Toro 4100-D manual

(Model 30413) Part No. 08162S L (Rev . A) Service Manual Groundsmaster R 4100 - - D Preface The pur pose of this public ation is to pr ovide t he service technic ian with inf orm ation f or t roubles hooting, test ing and repair of maj or syst ems and co mponents on the Gr oundsmas ter 4100 - - D (Model 30413) . REFE R TO THE O PERA TOR’S MANUAL [...]

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Gr oundsmas ter 4100 - - D T able Of Contents Chapter 1 - - Safety Gener al Safet y I nst ruc tions 1 - - 2 .................. Jackin g Instructions 1 - - 4 ......................... Safet y and I nst ruc tion Dec als 1 - - 5 ................ Cha pter 2 - - Produc t Rec ords and Ma intena nce Produc t Records 2 - - 1 ........................... Mai[...]

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Groundsmaster 4100 - -D Page 1 - - 1 Safety Chapter 1 Safety T able of Contents GENERAL SAFETY INSTRUCTIONS 2 ............ Before Operating 2 ............................ While Operating 2 ............................. Maintenance and Service 3 .................... JACKING INSTRUCTIONS 4 ..................... Jacking the Front End 4 ...............[...]

Groundsmaster 4100 - -D Page 1 - - 2 Safety General Safety Instructions The GROUNDSMASTER 4100-D was tested and certi- fied by TORO for compliance with existing safety stan- dards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also depen[...]

Groundsmaster 4100 - -D Page 1 - - 3 Safety Maintenance and Service 1. Before servicing or making adjustments, lower deck, stop engine, apply parking brake and remove key from the switch. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 3. Never store the machine or fuel container inside where there i[...]

Groundsmaster 4100 - -D Page 1 - - 4 Safety Jacking Instructions CAUTION When changing attachments, tires or perform- ing other service, use correct jacks and sup - ports. 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 rais[...]

Groundsmaster 4100 - -D Page 1 - - 5 Safety 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. D ecal part num- bers are listed in your Parts Catalog. Safety[...]

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Rev . A Groundsmaster 4100- - D Page 2 - - 1 Product Records and Ma intenance Chapter 2 Product Records and Maintenance T able of Contents PRODUCT RECORDS 1 ......................... MAINTENANCE 1 .............................. EQUIV ALENTS AND CONVERSIONS 2 ........... Decimal and Millimeter Equivalents 2 ............ U.S. to Metric Conversions 2 [...]

0.09375 Groundsmaster 4100 - - D Page 2 - - 2 Product Records and Maintenance Equivalents and Conversions[...]

Rev . A Groundsmaster 4100- - D Page 2 - - 3 Product Records and Ma intenance T orque Specifications Recommended fastener torque values are listed in the following tables. For critical applica tions, as determined by T oro, either the recommended torque or a torque that is unique to the application is clearly iden tified and spe- cified in this Ser[...]

Groundsmaster 4100 - - D Page 2 - - 4 Product Records and Maintenance Standard T orque for Dry , Zinc Plated and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 & 8w i t hT h i n Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) SAE Grade 5 Bolts, Screws, Studs & Sems w[...]

Groundsmaster 4100 - - D Page 2 - - 5 Product Records and Maintenance Standard T orque for Dry , Zinc Plated and Steel Fasteners (Metric Series) T h r e a d S i z e Class 8.8 Bolts, Screws and Studs with R e g u l a r H e i g h t N u t s Class 10.9 Bolts, Screws and Studs with R e g u l a r H e i g h t N u t s Thread Size Regular Height Nuts (Class[...]

Groundsmaster 4100 - - D Page 2 - - 6 Product Records and Maintenance Other T orque Specifications SAE Grade 8 Steel Set Screws T h r e a d S i z e Recommended T orque 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 + 3f [...]

Groundsmaster 4100 - - D Page 3 - - 1 Kubota Diesel Engine Chapter 3 Kubota Diesel Engine T able of Contents GENERAL INFORMA TION 2 ..................... Operator ’s Manual 2 .......................... Stopping the Engine 2 ......................... SPECIFICA TIONS 3 ............................. SERVICE AND REP AIRS 4 ...................... Air [...]

Groundsmaster 4100 - - D Page 3 - - 2 Kubota Diesel Engine 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 troubleshoot- ing, testing, disassembly and reassemb[...]

Groundsmaster 4100 - - D Page 3 - - 3 Kubota Diesel Engine Specifications Item Description Make / Designation Kubota Model V2403 - - M - - T - - E3B: 4 - - Cycle, 4 Cylinder , W ater Cooled, Turbocharged, Diesel Engine Bore 3.43” (87.0 mm) Stroke 4.031” (102.4 mm) T otal Displacement cc (cu. in.) 148.5 in 3 (2434 cc) Firing Order 1 (closest to [...]

Groundsmaster 4100 - - D Page 3 - - 4 Kubota Diesel Engine Service and Repairs Air Filter System Figure 1 1. Air cleaner hose 2. Hose clamp 3. Air cleaner assembly 4. Indicator 5. Air cleaner strap 6. Lock nut (2 used) 7. Hose clamp 8. Air cleaner hose 9. Hose clamp 10. Cap screw (2 used) 1 1. Flat washer (4 used) 12. Spring (2 used) 13. Flat washe[...]

Groundsmaster 4100 - - D Page 3 - - 5 Kubota Diesel Engine Removal (Fig. 1) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. Raise and support hood. 3. Remove air cleaner components as needed using Figure 1 as a guide. Installation (Fig. 1) IMPORT ANT : Any leaks in[...]

Groundsmaster 4100 - - D Page 3 - - 6 Kubota Diesel Engine Exhaust System Figure 5 1. Muffler 2. Muffler bracket 3. Exhaust pipe 4. Flange head screw (4 used) 5. Exhaust gasket 6. Lock nut (2 used) 7. Cap screw (2 used) 8. Flat washer (4 used) 9. Spacer (2 used) 10. Rubber hanger 1 1. Flange nut (4 used) 12. Flange head screw (2 used) 13. Engine mo[...]

Rev . A Groundsmaster 4100- - D Page 3 - - 7 Kubota Diesel Engine Removal (Fig. 5) CAUTION The muffler and exhaust pipe may be hot. T o avoid possible burns, allow the e ngine and ex - haust system to cool befor e working on the muf- fler . 1. Park machi ne on a level surface, lower cutting deck, stop engine, apply pa rking brake and remove key fro[...]

Groundsmaster 4100 - - D Page 3 - - 8 Kubota Diesel Engine Fuel System Figure 7 1. Fuel tank 2. Fuel tank bracket 3. Air breather 4. Female hose barb 5. T ank support assembly 6. Fuel hose 7. Flange nut 8. Cap screw (4 used) 9. Flat washer 10. Cap screw (4 used) 1 1. Carriage screw (2 used) 12. W asher 13. Battery strap 14. Battery 15. Retaining ri[...]

Groundsmaster 4100 - - D Page 3 - - 9 Kubota Diesel Engine DANGER Because diesel fuel is highly f lammable, use cau- tion 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 [...]

Groundsmaster 4100 - - D Page 3 - - 10 Kubota Diesel Engine Radiator Figure 8 1. Radiator cap 2. Foam strip (2 used) 3. Foam strip (2 used) 4. Lower radiator hose 5. Upper radiator hose 6. Clamp (4 used) 7. Lower radiator shroud 8. T emperature sender 9. Radiator 10. Hose clamp (3 used) 1 1 . H o s e( 2u s e d ) 12. Screw (4 used) 13. Rubber gromme[...]

Groundsmaster 4100 - - D Page 3 - - 1 1 Kubota Diesel Engine Removal (Fig. 8) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. Open and support hood. CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot cool- ant can e[...]

Groundsmaster 4100 - - D Page 3 - - 12 Kubota Diesel Engine Engine Figure 9 1. Engine 2. Cap screw (4 used) 3. LH engine mount 4. Lock washer 5. Cap screw 6. Lock washer (5 used) 7. Cap screw (5 used) 8. Engine support (4 used) 9. Flange nut (12 used) 10. Rebound washer (4 used) 1 1. Cap screw (8 used) 12. Spring coupler 13. Washer (14 used) 14. Ca[...]

Groundsmaster 4100 - - D Page 3 - - 13 Kubota Diesel Engine Engine Removal (Fig. 9) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove battery cover and strap. Disconnect nega- tive battery cable first and then positive battery cable. Remove battery from machin[...]

Groundsmaster 4100 - - D Page 3 - - 14 Kubota Diesel Engine 9. Disconnect throttle cable from the speed control le- ver by removing the flat washer and lock nut (Fig. 14). Loosen jam nut and separate cable from cable support. Position cable away from engine. 10. Remove fasteners that secure the upper radiator shroud to the lower shroud and radiator[...]

Groundsmaster 4100 - - D Page 3 - - 15 Kubota Diesel Engine 3. Slowly lower engine into the machine. 4. Align engine to the engine supports and hydraulic pump input shaft. Secure engine to engine supports with cap screws, rebound washers and flange nuts. 5. Secure hydraulic pump assembly to engine (see Pump Assembly Installation in the Service and [...]

Groundsmaster 4100 - - D Page 3 - - 16 Kubota Diesel Engine Spring Coupler Figure 16 1. Spring coupler 2. W asher (14 used) 3. Cap screw (6 used) 4. Flywheel plate 5. Cap screw (4 used) 6. LH engine mount 7. Cap screw (2 used) 8. RH engine mount 1 2 3 6 5 4 7 2 8 FRONT RIGHT ( 3 8t o4 3N - - m ) 28 to 32 ft - - lb ( 4 0t o4 4N - - m ) 29 to 33 ft -[...]

Groundsmaster 4100 - - D Page 3 - - 17 Kubota Diesel Engine Coupler Removal (Fig. 16) NOTE: The hydraulic pump assembly needs to be re- moved from engine before coupler can be removed. 1. If engine is in machine, support engine from below to prevent it from shifting while removing hydraulic pump assembly (see Piston (T raction) Pump Removal in the [...]

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Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 Chapter 4 Hydraulic System T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ..................... Operator ’s Manual 3 .......................... T owing Traction Unit 3 ......................... Check Hydraulic Fluid 3 ....................... Hydrauli[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 2 Specifications Item Description Piston (T raction) Pump Eaton V ariable Displacement Piston Pump (Model 72400) System Relief Pressure: Forward 4000 PSI (274 bar) System Relief Pressure: Reverse 5000 PSI (343 bar) Charge Pressure 250 PSI (17 bar) Front Wheel Motors Eaton Fixed Displacement Pisto[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 3 General Information Operator ’s Manual The Operator ’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. T owing T raction Unit I[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 4 Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather , sun, chemicals, very warm storage condi- tions or mishandling during operation and maintenance. These conditions can cause hose damage and deterio- ration.[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 5 Hydraulic Hose and T ube Installation (O - - Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is rec- ommended that the face seal O - [...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 6 Hydraulic Fitting Installation (SAE Straight Thread O - - Ring Fitting into Component Port) Non - - Adjustable Fitting (Fig. 6) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure a[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 7 Adjustable Fitting (Fig. 8) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is rec- ommended that the O - - ring be replaced any time the connection is opene[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 8 Hydraulic Schematic NOTE: A larger hydraulic schematic is 4WD MANIFOLD COUNTERBALANCE MANIFOLD FIL TER MANIFOLD F AN DRIVE MANIFOLD RH WING DECK MANIFOLD LH WING DECK MANIFOLD CENTER DECK MANIFOLD included in Chapter 9: Foldout Drawings[...]

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Groundsmaster 4100 - - D Hydraulic System Page 4 - - 10 Hydraulic Flow Diagrams T raction Circuit (4WD Forward Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100 - - D FAN DRIVE MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD M1 M2 ST L P1 P2 T P1 P2 P1 P2 P1 P2 LC2 LC1 RV1 RV2 RV1 RV2 M1 M2 M1 M2 S LC2 LC1 OR OR [...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 1 T raction Circuit: 4WD (Mow) The traction circuit piston pump is a variable displace- ment pump that is directly coupled to the engine fly- wheel. Pushing the traction pedal engages a hydraulic servo valve which controls the variable displacement piston pump swash plate to create a flow of oi[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 12 T raction Circuit (T ransport Forward Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100 - - D FAN DRIVE MANIFOLD COUNTERBALANCE MANIFOLD M1 M2 ST L P1 P2 T P1 P2 P1 P2 P1 P2 LC2 LC1 RV1 RV2 RV1 RV2 M1 M2 M1 M2 S LC2 LC1 OR OR S M1 M2 RV1 RV2 LC2 LC1 S RH W[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 13 T raction Circuit: T ransport (2WD) The traction circuit piston pump is a variable displace- ment pump that is directly coupled to the engine fly- wheel. Pushing the traction pedal engages a hydraulic servo valve which controls the variable displacement piston pump swash plate to create a flow[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 14 Lower Cutting Deck (LH Deck Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100 - - D FAN DRIVE MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD M1 M2 ST L P1 P2 T RV1 RV2 LC2 LC1 S P1 P2 M1 M2 RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR R[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 15 Lower Cutting Deck A four section gear pump is coupled to the piston (trac- tion) pump. The third gear pump section supplies hy- draulic flow to both the lift/lower c ontrol valve and the steering control valve. Hydraulic flow from this pump section is delivered to the steering and lift/lower [...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 16 Raise Cutting Deck (LH Deck Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100 - - D FAN DRIVE MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD M1 M2 ST L P1 P2 T RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR RV1 RV2 LC2 LC1 S P1 P2 M1 M2 RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR R[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 17 Raise Cutting Deck A four section gear pump is coupled to the piston (trac- tion) pump. The third gear pump section supplies hy- draulic 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 proport[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 18 Mow Circuit (All Deck Motors Rotating) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100 - - D FAN DRIVE MANIFOLD RH WING DECK MANIFOLD 4WD MANIFOLD LH WING DECK MANIFOLD CENTER DECK MANIFOLD COUNTERBALANCE MANIFOLD M1 M2 ST L P1 P2 T RV1 RV2 LC2 LC1 S P1 P2 M1 M[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 19 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 the wing decks, while the next gear pump section sup- plies the center deck. Each cutting deck is controlled by [...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 20 Mow Circuit Cutting Deck Blade Braking When the operator turns the PTO switch OFF or if a deck is raised with the PTO switch ON, deck control manifold solenoid valve (S) is de - - energized causing logic car- tridge (LC1) to shift (refer to information in PT O Mow Cir- cuit in this section). T[...]

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Groundsmaster 4100 - - D Hydraulic System Page 4 - - 22 Steering Circuit (Left T urn Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100 - - D FAN DRIVE MANIFOLD RH PTO MANIFOLD 4WD MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD COUNTERBALANCE MANIFOLD M1 M2 ST L P1 P2 T RV1 RV2 LC2 LC1 S P1 P2 M1 M2 RV1 RV2 LC2 LC1[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 23 Steering Circuit A four section gear pump is coupled to the piston (trac- tion) pump. The third gear pump section supplies hy- draulic 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 l[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 24 Engine Cooling Fan Circuit (Forward Direction Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100 - - D FAN DRIVE MANIFOLD RH PTO MANIFOLD 4WD MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD COUNTERBALANCE MANIFOLD M1 M2 ST L P1 P2 T RV1 RV2 LC2 LC1 S P1 P2 M1 M[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 25 Engine Cooling Fan Circuit A four section gear pump is coupled to the piston (trac- tion) pump. The gear pump section farthest from the pis- ton pump supplies hydraulic flow for the fan drive manifold and hydraulic engine cooling fan motor (Fig. 14). The fan drive manifold controls the operati[...]

Rev . A Groundsmaster 4100- - D Hydraulic Sys tem Page 4 - - 26 Special T ools Order these spe cial tools from y our T oro Distributor . Hydraulic Pressure T est Kit Use to take various pressure read ings for diagnostic tests. Quick disconnect fitti ngs provided attach directly to mating fittings on machi ne test ports without tools. A high pressur[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 27 Hydraulic T est Fitting Kit This kit includes a variety of O - - ring Face Seal fittings to enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. T oro Part Number: TOR4079 Figure 18 TORO TEST FITTING KIT (NO. T OR40[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 28 T roubleshooting The charts that follow contain suggestions to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the T esting section of this Chapter for precau- tions and specific test procedures. NOTE: When troubleshooting traction probl[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 29 Problem Possible Causes T raction power is lost or unit w ill not operate in either direction. Hydraulic reservoir oil level is low . Piston pump by - - pass valve is open or damaged. Charge pressure is low . T raction circuit pressure is low . Front wheel motor couplers are damaged. Four whee[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 30 Problem Possible Causes Cutting deck (or wing decks) will not raise. Engine RPM is too low . Hydraulic oil level in reservoir is low . Lift arm pivots are binding. Relief valve in lift/lower control valve is stuck. Pilot valve in lift/lower control valve is damaged or sticking. Lift cylinder(s[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 31 T esting 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 T ools section in this Chapter). Before Performing Hydraulic T ests [...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 32 T raction Circuit Charge Pressure (Using Pressure Gauge) 4WD MANIFOLD FIL TER MANIFOLD TO COOLING F AN CIRCUIT TO STEERING & LIFT CIRCUITS FROM FRONT DECK FROM COUNTERBALANCE MANIFOLD TO MOW CIRCUIT CYLINDERS FROM FRONT PTO MANIFOLD FROM STEERING V AL VE PORT T FROM STEERING V AL VE PORT P[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 33 Procedure for T raction Circuit Charge Pressure T est 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 c utting deck lowered and off. Make sur[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 34 T raction Circuit Relief Pressure (Using Pressure Gauge) 4WD MANIFOLD FIL TER MANIFOLD TO COOLING F AN CIRCUIT TO STEERING & LIFT CIRCUITS FROM FRONT DECK FROM COUNTERBALANCE MANIFOLD FROM DECK MANIFOLDS TO MOW CIRCUIT CYLINDERS FROM FRONT PTO MANIFOLD FROM STEERING V AL VE PORT T FROM STE[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 35 Procedure for T raction Circuit Relief Pressure T est 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. 2. Drive m[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 36 Counterbalance Pressure (Using Pressure Gauge) F AN DRIVE MANIFOLD 4WD MANIFOLD FIL TER MANIFOLD TO MOW CIRCUIT TO MOW CIRCUIT FROM FRONT DECK MANIFOLD FROM DECK MOTORS FROM RH DECK MANIFOLD FROM RH DECK CIRCUIT PRESSURE GAUGE COUNTERBALANCE MANIFOLD M1 M2 ST L P1 P2 T FROM DECK MANIFOLDS[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 37 Procedure for Counterbalance Pressure T est 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 c utting deck lowered and off. Make sure engine i[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 38 Rear T raction Circuit (RV) Relief Pressure (Using Pressure Gauge) 4WD MANIFOLD FIL TER MANIFOLD TO COOLING F AN CIRCUIT TO STEERING & LIFT CIRCUITS FROM FRONT DECK FROM COUNTERBALANCE MANIFOLD FROM DECK MANIFOLDS TO MOW CIRCUIT CYLINDERS FROM FRONT PTO MANIFOLD FROM STEERING V ALVE PORT T[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 39 Procedure f or Rear T raction C ircuit (RV) Relief Pres - sure T est 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 c utting deck lowered an[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 40 T raction Circuit Reducing V alve (PR) Pressure (Using Pressure Gauge) 4WD MANIFOLD FIL TER MANIFOLD TO COOLING F AN CIRCUIT TO STEERING & LIFT CIRCUITS FROM FRONT DECK FROM COUNTERBALANCE MANIFOLD CYLINDERS FROM FRONT PTO MANIFOLD FROM STEERING V ALVE PORT T FROM STEERING V ALVE PORT PB P[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 41 Procedure for T raction Circuit Reducing V alve (PR) Pressure T est 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 c utting deck lowered and[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 42 Cutting Deck Circuit Pressure (Using Pressure Gauge) NOTE: CENTER DECK PRESSURE TEST SHOWN MANIFOLD MANIFOLD MANIFOLD FIL TER MANIFOLD TO COOLING F AN CIRCUIT FROM RE AR AXLE MOTOR TO STEERING & LIFT CIRCUITS CHARGE CIRCUIT FROM FRONT WHEEL MOTORS FROM 4WD MANIFOLD TRACTION CIRCUIT FLOW FR[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 43 Procedure for Cutting Deck Circuit Pressure T est 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 c utting deck lowered and off. Make sure en[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 44 PT O Relief Pressure (Using T ester with Pressure Gauges and Flow Meter) RH WING DECK MANIFOLD LH WING DECK MANIFOLD CENTER DECK MANIFOLD FIL TER MANIFOLD TO COOLING F AN CIRCUIT FROM RE AR AXLE MOTOR TO STEERING & LIFT CIRCUITS CHARGE CIRCUIT FROM FRONT WHEEL MOTORS FROM 4WD MANIFOLD TRAC[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 45 Procedure for Cutting Deck Manifold Relief Pressure T est 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 c utting deck lowered and off. Make[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 46 Cutting Deck Gear Pump Flow (Using T ester with Pressure Gauges and Flow Meter) N O T E :C E N T E RG E A RP U M P SECTION FLOW TEST SHOWN MANIFOLD MANIFOLD MANIFOLD FIL TER MANIFOLD TO COOLING F AN CIRCUIT FROM RE AR AXLE MOTOR TO STEERING & LIFT CIRCUITS CHARGE CIRCUIT FROM FRONT WHEEL M[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 47 Procedure for Cutting Deck Gear Pump Flow T est 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 ef ficient. Eventually , enough oil loss will occur to cause the cutting deck motors to stall under heavy c[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 48 Cutting Deck Motor Case Drain Leakage (Using T ester with Pressure Gauges and Flow Meter) MANIFOLD MANIFOLD MANIFOLD FIL TER MANIFOLD TO COOLING F AN CIRCUIT FROM RE AR AXLE MOTOR TO STEERING & LIFT CIRCUITS TRACTION CIRCUIT FLOW CHARGE CIRCUIT FROM FRONT WHEEL MOTORS FROM 4WD MANIFOLD TRA[...]

Rev . A Groundsmaster 4100- - D Hydraulic System Page 4 - - 4 9 Procedure for Cutting Deck Motor Case Drain Leakage T est NOTE: Over a period of time, a deck motor can wear in- ternally . A worn motor may by - - pass oil to its case drai n causing the motor to be less efficien t. Eventually , enough oil loss will cause the deck motor to stall un de[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 50 Steering Circuit Relief Pressure (Using Pressure Gauge) F AN DRIVE MANIFOLD 4WD MANIFOLD FIL TER MANIFOLD TO MOW CIRCUIT FROM FRONT DECK MANIFOLD TO LIFT/LOWER CONTROL V AL VE FROM FRONT DECK LIFT CYLINDERS FROM COUNTERBALANCE MANIFOLD FROM DECK MOTORS FROM RH DECK MANIFOLD FROM RH DECK CIRCUI[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 51 Procedure for Steering Circuit Relief Pressure T est 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 c utting deck lowered and off. Make sure[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 52 Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) F AN DRIVE MANIFOLD 4WD MANIFOLD FIL TER MANIFOLD TO MOW CIRCUIT FROM DECK MANIFOLDS TO MOW CIRCUIT FROM FRONT DECK MANIFOLD FROM DECK MOTORS FROM RH DECK MANIFOLD FROM RH DECK CIRCUIT PRESSURE GAUGE COUNTERBALANCE MANIFOLD M1 M2 ST L P[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 53 Procedure for Lift/Lower Circuit Relief Pressure T est 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 minut[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 54 Steering and Lift/Lower Gear Pump Flow (Usi ng T ester with Pressure Gauges and Flow Meter) F AN DRIVE MANIFOLD 4WD MANIFOLD FIL TER MANIFOLD TO MOW CIRCUIT FROM DECK MANIFOLDS TO MOW CIRCUIT FROM FRONT DECK MANIFOLD FROM DECK MOTORS FROM RH DECK MANIFOLD FROM RH DECK CIRCUIT COUNTERBALANCE MA[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 55 Procedure for Steering and Lift/Lower Gear Pump Flow T est Output from the steering and lift/lower gear pump sec- tion is equally divided by a proportional valve to provide flow to the steering circuit and the lift circuit. T o test gear pump flow , testing of both steering and lift/lower circ[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 56 Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac) F AN DRIVE MANIFOLD 4WD MANIFOLD FIL TER MANIFOLD FROM DECK MANIFOLDS TO MOW MANIFOLD FROM FRONT PTO MANIFOLD FROM DECK MOTORS FROM RH PTO MANIFOLD FROM RH PTO CIRCUIT COUNTERBALANCE MANIFOLD M1 M2 ST L P1 P2 T TO MOW MANIFOLD[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 57 Procedure for Engine Cooling Fan Circuit T est 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. Make sure engin[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 58 Engine Cooling Fan Circuit Gear Pump Flow (Using T ester with Pressure Gauges and Flow Meter) F AN DRIVE MANIFOLD 4WD MANIFOLD FIL TER MANIFOLD FROM DECK MANIFOLDS TO MOW MANIFOLD FROM FRONT PTO MANIFOLD FROM DECK MOTORS FROM RH PTO MANIFOLD FROM RH PTO CIRCUIT COUNTERBALANCE MANIFOLD M1 M2 ST[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 59 Procedure for Engine Cooling Fan Circuit Gear Pump Flow T est 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 c utting deck lowered and off. [...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 60 Adjustments Adjust Cutting Deck Flow Control V alve The cutting deck lift circuit is equipped with an adjust- able flow control valve used to adjust the rate at which the cutting deck lowers. The control valve is located un- der the front platform. Adjust flow control valve as follows: 1. Run [...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 61 Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- tem, park machine on a level surface, engage parking brake, lower cutting deck or attachments and stop[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 62 Flush Hydraulic System IMPORT ANT : 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). 1. Park machine on a level surface. Lower cutting deck to the ground, stop engine and engage parkin[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 63 Charge 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 damag[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 64 Hydraulic Reservoir 1. Hydraulic reservoir 2. Petcock 3. O - - ring 4. Strap 5. Felt strap (2 used) 6. Bushing (2 used) 7. Bushing 8. Strap 9. Stand pipe (2 used) 10. Hose clamp (2 used) 1 1. Screen filter 12. Dipstick 13. O - - ring 14. Reservoir cap 15. Suction hose 16. T ank strainer 17. Ho[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 65 NOTE: The front frame needs to be lowered from the main frame to allow clearance to remove the hydraulic reservoir from the machine. Removal (Fig. 47) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove fr[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 66 Hydraulic Oil Cooler 1. Radiator 2. RH radiator support 3. T op radiator support 4. Knob (2 used) 5. Oil cooler bracket 6. Retaining ring (2 used) 7. Carriage screw (2 used) 8. O - - ring 9. 90 o hydraulic fitting (2 used) 10. O - - ring 1 1. Cap screw (2 used) 12. Lock washer (6 used) 13. Oil[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 67 Removal (Fig. 48) CAUTION The radiator and oil cooler may be hot. T o avoid possible burns, allow the engine and cooling systems t o cool before working on the oil cooler . 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 68 Gear Pump 1. Hydraulic tee fitting 2. Roll pin 3. 90 o hydraulic fitting 4. Piston pump 5. Flat washer (2 used) 6. Cap screw (2 used) 7. Hydraulic fitting (2 used) 8. 90 o hydraulic fitting 9. Hydraulic fitting 10. Hydraulic hose 11 . O - - r i n g 12. Pump spacer 13. O - - ring (2 used) 14. O[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 69 Removal (Fig 49) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Raise seat and secure it with prop rod to gain access to gear pump. 3. Drain the hydraulic reservoir . 4. T o prevent contamination of hydrauli[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 70 Gear Pump Service 1. Dust seal 2. Retaining ring 3. Flange washer 4. Shaft seal 5. Front cover 6. Dowel pin (16 used) 7. Pressure seal 8. Back - - up gasket 9. Thrust plate (8 used) 10. Seal (8 used) 1 1. Idler gear 12. Drive shaft 13. Back - - up gasket 14. Pressure seal 15. Front body 16. Sp[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 71 IMPORT ANT : Use caution when clamping gear pump in a vise to avoid distorting any pump c ompo- nents. 3. Secure the front cover of the pump in a vise with the drive shaft pointing down. 4. Loosen the four (4) cap screws that secure pump as- sembly . 5. Remove pump from vise and remove fastene[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 72 T raction Circuit 1. Piston (traction) pump 2. Gear pump 3. LH front wheel motor 4. Check valve 5. RH front wheel motor 6. 4WD manifold 7. Filter manifold 8. Rear axle motor 9. Cooling fan motor Figure 52 FRONT RIGHT 2 1 5 4 3 7 6 8 9 Figure 52 illustrates the components that are used in the G[...]

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Groundsmaster 4100 - - D Hydraulic System Page 4 - - 74 Piston (T raction) Pump 1. Hydraulic T fitting 2. Roll pin 3. 90 o hydraulic fitting 4. Piston pump 5. Flat washer (2 used) 6. Cap screw (2 used) 7. Hydraulic fitting (2 used) 8. 90 o hydraulic fitting 9. Hydraulic fitting 10. Hydraulic hose 11 . O - - r i n g 12. Pump spacer 13. O - - ring (2[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 75 Removal (Fig. 53) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. T o prevent contamination of hydraulic system during removal, thoroughly clean exterior of pump assembly . 3. Remove traction rod from control [...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 76 Piston (T raction) Pump Service 1. Jam nut 2. Retaining ring 3. Retaining ring 4. Seal washer 5. Socket head screw 6. Rotating kit assembly 7. Servo piston assembly 8. Piston follower 9. Cover plate 10. Cover plate 1 1. Camplate assembly 12. Thrust race 13. Thrust bearing 14. Bypass valve 15. [...]

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Groundsmaster 4100 - - D Hydraulic System Page 4 - - 78 Rear Axle Motor 1. Axle motor 2. 90 o hydraulic fitting (2 used) 3. Hydraulic fitting 4. Cap screw (2 used) 5. Flat washer (2 used) 6. O - - ring 7. External snap ring (2 used) 8. Pinion gear 9. External snap ring (2 used) 10. Gear 1 1. Needle bearing 12. O - - ring 13. O - - ring 14. O - - ri[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 79 Removal (Fig. 56) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of t[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 80 Front Wheel Motors 1. Front wheel motor 2. Internal retaining ring 3. Splined brake shaft 4. RH brake assembly 5. Planetary assembly 6. Cap screw (2 used per motor) 7. Flat washer (2 used per motor) 8. O - - ring 9. Hex head plug 10. 90 o hydraulic fitting 11 . 9 0 o hydraulic fitting 12. O - [...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 81 Removal (Fig. 57) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of t[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 82 Rear Axle and Front Wheel Motor Service 1. Drive shaft 2. Backplate (front motor shown) 3. Housing assembly 4. Rotating assembly 5. Cam plate insert 6. Retaining ring 7. Cap screw (6 used) 8. Shaft seal 9. Retaining ring 10. Thrust race 11 . O - - r i n g 12. V alve plate 13. Thrust bearing 14[...]

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Groundsmaster 4100 - - D Hydraulic System Page 4 - - 84 4WD Manifold 1. Frame assembly 2. 4 wheel drive manifold 3. 90 o hydraulic fitting 4. O - - ring 5. O - - ring 6. Quick fitting 7. O - - ring 8. Fitting cap 9. Hydraulic fitting 10. O - - ring 11 . O - - r i n g 12. 90 o hydraulic fitting 13. O - - ring 14. O - - ring 15. Hydraulic fitting 16.[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 85 Removal (Fig. 59) NOTE: The ports on the manifold are marked for easy identification of components. Example: P1 is a piston pump c onnection port and SV is the location for the sole- noid valve (See Hydraulic Schematic in Chapter 9 - - Foldout Drawings to identify the function of the hydraulic[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 86 4WD Manifold Service 1. Manifold body 2. Solenoid valve (port SV) 3. Solenoid coil 4. Check valve (port CV) 5. Nut 6. Directional valve (ports PD1 & PD2) 7. Pressure reducing valve (port PR) 8. Relief valve (port RV) 9. Orifice (0.030) (port SV) 10. #4 zero leak plug with O - - ring 1 1. #[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 87 4WD Manifold Service (Fig. 60) 1. Make sure the manifold is clean before removing the valve. 2. If cartridge is solenoid operated, remove nut secur- ing solenoid to the cartridge valve. Carefully slide sole- noid off the valve. IMPORT ANT : Use care when handling the valve car- tridge. Slight [...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 88 Filter Manifold 1. Filter manifold 2. 45 o hydraulic fitting 3. T est nipple 4. Dust cap 5. O - - ring 6. O - - ring 7. O - - ring 8. Cap screw (3 used) 9. Flat washer (3 used) 10. Hydraulic fitting 11 . O - - r i n g 12. O - - ring 13. 90 o hydraulic fitting 14. Hydraulic hose 15. O - - ring [...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 89 Removal (Fig. 61) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter . 2. T o prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of manifold and [...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 90 Filter Manifold Service 1. Filter manifold 2. Check valve (reservoir return) 3. Oil filter element 4. Check valve (filter bypass) 5. Plug (Zero Leak #6) 6. Charge relief valve 7. Plug (Zero Leak #8) Figure 62 FRONT UP 6 7 1 5 5 4 2 FRONT UP 3 3 25 ft - - lb (34 N - - m) 30 ft - - lb (41 N - - [...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 91 Filter Manifold Service (Fig. 62) For cartridge valve service procedures, see 4WD Man- ifold Service in this section. Refer to Figure 62 for filter manifold cartridge valve and plug installation torque. Hydraulic System[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 92 Steering and Cooling Fan Circuits 1. Gear pump 2. Steering control valve 3. Fan drive manifold 4. Fan motor 5. Steering cylinder Figure 63 FRONT RIGHT 2 1 5 4 3 Figure 63 illustrates the components that are used in the Groundsmaster 4100 - - D steering and cooling fan circuit. Procedures for r[...]

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Groundsmaster 4100 - - D Hydraulic System Page 4 - - 94 Steering V alve 1. Hex nut 2. Flat washer 3. Steering wheel 4. Foam collar 5. Steering seal 6. External snap ring 7. Steering shaft assembly 8. Steering tower cover 9. O - - ring 10. 90 o hydraulic fitting 11 . O - - r i n g 12. Flange head screw 13. Hydraulic adapter (4 used) 14. Steering val[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 95 Removal (Fig. 64) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of this section. 3. T o prevent contam[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 96 Steering V alve Service 1. Steering valve housing 2. Dust seal 3. O - - ring 4. Spool 5. Spring retaining ring 6. Pin 7. Sleeve 8. Centering springs/spacers 9. Cap screw (7 used) 10. End cap 11 . O - - r i n g 12. Seal ring 13. O - - ring 14. Geroter 15. O - - ring 16. Spacer 17. Geroter drive[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 97 CAUTION The centering springs are under tension. Re- move the retaining ring carefully . 10. Remove the spring retaining ring and centering springs from the spool. Reassembly (Fig. 65) Check all mating surfaces. Replace any parts with scratches or burrs that could cause leakage. W ash all meta[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 98 Steering Cylinder 1. Steering cylinder 2. Ball joint 3. Ball joint 4. Retaining ring 5. Grease fitting 6. Grease fitting 7. 90 o hydraulic fitting 8. O - - ring 9. O - - ring 10. Drive axle assembly 1 1. Ball joint spacer 12. Axle washer 13. Hex slotted nut 14. Cotter pin Figure 67 6 4 1 2 5 4[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 99 Removal (Fig. 67) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of this section. 3. T o prevent contam[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 100 Steering Cylinder Service 1. T ube assembly 2. Rod 3. Piston assembly 4. Head 5. Retaining ring 6. Backup ring 7. O - - ring 8. Cap seal 9. Rod seal 10. O - - ring 11 . O - - r i n g 12. Wiper Figure 68 45 to 55 ft - - lb ( 6 2t o7 4N - - m ) 1 6 7 3 9 10 4 11 2 8 5 12[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 101 Disassembly (Fig. 68) 1. Pump oil out of cylinder into a drain pan by SLOWL Y moving rod and piston in and out of cylinder bore. Plug ports and clean outside of cylinder . IMPORT ANT : T o prevent damage when clamping cylinder in a vise, clamp only on pivotal ends. Use of a vise with soft jaw[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 102 Engine Cooling Fan Motor 1. Hydraulic fan motor 2. O - - ring 3. Bracket 4. 45 o hydraulic fitting 5. O - - ring 6. Hydraulic hose 7. Fan hub 8. W asher 9. Hex nut 10. Engine 1 1. Cap screw (4 used) 12. Washer (4 used) 13. Fan 14. Lock nut (2 used) 15. Hydraulic hose 16. O - - ring 17. Hydrau[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 103 Removal (Fig. 69) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of [...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 104 Engine Cooling Fan Motor Service 1. Flange washer 2. O - - ring 3. Front flange 4. Dust seal 5. Retaining ring 6. Front wear plate 7. Shaft seal 8. Backup gasket 9. Pressure seal 10. Rear wear plate 1 1. Body 12. Idler gear 13. Cap screw (4 used) 14. Dowel (2 used) 15. Drive gear 16. Washer ([...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 105 8. Remove and discard back - - up gaskets and pressure seals from wear plates. 9. Turn front flange over , with seal side up. IMPORT ANT : Make sure not to damage the front flange counter bore when removing the seals from the front flange. 10. Carefully remove dust seal, retaining ring, flang[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 106 4. Install the pressure seals, flat side outward, into the grooves in the wear plates. Follow by carefully placing the backup gaskets, flat side outward, between the pressure seals and the grooves in the wear plate. 5. Apply a light coating of petroleum jelly to the exposed side of the front [...]

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Groundsmaster 4100 - - D Hydraulic System Page 4 - - 108 Fan Drive Manifold 1. Fan drive manifold 2. O - - ring 3. T est fitting 4. Dust cap (2 used) 5. O - - ring 6. 45 o hydraulic fitting (2 used) 7. O - - ring 8. Hydraulic hose 9. Hydraulic hose 10. Hydraulic fitting 1 1. Hydraulic hose 12. Hydraulic hose 13. 90 o hydraulic fitting 14. 90 o hydr[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 109 Removal (Fig. 75) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter . 2. T o prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of manifold and[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 10 Fan Drive Manifold Service 1. Fan drive manifold 2. #4 zero leak plug (3 used) 3. Check valve 4. #6 zero leak plug (2 used) 5. Flow divider valve 6. Nut 7. Solenoid coil (2 used) 8. Proportional relief valve 9. Solenoid valve 10. Nut Figure 76 FRONT UP B 1 2 3 4 5 2 2 4 7 9 8 6 10 7 20 ft - [...]

Groundsmaster 4100 - - D Hydraulic System P a g e 4 - - 111 Fan Drive Manifold Service (Fig. 76) For cartridge valve service procedures, see 4WD Man- ifold Service in this section. Refer to Figure 76 for fan drive manifold cartridge valve and plug installation torque. Hydraulic System[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 12 Mow Circuit 1. Gear pump 2. RH wing deck motor 3. LH wing deck motor 4. RH Wing Deck manifold 5. Front cutting deck motor 6. LH Wing Deck manifold 7. Front Deck manifold 8. Filter manifold 9. Oil cooler Figure 77 FRONT RIGHT 2 1 5 4 3 7 6 8 9 Figure 77 illustrates the components that are use[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 13 Cutting Deck Motor Removal 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of this section. 3. T o pre[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 14 Cutting Deck Motor Service 1. Rear cover 2. Drive gear 3. Seal 4. Woodruff key 5. Nut 6. T ab washer 7. Spider hub 8. Pressure seal 9. Back - - up ring 10. O - - ring 1 1. Body 12. Idler gear 13. Cap screw (4 used) 14. Front flange 15. Dowel pin Figure 80 8 7 4 3 1 2 5 6 9 10 11 10 9 12 ( 4 [...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 15 IMPORT ANT : 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 t he 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 rem[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 16 Assembly (Fig. 80) NOTE: When assembling the motor , check the identifi- cation marks made during disassembly to make sure the parts are properly aligned during assembly . 1. Lubricate O - - rings, pressure seals, back - - up gaskets and seal grooves with a thin coat of petroleum jelly . Lu-[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 17 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 18 Deck Manifolds 1. Center deck manifold 2. O - - ring 3. Hydraulic adapter 4. O - - ring 5. Straight hydraulic fitting 6. O - - ring 7. 90 o hydraulic fitting 8. O - - ring 9. Hydraulic tee fitting 10. O - - ring 11 . O - - r i n g 12. Dust cap 13. Quick fitting 14. Flange nut 15. LH wing dec[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 19 Removal (Fig. 85) NOTE: The ports on the manifold are marked for easy identification of components. Example: SV1 is the deck solenoid valve and P1 is a gear pump connection port. (See Hydraulic Schematic in Chapter 9 - - Foldout Draw- ings to identify the function of the hydraulic lines and [...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 120 Deck Manifold Service 1. Manifold body 2. NWD SAE #4 plug with O - - ring 3. Orifice (0.063) (port OR) 4. #8 zero leak plug with O - - ring 5. Relief valve (port RV2) 6. Solenoid valve (port S) 7. Solenoid coil 8. Nut 9. Relief valve (port RV1) 10. Spool logic cartridge (port LC2) 1 1. S pool[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 121 PTO Manifold Service (Fig. 86) For solenoid and control valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 86 for PTO manifold cartridge valve and plug installation torque. Hydraulic System[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 122 Lift/Lower Circuit 1. Counterbalance manifold 2. RH wing deck lift cylinder 3. LH wing deck lift cylinder 4. Fan drive manifold 5. Lift control valve 6. Front deck flow control valve 7. Front lift cylinder 8. Oil filter Figure 87 FRONT RIGHT 2 1 5 4 3 7 6 8 7 Figure 87 illustrates the compone[...]

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Groundsmaster 4100 - - D Hydraulic System Page 4 - - 124 Lift/Lower Control V alve 1. Control valve assembly 2. V alve bracket 3. Isolator (6 used) 4. Cap screw 5. Lock nut (2 used) 6. Pivot bracket 7. LH lever assembly 8. Lever link (3 used) 9. Center lever assembly 10. Cotter pin (6 used) 1 1. RH lever assembly 12. Spacer 13. Flange head screw (2[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 125 Removal (Fig. 88) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of this section. 3. T o prevent conta[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 126 Lift/Lower Control V alve Service 1. Poppet 2. Spacer 3. Wiper seal 4. Seat 5. O - - ring 6. Plug (3 used) 7. O - - ring 8. Bushing 9. Spool cap (3 used) 10. Relief valve poppet 11 . O - - r i n g 12. Retaining ring 13. W asher 14. W asher 15. W asher 16. W asher 17. Plug 18. O - - ring 19. S[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 127 Disassembly (Fig. 89) 1. Plug all ports and clean outside of valve thoroughly . 2. Remove spool caps (item 9). Do not remove retain- ing rings (item 12) from spools unless spool spring (item 19) is broken. NOTE: Spools and spool bores are matched sets. Be sure each spool is identified with th[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 128 Front Deck Lift Cylinder 1. Lift cylinder (2 used) 2. Lift arm (LH shown) 3. Lock nut 4. Pin 5. Flange head screw 6. Grease fitting 7. O - - ring 8. 90 o hydraulic fitting 9. O - - ring 10. Hydraulic fitting 1 1. P ivot pin 12. Cotter pin 13. Grease fitting Figure 90 FRONT RIGHT 8 5 4 2 7 13 [...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 129 Removal (Fig. 90) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of this section. 3. T o prevent conta[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 130 Wing Deck Lift Cylinder 1. Center deck 2. Grease fitting 3. T apered stud 4. Spherical bearing 5. Flange nut 6. Retaining ring 7. Wing deck lift cylinder 8. Lock nut 9. Flat washer 10. Lock nut 1 1. Pilot spacer 12. Cap screw 13. Wing deck (RH shown) Figure 91 FRONT RIGHT 6 5 7 8 4 3 2 9 10 1[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 131 Removal (Fig. 91) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of this section. 3. Remove deck cover[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 132 Deck Lift Cylinder Service 1. Barrel with clevis 2. Retaining ring 3. Shaft with clevis 4. Dust seal 5. Rod seal 6. O - - ring 7. Back - - up ring 8. Head 9. O - - ring 10. Wear ring 11 . P i s t o n 12. Locking nut 13. Seal with loader Figure 92 11 6 5 7 8 4 3 2 9 12 1 10 13 100 to 120 ft - [...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 133 Disassembly (Figs. 92 and 93) 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder . IMPORT ANT : Prevent damage when c lamping the cylinder in a vise; clamp on the clevis only . Do not close vise enough [...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 134 Counterbalance Manifold 1. Counterbalance hydraulic manifold 2. V alve plate 3. Flat washer (2 used) 4. Cap screw (2 used) 5. Isolator (4 used) 6. Flat washer (2 used) 7. Lock nut (2 used) 8. Hydraulic fitting (2 used) 9. O - - ring 10. O - - ring 11 . 9 0 o hydraulic fitting (4 used) 12. Cap[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 135 Removal (Fig. 94) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter . 2. T o prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of manifold and[...]

Groundsmaster 4100 - - D Hydraulic System Page 4 - - 136 Counterbalance Manifold Service 1. Manifold body 2. Pilot valve 3. Seal kit 4. Relief valve (counterbalance) 5. Seal kit Figure 95 2 1 2 3 5 4 3 35 to 40 ft - - lb ( 4 7t o5 4N - - m ) 35 to 40 ft - - lb ( 4 7t o5 4N - - m ) 35 to 40 ft - - lb ( 4 7t o5 4N - - m ) FRONT UP NOTE: The ports on [...]

Groundsmaster 4100 - - D Page 5 - - 1 Electrical System Chapter 5 Electrical System T able of Contents GENERAL INFORMA TION 2 ..................... Operator ’s Manual 2 .......................... Electrical Drawings 2 .......................... SPECIAL TOOLS 3 ............................. TROUBLESHOOTING 5 ......................... Starting Prob[...]

Groundsmaster 4100 - - D Page 5 - - 2 Electrical System General Information Operator ’s Manual The Operator ’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Electrical Drawings The[...]

Groundsmaster 4100 - - D Page 5 - - 3 Electrical System Special T ools Order special tools from your T oro 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: T oro recommends the use of a D IGIT AL V olt - - Ohm - - Amp mul[...]

Groundsmaster 4100 - - D Page 5 - - 4 Electrical System Dielectric Gel Dielectric gel should be used to prevent corrosion of connection terminals. T o ensure complete coating of ter- minals, liberally apply gel to both c omponent and wire harness connector , plug connector to component, un- plug connector , reapply gel to both surfaces and recon- n[...]

Groundsmaster 4100 - - D Page 5 - - 5 Electrical System T roubleshooting CAUTION Remove all jewelry , especially rings and watches, before doing any electrical trouble- shooting or testing. Disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting and repairs, there must be a good understanding of the ele[...]

Groundsmaster 4100 - - D Page 5 - - 6 Electrical System Problem Possible Causes Engine cranks, but does not start. Engine is not cranking fast enough. The engine run solenoid or circuit wiring is faulty . The fuel pump is faulty . An engine problem exists (see Chapter 3 - - Kubota Engine). Starter cranks, but should not when the traction pedal is d[...]

Groundsmaster 4100 - - D Page 5 - - 7 Electrical System Cutting Deck Operating Problems The cutting deck remains engaged, but should not, with no operator in the seat. The seat switch or circuit wiring is faulty . Cutting deck runs, but should not, when raised. Deck shuts off with PT O switch. The deck position switch or circuit wiring is faulty . [...]

Groundsmaster 4100 - - D Page 5 - - 8 Electrical System Electrical System Quick Checks Battery T est (Open Circuit T est) Use a multimeter to measure the voltage between the battery terminals. Set multimeter to the DC volts setting. The battery should be at a temperature of 60 o F to 100 o F( 1 6 o Ct o 38 o C). The ignition key should be off and a[...]

Groundsmaster 4100 - - D Page 5 - - 9 Electrical System 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 Pro[...]

Groundsmaster 4100 - - D Page 5 - - 10 Electrical System Cutting Deck Raise and Lower Switches Adjustment (Fig. 9) 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 c utting deck raise and lower switches can be ad- justed for correct oper[...]

Groundsmaster 4100 - - D Page 5 - - 1 1 Electrical System Component T esting For accurate resistance and/or continuity checks, elec- trically 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 Manu[...]

Groundsmaster 4100 - - D Page 5 - - 12 Electrical System Fuses The fuse blocks are located under the operator ’s control console. Identification, Function and Wiring The fuses are held in three (3) fuse blocks. Use Figures 13 and 14 to identify each individual fuse and its correct amperage. Each fuse holder has the following functions and wire co[...]

Groundsmaster 4100 - - D Page 5 - - 13 Electrical System W arning Lights Engine Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON position with the engine not running. Also, it should light with the engine running if the engine oil pressure drops below 7 PSI (0.5 kg/cm 2 ). 1. Disconnect green wire from [...]

Groundsmaster 4100 - - D Page 5 - - 14 Electrical System PT O Switch The PTO switch is used to engage or disengage the cut- ting deck. The PTO switch is attached to the control con- sole next to the operator seat (Fig. 17). The switch terminals are marked as shown in Figure 18. The circuitry of the P TO switch is shown in the chart be- low . With t[...]

Groundsmaster 4100 - - D Page 5 - - 15 Electrical System T ransport / 4WD Switch The transport/4WD switch is used to set the machine traction speed for transport or mow . The transport/4WD rocker switch is located on the control console next to the operator seat (Fig. 21). T esting The switch terminals are shown in Figure 22. The circuit- ry of the[...]

Groundsmaster 4100 - - D Page 5 - - 16 Electrical System Cooling Fan Switch The cooling fan switch is used to control the operation of the hydraulic cooling fan and is located on the control console (Fig. 23). This switch has three (3) positions: Reverse, Auto and Forward. When the cooling fan switch is in the normal Auto posi- tion, cooling fan op[...]

Groundsmaster 4100 - - D Page 5 - - 17 Electrical System Seat Switch The seat switch is normally open and closes when the operator is on the seat. The seat switch and its electrical connector are located in the seat assembly . If the trac- tion system or PTO switch is engaged when the operator raises out of the seat, the engine will stop. T esting [...]

Groundsmaster 4100 - - D Page 5 - - 18 Electrical System Parking Brake Switch The s witch used for the parking brake is a normally open switch that is located under the steering tower cover (Fig. 26). When the parking brake is not applied, the parking brake pawl depresses the switch plunger to close the switch. When the parking brake is applied, th[...]

Groundsmaster 4100 - - D Page 5 - - 19 Electrical System Hour Meter The hour meter is located on the control console next to the operator seat. T esting 1. Disconnect wire harness connector from hour meter . 2. Connect the positive ( +) terminal of a 12 VDC source to the positive (+) terminal of the hour meter . 3. Connect the negative ( - - ) term[...]

Groundsmaster 4100 - - D Page 5 - - 20 Electrical System Glow and Power Relays The Groundsmaster 4100 - - D uses two (2) identical re- lays to control electrical power circuits. The glow relay is attached to the the right side of the fuel tank support under the hood. The power relay is attached to the con- trol panel under the console housing. The [...]

Groundsmaster 4100 - - D Page 5 - - 21 Electrical System Start, Engine Shutdown, Seat, Alarm, PT O, PTO Overtemp, Down Latching and Over T emperature Relays These eight (8) relays are located under the console housing cover (Fig. 30). The wiring harness is tagged to identify each relay . T esting 1. Make sure that ignition switch is OFF . 2. Locate[...]

Groundsmaster 4100 - - D Page 5 - - 22 Electrical System Hydraulic V alve Solenoids Figure 32 1. 4WD manifold 2. LH deck manifold 3. RH deck manifold 4. Front deck manifold 5. Fan drive manifold FRONT RIGHT 1 2 3 4 5 There are several hydraulic valve solenoids on the Groundsmaster 4100 - - D (Fig. 32). T esting of these sole- noids can be done with[...]

Groundsmaster 4100 - - D Page 5 - - 23 Electrical System TEC - - 5002 Controller Groundsmaster 4100 - - D machines use a T oro Electron- ic Controller (TEC) to control the operation of the hy- draulic cooling fan. The controller is attached to the operator platform under the console housing cover (Fig. 34). Logic power is provided to the controller[...]

Groundsmaster 4100 - - D Page 5 - - 24 Electrical System Fuel Sender The fuel sender is located on top of the fuel tank. T esting 1. Remove white wire and black ground wire from the sender . CAUTION If testing circuit wiring and fuel gauge, make sure wire connections are secure before turning igni- tion switch ON to prevent an explosion or fire fro[...]

Groundsmaster 4100 - - D Page 5 - - 25 Electrical System 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 T esting in this section for additional information). T esting CAUTION Make sure the voltage source is turned OFF be- fore connecting[...]

Groundsmaster 4100 - - D Page 5 - - 26 Electrical System Fuel Pump The fuel pump is attached to the frame above the fuel water separator (Fig. 38). Operational T est 1. Park machine on a level surface, lower cutting deck, stop engine and apply parking brake. 2. Disconnect wire harness electrical connector from the fuel stop solenoid to prevent the [...]

Groundsmaster 4100 - - D Page 5 - - 27 Electrical System Glow Controller The glow controller is located under the console cover (Fig. 39). NOTE: Refer to electrical schematic and circuit draw- ings in Chapter 9 - - Foldout Drawings when trouble- shooting the glow controller . Glow Controller Operation 1. When the ignition switch is placed in the ON[...]

Groundsmaster 4100 - - D Page 5 - - 28 Electrical System T emperature Sender The temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 41). The resistance of the temperature sender re- duces as the engine coolant temperature increases. There is a gray harness wire attached to the terminal o[...]

Rev . A Groundsmaster 4100- - D Page 5 - - 29 Electrical S ystem Dual T emperature Switch The dual temperature switch is attached to the engine near the alternator on the water flange attached to the engine cylinder head (Fig. 43). T wo (2) electrical har- ness wires (a blue wire and a ye llow wire) are attached to the switch. The terminal on the s[...]

Groundsmaster 4100 - - D Page 5 - - 30 Electrical System T emperature 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. T esting CAUTION Make sure the voltage source is turned OFF be- fore connecting variable resistance to the elec- trical circuit to avo[...]

Groundsmaster 4100 - - D Page 5 - - 31 Electrical System T raction Neutral Switch The traction neutral switch is closed when the traction pedal is in the neutral position and opens when the pedal is depressed in either direction. The switch is located on the right side of the piston (traction) pump (Fig. 48). T esting T est the switch by disconnect[...]

Groundsmaster 4100 - - D Page 5 - - 32 Electrical System Diode Circuit Board The diode circuit board (Fig. 50) contains four (4) diodes and is located under the console housing. Diode D1 - - A provides logic for the interlock system. Diodes D1 - - B (right wing deck), D1- - C (front deck) and D1 - - D (left wing deck) provide latching circuits for [...]

Groundsmaster 4100 - - D Page 5 - - 33 Electrical System Fusible Links The Groundsmaster 4100 - - D uses five (5) fusible links for circuit protection. Three (3) of these fusible links are located in a harness that connects the starter B+ termi- nal to the wire harness (Fig. 51). An additional fusible link is used that connects the starter B+ termi[...]

Groundsmaster 4100 - - D Page 5 - - 34 Electrical System Wing Deck Position Switches The wing deck position switches on the Groundsmaster 4100 - - D are attached to the center deck housing (Fig. 53) and are normally open. The wing deck position switch is a powered proximity switch that incorporates an internal reed switch and relay (see schematic i[...]

Groundsmaster 4100 - - D Page 5 - - 35 Electrical System Cutting Deck Raise and Lower Switches The deck raise and lower switches are normally open proximity switches that are located under the console housing (Fig. 56). These identical switches are mounted in opposite directions so their circuit logic differs. The ac- tuator for the switches is on [...]

Rev . A Groundsmaster 4100- - D Page 5 - - 36 Electrical Syst em Engine Coolant and Hydraulic Oil T emperature Senders The Groundsmaster 4100- - D uses two (2) temperature senders as inputs for the TEC - - 5002 to identify if either the engine coolant or hydraulic oil temperatu re has reached an excessive level. These senders are iden ti- cal. The [...]

Groundsmaster 4100 - - D Page 5 - - 37 Electrical System Service and Repairs NOTE: For engine component repair information, see the Kubota Workshop Manual, Diesel Engine, V2403 - - M - - T - - E3B Series at the end of Chapter 3 - - Ku- bota Diesel Engine. Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery and[...]

Groundsmaster 4100 - - D Page 5 - - 38 Electrical System 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[...]

Groundsmaster 4100 - - D Page 5 - - 39 Electrical System 2. Conduct a hydrometer test of the battery electrolyte. IMPORT ANT : 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 t[...]

Groundsmaster 4100 - - D Page 5 - - 40 Electrical System Battery Charging T o 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- complished with a constant current battery charger which is readily available locally . CAUTION Follow the manu[...]

Groundsmaster 4100 - - D Page 6 - - 1 Axles, Planetaries and Brakes Chapter 6 Axles, Planetaries and Brakes T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ..................... Operator ’s Manual 3 .......................... SERVICE AND REP AIRS 4 ...................... Brake Assembly 4 .................[...]

Groundsmaster 4100 - - D Page 6 - - 2 Axles, Planetaries and Brakes Specifications Item Specification T ire pressure (front and rear) 25 to 30 PSI (172 to 207 kPa) Rear wheel toe - - in 0.125 in (3.18 mm) Planetary gear drive oil SAE 85W - - 140 wt. gear lube System gear lube capacity (each wheel) 16 fl. oz. (0.47 liters) Rear axle lubricant SAE 85[...]

Groundsmaster 4100 - - D Page 6 - - 3 Axles, Planetaries and Brakes General Information Operator ’s Manual The Operator ’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Axles, Plan[...]

Groundsmaster 4100 - - D Page 6 - - 4 Axles, Planetaries and Brakes Service and Repairs Brake Assembly 1. Planetary assembly 2. Retaining ring 3. Splined brake coupler 4. Brake assembly (RH) 5. O - - ring 6. Hydraulic wheel motor 7. Flat washer 8. Cap screw (2 used per side) 9. Flange head screw (4 used per side) 10. Brake assembly (LH) 1 1. Gasket[...]

Groundsmaster 4100 - - D Page 6 - - 5 Axles, Planetaries and Brakes 3. Chock rear wheels and jack up front of machine (see Jacking Instructions in Chapter 1 - - Safety). Support ma- chine with suitable jack stands. 4. Remove front wheel assembly . 5. Remove hydraulic wheel motor (see Front Wheel Motors in Service and Repairs section of Chapter 4 - [...]

Groundsmaster 4100 - - D Page 6 - - 6 Axles, Planetaries and Brakes Brake Service 1. Brake housing (LH shown) 2. Seal 3. Pull rod 4. Clevis pin (2 used) 5. Link 6. Hitch pin (2 used) 7. Stationary disc (4 used) 8. Rotating disc (3 used) 9. Retaining ring 10. Gasket 1 1. Rotating actuator 12. Extension spring (3 used) 13. Ball (3 used) 14. Plug 15. [...]

Groundsmaster 4100 - - D Page 6 - - 7 Axles, Planetaries and Brakes This page is intentionally blank. Axles, Planetaries and Brakes[...]

Groundsmaster 4100 - - D Page 6 - - 8 Axles, Planetaries and Brakes Planetary Wheel Drive Assembly 1. Planetary assembly 2. Retaining ring 3. Splined brake coupler 4. Brake assembly (RH) 5. O - - ring 6. Hydraulic wheel motor 7. Flat washer 8. Cap screw (2 used per side) 9. Flange head screw (4 used per side) 10. Brake assembly (LH) 1 1. Gasket 12.[...]

Groundsmaster 4100 - - D Page 6 - - 9 Axles, Planetaries and Brakes Removal (Fig. 6) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Drain oil from planetary wheel drive/brake assembly . CAUTION When removing front wheel, use correct jacks and supports. Make sure [...]

Groundsmaster 4100 - - D Page 6 - - 10 Axles, Planetaries and Brakes Planetary Wheel Drive Service 1. Spindle 2. Boot seal 3. Bearing cone 4. Bearing cup 5. Wheel stud (8 used) 6. Housing 7. Bearing cup 8. Bearing cone 9. Thrust washer 10. Retaining ring (external) 1 1. Ring gear 12. Retaining ring (internal) 13. Plug (2 used) 14. End cap 15. Thrus[...]

Groundsmaster 4100 - - D Page 6 - - 1 1 Axles, Planetaries and Brakes NOTE: The planetary wheel drive assembly can be ser- viced with the planetary installed to machine. If the spindle (item 1) needs to be removed from machine, see Planetary Wheel Drive Assembly Removal in this sec- tion. Disassembly (Figs. 8 and 9) 1. If planetary wheel drive asse[...]

Groundsmaster 4100 - - D Page 6 - - 12 Axles, Planetaries and Brakes F . Lightly oil bearing journals on spindle shaft. Slide housing onto spindle (item 1) taking care to not dam- age seal or spindle. Make sure that bearing in hous- ing fully seats against spindle shaft shoulder . G. Install outer bearing cone (item 8) onto spindle. NOTE: The plane[...]

Groundsmaster 4100 - - D Page 6 - - 13 Axles, Planetaries and Brakes This page is intentionally blank. Axles, Planetaries and Brakes[...]

Groundsmaster 4100 - - D Page 6 - - 14 Axles, Planetaries and Brakes Rear Axle Assembly 1. Frame 2. Cap screw (6 used) 3. Flat washer 4. Bulkhead lock nut (2 used) 5. W asher 6. Thrust washer (thick) 7. Grease fitting (2 used) 8. Rear axle assembly 9. Thrust washer (thin) 10. Washer head screw 1 1. P ivot pin 12. Rear frame mount 13. W asher 14. Lo[...]

Groundsmaster 4100 - - D Page 6 - - 15 Axles, Planetaries and Brakes 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. 12). Remove the cotter pins and castle nuts from the tie rod ball joints. Use a ball joint fork and[...]

Groundsmaster 4100 - - D Page 6 - - 16 Axles, Planetaries and Brakes 8. Install steering cylinder to axle assembly (see Steer- ing Cylinder Installation in the Service and Repairs sec- tion of Chapter 4 - - Hydraulic System). 9. Install hydraulic motor to axle assembly (see Rear Axle Motor Installation in the Service and Repairs sec- tion of Chapte[...]

Groundsmaster 4100 - - D Page 6 - - 17 Axles, Planetaries and Brakes Bevel Gear Case and Axle Case The following procedures assume the rear axle assem- bly has been removed from the machine (see Rear Axle Assembly Removal in this section). Bevel Gear Case and Axle Case Removal 1. Remove the mounting screws, nuts and lock wash- ers. Remove the bevel[...]

Groundsmaster 4100 - - D Page 6 - - 18 Axles, Planetaries and Brakes 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. 18). 6. While holding the bevel gear case, tap the upper end of the bevel gear shaft out of the upper bearing and up- per bevel gea[...]

Groundsmaster 4100 - - D Page 6 - - 19 Axles, Planetaries and Brakes Bevel Gear Case and Axle Case Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 20). 1. Axle case 2. Bevel gear case 3. Shaft seal Figure 20 1 2 3 2. Install the lower bevel gear and bevel gear shaft in the axle case cover . Coat a new O-ring [...]

Groundsmaster 4100 - - D Page 6 - - 20 Axles, Planetaries and Brakes 5. Determine necessary quantity of support shims. 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 mou[...]

Groundsmaster 4100 - - D Page 6 - - 21 Axles, Planetaries and Brakes 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 back[...]

Groundsmaster 4100 - - D Page 6 - - 22 Axles, Planetaries and Brakes Differential Shafts The following procedures assume the rear axle assem- bly has been removed from the machine (see Rear Axle Assembly Removal in this section). Differential Shaft Removal IMPORT ANT : Do not interchange right and left dif- ferential shaft assemblies. 1. Remove the[...]

Groundsmaster 4100 - - D Page 6 - - 23 Axles, Planetaries and Brakes Axle Shafts The following procedures assume the rear axle assem- bly has been removed from the machine (see Rear Axle Assembly Removal in this section). Axle Shaft Removal 1. Remove the axle cover mounting screws. Remove t h ea x l ec o v e rf r o mt h ea x l ec a s ea sa na s s e[...]

Groundsmaster 4100 - - D Page 6 - - 24 Axles, Planetaries and Brakes Input Shaft/Pinion Gear Figure 30 1 1. Nut (2 used) 2. Lockwasher (2 used) 3. Stud (2 used) 4. Locknut 5. Stake washer 6. Oil seal 7. O-ring 8. Seal collar 9. Bearing 10. O-ring 1 1. I nput shaft/pinion gear 12. Bearing case 13. Shim 14. Screw (2 used) 15. Gear case 16. Gasket 17.[...]

Groundsmaster 4100 - - D Page 6 - - 25 Axles, Planetaries and Brakes 7. Secure the lock nut with the stake washer . 8. Use a depth gauge to measure the distance from the end face of the input shaft/pinion gear to the mating sur- face of the bearing case. Subtract the “Design Cone Center Distance” from this distance to determine initial shim thi[...]

Groundsmaster 4100 - - D Page 6 - - 26 Axles, Planetaries and Brakes Differential Gear The following procedures assume the rear axle assem- bly has been removed from the machine (see Rear Axle Assembly Removal in this section). Differential Gear Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this s[...]

Groundsmaster 4100 - - D Page 6 - - 27 Axles, Planetaries and Brakes Differential Gear 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. 37). 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. (Fact[...]

Groundsmaster 4100 - - D Page 6 - - 28 Axles, Planetaries and Brakes Differential Gear 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 s urfaces of the differential pinion[...]

Groundsmaster 4100 - - D Page 6 - - 29 Axles, Planetaries and Brakes 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 fol- lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 41): To e - - the portion of the tooth surface at the end to- wards the center . H[...]

Groundsmaster 4100 - - D Page 6 - - 30 Axles, Planetaries and Brakes Gear Pattern Movement Summary Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as gear location is changed. 1. If contact is toward the heel or base of the gear (Fig. 44): A. Install thicker or additional bearing [...]

Groundsmaster 4100 - - D Page 7 - - 1 Chassis Chapter 7 Chassis T able of Contents GENERAL INFORMA TION 1 ..................... Operator ’s Manual 1 .......................... SERVICE AND REP AIRS 2 ...................... Steering T ower 2 .............................. Cutting Deck Lift Arms 4 ....................... Operator Seat 6 ............[...]

Groundsmaster 4100 - - D Page 7 - - 2 Chassis Service and Repairs Steering T ower 1. Hex nut 2. Flat washer 3. Steering wheel 4. Foam collar 5. Steering seal 6. External snap ring (2 used) 7. Knob 8. Steering tower cover 9. Steering shaft 10. Compression spring 11 . C a p 12. Rod assembly 13. Extension spring 14. Tilt rod 15. Lock nut (2 used) 16. [...]

Groundsmaster 4100 - - D Page 7 - - 3 Chassis Disassembly (Fig. 1) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Disassemble steering tower as needed using Figure 1 as a guide. Assembly (Fig. 1) 1. Assemble steering tower using Figure 1 as a guide. A. Thrust was[...]

Groundsmaster 4100 - - D Page 7 - - 4 Chassis Cutting Deck Lift Arms 1. Lift cylinder 2. Clevis pin 3. Cap screw 4. Grease fitting 5. Lift arm pin 6. Slotted roll pin 7. Lock nut 8. Cotter pin 9. Pivot pin 10. Hair pin 1 1. S pherical rod end 12. Damper 13. Y oke spacer 14. Flange nut 15. Lock nut 16. Flat washer 17. Grease fitting 18. Flange head [...]

Groundsmaster 4100 - - D Page 7 - - 5 Chassis CAUTION When changing attachments, tires or perform- ing other service, use correct jacks and sup - ports. 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.[...]

Groundsmaster 4100 - - D Page 7 - - 6 Chassis Operator Seat 1. Seat assembly 2. Flat washer (5 used) 3. Seat belt 4. Cap screw (4 used) 5. Seat platform 6. Flange nut (4 used) 7. Seat belt buckle 8. Cap screw (2 used) 9. R - - clamp (2 used) 10. Manual tube 1 1. Screw 12. Lock nut 13. Seat belt mount 14. Lock washer (2 used) 15. R - - clamp (2 used[...]

Groundsmaster 4100 - - D Page 7 - - 7 Chassis Removal (Fig. 5) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove seat from seat suspension: A. Disconnect seat electrical connectors from ma- chine wire harness (Fig. 6). B. Remove four (4) T orx head screws that[...]

Groundsmaster 4100 - - D Page 7 - - 8 Chassis Operator Seat Service 1. Backrest cushion 2. Seat cushion 3. Armrest cover 4. LH armrest 5. Bushing (2 used) 6. Backrest 7. Plug (2 used) 8. Cable tie (3 used) 9. LH adjustment rail 10. Bumper (2 used) 1 1. W asher 12. Cap screw (2 used) 13. Seat 14. Nut 15. Spring (2 used) 16. Magnet 17. Seat switch 18[...]

Groundsmaster 4100 - - D Page 7 - - 9 Chassis Disassembly (Fig. 8) 1. Disassemble operator seat as necessary using Fig- ure 8 as a guide. Assembly (Fig. 8) 1. Assemble operator seat using Figure 8 as a guide. Chassis[...]

Groundsmaster 4100 - - D Page 7 - - 10 Chassis Operator Seat Suspension 1. Cover 2. Cover 3. Level control 4. Air control valve 5. Shock absorber 6. Air spring 7. Air tube assembly 8. Wire harness 9. Compressor 10. Bellows 11 . S t o p 12. Bumper set (2 used) 13. Roller (4 used) 14. Washer (2 used) 15. T ether 16. Rivet (2 used) 17. Washer (4 used)[...]

Groundsmaster 4100 - - D Page 7 - - 1 1 Chassis NOTE: Most of the seat suspension components can be serviced with the seat suspension base mounted to the frame platform. If the air spring assembly (item 6) re- quires removal, the seat suspension base w ill have to be removed from the seat platform. Disassembly (Fig. 9) 1. Remove operator seat from [...]

Groundsmaster 4100 - - D Page 7 - - 12 Chassis Hood 1. Rear screen 2. T op screen 3. Cap screw (22 used) 4. Screen assembly 5. Bulb seal 6. Flange nut (2 used) 7. Bulb seal 8. Screen corner seal (2 used) 9. Hair pin (2 used) 10. Screw (8 used) 1 1. H ood pivot (2 used) 12. Pivot bracket (2 used) 13. Hood 14. Handle (2 used) 15. Flange head screw (4[...]

Groundsmaster 4100 - - D Page 7 - - 13 Chassis 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 1 1 as a guide. Installation 1. Install hood using Figure 1 1 as a guide. 2. Align hood to machine to allow correct operation of hood la[...]

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Groundsmaster 4100 - - D Cutting Deck Page 8 - - 1 Chapter 8 Cutting Deck T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ..................... Operator ’s Manual 3 .......................... Castor Wheel T ire Pressure 3 .................. Blade Stopping T ime 3 ........................ TROUBLESHOOTING 4[...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 2 Specifications MOUNTING: Cutting deck is supported by lift arms con- trolled with hydraulic lift levers. CONSTRUCTION: Deck chamber is welded 12 gauge steel construction reinforced with channels and plates. HEIGHT - - OF - - CUT RANGE: 1” to 5” (25.4 mm to 127 mm) adjustable in 1/2” (12.7 mm)[...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 3 General Information 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. Operator ’s Manual The Operator ’s Manual provides information regarding the operation, general maintenance, adjustments and maintenanc[...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 4 T roubleshooting There are a number of factors that can contribute to un- satisfactory quality of cut, some of which may be turf conditions. T urf conditions such as excessive thatch, uneven ground conditions, “sponginess” or attempting to cut of f too much grass height may not always be over- [...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 5 This page is intentionally blank. Cutting Deck[...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 6 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 1. Cutting deck 2. Cap screw 3. Lift arm (LH shown) 4. Flange nut 5. Spacer 6. Damper 7. Damper rod end (2 per damper) 8. Hair[...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 7 Removal (Fig. 1) 1. Position machine on a clean, level s urface. Lower cutting deck, stop engine, engage parking brake and re- move 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. Remove hairpins and cle[...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 8 NOTE: Installation of clevis pins to deck and height - - of - - cut chains is easier if deck is lifted slightly . 4. Install clevis pins and hairpins that secure the height - - of - - cut chains to the rear of the cutting deck (Fig. 2). 5. Remove plugs from hydraulic hoses and fittings on wing deck[...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 9 This page is intentionally blank. Cutting Deck[...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 10 Wing Deck Service 1. Wing deck (RH shown) 2. Skid (RH shown) 3. Flange screw (2 used per skid) 4. Flange nut (2 used per skid) 5. Cap screw 6. Roller (2 used) 7. Lock nut 8. Pivot latch (2 used) 9. Flat washer 10. Retaining ring (2 used per latch) 1 1. Cap screw (3 used per latch) 12. Lock nut (3 [...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 1 1 Removal (Fig. 6) 1. Position machine on a clean, level s urface. 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. [...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 12 4. Position upper end of links to center cutting deck brackets. 5. Align upper end of links with mounting holes in center deck. While installing pivot pins to center deck and links, insert spacers and washers as follows: A. Place a hardened spacer (item 42) on each side of the front link. Use one [...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 13 Cutting Deck Link Service Disassembly (Fig. 10) 1. Press bushings from top of link. 2. Remove dust cap and retaining ring from link. 3. Press tapered stud with spherical bearing, flat wash- ers and flange nut from link. 4. Remove flange nut and press spherical bearing from tapered stud. Assembly ([...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 14 Wing Deck Latch Disassembly (Fig. 12) 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 [...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 15 This page is intentionally blank. Cutting Deck[...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 16 Blade Spindle 1. Cutting deck 2. Drive spindle: single pulley (2 used) 3. Low driven spindle (3 used) 4. Drive spindle: double pulley (1 used) 5. Flange head screw 6. Flange nut 7. Blade bolt 8. Cutting blade (7 used) 9. Anti - - scalp c up 10. High driven spindle (1 used) 1 1. Flat washer 12. Cap[...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 17 Installation (Fig. 13) 1. Position spindle on cutting deck noting orientation of grease fitting (Fig. 15). Secure spindle assembly to deck with removed fasteners. 2. Install cutting blade, anti - - scalp cup and blade bolt. T ighten blade bolt from 88 to 108 ft - - lb (1 19 to 146 N- -m ) . 3. Slo[...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 18 Blade Spindle Service 1. Lock nut 2. Flat washer 3. Driven pulley 4. Spindle shaft 5. Drive pulley (single shown) 6. Hydraulic motor mount 7. O - - ring 8. Oil seal 9. Bearing cup and cone 10. Outer bearing spacer 1 1. Inner bearing spacer 12. Spacer ring 13. Snap ring 14. Grease fitting 15. Spind[...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 19 2. Install outer bearing spacer into top of spindle hous- ing. The spacer should fit against the snap ring. 3. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the outer bearing spacer previously installed, and the bottom [...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 20 Idler Assembly 1. Center deck 2. Flange nut 3. Flange nut 4. Adjusting screw 5. Idler pulley 6. High driven pulley 7. Flat washer 8. Lock washer 9. Socket head screw 10. Stop bolt 1 1. Flange nut 12. Cap screw 13. Spacer 14. Shoulder bolt 15. Spring 16. Lock nut 17. Idler arm 18. Retaining ring 19[...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 21 Removal (Fig. 20) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove deck covers from top of cutting deck. CAUTION Be careful when removing idler spring. The spring is under heavy load and may cause per - son[...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 22 Castor Forks and Wheels 1. Castor arm (wing deck shown) 2. Cap screw (6 per arm) 3. Castor fork 4. Castor wheel bolt 5. Lock nut 6. Castor spacer 7. Thrust washer 8. Flange lock nut 9. Grease fitting 10. Flange bushing 1 1. Retaining ring 12. Cap washer 13. Compression spring 14. Cap 15. Flat wash[...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 23 Disassembly (Fig. 22) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Disassemble castor forks and wheels using Figure 22 as a guide. Assembly (Fig. 22) 1. Assemble castor forks and wheels using Figure 22 as a gu[...]

Groundsmaster 4100 - - D Cutting Deck Page 8 - - 24 Deck Rollers and Skids 1. Roller 2. Flange head screw 3. Roller shaft 4. Flange nut 5. Lock nut 6. Roller 7. Cap screw 8. Flange nut 9. Skid (RH shown) 10. Flange head screw Figure 23 1 2 3 4 5 6 7 5 6 7 5 6 7 8 10 9 FRONT RIGHT Removal (Fig. 23) 1. Remove skids and rollers from deck using Figure [...]

Groundsmaster 4100 - - D Foldout Drawings Page 9 - 1 Chapter 9 Foldout Drawings T able of Contents HYDRAULIC SCHEMA TIC 3 ..................... ELECTRICAL SCHEMA TIC Sheet 1 of 2 4 ................................ Sheet 2 of 2 5 ................................ CIRCUIT DIAGRAMS Glow Plug Circuits 6 ........................... Crank Circuits 7 .....[...]

Groundsmaster 4100 - - D Foldout Drawings Page 9 - 2 This page is intentionally blank.[...]

Page 9 - 3 Hydr aulic S chem atic Groundsmaster 4100 - - D 4WD MANI F OLD COUNTERBAL ANCE MANI F OLD FIL TER MANI F OLD FAN DRIVE MANI F OLD RH WING DECK MANI F OLD LH WI NG DECK MANI F OLD CENTER DECK MANI F OLD[...]

Page 9 - 4 All r elays and so lenoid s are shown as de - - energized. All gr ound wir es are black. CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 (OP TIO NAL CRUIS E CONT ROL KI T) (OPT IONA L CRUISE CONT ROL KI T) (OP TIO NAL CRUIS E CONT ROL KI T) (OP TIO NAL CRUIS E CONT ROL KI T) (OP TIO NAL CRUIS E CON[...]

Page 9 - 5 Electr ical Schematic Groundsmaster 4100 - - D All r elays and so lenoid s are shown as de - - energized. All gr ound wir es are black. Sheet 2 of 2 CONTINUES FROM SHEET 1 COOLI NG FAN CONTINUES FROM SHEET 1 CONTINUES FROM SHEET 1 SWITCH CONTINUES FROM SHEET 1 POWER RELA Y[...]

Page 9 - 6 Glow Plug Circuits Power C urr ent Contr ol Curr ent Indicat ion Cur rent Groundsmaster 4100 - - D CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 (UNOCCUP IED) RIG HT DECK FRON T DE CK PTO SOL EN OID LEFT DECK PTO SOL EN OID PTO SOL EN OID (OP TIO NAL CRUIS E CONT ROL KI T) (OP TIO NAL CRUIS E CON[...]

Page 9 - 7 Crank Cir cuits Power C urr ent Contr ol Curr ent Indicat ion Cur rent Groundsmaster 4100 - - D CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 (UNOCCUP IED) RIG HT DECK FRON T DE CK PTO SOLENOID LEFT DECK PTO SOL EN OID PTO SOL EN OID (OP TIO NAL CRUIS E CONT ROL KI T) (OP TIO NAL CRUIS E CONT ROL[...]

Page 9 - 8 Run (T ranspor t) Cir cuits Power C urr ent Contr ol Curr ent Indicat ion Cur rent Groundsmaster 4100 - - D CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 (OCCUP IED) RIGH T DE CK FRON T DE CK PTO SOL EN OID LEFT DECK PTO SOLENOID PTO SOLENOID (OP TIO NAL CRUIS E CONT ROL KI T) (OP TIO NAL CRUIS E[...]

Page 9 - 9 Run (Mow) Cir cuits Power C urr ent Contr ol Curr ent Indicat ion Curr ent Groundsmaster 4100 - - D CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 (OCCUP IED) RIG HT DECK FRON T DE CK PTO SOLENOID LEFT DECK PTO SOLENOID PTO SOLENOID (OP TIO NAL CRUIS E CONT ROL KI T) (OP TIO NAL CRUIS E CONT ROL K[...]

Page 9 - 10 High T emper atur e W arning C irc uits Power C urr ent Contr ol Curr ent Indicat ion Cur rent Groundsmaster 4100 - - D CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 (OCCUP IED) RIGH T DE CK FRON T DE CK PTO SOLENOID LEFT DECK PTO SOLENOID PTO SOLENOID (OP TIO NAL CRUIS E CONT ROL KI T) (OP TIO [...]

Page 9 - 1 1 Over T emper atur e Shutdown Cir cuits Power C urr ent Contr ol Curr ent Indicat ion Cur rent Groundsmaster 4100 - - D CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 (OCCUP IED) RIG HT DECK FRON T DE CK PTO SOLENOID LEFT DECK PTO SOLENOID PTO SOLENOID (OP TIO NAL CRUIS E CONT ROL KI T) (OP TIO N[...]

Page 9 - 12 Gr oundsmas ter 4100 - - D Cons ole Wire Ha rne ss COOLI NG FAN SWITCH (PTO S HUTDOWN DEL A Y) (ENGINE SHUT DOWN DELAY) FLOW SWITCH TRANSPORT/4WD DIVIDER SWITCH[...]

Page 9 - 13 Gr oundsmas ter 4100 - - D Cons ole Wire Ha rne ss YELLO W GRA Y WHITE Sheet 1 of 2 YELLOW/BLACK VIOLET YELLO W YELLOW GREEN RED BLACK RED RED WHITE RED BLACK GREEN ORANGE VIOLET VIOLET YELLO W YELLO W BLACK YELLO W TA N BL ACK BLUE BLACK VIOLET BLACK YELLO W ORANGE BLACK BLUE ORANGE BLACK TA N YELLOW BLACK TA N TA N TA N TA N GRA Y GRA[...]

Page 9 - 14 BLACK RED YELLO W T AN/BLACK RED BLACK RED RED BLACK RED RED BLACK T AN/BLACK YELLOW/GREEN T AN/BLACK VIOLET GREEN/BLACK BLACK BLACK YELLO W BLACK T AN/BLACK BLACK ORANGE/ BL ACK YELLOW/WHITE WHITE/GREEN WHITE/BLACK BLUE/ BLACK BROWN/WHITE GRA Y T AN/BLACK BLACK BLACK BLACK Gr oundsmas ter 4100 - - D Cons ole Wire Ha rne ss Sheet 2 of 2[...]

Page 9 - 15 Gr oundsmas ter 4100 - - D Front Wire H ar ness FLOW DIVIDER SOLENOID[...]

Page 9 - 16 Gr oundsmas ter 4100 - - D Front Wire H ar ness PINK BLACK WHITE PINK PINK PINK BLACK GREEN/BLACK GRA Y TA N BLACK BROWN YELLO W PINK ORANGE WHITE TA N PINK PINK TA N TA N BLACK BLACK ORANGE ORA NGE BLACK YELLOW/BLACK GREEN/BLACK GREEN/BLACK GREEN/BLACK BLACK ORANGE BLUE BLACK GRA Y GREEN BLUE VIOLET/BLACK FLOW DIV IDER SOLENOID[...]

Page 9 - 17 Gr oundsmas ter 4000 - - D Engine Wir e Har ness (ST ART ER) (ST ART ER) (ST ART ER)[...]

Page 9 - 18 Gr oundsmas ter 4000 - - D Engine Wir e Har ness RED/BL ACK BLACK WHITE RED/BLACK RED YELLO W ORANGE BLACK BLACK BLACK ORANGE VIOLET/BLACK BLACK VIOLET/BLACK BLACK BLACK BLACK VIOLET/BLACK BLACK YELLOW/BLACK ORANGE YELLOW/BLACK BLACK YELLOW/BLACK GREEN BLACK BLACK RED BLACK BLACK BROWN/WHITE YELLOW/BLACK ORANGE BLUE YELLO W YELLOW/WHITE[...]

Page 9 - 19 Gr oundsmas ter 4100 - - D Jump er W ire Harn ess BLACK BLUE VIOLET GRA Y YELLO W GRA Y BLUE GRA Y VIOLET BLUE VIOLET[...]

Page 9 - 20 Gr oundsmas ter 4100 - - D Cut ti ng Deck Wi re Harness ORANGE YELLOW/BLACK BLACK VIOLET/BLACK BLACK ORANGE BLACK ORANGE P15 P2 P1 DECK LIF T SENSOR (LH) DECK LIFT SENSOR (RH)[...]