
16
17
5
13
9
FRONT
20
3
Figure 63
1.
2.
3.
4.
5.
6.
7.
Front wheel motor
Internal retaining ring
Splined brake shaft
RH brake assembly
Planetary assembly
Cap screw (2 used per motor)
Flat washer (2 used per motor)
Hydraulic System
8.
9.
10.
11.
12.
13.
14.
O--ring
Hex head plug
90o hydraulic fitting
90o hydraulic fitting
O--ring
O--ring
Hydraulic fitting
Page 4 -- 80
15.
16.
17.
18.
19.
20.
O--ring
O--ring
Hydraulic tee fitting
O--ring
O--ring
LH brake assembly
Groundsmaster 4100--D
Removal
Installation
1. Park machine on a level surface, lower cutting
decks, stop engine, engage parking brake, and remove
key from the ignition switch.
1. Position wheel motor to brake assembly making sure
that arrows on the side of motor case point upward.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
3. To prevent contamination of hydraulic system during
motor removal, thoroughly clean exterior of motor and
fittings.
NOTE: To ease reassembly, tag the hydraulic hoses to
show their correct position on the wheel motor.
4. Disconnect hydraulic hoses and tubes from wheel
motor. Put caps or plugs on hydraulic lines, fittings, and
ports to prevent contamination.
2. Align splines on motor shaft and splined brake shaft.
Slide motor into brake assembly.
3. Secure motor to brake assembly with cap screws
and flat washers. Tighten cap screws from 75 to 85 ft--lb
(101 to 115 N--m).
4. Remove plugs from hydraulic lines, fittings, and
ports. Attach hydraulic hoses and tubes to wheel motor.
5. Fill reservoir with hydraulic fluid as required (see Operator’s Manual).
Hydraulic
System
IMPORTANT: Before loosening fasteners, support
wheel motor to prevent motor from falling during removal.
5. Remove wheel motor using Figure 63 as a guide.
Groundsmaster 4100--D
Page 4 -- 81
Hydraulic System
Rear Axle/Front Wheel Motor Service
15 to 18 ft--lb
(20 to 24 N--m)
9
9
10
13
10
7
2
1
11
18
8
6
14
15
16
12
4
5
3
17
Figure 64
1.
2.
3.
4.
5.
6.
Drive shaft
Backplate (front motor shown)
Housing assembly
Rotating assembly
Cam plate insert
Retaining ring
7.
8.
9.
10.
11.
12.
Cap screw (6 used)
Shaft seal
Retaining ring
Thrust race
O--ring
Valve plate
NOTE: The front wheel motors are identical. The rear
axle motor has some differences from the front motors.
Service of the front and rear motors requires the same
procedures.
Cleanliness is extremely important when repairing
these motors. Work in a clean area. Before disconnecting the lines, clean port area of motor. Thoroughly clean
the outside of the motor. After cleaning, remove port
plugs and drain oil.
Hydraulic System
13.
14.
15.
16.
17.
18.
Thrust bearing
Roll pin
Roll pin
Bearing
Bearing
Washer
Disassembly (Fig. 64)
1. Clamp the drive shaft end of the piston motor in a protected jaw vise with the cap screws up. Remove the six
cap screws (7) from the motor assembly.
2. Use a soft face hammer and tap the backplate (2) to
loosen and remove from housing.
3. Remove valve plate (12) and O--ring (11) from backplate. It is not necessary to remove roll pins (14, 15) in
backplate.
Page 4 -- 82
Groundsmaster 4100--D
2. If necessary, install new needle bearing (17) in housing (3) with numbered end of the bearing outward.
5. Remove the camplate insert (5) from housing. Use
caution not to mar the finish that makes contact with pistons.
3. Install retaining ring (9) on shaft. Install thrust race
(10), thrust bearing (13), and second thrust race (10).
Secure with second retaining ring (9).
6. Remove retaining ring (6) from housing. Press shaft
from housing and remove shaft seal (8) and washer
(18).
4. Install shaft in housing. Install washer (18), new shaft
seal (8), and retaining ring (6).
7. Remove retaining rings (9) from shaft and remove
thrust races (10) and thrust bearing (13).
5. Install camplate insert (5) with the lettering side of insert to the front of the housing. Use petroleum jelly to
hold in place during assembly.
8. Discard the shaft seal and o--ring, and replace with
new items upon reassembly.
6. Install rotating assembly (4) into housing. Make sure
that piston shoes make contact with the camplate insert.
Inspection
7. Clamp motor assembly in a protected jaw vise with
the open end of the housing up.
1. Check the condition of the needle bearing (16) in
backplate (2) and replace if necessary.
2. Inspect valve plate (12) on the bronze side next to the
piston block for wear. A smooth surface is required. Do
not lap valve plate bronze surface. Replace valve
plate if any wear exists.
3. Inspect the piston block surface that makes contact
with valve plate. This surface should be smooth and free
of deep scratches. Do not lap piston block.
8. If roll pins were removed, install to dimension shown
in Figure 65 and with opening of roll pin oriented away
from bearing within 5 degrees of bearing center line.
9. To replace bearing (16) in backplate (2). Press bearing down to the dimension shown (Fig. 65) protruding
from backplate with numbered end of bearing facing up
next to valve plate.
.173 in (4.39 mm)
Roll Pin (15)
4. The pistons should move freely in the piston block
bore. If they are sticky in the bore, examine the bore for
scoring or contamination.
.090 in (2.3 mm)
Bearing
5. Examine the O.D. of the pistons for finish condition.
They should not show wear or deep scratches. Inspect
the shoes for a snug fit on the ball end of the pistons and
a flat smooth surface that comes in contact with the camplate. Do not lap piston shoes.
6. Examine the spider for wear in the pivot area.
7. Examine the spider pivot to insure smoothness and
no signs of wear.
8. The polished finish on the shoe surface of the camplate insert (5) should show no signs of scoring.
9. Inspect the shaft for wear in the seal, bearing and
spline areas.
10.Inspect thrust bearing (13) and races (10) for wear.
11. Check the condition of the needle bearing (17) in
housing and replace if necessary.
Figure 65
10.Apply small amount of petroleum jelly to the steel
side of valve plate (12) to hold in place for installation.
Place the valve plate in position onto the backplate (2),
with steel side against backplate, bronze colored side
against piston block.
11. Placing new o--ring (11) onto backplate, install backplate assembly (2) onto housing assembly. Make sure
valve plate stays in position.
Reassembly (Fig. 64)
12.Insert cap screws and torque from 15 to 18 ft--Ib (20
to 24 N--m) in a criss--cross pattern.
1. Clean all parts in suitable solvent and lubricate all internal parts with clean hydraulic oil before reassembly.
13.Fill case half full of new hydraulic oil.
Groundsmaster 4100--D
Page 4 -- 83
Hydraulic System
Hydraulic
System
4. Remove motor from vise and remove rotating assembly (4) from motor housing.
This page is intentionally blank.
Hydraulic System
Page 4 -- 84
Groundsmaster 4100--D
Cutting Deck Motor
Removal
1
1. Park machine on a level surface, lower cutting
decks, stop engine, engage parking brake, and remove
key from the ignition switch.
5
4
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
3. Disconnect hydraulic lines from deck motor. Put
caps or plugs on fittings and hoses to prevent contamination. Tag hydraulic lines for proper reassembly.
2
3
4. Remove two flange head screws that secure hydraulic motor to motor mount (Fig. 66).
Figure 66
1. Cutting deck motor
2. Flange head screw
3. Inlet hose
4. Return hose
5. Case drain hose
5
6. If required, remove spider hub from motor shaft.
Straighten tab washer and remove nut and spider.
2
9
Installation
2
3
4
1
6
4
1. If removed, install spider hub to motor shaft with tab
washer and nut. Torque nut from 27 to 33 ft--lb (37 to 45
N--m). Bend small tab of washer into keyway and large
tab against nut.
8
10
11
12
13
14
15
2. Check for proper clearance between spider hub and
spindle pulley. Install motor to cutting deck without placing the spider in the spindle pulley. The clearance between hub and pulley valleys should be from .830” to
.930” (21.1 to 23.6 mm). If required, use mounting shims
between motor and motor mount to adjust clearance.
IMPORTANT: For proper hydraulic hose routing,
make sure cutting decks are fully lowered before
installing hoses to deck motor.
7
27 to 33 ft--lb
(37 to 45 N--m)
16
3. Position spider in spindle pulley. Place mounting
shim(s) (if required) on deck. Carefully install hydraulic
motor to the cutting deck taking care not to damage spider hub attached to motor.
4. Secure motor to cutting deck with two flange head
screws (Fig. 66).
Hydraulic
System
5. Carefully remove hydraulic motor from cutting deck
taking care not to damage spider hub attached to motor.
Locate and remove spider and mounting shim(s) (if
present) from the deck.
Figure 67
1.
2.
3.
4.
5.
6.
7.
8.
Cutting deck motor
O--ring
Hydraulic adapter
O--ring
Flange head screw (2)
O--ring
90o hydraulic fitting
O--ring
9.
10.
11.
12.
13.
14.
15.
16.
90o hydraulic fitting
Woodruff key
Shim (if required)
Spider hub
Tab washer
Nut
Spider
Cutting deck
5. Remove caps or plugs from fittings and hoses. Connect hydraulic hoses to deck motor.
6. After assembly is completed, verify that hydraulic
hoses and fittings are not contacted by moving components through full range of deck movement.
Groundsmaster 4100--D
Page 4 -- 85
Hydraulic System
Cutting Deck Motor Service
15
12
27 to 33 ft--lb
(37 to 45 N--m)
9
10
10
14
15
13
9
1
8
7
6
15
5
11
8
4
33 to 40 ft--lb
(45 to 55 N--m)
2
3
Figure 68
1.
2.
3.
4.
5.
Rear cover
Drive gear
Seal
Woodruff key
Nut
6.
7.
8.
9.
10.
Tab washer
Spider hub
Pressure seal
Back--up ring
O--ring
11.
12.
13.
14.
15.
Body
Idler gear
Cap screw (4 used)
Front flange
Dowel pin
Disassembly (Fig. 68)
6. Take motor from the vise and remove cap screws.
1. Plug motor ports and clean the outside of the motor
thoroughly. After cleaning, remove plugs and drain any
oil out of the motor.
7. Remove front flange from the body, then remove rear
cover. Locate and remove dowel pins from body.
2. Straighten tabs on tab washer to allow removal of nut
from motor shaft. Remove tab washer, spider hub and
woodruff key from motor.
DIAGONAL MARK
3. Use a marker or scribe to make a diagonal mark
across the front flange, body, and rear cover for reassembly purposes (Fig. 69).
IMPORTANT: Avoid using excessive clamping
pressure on the motor flange to prevent distorting
the casting.
4. Clamp mounting flange of motor in a vise with the
shaft end down.
Figure 69
5. Loosen cap screws that secure the rear cover.
Hydraulic System
Page 4 -- 86
Groundsmaster 4100--D
IMPORTANT: Mark the relative positions of the gear
teeth and the bearing blocks so they can be reassembled in the same position. Do not touch the
gear surfaces as residue on hands may be corrosive
to gear finish.
1
8. Place the motor on its side and push on the rear bearing block to remove the bearing block and gear set (Fig.
70).
9. Carefully remove and discard o--rings, pressure
seals, and back--up rings (Fig. 71) from motor. Do not
cause any damage to the machined grooves during the
removal process.
IMPORTANT: Make sure not to damage the counter
bore when removing the shaft seal from the front
plate.
2
Figure 70
1. Motor body
2. Bearing block & gear set
10.Position front flange with seal side up. Remove shaft
seal.
Hydraulic
System
Inspection
1. Remove any nicks and burrs from all motor components with emery cloth.
CAUTION
Use eye protection such as goggles when using
compressed air.
Figure 71
2. Clean all motor components with solvent. Dry all
parts with compressed air.
3. Inspect drive gear, idler gear and bearing blocks
(Fig. 72) for the following:
1
A. Gear shafts should be free of rough surfaces and
excessive wear at bushing points and sealing areas.
Scoring, rough surfaces, or wear on gear shafts indicates need for replacement.
2
B. Gear teeth should be free of excessive scoring
and wear. Any broken or nicked gear teeth must be
replaced.
3
C. Inspect gear face edge for sharpness. Sharp
edges of gears will mill into bearing blocks and, thus,
must be replaced.
D. Bearing areas of bearing blocks should not have
excessive wear or scoring.
3
E. Face of bearing blocks that are in contact with
gears should be free of wear, roughness or scoring.
4. Inspect front flange and rear cover for damage or
wear.
Groundsmaster 4100--D
Figure 72
1. Drive gear
2. Idler gear
Page 4 -- 87
3. Bearing block
Hydraulic System
Reassembly (Fig. 68)
NOTE: When reassembling the motor, check the identification marks made during disassembly to make sure
the parts are properly aligned during reassembly.
1. Lubricate o--rings, pressure seals, back--up gaskets,
and seal grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic
oil.
IMPORTANT: Do not dislodge o--rings, pressure
seals, or back--up rings during final assembly.
9. Gently slide the rear cover onto the assembly using
marker or scribe mark for proper location. Firm hand
pressure should be sufficient to engage the dowel pins.
10.Position the motor with rear cover downwards. Carefully slide the front flange onto the assembly using marker or scribe mark for proper location.
2. Install new shaft seal into front flange.
11. Install the four cap screws and hand tighten.
3. Install lubricated pressure seals into the grooves in
the front flange and rear cover. Follow by carefully placing the back--up rings into the grooves.
IMPORTANT: Avoid using excessive clamping
pressure on the motor housing to prevent distorting
the housing.
4. Install new o--rings to the body.
12.Place motor front flange in a vise and alternately
torque the screws from 33 to 40 ft--lb (45 to 55 N--m).
5. Lubricate gear faces and bearing surfaces of drive
gear, idler gear and bearing blocks. Carefully assemble
bearing blocks and gears noting identification marks
made during disassembly.
6. Position the motor body on its side. Carefully slide
bearing block and gear assembly into the body cavity
using identification marks made during disassembly.
7. Remove any excess lubrication from mating surfaces of body, rear cover, and front flange. Make sure
that these surfaces are clean and dry.
8. Install dowel pins in body.
Hydraulic System
13.Put a small amount of hydraulic oil in port on motor
and rotate driveshaft one revolution. Protect the shaft if
using a pliers. If drive shaft binds, disassemble motor
and repeat assembly process.
14.Place woodruff key in motor shaft slot. Install spider
hub and tab washer on shaft. Secure spider hub to shaft
with nut. Torque nut from 27 to 33 ft--lb (37 to 45 N--m).
15.Secure nut to motor shaft by bending small tab of tab
washer into keyway and large tab against nut.
16.Remove motor from vise.
Page 4 -- 88
Groundsmaster 4100--D
Hydraulic
System
This page is intentionally blank.
Groundsmaster 4100--D
Page 4 -- 89
Hydraulic System
Lift/Lower Control Valve
13
25
17
16
14
24
18
18
19
15
1
2
27
23
17
20
17
21
22
26
12
RIGHT
FRONT
11
10
9
6
8 7
5
4
3
15
Figure 73
1.
2.
3.
4.
5.
6.
7.
8.
9.
Control valve assembly
Valve bracket
Grommet
Cap screw
Lock nut
Pivot bracket
LH lever assembly
Lever link (3 used)
Center lever assembly
Hydraulic System
10.
11.
12.
13.
14.
15.
16.
17.
18.
Cotter pin (3 used)
RH lever assembly
Spacer
Flange head screw (2 used)
Knob (3 used)
Lock nut
90o hydraulic fitting (2 used)
O--ring
O--ring
Page 4 -- 90
19.
20.
21.
22.
23.
24.
25.
26.
27.
Cap screw (2 used)
Hydraulic fitting (3 used)
Hydraulic fitting
O--ring
Flat washer (3 used)
Cap screw (3 used)
Control panel
Spring bracket
Extension spring
Groundsmaster 4100--D
Removal
Installation
1. Park machine on a level surface, lower cutting
decks, stop engine, engage parking brake, and remove
key from the ignition switch.
1. Install lift/lower control valve using Figure 73 as a
guide.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
3. To prevent contamination of hydraulic system during
control valve removal, thoroughly clean exterior of control valve and fittings.
2. After reassembly, check operation of cutting deck
raise and lower switches (see Operator’s Manual).
3. Make sure hydraulic tank is full. Add correct oil if necessary before returning machine to service (see Operator’s Manual).
Hydraulic
System
4. Remove lift/lower control valve using Figure 73 as a
guide.
Groundsmaster 4100--D
Page 4 -- 91
Hydraulic System
Lift/Lower Control Valve Service
6
32
20
34
13
14
15
31
10
7
11
23
27
21
22
24
17
18
35
3
36
28
5
33
4
25
1
11
8
16
19
2
12
26
20 to 25 ft--lb
(27 to 33 N--m)
9
30
29
Figure 74
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Poppet
Spacer
Wiper seal
Seat
O--ring
Plug (3 used)
O--ring
Bushing
Spool cap (3 used)
Relief valve poppet
O--ring
Retaining ring
Hydraulic System
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Washer
Washer
Washer
Washer
Plug
O--ring
Spool spring
Backup washer
Detent spring
Detent plunger
Detent plug (3 used)
O--ring
Page 4 -- 92
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
O--ring
Backup washer
Disc
Plunger (2 used)
Plug assembly (3 used)
Lockout spring
Relief valve spring
Relief plug assembly
Plunger
O--ring
Spool
Control valve body
Groundsmaster 4100--D
Disassembly (Fig. 74)
Assembly (Fig. 74)
1. Plug all ports and clean outside of valve thoroughly.
1. Thoroughly clean and dry all parts. Apply a light coating of clean hydraulic oil to parts prior to assembly.
NOTE: Spools and spool bores are matched sets. Be
sure each spool is identified with the correct valve body
spool bore.
3. Remove spools (35) from valve body (36).
4. Remove bushings (8) and O--rings (11) from spools.
5. Remove plugs (6).
IMPORTANT: Check location and positioning of
plungers when removing from body to assure proper assembly.
NOTE: All O--rings, back--up washers, wiper seals, and
nylon poppets should be replaced as new items.
2. Install new O--rings (11) in proper grooves in spool
bores.
3. Install relief valve components (13, 14, 15, 31, and
10) with new O--ring (34) on plug assembly (32).
4. Install plugs (6) with new back--up washers (20) and
O--rings (7).
5. Install plungers (33 and 28).
IMPORTANT: Check location and positioning of
plungers during installation.
6. Remove plugs (29), lockout springs (30), poppets
(1), seats (4) and plungers (28 and 33).
6. Install new O--rings (5) on seats (4). Install new
back--up washers (26) and O--rings (25) on plugs (29).
7. Remove plug (17).
7. Install seats (4), new poppets (1), and plugs (29).
8. Remove detent plug (23), disc (27), detent spring
(21) and detent plunger (22).
8. Install plug (17) with new O--ring (18).
9. Remove relief plug assembly (32), washers (13, 14,
and 15), relief valve spring (31), and relief valve poppet
(10).
10.Remove all O--rings and back--up rings from all plugs
and seats.
Inspection
1. Remove all nicks and burns from parts and inspect
for excessive wear.
2. Inspect all plungers and poppet seats for burrs or
roughness.
3. Inspect spool springs (19), relief valve spring (31),
lockout springs (30), and detent spring (21) for breakage.
9. Install detent plunger (22), spring (21), disc (27), and
plug (23) with new O--ring (24).
10.If retaining ring (12) has been removed to replace
spool spring (19), install washer (16), spring (19), and
spacer (2) on spool. Secure with retaining ring (12).
11. Slide bushings (8) over spools. Slide new O--rings
(11) over spools and position next to bushings. Dip
spools in clean hydraulic oil and install spool assemblies
into proper location of valve body.
12.Install spool caps (9) and tighten from 20 to 25 ft--lb
(27 to 33 N--m).
13.Install new wiper seals (3).
4. If spools (35) have excessive wear, the control valve
becomes non--serviceable as the spools and spool
bores are matched. Damaged spools cannot be replaced individually.
5. Inspect relief valve poppet (10) for breakage or wear.
Groundsmaster 4100--D
Page 4 -- 93
Hydraulic System
Hydraulic
System
2. Remove spool caps (9). Do not remove retaining
rings (12) from spools unless spool spring (19) is broken.
Steering Valve
24
23
1
3
2
22
29
4
28
27
25
5
21
12
26
6
8
20
18 to 22 ft--lb
(25 to 29 N--m)
19
18
7
17
16
15
RIGHT
9
10
11
9
12
13
11
14
FRONT
Figure 75
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Hex nut
Flat washer
Steering wheel
Foam collar
Steering seal
External snap ring
Steering shaft assembly
Steering tower cover
O--ring
90o hydraulic fitting
Hydraulic System
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
O--ring
Flange head screw
Hydraulic adapter (4 used)
Steering valve assembly
Nut insert
Steering tower
Flange locking nut (2 used)
Flange head screw (4 used)
Pivot hub (2 used)
Cap screw (2 used)
Page 4 -- 94 Rev. E
21.
22.
23.
24.
25.
26.
27.
28.
29.
Steering column assembly
Flange bushing
Thrust washer
Steering wheel cover
In port (P)
Right turn port (R)
Load sensing port (PB)
Left turn port (L)
Out port (T)
Groundsmaster 4100--D
Removal
Installation
1. Park machine on a level surface, lower cutting
decks, stop engine, engage parking brake, and remove
key from the ignition switch.
1. Install steering valve using Figure 75 as a guide.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
2. Make sure hydraulic tank is full. Add correct oil if necessary before returning machine to service (see Operator’s Manual).
3. To prevent contamination of hydraulic system during
steering valve removal, thoroughly clean exterior of
steering valve and fittings.
Hydraulic
System
4. Remove steering valve from machine using Figure
75 as a guide.
Groundsmaster 4100--D
Page 4 -- 95
Hydraulic System
Steering Valve Service
8
1
3
24
2
4
5
20
19
23
6
7
19
22
21
150 in--lb
(17 N--m)
9
10
14
18
17
16
13
12
11
140 to 160 in--lb
(16 to 18 N--m)
15
Figure 76
1.
2.
3.
4.
5.
6.
7.
8.
Steering valve housing
Dust seal
O--ring
Spool
Spring retaining ring
Pin
Sleeve
Centering springs/spacers
9.
10.
11.
12.
13.
14.
15.
16.
Cap screw (7 used)
End cap
O--ring
Seal ring
O--ring
Geroter
O--ring
Spacer
Disassembly (Fig. 76)
NOTE: Cleanliness is extremely important when
repairing steering control units. Work in a clean area.
Before disconnecting the hydraulic lines, clean the port
area of the steering valve assembly. Before disassembly, drain the oil, then plug the ports and thoroughly
clean the exterior. During repairs, always protect
machined surfaces.
1. Remove the seven cap screws from the steering
valve assembly.
2. Remove end cap, geroter, spacer, geroter drive,
wear plate, seal ring, and o--rings from housing.
3. Remove the plug and relief valve.
Hydraulic System
17.
18.
19.
20.
21.
22.
23.
24.
Geroter drive
Wear plate
Bearing race
Thrust bearing
Plug
O--ring
Relief valve
Quad seal
4. Slide the spool and sleeve assembly from the housing.
5. Remove the thrust bearing and bearing races (2).
6. Remove the quad seal.
7. Use a small blade screwdriver to carefully pry the
dust seal from the housing. Be careful to not damage the
dust seal seat in the housing.
8. Remove the pin that holds the spool and sleeve together.
9. Carefully slide the spool out of the sleeve. The centering springs and spring retaining ring will stay with the
spool as it is removed.
Page 4 -- 96
Groundsmaster 4100--D
8. Put the thrust bearing and races into the housing.
The thrust bearing goes between the two races
(Fig. 77).
The centering springs are under tension. Remove the retaining ring carefully.
IMPORTANT: Do not damage the dust or quad seals
when installing the spool and sleeve assembly.
10.Remove the spring retaining ring and centering
springs from the spool.
9. Apply a light coating of clean hydraulic fluid to the
spool and sleeve assembly and carefully slide the assembly into the housing.
Reassembly (Fig. 76)
Check all mating surfaces. Replace any parts with
scratches or burrs that could cause leakage. Wash all
metal parts in clean solvent. Blow them dry with pressurized air. Do not wipe parts dry with paper towels or cloth
as lint in a hydraulic system will cause damage.
NOTE: Always use new seals and o--rings when
reassembling the steering valve.
IMPORTANT: During reassembly, lubricate the new
seals with petroleum jelly. Also, lubricate machined
surfaces and bearings with clean hydraulic fluid.
10.Clamp the housing in a vise. Use only enough clamping force to hold the housing securely.
11. Lubricate and install a new o-ring seal in the groove
in the housing.
12.Install the wear plate and align screw holes in the
wear plate with threaded holes in the housing.
NOTE: The holes in the wear plate are symmetrical.
13.Install the geroter drive, making sure the slot in the
drive engages the pin.
14.Lubricate and install new o-ring in wear plate groove.
1. Install the quad seal (Fig. 77):
A. Put one of the bearing races and sleeve into the
housing.
B. Together, the housing and bearing race create a
groove into which the quad seal will be installed.
C. Hold the bearing race tightly against the input end
of the housing by pushing on the gerotor end of the
sleeve.
15.Install the gerotor and align the screw holes.
16.Lubricate and install new o-ring in gerotor ring
groove.
17.Lubricate and install new o-ring and seal ring in gerotor star groove.
18.Install the spacer.
D. Fit the quad seal into its seat through the input end
of the housing. Be sure the seal is not twisted.
19.Install the end cap and seven cap screws. Tighten
the cap screws, in a crossing pattern, from 140 to 160
in-lb (16 to 18 N--m).
E. Remove the sleeve and bearing race.
20.Remove the steering valve from the vise.
2. Lubricate and install the dust seal.
3. Install the centering springs in the spool. It is best to
install the two flat pieces first. Next, install the curved
pieces, three at a time.
4. Fit the retaining ring over the centering springs.
21.Install the relief valve and plug. Tighten the plug to
150 in-lb (17 N--m).
Thrust Bearing
and Race (2)
Dust Seal
5. Apply a light coating of clean hydraulic fluid to the
spool and slide it into the sleeve. Be sure the centering
springs fit into the notches in the sleeve.
Quad Seal
6. Install the pin.
7. Apply a light coating of petroleum jelly to the inner
edge of the dust and quad seals.
Groundsmaster 4100--D
Page 4 -- 97
Figure 77
Hydraulic System
Hydraulic
System
CAUTION
Front Deck Lift Cylinder
10 9
7
8
11
9
12
7
RIGHT
FRONT
6
13
5
1
4
2
3
Figure 78
1.
2.
3.
4.
5.
Lift cylinder
Lift arm (LH shown)
Lock nut
Pin
Flange head screw
Hydraulic System
6.
7.
8.
9.
Grease fitting
O--ring
90o hydraulic fitting
O--ring
Page 4 -- 98
10.
11.
12.
13.
Hydraulic fitting
Pivot pin
Cotter pin
Grease fitting
Groundsmaster 4100--D
Removal (Fig. 78)
Installation (Fig. 78)
1. Park machine on a level surface, lower cutting
decks, stop engine, engage parking brake, and remove
key from the ignition switch.
1. Position cylinder barrel clevis to frame and insert upper lift pin into frame and clevis. Secure lift pin with cotter
pin.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
2. Insert pin through lift arm and cylinder shaft clevis.
Secure pin to lift arm with flange head screw and lock
nut.
3. To prevent contamination of hydraulic system during
lift cylinder removal, thoroughly clean exterior of cylinder and fittings.
3. Attach hydraulic hoses to lift cylinder.
NOTE: To ease reassembly, tag the hydraulic hoses to
show their correct position on the lift cylinder.
4. Disconnect hydraulic hoses from lift cylinder.
4. Fill reservoir with hydraulic fluid as required (see Operator’s Manual).
5. After assembly is completed, operate lift cylinder to
verify that hydraulic hoses and fittings are not contacted
by anything.
Hydraulic
System
5. Remove flange head screw and lock nut that secure
the pin to the lift arm. Remove pin from lift arm and cylinder shaft clevis which will free lift cylinder from lift arm.
6. Remove one cotter pin from upper lift pin. Pull upper
lift pin from frame and cylinder barrel clevis.
7. Remove lift cylinder from machine.
Groundsmaster 4100--D
Page 4 -- 99
Hydraulic System
Front Deck Lift Cylinder Service
1
12
11
8
2
3
10
9
6
7
1
9
5
4
3
12
11
8
10
6
7
5
2
4
Figure 79
1.
2.
3.
4.
Barrel with clevis
Retaining ring
Shaft with clevis
Dust seal
Hydraulic System
5.
6.
7.
8.
Rod seal
O--ring
Back--up ring
Head
Page 4 -- 100
9.
10.
11.
12.
O--ring
T--seal
Piston
Locking nut
Groundsmaster 4100--D
Disassembly (Fig. 79)
Assembly (Fig. 79)
1. Remove oil from lift cylinder into a drain pan by slowly
pumping the cylinder shaft. Plug both ports and clean
the outside of the cylinder.
1. Make sure all parts are clean before reassembly.
2. Mount lift cylinder into a vise. Use of a vise with soft
jaws is recommended.
3. Remove retaining ring that secures head in barrel.
A. Use a spanner wrench to rotate head clockwise
until the edge of the retaining ring appears in the barrel opening.
B. Insert a screwdriver under the beveled edge of
the retaining ring to start the retaining ring through
the opening.
C. Rotate the head counter--clockwise to remove retaining ring from barrel and head.
4. Extract shaft with head and piston by carefully twisting and pulling on the shaft.
IMPORTANT: Do not clamp vise jaws against the
shaft surface. Protect shaft surface before mounting in a vise.
A. Install T--seal, wear ring, and O--ring to the piston.
B. Install dust seal, O--ring, back--up ring, and dust
seal to the head.
IMPORTANT: Do not clamp vise jaws against the
shaft surface. Protect shaft surface before mounting in a vise.
3. Mount shaft securely in a vise by clamping on the clevis of the shaft.
A. Coat shaft with clean hydraulic oil.
B. Slide head and piston onto the shaft. Secure piston to shaft with locknut.
4. Lubricate head and piston with hydraulic oil. Slide
shaft assembly carefully into cylinder barrel.
IMPORTANT: Prevent damage when clamping the
cylinder’s barrel into a vise; clamp on the clevis
only. Do not close vise enough to distort the barrel.
5. Mount lift cylinder into a vise. Secure head in barrel
with retaining ring.
5. Mount shaft securely in a vise by clamping on the clevis of the shaft. Remove lock nut and piston from the
shaft. Slide head off the shaft.
A. Align retaining ring hole in the head with the access slot in the barrel.
6. Remove T--seal, o--ring, and wear ring from the piston. Remove O--ring, back--up ring, rod seal, and dust
seal from the head.
B. Insert the retaining ring hook into the hole and rotate head clockwise until the retaining ring is completely pulled into the barrel and the ring ends are
covered.
7. Wash parts in clean solvent. Dry parts with compressed air. Do not wipe parts dry with paper towels or
cloth. Lint in a hydraulic system will cause damage.
8. Carefully inspect internal surface of barrel for damage (deep scratches, out--of--round, etc.). Replace entire cylinder if barrel is damaged. Inspect piston rod and
piston for evidence of excessive scoring, pitting, or
wear. Replace any damaged parts.
Groundsmaster 4100--D
Page 4 -- 101 Rev. E
Hydraulic System
Hydraulic
System
IMPORTANT: Prevent damage when clamping the
cylinder’s barrel into a vise; clamp on the clevis
only. Do not close vise enough to distort the barrel.
2. Coat new O--rings, T--seal, wear ring, rod seal,
back--up ring, and dust seal with clean hydraulic oil.
Wing Deck Lift Cylinder
11
6
2
10
4
9
8
100 to 140 in--lb
(11.3 to 15.8 N--m)
7
6
12
5
16
2
4
3
160 to 180 ft--lb
(217 to 244 N--m)
15
14
1
13
RIGHT
FRONT
Figure 80
1.
2.
3.
4.
5.
6.
Center deck
Grease fitting
Tapered stud
Spherical bearing
Flange nut
Retaining ring
Hydraulic System
7.
8.
9.
10.
11.
Wing deck lift cylinder
O--ring (2 used per cylinder)
Hydraulic fitting (2 used per cylinder)
O--ring (2 used per cylinder)
Pilot spacer
Page 4 -- 102
12.
13.
14.
15.
16.
Cap screw
Wing deck (RH shown)
Flat washer
Flange nut
Lock nut
Groundsmaster 4100--D
Removal (Fig. 80)
Installation (Fig. 80)
1. Park machine on a level surface, lower cutting
decks, stop engine, engage parking brake, and remove
key from the ignition switch.
1. If removed, install spherical bearings into lift cylinder
clevis ends.
3. Remove deck covers as needed to allow access to
lift cylinder hoses and fasteners.
4. To prevent contamination of hydraulic system during
lift cylinder removal, thoroughly clean exterior of cylinder and fittings.
NOTE: To ease reassembly, tag the hydraulic hoses to
show their correct position on the lift cylinder.
5. Disconnect hydraulic hoses from lift cylinder.
6. Remove cap screw and lock nut that secure the lift
cylinder clevis to the wing deck.
7. Remove flange nut and flat washer from the tapered
stud on the barrel end of the lift cylinder.
B. On barrel clevis, install spherical bearing on tapered stud and secure with flange nut. Torque flange
nut from 100 to 140 in--lb (11.3 to 15.8 N--m). Install
stud with spherical bearing into clevis and secure
with retaining ring.
2. Thoroughly clean tapered surfaces of lift cylinder
stud and mounting boss on deck.
3. Position lift cylinder to cutting deck. Insert tapered
stud into deck mounting boss. Secure stud with flat
washer and flange nut. Torque flange nut from 160 to
180 ft--lb (217 to 244 N--m).
4. Insert cap screw from the front of the deck through
the deck brackets and cylinder shaft clevis. Secure cap
screw with lock nut. Torque lock nut from 160 to 180 ft--lb
(217 to 244 N--m).
5. Attach hydraulic hoses to lift cylinder.
8. Remove lift cylinder from deck assembly.
9. Remove spherical bearings from lift cylinder clevis
ends, if required.
A. On shaft clevis, remove retaining ring and then
press spherical bearing from clevis.
B. On barrel clevis, remove retaining ring and then
press tapered stud with spherical bearing and flange
nut from clevis. Remove flange nut and then spherical bearing from stud.
Groundsmaster 4100--D
A. On shaft clevis, press spherical bearing into clevis and secure with retaining ring.
6. Install any removed deck covers.
7. Fill reservoir with hydraulic fluid as required (see Operator’s Manual).
8. After assembly is completed, operate lift cylinder to
verify that hydraulic hoses and fittings are not contacted
by anything.
Page 4 -- 103
Hydraulic System
Hydraulic
System
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
Wing Deck Lift Cylinder Service
13
11
8
2
3
1
12
12
13 11
10
9
6
7
5
1
9
5
8
10
4
6
7
4
3
2
Figure 81
1.
2.
3.
4.
5.
Barrel with clevis
Internal collar
Shaft with clevis
Dust seal
Rod seal
Hydraulic System
6.
7.
8.
9.
O--ring
Back--up ring
Head
O--ring
Page 4 -- 104
10.
11.
12.
13.
T--seal
Piston
Locking nut
Steel ring
Groundsmaster 4100--D
1. Remove oil from lift cylinder by slowly pumping the
cylinder shaft. After removing oil from cylinder, plug both
ports and clean the outside of the cylinder.
IMPORTANT: Prevent damage when clamping the
cylinder’s barrel into a vise; clamp on the clevis
only. Do not close vise enough to distort the barrel.
2. Mount lift cylinder into a vise. Use of a vise with soft
jaws is recommended. Remove internal collar with a
spanner wrench.
3. Loosen head from barrel:
A. On cylinders with a collar in the barrel (Fig. 81),
use a spanner wrench to loosen and remove collar
from barrel.
B. On cylinders with a retaining ring (Fig. 82), use a
spanner wrench to rotate head clockwise until the
edge of the retaining ring appears in the barrel opening. Insert a screwdriver under the beveled edge of
the retaining ring to start the retaining ring through
the opening. Rotate the head counter--clockwise to
remove retaining ring from barrel and head.
4. Extract shaft with head and piston by carefully twisting and pulling on the shaft.
IMPORTANT: Do not clamp vise jaws against the
shaft surface. Protect shaft surface before mounting in a vise.
5. Mount shaft securely in a vise by clamping on the clevis of the shaft. Remove lock nut and piston from the
shaft. Slide head off the shaft.
6. Remove T--seal and O--ring from the piston. Remove
O--ring, back--up ring, rod seal, and dust seal from the
head.
2. Coat new O--rings, T--seal, rod seal, back--up ring,
and dust seal with clean hydraulic oil.
A. Install T--seal and O--ring to the piston.
B. Install dust seal, O--ring, back--up ring, and dust
seal to the head.
IMPORTANT: Do not clamp vise jaws against the
shaft surface. Protect shaft surface before mounting in a vise.
3. Mount shaft securely in a vise by clamping on the clevis of the shaft.
A. Coat shaft with clean hydraulic oil.
B. If removed, install internal collar onto shaft.
C. Slide head and piston onto the shaft. Secure piston to shaft with locknut.
4. Lubricate head and piston with hydraulic oil. Slide
shaft assembly carefully into cylinder barrel.
IMPORTANT: Prevent damage when clamping the
cylinder’s barrel into a vise; clamp on the clevis
only. Do not close vise enough to distort the barrel.
5. Mount lift cylinder in a vise with soft jaws. Secure
head in barrel:
A. On cylinders with a collar in the barrel (Fig. 81),
use a spanner wrench to tighten collar into barrel.
B. On cylinders with a retaining ring (Fig. 82), align
retaining ring hole in the head with the access slot in
the barrel. Insert the retaining ring hook into the hole
and rotate head clockwise until the retaining ring is
completely pulled into the barrel and the ring ends
are covered.
7. Wash parts in clean solvent. Dry parts with compressed air. Do not wipe parts dry with paper towels or
cloth. Lint in a hydraulic system will cause damage.
3
1
2
8. Carefully inspect internal surface of barrel for damage (deep scratches, out--of--round, etc.). Replace entire cylinder if barrel is damaged. Inspect piston rod and
piston for evidence of excessive scoring, pitting, or
wear. Replace any damaged parts.
Assembly (Fig. 81)
Figure 82
1. Make sure all parts are clean before reassembly.
Groundsmaster 4100--D
1. Barrel
2. Head
Page 4 -- 105 Rev. E
3. Retaining ring
Hydraulic System
Hydraulic
System
Disassembly (Fig. 81)
Steering Cylinder
9
6
4
7
9
1
8
5
2
4
3
10
12
100 to 125 ft--lb
(135 to 169 N--m)
13
14
11
RIGHT
100 to 125 ft--lb
(135 to 169 N--m)
FRONT
Figure 83
1.
2.
3.
4.
5.
Steering cylinder
Ball joint
Ball joint
Retaining ring
Grease fitting
Hydraulic System
6.
7.
8.
9.
10.
Grease fitting
90o hydraulic fitting
O--ring
O--ring
Drive axle assembly
Page 4 -- 106
11.
12.
13.
14.
Ball joint spacer
Axle washer
Hex slotted nut
Cotter pin
Groundsmaster 4100--D
Removal (Fig. 83)
Installation (Fig. 83)
1. Park machine on a level surface, lower cutting
decks, stop engine, engage parking brake, and remove
key from the ignition switch.
1. If removed, install ball joints into steering cylinder.
3. To prevent contamination of hydraulic system during
steering cylinder removal, thoroughly clean exterior of
cylinder and fittings.
NOTE: To ease reassembly, tag the hydraulic hoses to
show their correct position on the steering cylinder.
4. Remove hydraulic hoses from steering cylinder.
5. Remove cotter pins, hex slotted nuts, axle washer,
and ball joint spacer from the threaded ends of ball joints
(Fig. 83). Remove steering cylinder with ball joints from
machine.
3. Install hydraulic hoses to steering cylinder.
4. Fill reservoir with hydraulic fluid as required (see Operator’s Manual).
5. After assembly is completed, operate steering cylinder to verify that hydraulic hoses and fittings are not contacted by anything.
Hydraulic
System
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
2. Slide ram end ball joint through hole on steering arm.
Secure with axle washer and hex slotted nut. Slide fixed
end of cylinder through hole on axle. Install spacer onto
ball joint and secure with hex slotted nut. Torque slotted
nuts from 100 to 125 ft--lbs (135 to 169 N--m) prior to inserting cotter pins.
6. If needed, remove ball joints from steering cylinder.
Groundsmaster 4100--D
Page 4 -- 107
Hydraulic System
Steering Cylinder Service
11
4
10
8
7
2
5
9
3
6
1
Figure 84
1.
2.
3.
4.
Butt and tube assembly
Shaft
Piston rod assembly
Gland
Hydraulic System
5.
6.
7.
8.
Locking nut
O--ring
PTFE seal
O--ring
Page 4 -- 108 Rev. D
9. O--ring
10. U--cup
11. Wiper
Groundsmaster 4100--D
Disassembly (Fig. 84)
Assembly (Fig. 84)
1. Remove oil from lift cylinder by slowly pumping the
cylinder shaft. After removing oil from cylinder, plug both
ports and clean the outside of the cylinder.
1. Use a complete repair kit when rebuilding the cylinder. Put a coating of clean hydraulic oil on all new seals,
and O--rings.
IMPORTANT: To prevent damage when clamping
cylinder barrel or rod in a vise, clamp only on pivotal
ends. Use of a vise with soft jaws is recommended.
2. Install new O--rings and PTFE seal to the piston rod
and new O--ring, U--cup, and wiper to gland.
3. Loosen gland (head) from barrel:
A. On cylinders without a retaining ring slot in the
barrel (Fig. 84), use a spanner wrench to loosen and
remove gland from barrel.
B. On cylinders with a retaining ring (Fig. 85), use a
spanner wrench to rotate head clockwise until the
edge of the retaining ring appears in the barrel opening. Insert a screwdriver under the beveled edge of
the retaining ring to start the retaining ring through
the opening. Rotate the head counter--clockwise to
remove retaining ring from barrel and head.
4. Grasp end of piston rod and use a twisting and pulling motion to carefully extract piston, piston rod, and
gland from cylinder tube.
IMPORTANT: Do not clamp vise jaws against
smooth piston rod surface; the piston rod will become damaged.
3. Lubricate shaft with clean hydraulic oil. Slide gland
and piston onto shaft. Install and tighten locking nut.
4. Put a coating of clean hydraulic oil on all cylinder
parts to ease assembly.
5. Slide piston rod assembly into cylinder tube.
6. Mount lift cylinder in a vise with soft jaws. Secure
gland (head) in barrel:
A. On cylinders without a retaining ring slot in the
barrel (Fig. 84), use a spanner wrench to tighten
gland into barrel.
B. On cylinders with a retaining ring (Fig. 85), align
retaining ring hole in the head with the access slot in
the barrel. Insert the retaining ring hook into the hole
and rotate head clockwise until the retaining ring is
completely pulled into the barrel and the ring ends
are covered.
1
5. Securely mount piston, piston rod, and gland into
vise and remove nut. Remove piston and gland from
rod.
6. Remove all seals and O--rings.
7. Wash parts in clean solvent. Dry parts with compressed air. Do not wipe parts dry with paper towels or
cloth. Lint in a hydraulic system will cause damage.
8. Carefully inspect internal surface of barrel for damage (deep scratches, out--of--round, etc.). Replace entire cylinder if barrel is damaged. Inspect piston rod and
piston for evidence of excessive scoring, pitting, or
wear. Replace any damaged parts.
Groundsmaster 4100--D
2
3
Figure 85
1. Barrel
2. Gland (head)
Page 4 -- 109 Rev. E
3. Retaining ring
Hydraulic System
Hydraulic
System
2. Mount cylinder in a vise so piston rod end of cylinder
is tilted up slightly. Do not close vise so firmly that cylinder tube could become distorted.
Hydraulic Reservoir
8
19
23
14
13
10 18
9
12
15
11
7
24
6
4
1
5
16
17
3
2
20
4
25
22
RIGHT
FRONT
4
21
1.
2.
3.
4.
5.
6.
7.
8.
9.
Hydraulic reservoir
Petcock
O--ring
Strap (2 used)
Felt strap (2 used)
Bushing
Bushing
Hydraulic fitting
Stand pipe
Hydraulic System
10.
11.
12.
13.
14.
15.
16.
17.
Figure 86
Hose clamp
Screen filter
Dipstick
O--ring
Reservoir cap
Suction hose
Tank strainer w/o--ring
Hose clamp
Page 4 -- 110
18.
19.
20.
21.
22.
23.
24.
25.
Hose
Hose clamp
Cap screw (2 used)
Cap screw (2 used)
Lock nut (2 used)
Hose
Hose
Hex flange nut (2 used)
Groundsmaster 4100--D
Removal
Inspection
1. Park machine on a level surface, lower cutting
decks, stop engine, engage parking brake, and remove
key from the ignition switch.
1. Clean hydraulic reservoir and suction strainer with
solvent.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
3. Drain reservoir into a suitable container (see Operator’s Manual).
4. Disconnect hydraulic hoses from reservoir.
2. Inspect for leaks, cracks, or other damage.
Installation
1. Install reservoir using Figure 86 as a guide.
2. Using a wrench, turn strainer into port 1--1/2 to 2 full
turns beyond finger tight.
3. Reconnect hydraulic hoses.
4. Fill reservoir with hydraulic fluid as required (see Operator’s Manual).
Hydraulic
System
5. Remove hydraulic reservoir using Figure 86 as a
guide.
Groundsmaster 4100--D
Page 4 -- 111
Hydraulic System
Hydraulic Oil Cooler
Removal
CAUTION
The radiator and oil cooler may be hot. To avoid
possible burns, allow the engine and cooling
systems to cool before working on the oil cooler.
1. Park machine on a level surface, lower cutting
decks, stop engine, engage parking brake, and remove
key from the ignition switch.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
Figure 87
1.
Oil cooler
3. To prevent contamination of hydraulic system during
oil cooler removal, thoroughly clean exterior of oil cooler
and fittings.
4. Remove oil cooler using Figures 87 and 88 as
guides.
2
1
2. Radiator assembly
2
4
3
3
1
12
Inspection
2
7
4
5
1. Back flush oil cooler with cleaning solvent. After cooler is clean, make sure all solvent is drained from the
cooler.
6
CAUTION
10
11
8
8
Use eye protection such as goggles when using
compressed air.
9
RIGHT
2. Dry inside of oil cooler using compressed air in the
opposite direction of the oil flow.
FRONT
3. Plug both ends of oil cooler. Clean exterior of cooler.
Make sure fins are clear of dirt and debris.
4. The oil cooler should be free of corrosion, cracked
tubes, and excessive pitting of tubes.
Installation
1. Install oil cooler using Figures 87 and 88 as guides.
Figure 88
1.
2.
3.
4.
5.
6.
Oil cooler
90o hydraulic fitting
O--ring
O--ring
Knob (2 used)
Retaining ring (2 used)
7.
8.
9.
10.
11.
12.
Carriage screw (2 used)
Clamp
Oil cooler bracket (RH)
Flange screw
Flange locking nut
Radiator support
2. Fill reservoir with hydraulic fluid as required (see Operator’s Manual).
Hydraulic System
Page 4 -- 112
Groundsmaster 4100--D
Chapter 5
Electrical System
Table of Contents
Groundsmaster 4100−D
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start, Engine Shutdown, Seat, PTO, Alarm,
Down Latching, and Over Temperature Relays
Hydraulic Valve Solenoids . . . . . . . . . . . . . . . . . . .
Engine Run Solenoid . . . . . . . . . . . . . . . . . . . . . . .
Fuel Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . .
High Temperature Shutdown Switch . . . . . . . . . .
Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . .
Traction Neutral Switch . . . . . . . . . . . . . . . . . . . . .
Diode Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . .
Diode Circuit Board . . . . . . . . . . . . . . . . . . . . . . . .
Wing Deck Position Switches . . . . . . . . . . . . . . . .
Cutting Deck Raise and Lower Switches . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . .
Hydraulic Valve Solenoids . . . . . . . . . . . . . . . . . . .
Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 5 − 1
16
16
17
18
19
20
21
22
23
24
25
26
27
27
28
29
30
31
31
32
32
33
Electrical System
Electrical
System
ELECTRICAL SCHEMATIC, CIRCUIT DIAGRAMS,
AND WIRE HARNESS DRAWINGS . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Run & Transport Problems . . . . . . . . . . . . 5
Cutting Deck Operating Problems . . . . . . . . . . . . . 6
ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . . 7
Battery Test (Open Circuit Test) . . . . . . . . . . . . . . . 7
Check Operation of Interlock Switches . . . . . . . . . 7
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wing Deck Position Switches . . . . . . . . . . . . . . . . . 8
Cutting Deck Raise and Lower Switches . . . . . . . 9
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . 10
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Audio Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Transport, Alarm Silence, and
Temperature Override Switches . . . . . . . . . . . . 14
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical Schematic, Circuit Diagrams, and
Wire Harness Drawings
The electrical schematic, circuit diagrams, and wire harness drawings for the Groundsmaster 4100−D are located in Chapter 9 − Electrical Diagrams.
Electrical System
Page 5 − 2
Groundsmaster 4100−D
Special Tools
Order special tools from your Toro Distributor. Some
tools may also be available from a local supplier.
Multimeter
The meter can test electrical components and circuits
for current, resistance, or voltage.
NOTE: Toro recommends the use of a DIGITAL Volt−
Ohm−Amp multimeter when testing electrical circuits.
The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter. This excess
current can cause damage to circuits not designed to
carry it.
Figure 1
Skin−Over Grease
Electrical
System
Special non−conductive grease (Toro Part No.
505−165) which forms a light protective skin which helps
waterproof electrical switches and contacts.
Figure 2
Deck Proximity Switch Adjustment Tool
The Deck Proximity Switch Adjustment Tool (TOR4095)
is designed to assist in the adjustment of the cutting
deck position switches for cutting blade shutdown during deck lift.
Figure 3
Groundsmaster 4100−D
Page 5 − 3 Rev. E
Electrical System
Troubleshooting
For effective troubleshooting and repairs, you must
have a good understanding of the electrical circuits and
components used on this machine (see Chapter 9 −
Electrical Diagrams).
CAUTION
Remove all jewelry, especially rings and
watches, before doing any electrical troubleshooting or testing. Disconnect the battery
cables unless the test requires battery voltage.
If the machine has any interlock switches by−passed,
reconnect the switches for proper troubleshooting and
safety.
Starting Problems
Problem
Possible Causes
All electrical power is dead, including gauges.
The battery charge is low.
The 10 amp fuse to the ignition switch is open.
Bad ground connection on machine.
The ignition switch or circuit wiring is faulty.
The fusible link from the battery is faulty.
Starter solenoid clicks, but starter will not crank.
Low battery charge.
NOTE: If the solenoid clicks, the problem is not in the in- Loose or corroded battery cables.
terlock circuit wiring.
Loose or corroded ground.
Faulty wiring at the starter.
Faulty starter solenoid.
Faulty starter.
Nothing happens when start attempt is made. Control
panel lights and gauges operate with the ignition
switch in ON.
The traction pedal is not in neutral position or the
neutral switch or circuit wiring is faulty.
Faulty ignition switch or circuit wiring.
Start relay or circuit wiring is faulty.
Starter solenoid or starter is faulty.
Engine starts, but stops when the ignition switch is
released from the START position.
Engine run solenoid is out of adjustment or circuit
wiring is faulty.
High temperature shutdown switch or circuit wiring is
faulty.
Electrical System
Page 5 − 4
Groundsmaster 4100−D
Problem
Possible Causes
Engine cranks, but does not start.
Engine is not cranking fast enough.
Engine run solenoid, circuit wiring, or fuel pump is
faulty.
The problem is not electrical (see Chapter 3 − Kubota
Engine).
Starter cranks, but should not when the traction pedal
is depressed.
The traction neutral switch is out of adjustment.
The traction neutral switch or circuit wiring is faulty.
General Run and Transport Problems
Engine continues to run, but should not, when the
ignition switch is turned off.
The engine run solenoid is stuck open.
Engine continues to run, but should not, when the
traction pedal is engaged with no operator in the seat.
The seat sensor or circuit wiring is faulty.
The engine stops during operation, but is able to
restart.
The operator is lifting off the seat switch.
Ignition switch or circuit wiring is faulty.
Traction neutral switch or circuit wiring is faulty.
The engine shutdown delay is faulty.
Engine run solenoid is out of adjustment or circuit
wiring is faulty.
The ignition switch or circuit wiring is faulty.
The engine kills when the traction pedal is depressed.
The operator is lifting off the seat switch.
The seat switch or circuit wiring is faulty.
Battery does not charge.
Loose, corroded, or broken wire(s).
The fusible link to the battery is faulty.
Faulty alternator or dead battery.
Charge indicator lamp is faulty or burned out.
Charge indicator lamp wiring loose, corroded, or
damaged.
Groundsmaster 4100−D
Page 5 − 5
Electrical System
Electrical
System
The seat switch or circuit wiring is faulty.
Cutting Deck Operating Problems
The cutting deck remains engaged, but should not,
with no operator in the seat.
The seat switch or circuit wiring is faulty.
Cutting decks run, but should not, when raised. Decks
shut off with PTO switch.
The deck position switch or circuit wiring is faulty.
Cutting decks run, but should not, when raised. Units
do not shut off with the PTO switch.
The deck position switch or circuit wiring, and PTO
switch or circuit wiring are faulty.
A hydraulic problem exists (see Troubleshooting
section of Chapter 4 − Hydraulic System).
Cutting decks run, but should not, when lowered with
PTO switch in the OFF (disengage) position.
The PTO switch or circuit wiring is faulty.
Cutting deck(s) do not operate.
The operator is lifting off the seat switch.
The seat switch, relay, or circuit wiring is faulty.
The PTO switch, relay, or circuit wiring is faulty.
The deck position switch or circuit wiring is faulty.
Center lift lever position switch is out of adjustment or
faulty.
The transport/4WD switch or circuit wiring is faulty.
Hydraulic valve solenoid(s) or circuit wiring is faulty.
A hydraulic problem exists (see Troubleshooting
section of Chapter 4 − Hydraulic System).
Cutting decks shut off when PTO switch is released
from the engage position.
Diode circuit board or circuit wiring is faulty.
PTO fuse blows when engaging cutting deck.
Hydraulic valve solenoid coil is shorted.
Deck position switch is faulty.
Electrical System
Page 5 − 6
Groundsmaster 4100−D
Electrical System Quick Checks
Battery Test (Open Circuit Test)
Use a multimeter to measure the voltage between the
battery terminals.
Voltage Measured
Battery Charge Level
12.68 V (or higher)
Fully charged (100%)
Set multimeter to the DC volts setting. The battery
should be at a temperature of 60oF to 100oF (16oC to
38oC). The ignition key should be off and all accessories
turned off. Connect the positive (+) meter lead to the
positive battery post and the negative (−) meter lead to
the negative battery post.
12.45 V
75% charged
12.24 V
50% charged
12.06 V
25% charged
11.89 V
0% charged
NOTE: This test provides a relative condition of the battery. Load testing of the battery will provide additional
and more accurate information.
Check Operation of Interlock Switches
Interlock switch operation is described in the Operator’s
Manual. Testing of interlock switches and relays is included in the Component Testing section of this Chapter.
CAUTION
Groundsmaster 4100−D
Page 5 − 7 Rev. E
Electrical
System
Do not disconnect safety switches. They are for
the operator’s protection. Check the operation of
the interlock switches daily for proper operation.
Replace any malfunctioning switches before operating the machine.
Electrical System
Adjustments
Wing Deck Position Switches
Adjustment
5
1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake, and remove key
from the ignition switch.
2. Remove switch cover from deck to allow access to
position switch that requires adjustment.
NOTE: Use Deck Proximity Switch Adjustment Tool
(TOR4095) to assist with switch adjustment (see Special Tools).
4
3. Loosen two (2) lock nuts that secure switch bracket
to center cutting deck (Fig. 4).
3
2
4. When adjusting switch location, the target surface of
position switch should be approximately 0.188” (4.8
mm) from actuator tab on wing deck link (Fig. 5).
5. When wing deck position switch is properly adjusted,
hydraulic motor on wing deck should turn off when wing
deck is raised and wing deck latch opens.
6. For switch testing information, see Wing Deck Position Switches in the Component Testing section of this
chapter.
6
7
1
Figure 4
1.
2.
3.
4.
5. Carriage screw (2 used)
6. Center cutting deck
7. Screw (2 used)
Position switch
Lock nut (2 used)
Flat washer (2 used)
Switch bracket
1
.188”
(4.8 mm)
2
3
Figure 5
1. Position switch
2. Actuator tab
Electrical System
Page 5 − 8 Rev. E
3. Wing deck link
Groundsmaster 4100−D
Cutting Deck Raise and Lower Switches
Adjustment (Fig. 6)
1
1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake, and remove key
from the ignition switch. Remove console housing.
2
3
5
4
6
2. The cutting deck raise and lower switches can be adjusted for correct operation by repositioning the
switch(es).
7
A. The distance between switches should be
approximately .625” (15.9 mm) (Fig. 7).
B. The lever bracket (item 4) should be parallel with
the center deck lift/lower lever. If lever bracket adjustment is needed, loosen flange bolts (item 6) and
reposition lever bracket.
C. Switch surfaces need to be parallel to each other
and also to the switch actuator on center lift/lower lever (item 9). If necessary, switch plate (item 3) can be
rotated after loosening flange nut (item 5).
8
3. After any switch adjustment, unplug switch connector from machine harness and check for correct switch
operation using a multimeter:
10
Figure 6
1.
2.
3.
4.
5.
Deck lower switch
Deck raise switch
Switch plate
Lever bracket
Flange nut
6.
7.
8.
9.
10.
Flange bolt (2 used)
Tab plate
Deck lift/lower lever
Switch actuator
Lock nut
B. The lower switch should be open (no continuity)
when the center deck lift/lower lever is in the neutral
position. As the lift/lower lever is slowly pushed forward, the lower switch should close (continuity) before the lever reaches full forward travel.
4. If switch operation is too sensitive, increase distance
between switches by repositioning one or both
switches. If switch operation is not sensitive enough, decrease distance between switches by repositioning one
or both switches. Recheck operation of switches after
repositioning.
1
2
5. If switches cannot be adjusted for correct operation,
exchange position of switches. Recheck operation of
switches.
NOTE: If correct switch operation cannot be achieved,
replace one or both switches. Recheck switch operation
after replacement.
Groundsmaster 4100−D
.625”
(15.9 mm)
Figure 7
1. Deck lower switch
Page 5 − 9
2. Deck raise switch
Electrical System
Electrical
System
A. The raise switch should be closed (continuity)
when the center deck lift/lower lever is in the neutral
position. As the lift/lower lever is slowly pulled back,
the raise switch should open (no continuity) after the
lever has removed all free play (with no spool movement in lift/lower control valve) but before the deck is
lifted.
9
Component Testing
For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the
circuit (e.g. unplug the ignition switch connector before
doing a continuity check).
NOTE: For engine component testing information, see
the Kubota Workshop Manual, Diesel Engine, V2003−T
Series at the end of Chapter 3 − Kubota Diesel Engine.
CAUTION
When testing electrical components for continuity with a multimeter (ohms setting), make sure
that power to the circuit has been disconnected.
Ignition Switch
The ignition (key) switch has three positions (OFF, ON/
PREHEAT, and START). The terminals are marked as
shown. The circuit wiring of the ignition switch is shown
in the chart. With the use of a multimeter (ohms setting),
the switch functions may be tested to determine whether
continuity exists between the various terminals for each
position. Verify continuity between switch terminals.
A
B
Y
S
POSITION
OFF
ON / PREHEAT
START
CIRCUIT
NONE
X
I
B + I + A, X + Y
B+I+S
Figure 8
2
4
1
3
Figure 9
1. Key
2. Hex nut
3. Lock washer
4. Ignition switch
OFF
45 °
ON / PREHEAT
45 °
START
Figure 10
Electrical System
Page 5 − 10
Groundsmaster 4100−D
Fuses
1
2
3
A
5A
10A
10A
B
10A
The fuse blocks are located under the operator’s control
console.
2
3
4
OPT.
The fuses are held in two fuse blocks. Use Figure 11 to
identify each individual fuse and its correct amperage.
Each fuse holder has the following functions and wires
connected to it.
10A
Identification, Function, and Wiring
Fuse A1 (5 amp)
1
A. Supplies power to the seat switch.
B. Has green wire and red wire (battery).
4
Figure 11
Fuse A2 (10 amp)
SEAT
5A
B. Has pink wire and red wire (battery).
Fuse A3 (10 amp)
SWITCH
POWER
IMPLEMENT
OUTLET
B. Has yellow wire and red wire (battery).
10A
SWITCH
10A
A. Supplies power to the PTO switch.
IGNITION
5A
PTO
STARTER
10A
10A
SOLENOID
THERMAL
LIGHT
25A
20A
BREAKER
KIT
Electrical
System
A. Supplies power to ignition switch terminal B.
Figure 12
Fuse A4 (10 amp)
A. Supplies power to the starter solenoid.
B. Has orange wire and red wire (battery).
Fuse B1 (10 amp)
A. Supplies power to the power point outlet.
B. Has white wire and red wire (battery).
Fuse B4 (when optional lighting is installed)
A. Supplies power for optional light kit.
B. Has two red wires.
Groundsmaster 4100−D
Page 5 − 11
Electrical System
Warning Lights
Testing Warning Lights
1. Apply 12 VDC to terminals 1A and 2A.
2. Ground terminals 1B and 2B.
3
3. Both indicator lights should light.
4
2
Engine Oil Pressure Light
The oil pressure light should come on when the ignition
switch is in the ON position with the engine not running.
Also, it should light with the engine running if the engine
oil pressure drops below 7 PSI (0.5 kg/cm2).
1
1. Disconnect green wire from the oil pressure switch
on the engine (located near the starter motor).
2. Ground green wire to the engine block.
3. Turn ignition switch to ON; the oil pressure light
should come on indicating correct operation of the electrical wiring to the oil pressure switch.
Figure 13
4. Turn ignition switch to OFF. Reconnect green wire to
the oil pressure switch. Apply skin−over grease (Toro
Part No. 505−165) to switch terminal.
1. Charge indicator
2. Engine oil pressure
High Temperature Shutdown Light
3. High temp shutdown
4. Glow plug indicator
5
If the coolant temperature rises to approximately 230oF
(110oC), the high temperature light should come on as
the high temperature shutdown switch stops the engine.
2
3
1. Disconnect and ground the blue wire attached to
temperature switch on flywheel end of engine. The
warning light should illuminate and the engine should
stop running.
1
4
6
2. Depress high temperature override switch and hold.
Engine should start and run.
3. Reconnect blue wire to temperature switch.
1B
1A (+)
2B
2A (+)
Glow Plug Indicator Light
The glow plug indicator light should come on when the
ignition switch is placed in ON prior to placing the ignition
switch in START. The light should stay lit for approximately 7 seconds while the ignition switch is left in ON.
Figure 14
1. Charge indicator
2. Engine oil pressure
3. High temp shutdown
Charge Indicator Light
4. Glow plug indicator
5. Warning light front
6. Warning light back
The charge indicator light should come on when the ignition switch is in ON with the engine not running, or with
an improperly operating charging circuit while the engine is running.
Electrical System
Page 5 − 12
Rev. E
Groundsmaster 4100−D
PTO Switch
The PTO switch is attached to the control console next
to the operator seat (Fig. 15).
The switch terminals are marked as shown in Figure 16.
The circuitry of the PTO switch is shown in the chart below. With the use of a multimeter (ohms setting), the
switch functions may be tested to determine whether
continuity exists between the various terminals for each
position. Verify continuity between switch terminals.
2
NOTE: The PTO ENGAGE position requires lifting and
pushing the lever toward the switch keyway. The PTO
OFF position occurs when the lever is pushed opposite
the keyway.
1
Figure 15
1. PTO switch
2. Control console
SWITCH
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
PTO ENGAGE
1+2
4+5
CENTER (ON)
1+2
NONE
2
1
PTO OFF
NONE
NONE
5
4
Electrical
System
BACK OF PTO SWITCH
Figure 16
Audio Alarm
The audio alarm for low engine oil pressure is attached
to the control console next to the operator seat.
4
3
IMPORTANT: Make sure to observe polarity on the
alarm terminals when testing. Damage to the alarm
may result from an improper connection.
1. Isolate alarm from the circuit. Correctly connect
12VDC source to the terminals (Fig. 17).
2. Alarm should sound. Remove voltage source from
the alarm. Reconnect alarm to the circuit.
Groundsmaster 4100−D
1
2
Figure 17
1. Alarm top view
2. Alarm bottom view
Page 5 − 13
3. Positive (+) terminal
4. Negative (−) terminal
Electrical System
Transport, Alarm Silence, and Temperature Override Switches
The transport, alarm silence, and temperature override
rocker switches are located on the control console (Fig.
18). These switches have common switching logic.
3
The switch terminals are marked as shown in Figure 19
and Figure 20. The circuitry of these switches is shown
in the chart below. With the use of a multimeter (ohms
setting), the switch functions may be tested to determine
whether continuity exists between the various terminals
for each position. Verify continuity between switch terminals.
1
2
SWITCH
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
ON
2+3
5+6
OFF
1+2
4+5
Figure 18
1. Transport switch
2. Alarm silence switch
3. Temp. override switch
NOTE: Terminals 7 (−) and 8 (+) on alarm silence and
temperature override switches are for the switch light.
4
5
6
1
2
3
BACK OF TRANSPORT SWITCH
Figure 19
7
4
5
6
8
1
2
3
BACK OF ALARM SILENCE AND
TEMPERATURE OVERRIDE SWITCHES
Figure 20
Electrical System
Page 5 − 14
Groundsmaster 4100−D
Seat Switch
The seat switch is normally open and closes when the
operator is on the seat. If the traction system or PTO
switch is engaged when the operator raises out of the
seat, the engine will stop. The seat switch and its electrical connector are located directly under the seat (Fig.
21). Testing of the switch can be done without seat removal by disconnecting the seat wire from the machine
wiring harness.
1
2
Testing
1. Make sure the engine is off.
2. Disconnect electrical connector for the seat switch.
3. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the connector terminals.
Figure 21
1. Electrical connector
2. Seat switch
4. With no pressure on the seat, there should be no
continuity between the seat switch terminals.
5. Press directly onto the seat switch through the seat
cushion. There should be continuity as the seat cushion
approaches the bottom of its travel.
Electrical
System
6. Reconnect switch connector.
Parking Brake Switch
The switch used for the parking brake is a normally
closed switch. The parking brake switch is located under
the steering tower cover (Fig. 22) and opens when the
parking brake lever is engaged.
Testing
1. Make sure the engine is off. Locate brake switch for
testing.
2. Disconnect electrical connector from the switch.
1
3. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the connector terminals.
4. When the switch plunger is extended there should be
continuity between the switch terminals.
2
3
5. When the switch plunger is depressed, there should
be no continuity between the switch terminals.
6. Reconnect switch connector.
Groundsmaster 4100−D
Figure 22
1. Parking brake switch
2. Parking brake rod
Page 5 − 15
3. Parking brake pawl
Electrical System
Hour Meter
The hour meter is located on the control console next to
the operator seat.
1. Disconnect harness connector from hour meter.
2. Connect the positive (+) terminal of a 12 VDC source
to the positive (+) terminal of the hour meter.
3. Connect the negative (−) terminal of the voltage
source to the other terminal of the hour meter.
4. The hour meter should move a 1/10 of an hour in six
minutes.
Figure 23
5. Disconnect voltage source from the hour meter. Reconnect harness connector to hour meter.
Glow Relay
The glow relay is attached to the the right side of the fuel
tank support under the hood (Fig. 24).
2
Testing
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this value from the measured value for the tested component.
1
1. Disconnect the harness connector from the glow
relay.
2. Using a multimeter (ohms setting), measure coil resistance between terminals 85 and 86 (Fig. 25). Resistance should be between 70 and 100 ohms.
Figure 24
1. Glow relay
2. Fuel tank support
3. Verify infinite resistance (no continuity) between terminals 30 and 87.
30
4. 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.
5. Disconnect meter leads and jumper wires from the
relay terminals. Reconnect glow relay to machine wire
harness.
85
86
87
86
87
85
30
Figure 25
Electrical System
Page 5 − 16
Groundsmaster 4100−D
Start, Engine Shutdown, Seat, PTO, Alarm, Down Latching, and
Over Temperature Relays
These seven relays are located under the console housing cover. The wiring harness is tagged to identify each
relay.
Testing
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this value from from the measured value of the component you
are testing.
86
87A
87
1. Disconnect the harness connector from the relay
that is to be tested.
3. 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.
85
30
Figure 26
Electrical
System
2. Using a multimeter (ohms setting), measure coil resistance between terminals 85 and 86 (Fig. 26). Resistance should be between 70 and 90 ohms.
4. Disconnect voltage from terminal 85 and multimeter
lead from terminal 87.
5. 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.
6. Disconnect voltage and multimeter leads from the
relay terminals. Reconnect relay to machine wire harness.
Groundsmaster 4100−D
Page 5 − 17
Electrical System
Hydraulic Valve Solenoids
There are four hydraulic valve solenoids on the Groundsmaster 4100−D (Fig. 28). Testing of these solenoids
can be done with the solenoid on the hydraulic valve.
4. Measure resistance between the two connector terminals. The resistance for the solenoid coil should be
approximately 7.2 ohms.
Testing
5. Reconnect electrical connector to the solenoid.
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this value from from the measured value of the component you
are testing.
1
2
1. Make sure engine is off. Disconnect hydraulic valve
solenoid electrical connector (Fig. 27).
2. Apply 12VDC source directly to the solenoid. Listen
for solenoid to switch on.
Figure 27
1. Manifold (LH deck shown)
2. Valve solenoid
3. Remove 12VDC source from the solenoid. Listen for
solenoid to switch off.
3
2
RIGHT
FRONT
1
4
Figure 28
1. LH wing deck solenoid
2. 2WD/4WD manifold solenoid
Electrical System
3. RH wing deck solenoid
Page 5 − 18
4. Center deck solenoid
Groundsmaster 4100−D
Engine Run Solenoid
The engine run solenoid must be energized for the engine to run. It is mounted on the engine block near the
injection pump (Fig. 29).
In Place Testing
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this value from from the measured value of the component you
are testing.
1
3
2
1. Disconnect the connector from the engine run solenoid.
Figure 29
1. Engine run solenoid
2. Solenoid connector
3. Injection pump
2
3. Using a digital multimeter, touch one lead to the pin
of the black wire and the other lead to the pin of the red
wire. The resistance of the hold coil should be approximately 10.9 ohms.
3
4
Electrical
System
2. Using a digital multimeter, touch one lead to the pin
of the black wire and the other lead to the pin of the white
wire. The resistance of the pull coil should be approximately 0.26 ohms.
4. Reconnect solenoid to the wiring harness.
Live Testing
1
1. Disconnect connector from the engine run solenoid.
Figure 30
NOTE: The solenoid may be removed from the engine
or tested in place.
1. Engine run solenoid
2. Red wire (hold coil)
3. White wire (pull coil)
4. Black wire (common)
2. If the solenoid is removed from the engine, make
sure that the solenoid linkage moves freely and is free
of dirt, debris, and corrosion.
3. Connect a positive (+) test lead from a 12 VDC
source to the pins of the red and white wires.
4. Touch a negative (−) test lead from the 12 VDC
source to the pin of the black wire. The solenoid should
engage making an audible “click”.
5. Remove positive (+) voltage from the pin of the white
wire. The solenoid should stay engaged.
6. Remove positive (+) voltage from the pin of the red
wire. The solenoid should release.
7. Reinstall solenoid if removed from engine.
8. Reconnect the harness wire connector to the solenoid.
Groundsmaster 4100−D
Page 5 − 19
Electrical System
Fuel Sender
The fuel sender is located on top of the fuel tank.
Testing
1. Remove white wire and black ground wire from the
sender.
FULL POSITION
EMPTY POSITION
CAUTION
If testing circuit wiring and fuel gauge, make sure
wire connections are secure before turning ignition switch ON to prevent an explosion or fire
from sparks.
Figure 31
2. To test the circuit wiring and fuel gauge, connect
white and black wires and turn ignition switch to ON.
Fuel gauge needle should point to the right edge of the
green area (full). Turn ignition switch OFF and continue
testing fuel sender if circuit wiring and gauge are acceptable.
3. Remove screws and lock washers that secure the
sender to the fuel tank.
4. Remove sender and gasket from the fuel tank. Clean
any fuel from the sender.
NOTE: Before taking small resistance readings with a
digital multimeter, short meter test leads together. The
meter will display a small resistance value. This internal
resistance of the meter and test leads should be subtracted from the measured value of the component.
CAUTION
Make sure sending unit is completely dry (no fuel
on it) before testing. Perform test away from the
tank to prevent an explosion or fire from sparks.
5. Check resistance of the sender with a multimeter
(Fig. 31).
A. Resistance with the float in the full position should
be 27.5 to 39.5 ohms.
B. Resistance with the float in the empty position
should be 240 to 260 ohms.
6. Replace sender as necessary. Reinstall sender into
fuel tank.
7. Reconnect wires to fuel sender. Apply skin−over
grease (Toro Part No. 505−165) to sender terminals.
Electrical System
Page 5 − 20 Rev. E
Groundsmaster 4100−D
Fuel Gauge
The fuel gauge can be tested using a new gauge as a
substitute or with the use of a DC voltage source and a
variable resistance box (see Fuel Sender Testing in this
section for additional information).
Testing
CAUTION
VARIABLE
RESISTANCE
Make sure the voltage source is turned OFF before connecting it to the electrical circuit to avoid
electrical shock and prevent damaging the
gauge.
14 VDC + 0.01 VDC
−
1. Connect fuel gauge to the variable resistance and
DC voltage source (Fig. 32).
NOTE: When reading the gauge test point, there are
two white dots on the gauge face below the edge of the
glass cover for each test point. For each variable resistance setting, the needle must be pointed between the
two white dots.
+
Figure 32
2
1
Electrical
System
2. Take test point readings (Fig. 33).
IMPORTANT: Allow circuit to warm up for at least 5
minutes before taking test readings.
A. Set variable resistance to 240 ohms. Apply a 14 +
0.01 VDC to the circuit. The needle should point to
the left edge of the red area (empty).
B. Set variable resistance to 33 ohms. The needle
should point to the right edge of the green area (full).
3
3. Turn off the voltage source. Disconnect voltage
source, gauge, and variable resistance.
Figure 33
1. Empty position
2. Full position
Groundsmaster 4100−D
Page 5 − 21
3. Glass face edge
Electrical System
Fuel Pump
The fuel pump is attached to the fuel tank support above
the fuel/water separator (Fig. 34).
IMPORTANT: When testing fuel pump, make sure
that pump is not operated dry.
1
Operational Test
1. Park machine on a level surface, lower cutting units,
stop engine, and engage parking brake.
2
3
2. Disconnect electrical connector from the fuel stop
solenoid to prevent the engine from firing.
DANGER
Figure 34
Because diesel fuel is highly flammable, use caution when testing. Do not smoke while testing the
fuel pump. Do not perform this test while engine
is running, hot, or when machine is in an enclosed area. Always wipe up any spilled diesel
fuel before starting the engine.
1. Fuel pump
2. Fuel/water separator
Fuel Pump Specifications
Pump Capacity
Pressure
3. Disconnect fuel hose (pump discharge) from the water separator.
3. Pump discharge hose
Maximum Current
Draw
23.5 fl oz/min (695 ml/min)
3.3 psi (22.8 kPa)
0.9 amp
4. Make sure fuel hoses attached to the fuel pump are
free of obstructions.
5. Place fuel hose (pump discharge) into a large, graduated cylinder sufficient enough to collect 1 quart (0.95
liter).
6. Collect fuel in the graduated cylinder by turning ignition switch and holding it in the START position. Allow
pump to run for 30 seconds, then release switch to OFF.
7. The amount of fuel collected in the graduated cylinder should be approximately 11.75 fl oz (350 ml) after 30
seconds.
8. Replace fuel pump as necessary. Reconnect fuel
hoses.
9. Reconnect electrical connector to the fuel stop solenoid.
10.Bleed the fuel system (see Operator’s Manual).
Electrical System
Page 5 − 22
Rev. E
Groundsmaster 4100−D
Glow Controller
The glow controller is located under the console cover.
2
NOTE: Refer to Chapter 9 − Electrical Schematics and
Diagrams when troubleshooting the controller.
Controller Operation
1. When the ignition switch is placed in the ON position,
the controller energizes the glow plugs and illuminates
the glow indicator light for approximately 7 seconds.
2. When the ignition switch is held in the START position, the glow plugs will energize and the glow indicator
light will not light.
3. Place ignition switch in the ON position. Verify the following while in the ON position:
5
1
4
Figure 35
3. Controller side view
5. If any of the conditions in step 3 are not met or power
to terminal 1 exists and any of the other conditions in
step 4 are not met:
A. Verify continuity of the circuitry from the battery to
the glow relay and glow plugs (see Chapter 9 − Electrical Schematics and Diagrams).
A. Glow indicator light is on.
B. Verify continuity of the circuitry from the battery to
ignition switch, glow controller, glow indicator light,
glow relay, and ground (see Chapter 9 − Electrical
Schematics and Diagrams).
B. Glow relay is energized.
C. Glow plugs are energized.
D. Glow indicator light goes out and glow plugs de−
energize after 7 seconds.
C. Replace components as necessary.
6. Reconnect electrical connector to the run solenoid.
4. Place ignition switch in the START position. Verify
the following while in the START position:
A. Glow indicator light is out.
B. Glow relay is energized.
C. Glow plugs are energized.
D. Power exists to terminal 1 of the glow controller.
NOTE: If there is no power to terminal 1 of the glow controller, verify continuity of the circuitry from the ignition
switch to the controller and perform step 4 again (see
Chapter 9 − Electrical Schematics and Diagrams).
Groundsmaster 4100−D
Page 5 − 23
Electrical System
Electrical
System
2. Disconnect electrical connector to the engine run solenoid to prevent the engine from starting.
2
3
1. Glow controller end view
2. Controller top view
1. Make sure there is power from the battery.
6
1
3. When the ignition switch is released from START to
ON, the glow plugs will de−energize and the glow indicator light will remain off.
Controller Checks
3
Temperature Sender
The temperature sender is located near the alternator
on the water flange attached to the engine cylinder head
(Fig. 36). There is a gray wire attached to the terminal
of the switch.
1
Testing
1. Lower coolant level in the engine and remove the
temperature sender from water flange.
2. Put switch in a container of oil with a thermometer
and slowly heat the oil (Fig. 37).
2
CAUTION
Handle the hot oil with extreme care to prevent
personal injury or fire.
Figure 36
1. Temperature sender
2. Alternator
NOTE: Prior to taking resistance readings with a digital
multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value
from from the measured value of the component you are
testing.
VOA
3. Check resistance of the sender with a multimeter
(ohms setting) as the temperature increases.
Figure 37
A. The meter should indicate more than 600 ohms at
70oF (21oC).
B. The meter should indicate approximately 460
ohms at 100oF (38oC).
C. The meter should indicate from 54 to 78 ohms at
200oF (93oC).
D. Replace sender if specifications are not met.
4. Install sender to the water flange.
A. Clean threads of water flange and sender thoroughly. Apply thread sealant to the threads of the
sender.
B. Screw sender into the water flange. Torque sender from 16 to 20 ft−lb (21.7 to 27.1 N−m).
C. Reconnect gray wire to sender. Apply skin−over
grease (Toro Part No. 505−165) to sender terminal.
5. Fill engine cooling system (see Operator’s Manual).
Electrical System
Page 5 − 24
Rev. E
Groundsmaster 4100−D
High Temperature Shutdown Switch
The high temperature shutdown switch is located near
the glow plug connection on the engine cylinder head
(Fig. 38). There is a blue wire attached to the switch.
Testing
CAUTION
2
Make sure engine is cool before removing the
temperature switch.
1. Lower coolant level in the engine and remove the
temperature shutdown switch.
2. Put switch in a container of oil with a thermometer
and slowly heat the oil (Fig. 39).
1
Figure 38
1. Temp. shutdown switch
2. Glow plug connection
VOA
CAUTION
3. Check continuity of the switch with a multimeter
(ohms setting). The temperature switch is normally
open and should close between 225o to 235oF (107o to
113oC).
Electrical
System
Handle the hot oil with extreme care to prevent
personal injury or fire.
Figure 39
4. Allow oil to cool while observing temperature. The
temperature switch should open at about 219oF
(104oC).
5. Replace switch if necessary.
6. Install switch to the water flange.
A. Clean threads of cylinder head and switch thoroughly. Apply thread sealant to the threads of the
switch.
B. Screw switch into the cylinder head and tighten.
C. Connect blue wire to switch.
7. Fill engine cooling system (see Operator’s Manual).
Groundsmaster 4100−D
Page 5 − 25
Electrical System
Temperature Gauge
The temperature gauge can be tested using a new
gauge as a substitute or with the use of a DC voltage
source and a variable resistance box.
Testing
CAUTION
Make sure the voltage source is turned OFF before connecting variable resistance to the electrical circuit to avoid electrical shock and to prevent damaging the gauge.
VARIABLE
RESISTANCE
14 VDC + 0.01 VDC
1. Connect temperature gauge to the variable resistance and DC voltage source (Fig. 40).
−
+
Figure 40
NOTE: When reading the gauge test point, there are
two white dots on the gauge face below the edge of the
glass cover for each test point. For each variable resistance setting, the needle must be pointed between the
two white dots.
1
2
2. Take test point readings (Fig. 41).
IMPORTANT: Allow circuit to warm up for at least 5
minutes before taking test readings.
A. Set variable resistance to 71 ohms. Apply a 14 +
0.01 VDC to the circuit. The needle should point to
the middle of the green area (80oC).
B. Set variable resistance to 38 ohms. The needle
should point between the green and red area
(105oC).
3. Turn off the voltage source. Disconnect voltage
source, gauge, and variable resistance.
3
Figure 41
1. Middle position
2. High temp. position
Electrical System
Page 5 − 26
3. Edge of glass cover
Groundsmaster 4100−D
Traction Neutral Switch
The traction neutral switch is closed when the traction
pedal is in the neutral position and opens when the pedal
is depressed in either direction. The switch is located on
the right side of the piston (traction) pump (Fig. 42).
2
Test the switch by disconnecting the wires from the
switch terminals and connecting a continuity tester
across the two switch terminals. With the engine turned
off, slowly push the traction pedal in a forward or reverse
direction while watching the continuity tester. There
should be indications that the traction neutral switch is
opening and closing. Allow the traction pedal to return
to the neutral position. There should be continuity
across the switch terminals when the traction pedal is in
the neutral position.
See Piston Pump Control Assembly in Chapter 4 − Hydraulic Systems for disassembly and reassembly procedures for the neutral switch.
1
Figure 42
1. Piston pump (bottom)
2. Neutral switch
Diode Assemblies (Fig. 43)
Diodes D2, D4, D5, and D6 are used for circuit protection from voltage spikes that occur when a hydraulic
valve solenoid is de−energized. Diode D2 is in the
Transport/Mow circuit, D4 is in the left wing deck circuit,
D5 is in the front deck circuit, and D6 is in the right wing
deck circuit.
Diode D3 provides logic for the cutting deck lift/lower
switches and down latching relay.
The optional cruise control kit includes diodes D7 and
D8. Diode D7 is used for circuit protection from voltage
spikes that occur when the cruise coil is de−energized
and D8 provides a latching circuit for the cruise relay.
These diodes plug into the machine wiring harness at
various locations (see wire harness drawings in Chapter
9 − Electrical Diagrams).
Testing
3
1
Figure 43
1. Diode
2. Male terminal
Multimeter
Red Lead (+)
on Terminal
Multimeter
Black Lead (−)
on Terminal
Continuity
Female
Male
YES
Male
Female
NO
The diodes can be individually tested using a digital
multimeter (diode test or ohms setting) and the table to
the right.
Groundsmaster 4100−D
3. Female terminal
Page 5 − 27
Electrical System
Electrical
System
2
Diode Circuit Board (Fig. 44)
The diode circuit board contains four diodes and is located under the console housing. Diode D1−A provides
logic for the interlock system. Diodes D1−B (right wing
deck), D1−C (front deck), and D1−D (left wing deck) provide latching circuits for the PTO relay.
H
G
D1−D
F
D1−A
D1−C
D1−D
D
C
B
A
CIRCUIT BOARD
DIODE DIAGRAM
Apply dielectric grease to circuit board contacts whenever the circuit board is installed into the wire harness.
Electrical System
D1−A
The diodes can be individually tested using a digital
multimeter (ohms setting) and the table to the right. If
any of the diodes are damaged, the diode circuit board
must be replaced.
D1−C
E
D1−B
D1−B
Testing
Figure 44
Red Lead (+)
on
Terminal
Black Lead (−)
on
Terminal
Continuity
H
A
YES
A
H
NO
G
B
YES
B
G
NO
F
C
YES
C
F
NO
E
D
YES
D
E
NO
Page 5 − 28
Groundsmaster 4100−D
Wing Deck Position Switches
The wing deck position switches on the Groundsmaster
4100−D are attached to the center deck housing (Fig.
45) and are normally open. The wing deck position
switch is a powered proximity switch that incorporates
an internal reed switch and relay (see schematic in Figure 46). The actuator for the position switch is bolted to
the wing deck link (Fig. 47).
When a wing deck is lowered, the actuator tab on the
wing deck link is positioned close to the position switch
causing the switch to close. The closed switch allows
current flow to the wing deck hydraulic valve solenoid
and allows that wing deck to operate.
When a wing deck is raised, the actuator tab is moved
away from the position switch and the switch opens. The
open switch prevents current flow to the wing deck hydraulic valve solenoid and keeps that wing deck from operating.
3
1
2
Figure 45
1. Switch cover
2. Position switch
3. Switch bracket
Testing
BLUE
WHITE
1. Park machine on a level surface, lower cutting deck,
and raise wing decks. Stop engine, engage parking
brake, and remove key from the ignition switch.
BLACK
2. Remove switch cover from deck to allow access to
switch that requires testing. Disconnect switch from wiring harness.
CONNECTOR
POSITION SWITCH
Figure 46
NOTE: Deck Proximity Switch Adjustment Tool
(TOR4095) can be used for switch testing and adjustment.
1
.188”
(4.8 mm)
3. Ground switch connector terminal for black wire and
apply 12 VDC to switch connector terminal for red wire.
4. Using a multimeter, verify that switch connector terminal for blue wire has 12 VDC and terminal for white
wire has 0 VDC.
2
3
5. Place a metal object near sensing area of switch (opposite end from wires). Ground switch connector terminal for black wire and apply 12 VDC to switch connector
terminal for red wire.
6. Using a multimeter, verify that switch connector terminal for blue wire has 0 VDC and terminal for white wire
has 12 VDC.
Figure 47
1. Position switch
2. Actuator tab
3. Wing deck link
7. Replace switch as needed. For switch adjustment
procedure, see Wing Deck Position Switches in the Adjustments section of this chapter.
8. Reinstall switch cover to deck.
Groundsmaster 4100−D
Page 5 − 29
Electrical System
Electrical
System
RED
Cutting Deck Raise and Lower Switches
The deck raise and lower switches are normally open
proximity switches that are located under the console
housing (Fig. 48). These identical switches are mounted
in opposite directions so their circuit logic differs. The actuator for the switches is on the center deck lift/lower lever. The raise and lower switches are used in
conjunction with the down latching relay to provide current to the PTO switch.
1
2
3
5
4
6
7
The deck raise switch is closed when the center deck lift/
lower lever is either in the neutral (center) position or
pushed to the lower (forward) position. If the center deck
lift/lower lever is pulled to the raise (rear) position, the
deck raise switch opens.
The deck lower switch is closed when the center deck
lift/lower lever is pushed to the lower (forward) position.
If the center deck lift/lower lever is in either the neutral
(center) position or the raise (rear) position, the deck
lower switch remains open.
8
Once the down latching relay is energized by lowering
the cutting deck, the cutting deck raise switch and diode
D3 provide a latching circuit to keep the relay energized.
9
Testing
1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake, and remove key
from the ignition switch.
2. Remove console cover and locate cutting deck raise
or lower switch to be tested. Disconnect switch connector from machine wiring harness.
10
Figure 48
1.
2.
3.
4.
5.
Deck lower switch
Deck raise switch
Switch plate
Lever bracket
Flange nut
6.
7.
8.
9.
10.
Flange bolt (2 used)
Tab plate
Deck lift/lower lever
Switch actuator
Lock nut
3. Check switch continuity by connecting a multimeter
(ohms setting) across the switch connector terminals.
4. The raise switch should be closed (continuity) when
the center deck lift/lower lever is in the neutral position.
As the lift/lower lever is slowly pulled back, the raise
switch should open (no continuity) after the lever has removed all free play (with no spool movement in lift/lower
control valve) but before the deck is lifted.
5. The lower switch should be open (no continuity)
when the center deck lift/lower lever is in the neutral
position. As the lift/lower lever is slowly pushed forward,
the lower switch should close (continuity) before the lever reaches full forward travel.
6. For switch adjustment procedure, see Cutting Deck
Raise and Lower Switches in the Adjustments section of
this chapter.
7. Reconnect switch to wiring harness. Install console
cover to machine.
Electrical System
Page 5 − 30
Groundsmaster 4100−D
Service and Repairs
NOTE: For more component repair information, see
the Kubota Workshop Manual, Diesel Engine, V2003−T
Series at the end of Chapter 3 − Kubota Diesel Engine.
Hydraulic Valve Solenoids
The hydraulic valve solenoids can be replaced without
opening the hydraulic system.
1. Make sure ignition switch is off. Disconnect hydraulic
valve solenoid electrical connector from wiring harness
(Fig. 49).
1
2
2. Remove nut that secures solenoid coil to valve.
Carefully slide coil from valve stem.
3. Install new solenoid to valve.
A. Apply Loctite 242 or equivalent to threads on end
of valve stem before installing nut.
Figure 49
1. Manifold (LH deck shown)
2. Valve solenoid
B. Torque solenoid nut to specification identified in
Figure 50. Over−tightening may damage the solenoid or cause the valve to malfunction.
Electrical
System
4. Reconnect electrical connector to the solenoid.
3
50 to 55 in−lb
(5.6 to 6.2 N−m)
4 to 6 ft−lb
(5 to 8 N−m)
RIGHT
2
FRONT
50 to 55 in−lb
(5.6 to 6.2 N−m)
1
50 to 55 in−lb
(5.6 to 6.2 N−m)
4
Figure 50
1. LH wing deck solenoid
2. 2WD/4WD manifold solenoid
Groundsmaster 4100−D
3. RH wing deck solenoid
Page 5 − 31
4. Center deck solenoid
Electrical System
Battery Storage
If the machine will be stored for more than 30 days:
1. Remove the battery and charge it fully (see Battery
Service).
4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge.
5. To help prevent the battery from freezing, make sure
it is fully charged (see Battery Service).
2. Either store battery on a shelf or on the machine.
3. Leave cables disconnected if the battery is stored on
the machine.
Battery Care
1. Battery electrolyte level must be properly maintained. 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.
3. Battery cables must be tight on terminals to provide
good electrical contact.
WARNING
Connecting cables to the wrong post could result in personal injury and/or damage to the
electrical system.
WARNING
Wear safety goggles and rubber gloves when
working with electrolyte. Charge battery in a
well ventilated place so gasses produced
while charging can dissipate. Since the gases
are explosive, keep open flames and electrical
sparks away from the battery; do not smoke.
Nausea may result if the gases are inhaled. Unplug charger from electrical outlet before connecting or disconnecting charger leads to or
from battery posts.
IMPORTANT: Do not remove fill caps while cleaning.
4. If corrosion occurs at terminals, disconnect cables.
Always disconnect negative (−) cable first. Clean
clamps and terminals separately. Reconnect cables
with positive (+) cable first. Coat battery posts and cable
connectors with skin−over grease (Toro Part No.
505-165) or petroleum jelly to prevent corrosion.
5. Check electrolyte level every 25 operating hours,
and every 30 days if machine is in storage.
6. Maintain cell level with distilled or demineralized water. Do not fill cells above the fill line.
2. Check battery condition weekly or after every 50
hours of operation. Keep terminals and entire battery
case clean because a dirty battery will discharge slowly.
A. Clean battery by washing entire case with a solution of baking soda and water. Rinse with clear water.
B. Coat battery posts and cable connectors with
skin−over grease (Toro Part No. 505-165) or petroleum jelly to prevent corrosion.
Electrical System
Page 5 − 32
Rev. E
Groundsmaster 4100−D
Battery Service
The battery is the heart of the electrical system. With
regular and proper service, battery life can be extended.
Additionally, battery and electrical component failure
can be prevented.
2
CAUTION
When working with batteries, use extreme caution to avoid splashing or spilling electrolyte.
Electrolyte can destroy clothing and burn skin or
eyes. Always wear safety goggles and a face
shield when working with batteries.
3
Electrolyte Specific Gravity
Fully charged: 1.265 corrected to 80oF (26.7oC)
Discharged: less than 1.240
Figure 51
1. Negative (−) cable
2. Positive (+) cable
Battery Specifications
BCI Group Size 24
650 CCA at 0o F (−17.8o C)
Reserve Capacity of 110 minutes at 80oF (26.7oC)
3. Battery retainer
Removal and Installation (Fig. 51)
See Operator’s Manual for battery removal and installation information.
NOTE: Before connecting the negative (ground) cable,
connect a digital multimeter (set to amps) between the
negative battery post and the negative (ground) cable
connector. The reading should be less than 0.1 amp. If
the reading is 0.1 amp or more, the unit’s electrical system should be tested and repaired.
Inspection, Maintenance, and Testing
1. Perform following inspections and maintenance:
A. Check for cracks. Replace battery if cracked or
leaking.
B. Check battery terminal posts for corrosion. Use
wire brush to clean corrosion from posts.
E. Check the electrolyte level in each cell. If the level
is below the tops of the plates in any cell, fill all cells
with distilled water between the minimum and maximum fill lines. Charge at 15 to 25 amps for 15 minutes to allow sufficient mixing of the electrolyte.
2. Conduct a hydrometer test of the battery electrolyte.
IMPORTANT: Make sure the area around the cells is
clean before opening the battery caps.
A. Measure the specific gravity of each cell with a
hydrometer. Draw electrolyte in and out of the
hydrometer barrel prior to taking a reading to warm−
up the hydrometer. At the same time take the temperature of the cell.
B. Temperature correct each cell reading. For each
10oF (5.5oC) above 80oF (26.7oC) add 0.004 to the
specific gravity reading. For each 10oF (5.5oC) below 80oF (26.7oC) subtract 0.004 from the specific
gravity reading.
IMPORTANT: Before cleaning the battery, tape or
block vent holes to the filler caps and make sure the
caps are on tightly.
C. Check for signs of wetness or leakage on the top
of the battery which might indicate a loose or missing
filler cap, overcharging, loose terminal post, or overfilling. Also, check battery case for dirt and oil. Clean
the battery with a solution of baking soda and water,
then rinse it with clean water.
Page 5 − 33
Example: Cell Temperature
100oF
Cell Gravity
1.245
100oF minus 80oF equals 20oF
(37.7oC minus 26.7oC equals 11.0oC)
20oF multiply by 0.004/10oF equals 0.008
(11oC multiply by 0.004/5.5oC equals 0.008)
ADD (conversion above)
0.008
Correction to 80oF (26.7oC)
1.253
Electrical System
Electrical
System
D. Check that the cover seal is not broken away. Replace the battery if the seal is broken or leaking.
Dimensions (including terminal posts and caps)
Length
10.2 inches (25.9 cm)
Width
6.64 inches (16.9 cm)
Height
8.99 inches (22.8 cm)
Groundsmaster 4100−D
1
C. If the difference between the highest and lowest
cell specific gravity is 0.050 or greater or the lowest
cell specific gravity is less than 1.225, charge the battery. Charge at the recommended rate and time given in Charging or until all cells specific gravity is
1.225 or greater with the difference in specific gravity
between the highest and lowest cell less than 0.050.
If these charging conditions can not be met, replace
the battery.
H. Using the table below, determine the minimum
voltage for the cell temperature reading:
Minimum
Voltage
Battery Electrolyte
Temperature
9.6
70oF (and up)
21.1oC (and up)
9.5
60oF
15.6oC
9.4
50oF
10.0oC
3. Perform a high−discharge test with an adjustable
load tester.
9.3
40oF
4.4oC
9.1
30oF
−1.1oC
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.
8.9
20oF
−6.7oC
8.7
10oF
−12.2oC
8.5
0oF
−17.8oC
CAUTION
Follow the manufacturer’s instructions when using a battery tester.
I. If the test voltage is below the minimum, replace
the battery. If the test voltage is at or above the minimum, return the battery to service.
A. Check the voltage across the battery terminals
prior to testing the battery. If the voltage is less than
12.4 VDC, recharge the battery.
B. If the battery has been charged, apply a 150 amp
load for 15 seconds to remove the surface charge.
Use a battery load tester following the manufacturer’s instructions.
C. Make sure battery terminals are free of corrosion.
D. Measure the temperature of the center cell.
E. Connect a battery load tester to the battery terminals following the manufacturer’s instructions.
Connect a digital multimeter to the battery terminals.
F. Apply a test load of one half the Cranking Performance (see Battery Specifications) rating of the battery for 15 seconds.
G. Take a voltage reading at 15 seconds, then remove the load.
Electrical System
Page 5 − 34
Groundsmaster 4100−D
Charging
To minimize possible damage to the battery and allow
the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger
which is available in most shops.
CAUTION
Follow the manufacturer’s instructions when using a battery charger.
NOTE: Using specific gravity of the battery cells is the
most accurate method of determining battery condition.
1. Determine the battery charge level from either its
specific gravity or open circuit voltage.
Battery Charge
Level
Specific
Gravity
Open Circuit
Voltage
100%
1.265
12.68
75%
1.225
12.45
50%
1.190
12.24
25%
1.155
12.06
0%
1.120
11.89
Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to
60oF (15.5o C) before connecting to a charger.
Charge the battery in a well−ventilated place to
dissipate gases produced from charging. These
gases are explosive; keep open flame and electrical spark away from the battery. Do not smoke.
Nausea may result if the gases are inhaled. Unplug the charger from the electrical outlet before
connecting or disconnecting the charger leads
from the battery posts.
3. Following the manufacturer’s instructions, connect the charger cables to the battery. Make sure a good
connection is made.
4. Charge the battery following the manufacturer’s
instructions.
6. Three hours prior to the end of the charging, measure the specific gravity of a battery cell once per hour.
The battery is fully charged when the cells are gassing
freely at a low charging rate and there is less than a
0.003 change in specific gravity for three consecutive
readings.
Battery Charge Level
(Percent of Fully Charged)
75%
50%
25%
0%
80 or less
3.8 hrs
@
3 amps
7.5 hrs
@
3 amps
11.3 hrs
@
3 amps
15 hrs
@
3 amps
81 to 125
5.3 hrs
@
4 amps
10.5 hrs
@
4 amps
15.8 hrs
@
4 amps
21 hrs
@
4 amps
126 to
170
5.5 hrs
@
5 amps
11 hrs
@
5 amps
16.5 hrs
@
5 amps
22 hrs
@
5 amps
171 to
250
5.8 hrs
@
6 amps
11.5 hrs
@
6 amps
17.3 hrs
@
6 amps
23 hrs
@
6 amps
above
250
6 hrs
12 hrs
18 hrs
24 hrs
@
@
@
@
10 amps 10 amps 10 amps 10 amps
Groundsmaster 4100−D
Page 5 − 35
Electrical System
Electrical
System
5. Occasionally check the temperature of the battery
electrolyte. If the temperature exceeds 125oF (51.6oC)
or the electrolyte is violently gassing or spewing, the
charging rate must be lowered or temporarily stopped.
2. Determine the charging time and rate using the
manufacturer’s battery charger instructions or the
following table.
Battery
Reserve
Capacity
(Minutes)
CAUTION
This page is intentionally blank.
Electrical System
Page 5 − 36
Groundsmaster 4100−D
Chapter 6
Axles, Planetaries, and Brakes
Table of Contents
Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . .
Bevel Gear Case and Axle Case . . . . . . . . . . . . .
Differential Shafts . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Shaft/Pinion Gear . . . . . . . . . . . . . . . . . . . . .
Differential Gear . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Gear to Ring Gear Engagement . . . . . . .
12
15
20
21
22
24
27
Axles, Planetaries,
and Brakes
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4
Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Brake Inspection and Repair . . . . . . . . . . . . . . . . . . 6
Planetary Wheel Drive Assembly . . . . . . . . . . . . . . 8
Planetary Wheel Drive Service . . . . . . . . . . . . . . . 10
Groundsmaster 4100−D
Page 6 − 1
Axles, Planetaries, and Brakes
Specifications
Item
Specification
Wheel lug nut torque
85 to 100 ft−lb (115 to 135 N−m), front and rear
Steering cylinder bolt torque
100 to 125 ft−lb (139 to 169 N−m)
Rear wheel toe−in
.125 in (3.18 mm)
Tire pressure
25 to 30 psi (1.7 to 2.1 bar), front and rear
Planetary, brake housing, and front wheel motor
mounting screw torque
75 to 85 ft−lb (101 to 115 N−m)
Planetary gear drive oil
System gear lube capacity (each wheel)
SAE 85W−140 wt. gear lube
16 fl oz (.47 l)
Rear axle lubricant
System gear lube capacity
SAE 85W−140 wt. gear lube
80 fl oz (2.37 l)
Rear axle gear box lubricant
System gear lube capacity
SAE 85W−140 wt. gear lube
16 fl oz (.47 l)
Axles, Planetaries, and Brakes
Page 6 − 2
Groundsmaster 4100−D
Adjustments
Axles, Planetaries,
and Brakes
See Operator’s Manual for adjustment procedures for
Groundsmaster 4100−D axles, planetaries, and brakes.
Groundsmaster 4100−D
Page 6 − 3
Axles, Planetaries, and Brakes
Service and Repairs
Brake Assembly
85 to 100 ft−lb
(115 to 135 N−m)
13
14
2
12
6
1
75 to 85 ft−lb
(101 to 115 N−m)
3
11
4
17
5
16
5
7
8
18
15
3
6
RIGHT
9
10
FRONT
75 to 85 ft−lb
(101 to 115 N−m)
11
2
1
Figure 1
1.
2.
3.
4.
5.
6.
Planetary assembly
Retaining ring
Splined brake coupler
Brake assembly (RH)
O−ring
Hydraulic wheel motor
7.
8.
9.
10.
11.
12.
Flat washer
Cap screw (2 used per side)
Flange head screw (4 used per side)
Brake assembly (LH)
Gasket
Flange head screw (6 used per side)
13.
14.
15.
16.
17.
18.
Tire and wheel assembly
Lug nut (8 used per wheel)
Jam nut
Compression spring
Spring plate
Brake cable
2. Drain oil from planetary wheel drive/brake assembly
(see Operator’s Manual).
Remove Brake Assembly (Fig. 1)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
Axles, Planetaries, and Brakes
Page 6 − 4
Groundsmaster 4100−D
CAUTION
WARNING
When changing attachments, tires, or performing other service, use correct blocks, hoists,
and jacks. Make sure machine is parked on a
solid, level surface such as a concrete floor.
Prior to raising machine, remove any attachments that may interfere with the safe and
proper raising of the machine. Always chock or
block wheels. Use jack stands or solid wood
blocks to support the raised machine. If the machine is not properly supported by blocks or
jack stands, the machine may move or fall,
which may result in personal injury.
3. Chock rear wheels and jack up front of machine (see
Jacking Instructions in Chapter 1 − Safety). Support machine with jack stands or solid wood blocks.
Failure to maintain proper torque could result
in failure or loss of wheel and may result in
personal injury.
6. Install wheel assembly. Torque lug nuts from 85 to
100 ft−lb (115 to 135 N−m).
7. Lower machine to ground.
8. Make sure drain plug is installed in bottom of brake
assembly (Fig. 3). Fill planetary wheel drive/brake assembly with SAE 85W−140 gear lube (see Operator’s
Manual). Capacity is approximately 16 oz. (.47 l) per
wheel.
9. Check and adjust brake cable for proper brake operation (see Operator’s Manual).
4. Remove wheel assembly.
5. Remove hydraulic wheel motor (see Front Wheel
Motors in Service and Repairs section of Chapter 4 −
Hydraulic System).
3
2
6. Disconnect brake cable from pull rod on brake assembly.
8. Remove splined brake coupler.
1
Figure 2
1. Brake coupler step
2. Hydraulic motor end
3. Planetary assembly end
Axles, Planetaries,
and Brakes
7. Remove four (4) flange head screws (9) securing
brake assembly to machine. Remove brake assembly
taking care not to drop splined brake coupler as brake
assembly is removed.
9. Complete brake inspection and repair.
Install Brake Assembly (Fig. 1)
1
1. Slide splined brake coupler into brake assembly.
Note: The stepped end of the coupler must be installed
toward the hydraulic wheel motor (Fig. 2).
2
2. Position brake assembly to frame, aligning splined
brake coupler with input shaft on planetary wheel drive.
3. Install four (4) flange head screws to secure brake
assembly to frame. Torque screws in a crossing pattern
from 75 to 85 ft−lb (101 to 115 N−m).
3
4. Install brake cable to pull rod on brake assembly.
Brake cable end should be completely threaded onto
pull rod.
5. Install new o−ring on hydraulic wheel motor. Install
wheel motor and torque cap screws from 75 to 85 ft−lb
(101 to 115 N−m).
Groundsmaster 4100−D
Figure 3
1. Brake housing
2. Check plug
Page 6 − 5
3. Drain plug
Axles, Planetaries, and Brakes
Brake Inspection and Repair
3
2
1
4
5
5
6
7
8
7
8
7
15
10
14
13
12
11
7
8
9
Figure 4
1.
2.
3.
4.
5.
Brake housing (LH shown)
Seal
Pull rod
Clevis pin (2 used)
Link
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Hitch pin (2 used)
Stationary disc
Rotating disc
Retaining ring
Gasket
Rotating actuator
Extension spring (3 used)
Ball (3 used)
Plug
O−ring
Brake Inspection and Repair (Fig. 4)
6. Remove seal (2) from brake housing.
1. Scrape gasket material (10) from brake housing and
planetary wheel drive mounting surfaces.
7. Wash parts in cleaning solvent. Inspect components
for wear or damage.
A. The stack of four stationary and three rotating
discs should have a minimum thickness of .440”
(11.2 mm).
2. Remove retaining ring (9).
3. Remove four stationary discs (7) and three rotating
discs (8).
4. Remove three extension springs (12).
8. Reverse steps 2 − 6 to assemble brakes, installing
new parts as necessary. Install a new seal (2).
5. Remove actuator assembly (11, 6, 5, 4, 3) and balls
(13).
9. Use a new gasket (10) when installing brake assembly to machine.
Axles, Planetaries, and Brakes
Page 6 − 6
Groundsmaster 4100−D
Axles, Planetaries,
and Brakes
This page is intentionally blank.
Groundsmaster 4100−D
Page 6 − 7
Axles, Planetaries, and Brakes
Planetary Wheel Drive Assembly
85 to 100 ft−lb
(115 to 135 N−m)
13
14
2
12
6
1
75 to 85 ft−lb
(101 to 115 N−m)
3
11
4
5
5
7
8
3
6
RIGHT
9
10
FRONT
75 to 85 ft−lb
(101 to 115 N−m)
11
2
1
Figure 5
1.
2.
3.
4.
5.
Planetary assembly
Retaining ring
Splined brake coupler
Brake assembly (RH)
O−ring
Axles, Planetaries, and Brakes
6.
7.
8.
9.
10.
Hydraulic wheel motor
Flat washer
Cap screw (2 used per side)
Flange head screw (4 used per side)
Brake assembly (LH)
Page 6 − 8
11.
12.
13.
14.
Gasket
Flange head screw (6 used per side)
Tire and wheel assembly
Lug nut (8 used per wheel)
Groundsmaster 4100−D
Planetary Wheel Drive Removal (Fig. 5)
1. Park machine on a level surface, lower cutting unit,
stop engine, engage parking brake, and remove key
from the ignition switch.
4. Secure hydraulic wheel motor to planetary assembly
with two (2) cap screws. Torque screws from 75 to 85 ft−
lb (101 to 115 N−m).
WARNING
2. Drain oil from planetary wheel drive/brake assembly
(see Operator’s Manual).
Failure to maintain proper wheel lug nut
torque could result in failure or loss of wheel
and may result in personal injury.
CAUTION
When changing attachments, tires, or performing other service, use correct blocks, hoists,
and jacks. Make sure machine is parked on a
solid, level surface such as a concrete floor.
Prior to raising machine, remove any attachments that may interfere with the safe and
proper raising of the machine. Always chock or
block wheels. Use jack stands or solid wood
blocks to support the raised machine. If the machine is not properly supported by blocks or
jack stands, the machine may move or fall,
which may result in personal injury.
5. Install wheel assembly. Torque lug nuts from 85 to
100 ft−lb (115 to 135 N−m).
6. Lower machine from jack stands.
7. Make sure drain plug is installed in bottom of brake
assembly (Fig. 6). Fill planetary wheel drive/brake assembly with SAE 85W−140 gear lube (see Operator’s
Manual). Capacity is approximately 16 oz. (.47 l) per
wheel.
8. Check for proper brake operation (see Operator’s
Manual).
3. Chock rear wheels and jack up front of machine (see
Jacking Instructions in Chapter 1 − Safety). Support machine with jack stands or solid wood blocks.
2
1
5. Remove four (4) flange head screws that secure
brake assembly to planetary assembly (see Brake Assembly in this Chapter).
3
6. Support hydraulic wheel motor to prevent it from falling. Remove two (2) cap screws that secure wheel motor to planetary assembly.
4
7. Support planetary assembly to prevent it from falling.
Loosen and remove flange head screws that secure
planetary assembly to frame. Remove planetary assembly from machine.
5
Figure 6
1. Brake housing
2. Wheel motor cap screw
3. Brake flange screw
Planetary Wheel Drive Installation (Fig. 5)
4. Planetary flange screw
5. Brake drain plug
1. Inspect gasket between brake and planetary assemblies. Replace as needed.
2. Position planetary assembly to machine. Install
flange head screws that secure planetary assembly to
frame. Torque screws from 75 to 85 ft−lb (101 to 115
N−m).
3. Secure brake assembly to planetary assembly with
four (4) flange head screws (see Brake Assembly in this
Chapter). Torque screws from 75 to 85 ft−lb (101 to 115
N−m).
Groundsmaster 4100−D
Page 6 − 9
Axles, Planetaries, and Brakes
Axles, Planetaries,
and Brakes
4. Remove front wheel assembly.
Planetary Wheel Drive Service
2
24
9 ft−lb
(12 N−m)
3
19
20
6
7
1
8
21
9
10
4
11
5
23
18
17
12
16
15
22
14
25
13
Figure 7
1.
2.
3.
4.
5.
6.
7.
8.
9.
Spindle
Boot seal
Bearing cone
Bearing cup
Wheel stud (8 used)
Housing
Bearing cup
Bearing cone
Thrust washer
Axles, Planetaries, and Brakes
10.
11.
12.
13.
14.
15.
16.
17.
Retaining ring (external)
Ring gear
Retaining ring (internal)
Plug (2 used)
End cap
Thrust plug
Thrust washer
Drive shaft
Page 6 − 10
18.
19.
20.
21.
22.
23.
24.
25.
Carrier assembly
Socket head screw (16 used)
Lock washer (16 used)
O−ring
O−ring
Dowel pin (2 used)
Seal
O−ring
Groundsmaster 4100−D
Planetary Wheel Drive Disassembly (Figure 7)
Planetary Wheel Drive Assembly (Figure 7)
1. Remove retaining ring (12).
NOTE: Use new seal kit when assembling planetary
wheel drive.
2. Remove end cap (14). Thrust plug (15) and thrust
washer (16) are captive on inside of end cap.
1. Clean parts in solvent. Inspect parts for damage or
excessive wear and replace as necessary.
3. Remove drive shaft (17).
2. If spindle and housing were separated:
4. Remove carrier assembly (18).
A. Install boot seal (2) to spindle (1).
NOTE: Steps 6 −10 are necessary only if inspecting or
replacing bearings and/or seals.
B. Press bearing cups (4 and 7) into housing (6).
C. Install bearing cone (3) onto spindle (1).
5. Remove socket head screws (19) with lock washers
(20) and remove ring gear (11).
6. Remove retaining ring (10) and thrust washer (9).
D. Install seal (24) to housing (6). Assemble housing
(6) to spindle (1).
7. Remove spindle (1) from housing (6). Remove bearing cone (8).
E. Install bearing cone (8) onto spindle and secure
with thrust washer (9) and retaining ring (10).
8. Remove and discard all seals.
F. After retaining ring is installed, make sure that
there is minimal endplay in assembly. If required,
thrust washer options are identified in the parts
manual.
9. If bearings will be replaced, remove bearing cone (3)
from spindle. Remove bearing cups (4 and 7) from housing (6).
G. Install o−ring (21) and then assemble ring gear
(11) to housing (6) with lock washers (20) and socket
head screws (19). Torque socket head screws to 9 ft−
lb (12 N−m).
3. Install carrier assembly (18).
5. Install thrust washer (16) and thrust plug (15).
6. Make sure that thrust plug (15) and thrust washer
(16) are captive on inside of end cap. Install o−ring (22)
to end cap and then install end cap (14). Secure cap with
retaining ring (12).
7. Check operation of planetary wheel drive before
installing assembly on the machine. With a constant
turning force applied, rotation of the planetary should be
consistent. If there is more drag at certain points, gears
are not rolling freely and the planetary should be examined for improper assembly or damaged components.
Groundsmaster 4100−D
Page 6 − 11
Axles, Planetaries, and Brakes
Axles, Planetaries,
and Brakes
4. Install drive shaft (17).
Rear Axle Assembly
18
17
16
2
3
RIGHT
70 ft−lb maximum
(94 N−m maximum)
FRONT
19
7
15
14
13
12
5
11
10
4
9
8
6
1
Figure 8
1.
2.
3.
4.
5.
6.
7.
Frame
Cap screw (6 used)
Flat washer
Bulkhead lock nut (2 used)
Washer
Thrust washer (thick)
Grease fitting (2 used)
8.
9.
10.
11.
12.
13.
Rear axle assembly
Thrust washer (thin)
Washer head screw
Pivot pin
Rear frame mount
Washer
Remove Rear Axle
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
CAUTION
Lock nut
Flange nut
Rear bumper
Hydraulic manifold (4WD)
Cap screw (2 used)
Flange nut
2. Chock front wheels and jack up rear of machine (see
Jacking Instructions in Chapter 1 − Safety). Support machine with jack stands or solid wood blocks.
3. Drain oil from rear axle and axle gearbox (see Operator’s Manual).
4. Remove wheels from rear axle.
When changing attachments, tires, or performing other service, use correct blocks, hoists,
and jacks. Make sure machine is parked on a
solid, level surface such as a concrete floor.
Prior to raising machine, remove any attachments that may interfere with the safe and
proper raising of the machine. Always chock or
block wheels. Use jack stands or solid wood
blocks to support the raised machine. If the machine is not properly supported by blocks or
jack stands, the machine may move or fall,
which may result in personal injury.
Axles, Planetaries, and Brakes
14.
15.
16.
17.
18.
19.
5. Remove hydraulic motor from rear axle assembly
(see Rear Axle Motor in Service and Repairs section of
Chapter 4 − Hydraulic System).
6. Remove steering cylinder from rear axle (see Steering Cylinder in Service and Repairs section of Chapter
4 − Hydraulic System).
7. Disconnect both steering cylinder hydraulic hoses
from hydraulic tubes at rear frame mount (Fig. 9). Remove bulkhead locknuts and washers that secure steering cylinder hydraulic tubes to rear frame mount.
Separate tubes from frame mount.
Page 6 − 12
Groundsmaster 4100−D
8. Remove cap screw and flange nut that secures front
corner of 4WD hydraulic manifold to rear frame mount.
1
2
3
9. If required, remove tie rod ends from steering arms
on rear axle (Fig. 10). Remove the cotter pins and castle
nuts from the tie rod ball joints. Use a ball joint fork and
remove the tie rod ends from the axle steering arms.
10.Support rear axle to prevent it from falling. Remove
six cap screws, flat washers, and flange nuts that secure
rear frame mount to equipment frame. Lower rear axle
and rear frame mount from machine.
5
11. Remove lock nut and washer from pivot pin that attaches rear axle to rear frame mount. Remove washer
head screw that secures flange of pivot pin to frame
mount (Fig. 11).
Figure 9
Install Rear Axle
4
1. Position rear frame mount to axle. Install thrust
washers between axle boss and frame mount. The thinner thrust washer should be installed on the hydraulic
motor end of the axle (toward the rear of the machine).
With washers installed, there should be .002” to .020”
(.05 mm to .51 mm) clearance between rear frame
mount and axle mounting boss. Add thrust washers if
needed to adjust clearance.
2. Install axle pivot pin to secure axle to rear frame
mount. Install washer and lock nut onto pivot pin. Lock
nut should be tightened enough to allow pivot pin to rotate (70 ft−lb (94 N−m) maximum). Secure pivot pin to
frame mount with washer head screw (Fig. 11).
3. If removed, install the tie rod to rear axle (Fig. 10).
Tighten ball joint castle nuts and install new cotter pins.
4. Hydraulic tube
5. Rear frame mount
1. Hydraulic hose
2. Hydraulic hose
3. Hydraulic tube
2
3
5
1
6
Figure 10
4. Castle nut
5. Tie rod end
6. Steering arm (LH)
1. Tie rod
2. Dust cover
3. Cotter pin
4. Position axle and rear mount under machine with a
jack. Raise assembly to machine frame and align
mounting holes of rear mount and machine frame.
2
1
5. Secure rear mount to frame with six cap screws, flat
washers, and flange nuts.
6. Install cap screw and flange nut that secures front
corner of 4WD hydraulic manifold to rear frame mount.
7. If removed, install the tie rod to rear axle. Tighten ball
joint castle nuts and install new cotter pins.
Figure 11
1. Pivot pin
2. Washer head screw
8. Attach steering cylinder hydraulic tubes to rear frame
mount with washers and bulkhead locknuts (Fig. 9).
Install steering cylinder hoses to hydraulic tubes.
Groundsmaster 4100−D
Page 6 − 13
Axles, Planetaries, and Brakes
Axles, Planetaries,
and Brakes
12.Remove pivot pin. Separate rear frame mount from
rear axle. Note location of thrust washers on both ends
of axle mounting boss.
4
9. Install steering cylinder to axle assembly (see Steering Cylinder in Service and Repairs section of Chapter
4 − Hydraulic System).
10.Install hydraulic motor to axle assembly (see Rear
Axle Motor in Service and Repairs section of Chapter 4
− Hydraulic System).
1
2
WARNING
Failure to maintain proper wheel lug nut
torque could result in failure or loss of wheel
and may result in personal injury.
11. Install wheels to axle. Torque wheel lug nuts from 85
to 100 ft−lb (115 to 135 N−m).
Figure 12
1. Steering stop bolt
2. Bevel gear case (LH)
12.Lower machine to ground.
13.Fill axle and input gearbox with SAE 85W−140
weight gear lube (see Operator’s Manual). Lubricant capacity is approximately 80 fl oz (2.37 l) for the axle and
16 fl oz (.47 l) for the gearbox.
14.Check rear wheel toe−in and adjust if necessary (see
Operator’s Manual).
15.Check steering stop bolt adjustment. When the
steering cylinder is fully extended (right turn), a gap of
1/16” (1.6 mm) should exist between bevel gear case
casting and stop bolt on left axle case. Figure 12 shows
stop bolt location.
Axles, Planetaries, and Brakes
Page 6 − 14
Groundsmaster 4100−D
Bevel Gear Case and Axle Case
The following procedures assume the rear axle assembly has been removed from the machine.
35 to 41 ft−lb
(47 to 56 N−m)
Removal
1
6
5
1. Remove the mounting screws, nuts, and lock washers. Remove the bevel gear case/axle case assembly
and O-ring from the axle support (Fig. 13).
4
2
2. Mark both right and left bevel gear case/axle case
assemblies.
3
35 to 41 ft−lb
(47 to 56 N−m)
IMPORTANT: Do not interchange right and left bevel gear case/axle case assemblies.
Figure 13
1.
2.
3.
4.
5. Bevel gear case/axle
case assembly
6. O-ring
Cap screw (4 used)
Lock nut (2 used)
Lock washer (2 used)
Axle support
3. Remove the axle cover mounting screws. Remove
the axle cover from the axle case as an assembly
(Fig. 14).
17 to 20 ft−lb
(23 to 27 N−m)
1
4
2
Figure 14
1. Axle case
2. Axle cover assembly
4. Remove the axle case support mounting screws, the
axle case support, and the support shims (Fig. 15).
3. Mounting screw (6 used)
4. O-ring
Threadlocking
Compound
3
2
57 to 67 ft−lb
(77 to 91 N−m)
4
1
Figure 15
1. Axle case
2. Axle case support
Groundsmaster 4100−D
Page 6 − 15
3. Mounting screw (2 used)
4. Support shim
Axles, Planetaries, and Brakes
Axles, Planetaries,
and Brakes
3
5. Remove the knuckle pin mounting screws and the
knuckle pin. Remove the gasket and any remaining gasket material from either mating surface (Fig. 16).
6. While holding the bevel gear case, tap the upper end
of the bevel gear shaft out of the upper bearing and upper bevel gear.
2
1
17 to 20 ft−lb
(23 to 27 N−m)
3
4
Threadlocking
Compound
7. Pull the bevel gear case from the axle case and remove the upper bevel gear, and collar from the gear
case.
5
14
8. Remove the axle case cover screws, cover, and the
O-ring from the axle case.
7
15
8
9. Remove the plug and sealing washer from the center
of the axle case cover. While holding the axle case cover, lightly tap the lower end of the bevel gear shaft out of
the lower bearing and lower bevel gear.
11
6
10.Remove and discard bevel gear shaft seal from axle
case (Fig. 16).
13
9
12
10
17 to 20 ft−lb
(23 to 27 N−m)
Figure 16
1.
2.
3.
4.
5.
6.
7.
8.
Knuckle pin
Mounting screw (4 used)
O−ring
Bevel gear case
Upper bearing
Bevel gear shaft
Collar
Upper bevel gear
9.
10.
11.
12.
13.
14.
15.
Lower bevel gear
Lower bearing
Axle case
Axle case cover
O-ring
Shaft seal
Bushing
Inspection
1. Measure the knuckle pin O.D. and the axle case support bushing I.D. to determine the bushing to pin clearance (Fig. 17). Replace components as necessary.
1
2
BUSHING TO PIN CLEARANCE:
0.002 to 0.016 in. (0.05 to 0.40 mm)
KNUCKLE PIN O.D. (Factory Spec.):
0.982 to 0.983 in. (24.95 to 24.98 mm)
AXLE CASE SUPPORT BUSHING I.D.
(Factory Spec.):
0.984 to 0.987 in. (25.00 to 25.08 mm)
Figure 17
2. Inspect all gears, shafts, bearings, cases, and covers for damage and wear. Replace components as necessary.
Axles, Planetaries, and Brakes
1. Knuckle pin
Page 6 − 16
2. Axle case support
Groundsmaster 4100−D
Installation
1. Coat new shaft seal with grease and install in axle
case as shown (Fig. 18).
3
2
1
Figure 18
1. Axle case
2. Bevel gear case
2. Install the lower bevel gear, and bevel gear shaft in
the axle case cover. Coat a new O-ring with grease and
install the axle case cover (Fig. 19). Tighten cover
screws from 17 to 20 ft-lb (23 to 27 N−m).
3. Shaft seal
7
8
3. Slide the bevel gear case over the bevel gear shaft
and install the bevel gear and collar. Make sure the bevel
gear shaft is completely seated in the upper and lower
bearings (Fig. 19).
6
4. Install the knuckle pin. Use medium strength Loctite
thread locker and tighten the knuckle pin mounting
screws from 17 to 20 ft-lb (23 to 27 N−m).
5
2
1
4
Figure 19
1.
2.
3.
4.
Groundsmaster 4100−D
Page 6 − 17
Axle case cover
Lower bevel gear
Bevel gear shaft
Lower bearing
5.
6.
7.
8.
Upper bevel gear
Collar
Upper bearing
Knuckle pin
Axles, Planetaries, and Brakes
Axles, Planetaries,
and Brakes
3
5. Determine necessary quantity of support shims.
4
A. Lubricate the axle case support bushing with a
thin coat of grease and slide axle case support onto
knuckle pin.
B. Position support shims that were removed during
disassembly between axle case support and axle
case. Install mounting screws into axle case. Slowly
tighten screws while frequently checking for clearance (vertical endplay) between axle case support
and knuckle pin. 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. Use dial indicator to measure vertical endplay of
axle case (Fig. 20).
57 to 67 ft−lb
(77 to 91 N−m)
1
VERTICAL
ENDPLAY
6
5
2
3
Figure 20
4. Dial indicator
5. Knuckle pin
6. Support shim location
1. Axle case support
2. Axle case
3. Bevel gearcase
AXLE CASE ASSEMBLY ENDPLAY:
0.001 to 0.008 in. (0.02 to 0.20 mm)
3
D. Adjust endplay by increasing or reducing number
of axle case support shims.
2
1
NOTE: Axle case support shims are available in
0.004 in. (0.1 mm), 0.008 in. (0.2 mm), and 0.016 in.
(0.4 mm) thickness.
4
6. After correct support shims have been determined,
remove mounting screws, apply heavy strength thread−
locking compound to screw threads, reinstall screws,
and torque from 57 to 67 ft−lb (77 to 91 N−m).
5
IMPORTANT: Correct engagement between bevel
gears is critical to axle performance and durability.
7. Temporarily install the bevel gear case/axle case assembly on the axle support. Position a dial indicator at
the tooths center. Prevent the axle from turning and
measure the upper bevel gear to differential shaft gear
backlash (Fig. 21).
Figure 21
1. Axle support
2. Upper bevel gear
3. Differential shaft gear
4. Dial indicator
5. Axle bearing shims
4
UPPER BEVEL GEAR BACKLASH:
0.004 to 0.016 in. (0.10 to 0.40 mm)
5
1
8. Adjust backlash by increasing or reducing axle bearing shim thickness (see Differential Shafts in this section
of this manual).
NOTE: Axle bearing shims are available in 0.004 in.
(0.1 mm), 0.008 in. (0.2 mm), and 0.020 in. (0.5 mm)
thickness.
2
3
Figure 22
1. Axle cover assembly
2. Lower bevel gear
3. Axle gear
Axles, Planetaries, and Brakes
Page 6 − 18
4. Dial indicator
5. Axle bearing shims
Groundsmaster 4100−D
9. Remove the bevel gear case/axle case assembly
from the axle support. Coat a new O-ring with grease
and temporarily install the axle cover assembly. Position
a dial indicator at the tooths center. Prevent the axle
from turning and measure the lower bevel gear to axle
gear backlash (Fig. 22).
LOWER BEVEL GEAR BACKLASH:
0.004 to 0.016 in. (0.10 to 0.40 mm)
11. Tighten axle cover screws from 17 to 20 ft-lb (23 to
27 N−m).
12.Coat a new O-ring with grease and install the bevel
gear case/axle case assembly on the axle support.
Tighten mounting screws and nuts from 35 to 41 ft-lb (47
to 56 N−m) (Fig. 13).
Axles, Planetaries,
and Brakes
10.Adjust backlash by increasing or reducing axle bearing shim thickness (see Axle Shafts in this section of this
manual).
NOTE: Axle bearing shims are available in 0.008 in.
(0.2 mm), 0.012 in. (0.3 mm), and 0.020 in. (0.5 mm)
thickness.
Groundsmaster 4100−D
Page 6 − 19
Axles, Planetaries, and Brakes
Differential Shafts
The following procedures assume the rear axle assembly has been removed from the machine.
35 to 41 ft−lb
(47 to 56 N−m)
Removal
1
6
IMPORTANT: Do not interchange right and left differential shaft assemblies.
1. Remove the mounting screws, nuts, and lock washers. Remove the bevel gear case/axle case assembly
and O-ring from the axle support (Fig. 23).
4
2
3
4. Drive the differential shaft out of the bearings. Remove the bearings and bearing shims.
7
35 to 41 ft−lb
(47 to 56 N−m)
2. Mark and pull the differential shaft assembly from the
axle support.
3. Remove the retaining ring and bevel gear (Fig 24).
5
Figure 23
1.
2.
3.
4.
Cap screw (4 used)
Lock nut (2 used)
Lock washer (2 used)
Axle support
5. Bevel gear/axle case
assembly
6. O-ring
7. Stud (2 used)
5. Inspect all gears, shafts, bearings, and cases for
damage and wear. Replace components as necessary.
Installation
1. Press bearings onto differential shaft. Place correct
combination of bearing shims in axle support and drive
differential shaft and bearing assembly into axle support.
6
3
5
4
2
1
2. Install bevel gear and retaining ring.
3. Coat new O-ring with grease. Align differential shaft
splines with differential gear assembly and slide differential shaft assembly onto axle support.
4. Install bevel gear case/axle case assembly (see
Bevel Gear Case/Axle Case Assembly in this section of
this manual).
Axles, Planetaries, and Brakes
Figure 24
1. Retaining ring
2. Bevel gear
3. Differential shaft
Page 6 − 20
4. Bearing
5. Bearing shims
6. O-ring
Groundsmaster 4100−D
Axle Shafts
The following procedures assume the rear axle assembly has been removed from the machine.
17 to 20 ft−lb
(23 to 27 N−m)
1
Removal
4
3
1. Remove the axle cover mounting screws. Remove
the axle cover from the axle case as an assembly
(Fig. 25).
2. Use a bearing puller to remove the bearing and bevel
gear as shown (Fig. 26).
2
3. Remove the shims, spacer, and retaining ring. Drive
the axle out of the bearing and cover. Remove and discard the axle shaft seal.
Figure 25
1. Axle case
2. Axle cover assembly
3. Mounting screw (6 used)
4. O-ring
4. Inspect all gears, shafts, bearings, spacers, and
cases for damage and wear. Replace components as
necessary.
Installation
1
1. Coat new axle shaft seal with grease and install in
axle cover as shown (Fig. 27).
2
2. Press the axle cover and bearing assembly onto the
axle shaft. Press only on the inner race of the cover
bearing (Fig. 27).
4
3
5
4. Coat a new O-ring with grease and install the axle
cover assembly. Tighten axle cover screws from 17 to 20
ft-lb (23 to 27 N−m).
Figure 26
1. Bearing
2. Bevel gear
3. Bearing shims
4. Spacer
5. Retaining ring
1
4
2
3
Figure 27
1. Axle shaft seal
2. Axle cover
Groundsmaster 4100−D
Page 6 − 21
3. Bearing
4. Axle shaft
Axles, Planetaries, and Brakes
Axles, Planetaries,
and Brakes
3. Install retaining ring, spacer, and correct combination of bearing shims. Install bevel gear and bearing.
Input Shaft/Pinion Gear
1
35 to 41 ft−lb
(47 to 56 N−m)
3
2
18
17
4
5
7
8
6
16
18
9
15
10
14
10
9
13
35 to 41 ft−lb
(47 to 56 N−m)
11
12
Figure 28
1.
2.
3.
4.
5.
6.
Nut (2 used)
Lockwasher (2 used)
Stud (2 used)
Locknut
Stake washer
Oil seal
7.
8.
9.
10.
11.
12.
O-ring
Seal collar
Bearing
O-ring
Input shaft/pinion gear
Bearing case
13.
14.
15.
16.
17.
18.
Shim
Screw (2 used)
Gear case
Gasket
Cover plate
Dowel pin
The following procedures assume the rear axle assembly has been removed from the machine.
NOTE: Replacement input shaft/pinion gears are only
available in matched ring and pinion sets.
Removal
Installation
1. Remove the cover plate, gasket, and gear case assembly from the axle assembly. Remove the gasket and
any remaining gasket material.
NOTE: When installing new bearing cones, press only
on the inner race of the bearing cone.
2. Remove the retaining rings and the driven gear from
the input shaft/pinion gear.
3. Remove input shaft/pinion gear assembly from the
gear case. Remove the shims and bearing case Orings.
4. Release the stake washer and remove the locknut.
Remove and discard the stake washer.
5. Drive the input shaft/pinion gear out from the outer
bearing cone and bearing case. Remove and discard
the oil seal and O-ring.
6. Inspect all gears, shafts, bearings, spacers, and
cases for damage and wear. Replace components as
necessary.
Axles, Planetaries, and Brakes
1. If the inner bearing cone was removed, press a new
bearing cone all the way onto the input shaft/pinion gear.
2. Place the shaft and bearing assembly in the bearing
case and install the outer bearing cone.
NOTE: The bearings must be completely seated.
There should be no input shaft/pinion gear end play.
3. Coat a new oil seal with grease and install as shown
(Fig. 29). The seal should be installed with the garter
spring towards the hydraulic motor.
4. Coat new O-ring with grease. Install O-ring in the oil
seal collar, and install the collar.
5. Install a new stake washer. Install the lock nut finger
tight.
Page 6 − 22
Groundsmaster 4100−D
6. Set the bearing preload by securing the bearing case
in a vise. Thread a M12 x 1.5 hex head cap screw into
the splined end of the input shaft/pinion gear and slowly
tighten the locknut until 4 to 6 in-lb (0.4 to 0.7 N−m) of
force is required to rotate the input shaft/pinion gear in
the bearing case.
0.040 in. (1.0 mm)
7. Secure the lock nut with the stake washer.
2
1
8. Use a depth gauge to measure the distance from the
end face of the input shaft/pinion gear to the mating surface of the bearing case. Subtract the “Design Cone
Center Distance” from this distance to determine initial
shim thickness (Fig. 30).
DESIGN CONE CENTER DISTANCE (distance
from mating surface of axle support to end face of
pinion gear):
1.870 + 0.002 in. (47.5 + 0.05 mm)
3
Figure 29
1. Oil seal
2. Bearing case
3. Seal garter spring
NOTE: Bearing case shims are available in 0.004 in.
(0.1 mm) and 0.008 in. (0.2 mm) thickness.
1
9. Coat new O-rings with grease and install the bearing
case in the gear case. Place shims on the gear case and
temporarily install gear case assembly into axle case.
Tighten mounting nuts and screws from 35 to 41 ft-lb (47
to 56 N−m).
Design
Cone Center
Distance
10.Insert a screwdriver through the drain plug hole to
hold ring gear and measure the pinion gear to ring gear
backlash (Fig. 31).
2
11. Adjust backlash by increasing or reducing gear case
shim thickness.
Axles, Planetaries,
and Brakes
PINION GEAR TO RING GEAR BACKLASH:
0.004 to 0.016 in. (0.10 to 0.40 mm)
Figure 30
1. Input shaft/pinion gear
2. Bearing case
12.Check pinion gear to ring gear engagement (see Pinion Gear to Ring Gear Engagement in this section of this
manual).
1
13.Place the correct combination of shims on the gear
case. Tighten mounting nuts and screws from 35 to 41
ft-lb (47 to 56 N−m).
3
2
14.Install retaining rings and driven gear on input shaft/
pinion gear.
15.If the drive gear (on drive motor shaft) was removed,
install the retaining rings and drive gear on the motor
shaft.
16.Use a new gasket and install the cover plate. Use a
new O-ring and install the drive motor.
Groundsmaster 4100−D
4
Figure 31
1. Axle case
2. Screwdriver
Page 6 − 23
3. Dial indicator
4. Input shaft/pinion gear
Axles, Planetaries, and Brakes
Differential Gear
The following procedures assume the rear axle assembly has been removed from the machine.
35 to 41 ft−lb
(47 to 56 N−m)
5
Removal
1
2
6
1. Remove bevel gear case/axle case assemblies (see
Bevel Gear Case/Axle Case Assembly in this section of
this manual).
IMPORTANT: Do not interchange right and left differential shafts assemblies.
7
4
2. Mark and pull the differential shaft assemblies from
the axle support.
3
35 to 41 ft−lb
(47 to 56 N−m)
3. Remove input shaft/pinion gear assembly, shims,
and O-ring from the axle support (Fig. 32).
4. Remove the axle support case screws. Separate the
axle support halves and remove the O-ring.
Figure 32
1.
2.
3.
4.
5. Case screw (8 used)
6. Differential gear
7. O-ring
Gear Case
Pinion Gear
Axle support (left)
Axle support (right)
5. Remove the differential gear assembly, bearings,
and adjusting shims from the axle case.
2
6. Drive the spring pin from the differential case with a
punch and hammer. Discard the spring pin (Fig. 33).
1
NOTE: Mark and arrange all components so they can
be reassembled in their original position.
7. Remove the differential pinion shaft, pinion gears,
and pinion washers. Remove the differential side gears
and side gear shims. Remove the ring gear only if it will
be replaced (Fig. 34).
NOTE: Replacement ring gears are only available in
matched ring and pinion sets.
Figure 33
1. Differential case
2. Spring pin
1
3
2
5
22 to 25 ft−lb
(30 to 34 N−m)
4
4
5
2
3
8
Threadlocking
Compound
7
6
Figure 34
1.
2.
3.
4.
Axles, Planetaries, and Brakes
Page 6 − 24
Differential pinion shaft
Pinion gear
Pinion washer
Side gear
5.
6.
7.
8.
Side gear shims
Ring gear
Differential case
Bolt/washer (8 used)
Groundsmaster 4100−D
Inspection
1. Measure the differential side gear O.D. and the differential case I.D. to determine the side gear to case
clearance (Fig. 35). Replace components as necessary.
SIDE GEAR TO CASE CLEARANCE:
0.002 to 0.012 in. (0.05 to 0.30 mm)
1
SIDE GEAR O.D. (Factory Spec.):
1.335 to 1.337 in. (33.91 to 33.95 mm)
DIFFERENTIAL CASE I.D. (Factory Spec.):
1.339 to 1.341 in. (34.00 to 34.06 mm)
2
2. Measure the differential pinion shaft O.D. and the
pinion gear I.D. to determine the pinion shaft to pinion
gear clearance (Fig. 36). Replace components as necessary.
PINION SHAFT TO PINION GEAR CLEARANCE:
0.001 to 0.010 in. (0.03 to 0.25 mm)
PINION SHAFT O.D. (Factory Spec.):
0.550 to 0.551 in. (13.97 to 13.10 mm)
Figure 35
1. Side gear
2. Differential case
PINION GEAR I.D. (Factory Spec.):
0.551 to 0.552 in. (13.10 to 14.02 mm)
Axles, Planetaries,
and Brakes
3. Inspect all gears, shafts, bearings, cases, and covers for damage and wear. Replace components as necessary.
1
2
Figure 36
1. Pinion shaft
Groundsmaster 4100−D
Page 6 − 25
2. Pinion gear
Axles, Planetaries, and Brakes
Installation
3
1. If the ring gear was removed, use medium strength
thread locking compound and tighten the mounting
screws from 22 to 25 ft-lb (30 to 34 N−m).
2
1
2. Apply molybdenum disulfide grease to the splines
and bearing surfaces of the differential pinion gears, pinion washers, and side gears.
3. Install the side gear shims and side gears in their
original location in the differential case.
4. Place the differential pinion gears and pinion washers in their original location in the differential case. Temporarily install the differential pinion shaft.
5. Secure the differential case in a vise. Position a dial
indicator at the tooths center and measure the differential pinion gear to side gear backlash (Fig. 37).
Figure 37
1. Vise
2. Differential gear case
3. Dial indicator
More than 35% total tooth contact
PINION GEAR TO SIDE GEAR BACKLASH:
0.004 to 0.016 in. (0.10 to 0.40 mm)
6. Adjust backlash by increasing or reducing side gear
shim thickness.
NOTE: Side gear shims are available in 0.043 in. (1.1
mm), 0.047 in. (1.2 mm), and 0.051 in. (1.3 mm) thickness.
1/3 to 1/2 of entire width
from small end of tooth
Figure 38
7. Apply gear marking compound, such as DyKem
Steel Blue lightly over several gear teeth.
8. While applying a light load to either side gear, rotate
either pinion gear until the side gears have made one
complete revolution.
9. Ideal tooth contact should cover more than 35% of
each tooth surface. The contact area should be in the
center of each tooth and extend 1/3 to 1/2 way across
each tooth from the toe (small) end (Fig. 38).
10.Adjust side gear shims if necessary to correct tooth
contact. Recheck differential pinion gear to side gear
backlash if any changes are made.
11. After backlash and tooth contact have been adjusted, align the hole in the differential pinion shaft with
the hole in the differential case and install a new spring
pin.
Axles, Planetaries, and Brakes
12.Install differential gear assembly in right side axle
support half.
13.Coat a new O-ring with grease and install left side
axle support half. Tighten axle support case screws from
35 to 41 ft-lb (47 to 56 N−m).
14.Install input shaft/pinion gear assembly (see Input
shaft/Pinion in this section of this manual).
15.Coat new O-rings with grease, align differential shaft
splines with differential gear assembly, and slide differential shaft assemblies onto axle support.
16.Install bevel gear case/axle case assemblies (see
Bevel Gear Case/Axle Case Assembly in this section of
this manual).
Page 6 − 26
Rev. C
Groundsmaster 4100−D
Pinion Gear to Ring Gear Engagement
The final position of the pinion gear is verified by using
the gear contact pattern method as described in the following procedure.
PROFILE
TOP LAND
GEAR TOOTH DEFINITIONS (Fig. 39):
TOE
Toe − the portion of the tooth surface at the end towards the center.
LENGTHWISE
BEARING
ARC
HEEL
Heel − the portion of the gear tooth at the outer end.
Top Land − top surface of tooth.
1. Paint the teeth of the ring gear, both drive and coast
side, with a gear marking compound, such as DyKem
Steel Blue.
ROOT
Figure 39
2. Install the input shaft/pinion gear assembly into axle
case.
More than 35% total tooth contact
3. While applying a light load to the ring gear, rotate the
pinion gear in the direction of forward travel until the ring
gear has made one complete revolution.
Ideal tooth contact observed on the ring gear should
cover more than 35% of each tooth surface. The contact
area should be in the center of each tooth and extend 1/3
to 1/2 way across each tooth from the toe end (Fig. 40).
1/3 to 1/2 of entire width
from small end of tooth
4
Axles, Planetaries,
and Brakes
Figure 40
Adjustments to the gear contact position are made by
moving the input shaft/pinion gear (bearing case shims)
or by moving the differential gear case (differential bearing shims) (Fig. 41).
3
NOTE: Bearing case shims are available in 0.004 in.
(0.10 mm) and 0.008 in. (0.20 mm) thickness.
NOTE: Differential bearing shims are available in
0.004 in. (0.10 mm), 0.008 in. (0.20 mm) and 0.016 in.
(0.40 mm) thickness.
Study the different contact patterns (Figs. 42 and 43)
and correct gear engagement as necessary.
2
NOTE: When making changes, note that two variables
are involved (see Gear Pattern Movement Summary in
this section of this manual).
Example: If the pinion gear to ring gear backlash is set
correctly to specifications and the bearing case shim is
changed to adjust tooth contact, it may be necessary to
readjust backlash to the correct specification before
checking the contact pattern.
Groundsmaster 4100−D
1
Figure 41
1. Input shaft/pinion gear
2. Bearing case shims
3. Differential gear case
Page 6 − 27
Rev. C
4. Differential bearing
shims
Axles, Planetaries, and Brakes
Gear Pattern Movement Summary
Heel Contact
Base Contact
Every gear has a characteristic pattern. The illustrations
show typical patterns only and explain how patterns shift
as gear location is changed.
1. If contact is toward the heel or base of the gear (Fig.
42):
A. Install thicker or additional bearing case shim(s)
to move pinion shaft toward ring gear.
Figure 42
B. Install thinner or remove differential bearing
shim(s) to move ring gear backward.
Toe Contact
Tip Contact
C. Repeat until proper tooth contact and pinion gear
to ring gear backlash are correct.
2. If contact is toward the toe or tip of the gear (Fig. 43):
A. Install thinner or remove bearing case shim(s) to
move pinion shaft away from ring gear.
B. Install thicker or additional differential bearing
shim(s) to move ring gear forward.
Figure 43
C. Repeat until proper tooth contact and pinion gear
to ring gear backlash are correct.
Axles, Planetaries, and Brakes
Page 6 − 28
Rev. C
Groundsmaster 4100−D
Chapter 7
Chassis
Table of Contents
2
2
4
6
Chassis
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
Steering Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Deck Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . .
Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Groundsmaster 4100−D
Page 7 − 1
Chassis
Service and Repairs
Steering Tower
39
24
1
3
2
23
25
26
27
4
5
6
41
7
21
40
8
28
22
33
34
35
36
37
9
10
29
30
31
11
12
13
14
32
18 to 22 ft−lb
(25 to 29 N−m)
41
15
16
17
18
19
38
20
21
RIGHT
FRONT
Figure 1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Hex nut
Flat washer
Steering wheel
Foam collar
Steering seal
External snap ring (2 used)
Knob
Steering tower cover
Steering shaft
Compression spring
Cap
Rod assembly
Extension spring
Tilt rod
Chassis
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Lock nut
Parking brake switch
Cotter pin
Brake pawl
Cotter pin
Lock nut
Nut insert
Flange head screw
Flange bushing
Thrust washer
Temperature gauge
Warning lamp (temp/glow plug)
Warning lamp (charge/oil pressure)
Steering column
Page 7 − 2
Rev. E
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
Cap screw (2 used)
Pivot hub(2 used)
Flange head screw (4 used)
Switch bracket
Flange nut
Cap screw (2 used)
Steering tower
Phillips head screw (2 used)
Clevis pin
Steering valve
Steering wheel cover
Front wire harness
Snap ring location
Groundsmaster 4100−D
Disassembly
Assembly
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1. Assemble steering tower using Figure 1 as a guide.
Note: Thrust washer(s) (24) on steering column are
used as needed to remove end play of steering shaft.
Chassis
2. Disassemble steering tower as needed using Figure
1 as a guide.
Groundsmaster 4100−D
Page 7 − 3
Chassis
Front Deck Lift Arms
8
60 to 70 ft−lb
(81 to 94 N−m)
9
38
Loctite 242
on threads
10
11
RIGHT
100 to 140 in−lb
(11.3 to 15.8 N−m)
12
14
15
16
17
18
19
20 21
22
FRONT
23
3
13
7
2
1
6
11
36
34
25
16
32
26
5
35
33
24
25 16
4
27
30
28
29
155 to 185 ft−lb
(210 to 321 N−m)
31
16
37
75 to 85 ft−lb
(102 to 115 N−m)
Figure 2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Lift cylinder
Clevis pin
Cap screw
Grease fitting
Lift arm pin
Slotted roll pin
Lock nut
Cotter pin
Pivot pin
Hair pin
Spherical rod end
Damper
Yoke spacer
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Flange nut
Lock nut
Flat washer
Grease fitting
Flange head screw
Lift cylinder pin
Flange nut
Spherical bearing
Tapered stud
Retaining ring
Cap screw
Grease fitting
Support hub
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
Clevis pin
Hair pin
Flat washer
Flange nut
Height−of−cut chain
U−bolt
Nut
Lock nut
Flange bushing (2 per lift arm)
Lift arm (LH)
Lock nut
Lift arm (RH)
Removal
1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake, and remove key
from the ignition switch.
2. Remove front cutting deck (see Cutting Deck Removal in Chapter 8 − Cutting Units).
Chassis
Page 7 − 4
Groundsmaster 4100−D
E. Thoroughly clean tapered surfaces of stud and
mounting boss of support hub. Secure support hub
(position slotted hole in hub toward rear of deck) to
tapered stud with flat washer and flange nut. Tighten
flange nut from 155 to 185 ft−lb (210 to 321 N−m).
CAUTION
When raising machine, use correct blocks,
hoists, and jacks. Make sure machine is parked
on a solid, level surface such as a concrete
floor. Prior to raising machine, remove any attachments that may interfere with the safe and
proper raising of the machine. Always chock or
block wheels. Use jack stands or solid wood
blocks to support the raised machine. If the machine is not properly supported by blocks or
jack stands, the machine may move or fall,
which may result in personal injury.
3. Chock rear wheels and jack up front of machine.
Support machine on jack stands. Remove front wheel
next to lift arm that is being removed.
4. Remove flange head screw and lock nut that secure
lift cylinder pin to lift arm. Remove pin and separate lift
cylinder from lift arm.
5. Remove lock nut that secures lift arm pin. Support lift
arm and slide pin from frame and lift arm. Remove lift
arm from frame.
6. As needed, disassemble lift arm:
2. Position lift arm to frame and insert lift arm pin. Engage roll pin into frame slots and install lock nut on pin.
Torque lock nut from 60 to 70 ft−lb (81 to 94 N−m).
3. Align lift cylinder with lift arm. Slide lift cylinder pin
through lift arm and cylinder end. Secure pin with flange
head screw and lock nut.
4. Install front wheel assembly. Lower machine to the
ground.
5. Install cutting deck (see Cutting Deck Installation in
Chapter 8 − Cutting Deck).
6. Lubricate lift arm grease fittings (see Operator’s
Manual).
7. After assembly is completed, raise and lower the cutting deck to verify that hydraulic hoses and fittings do not
contact anything.
8. Check height−of−cut and deck pitch adjustment (see
Operator’s Manual).
A. Remove height−of−cut chain and damper assembly.
.750”
(19.1 mm)
B. Press flange bearings from lift arm.
2
C. Remove flange nut, flat washer, and support hub
from tapered stud. Remove tapered stud with spherical bearing from lift arm after removing retaining ring
from lift arm. Remove flange nut and spherical bearing from stud.
1
Figure 3
Installation
1. Lift arm
2. U−bolt threads
Chassis
1. If removed, install components to lift arm.
A. Assemble height−of−cut chain u−bolt so that
threaded portion of u−bolt extends .750” (19.1 mm)
above mounting plate on lift arm (Fig. 3).
2
B. If rod ends were removed from damper, apply
Loctite #242 to threads and install on damper. Install
damper assembly to lift arm with damper rod end toward deck (Fig. 4).
4
3
C. Press flange bearings into lift arm.
1
D. Install spherical bearing on tapered stud and secure with flange nut. Torque flange nut from 100 to
140 in−lb (11.3 to 15.8 N−m). Install stud with spherical bearing into lift arm and secure with retaining ring.
Groundsmaster 4100−D
Figure 4
1. Lift arm
2. Deck castor arm
Page 7 − 5
3. Support hub
4. Damper
Chassis
Hood
28
29
RIGHT
27
30
1
FRONT
3
2
31
3
26
32
4
25
22
24
23
32
5
22
34
33
20
21
14
6
19
35
8
18
7
17
15
13
9
8
10
11
16
14
12
Figure 5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Hood
R−clamp (2 used)
Cap screw
Hood support
Latch bracket (RH)
Fuel tank support
Flange nut
Lock nut
Latch bracket (LH)
Screw (2 used per handle)
Latch bracket (2 used)
Latch handle (2 used)
Chassis
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Flange head screw (4 used)
Flange head screw (4 used)
Washer head screw (2 used)
Hood latch bracket
Latch
Latch cover
Oil filter deflector
Handle (2 used)
Hood pivot (2 used)
Self tapping screw
Pivot bracket (2 used)
Hair pin
Page 7 − 6
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Screen corner seal (2 used)
Bulb seal
Screen
Hood rod
Bulb seal
Hair pin
Clevis pin
Flange nut
Cap screw (2 used)
Screw (4 used)
Latch keeper (2 used)
Groundsmaster 4100−D
Removal
1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake, and remove key
from the ignition switch.
3
2. Remove hood using Figure 5 as a guide.
Installation
2
1. Install hood using Figure 5 as a guide.
2. Align hood to machine to allow correct operation of
hood latches and dust seals:
A. Place shim that is 3/8” to 7/16” (9.5 to 11.1 mm)
thick on top of frame (both RH and LH sides) near the
sides of oil cooler (Figs. 6 and 7).
1
Figure 6
1. LH shim location
2. LH hood pivot
3. LH pivot bracket
B. Close hood so that it rests on shims and fasten
the hood latches.
C. Loosen hood pivots at frame to adjust vertical
placement of pivots. Re−tighten hood pivot fasteners.
3
D. Loosen pivot brackets to allow hood latches to
pull hood against radiator support. Re−tighten pivot
bracket fasteners.
3. After hood is assembled to machine, check for the
following:
A. Check that bulb seals are equally compressed at
all contact points with hood.
1
Figure 7
1. RH shim location
2. RH hood pivot
3. RH pivot bracket
Chassis
B. Hood should open and close without contacting
oil cooler hardware.
2
Groundsmaster 4100−D
Page 7 − 7
Chassis
This page is intentionally blank.
Chassis
Page 7 − 8
Groundsmaster 4100−D
Chapter 8
Cutting Deck
Table of Contents
2
3
3
4
4
4
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 6
Cutting Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wing Deck Service . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cutting Deck Link Service . . . . . . . . . . . . . . . . . . . 12
Wing Deck Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Blade Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Blade Spindle Service . . . . . . . . . . . . . . . . . . . . . . 16
Castor Forks and Wheels . . . . . . . . . . . . . . . . . . . 18
Deck Rollers and Skids . . . . . . . . . . . . . . . . . . . . . 19
Cutting Deck
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .
Factors That Can Affect Quality of Cut . . . . . . . . .
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Castor Wheel Tire Pressure . . . . . . . . . . . . . . . . . .
Blade Stopping Time . . . . . . . . . . . . . . . . . . . . . . . .
Groundsmaster 4100−D
Page 8 − 1
Cutting Deck
Specifications
MOUNTING: Cutting deck is supported by lift arms controlled with hydraulic lift levers.
CONSTRUCTION: Deck chamber is welded 12 gauge
steel construction reinforced with channels and plates.
HEIGHT−OF−CUT RANGE: 1” to 5” (2.54 cm to 12.7
cm) adjustable in 1/2” (1.27 cm) increments. Center
deck height−of−cut adjustment is achieved by changing
spacers on castor wheels and adjusting length of deck
support chains. Wing deck adjustment achieved by
changing spacers on castor wheels, re−positioning the
castor wheel axles in the castor forks, and securing the
castor wheel bracket to the correct height−of−cut bracket holes.
DECK DRIVE: Closed loop hydraulic system operates
hydraulic motor on each cutting deck section. Motor
drives one spindle directly with remaining deck section
spindle(s) driven by B section kevlar v−belt(s). Blade
spindles are 1−1/4” (3.17 cm) shafts supported by
greaseable, tapered roller bearings.
Cutting Deck
CUTTING BLADE: Cutting blade dimensions are 19”
(48.3 cm) long, 2.5” (6.4 cm) wide, and .250” (.64 cm)
thick. Anti−scalp cup installed on each cutting blade.
Center deck includes three blades and each wing deck
includes two blades.
WIDTH OF CUT: Front deck provides 54” (137.2 cm)
width of cut. Each side deck has 37” (94 cm) width of cut.
Total width of cut is 124” (315 cm).
DISCHARGE: Clippings are discharged from the rear of
the cutting deck.
SUSPENSION SYSTEM: A fully floating suspension
with hydraulic counterbalance. Front deck suspended
from lift arms and has six castor wheels, two adjustable
skids, and five anti−scalp rollers.
Page 8 − 2
Groundsmaster 4100−D
Troubleshooting
There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf
conditions. Turf conditions such as excessive thatch,
uneven ground conditions, “sponginess” or attempting
to cut off too much grass height may not always be overcome by adjusting the machine.
Remember that the “effective” or actual height−of−cut
depends on cutting unit weight, tire pressures, hydraulic
counterbalance settings, and turf conditions. Effective
height−of−cut will be different than the bench set height−
of−cut.
Factors That Can Affect Quality of Cut
Factor
Possible Problem/Correction
1. Maximum governed engine speed.
Check maximum governed engine speed. Adjust
speed to specifications if necessary (see Chapter 3 −
Kubota Diesel Engine).
2. Blade speed.
All deck blades should rotate at the same speed.
See items in Troubleshooting Section of Chapter 4 −
Hydraulic System.
3. Tire pressure.
Check air pressure of each tire including castor tires.
Adjust to pressures specified in Operator’s Manual.
4. Blade condition.
Sharpen blades if their cutting edges are dull or nicked.
Inspect blade sail for wear or damage. Replace blade if
needed.
5. Mower housing condition.
Make sure that cutting chambers are in good condition.
6. Height−of−cut.
Make sure all deck height−of−cut adjustments are the
same. Adjust deck as specified in the Operator’s
Manual.
7. Cutting deck alignment and ground following.
Check lift arms and cutting deck pivot linkages for
wear, damage, or binding. Also, inspect for bent or
damaged pivot shafts.
8. Roller and castor wheel condition.
All rollers and caster wheels should rotate freely.
Replace bearings if worn or damaged.
9. Grass conditions.
Mow when grass is dry for best cutting results. Also,
remove only 1” (2.5 cm) or 1/3 of the grass blade when
cutting.
Groundsmaster 4100−D
Page 8 − 3
Cutting Deck
Cutting Deck
Keep underside of deck clean. Debris buildup will
reduce cutting performance.
Adjustments
CAUTION
Never install or work on the cutting deck or lift
arms with the engine running. Always stop engine and remove ignition key first.
See Operator’s Manual for adjustment procedures for
the cutting deck on the Groundsmaster 4100−D.
Castor Wheel Tire Pressure
Castor tires on the cutting deck should be inflated to 50
psi (3.5 bar).
Blade Stopping Time
The blades of the cutting deck should come to a complete stop in approximately 5 seconds after the cutting
deck engagement switch is shut down.
NOTE: Make sure the decks are lowered onto a clean
section of turf or hard surface to avoid dust and debris.
To verify blade stopping stopping time, have a second
person stand back from the deck at least 20 feet and
watch one of the cutting deck blades. Have the operator
shut the cutting deck down and record the time it takes
for the blades to come to a complete stop. If this stopping
time is greater than 7 seconds, the braking valve(s)
(R1BR) on the deck drive hydraulic control manifold(s)
need adjustment.
Cutting Deck
Page 8 − 4
Groundsmaster 4100−D
Cutting Deck
This page is intentionally blank.
Groundsmaster 4100−D
Page 8 − 5
Cutting Deck
Service and Repairs
CAUTION
Never install or work on the cutting deck or lift
arms with the engine running. Always stop engine and remove ignition key first.
Cutting Deck
8
RIGHT
FRONT
9
7
6
5
10
11
4
1
12
3
2
13
12
14
15
12
16
17
18
12
11
Figure 1
1.
2.
3.
4.
5.
6.
Cutting deck
Cap screw
Lift arm (LH shown)
Flange nut
Spacer
Damper
Cutting Deck
7.
8.
9.
10.
11.
12.
Damper rod end (2 per damper)
Hair pin
Clevis pin
Cap screw
Lock nut
Flat washer
Page 8 − 6
13.
14.
15.
16.
17.
18.
Hex nut
U−bolt
Height of cut chain
Support hub
Clevis pin
Hair pin
Groundsmaster 4100−D
Removal (Fig. 1)
1. Position machine on a clean, level surface. Lower
cutting deck, stop engine, engage parking brake, and
remove key from the ignition switch.
2
NOTE: Removal of clevis pins from deck and height−
of−cut chains is easier if deck is lifted slightly.
1
2. Remove hairpins and clevis pins that secure the
height−of−cut chains to the rear of the cutting deck (Fig.
2).
3. Remove hydraulic motors from cutting deck (see
Cutting Deck Motor Removal in the Service and Repairs
Section of Chapter 4 − Hydraulic Systems). Position motors away from cutting deck.
Figure 2
1. Hairpin and clevis pin
2. Height−of−cut chain
1
4. Remove hairpins and clevis pins that secure dampers to lift arms (Fig. 3). Rotate dampers and place on cutting deck.
2
5. Remove wing deck lift cylinders from cutting deck
(Fig. 4):
4
A. Remove deck covers as needed to allow access
to lift cylinder fasteners.
3
B. Remove cap screw and lock nut that secure the
lift cylinder clevis to the wing deck.
C. Remove flange nut and flat washer from the tapered stud on the barrel end of the lift cylinder.
D. Remove lift cylinder from the deck. Locate and retrieve spacers from each side of the lift cylinder clevis.
Figure 3
1. Lift arm
2. Castor arm
3. Support hub
4. Damper
6
6. Disconnect cutting deck wire harness from main machine harness (Fig. 5).
1
5
4
7. Remove cap screws, flat washers, and flange nuts
that secure support hubs to cutting deck castor arms
(Fig. 3).
3
160 to 180 ft−lb
(217 to 244 N−m)
2
8. Slide the cutting deck away from the traction unit.
1. Position machine on a clean, level surface. Lower lift
arms, stop engine, engage parking brake, and remove
key from the ignition switch.
2. Position the cutting deck to the lift arms.
Figure 4
3. Align support hub to cutting deck castor arms and secure with cap screws, flat washers, and flange nuts (Fig.
3).
Groundsmaster 4100−D
1. Wing deck lift cylinder
2. Flat washer
3. Flange nut
Page 8 − 7
4. Lock nut
5. Cap screw
6. Spacer
Cutting Deck
Cutting Deck
Installation (Fig. 1)
NOTE: Installation of clevis pins to deck and height−of−
cut chains is easier if deck is lifted slightly.
4. Install clevis pins and hairpins that secure the
height−of−cut chains to the rear of the cutting deck (Fig.
2).
5. Install wing deck lift cylinders to cutting deck (Fig. 4):
A. Thoroughly clean tapered surfaces of lift cylinder
studs and mounting bosses on deck.
1
B. Position lift cylinders to the deck.
C. Secure the barrel end of each lift cylinder to the
center deck with flange nut and flat washer. Torque
flange nut from 160 to 180 ft−lb (217 to 244 N−m).
Figure 5
1. Cutting deck wire harness connection
D. Make sure that spacers are positioned on each
side of the lift cylinder clevis. Install cap screw from
the front side of the deck and secure each lift cylinder
clevis to the wing deck with lock nut. Torque lock nut
from 160 to 180 ft−lb (217 to 244 N−m).
6. Connect cutting deck wire harness to main machine
wire harness (Fig. 5).
7. Position dampers to lift arms. Install clevis pins and
hairpins to secure dampers to lift arms (Fig. 3).
8. Install any removed cutting deck covers.
9. Install hydraulic motors to cutting deck (see Cutting
Deck Motor Installation in the Service and Repairs Section of Chapter 4 − Hydraulic Systems).
10.Lubricate grease fittings on cutting deck and lift assemblies (see Operator’s Manual).
Cutting Deck
Page 8 − 8
Groundsmaster 4100−D
Cutting Deck
This page is intentionally blank.
Groundsmaster 4100−D
Page 8 − 9
Cutting Deck
Wing Deck Service
16
1
15
2
6
7
32
10
160 to 180 ft−lb
(217 to 244 N−m)
31
40
33
34
14
41
37
9
8
6
13
3
11
35
39
42
12
36
38
5
29
4
42
7
21
23
18
17
28
18
RIGHT
FRONT
27
19
17
20
30
37
23
22
24
25
26
Figure 6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Wing deck (RH shown)
Flex shield
Cap screw
Switch actuator
Lock nut
Thrust washer (.030” thick)
Link assembly
Flat washer
Flange nut
Screw (6 used per flex shield)
Lock nut
Anti−scalp roller
Cap screw
Flange nut
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Flange screw (2 used per skid)
Skid (RH shown)
Flange bushing
Grease fitting
Latch
Flat washer
Cap screw (3 used per latch)
Lock nut (3 used per latch)
Bushing (3 used per latch)
Spring support
Compression spring
Lug nut
Lock roller (2 used per latch)
Flange nut
Removal (Fig. 6)
1. Position machine on a clean, level surface. Lower
cutting deck and engage parking brake.
2. Fully raise wing deck, stop engine, and remove key
from the ignition switch. Remove three (3) washer head
screws and shield strap that secure flex shield to wing
deck. Lower wing deck.
Cutting Deck
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
Pivot pin
Center deck
Cap screw
Hex jam nut
Shield strap (wing deck)
Shield strap (center deck)
Cap screw
Washer
Retaining ring
Latch pin
Carriage bolt
Switch shield (RH shown)
Washer head screw
Hardened spacer (.120” thick)
3. Remove hydraulic motor from wing deck (see Cutting Deck Motor Removal in the Service and Repairs
Section of Chapter 4 − Hydraulic Systems).
4. Remove cap screw and lock nut that secure lift cylinder clevis to the wing deck (Fig. 7).
5. Remove switch shield from center deck.
Page 8 − 10
Rev. C
Groundsmaster 4100−D
6. Support wing deck to prevent it from falling as links
are removed.
3
7. Remove cap screw and washer from pivot pin on upper end of both links. Remove flange nut from carriage
bolt and pull pivot pins from deck. Locate and retrieve
two thrust washers (item 6) from upper end of both links
and two hardened spacers (item 42) from front link.
2
8. Slide the wing deck away from the center deck.
9. If required, remove link(s) from wing deck by removing flange nut and flat washer that secure tapered stud
to deck. Press tapered stud from deck to remove link assembly.
2
1
Figure 7
1. Hydraulic motor
2. Flange head screw
Installation (Fig. 6)
3. Lift cylinder clevis
1. Park machine on a clean, level surface. Stop engine,
engage parking brake, and remove key from the ignition
switch.
2. If links were removed from wing deck, thoroughly
clean tapered stud on link and mounting boss of wing
deck. Insert tapered stud into deck mounting boss and
secure with flat washer and flange nut. Torque flange nut
from 160 to 180 ft−lb (217 to 244 N−m).
.380” to .620”
(9.7 to 15.7 mm)
1
3. Position the wing deck to the center deck.
2
4. Position thrust washers (item 6) to upper end of links.
Front link has both thrust washers toward the rear. Rear
link has thrust washer on each side. Also, place hardened spacer (item 42) on each side of front link. Align upper end of links with mounting holes in center deck.
Install pivot pins.
5. Secure pivot pins to center deck with carriage screw
and flange head screw. Install washer and cap screw to
pivot pins.
6. Position lift cylinder to the wing deck (Fig. 7). Secure
cylinder with cap screw and lock nut.
7. Install hydraulic motor to cutting deck (see Cutting
Deck Motor Installation in the Service and Repairs Section of Chapter 4 − Hydraulic Systems).
Figure 8
1. Wing deck blade
2. Center deck blade
9. Lubricate grease fittings on cutting deck and lift components (see Operator’s Manual).
10.Check distance between inner deck blade on wing
deck and outer deck blade on center deck. Distance between blades should be .380” to .620” (9.7 to 15.7 mm)
(Fig. 8). If blade distance is incorrect, loosen hex jam nut
(item 32) on rear link assembly and adjust cap screw
(item 31). Tighten jam nut when blade distance is correct.
11. Inspect deck latch assembly to insure that link is
locked when wing deck is in the lowered position.
12.Check operation of wing deck position switch. Adjust
if necessary (see Wing Deck Position Switches in the
Adjustments section of Chapter 5 − Electrical System).
8. Fully raise wing deck, stop engine, and remove key
from the ignition switch. Secure flex shield to wing deck
with shield strap and three (3) washer head screws.
Lower wing deck.
Groundsmaster 4100−D
Page 8 − 11 Rev. C
Cutting Deck
Cutting Deck
NOTE: If two thrust washers (item 6) cause front link to
bind, use only one thrust washer on rear side of front
link.
Cutting Deck Link Service
Disassembly (Fig. 9)
2
1. Press flange bushings from top of link.
7
1
5
2. Remove retaining ring and press tapered stud with
spherical bearing and flange nut from link.
2
3. Remove flange nut and press spherical bearing from
tapered stud.
6
Reassembly (Fig. 9)
4
1. Install new spherical bearing onto tapered stud. Secure bearing with flange nut. Torque nut from 30 to 40
ft−lb (41 to 54 N−m).
2. Press tapered stud with spherical bearing and flange
nut into link. Secure spherical bearing into link with retaining ring.
3. Press flange bushings into bore of link.
30 to 40 ft−lb
(41 to 54 N−m)
3
Figure 9
1.
2.
3.
4.
Link
Flange bushing
Grease fitting
Tapered stud
5. Spherical bearing
6. Flange nut
7. Retaining ring
4. If cap screw and jam nut were removed from rear
link, install cap screw to allow 1.625” (41.3 mm) between
the head of the screw and the side of the link (Fig. 10).
5. After link is installed on deck, check distance between center deck blade and wing deck blade. Readjust
cap screw and jam nut if needed (see Wing Deck Service in this Chapter).
1.625”
(41.3 mm)
1
2
3
Figure 10
1. Rear link
2. Cap screw
Cutting Deck
Page 8 − 12
3. Hex jam nut
Groundsmaster 4100−D
Wing Deck Latch
Disassembly (Fig. 11)
9
1. Raise wing deck to transport position. Carefully rotate latch to closed position.
13
2. Loosen lug nut to release compression spring tension.
3. Remove retaining ring and flat washer from bottom
of latch pin. Rotate lug nut enough to allow latch pin to
be removed from latch.
14
5
4. Remove lug nut from spring support. Remove latch
assembly from deck.
4
6
3
5. Disassemble latch (items 1 through 8) using Figure
11 as a guide.
4
12
3
2
1
Assembly (Fig. 11)
5
1. Assemble latch (items 1 through 8) using Figure 11
as a guide.
2. Slide spring onto spring support and insert end of
spring support into hole located on underside of center
deck. Start lug nut (tapered side towards plate on deck)
onto spring support.
3. Tighten lug nut until holes in front of deck align with
bushings in latch. Insert latch pin with retaining ring
down through deck and latch. Secure latch pin on underside of deck with flat washer and retaining ring.
10
9
8
4
7
11
Figure 11
1.
2.
3.
4.
5.
6.
7.
Latch
Grease fitting
Lock roller
Bushing
Flange bushing
Cap screw (3 used)
Spring support
8.
9.
10.
11.
12.
13.
14.
Lock nut (3 used)
Retaining ring
Flat washer
Compression spring
Lug nut
Latch pin
Center deck
4. Carefully rotate latch to the open position. Lower
wing deck.
Cutting Deck
5. Lubricate latch grease fitting.
Groundsmaster 4100−D
Page 8 − 13
Cutting Deck
Blade Spindle
4
2
5
6
3
7
18
8
9
10
1
11
17
12
13
RIGHT
88 to 108 ft−lb
(119 to 146 N−m)
FRONT
14
15
16
Figure 12
1.
2.
3.
4.
5.
6.
Cutting deck
Drive spindle: single pulley (2 used)
Low driven spindle (3 used)
Drive spindle: double pulley (1 used)
Lock nut
Flat washer
7.
8.
9.
10.
11.
12.
Idler pulley (4 used)
Flat washer
Idler spacer
High driven spindle (1 used)
Flat washer
Cap screw
Removal (Fig. 12)
1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake, and remove key
from the ignition switch.
2. If drive spindle is to be serviced, remove hydraulic
motor from cutting deck (see Cutting Deck Motor Removal in the Service and Repairs Section of Chapter 4
− Hydraulic Systems). Position motor away from
spindle.
3. Remove belt covers from top of cutting deck (see Operator’s Manual). Loosen idler pulley to release belt tension. Remove drive belt from spindle to be serviced.
13.
14.
15.
16.
17.
18.
Carriage screw
Cutting blade
Anti−scalp cup
Blade bolt
Flange nut
Flange head screw
5. Remove cutting blade, anti−scalp cup, and blade
bolt from spindle to be serviced (see Operator’s Manual).
6. Remove spindle housing assembly from deck.
A. For driven spindle assemblies, remove eight (8)
flange head screws with lock nuts that secure
spindle to deck.
B. For drive spindle assemblies, loosen and remove
four (4) flange head screws with lock nuts that secure
spindle to deck. Then, remove four (4) cap screws
with washers that secure spindle and motor mount to
deck.
4. Start the engine and raise the cutting deck. Stop engine and remove key from the ignition switch. Latch or
block up the cutting deck so it cannot fall accidentally.
Cutting Deck
Page 8 − 14
Rev. C
Groundsmaster 4100−D
Installation (Fig. 12)
1. Position spindle on cutting deck noting orientation of
grease fitting (Fig. 14). Secure spindle assembly to deck
with correct fasteners.
1
2. Install cutting blade, anti−scalp cup, and blade bolt
(see Operator’s Manual). Tighten blade bolt from 88 to
108 ft−lb (119 to 146 N−m).
3. Slowly rotate cutting blades to verify that blades do
not contact any deck component(s).
1
2
4. Install drive belt and adjust belt tension (see Operator’s Manual).
Figure 13
1. Flange head screw
5. If drive spindle was removed, install hydraulic motor
to cutting deck (see Cutting Deck Motor Installation in
the Service and Repairs Section of Chapter 4 − Hydraulic Systems).
2. Hydraulic motor
6. Install belt covers to cutting deck (see Operator’s
Manual).
1
1
2
5
7
4
7
2
5
3
7
7
2
5
3
7
7
5
6
2
1
Driven spindle
Drive belt
Drive spindle (wing deck)
Groundsmaster 4100−D
4.
5.
Drive spindle (center deck)
Idler pulley
Page 8 − 15 Rev. C
6.
7.
Driven spindle (high pulley)
Spindle grease fitting location
Cutting Deck
Cutting Deck
Figure 14
1.
2.
3.
Blade Spindle Service
DRIVEN SPINDLE
7
1
8
2
9
3
10
11
12
13
14
4
130 to 150 ft−lb
(176 to 203 N−m)
17
DRIVE SPINDLE
15
1
2
9
5
16
8
4
17
6
17
Figure 15
1.
2.
3.
4.
5.
6.
Lock nut
Flat washer
Driven pulley
V−ring seal (if equipped)
Drive pulley (single shown)
Hydraulic motor mount
7.
8.
9.
10.
11.
12.
O−ring
Oil seal
Bearing cup and cone
Outer bearing spacer
Inner bearing spacer
Spacer ring
Disassembly (Fig. 15)
NOTE: Early production spindle assemblies included a
v−ring seal (item 4) which has been found to be unnecessary. Discard v−ring seal if found in spindle assembly.
1. Loosen and remove lock nut from top of spindle
shaft. Remove flat washer, pulley, and v−ring seal (if
equipped) from spindle. For drive spindle, remove hydraulic motor mount.
2. Remove the spindle shaft from the spindle housing
which may require the use of an arbor press. The spindle
shaft spacer should remain on the spindle shaft as the
shaft is being removed.
3. Remove oil seals from spindle housing.
4. Allow the bearing cones, inner bearing spacer, and
spacer ring to drop out of the spindle housing.
13.
14.
15.
16.
17.
Snap ring
Grease fitting
Spindle housing
Spindle shaft spacer
Spindle shaft
6. The large snap ring can remain inside the spindle
housing. Removal of this snap ring is very difficult.
Assembly (Fig. 15)
IMPORTANT: If new bearings are installed into a
used spindle housing, it may not be necessary to replace the original large snap ring. If the original
snap ring is in good condition with no evidence of
damage (e.g. spun bearing), leave the snap ring in
the housing and discard the snap ring that comes
with the new bearings. If the large snap ring is found
to be damaged, replace the snap ring. Replacement
bearings are sold only with a matched spacer ring
and large snap ring (Fig. 17). These parts cannot be
purchased separately.
1. If large snap ring was removed, install snap ring into
spindle housing groove. Make sure snap ring is fully
seated in housing groove.
5. Using a punch and hammer, drive both of the bearing
2. Install large outer bearing spacer into top of spindle
cups out of the spindle housing. Remove the outer bearhousing. The spacer should fit against the snap ring.
ing spacer from the housing.
Page 8 − 16 Rev. E
Cutting Deck
Groundsmaster 4100−D
3. Using an arbor press, push the bearing cups into the
top and bottom of the spindle housing. The top bearing
cup must contact the spacer previously installed, and
the bottom bearing cup must contact the snap ring.
Make sure that the assembly is correct by supporting the
first bearing cup and pressing the second against it (Fig
16).
4. Pack the bearing cones with grease. Apply a film of
grease on lips of oil seals.
PRESS
4
3
1
5. Install lower bearing cone and oil seal into bottom of
spindle housing. Note: The lower seal must have the lip
facing out (down) (Fig. 18).
6
2
5
Figure 16
IMPORTANT: If bearings are being replaced, make
sure to use the spacer ring that is included in bearing set.
4. Arbor press
5. Support
6. Arbor press base
1. Bearing cups
2. Large snap ring
3. Large outer spacer
6. Slide spacer ring and inner bearing spacer into
spindle housing, then install upper bearing cone and oil
seal into top of housing. Note: The upper seal must have
the lip facing in (down) and be recessed into the spindle
housing .095” (2.4 mm) (Fig. 18).
1
4
2
7. Inspect the spindle shaft and shaft spacer to make
sure they are free of burrs or nicks that could possibly
damage the oil seals. Lubricate the shaft with grease.
5
3
8. Install spindle shaft spacer onto shaft. Carefully slide
spindle shaft with spacer up through spindle housing.
The bottom oil seal and spindle spacer fit together when
the spindle is installed fully.
9. Lightly grease o−ring and install to top of spindle
shaft.
1
Figure 17
4. Inner spacer
5. Outer spacer
1. Bearing
2. Spacer ring
3. Large snap ring
10.For drive spindle, position motor mount to top of
spindle assembly.
.095” (2.4 mm)
NOTE: Early production spindle assemblies included a
v−ring seal (item 4) which has been found to be unnecessary. Do not install a v−ring seal when assembling the
spindle.
2
11. Install pulley (hub down), flat washer, and lock nut to
spindle shaft. Tighten lock nut from 130 to 150 ft−lb (176
to 203 N−m).
Cutting Deck
12.Attach a hand pump grease gun to grease fitting on
housing and fill housing cavity with grease until grease
starts to come out of lower seal. Note: Pneumatic
grease guns can produce air pockets when filling large
cavities and therefore, are not recommended to be used
for proper greasing of spindle housings.
1
13.Rotate spindle shaft to make sure that it turns freely.
Figure 18
1. Bottom seal installation
Groundsmaster 4100−D
Page 8 − 17 Rev. E
2. Upper seal installation
Cutting Deck
Castor Forks and Wheels
DECK CASTOR ARM
WING DECK CASTOR FORK
14
13
17
20
24
12
21
11
25
6
20
60 to 80 ft−lb
(81 to 108 N−m)
26
19
8
7
1
5
10
4
9
7
18
22
16
23
CASTOR WHEEL
32
8
33
27
15
4
3
34
28
2
29
5
27
30
60 to 80 ft−lb
(81 to 108 N−m)
31
Figure 19
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Castor arm (wing deck shown)
Cap screw (6 per arm)
Castor fork
Castor wheel bolt
Lock nut
Castor spacer
Thrust washer
Flange lock nut
Grease fitting
Flange bushing
Retaining ring
Cap washer
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Compression spring
Cap
Flat washer (6 per arm)
Clevis pin (2 used per fork)
Lock nut
Carriage screw (3 used per fork)
Castor fork bracket
Shim
Castor fork bracket
Hairpin
Cutting deck (LH shown)
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
Decal
Flat washer
Tension rod
Bearing
Inner bearing spacer
Wheel hub
Wheel rim half
Castor tire
Wheel rim half
Plate
Flange nut (4 used per wheel)
Disassembly
Assembly
1. Disassemble castor forks and wheels using Figure
19 as a guide.
1. Assemble castor forks and wheels using Figure 19
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.
4. See Operator’s Manual for castor wheel adjustment.
Cutting Deck
Page 8 − 18
Groundsmaster 4100−D
Deck Rollers and Skids
9
7
10
6
5
8
7
6
5
5
7
6
RIGHT
4
FRONT
3
2
1
Figure 20
1.
2.
3.
4.
Roller
Flange head screw
Roller shaft
Flange nut
5.
6.
7.
Lock nut
Roller
Cap screw
8. Flange nut
9. Skid (RH shown)
10. Flange head screw
Removal
1. Remove skids and rollers from deck using Figure 20
as a guide.
Installation
Cutting Deck
1. Install skids to deck using Figure 20 as a guide. Make
sure to install skids in the same mounting hole height
position (lower or upper).
2. When installing roller (item 6), install cap screw with
the threads orientated toward the centerline of the deck.
Install and tighten lock nut until roller will not rotate, then
loosen lock nut only enough to allow roller to rotate freely. Make sure to install all deck rollers in the same mounting hole height position (lower or upper).
Groundsmaster 4100−D
Page 8 − 19
Cutting Deck
This page is intentionally blank.
Cutting Deck
Page 8 − 20
Groundsmaster 4100−D
Chapter 9
Electrical Diagrams
Table of Contents
Electrical
Diagrams
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . 3
CIRCUIT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Glow Plug Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Crank Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Run (Transport) Circuit . . . . . . . . . . . . . . . . . . . . . . . 6
Run (Mow) Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
WIRE HARNESS DRAWINGS . . . . . . . . . . . . . . . . . . 8
Main Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Main Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine Wire Harness . . . . . . . . . . . . . . . . . . . . . . . 10
Engine Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . 11
Front Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . 12
Front Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . 13
Cutting Deck Wire Harnesses . . . . . . . . . . . . . . . . 14
Cutting Deck Wire Harnesses . . . . . . . . . . . . . . . . 15
Groundsmaster 4100−D
Page 9 - 1
Electrical Diagrams
This page is intentionally blank.
Electrical Diagrams
Page 9 - 2
Groundsmaster 4100−D
Groundsmaster 4100−D
Electrical Schematic
All relays and solenoids
are shown as de−energized.
All ground wires are black.
Page 9 - 3
Groundsmaster 4100−D
Glow Plug Circuit
Power Current
Control Current
Indication Current
Logic Direction
Page 9 - 4
Groundsmaster 4100−D
Crank Circuit
Power Current
Control Current
Indication Current
Logic Direction
Page 9 - 5
Groundsmaster 4100−D
Run (Transport) Circuit
Power Current
Control Current
Indication Current
Logic Direction
Page 9 - 6
NOTE: The drawing on this page shows the center deck and the
left wing deck lowered and the right wing deck raised.
Groundsmaster 4100−D
Run (Mow) Circuit
Power Current
Control Current
Indication Current
Logic Direction
Page 9 - 7
P22
BLUE
WHITE
YELLOW
YELLOW
YELLOW
TAN
J4
ORANGE
P34
BLUE
YELLOW
J3
J1 J2
P21
YELLOW
YELLOW
BLUE
PINK
P20
YELLOW/BLACK
P19
P18
ORANGE
P17
PINK
PINK
P16
BLACK
J6
PINK
P15
BLACK
GREEN
WHITE
P14
TAN
YELLOW
WHITE
WHITE
YELLOW
YELLOW
YELLOW
P13
BLUE
TAN
TAN
BLACK
BLACK
BLACK
P11
P23
TAN
VIOLET/BLACK
YELLOW/BLACK
RED
BLACK
GRAY
P10
GREEN
GRAY
GRAY
GREEN/BLACK
WHITE
BLACK
WHITE
YELLOW
GREEN
GRAY
P24
TAN
P8
RED/BLACK
BLUE
BLACK
YELLOW
TAN
P25
VIOLET/BLACK
PINK
GREEN
BLACK
WHITE
PINK
RED
RED
P31
BLACK
ORANGE
VIOLET
P26
PINK
YELLOW
ORANGE
P7
BLUE
BLACK
BLACK
BLACK
VIOLET
RED
P9
ORANGE
YELLOW
RED
P27
BROWN
BLACK
WHITE
GREEN
P6
PINK
ORANGE
GREEN
GREEN
YELLOW
P28
WHITE
TAN
YELLOW
BLUE
BLACK
GRAY
RED
P3
P5
BLACK
P32
P29
P33
P35
VIOLET
P1
P30
RED
WHITE
GREEN
GREEN
BLUE
P4
ORANGE
BLUE
BLACK
J5
P2
P36
Groundsmaster 4100−D
Main Wire Harness
Page 9 - 8
Groundsmaster 4100−D
Main Wire Harness
Page 9 - 9
P1
P1
P2
J1
J2
J4
J3
P17
RED/BLACK
FUSIBLE LINK (14 GA.)
FUSIBLE LINK (16 GA.)
FUSIBLE LINK (14 GA.)
FUSIBLE LINK (16 GA.)
J1
RED
J13
BLACK
P3
BLACK
RED
RED
RED/BLACK
P16
RED/BLACK
PINK
WHITE
ORANGE
BLACK
BLUE
P4
WHITE
GRAY
BLACK
J12
BLACK
YELLOW
P15
GREEN
YELLOW
BROWN
ORANGE
BLUE
WHITE
P5
ORANGE
VIOLET/BLACK
YELLOW/BLACK
BLACK
GREEN
P14
GREEN
BLACK
BLACK
BLACK
BLACK
J9
J8
J7
J6
J5
P13
P7
(D2)
YELLOW/BLACK
YELLOW/BLACK
YELLOW/BLACK
BLACK
BLACK
VIOLET/BLACK
BLACK
BLACK
VIOLET/BLACK
ORANGE
VIOLET/BLACK
ORANGE
P6
Groundsmaster 4100−D
Engine Wire Harness
P12
(D4)
P11
P10
P9
P8
(D6)
Page 9 - 10
(D4)
(D2)
(D6)
Groundsmaster 4100−D
Engine Wire Harness
Page 9 - 11
P3
J1
PINK
BLACK
YELLOW
P14
P4
PINK
BROWN
YELLOW
P5
PINK
GRAY
P6
(D8)
PINK
P2
BLACK
TAN
PINK
BLACK
P7
PINK
PINK
TAN
GREEN/BLACK
GRAY
TAN
GREEN
WHITE
P1
P8
BLUE
ORANGE
VIOLET/BLACK
J2
BLACK
P13
P15
P12
P11
BLACK
P9
(D7)
GREEN/BLACK
GREEN/BLACK
BLACK
GREEN/BLACK
BLACK
YELLOW/BLACK
ORANGE
ORANGE
BLUE
ORANGE
BLACK
TAN
P10
Groundsmaster 4100−D
Front Wire Harness
(D5)
Page 9 - 12
(D8)
(D7)
(D5)
Groundsmaster 4100−D
Front Wire Harness
Page 9 - 13
P15
BLUE
GRAY
VIOLET
P35
P2
BLUE
GRAY
GRAY
P1
VIOLET
VIOLET/BLACK
BLACK
BLUE
VIOLET
BLACK
ORANGE
BLACK
ORANGE
P4
BLACK
YELLOW
P3
ORANGE
YELLOW/BLACK
P1
P2
DECK LIFT
SENSOR (LH)
DECK LIFT
SENSOR (RH)
Groundsmaster 4100−D
Cutting Deck Wire Harnesses
Page 9 - 14
Groundsmaster 4100−D
Cutting Deck Wire Harnesses
Page 9 - 15
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