Toro Groundsmaster 4100-D Service Manual
  1. Manuals
  2. Brands
  3. Toro Manuals
  4. Lawn Mower
  5. Groundsmaster 4100-D
  6. Service manual

Toro Groundsmaster 4100-D Service Manual

Hide thumbs Also See for Groundsmaster 4100-D:
Table of Contents

Advertisement

Quick Links

Form No. 03116SL Rev G
®
Groundsmaster
4100-D
(Model 30411)
Original Instructions (EN)

Advertisement

Table of Contents
loading

Related Manuals for Toro Groundsmaster 4100-D

Summary of Contents for Toro Groundsmaster 4100-D

  • Page 1 Form No. 03116SL Rev G ® Groundsmaster 4100-D (Model 30411) Original Instructions (EN)
  • Page 2 THE TORO COMPANY 2018 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be...
  • Page 3 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.com...
  • Page 4 NOTES...
  • Page 5 IMPORTANT: The IMPORTANT notice will give im- portant instructions which must be followed to pre- vent damage to systems or components on the machine. E The Toro Company - - 2003, 2004, 2005, 2007, 2012, 2018...
  • Page 6 This page is intentionally blank. Groundsmaster 4100−D...
  • Page 7 Table Of Contents Chapter 1 − Safety Chapter 5 − Electrical System General Safety Instructions ....1 − 2 Electrical Schematic, Circuit Diagrams, and Jacking Instructions .
  • Page 8 This page is intentionally blank. Groundsmaster 4100−D...
  • Page 9 Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS ... . JACKING INSTRUCTIONS ..... Before Operating .
  • Page 10 The GROUNDSMASTER 4100-D was tested and certi- result in injury or death. To reduce the potential for injury fied by TORO for compliance with existing safety stan- or death, comply with the following safety instructions. dards and specifications. Although hazard control and...
  • Page 11 Toro replacement parts and 6. Before disconnecting or performing any work on the accessories. Replacement parts and accessories made...
  • Page 12 Jacking Instructions CAUTION When changing attachments, tires, or perform- ing 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 attach- ments that may interfere with the safe and prop- er raising of the machine.
  • Page 13 Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 4100−D. If any decal becomes illeg- ible or damaged, install a new decal. Decal part num- bers are listed in your Parts Catalog. Groundsmaster 4100−D Safety Page 1 −...
  • Page 14 This page is intentionally blank. Safety Groundsmaster 4100−D Page 1 − 6...

  • Page 15: Table Of Contents

    Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......Standard Torque for Dry, Zinc Plated, and EQUIVALENTS AND CONVERSIONS .

  • Page 16: Equivalents And Conversions

    Equivalents and Conversions Product Records and Maintenance Page 2 − 2 Groundsmaster 4100−D...

  • Page 17: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.

  • Page 18: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch Series)

    Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Grade 1, 5, & SAE Grade 1 Bolts, Screws, Studs, & SAE Grade 5 Bolts, Screws, Studs, & SAE Grade 8 Bolts, Screws, Studs, & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...

  • Page 19: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Metric)

    Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric) Class 8.8 Bolts, Screws, and Studs with Class 10.9 Bolts, Screws, and Studs with Thread Size Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...

  • Page 20: Other Torque Specifications

    Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Thread Size Square Head Hex Socket 7/16 − 20 UNF 65 + 10 ft−lb 88 + 14 N−m Grade 5 1/4 −...

  • Page 21: Maintenance

    Maintenance Maintenance procedures and recommended service in- tervals 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 identi- fied in the Operator’s Manual. Refer to the Engine Oper- ator’s Manual additional...
  • Page 22 This page is intentionally blank. Product Records and Maintenance Page 2 − 8 Groundsmaster 4100−D...
  • Page 23 Chapter 3 Kubota Diesel Engine Table of Contents GENERAL INFORMATION ..... Radiator ........Stopping the Engine .

  • Page 24: General Information

    Authorized Toro Distributor. If no parts list is available, be prepared to provide your distrib- Most repairs and adjustments require tools which are utor with the Toro model and serial number of your ma- commonly available in many service shops. Special chine.

  • Page 25: Specifications

    Specifications Item Description Make / Designation Kubota, 4−Cycle, 4 Cylinder, Water Cooled, Turbocharged, Diesel Engine Horse Power 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...

  • Page 26: Adjustments

    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. 2. If adjustment is needed, loosen lock nut and rotate the threaded end of the swivel until the lever is properly positioned.
  • Page 27 This page is intentionally blank. Groundsmaster 4100−D Page 3 − 5 Kubota Diesel Engine (Rev. A)

  • Page 28: Service And Repairs

    Service and Repairs Air Filter System RIGHT FRONT EVACUATOR DIRECTION Figure 3 1. Air cleaner hose 5. Air cleaner strap 9. Hose clamp 2. Hose clamp 6. Lock nut (2 used) 10. Cap screw (2 used) 3. Air cleaner assembly 7.
  • Page 29 Removal 1. Remove air cleaner components as needed using Figure 3 as a guide. 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.

  • Page 30: Exhaust System

    Exhaust System 16 to 22 ft−lb (21 to 29 N−m) 16 to 22 ft−lb (21 to 29 N−m) RIGHT FRONT 16 to 22 ft−lb (21 to 29 N−m) Figure 5 1. Muffler 6. Lock nut 11. Flange nut (2 used) 2.
  • Page 31 Removal CAUTION The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and ex- haust system to cool before working on the muf- fler. 1. Park machine on a level surface, lower cutting unit, stop engine, engage parking brake, and remove key from the ignition switch.

  • Page 32: Fuel System

    Fuel System RIGHT 36 35 FRONT 27 28 18 17 16 135 to 165 ft−lb (183 to 223 N−m) 60 to 80 in−lb (7 to 9 N−m) Figure 7 1. Fuel tank 15. Retaining ring (2 used) 29. Fuel hose 2.

  • Page 33: Check Fuel Lines And Connections

    Fuel Tank Installation DANGER 1. Install fuel tank using Figure 7 as a guide. A. Torque two locking flange nuts that secure the Because diesel fuel is highly flammable, use cau- fuel tank to the frame from 60 to 80 in−lb (7 to 9 N−m). tion when storing or handling it.

  • Page 34: Radiator

    Radiator RIGHT FRONT Figure 8 1. Radiator cap 17. Bulb seal 33. Flange head screw (4 used) 18. Radiator support assembly 34. Bulb seal 2. Foam strip 3. Foam strip 19. Retaining ring 35. Grommet (2 used) 4. Lower radiator hose 20.
  • Page 35 Removal Installation 1. Park machine on a level surface, lower cutting unit, 1. Remove plugs from radiator and hoses placed dur- stop engine, engage parking brake, and remove key ing the removal procedure. from the ignition switch. 2. Position radiator to the support frame. Secure radia- 2.

  • Page 36: Engine

    Engine RIGHT FRONT Figure 10 1. Engine 10. Fuel line 19. Lock washer 2. Engine mount bracket (RH shown) 11. Coolant drain hose 20. Cap screw 3. Lock washer 12. Hose clamp 21. Cap screw (8 used) 4. Cap screw 13.

  • Page 37: Engine Removal

    Engine Removal 1. Park machine on a level surface, lower cutting unit, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove battery cover and strap. Disconnect nega- tive battery cable first and then positive battery cable. Remove battery from machine.
  • Page 38 8. Disconnect fuel line from injection pump (Fig. 12). Cap fuel line and injector pump fuel inlet to prevent con- tamination. 9. Disconnect throttle cable from the speed control le- ver by removing the washer and lock nut. Loosen jam nut and take cable from mounting bracket (Fig.

  • Page 39: Engine Installation

    Engine Installation 12.Connect wires and/or electrical connections to the following electrical components: 1. If removed, install engine mount brackets to the en- gine using Figure 10 as a guide. A. The temperature sender and alternator (Fig 11). 2. Connect hoist or lift to the front and rear lift tabs on B.

  • Page 40: Pump Adapter Plate

    Pump Adapter Plate 17 to 21 ft−lb (23 to 28 N−m) 17 to 21 ft−lb RIGHT (23 to 28 N−m) FRONT 35 to 43 ft−lb (48 to 58 N−m) Figure 16 1. Engine 5. Plate pin (2 used) 9. Spring center coupling 2.
  • Page 41 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 − Hy- draulic Systems). 2. Remove pump adapter plate, spring center coupling, and coupling spacer from engine using Figure 16 as a guide.
  • Page 42 This page is intentionally blank. Kubota Diesel Engine (Rev. A) Page 3 − 20 Groundsmaster 4100−D...
  • Page 43 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......SERVICE AND REPAIRS .

  • Page 44: Specifications

    Specifications Item Description Piston (Traction) Pump Variable displacement piston pump System Relief Pressure: Forward 4000 PSI (274 bar) System Relief Pressure: Reverse 5000 PSI (343 bar) Charge Pressure 250 PSI (17 bar) Gear Pump 3 section, positive displacement gear type pump Steering Relief Pressure 1350 PSI (93 bar) Lift/Lower Relief Pressure...

  • Page 45: General Information

    General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure WARNING to weather, sun, chemicals, very warm storage condi- tions, or mishandling during operation or maintenance. Before disconnecting or performing any work These conditions can cause damage or premature dete- on hydraulic system, relieve all pressure in rioration.
  • Page 46 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 fit- ting shows signs of leakage. 3.

  • Page 47: Towing Traction Unit

    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 for towing.
  • Page 48 This page is intentionally blank. Hydraulic System Page 4 - - 6 Groundsmaster 4100--D...

  • Page 49: Hydraulic Schematic

    Hydraulic Schematic Groundsmaster 4100--D Page 4 - - 7 Hydraulic System...

  • Page 50: Hydraulic Flow Diagrams

    Hydraulic Flow Diagrams Hydraulic System Page 4 - - 8 Groundsmaster 4100--D...

  • Page 51: Traction Circuit

    Traction Circuit The traction circuit piston pump is a variable displace- Charge pump flow is directed through the oil filter and to ment pump that is directly coupled to the engine fly- the low pressure side of the closed loop traction circuit. wheel.
  • Page 52 Rev. E Hydraulic System Page 4 - - 10 Groundsmaster 4100--D...

  • Page 53: Lower Cutting Deck

    Lower Cutting Deck A three section gear pump is coupled to the piston (trac- The drop speed of the cutting deck is regulated by an ad- tion) pump. The gear pump section farthest from the pis- justable flow control valve that is located in the hydraulic ton pump supplies hydraulic flow to both the lift/lower lines between the lift/lower control valve and the deck lift control valve and the steering control valve.
  • Page 54 Rev. E Hydraulic System Page 4 - - 12 Groundsmaster 4100--D...

  • Page 55: Raise Cutting Deck

    Raise Cutting Deck A three section gear pump is coupled to the piston (trac- To raise a wing deck, the appropriate lift lever (right side tion) pump. The gear pump section farthest from the pis- or left side) on the lift/lower control valve is pulled to al- ton pump supplies hydraulic flow to the lift/lower control low valve shift in the lift/lower control.
  • Page 56 Hydraulic System Page 4 - - 14 Groundsmaster 4100--D...

  • Page 57: Mow Circuit

    Mow Circuit Hydraulic flow for the mow circuit is supplied by two sec- tions of the gear pump. The gear pump section closest to the piston (traction) pump supplies hydraulic flow to TO DECK PUMP FLOW MOTOR the wing decks, while the next gear pump section sup- plies the center deck.
  • Page 58 Hydraulic System Page 4 - - 16 Groundsmaster 4100--D...

  • Page 59: Steering Circuit

    Steering Circuit A three section gear pump is coupled to the piston (trac- ensures that the oil flow to the cylinder is proportional to tion) pump. The gear pump section farthest from the pis- the amount of the turning on the steering wheel. Fluid ton pump supplies hydraulic flow to the steering control leaving the cylinder flows back through the spool valve valve and the lift/lower control valve.

  • Page 60: Special Tools

    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.

  • Page 61: Hydraulic Test Fitting Kit

    Hydraulic Test Fitting Kit - - TOR4079 This kit includes a variety of O--ring Face Seal fittings to TORO TEST FITTING KIT (NO. TOR4079) enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings.

  • Page 62: Troubleshooting

    Troubleshooting The charts that follow contain information to assist in Refer to the Testing section of this Chapter for precau- troubleshooting. There may possibly be more than one tions and specific test procedures. cause for a machine malfunction. Problem Possible Cause Hydraulic system operates hot.
  • Page 63 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.
  • Page 64 Problem Possible Causes Cutting decks drop too fast or too Flow control valve is not adjusted properly. slow. 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.

  • Page 65: Testing

    Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment WARNING such as pressure gauges and flow meters in the circuits during various operational checks (See the Special Before disconnecting or performing any work Tools section in this Chapter).

  • Page 66: Test No. 1: Traction Circuit Charge Pressure

    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...
  • Page 67 Procedure for Traction Circuit Charge Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature 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.

  • Page 68: Test No. 2: Traction Circuit Relief Pressure

    TEST NO. 2: Traction Circuit Relief Pressure (Using Pressure Gauge) CHARGE OIL FROM NOTE: FORWARD LIFT AND STEERING CIRCUITS 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...
  • Page 69 Procedure for Traction Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. CAUTION Move machine to an open area, away from people and obstructions.

  • Page 70: Test No. 3: Cutting Deck Circuit Pressure

    TEST NO. 3: Cutting Deck Circuit Pressure (Using Pressure Gauge) NOTE: CENTER DECK TEST SHOWN TRACTION CIRCUIT 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...
  • Page 71 Procedure for Cutting Deck Circuit Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature 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.

  • Page 72: Test No. 4: Cutting Deck Gear Pump Flow

    TEST NO. 4: Cutting Deck Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter) NOTE: CENTER GEAR PUMP SECTION FLOW TEST SHOWN TRACTION CIRCUIT TO LIFT/LOWER CONTROL VALVE TO STEERING CONTROL VALVE Working Pressure Low (Charge) Pressure Return or Suction Flow Hydraulic System Page 4 - - 30...
  • Page 73 Procedure for Cutting Deck Gear Pump Flow Test IMPORTANT: Do not fully restrict oil flow through tester. In this test, the flow tester is positioned be- NOTE: Over a period of time, the gears and wear plates fore the relief valve. Pump damage can occur if the in the gear pump can wear.

  • Page 74: Test No. 5: Cutting Deck Manifold Relief Pressure

    TEST NO. 5: Cutting Deck Manifold Relief Pressure (Using Tester with Pressure Gauges and Flow Meter) NOTE: CENTER DECK TEST SHOWN TRACTION CIRCUIT 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...
  • Page 75 Procedure for Cutting Deck Manifold Relief 11. If specification is not met, adjust or clean relief valve Pressure Test in deck manifold port (R1BY). Adjust relief valve as fol- lows: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 NOTE: Do not remove valve from the hydraulic man- minutes.

  • Page 76: Test No. 6: Cutting Deck Motor Case Drain Leakage

    TEST NO. 6: Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauges and Flow Meter) NOTE: CENTER DECK MOTOR TEST SHOWN TRACTION CIRCUIT TO LIFT/LOWER CONTROL VALVE TO STEERING CONTROL VALVE Working Pressure Low (Charge) Pressure MEASURING Return or Suction CONTAINER Flow Hydraulic System...
  • Page 77 Procedure for Cutting Deck Motor Case Drain 6. Sit on seat and operate the engine at full speed (2730 Leakage Test + 30 RPM). Move PTO switch to ON. NOTE: Over a period of time, a deck motor can wear in- 7.

  • Page 78: Test No. 7: Steering Circuit Relief Pressure

    TEST NO. 7: Steering Circuit Relief Pressure (Using Pressure Gauge) STEERING CYLINDER PISTON MOVEMENT NOTE: LEFT TURN SHOWN 1350 STEERING CONTROL T TO LIFT/LOWER CIRCUIT CHARGE CIRCUIT TO PTO (MOW) CIRCUIT RESERVOIR TRACTION 2.48 1.37 1.37 CIRCUIT FROM RESERVOIR FROM OIL FILTER High Pressure Low (Charge) Pressure...
  • Page 79 Procedure for Steering Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature 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.

  • Page 80: Test No. 8: Lift/Lower Circuit Relief Pressure

    TEST NO. 8: Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) NOTE: CENTER LIFT LEVER SHOWN IN RAISE POSITION FROM PTO (MOW) CIRCUIT High Pressure Low (Charge) Pressure Return or Suction Flow Hydraulic System Page 4 - - 38 Groundsmaster 4100--D...
  • Page 81 Procedure for Lift/Lower Circuit Relief Pressure Test NOTE: Before attempting to check or adjust lift pres- sure, make sure that counterbalance pressure is cor- rectly adjusted. 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes.

  • Page 82: Test No. 9: Steering And Lift/Lower Gear Pump Flow

    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 TO LIFT/LOWER CIRCUIT TRACTION 2.48 1.37 1.37 CIRCUIT FROM RESERVOIR FROM OIL FILTER High Pressure Low (Charge) Pressure Return or Suction Flow...
  • Page 83 Procedure for Steering and Lift/Lower Gear Pump 8. If the total of the two flows is lower than 7 GPM or a Flow Test pressure of 1000 PSI could not be obtained, check for restriction in pump intake line. If intake line is not re- Output from the steering and lift/lower gear pump sec- stricted, remove gear pump and repair or replace as tion is equally divided by a proportional valve to provide...

  • Page 84: Test No. 10: Counterbalance Pressure

    TEST NO. 10: Counterbalance Pressure (Using Pressure Gauge) FROM PTO (MOW) CIRCUIT High Pressure Low (Charge) Pressure Return or Suction Flow Hydraulic System Page 4 - - 42 Groundsmaster 4100--D...
  • Page 85 Procedure for Counterbalance Pressure Test C. To decrease pressure setting, turn the adjust- ment screw on the valve in a counterclockwise direc- 1. Make sure hydraulic oil is at normal operating tem- tion. A 1/8 turn on the screw will make a measurable perature by operating the machine for approximately 10 change in counterbalance pressure.

  • Page 86: Test No. 11: Rear Traction Circuit (Rv5) Relief Pressure

    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 PTO (MOW) CIRCUIT TO LIFT/LOWER CIRCUIT TO STEERING CIRCUIT FROM PTO (MOW) CIRCUIT Working Pressure Low (Charge) Pressure Return or Suction Flow...
  • Page 87 Procedure for Rear Traction Circuit (RV5) Relief Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature 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.

  • Page 88: Test No. 12: Traction Circuit Reducing Valve (Pr) Pressure

    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 TO PTO (MOW) CIRCUIT TO LIFT/LOWER CIRCUIT TO STEERING CIRCUIT FROM PTO (MOW) CIRCUIT Working Pressure Low (Charge) Pressure Return or Suction Flow...
  • Page 89 Procedure for Traction Circuit Reducing Valve (PR) Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature 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.

  • Page 90: Adjustments

    Adjustments Adjust Cutting Deck Flow Control Valve The cutting deck lift circuit is equipped with an adjust- able flow control valve used to adjust the rate at which the cutting decks lower. The control valve is located un- der the front platform. Adjust flow control valve as fol- lows: 1.

  • Page 91: Service And Repairs

    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 sys- 1. Check oil level in the hydraulic reservoir and add cor- tem, park machine on a level surface, engage parking rect oil if necessary.

  • Page 92: Flush Hydraulic System

    Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time 6. Reconnect all hydraulic hoses, tubes, and compo- there is a severe component failure or the system is nents that were disconnected while draining system. contaminated (oil appears milky, black, or contains NOTE: Use only hydraulic fluids specified in the Opera- metal particles).

  • Page 93: Charge Hydraulic System

    Charge Hydraulic System NOTE: When initially starting the hydraulic system with 11. After the hydraulic system starts to show signs of fill, new or rebuilt components such as motors, pumps, or actuate lift control lever until the lift cylinder rod moves lift cylinders, it is important that the hydraulic system be in and out several times.

  • Page 94: Gear Pump

    Gear Pump RIGHT FRONT Figure 43 1. 90 hydraulic fitting 10. O- -ring 19. Flat washer (2 used) 2. O- -ring 11. Clamp 20. Engine 3. O- -ring 12. Hydraulic T fitting 21. Piston pump 4. 90 hydraulic fitting 13. O- -ring 22.
  • Page 95 Removal (Fig 43) Installation (Fig 43) 1. Park machine on a level surface, lower cutting 1. Lubricate new o--rings with clean hydraulic oil and decks, stop engine, engage parking brake, and remove position on pump. key from the ignition switch. 2.

  • Page 96: Gear Pump Service

    Gear Pump Service 25 to 28 ft- -lb (34 to 38 N- -m) 20 21 21 to 24 ft- -lb (29 to 33 N- -m) 21 to 24 ft- -lb (29 to 33 N- -m) Figure 44 1. Shaft seal 11.
  • Page 97 3. Remove pump from vise, hold pump in hands and Inspection bump shaft against wooden block to separate front 1. Clean and dry all pump components. Remove nicks pump sections. Front body (10) will remain with either and burrs from all parts with emery cloth. front plate (15) or front adapter plate (23).
  • Page 98 Reassembly (Fig. 44) 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 It is important that the relationship of the backplate, gear pocket of middle body (19). Check key for proper adapter plates, bodies, wear plates and front plate is alignment.
  • Page 99 This page is intentionally blank. Groundsmaster 4100--D Page 4 - - 57 Hydraulic System...

  • Page 100: Piston (Traction) Pump

    Piston (Traction) Pump 85 to 95 ft- -lb (115 to 128 N- -m) RIGHT FRONT Figure 45 1. Hydraulic T fitting 13. 90 hydraulic fitting 24. Gear pump 2. O- -ring 14. O- -ring 25. Coupler 3. O- -ring 15. Hydraulic T fitting 26.
  • Page 101 Removal (Fig. 45) Installation (Fig. 45) 1. Park machine on a level surface, lower cutting 1. Carefully lower piston pump into the machine and decks, stop engine, engage parking brake, and remove position it to the engine adapter plate. Support pump to key from the ignition switch.

  • Page 102: Piston (Traction) Pump Service

    Piston (Traction) Pump Service 100 to 110 ft- -lb 27 to 31 ft- -lb (136 to 149 N- -m) (37 to 42 N- -m) 100 to 110 ft- -lb (136 to 149 N- -m) 150 to 160 in- -lb (17 to 18 N- -m) 4 to 6 ft- -lb (5 to 8 N- -m) 40 to 48 in- -lb...
  • Page 103 Disassembly (Fig. 46) 12.Remove the two cap screws (42) that secure cradle sub--assembly inside housing. Move the cradle sub--as- 1. Position the pump into a protected jaw vise, clamp- sembly back--and--forth to release dowel bushings (40) ing onto the outer portion of the flange, with the cap and remove cradle sub--assembly from housing.
  • Page 104 3. Inspect camplate assembly: A. The finish on the piston shoe surfaces of the cam- plate (11) should show no signs of scoring. B. Inspect camplate (11) bushing surface for wear. Also inspect surface for coating transfer from bush- ing. 4.
  • Page 105 8. Place exterior retaining ring (3), thrust race (12), 16.Apply a small amount of petroleum jelly to the steel thrust bearing (13), second thrust race (12), and second side of valve plate (18) to hold in place for installation. retaining ring (3) onto drive shaft (21). Position washer Aligning the index pin, place the valve plate (18) in posi- (24) and shaft seal (25) onto shaft.

  • Page 106: Piston Pump Control Assembly

    Piston Pump Control Assembly 44 to 52 ft- -lb (60 to 70 N- -m) 17 to 26 in- -lb Loctite #222 (2 to 3 N- -m) 28 to 34 in- -lb (3.2 to 3.8 N- -m) Loctite #242 Figure 51 1.
  • Page 107 6. Install wiper seal on input shaft. 5. Test the switch by moving the control arm to the det- ent position, the light should be on. Move the control arm 7. Install new o--ring (2) onto plug and install plug. Ad- out of detent, the light should go off.

  • Page 108: Hydraulic Control Manifold: 4 Wheel Drive

    Hydraulic Control Manifold: 4 Wheel Drive RIGHT FRONT Figure 53 1. Frame assembly 8. Fitting cap 14. O- -ring 2. 4 wheel drive manifold 9. Hydraulic fitting 15. Hydraulic fitting 3. 90 hydraulic fitting 10. O- -ring 16. Adapter 4. O- -ring 11.
  • Page 109 Removal Installation NOTE: The ports on the manifold are marked for easy 1. Install hydraulic manifold to the frame using Figure identification of components. Example: P1 is a piston 53 as guide. pump connection port and 2 is the location for the sole- 2.

  • Page 110: Hydraulic Control Manifold Service: 4 Wheel Drive

    Hydraulic Control Manifold Service: 4 Wheel Drive 80 to 90 ft- -lb 19 18 EATON/VICKERS MANIFOLD (108 to 122 N- -m) 80 to 90 ft- -lb (108 to 122 N- -m) 60 to 70 ft- -lb (81 to 95 N- -m) PLUG TORQUE #2: 41 to 49 in- -lb (4.6 to 5.6 N- -m) 25 to 30 ft- -lb...
  • Page 111 IMPORTANT: Use care when handling the valve car- tridge design allows, use a wood or plastic probe to push tridge. Slight bending or distortion of the stem tube the internal spool in and out 20 to 30 times to flush out can cause binding and malfunction.

  • Page 112: Hydraulic Control Manifold: Deck Drive

    Hydraulic Control Manifold: Deck Drive RIGHT FRONT Figure 56 1. Hydraulic manifold (center deck) 10. O- -ring 18. O- -ring 2. O- -ring 11. O- -ring 19. Hydraulic tee fitting 3. Hydraulic adapter 12. Dust cap 20. Hydraulic manifold (RH wing deck) 4.
  • Page 113 Removal Installation NOTE: The ports on the manifold are marked for easy 1. Install hydraulic manifold to the frame using Figure identification of components. Example: SV1 is the deck 56 as guide. solenoid valve and P1 is a gear pump connection port. 2.

  • Page 114: Hydraulic Control Manifold Service: Deck Drive

    Hydraulic Control Manifold Service: Deck Drive 30 to 35 ft- -lb 30 to 35 ft- -lb (41 to 47 N- -m) (41 to 47 N- -m) 12 to 15 ft- -lb (16 to 20 N- -m) Loctite #242 50 to 55 in- -lb (5.6 to 6.2 N- -m) PLUG TORQUE SAE #2: 60 to 65 in- -lb (6.8 to 9.5 N- -m)
  • Page 115 This page is intentionally blank. Groundsmaster 4100--D Page 4 - - 73 Hydraulic System...

  • Page 116: Hydraulic Control Manifold: Cutting Deck Lift/Lower

    Hydraulic Control Manifold: Cutting Deck Lift/Lower RIGHT FRONT Figure 58 1. Lift/lower hydraulic manifold 7. Lock nut 12. Cap screw (2 used) 2. Valve plate 8. Hydraulic fitting (2 used) 13. 90 hydraulic fitting 3. Flat washer (2 used) 9. O- -ring 14.

  • Page 117: Hydraulic Control Manifold Service: Cutting Deck Lift/Lower

    Hydraulic Control Manifold Service: Cutting Deck Lift/Lower 35 to 40 ft- -lb 35 to 40 ft- -lb (47 to 54 N- -m) (47 to 54 N- -m) 35 to 40 ft- -lb (47 to 54 N- -m) 41 to 49 in- -lb (4.6 to 5.6 N- -m) Figure 59 1.

  • Page 118: Hydraulic Control Manifold: Filter Manifold

    Hydraulic Control Manifold: Filter Manifold RIGHT FRONT Figure 60 1. Filter manifold 9. Flat washer (3 used) 17. 90 hydraulic elbow 2. 45 hydraulic elbow 10. Hydraulic fitting 18. Hydraulic hose 3. Test nipple 11. O- -ring 19. Hydraulic fitting (2 used) 4.

  • Page 119: Hydraulic Control Manifold Service: Filter Manifold

    Hydraulic Control Manifold Service: Filter Manifold 35 to 40 ft- -lb (47 to 54 N- -m) 60 to 70 ft- -lb (81 to 95 N- -m) 13 12 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)

  • Page 120: Rear Axle Motor

    Rear Axle Motor Arrow on side of motor case points up 59 to 73 ft- -lb (80 to 99 N- -m) RIGHT FRONT Figure 62 1. Rear axle motor 6. O- -ring 10. O- -ring 2. 90 hydraulic fitting 7. External snap ring 11.
  • Page 121 Removal Installation 1. Park machine on a level surface, lower cutting 1. If removed, install pinion gear to axle motor. decks, stop engine, engage parking brake, and remove 2. Install o--ring onto motor. Position motor to rear axle key from the ignition switch. assembly making sure that arrows on the side of motor 2.

  • Page 122: Front Wheel Motors

    Front Wheel Motors Arrow on side of motor case points up Arrow on side of motor case points up 75 to 85 ft- -lb RIGHT (101 to 115 N- -m) FRONT Figure 63 1. Front wheel motor 8. O- -ring 15.
  • Page 123 Removal Installation 1. Park machine on a level surface, lower cutting 1. Position wheel motor to brake assembly making sure decks, stop engine, engage parking brake, and remove that arrows on the side of motor case point upward. key from the ignition switch. 2.

  • Page 124: Rear Axle/Front Wheel Motor Service

    Rear Axle/Front Wheel Motor Service 15 to 18 ft- -lb (20 to 24 N- -m) Figure 64 1. Drive shaft 7. Cap screw (6 used) 13. Thrust bearing 2. Backplate (front motor shown) 8. Shaft seal 14. Roll pin 3. Housing assembly 9.
  • Page 125 4. Remove motor from vise and remove rotating as- 2. If necessary, install new needle bearing (17) in hous- sembly (4) from motor housing. ing (3) with numbered end of the bearing outward. 5. Remove the camplate insert (5) from housing. Use 3.
  • Page 126 This page is intentionally blank. Hydraulic System Page 4 - - 84 Groundsmaster 4100--D...

  • Page 127: Cutting Deck Motor

    Cutting Deck Motor Removal 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 begin- ning of the Service and Repairs section of this chapter.

  • Page 128: Cutting Deck Motor Service

    Cutting Deck Motor Service 27 to 33 ft- -lb (37 to 45 N- -m) 33 to 40 ft- -lb (45 to 55 N- -m) Figure 68 1. Rear cover 6. Tab washer 11. Body 2. Drive gear 7. Spider hub 12.
  • Page 129 IMPORTANT: Mark the relative positions of the gear teeth and the bearing blocks so they can be re- assembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. 8. Place the motor on its side and push on the rear bear- ing block to remove the bearing block and gear set (Fig.
  • Page 130 Reassembly (Fig. 68) IMPORTANT: Do not dislodge o- -rings, pressure seals, or back- -up rings during final assembly. NOTE: When reassembling the motor, check the identi- fication marks made during disassembly to make sure 9. Gently slide the rear cover onto the assembly using the parts are properly aligned during reassembly.
  • Page 131 This page is intentionally blank. Groundsmaster 4100--D Page 4 - - 89 Hydraulic System...

  • Page 132: Lift/Lower Control Valve

    Lift/Lower Control Valve RIGHT FRONT Figure 73 1. Control valve assembly 10. Cotter pin (3 used) 19. Cap screw (2 used) 2. Valve bracket 11. RH lever assembly 20. Hydraulic fitting (3 used) 3. Grommet 12. Spacer 21. Hydraulic fitting 4.
  • Page 133 Removal Installation 1. Park machine on a level surface, lower cutting 1. Install lift/lower control valve using Figure 73 as a decks, stop engine, engage parking brake, and remove guide. key from the ignition switch. 2. After reassembly, check operation of cutting deck 2.

  • Page 134: Lift/Lower Control Valve Service

    Lift/Lower Control Valve Service 20 to 25 ft- -lb (27 to 33 N- -m) Figure 74 1. Poppet 13. Washer 25. O- -ring 2. Spacer 14. Washer 26. Backup washer 3. Wiper seal 15. Washer 27. Disc 4. Seat 16. Washer 28.
  • Page 135 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 coat- ing of clean hydraulic oil to parts prior to assembly. 2. Remove spool caps (9). Do not remove retaining rings (12) from spools unless spool spring (19) is bro- NOTE: All O--rings, back--up washers, wiper seals, and ken.

  • Page 136: Steering Valve

    Steering Valve 18 to 22 ft- -lb (25 to 29 N- -m) RIGHT FRONT Figure 75 1. Hex nut 11. O- -ring 21. Steering column assembly 2. Flat washer 12. Flange head screw 22. Flange bushing 3. Steering wheel 13. Hydraulic adapter (4 used) 23.
  • Page 137 Removal Installation 1. Park machine on a level surface, lower cutting 1. Install steering valve using Figure 75 as a guide. decks, stop engine, engage parking brake, and remove 2. Make sure hydraulic tank is full. Add correct oil if nec- key from the ignition switch.

  • Page 138: Steering Valve Service

    Steering Valve Service 150 in- -lb (17 N- -m) 140 to 160 in- -lb (16 to 18 N- -m) Figure 76 1. Steering valve housing 9. Cap screw (7 used) 17. Geroter drive 2. Dust seal 10. End cap 18. Wear plate 3.
  • Page 139 8. Put the thrust bearing and races into the housing. CAUTION The thrust bearing goes between the two races (Fig. 77). IMPORTANT: Do not damage the dust or quad seals The centering springs are under tension. Re- when installing the spool and sleeve assembly. move the retaining ring carefully.

  • Page 140: Front Deck Lift Cylinder

    Front Deck Lift Cylinder RIGHT FRONT Figure 78 1. Lift cylinder 6. Grease fitting 10. Hydraulic fitting 2. Lift arm (LH shown) 7. O- -ring 11. Pivot pin 3. Lock nut 8. 90 hydraulic fitting 12. Cotter pin 4. Pin 9.
  • Page 141 Removal (Fig. 78) Installation (Fig. 78) 1. Park machine on a level surface, lower cutting 1. Position cylinder barrel clevis to frame and insert up- decks, stop engine, engage parking brake, and remove per lift pin into frame and clevis. Secure lift pin with cotter key from the ignition switch.

  • Page 142: Front Deck Lift Cylinder Service

    Front Deck Lift Cylinder Service Figure 79 1. Barrel with clevis 5. Rod seal 9. O- -ring 2. Retaining ring 6. O- -ring 10. T- -seal 3. Shaft with clevis 7. Back- -up ring 11. Piston 4. Dust seal 8. Head 12.
  • Page 143 Disassembly (Fig. 79) Assembly (Fig. 79) 1. Remove oil from lift cylinder into a drain pan by slowly 1. Make sure all parts are clean before reassembly. pumping the cylinder shaft. Plug both ports and clean 2. Coat new O--rings, T--seal, wear ring, rod seal, the outside of the cylinder.

  • Page 144: Wing Deck Lift Cylinder

    Wing Deck Lift Cylinder 100 to 140 in- -lb (11.3 to 15.8 N- -m) 160 to 180 ft- -lb (217 to 244 N- -m) RIGHT FRONT Figure 80 1. Center deck 7. Wing deck lift cylinder 12. Cap screw 2. Grease fitting 8.
  • Page 145 Removal (Fig. 80) Installation (Fig. 80) 1. Park machine on a level surface, lower cutting 1. If removed, install spherical bearings into lift cylinder decks, stop engine, engage parking brake, and remove clevis ends. key from the ignition switch. A. On shaft clevis, press spherical bearing into cle- 2.

  • Page 146: Wing Deck Lift Cylinder Service

    Wing Deck Lift Cylinder Service Figure 81 1. Barrel with clevis 6. O- -ring 10. T- -seal 2. Internal collar 7. Back- -up ring 11. Piston 3. Shaft with clevis 8. Head 12. Locking nut 4. Dust seal 9. O- -ring 13.
  • Page 147 Disassembly (Fig. 81) 2. Coat new O--rings, T--seal, rod seal, back--up ring, and dust seal with clean hydraulic oil. 1. Remove oil from lift cylinder by slowly pumping the cylinder shaft. After removing oil from cylinder, plug both A. Install T--seal and O--ring to the piston. ports and clean the outside of the cylinder.

  • Page 148: Steering Cylinder

    Steering Cylinder 100 to 125 ft- -lb (135 to 169 N- -m) RIGHT 100 to 125 ft- -lb (135 to 169 N- -m) FRONT Figure 83 1. Steering cylinder 6. Grease fitting 11. Ball joint spacer 2. Ball joint 7. 90 hydraulic fitting 12.
  • Page 149 Removal (Fig. 83) Installation (Fig. 83) 1. Park machine on a level surface, lower cutting 1. If removed, install ball joints into steering cylinder. decks, stop engine, engage parking brake, and remove 2. Slide ram end ball joint through hole on steering arm. key from the ignition switch.

  • Page 150: Steering Cylinder Service

    Steering Cylinder Service Figure 84 1. Butt and tube assembly 5. Locking nut 9. O- -ring 2. Shaft 6. O- -ring 10. U- -cup 3. Piston rod assembly 7. PTFE seal 11. Wiper 4. Gland 8. O- -ring Rev. D Hydraulic System Page 4 - - 108 Groundsmaster 4100--D...
  • Page 151 Disassembly (Fig. 84) Assembly (Fig. 84) 1. Remove oil from lift cylinder by slowly pumping the 1. Use a complete repair kit when rebuilding the cylin- cylinder shaft. After removing oil from cylinder, plug both der. Put a coating of clean hydraulic oil on all new seals, ports and clean the outside of the cylinder.

  • Page 152: Hydraulic Reservoir

    Hydraulic Reservoir RIGHT FRONT Figure 86 1. Hydraulic reservoir 10. Hose clamp 18. Hose 2. Petcock 11. Screen filter 19. Hose clamp 3. O- -ring 12. Dipstick 20. Cap screw (2 used) 4. Strap (2 used) 13. O- -ring 21. Cap screw (2 used) 5.
  • Page 153 Removal Inspection 1. Park machine on a level surface, lower cutting 1. Clean hydraulic reservoir and suction strainer with decks, stop engine, engage parking brake, and remove solvent. key from the ignition switch. 2. Inspect for leaks, cracks, or other damage. 2.

  • Page 154: Hydraulic Oil Cooler

    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.
  • Page 155 Chapter 5 Electrical System Table of Contents ELECTRICAL SCHEMATIC, CIRCUIT DIAGRAMS, Hour Meter ....... . AND WIRE HARNESS DRAWINGS .

  • Page 156: Electrical Schematic, Circuit Diagrams, And Wire Harness Drawings

    Electrical Schematic, Circuit Diagrams, and Wire Harness Drawings The electrical schematic, circuit diagrams, and wire har- ness drawings for the Groundsmaster 4100−D are lo- cated in Chapter 9 − Electrical Diagrams. Electrical System Page 5 − 2 Groundsmaster 4100−D...

  • Page 157: Special Tools

    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 me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.

  • Page 158: Troubleshooting

    Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and CAUTION components used on this machine (see Chapter 9 − Electrical Diagrams). Remove all jewelry, especially rings and If the machine has any interlock switches by−passed, watches, before doing any electrical trouble- shooting or testing.

  • Page 159: General Run & Transport Problems

    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 The traction neutral switch is out of adjustment.

  • Page 160: Cutting Deck Operating Problems

    Cutting Deck Operating Problems The cutting deck remains engaged, but should not, The seat switch or circuit wiring is faulty. with no operator in the seat. Cutting decks run, but should not, when raised. Decks The deck position switch or circuit wiring is faulty. shut off with PTO switch.

  • Page 161: Electrical System Quick Checks

    Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level battery terminals. 12.68 V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery 12.45 V 75% charged should be at a temperature of 60...

  • Page 162: Adjustments

    Adjustments Wing Deck Position Switches Adjustment 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove switch cover from deck to allow access to position switch that requires adjustment. NOTE: Use Deck Proximity Switch Adjustment Tool (TOR4095) to assist with switch adjustment (see Spe- cial Tools).

  • Page 163: Cutting Deck Raise And Lower Switches

    Cutting Deck Raise and Lower Switches Adjustment (Fig. 6) 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. The cutting deck raise and lower switches can be ad- justed for correct operation by repositioning the switch(es).

  • Page 164: Component Testing

    Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the CAUTION circuit (e.g. unplug the ignition switch connector before doing a continuity check). When testing electrical components for continu- NOTE: For engine component testing information, see ity with a multimeter (ohms setting), make sure the Kubota Workshop Manual, Diesel Engine, V2003−T that power to the circuit has been disconnected.

  • Page 165: Fuses

    Fuses The fuse blocks are located under the operator’s control console. Identification, Function, and Wiring 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.

  • Page 166: Warning Lights

    Figure 13 4. Turn ignition switch to OFF. Reconnect green wire to 1. Charge indicator 3. High temp shutdown the oil pressure switch. Apply skin−over grease (Toro 2. Engine oil pressure 4. Glow plug indicator Part No. 505−165) to switch terminal.

  • Page 167: Pto Switch

    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 be- low.

  • Page 168: Transport, Alarm Silence, And Temperature Override Switches

    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. The switch terminals are marked as shown in Figure 19 and Figure 20.

  • Page 169: Seat Switch

    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 electri- cal connector are located directly under the seat (Fig.

  • Page 170: Hour Meter

    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.

  • Page 171: Start, Engine Shutdown, Seat, Pto, Alarm, Down Latching, And Over Temperature Relays

    Start, Engine Shutdown, Seat, PTO, Alarm, Down Latching, and Over Temperature Relays These seven relays are located under the console hous- ing 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.

  • Page 172: Hydraulic Valve Solenoids

    Hydraulic Valve Solenoids There are four hydraulic valve solenoids on the Ground- 4. Measure resistance between the two connector ter- smaster 4100−D (Fig. 28). Testing of these solenoids minals. The resistance for the solenoid coil should be can be done with the solenoid on the hydraulic valve. approximately 7.2 ohms.

  • Page 173: Engine Run Solenoid

    Engine Run Solenoid The engine run solenoid must be energized for the en- gine 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.

  • Page 174: Fuel Sender

    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. Rev. E Electrical System Page 5 − 20...

  • Page 175: Fuel Gauge

    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...

  • Page 176: Fuel Pump

    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. Operational Test 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake.

  • Page 177: Glow Controller

    Glow Controller The glow controller is located under the console cover. 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.

  • Page 178: Temperature Sender

    B. Screw sender into the water flange. Torque send- er 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). Rev. E Electrical System Page 5 −...

  • Page 179: High Temperature Shutdown Switch

    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 Make sure engine is cool before removing the temperature switch.

  • Page 180: Temperature Gauge

    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 VARIABLE Make sure the voltage source is turned OFF be- RESISTANCE fore connecting variable resistance to the elec- trical circuit to avoid electrical shock and to pre-...

  • Page 181: Traction Neutral Switch

    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). Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester across the two switch terminals.

  • Page 182: Diode Circuit Board

    Diode Circuit Board (Fig. 44) The diode circuit board contains four diodes and is lo- cated 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) pro- D1−D vide latching circuits for the PTO relay.

  • Page 183: Wing Deck Position Switches

    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 Fig- ure 46).

  • Page 184: Cutting Deck Raise And Lower Switches

    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 ac- tuator for the switches is on the center deck lift/lower le- ver.

  • Page 185: Service And Repairs

    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.

  • Page 186: Battery Storage

    A. Clean battery by washing entire case with a solu- tion 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 petro- leum jelly to prevent corrosion. Rev. E Electrical System Page 5 −...

  • Page 187: Battery Service

    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. CAUTION When working with batteries, use extreme cau- tion to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes.
  • Page 188 C. If the difference between the highest and lowest H. Using the table below, determine the minimum cell specific gravity is 0.050 or greater or the lowest voltage for the cell temperature reading: cell specific gravity is less than 1.225, charge the bat- tery.
  • Page 189 Charging CAUTION To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging meth- od is presented here. This charging method can be ac- Do not charge a frozen battery because it can ex- complished with a constant current battery charger plode and cause injury.
  • Page 190 This page is intentionally blank. Electrical System Page 5 − 36 Groundsmaster 4100−D...
  • Page 191 Chapter 6 Axles, Planetaries, and Brakes Table of Contents SPECIFICATIONS ......Rear Axle Assembly .

  • Page 192: Specifications

    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 75 to 85 ft−lb (101 to 115 N−m) mounting screw torque...

  • Page 193: Adjustments

    Adjustments 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...

  • Page 194: Service And Repairs

    Service and Repairs Brake Assembly 85 to 100 ft−lb (115 to 135 N−m) 75 to 85 ft−lb (101 to 115 N−m) RIGHT FRONT 75 to 85 ft−lb (101 to 115 N−m) Figure 1 1. Planetary assembly 7. Flat washer 13. Tire and wheel assembly 2.
  • Page 195 CAUTION WARNING When changing attachments, tires, or perform- Failure to maintain proper torque could result ing other service, use correct blocks, hoists, in failure or loss of wheel and may result in and jacks. Make sure machine is parked on a personal injury.

  • Page 196: Brake Inspection And Repair

    Brake Inspection and Repair Figure 4 1. Brake housing (LH shown) 6. Hitch pin (2 used) 11. Rotating actuator 2. Seal 7. Stationary disc 12. Extension spring (3 used) 3. Pull rod 8. Rotating disc 13. Ball (3 used) 4. Clevis pin (2 used) 9.
  • Page 197 This page is intentionally blank. Groundsmaster 4100−D Page 6 − 7 Axles, Planetaries, and Brakes...

  • Page 198: Planetary Wheel Drive Assembly

    Planetary Wheel Drive Assembly 85 to 100 ft−lb (115 to 135 N−m) 75 to 85 ft−lb (101 to 115 N−m) RIGHT FRONT 75 to 85 ft−lb (101 to 115 N−m) Figure 5 1. Planetary assembly 6. Hydraulic wheel motor 11. Gasket 12.
  • Page 199 Planetary Wheel Drive Removal (Fig. 5) 4. Secure hydraulic wheel motor to planetary assembly with two (2) cap screws. Torque screws from 75 to 85 ft− 1. Park machine on a level surface, lower cutting unit, lb (101 to 115 N−m). stop engine, engage parking brake, and remove key from the ignition switch.

  • Page 200: Planetary Wheel Drive Service

    Planetary Wheel Drive Service 9 ft−lb (12 N−m) Figure 7 1. Spindle 10. Retaining ring (external) 18. Carrier assembly 2. Boot seal 11. Ring gear 19. Socket head screw (16 used) 12. Retaining ring (internal) 20. Lock washer (16 used) 3.
  • Page 201 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.

  • Page 202: Rear Axle Assembly

    Rear Axle Assembly RIGHT 70 ft−lb maximum (94 N−m maximum) FRONT Figure 8 1. Frame 8. Rear axle assembly 14. Lock nut 2. Cap screw (6 used) 9. Thrust washer (thin) 15. Flange nut 3. Flat washer 10. Washer head screw 16.
  • Page 203 8. Remove cap screw and flange nut that secures front corner of 4WD hydraulic manifold to rear frame mount. 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.
  • Page 204 9. Install steering cylinder to axle assembly (see Steer- ing 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 −...

  • Page 205: Bevel Gear Case And Axle Case

    Bevel Gear Case and Axle Case The following procedures assume the rear axle assem- 35 to 41 ft−lb bly has been removed from the machine. (47 to 56 N−m) Removal 1. Remove the mounting screws, nuts, and lock wash- ers. Remove the bevel gear case/axle case assembly and O-ring from the axle support (Fig.
  • Page 206 5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gas- ket material from either mating surface (Fig. 16). 17 to 20 ft−lb 6. While holding the bevel gear case, tap the upper end (23 to 27 N−m) of the bevel gear shaft out of the upper bearing and up- per bevel gear.
  • Page 207 Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 18). Figure 18 1. Axle case 3. Shaft seal 2. Bevel gear case 2. Install the lower bevel gear, and bevel gear shaft in the axle case cover.
  • Page 208 5. Determine necessary quantity of support shims. 57 to 67 ft−lb A. Lubricate the axle case support bushing with a (77 to 91 N−m) thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during VERTICAL disassembly between axle case support and axle ENDPLAY...
  • Page 209 9. Remove the bevel gear case/axle case assembly NOTE: Axle bearing shims are available in 0.008 in. from the axle support. Coat a new O-ring with grease (0.2 mm), 0.012 in. (0.3 mm), and 0.020 in. (0.5 mm) and temporarily install the axle cover assembly. Position thickness.

  • Page 210: Differential Shafts

    Differential Shafts The following procedures assume the rear axle assem- 35 to 41 ft−lb bly has been removed from the machine. (47 to 56 N−m) Removal IMPORTANT: Do not interchange right and left dif- ferential shaft assemblies. 1. Remove the mounting screws, nuts, and lock wash- ers.

  • Page 211: Axle Shafts

    Axle Shafts The following procedures assume the rear axle assem- 17 to 20 ft−lb bly has been removed from the machine. (23 to 27 N−m) Removal 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig.

  • Page 212: Input Shaft/Pinion Gear

    Input Shaft/Pinion Gear 35 to 41 ft−lb (47 to 56 N−m) 35 to 41 ft−lb (47 to 56 N−m) Figure 28 1. Nut (2 used) 7. O-ring 13. Shim 2. Lockwasher (2 used) 8. Seal collar 14. Screw (2 used) 3.
  • Page 213 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.

  • Page 214: Differential Gear

    Differential Gear The following procedures assume the rear axle assem- 35 to 41 ft−lb bly has been removed from the machine. (47 to 56 N−m) Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual).
  • Page 215 Inspection 1. Measure the differential side gear O.D. and the dif- ferential 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) SIDE GEAR O.D.
  • Page 216 Installation 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. Apply molybdenum disulfide grease to the splines and bearing surfaces of the differential pinion gears, pin- ion washers, and side gears.

  • Page 217: Pinion Gear To Ring Gear Engagement

    Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using PROFILE the gear contact pattern method as described in the fol- TOP LAND lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 39): Toe − the portion of the tooth surface at the end to- LENGTHWISE wards the center.
  • Page 218 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.
  • Page 219 Chapter 7 Chassis Table of Contents SERVICE AND REPAIRS ..... . Steering Tower ......Front Deck Lift Arms .

  • Page 220: Service And Repairs

    Service and Repairs Steering Tower 18 to 22 ft−lb (25 to 29 N−m) RIGHT FRONT Figure 1 Hex nut 15. Lock nut 29. Cap screw (2 used) Flat washer 16. Parking brake switch 30. Pivot hub(2 used) 31. Flange head screw (4 used) Steering wheel 17.
  • Page 221 Disassembly Assembly 1. Park machine on a level surface, lower cutting units, 1. Assemble steering tower using Figure 1 as a guide. stop engine, engage parking brake, and remove key Note: Thrust washer(s) (24) on steering column are from the ignition switch. used as needed to remove end play of steering shaft.

  • Page 222: Front Deck Lift Arms

    Front Deck Lift Arms 60 to 70 ft−lb (81 to 94 N−m) Loctite 242 on threads 100 to 140 in−lb (11.3 to 15.8 N−m) RIGHT FRONT 20 21 155 to 185 ft−lb (210 to 321 N−m) 25 16 75 to 85 ft−lb (102 to 115 N−m) Figure 2 Lift cylinder...
  • Page 223 E. Thoroughly clean tapered surfaces of stud and mounting boss of support hub. Secure support hub CAUTION (position slotted hole in hub toward rear of deck) to tapered stud with flat washer and flange nut. Tighten When raising machine, use correct blocks, flange nut from 155 to 185 ft−lb (210 to 321 N−m).

  • Page 224: Hood

    Hood RIGHT FRONT Figure 5 Hood 13. Flange head screw (4 used) 25. Screen corner seal (2 used) R−clamp (2 used) 14. Flange head screw (4 used) 26. Bulb seal Cap screw 15. Washer head screw (2 used) 27. Screen 28.
  • Page 225 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 hood using Figure 5 as a guide. Installation 1. Install hood using Figure 5 as a guide. 2.
  • Page 226 This page is intentionally blank. Chassis Page 7 − 8 Groundsmaster 4100−D...
  • Page 227 Chapter 8 Cutting Deck Table of Contents SPECIFICATIONS ......SERVICE AND REPAIRS ..... . TROUBLESHOOTING .
  • Page 228 Specifications MOUNTING: Cutting deck is supported by lift arms con- CUTTING BLADE: Cutting blade dimensions are 19” trolled with hydraulic lift levers. (48.3 cm) long, 2.5” (6.4 cm) wide, and .250” (.64 cm) thick. Anti−scalp cup installed on each cutting blade. CONSTRUCTION: Deck chamber is welded 12 gauge Center deck includes three blades and each wing deck steel construction reinforced with channels and plates.

  • Page 229: Factors That Can Affect Quality Of Cut

    Troubleshooting There are a number of factors that can contribute to un- Remember that the “effective” or actual height−of−cut satisfactory quality of cut, some of which may be turf depends on cutting unit weight, tire pressures, hydraulic conditions. Turf conditions such as excessive thatch, counterbalance settings, and turf conditions.

  • Page 230: Adjustments

    Adjustments CAUTION Never install or work on the cutting deck or lift arms with the engine running. Always stop en- gine 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).
  • Page 231 This page is intentionally blank. Groundsmaster 4100−D Page 8 − 5 Cutting Deck...

  • Page 232: Service And Repairs

    Service and Repairs CAUTION Never install or work on the cutting deck or lift arms with the engine running. Always stop en- gine and remove ignition key first. Cutting Deck RIGHT FRONT Figure 1 1. Cutting deck 7. Damper rod end (2 per damper) 13.
  • Page 233 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. NOTE: Removal of clevis pins from deck and height− of−cut chains is easier if deck is lifted slightly. 2.
  • Page 234 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. 5. Install wing deck lift cylinders to cutting deck (Fig. 4): A.
  • Page 235 This page is intentionally blank. Groundsmaster 4100−D Page 8 − 9 Cutting Deck...

  • Page 236: Cutting Deck

    Wing Deck Service 160 to 180 ft−lb (217 to 244 N−m) RIGHT FRONT Figure 6 Wing deck (RH shown) 15. Flange screw (2 used per skid) 29. Pivot pin Flex shield 16. Skid (RH shown) 30. Center deck 31. Cap screw Cap screw 17.
  • Page 237 6. Support wing deck to prevent it from falling as links are removed. 7. Remove cap screw and washer from pivot pin on up- per 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.

  • Page 238: Cutting Deck Link Service

    Cutting Deck Link Service Disassembly (Fig. 9) 1. Press flange bushings from top of link. 2. Remove retaining ring and press tapered stud with spherical bearing and flange nut from link. 3. Remove flange nut and press spherical bearing from tapered stud.

  • Page 239: Wing Deck Latch

    Wing Deck Latch Disassembly (Fig. 11) 1. Raise wing deck to transport position. Carefully ro- tate latch to closed position. 2. Loosen lug nut to release compression spring ten- sion. 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.

  • Page 240: Blade Spindle

    Blade Spindle RIGHT 88 to 108 ft−lb (119 to 146 N−m) FRONT Figure 12 Cutting deck Idler pulley (4 used) 13. Carriage screw Drive spindle: single pulley (2 used) Flat washer 14. Cutting blade Low driven spindle (3 used) Idler spacer 15.
  • Page 241 Installation (Fig. 12) 1. Position spindle on cutting deck noting orientation of grease fitting (Fig. 14). Secure spindle assembly to deck with correct fasteners. 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).

  • Page 242: Blade Spindle Service

    Blade Spindle Service DRIVEN SPINDLE 130 to 150 ft−lb (176 to 203 N−m) DRIVE SPINDLE Figure 15 Lock nut O−ring 13. Snap ring Flat washer Oil seal 14. Grease fitting Driven pulley Bearing cup and cone 15. Spindle housing V−ring seal (if equipped) 10.
  • Page 243 3. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing. The top bearing PRESS 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).

  • Page 244: Castor Forks And Wheels

    Castor Forks and Wheels DECK CASTOR ARM WING DECK CASTOR FORK 60 to 80 ft−lb (81 to 108 N−m) CASTOR WHEEL 60 to 80 ft−lb (81 to 108 N−m) Figure 19 Castor arm (wing deck shown) 13. Compression spring 24. Decal 25.

  • Page 245: Deck Rollers And Skids

    Deck Rollers and Skids RIGHT FRONT Figure 20 Roller Lock nut Flange nut Flange head screw Roller Skid (RH shown) Roller shaft Cap screw 10. Flange head screw Flange nut Removal 1. Remove skids and rollers from deck using Figure 20 as a guide.
  • Page 246 This page is intentionally blank. Page 8 − 20 Cutting Deck Groundsmaster 4100−D...
  • Page 247 Chapter 9 Electrical Diagrams Table of Contents ELECTRICAL SCHEMATIC ....CIRCUIT DIAGRAMS ......Glow Plug Circuit .
  • Page 248 This page is intentionally blank. Page 9 - 2 Electrical Diagrams Groundsmaster 4100−D...

  • Page 249: Electrical Schematic

    Groundsmaster 4100−D Electrical Schematic All relays and solenoids are shown as de−energized. All ground wires are black. Page 9 - 3...

  • Page 250: Glow Plug Circuit

    Groundsmaster 4100−D Glow Plug Circuit Power Current Control Current Indication Current Logic Direction Page 9 - 4...

  • Page 251: Crank Circuit

    Groundsmaster 4100−D Crank Circuit Power Current Control Current Indication Current Logic Direction Page 9 - 5...

  • Page 252: Run (Transport) Circuit

    Groundsmaster 4100−D Run (Transport) Circuit Power Current Control Current Indication Current Logic Direction Page 9 - 6...

  • Page 253: Run (Mow) Circuit

    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...

  • Page 254: Main Wire Harness

    J1 J2 ORANGE YELLOW YELLOW WHITE YELLOW YELLOW YELLOW BLUE BLACK BLACK BLACK VIOLET/BLACK GRAY GREEN GRAY GRAY GREEN/BLACK BLACK WHITE GREEN GRAY BLACK YELLOW PINK GREEN BLACK BLACK WHITE ORANGE VIOLET ORANGE BLUE BLACK BLACK BLACK VIOLET ORANGE YELLOW BROWN BLACK WHITE...

  • Page 255: Main Wire Harness

    Groundsmaster 4100−D Main Wire Harness Page 9 - 9...
  • Page 256 FUSIBLE LINK (14 GA.) FUSIBLE LINK (16 GA.) FUSIBLE LINK (14 GA.) BLACK BLACK RED/BLACK RED/BLACK PINK WHITE ORANGE BLACK BLUE WHITE GRAY BLACK GREEN YELLOW BROWN BLUE WHITE ORANGE VIOLET/BLACK YELLOW/BLACK GREEN BLACK GREEN BLACK BLACK BLACK (D2) ORANGE YELLOW/BLACK Groundsmaster 4100−D Engine Wire Harness...
  • Page 257 (D4) (D2) (D6) Groundsmaster 4100−D Engine Wire Harness Page 9 - 11...

  • Page 258: Front Wire Harness

    BROWN YELLOW PINK GRAY (D8) BLACK PINK GREEN/BLACK GRAY GREEN WHITE BLUE ORANGE VIOLET/BLACK BLACK ORANGE ORANGE BLACK (D7) Groundsmaster 4100−D Front Wire Harness (D5) Page 9 - 12...

  • Page 259: Front Wire Harness

    (D8) (D7) (D5) Groundsmaster 4100−D Front Wire Harness Page 9 - 13...

  • Page 260: Cutting Deck Wire Harnesses

    YELLOW/BLACK BLUE BLUE GRAY GRAY VIOLET VIOLET BLACK ORANGE BLACK DECK LIFT DECK LIFT SENSOR (LH) SENSOR (RH) Groundsmaster 4100−D Cutting Deck Wire Harnesses Page 9 - 14...

  • Page 261: Cutting Deck Wire Harnesses

    Groundsmaster 4100−D Cutting Deck Wire Harnesses Page 9 - 15...

This manual is also suitable for:

30411

Table of Contents