Instruction/ maintenance manual of the product 4100-D Toro
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(Model 30413) Part No. 08162S L (Rev . A) Service Manual Groundsmaster R 4100 - - D Preface The pur pose of this public ation is to pr ovide t he service technic ian with inf orm ation f or t roubles hooting, test ing and repair of maj or syst ems and co mponents on the Gr oundsmas ter 4100 - - D (Model 30413) .
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Gr oundsmas ter 4100 - - D T able Of Contents Chapter 1 - - Safety Gener al Safet y I nst ruc tions 1 - - 2 .................. Jackin g Instructions 1 - - 4 ......................... Safet y and I nst ruc tion Dec als 1 - - 5 ................ Cha pter 2 - - Produc t Rec ords and Ma intena nce Produc t Records 2 - - 1 .
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Groundsmaster 4100 - -D Page 1 - - 1 Safety Chapter 1 Safety T able of Contents GENERAL SAFETY INSTRUCTIONS 2 ............ Before Operating 2 ............................ While Operating 2 ............................. Maintenance and Service 3 ......
Groundsmaster 4100 - -D Page 1 - - 2 Safety General Safety Instructions The GROUNDSMASTER 4100-D was tested and certi- fied by TORO for compliance with existing safety stan- dards and specifications.
Groundsmaster 4100 - -D Page 1 - - 3 Safety Maintenance and Service 1. Before servicing or making adjustments, lower deck, stop engine, apply parking brake and remove key from the switch. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight.
Groundsmaster 4100 - -D Page 1 - - 4 Safety Jacking Instructions CAUTION When changing attachments, tires or perform- ing other service, use correct jacks and sup - ports. Make sure machine is parked on a solid, level surface such as a concrete floor .
Groundsmaster 4100 - -D Page 1 - - 5 Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 4100 - - D. If any decal becomes illeg- ible or damaged, install a new decal. D ecal part num- bers are listed in your Parts Catalog.
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Rev . A Groundsmaster 4100- - D Page 2 - - 1 Product Records and Ma intenance Chapter 2 Product Records and Maintenance T able of Contents PRODUCT RECORDS 1 ......................... MAINTENANCE 1 .............................. EQUIV ALENTS AND CONVERSIONS 2 .
0.09375 Groundsmaster 4100 - - D Page 2 - - 2 Product Records and Maintenance Equivalents and Conversions.
Rev . A Groundsmaster 4100- - D Page 2 - - 3 Product Records and Ma intenance T orque Specifications Recommended fastener torque values are listed in the following tables.
Groundsmaster 4100 - - D Page 2 - - 4 Product Records and Maintenance Standard T orque for Dry , Zinc Plated and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 & 8w i t hT h i n Height Nuts .
Groundsmaster 4100 - - D Page 2 - - 5 Product Records and Maintenance Standard T orque for Dry , Zinc Plated and Steel Fasteners (Metric Series) T h r e a d S i z e Class 8.
Groundsmaster 4100 - - D Page 2 - - 6 Product Records and Maintenance Other T orque Specifications SAE Grade 8 Steel Set Screws T h r e a d S i z e Recommended T orque Thread Size Square Head Hex Sock.
Groundsmaster 4100 - - D Page 3 - - 1 Kubota Diesel Engine Chapter 3 Kubota Diesel Engine T able of Contents GENERAL INFORMA TION 2 ..................... Operator ’s Manual 2 .......................... Stopping the Engine 2 .........................
Groundsmaster 4100 - - D Page 3 - - 2 Kubota Diesel Engine General Information This Chapter gives information about specifications and repair of the diesel engine used in the Groundsmaster 4100 - - D. General maintenance procedures are described in your Operator ’s Manual.
Groundsmaster 4100 - - D Page 3 - - 3 Kubota Diesel Engine Specifications Item Description Make / Designation Kubota Model V2403 - - M - - T - - E3B: 4 - - Cycle, 4 Cylinder , W ater Cooled, Turbocharged, Diesel Engine Bore 3.43” (87.0 mm) Stroke 4.
Groundsmaster 4100 - - D Page 3 - - 4 Kubota Diesel Engine Service and Repairs Air Filter System Figure 1 1. Air cleaner hose 2. Hose clamp 3. Air cleaner assembly 4. Indicator 5. Air cleaner strap 6. Lock nut (2 used) 7. Hose clamp 8. Air cleaner hose 9.
Groundsmaster 4100 - - D Page 3 - - 5 Kubota Diesel Engine Removal (Fig. 1) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. Raise and support hood. 3. Remove air cleaner components as needed using Figure 1 as a guide.
Groundsmaster 4100 - - D Page 3 - - 6 Kubota Diesel Engine Exhaust System Figure 5 1. Muffler 2. Muffler bracket 3. Exhaust pipe 4. Flange head screw (4 used) 5. Exhaust gasket 6. Lock nut (2 used) 7. Cap screw (2 used) 8. Flat washer (4 used) 9. Spacer (2 used) 10.
Rev . A Groundsmaster 4100- - D Page 3 - - 7 Kubota Diesel Engine Removal (Fig. 5) CAUTION The muffler and exhaust pipe may be hot. T o avoid possible burns, allow the e ngine and ex - haust system to cool befor e working on the muf- fler .
Groundsmaster 4100 - - D Page 3 - - 8 Kubota Diesel Engine Fuel System Figure 7 1. Fuel tank 2. Fuel tank bracket 3. Air breather 4. Female hose barb 5. T ank support assembly 6. Fuel hose 7. Flange nut 8. Cap screw (4 used) 9. Flat washer 10. Cap screw (4 used) 1 1.
Groundsmaster 4100 - - D Page 3 - - 9 Kubota Diesel Engine DANGER Because diesel fuel is highly f lammable, use cau- tion when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot or when machine is in an enclosed area.
Groundsmaster 4100 - - D Page 3 - - 10 Kubota Diesel Engine Radiator Figure 8 1. Radiator cap 2. Foam strip (2 used) 3. Foam strip (2 used) 4. Lower radiator hose 5. Upper radiator hose 6. Clamp (4 used) 7. Lower radiator shroud 8. T emperature sender 9.
Groundsmaster 4100 - - D Page 3 - - 1 1 Kubota Diesel Engine Removal (Fig. 8) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. Open and support hood. CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot.
Groundsmaster 4100 - - D Page 3 - - 12 Kubota Diesel Engine Engine Figure 9 1. Engine 2. Cap screw (4 used) 3. LH engine mount 4. Lock washer 5. Cap screw 6. Lock washer (5 used) 7. Cap screw (5 used) 8. Engine support (4 used) 9. Flange nut (12 used) 10.
Groundsmaster 4100 - - D Page 3 - - 13 Kubota Diesel Engine Engine Removal (Fig. 9) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove battery cover and strap. Disconnect nega- tive battery cable first and then positive battery cable.
Groundsmaster 4100 - - D Page 3 - - 14 Kubota Diesel Engine 9. Disconnect throttle cable from the speed control le- ver by removing the flat washer and lock nut (Fig. 14). Loosen jam nut and separate cable from cable support. Position cable away from engine.
Groundsmaster 4100 - - D Page 3 - - 15 Kubota Diesel Engine 3. Slowly lower engine into the machine. 4. Align engine to the engine supports and hydraulic pump input shaft. Secure engine to engine supports with cap screws, rebound washers and flange nuts.
Groundsmaster 4100 - - D Page 3 - - 16 Kubota Diesel Engine Spring Coupler Figure 16 1. Spring coupler 2. W asher (14 used) 3. Cap screw (6 used) 4. Flywheel plate 5.
Groundsmaster 4100 - - D Page 3 - - 17 Kubota Diesel Engine Coupler Removal (Fig. 16) NOTE: The hydraulic pump assembly needs to be re- moved from engine before coupler can be removed.
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Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 Chapter 4 Hydraulic System T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ..................... Operator ’s Manual 3 .......................... T owing Traction Unit 3 .
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 2 Specifications Item Description Piston (T raction) Pump Eaton V ariable Displacement Piston Pump (Model 72400) System Relief Pressure: Forward 40.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 3 General Information Operator ’s Manual The Operator ’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 4 Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather , sun, chemicals, very warm storage condi- tions or mishandling during operation and maintenance.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 5 Hydraulic Hose and T ube Installation (O - - Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 6 Hydraulic Fitting Installation (SAE Straight Thread O - - Ring Fitting into Component Port) Non - - Adjustable Fitting (Fig. 6) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 7 Adjustable Fitting (Fig. 8) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 8 Hydraulic Schematic NOTE: A larger hydraulic schematic is 4WD MANIFOLD COUNTERBALANCE MANIFOLD FIL TER MANIFOLD F AN DRIVE MANIFOLD RH WING DECK .
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Groundsmaster 4100 - - D Hydraulic System Page 4 - - 10 Hydraulic Flow Diagrams T raction Circuit (4WD Forward Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100 -.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 1 T raction Circuit: 4WD (Mow) The traction circuit piston pump is a variable displace- ment pump that is directly coupled to the engine fly- wheel.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 12 T raction Circuit (T ransport Forward Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100 - - D FAN DRIVE MA.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 13 T raction Circuit: T ransport (2WD) The traction circuit piston pump is a variable displace- ment pump that is directly coupled to the engine fly- wheel.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 14 Lower Cutting Deck (LH Deck Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100 - - D FAN DRIVE MANIFOLD 4WD.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 15 Lower Cutting Deck A four section gear pump is coupled to the piston (trac- tion) pump. The third gear pump section supplies hy- draulic flow to both the lift/lower c ontrol valve and the steering control valve.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 16 Raise Cutting Deck (LH Deck Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100 - - D FAN DRIVE MANIFOLD 4WD.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 17 Raise Cutting Deck A four section gear pump is coupled to the piston (trac- tion) pump. The third gear pump section supplies hy- draulic flow to the lift/lower control valve and the steering control valve.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 18 Mow Circuit (All Deck Motors Rotating) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100 - - D FAN DRIVE MANIFOLD.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 19 Mow Circuit Hydraulic flow for the mow circuit is supplied by two sec- tions of the gear pump. The gear pump section closest to the piston (traction) pump supplies hydraulic flow to the wing decks, while the next gear pump section sup- plies the center deck.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 20 Mow Circuit Cutting Deck Blade Braking When the operator turns the PTO switch OFF or if a deck is raised with the PTO switch ON, deck control manifold solenoid valve (S) is de - - energized causing logic car- tridge (LC1) to shift (refer to information in PT O Mow Cir- cuit in this section).
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Groundsmaster 4100 - - D Hydraulic System Page 4 - - 22 Steering Circuit (Left T urn Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100 - - D FAN DRIVE MANIFOLD RH.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 23 Steering Circuit A four section gear pump is coupled to the piston (trac- tion) pump. The third gear pump section supplies hy- draulic flow to the steering control valve and the lift/lower control valve.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 24 Engine Cooling Fan Circuit (Forward Direction Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4100 - - D FAN .
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 25 Engine Cooling Fan Circuit A four section gear pump is coupled to the piston (trac- tion) pump. The gear pump section farthest from the pis- ton pump supplies hydraulic flow for the fan drive manifold and hydraulic engine cooling fan motor (Fig.
Rev . A Groundsmaster 4100- - D Hydraulic Sys tem Page 4 - - 26 Special T ools Order these spe cial tools from y our T oro Distributor . Hydraulic Pressure T est Kit Use to take various pressure read ings for diagnostic tests. Quick disconnect fitti ngs provided attach directly to mating fittings on machi ne test ports without tools.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 27 Hydraulic T est Fitting Kit This kit includes a variety of O - - ring Face Seal fittings to enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 28 T roubleshooting The charts that follow contain suggestions to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the T esting section of this Chapter for precau- tions and specific test procedures.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 29 Problem Possible Causes T raction power is lost or unit w ill not operate in either direction. Hydraulic reservoir oil level is low . Piston pump by - - pass valve is open or damaged. Charge pressure is low .
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 30 Problem Possible Causes Cutting deck (or wing decks) will not raise. Engine RPM is too low . Hydraulic oil level in reservoir is low . Lift arm pivots are binding. Relief valve in lift/lower control valve is stuck.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 31 T esting The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (See the Special T ools section in this Chapter).
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 32 T raction Circuit Charge Pressure (Using Pressure Gauge) 4WD MANIFOLD FIL TER MANIFOLD TO COOLING F AN CIRCUIT TO STEERING & LIFT CIRCUITS F.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 33 Procedure for T raction Circuit Charge Pressure T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 34 T raction Circuit Relief Pressure (Using Pressure Gauge) 4WD MANIFOLD FIL TER MANIFOLD TO COOLING F AN CIRCUIT TO STEERING & LIFT CIRCUITS F.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 35 Procedure for T raction Circuit Relief Pressure T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 36 Counterbalance Pressure (Using Pressure Gauge) F AN DRIVE MANIFOLD 4WD MANIFOLD FIL TER MANIFOLD TO MOW CIRCUIT TO MOW CIRCUIT FROM FRONT DECK M.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 37 Procedure for Counterbalance Pressure T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 38 Rear T raction Circuit (RV) Relief Pressure (Using Pressure Gauge) 4WD MANIFOLD FIL TER MANIFOLD TO COOLING F AN CIRCUIT TO STEERING & LIFT .
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 39 Procedure f or Rear T raction C ircuit (RV) Relief Pres - sure T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 40 T raction Circuit Reducing V alve (PR) Pressure (Using Pressure Gauge) 4WD MANIFOLD FIL TER MANIFOLD TO COOLING F AN CIRCUIT TO STEERING & L.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 41 Procedure for T raction Circuit Reducing V alve (PR) Pressure T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 42 Cutting Deck Circuit Pressure (Using Pressure Gauge) NOTE: CENTER DECK PRESSURE TEST SHOWN MANIFOLD MANIFOLD MANIFOLD FIL TER MANIFOLD TO COOLIN.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 43 Procedure for Cutting Deck Circuit Pressure T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 44 PT O Relief Pressure (Using T ester with Pressure Gauges and Flow Meter) RH WING DECK MANIFOLD LH WING DECK MANIFOLD CENTER DECK MANIFOLD FIL TE.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 45 Procedure for Cutting Deck Manifold Relief Pressure T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 46 Cutting Deck Gear Pump Flow (Using T ester with Pressure Gauges and Flow Meter) N O T E :C E N T E RG E A RP U M P SECTION FLOW TEST SHOWN MANIF.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 47 Procedure for Cutting Deck Gear Pump Flow T est NOTE: Over a period of time, the gears and wear plates in the gear pump can wear . A worn pump will by - - pass oil and make the pump less ef ficient.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 48 Cutting Deck Motor Case Drain Leakage (Using T ester with Pressure Gauges and Flow Meter) MANIFOLD MANIFOLD MANIFOLD FIL TER MANIFOLD TO COOLING.
Rev . A Groundsmaster 4100- - D Hydraulic System Page 4 - - 4 9 Procedure for Cutting Deck Motor Case Drain Leakage T est NOTE: Over a period of time, a deck motor can wear in- ternally . A worn motor may by - - pass oil to its case drai n causing the motor to be less efficien t.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 50 Steering Circuit Relief Pressure (Using Pressure Gauge) F AN DRIVE MANIFOLD 4WD MANIFOLD FIL TER MANIFOLD TO MOW CIRCUIT FROM FRONT DECK MANIFOL.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 51 Procedure for Steering Circuit Relief Pressure T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 52 Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) F AN DRIVE MANIFOLD 4WD MANIFOLD FIL TER MANIFOLD TO MOW CIRCUIT FROM DECK MANIFOLDS T.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 53 Procedure for Lift/Lower Circuit Relief Pressure T est NOTE: Before attempting to check or adjust lift pres- sure, make sure that counterbalance pressure is cor- rectly adjusted.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 54 Steering and Lift/Lower Gear Pump Flow (Usi ng T ester with Pressure Gauges and Flow Meter) F AN DRIVE MANIFOLD 4WD MANIFOLD FIL TER MANIFOLD TO.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 55 Procedure for Steering and Lift/Lower Gear Pump Flow T est Output from the steering and lift/lower gear pump sec- tion is equally divided by a proportional valve to provide flow to the steering circuit and the lift circuit.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 56 Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac) F AN DRIVE MANIFOLD 4WD MANIFOLD FIL TER MANIFOLD FROM DECK MANIFOLDS TO MOW MANI.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 57 Procedure for Engine Cooling Fan Circuit T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 58 Engine Cooling Fan Circuit Gear Pump Flow (Using T ester with Pressure Gauges and Flow Meter) F AN DRIVE MANIFOLD 4WD MANIFOLD FIL TER MANIFOLD .
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 59 Procedure for Engine Cooling Fan Circuit Gear Pump Flow T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 60 Adjustments Adjust Cutting Deck Flow Control V alve The cutting deck lift circuit is equipped with an adjust- able flow control valve used to adjust the rate at which the cutting deck lowers. The control valve is located un- der the front platform.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 61 Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 62 Flush Hydraulic System IMPORT ANT : Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky , black or contains metal particles). 1.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 63 Charge Hydraulic System NOTE: When initially starting the hydraulic system with new or rebuilt components such as motors, pumps or lift cylinders, it is important that the hydraulic system be charged properly .
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 64 Hydraulic Reservoir 1. Hydraulic reservoir 2. Petcock 3. O - - ring 4. Strap 5. Felt strap (2 used) 6. Bushing (2 used) 7. Bushing 8. Strap 9. Stand pipe (2 used) 10. Hose clamp (2 used) 1 1. Screen filter 12.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 65 NOTE: The front frame needs to be lowered from the main frame to allow clearance to remove the hydraulic reservoir from the machine. Removal (Fig. 47) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 66 Hydraulic Oil Cooler 1. Radiator 2. RH radiator support 3. T op radiator support 4. Knob (2 used) 5. Oil cooler bracket 6. Retaining ring (2 used) 7. Carriage screw (2 used) 8. O - - ring 9. 90 o hydraulic fitting (2 used) 10.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 67 Removal (Fig. 48) CAUTION The radiator and oil cooler may be hot. T o avoid possible burns, allow the engine and cooling systems t o cool before working on the oil cooler .
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 68 Gear Pump 1. Hydraulic tee fitting 2. Roll pin 3. 90 o hydraulic fitting 4. Piston pump 5. Flat washer (2 used) 6. Cap screw (2 used) 7. Hydraulic fitting (2 used) 8. 90 o hydraulic fitting 9. Hydraulic fitting 10.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 69 Removal (Fig 49) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Raise seat and secure it with prop rod to gain access to gear pump.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 70 Gear Pump Service 1. Dust seal 2. Retaining ring 3. Flange washer 4. Shaft seal 5. Front cover 6. Dowel pin (16 used) 7. Pressure seal 8. Back - - up gasket 9. Thrust plate (8 used) 10. Seal (8 used) 1 1.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 71 IMPORT ANT : Use caution when clamping gear pump in a vise to avoid distorting any pump c ompo- nents. 3. Secure the front cover of the pump in a vise with the drive shaft pointing down. 4. Loosen the four (4) cap screws that secure pump as- sembly .
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 72 T raction Circuit 1. Piston (traction) pump 2. Gear pump 3. LH front wheel motor 4. Check valve 5.
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Groundsmaster 4100 - - D Hydraulic System Page 4 - - 74 Piston (T raction) Pump 1. Hydraulic T fitting 2. Roll pin 3. 90 o hydraulic fitting 4. Piston pump 5. Flat washer (2 used) 6. Cap screw (2 used) 7. Hydraulic fitting (2 used) 8. 90 o hydraulic fitting 9.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 75 Removal (Fig. 53) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. T o prevent contamination of hydraulic system during removal, thoroughly clean exterior of pump assembly .
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 76 Piston (T raction) Pump Service 1. Jam nut 2. Retaining ring 3. Retaining ring 4. Seal washer 5. Socket head screw 6. Rotating kit assembly 7. Servo piston assembly 8. Piston follower 9. Cover plate 10.
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Groundsmaster 4100 - - D Hydraulic System Page 4 - - 78 Rear Axle Motor 1. Axle motor 2. 90 o hydraulic fitting (2 used) 3. Hydraulic fitting 4. Cap screw (2 used) 5. Flat washer (2 used) 6. O - - ring 7. External snap ring (2 used) 8. Pinion gear 9. External snap ring (2 used) 10.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 79 Removal (Fig. 56) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 80 Front Wheel Motors 1. Front wheel motor 2. Internal retaining ring 3. Splined brake shaft 4. RH brake assembly 5. Planetary assembly 6. Cap screw (2 used per motor) 7. Flat washer (2 used per motor) 8.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 81 Removal (Fig. 57) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 82 Rear Axle and Front Wheel Motor Service 1. Drive shaft 2. Backplate (front motor shown) 3. Housing assembly 4. Rotating assembly 5. Cam plate insert 6. Retaining ring 7. Cap screw (6 used) 8. Shaft seal 9.
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Groundsmaster 4100 - - D Hydraulic System Page 4 - - 84 4WD Manifold 1. Frame assembly 2. 4 wheel drive manifold 3. 90 o hydraulic fitting 4. O - - ring 5. O - - ring 6. Quick fitting 7. O - - ring 8. Fitting cap 9. Hydraulic fitting 10. O - - ring 11 .
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 85 Removal (Fig. 59) NOTE: The ports on the manifold are marked for easy identification of components.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 86 4WD Manifold Service 1. Manifold body 2. Solenoid valve (port SV) 3. Solenoid coil 4. Check valve (port CV) 5. Nut 6. Directional valve (ports PD1 & PD2) 7. Pressure reducing valve (port PR) 8.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 87 4WD Manifold Service (Fig. 60) 1. Make sure the manifold is clean before removing the valve. 2. If cartridge is solenoid operated, remove nut secur- ing solenoid to the cartridge valve. Carefully slide sole- noid off the valve.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 88 Filter Manifold 1. Filter manifold 2. 45 o hydraulic fitting 3. T est nipple 4. Dust cap 5. O - - ring 6. O - - ring 7. O - - ring 8. Cap screw (3 used) 9. Flat washer (3 used) 10. Hydraulic fitting 11 .
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 89 Removal (Fig. 61) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter .
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 90 Filter Manifold Service 1. Filter manifold 2. Check valve (reservoir return) 3. Oil filter element 4.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 91 Filter Manifold Service (Fig. 62) For cartridge valve service procedures, see 4WD Man- ifold Service in this section. Refer to Figure 62 for filter manifold cartridge valve and plug installation torque.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 92 Steering and Cooling Fan Circuits 1. Gear pump 2. Steering control valve 3. Fan drive manifold 4. Fan motor 5. Steering cylinder Figure 63 FRONT RIGHT 2 1 5 4 3 Figure 63 illustrates the components that are used in the Groundsmaster 4100 - - D steering and cooling fan circuit.
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Groundsmaster 4100 - - D Hydraulic System Page 4 - - 94 Steering V alve 1. Hex nut 2. Flat washer 3. Steering wheel 4. Foam collar 5. Steering seal 6. External snap ring 7. Steering shaft assembly 8. Steering tower cover 9. O - - ring 10. 90 o hydraulic fitting 11 .
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 95 Removal (Fig. 64) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of this section.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 96 Steering V alve Service 1. Steering valve housing 2. Dust seal 3. O - - ring 4. Spool 5. Spring retaining ring 6. Pin 7. Sleeve 8. Centering springs/spacers 9. Cap screw (7 used) 10. End cap 11 .
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 97 CAUTION The centering springs are under tension. Re- move the retaining ring carefully . 10. Remove the spring retaining ring and centering springs from the spool. Reassembly (Fig. 65) Check all mating surfaces.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 98 Steering Cylinder 1. Steering cylinder 2. Ball joint 3. Ball joint 4. Retaining ring 5. Grease fitting 6. Grease fitting 7. 90 o hydraulic fitting 8. O - - ring 9. O - - ring 10. Drive axle assembly 1 1.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 99 Removal (Fig. 67) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of this section.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 100 Steering Cylinder Service 1. T ube assembly 2. Rod 3. Piston assembly 4. Head 5. Retaining ring 6.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 101 Disassembly (Fig. 68) 1. Pump oil out of cylinder into a drain pan by SLOWL Y moving rod and piston in and out of cylinder bore. Plug ports and clean outside of cylinder . IMPORT ANT : T o prevent damage when clamping cylinder in a vise, clamp only on pivotal ends.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 102 Engine Cooling Fan Motor 1. Hydraulic fan motor 2. O - - ring 3. Bracket 4. 45 o hydraulic fitting 5. O - - ring 6. Hydraulic hose 7. Fan hub 8. W asher 9. Hex nut 10. Engine 1 1. Cap screw (4 used) 12.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 103 Removal (Fig. 69) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 104 Engine Cooling Fan Motor Service 1. Flange washer 2. O - - ring 3. Front flange 4. Dust seal 5. Retaining ring 6. Front wear plate 7. Shaft seal 8. Backup gasket 9. Pressure seal 10. Rear wear plate 1 1.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 105 8. Remove and discard back - - up gaskets and pressure seals from wear plates. 9. Turn front flange over , with seal side up. IMPORT ANT : Make sure not to damage the front flange counter bore when removing the seals from the front flange.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 106 4. Install the pressure seals, flat side outward, into the grooves in the wear plates. Follow by carefully placing the backup gaskets, flat side outward, between the pressure seals and the grooves in the wear plate.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 107 This page is intentionally blank. Hydraulic System.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 108 Fan Drive Manifold 1. Fan drive manifold 2. O - - ring 3. T est fitting 4. Dust cap (2 used) 5. O - - ring 6. 45 o hydraulic fitting (2 used) 7. O - - ring 8. Hydraulic hose 9. Hydraulic hose 10.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 109 Removal (Fig. 75) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter .
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 10 Fan Drive Manifold Service 1. Fan drive manifold 2. #4 zero leak plug (3 used) 3. Check valve 4. #6 zero leak plug (2 used) 5. Flow divider valve 6. Nut 7. Solenoid coil (2 used) 8. Proportional relief valve 9.
Groundsmaster 4100 - - D Hydraulic System P a g e 4 - - 111 Fan Drive Manifold Service (Fig. 76) For cartridge valve service procedures, see 4WD Man- ifold Service in this section. Refer to Figure 76 for fan drive manifold cartridge valve and plug installation torque.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 12 Mow Circuit 1. Gear pump 2. RH wing deck motor 3. LH wing deck motor 4. RH Wing Deck manifold 5.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 13 Cutting Deck Motor Removal 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of this section.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 14 Cutting Deck Motor Service 1. Rear cover 2. Drive gear 3. Seal 4. Woodruff key 5. Nut 6. T ab washer 7. Spider hub 8. Pressure seal 9. Back - - up ring 10. O - - ring 1 1. Body 12. Idler gear 13.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 15 IMPORT ANT : Mark the relative positions of the gear teeth and the bearing blocks so they can be re- assembled in the same position. Do not touch t he gear surfaces as residue on hands may be corrosive to gear finish.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 16 Assembly (Fig. 80) NOTE: When assembling the motor , check the identifi- cation marks made during disassembly to make sure the parts are properly aligned during assembly . 1. Lubricate O - - rings, pressure seals, back - - up gaskets and seal grooves with a thin coat of petroleum jelly .
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 17 This page is intentionally blank. Hydraulic System.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 18 Deck Manifolds 1. Center deck manifold 2. O - - ring 3. Hydraulic adapter 4. O - - ring 5. Straight hydraulic fitting 6. O - - ring 7. 90 o hydraulic fitting 8. O - - ring 9. Hydraulic tee fitting 10.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 1 19 Removal (Fig. 85) NOTE: The ports on the manifold are marked for easy identification of components.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 120 Deck Manifold Service 1. Manifold body 2. NWD SAE #4 plug with O - - ring 3. Orifice (0.063) (port OR) 4. #8 zero leak plug with O - - ring 5. Relief valve (port RV2) 6. Solenoid valve (port S) 7.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 121 PTO Manifold Service (Fig. 86) For solenoid and control valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 86 for PTO manifold cartridge valve and plug installation torque.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 122 Lift/Lower Circuit 1. Counterbalance manifold 2. RH wing deck lift cylinder 3. LH wing deck lift cylinder 4. Fan drive manifold 5. Lift control valve 6. Front deck flow control valve 7. Front lift cylinder 8.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 123 This page is intentionally blank. Hydraulic System.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 124 Lift/Lower Control V alve 1. Control valve assembly 2. V alve bracket 3. Isolator (6 used) 4. Cap screw 5. Lock nut (2 used) 6. Pivot bracket 7. LH lever assembly 8. Lever link (3 used) 9. Center lever assembly 10.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 125 Removal (Fig. 88) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of this section.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 126 Lift/Lower Control V alve Service 1. Poppet 2. Spacer 3. Wiper seal 4. Seat 5. O - - ring 6. Plug (3 used) 7. O - - ring 8. Bushing 9. Spool cap (3 used) 10. Relief valve poppet 11 . O - - r i n g 12.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 127 Disassembly (Fig. 89) 1. Plug all ports and clean outside of valve thoroughly . 2. Remove spool caps (item 9). Do not remove retain- ing rings (item 12) from spools unless spool spring (item 19) is broken.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 128 Front Deck Lift Cylinder 1. Lift cylinder (2 used) 2. Lift arm (LH shown) 3. Lock nut 4. Pin 5. Flange head screw 6. Grease fitting 7. O - - ring 8. 90 o hydraulic fitting 9. O - - ring 10. Hydraulic fitting 1 1.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 129 Removal (Fig. 90) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of this section.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 130 Wing Deck Lift Cylinder 1. Center deck 2. Grease fitting 3. T apered stud 4. Spherical bearing 5. Flange nut 6. Retaining ring 7. Wing deck lift cylinder 8. Lock nut 9. Flat washer 10. Lock nut 1 1.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 131 Removal (Fig. 91) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of this section.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 132 Deck Lift Cylinder Service 1. Barrel with clevis 2. Retaining ring 3. Shaft with clevis 4. Dust seal 5. Rod seal 6. O - - ring 7. Back - - up ring 8. Head 9. O - - ring 10. Wear ring 11 . P i s t o n 12.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 133 Disassembly (Figs. 92 and 93) 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder . IMPORT ANT : Prevent damage when c lamping the cylinder in a vise; clamp on the clevis only .
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 134 Counterbalance Manifold 1. Counterbalance hydraulic manifold 2. V alve plate 3. Flat washer (2 used) 4. Cap screw (2 used) 5. Isolator (4 used) 6. Flat washer (2 used) 7. Lock nut (2 used) 8. Hydraulic fitting (2 used) 9.
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 135 Removal (Fig. 94) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter .
Groundsmaster 4100 - - D Hydraulic System Page 4 - - 136 Counterbalance Manifold Service 1. Manifold body 2. Pilot valve 3. Seal kit 4. Relief valve (counterbalance) 5.
Groundsmaster 4100 - - D Page 5 - - 1 Electrical System Chapter 5 Electrical System T able of Contents GENERAL INFORMA TION 2 ..................... Operator ’s Manual 2 .......................... Electrical Drawings 2 .......................... SPECIAL TOOLS 3 .
Groundsmaster 4100 - - D Page 5 - - 2 Electrical System General Information Operator ’s Manual The Operator ’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine.
Groundsmaster 4100 - - D Page 5 - - 3 Electrical System Special T ools Order special tools from your T oro Distributor . Some tools may also be available from a local supplier . Multimeter The meter can test electrical components and circuits for current, resistance or voltage.
Groundsmaster 4100 - - D Page 5 - - 4 Electrical System Dielectric Gel Dielectric gel should be used to prevent corrosion of connection terminals. T o ensure complete coating of ter- minals, liberally.
Groundsmaster 4100 - - D Page 5 - - 5 Electrical System T roubleshooting CAUTION Remove all jewelry , especially rings and watches, before doing any electrical trouble- shooting or testing. Disconnect the battery cables unless the test requires battery voltage.
Groundsmaster 4100 - - D Page 5 - - 6 Electrical System Problem Possible Causes Engine cranks, but does not start. Engine is not cranking fast enough. The engine run solenoid or circuit wiring is faulty . The fuel pump is faulty . An engine problem exists (see Chapter 3 - - Kubota Engine).
Groundsmaster 4100 - - D Page 5 - - 7 Electrical System Cutting Deck Operating Problems The cutting deck remains engaged, but should not, with no operator in the seat. The seat switch or circuit wiring is faulty . Cutting deck runs, but should not, when raised.
Groundsmaster 4100 - - D Page 5 - - 8 Electrical System Electrical System Quick Checks Battery T est (Open Circuit T est) Use a multimeter to measure the voltage between the battery terminals. Set multimeter to the DC volts setting. The battery should be at a temperature of 60 o F to 100 o F( 1 6 o Ct o 38 o C).
Groundsmaster 4100 - - D Page 5 - - 9 Electrical System Adjustments Wing Deck Position Switches Adjustment 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove switch cover from deck to allow access to position switch that requires adjustment.
Groundsmaster 4100 - - D Page 5 - - 10 Electrical System Cutting Deck Raise and Lower Switches Adjustment (Fig. 9) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. Remove console housing.
Groundsmaster 4100 - - D Page 5 - - 1 1 Electrical System Component T esting For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check).
Groundsmaster 4100 - - D Page 5 - - 12 Electrical System Fuses The fuse blocks are located under the operator ’s control console. Identification, Function and Wiring The fuses are held in three (3) fuse blocks. Use Figures 13 and 14 to identify each individual fuse and its correct amperage.
Groundsmaster 4100 - - D Page 5 - - 13 Electrical System W arning Lights Engine Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON position with the engine not running. Also, it should light with the engine running if the engine oil pressure drops below 7 PSI (0.
Groundsmaster 4100 - - D Page 5 - - 14 Electrical System PT O Switch The PTO switch is used to engage or disengage the cut- ting deck. The PTO switch is attached to the control con- sole next to the operator seat (Fig. 17). The switch terminals are marked as shown in Figure 18.
Groundsmaster 4100 - - D Page 5 - - 15 Electrical System T ransport / 4WD Switch The transport/4WD switch is used to set the machine traction speed for transport or mow . The transport/4WD rocker switch is located on the control console next to the operator seat (Fig.
Groundsmaster 4100 - - D Page 5 - - 16 Electrical System Cooling Fan Switch The cooling fan switch is used to control the operation of the hydraulic cooling fan and is located on the control console (Fig. 23). This switch has three (3) positions: Reverse, Auto and Forward.
Groundsmaster 4100 - - D Page 5 - - 17 Electrical System Seat Switch The seat switch is normally open and closes when the operator is on the seat. The seat switch and its electrical connector are located in the seat assembly . If the trac- tion system or PTO switch is engaged when the operator raises out of the seat, the engine will stop.
Groundsmaster 4100 - - D Page 5 - - 18 Electrical System Parking Brake Switch The s witch used for the parking brake is a normally open switch that is located under the steering tower cover (Fig. 26). When the parking brake is not applied, the parking brake pawl depresses the switch plunger to close the switch.
Groundsmaster 4100 - - D Page 5 - - 19 Electrical System Hour Meter The hour meter is located on the control console next to the operator seat. T esting 1. Disconnect wire harness connector from hour meter . 2. Connect the positive ( +) terminal of a 12 VDC source to the positive (+) terminal of the hour meter .
Groundsmaster 4100 - - D Page 5 - - 20 Electrical System Glow and Power Relays The Groundsmaster 4100 - - D uses two (2) identical re- lays to control electrical power circuits. The glow relay is attached to the the right side of the fuel tank support under the hood.
Groundsmaster 4100 - - D Page 5 - - 21 Electrical System Start, Engine Shutdown, Seat, Alarm, PT O, PTO Overtemp, Down Latching and Over T emperature Relays These eight (8) relays are located under the console housing cover (Fig. 30). The wiring harness is tagged to identify each relay .
Groundsmaster 4100 - - D Page 5 - - 22 Electrical System Hydraulic V alve Solenoids Figure 32 1. 4WD manifold 2. LH deck manifold 3. RH deck manifold 4. Front deck manifold 5. Fan drive manifold FRONT RIGHT 1 2 3 4 5 There are several hydraulic valve solenoids on the Groundsmaster 4100 - - D (Fig.
Groundsmaster 4100 - - D Page 5 - - 23 Electrical System TEC - - 5002 Controller Groundsmaster 4100 - - D machines use a T oro Electron- ic Controller (TEC) to control the operation of the hy- draulic cooling fan. The controller is attached to the operator platform under the console housing cover (Fig.
Groundsmaster 4100 - - D Page 5 - - 24 Electrical System Fuel Sender The fuel sender is located on top of the fuel tank. T esting 1. Remove white wire and black ground wire from the sender .
Groundsmaster 4100 - - D Page 5 - - 25 Electrical System Fuel Gauge The fuel gauge can be tested using a new gauge as a substitute or with the use of a DC voltage source and a variable resistance box (see Fuel Sender T esting in this section for additional information).
Groundsmaster 4100 - - D Page 5 - - 26 Electrical System Fuel Pump The fuel pump is attached to the frame above the fuel water separator (Fig. 38). Operational T est 1. Park machine on a level surface, lower cutting deck, stop engine and apply parking brake.
Groundsmaster 4100 - - D Page 5 - - 27 Electrical System Glow Controller The glow controller is located under the console cover (Fig. 39). NOTE: Refer to electrical schematic and circuit draw- ings in Chapter 9 - - Foldout Drawings when trouble- shooting the glow controller .
Groundsmaster 4100 - - D Page 5 - - 28 Electrical System T emperature Sender The temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 41). The resistance of the temperature sender re- duces as the engine coolant temperature increases.
Rev . A Groundsmaster 4100- - D Page 5 - - 29 Electrical S ystem Dual T emperature Switch The dual temperature switch is attached to the engine near the alternator on the water flange attached to the engine cylinder head (Fig. 43). T wo (2) electrical har- ness wires (a blue wire and a ye llow wire) are attached to the switch.
Groundsmaster 4100 - - D Page 5 - - 30 Electrical System T emperature Gauge The temperature gauge can be tested using a new gauge as a substitute or with the use of a DC voltage source and a variable resistance box.
Groundsmaster 4100 - - D Page 5 - - 31 Electrical System T raction Neutral Switch The traction neutral switch is closed when the traction pedal is in the neutral position and opens when the pedal is depressed in either direction. The switch is located on the right side of the piston (traction) pump (Fig.
Groundsmaster 4100 - - D Page 5 - - 32 Electrical System Diode Circuit Board The diode circuit board (Fig. 50) contains four (4) diodes and is located under the console housing.
Groundsmaster 4100 - - D Page 5 - - 33 Electrical System Fusible Links The Groundsmaster 4100 - - D uses five (5) fusible links for circuit protection. Three (3) of these fusible links are located in a harness that connects the starter B+ termi- nal to the wire harness (Fig.
Groundsmaster 4100 - - D Page 5 - - 34 Electrical System Wing Deck Position Switches The wing deck position switches on the Groundsmaster 4100 - - D are attached to the center deck housing (Fig.
Groundsmaster 4100 - - D Page 5 - - 35 Electrical System Cutting Deck Raise and Lower Switches The deck raise and lower switches are normally open proximity switches that are located under the console housing (Fig. 56). These identical switches are mounted in opposite directions so their circuit logic differs.
Rev . A Groundsmaster 4100- - D Page 5 - - 36 Electrical Syst em Engine Coolant and Hydraulic Oil T emperature Senders The Groundsmaster 4100- - D uses two (2) temperature senders as inputs for the TEC - - 5002 to identify if either the engine coolant or hydraulic oil temperatu re has reached an excessive level.
Groundsmaster 4100 - - D Page 5 - - 37 Electrical System Service and Repairs NOTE: For engine component repair information, see the Kubota Workshop Manual, Diesel Engine, V2403 - - M - - T - - E3B Series at the end of Chapter 3 - - Ku- bota Diesel Engine.
Groundsmaster 4100 - - D Page 5 - - 38 Electrical System Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally , battery and electrical component failure can be prevented.
Groundsmaster 4100 - - D Page 5 - - 39 Electrical System 2. Conduct a hydrometer test of the battery electrolyte. IMPORT ANT : Make sure the area around the cells is clean before opening the battery caps. A. Measure the specific gravity of each cell with a hydrometer .
Groundsmaster 4100 - - D Page 5 - - 40 Electrical System Battery Charging T o minimize possible damage to the battery and allow the battery to be fully charged, the slow charging meth- od is presented here. This charging method can be ac- complished with a constant current battery charger which is readily available locally .
Groundsmaster 4100 - - D Page 6 - - 1 Axles, Planetaries and Brakes Chapter 6 Axles, Planetaries and Brakes T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ..................... Operator ’s Manual 3 ........
Groundsmaster 4100 - - D Page 6 - - 2 Axles, Planetaries and Brakes Specifications Item Specification T ire pressure (front and rear) 25 to 30 PSI (172 to 207 kPa) Rear wheel toe - - in 0.125 in (3.18 mm) Planetary gear drive oil SAE 85W - - 140 wt. gear lube System gear lube capacity (each wheel) 16 fl.
Groundsmaster 4100 - - D Page 6 - - 3 Axles, Planetaries and Brakes General Information Operator ’s Manual The Operator ’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine.
Groundsmaster 4100 - - D Page 6 - - 4 Axles, Planetaries and Brakes Service and Repairs Brake Assembly 1. Planetary assembly 2. Retaining ring 3. Splined brake coupler 4. Brake assembly (RH) 5. O - - ring 6. Hydraulic wheel motor 7. Flat washer 8. Cap screw (2 used per side) 9.
Groundsmaster 4100 - - D Page 6 - - 5 Axles, Planetaries and Brakes 3. Chock rear wheels and jack up front of machine (see Jacking Instructions in Chapter 1 - - Safety).
Groundsmaster 4100 - - D Page 6 - - 6 Axles, Planetaries and Brakes Brake Service 1. Brake housing (LH shown) 2. Seal 3. Pull rod 4. Clevis pin (2 used) 5. Link 6. Hitch pin (2 used) 7. Stationary disc (4 used) 8. Rotating disc (3 used) 9. Retaining ring 10.
Groundsmaster 4100 - - D Page 6 - - 7 Axles, Planetaries and Brakes This page is intentionally blank. Axles, Planetaries and Brakes.
Groundsmaster 4100 - - D Page 6 - - 8 Axles, Planetaries and Brakes Planetary Wheel Drive Assembly 1. Planetary assembly 2. Retaining ring 3. Splined brake coupler 4. Brake assembly (RH) 5. O - - ring 6. Hydraulic wheel motor 7. Flat washer 8. Cap screw (2 used per side) 9.
Groundsmaster 4100 - - D Page 6 - - 9 Axles, Planetaries and Brakes Removal (Fig. 6) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Drain oil from planetary wheel drive/brake assembly .
Groundsmaster 4100 - - D Page 6 - - 10 Axles, Planetaries and Brakes Planetary Wheel Drive Service 1. Spindle 2. Boot seal 3. Bearing cone 4. Bearing cup 5. Wheel stud (8 used) 6. Housing 7. Bearing cup 8. Bearing cone 9. Thrust washer 10. Retaining ring (external) 1 1.
Groundsmaster 4100 - - D Page 6 - - 1 1 Axles, Planetaries and Brakes NOTE: The planetary wheel drive assembly can be ser- viced with the planetary installed to machine. If the spindle (item 1) needs to be removed from machine, see Planetary Wheel Drive Assembly Removal in this sec- tion.
Groundsmaster 4100 - - D Page 6 - - 12 Axles, Planetaries and Brakes F . Lightly oil bearing journals on spindle shaft. Slide housing onto spindle (item 1) taking care to not dam- age seal or spindle. Make sure that bearing in hous- ing fully seats against spindle shaft shoulder .
Groundsmaster 4100 - - D Page 6 - - 13 Axles, Planetaries and Brakes This page is intentionally blank. Axles, Planetaries and Brakes.
Groundsmaster 4100 - - D Page 6 - - 14 Axles, Planetaries and Brakes Rear Axle Assembly 1. Frame 2. Cap screw (6 used) 3. Flat washer 4. Bulkhead lock nut (2 used) 5. W asher 6. Thrust washer (thick) 7. Grease fitting (2 used) 8. Rear axle assembly 9.
Groundsmaster 4100 - - D Page 6 - - 15 Axles, Planetaries and Brakes 8. Remove cap screw and flange nut that secures front corner of 4WD hydraulic manifold to rear frame mount. 9. If required, remove tie rod ends from steering arms on rear axle (Fig. 12).
Groundsmaster 4100 - - D Page 6 - - 16 Axles, Planetaries and Brakes 8. Install steering cylinder to axle assembly (see Steer- ing Cylinder Installation in the Service and Repairs sec- tion of Chapter 4 - - Hydraulic System).
Groundsmaster 4100 - - D Page 6 - - 17 Axles, Planetaries and Brakes Bevel Gear Case and Axle Case The following procedures assume the rear axle assem- bly has been removed from the machine (see Rear Axle Assembly Removal in this section). Bevel Gear Case and Axle Case Removal 1.
Groundsmaster 4100 - - D Page 6 - - 18 Axles, Planetaries and Brakes 5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gas- ket material from either mating surface (Fig.
Groundsmaster 4100 - - D Page 6 - - 19 Axles, Planetaries and Brakes Bevel Gear Case and Axle Case Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 20). 1. Axle case 2. Bevel gear case 3. Shaft seal Figure 20 1 2 3 2.
Groundsmaster 4100 - - D Page 6 - - 20 Axles, Planetaries and Brakes 5. Determine necessary quantity of support shims. A. Lubricate the axle case support bushing with a thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during disassembly between axle case support and axle case.
Groundsmaster 4100 - - D Page 6 - - 21 Axles, Planetaries and Brakes 9. Remove the bevel gear case/axle case assembly from the axle support. Coat a new O-ring with grease and temporarily install the axle cover assembly . Position a dial indicator at the tooths center .
Groundsmaster 4100 - - D Page 6 - - 22 Axles, Planetaries and Brakes Differential Shafts The following procedures assume the rear axle assem- bly has been removed from the machine (see Rear Axle Assembly Removal in this section). Differential Shaft Removal IMPORT ANT : Do not interchange right and left dif- ferential shaft assemblies.
Groundsmaster 4100 - - D Page 6 - - 23 Axles, Planetaries and Brakes Axle Shafts The following procedures assume the rear axle assem- bly has been removed from the machine (see Rear Axle Assembly Removal in this section). Axle Shaft Removal 1. Remove the axle cover mounting screws.
Groundsmaster 4100 - - D Page 6 - - 24 Axles, Planetaries and Brakes Input Shaft/Pinion Gear Figure 30 1 1. Nut (2 used) 2. Lockwasher (2 used) 3. Stud (2 used) 4. Locknut 5. Stake washer 6. Oil seal 7. O-ring 8. Seal collar 9. Bearing 10. O-ring 1 1.
Groundsmaster 4100 - - D Page 6 - - 25 Axles, Planetaries and Brakes 7. Secure the lock nut with the stake washer . 8. Use a depth gauge to measure the distance from the end face of the input shaft/pinion gear to the mating sur- face of the bearing case.
Groundsmaster 4100 - - D Page 6 - - 26 Axles, Planetaries and Brakes Differential Gear The following procedures assume the rear axle assem- bly has been removed from the machine (see Rear Axle Assembly Removal in this section). Differential Gear Removal 1.
Groundsmaster 4100 - - D Page 6 - - 27 Axles, Planetaries and Brakes Differential Gear Inspection 1. Measure the differential side gear O.D. and the dif- ferential case I.D. to determine the side gear to case clearance (Fig. 37). Replace components as necessary .
Groundsmaster 4100 - - D Page 6 - - 28 Axles, Planetaries and Brakes Differential Gear Installation 1. If the ring gear was removed, use medium strength thread locking compound and tighten the mounting screws from 22 to 25 ft-lb (30 to 34 N - - m) . 2.
Groundsmaster 4100 - - D Page 6 - - 29 Axles, Planetaries and Brakes Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using the gear contact pattern method as described in the fol- lowing procedure. GEAR TOOTH DEFINITIONS (Fig.
Groundsmaster 4100 - - D Page 6 - - 30 Axles, Planetaries and Brakes Gear Pattern Movement Summary Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as gear location is changed. 1. If contact is toward the heel or base of the gear (Fig.
Groundsmaster 4100 - - D Page 7 - - 1 Chassis Chapter 7 Chassis T able of Contents GENERAL INFORMA TION 1 ..................... Operator ’s Manual 1 .......................... SERVICE AND REP AIRS 2 ...................... Steering T ower 2 .........
Groundsmaster 4100 - - D Page 7 - - 2 Chassis Service and Repairs Steering T ower 1. Hex nut 2. Flat washer 3. Steering wheel 4. Foam collar 5. Steering seal 6. External snap ring (2 used) 7. Knob 8. Steering tower cover 9. Steering shaft 10. Compression spring 11 .
Groundsmaster 4100 - - D Page 7 - - 3 Chassis Disassembly (Fig. 1) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Disassemble steering tower as needed using Figure 1 as a guide.
Groundsmaster 4100 - - D Page 7 - - 4 Chassis Cutting Deck Lift Arms 1. Lift cylinder 2. Clevis pin 3. Cap screw 4. Grease fitting 5. Lift arm pin 6. Slotted roll pin 7. Lock nut 8. Cotter pin 9. Pivot pin 10. Hair pin 1 1. S pherical rod end 12. Damper 13.
Groundsmaster 4100 - - D Page 7 - - 5 Chassis CAUTION When changing attachments, tires or perform- ing other service, use correct jacks and sup - ports. Make sure machine is parked on a solid, level surface such as a concrete floor . Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine.
Groundsmaster 4100 - - D Page 7 - - 6 Chassis Operator Seat 1. Seat assembly 2. Flat washer (5 used) 3. Seat belt 4. Cap screw (4 used) 5. Seat platform 6. Flange nut (4 used) 7. Seat belt buckle 8. Cap screw (2 used) 9. R - - clamp (2 used) 10. Manual tube 1 1.
Groundsmaster 4100 - - D Page 7 - - 7 Chassis Removal (Fig. 5) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove seat from seat suspension: A. Disconnect seat electrical connectors from ma- chine wire harness (Fig.
Groundsmaster 4100 - - D Page 7 - - 8 Chassis Operator Seat Service 1. Backrest cushion 2. Seat cushion 3. Armrest cover 4. LH armrest 5. Bushing (2 used) 6. Backrest 7. Plug (2 used) 8. Cable tie (3 used) 9. LH adjustment rail 10. Bumper (2 used) 1 1.
Groundsmaster 4100 - - D Page 7 - - 9 Chassis Disassembly (Fig. 8) 1. Disassemble operator seat as necessary using Fig- ure 8 as a guide. Assembly (Fig.
Groundsmaster 4100 - - D Page 7 - - 10 Chassis Operator Seat Suspension 1. Cover 2. Cover 3. Level control 4. Air control valve 5. Shock absorber 6. Air spring 7. Air tube assembly 8. Wire harness 9. Compressor 10. Bellows 11 . S t o p 12. Bumper set (2 used) 13.
Groundsmaster 4100 - - D Page 7 - - 1 1 Chassis NOTE: Most of the seat suspension components can be serviced with the seat suspension base mounted to the frame platform. If the air spring assembly (item 6) re- quires removal, the seat suspension base w ill have to be removed from the seat platform.
Groundsmaster 4100 - - D Page 7 - - 12 Chassis Hood 1. Rear screen 2. T op screen 3. Cap screw (22 used) 4. Screen assembly 5. Bulb seal 6. Flange nut (2 used) 7. Bulb seal 8. Screen corner seal (2 used) 9. Hair pin (2 used) 10. Screw (8 used) 1 1. H ood pivot (2 used) 12.
Groundsmaster 4100 - - D Page 7 - - 13 Chassis Removal 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove hood using Figure 1 1 as a guide. Installation 1. Install hood using Figure 1 1 as a guide.
Groundsmaster 4100 - - D Page 7 - - 14 Chassis This page is intentionally blank..
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 1 Chapter 8 Cutting Deck T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ..................... Operator ’s Manual 3 .......................... Castor Wheel T ire Pressure 3 .
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 2 Specifications MOUNTING: Cutting deck is supported by lift arms con- trolled with hydraulic lift levers. CONSTRUCTION: Deck chamber is welded 12 gauge steel construction reinforced with channels and plates.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 3 General Information CAUTION Never install or work on the cutting deck or lift arms with the engine running.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 4 T roubleshooting There are a number of factors that can contribute to un- satisfactory quality of cut, some of which may be turf conditions.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 5 This page is intentionally blank. Cutting Deck.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 6 Service and Repairs CAUTION Never install or work on the cutting deck or lift arms with the engine running. Always stop en- gine and remove ignition key first. Cutting Deck 1. Cutting deck 2. Cap screw 3.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 7 Removal (Fig. 1) 1. Position machine on a clean, level s urface. Lower cutting deck, stop engine, engage parking brake and re- move key from the ignition switch. NOTE: Removal of clevis pins from deck and height - - of - - cut chains is easier if deck is lifted slightly .
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 8 NOTE: Installation of clevis pins to deck and height - - of - - cut chains is easier if deck is lifted slightly . 4. Install clevis pins and hairpins that secure the height - - of - - cut chains to the rear of the cutting deck (Fig.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 9 This page is intentionally blank. Cutting Deck.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 10 Wing Deck Service 1. Wing deck (RH shown) 2. Skid (RH shown) 3. Flange screw (2 used per skid) 4. Flange nut (2 used per skid) 5. Cap screw 6. Roller (2 used) 7. Lock nut 8. Pivot latch (2 used) 9. Flat washer 10.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 1 1 Removal (Fig. 6) 1. Position machine on a clean, level s urface. Lower cutting deck and engage parking brake. 2. Fully raise wing deck, stop engine and remove key from the ignition switch. Remove three (3) washer head screws and shield strap that secure flex shield to wing deck.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 12 4. Position upper end of links to center cutting deck brackets. 5. Align upper end of links with mounting holes in center deck. While installing pivot pins to center deck and links, insert spacers and washers as follows: A.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 13 Cutting Deck Link Service Disassembly (Fig. 10) 1. Press bushings from top of link. 2. Remove dust cap and retaining ring from link. 3. Press tapered stud with spherical bearing, flat wash- ers and flange nut from link.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 14 Wing Deck Latch Disassembly (Fig. 12) 1. Raise wing deck to transport position. Carefully ro- tate latch to closed position. 2. Loosen lug nut to release compression spring ten- sion. 3. Remove retaining ring and flat washer from bottom of latch pin.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 15 This page is intentionally blank. Cutting Deck.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 16 Blade Spindle 1. Cutting deck 2. Drive spindle: single pulley (2 used) 3. Low driven spindle (3 used) 4. Drive spindle: double pulley (1 used) 5. Flange head screw 6. Flange nut 7. Blade bolt 8. Cutting blade (7 used) 9.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 17 Installation (Fig. 13) 1. Position spindle on cutting deck noting orientation of grease fitting (Fig. 15). Secure spindle assembly to deck with removed fasteners. 2. Install cutting blade, anti - - scalp cup and blade bolt.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 18 Blade Spindle Service 1. Lock nut 2. Flat washer 3. Driven pulley 4. Spindle shaft 5. Drive pulley (single shown) 6. Hydraulic motor mount 7. O - - ring 8. Oil seal 9. Bearing cup and cone 10. Outer bearing spacer 1 1.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 19 2. Install outer bearing spacer into top of spindle hous- ing. The spacer should fit against the snap ring. 3. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 20 Idler Assembly 1. Center deck 2. Flange nut 3. Flange nut 4. Adjusting screw 5. Idler pulley 6. High driven pulley 7. Flat washer 8. Lock washer 9. Socket head screw 10. Stop bolt 1 1. Flange nut 12.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 21 Removal (Fig. 20) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove deck covers from top of cutting deck. CAUTION Be careful when removing idler spring.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 22 Castor Forks and Wheels 1. Castor arm (wing deck shown) 2. Cap screw (6 per arm) 3. Castor fork 4. Castor wheel bolt 5. Lock nut 6. Castor spacer 7. Thrust washer 8. Flange lock nut 9. Grease fitting 10.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 23 Disassembly (Fig. 22) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Disassemble castor forks and wheels using Figure 22 as a guide.
Groundsmaster 4100 - - D Cutting Deck Page 8 - - 24 Deck Rollers and Skids 1. Roller 2. Flange head screw 3. Roller shaft 4. Flange nut 5. Lock nut 6. Roller 7. Cap screw 8. Flange nut 9. Skid (RH shown) 10. Flange head screw Figure 23 1 2 3 4 5 6 7 5 6 7 5 6 7 8 10 9 FRONT RIGHT Removal (Fig.
Groundsmaster 4100 - - D Foldout Drawings Page 9 - 1 Chapter 9 Foldout Drawings T able of Contents HYDRAULIC SCHEMA TIC 3 ..................... ELECTRICAL SCHEMA TIC Sheet 1 of 2 4 ................................ Sheet 2 of 2 5 ......................
Groundsmaster 4100 - - D Foldout Drawings Page 9 - 2 This page is intentionally blank..
Page 9 - 3 Hydr aulic S chem atic Groundsmaster 4100 - - D 4WD MANI F OLD COUNTERBAL ANCE MANI F OLD FIL TER MANI F OLD FAN DRIVE MANI F OLD RH WING DECK MANI F OLD LH WI NG DECK MANI F OLD CENTER DEC.
Page 9 - 4 All r elays and so lenoid s are shown as de - - energized. All gr ound wir es are black. CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 (OP TIO NAL .
Page 9 - 5 Electr ical Schematic Groundsmaster 4100 - - D All r elays and so lenoid s are shown as de - - energized. All gr ound wir es are black. Sheet 2 of 2 CONTINUES FROM SHEET 1 COOLI NG FAN CONT.
Page 9 - 6 Glow Plug Circuits Power C urr ent Contr ol Curr ent Indicat ion Cur rent Groundsmaster 4100 - - D CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 (U.
Page 9 - 7 Crank Cir cuits Power C urr ent Contr ol Curr ent Indicat ion Cur rent Groundsmaster 4100 - - D CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 (UNOC.
Page 9 - 8 Run (T ranspor t) Cir cuits Power C urr ent Contr ol Curr ent Indicat ion Cur rent Groundsmaster 4100 - - D CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O S.
Page 9 - 9 Run (Mow) Cir cuits Power C urr ent Contr ol Curr ent Indicat ion Curr ent Groundsmaster 4100 - - D CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 (.
Page 9 - 10 High T emper atur e W arning C irc uits Power C urr ent Contr ol Curr ent Indicat ion Cur rent Groundsmaster 4100 - - D CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CO.
Page 9 - 1 1 Over T emper atur e Shutdown Cir cuits Power C urr ent Contr ol Curr ent Indicat ion Cur rent Groundsmaster 4100 - - D CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CONTINUES T O SHEET 2 CO.
Page 9 - 12 Gr oundsmas ter 4100 - - D Cons ole Wire Ha rne ss COOLI NG FAN SWITCH (PTO S HUTDOWN DEL A Y) (ENGINE SHUT DOWN DELAY) FLOW SWITCH TRANSPORT/4WD DIVIDER SWITCH.
Page 9 - 13 Gr oundsmas ter 4100 - - D Cons ole Wire Ha rne ss YELLO W GRA Y WHITE Sheet 1 of 2 YELLOW/BLACK VIOLET YELLO W YELLOW GREEN RED BLACK RED RED WHITE RED BLACK GREEN ORANGE VIOLET VIOLET YE.
Page 9 - 14 BLACK RED YELLO W T AN/BLACK RED BLACK RED RED BLACK RED RED BLACK T AN/BLACK YELLOW/GREEN T AN/BLACK VIOLET GREEN/BLACK BLACK BLACK YELLO W BLACK T AN/BLACK BLACK ORANGE/ BL ACK YELLOW/WH.
Page 9 - 15 Gr oundsmas ter 4100 - - D Front Wire H ar ness FLOW DIVIDER SOLENOID.
Page 9 - 16 Gr oundsmas ter 4100 - - D Front Wire H ar ness PINK BLACK WHITE PINK PINK PINK BLACK GREEN/BLACK GRA Y TA N BLACK BROWN YELLO W PINK ORANGE WHITE TA N PINK PINK TA N TA N BLACK BLACK ORAN.
Page 9 - 17 Gr oundsmas ter 4000 - - D Engine Wir e Har ness (ST ART ER) (ST ART ER) (ST ART ER).
Page 9 - 18 Gr oundsmas ter 4000 - - D Engine Wir e Har ness RED/BL ACK BLACK WHITE RED/BLACK RED YELLO W ORANGE BLACK BLACK BLACK ORANGE VIOLET/BLACK BLACK VIOLET/BLACK BLACK BLACK BLACK VIOLET/BLACK.
Page 9 - 19 Gr oundsmas ter 4100 - - D Jump er W ire Harn ess BLACK BLUE VIOLET GRA Y YELLO W GRA Y BLUE GRA Y VIOLET BLUE VIOLET.
Page 9 - 20 Gr oundsmas ter 4100 - - D Cut ti ng Deck Wi re Harness ORANGE YELLOW/BLACK BLACK VIOLET/BLACK BLACK ORANGE BLACK ORANGE P15 P2 P1 DECK LIF T SENSOR (LH) DECK LIFT SENSOR (RH).
An important point after buying a device Toro 4100-D (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Toro 4100-D yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Toro 4100-D - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Toro 4100-D you will learn all the available features of the product, as well as information on its operation. The information that you get Toro 4100-D will certainly help you make a decision on the purchase.
If you already are a holder of Toro 4100-D, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Toro 4100-D.
However, one of the most important roles played by the user manual is to help in solving problems with Toro 4100-D. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Toro 4100-D along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
