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Toro 30411, Service Manual

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Toro 30411 Service Manual Download Page 191

Groundsmaster 4100−D

Page 6 − 1

Axles, Planetaries, and Brakes

Chapter 6

Axles, Planetaries, and Brakes

Table of Contents

SPECIFICATIONS

2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

ADJUSTMENTS

3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

SERVICE AND REPAIRS

4

. . . . . . . . . . . . . . . . . . . . . . 

Brake Assembly

4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Brake Inspection and Repair

6

. . . . . . . . . . . . . . . . . . 

Planetary Wheel Drive Assembly

8

. . . . . . . . . . . . . . 

Planetary Wheel Drive Service

10

. . . . . . . . . . . . . . . 

Rear Axle Assembly

12

. . . . . . . . . . . . . . . . . . . . . . . . 

Bevel Gear Case and Axle Case

15

. . . . . . . . . . . . . 

Differential Shafts

20

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Axle Shafts

21

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Input Shaft/Pinion Gear

22

. . . . . . . . . . . . . . . . . . . . . 

Differential Gear

24

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

Pinion Gear to Ring Gear Engagement

27

. . . . . . . 

Axles, Planetaries,

and Brakes

Summary of Contents for 30411

Page 1: ...Form No 03116SL Rev G Groundsmaster 4100 D Model 30411 Original Instructions EN...

Page 2: ...content This document shall not be reproduced by a third party without the express written consent of The Toro Company and or the appropriate affiliated company Revision History Revision Date Descript...

Page 3: ...lications To do this effectively we encourage user feedback Please comment on the completeness accuracy organization usability and readability of this manual by an e mail to servicemanuals toro com or...

Page 4: ...NOTES _...

Page 5: ...nd Parts Catalogs are available on the internet at www Toro com The Toro Company reserves the right to change product specifications or this publication without notice This safety symbol means DANGER...

Page 6: ...Groundsmaster 4100 D This page is intentionally blank...

Page 7: ...g 4 20 Testing 4 23 Adjustments 4 48 Service and Repairs 4 49 Chapter 5 Electrical System Electrical Schematic Circuit Diagrams and Wire Harness Drawings 5 2 Special Tools 5 3 Troubleshooting 5 4 Elec...

Page 8: ...Groundsmaster 4100 D This page is intentionally blank...

Page 9: ...Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS 2 Before Operating 2 While Operating 2 Maintenance and Service 3 JACKING INSTRUCTIONS 4 Jacking the Front End 4 Jacking the Rear End 4 SA...

Page 10: ...d correctly so engine cannot be started unless traction pedal is in NEUTRAL and cutting unit is DISENGAGED 4 Since diesel fuel is highly flammable handle it care fully A Use an approved fuel container...

Page 11: ...utting units and other mov ing parts Keep bystanders away 10 Do not overspeed the engine by changing governor setting To assure safety and accuracy check maximum engine speed 11 Shut engine off before...

Page 12: ...ks or jack stands the machine may move or fall which may result in personal injury Jacking the Front End Fig 1 1 Set parking brake and chock both rear tires to pre vent the machine from moving 2 Posit...

Page 13: ...ty Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 4100 D If any decal becomes illeg ible or damaged install a new decal Decal part num bers are l...

Page 14: ...Groundsmaster 4100 D Page 1 6 Safety This page is intentionally blank...

Page 15: ...ers Inch Series 4 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric 5 Other Torque Specifications 6 Conversion Factors 6 MAINTENANCE 7 Product Records Insert Operator s Manual and Parts C...

Page 16: ...Groundsmaster 4100 D Page 2 2 Product Records and Maintenance Equivalents and Conversions...

Page 17: ...orque feature hardness of the surface underneath the fastener s head or similar condition which affects the installation As noted in the following tables torque values should be reduced by 25 for lubr...

Page 18: ...6 2 22 3 30 3 41 4 43 4 58 5 3 8 24 UNF 17 2 18 2 24 3 35 3 47 4 50 4 68 5 7 16 14 UNC 27 3 27 3 37 4 50 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 5 75 7 77 7 104 9 1 2 13 UNC 30 3 48 7 65 9 75 8...

Page 19: ...10 N m 92 9 ft lb 125 12 N m M16 X 2 0 166 15 ft lb 225 20 N m 229 22 ft lb 310 30 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 37 ft lb 610 50 N m NOTE Reduce torque values listed in the table above by...

Page 20: ...lb Wheel Bolts and Lug Nuts Thread Size Recommended Torque 7 16 20 UNF Grade 5 65 10 ft lb 88 14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1 5 Cl...

Page 21: ...undsmaster 4100 D are covered in the Operator s Manual Refer to that publication when performing regular equipment maintenance Several maintenance procedures have break in intervals identi fied in the...

Page 22: ...Groundsmaster 4100 D Page 2 8 Product Records and Maintenance This page is intentionally blank...

Page 23: ...USTMENTS 4 Run Solenoid 4 SERVICE AND REPAIRS 6 Air Filter System 6 Exhaust System 8 Fuel System 10 Check Fuel Lines and Connections 11 Drain and Clean Fuel Tank 11 Fuel Tank Removal 11 Fuel Tank Inst...

Page 24: ...hops Special tools are described in the Kubota Workshop Manual Diesel Engine V2003 T The use of some specialized test equipment is explained However the cost of the test equipment and the specialized...

Page 25: ...allons 72 19 0 Fuel Injection Pump Bosch Type Mini Pump PFR Governor Centrifugal Mechanical Low Idle no load 1375 50 RPM High Idle no load 2730 30 RPM Direction of Rotation Counterclockwise Viewed fro...

Page 26: ...fuel stop lever to within 1 16 1 6 mm of stop on the injection pump 2 If adjustment is needed loosen lock nut and rotate the threaded end of the swivel until the lever is properly positioned 3 Tighte...

Page 27: ...Groundsmaster 4100 D Page 3 5 Kubota Diesel Engine Rev A This page is intentionally blank Kubota Diesel Engine...

Page 28: ...Air Filter System Figure 3 1 Air cleaner hose 2 Hose clamp 3 Air cleaner assembly 4 Indicator 5 Air cleaner strap 6 Lock nut 2 used 7 Hose clamp 8 Air cleaner hose 9 Hose clamp 10 Cap screw 2 used 11...

Page 29: ...r cleaner system using Figure 3 as a guide 2 When installing air cleaner hose 8 between air cleaner and turbo charger Fig 4 A Make sure that hose does not contact engine valve cover To modify clearanc...

Page 30: ...Flange head screw 4 used 5 Exhaust gasket 6 Lock nut 7 Cap screw 8 Flat washer 9 Spacer 10 Rubber hanger 11 Flange nut 2 used 12 Flange head screw 2 used 13 Engine mount 14 Muffler clamp 11 2 1 14 3...

Page 31: ...into head NOTE Make sure muffler flange and exhaust manifold sealing surfaces are free of debris or damage that may prevent a tight seal 1 Install new gasket if original gasket is damaged or torn IMP...

Page 32: ...late 20 Negative battery cable 21 Positive battery cable 22 Carriage screw 2 used 23 Gasket 24 Bushing 3 used 25 Stand pipe 26 Fuel sender 27 Lock washer 5 used 28 Phillips head screw 5 used 29 Fuel h...

Page 33: ...ion switch 2 Raise seat and hood 3 Remove battery cover and strap Disconnect nega tive battery cable first and then positive battery cable Remove battery from machine 4 Use a fuel transfer pump to rem...

Page 34: ...3 Oil cooler hydraulic fitting 2 used 24 Flange head screw 25 Clamp 6 used 26 Flange nut 27 Oil cooler bracket RH shown 28 Flat washer 29 Foam plug 30 Lock nut 31 Foam strip 32 Lower radiator support...

Page 35: ...e radiator by remov ing four flange head screws and flat washers Position shroud away from radiator 8 Remove flange head screws flat washers and lock nuts that secure the radiator to the support frame...

Page 36: ...1 Coolant drain hose 12 Hose clamp 13 Cap screw 4 used 14 Barb fitting female 15 Coolant drain cock fitting 16 Engine mount bracket RH shown 17 Lock washer 18 Cap screw 19 Lock washer 20 Cap screw 21...

Page 37: ...ot To avoid possible burns allow the exhaust system to cool before working on or near the muffler 5 Remove exhaust system from engine see Muffler Removal 6 Remove air cleaner system from engine see Ai...

Page 38: ...ure all cable ties securing the wiring harness fuel lines or hydraulic hoses to the engine are removed 15 Connect hoist or lift to the front and rear lift tabs on engine 16 Remove flange head locking...

Page 39: ...10 Install hydraulic pump assembly to engine see Pump Assembly in Chapter 4 Hydraulic Systems 11 Connect two wires to neutral switch on traction pump 12 Connect wires and or electrical connections to...

Page 40: ...screw 4 used 4 Pump adapter plate 5 Plate pin 2 used 6 Dowel 2 used 7 Coupling spacer 8 Shoulder bolt 2 used 9 Spring center coupling 10 Lock washer 11 Cap screw 6 used 12 Cap screw 8 used 5 4 2 12 10...

Page 41: ...to coupling spacer and flywheel Torque cap screws from 17 to 21 ft lb 23 to 28 N m 3 Place dowels in locating holes of coupling spacer Fig 17 4 Position spring center coupling coil springs toward engi...

Page 42: ...Groundsmaster 4100 D Page 3 20 Kubota Diesel Engine Rev A This page is intentionally blank...

Page 43: ...uit Reducing Valve PR Pressure 46 ADJUSTMENTS 48 Adjust Cutting Deck Flow Control Valve 48 SERVICE AND REPAIRS 49 General Precautions for Removing and Installing Hydraulic System Components 49 Check H...

Page 44: ...ent gear type pump Steering Relief Pressure 1350 PSI 93 bar Lift Lower Relief Pressure 2525 PSI 174 bar Front Wheel Motors Fixed displacement piston motors Rear Axle Motor Fixed displacement piston mo...

Page 45: ...fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is injected into the skin it must be surgi cally removed within a few hours by a doctor...

Page 46: ...b 12 13 N m 6 20 21 ft lb 27 28 N m 8 35 37 ft lb 47 50 N m 10 60 66 ft lb 81 89 N m 12 81 87 ft lb 110 117 N m 16 121 131 ft lb 164 177 N m Figure 4 SAE Straight Thread O Ring Port Adjustable 1 Make...

Page 47: ...a by pass valve that needs to be turned 90o for towing See Operator s Manual for Towing Pro cedures 1 By pass valve location Figure 7 1 Check Hydraulic Fluid The Groundsmaster 4100 D hydraulic system...

Page 48: ...Groundsmaster 4100 D Hydraulic System Page 4 6 This page is intentionally blank...

Page 49: ...Groundsmaster 4100 D Hydraulic System Page 4 7 Hydraulic Schematic Hydraulic Schematic Groundsmaster 4100 D All solenoids are shown as de energized Hydraulic System...

Page 50: ...Groundsmaster 4100 D Hydraulic System Page 4 8 Hydraulic Flow Diagrams Traction Circuit Forward Mow Shown Working Pressure Low Pressure Charge Return or Suction Flow Groundsmaster 4100 D...

Page 51: ...action circuit to make up for oil that is lost due to inter nal leakage in the traction pump and motors Charge pump flow is directed through the oil filter and to the low pressure side of the closed l...

Page 52: ...Rev E Groundsmaster 4100 D Hydraulic System Page 4 10 Lower Cutting Deck Working Pressure Low Pressure Charge Return or Suction Flow Groundsmaster 4100 D...

Page 53: ...of the cylinders is allowed to return to the traction charge circuit When the lift lever is released the lift cylinders and cutting deck are held in position The drop speed of the cutting deck is regu...

Page 54: ...Rev E Groundsmaster 4100 D Hydraulic System Page 4 12 Raise Cutting Deck Working Pressure Low Pressure Charge Return or Suction Flow Groundsmaster 4100 D...

Page 55: ...ure to the rod end of the deck lift cylinders causing the cylinders to retract As the cylinders retract the cut ting deck raises Oil from the piston end of the cylinders returns to the hydraulic reser...

Page 56: ...Groundsmaster 4100 D Hydraulic System Page 4 14 Mow Circuit All Deck Motors Rotating Working Pressure Low Pressure Charge Return or Suction Flow Groundsmaster 4100 D...

Page 57: ...oilcool er and oil filter Deck motor case drain leakage returns to the hydraulic reservoir Maximum mow circuit pressure is limited at each deck by a relief valve R1BY in the hydraulic manifold The ce...

Page 58: ...Groundsmaster 4100 D Hydraulic System Page 4 16 Steering Circuit Left Turn Shown Working Pressure Low Pressure Charge Return or Suction Flow Groundsmaster 4100 D...

Page 59: ...e L port Pres sure contracts the piston for a left turn The rotary meter ensures that the oil flow to the cylinder is proportional to the amount of the turning on the steering wheel Fluid leaving the...

Page 60: ...or use on this machine see Hydraulic Test Fit ting Kit TOR4079 in this section 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated w...

Page 61: ...NG KIT NO TOR4079 Measuring Container TOR4077 Use this container for doing hydraulic motor efficiency testing motors with case drain lines only Measure effi ciency of a hydraulic motor by restricting...

Page 62: ...of oil is in the hydraulic system Air is leaking in suction line Machine operates in one direction only Traction control linkage is faulty System charge check valve and or system relief valve is defe...

Page 63: ...r is damaged motor rotates but deck blades don t rotate Solenoid valve in deck manifold is faulty Cartridge valve in deck manifold is damaged or sticking Deck motor or gear pump section is damaged All...

Page 64: ...op too fast or too slow Flow control valve is not adjusted properly Cutting deck will not lower Lift arm pivots are binding Lift cylinder is damaged Counterbalance pressure is excessive Lift lower con...

Page 65: ...ic system all pressure in the system must be relieved and all rotating ma chine parts must be stopped Stop engine lower or support attachments 1 Clean machine thoroughly before disconnecting or disass...

Page 66: ...re Using Pressure Gauge Working Pressure Low Charge Pressure Return or Suction Flow TO LIFT LOWER CONTROL VALVE TO STEERING CONTROL TO CUTTING DECK CASE DRAIN FROM PTO MOW CIRCUIT CHARGE OIL FROM LIFT...

Page 67: ...gine and record test results 7 If there is no pressure or pressure is low check for restriction in pump intake line Also inspect charge relief valve located in filter manifold see Hydraulic Manifold S...

Page 68: ...Gauge Working Pressure Low Charge Pressure Return or Suction Flow TO LIFT LOWER CONTROL VALVE TO STEERING CONTROL TO CUTTING DECK CASE DRAIN FROM PTO MOW CIRCUIT CHARGE OIL FROM LIFT AND STEERING CIR...

Page 69: ...ed Check for hydraulic leakage and correct before proceeding with test 5 Operate the engine at full speed 2730 30 RPM 6 Siton seat apply brakesfully andslowly depressthe traction pedal in the appropri...

Page 70: ...ST NO 3 Cutting Deck Circuit Pressure Using Pressure Gauge Working Pressure Low Charge Pressure Return or Suction Flow TO LIFT LOWER CONTROL VALVE TO STEERING CONTROL VALVE TRACTION CIRCUIT CHARGE CIR...

Page 71: ...22 23 and 24 4 After installing pressure gauge start engine and run at idle speed Check for hydraulic leakage and correct before proceeding with test CAUTION Keep away from decks during test to preve...

Page 72: ...ear Pump Flow Using Tester with Pressure Gauges and Flow Meter Working Pressure Low Charge Pressure Return or Suction Flow TO LIFT LOWER CONTROL VALVE TO STEERING CONTROL VALVE TRACTION CIRCUIT CHARGE...

Page 73: ...1 5 Make sure the flow control valve on the tester is fully open 6 After installing tester start engine and run at idle speed Check for hydraulic leakage and correct before proceeding with test IMPORT...

Page 74: ...ck Manifold Relief Pressure Using Tester with Pressure Gauges and Flow Meter Working Pressure Low Charge Pressure Return or Suction Flow TO LIFT LOWER CONTROL VALVE TO STEERING CONTROL VALVE TRACTION...

Page 75: ...jury from the cutting blades 7 Operate engine at full speed 2730 30 RPM En gage the cutting decks 8 Watch pressure gauge carefully while slowly closing the flow control valve to fully closed 9 As the...

Page 76: ...Drain Leakage Using Tester with Pressure Gauges and Flow Meter Working Pressure Low Charge Pressure Return or Suction Flow MEASURING CONTAINER TO LIFT LOWER CONTROL VALVE TO STEERING CONTROL VALVE TR...

Page 77: ...e tested Fig 28 Install flow tester in series with the motor and the disconnected return hose Make sure the flow con trol valve on tester is fully open 4 Disconnect the motor case drain hose small dia...

Page 78: ...essure Gauge High Pressure Low Charge Pressure Return or Suction Flow G 1 37 1 37 1350 PSI PB 58 2 48 STEERING CYLINDER STEERING CONTROL T R P L TO LIFT LOWER CIRCUIT TRACTION CIRCUIT RESERVOIR FROM T...

Page 79: ...Operate the engine at full engine speed 2730 30 RPM IMPORTANT Hold steering wheel at full lock only long enough to get a system pressure reading Holding the steering wheel against the stop for an ext...

Page 80: ...4 38 TEST NO 8 Lift Lower Circuit Relief Pressure Using Pressure Gauge High Pressure Low Charge Pressure Return or Suction Flow FROM PTO MOW CIRCUIT TO PTO MOW CIRCUIT PTO MOW CIRCUIT CASE DRAIN NOTE...

Page 81: ...pressure gauge start engine and run at idle speed Check for hydraulic leakage and correct before proceeding with test 5 Sit on the seat and operate the engine at full speed 2730 30 RPM 6 While sitting...

Page 82: ...ow Using Tester with Pressure Gauges and Flow Meter High Pressure Low Charge Pressure Return or Suction Flow 1 37 1 37 58 2 48 RESERVOIR FROM FROM OIL FILTER TRACTION CIRCUIT TO PTO MOW CIRCUIT TO STE...

Page 83: ...ester flow control valve is open 4 After installing tester start engine and run at idle speed Check for hydraulic leakage and correct before proceeding with test IMPORTANT The pump is a positive displ...

Page 84: ...4100 D Hydraulic System Page 4 42 TEST NO 10 Counterbalance Pressure Using Pressure Gauge High Pressure Low Charge Pressure Return or Suction Flow FROM PTO MOW CIRCUIT TO PTO MOW CIRCUIT PTO MOW CIRCU...

Page 85: ...engine at full engine speed 2730 30 RPM with no load on the system Do not engage the cutting decks GAUGE READING TO BE 225 PSI 17 3 bar over system charge pressure e g if charge pressure is 250 PSI co...

Page 86: ...lief Pressure Using Pressure Gauge Working Pressure Low Charge Pressure Return or Suction Flow RETURN FROM LIFT AND STEERING CYLINDERS CHARGE OIL FROM LIFT AND STEERING CIRCUITS TO LIFT LOWER CIRCUIT...

Page 87: ...pressure on the traction pedal and monitor the pressure gauge Pressure should increase until the re lief valve RV5 lifts Record test results GAUGE READING TO BE 750 PSI approximate 7 Relief valve RV5...

Page 88: ...ve PR Pressure Using Pressure Gauge Working Pressure Low Charge Pressure Return or Suction Flow RETURN FROM LIFT AND STEERING CYLINDERS CHARGE OIL FROM LIFT AND STEERING CIRCUITS TO LIFT LOWER CIRCUIT...

Page 89: ...ressthe traction pedal in the reverse direction While pushing traction pedal look at pressure reading on gauge GAUGE READING TO BE 650 PSI approximate 7 Stop engine and record test results 8 Pressure...

Page 90: ...chine to gethydraulic oilat operating temper atures Park machine on a level surface shut engine off and lower cutting decks to the ground 2 Locate valve under front of machine Fig 42 3 Loosen setscrew...

Page 91: ...nt of Components 1 Check oil level in the hydraulic reservoir and add cor rect oil if necessary Drain and refill hydraulic system reservoir and change oil filter if component failure was severe or sys...

Page 92: ...Service and Repairs section of this chapter 6 Reconnect all hydraulic hoses tubes and compo nents that were disconnected while draining system NOTE Use only hydraulic fluids specified in the Opera to...

Page 93: ...nt movement of the machine 10 Make sure traction pedal and lift control lever are in neutral Start engine and run it at low idle 1375 50 RPM The charge pump should pick up oil and fill the hydraulic s...

Page 94: ...ulic fitting 10 O ring 11 Clamp 12 Hydraulic T fitting 13 O ring 14 Hydraulic fitting 15 Fitting cap 16 Hydraulic fitting 17 O ring 18 Cap screw 2 used 19 Flat washer 2 used 20 Engine 21 Piston pump 2...

Page 95: ...spacer and o rings from machine through the seat opening Installation Fig 43 1 Lubricate new o rings with clean hydraulic oil and position on pump 2 Slide coupler onto the piston pump output shaft 3...

Page 96: ...4 4 4 4 14 13 12 28 29 25 to 28 ft lb 34 to 38 N m 21 to 24 ft lb 29 to 33 N m 21 to 24 ft lb 29 to 33 N m Disassembly Fig 44 Work in a clean area as cleanliness is extremely impor tant when repairing...

Page 97: ...ove plug 7 and washer 9 from rear adapter plate 24 16 Remove proportional valve 6 from backplate as sembly 27 Inspection 1 Clean and dry all pump components Remove nicks and burrs from all parts with...

Page 98: ...cket of front body 10 and into front plate bushings 8 Install front adapter plate 23 in place on front body 10 Check positioning marks for correct orientation 9 Install middle body 19 onto front adapt...

Page 99: ...Groundsmaster 4100 D Hydraulic System Page 4 57 This page is intentionally blank Hydraulic System...

Page 100: ...15 Hydraulic T fitting 16 Hydraulic fitting 17 Fitting cap 18 Hydraulic fitting 19 Cap screw 2 used 20 Flat washer 2 used 21 Clamp 22 Roll pin 23 Piston pump 24 Gear pump 25 Coupler 26 O ring 27 Spac...

Page 101: ...ump assembly from adapter plate and raise it out of the machine Installation Fig 45 1 Carefully lower piston pump into the machine and position it to the engine adapter plate Support pump to prevent i...

Page 102: ...ntrol arm 28 Servo control assembly 29 Washer 30 Orifice plate 3 used 31 Flat washer 32 Housing gasket 33 Cover plate gasket 34 Control assembly gasket 35 Plug 36 O ring 37 Seal sub assembly 38 Roll p...

Page 103: ...ve camplate 11 from rotating kit assembly 6 and servo piston follower 8 from camplate 11 8 Remove the four socket head screws 5 and wash ers 31 retaining each cover plate 9 10 9 Remove jam nut 1 washe...

Page 104: ...n pump housing Install servo piston assembly 7 and cover plate 10 into servo piston bore in right side of housing Fig 50 Retain cover plate with four washers 31 and socket head screws 5 Torque screws...

Page 105: ...valve in the cavity in backplate that it was removed and torque from 100 to 110 ft lb 136 to 149 N m 15 Install new o ring on bypass valve 14 Install by pass valve 14 into backplate 20 Note Make sure...

Page 106: ...nd spool valve Remove pin feedback link spool valve and bell crank from control housing 4 Compress spring and remove retaining ring 3 Re move spring retainer spring and second spring retainer from spo...

Page 107: ...oving link back and forth until detent action is detected Back out the switch until the detent action is very slight B Attach the leads from a test light to the switch ter minals Note A multimeter cou...

Page 108: ...hydraulic fitting 4 O ring 5 O ring 6 Quick fitting 7 O ring 8 Fitting cap 9 Hydraulic fitting 10 O ring 11 O ring 12 90o hydraulic fitting 13 O ring 14 O ring 15 Hydraulic fitting 16 Adapter 17 Plug...

Page 109: ...on of this chapter 2 To prevent contamination of hydraulic system during manifold removal thoroughly clean exterior of manifold and fittings 3 Disconnect electrical connector from the solenoid valve 4...

Page 110: ...VICKERS MANIFOLD NOTE The ports on the manifold are marked for easy identification of components Example P1 is a piston pump connection port and 2 is the location for the sole noid valve See Hydraulic...

Page 111: ...the cartridge valve A Lubricate new seal kit components with clean hy draulic oil and install on valve The o rings sealing rings and backup rings must be arranged properly on the cartridge valve for p...

Page 112: ...Dust cap 13 Quick fitting 14 Flange nut 15 Hydraulic manifold LH wing deck 16 45o hydraulic fitting 17 Cap screw 2 used per manifold 18 O ring 19 Hydraulic tee fitting 20 Hydraulic manifold RH wing d...

Page 113: ...talling Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 2 To prevent contamination of hydraulic system during manifold removal thoroughly clean exterio...

Page 114: ...to 47 N m 50 to 55 in lb 5 6 to 6 2 N m PLUG TORQUE SAE 4 9 to 11 ft lb 12 to 15 N m SAE 8 43 to 46 ft lb 58 to 62 N m SAE 2 60 to 65 in lb 6 8 to 9 5 N m Loctite 242 NOTE The ports on the manifold ar...

Page 115: ...Groundsmaster 4100 D Hydraulic System Page 4 73 This page is intentionally blank Hydraulic System...

Page 116: ...and CHG is the charge circuit connection See Hydraulic Sche matic to identify the function of the hydraulic lines and cartridge valves at each port 1 Read the General Precautions for Removing and Ins...

Page 117: ...41 to 49 in lb 4 6 to 5 6 N m NOTE The ports on the manifold are marked for easy identification of components Example C1 is the con nection port from the LH wing deck lift cylinder and CHG is the char...

Page 118: ...r pump connection port and T is the connection for the reservoir return See Hydraulic Schematic to identify the function of the hydraulic lines and cartridge valves at each port 1 Read the General Pre...

Page 119: ...81 to 95 N m 35 to 40 ft lb 47 to 54 N m PLUG TORQUE SAE 4 6 to 10 ft lb 8 to 13 N m SAE 5 10 to 15 ft lb 13 to 20 N m SAE 6 15 to 20 ft lb 20 to 27 N m SAE 10 35 to 40 ft lb 48 to 54 N m NOTE The po...

Page 120: ...itting 3 Hydraulic fitting 4 Cap screw 2 used 5 Flat washer 2 used 6 O ring 7 External snap ring 8 Pinion gear 9 O ring 10 O ring 11 O ring 12 O ring 13 Drive axle assembly Figure 62 FRONT RIGHT Arrow...

Page 121: ...es fittings and ports to prevent contamination IMPORTANT Support axle motor to prevent motor from falling during removal 5 Remove motor using Figure 62 as a guide Installation 1 If removed install pin...

Page 122: ...O ring 9 Hex head plug 10 90o hydraulic fitting 11 90o hydraulic fitting 12 O ring 13 O ring 14 Hydraulic fitting 15 O ring 16 O ring 17 Hydraulic tee fitting 18 O ring 19 O ring 20 LH brake assembly...

Page 123: ...oses and tubes from wheel motor Put caps or plugs on hydraulic lines fittings and ports to prevent contamination IMPORTANT Before loosening fasteners support wheel motor to prevent motor from falling...

Page 124: ...e motor has some differences from the front motors Service of the front and rear motors requires the same procedures Cleanliness is extremely important when repairing these motors Work in a clean area...

Page 125: ...g 13 and races 10 for wear 11 Check the condition of the needle bearing 17 in housing and replace if necessary Reassembly Fig 64 1 Clean all parts in suitable solvent and lubricate all in ternal parts...

Page 126: ...Groundsmaster 4100 D Hydraulic System Page 4 84 This page is intentionally blank...

Page 127: ...le pulley Install motor to cutting deck without plac ing the spider in the spindle pulley The clearance be tween hub and pulley valleys should be from 830 to 930 21 1 to 23 6 mm If required use mounti...

Page 128: ...e plugs and drain any oil out of the motor 2 Straighten tabs on tab washer to allow removal of nut from motor shaft Remove tab washer spider hub and woodruff key from motor 3 Use a marker or scribe to...

Page 129: ...N Use eye protection such as goggles when using compressed air 2 Clean all motor components with solvent Dry all parts with compressed air 3 Inspect drive gear idler gear and bearing blocks Fig 72 for...

Page 130: ...front flange Make sure that these surfaces are clean and dry 8 Install dowel pins in body IMPORTANT Do not dislodge o rings pressure seals or back up rings during final assembly 9 Gently slide the re...

Page 131: ...Groundsmaster 4100 D Hydraulic System Page 4 89 This page is intentionally blank Hydraulic System...

Page 132: ...er pin 3 used 11 RH lever assembly 12 Spacer 13 Flange head screw 2 used 14 Knob 3 used 15 Lock nut 16 90o hydraulic fitting 2 used 17 O ring 18 O ring 19 Cap screw 2 used 20 Hydraulic fitting 3 used...

Page 133: ...of this chapter 3 To prevent contamination of hydraulic system during control valve removal thoroughly clean exterior of con trol valve and fittings 4 Remove lift lower control valve using Figure 73 a...

Page 134: ...16 Washer 17 Plug 18 O ring 19 Spool spring 20 Backup washer 21 Detent spring 22 Detent plunger 23 Detent plug 3 used 24 O ring 25 O ring 26 Backup washer 27 Disc 28 Plunger 2 used 29 Plug assembly 3...

Page 135: ...serviceable as the spools and spool bores are matched Damaged spools cannot be re placed individually 5 Inspect relief valve poppet 10 for breakage or wear Assembly Fig 74 1 Thoroughly clean and dry a...

Page 136: ...adapter 4 used 14 Steering valve assembly 15 Nut insert 16 Steering tower 17 Flange locking nut 2 used 18 Flange head screw 4 used 19 Pivot hub 2 used 20 Cap screw 2 used 21 Steering column assembly...

Page 137: ...t the begin ning of the Service and Repairs section of this chapter 3 To prevent contamination of hydraulic system during steering valve removal thoroughly clean exterior of steering valve and fitting...

Page 138: ...the hydraulic lines clean the port area of the steering valve assembly Before disassem bly drain the oil then plug the ports and thoroughly clean the exterior During repairs always protect machined s...

Page 139: ...ring springs 5 Apply a light coating of clean hydraulic fluid to the spool and slide it into the sleeve Be sure the centering springs fit into the notches in the sleeve 6 Install the pin 7 Apply a lig...

Page 140: ...Cylinder 1 Lift cylinder 2 Lift arm LH shown 3 Lock nut 4 Pin 5 Flange head screw 6 Grease fitting 7 O ring 8 90o hydraulic fitting 9 O ring 10 Hydraulic fitting 11 Pivot pin 12 Cotter pin 13 Grease...

Page 141: ...Remove flange head screw and lock nut that secure the pin to the lift arm Remove pin from lift arm and cylin der shaft clevis which will free lift cylinder from lift arm 6 Remove one cotter pin from u...

Page 142: ...ont Deck Lift Cylinder Service 1 Barrel with clevis 2 Retaining ring 3 Shaft with clevis 4 Dust seal 5 Rod seal 6 O ring 7 Back up ring 8 Head 9 O ring 10 T seal 11 Piston 12 Locking nut Figure 79 11...

Page 143: ...ssed air Do not wipe parts dry with paper towels or cloth Lint in a hydraulic system will cause damage 8 Carefully inspect internal surface of barrel for dam age deep scratches out of round etc Replac...

Page 144: ...ning ring 7 Wing deck lift cylinder 8 O ring 2 used per cylinder 9 Hydraulic fitting 2 used per cylinder 10 O ring 2 used per cylinder 11 Pilot spacer 12 Cap screw 13 Wing deck RH shown 14 Flat washer...

Page 145: ...vis remove retaining ring and then press tapered stud with spherical bearing and flange nut from clevis Remove flange nut and then spheri cal bearing from stud Installation Fig 80 1 If removed install...

Page 146: ...ft 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 T seal 11 Piston 12 Locking nut 13 Steel ring Figure 81...

Page 147: ...pe parts dry with paper towels or cloth Lint in a hydraulic system will cause damage 8 Carefully inspect internal surface of barrel for dam age deep scratches out of round etc Replace en tire cylinder...

Page 148: ...nt 4 Retaining ring 5 Grease fitting 6 Grease fitting 7 90o hydraulic fitting 8 O ring 9 O ring 10 Drive axle assembly 11 Ball joint spacer 12 Axle washer 13 Hex slotted nut 14 Cotter pin Figure 83 6...

Page 149: ...hex slotted nuts axle washer and ball joint spacer from the threaded ends of ball joints Fig 83 Remove steering cylinder with ball joints from machine 6 If needed remove ball joints from steering cyli...

Page 150: ...D Hydraulic System Page 4 108 Steering Cylinder Service 1 Butt and tube assembly 2 Shaft 3 Piston rod assembly 4 Gland 5 Locking nut 6 O ring 7 PTFE seal 8 O ring 9 O ring 10 U cup 11 Wiper Figure 84...

Page 151: ...and gland into vise and remove nut Remove piston and gland from rod 6 Remove all seals and O rings 7 Wash parts in clean solvent Dry parts with com pressed air Do not wipe parts dry with paper towels...

Page 152: ...draulic fitting 9 Stand pipe 10 Hose clamp 11 Screen filter 12 Dipstick 13 O ring 14 Reservoir cap 15 Suction hose 16 Tank strainer w o ring 17 Hose clamp 18 Hose 19 Hose clamp 20 Cap screw 2 used 21...

Page 153: ...Drain reservoir into a suitable container see Opera tor s Manual 4 Disconnect hydraulic hoses from reservoir 5 Remove hydraulic reservoir using Figure 86 as a guide Inspection 1 Clean hydraulic reserv...

Page 154: ...lush oilcooler with cleaning solvent After cool er is clean make sure all solvent is drained from the cooler CAUTION Use eye protection such as goggles when using compressed air 2 Dry inside of oil co...

Page 155: ...11 Warning Lights 12 PTO Switch 13 Audio Alarm 13 Transport Alarm Silence and Temperature Override Switches 14 Seat Switch 15 Parking Brake Switch 15 Hour Meter 16 Glow Relay 16 Start Engine Shutdown...

Page 156: ...2 Electrical System Electrical Schematic Circuit Diagrams and Wire Harness Drawings The electrical schematic circuit diagrams and wire har ness drawings for the Groundsmaster 4100 D are lo cated in Ch...

Page 157: ...nce of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Figure 1 Skin...

Page 158: ...machine The ignition switch or circuit wiring is faulty The fusible link from the battery is faulty Starter solenoid clicks but starter will not crank NOTE If the solenoid clicks the problem is not in...

Page 159: ...d not when the traction pedal is engaged with no operator in the seat The seat sensor or circuit wiring is faulty Traction neutral switch or circuit wiring is faulty The engine stops during operation...

Page 160: ...hen lowered with PTO switch in the OFF disengage position The PTO switch or circuit wiring is faulty Cutting deck s do not operate The operator is lifting off the seat switch The seat switch relay or...

Page 161: ...ive condition of the bat tery Load testing of the battery will provide additional and more accurate information Voltage Measured Battery Charge Level 12 68 V or higher Fully charged 100 12 45 V 75 cha...

Page 162: ...t to center cutting deck Fig 4 4 When adjusting switch location the target surface of position switch should be approximately 0 188 4 8 mm from actuator tab on wing deck link Fig 5 5 When wing deck po...

Page 163: ...As the lift lower lever is slowly pulled back the raise switch should open no continuity after the lever has removed all free play with no spool move ment in lift lower control valve but before the de...

Page 164: ...ity with a multimeter ohms setting make sure that power to the circuit has been disconnected Ignition Switch The ignition key switch has three positions OFF ON PREHEAT and START The terminals are mark...

Page 165: ...ignition switch terminal B B Has pink wire and red wire battery Fuse A3 10 amp A Supplies power to the PTO switch B Has yellow wire and red wire battery Fuse A4 10 amp A Supplies power to the starter...

Page 166: ...proximately 230oF 110oC the high temperature light should come on as the high temperature shutdown switch stops the engine 1 Disconnect and ground the blue wire attached to temperature switch on flywh...

Page 167: ...occurs when the lever is pushed opposite the keyway SWITCH POSITION NORMAL CIRCUITS OTHER CIRCUITS PTO ENGAGE 1 2 4 5 CENTER ON 1 2 NONE PTO OFF NONE NONE 1 PTO switch 2 Control console Figure 15 1 2...

Page 168: ...With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each position Verify continuity between switch te...

Page 169: ...onto the seat switch through the seat cushion There should be continuity as the seat cushion approaches the bottom of its travel 6 Reconnect switch connector 1 Electrical connector 2 Seat switch Figu...

Page 170: ...t leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from the me...

Page 171: ...t is to be tested 2 Using a multimeter ohms setting measure coil re sistance between terminals 85 and 86 Fig 26 Resist ance should be between 70 and 90 ohms 3 Connect multimeter ohms setting leads to...

Page 172: ...leads Subtract this val ue from from the measured value of the component you are testing 1 Make sure engine is off Disconnect hydraulic valve solenoid electrical connector Fig 27 2 Apply 12VDC source...

Page 173: ...o the pin of the red wire The resistance of the hold coil should be approxi mately 10 9 ohms 4 Reconnect solenoid to the wiring harness Live Testing 1 Disconnect connector from the engine run solenoid...

Page 174: ...Remove sender and gasket from the fuel tank Clean any fuel from the sender NOTE Before taking small resistance readings with a digital multimeter short meter test leads together The meter will display...

Page 175: ...o white dots on the gauge face below the edge of the glass cover for each test point For each variable resist ance setting the needle must be pointed between the two white dots 2 Take test point readi...

Page 176: ...engine 3 Disconnect fuel hose pump discharge from the wa ter separator 4 Make sure fuel hoses attached to the fuel pump are free of obstructions 5 Place fuel hose pump discharge into a large grad uate...

Page 177: ...energized D Glow indicator light goes out and glow plugs de energize after 7 seconds 4 Place ignition switch in the START position Verify the following while in the START position A Glow indicator li...

Page 178: ...due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing 3 Check resistance of the sender with a multimeter ohms s...

Page 179: ...with extreme care to prevent personal injury or fire 3 Check continuity of the switch with a multimeter ohms setting The temperature switch is normally open and should close between 225o to 235oF 107o...

Page 180: ...ite dots on the gauge face below the edge of the glass cover for each test point For each variable resist ance setting the needle must be pointed between the two white dots 2 Take test point readings...

Page 181: ...eutral switch 1 Piston pump bottom 2 Neutral switch Figure 42 1 2 Diode Assemblies Fig 43 Diodes D2 D4 D5 and D6 are used for circuit protec tion from voltage spikes that occur when a hydraulic valve...

Page 182: ...TO relay Testing The diodes can be individually tested using a digital multimeter ohms setting and the table to the right If any of the diodes are damaged the diode circuit board must be replaced Appl...

Page 183: ...age parking brake and remove key from the ignition switch 2 Remove switch cover from deck to allow access to switch that requires testing Disconnect switch from wir ing harness NOTE Deck Proximity Swi...

Page 184: ...nergized Testing 1 Park machine on a level surface lower cutting deck stop engine engage parking brake and remove key from the ignition switch 2 Remove console cover and locate cutting deck raise or l...

Page 185: ...id coil to valve Carefully slide coil from valve stem 3 Install new solenoid to valve A Apply Loctite 242 or equivalent to threads on end of valve stem before installing nut B Torque solenoid nut to s...

Page 186: ...result if the gases are inhaled Un plug charger from electrical outlet before con necting or disconnecting charger leads to or from battery posts IMPORTANT Do not remove fill caps while clean ing 2 Ch...

Page 187: ...g the battery tape or block vent holes to the filler caps and make sure the caps are on tightly C Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missin...

Page 188: ...the voltage is less than 12 4 VDC recharge the battery B If the battery has been charged apply a 150 amp load for 15 seconds to remove the surface charge Use a battery load tester following the manuf...

Page 189: ...171 to 250 5 8 hrs 6 amps 11 5 hrs 6 amps 17 3 hrs 6 amps 23 hrs 6 amps above 250 6 hrs 10 amps 12 hrs 10 amps 18 hrs 10 amps 24 hrs 10 amps CAUTION Do not charge a frozen battery because it can ex p...

Page 190: ...Groundsmaster 4100 D Page 5 36 Electrical System This page is intentionally blank...

Page 191: ...3 SERVICE AND REPAIRS 4 Brake Assembly 4 Brake Inspection and Repair 6 Planetary Wheel Drive Assembly 8 Planetary Wheel Drive Service 10 Rear Axle Assembly 12 Bevel Gear Case and Axle Case 15 Differen...

Page 192: ...3 18 mm Tire pressure 25 to 30 psi 1 7 to 2 1 bar front and rear Planetary brake housing and front wheel motor 75 to 85 ft lb 101 to 115 N m mounting screw torque Planetary gear drive oil SAE 85W 140...

Page 193: ...roundsmaster 4100 D Page 6 3 Axles Planetaries and Brakes Adjustments See Operator s Manual for adjustment procedures for Groundsmaster 4100 D axles planetaries and brakes Axles Planetaries and Brakes...

Page 194: ...w 6 used per side 13 Tire and wheel assembly 14 Lug nut 8 used per wheel 15 Jam nut 16 Compression spring 17 Spring plate 18 Brake cable Figure 1 FRONT RIGHT 75 to 85 ft lb 101 to 115 N m 85 to 100 ft...

Page 195: ...ection and repair Install Brake Assembly Fig 1 1 Slide splined brake coupler into brake assembly Note The stepped end of the coupler must be installed toward the hydraulic wheel motor Fig 2 2 Position...

Page 196: ...sket material 10 from brake housing and planetary wheel drive mounting surfaces 2 Remove retaining ring 9 3 Remove four stationary discs 7 and three rotating discs 8 4 Remove three extension springs 1...

Page 197: ...Groundsmaster 4100 D Page 6 7 Axles Planetaries and Brakes This page is intentionally blank Axles Planetaries and Brakes...

Page 198: ...Hydraulic wheel motor 7 Flat washer 8 Cap screw 2 used per side 9 Flange head screw 4 used per side 10 Brake assembly LH 11 Gasket 12 Flange head screw 6 used per side 13 Tire and wheel assembly 14 L...

Page 199: ...el mo tor to planetary assembly 7 Support planetary assembly to prevent it from falling Loosen and remove flange head screws that secure planetary assembly to frame Remove planetary as sembly from mac...

Page 200: ...earing cone 9 Thrust washer 10 Retaining ring external 11 Ring gear 12 Retaining ring internal 13 Plug 2 used 14 End cap 15 Thrust plug 16 Thrust washer 17 Drive shaft 18 Carrier assembly 19 Socket he...

Page 201: ...ups 4 and 7 into housing 6 C Install bearing cone 3 onto spindle 1 D Install seal 24 to housing 6 Assemble housing 6 to spindle 1 E Install bearing cone 8 onto spindle and secure with thrust washer 9...

Page 202: ...e remove any attach ments that may interfere with the safe and proper raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the ma c...

Page 203: ...mm to 51 mm clearance between rear frame mount and axle mounting boss Add thrust washers if needed to adjust clearance 2 Install axle pivot pin to secure axle to rear frame mount Install washer and lo...

Page 204: ...stall wheels to axle Torque wheel lug nuts from 85 to 100 ft lb 115 to 135 N m 12 Lower machine to ground 13 Fill axle and input gearbox with SAE 85W 140 weight gear lube see Operator s Manual Lubrica...

Page 205: ...3 4 5 6 1 Cap screw 4 used 2 Lock nut 2 used 3 Lock washer 2 used 4 Axle support 5 Bevel gear case axle case assembly 6 O ring Figure 13 35 to 41 ft lb 47 to 56 N m 35 to 41 ft lb 47 to 56 N m 3 Remov...

Page 206: ...e and discard bevel gear shaft seal from axle case Fig 16 1 Knuckle pin 2 Mounting screw 4 used 3 O ring 4 Bevel gear case 5 Upper bearing 6 Bevel gear shaft 7 Collar 8 Upper bevel gear 9 Lower bevel...

Page 207: ...cover screws from 17 to 20 ft lb 23 to 27 N m 3 Slide the bevel gear case over the bevel gear shaft and install the bevel gear and collar Make sure the bevel gear shaft is completely seated in the upp...

Page 208: ...en determined remove mounting screws apply heavy strength thread locking compound to screw threads reinstall screws and torque from 57 to 67 ft lb 77 to 91 N m IMPORTANT Correct engagement between bev...

Page 209: ...WER BEVEL GEAR BACKLASH 0 004 to 0 016 in 0 10 to 0 40 mm 10 Adjust backlash by increasing or reducing axle bear ing shim thickness see Axle Shafts in this section of this manual NOTE Axle bearing shi...

Page 210: ...amage and wear Replace components as necessary Installation 1 Press bearings onto differential shaft Place correct combination of bearing shims in axle support and drive differential shaft and bearing...

Page 211: ...nents as necessary Installation 1 Coat new axle shaft seal with grease and install in axle cover as shown Fig 27 2 Press the axle cover and bearing assembly onto the axle shaft Press only on the inner...

Page 212: ...er and remove the locknut Remove and discard the stake washer 5 Drive the input shaft pinion gear out from the outer bearing cone and bearing case Remove and discard the oil seal and O ring 6 Inspect...

Page 213: ...ily install gear case assembly into axle case Tighten mounting nuts and screws from 35 to 41 ft lb 47 to 56 N m 10 Insert a screwdriver through the drain plug hole to hold ring gear and measure the pi...

Page 214: ...the spring pin from the differential case with a punch and hammer Discard the spring pin Fig 33 NOTE Mark and arrange all components so they can be reassembled in their original position 7 Remove the...

Page 215: ...00 to 34 06 mm 2 Measure the differential pinion shaft O D and the pinion gear I D to determine the pinion shaft to pinion gear clearance Fig 36 Replace components as nec essary PINION SHAFT TO PINIO...

Page 216: ...gear rotate either pinion gear until the side gears have made one complete revolution 9 Ideal tooth contact should cover more than 35 of each tooth surface The contact area should be in the center of...

Page 217: ...0 Adjustments to the gear contact position are made by moving the input shaft pinion gear bearing case shims or by moving the differential gear case differential bear ing shims Fig 41 NOTE Bearing cas...

Page 218: ...oward ring gear B Install thinner or remove differential bearing shim s to move ring gear backward C Repeat until proper tooth contact and pinion gear to ring gear backlash are correct 2 If contact is...

Page 219: ...Groundsmaster 4100 D Page 7 1 Chassis Chapter 7 Chassis Table of Contents SERVICE AND REPAIRS 2 Steering Tower 2 Front Deck Lift Arms 4 Hood 6 Chassis...

Page 220: ...rt 22 Flange head screw 23 Flange bushing 24 Thrust washer 25 Temperature gauge 26 Warning lamp temp glow plug 27 Warning lamp charge oil pressure 28 Steering column 29 Cap screw 2 used 30 Pivot hub 2...

Page 221: ...top engine engage parking brake and remove key from the ignition switch 2 Disassemble steering tower as needed using Figure 1 as a guide Assembly 1 Assemble steering tower using Figure 1 as a guide No...

Page 222: ...n 28 Hair pin 29 Flat washer 30 Flange nut 31 Height of cut chain 32 U bolt 33 Nut 34 Lock nut 35 Flange bushing 2 per lift arm 36 Lift arm LH 37 Lock nut 38 Lift arm RH Figure 2 FRONT RIGHT 155 to 18...

Page 223: ...portion of u bolt extends 750 19 1 mm above mounting plate on lift arm Fig 3 B If rod ends were removed from damper apply Loctite 242 to threads and install on damper Install damper assembly to lift...

Page 224: ...ed 15 Washer head screw 2 used 16 Hood latch bracket 17 Latch 18 Latch cover 19 Oil filter deflector 20 Handle 2 used 21 Hood pivot 2 used 22 Self tapping screw 23 Pivot bracket 2 used 24 Hair pin 25...

Page 225: ...cooler Figs 6 and 7 B Close hood so that it rests on shims and fasten the hood latches C Loosen hood pivots at frame to adjust vertical placement of pivots Re tighten hood pivot fasten ers D Loosen pi...

Page 226: ...Groundsmaster 4100 D Page 7 8 Chassis This page is intentionally blank...

Page 227: ...Factors That Can Affect Quality of Cut 3 ADJUSTMENTS 4 Castor Wheel Tire Pressure 4 Blade Stopping Time 4 SERVICE AND REPAIRS 6 Cutting Deck 6 Wing Deck Service 10 Cutting Deck Link Service 12 Wing De...

Page 228: ...sed loop hydraulic system operates hydraulic motor on each cutting deck section Motor drives one spindle directly with remaining deck section spindle s driven by B section kevlar v belt s Blade spindl...

Page 229: ...he same speed See items in Troubleshooting Section of Chapter 4 Hydraulic System 3 Tire pressure Check air pressure of each tire including castor tires Adjust to pressures specified in Operator s Manu...

Page 230: ...tting deck should come to a com plete stop in approximately 5 seconds after the cutting deck engagement switch is shut down NOTE Make sure the decks are lowered onto a clean section of turf or hard su...

Page 231: ...Groundsmaster 4100 D Cutting Deck Page 8 5 This page is intentionally blank Cutting Deck...

Page 232: ...remove ignition key first Cutting Deck 1 Cutting deck 2 Cap screw 3 Lift arm LH shown 4 Flange nut 5 Spacer 6 Damper 7 Damper rod end 2 per damper 8 Hair pin 9 Clevis pin 10 Cap screw 11 Lock nut 12 F...

Page 233: ...cure the lift cylinder clevis to the wing deck C Remove flange nut and flat washer from the ta pered stud on the barrel end of the lift cylinder D Remove lift cylinder from the deck Locate and re trie...

Page 234: ...t lb 217 to 244 N m D Make sure that spacers are positioned on each side of the lift cylinder clevis Install cap screw from the front side of the deck and secure each lift cylinder clevis to the wing...

Page 235: ...Groundsmaster 4100 D Cutting Deck Page 8 9 This page is intentionally blank Cutting Deck...

Page 236: ...center deck 35 Cap screw 36 Washer 37 Retaining ring 38 Latch pin 39 Carriage bolt 40 Switch shield RH shown 41 Washer head screw 42 Hardened spacer 120 thick Figure 6 FRONT RIGHT 1 2 7 10 11 14 15 9...

Page 237: ...e hard ened spacer item 42 on each side of front link Align up per end of links with mounting holes in center deck Install pivot pins 5 Secure pivot pins to center deck with carriage screw and flange...

Page 238: ...flange nut into link Secure spherical bearing into link with re taining ring 3 Press flange bushings into bore of link 4 If cap screw and jam nut were removed from rear link install cap screw to allo...

Page 239: ...e spring onto spring support and insert end of spring support into hole located on underside of center deck Start lug nut tapered side towards plate on deck onto spring support 3 Tighten lug nut until...

Page 240: ...ng deck see Cutting Deck Motor Re moval in the Service and Repairs Section of Chapter 4 Hydraulic Systems Position motor away from spindle 3 Remove belt covers from top of cutting deck see Op erator s...

Page 241: ...any deck component s 4 Install drive belt and adjust belt tension see Opera tor s Manual 5 If drive spindle was removed install hydraulic motor to cutting deck see Cutting Deck Motor Installation in t...

Page 242: ...n the spindle shaft as the shaft is being removed 3 Remove oil seals from spindle housing 4 Allow the bearing cones inner bearing spacer and spacer ring to drop out of the spindle housing 5 Using a pu...

Page 243: ...rease 8 Install spindle shaft spacer onto shaft Carefully slide spindle shaft with spacer up through spindle housing The bottom oil seal and spindle spacer fit together when the spindle is installed f...

Page 244: ...Flat washer 26 Tension rod 27 Bearing 28 Inner bearing spacer 29 Wheel hub 30 Wheel rim half 31 Castor tire 32 Wheel rim half 33 Plate 34 Flange nut 4 used per wheel Figure 19 34 32 33 30 27 28 29 31...

Page 245: ...igure 20 as a guide Installation 1 Install skids to deck using Figure 20 as a guide Make sure to install skids in the same mounting hole height position lower or upper 2 When installing roller item 6...

Page 246: ...Groundsmaster 4100 D Cutting Deck Page 8 20 This page is intentionally blank...

Page 247: ...T DIAGRAMS 4 Glow Plug Circuit 4 Crank Circuit 5 Run Transport Circuit 6 Run Mow Circuit 7 WIRE HARNESS DRAWINGS 8 Main Wire Harness 8 Main Wire Harness 9 Engine Wire Harness 10 Engine Wire Harness 11...

Page 248: ...Groundsmaster 4100 D Electrical Diagrams Page 9 2 This page is intentionally blank...

Page 249: ...Page 9 3 Electrical Schematic Groundsmaster 4100 D All relays and solenoids are shown as de energized All ground wires are black...

Page 250: ...Page 9 4 Glow Plug Circuit Power Current Control Current Indication Current Logic Direction Groundsmaster 4100 D...

Page 251: ...Page 9 5 Crank Circuit Power Current Control Current Indication Current Logic Direction Groundsmaster 4100 D...

Page 252: ...Page 9 6 Run Transport Circuit Power Current Control Current Indication Current Logic Direction Groundsmaster 4100 D...

Page 253: ...Mow Circuit Power Current Control Current Indication Current Logic Direction Groundsmaster 4100 D NOTE The drawing on this page shows the center deck and the left wing deck lowered and the right wing...

Page 254: ...K VIOLET WHITE PINK GREEN WHITE BLUE ORANGE GREEN GREEN GRAY BLUE GREEN BROWN WHITE TAN BLUE YELLOW BLACK VIOLET RED BLACK BLACK ORANGE YELLOW BLACK BLUE ORANGE BLACK TAN BLACK TAN GRAY WHITE GRAY GRA...

Page 255: ...Page 9 9 Groundsmaster 4100 D Main Wire Harness...

Page 256: ...BLE LINK 16 GA FUSIBLE LINK 14 GA FUSIBLE LINK 16 GA BLACK WHITE YELLOW BROWN RED RED ORANGE VIOLET BLACK BLACK BLACK ORANGE BLACK VIOLET BLACK BLACK BLACK BLACK YELLOW BLACK YELLOW BLACK YELLOW BLACK...

Page 257: ...Page 9 11 Groundsmaster 4100 D Engine Wire Harness D4 D2 D6...

Page 258: ...ORANGE P2 P1 P13 P15 P12 P11 P10 P9 J2 P8 P7 P6 P5 P4 J1 P3 P14 PINK PINK GRAY BLACK TAN GRAY VIOLET BLACK ORANGE BLUE TAN BLACK ORANGE GREEN BLACK BLACK YELLOW BLACK ORANGE GREEN BLACK BLACK PINK BR...

Page 259: ...Page 9 13 Groundsmaster 4100 D Front Wire Harness D7 D8 D5...

Page 260: ...0 D Cutting Deck Wire Harnesses VIOLET YELLOW BLACK BLUE ORANGE YELLOW BLACK BLACK VIOLET BLACK GRAY GRAY GRAY BLUE VIOLET BLUE VIOLET BLACK ORANGE BLACK ORANGE P15 P2 P1 P1 P35 P2 P4 P3 DECK LIFT SEN...

Page 261: ...Page 9 15 Groundsmaster 4100 D Cutting Deck Wire Harnesses...

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