Toro 4100-D - Manuals

Groundsmaster 4100--D/4110--D Page 1 -- 1 Safety Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS 2 . . . . . . . . . . . . Before Operating 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance a...

Groundsmaster 4100--D/4110--D Page 1 -- 2 Safety General Safety Instructions The Groundsmaster 4100-D and 4110--D are tested and certified by Toro for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design...

Groundsmaster 4100--D/4110--D Page 1 -- 3 Safety While Operating 1. Sit on the seat when starting and operating the ma- chine. 2. Before starting the engine: A. Apply the parking brake. B. Make sure traction pedal is in neutral and the PTO switch is OFF (disengaged). 3. After engine is started, rele...

Groundsmaster 4100--D/4110--D Page 1 -- 4 Safety Maintenance and Service 1. Before servicing or making adjustments, lower deck, stop engine, apply parking brake and remove key from the switch. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 3. Never s...

Groundsmaster 4100--D/4110--D Page 1 -- 5 Safety Jacking Instructions CAUTION When changing attachments, tires or perform- ing other service, use correct jacks and sup-ports. Make sure machine is parked on a solid,level surface such as a concrete floor. Prior to raising machine, remove any attachmen...

Groundsmaster 4100--D/4110--D Page 1 -- 6 Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to your Groundsmaster machine. If any decal becomes il- legible or damaged, install a new decal. Decal part num- bers are listed in your Parts Catalog.

Groundsmaster 4100--D/4110--D Page 2 -- 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS 1 . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSI...

0.09375 Groundsmaster 4100--D/4110--D Page 2 -- 2 Product Records and Maintenance Equivalents and Conversions

Groundsmaster 4100--D/4110--D Page 2 -- 3 Product Records and Maintenance Torque Specifications Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clea...

Groundsmaster 4100--D/4110--D Page 2 -- 6 Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended Torque Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 UNC 35 + 10 f...

Groundsmaster 4100--D/4110--D Page 3 -- 1 Yanmar Diesel Engine Chapter 3 Yanmar Diesel Engine Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Models 30602 and 30604 2 . . . . . . . . . . . . . . . . . . . . Models 30606 and 30608 3 . . . . . . . . . . . . ....

Groundsmaster 4100--D/4110--D Page 3 -- 5 Yanmar Diesel Engine General Information This Chapter gives information about specifications and repair of the diesel engine used in the Groundsmaster 4100--D and 4110--D. General maintenance procedures are described in your Operator’s Manual. Information on...

Groundsmaster 4100--D/4110--D Page 3 -- 10 Yanmar Diesel Engine Service and Repairs Air Filter System Figure 6 FRONT RIGHT 1. Air cleaner assembly 2. Tank support 3. Indicator 4. Adapter 5. Air cleaner strap 6. Flat washer (4 used) 7. Cap screw (2 used) 8. Lock nut (2 used) 9. Flat washer (2 used) 1...

Groundsmaster 4100--D/4110--D Page 3 -- 12 Yanmar Diesel Engine Fuel System Figure 9 1. Carriage screw (2 used) 2. Retaining ring (2 used) 3. Flat washer (2 used) 4. Flange nut (6 used) 5. Vent hose 6. Fuel tank 7. Hose clamp (2 used) 8. Elbow fitting (2 used) 9. Stand pipe 10. Grommet (3 used) 11. ...

Groundsmaster 4100--D/4110--D Page 3 -- 13 Yanmar Diesel Engine DANGER Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while en- gine is running, hot or when machine is in an en- closed area. Always fill fuel ...

Groundsmaster 4100--D/4110--D Page 3 -- 14 Yanmar Diesel Engine Radiator and Oil Cooler Assembly Figure 11 FRONT RIGHT 2 3 6 8 9 10 11 1 5 7 4 24 25 3 26 27 28 29 30 31 32 33 34 35 Thread Sealant 1. LH radiator support 2. Cap screw (2 used) 3. Flange nut (12 used) 4. Hose clamp (3 used) 5. Hose 6. F...

Groundsmaster 4100--D/4110--D Page 3 -- 15 Yanmar Diesel Engine Removal (Fig. 11) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. Open and support hood. CAUTION Do not open radiator cap or drain coolant if the radiator...

Groundsmaster 4100--D/4110--D Page 3 -- 18 Yanmar Diesel Engine Engine Figure 15 1. Engine (model 30604 shown) 2. Cap screw (4 used) 3. Rebound washer (4 used) 4. Flange nut (12 used) 5. Engine mount (4 used) 6. Cap screw (2 used per mount) 7. Engine mount bracket (2 used) 8. Lock washer 9. Engine m...

Groundsmaster 4100--D/4110--D Page 3 -- 19 Yanmar Diesel Engine Engine Removal (Fig. 15) 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the ignition switch. 2. Disconnect negative battery cable from battery ter- minal and then disconnect ...

Groundsmaster 4100--D/4110--D Page 3 -- 24 Yanmar Diesel Engine Spring Coupler Figure 21 1. Cap screw (8 used) 2. Washer (8 used) 3. Flywheel plate 4. Cap screw (8 used) 5. Washer (8 used) 6. Spring coupler 7. Engine (model 30604 shown) FRONT RIGHT 29 to 33 ft--lb (40 to 44 N--m) 28 to 32 ft--lb (38...

Groundsmaster 4100--D/4110--D Page 3 -- 25 Yanmar Diesel Engine Coupler Removal (Fig. 21) NOTE: The hydraulic pump assembly needs to be re- moved from engine before coupler can be removed. 1. If engine is in machine, remove hydraulic pump as- sembly from machine (see Piston (Traction) Pump Re- moval...

Groundsmaster 4100--D/4110--D Page 3 -- 27 Yanmar Diesel Engine Groundsmaster models that are powered by a diesel en- gine that complies with EPA Tier 4 emission regulations are equipped with an exhaust system that includes a diesel oxidation catalyst (DOC) and a diesel particulate filter (DPF). The...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 1 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 3 . . . . . . . . . . . . . . . . . . . ....

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 2 Specifications Item Description Piston (Traction) Pump Sauer--Danfoss Variable Displacement Axial Piston Pump Maximum Displacement (per revolution) 2.75 in 3 (45 cc) System Relief Pressure: Forward 4350 PSI (300 bar) System Relief Pressure: ...

Groundsmaster 4100--D/4110--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...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 5 Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage condi- tions or mishandling during operation and maintenance. These ...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 9 Hydraulic Schematic NOTE: A larger hydraulic schematic is includ ed in Chap te r 10 -- Fo ldo ut Drawin gs S1 0 RV 1 CV1 S2 S4 S5 PR V P4 CH 2 P3 EC CF LS S3 OR1 C3 OR 4 .04 0 S6 OR5 .070 C4 C2 C5 RV 2 25 00 P S I S7 S9 S8 C6 M1 M2 CH 1 CV 3...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 10 Hydraulic Flow Diagrams Tr ac tion Cir cuit: LOW S pe ed (Mow) (Fo rw ar d S hown) W or king P res su re Low Pressure (C harge ) Return or Suction Fl ow Gr oun dsmaster 41 00 --D/41 10 --D S1 0 RV 1 CV 1 S2 S4 S5 PR V P4 CH 2 P3 EC CF LS S3...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 11 Traction Circuit: LOW Speed (Mow) The traction circuit piston pump is a variable displace- ment pump that is directly coupled to the engine fly- wheel. This pump utilizes an integral electro--hydraulic servo piston assembly that controls th...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 12 Tr ac tio n Cir cuit: HI S peed (T ra nspor t) (For wa rd S hown) W ork in g P res su re Lo w P re ssu re (C ha rg e) Retu rn or Suct io n Flow G rou ndsma ste r 41 00 --D/4 110 --D S1 0 RV 1 CV 1 S2 S4 S5 PR V P4 CH 2 P3 EC CF LS S3 OR 1 C...

Groundsmaster 4100--D/4110--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 the lift/lower circuit, the engine cooling fan circuit and the traction charge circuit. Each of...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 16 Ra is e C utting Deck (LH W ing D eck Shown) W orki ng P re ssu re Low Pressure (C harge ) Return or Suction Fl ow Gro un dsmaster 4100 --D/41 10 --D S1 0 RV 1 CV1 S2 S4 S5 PR V P4 CH 2 P3 EC CF LS S3 OR1 C3 OR 4 .04 0 S6 OR 5 .0 70 C4 C2 C...

Groundsmaster 4100--D/4110--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 circuit, the engine cooling fan circuit and the traction charge circuit. Each of...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 18 Mow C ir cuit (All Deck Motors Rotating) W ork ing P res su re Low P ressu re (C ha rg e) Return or Suction Flow G ro und sm as te r 41 00 --D/41 10 --D S1 0 RV 1 CV 1 S2 S4 S5 PR V P4 CH 2 P3 EC CF LS S3 OR 1 C3 OR 4 .040 S6 OR5 .070 C4 C ...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 19 Mow Circuit A four section gear pump is coupled to the piston (trac- tion) pump. Hydraulic flow for the mow circuit is supplied by two sections of the gear pump. The gear pump sec- tion closest to the piston (traction) pump supplies hy- dra...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 20 Mow Circuit Cutting Deck Blade Braking When the operator turns the PTO switch OFF or if a wing deck is raised with the PTO switch ON, PTO manifold proportional relief valve (PRV) is de--energized causing logic valve (LC1) to shift (refer to...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 23 Steering Circuit A four section gear pump is coupled to the piston (trac- tion) pump. The fourth gear pump section (farthest from the piston pump) supplies hydraulic flow to the steering circuit, the engine cooling fan circuit and the tract...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 24 E ngin e Coo ling F an Cir cuit (For wa rd Dir ection S hown) W orki ng P re ss ur e Low P res sur e (C har ge ) Re tu rn or S uct io n Flow Gr ou ndsma ste r 410 0- -D /4 11 0- -D S1 0 RV 1 CV 1 S2 S4 S5 PR V P4 CH 2 P3 EC CF LS S3 OR 1 C3...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 25 Engine Cooling Fan Circuit A four section gear pump is coupled to the piston (trac- tion) pump (Fig. 14). The fourth gear pump section (farthest from the piston pump) supplies hydraulic flow to the steering circuit, the engine cooling fan c...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 26 Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine tes...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 27 40 GPM Hydraulic Tester (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter. This tester includes the following: 1. LOAD VALVE: A simulated...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 28 High Flow Hydraulic Filter Kit The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi--direc- tional filtration which prevents filtered deb...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 29 Hydraulic Test Fitting Kit This kit includes a variety of O--ring face seal fittings to enable the connection of test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Toro Part Number: T...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 30 Remote Starter Switch After flushing the hydraulic system or replacing a hy- draulic component (e.g. gear pump, piston pump, wheel motor), it is necessary to prime the hydraulic pumps. A remote starter switch (Fig. 24) can be used for this ...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 31 Troubleshooting The charts that follow contain suggestions that can be used to assist in diagnosing hydraulic system perfor- mance issues. The suggestions are not all--inclusive. Also, consider that there may be more than one cause for a ma...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 32 Traction Circuit Problems Problem Possible Cause Machine operates in one direction only. Piston (traction) pump by--pass valve is open or damaged. Traction relief valve is leaking or faulty. Piston (traction) pump servo control valve orific...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 33 Mow Circuit Problems Problem Possible Cause None of the cutting deck sections will operate. NOTE: To engage the mow circuit, the seat must be occupied, the cut- ting deck(s) must be fully lowered, the traction speed must be in the LOW (mow)...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 34 Lift Circuit Problems Problem Possible Cause Cutting deck (or wing decks) will not raise. NOTE: The seat must be occupied in order to raise cutting deck. Engine RPM is too low. Hydraulic oil level in reservoir is low (NOTE: Other hydraulic ...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 35 Steering Circuit Problems Problem Possible Cause Steering is inoperative or sluggish. Steering components (e.g. tie rods, steering cylinder ends) are worn or binding. Steering cylinder is binding. Oil level in hydraulic reservoir is low (NO...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 36 Engine Cooling Fan Circuit Problems Problem Possible Cause Cooling fan runs only in forward di- rection (fan does not run in reverse direction). Solenoid cartridge valve (S10) in combination control manifold is faulty. Electrical problem ex...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 40 Traction Circuit Charge Pressure (Using Pressure Gauge) 3. 3 G P M 4. 4 G PM 14 .3 GP M 14. 3 G PM PR 38 0 P S I RV 650 PSI .05 0 CV T P2 M8 CH OR 1 25 0 PSI 2. 14 CID / 1. 16 CI D 20 0 P S I 4350 PSI 50 00 PSI .0 315 .0 31 5 0. 4 CI D 0.3 ...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 41 The traction charge circuit is designed to replace loss of hydraulic fluid from the closed loop traction circuit. This test is used to make sure that traction charge pressure is correct. Procedure for Traction Circuit Charge Pressure Test C...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 42 Traction Circuit Relief Pressure (Using Pressure Gauge) 3. 3 G PM 4.4 G P M 14 .3 G P M 14 .3 G P M PR 38 0 P SI RV 65 0 P S I .050 CV T P2 M8 CH OR1 25 0 PSI 2.14 C ID / 1.16 CID 20 0 PSI 435 0 P S I 50 00 PSI .0315 .031 5 0. 4 CID 0. 3 1....

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 44 Counterbalance Pressure (Using Pressure Gauge) PRESSURE GAUGE S1 0 RV 1 CV 1 S2 S4 S5 PR V P4 CH2 P3 EC CF LS S3 OR1 C3 OR 4 .040 S6 OR 5 .07 0 C4 C2 C5 RV 2 S7 S9 S8 C6 M1 M2 CH 1 CV 3 CH 4 OR2 .0 63 OR6 .063 OR 3 .0 70 OR 7 .0 70 T 2S P C...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 50 Piston (Traction) Pump Flow (Using Tester with Flow meter and Pressure Gauge) 3. 3 G PM 4.4 G P M 14 .3 G P M 14 .3 G P M PR 38 0 P SI RV 65 0 P S I .050 CV T P2 M8 CH OR1 25 0 PSI 2.14 C ID / 1.16 CID 20 0 PSI 435 0 P S I 50 00 PSI .0315 ....

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 52 Cutting Deck Circuit Pressure (Using Pressure Gauge) CENTER DECK CIRCUIT PRESSURE TEST SHOWN PRESSURE GAUGE 3.3 G P M 14 .3 G P M 14 .3 G P M 1.17 C ID 30 00 P S I P1 P1 P1 P2 P2 P2 M1 M2 LC 1 PR V PD CD RV 20 00 PSI M1 M2 LC 1 PR V PD RV 3...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 56 Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauge and Flow Meter) CENTER CUTTING DECK MOTOR CASE DRAIN LEAKAGE TEST SHOWN 1.17 CID 3000 PSI P1 P1 P2 P2 M1 M2 LC1 PRV PD CD RV 2000 PSI M1 M2 LC1 PRV PD RV 3000 PSI M1 M2...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 58 Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) S1 0 RV 1 CV 1 S2 S4 S5 PR V P4 CH 2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV 2 S7 S9 S8 C6 M1 M2 CH 1 CV 3 CH 4 OR2 .063 OR 6 .063 OR3 .070 OR 7 .0 70 T 2SP CH 3 G2 G4...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 60 Steering Circuit Relief Pressure (Using Pressure Gauge) S1 0 RV 1 CV1 S2 S4 S5 PR V P4 CH 2 P3 EC CF LS S3 OR 1 C3 OR4 .040 S6 OR 5 .07 0 C4 C 2 C5 RV 2 25 00 PSI S7 S9 S8 C6 M1 M2 CH 1 CV3 CH 4 OR 2 .0 63 OR 6 .0 63 OR 3 .07 0 OR7 .070 T 2...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 62 Steering Cylinder Internal Leakage 6.1 CID E P L R T STEERING CYLINDER 2.00” BORE 4.20” STROKE 0.625” ROD STEERING CONTROL VALVE STEERING WHEEL TURNED FOR RIGHT TURN CYLINDER FULLY EXTENDED LOOK FOR LEAKAGE STEEL CAP FROM COMBINATION MANIFO...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 64 Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac) S1 0 RV 1 CV 1 S2 S4 S5 PR V P4 CH 2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR 5 .0 70 C4 C 2 C5 RV 2 250 0 PS I S7 S9 S8 C6 M1 M2 CH 1 CV 3 CH 4 OR 2 .063 OR 6 .0 63 OR 3 .0 70 OR 7...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 66 Gear Pump Flow (Using Tester with Pressure Gauge and Flow Meter) SECOND GEAR PUMP SECTION FLOW TEST SHOWN 3. 3 G P M 14 .3 G P M 14 .3 G P M 25 0 PSI 435 0 P S I 50 00 P S I .031 5 .03 15 0.4 CI D 0. 3 1.29 1.29 CI D CI D C ID 2. 75 CI D EN...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 68 Adjustments Adjust Control Manifold Relief Valves Several of the hydraulic control manifolds on the Groundsmaster include adjustable relief valves. The fol- lowing procedure can be used to adjust these relief valves. Refer to the Testing se...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 70 Check Hydraulic Lines and Hoses WARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under highpressure. Use paper or cardboard, not hands, tosearch for leaks. Hydraulic fluid escaping under pressure ca...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 71 Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated. Contaminated oil may appear milky or black or may contain metal particles. IMPORTANT: If a component fa...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 73 Charge Hydraulic System NOTE: When initially starting the hydraulic system with new or rebuilt components such as motors, pumps or lift cylinders, it is important that the hydraulic system be charged properly. Air must be purged from the sy...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 74 Hydraulic Reservoir Figure 52 FRONT RIGHT 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 23 24 25 26 27 28 29 30 3 31 1. Hydraulic reservoir 2. Cap screw 3. Recess bumper (2 used) 4. Thin spacer 5. Flange nut 6. Breather 7. Bushin...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 76 Radiator and Oil Cooler Assembly 1. LH radiator support 2. Cap screw (2 used) 3. Flange nut (12 used) 4. Hose clamp (3 used) 5. Hose 6. Flange nut (6 used) 7. Foam plug (2 used) 8. Flange head screw (6 used) 9. Flange head screw (9 used) 10...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 78 Gear Pump Figure 55 FRONT RIGHT 2 3 8 9 10 11 13 1 7 12 14 15 16 17 18 19 20 4 21 22 23 24 2 1 15 9 20 26 6 25 1 5 27 1. Hose clamp (3 used) 2. Hose clamp (2 used) 3. Hydraulic hose 4. Suction hose 5. Tee fitting 6. Straight hydraulic fitti...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 82 Gear Pump Service 1. Front cover 2. Dowel pin (4 used) 3. Pressure seal 4. Back--up gasket 5. Front thrust plate 6. Seal (8 used) 7. Front body 8. Idler gear 9. Drive shaft 10. Thrust plate (7 used) 11. Dowel pin (6 used) 12. Splined connec...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 89 1. Screen (2 used) 2. Plug with O --ring (2 used) 3. Plug with O --ring (2 used) 4. Cylinder block assembly 5. Valve plate 6. Servo piston 7. Screw (4 used) 8. Orifice (2 used) 9. Screw (4 used) 10. Plug with O --ring (4 used) 11. Screw (2 ...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 90 Rear Axle Motor 1. Rear axle motor 2. 90 o hydraulic fitting (2 used) 3. 90 o hydraulic fitting 4. Straight hydraulic fitting 5. 90 o hydraulic fitting 6. Temperature sender 7. Cap screw (2 used) 8. Flat washer (2 used) 9. O--ring 10. Exter...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 92 Front Wheel Motors 1. Front wheel motor 2. Internal retaining ring 3. Splined brake shaft 4. RH brake assembly 5. Planetary assembly (2 used) 6. Cap screw (2 used per motor) 7. Flat washer (2 used per motor) 8. O--ring 9. LH brake assembly ...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 94 Rear Axle and Front Wheel Motor Service Figure 68 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 23 21 25 1. Plug with O --ring 2. Minimum angle stop 3. Bias spring 4. Servo piston 5. O--ring 6. O--ring 7. Socket head screw (5 use...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 95 NOTE: The front wheel motors on your Groundsmaster are identical (Fig. 68). The rear axle motor includes a flushing valve for cooling of the closed loop traction cir- cuit and therefore has some differences from the front motors (Fig. 69). ...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 96 Rear Traction Manifold 1. Front frame 2. PTO manifold (center deck section) 3. Rear traction manifold 4. Cap screw (2 used) 5. Flange nut (2 used) 6. 90 o hydraulic fitting 7. O--ring 8. 45 o hydraulic fitting 9. O--ring 10. O--ring 11. Str...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 98 Rear Traction Manifold Service 1. Rear traction manifold body 2. Relief valve (port RV) 3. Pressure reducing valve (port PR) 4. #4 zero leak plug with O --ring 5. #6 zero leak plug with O --ring 6. Check valve (port CV) 7. Orifice (0.050) (...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 99 Control Manifold Cartridge Valve Service 1. Make sure the control manifold is clean before re- moving the cartridge valve from the control manifold. 2. If cartridge valve is solenoid operated, remove nut securing solenoid coil to the cartri...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 100 Combination Manifold 1. Combination manifold 2. Flange nut (3 used) 3. Flat washer (3 used) 4. Mount (3 used) 5. Spacer (3 used) Figure 72 FRONT RIGHT 2 3 1 5 4 NOTE: The ports on the combination manifold are marked for easy identification...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 102 Combination Manifold Service 1. Combination manifold 2. #6 zero leak plug with O--ring 3. Check valve (CV3) 4. #4 zero leak plug with O--ring 5. Solenoid valve (S4, S6 and S9) 6. Solenoid valve (S5) 7. Relief valve (RV2) 8. Solenoid valve ...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 104 Steering Control Valve 1. Steering wheel cover 2. Hex nut 3. Flat washer 4. Steering wheel 5. Foam collar 6. Steering seal 7. External snap ring (2 used) 8. Steering shaft 9. Flange bushing 10. Thrust washer (as needed) 11. Cap screw (4 us...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 106 Steering Control Valve Service 1. Steering valve housing 2. Dust seal 3. O--ring 4. Spool 5. Spring retaining ring 6. Pin 7. Sleeve 8. Centering springs/spacers 9. Cap screw (7 used) 10. End cap 11. O--ring 12. Seal ring 13. O--ring 14. Ge...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 108 Steering Cylinder 1. Steering cylinder 2. Ball joint 3. Ball joint 4. Retaining ring (2 used) 5. Grease fitting 6. Grease fitting 7. 90 o hydraulic fitting (2 used) 8. Drive axle assembly 9. Ball joint spacer 10. Axle washer 11. Slotted he...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 110 Steering Cylinder Service 1. Barrel 2. Rod 3. Piston 4. Head 5. Internal collar 6. Backup ring 7. O--ring 8. Dust seal 9. Rod seal 10. O--ring 11. Piston seal 12. Lock nut Figure 83 40 ft--lb (54 N--m) 1 6 7 3 9 10 4 11 2 8 5 12 1 6 7 3 9 ...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 112 Engine Cooling Fan Motor 1. Hydraulic fan motor 2. O--ring 3. Fan bracket 4. Hydraulic fitting (2 used) 5. O--ring 6. Radiator/oil cooler assembly 7. Fan hub 8. Washer 9. Hex nut 10. Lower radiator shroud 11. Cap screw (4 used) 12. Washer ...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 116 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 11. Body 12. Idler gear 13. Cap screw (4 us...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 117 9. Turn front flange over, with seal side up. IMPORTANT: Make sure not to damage the front flange counter bore when removing the seals from the front flange. 10.Carefully remove dust seal, retaining ring, flange washer and shaft seal from ...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 119 Cutting Deck Motor Removal (Fig. 90) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic S...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 126 PTO Manifolds 1. Hydraulic PTO manifold (center deck) 2. Quick fitting (1 used per manifold) 3. Flange screw (2 used per manifold) 4. O--ring 5. Hydraulic tee fitting 6. O--ring 7. O--ring 8. O--ring 9. Hydraulic adapter 10. Straight fitti...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 128 PTO Manifold Service 1. PTO manifold body 2. NWD SAE #4 plug with O --ring 3. Orifice (0.025) (port OR) 4. #6 zero leak plug with O--ring 5. Relief valve (port RV1) 6. Proportional relief valve (port PRV) 7. Solenoid coil 8. Nut 9. Logic c...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 130 Cutting Deck Lift Cylinders FRONT RIGHT 1. Cutting deck 2. RH lift arm 3. LH lift arm 4. Lift cylinder (2 used) 5. Pin (1 used per cylinder) 6. Flange nut (1 used per pin) 7. Cap screw (1 used per pin) 8. Grease fitting (1 used per pin) 9....

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 132 Wing Deck Lift Cylinders 1. Center deck 2. Grease fitting 3. Tapered stud 4. Spherical bearing 5. Flange nut 6. Retaining ring 7. Wing deck lift cylinder 8. Lock nut 9. Flat washer 10. Lock nut 11. Pilot spacer 12. Cap screw 13. Wing deck ...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 133 Removal (Fig. 104) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components a...

Groundsmaster 4100--D/4110--D Hydraulic System Page 4 -- 134 Lift Cylinder Service 1. Barrel with clevis 2. Internal collar 3. Shaft with clevis 4. Dust seal 5. Rod seal 6. O--ring 7. Back--up ring 8. Head 9. O--ring 10. Wear ring 11. Piston 12. Lock nut 13. Piston seal 14. Grease fitting Figure 105...

Groundsmaster 4100--D/4110--D Page 5 -- 1 Electrical System Chapter 5 Electrical System Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Toro Electronic Controllers (TEC) 2 . . . . . . . . . . . ...

Groundsmaster 4100--D/4110--D Page 5 -- 3 Electrical System Yanmar Engine Electronic Control Unit (ECU) The Yanmar engine that powers the Groundsmaster 4100--D and 4110--D uses an electronic control unit (ECU) for engine management and also to communi- cate with the TEC controllers and the InfoCente...

Groundsmaster 4100--D/4110--D Page 5 -- 4 Electrical System CAN--bus Communications The two (2) TEC controllers, the Yanmar engine elec- tronic control unit and the InfoCenter Display used on the Groundsmaster 4100--D and 4110--D communicate with each other on a CAN--bus system. Using this sys- tem ...

Groundsmaster 4100--D/4110--D Page 5 -- 6 Electrical System Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The multimeter can test electrical components and cir- cuits for current, resistance or voltage. NOTE: Toro rec...

Groundsmaster 4100--D/4110--D Page 5 -- 7 Electrical System Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally. Figure 7 El ec tr ic al System

Groundsmaster 4100--D/4110--D Page 5 -- 8 Electrical System InfoCenter Display The InfoCenter Display used on your Groundsmaster is a LCD device that is located on the console. The Info- Center provides information for the machine operator during machine operation, provides electrical system diagnos...

Groundsmaster 4100--D/4110--D Page 5 -- 9 Electrical System Main Information Screen The two (2) InfoCenter main information screens (Figs. 10 and 11) are displayed after the initial splash screen has been displayed for several seconds. During normal machine operation, the main information screens pr...

Groundsmaster 4100--D/4110--D Page 5 -- 10 Electrical System Main Menu Screen The main menu screen can be accessed from the Info- Center main information or splash screen by pressing and releasing the menu/back button (left button) on the display. Once to the main menu screen (Fig. 12), naviga- tion...

Groundsmaster 4100--D/4110--D Page 5 -- 11 Electrical System Service Screen The service screen (Fig. 15) contains machine opera- tional information including hours and counts. Values listed for these service menu items cannot be changed. If the machine PIN has been entered to allow access to protect...

Groundsmaster 4100--D/4110--D Page 5 -- 12 Electrical System Diagnostics Screen The diagnostics screen (Fig. 16) lists the various states of machine electrical components. The diagnostics screen should be used to check operation of machine controls and to verify that switches and circuit wiring are ...

Groundsmaster 4100--D/4110--D Page 5 -- 13 Electrical System Settings Screen The settings screen identifies the InfoCenter language and units (English or Metric). The settings screen also allows the operator to customize the backlight (bright- ness) and contrast settings for the InfoCenter display. ...

Groundsmaster 4100--D/4110--D Page 5 -- 14 Electrical System About Screen The about screen (Fig. 19) identifies the machine model number, serial number and software revisions for the TEC controllers, InfoCenter and engine electronic con- trol unit (if available). The about screen also lists the CAN-...

Groundsmaster 4100--D/4110--D Page 5 -- 15 Electrical System Troubleshooting CAUTION Remove all jewelry, especially rings and watches, before doing any electrical trouble- shooting or testing. Also, disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting...

Groundsmaster 4100--D/4110--D Page 5 -- 16 Electrical System Fault Codes The list below identifies the fault codes that are gener- ated by the TEC controller to identify an electrical sys- tem malfunction (fault) that occurred during machine operation. Use the InfoCenter Display for fault retrieval....

Groundsmaster 4100--D/4110--D Page 5 -- 18 Electrical System Starting Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical problems. Problem Possible Causes No electrical power to machine. The battery is discharged. The battery c...

Groundsmaster 4100--D/4110--D Page 5 -- 20 Electrical System General Run and Transport Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical problems. Problem Possible Causes Engine continues to run, but should not, when the ignit...

Groundsmaster 4100--D/4110--D Page 5 -- 21 Electrical System Cutting Deck Operating Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical problems. NOTE: To engage the mow circuit, the operator must be in the operator seat, the tr...

Groundsmaster 4100--D/4110--D Page 5 -- 22 Electrical System Cutting Deck Operating Problems (Continued) Problem Possible Causes Wing cutting deck does not operate. The wing cutting deck is not fully lowered. The wing deck position switch or circuit wiring is faulty. Hydraulic valve solenoid(s) or c...

Groundsmaster 4100--D/4110--D Page 5 -- 23 Electrical System Cutting Deck Lift/Lower Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical problems. NOTE: To lower a cutting deck, the operator must be in the operator seat and the ...

Groundsmaster 4100--D/4110--D Page 5 -- 26 Electrical System Electrical System Quick Checks Battery Test (Open Circuit) 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 to 100 o F (16 o to 38...

Groundsmaster 4100--D/4110--D Page 5 -- 27 Electrical System Adjustments Wing Deck Position Switch 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 positio...

Groundsmaster 4100--D/4110--D Page 5 -- 28 Electrical System Traction Pedal Adjustment The traction pedal includes a neutral assembly that is used to adjust the traction neutral position (Fig. 22). Traction pedal adjustment may be necessary to make sure that traction pedal movement provides the corr...

Groundsmaster 4100--D/4110--D Page 5 -- 30 Electrical System Traction Pedal Position Sensor Calibration IMPORTANT: A properly installed and calibrated traction pedal position sensor is critical to accurate traction system response and for reliable sensor life. Use care when removing, installing and ...

Groundsmaster 4100--D/4110--D Page 5 -- 31 Electrical System Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check). NOTE: For engine compone...

Groundsmaster 4100--D/4110--D Page 5 -- 32 Electrical System Fuses The fuse block is located under the controller cover next to the operator seat (Fig. 30). In addition to the fuses in the fuse block, a 60 Amp fuse is included in the wire harness to protect the power cir- cuit for the operator cab. ...

Groundsmaster 4100--D/4110--D Page 5 -- 34 Electrical System Fusible Link Harness Your Groundsmaster uses two (2) fusible links for circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the wire harness (Fig. 35). If either of these links should fa...

Groundsmaster 4100--D/4110--D Page 5 -- 35 Electrical System PTO Switch The PTO switch is located on the control arm (Fig. 37). The PTO switch is pulled up to engage the PTO and pushed in to disengage the PTO. The TEC controller monitors the position of the PTO switch (up or down). Using inputs from...

Groundsmaster 4100--D/4110--D Page 5 -- 36 Electrical System HI/LOW Speed, Engine Speed and Cutting Deck Lift Switches The HI/LOW, engine speed and cutting deck lift switches are all identical momentary switches. These switches are located on the control arm (Fig. 39). The HI/LOW speed switch is use...

Groundsmaster 4100--D/4110--D Page 5 -- 37 Electrical System Cruise Control Switch The cruise control switch is used as an input for the TEC controller to maintain ground speed when engaged. The cruise control function is enabled when the switch is in the ON (center) position. Pressing the front of ...

Groundsmaster 4100--D/4110--D Page 5 -- 38 Electrical System Seat Switch The seat switch is normally open and closes when the operator is on the seat. This switch is used as an input for the TEC controller. The seat switch and its electrical connector are located in the seat assembly. If the trac- t...

Groundsmaster 4100--D/4110--D Page 5 -- 39 Electrical System Parking Brake Switch The switch used for the parking brake is a normally open proximity switch that is located under the steering tower cover (Fig. 44). The parking brake switch is an input for the TEC controller. When the parking brake is...

Groundsmaster 4100--D/4110--D Page 5 -- 40 Electrical System Service Brake Switches The two (2) switches used for the service brakes are nor- mally open switches that are located under the footrest panel (Fig. 45). The service brake switches provide in- puts for the TEC controller. When a brake peda...

Groundsmaster 4100--D/4110--D Page 5 -- 52 Electrical System Traction Pedal Position Sensor The traction pedal position sensor is connected to the traction pedal assembly (Fig. 67). This position sensor determines the neutral band for the traction pedal, the direction of travel desired by the operat...

Groundsmaster 4100--D/4110--D Page 5 -- 53 Electrical System Audio Alarm The audio alarm sounds to notify the operator when a machine problem exists. Electrical current for the alarm is provided as an output from the TEC controller. The alarm is attached to the console arm next to the operator seat....

Groundsmaster 4100--D/4110--D Page 5 -- 54 Electrical System Hydraulic Valve Solenoid Coils Figure 69 1. Front PTO manifold 2. RH PTO manifold 3. LH PTO manifold 4. Combination manifold FRONT RIGHT 2 3 1 4 Several hydraulic solenoid valve coils are used on the hydraulic control manifolds of Groundsm...

Groundsmaster 4100--D/4110--D Page 5 -- 56 Electrical System Piston (Traction) Pump Control Solenoid Coils The piston (traction) pump uses an electronic control as- sembly for swash plate rotation. Electrical outputs from the machine TEC controller are provided to two (2) solenoid coils for pump con...

Groundsmaster 4100--D/4110--D Page 5 -- 59 Electrical System Fuel Sender The fuel sender is attached to the top of the fuel tank. The resistance of the fuel sender increases as the fuel level in the fuel tank decreases. The TEC controller uses the fuel sender as an input to generate an output for th...

Groundsmaster 4100--D/4110--D Page 5 -- 62 Electrical System Wing Deck Position Switches Two (2) wing deck position switches are used on the Groundsmaster 4100--D and 4110--D as inputs for the TEC controller. The position switches are powered prox- imity switches that are normally open. The switches...

Groundsmaster 4100--D/4110--D Page 5 -- 63 Electrical System Hydraulic Oil Temperature Sender The Groundsmaster 4100--D and 4110--D use a temper- ature sender as an input for the TEC controller to identify if the hydraulic oil temperature has reached an exces- sive level. The hydraulic oil temperatu...

Groundsmaster 4100--D/4110--D Page 5 -- 64 Electrical System Service and Repairs NOTE: For engine component repair information (e.g. starter motor), refer to the Yanmar Service Manual that is correct for your Groundsmaster model. Battery Care 1. The top of the battery must be kept clean. lf the ma- ...

Groundsmaster 4100--D/4110--D Page 5 -- 65 Electrical System Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. CAUTION When working with batteries,...

Groundsmaster 4100--D/4110--D Page 6 -- 1 Axles, Planetaries and Brakes Chapter 6 Axles, Planetaries and Brakes Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 3 . . . . . . ....

Groundsmaster 4100--D/4110--D Page 6 -- 3 Axles, Planetaries and Brakes General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional inf...

Groundsmaster 4100--D/4110--D Page 6 -- 4 Axles, Planetaries and Brakes Adjustments Planetary Wheel Drive Assembly Endplay A front planetary wheel drive assembly that is properly operating should have no endplay. Any endplay in a planetary assembly indicates that there are potential problems with th...

Groundsmaster 4100--D/4110--D Page 6 -- 6 Axles, Planetaries and Brakes Service and Repairs Brake Assembly Figure 1 FRONT RIGHT 75 to 85 ft--lb (101 to 115 N--m) 85 to 100 ft--lb (115 to 135 N--m) 75 to 85 ft--lb (101 to 115 N--m) 2 3 6 8 9 11 13 1 5 7 12 14 15 4 10 1 6 7 8 13 1. Front wheel motor 2...

Groundsmaster 4100--D/4110--D Page 6 -- 7 Axles, Planetaries and Brakes Removal (Fig. 1) 1. Park machine on a level surface, lower cutting deck, stop engine and remove key from the ignition switch. 2. Drain oil from planetary wheel drive/brake assembly (Fig. 2). CAUTION When removing front wheel, us...

Groundsmaster 4100--D/4110--D Page 6 -- 8 Axles, Planetaries and Brakes 2. Apply gasket sealant to sealing surfaces of new gas- ket (item 18). Apply gasket to brake assembly. 3. Install brake assembly onto machine, aligning splined brake shaft with input shaft on planetary wheel drive. Make sure tha...

Groundsmaster 4100--D/4110--D Page 6 -- 10 Axles, Planetaries and Brakes Brake Inspection and Repair 1. Brake housing (LH shown) 2. Seal 3. Pull rod 4. Clevis pin (2 used) 5. Link (2 used) 6. Hitch pin (2 used) 7. Stationary disc (4 used) 8. Rotating disc (3 used) 9. Retaining ring 10. Gasket 11. Ro...

Groundsmaster 4100--D/4110--D Page 6 -- 12 Axles, Planetaries and Brakes Planetary Wheel Drive Assembly Figure 7 FRONT RIGHT 75 to 85 ft--lb (101 to 115 N--m) 85 to 100 ft--lb (115 to 135 N--m) 75 to 85 ft--lb (101 to 115 N--m) 1. Front wheel motor 2. Internal retaining ring 3. Splined brake shaft 4...

Groundsmaster 4100--D/4110--D Page 6 -- 14 Axles, Planetaries and Brakes Planetary Wheel Drive Service 1. Spindle 2. Boot seal 3. Oil seal 4. Inner bearing cone 5. Inner bearing cup 6. Wheel stud (8 used) 7. Socket head screw (16 used) 8. Lock washer (16 used) 9. Housing 10. Dowel pin (2 used) 11. O...

Groundsmaster 4100--D/4110--D Page 6 -- 18 Axles, Planetaries and Brakes Rear Axle Assembly 1. Plug with O --ring 2. Lug nut (5 used per wheel) 3. Rear wheel assembly (2 used) 4. Cap screw (2 used) 5. Flat washer (8 used) 6. Rear axle motor 7. O--ring 8. Steering cylinder 9. Spacer 10. Cotter pin (2...

Groundsmaster 4100--D/4110--D Page 6 -- 22 Axles, Planetaries and Brakes Rear Axle Service Figure 19 3 2 4 5 6 7 8 9 10 14 13 12 11 15 1 10 11 8 9 8 13 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 20 41 42 43 50 44 45 46 47 48 49 51 54 55 56 57 58 59 52 53 60 61 62 63 64 2...

Groundsmaster 4100--D/4110--D Page 6 -- 23 Axles, Planetaries and Brakes 1. LH axle support 2. Flange bushing (2 used) 3. Axle vent 4. Filter 5. Vent extension 6. Cap screw (4 used per gear case) 7. Shim set 8. Seal washer 9. Plug 10. Lock nut 11. Lock washer 12. Grease fitting 13. Ball bearing 14. ...

Groundsmaster 4100--D/4110--D Page 6 -- 24 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. Removal 1. Remove the mounting screws, nuts and lock wash- ers. Remove the bevel gear case/axle case asse...

Groundsmaster 4100--D/4110--D Page 6 -- 25 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. 23). 6. While holding the bevel gear case, tap the upper end of the bevel gea...

Groundsmaster 4100--D/4110--D Page 6 -- 27 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 disassembl...

Groundsmaster 4100--D/4110--D Page 6 -- 28 Axles, Planetaries and Brakes 9. Remove the bevel gear case/axle case assembly from the axle support. Coat a new O-ring with grease and temporarily install the axle cover assembly. Position a dial indicator at the tooths center. Prevent the axle from turnin...

Groundsmaster 4100--D/4110--D Page 6 -- 29 Axles, Planetaries and Brakes Axle Shafts The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig. 32). 2. Use...

Groundsmaster 4100--D/4110--D Page 6 -- 30 Axles, Planetaries and Brakes Input Shaft/Pinion Gear Figure 35 1 1. Nut (2 used) 2. Lock washer (2 used) 3. Stud (2 used) 4. Lock nut 5. Stake washer 6. Oil seal 7. O-ring 8. Seal collar 9. Bearing 10. O-ring 11. Input shaft/pinion gear 12. Bearing case 13...

Groundsmaster 4100--D/4110--D Page 6 -- 32 Axles, Planetaries and Brakes Differential Gear The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of thi...

Groundsmaster 4100--D/4110--D Page 6 -- 33 Axles, Planetaries and Brakes 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. 42). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 inch (0...

Groundsmaster 4100--D/4110--D Page 6 -- 35 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. 46): Toe -- the portion of t...

Groundsmaster 4100--D/4110--D Page 7 -- 1 Chassis Chapter 7 Chassis Table of Contents GENERAL INFORMATION 1 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 1 . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE AND REPAIRS 2 . . . . . . . . . . . . . . . . . . . . . . Steering Tow...

Groundsmaster 4100--D/4110--D Page 7 -- 2 Chassis Service and Repairs Steering Tower Figure 1 FRONT RIGHT 27 to 33 ft--lb (37 to 44 N--m) 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 7 10 20 to 26 ft--lb (28 to 35 N--m) 20 19 1. Steering wheel cover 2. Hex nut 3. Flat washer 4. Steering wheel ...

Groundsmaster 4100--D/4110--D Page 7 -- 4 Chassis Cutting Deck Lift Arms 1. Deck assembly 2. Deck motor (3 used) 3. Spider hub (3 used) 4. Spider (3 used) 5. Damper support 6. Clevis rod end 7. Spherical rod end 8. Damper 9. Spacer 10. Spring pin 11. LH lift arm 12. Pin (2 used) 13. Grease fitting (...

Groundsmaster 4100--D/4110--D Page 7 -- 8 Chassis Console Arm 1. Flange nut (3 used) 2. Flange head screw (2 used) 3. Washer head screw (10 used) 4. LH cover 5. Lock nut 6. Control arm panel 7. Ignition switch 8. InfoCenter display 9. R--clamp 10. Audio alarm 11. PTO switch 12. Nut 13. Bracket 14. U...

Groundsmaster 4100--D/4110--D Page 7 -- 10 Chassis Traction Pedal Assembly 1. Carriage bolt (6 used) 2. Traction pedal 3. Bushing 4. Operator platform 5. Cap screw 6. Rod end bearing 7. Hex nut 8. Flange nut (10 used) 9. Traction pedal shaft 10. Roll pin 11. Cap screw (2 used) 12. Clamp block (2 use...

Groundsmaster 4100--D/4110--D Page 7 -- 12 Chassis Operator Platform 1. Operator platform 2. Cap screw (2 used) 3. Flat washer (4 used) 4. Center mount (4 used) 5. Plain washer (4 used) 6. Lock nut (4 used) 7. Cap screw (2 used) Figure 12 FRONT RIGHT 3 2 1 4 5 6 7 3 4 5 6 95 to 115 ft--lb (129 to 15...

Groundsmaster 4100--D/4110--D Page 7 -- 16 Chassis Operator Seat 1. Carriage screw (5 used) 2. Support channel 3. Support bracket 4. Flange nut (6 used) 5. Cap screw 6. Flat washer (4 used) 7. Arm support 8. Screw 9. Coupler nut 10. Spacer 11. Flange nut (4 used) 12. Seat belt 13. Cap screw 14. Seat...

Groundsmaster 4100--D/4110--D Page 7 -- 18 Chassis Operator Seat Service 1. Backrest cushion 2. Seat cushion 3. Armrest cover 4. LH armrest 5. Bushing (2 used) 6. Backrest 7. Plug (2 used) 8. Cable tie (3 used) 9. LH adjustment rail 10. Bumper (2 used) 11. Washer 12. Cap screw (2 used) 13. Seat 14. ...

Groundsmaster 4100--D/4110--D Page 7 -- 19 Chassis Disassembly (Fig. 20) 1. Disassemble operator seat as necessary using Fig- ures 20 and 21 as guides. Assembly (Fig. 20) 1. Assemble operator seat using Figures 20 and 21 as guides. 1. Operator seat 2. R--clamp (2 used) 3. Screw (2 used) 4. Manual tu...

Groundsmaster 4100--D/4110--D Page 7 -- 20 Chassis Operator Seat Suspension 1. Cover 2. Cover 3. Level control 4. Air control valve 5. Shock absorber 6. Air spring 7. Air tube assembly 8. Wire harness 9. Compressor 10. Bellows 11. Stop 12. Bumper set (2 used) 13. Roller (4 used) 14. Washer (2 used) ...

Groundsmaster 4100--D/4110--D Page 7 -- 22 Chassis Hood 1. Hood 2. Screen assembly 3. Bulb seal 4. Flange nut (2 used) 5. Screen pivot (2 used) 6. Hair pin (2 used) 7. Hood support 8. Plastite screw (4 used) 9. Door handle (2 used) 10. Bulb seal 11. Hood pivot (2 used) 12. Flexible draw latch (2 use...

Groundsmaster 4100--D/4110--D Cutting Deck Page 8 -- 1 Chapter 8 Cutting Deck Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 3 . . . . . . . . . . . . . . . . . . . . . . . ....

Groundsmaster 4100--D/4110--D Cutting Deck Page 8 -- 3 General Information CAUTION Never install or work on the cutting deck or lift arms with the engine running. Always stop en- gine and remove ignition key first. Operator’s Manual The Operator’s Manual provides information regarding the operation,...

Groundsmaster 4100--D/4110--D Cutting Deck Page 8 -- 4 Troubleshooting There are a number of factors that can contribute to un- satisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, uneven ground conditions, “sponginess” or attempting to cut off...

Groundsmaster 4100--D/4110--D Cutting Deck Page 8 -- 10 Wing Deck Service 1. Wing deck (RH shown) 2. Skid (RH shown) 3. Flange screw (2 used per skid) 4. Flange nut (2 used per skid) 5. Cap screw 6. Roller (2 used) 7. Lock nut 8. Pivot latch (2 used) 9. Flat washer 10. Retaining ring (2 used per lat...

Groundsmaster 4100--D/4110--D Cutting Deck Page 8 -- 13 Cutting Deck Link Service Disassembly (Fig. 10) 1. Press bushings from top of link. 2. Remove dust cap and retaining ring from link. 3. Press tapered stud with spherical bearing, flat wash- ers and flange nut from link. 4. Remove flange nut and...

Groundsmaster 4100--D/4110--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 latc...

Groundsmaster 4100--D/4110--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. High driven spindle (1 used) 6. Flange nut 7. Blade bolt 8. Cutting blade (7 used) 9. Anti--scalp ...

Groundsmaster 4100--D/4110--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 11. Inner bearing spacer 12. Spac...

Groundsmaster 4100--D/4110--D Cutting Deck Page 8 -- 20 Idler Assembly 1. Center deck 2. Flange nut 3. Flange nut 4. Adjusting screw 5. Idler pulley 6. High driven pulley 7. Flat washer 8. Lock washer 9. Socket head screw 10. Idler stop bolt 11. Flange nut 12. Cap screw 13. Spacer 14. Shoulder bolt ...

Groundsmaster 4100--D/4110--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/4110--D Cutting Deck Page 8 -- 22 Castor Forks and Wheels 1. Castor arm (wing deck shown) 2. Cap screw (6 per arm) 3. Castor fork 4. Castor wheel bolt 5. Lock nut 6. Castor spacer 7. Thrust washer 8. Flange lock nut 9. Grease fitting 10. Flange bushing 11. Retaining ring 12. Ca...

Groundsmaster 4100--D/4110--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. 2...

Groundsmaster 4110--D Operator Cab Page 9 -- 1 Chapter 9 Operator Cab Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Components and Schematic 2 . . . . . . . . . Air Conditioning Sys...

Groundsmaster 4110--D Operator Cab Page 9 -- 4 Air Conditioning Compressor Figure 1 FRONT RIGHT 1. Cap screw (2 used) 2. Flat washer (4 used) 3. Lock washer (6 used) 4. Hex nut (2 used) 5. Conduit 6. O--ring (2 used) 7. 90 o fitting 8. O --ring 9. A/C compressor 10. Cap screw (4 used) 11. Cap screw ...

Groundsmaster 4110--D Operator Cab Page 9 -- 6 Roof Assembly 1. Roof 2. Screw (2 used) 3. Flat washer (6 used) 4. Bushing (10 used) 5. Rear fastener (2 used) 6. Rear spacer (2 used) 7. Panel nut 8. Roof mount 9. Flange nut (2 used) 10. Flange nut (4 used) 11. Headliner 12. Front spacer (2 used) 13. ...

Groundsmaster 4110--D Operator Cab Page 9 -- 8 Air Conditioning Condenser Assembly 1. Condenser cover 2. Lock nut (4 used) 3. Condenser fan 4. Condenser coil assembly 5. Carriage screw (2 used) 6. Flat washer (8 used) 7. Roof 8. Bushing (4 used) 9. Mounting strap 10. Button head screw (4 used) Figur...

Groundsmaster 4110--D Operator Cab Page 9 -- 10 Heater/Evaporator Assembly 1. Heater/evaporator assembly 2. Top cover 3. Flange head screw (2 used) 4. Drier--receiver mount 5. Bottom cover 6. Hose clamp (2 used) 7. Speed nut (8 used) 8. Panel nut (4 used) 9. Drier--receiver assembly 10. Screw (8 use...

Groundsmaster 4110--D Operator Cab Page 9 -- 12 Windshield Wiper 1. Wiper motor 2. Gasket 3. Linkage bracket 4. Lock washer 5. Cap screw 6. Cap (2 used) 7. Washer 8. Nut 9. Flange nut (2 used) 10. Cover (2 used) 11. Wiper arm assembly 12. Wiper blade 13. Screw (2 used) Figure 10 2 3 6 8 9 10 11 13 1...

Groundsmaster 4100--D/4110--D Foldout Drawings Page 10 -- 1 Chapter 10 Foldout Drawings Table of Contents ELECTRICAL DRAWING DESIGNATIONS 2 . . . . . . . HYDRAULIC SCHEMATIC 3 . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SCHEMATICS Models 30602 and 30604 4 . . . . . . . . . . . . . . . . . ....

Groundsmaster 4100--D/4110--D Foldout Drawings Page 10 -- 2 Electrical Drawing Designations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. ABBREVIATION COLOR BK BLACK BR or BN BROWN BU BLUE GN GREEN GY GRAY OR ORAN...

Page 10 -- 4 Electrical Schematic Groundsmaster 4100--D/4110--D All relays and solenoids are shown as de-- energized.All ground wires are black. Models 30602 and 30604 1 2 3 4 5 CAB, A REFERENCE NUMBER WILL BE LISTED. THE CAB SCHEMATIC WILL ALSO INCLUDE THE REFERENCE NUMBER. NOTE: WHEN A WIRE FROM T...

Page 10 -- 6 TO GROUNDBLOCK PLATFORM WIRE HARNESS FROM OPERATOR PLATFORM WIRE HARNESS TO OPERATOR Operator Cab (shown with lights for US model) Groundsmaster 4110--D All relays and solenoids are shown as de-- energized.All ground wires are black. Electrical Schematic 1 2 3 4 TO CAB WIRE HARNESS SCHE...

Page 10 -- 7 Electrical Schematic Groundsmaster 4110--D All relays and solenoids are shown as de-- energized.All ground wires are black. International Light Kits 2 3 4 5 PLATFORM WIRE HARNESS FROM OPERATOR PLATFORM WIRE HARNESS TO OPERATOR TO CAB WIRE HARNESS PLATFORM WIRE HARNESS TO OPERATOR SCHEMA...

Page 10 -- 9 Groundsmaster 4100--D/4110--D Platform Wire Harness Drawing A B C D 12345

Page 10 -- 10 Groundsmaster 4100--D/4110--D Platform Wire Harness Diagram Sheet 1 of 2 REFERENCE NUMBER WILL BE IDENTIFIED. NOTE: THE PLATFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2)SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, A DRAWING DESIGNATIONS IN THIS CHAPTER NOTE: THIS DRAWING IDENTI...

Page 10 -- 12 Groundsmaster 4100--D/4110--D Rear Wire Harness Drawing

Page 10 -- 13 Groundsmaster 4100--D/4110--D Rear Wire Harness Diagram DRAWING DESIGNATIONS IN THIS CHAPTER NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIONAL INFORMATION.

Page 10 -- 14 Models 30606 and 30608 Engine Wire Harness Drawing Groundsmaster 4100--D/4110--D

Page 10 -- 15 Models 30606 and 30608 Engine Wire Harness Diagram Groundsmaster 4100--D/4110--D DRAWING DESIGNATIONS IN THIS CHAPTER NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIONAL INFORMATION.

Page 10 -- 18 Groundsmaster 4100--D/4110--D Cutting Deck Wire Harness DRAWING DESIGNATIONS IN THIS CHAPTER NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIONAL INFORMATION.

Page 10 -- 19 Groundsmaster 4110--D Operator Cab Interconnect Wire Harness DRAWING DESIGNATIONS IN THIS CHAPTER NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIONAL INFORMATION.

Page 10 -- 20 Groundsmaster 4110--D Operator Cab Wire Harness Drawing

Page 10 -- 21 Groundsmaster 4110--D Operator Cab Wire Harness Diagram DRAWING DESIGNATIONS IN THIS CHAPTER NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIONAL INFORMATION.