Toro 4100-D manual

(Models 30602, 30604, 30606 and 30608) Part No. 13203S L Service Manual Groundsmaster R 4100 - - D & 41 10 - - 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 30604 and 30[...]

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Gr oundsmas ter 4100 - - D/ 41 10 - - D T able Of Contents Chapter 1 - - Safety Gener al Safet y I nst ruc tions 1 - - 2 .................. Jackin g Instructions 1 - - 5 ......................... Safet y and I nst ruc tion Dec als 1 - - 6 ................ Cha pter 2 - - Produc t Rec ords and Ma intena nce Produc t Records 2 - - 1 ..................[...]

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Gr oundsmas ter 4100 - - D/ 41 10 - - D T able Of Contents (Continued) Chap ter 9 - - Op erato r Cab Gener al Inf orm ation 9 - - 2 ........................ Serv ice and Repairs 9 - - 3 ........................ SANDEN SD COMPRESSOR SER VICE GUIDE Cha pter 1 0 - - Foldout Dra wings Elect rical Dr awing Designat ions 10 - - 2 ............. Hydraulic [...]

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Groundsmaster 4100- - D/41 10 - - D Page 1 - - 1 Safety Chapter 1 Safety T able of Contents GENERAL SAFETY INSTRUCTIONS 2 ............ Before Oper ating 2 ............................ While Operating 3 ............................ Maintenance and Service 4 .................... JACKING INSTRUCTIONS 5 ..................... Jacking the Front End 5 ...[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 1 - - 2 Safety General Safety Instructions The Groundsmaster 4100-D and 41 10 - - D are tested and certified by T oro for complia nce with existing safety standards and specificatio ns. Al though hazard control and accident prevention partially are dependent u pon the design and configuration of the machin[...]

Groundsmaster 4100- - D/41 10 - - D Page 1 - - 3 Safety While Operating 1. Sit on the seat wh en starting an d operating the ma- chine. 2. Before starting th e engine: A. Apply the parking bra ke. B. Make sure traction pedal i s in neutral and the PTO switch is OFF (disenga ged). 3. After engine is start ed, release pa rking brake and keep foot off[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 1 - - 4 Safety Maintenance and Service 1. Before servicing or making adjustments, lower deck, stop engine, apply parking brake and remo ve key from the switch. 2. Make sure machine is in safe oper ating condit ion by keeping all nuts, b olts and screws tight. 3. Never store the m achine or f uel container [...]

Groundsmaster 4100- - D/41 10 - - D Page 1 - - 5 Safety Jacking Instructions CAUTION When changing attachments, tires or perform - ing other servic e, use correct ja cks and sup - ports. Make sure machine is park ed on a solid, level surface such as a concr ete floor . Prior to raising machine, rem ove any attachments that may interfere with the sa[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 1 - - 6 Safety Safety and Instruction Decals Numerous safe ty and instruction decals are af fixed to your Groundsmaster mach ine. If any decal becomes il- legible or damaged, install a new deca l. Decal part num- bers are listed in your P arts Catalog.[...]

Groundsmaster 4100- - D/41 10 - - 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 Conversion[...]

0.09375 Groundsmaster 41 00 - - D/41 10 - - D Page 2 - - 2 Product Records a nd Maintenance Equivalents and Conversions[...]

Groundsmaster 4100- - D/41 10 - - D Page 2 - - 3 Product Records and Ma intenance T orque Specifications Recommended fastener torque values are listed in the following tables. For critical applications, as determine d by T oro, either the recommend ed torque or a torque that is unique to the application is clearly iden tified and spe- cified in thi[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 2 - - 4 Product Records a nd Maintenance Standard T orque for Dry , Zinc Plate d 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 Hei ght Nuts (SAE J995 G rade 2 or St ronger Nuts) SAE Grade 5 Bol ts, Scr ews[...]

Groundsmaster 4100- - D/41 10 - - D Page 2 - - 5 Product Records and Ma intenance Standard T orque for Dry , Zinc Plated a nd Steel Fasteners (Metric Series) Thre ad Size Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X [...]

Groundsmaster 41 00 - - D/41 10 - - D Page 2 - - 6 Product Records a nd Maintenance Other T orque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended T orque 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 t - - [...]

Groundsmaster 4100- - D/41 10 - - D Page 3 - - 1 Y anmar Diesel Engine Chapter 3 Y anmar Diesel Engine T able of Contents SPECIFICA TIONS 2 ............................ Models 30602 an d 30604 2 ........ ............ Models 30606 an d 30608 3 ........ ............ GENERAL INFORMA TION 5 ..................... Operator ’s Manu als 5 ...............[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 3 - - 2 Y anmar Diesel Engine Specifications (Models 30602 and 30604) Item Description Make / Designation Y anmar Model 4TNV84T - - ZMTR: 4 - - Cycle, 4 Cylinder , W ater Cooled, Turbocharged, T ier 4i Diesel Engine Bore 3.307 in (84 mm) Stroke 3.543 in (90 mm) T ot al Dis placem ent 121.7 in 3 (19 95 cc) [...]

Groundsmaster 4100- - D/41 10 - - D Page 3 - - 3 Y anmar Diesel Engine Specifications (Models 30606 and 30608) Item Description Make / Designation Y anmar Model 4TNV86CT - - DTR: 4 - - Cycle, 4 Cylinder , W ater Cooled, Tier 4 Diesel En gine Bore 3.386 in (86 mm) Stroke 3.543 in (90 mm) T otal Displacement 127 .5 in 3 (2090 cc) Firing Order 1 (clos[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 3 - - 4 Y anmar Diesel Engine This page is intentionally blank.[...]

Groundsmaster 4100- - D/41 10 - - D Page 3 - - 5 Y anmar Diesel Engine General Information This Chapter gives information about specifications an d repair of the diese l engine used in t he Groundsm aster 4100 - - D and 41 10 - - D. General maintenance procedure s are described in your Operator ’s Man ual. Information on engine troublesho ot- ing[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 3 - - 6 Y anmar Diesel Engine Engine Elec tronic Control Unit (ECU) The Y anmar engine that powers your Groundsmaster uses an electronic control unit (ECU) for engine man- agement and a lso to communica te with the machin e TEC controllers an d the operator Info Center display on the machine. All wire harn[...]

Groundsmaster 4100- - D/41 10 - - D Page 3 - - 7 Y anmar Diesel Engine Y anmar Engine : Models 30602 and 30604 The engine used on Groundsmaster models 30602 and 30604 is a Y anmar TNV Series, turbocharged, die sel engine that complies with EP A interim T ier 4 emission regulations. Eng ine features include an elec tronic con- trol unit (ECU) contro[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 3 - - 8 Y anmar Diesel Engine Y anmar E ngine: Models 30606 a nd 30608 The engine u sed on Groundsmaster models 30606 and 30608 is a Y anmar T NV Series, tur bocharged , diesel engine that complies with EP A T ier 4 emission regula- tions. Engine features in clude an electronic control unit (ECU) that cont[...]

Groundsmaster 4100- - D/41 10 - - D Page 3 - - 9 Y anmar Diesel Engine Station ary regenera tion is requested by the engine ECU if the assist and reset regenerations d o not return the DPF p articulate level to an acceptable level. During the stationary regeneration , the engine ECU controls engine speed, load and air/fuel mixture to perform a cont[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 3 - - 10 Y anmar Diesel Engine Service and Repairs A i rF i l t e rS y s t e m Figure 6 FRONT RIGHT 1. Air cleaner assembly 2. T ank support 3. Indicator 4. Adapter 5. Air cleaner strap 6. Flat washer (4 used) 7. Cap s crew (2 us ed) 8. Lock nut (2 used) 9. Flat washer (2 used) 10. Lock nut ( 2 used) 1 1 .[...]

Groundsmaster 4100- - D/41 10 - - D Page 3 - - 1 1 Y anmar Diesel Engine Removal (Fig. 6) 1. Park machi ne on a level surface, lower cutting deck, stop engine, apply pa rking brake and remove key from the ignition switch. 2. Raise and support h ood. 3. Remove air clea ner components as needed using Figure 6 as a guide. Installation (Fig. 6) IMPORT [...]

Groundsmaster 41 00 - - D/41 10 - - D Page 3 - - 12 Y anmar Diesel Engine Fuel System Figure 9 1. Car riage s crew (2 u sed) 2. Retaining ring (2 used) 3. Flat washer (2 used) 4. Flange nut (6 used) 5. V ent hose 6. Fuel tank 7. Hose clamp (2 used) 8. Elbow fitting (2 used) 9. Sta nd pipe 10. Grommet (3 used) 11 . H o s e c l a m p 12. Lock washer [...]

Groundsmaster 4100- - D/41 10 - - D P age 3 - - 13 Y anmar Diesel Engine DANGER Because diesel fuel is f lammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while en- gine is running, hot or when m achine is in an en - closed area. Always fill f uel tan k outsi de and wipe up any spille[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 3 - - 14 Y anmar Diesel Engine Radiator and Oil Cooler Assem bly Figure 1 1 FRONT RIGHT 2 3 6 8 9 10 11 1 5 7 4 24 25 3 26 27 28 29 30 31 32 33 34 35 Thread Sealant 1. LH radiator support 2. Cap s crew (2 us ed) 3. Flange nut (12 used) 4. Hose clamp (3 used) 5. Hose 6. Flange nut (6 used) 7. Foam plug (2 u[...]

Groundsmaster 4100- - D/41 10 - - D P age 3 - - 15 Y anmar Diesel Engine Removal (Fig. 1 1) 1. Park machi ne on a level surface, lower cutting deck, stop engine, apply pa rking brake and remove key from the ignition switch. Open an d support hood. CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pres surized, hot [...]

Groundsmaster 41 00 - - D/41 10 - - D Page 3 - - 16 Y anmar Diesel Engine Installation (Fig. 1 1) 1. Inspect seals (items 7, 10, 27 and 34) around radiat- or location for wear or damage. Replace seal s if neces- sary . 2. Rem ove all plugs plac ed during the r emoval proce- dure. 3. If hydraulic fittings (items 29 and 31) were removed from oil cool[...]

Groundsmaster 4100- - D/41 10 - - D P age 3 - - 17 Y anmar Diesel Engine This page is intentionally blank. Ya n m a r Diesel Engine[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 3 - - 18 Y anmar Diesel Engine Engine Figure 15 1. Engine (model 30604 shown) 2. Cap s crew (4 us ed) 3. Reb ound w asher ( 4 used) 4. Flange nut (12 used) 5. Engine mount (4 used) 6. Cap s crew (2 us ed per mo unt) 7. Engine mount bracket (2 used) 8. Lock washer 9. Engine mount bracket (2 used) 10. Cap sc[...]

Groundsmaster 4100- - D/41 10 - - D P age 3 - - 19 Y anmar Diesel Engine Engine Removal (Fig. 15) 1. Park machine on a level surface , lower cutting deck, stop engine, apply pa rking brake and remove key from the ignition switch. 2. Disconnect negative battery cabl e from battery ter- minal and then disconnect positive cable from battery (see Batte[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 3 - - 20 Y anmar Diesel Engine 1 1. On machines w ith a T ier 4 compliant engine (m odels 30606 and 306 08): A . R e m o v e f u e lt a n kt oa l l o we n g i n et ob er a i s e d f r o mm a c h i n e( s e eF u e lS y s t e mi nt h i ss e c t i o n ) . B. Install lift bracket to front of engine cylinder he[...]

Groundsmaster 4100- - D/41 10 - - D P age 3 - - 21 Y anmar Diesel Engine CAUTION One person should opera te lift or hoist while a second person guides the engine out of the ma- chine. IMPORT ANT : Make sure to not damage the engine, radiator assembly , fuel lines, hydraulic lines, elec- trical wire harness or other components while re- moving the e[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 3 - - 22 Y anmar Diesel Engine 17. Check pos ition of ele ctrical wir es, fue l lines and hy - draulic lines for proper cle arance with rotating , high tem- perature and moving com ponents. 18. Connect positive b attery cable to positive bat tery ter- minal first and then connect neg ative cable to battery[...]

Groundsmaster 4100- - D/41 10 - - D P age 3 - - 23 Y anmar Diesel Engine This page is intentionally blank. Ya n m a r Diesel Engine[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 3 - - 24 Y anmar Diesel Engine Spring Coupler Figure 21 1. Cap s crew (8 us ed) 2. W asher (8 used) 3. Flyw heel p late 4. Cap screw (8 used) 5. W asher (8 used) 6. Spring coupler 7. Engine (model 30604 shown) FRONT RIGHT 29 to 33 ft - - lb ( 4 0t o4 4N - - m ) 28 to 32 ft - - lb (38 to 43 N - - m) 1 2 3 6[...]

Groundsmaster 4100- - D/41 10 - - D P age 3 - - 25 Y anmar Diesel Engine Coupler Removal (Fig. 21) NOTE: The hydraulic pump assembly need s to be re- moved from engine befor e coupler can be removed. 1. If engine is in machine, remove hydraulic pump as- sembly from machine ( see Piston (T raction) Pump Re- moval in the Service and Re pairs section [...]

Groundsmaster 41 00 - - D/41 10 - - D Page 3 - - 26 Y anmar Diesel Engine Exhaust System (Models 30606 and 30608) Figure 23 1. Gasket 2. Exhaust assembly stay 3. Exhaust assembly stay 4. Exhaust assembly stay 5. Exhaust assembly stay 6. Nut 7. DOC t emp senso r (inle t) 8. DOC temp sensor (outlet) 9. Nut (4 use d) 10. DOC assembly 1 1. Nut (3 used)[...]

Groundsmaster 4100- - D/41 10 - - D P age 3 - - 27 Y anmar Diesel Engine Groundsmaster models that are powered by a diesel en- gine that complies with EP A Tier 4 emissi on regulations are equipped with an exhau st system that includes a diesel oxidation catalyst (DOC) and a diesel particulate filter (DPF). These exhau st components require service[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 3 - - 28 Y anmar Diesel Engine This page is intentionally blank.[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Pa ge 4 - - 1 Chapter 4 Hydraulic System T able of Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TION 3 ..................... Operator ’s Manu al 3 .......................... Check Hydraulic Fluid 3 ................. ...... Relieving Hydraulic System Pressure 3 .......[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 2 Specifications Item Description Piston (Traction ) Pump Sauer - - Danfoss V ariable Displacement Axial Piston Pump Maximum Displacement (per revolution) 2.75 in 3 (45 c c) System Relief Pressure: Forward 4350 PSI (300 bar) System Relief P ressure: Reverse 5000 PSI (345 bar) Charge [...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Pa ge 4 - - 3 General Information Operator ’ s Manual The Operator ’s Manu al provides information re garding the operation, general maintenance and maintenan ce intervals for your Groundsmaster ma chine. Refer to that publication for additional information when servicing the machine. Check H[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 4 T owing T raction Unit IMPORT ANT : If towing limits are exce eded, severe damage to the piston (traction) pump m ay occur . If it becomes necessary to tow (or push) the machine, tow (or push) in a forward direction only and at a speed below 3 mph (5 kph) . The piston (traction) pu[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Pa ge 4 - - 5 Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure dif ferentials during operation and exp osure to weather , sun, chemicals, very warm storage cond i- tions or mishandling dur ing opera tion and maint enance. These conditions can cause hose damage an[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 6 Hydraulic Hose and T ube Installa tion (O - - Ring Face Seal Fitting) 1. M ake sure thread s and sealing surfac es of the hose/ tube and the fitting are free of burrs, n icks, scratches or any foreign mate rial. 2. As a pre ventat ive meas ure agains t leakage, it is r ec- ommended[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Pa ge 4 - - 7 Hydraulic Fitting Installati on (SAE Straight Thread O - - Ring Fitting into Component Port) Non - - Adjustable Fitting (Fig. 6) 1. Make sure all threads and sealing surfa ces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventa[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 8 Adjustable Fitting (Fig. 8) 1. Make sure all threads and sealing s urfaces of fitting and component port are free of burrs, nicks, scratches or any foreign m aterial. 2. As a pre ventat ive meas ure agains t leakage, it is r ec- ommended that the O - - ring be replaced any time the[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Pa ge 4 - - 9 Hydraulic Schematic NOTE: A larger hydraulic schematic is included in Chapter 10 - - Foldout Drawings S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 2500 PSI S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 OR7 .070 T 2SP CH3 G2 G4 CV[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 10 Hydraulic Flow Diagrams T raction Circuit: LOW Speed (Mow) (Forward S hown) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100- - D/41 10 - - D S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 S7 S9 S8 C6 M1 M2 C[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 1 1 T raction Circ uit: LOW Speed (Mow) The traction circuit piston pump is a variabl e displace- ment pump that is directly coupled to the engine fly- wheel. This pump utilizes an in tegral electro - - hydraulic servo piston assembly that co ntrols the rate and direc- tion of hydrauli[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 12 T raction Circuit: HI Speed (T ransport) (Forward Shown) Working Pressure Low Pressure ( Charge) Return or Suction Flow Groundsmaster 41 00 - - D/41 10 - - D S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 13 T raction Circ uit: HI Speed (T ransport) The traction circuit piston pump is a variabl e displace- ment pump that is directly coupled to the engine fly- wheel. This pump utilizes an in tegral electro - - hydraulic servo piston assembly that co ntrols the rate and direc- tion of hyd[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 14 Lower Cutting Deck (LH W ing Deck Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100- - D/41 10 - - D S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .0[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 15 Lower Cutting Deck A four section gear pump is cou pled to the piston (trac- tion) pump . The third gea r pump sectio n supplies hy - draulic flow to the lift/lower c ircuit, the engine cooling fan circuit and the traction charg e circuit. Each of the cuttin g deck sections (main, r[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 16 Raise Cutting Deck (LH Wing Deck Shown) Wo rking Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100- - D/41 10 - - D S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .0[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 17 Raise Cut ting Deck A four section gear pump is cou pled to the piston (trac- tion) pump . The third gea r pump sectio n supplies hy - draulic flow to the lift/lower c ircuit, the engine cooling fan circuit and the traction charg e circuit. Each of the cuttin g deck sections (main, [...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 18 Mow Circuit (All Deck Motors Rotating) Working Pressure Low Pressure (Charge) Return or Suction Flow Grounds master 41 00 - - D/41 10 - - D S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 19 Mow Circuit A four section gear pump is cou pled to the piston (trac- tion) pump. Hydraulic f low for the mow circuit is supplied by two sections of the gear pump. The gear pump sec- tion closest to the piston (tra ction) pump supp lies hy- draulic flow to the wings of the cutting d[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 20 Mow Circuit Cutting Deck Blade Braking When the operator turns the PT O switch OFF or if a wing deck is raised with the PTO switch ON, PTO manifold proportional rel ief valve (PRV ) is de - - energized causing logic valve (LC1) to sh ift (refer to information in Mow Cir- cuit in t[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 21 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 22 Steering Circuit (Right T urn Shown) Wor king Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100- - D/41 10 - - D S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 [...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 23 Steering Circuit A four section gear pump is cou pled to the piston (trac- tion) pump. The fourth g ear pump section (farthest from the piston pump) supplies hyd raulic flow to the steering circuit, the engine cooling fan circuit and th e traction charge circuit. Priority hydrauli c[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 24 Engine Cooling Fan Circuit (Forward Direction Shown) Wo rking Pressure Low Pr ess ure (C harge ) Return or Sucti on Flow Groundsmaster 410 0 - - D/41 10 - - D S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 2500 PSI S7 S9 S8 C6 M1 M2 CH1 CV3[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 25 Engine Cooling Fan Circuit A four section gear pump is cou pled to the piston (trac- tion) pump (Fig. 14). The f ourth gear pump section (farthes t from the pi ston pump) s upplies h ydraulic flow to the steering circuit, the engin e cooling fan circuit and the traction charge circu[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System 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 pr[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 27 40 GPM Hydraulic T ester (Pres sure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the T esting section of this chapte r . T his tester includes the f ollowing: 1. LOAD V AL VE: A simulated working load is created in the ci[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 28 High Flow Hydraulic Filter Kit The high flow hydraulic filt er kit is designed with large flow (40 GPM/150 LPM) and high pressu re (5000 PSI/345 bar) capabilities. This kit provides for bi - - direc- tional filtration whi ch prevents filtered debris from being allowed back into th[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 29 Hydraulic T est Fitting Kit This kit includes a vari ety of O - - ring face seal fittings to enable the connection of test gauges into the system. The kit includes: tee ’s, unions, reducers, plugs, ca ps and male test fittings. T oro Part Number: TOR4 07 9 Figure 21 TORO TEST FITT[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 30 Remote Starter Switch After flushing the hydraulic system or replacing a hy- draulic component (e.g. gear pump, pi ston pump, wheel motor), it is nec essary to prim e the hydraulic p umps. A remote starter switch (Fig. 24) ca n be used for this pur- pose. Obtain a remo te starter [...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 31 T roubleshooting The charts that follow contain suggestions that can be used to assist in diagnosing hyd raulic system perfor- mance issues. The suggestions are not all - - inclusive. Also, consider that th ere may be m ore than one ca use for a machine pr oblem. Review the hydrauli[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 32 T raction Circuit Pr oblems Problem Possible Cause M a c h i n eo p e r a t e si no n ed i r e c t i o n only . Piston (traction) pump by- - pass valve is open or da maged. T raction relief valve is leaking or faulty . Piston (traction) pump servo contro l valve orifices or screen[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 33 Mow Circuit Problems Problem Possible Cause None of the cutting deck sections will operate. NOTE: T o engage the mow circuit, t h es e a tm u s tb eo c c u p i e d ,t h ec u t - ting deck(s) must be fully lowered, the traction speed mu st be in the LOW (mow) position and the PT O sw[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 34 Lift Circuit Problems Problem Possible Cause Cutting deck (or wing decks) will not raise. NOTE: The seat must be occupie d in order to raise cutting deck. Engine RPM is too low . Hydraulic oil lev el in reservoir is low (NOTE : Other hydraulic systems are affected a s well). Solen[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 35 Steering Circui t Problems Problem Possible Cause Steering is inoperative or sluggish. Steering compo nents (e.g. tie rods, steering cylinder ends) are worn or binding. Steering cylinder is b inding. Oil level in hydraulic reservoir is low (NOTE: other hydrauli c sys- tems are af fe[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 36 Engine Cooling Fan Cir cuit Problems Problem Possible Cause Cooling fan runs on ly in forward di- r e c t i o n( f a nd o e sn o tr u ni nr e v e r s e direction). Solenoid cartridge valve (S10) in combination contro l manifold is faulty . Electrical problem exists that prev ents [...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 37 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 38 Te s t i n g The most effective method for isol ating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flo w meters in the circuits during variou s operationa l checks (see the S pecial T ools section in this Chapter). IMPORT ANT : [...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 39 Which Hydraulic T ests Are Necessar y? Before beginnin g any hydrau lic test, ide ntify if the prob- lem is related to the tractio n circuit, cutting (mow) circuit, lift/lower circuit, steeri ng circuit or engine cooli ng fan cir- cuit. Once the faulty system has been i dentified, p[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 40 T raction Circuit Charge P ressure (Using Pressure Gauge) 3.3 GPM 4.4 GPM 14.3 GPM 14.3 GPM PR 380 PSI RV 650 PSI .050 CV T P2 M8 CH OR1 250 PSI 2.14 CID / 1.16 CID 200 PSI 4350 PSI 5000 PSI .0315 .0315 0.4 CID 0.3 1.29 1.29 CID CID CID 2.75 CID REAR TRACTIO N MANIFOLD ENGINE 30.5[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 41 The traction charge circuit is design ed to replace loss of hydraulic fluid from the close d loop traction circuit. This test is used to ma ke sure tha t traction ch arge pressu re is correct. Procedure for T raction Circuit Charge Pressure Te s t CAUTION Prevent personal injury and[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 42 T raction Circuit Rel ief Pressure (Using Pressur e Gauge) 3.3 GPM 4.4 GPM 14.3 GPM 14.3 GPM PR 380 PSI RV 650 PSI .050 CV T P2 M8 CH OR1 250 PSI 2.14 CID / 1.16 CID 200 PSI 4350 PSI 5000 PSI .0315 .0315 0.4 CID 0.3 1.29 1. 29 CID CID CID 2.75 CID REAR TRACTION MANIFOLD ENGINE 30.[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 43 Procedure for T raction Circuit Relief Pressur e Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre - cautions for Hydraulic T esting at the beginning of this section. 1. Park machine on a level surface with the cutting deck low[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 44 Counterbalance P ressure (Using Pressure Gauge) PRESSURE GAUGE S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 OR7 .070 T 2SP CH3 G2 G4 CV4 PR G1 G3 3250 PSI 1350 PSI 4P S I 4P S I .03[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 45 Procedure for Counter balance Pressure Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre - cautions for Hydraulic T esting at the beginning of this section. 1. Park machine on a level surface with the cutting deck lowered and o[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 46 Reverse T rac tion Circuit Re ducing V alv e (PR) Pressure (Using Pressu re Gauge) 3.3 GPM 4.4 GPM 14.3 GP M 14.3 GPM PR 380 PSI RV 650 PSI .050 CV T P2 M8 CH OR1 250 PSI 2.14 CID / 1.16 CID 200 PSI 4350 PSI 5000 PSI .0315 .031 5 0.4 CID 0.3 1. 29 1.29 CID CID CID 2.75 CID REAR TR[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 47 Procedure for Rever se T raction Circuit Reducing Va l v e ( P R ) P r e s s u r e Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre - cautions for Hydraulic T esting at the beginning of this section. 1. Park machine on a level[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 48 Rear T raction Circuit Relief V alve (R V) Pressure (Using Pressure Gauge) 3.3 GPM 4.4 GPM 14.3 GP M 14.3 GPM PR 380 PSI RV 650 PSI .050 CV T P2 M8 CH OR1 250 PSI 2.14 CID / 1.16 CID 200 PSI 4350 PSI 5000 PSI .0315 .031 5 0.4 CID 0.3 1. 29 1.29 CID CID CID 2.75 CID REAR TRACTION M[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 49 Procedure for Rear T raction Circuit Relief V alve (R V) Pressure Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre - cautions for Hydraulic T esting at the beginning of this section. 1. Park machine on a level surface with the[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 50 Piston (T raction) Pump Flow (Using T ester with Flow meter and P ressure Gauge) 3.3 GPM 4.4 GPM 14.3 GPM 14.3 GPM PR 380 PSI RV 650 PSI .050 CV T P2 M8 CH OR1 250 PSI 2.14 CID / 1.16 CID 200 PSI 4350 PSI 5000 PSI .0315 .0315 0.4 CID 0.3 1.29 1. 29 CID CID CID 2.75 CID REAR TRACTI[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 51 Procedure for Piston (T raction) Pump Flow Te s t This test me asures pisto n (tractio n) pump output (f low). During this tes t, pump load is creat ed at the flow meter using the adjustable loa d valve on the tester . NOTE: Before perfor ming piston pum p flow test, make sure that [...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 52 Cutting Deck Circuit Pressure (Using Pressure Gau ge) CENTER DECK CIRCUIT PRESSURE TEST SHOWN PRESSURE GAUGE 3.3 GPM 14.3 GPM 14.3 GPM 1.17 CID 3000 PSI P1 P1 P1 P2 P2 P2 M1 M2 LC1 PRV PD CD RV 2000 PSI M1 M2 LC1 PRV PD RV 3000 PSI M1 M2 LC1 PRV PD RV CD CD LEFT DECK CENTER DECK R[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 53 Procedure for Cutting Deck Circuit Pressure Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre - cautions for Hydraulic T esting at the beginning of this section. 1. Park machine on a level surface with the cutting deck lowered [...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 54 PTO Relief Pr essure (Using T ester with Pressure Gauge and Flow Meter) CENTER DECK PTO RELIEF PRESSURE TEST SHOWN 3.3 GPM 14.3 GPM 14.3 GP M 1.17 CID 3000 PSI P1 P1 P1 P2 P2 P2 M1 M2 LC1 PRV PD CD RV 2000 PSI M1 M2 LC1 PRV PD RV 3000 PSI M1 M2 LC1 PRV PD RV CD CD LEFT DECK CENTER[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 55 The PTO circuit relief pressure test should be performed to make sure that the PTO ci rcuit relief pressures are correct. Procedure for PTO Relief Pressur e Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre - cautions for Hydra[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 56 Cutting Deck Motor Case Drain Leakage (Using T ester with Pressure Gauge and Flow Meter) CENTER CUTTING DECK MOTOR CASE DRAIN LEAKAGE TEST SHOWN 1.17 CID 3000 PSI P1 P1 P2 P2 M1 M2 LC1 PRV PD CD RV 2000 PSI M1 M2 LC1 PRV PD RV 3000 PSI M1 M2 LC1 PRV PD RV CD CD LEFT DECK CENTER DE[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 57 Procedure for Cutting Deck Motor Case Drain Leakage Te s t NOTE: Over a period of time, a dec k 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 [...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 58 Lift/Lower Circuit Relief Press ure (Us ing Pressure Gauge) S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 OR7 .070 T 2SP CH3 G2 G4 CV4 PR G1 G3 3250 PSI 1350 PSI 3.3 GPM 4.4 GPM 14.3[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 59 The lift/lower circuit relief pressure test sho uld be per- formed to make sure that the cutting unit lift and lower circuit relief pressure is correct. Procedure for Lift/Lower Circuit Relief Pressur e Te s t NOTE: Before attempting to check or adjust lift/lower circuit relief pr e[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 60 Steering Cir cuit Relief Pressure (Using Pressure Gauge) S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 2500 PSI S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 OR7 .070 T 2SP CH3 G2 G4 CV4 PR G1 G3 3250 PSI 1350 PSI 3.3 GPM 4.4 GP[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 61 The steering circuit relief pressure test shou ld be per- formed to make sure that the ste ering circuit relief pres- sure is correct. Procedure for Ste ering Circuit Relief Pressur e Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS a[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 62 Steer ing Cylinder Internal Leakage 6.1 CID E P L R T STEERING CYLINDER 2.00” BORE 4.20” STROKE 0.625” ROD STEERING CONTROL VA LV E STEERING WHEEL TURNED FOR RIGHT TURN CYLINDER FULL Y EXTENDED LOOK FOR LEAKAGE STEEL CAP FROM COMBINA TION MANIFOLD FROM COMBINA TION MANIFOLD [...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 63 The steering cy linder intern al leakage test sho uld be performed if a steering problem is identified. This test will determine if the stee ring cylinder is faulty . Procedure for Steering Cylinder Internal Lea kage Te s t NOTE: Steering circuit operat ion will be affected by rear [...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 64 Engine Cool ing Fan Circuit (Using P ressure Gauge and P hototac) S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 2500 PSI S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 OR7 .070 T 2SP CH3 G2 G4 CV4 PR G1 G3 3250 PSI 1350 PSI 3.3 G[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 65 The cooling fan circuit test shoul d be performed to make sure that the engi ne cooling fan circuit has the c orrect system pressure and fan spee d. Procedure for Engine Cooling Fan Circuit T est CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTI[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 66 Gear Pump Flow (Using T ester with Pressure Gauge and Flow Meter) SECOND GEAR PUMP SECTION FLOW TEST SHOWN 3.3 GPM 14.3 GPM 14.3 GPM 250 PSI 4350 PSI 5000 PSI .0315 .0315 0.4 CID 0.3 1.29 1.29 CID CID CID 2.75 CID ENGINE 30.5 GPM G G G G TO COMBINATION MANIFOLD FROM COMBINA TION M[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 67 Procedure for Gear Pump Flow Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre - cautions for Hydraulic T esting at the beginning of this section. 1. Park machine on a level surface with the cutting deck lowered and of f. Make [...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 68 Adjustments Adjust Control Man ifold Relie f V alves Several of th e hydrau lic control m anifolds on the Groundsmaster include a djustable relief valves. The fol- lowing procedure can be used to adjust th ese relief valves. Refer to the T esting sectio n of this chapter for in - [...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 69 Service and Repairs General Precautions for R emoving and In stalling Hydraulic System Components Before Repair or Re placement 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 atta c[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 70 Check Hydraulic Li nes and Hoses W ARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use pape r or cardboard, not hands, to search for l eaks. H ydraulic fl uid esc aping u nder pressure can h ave suff icient f orce to p[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 71 Flush Hydraulic Sy stem IMPORT ANT : Flush the hydraulic system any time there is a severe component failure or the s ystem is contaminated. Contaminated oil may appear milky or black or may contain metal particles. IMPORT ANT : If a component failure occurred in the closed loop tra[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 72 Filtering Closed - - Loop T raction Circuit Filtering of a closed - - loop hydraulic system after a major component failure (e.g. traction (piston) pu mp or front wheel motor) is a requirement to prevent debris from transmitting throughout the system. If a closed - - loop hy- drau[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 73 Charge Hydr aulic System NOTE: When initially starting the hydraulic syst em with new or rebuilt components such as motors, pumps or lift cylinders, it is important that the hydrau lic system be charged properly . Air must be purged from t he system to reduce the cha nce of componen[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 74 Hydraulic Reservoir Figure 52 FRONT RIGHT 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 23 24 25 26 27 28 29 30 3 31 1. Hydraulic reservoir 2. Cap s crew 3. Recess bumper (2 used) 4. Thin spacer 5. Flange nut 6. Breather 7. Bus hing ( 3 used) 8. Stand pipe (3 used) 9. H[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 75 NOTE: The operator platform needs to be raised from the main frame so that the hydraulic reservoir can be re- moved from the machine (se e Operato r Platform in the Service and Repairs section of Chapter 6 - - Chassis). Removal (Fig. 52) 1. Park machine on a level surface , lower cu[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 76 Radiator and Oil Cooler Assem bly 1. LH radiator support 2. Cap screw (2 used) 3. Flange nut (12 used) 4. Hose clamp (3 used) 5. Hose 6. Flange nut (6 used) 7. Foam plug (2 used) 8. Flange head screw (6 used) 9. Flange head screw (9 used) 10. Foam strip 1 1. Hose bracket 12. R - -[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 77 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 78 Gear Pump Figure 55 FRONT RIGHT 2 3 8 9 10 11 13 1 7 12 14 15 16 17 18 19 20 4 21 22 23 24 2 1 15 9 20 26 6 25 1 5 27 1. Hose clamp (3 used) 2. Hose clamp (2 used) 3. Hydraulic hose 4. Suct ion ho se 5. T ee fitt ing 6. Straight hydraulic fitting 7. Plug 8. Cap s crew (2 us ed) 9.[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 79 Removal (Fig. 55) 1. Park machine on a level surface , lower cutting deck, stop engine, apply pa rking brake and remove key from the ignition switch. 2. Raise and support machine to gain access to gear pump from the underside o f the machine. 3. Drain the hydraulic reservoir . IMPOR[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 80 10. Replace hydrau lic filters a nd fill hydraulic reservoir with new hydraulic oil. 1 1. Prime hydraulic pumps (see Priming Hydraulic Pumps in this section ). 12. Properly fill hydraulic system (see Charge Hydraulic System in this section). 13. Stop engine and check for hydraulic[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 81 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 82 Gear Pump Se rvice 1. Front cover 2. Dowel pin (4 used) 3. Pressure seal 4. Back - - up gasket 5. Front thrust plate 6. Seal (8 used) 7. Front body 8. Idler gear 9. Drive shaft 10. Thrust plat e (7 used) 1 1. Dowel pin (6 used) 12. Splin ed conne ctin g shaft ( 3 used) 1 3 . F l a[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 83 IMPORT ANT : Use caution wh en clamping gear pump in a vise to avoid distorting any pump compo- nents . 3 . S e c u r et h ef r o n tc o v e ro ft h ep u m pi nav i s ew i t ht h e drive shaft pointing down. 4. Loosen the four (4) cap screw s that secure pump as- sembly . 5. Remove [...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 84 Piston (T raction) Pump Figure 61 FRONT RIGHT 1. Hose clamp (2 used) 2. Hose clamp (2 used) 3. Hose 4. Suct ion ho se 5. T ee fitt ing 6. Straight hydraulic fitting 7. Plug 8. Cap s crew (2 us ed) 9. Flat washer (4 used) 10. Gear pump 11 . O - - r i n g 12. Hydraulic fitting 13. 4[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 85 Removal (Fig. 61) 1. Park machine on a level surface , lower cutting deck, stop engine, apply pa rking brake and remove key from the ignition switch. 2. T o prevent contamination of hydraulic system during removal, thoroughly clean exterior of pump as sembly . 3. Raise and support m[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 86 Installation (Fig. 61) 1. If fittings were removed from piston pump, lubricate and place new O - - rings onto fittings. Install fittings into pump openings using marks made during the removal process to prop erly orientate fit tings. T ighten fit tings (see Hydraulic Fitting Insta[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 87 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 88 Piston (T raction) Pump Service Figure 65 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 2 3 10 7 25 10 29 33 34 36 37 38 39 40 41 46 47 42 43 48 49 44 45 41 42 42 55 42 44 45 46 50 51 52 53 54 10[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 89 1. Scre en (2 us ed) 2. Plug with O - - ring (2 used) 3. Plug with O - - ring (2 used) 4. Cylinder block assembly 5. V alve p late 6. Serv o piston 7. Scre w (4 used ) 8 . O r i f i c e( 2u s e d ) 9. Scre w (4 used ) 10. Plug with O - - ring (4 used) 1 1. Screw (2 used) 12. Plug 13[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 90 Rear Axle Motor 1. Rear axle motor 2. 90 o hydraulic fitting (2 used) 3. 90 o hydraulic fitting 4. Straight hydraulic fitting 5. 90 o hydraulic fitting 6. T emperature sender 7. Cap screw (2 used) 8. Flat washer (2 used) 9. O - - ring 10. External snap ring (2 used) 11 . P i n i o[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 91 Removal (Fig. 66) 1. Park machine on a level surface , lower cutting deck, stop engine, apply pa rking brake and remove key from the ignition switch. 2. Drain lubricant from rear axle gearbox. 3. Read the General Precautions for Removing an d Installing Hydraulic System Components a[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 92 Front Wheel Motors 1. Front wheel motor 2. Internal retaining ring 3. Splined brake shaft 4. RH brake assembly 5. Planetary assembly (2 used) 6. Cap s crew (2 us ed per mo tor) 7. Flat washer (2 used per motor) 8. O - - ring 9. LH brake assembly 10. Hydraulic tee fitting 11 . 9 0 [...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 93 Removal (Fig. 67) 1. Park machine on a level surface , lower cutting deck, stop engine, apply pa rking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing an d Installing Hydraulic System Components at the b egin- ning of the Service and Repai[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 94 Rear Axle and Front Wheel Motor Service Figure 68 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 23 21 25 1. Plu g with O - - ring 2. Minimum angle stop 3. Bias spring 4. Serv o piston 5. O - - ring 6. O - - ring 7. Socket head screw (5 used) 8. Endcap 9. Dowel 10. Dowel[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 95 NOTE: The front wheel motors on yo ur Groundsmaster are identical (Fig. 68). The rear axle motor includes a flushing valve for cooling of the clo sed loop trac tion cir- cuit and therefore has some dif ferences from the front motors (Fig. 69). Se rvice of the wheel and axle motors u[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 96 Rear T raction Manifold 1. Front frame 2. PTO manifold (center deck section) 3. Rear traction manifold 4. Cap screw (2 used) 5. Flange nut (2 used) 6. 90 o hydraulic fitting 7. O - - ring 8. 45 o hydraulic fitting 9. O - - ring 10. O - - rin g 11 . S t r a i g h t f i t t i n g 12[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 97 Removal (Fig. 70) 1. Read the General Precautions for Removing an d Installing Hydraulic System Components at the b egin- ning of the Service and Repairs section of this chapter . 2. T o prevent contamination of hydraulic system during manifold removal, thoroughl y clean exterior of[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 98 Rear T raction Manifold Service 1. Rear traction manifold body 2. Relief valve (port RV) 3. Pressure reducing valve (port PR) 4. #4 ze ro leak p lug wi th O - - ri ng 5. #6 ze ro leak p lug wi th O - - ri ng 6. Check valve (port CV) 7. Orifice (0.050) (port T/OR1) Figure 71 25 ft [...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 99 Control Manifold Cartr idge V alve Service 1. Make sure the control manifold is clean before re- moving the cartridge val ve from the control manifold. 2. If cartridge valve i s solenoid operated, remo ve nut securing solenoid coil to th e cartridge valve. Carefully s l i d ec o i l[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic Syst em Page 4 - - 100 Combination Ma nifold 1. Combination manifold 2. Flange nut (3 used) 3. Flat washer (3 used) 4. Mount (3 used) 5. Spacer (3 used) Figure 72 FRONT RIGHT 2 3 1 5 4 NOTE: The ports on the combi nation manifold are marked for easy i dentification of compone nts. Example: P 3a n dP 4[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 101 Removal (Fig. 72) 1. Read the General Precautions for Removing an d Installing Hydraulic System Components at the b egin- ning of the Service and Repairs section of this chapter . 2. T o prevent contamination of hydraulic system during manifold removal , thoroughly clean exterior o[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic Syst em Page 4 - - 102 Combination Manifo ld Service 1. Combination manifold 2. #6 zero leak plug with O - - ring 3. Check valve (CV3) 4. #4 zero leak plug with O - - ring 5. Solenoid valve (S4, S6 and S9) 6. Solenoid valve (S5) 7. Relief valve (RV2) 8. Solenoid valve (S2, S3, S7 and S8) 9. Solenoid v[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 103 NOTE: The ports on the combina tion manifold are marked for easy iden tification of compon ents. Example: P4 is the gear pump connection port, S 1 is the lift/lower solenoid valve and SV10 is the engine cooling fan solen- oid valve (see Hydraulic Schematic in Chapter 10 - - Foldout[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic Syst em Page 4 - - 104 Steering Contro l V alve 1. Steering wheel cover 2. Hex nut 3. Flat washer 4. Steering wheel 5. Foam collar 6. Steering seal 7. External snap ring (2 used) 8. Steering shaft 9. Flange bushing 10. Thrust washer (as needed) 1 1. Cap screw (4 used) 12. Washer (4 used) 13. Washer (4[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 105 Removal (Fig. 77) 1. Park machine on a level surface , lower cutting deck, stop engine, apply pa rking brake and remove key from the ignition switch. 2. Remove steering tower cover to allow access to steering control valve. 3. Read the General Precautions for Removing an d Installi[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic Syst em Page 4 - - 106 Steering Control 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 s crew (7 us ed) 10. End cap 11 . O - - r i n g 12. Seal ring 13. O - - rin g 14. Gero ter 15. O - - rin g [...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 107 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic Syst em Page 4 - - 108 Steer ing Cylinder 1. Steering cylinder 2. Ball joint 3. Ball joint 4. Retaining ring (2 used) 5. Grease fitting 6. Grease fi tting 7. 90 o hydraulic fitting (2 used) 8. Drive axle assembly 9. Ball joint spacer 10. Axle washer 1 1. Slot ted hex nut (2 used) 12. Cotter pin (2 use[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 109 Removal (Fig. 81) 1. Park machine on a level surface , lower cutting deck, stop engine, apply pa rking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing an d Installing Hydraulic System Components at the b egin- ning of the Service and Repa[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 1 10 Steering Cylinder Service 1. Barrel 2. Rod 3. Piston 4. Head 5. Int ernal co llar 6. Backup ring 7. O - - ring 8. Dust seal 9. Rod seal 10. O - - rin g 1 1. Pisto n seal 12. Lock nut Figure 83 40 ft - - lb (54 N - - m) 1 6 7 3 9 10 4 11 2 8 5 12 1 6 7 3 9 8 10 4 11 2 5 12[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 1 1 1 Disassembly (Fig. 83) 1. Pump oil out of steering cyl inder into a drain pan by slowly moving rod in an d out of cylinder bore. After oil has been removed from cylinder , plug ports and clean outside of cylinder . IMPORT ANT : Prevent damage when clamping the cylinder in a vise, [...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 1 12 Engine Cooling Fan Motor 1. Hydraulic fan motor 2. O - - ring 3. Fan bracket 4. Hydraulic fitting (2 used) 5. O - - ring 6. Radiator/oil cooler assembly 7. Fan hub 8. W asher 9. Hex nut 10. Lower radiator shroud 1 1. Cap screw (4 used) 12. Washer (4 used) 13. Fan 14. Lock nut ( [...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 1 13 Removal (Fig. 84) 1. Park machine on a level surface , lower cutting deck, stop engine, apply pa rking brake and remove key from the ignition switch. 2. Unlatch and raise hood. CAUTION The radiator and oil cooler m ay be hot. T o avoid possible burns, allow the engine and cooling [...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 1 14 4. Position fan hub onto motor shaft and secure with washer (item 8) and hex n ut (item 9). IMPORT ANT : Make sure to not damage the radia tor or other mac hine components while installing the fan motor and bracket as sembly . 5. Car efully pos ition fan mo tor and bra cket asse[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 1 15 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 1 16 Engine Cooling Fan Motor S ervice 1. Flange washer 2. O - - ring 3. Front flange 4. Dust seal 5. Retaining ring 6. Front wear plate 7. Shaf t seal 8. Backup gasket 9. Pressure seal 10. Rear wear plate 11 . B o d y 12. Idler gear 13. Cap scre w (4 used ) 14. Dowel (2 used) 15. Dr[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 1 17 9. Tur n 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, flange washer and shaft seal from the front flange (Fig. 88). Note orie[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic System Page 4 - - 1 18 3. Place front flange, seal side down , on a flat surface. 4. Install the pressure seals, flat side outward, into the grooves in the wear plates. Follow by carefully placing t h eb a c k u pg a s k e t s ,f l a ts i d eo u t w a r d ,b e t w e e nt h e pressure seals and the gro[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 1 19 Cutting Deck Motor Removal (Fig. 90) 1. Park machine on a level surface , lower cutting deck, stop engine, engage parking brake and remove key from the ignit ion switch. 2. Read the General Precautions for Removing an d Installing Hydraulic System Components at the b egin- ning of[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic Syst em Page 4 - - 120 Cutting Deck Motor Service (Sauer - - Danfoss) 1. Rear cover 2. Drive gear 3. Seal 4. Woodruff key 5. Nut 6. T ab washer 7. Spi der hub 8. Pressure seal 9. Back - - up ring 10. O - - rin g 1 1. Body 12. Idler gear 13. Cap scre w (4 used ) 14. Front flange 15. Dowel pin Figure 91[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 121 IMPORT ANT : Mark the relative positions of the gear teeth and the b earing b lock s so they ca n be re - assembled in the same position. Do not touch the gear surfaces as re sidue on hands may be corrosive to gear finish. 8. Place the motor on its side and push on the rear bear- i[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic Syst em Page 4 - - 122 Assembly (Fig. 91) NOTE: When assembling the motor , check the identifi- cation marks made during d isassembly to make sure the parts are proper ly aligned during assembly . 1. Lubricate O - - rings, pressure seals, back- - up gaskets and seal grooves with a thin c oat of petrol[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 123 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic Syst em Page 4 - - 124 Cutting Deck Motor Service (Casappa) (45 to 55 N - - m) 33 to 40 ft - - lb 8 7 4 3 2 6 9 10 11 9 12 13 8 14 16 15 14 1 1. Flange washer 2. O - - ring 3. Front flange 4. Dust seal 5. Retaining ring 6. Front wear plate 7. Sh aft seal 8. Backup gasket 9. Pressure seal 10. Rear wear[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 125 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic Syst em Page 4 - - 126 PTO Manifolds 1. Hydraulic PTO manifold (center deck) 2. Quick fitting (1 used per manifo ld) 3. Flange screw (2 used per manifold) 4. O - - ring 5. Hydraulic tee fitting 6. O - - ring 7. O - - ring 8. O - - ring 9. Hydraulic adapter 10. Straig ht fit ting 1 1. Flange screw (2 u[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 127 Removal (Fig. 98) 1. Read the General Precautions for Removing an d Installing Hydraulic System Components at the b egin- ning of the Service and Repairs section of this chapter . 2. T o prevent contamination of hydraulic system during manifold remo val, thoroughly clean ext erior [...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic Syst em Page 4 - - 128 PT O Manifold Service 1. PTO manifold body 2. NWD SAE #4 plug with O - - ring 3. Orifice (0.025) (port OR) 4. #6 zero leak plug with O - - ring 5. Relief valve (port RV1) 6. Proportional relief valve (port PRV) 7. Solenoid coil 8. Nut 9. Logic cartridge valve (port LC1) 10. Pilo[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 129 The manifolds for the three (3) cutting deck sections are very similar . The front and right side PTO manifolds are identical. The left side PT O manifold uses the same cart- ridges and plugs a s the front and right side manifolds but also includes an additional o rifice that threa[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic Syst em Page 4 - - 130 Cutting Deck Lift Cylinders FRONT RIGHT 1. Cut ting d eck 2. RH lift arm 3. LH lift arm 4. Lift cylinder (2 used) 5. Pin (1 used per cylinder) 6. Flange nut (1 used per pin) 7. Cap screw (1 used per pin) 8. Grease fitting (1 used per pin) 9. Clevis pin (1 used per cylinder) 10. [...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 131 Removal (Fig. 102) 1. Park machine on a level surface , lower cutting deck, stop engine, engage parking brake and remove key from the ignit ion switch. 2. Read the General Precautions for Removing an d Installing Hydraulic System Components at the b egin- ning of this section. 3. T[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic Syst em Page 4 - - 132 Wing Deck Lift Cylinder s 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 w asher 10. Lock nut 1 1. Pilot spacer 12. Cap scre w 13. Wing deck (R H sho wn) Figure 104 FRONT RIGHT[...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 133 Removal (Fig. 104) 1. Park machine on a level surface , lower cutting deck, stop engine, engage parking brake and remove key from the ignit ion switch. 2. Read the General Precautions for Removing an d Installing Hydraulic System Components at the b egin- ning of this section. W AR[...]

Groundsmaster 41 00 - - D/41 10 - - D Hydraulic Syst em Page 4 - - 134 Lift Cylinder Service 1. Barrel with clevis 2. Internal collar 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. Lock nut 13. Piston seal 14. Grease fitting Figure 105 11 6 5 7 8 4 3 2 9 12 1 [...]

Groundsmaster 4100- - D/41 10 - - D Hydraulic System Page 4 - - 135 Disassembly (Figs. 105 and 106) 1. Remove oil from lift cylinder into a drain pa n by slowly pumping th e cylinder s haft. Plug bo th ports and clean the outside of t he cylinder . IMPORT ANT : Prevent damage when clamping the cylinder in a vise; clamp on the clevis only . 2. Mount[...]

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Groundsmaster 4100- - D/41 10 - - D Pag e 5 - - 1 Electric al Sy stem Chapter 5 Electrical System T able of Contents GENERAL INFORMA TION 2 ..................... Operator ’s Manu al 2 .......................... T oro Electr onic Controllers ( TEC) 2 . ............ Y anmar Engine Electronic Control Unit (ECU) 3 ... Y anmar Engine Electrical Compon[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 2 Electrica l System General Information Operator ’ s Manual The Operator’s Manual provi des information regarding the operation, general maintenance and maintenance intervals for your G roundsmaster machine. Re fer to that publication for additional informati on when servicing the machine. T oro[...]

Groundsmaster 4100- - D/41 10 - - D Pag e 5 - - 3 Electric al Sy stem Y anmar Engine Ele ctronic Control Unit (ECU) The Y anmar engine that p owers the Groundsmaster 4100 - - D and 41 10 - - D uses an electronic control unit (ECU) for engine management and a lso to communi- cate with the TEC controller s and the InfoCenter Display on the machi ne. [...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 4 Electrica l System CAN - - bus Communications The two (2) TEC controllers, the Y anmar engine elec- tronic control unit and the I nfoCenter Display used on the Groundsmaster 410 0 - - D and 41 10 - - D communicate with each other on a CAN - - bus system. Using this sys- tem allows the traction unit[...]

Groundsmaster 4100- - D/41 10 - - D Pag e 5 - - 5 Electric al Sy stem This page is intentionally blank. Electric al System[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 6 Electrica l System Special T ools Order special tools from your T o ro Distributor . Some tools may also be available from a local supplier . Multimet er The multimeter can test ele ctrical components and cir- cuits for current, re sistance or voltage. NOTE: T oro recommen ds the use of a DIGIT AL [...]

Groundsmaster 4100- - D/41 10 - - D Pag e 5 - - 7 Electric al Sy stem Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool loca lly . Figure 7 Electric al System[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 8 Electrica l System InfoCenter Display The InfoCenter Display us ed on your Groundsmaster is a LCD device that is located on the consol e. The Info- Center provides information f or the machine operator during machine operation, p rovides elec trical system diagnostic assistance for technicians an d[...]

Groundsmaster 4100- - D/41 10 - - D Pag e 5 - - 9 Electric al Sy stem Main Information Scr een The two (2) InfoCenter main information scre ens (Figs. 10 and 1 1) are displ ayed after the init ial splash scre en has been displayed for se veral seconds. Dur ing normal machine operation, the ma in information screens provide machine informatio n for [...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 10 Electrical S ystem Main Menu Screen The main menu screen can be accessed from the Info- Center main informatio n or splash screen by pressing and releasing th e menu/back button (left button) on the display . Once to the main menu screen (Fig. 12), naviga- tion to the five (5) dif ferent menu item[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 1 1 Electri cal System Service Screen The service screen (Fi g. 15) cont ains machine o pera- tional information including hours and counts. V alues listed for these service menu items cannot be changed. If the machin e PIN has been entered t o allow access to protected menu item s in the settings scre[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 12 Electrical S ystem Diagnos tics Screen The diagnostics scr een (Fig. 16 ) lists the vario us states of machine electrical com ponents. The diagnostics screen should be used to check operation of machi ne controls and to v erify t hat switches and circuit wir ing are functioning correctly . For eac[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 13 Electri cal System Settings Screen The settings screen iden tifies the InfoCenter language and units (English or Metric). The settings screen also allows the operator to customize the backlight (bright- ness) and contrast settings for the InfoCenter display . If either the backligh t (brigh tness) o[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 14 Electrical S ystem About Screen The about scree n (Fig. 19) i dentifies the ma chine model number , serial number and software re visions for the TEC controllers, In foCenter and engine electronic con- trol unit (if available). The about screen also lists the CAN - - bus sta tus. Additiona l infor[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 15 Electri cal System T roubleshooting CAUTION Remove all jewelr y , especially rings and watches, before doing any elec trical trouble- shooting or testing. Also, disconnect the battery cables unless the tes t requires battery voltage. For effective troublesho oting and repairs, you must have a good u[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 16 Electrical S ystem Fault Codes The list below identifies the fault codes that are gen er- ated by the TEC controller to identify an electrical sys- tem malfunction (fault) that occurred during ma chine operation. Use the InfoCenter Disp lay for fault retrieval. NOTE: The following list of fault co[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 17 Electri cal System Fault Code Fault Description 31 Brake/RH turn light output ha s open or short to ground 32 Brake/LH tu rn light output has open or short to grou nd 33 Forward piston (traction) pump outpu t has open or short to ground 34 Reverse piston (traction) pump outp ut has open or short to [...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 18 Electrical S ystem Starting Pr oblems NOTE: Check InfoCenter Display for possi ble operator advisories or faults whenever diagno sing machine elec- trical pr oblems. Problem Possible Causes No electrical power to machine. The battery is discharged. The battery cables are l oose or corroded. F u s [...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 19 Electri cal System Starting Problems (C ontinued) Problem Possible Causes Starter cranks, but shoul d not, when the traction pedal is depressed. T raction pedal position sensor is out of adjustment. T raction pedal position sensor or ci rcuit wiring is faulty . Engine cranks, but do es not start. Th[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 20 Electrical S ystem General Run a nd T ransport Problems NOTE: Check InfoCenter Display for possi ble operator advisories or faults whenever diagno sing machine elec- trical pr oblems. Problem Possible Causes Engine conti nues to run, but should not, whe n the ignition switch is turned of f. The ig[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 21 Electri cal System Cutting Deck Operating Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine ele c- trical p roblems. NOTE: T o engage the mow circuit, the operator must be in the operator seat, the t raction speed must be in the LOW speed [...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 22 Electrical S ystem Cutting Deck Operating Pr oblems (Continued) Problem Possible Causes Wing cutting deck does not oper ate. The wing cutting deck is not fully lowered. The wing deck position switch or circuit wiring is faulty . Hydraulic valve solenoid(s) or circuit wir ing to the affected wing d[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 23 Electri cal System Cutting Deck Lift/Lower Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine ele c- trical p roblems. NOTE: T ol o w e rac u t t i n gd e c k ,t h eo p e r a t o rm u s tb ei n the operator seat and the traction speed must [...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 24 Electrical S ystem Cutting Deck Lift/Lower Problems (Continued) Problem Possible Causes RH wing cutting deck will not raise or lower , but the front and LH wing cutting decks will raise and lower . The RH deck lift switch or circuit wiring is faulty . Fuse is faulty . Combination control manifold [...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 25 Electri cal System This page is intentionally blank. Electric al System[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 26 Electrical S ystem Electrical System Quick Checks Battery T est (Open Circuit) Use a multimeter to measure the voltage between the battery terminals. Set multimeter to th e DC volts setting. The battery should be at a temperature of 60 o to 1 00 o F( 1 6 o to 38 o C). The ignition key should be of[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 27 Electri cal System Adjustments Wing Deck P osition Switch Adjustment 1. Park machine on a level surface , lower cutting deck, stop engine, engage parking brake and remove key from the ignit ion switch. 2. Remove switch cover from deck to allow a ccess to position switch that requires adjustmen t. 3.[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 28 Electrical S ystem T raction Pedal Adjustment The traction pedal includes a neutral asse mbly that is used to adjust the traction neutral position (Fig. 22). T raction pe dal adjustmen t may be necessa ry to make sure that traction pe dal movement provides the correct full reverse and full forward[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 29 Electri cal System 6. After any adjustment of the spring shaft an d rod end bearing, use the InfoCenter Display Diagnostics menu (see InfoCenter Display in this chap ter) to obtain and se- lect the T raction Ped al menu item. Choo se Outputs and the InfoCenter display will identify the traction peda[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 30 Electrical S ystem T raction Pedal Position Sensor Calibr ation IMPORT ANT : A properly installed and calibrated traction pedal position sensor is critical to accurate traction system respons e and for reliable sensor life. Use care when rem oving, installing and cali - brating the traction pedal [...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 31 Electri cal System Component T esting For accurate resistance and/or continuity checks, elec - trically disconnect th e component being tested from the circuit (e.g. unplug the ig nition switch connector before doing a continui ty check). NOTE: For engine component testing informati on, see the Y an[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 32 Electrical S ystem Fuses The fuse block is located under th e controller cover next to the operator seat (Fig. 30). In addition to the fuses in the fuse block, a 60 Amp fuse is included i n the wire harness to protect the power cir- cuit for the operator cab. Thi s fuse resides in a fuse hold- er [...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 33 Electri cal System Operator Cab Fuses (Groundsmas ter 41 10 - - D) The operator cab fuse blocks are loca ted in the cab headliner (Fig. 32). Identification and Function (Figs. 33 and 34 ) Fuse F1 - - 2 (15 Amp) protects the cab fan cir cuit. Fuse F1 - - 3 (30 Amp) protects the air conditioner circui[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 34 Electrical S ystem Fusible Link Harness Y our Groundsmaster uses two (2) fusible links for circuit protection. T hese fusible links ar e located in a ha rness that connects the starter B+ terminal to the wire harness (Fig. 35). If either of these links should fail, current to the protected circuit[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 35 Electri cal System PTO Swi tch The PTO switch is located on the control arm (Fig. 37). The PTO switch is pull ed up to engage the PTO and pushed in to disengage th e PTO. The TEC controller moni tors the position of the PT O switch (up or down). Using inputs from the PTO switch and other switches in[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 36 Electrical S ystem HI/LOW Spee d, Engine Speed and Cutting D eck Lift Switches The HI/LOW , engine speed and cutti ng deck lift switches are all ide ntical moment ary switches. Thes e switches are locate d on the control a rm (Fig. 39) . The HI/LOW speed switch i s used as an input for the TEC con[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 37 Electri cal System Cruise Control Switch The cruise control switch is used as an inpu t for the TEC controller to maintain g round speed when engaged. Th e cruise control functio n is enabled when the switch is i n the ON (center) position. Pressin g the front of the switch to the momentary position[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 38 Electrical S ystem Seat Switch The seat switch is normally ope n and closes when the operator is on the seat. This switch is used as an input for the TEC con troller . The seat switc h and its ele ctrical connector are located in the seat assembly . If the trac- tion system or PTO switch i s engag[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 39 Electri cal System Parking Brake Switch T h es w i t c hu s e df o r t h ep a r k i n gb r a k ei san o r m a l l yo p e n proximity switch that is loc ated under th e steering to wer cover (Fig. 44). The parking brak e switch is an input for the TEC controller . When the parking brake is not ap- pl[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 40 Electrical S ystem Service Brake Switches The two (2) switches used for the service brakes are nor- mally open switches that ar e located under the footrest panel (Fig. 45). The servi ce brake switches provide in- puts for the TEC c ontroller . When a brake pedal is not depressed, the brake pedal [...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 41 Electri cal System Headlight Switch (Groundsmaster 4 1 10 - - D) The Groundsmaster 41 10 - - D headlight switch is a t wo (2) position rocker switch that is located on the inside of the control arm (Fig. 46). The hea dlight switch allows the headlights and taillights to be turned on and off. Te s t [...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 42 Electrical S ystem Windshiel d Wiper/W asher Switch (Groundsmaster 41 10 - - D) The windshield w iper/washer switch is used to contro l operation of the windshield wipe r and washer pump on the Groundsmaster 41 10 - - D. The windshield wiper/wa- sher switch is located in the cab headlin er (Fig. 4[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 43 Electri cal System Air Conditioning Switch (Groundsmaster 41 10 - - D) The air conditioning switch is used to control operatio n of the air conditioning syst em on the Groundsmaster 41 10 - - D. Th e switch is lo cated in the c ab headline r (Fig. 50). Te s t i n g 1. Make sure ignition switch is OF[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 44 Electrical S ystem T urn Signal Switch (Groundsmaster 41 10 - - D) On Groundsmaster 41 10 - - D machines, the turn signal switch is used as an input for the TEC contro ller to pro- vide power for th e turn signals. The switch is located on the steering tower (Fig. 52). T esting 1. Before disconnec[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 45 Electri cal System Flasher Switch (Groundsma ster 41 10 - - D) On Groundsmaste r 41 10 - - D machines, the flasher switch is used as an input for the TEC controller to pro- vide power for the four way flashers. The switch is lo- cated on the stee ring tower (F ig. 54). Te s t i n g 1. Before disconn[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 46 Electrical S ystem Relays with Four (4) T erminals Y our Groundsmaster uses a number of e lectrical relays that have four (4) terminals. A tag near the wire h arness relay connector can be u sed to identify each relay . The main power r elay is used to pro vide current to most of the fuse protecte[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 47 Electri cal System 5. Using a multimeter , verify that coil resistance be- tween terminals 86 and 85 is approximately 72 ohms. 6. Connect multimeter (ohms setting) leads to relay ter- minals 30 and 87. Ground terminal 86 an d apply +12 VDC to terminal 8 5. The relay should make and break continuity [...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 48 Electrical S ystem Relays with Five (5) T erminals Y our Groundsmaster uses a number of e lectrical relays that have five (5 ) termin als. A tag near the wire har ness relay connector can be u sed to identify each relay . The air conditioning rel ay is used to control the air condi- tioning electr[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 49 Electri cal System 8. Connect multimeter (ohms setting) leads to relay ter- minals 30 and 87A. Appl y +12 VDC t o terminal 85. The relay should make and break continuity between termi- nals 30 and 87A as +12 VDC is applied an d removed from terminal 85. 9. After testing, disconnect voltage and multi[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 50 Electrical S ystem T oro Electronic Controllers (TE C) Groundsmaster 4100 - - D and 41 10 - - D machines use two (2) T oro Electronic Controllers (TEC) to control electrica l system operation. The controllers are attached to the operator platform under the co ntroller cover (Figs. 63 and 64). Logi[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 51 Electri cal System IMPORT ANT : When testing for wire harness c on - tinuity at the connector for the TEC controller , take care to not damage the connector pins with multi- meter test leads. If connector pins are enlar ged or damaged during testing, connector repair will be necessary for pr oper ma[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 52 Electrical S ystem T raction Pedal Pos ition Sensor The traction peda l position sensor is connected t o the traction pedal a ssembly (Fig. 67). This position sensor determines the neutral band f or the traction pedal, the direction of travel desired by the operator and the tra c- tion speed. The [...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 53 Electri cal System Audio Alar m The audio alarm soun ds to notify the operator when a machine problem exists. Electrical current for the alarm is provided as a n output from th e TEC controller . The alarm is attached to t he console arm next to the operato r seat. Te s t i n g 1. Make sure ignition[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 54 Electrical S ystem Hydraulic V alve Solenoid Coils Figure 69 1. Front PTO manifold 2. RH P TO manifo ld 3. LH PTO manifold 4. Combination manifold FRONT RIGHT 2 3 1 4 Several hydraulic solenoid v a l v ec o i l sa r eu s e do nt h e hydraulic control manifol ds of Groundsmaster 4100 - - D and 41 1[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 55 Electri cal System Te s t i n g 1. Park machine on a level surface , lower cutting deck, stop engine, engage parking brake and remove key from the ignit ion switch. 2. Locate hydraulic solenoid valve coil to be tested (Fig. 69). Disconnect wire harness co nnector from coil. 3. Identify coil resistan[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 56 Electrical S ystem Piston (T raction) Pump Control Solenoid Coils The piston (tract ion) pump us es an electronic con trol as- sembly for swash p late rotation. Electrical outputs from the machine TEC controller are p rovided to two (2) solenoid coils for pump control. The piston pump control asse[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 57 Electri cal System CAN - - bus T ermination Resistor System communication between electrical comp onents on Groundsmaster 4100 - - D and 41 10 - - D machines is accomplished on a CAN - - bus communication system. T wo (2) specially designed, twisted wires form the bus for the network used on the mac[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 58 Electrical S ystem Diode Assemblies The Groundsmaster engine wire ha rness contains a diode assembly that i s used for circuit protection from voltage spikes when the en gine starter solenoid is de- - energized . Groundsmaster models 30606 an d 30608 use an addi- tional diode assembly in the engi [...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 59 Electri cal System Fuel Sender The fuel sender is attached to the top of the fuel tank. The resistance of the fue l sender increases as the fue l level in the fuel tank decreases. The TEC contr oller uses the fuel sender as an in put to generate an output for th e InfoCente r fuel gauge. T wo (2) st[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 60 Electrical S ystem Fuel Pump (Models 30602 and 30604) The fuel pump is atta ched to the fuel tank support above the fuel water separator (Fig . 79). Operational T est 1 . P a r km a c h i n eo nal e v e ls urface, lower cutting deck, stop engine and apply parking brake. Raise hood to ac- cess fuel[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 61 Electri cal System Fuel Pump (Models 30606 and 30608) The fuel pump is atta ched to the fuel tank s upport above the fuel water se parator (Fig. 81). Operatio nal T est 1. Park machine on a level surface , lower cutting deck, stop engine an d apply parking br ake. Raise hood to ac- cess fuel pu mp. [...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 62 Electrical S ystem Wing Deck Position Switches T wo (2) wing deck position switches are used on the Groundsmaster 4100- - D and 41 10 - - D as inputs for the TEC controller . The position switches are powered prox- imity switches that are normally open. The switches in- corporate an internal reed [...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 63 Electri cal System Hydraulic Oil T emperature Sender The Groundsmaster 4100- - D and 41 10 - - D use a temper- ature sender as an input for the TEC controlle r to identify if the hydraulic o il temperat ure has reac hed an exces - sive level. The hydrauli c oil temperature sender is at- tached to th[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 64 Electrical S ystem Service and Repairs NOTE: For engine component repair information (e.g. starter mo tor), re fer to the Y anmar Serv ice Manua l that is correct for your G roundsmaster model. Battery Care 1. T he top of the b attery mus t be kept clean. lf the ma - chine is stored in a location [...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 65 Electri cal System Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be ex tended. Additionally , battery and electrical component failure c a nb ep r e v e n t e d . CAUTION When working with batt eries, use extreme cau- tion to avo[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 66 Electrical S ystem Battery T esting 1. Perform a high - - discharge test with an adjustable load tester . This is one of the most reliabl e means of test- ing a battery as it simulates the col d - - cranking test. A commercial battery load tester is requ ired to perform this test. CAUTION Follow t[...]

Groundsmaster 4100- - D/41 10 - - D Page 5 - - 67 Electri cal System Battery Charging T o minimize possible damage to the battery and allow the battery to be fully charged, the slow ch arging meth- od is presented here. This charging me thod can be ac- complishe d with a constan t current b attery ch arger which is readily available. CAUTION Follow[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 5 - - 68 Electrical S ystem This page is intentionally blank.[...]

Groundsmaster 4100- - D/41 10 - - D Pag e 6 - - 1 Ax les, Planetarie s and Brakes Chapter 6 Axles, Planetaries and Brakes T able of Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TION 3 ..................... Operator ’s Manu al 3 .......................... ADJUSTMENTS 4 .............................. Planetary Wheel Drive[...]

Groundsmaster 41 00 - - D/41 10 - - 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 . 2 5 0i n( 6m m ) Planetary gear drive oil SAE 85W - - 140 wt. gear lube System gear lube capacity (each wheel) 22 fl. oz. (0.65 l iters) Rear axle [...]

Groundsmaster 4100- - D/41 10 - - D Pag e 6 - - 3 Ax les, Planetarie s and Brakes General Information Operator ’ s Manual The Operator ’s Manu al provides information re garding the operation, general maintenance and maintenan ce intervals for your Groundsmaster ma chine. Refer to that publication for additional information when servicing the m[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 6 - - 4 Axles, Planetaries and Brakes Adjustments Planetar y Wheel Drive Ass embly Endplay A front planetary wheel drive assembly that is properly operating should have no en dplay . Any endplay in a planetary assembly ind icates that there are potential problems with the planetary . Check planetary endpla[...]

Groundsmaster 4100- - D/41 10 - - D Pag e 6 - - 5 Ax les, Planetarie s and Brakes This page is intentionally blank. Axles, Planetari es and Brakes[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 6 - - 6 Axles, Planetaries and Brakes Service and Repairs Brake Assembly Figure 1 FRONT RIGHT 75 to 85 ft - - lb (101 to 1 15 N - - m) 85 to 100 ft - - lb (1 15 to 135 N - - m) 75 to 85 ft - - lb (101 to 1 15 N - - m) 2 3 6 8 9 11 13 1 5 7 12 14 15 4 10 1 6 7 8 13 1. Front wheel motor 2. Internal retaining[...]

Groundsmaster 4100- - D/41 10 - - D Pag e 6 - - 7 Ax les, Planetarie s and Brakes Removal (Fig. 1) 1. Park machine on a level surface , lower cutting deck, stop engine and remove key fro m the ignition switch. 2. Drain oil from planetary wheel drive/bra ke assembly (Fig. 2). CAUTION When remov ing fron t wheel, u se correc t jacks and supports. Mak[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 6 - - 8 Axles, Planetaries and Brakes 2. Apply gasket sealant to sea ling surfaces of new gas- ket (item 18). Apply gas ket to brake assembly . 3. Install brake assembly onto machine, aligning splined brake shaf t with input shaft on planet ary wheel drive. Make sure th at brake pull rod is orientated towa[...]

Groundsmaster 4100- - D/41 10 - - D Pag e 6 - - 9 Ax les, Planetarie s and Brakes This page is intentionally blank. Axles, Planetari es and Brakes[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 6 - - 10 Axles, Planetaries and Brakes Brake Inspection and Repair 1. Brake housing (LH shown) 2. Seal 3. Pull rod 4. Clevis pin (2 used) 5. Link (2 used) 6. Hit ch pin ( 2 used) 7. Stationary disc (4 used) 8. Rotating disc (3 use d) 9. Retaining ring 10. Gask et 1 1. Rot atin g actua tor 12. Extension spr[...]

Groundsmaster 4100- - D/41 10 - - D Page 6 - - 1 1 Axles, Planetaries and Brakes This page is intentionally blank. Axles, Planetari es and Brakes[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 6 - - 12 Axles, Planetaries and Brakes Planetary Wheel Drive Assembly Figure 7 FRONT RIGHT 75 to 85 ft - - lb (101 to 1 15 N - - m) 85 to 100 ft - - lb (1 15 to 135 N - - m) 75 to 85 ft - - lb (101 to 1 15 N - - m) 1. Front wheel motor 2. Internal retaining ring 3. Spl ined br ake shaf t 4. RH brake assemb[...]

Groundsmaster 4100- - D/41 10 - - D Page 6 - - 13 Axles , Planetaries and Brakes Removal (Fig. 7) 1. Park machine on a level surface , lower cutting deck, stop engine and remove key fro m the ignition switch. 2. Drain oil from planetary wheel drive/bra ke assembly (Fig. 8). CAUTION When remov ing fron t wheel, u se correc t jacks and supports. Make[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 6 - - 14 Axles, Planetaries and Brakes Planetary Wheel Drive Service 1. Spindle 2. Boot seal 3. Oil seal 4. Inner bearing cone 5. Inner bearing cup 6. Whee l stud (8 u sed) 7. Socket head screw (16 used) 8. Lock washer (16 used) 9. Housing 10. Dowel pin (2 used) 1 1. O uter bearing cup 12. Outer bearing co[...]

Groundsmaster 4100- - D/41 10 - - D Page 6 - - 15 Axles , Planetaries and Brakes NOTE: The planetary wheel drive assem bly can be ser- viced with the p lanetary installed to machine . If the spindle (item 1) ne eds to be remove d from machine , see Planetary Wheel Drive A ssembly in this section. Disassembly (Figs. 10 and 1 1) 1. If planetary wheel[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 6 - - 16 Axles, Planetaries and Brakes F . Lightl y oil bearing journals on spindle shaft. Slide housing assembly onto spindle (item 1) taking c are to not damage seal or spindle. Make sure that inne r bearing in housing fully seats aga inst spindle shaft shoulder . G. Install outer bearing cone (item 12) [...]

Groundsmaster 4100- - D/41 10 - - D Page 6 - - 17 Axles , Planetaries and Brakes This page is intentionally blank. Axles, Planetari es and Brakes[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 6 - - 18 Axles, Planetaries and Brakes Rear Axle Assembly 1. Plug with O - - r ing 2. Lug nut (5 used per wheel) 3. Rear wheel assembly (2 used) 4. Cap screw (2 used) 5. Flat washer (8 used) 6. Rear axle motor 7. O - - ring 8. Steering cylinder 9. Spacer 10. Cotter pin (2 used) 1 1. Slo tted hex nut (2 u s[...]

Groundsmaster 4100- - D/41 10 - - D Page 6 - - 19 Axles , Planetaries and Brakes Removal (Fig. 12) 1. Park machine on a level surface , lower cutting deck, stop engine, apply pa rking brake and remove key from the ignition switch. 2. Drain oil from rear axle and axle gearbox (Figs. 13 and 14). 3. Chock front wheels and jack up rear of machine (see [...]

Groundsmaster 41 00 - - D/41 10 - - D Page 6 - - 20 Axles, Planetaries and Brakes 2. Secure rear axle to rear axle mount. A. Slide rear axle pin through rear axle mount and rear axle. I nstall washer an d lock nut onto rea r axle pin. B. Secure pivot pin to axle mou nt with washer head screw (Fig. 16). C. T orque lock nut from 135 to 165 ft - - lb [...]

Groundsmaster 4100- - D/41 10 - - D Page 6 - - 21 Axles , Planetaries and Brakes This page is intentionally blank. Axles, Planetari es and Brakes[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 6 - - 22 Axles, Planetaries and Brakes Rear Axle Service Figure 19 3 2 4 5 6 7 8 9 10 14 13 12 11 15 1 10 11 8 9 8 13 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 20 41 42 43 50 44 45 46 47 48 49 51 54 55 56 57 58 59 52 53 60 61 62 63 64 22[...]

Groundsmaster 4100- - D/41 10 - - D Page 6 - - 23 Axles , Planetaries and Brakes 1. LH axle support 2. Flange bushing (2 used) 3. Axle vent 4. Filter 5. V ent extension 6. Cap screw (4 used per gear case) 7. Shi m set 8. Seal washer 9. Plug 10. Lock nut 1 1. Lock w asher 12. Grease fittin g 13. Ball bea ring 14. Screw (2 used per steering arm) 15. [...]

Groundsmaster 41 00 - - D/41 10 - - D Page 6 - - 24 Axles, Planetaries and Brakes Bevel Gear Case and Axle Case The following proce dures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove the mounting screws, nuts an d lock wash- ers. Remove th e bevel ge ar case/axle case assembly and O-ring from the ax le suppor[...]

Groundsmaster 4100- - D/41 10 - - D Page 6 - - 25 Axles , Planetaries and Brakes 5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the g asket and any remaining gas- ket mater ial from either m ating surface (Fig. 23). 6. While holding the bevel ge ar case, tap the upper end of the bevel gear shaft out o f the upper bearing and [...]

Groundsmaster 41 00 - - D/41 10 - - D Page 6 - - 26 Axles, Planetaries and Brakes Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 25). 1. Axle case 2. Bevel gear case 3. Sh aft seal Figure 25 1 2 3 2. Install the lower bevel gear and bevel gear shaft in the axle case cover . Coat a new O-ring with grease and [...]

Groundsmaster 4100- - D/41 10 - - D Page 6 - - 27 Axles , Planetaries and Brakes 5. Determine necessary quantity of support shims. A . L u b r i c a t et h ea x l ec a s es u p p o r tb u s h i n gw i t ha thin coat of grease and slide axle case support on to knuckle pin. B. Position support shims th at were removed during disassembly between axle [...]

Groundsmaster 41 00 - - D/41 10 - - D Page 6 - - 28 Axles, Planetaries and Brakes 9. Remove the bevel gear case/axle case assembly from the axle suppo rt. Coat a new O-ring with gr ease and tempora rily install the ax le cover assembly . Position a dial indica tor at the tooths center . Prevent the axle from turning and measure the lower bevel gear[...]

Groundsmaster 4100- - D/41 10 - - D Page 6 - - 29 Axles , Planetaries and Brakes Axle Shafts The following p rocedure s assume t he rear a xle assem- bly has been removed fr om the machine. Removal 1. Remove the axle cover mounting screws. Remove t h ea x l ec o v e r f r o mt h ea x l ec a s ea sa na s s e m b l y (Fig. 32). 2. Use a bearing pulle[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 6 - - 30 Axles, Planetaries and Brakes Input Shaft/Pinion Gea r Figure 35 1 1. Nut (2 used) 2. Lock washer (2 used) 3. Stud (2 used) 4. Lock nut 5. Stake washer 6. Oil seal 7. O-ring 8. Seal collar 9. Bearin g 10. O -ring 1 1. I nput shaft/pinion gear 12. Bearing case 13. Shim 14. Screw (2 used) 15. Gear c[...]

Groundsmaster 4100- - D/41 10 - - D Page 6 - - 31 Axles , Planetaries and Brakes 5. Install a new stake washer . Install the lock nut fi nger tight. 6. Set the bearing preload by securing the bea ring case in a vise. Thread a M12 x 1.5 hex head cap screw in to the splined end of the input shaft/pinion gear and slowly tighten the lock nut un til 4 t[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 6 - - 32 Axles, Planetaries and Brakes Differential G ear The following proce dures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual). IMPORT ANT : Do not intercha[...]

Groundsmaster 4100- - D/41 10 - - D Page 6 - - 33 Axles , Planetaries and Brakes Inspection 1. Measure the differential sid e gear O.D. and the dif- ferential case I.D. t o determine the side gear to c ase clearance (Fig. 42) . Replace components as necessary . SIDE GEAR TO CASE CLEARANCE: 0 . 0 0 2t o0 . 0 1 2i n c h( 0 . 0 5t o0 . 3 0m m ) SIDE G[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 6 - - 34 Axles, Planetaries and Brakes Installation 1. If the ring gear was removed from the d ifferential case, use medium strength Loctite thread locker and tighten the mountin g screws from 22 to 25 ft -l b (30 to 34 N - - m) . 2. Apply molybdenum disul fide lubricant (Three Bond 1901 or equivalent ) to[...]

Groundsmaster 4100- - D/41 10 - - D Page 6 - - 35 Axles , Planetaries and Brakes Pinion Gear to Ring Gear Engagement The final position o f the pinion gear is verified b y using the gear contact pattern method a s described in the fol- lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 46): To e - - th e portion of the tooth surf ace at the end to- war[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 6 - - 36 Axles, Planetaries and Brakes Gear Patter n Movement Summary Every gear has a characteristic pa ttern. The illustrations show typical patte rns only and exp lain how patt erns shift as gear location is chan ged. 1. If co ntact is toward t he heel or base of the g ear (Fig. 49): A. Install thick er[...]

Groundsmaster 4100- - D/41 10 - - D Page 7 - - 1 Chassis Chapter 7 Chassis T able of Contents GENERAL INFORMA TION 1 ..................... Operator ’s Manu al 1 .......................... SERVICE AND REP AIRS 2 ...................... Steering T ower 2 ............................. Cutting Deck Lift Arms 4 ....................... Console Arm 8 ...[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 7 - - 2 Chassis Service and Repairs Steering T owe r Figure 1 FRONT RIGHT 27 to 33 ft - - lb ( 3 7t o4 4N - - m ) 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 7 10 20 to 26 ft - - lb ( 2 8t o3 5N - - m ) 20 19 1. Ste ering wh eel co ver 2. Hex n ut 3. Flat w asher 4. Ste ering wh eel 5. Foam collar 6[...]

Groundsmaster 4100- - D/41 10 - - D Page 7 - - 3 Chassis Disassembly (Fig. 1) 1. Park machine on a level surface , lower cutting deck, stop engine, apply pa rking brake and remove key from the ignition switch. 2. Re move steering tower covers to access ste ering tower components (Fig. 2). 3. Disassemble steering tower as neede d using Figure 1 as a[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 7 - - 4 Chassis Cutting Deck Lift Arms 1. Deck assembly 2. Deck motor (3 used) 3. Spider hub (3 used) 4. Spider (3 used) 5. Damper support 6. Clevis rod end 7. Spherical rod end 8. Damper 9. Spacer 10. Spring pin 1 1. LH lift arm 12. Pin (2 used) 13. Grease fitting (2 u sed) 14. RH lift arm 15. Flange nut [...]

Groundsmaster 4100- - D/41 10 - - D Page 7 - - 5 Chassis Removal (Fig. 3) 1. Park machine on a level surface , lower cutting deck, stop engine, engage parking brake and remove key from the ignit ion switch. 2. Remove front cutting deck (see Cutting Deck Re- moval in Chapt er 8 - - Cutting Deck). CAUTION When changing attachme nts, tires or per form[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 7 - - 6 Chassis Installation (Fig. 3) 1. If removed, install components to lift arm. A. Press flange bushings into lift arm. B. Install spherical bearing on tapered stud and se- cure with flange n ut. T orque flange nut from 30 to 40 f t - - l b( 4 1t o5 4N - - m ) . Install stud with spherical bear- ing i[...]

Groundsmaster 4100- - D/41 10 - - D Page 7 - - 7 Chassis This page is intentionally blank. Chassis[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 7 - - 8 Chassis Console Arm 1. Flange nut (3 used) 2. Flange head screw (2 used) 3. W asher head screw (10 u sed) 4. LH cover 5. Lock nut 6. Control arm panel 7. Igni tio n swit ch 8. InfoCenter display 9. R - - c lamp 10. Audio alarm 11 . P T O s w i t c h 12. Nut 13. Bracket 14. U - - nut (5 used) 15. Cl[...]

Groundsmaster 4100- - D/41 10 - - D Page 7 - - 9 Chassis Disassembly (Fig. 8) 1. Park machine on a level surface, l ower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 2. Re move two (2) fl ange head screw s (item 27) and then cover plate (ite m 26) from outside of control arm. Locate and retrieve two (2) spac[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 7 - - 10 Chassis T raction Pedal Assembly 1. Carriage bolt (6 used) 2. T raction pedal 3. Bushing 4. Operator platform 5. Cap screw 6. Rod end bearing 7. Hex nut 8. Flange nut ( 10 used) 9. T raction pedal shaft 10. Roll pin 1 1. Cap screw (2 used) 12. Clamp block (2 used) 13. Lock nut 14. Cap screw 15. Fl[...]

Groundsmaster 4100- - D/41 10 - - D Page 7 - - 1 1 Chassis IMPORT ANT : A properly installed and calibrated traction pedal position sensor is cr itical to accurate traction system response and for reliable sensor life. Use care when r emoving, installing and cali - brating the traction pedal position s ensor . Disassembly (Fig. 10) 1. Park machine [...]

Groundsmaster 41 00 - - D/41 10 - - D Page 7 - - 12 Chassis Operator Platform 1. Operator platform 2. Cap screw (2 used) 3. Flat washer (4 used) 4. Center mount (4 used) 5. Plain washer (4 used) 6. Lock nut (4 used) 7. Cap screw (2 used) Figure 12 FRONT RIGHT 3 2 1 4 5 6 7 3 4 5 6 95 to 1 15 ft - - lb (129 to 155 N - - m)[...]

Groundsmaster 4100- - D/41 10 - - D Page 7 - - 13 Chass is Some service procedures (e.g. removing the hyd raulic reservoir) require the operator platform to be raised. The f o l l o w i n gs t e p sc a nb eu s e dt or a i s et h ep l a t f o r m . Disassembly (Fig. 12) 1. Park machine on a level surface , lower cutting deck, stop engine, apply pa r[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 7 - - 14 Chassis Assembly (Fig. 12) 1. Make sure that all machine components are installed below operator platfo rm before platform is lowered to frame. IMPORT ANT : Make sure to not damage the electric- al wire harness or other components while lowering the operator platform . 2. Car efully lower ope rato[...]

Groundsmaster 4100- - D/41 10 - - D Page 7 - - 15 Chass is This page is intentionally blank. Chassis[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 7 - - 16 Chassis Operator Seat 1. Carriage screw (5 used) 2. Support channel 3. Support bracket 4. Flange nut (6 used) 5. Cap screw 6. Flat washer (4 used) 7. Arm support 8. Screw 9. Coupler nut 10. Spacer 1 1. Flang e nut (4 used) 12. Seat belt 13. Cap screw 14. Seat latch 15. Locking cotter pin 16. Latch[...]

Groundsmaster 4100- - D/41 10 - - D Page 7 - - 17 Chass is Removal (Fig. 17) 1. Park machine on a level surface , lower cutting deck, stop engine, apply pa rking brake and remove key from the ignition switch. 2. Disconnect seat electrical connector from machine wire harness ( Fig. 18). 3. Support control arm asse mbly to prevent it from shift- ing.[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 7 - - 18 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 u sed) 11 . W a s h e r 12. Cap screw (2 used) 13. Seat 14. Nut 15. Spring (2 used) 16. Magnet[...]

Groundsmaster 4100- - D/41 10 - - D Page 7 - - 19 Chass is Disassembly (Fig. 20) 1. Disassemble operator seat as necessary using Fig- ures 20 and 21 as gu ides. Assembly (Fig. 20) 1. Assemble operator seat using Figures 20 and 21 as guides. 1. Operator seat 2. R - - clamp (2 u sed) 3. Scr ew (2 used ) 4. Manu al tube 5. Flat washer 6. Seat belt 7. [...]

Groundsmaster 41 00 - - D/41 10 - - D Page 7 - - 20 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. W[...]

Groundsmaster 4100- - D/41 10 - - D Page 7 - - 21 Chass is NOTE: Most of the seat suspension com ponents can be serviced with the seat suspension base mounte d to the frame platform. If the air spring assembly (item 6) re- quires removal, the seat su spension base will have to be removed from the seat platform. Disassembly (Fig. 22) 1. Remove opera[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 7 - - 22 Chassis Hood 1. Hood 2. Screen assembly 3. Bulb seal 4. Flange nut (2 used) 5. Screen pivot (2 used) 6. Hair pin (2 used) 7. Hood support 8. Plastite screw (4 used) 9. Door handle (2 used) 10. Bulb seal 1 1. Hood pivot (2 used) 12. Flexible draw latch (2 used) 13. Corner screen seal (2 used) 14. S[...]

Groundsmaster 4100- - D/41 10 - - D Page 7 - - 23 Chass is Removal 1. Park machine on a level surface , lower cutting deck, stop engine, apply pa rking brake and remove key from the ignition switch. 2. Remove hood asse mbly from machine: A. Remove ha ir pins (item 6) that retain screen pivots to hood pi vots. B. Slide hood assembly to disengage scr[...]

Groundsmaster 41 00 - - D/41 10 - - D Page 7 - - 24 Chassis This page is intentionally blank.[...]

Groundsmaster 4100- - D/41 10 - - D Cutting Deck Page 8 - - 1 Chapter 8 Cutting Deck T able of Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TION 3 ..................... Operator ’s Manu al 3 .......................... Castor Wheel T ire Pressure 3 .................. Blade Stopping T ime 3 ........................ TROUBL[...]

Groundsmaster 41 00 - - D/41 10 - - D Cutting Deck Page 8 - - 2 Specifications MOUNTING: Cutting deck is supported by lift arms con- trolled with individual lif t switches for complete deck, right wing deck and left wing deck. CONSTRUCTION: Deck chamber is welded 12 gauge steel construction r einfor ced with chan nels and plates. HEIGHT - - OF - - [...]

Groundsmaster 4100- - D/41 10 - - 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 firs t. Operator ’ s Manual The Operator ’s Manu al provides information re garding the operation, gene ral maintenance, adjustment[...]

Groundsmaster 41 00 - - D/41 10 - - 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, “spong iness” or attempting to cut off too much grass height may not alw[...]

Groundsmaster 4100- - D/41 10 - - D Cutting Deck Page 8 - - 5 This page is intentionally blank. Cutting Deck[...]

Groundsmaster 41 00 - - D/41 10 - - 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 fir st. Cutting Deck 1. Cutting deck 2. Cap screw (4 used) 3. LH lift arm 4. Flange nut (4 used) 5. Spacer 6. Damper 7. Damper rod en[...]

Groundsmaster 4100- - D/41 10 - - D Cutting Deck Page 8 - - 7 Removal (Fig. 1) 1. Position machine on a cl ea n, level s urface. Lo wer cutting deck, stop engi ne, engage parking brake an d re- move key from the ignition switch. NOTE: Removal of clev is pins from deck and height - - of - - cut chains is easier if deck is lifted slightly . 2. No te [...]

Groundsmaster 41 00 - - D/41 10 - - D Cutting Deck Page 8 - - 8 NOTE: Installation of clevis pin s to deck and height - - of - - cut chains is easier if deck is lifted slightly . 4. Instal l 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 fittin[...]

Groundsmaster 4100- - D/41 10 - - D Cutting Deck Page 8 - - 9 This page is intentionally blank. Cutting Deck[...]

Groundsmaster 41 00 - - D/41 10 - - D Cutting Deck Page 8 - - 10 Wing D ec k Se rvi c e 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. Pivo t lat ch (2 used ) 9. Flat washer 10. Retaining ring (2 used per latch) 1 1. Cap screw ( 3 used per [...]

Groundsmaster 4100- - D/41 10 - - D Cutting Deck Page 8 - - 1 1 Removal (Fig. 6) 1. Position machine on a cl ea n, level s urface. Lo wer cutting deck an d engage parking brake. 2. F ully raise wing deck, stop engine an d remove key from the ig nition switch. Remo ve three (3) wa sher head screws and shield strap that secure flex shield to wing dec[...]

Groundsmaster 41 00 - - D/41 10 - - D Cutting Deck Page 8 - - 12 4. Position upper end of link assem blies to center cut- ting deck brackets. 5. Alig n upper end of lin k a ssemblies with mounting holes in center deck. While in stalling pivot pins to center deck and links, insert spacers and washers as follows: A. Place one (1) hardened spacer (ite[...]

Groundsmaster 4100- - D/41 10 - - D Cutting Deck Page 8 - - 13 Cutting Deck Link Service Disassembly (Fig. 10) 1. Pr ess bushing s from top of link. 2. Remove dust cap and re taining ring f rom link. 3. Press tapered stud with spherical bearing, flat wash- ers and flange nut from lin k. 4. Remove flange nut and press spherical bearing from tapered [...]

Groundsmaster 41 00 - - D/41 10 - - D Cutting Deck Page 8 - - 14 Wing D eck Latch Disassembly (Fig. 12) 1. Raise wing deck to transpor t position. Carefully ro- tate latch to closed position. 2. Lo osen lug nut to r elease compr ession spring ten - sion. 3. Remove retaining ring and flat washer from bottom of latch pin. Rotate lug nut eno ugh to al[...]

Groundsmaster 4100- - D/41 10 - - D Cutting Deck Page 8 - - 15 This page is intentionally blank. Cutting Deck[...]

Groundsmaster 41 00 - - D/41 10 - - D Cutting Deck Page 8 - - 16 Blade Spi ndle 1. Cutting deck 2. Drive spindle: single pulley (2 u sed) 3. Low driven spindle (3 used) 4. Drive spindle: double pulley (1 used) 5. High driven spindle (1 used) 6. Flange nut 7. Bla de bol t 8. Cutting blade (7 used) 9. Anti - - scalp cup 10. Flat wash er 11 . C a p s [...]

Groundsmaster 4100- - D/41 10 - - D Cutting Deck Page 8 - - 17 Installation (Fig. 13) 1. If screws were removed from spindle housing, press new screws into housing. Make sure that scre w head is squarely seated against housing af ter installation. 2. Position spindle on cutting deck noting orientation of grease fitting (Fig. 15). Se cure spindle as[...]

Groundsmaster 41 00 - - D/41 10 - - D Cutting Deck Page 8 - - 18 Blade Spindle Ser vice 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. Bear ing cu p and co ne 10. Outer bearing spacer 1 1. Inner bearing spacer 12. Spacer ri ng 13. Snap rin g 14. Greas[...]

Groundsmaster 4100- - D/41 10 - - D Cutting Deck Page 8 - - 19 2. Install outer bearing spacer into top of spindle hou s- 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 housin g. The top bearing cup must contact the outer bearing s pacer previously installed, a[...]

Groundsmaster 41 00 - - D/41 10 - - 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. Idler stop bolt 1 1. Flange nut 12. Cap screw 13. Spacer 14. Shoulder bolt 15. Idler spr ing 16. Lock nut 17. Idler[...]

Groundsmaster 4100- - D/41 10 - - 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 ignit ion switch. 2. Remove deck covers from top of cutting deck. CAUTION Be careful when removing idler spr ing. The spring is under heavy load and may c[...]

Groundsmaster 41 00 - - D/41 10 - - D Cutting Deck Page 8 - - 22 Castor Forks and W heels 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[...]

Groundsmaster 4100- - D/41 10 - - 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 ignit ion switch. 2. Disassemble castor forks and wheels using Figur e 22 as a guide. Assembly (Fig. 22) 1. Assemble castor forks and wheels using Fig[...]

Groundsmaster 41 00 - - D/41 10 - - 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 s crew 8. Flan ge nu t 9. Skid (RH shown) 10. Flange h ead sc rew 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 [...]

Groundsm aster 41 10 - - D Operator Cab Page 9 - - 1 Chapter 9 Operator Cab T able of Contents GENERAL INFORMA TION 2 ..................... Operator ’s Manu al 2 .......................... Electrical Components an d Schematic 2 ... ...... Air Conditioning S ystem 2 ............... ...... Cab Heater System 2 ................... ...... SERVICE AND [...]

Groundsmaster 41 10 - - D Oper ator Cab Page 9 - - 2 General Information The information in this ch apter pertains to the operator cab on the Groundsmaster 41 10 - - D. Operator ’ s Manual The Operator’s Manual provi des information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster . Refer to the Oper[...]

Groundsm aster 41 10 - - D Operator Cab Page 9 - - 3 Service and Repairs General Precautions for R emoving and Inst alling Air Conditi oning System Components CAUTION The air conditioning system is under high pres- sure. Do not loosen any system fitting or compo - nent until after the system has been com pletely discharged by a cer tified A/C servi[...]

Groundsmaster 41 10 - - D Oper ator Cab Page 9 - - 4 Air Conditioning Compressor Figure 1 FRONT RIGHT 1. Cap s crew (2 us ed) 2. Flat washer (4 used) 3. Lock washer (6 used) 4. Hex nut (2 used) 5. Conduit 6. O - - ri ng (2 u sed) 7. 90 o fitting 8. O - - ring 9. A/C compressor 10. Cap screw (4 u sed) 1 1. Ca p scre w (2 use d) 12. A/C compressor m [...]

Groundsm aster 41 10 - - D Operator Cab Page 9 - - 5 7. Read the General Precautions for Removing an d Installing Air Conditioning System Components at the beginning of the Service and Repairs section of this chapter . CAUTION The air conditioning system is under high pres- sure. Do not loosen any system fitting or compo - nent until after the syst[...]

Groundsmaster 41 10 - - D Oper ator Cab Page 9 - - 6 Roof Assem bly 1. Roof 2. Screw (2 used) 3. Flat washer (6 used) 4. Bushing (10 used) 5. Rear fastener (2 used) 6. Rear spacer (2 used) 7. Panel nut 8. Roof mount 9. Flange nut (2 used) 10. Flange nut (4 us ed) 11 . H e a d l i n e r 12. Front spacer (2 used) 13. Front fast ener ( 2 use d) 14. Ru[...]

Groundsm aster 41 10 - - D Operator Cab Page 9 - - 7 T o gain access to the heater core and air conditioning components that are l ocated under the cab roof, the ro of panel can be loosene d, raised and supported. Removal (Fig. 3) 1. Park machine on a level surface , lower cutting deck, stop engine, engage parking brake and remove key from the igni[...]

Groundsmaster 41 10 - - D Oper ator Cab Page 9 - - 8 Air Conditioning Condenser As sembly 1. Condenser cover 2. Lock nut (4 used) 3. Condenser fan 4. Condenser coil assembly 5. Car riage s crew (2 u sed) 6. Flat washer (8 used) 7. Roof 8. Bus hing ( 4 used) 9. Moun ting st rap 10. Button h ead sc rew (4 us ed) Figure 5 2 1 3 4 7 8 5 9 6 2 6 8 10 6 [...]

Groundsm aster 41 10 - - D Operator Cab Page 9 - - 9 8. Label and remove hoses from condenser coil. Imme- diately cap hoses and fittings to prevent moisture and contaminants from entering the system. 9. Remove condenser coil from roof using Figure 6 as a guide. NOTE: The replacement of the drier- - receiver is recom- mended whenever the air conditi[...]

Groundsmaster 41 10 - - D Oper ator Cab Page 9 - - 10 Heater/Evapor ator Assembly 1. Heater/evaporator assembly 2. T op cover 3. Flange head screw (2 used) 4. Drier - - receiver mount 5. Bottom cover 6. Hose clamp (2 used) 7. Spee d nut (8 u sed) 8. Panel nut (4 used) 9. Drier - - receiver assembly 10. Screw (8 used) 1 1. Screw (4 used) 12. Blower [...]

Groundsm aster 41 10 - - D Operator Cab Page 9 - - 1 1 7. Loosen hose clamp that secures air duct hose to heater/evaporator assemb ly covers. Slide hose from covers. 8. Remove screws that secure top cover to bottom cov- er . Remove top cover to access heater/evaporator as- sembly . 9. Disassemble heater/evaporator assembly using Fig. 7 as a guide. [...]

Groundsmaster 41 10 - - D Oper ator Cab Page 9 - - 12 Windshiel d Wiper 1. Wiper motor 2. Gasket 3. Linkage bracket 4. Lock washer 5. Cap screw 6. Cap (2 u sed) 7. W asher 8. Nut 9. Flange nut (2 used) 10. Cover (2 used) 1 1. Wiper arm assembly 12. W iper b lade 13. Screw (2 used) Figure 10 2 3 6 8 9 10 11 13 1 5 7 12 4[...]

Groundsm aster 41 10 - - D Operator Cab Page 9 - - 13 Disassembly (Fig. 10) 1. Park machine on a level surface , lower cutting deck, stop engine, engage parking brake and remove key from the ignit ion switch. 2. If access to wiper motor is necessary , remove fasten- ers that secure roof in place. Raise and supp ort roof to allow access to condenser[...]

Groundsmaster 41 10 - - D Oper ator Cab Page 9 - - 14 This page is intentionally blank.[...]

Groundsmaster 4100- - D/41 10 - - D Foldout Drawings Page 10 - - 1 Chapter 10 Foldout Drawings T able of Contents ELECTRICAL DRA WING DESIGNA TIONS 2 ....... HYDRAULIC SCHEMA TIC 3 ..................... ELECTRICAL SCHEMA TICS Models 30602 an d 30604 4 ........ ............ Models 30606 an d 30608 5 ........ ............ Operator Cab 6 ...... ......[...]

Groundsmaster 41 00 - - D/41 10 - - D Foldout Drawings Page 10 - - 2 Electrical Drawing Designations The following a bbreviations are used for wire h arness colors on the electrical sch ematics and wire harness drawings in this chapter . ABBREVIA TION COLOR BK BLACK BR or BN BROWN BU BLUE GN GREEN GY GRA Y OR ORANGE PK PINK Ro rR D R E D TT A N VIO[...]

Page 10 - - 3 Hydr aulic S chem atic Groundsmaster 4100 - - D/41 10 - - D S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 2500 PSI S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 OR7 .070 T 2SP CH3 G2 G4 CV4 PR G1 G3 3250 PSI 1350 PSI 3.3 GPM 4.4 GPM 15.2 GPM 310 PSI 4 PSI 4 PSI .030 OR9 S1 3300 PSI [...]

Page 10 - - 4 Ele ct ric al Sc h ema t ic Groundsmaster 4100 - - D/41 10 - - D All r elays and so lenoid s are shown as de - - energized. All gr ound wir es are black. Models 30602 and 30604 1 2 3 4 5 CAB, A REFERE NCE NUMBER W ILL BE LISTED. THE CAB SCHE MA TIC WILL AL SO INCLUDE THE REFERENCE NUMBE R. NOTE: WHEN A W IRE FROM THIS SCHEMA TIC CONT [...]

Page 10 - - 5 All r elays and so lenoid s are shown as de - - energized. All gr ound wir es are black. Electr ical Schematic Models 30606 and 30608 Groundsmaster 4100 - - D/41 10 - - D 5 2 4 3 1 CAB, A REFERE NCE NUMBER W ILL BE LISTED. THE CAB SCHE MA TIC WILL AL SO INCLUDE THE REFERENCE NUMBE R. NOTE: WHEN A W IRE FROM THIS SCHEMA TIC CONT INUES [...]

Page 10 - - 6 TO GROUND BLOCK PLA TFORM WIRE HARNES S FROM OPE RA T OR PLA TFORM WIRE HARNES S TO OPERA TOR Operator Cab (shown with l ights for US model ) Groundsmaster 41 10 - - D All r elays and so lenoid s are shown as de - - energized. All gr ound wir es are black. Electr ical Schematic 1 2 3 4 TO CAB WIRE HARNES S SCHEMA TIC FOR THE APPROPRIA[...]

Page 10 - - 7 Electr ical Schematic Groundsmaster 41 10 - - D All r elays and so lenoid s are shown as de - - energized. All gr ound wir es are black. International Light Ki ts 2 3 4 5 PLA TFORM WIRE HARNES S FROM OPE RA T OR PLA TFORM WIRE HARNES S TO OPERA TOR TO CAB WIRE HARNES S PLA TFORM WIRE HARNES S TO OPERA TOR SCHEMA TIC FOR THE APPROPRIA [...]

Page 10 - - 8 This page is intent ionall y blank .[...]

Page 10 - - 9 Groundsmaster 4100 - - D/41 10 - - D Pla tf o rm Wire H arn e ss D raw in g AB CD 1 2 3 4 5[...]

Pag e 10 - - 10 Groundsmaster 4100 - - D/41 10 - - D Pla tf o rm Wire H arn e ss D ia g ram Sheet 1 of 2 REFERENCE NUMBE R WILL BE IDENTIFIED. NOTE: T HE PLA TFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2) SHEE TS. W HEN A CONDUCTOR CONTINUES ON ANOTHER S HEET , A DRA W ING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE[...]

Page 10 - - 1 1 Groundsmaster 4100 - - D/41 10 - - D Pla tf o rm Wire Ha rn es s Di ag ra m Sheet 2 of 2 REFERENCE NUMBE R WILL BE IDENTIFIED. NOTE: T HE PLA TFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2) SHEE TS. W HEN A CONDUCTOR CONTINUES ON ANOTHER S HEET , A DRA W ING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE[...]

Pag e 10 - - 12 Groundsmaster 4100 - - D/41 10 - - D Rear Wire Harness Drawing[...]

Pag e 10 - - 13 Groundsmaster 4100 - - D/41 10 - - D Rear Wire Harness Diag ram DRA W ING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION.[...]

Pag e 10 - - 14 Models 30606 and 30608 Engi ne Wir e Har ness Dr awing Groundsmaster 4100 - - D/41 10 - - D[...]

Pag e 10 - - 15 Models 30606 and 30608 Eng i n e Wire H arn e ss D ia g ram Groundsmaster 4100 - - D/41 10 - - D DRA W ING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION.[...]

Pag e 10 - - 16 Models 30602 and 30604 Engi ne Wir e Har ness Dr awing Groundsmaster 4100 - - D/41 10 - - D[...]

Pag e 10 - - 17 Models 30602 and 30604 Eng i n e Wire H arn e ss D ia g ram Groundsmaster 4100 - - D/41 10 - - D DRA W ING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION.[...]

Pag e 10 - - 18 Groundsmaster 4100 - - D/41 10 - - D Cutting Deck Wir e Harness DRA W ING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION.[...]

Pag e 10 - - 19 Groundsmaster 41 10 - - D Oper ator Cab Inter connect Wir e Harne ss DRA W ING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION.[...]

Pag e 10 - - 20 Groundsmaster 41 10 - - D Operator Cab W ire Harness Dr awing[...]

Pag e 10 - - 21 Groundsmaster 41 10 - - D Operator Cab W ire Harness Diagr am DRA W ING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION.[...]