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(Models 30602, 30604, 30606 and 30608)
Part No. 13203SL
Service Manual
GroundsmasterR4100--D & 4110--D
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing
and repair of major systems and components on the
Groundsmaster 4100--D (Model 30604 and 30608) and
4110--D (Model 30602 and 30606).
REFER TO THE OPERATOR’S MANUAL FOR OPER-
ATING, MAINTENANCE AND ADJUSTMENT
INSTRUCTIONS. For reference, insert a copy of the
Operator’s Manual and Parts Catalog for your machine
into Chapter 2 of this service manual. Additional copies
of the Operator’s Manual and Parts Catalog are avail-
able on the internet at www.Toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.
This safety symbol means DANGER, WARNING
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: ANOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
EThe Toro Company -- 2014
Groundsmaster 4110--D
Groundsmaster 4100--D
Groundsmaster 4100--D/4110--D
This page is intentionally blank.
Groundsmaster 4100--D/4110--D
Table Of Contents
Chapter 1 -- Safety
General Safety Instructions 1 -- 2..................
Jacking Instructions 1 -- 5.........................
Safety and Instruction Decals 1 -- 6................
Chapter 2 -- Product Records and Maintenance
Product Records 2 -- 1...........................
Maintenance 2 -- 1...............................
Equivalents and Conversions 2 -- 2................
Torque Specifications 2 -- 3.......................
Chapter 3 -- Yanmar Diesel Engine
Specifications 3 -- 2..............................
General Information 3 -- 5........................
Service and Repairs 3 -- 10.......................
YANMAR TNV (Tier 4i) SERIES SERVICE MANUAL
YANMAR TNV (Tier 4i) SERIES TROUBLE--
SHOOTING MANUAL
YANMAR TNV (Tier 4) SERIES SERVICE MANUAL
YANMAR TNV (Tier 4) SERIES TROUBLESHOOTING
MANUAL
Chapter 4 -- Hydraulic System
Specifications 4 -- 2..............................
General Information 4 -- 3........................
Hydraulic Schematic 4 -- 9........................
Hydraulic Flow Diagrams 4 -- 10...................
Special Tools 4 -- 26.............................
Troubleshooting 4 -- 31...........................
Testing 4 -- 38...................................
Adjustments 4 -- 68..............................
Service and Repairs 4 -- 69.......................
SAUER DANFOSS PISTON PUMP
SAUER DANFOSS WHEEL MOTORS
EATON PARTS AND REPAIR INFORMATION: 5
SERIES STEERING CONTROL UNITS
Chapter 5 -- Electrical System
General Information 5 -- 2........................
Special Tools 5 -- 6..............................
InfoCenter Display 5 -- 8..........................
Troubleshooting 5 -- 15...........................
Electrical System Quick Checks 5 -- 26.............
Adjustments 5 -- 27..............................
Component Testing 5 -- 31........................
Service and Repairs 5 -- 64.......................
Chapter 6 -- Axles, Planetaries and Brakes
Specifications 6 -- 2..............................
General Information 6 -- 3........................
Adjustments 6 -- 4...............................
Service and Repairs 6 -- 6........................
Chapter 7 -- Chassis
General Information 7 -- 1........................
Service and Repairs 7 -- 2........................
Chapter 8 -- Cutting Deck
Specifications 8 -- 2..............................
General Information 8 -- 3........................
Troubleshooting 8 -- 4............................
Service and Repairs 8 -- 6........................
SafetyProduct Records
and Maintenance
Yanmar
Diesel Engine
Hydraulic
System
Electrical
System
Axles, Planetaries
and Brakes
Chassis
Cutting
Deck
Groundsmaster 4100--D/4110--D
This page is intentionally blank.
Groundsmaster 4100--D/4110--D
Table Of Contents (Continued)
Chapter 9 -- Operator Cab
General Information 9 -- 2........................
Service and Repairs 9 -- 3........................
SANDEN SD COMPRESSOR SERVICE GUIDE
Chapter 10 -- Foldout Drawings
Electrical Drawing Designations 10 -- 2.............
Hydraulic Schematic 10 -- 3.......................
Electrical Schematics 10 -- 4......................
Wire Harness Drawings 10 -- 9....................
OperatorFoldout
Drawings Cab
Groundsmaster 4100--D/4110--D
This page is intentionally blank.
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 and Service 4....................
JACKING INSTRUCTIONS 5.....................
Jacking the Front End 5.......................
Jacking the Rear End 5........................
SAFETY AND INSTRUCTION DECALS 6..........
Safety
Groundsmaster 4100--D/4110--DPage 1 -- 2Safety
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 and configuration of the machine, these fac-
tors are also dependent upon the awareness, concern
and proper training of the personnel involved in the op-
eration, transport, maintenance and storage of the ma-
chine. Improper use or maintenance of the machine can
result in injury or death. To reduce the potential for injury
or death, comply with the following safety instructions.
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
Before Operating
1. Review and understand the contents of the Opera-
tor’s Manual and Operator’s DVD before starting and
operating the vehicle. Become familiar with the controls
and know how to stop the vehicle and engine quickly.
Additional copies of the Operator’s Manual are available
on the internet at www.Toro.com.
2. Keep all shields, safety devices and decals in place.
If a shield, safety device or decal is defective, illegible or
damaged, repair or replace it before operating the ma-
chine.
3. Tighten any loose nuts, bolts or screws to ensure
machine is in safe operating condition.
4. Assure interlock switches are adjusted correctly so
engine cannot be started unless traction pedal is in
NEUTRAL and cutting deck is DISENGAGED.
5. Since diesel fuel is highly flammable, handle it care-
fully:
A. Useanapprovedfuelcontainer.
B. Do not remove fuel tank cap while engine is hot or
running.
C. Do not smoke while handling fuel.
D. Fill fuel tank outdoors and only to within an inch of
the top of the tank, not the filler neck. Do not overfill.
E. Wipe up any spilled fuel.
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, release parking brake and
keep foot off traction pedal. Machine must not move. If
movement is evident, there may be a problem with trac-
tion pedal calibration or the piston (traction) pump that
needs to be corrected before using the machine.
4. Do not run engine in a confined area without ade-
quate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
5. Do not touch engine, muffler or exhaust pipe while
engine is running or soon after it is stopped. These areas
could be hot enough to cause burns.
6. Before getting off the seat:
A. Ensure that traction pedal is in neutral.
B. Fully lower and disengage cutting deck. Wait for
blades to stop.
C. Apply the parking brake.
D. Stop engine and remove key from switch.
7. Toro recommends that anytime the machine is
parked (short or long term), the cutting deck should be
lowered to the ground. This relieves pressure from the
deck lift circuit and eliminates the risk of the cutting deck
unexpectedly lowering to the ground.
8. Do not park on slopes unless wheels are chocked or
blocked.
Safety
Groundsmaster 4100--D/4110--DPage 1 -- 4Safety
Maintenance and Service
1. Before servicing or making adjustments, lower deck,
stop engine, apply parking brake and remove key from
the switch.
2. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
3. Never store the machine or fuel container inside
where there is an open flame, such as near a water heat-
er or furnace.
4. Make sure all hydraulic line connectors are tight and
all hydraulic hoses and lines are in good condition be-
fore applying pressure to the system.
5. Keep body and hands away from pin hole leaks in hy-
draulic lines that eject high pressure hydraulic fluid. Use
cardboard or paper to find hydraulic leaks. Hydraulic
fluid escaping under pressure can penetrate skin and
cause injury. Fluid accidentally injected into the skin
must be surgically removed within a few hours by a doc-
tor familiar with this form of injury or gangrene may re-
sult.
6. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be re-
lieved by lowering cutting deck to the ground and stop-
ping engine.
7. If major repairs are ever needed or assistance is de-
sired, contact an Authorized Toro Distributor.
8. To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt. Clean
protective screen on machine frequently.
9. If engine must be running to perform maintenance or
an adjustment, keep hands, feet, clothing and other
parts of the body away from cutting deck and other mov-
ing parts. Keep bystanders away.
10.To assure safety and accuracy, check maximum en-
gine speed.
11. Shut engine off before checking or adding oil to the
crankcase.
12.Disconnect battery before servicing the machine.
Disconnect negative cable first and positive cable last.
If battery voltage is required for troubleshooting or test
procedures, temporarily connect the battery. Reconnect
positive cable first and negative cable last.
13.Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes and clothing. Protect your
face, eyes and clothing when working with a battery.
14.Battery gases can explode. Keep cigarettes, sparks
and flames away from the battery.
15.At the time of manufacture, the machine conformed
to the safety standards for riding mowers. To assure op-
timum performance and continued safety certification of
the machine, use genuine Toro replacement parts and
accessories. Replacement partsandaccessoriesmade
by other manufacturers may result in non-conformance
with the safety standards and the warranty may be
voided.
16.When changing attachments, tires or performing
other service, use correct jacks and supports. Make
sure machine is parked on a solid level surface such as
a concrete floor. Prior to raising the machine, remove
any attachments that may interfere with the safe and
proper raising of the machine. Always chock or block
wheels. Use appropriate jack stands to support the
raised machine. If the machine is not properly supported
by jack stands, the machine may move or fall, which may
result in personal injury (see Jacking Instructions in this
chapter).
17.When welding on machine, disconnect battery
cables to prevent damage to machine electronic equip-
ment. Disconnect negative battery cable first and posi-
tive cable last. Also, disconnect wire harness connector
from both of the TEC controllers, disconnect and re-
move the engine ECU and disconnect the terminal con-
nector from the alternator. Attach welder ground cable
no more than two (2) feet (0.61 meters) from the welding
location.
18.Make sure to dispose of potentially harmful waste
(e.g. fuel, oil, engine coolant, filters, battery) in an envir-
onmentally safe manner. Follow all local codes and reg-
ulations when recycling or disposing of waste.
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 attachments that
may interfere with the safe and proper raising of
the machine. Always chock or block wheels. Use
jack stands to support the raised machine. If the
machine is not properly supported by jack
stands, the machine may move or fall, which
may result in personal injury.
Jacking the Front End
1. Set parking brake and chock both rear tires to pre-
vent the machine from moving.
2. Position jack securely under the frame, just to the in-
side of the front tire. Jack front wheel off the ground.
3. Once the machine is raised, position suitable jack
stand under the frame as close to the wheel as possible
to support the machine.
Jacking the Rear End
1. Set parking brake and chock both front tires to pre-
vent the machine from moving.
2. Place jack securely under the center of rear axle.
Jack rear of machine off the ground.
3. Once the machine is raised, use jack stands under
theaxletosupportthemachine.
Safety
Groundsmaster 4100--D/4110--DPage 1 -- 6Safety
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 CONVERSIONS 2...........
Decimal and Millimeter Equivalents 2............
U.S. to Metric Conversions 2...................
TORQUE SPECIFICATIONS 3...................
Fastener Identification 3.......................
Using a Torque Wrench with an Offset Wrench 3..
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Inch Series) 4...............
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Metric) 5....................
Other Torque Specifications 6..................
Conversion Factors 6.........................
Product Records
Insert Operator’s Manual and Parts Catalog for your
Groundsmaster at the end of this chapter. Refer to Oper-
ator’s Manual for recommended maintenance intervals.
Additionally, insert Installation Instructions, Operator’s
Manuals and Parts Catalogs for any accessories that
have been installed on your Groundsmaster at the end
of this section.
Maintenance
Maintenance procedures and recommended service in-
tervals for your Groundsmaster are covered in the Oper-
ator’s Manual. Refer to that publication when performing
regular equipment maintenance. Several maintenance
procedures have break--in intervals identified in the Op-
erator’s Manual. Refer to the Engine Operator’s Manual
for additional engine specific maintenance procedures.
Product Records
and Maintenance
0.09375
Groundsmaster 4100--D/4110--DPage 2 -- 2Product 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 clearly identified and spe-
cified in this Service Manual.
These Torque Specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in this Ser-
vice Manual. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (e.g. Loctite), degree of lubrication
on the fastener, presence of a prevailing torque feature
(e.g. Nylock nut), hardness of the surface underneath
the fastener’s head or similar condition which affects the
installation.
As noted in the following tables, torque values should be
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread en-
gagement, etc.
The standard method of verifying torque shall be per-
formed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
thelinesmatchup.
Fastener Identification
Figure 1
Grade 1 Grade 5 Grade 8
Inch Series Bolts and Screws
Figure 2
Class 8.8 Class 10.9
Metric Bolts and Screws
Using a Torque Wrench with an Offset Wrench
Use of an offset wrench (e.g. crowfoot wrench) will affect
torque wrench calibration due to the effective change of
torque wrench length. When using a torque wrench with
an offset wrench, multiply the listed torque recommen-
dation by the calculated torque conversion factor (Fig.
3) to determine proper tightening torque. Tightening
torque when using a torque wrench with an offset
wrench will be lower than the listed torque recommen-
dation.
Example: The measured effective length of the torque
wrench (distance from the center of the handle to the
center of the square drive) is 18”.
The measured effective length of the torque wrench with
the offset wrench installed (distance from the center of
the handle to the center of the offset wrench) is 19”.
The calculated torque conversion factor for this torque
wrench with this offset wrench would be 18 / 19 = 0.947.
If the listed torque recommendation for a fastener is
from 76 to 94 ft--lb, the proper torque when using this
torque wrench with an offset wrench would be from 72
to 89 ft--lb.
Figure 3
(effective length of
torque wrench)
TORQUE CONVERSION FACTOR = A / B
A
B
(effective length of torque
Torque wrenchOffset wrench
wrench + offset wrench)
Product Records
and Maintenance
Groundsmaster 4100--D/4110--DPage 2 -- 4Product Records and Maintenance
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Thread Size
Grade 1, 5 &
8withThin
Height Nuts
SAE Grade 1 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
in--lb in--lb N--cm in--lb N--cm in--lb N--cm
#6--32UNC
10 + 213 + 2147 + 23
15 + 2169 + 23 23 + 3262 + 34
#6--40UNF 17 + 2192 + 23 25 + 3282 + 34
#8--32UNC
13 + 225 + 5282 + 30
29 + 3328 + 34 41 + 5463 + 56
#8--36UNF 31 + 4350 + 45 43 + 5486 + 56
#10--24UNC
18 + 230 + 5339 + 56
42 + 5475 + 56 60 + 6678 + 68
#10--32UNF 48 + 5542 + 56 68 + 7768 + 79
1/4 -- 20 UNC 48 + 753 + 7599 + 79 100 + 10 1130 + 113 140 + 15 1582 + 169
1/4 -- 28 UNF 53 + 765 + 10 734 + 113 115 + 12 1299 + 136 160 + 17 1808 + 192
5/16 -- 18 UNC 115 + 15 105 + 15 1186 + 169 200 + 25 2260 + 282 300 + 30 3390 + 339
5/16 -- 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2542 + 282 325 + 33 3672 + 373
ft--lb ft--lb N--m ft--lb N--m ft--lb N--m
3/8 -- 16 UNC 16 + 216 + 222 + 330 + 341 + 443 + 558 + 7
3/8 -- 24 UNF 17 + 218 + 224 + 335 + 447 + 550 + 668 + 8
7/16 -- 14 UNC 27 + 327 + 337 + 450 + 568 + 770 + 795 + 9
7/16 -- 20 UNF 29 + 329 + 339 + 455 + 675 + 877 + 8104 + 11
1/2 -- 13 UNC 30 + 348 + 765 + 975 + 8102 + 11 105 + 11 142 + 15
1/2 -- 20 UNF 32 + 453 + 772 + 985 + 9115 + 12 120 + 12 163 + 16
5/8 -- 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 21 285 + 28
5/8 -- 18 UNF 75 + 10 95 + 15 129 + 20 170 + 18 230 + 24 240 + 24 325 + 33
3/4 -- 10 UNC 93 + 12 140 + 20 190 + 27 265 + 27 359 + 37 375 + 38 508 + 52
3/4 -- 16 UNF 115 + 15 165 + 25 224 + 34 300 + 30 407 + 41 420 + 43 569 + 58
7/8 -- 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81
7/8 -- 14 UNF 155 + 25 260 + 30 353 + 41 475 + 48 644 + 65 667 + 66 904 + 89
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
engine oil or thread sealant such as Loctite.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the mini-
mum proof load specified in SAE J429. The tolerance is
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.
Groundsmaster 4100--D/4110--D Page 2 -- 5 Product Records and Maintenance
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)
Thread Size
Class 8.8 Bolts, Screws and Studs with
Regular Height Nuts
(Class 8 or Stronger Nuts)
Class 10.9 Bolts, Screws and Studs with
Regular Height Nuts
(Class 10 or Stronger Nuts)
M5 X 0.8 57 + 6in--lb 644 + 68 N--cm 78 + 8in--lb 881 + 90 N--cm
M6 X 1.0 96 + 10 in--lb 1085 + 113 N-- cm 133 + 14 in--lb 1503 + 158 N--cm
M8 X 1.25 19 + 2ft--lb 26 + 3N--m 28 + 3ft--lb 38 + 4N--m
M10 X 1.5 38 + 4ft--lb 52 + 5N--m 54 + 6ft--lb 73 + 8N--m
M12 X 1.75 66 + 7ft--lb 90 + 10 N--m 93 + 10 ft--lb 126 + 14 N--m
M16 X 2.0 166 + 17 ft--lb 225 + 23 N--m 229 + 23 ft--lb 310 + 31 N--m
M20 X 2.5 325 + 33 ft--lb 440 + 45 N--m 450 + 46 ft--lb 610 + 62 N--m
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
engine oil or thread sealant such as Loctite.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately + 10% of the
nominal torque value.
Product Records
and Maintenance
Groundsmaster 4100--D/4110--DPage 2 -- 6Product 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 ft--lb 18 + 3ft--lb
1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Size Baseline Torque*
No. 6 -- 32 UNC 20 + 5in--lb
No. 8 -- 32 UNC 30 + 5in--lb
No. 10 -- 24 UNC 38 + 7in--lb
1/4 -- 20 UNC 85 + 15 in--lb
5/16 -- 18 UNC 110 + 20 in--lb
3/8 -- 16 UNC 200 + 100 in--lb
Wheel Bolts and Lug Nuts
Thread Size Recommended Torque**
7/16 -- 20 UNF
Grade 5
65 + 10 ft--lb 88 + 14 N--m
1/2 -- 20 UNF
Grade 5
80 + 10 ft--lb 108 + 14 N--m
M12 X 1.25
Class 8.8
80 + 10 ft--lb 108 + 14 N--m
M12 X 1.5
Class 8.8
80 + 10 ft--lb 108 + 14 N--m
** For steel wheels and non--lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
Threads per Inch
Baseline Torque*
Type A Type B
No. 6 18 20 20 + 5in--lb
No. 8 15 18 30 + 5in--lb
No. 10 12 16 38 + 7in--lb
No. 12 11 14 85 + 15 in--lb
* Hole size, material strength, material thickness and fin-
ish must be considered when determining specific
torque values. All torque values are based on non--lubri-
cated fasteners.
Conversion Factors
in--lb X 11.2985 = N--cm N--cm X 0.08851 = in--lb
ft--lb X 1.3558 = N--m N--m X 0.7376 = ft--lb
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....................
GENERAL INFORMATION 5.....................
Operator’s Manuals 5.........................
Yanmar Service and Troubleshooting Manuals 5..
Stopping the Engine 5.........................
Engine Electronic Control Unit (ECU) 6..........
Yanmar Engine: Models 30602 and 30604 7.....
Yanmar Engine: Models 30606 and 30608 8.....
SERVICE AND REPAIRS 10.....................
Air Filter System 10...........................
Fuel System 12...............................
Check Fuel Lines and Connections 13.........
Empty and Clean Fuel Tank 13................
Priming the Fuel System 13...................
Fuel Tank Removal 13.......................
Fuel Tank Installation 13......................
Radiator and Oil Cooler Assembly 14............
Engine 18....................................
Engine Removal 19..........................
Engine Installation 21........................
Spring Coupler 24............................
Exhaust System (Models 30606 and 30608) 26...
YANMAR TNV (Tier 4i) SERIES SERVICE MANUAL
YANMAR TNV (Tier 4i) SERIES TROUBLESHOOTING
MANUAL
YANMAR TNV (Tier 4) SERIES SERVICE MANUAL
YANMAR TNV (Tier 4) SERIES TROUBLESHOOTING
MANUAL
Yanmar
Diesel Engine
Groundsmaster 4100--D/4110--DPage 3 -- 2Yanmar Diesel Engine
Specifications (Models 30602 and 30604)
Item Description
Make / Designation Yanmar Model 4TNV84T--ZMTR: 4--Cycle, 4 Cylinder,
Water Cooled, Turbocharged, Tier 4i Diesel Engine
Bore 3.307 in (84 mm)
Stroke 3.543 in (90 mm)
Total Displacement 121.7 in3(1995 cc)
Firing Order 1 (closest to flywheel end) -- 3 -- 4 (farthest from flywheel) -- 2
Direction of Rotation Counterclockwise (viewed from flywheel)
Fuel Diesel or Biodiesel (up to B20) Fuel with Low or
Ultra Low Sulfur Content
Fuel Tank Capacity 21 U.S. gallons (79.5 liters)
Fuel Injection Pump Yanmar MP2 Distributor Type Pump
Fuel Injection Type Direct Injection
Starting Aid Intake Air Heater
Governor Electronic All Speed
Low Idle (no load) 1200 RPM
High Idle (no load) 2600 RPM
Engine Oil API CH--4, CI--4 or higher
Engine Oil Viscosity See Operator’s Manual
Crankcase Oil Capacity 6 U.S. quarts (5.7 liters) with Filter
Oil Pump Trochoid Type
Coolant Capacity
Groundsmaster 4100--D 9 U.S. quarts (8.5 liters)
Groundsmaster 4110--D 14.5 U.S. quarts (13.7 liters)
Alternator/Regulator 12 VDC, 80 amp
Engine Weight (Dry) 375 U.S. pounds (170 kg)
Groundsmaster 4100--D/4110--D Page 3 -- 3 Yanmar Diesel Engine
Specifications (Models 30606 and 30608)
Item Description
Make / Designation Yanmar Model 4TNV86CT--DTR: 4--Cycle, 4 Cylinder,
Water Cooled, Tier 4 Diesel Engine
Bore 3.386 in (86 mm)
Stroke 3.543 in (90 mm)
Total Displacement 127.5 in3(2090 cc)
Firing Order 1 (closest to flywheel end) -- 3 -- 4 (farthest from flywheel) -- 2
Direction of Rotation Counterclockwise (viewed from flywheel)
Fuel Diesel or Biodiesel (up to B7) Fuel with
Ultra Low Sulfur Content
Fuel Capacity 21 U.S. gallons (79.5 liters)
Fuel Pump Yanmar Supply Pump
Fuel Injection Type Common Rail with Direct Injection
Governor Electronic All Speed
Low Idle (no load) 1000 RPM
High Idle (no load) 2700 RPM
Engine Oil API CJ--4 or higher
Engine Oil Viscosity See Operator’s Manual
Crankcase Oil Capacity 6 U.S. quarts (5.7 liters) with Filter
Oil Pump Trochoid Type
Coolant Capacity
Groundsmaster 4100--D 9 U.S. quarts (8.5 liters)
Groundsmaster 4110--D 14.5 U.S. quarts (13.7 liters)
Alternator/Regulator 12 VDC
Groundsmaster 4100--D 40 amp
Groundsmaster 4110--D 80 amp
Engine Weight (Dry) 496 U.S. pounds (225 kg)
Yanmar
Diesel Engine
Groundsmaster 4100--D/4110--DPage 3 -- 4Yanmar Diesel Engine
This page is intentionally blank.
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 engine troubleshoot-
ing, testing, disassembly and reassembly is identified in
the Yanmar Service Manual.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
tools are described in the Yanmar Service Manual. The
use of some specialized test equipment is explained.
However, the cost of the test equipment and the special-
ized nature of some repairs may dictate that the work be
done at an engine repair facility.
Service and repair parts for Yanmar engines are sup-
plied through your Authorized Toro Distributor. If no
parts list is available, be prepared to provide your distrib-
utor with the Toro model and serial number of your ma-
chine.
Operator’s Manuals
The Operator’s Manual provides information regarding
the operation, general maintenance and maintenance
intervals for your Groundsmaster machine. The Yanmar
Operator’s Manual includes information specific to the
engine used in your Groundsmaster. Refer to these pub-
lications for additional information when servicing the
machine.
Yanmar Service and Troubleshooting Manuals
The engine that powers your Groundsmaster machine
is either a Yanmar model 4TNV84T--Z (used on
Groundsmaster models 30602 and 30604) (Tier 4i) or a
Yanmar model 4TNV86CT (used on Groundsmaster
models 30606 and 30608) (Tier 4). Both the Yanmar
Service Manual and Yanmar Troubleshooting Manual
are available for these engines. Make sure that the cor-
rect engine manuals are used when servicing the en-
gine on your Groundsmaster.
Stopping the Engine
IMPORTANT: Before stopping the engine after
mowing or full load operation, cool the turbo-char-
ger by allowing the engine to run at low idle speed
for five (5) minutes. Failure to do so may lead to tur-
bo-charger trouble.
Yanmar
Diesel Engine
Groundsmaster 4100--D/4110--DPage 3 -- 6Yanmar Diesel Engine
Engine Electronic Control Unit (ECU)
The Yanmar engine that powers your Groundsmaster
uses an electronic control unit (ECU) for engine man-
agement and also to communicate with the machine
TEC controllers and the operator Info Center display on
the machine. All wire harness electrical connectors
should be plugged into the ECU before the machine igni-
tion switch is moved from the OFF position to either the
ON or START position.
NOTE: On models 30606 and 30608, a ground wire is
used to ground the ECU to the machine frame. The
ground wire is connected to the ECU with one of the
ECU mounting screws and is connected to the frame at
the engine mount.
The engine electrical components (e.g. ECU, fuel inject-
ors, EGR, exhaust DPF) are identified and matched in
the engine ECU program. If engine electrical compon-
ents are replaced on the engine, the Yanmar electronic
tool must be used to update the ECU program which will
ensure correct engine operation.
If the engine ECU identifies that an engine problem ex-
ists, the engine speed may be reduced or the engine
might stop. The Yanmar electronic tool and
troubleshooting manual should be used to provide as-
sistance in identifying the cause of the problem and the
repairs that are necessary. Contact your Toro distributor
for assistance in Yanmar engine troubleshooting.
IMPORTANT: Do not plug or unplug the engine ECU
for a period of thirty (30) seconds after the machine
key switch is turned OFF. The ECU may remain ener-
gized even though the ignition switch is OFF.
If the engine ECU is to be disconnected for any reason,
make sure that the ignition switch is in the OFF position
with the key removed before disconnecting the engine
ECU. Also, to prevent possible ECU damage when
welding on the machine, disconnect and remove the en-
gine ECU from the machine before welding.
Figure 1
1. Electronic control unit (30602 / 30604)
2. Alternator
21
Figure 2
1. Electronic control unit (30606 / 30608)
2. Alternator
2
1
Groundsmaster 4100--D/4110--D Page 3 -- 7 Yanmar Diesel Engine
Yanmar Engine: Models 30602 and 30604
The engine used on Groundsmaster models 30602 and
30604 is a Yanmar TNV Series, turbocharged, diesel
engine that complies with EPA interim Tier 4 emission
regulations. Engine features include an electronic con-
trol unit (ECU) controlled direct fuel injection and elec-
tronic governor. An air heater in the intake system is
used to assist starting the engine. Numerous engine
sensors are used to allow the engine electronic control
unit (ECU) to monitor and control engine operation for
optimum engine performance.
During machine operation, if an engine fault occurs, the
machine InfoCenter display can be used to identify the
fault. Also, the Yanmar SMARTASSIST--Direct electron-
ic control diagnostics service system is available to con-
firm real--time engine running status and to offer timely
technical services.
Figure 3
Yanmar
Diesel Engine
Groundsmaster 4100--D/4110--DPage 3 -- 8Yanmar Diesel Engine
Yanmar Engine: Models 30606 and 30608
The engine used on Groundsmaster models 30606 and
30608 is a Yanmar TNV Series, turbocharged, diesel
engine that complies with EPA Tier 4 emission regula-
tions. Engine features include an electronic control unit
(ECU) that controls a common rail fuel injection system
with direct injection, water--cooled exhaust gas recircu-
lation (EGR), an electronic governor, an exhaust system
diesel oxidation catalyst (DOC) and an exhaust diesel
particulate filter (DPF) with active regeneration. Glow
plugs are used to assist starting the engine. Numerous
engine sensors are used to allow the engine ECU to
monitor and control engine operation for optimum en-
gine performance.
During machine operation, if an engine fault occurs, the
machine InfoCenter display can be used to identify the
fault. Also, the Yanmar SMARTASSIST--Direct electron-
ic control diagnostics service system is available to con-
firm the real--time engine running status and to offer
timely technical services.
The exhaust system DPF has four (4) modes for main-
tenance: passive regeneration, assist regeneration, re-
set regeneration and stationary regeneration.
Passive regeneration is the primary mode regenera-
tion that occurs during normal operation. When the en-
gine is running at normal loads, the exhaust
temperature will keep the DPF above the minimum tem-
perature for regeneration so normal particulate matter
(PM) accumulation in the DPF is expected.
Assist regeneration occurs if the engine ECU senses
that the DPF backpressure has increased to its maxim-
um threshold. During assist regeneration, the intake
throttle valve limits the air flow into the engine while the
injectors add additional fuel. This process increases the
DPF temperature which allows accumulated particulate
to burn off, without changing the load on the engine.
Burning of the accumulated PM decreases the pressure
across the DPF. The assist regeneration is completed
automatically when necessary. A small icon will be dis-
played on the InfoCenter during assist regeneration
(Fig. 5) to inform the operator. The machine can contin-
ue to be used during an assist regeneration.
Reset regeneration takes place at a time interval
(every 100 hours) to reset the baseline sensor readings
in the DPF. The reset regeneration ensures that the en-
gine is running at peak efficiency. During this mode, post
injection is the means of increasing the DPF temperat-
ure. The reset regeneration is completed automatically
when necessary. A small icon will be displayed on the In-
foCenter during reset regeneration (Fig. 5) to inform the
operator. The machine can continue to be used during
a reset regeneration.
Figure 4
Figure 5
ICON
ASSIST OR RESET
REGENERATION
ICON
REGENERATION
STATIONARY
IN PROCESS
ICON
REGENERATION
STATIONARY
REQUEST
NOTE: If the engine is turned off during an assist or re-
set regeneration process, the regeneration will resume
once the engine is restarted and required temperature
level is reached.
Groundsmaster 4100--D/4110--D Page 3 -- 9 Yanmar Diesel Engine
Stationary regeneration is requested by the engine
ECU if the assist and reset regenerations do not return
the DPF particulate level to an acceptable level. During
the stationary regeneration, the engine ECU controls
engine speed, load and air/fuel mixture to perform a
controlled burn of the particulate collected in the DPF.
This type of regeneration is not a normal condition and
may indicate that the DPF will require service soon, that
an engine problem exists (e.g. incorrect engine fuel or
oil) or that a DPF pressure sensor is failing. If a station-
ary regeneration is necessary, an advisory will occur on
the InfoCenter and the necessary steps will be listed. A
large icon will be displayed on the InfoCenter instead of
the temperature gauge during stationary regeneration
(Fig. 5). During the stationary regeneration process, the
InfoCenter display will identify the percent completed
during the process. The machine cannot be used during
a stationary regeneration.
When the regeneration process is completed, the In-
foCenter will remove the stationary regeneration icon
and cease periodic regeneration messages. The engine
will return to low idle speed with operator controls re-
turned to normal.
IMPORTANT: A stationary regeneration should
ONLY be initiated if an InfoCenter display advisory
requests that this be done.
IMPORTANT: During a stationary regeneration,
make sure that the machine is parked on a hard,
level surface in a well ventilated area. This process
runs the machine at a higher exhaust temperature
for a period of approximately thirty (30) minutes to
burn off collected particulate in the DPF.
Yanmar
Diesel Engine
Groundsmaster 4100--D/4110--DPage 3 -- 10Yanmar Diesel Engine
Service and Repairs
AirFilterSystem
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)
10. Lock nut (2 used)
11. Spring (2 used)
12. Flat washer (2 used)
13. Socket head screw (2 used)
14. Hose clamp
15. Air cleaner inlet hose
16. Hose clamp
17. Air cleaner outlet hose (tier 4)
18. Air cleaner outlet hose (tier 4i)
17
2
3
6
8
910
11
13
5
12
14
15
4
7
1
6
VACUATOR
DIRECTION
MODELS
30606 and
30608
MODELS
30602 and
30604
14
14 16
16
18
Groundsmaster 4100--D/4110--D Page 3 -- 11 Yanmar Diesel Engine
Removal (Fig. 6)
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 6 as a guide.
Installation (Fig. 6)
IMPORTANT: Any leaks in the air cleaner system
will cause serious engine damage. Make sure that
all air cleaner components are in good condition
and are properly secured during assembly.
1. Assemble air cleaner system using Figure 6 as a
guide.
A. If service indicator (item 4 in Fig. 6) and adapter
(item 15 in Fig. 6) were removed from air cleaner
housing, apply thread sealant to adapter threads be-
fore installing adapter and indicator to housing.
Install adapter so that grooves in adapter hex and
adapter filter element are installed toward service in-
dicator (shown in Fig. 8). Torque indicator from 12 to
15 in--lb (1.4 to 1.6 N--m).
B. When installing air cleaner, orientate the vacuat-
or valve on the air cleaner cover so that the valve is
pointing in a downward position and between 5:00 to
7:00 (approximate clock position) when viewed from
the end.
C. When securing air cleaner in air cleaner strap,
tighten cap screws (item 14) only enough to prevent
air cleaner from rotating in strap.
D. When installing air cleaner outlet hose between
air cleaner and engine, position hose to allow maxi-
mum clearance between air cleaner hose and muf-
fler bracket.
E. Make sure that air cleaner hoses do not contact
the engine or exhaust system after assembly. To en-
sure clearance, move and/or rotate air cleaner body
in air cleaner strap if necessary.
2. After all air cleaner components have been installed,
lower and secure hood.
Figure 7
1. Air cleaner housing
2. Safety filter element
3. Air filter element
4. Air cleaner cover
5. Vacuator valve
1
3
2
4
5
Figure 8
1. Air cleaner assembly
2. Service indicator
3. Adapter
1
3
2
12 to 15 in--lb
(1.4 to 1.6 N--m)
Yanmar
Diesel Engine
Groundsmaster 4100--D/4110--DPage 3 -- 12Yanmar 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. Hose clamp
12. Lock washer (5 used)
13. Phillips head screw (5 used)
14. Fuel sender
15. Gasket
16. Fuel cap
17. Fuel supply hose
18. Fuel return hose
19. RH latch bracket
20. Tank support assembly
21. Flange nut (2 used)
22. Fuel tank bracket
23. Carriage screw (2 used)
24. Lock nut (2 used)
25. Flat washer (2 used)
26. Flat washer (4 used)
27. Lock nut (2 used)
28. Spring (2 used)
29. Flat washer (2 used)
30. Socket head screw (2 used)
31. Indicator
32. Adapter
33. Air cleaner assembly
34. Air cleaner strap
35. Cap screw (2 used)
36. Screw (4 used)
37. LH latch bracket
38. Cap screw (4 used)
60 to 80 in--lb
(7 to 9 N--m)
FRONT
RIGHT
2
3
6
8
9
10
11
13
1
57
12
14
15
16
4
7
19
20 21
22
23
24 25 26
27 28 29
30
31
32
33
34
35
36
37
4
17
18
38
26
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 tank outside and
wipe up any spilled diesel fuel before starting the
engine. Store fuel in a clean, safety--approved
container and keep cap in place. Use diesel fuel
for the engine only; not for any other purpose.
Check Fuel Lines and Connections
Check fuel lines and connections periodically as recom-
mended in the Operator’s Manual. Check lines for dete-
rioration, damage, leaking or loose connections.
Replace hoses, clamps and connections as necessary.
Empty and Clean Fuel Tank
Empty and clean the fuel tank periodically as recom-
mended in the Operator’s Manual, if the fuel system be-
comes contaminated or if the machine is to be stored for
an extended period.
IMPORTANT: Follow all local codes and regulations
when recycling or disposing waste fuel.
To clean fuel tank, flush tank out with clean diesel fuel.
Make sure tank is free of contaminates and debris.
Priming the Fuel System
The fuel system needs to be primed before starting the
engine for the first time, after running out of fuel or after
fuel system maintenance (e.g. draining the filter/water
separator, replacing a fuel hose). To prime the fuel sys-
tem, make sure that the fuel tank has fuel in it. Then, turn
the ignition key to the RUN position for 10 to 15 seconds
which allows the fuel pump to prime the fuel system. DO
NOT use the engine starter motor to crank the engine in
order to prime the fuel system.
Fuel Tank 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. Raise and support operator seat and hood.
3. Use a fuel transfer pump to remove fuel from the fuel
tank and into a suitable container.
NOTE: Fuel sender may have two (2) wire harness ter-
minals (shown in Fig. 10) or a single harness connector.
4. Disconnect wire harness connections from the fuel
sender (item 14).
5. Disconnect fuel supply, vent and return hoses from
elbow fittings in top of tank (Fig. 10).
6. Remove fuel tank using Figure 9 as a guide. Tank is
secured to frame with fasteners (items 1, 2, 3 and 4) on
the forward side and bracket (item 22) on the rear side.
Fuel Tank Installation (Fig. 9)
1. Install fuel tank using Figure 9 as a guide. When se-
curing tank to frame, follow the following sequence:
A. Loosely install fasteners on front of tank (items 1,
2, 3 and 4).
B. Install and tighten bracket (item 22) at rear of
tank.
C. Torque two (2) flange nuts (item 4) from 60 to 80
in--lb (7 to 9 N--m).
2. Connect fuel supply hose to the standpipe and vent
and return hoses to the elbow fittings (Fig. 10). Secure
hoses with clamps.
3. Secure wire harness connector(s) to fuel sender. On
senders with two (2) wire harness terminals, apply skin--
over grease (see Special Tools in this chapter) to har-
ness terminals after installation.
4. Lower and secure operator seat and hood.
5. Fill fuel tank with new fuel.
6. Prime the fuel system (see above).
7. Before returning machine to operation, make sure
that no fuel leaks exist.
Figure 10
1. Fuel supply hose
2. Vent hose
3. Return hose
4. Fuel sender
2
1
3
4
Yanmar
Diesel Engine
Groundsmaster 4100--D/4110--DPage 3 -- 14Yanmar 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. Flange nut (6 used)
7. Foam plug (2 used)
8. Flange head screw (6 used)
9. Flange head screw (9 used)
10. Foam strip
11. Hose bracket
12. R--clamp (2 used)
13. Cap screw (2 used)
14. Hose
15. Coolant reservoir
16. Tank mount
17. Flat washer (7 used)
18. Cap screw (6 used)
19. Lower radiator hose
20. Hose clamp (4 used)
21. Upper radiator hose
22. Lower radiator shroud
23. Upper radiator shroud
24. Hose clamp
25. Air cleaner inlet hose
26. Radiator/hydraulic oil cooler
27. Bulb seal
28. RH radiator support
29. Straight hydraulic fitting
30. Intake bracket
31. 90ohydraulic fitting
32. Pipe plug
33. Hex plug with O--ring
34. Foam pad (2 used)
35. Draincock
36. Cap screw (2 used)
13
12
14 15
16
17
18
19
20
21
22
23
3
4
9
12
3
36
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 or engine is hot. Pressurized, hot cool-
ant can escape and cause burns.
Ethylene--glycol antifreeze is poisonous. Dis-
pose of coolant properly or store it in a properly
labeled container away from children and pets.
2. Drain radiator into a suitable container either by us-
ing the draincock (item 35) near the lower left side corner
of the radiator or by removing the lower radiator hose
from the radiator.
IMPORTANT: Follow all local codes and regulations
when recycling or disposing engine coolant.
3. Disconnect radiator hoses from the radiator.
Groundsmaster 4110--D machines with a Tier 4 compli-
ant engine (model 30606) use the lower radiator hose
assemblyshowninFigure12.
4. Remove air cleaner inlet hose (item 25).
5. Read the General Precautions for Removing and
Installing Hydraulic System Components in the Service
and Repairs section of Chapter 4 -- Hydraulic System.
6. Thoroughly clean hydraulic lines at lower radiator
shroud (Fig. 13) and oil cooler ports (Fig. 14). Discon-
nect hydraulic lines and put caps or plugs on lines to pre-
vent contamination. Label disconnected hydraulic lines
for proper installation.
7. Disconnect hood rods from hood and radiator sup-
ports (see Hood in the Service and Repairs section of
Chapter 7 -- Chassis).
8. Remove flange head screws (item 8) and flange nuts
(item 6) that secure the radiator supports (items 1 and
28) to the frame.
9. Carefully raise radiator assembly with shrouds, fan
motor assembly and supports from the machine.
10.Disassemble radiator/oil cooler assembly as needed
using Figures 11 and 13 as guides.
11.If necessary, remove hydraulic fittings (items 29 and
31) from oil cooler and discard O--rings.
12.Plug all radiator and hose openings to prevent con-
tamination.
Figure 12
1. Radiator/oil cooler
2. Lower radiator hose
3. Hose clamp
4. Radiator fitting
5. Hose clamp
6. Radiator hose
6
3
5
4
2
3
1
MODEL 30606 (WITH TIER 4 ENGINE)
FRONT
RIGHT
Figure 13
1. Radiator/oil cooler
2. Motor and fan assembly
3. Cap screw (6 used)
4. Flange nut (6 used)
5. Lower radiator shroud
FRONT
RIGHT
2
3
1
4
5
Yanmar
Diesel Engine
Groundsmaster 4100--D/4110--DPage 3 -- 16Yanmar Diesel Engine
Installation (Fig. 11)
1. Inspect seals (items 7, 10, 27 and 34) around radiat-
or location for wear or damage. Replace seals if neces-
sary.
2. Remove all plugs placed during the removal proce-
dure.
3. If hydraulic fittings (items 29 and 31) were removed
from oil cooler, lubricate and place new O--rings onto fit-
tings. Install fittings into port openings and tighten fit-
tings (see Hydraulic Fitting Installation in the General
Information section of Chapter 4 -- Hydraulic System).
4. Assemble radiator/oil cooler using Figures 11 and 13
as guides.
A. If fan motor bracket was removed, position brack-
et as far as possible from radiator to maximize dis-
tance between radiator and fan motor location.
B. Make sure that clearance between radiator
shrouds and cooling fan is at least 0.180” (4.6 mm)
at all points.
5. Carefully lower radiator assembly with shrouds, fan
motor assembly and supports to the machine frame.
6. Secure radiator supports (items 1 and 28) to the
frame with flange head screws (item 8) and flange nuts
(item 6).
7. Connect hydraulic lines to fittings in oil cooler ports
(Fig. 14) and at lower radiator shroud (Fig. 13) (see Hy-
draulic Hose and Tube Installation in the General Infor-
mation section of Chapter 4 -- Hydraulic System).
8. Connect upper and lower radiator hoses to the radi-
ator and secure with hose clamps.
9. Install and secure air cleaner inlet hose (item 25).
10.Make sure radiator draincock is closed. Fill radiator
with coolant.
11. Connect hood rods to radiator supports and hood
(see Hood in the Service and Repairs section of Chapter
7 -- Chassis).
12.Close and secure hood.
Figure 14
1. Radiator/oil cooler
2. Straight fitting
3. Hydraulic tube
4. 90ofitting
5. Hydraulic hose
6. Hydraulic tube
5
4
3
2
1
6
Groundsmaster 4100--D/4110--D Page 3 -- 17 Yanmar Diesel Engine
This page is intentionally blank.
Yanmar
Diesel Engine
Groundsmaster 4100--D/4110--DPage 3 -- 18Yanmar 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 mount bracket (2 used)
10. Cap screw (14 used)
11. Lock washer (18 used)
12. Cap screw (2 used)
13. Exhaust bracket
14. Cap screw (2 used)
15. Flange nut (2 used)
16. Exhaust pipe
17. Wire harness bracket
18. Cap screw (3 used)
19. Wire harness bracket
20. Lock washer (2 used)
21. Cap screw (2 used)
22. Clamp assembly
FRONT
RIGHT
2
3
6
8
9
11
13
1
5
7
12
14 15
16
19
20
4
21
11
5
22
7
9
11
4
10
17
18
MODEL 30604 SHOWN
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 positive cable from battery
(see Battery Service in the Service and Repairs section
of Chapter 5 -- Electrical System).
3. Raise and support hood.
CAUTION
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot cool-
ant can escape and cause burns.
Ethylene--glycol antifreeze is poisonous. Dis-
pose of coolant properly or store it in a properly
labeled container away from children and pets.
4. Drain coolant from the radiator into a suitable con-
tainer (see Radiator and Oil Cooler Assembly in this sec-
tion). Disconnect upper and lower hoses from the
radiator.
5. Remove air cleaner assembly from engine (see Air
Cleaner System in this section).
6. Remove exhaust pipe (item 16 in Fig. 15) and ex-
haust bracket (item 13 in Fig. 15 or item 6 in Fig. 20) from
engine.
7. Note location of cable ties used to secure wire har-
ness to the machine. Disconnect wires and/or electrical
connections from the following electrical components:
A. The engine wire harness from the machine wire
harness.
B. The positive battery cable from the engine starter
motor (Fig. 16).
C. The fusible link harness from the main wire har-
ness (Fig. 16).
D. The negative battery cable at the engine block
(Fig. 16).
8. Carefully disconnect engine wire harness connector
from engine ECU.
9. Disconnect fuel supply and return hoses from engine
(Fig. 17 or 18). Position fuel hoses away from engine.
10.Remove fasteners that secure the coolant reservoir
tank mount to the radiator and radiator shrouds (Fig.
19). Position and support coolant reservoir with mount
away from the engine.
Figure 16
1. Positive battery cable
2. Negative battery cable
3. Fusible link harness
2
3
1
Figure 17
1. Tier 4 engine
2. Hose clamp
3. Fuel supply hose
4. Hose clamp
5. Fuel return hose
6. Front lift bracket
2
3
1
4
5
MODELS 30606 and 30608
6
Figure 18
1. Tier 4i engine
2. Hose clamp
3. Fuel supply hose
4. Hose clamp
5. Fuel return hose
1
2
3
4
5
MODELS 30602 and 30604
Yanmar
Diesel Engine
Groundsmaster 4100--D/4110--DPage 3 -- 20Yanmar Diesel Engine
11. On machines with a Tier 4 compliant engine (models
30606 and 30608):
A.Removefueltanktoallowenginetoberaised
frommachine(seeFuelSysteminthissection).
B. Install lift bracket to front of engine cylinder head
(item 6 in Fig. 17). Front lift bracket was included with
new machine or is available as a service part (refer to
parts catalog for part number).
12.On Groundsmaster 4110--D machines:
A. Remove air conditioning compressor from com-
pressor mount (see Air Conditioning Compressor in
the Service and Repairs section of Chapter 9 -- Oper-
ator Cab). Position compressor away from engine
taking care to not damage compressor or AC hoses.
Support compressor to make sure it will not fall dur-
ing engine removal.
B. Disconnect coolant hoses from fittings on engine
water flange. On Groundsmaster 4110--D machines
with a Tier 4 compliant engine (model 30606), dis-
connect coolant hose from fitting on lower radiator
hose assembly. Label coolant hoses for proper as-
sembly.
IMPORTANT: The hydraulic pump assembly can re-
main in machine during engine removal. To prevent
pump from shifting or falling, make sure to support
pump assembly before the fasteners that secure
pump assembly to engine are removed.
13.Support hydraulic pump assembly. Remove fasten-
ers that secure pump assembly to engine (see Pump
Assembly in the Service and Repairs section of Chapter
4 -- Hydraulic System).
14.Note location of all cable ties securing the wire har-
ness, fuel lines and hydraulic hoses to the engine for as-
sembly purposes. Remove cable ties as needed for
engine removal.
15.Connect lift or hoist to the lift brackets on engine.
16.Remove flange nuts, rebound washers and cap
screws that secure the engine mount brackets to the en-
gine mounts.
Figure 19
1. Radiator/oil cooler
2. Tank Mount
3. Coolant reservoir
FRONT
RIGHT
2
3
1
Figure 20
1. Exhaust pipe
2. Flange screw (2 used)
3. Flange nut
4. Idler pulley
5. Carriage screw
6. Exhaust bracket
7. Compressor mount
8. Cap screw (2 used)
9. Cap screw (4 used)
10. Lock washer
11. Cap screw (3 used)
12. Pulley
2
3
6
8
9
10
1
5
7
4
11
12
10
MACHINES WITH
OPERATOR CAB
Groundsmaster 4100--D/4110--D Page 3 -- 21 Yanmar Diesel Engine
CAUTION
One person should operate lift or hoist while a
second person guides the engine out of the ma-
chine.
IMPORTANT: Make sure to not damage the engine,
radiator assembly, fuel lines, hydraulic lines, elec-
trical wire harness or other components while re-
moving the engine.
17.Slowly move the engine assembly away from the hy-
draulic pump assembly to allow the pump input shaft to
slide out of the spring coupler on the engine flywheel.
Once the engine has cleared the pump input shaft, care-
fully remove the engine from the machine.
18.If necessary, remove engine mount brackets from
theengineusingFigure15or20asaguide.
Engine Installation (Fig. 15)
1. Make sure that all parts removed from the engine
during maintenance or rebuilding are installed to the en-
gine.
2. If removed, install engine mount brackets to the en-
gine using Figure 15 or 20 as a guide.
3. Connect lift or hoist to the engine lift brackets.
CAUTION
One person should operate lift or hoist while a
second person guides the engine into the ma-
chine.
IMPORTANT: Make sure to not damage the engine,
radiator assembly, fuel lines, hydraulic lines, elec-
trical wire harness or other components while
installing the engine.
4. Carefully lower engine into the machine. Slowly
move the engine assembly toward the hydraulic pump
assembly to allow the pump input shaft to slide into the
spring coupler on the engine flywheel.
5. Align engine to the engine mounts. Secure engine to
engine mounts with cap screws, rebound washers and
flange nuts.
6. Secure hydraulic pump assembly to engine (see
Pump Assembly in the Service and Repairs section of
Chapter 4 -- Hydraulic System).
7. On machines with a Tier 4 compliant engine (models
30606 and 30608):
A. Remove lift bracket from front of engine cylinder
head (item 6 in Fig. 17). The bracket must be re-
moved before fuel tank installation. Retain lift brack-
et and fasteners for future use.
B. Install and secure fuel tank to machine (see Fuel
System in this section).
8. Position coolant reservoir with mount to the radiator.
Secure reservoir tank mount to the radiator and radiator
shrouds with removed fasteners.
9. Connect fuel supply and return hoses to the engine
fittings (Fig. 17 or 18).
10.On Groundsmaster 4110--D machines:
A. Install air conditioning compressor to compressor
mount (see Air Conditioning Compressor Installation
in the Service and Repairs section of Chapter 9 -- Op-
erator Cab). Make sure that drive belt is properly ten-
sioned.
B. Connect coolant hoses to fittings on engine water
flange.
11. Connect wires and/or electrical connections to en-
gine locations.
A. The engine wire harness from the machine wire
harness.
B. The positive battery cable from the engine starter
motor (Fig. 16).
C. The fusible link harness from the main wire har-
ness (Fig. 16).
D. The negative battery cable at the engine block
(Fig. 16).
12.Carefully connect engine wire harness connector to
engine ECU.
13.Install and secure exhaust bracket (item 13 in Fig. 15
or item 6 in Fig. 20) and exhaust pipe (item 16 in Fig. 15)
from engine.
14.Install air cleaner assembly to the engine (see Air
Cleaner System in this section).
15.Connect coolant hoses to the radiator. Make sure ra-
diator draincock is closed. Fill radiator and coolant
reservoir with coolant.
16.Secure the wire harness, fuel lines and hydraulic
hoses to the engine with cable ties as noted during en-
gine removal.
Yanmar
Diesel Engine
Groundsmaster 4100--D/4110--DPage 3 -- 22Yanmar Diesel Engine
17.Check position of electrical wires, fuel lines and hy-
draulic lines for proper clearance with rotating, high tem-
perature and moving components.
18.Connect positive battery cable to positive battery ter-
minal first and then connect negative cable to battery
(see Battery Service in the Service and Repairs section
of Chapter 5 -- Electrical System).
19.Check and adjust engine oil as needed.
20.Check and adjust oil level in hydraulic reservoir as
needed.
21.Prime the fuel system (see Fuel System in this sec-
tion).
22.Start engine and operate hydraulic controls to prop-
erly fill hydraulic system (see Charge Hydraulic System
in the Service and Repairs section of Chapter 4 -- Hy-
draulic System).
23.Close and secure hood.
Groundsmaster 4100--D/4110--D Page 3 -- 23 Yanmar Diesel Engine
This page is intentionally blank.
Yanmar
Diesel Engine
Groundsmaster 4100--D/4110--DPage 3 -- 24Yanmar 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
(40to44N--m)
28 to 32 ft--lb
(38 to 43 N--m)
1
2
3
6
5
4
7
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 in the Service and Repairs section of Chapter 4
-- Hydraulic System).
2. Remove flywheel plate and spring coupler from en-
gine using Figure 21 as a guide.
Coupler Installation (Fig. 21)
1. Position spring coupler to engine flywheel and align
mounting holes. Make sure that coupling hub is away
from engine flywheel (Fig. 22).
2. Secure coupler to flywheel with eight (8) cap screws
and washers. Torque cap screws in a crossing pattern
from 29 to 33 ft--lb (40 to 44 N--m).
3. Position flywheel plate to engine. Secure flywheel
plate with eight (8) cap screws (item 1) and washers us-
ing a crossing pattern tightening procedure. Torque cap
screws in a crossing pattern from 28 to 32 ft--lb (38 to
43 N--m).
4. If engine is in machine, install hydraulic pump as-
sembly to machine (see Piston (Traction) Pump Installa-
tion in the Service and Repairs section of Chapter 4 --
Hydraulic System).
Figure 22
1. Spring coupler 2. Engine flywheel
Engine Side Hydraulic
Pump Side
1
2
Yanmar
Diesel Engine
Groundsmaster 4100--D/4110--DPage 3 -- 26Yanmar Diesel Engine
Exhaust System (Models 30606 and 30608)
Figure 23
1. Gasket
2. Exhaust assembly stay
3. Exhaust assembly stay
4. Exhaust assembly stay
5. Exhaust assembly stay
6. Nut
7. DOC temp sensor (inlet)
8. DOC temp sensor (outlet)
9. Nut (4 used)
10. DOC assembly
11. Nut (3 used)
12. DPF assembly
13. Nut
14. Outlet flange
15. DPF gasket (2 used)
16. Bolt (20 used)
17. DPF lifter
18. DPF stiffener (5 used)
19. DPF stiffener
20. DPF stiffener
21. DPF stiffener
22. Bolt (2 used)
23. Nut (20 used)
24. Bolt (2 used)
25. Pipe joint bolt (2 used)
26. Exhaust pressure pipe (DPF inlet)
27. Sensor gasket (4 used)
28. Exhaust pressure pipe (DPF outlet)
29. Exhaust hose
30. Bolt (2 used)
31. Hose clip (2 used)
32. Hose
33. Bolt (3 used)
34. Hose clip (2 used)
35. Pressure sensor
36. Sensor bracket
37. Bolt (2 used)
38. Bolt (2 used)
39. Clip band
40. Band
41. Connector clip (2 used)
42. Bolt (2 used)
43. Bolt (2 used)
44. Bolt (2 used)
FRONT
RIGHT
19 to 29 ft--lb
(25to40N--m)
2
3
8
10
13
1
5
7
12
14
15
16
17
18
19
21
22
23
25
27
28
29
31
32
34
35
37
38
39
40
31
34
41
27
25
18
18
18
16
624
23
18
15
43
42
44
16
9
4
33
16
11
30 20
23
26
36
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). These exhaust components require service
or component replacement at intervals identified in your
Operator’s Manual. Additionally, the exhaust assembly
uses two (2) temperature sensors and a pressure differ-
ential sensor which are used as inputs for the engine
ECU to monitor the operation of the exhaust system.
The diesel particulate filter (DPF) is cleaned periodically
through a regenerative process that is controlled by the
engine ECU (see Yanmar Engine: Models 30606 and
30608 in the General Information section of this
chapter). The InfoCenter display will identify the status
of DPF regeneration. At recommended intervals, DPF
reconditioning is necessary which will require exhaust
system disassembly, DPF removal and DPF recondi-
tioning by a company that has the necessary equip-
ment. Once the DPF has gone through the
reconditioning process, it can be re--installed in the ex-
haust system. Contact your Toro Distributor for informa-
tion on reconditioning the DPF.
The diesel oxidation catalyst (DOC) has a service life ex-
pectancy and requires replacement at recommended
intervals. Replacement of the DOC will require exhaust
system disassembly, removal of the existing DOC and
installation of the new DOC.
Refer to the Parts Catalog to identify individual compon-
ents for the exhaust system on your Groundsmaster.
Removal (Figs. 23 and 24)
NOTE: TheexhaustsystemDPFandDOCcanbere-
moved from the exhaust system without removing the
entire exhaust from the engine. Certain engine service
procedures (e.g. rocker cover removal for valve clear-
ance adjustment) will require removal of the exhaust
system assembly.
CAUTION
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the engine and ex-
haust system to cool before working on the ex-
haust system.
1. Raise and support hood to gain access to exhaust
system. Allow engine and exhaust to cool before doing
any disassembly of exhaust system components.
2. Remove exhaust system components from the en-
gine as necessary using Figure 23 and 24 as guides.
Discard all removed gaskets (items 1 and 15 in Fig. 23
or item 6 in Fig. 24).
Installation (Figs. 23 and 24)
NOTE: Make sure that all exhaust system flanges and
sealing surfaces are free of debris or damage that may
prevent a tight seal.
1. Make sure to install new gaskets in place of all gas-
kets that were removed. Do not use any type of gasket
sealant on gasket or flange surfaces.
2. Assemble all removed exhaust system components
usingFigure23and24asguides.
A. If exhaust sensors (items 7 and 8 in Fig. 23) were
removed, torque sensors from 19 to 29 ft--lb (25 to
40 N--m).
B. If exhaust pressure pipes (items 26 and 28 in Fig.
23) were removed, replace sensor gaskets (item 27)
on both sides of the pressure pipe fitting.
C. If DPF stiffeners (items 18, 19, 20 and 21 in Fig.
23) were loosened or removed, tighten fasteners
that secure stiffeners before tightening fasteners
that secure exhaust system to DPF stays.
Figure 24
1. Engine
2. Exhaust pipe
3. Clamp assembly
4. Flange nut (4 used)
5. Exhaust flange
6. Exhaust gasket
1
2
3
4
5
6
Yanmar
Diesel Engine
Groundsmaster 4100--D/4110--DPage 3 -- 28Yanmar Diesel Engine
This page is intentionally blank.
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 4 -- 1
Chapter 4
Hydraulic System
Table of Contents
SPECIFICATIONS 2............................
GENERAL INFORMATION 3.....................
Operator’s Manual 3..........................
Check Hydraulic Fluid 3.......................
Relieving Hydraulic System Pressure 3..........
Towing Traction Unit 4.........................
Traction Circuit Component Failure 4............
Hydraulic Hoses 5............................
Hydraulic Hose and Tube Installation 6..........
Hydraulic Fitting Installation 7..................
HYDRAULIC SCHEMATIC 9.....................
HYDRAULIC FLOW DIAGRAMS 10...............
Traction Circuit: LOW Speed (Mow) 10..........
Traction Circuit: HI Speed (Transport) 12.........
Lower Cutting Deck 14........................
Raise Cutting Deck 16.........................
Mow Circuit 18...............................
Mow Circuit Cutting Deck Blade Braking 20......
Steering Circuit 22............................
Engine Cooling Fan Circuit 24..................
SPECIAL TOOLS 26............................
TROUBLESHOOTING 31........................
TESTING 38...................................
Traction Circuit Charge Pressure 40.............
Traction Circuit Relief Pressure 42..............
Counterbalance Pressure 44...................
Reverse Traction Circuit Reducing Valve (PR)
Pressure 46................................
Rear Traction Circuit Relief Valve (RV) Pressure 48
Piston (Traction) Pump Flow 50.................
Cutting Deck Circuit Pressure 52................
PTO Relief Pressure 54........................
Cutting Deck Motor Case Drain Leakage 56......
Lift/Lower Circuit Relief Pressure 58.............
Steering Circuit Relief Pressure 60..............
Steering Cylinder Internal Leakage 62...........
Engine Cooling Fan Circuit 64..................
Gear Pump Flow 66...........................
ADJUSTMENTS 68.............................
Adjust Control Manifold Relief Valves 68.........
SERVICE AND REPAIRS 69.....................
General Precautions for Removing and
Installing Hydraulic System Components 69....
Check Hydraulic Lines and Hoses 70............
Priming Hydraulic Pumps 70...................
Flush Hydraulic System 71.....................
Filtering Closed--Loop Traction Circuit 72........
Charge Hydraulic System 73...................
Hydraulic Reservoir 74........................
Radiator and Oil Cooler Assembly 76............
Gear Pump 78................................
Gear Pump Service 82........................
Piston (Traction) Pump 84.....................
Piston (Traction) Pump Service 88..............
Rear Axle Motor 90...........................
Front Wheel Motors 92........................
Rear Axle and Front Wheel Motor Service 94.....
Rear Traction Manifold 96......................
Rear Traction Manifold Service 98..............
Control Manifold Cartridge Valve Service 99......
Combination Manifold 100.....................
Combination Manifold Service 102..............
Steering Control Valve 104.....................
Steering Control Valve Service 106..............
Steering Cylinder 108.........................
Steering Cylinder Service 110..................
Engine Cooling Fan Motor 112..................
Engine Cooling Fan Motor Service 116..........
Cutting Deck Motor 119........................
Cutting Deck Motor Service (Sauer--Danfoss) 120.
Cutting Deck Motor Service (Casappa) 124.......
PTO Manifolds 126............................
PTO Manifold Service 128.....................
Cutting Deck Lift Cylinders 130.................
Wing Deck Lift Cylinders 132...................
Lift Cylinder Service 134.......................
SAUER--DANFOSS H1 CLOSED CIRCUIT AXIAL PIS-
TON PUMPS SERVICE MANUAL
SAUER--DANFOSS K and L FRAME VARIABLE MO-
TORS SERVICE MANUAL
EATON PARTS AND REPAIR INFORMATION: 5
SERIES STEERING CONTROL UNITS
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 2
Specifications
Item Description
Piston (Traction) Pump Sauer--Danfoss Variable Displacement Axial Piston Pump
Maximum Displacement (per revolution) 2.75 in3(45 cc)
System Relief Pressure: Forward 4350 PSI (300 bar)
System Relief Pressure: Reverse 5000 PSI (345 bar)
Charge Pressure 250PSI(17bar)
Front Wheel Motors Sauer--Danfoss 2--Position Axial Piston Motors
Displacement (per revolution) 1.40 in3(23 cc) Maximum / 0.79 in3(13 cc) Minimum
Rear Axle Motor Sauer--Danfoss 2--Position Axial Piston Motor
with Loop Flushing Valve
Displacement (per revolution) 2.14 in3(35 cc) Maximum / 1.16 in3(19 cc) Minimum
Gear Pump Casappa 4 Section, Positive Displacement Gear pump
Section P1/P2 Displacement (per revolution) 1.37 in3(22.46 cc)
Section P3 Displacement (per revolution) 0.40 in3(6.61 cc)
Section P4 Displacement (per revolution) 0.30 in3(4.96 cc)
Steering Control Valve Eaton Steering Unit, Series 5
Displacement (per revolution) 6.1 in3(100 cc)
Steering Circuit Relief Pressure 1350PSI(93bar)
Lift/Lower Circuit Relief Pressure 2500 PSI (172 bar)
Cutting Deck Motors Gear Motor
Displacement (per revolution) 1.17 in3(19.2 cc)
PTO Circuit Relief Pressure
Front and Left Side 3000 PSI (207 bar)
Right Side 2000 PSI (138 bar)
Engine Cooling Fan Motor Casappa Gear Motor
Displacement (per revolution) 0.51 in3(8.4 cc)
Engine Cooling Fan Circuit Relief Pressure 3000 PSI (207 bar)
Hydraulic Filters Spin--on Cartridge Type
In--line Suction Strainer 100 Mesh (In Reservoir)
Hydraulic Reservoir 7.75 U.S. Gallons (29.3 Liters)
Hydraulic Oil See Operator’s Manual
NOTE: Thepressurespecificationslistedaboveare
component settings. When using pressure gauges to
measure circuit pressures, values may be different than
these specifications. See the Testing section of this
chapter for hydraulic test procedures and expected test
results.
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 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.
Check Hydraulic Fluid
Your Groundsmaster hydraulic system is designed to
operate on anti--wear hydraulic fluid. The reservoir
holds approximately 7.75 U.S. gallons (29.3 liters) of
hydraulic fluid. Check level of hydraulic fluid daily.
See Operator’s Manual for fluid level checking proce-
dure and oil recommendations.
1. Hydraulic reservoir 2. Reservoir cap
Figure 1
1
2
Relieving Hydraulic System Pressure
Before disconnecting or performing any work on the hy-
draulic system, all pressure in the hydraulic system
must be relieved. Park machine on a level surface, make
sure that PTO switch is OFF, lower cutting deck fully,
stop engine and engage parking brake. Wait for all mov-
ing parts to come to a complete stop.
System pressure in lift circuit is relieved when the cutting
deck is fully lowered.
System pressure in mow circuit is relieved when the
PTO switch is disengaged.
To relieve hydraulic pressure in traction circuit, turn igni-
tion switch to ON (engine not running) and move traction
pedal to both forward and reverse directions. Turn igni-
tion switch to OFF after relieving traction circuit pres-
sure.
To relieve hydraulic pressure in steering circuit, rotate
steering wheel in both directions.
After all hydraulic system pressures have been relieved,
remove key from ignition switch.
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 4
Towing Traction Unit
IMPORTANT: If towing limits are exceeded, severe
damage to the piston (traction) pump may occur.
If it becomes necessary to tow (or push) the machine,
tow (or push) in a forward direction only and at a
speed below 3 mph (5 kph). The piston (traction) pump
relief valves (both forward and reverse) need to be
loosened three (3) revolutions to allow the machine to
be moved (Fig. 2). To prevent leakage from relief valves,
do not loosen them more than three (3) revolutions.
Refer to your Operator’s Manual for additional towing in-
structions.
IMPORTANT: Do not loosen relief valves when en-
gine is running.
Before returning machine to service, tighten both of the
relief valves until seated. Then, torque relief valves to 52
ft--lb (70 N--m).
IMPORTANT: If the machine must to be pushed or
towed in reverse, the check valve in the rear traction
manifold must also be bypassed. To bypass this
check valve, connect a hydraulic hose assembly to
the reverse traction pressure test port, located on
the piston (traction) pump, and on the port located
in--between ports M8 and P2 on the rear traction
manifold which is located behind the front tire. Use
Toro part numbers 95--8843 (hydraulic hose),
95--0985 (quantity 2) (coupler fitting) and 340--77
(quantity 2) (hydraulic fitting).
Figure 2
1. Piston pump
2. Relief valve (forward)
3. Relief valve (reverse)
1
2
3
Traction Circuit Component Failure
The traction circuit on Groundsmaster 4100--D and
4110--D machines is a closed loop system that includes
the piston (traction) pump, two (2) front wheel motors
and the rear axle motor. If a component in the traction
circuit should fail, debris and contamination from the
failed component will circulate throughout the traction
circuit. This contamination can damage other compo-
nents in the circuit so it must be removed to prevent
additional component failure.
The recommended method of removing traction circuit
contamination would be to temporarily install the Toro
high flow hydraulic filter (see Special Tools in this chap-
ter) into the circuit. This filter should be used when con-
necting hydraulic test gauges in order to test traction
circuit components or after replacing a failed traction cir-
cuit component (e.g. traction (piston) pump or wheel
motor). The filter will ensure that contaminates are re-
moved from the closed loop and thus, do not cause addi-
tional component damage.
Once the Toro high flow hydraulic filter kit has been
placed in the circuit, raise and support the machine with
all wheels off the ground. Then, operate the traction cir-
cuit to allow oil flow throughout the circuit. The filter will
remove contamination from the traction circuit during
operation. Because the Toro high flow filter is bi--direc-
tional, the traction circuit can be operated in both the for-
ward and reverse direction. The filter should be
removed from the machine after contamination has
been removed from the traction circuit. See Filtering
Closed--Loop Traction Circuit in the Service and Repairs
section of this chapter for additional information on us-
ing the Toro high flow hydraulic filter.
The alternative to using the Toro high flow hydraulic filter
kit after a traction circuit component failure would be to
disassemble, drain and thoroughly clean all compo-
nents, hydraulic tubes and hydraulic hoses in the trac-
tion circuit. If any debris remains in the traction circuit
and the machine is operated, the debris can cause addi-
tional circuit component failure.
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 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 conditions can cause hose damage and deterio-
ration. Some hoses are more susceptible to these
conditions than others. Inspect all machine hydraulic
hoses frequently for signs of deterioration or damage:
Hard, cracked, cut, abraded, charred, leaking or
otherwise damaged hose.
Kinked, crushed, flattened or twisted hose.
Blistered, soft, degraded or loose hose cover.
Cracked, damaged or badly corroded hose fittings.
When replacing a hydraulic hose, be sure that the hose
is straight (not twisted) before tightening the fittings.
This can be done by observing the imprint (layline) on
the hose. Use two wrenches when tightening a hose;
hold the hose straight with one wrench and tighten the
hose swivel nut onto the fitting with the second wrench
(see Hydraulic Hose and Tube Installation in this sec-
tion). If the hose has an elbow at one end, tighten the
swivel nut on that end before tightening the nut on the
straight end of the hose.
For additional hydraulic hose information, refer to Toro
Service Training Book, Hydraulic Hose Servicing (Part
Number 94813SL).
WARNING
Before disconnecting or performing any work on
hydraulic system, relieve all pressure in system
(see Relieving Hydraulic System Pressure in this
section).
Keep body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands, to
search for leaks. Hydraulic fluid escaping under
pressure can have sufficient force to penetrate
the skin and cause serious injury. If fluid is in-
jected into the skin, it must be surgically re-
moved within a few hours by a doctor familiar
with this type of injury. Gangrene may result from
such an injury.
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 6
Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting)
1. Make sure threads and sealing surfaces of the hose/
tube and the fitting are free of burrs, nicks, scratches or
any foreign material.
2. As a preventative measure against leakage, it is rec-
ommended that the face seal O--ring be replaced any
time the connection is opened. Make sure the O--ring is
installed and properly seated in the fitting groove. Lightly
lubricate the O--ring with clean hydraulic oil.
3. Place the hose/tube against the fitting body so that
theflatfaceofthehose/tubesleevefullycontactstheO--
ring in the fitting.
4. Thread the swivel nut onto the fitting by hand. While
holding the hose/tube with a wrench, use a torque
wrench to tighten the swivel nut to the recommended
installation torque shown in Figure 5. This tightening
process will require the use of an offset wrench (e.g.
crowfoot wrench). Use of an offset wrench will affect
torque wrench calibration due to the effective length
change of the torque wrench. Tightening torque when
usingatorquewrenchwithanoffsetwrenchwillbelower
than the listed installation torque (see Using a Torque
Wrench with an Offset Wrench in the Torque Specifica-
tions section of Chapter 2 -- Product Records and Main-
tenance).
5. If a torque wrench is not available or if space at the
swivel nut prevents use of a torque wrench, an alternate
method of assembly is the Flats From Wrench Resist-
ance (F.F.W.R.) method (Fig. 2).
A. Using a wrench, tighten the swivel nut onto the fit-
ting until light wrench resistance is reached (approxi-
mately 30 in--lb).
B. Mark the swivel nut and fitting body. Hold the
hose/tube with a wrench to prevent it from turning.
C. Useasecondwrenchtotightenthenuttothecor-
rect Flats From Wrench Resistance (F.F.W.R.). The
markings on the nut and fitting body will verify that the
connection has been properly tightened.
Siz e F.F.W.R .
4 (1/4 in. nominal hose or tubing) 1/2 to 3/4
6 (3/8 in.) 1/2 to 3/4
8 (1/2 in.) 1/2 to 3/4
10 (5/8 in.) 1/2 to 3/4
12 (3/4 in.) 1/3 to 1/2
16 (1 in.) 1/3 to 1/2
Figure 3
O--ring Fitting Body
Swivel Nut
Tube or Hose
Figure 4
Final
AT WRENCH RESISTANCE
Position
Mark Nut
and Fitting
Initial
Position
Extend Line
AFTER TIGHTENING
Body
Fitting Dash Size Hose/Tube Side Thread Size Installation Torque
49/16 -- 18 18to22ft--lb(25to29N--m)
611/16 -- 16 27to33ft--lb(37to44N--m)
813/16 -- 16 37to47ft--lb(51to63N--m)
10 1--14 60 to 74 ft--lb (82 to 100 N--m)
12 13/16--12 85 to 105 ft--lb (116 to 142 N--m)
16 17/16--12 110 to 136 ft--lb (150 to 184 N--m)
20 1 11/16 -- 12 140to172ft--lb(190to233N--m)
Figure 5
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 4 -- 7
Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port)
Non--Adjustable Fitting (Fig. 6)
1. Make sure all threads and sealing surfaces of fitting
and component port are free of burrs, nicks, scratches
or any foreign material.
2. As a preventative measure against leakage, it is rec-
ommended that the O--ring be replaced any time the
connection is opened.
3. Lightly lubricate the O--ring with clean hydraulic oil.
Fitting threads should be clean with no lubricant applied.
IMPORTANT: Before installing fitting into port, de-
termine port material. If fitting is to be installed into
an aluminum port, installation torque is reduced.
4. Install the fitting into the port. Then, use a torque
wrench and socket to tighten the fitting to the recom-
mended installation torque shown in Figure 7.
NOTE: Use of an offset wrench (e.g. crowfoot wrench)
will affect torque wrench calibration due to the effective
length change of the torque wrench. Tightening torque
when using a torque wrench with an offset wrench will
be less than the recommended installation torque. See
UsingaTorqueWrenchwithanOffsetWrenchinthe
Torque Specifications section of Chapter 2 -- Product
Records and Maintenance to determine necessary con-
version information.
5. If a torque wrench is not available, or if space at the
port prevents use of a torque wrench, an alternate meth-
od of assembly is the Flats From Finger Tight (F.F.F.T.)
method.
A. Install the fitting into the port and tighten it down
full length until finger tight.
B. If port material is steel, tighten the fitting to the
listed F.F.F.T. If port material is aluminum, tighten fit-
ting to 60% of listed F.F.F.T.
Siz e F.F.F.T.
4 (1/4 in. nominal hose or tubing) 1.00 + 0.25
6(3/8in.) 1.50+0.25
8(1/2in.) 1.50+0.25
10 (5/8 in.) 1.50 + 0.25
12 (3/4 in.) 1.50 + 0.25
16 (1 in.) 1.50 + 0.25
Figure 6
O--ring
Fitting
Fitting
Dash Size
Fitting Port Side
Thread Size
Installation Torque Into
Steel Port
Installation Torque Into
Aluminum Port
47/16 -- 20 15to19ft--lb(21to25N--m) 9to11ft--lb(13to15N--m)
51/2 -- 20 18to22ft--lb(25to29N--m) 11to15ft--lb(15to20N--m)
69/16 -- 18 34to42ft--lb(47to56N--m) 20to26ft--lb(28to35N--m)
83/4 -- 16 58to72ft--lb(79to97N--m) 35to43ft--lb(48to58N--m)
10 7/8 -- 14 99 to 121 ft--lb (135 to 164 N--m) 60 to 74 ft--lb (82 to 100 N--m)
12 11/16--12 134 to 164 ft--lb (182 to 222 N--m) 81 to 99 ft--lb (110 to 134 N--m)
14 13/16--12 160 to 196 ft--lb (217 to 265 N--m) 96to118ft--lb(131to160N--m)
16 15/16--12 202 to 248 ft--lb (274 to 336 N--m) 121 to 149 ft--lb (165 to 202 N--m)
20 15/8--12 247 to 303 ft--lb (335 to 410 N--m) 149 to 183 ft--lb (202 to 248 N--m)
Figure 7
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 8
Adjustable Fitting (Fig. 8)
1. Make sure all threads and sealing surfaces of fitting
and component port are free of burrs, nicks, scratches
or any foreign material.
2. As a preventative measure against leakage, it is rec-
ommended that the O--ring be replaced any time the
connection is opened.
3. Lightly lubricate the O--ring with clean hydraulic oil.
Fitting threads should be clean with no lubricant applied.
4. Turn back the lock nut as far as possible. Make sure
the back up washer is not loose and is pushed up as far
aspossible(Step1inFigure9).
IMPORTANT: Before installing fitting into port, de-
termine port material. If fitting is to be installed into
an aluminum port, installation torque is reduced.
5. Install the fitting into the port and tighten finger tight
until the washer contacts the face of the port (Step 2 in
Figure 9). Make sure that the fitting does not bottom in
the port during installation.
6. To put the fitting in the desired position, unscrew it by
therequiredamounttoalignfittingwithincominghose
or tube, but no more than one full turn (Step 3 in Figure
9).
7. Hold the fitting in the desired position with a wrench
and use a torque wrench to tighten the lock nut to the
recommended installation torque shown in Figure 7.
This tightening process will require the use of an offset
wrench (e.g. crowfoot wrench). Use of an offset wrench
will affect torque wrench calibration due to the effective
length change of the torque wrench. Tightening torque
when using a torque wrench with an offset wrench will
be lower than the listed installation torque (see Using a
Torque Wrench with an Offset Wrench in the Torque
Specifications section of Chapter 2 -- Product Records
and Maintenance).
8. If a torque wrench is not available, or if space at the
port prevents use of a torque wrench, an alternate meth-
od of assembly is the Flats From Finger Tight (F.F.F.T.)
method. Hold the fitting in the desired position with a
wrench and, if port material is steel, tighten the lock nut
withasecondwrenchtothelistedF.F.F.T.(Step4inFig-
ure 9). If port material is aluminum, tighten fitting to 60%
of listed F.F.F.T.
Si z e F.F. F. T.
4 (1/4 in. nominal hose or tubing) 1.00 + 0.25
6(3/8in.) 1.50+0.25
8(1/2in.) 1.50+0.25
10 (5/8 in.) 1.50 + 0.25
12 (3/4 in.) 1.50 + 0.25
16 (1 in.) 1.50 + 0.25
Figure 8
Lock Nut
Back--up Washer
O--ring
Figure 9
Step 3Step 1
Step 2 Step 4
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 4 -- 9
Hydraulic Schematic
NOTE: A larger hydraulic schematic is
included in Chapter 10 -- Foldout Drawings
S10
RV1
CV1
S2
S4
S5
PRV
P4 CH2 P3
EC
CF
LS
S3
OR1
C3
OR4
.040
S6
OR5
.070
C4 C2 C5
RV2
2500 PSI
S7
S9
S8
C6
M1 M2
CH1
CV3
CH4
OR2
.063
OR6
.063
OR3
.070
OR7
.070
T2SP
CH3
G2
G4
CV4
PR
G1
G3
3250
PSI
1350
PSI
3.3 GPM
4.4 GPM
15.2 GPM
310
PSI
4PSI
4PSI .030
OR9
S1
3300 PSI
RV3 S12
15.2 GPM
S11
CV2
4PSI
1.17 CID 3000 PSI
P1
P1
P1
P2
P2
P2
M1
M2
LC1
PRV
PD
CD
RV
2000 PSI
M1
M2
LC1
PRV
PD
RV
3000 PSI
M1
M2
LC1
PRV
PD
RV
CD
CD
LEFT DECK
CENTER DECK
RIGHT DECK
50 PSI
1.17 CID
1.17 CID
6.1 CID
0.625” ROD
EP
LR
T
STEERING
CYLINDER 0.51 CID
VALVE
PR
380 PSI RV
650 PSI
.050
CV
T
P2
M8
CH
OR1
250 psi
2.14 CID /
1.16 CID
600 PSI
600 PSI
600 PSI
.030”
200 PSI
2.75
CID
1.37
CID
1.37
CID
4350 PSI
5000 PSI
.025
.025
.025
.0315
G
G
G
2.00” BORE
4.20” STROKE
1.50” BORE
3.08” STROKE
CENTER DECK
RAM CYLINDERS
1.4 CID/
0.79 CID
1.4 CID/
0.79 CID
60 PSI
80
PSI
30.5 GPM
0.4
CID
0.3
CID ENGINE
REAR
TRACTION
.0315
1.125” ROD
2.50” BORE
6.50” STROKE
WING DECK
RIGHT
1.125” ROD
2.50” BORE
6.50” STROKE
WING DECK
LEFT
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 10
Hydraulic Flow Diagrams
Traction Circuit: LOW Speed (Mow) (Forward Shown)
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundsmaster 4100--D/4110--D
S10
RV1
CV1
S2
S4
S5
PRV
P4 CH2 P3
EC
CF
LS
S3
OR1
C3
OR4
.040
S6
OR5
.070
C4 C2 C5
RV2
S7
S9
S8
C6
M1 M2
CH1
CV3
CH4
OR2
.063
OR6
.063
OR3
.070
OR7
.070
T2SPCH3
G2
G4
CV4
PR
G1
G3
3250
PSI
1350
PSI
3.3 GPM
4.4 GPM
15.2 GPM
4 PSI
4PSI
.030
OR9
S1
3300 PSI
RV3
S12
S11
CV2
4 PSI
1.17 CID 3000 PSI
P1
P1
P1
P2
P2
P2
M1
M2
LC1
PRV
PD
CD
RV
2000 PSI
M1
M2
LC1
PRV
PD
RV
3000 PSI
M1
M2
LC1
PRV
PD
RV
CD
CD
LEFT DECK
CENTER DECK
RIGHT DECK
50 PSI
1.17 CID
1.17 CID
6.1 CID
EP
LR
T
STEERING
CYLINDER
0.51 CID
PR
380 PSI
RV
650 PSI
.050
CV
T
P2
M8
CH
OR1
250 PSI
2.14 CID /
1.16 CID
600 PSI
600 PSI
600 PSI
.030”
200 PSI
4350 PSI
5000 PSI
.025
.025
.025
.0315 .0315
0.4
CID
0.3 1.37 1.37
CID CID CID
2.75
CID
REAR
TRACTION
MANIFOLD
ENGINE
30.5
GPM
80
PSI 60
PSI
310
PSI
1.50” BORE
3.08” STROKE
RAM CYLINDERS
CENTER DECK
2.00” BORE
4.20” STROKE
0.625” ROD
GG
G
GG
G
COMBINATION MANIFOLD
STEERING
CONTROL
VALVE
G
G
G
2500 PSI
15.2 GPM
1.4 CID/
0.79 CID
1.4 CID/
0.79 CID
1.125” ROD
2.50” BORE
6.50” STROKE
WING DECK
RIGHT
1.125” ROD
2.50” BORE
6.50” STROKE
WING DECK
LEFT
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 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 the rate and direc-
tion of hydraulic flow. Pressing the traction pedal rotates
a potentiometer that provides an input to the machine
TEC controller. The controller in turn sends a corre-
sponding PWM (Pulse Width Modulation) output to the
electronic pump control to rotate the pump swash plate
accordingly to control pump output and direction. Trac-
tion circuit oil is directed to the dual displacement front
wheel and rear axle motors. Operating pressure on the
high pressure side of the closed traction circuit loop is
determined by the amount of load developed at the
wheel and axle motors. As the traction load increases,
circuit pressure can increase to relief valve settings:
4350 PSI (300 bar) in forward and 5000 PSI (345 bar)
in reverse. If traction circuit pressure exceeds the relief
setting, oil flows through the piston pump relief valve to
the low pressure side of the closed loop traction circuit.
Traction circuit pressure can be measured at test ports
attached to the sides of the piston pump. The forward
traction port is on the right side of the pump and the re-
verse traction port is on the left side.
Front wheel and rear axle motors are positive displace-
ment, two speed variable motors that allow operation in
either LOW (mow) or HI (transport) speed. The motors
are spring biased to maximum displacement for LOW
speed and are hydraulically shifted to minimum dis-
placement for HI speed. The rear axle motor includes a
flushing valve that bleeds off a small amount of hydraulic
oil for cooling of the closed loop traction circuit. The
charge circuit replaces oil that is bled from the circuit by
theflushingvalve.
The Smart PowerTM feature prevents the engine from
slowing down in heavy load conditions (e.g. cutting tall
grass) by automatically decreasing the traction speed if
necessary. With a reduced traction speed, the cutting
blades can continue to be at optimum speed.
Traction circuit components use small amounts of hy-
draulic oil for internal lubrication. Fluid is designed to
leak across traction pump and motor components into
the case drain. This leakage results in the loss of hy-
draulic oil from the closed loop traction circuit that is re-
placed by the charge circuit. The gear pump sections
that supply the steering, cooling fan and lift/lower cir-
cuits also provide charge circuit oil.
Gear pump flow for the charge circuit is directed through
the oil filter and to the low pressure side of the closed
loop traction circuit. Charge pressure is limited to 250
PSI (17 bar) by a relief valve located in the piston pump.
An optional traction circuit flow divider splits traction
pump hydraulic flow between the front wheel motors
(approximately 43%) and rear axle motor (approximate-
ly 57%) to prevent excessive circuit flow going to a spin-
ning wheel.
Forward Direction
With the armrest console HI/LOW speed switch in the
LOW speed (mow) position, solenoid valve (S12) in the
combination manifold is not energized which keeps the
front wheel motors and rear axle motor at their maxim-
um displacement. With the motors at maximum dis-
placement, a lower traction speed is available for
mowing conditions.
When the HI/LOW switch is in the LOW speed (mow)
position and the traction pedal is pushed in the forward
direction, oil from the piston pump is directed to the front
wheel motors and rear axle motor through a parallel sys-
tem. Oil flow to the front wheel motors drives the motors
in the forward direction and then returns to the piston
pump. Oil flow to the rear axle motor drives the motor in
the forward direction. Oil returning from the axle motor
entersthereartractionmanifoldattheM8port.Flowby-
passes the PR cartridge through the CV check valve, out
manifold port P2 and returns to the piston pump.
When going down a hill, the tractor becomes an over--
running load that drives the front wheel and rear axle
motors. In this condition, the rear axle motor could lock
up as the oil pumped from the motor increases pressure
as it returns to the piston pump. To prevent rear wheel
lock up, an adjustable relief valve (RV) in the rear trac-
tion manifold reduces rear axle motor pressure created
in down hill, dynamic braking conditions.
Reverse Direction
The traction circuit operates essentially the same in re-
verse LOW speed (mow) as it does in the forward direc-
tion. However, the flow through the circuit is reversed.
Oil flow from the piston pump is directed to the front
wheel motors and also to the rear traction manifold. The
oil to the front wheel motors drives them in the reverse
direction and then returns to the piston pump. The oil to
the rear traction manifold enters the manifold at port P2
and flows through pressure reducing valve (PR) which
limitsthedownstreampressuretotherearaxlemotor
to 380 PSI (26 bar) so the rear wheels will not scuff the
turf during reverse operation. This reduced pressure
flow is directed out rear traction manifold port M8 to drive
the rear axle motor in reverse. Return oil from the rear
motor returns to the piston pump.
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 12
Traction Circuit: HI Speed (Transport) (Forward Shown)
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundsmaster 4100--D/4110--D
S10
RV1
CV1
S2
S4
S5
PRV
P4 CH2 P3
EC
CF
LS
S3
OR1
C3
OR4
.040
S6
OR5
.070
C4 C2 C5
RV2
S7
S9
S8
C6
M1 M2
CH1
CV3
CH4
OR2
.063
OR6
.063
OR3
.070
OR7
.070
T2SPCH3
G2
G4
CV4
PR
G1
G3
3250
PSI
1350
PSI
3.3 GPM
4.4 GPM
4PSI
4 PSI
.030
OR9
S1
3300 PSI
RV3 S12
S11
CV2
4PSI
1.17 CID 3000 PSI
P1
P1
P1
P2
P2
P2
M1
M2
LC1
PRV
PD
CD
RV
2000 PSI
M1
M2
LC1
PRV
PD
RV
3000 PSI
M1
M2
LC1
PRV
PD
RV
CD
CD
LEFT DECK
CENTER DECK
RIGHT DECK
50 PSI
1.17 CID
1.17 CID
6.1 CID
EP
LR
T
STEERING
CYLINDER
0.51 CID
PR
380 PSI
RV
650 PSI
.050
CV
T
P2
M8
CH
OR1
250 PSI
2.14 CID /
1.16 CID
600 PSI
600 PSI
600 PSI
.030”
200 PSI
4350 PSI
5000 PSI
.025
.025
.025
.0315 .0315
0.4
CID
0.3 1.37 1.37
CID CID CID
2.75
CID
REAR
TRACTION
MANIFOLD
ENGINE
30.5
GPM
1.4 CID/
0.79 CID
80
PSI 60
PSI
310
PSI
1.50” BORE
3.08” STROKE
RAM CYLINDERS
CENTER DECK
2.00” BORE
4.20” STROKE
0.625” ROD
GG
G
GG
G
COMBINATION MANIFOLD
STEERING
CONTROL
VALVE
G
G
G
2500 PSI
1.4 CID/
0.79 CID
15.2 GPM
15.2 GPM
1.125” ROD
2.50” BORE
6.50” STROKE
WING DECK
RIGHT
1.125” ROD
2.50” BORE
6.50” STROKE
WING DECK
LEFT
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 4 -- 13
Traction Circuit: HI Speed (Transport)
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 the rate and direc-
tion of hydraulic flow. Pressing the traction pedal rotates
a potentiometer that provides an input to the machine
TEC controller. The controller in turn sends a corre-
sponding PWM (Pulse Width Modulation) output to the
electronic pump control to rotate the pump swash plate
accordingly to control pump output and direction. Trac-
tion circuit oil is directed to the dual displacement front
wheel and rear axle motors. Operating pressure on the
high pressure side of the closed traction circuit loop is
determined by the amount of load developed at the
wheel and axle motors. As the traction load increases,
circuit pressure can increase to relief valve settings:
4350 PSI (300 bar) in forward and 5000 PSI (345 bar)
in reverse. If traction circuit pressure exceeds the relief
setting, oil flows through the piston pump relief valve to
the low pressure side of the closed loop traction circuit.
Traction circuit pressure can be measured at test ports
attached to the sides of the piston pump. The forward
traction port is on the right side of the pump and the re-
verse traction port is on the left side.
Front wheel and rear axle motors are positive displace-
ment, two speed variable motors that allow operation in
either LOW (mow) or HI (transport) speed. The motors
are spring biased to maximum displacement for LOW
speed and are hydraulically shifted to minimum dis-
placement for HI speed. The rear axle motor includes a
flushing valve that bleeds off a small amount of hydraulic
oil for cooling of the closed loop traction circuit. The
charge circuit replaces oil that is bled from the circuit by
theflushingvalve.
Traction circuit components use small amounts of hy-
draulic oil for internal lubrication. Fluid is designed to
leak across traction pump and motor components into
the case drain. This leakage results in the loss of hy-
draulic oil from the closed loop traction circuit that is re-
placed by the charge circuit. The gear pump sections
that supply the steering, cooling fan and lift/lower cir-
cuits also provide charge circuit oil.
Gear pump flow for the charge circuit is directed through
the oil filter and to the low pressure side of the closed
loop traction circuit. Charge pressure is limited to 250
PSI (17 bar) by a relief valve located in the piston pump.
An optional traction circuit flow divider splits traction
pump hydraulic flow between the front wheel motors
(approximately 43%) and rear axle motor (approximate-
ly 57%) to prevent excessive circuit flow going to a spin-
ning wheel.
Forward Direction
WiththearmrestconsoleHI/LOWspeedswitchintheHI
speed (transport) position, solenoid valve (S12) in the
combination manifold is energized. The energized
solenoid valve directs charge pressure to shift the front
wheel motors and rear axle motor to their minimum dis-
placement. With the motors at their minimum displace-
ments, a higher traction speed is available for transport.
When the HI/LOW switch is in the HI speed (transport)
position and the traction pedal is pushed in the forward
direction, oil from the piston pump is directed to the front
wheel motors and rear axle motor through a parallel sys-
tem. Oil flow to the front wheel motors drives the motors
in the forward direction and then returns to the piston
pump. Oil flow to the rear axle motor drives the motor in
the forward direction. Oil returning from the axle motor
entersthereartractionmanifoldattheM8port.Flowby-
passes the PR cartridge through the CV check valve, out
manifold port P2 and returns to the piston pump.
When going down a hill, the tractor becomes an over--
running load that drives the front wheel and rear axle
motors. In this condition, the rear axle motor could lock
up as the oil pumped from the motor increases pressure
as it returns to the piston pump. To prevent rear wheel
lock up, an adjustable relief valve (RV) in the rear trac-
tion manifold reduces rear axle motor pressure created
in down hill, dynamic braking conditions.
Reverse Direction
The traction circuit operates essentially the same in re-
verse HI speed (transport) as it does in the forward
direction. However, the flow through the circuit is re-
versed. Oil flow from the piston pump is directed to the
front wheel motors and also to the rear traction manifold.
The oil to the front wheel motors drives them in the re-
verse direction and then returns to the piston pump. The
oil to the rear traction manifold enters the rear traction
manifold at port P2 and flows through pressure reducing
valve (PR) which limits the down stream pressure to the
rear axle motor to 380 PSI (26 bar) so the rear wheels
will not scuff the turf during reverse operation. This re-
duced pressure flow is directed out rear traction mani-
fold port M8 to drive the rear axle motor in reverse.
Return oil from the rear motor returns to the piston
pump.
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 14
Lower Cutting Deck (LH Wing Deck Shown)
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundsmaster 4100--D/4110--D
S10
RV1
CV1
S2
S4
S5
PRV
P4 CH2 P3
EC
CF
LS
S3
OR1
C3
OR4
.040
S6
OR5
.070
C4 C2 C5
RV2
S7
S9
S8
C6
M1 M2
CH1
CV3
CH4
OR2
.063
OR6
.063
OR3
.070
OR7
.070
T2SPCH3
G2
G4
CV4
PR
G1
G3
3250
PSI
1350
PSI
3.3 GPM
4.4 GPM
4PSI
4PSI
.030
OR9
S1
3300 PSI
RV3 S12
S11
CV2
4 PSI
1.17 CID 3000 PSI
P1
P1
P1
P2
P2
P2
M1
M2
LC1
PRV
PD
CD
RV
2000 PSI
M1
M2
LC1
PRV
PD
RV
3000 PSI
M1
M2
LC1
PRV
PD
RV
CD
CD
LEFT DECK
CENTER DECK
RIGHT DECK
50 PSI
1.17 CID
1.17 CID
6.1 CID
EP
LR
T
STEERING
CYLINDER
0.51 CID
PR
380 PSI
RV
650 PSI
.050
CV
T
P2
M8
CH
OR1
250 PSI
2.14 CID /
1.16 CID
600 PSI
600 PSI
600 PSI
.030”
200 PSI
4350 PSI
5000 PSI
.025
.025
.025
.0315 .0315
0.4
CID
0.3 1.37 1.37
CID CID CID
2.75
CID
REAR
TRACTION
MANIFOLD
ENGINE
30.5
GPM
80
PSI 60
PSI
310
PSI
1.50” BORE
3.08” STROKE
RAM CYLINDERS
CENTER DECK
2.00” BORE
4.20” STROKE
0.625” ROD
GG
G
GG
G
COMBINATION MANIFOLD
STEERING
CONTROL
VALVE
EXTENDING
G
G
G
2500 PSI
1.4 CID/
0.79 CID
15.2 GPM
15.2 GPM
1.4 CID/
0.79 CID
1.125” ROD
2.50” BORE
6.50” STROKE
WING DECK
RIGHT
1.125” ROD
2.50” BORE
6.50” STROKE
WING DECK
LEFT
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 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 the cutting deck sections (main, right wing and
left wing) can be lowered independently with the use of
three (3) switches on the armrest console. Pressing the
front of a lift switch provides an input for the TEC control-
ler to lower the cutting deck or wing deck. The controller
provides electrical outputs to solenoids in the combina-
tion control manifold to allow appropriate manifold valve
shift that causes a cutting deck to lower.
A relief valve (RV2) located in the combination control
manifold limits lift/lower circuit pressure to 2500 PSI
(172 bar). An adjustable pressure relieving valve (PR)
in the combination manifold maintains back pressure
(counterbalance) on the deck lift cylinders to allow some
of the cutting deck weight to be transferred to the traction
unit to improve traction.
When the lift/lower circuit is not being used (all lift
switches in the neutral position), solenoid valve S1 in the
combination manifold is not energized and gear pump
section oil flow is directed toward the engine cooling fan
motor.
NOTE: To lower a cutting deck, the operator must be in
the operator seat and the traction speed must be in the
LOW speed (mow) position.
Lower Cutting Deck
To lower the cutting deck, the front of the center console
liftswitchisdepressed.Theswitchsignalisaninputto
the TEC controller which provides an electrical output to
solenoid valve S6 in the combination manifold. The en-
ergized solenoid valve shifts to allow a passage for oil
flow from the barrel end of the cutting deck lift cylinders.
The weight of the cutting deck causes the cutting deck
lift cylinders to retract and lower the cutting deck. Check
orifice OR5 (.070) under the manifold fitting in port C2
controls the lowering speed of the cutting deck. Oil from
the retracting cylinders is directed to pressure reducing
valve (PR). As return oil pressure increases, the PR
valve will shift to direct circuit oil to the oil filter and then
to the traction charge circuit.
Lower Right Wing Deck
Tolowertherightwingdeck,thefrontoftherightconsole
lift switch is pushed as an input to the TEC controller.
The controller provides an electrical output to solenoid
valves S1, S8 and S9 in the combination manifold. The
energized solenoid valves shift to allow a passage for
circuit oil flow to the rod end of the right wing deck lift cyl-
inder. Shifted S1 allows gear pump section oil flow to be
available for the lift/lower circuits. Shifted S8 allows an
oilpathtotherodendoftherightliftcylindertoretract
the lift cylinder and lower the right wing deck. Check ori-
fice OR7 (.070) controls the lowering speed of the wing
deck. Oil from the retracting cylinder is directed through
energized S9, de--energized S7 and then to pressure re-
ducing valve (PR). As return oil pressure increases, the
PR valve will shift to direct circuit oil to the oil filter and
thentothetractionchargecircuit.
Lower Left Wing Deck
To lower the left wing deck, the front of the left console
lift switch is pushed as an input to the TEC controller.
The controller provides an electrical output to solenoid
valves S1, S3 and S4 in the combination manifold. The
energized solenoid valves shift to allow a passage for
circuit oil flow to the left deck lift cylinder rod end. Shifted
S1 allows gear pump section oil flow to be available for
the lift/lower circuits. ShiftedS3allowsanoilpathtothe
rod end of the left lift cylinder to retract the lift cylinder
and lower the left cutting deck. Check orifice OR3 (.070)
controls the lowering speed of the cutting deck. Oil from
the retracting cylinder is directed through energized S4,
de--energized S2 and then to pressure reducing valve
(PR). As return oil pressure increases, the PR valve will
shift to direct circuit oil to the oil filter and then to the trac-
tion charge circuit.
Cutting Deck Float
Cutting deck float allows the fully lowered cutting deck
to follow ground surface contours. Combination man-
ifold solenoid valves S4 (left wing deck), S6 (center
deck) and S9 (right wing deck) are energized when the
deck is fully lowered. These energized solenoids pro-
vide an oil passage to and from the lift cylinders to allow
cylinder and cutting deck movement while mowing.
Counterbalance pressure (PR) will affect deck float op-
eration.
NOTE: If a deck is already fully lowered when the igni-
tion switch is moved from OFF to RUN, the deck will not
be in float until the appropriate deck lift/lower switch is
momentarily pressed to lower.
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 16
Raise Cutting Deck (LH Wing Deck Shown)
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundsmaster 4100--D/4110--D
S10
RV1
CV1
S2
S4
S5
PRV
P4 CH2 P3
EC
CF
LS
S3
OR1
C3
OR4
.040
S6
OR5
.070
C4 C2 C5
RV2
S7
S9
S8
C6
M1 M2
CH1
CV3
CH4
OR2
.063
OR6
.063
OR3
.070
OR7
.070
T2SPCH3
G2
G4
CV4
PR
G1
G3
3250
PSI
1350
PSI
3.3 GPM
4.4 GPM
4PSI
4PSI
.030
OR9
S1
3300 PSI
RV3 S12
S11
CV2
4 PSI
1.17 CID 3000 PSI
P1
P1
P1
P2
P2
P2
M1
M2
LC1
PRV
PD
CD
RV
2000 PSI
M1
M2
LC1
PRV
PD
RV
3000 PSI
M1
M2
LC1
PRV
PD
RV
CD
CD
LEFT DECK
CENTER DECK
RIGHT DECK
50 PSI
1.17 CID
1.17 CID
6.1 CID
EP
LR
T
STEERING
CYLINDER
0.51 CID
1.125” ROD
PR
380 PSI
RV
650 PSI
.050
CV
T
P2
M8
CH
OR1
250 PSI
2.14 CID /
1.16 CID
600 PSI
600 PSI
600 PSI
.030”
200 PSI
4350 PSI
5000 PSI
.025
.025
.025
.0315 .0315
0.4
CID
0.3 1.37 1.37
CID CID CID
2.75
CID
REAR
TRACTION
MANIFOLD
ENGINE
30.5
GPM
80
PSI 60
PSI
310
PSI
2.50” BORE
6.50” STROKE
1.50” BORE
3.08” STROKE
RAM CYLINDERS
CENTER DECK
1.125” ROD
2.50” BORE
6.50” STROKE
2.00” BORE
4.20” STROKE
0.625” ROD
GG
G
GG
G
COMBINATION MANIFOLD
STEERING
CONTROL
VALVE
WING DECK
RETRACTING
G
G
G
2500 PSI
15.2 GPM
1.4 CID/
0.79 CID
1.4 CID/
0.79 CID
15.2 GPM
RIGHT
WING DECK
LEFT
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 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 the cutting deck sections (main, right wing and
left wing) can be raised independently with the use of
three (3) switches on the armrest console. Pressing the
rear of a lift switch provides an input for the TEC control-
ler to raise the cutting deck or wing deck. The controller
provides electrical outputs to solenoids in the combina-
tion control manifold to allow appropriate manifold valve
shift that causes a cutting deck to raise.
A relief valve (RV2) located in the combination control
manifold limits lift/lower circuit pressure to 2500 PSI
(172 bar). An adjustable pressure relieving valve (PR)
in the combination manifold maintains back pressure
(counterbalance) on the deck lift cylinders to allow some
of the cutting deck weight to be transferred to the traction
unit to improve traction.
When the lift/lower circuit is not being used (all lift
switches in the neutral position), solenoid valve S1 in the
combination manifold is not energized and gear pump
section oil flow is directed toward the engine cooling fan
motor.
NOTE: To raise a cutting deck, the operator must be in
the operator seat.
Raise Center Cutting Deck
To raise the cutting deck, the rear of the center console
liftswitchisdepressed.Theswitchsignalisaninputto
the TEC controller which provides an electrical output to
solenoid valves S1 and S5 in the combination manifold.
The energized solenoid valves shift to allow a passage
for circuit oil flow to the barrel end of the cutting deck lift
cylinders. Shifted S1 allows gear pump section oil flow
to be available for the lift/lower circuits. Shifted S5 allows
an oil path to the barrel end of the front lift cylinders caus-
ing the lift cylinders to extend and raise the cutting deck.
Check orifice OR5 under the fitting in manifold port C2
allows oil flow to bypass the orifice when the deck is rais-
ing. An orifice in manifold port OR4 (.040) exists to con-
trol the raise speed of the cutting deck.
Raise Right Wing Deck
To raise the right wing deck, the rear of the right console
lift switch is depressed as an input to the TEC controller.
The controller provides an electrical output to solenoid
valves S1, S7 and S9 in the combination manifold. The
energized solenoid valves shift to allow a passage for
circuit oil flow to the barrel end of the right wing deck lift
cylinder. Shifted S1 allows gear pump section oil flow to
be available for the lift/lower circuits. Shifted S7 and S9
allow an oil path to the barrel end of the right lift cylinder
to extend the lift cylinder and raise the right wing deck.
Orifice OR6 (.063) controls the raising of the wing deck.
Check orifice OR7 is bypassed when raising the right
wing deck. Oil from the extending cylinder is directed
through S8 (de--energized), to the oil filter and then to
thetractionchargecircuit.
Raise Left Wing Deck
To raise the left wing deck, the rear of the left console lift
switch is depressed as an input to the TEC controller.
The controller provides an electrical output to solenoid
valves S1, S2 and S4 in the combination manifold. The
energized solenoid valves shift to allow a passage for
circuit oil flow to the barrel end of the left wing deck lift
cylinder. Shifted S1 allows gear pump section oil flow to
be available for the lift/lower circuits. Shifted S2 and S4
allow an oil path to the barrel end of the right lift cylinder
to extend the lift cylinder and raise the right wing deck.
Orifice OR2 (.063) controls the raising of the wing deck.
Check orifice OR3 is bypassed when raising the left
wing deck. Oil from the extending cylinder is directed
through S3 (de--energized), to the oil filter and then to
thetractionchargecircuit.
1. Piston (traction) pump 2. 3rd gear pump section
Figure 10
2
1
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 18
Mow Circuit (All Deck Motors Rotating)
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundsmaster 4100--D/4110--D
S10
RV1
CV1
S2
S4
S5
PRV
P4 CH2 P3
EC
CF
LS
S3
OR1
C3
OR4
.040
S6
OR5
.070
C4 C2 C5
RV2
S7
S9
S8
C6
M1 M2
CH1
CV3
CH4
OR2
.063
OR6
.063
OR3
.070
OR7
.070
T2SPCH3
G2
G4
CV4
PR
G1
G3
3250
PSI
1350
PSI
3.3 GPM
4.4 GPM
4 PSI
4 PSI
.030
OR9
S1
3300 PSI
RV3 S12
S11
CV2
4PSI
1.17 CID 3000 PSI
P1
P1
P1
P2
P2
P2
M1
M2
LC1
PRV
PD
CD
RV
2000 PSI
M1
M2
LC1
PRV
PD
RV
3000 PSI
M1
M2
LC1
PRV
PD
RV
CD
CD
LEFT DECK
CENTER DECK
RIGHT DECK
50 PSI
1.17 CID
1.17 CID
6.1 CID
EP
LR
T
STEERING
CYLINDER
0.51 CID
PR
380 PSI
RV
650 PSI
.050
CV
T
P2
M8
CH
OR1
250 PSI
2.14 CID /
1.16 CID
600 PSI
600 PSI
600 PSI
.030”
200 PSI
4350 PSI
5000 PSI
.025
.025
.025
.0315 .0315
0.4
CID
0.3 1.37 1.37
CID CID CID
2.75
CID
REAR
TRACTION
MANIFOLD
ENGINE
30.5
GPM
80
PSI 60
PSI
310
PSI
1.50” BORE
3.08” STROKE
RAM CYLINDERS
CENTER DECK
2.00” BORE
4.20” STROKE
0.625” ROD
GG
G
GG
G
COMBINATION MANIFOLD
STEERING
CONTROL
VALVE
COOLING
FAN MOTOR
G
G
G
2500 PSI
15.2 GPM
1.4 CID/
0.79 CID
15.2 GPM
1.4 CID/
0.79 CID
1.125” ROD
2.50” BORE
6.50” STROKE
WING DECK
RIGHT
1.125” ROD
2.50” BORE
6.50” STROKE
WING DECK
LEFT
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 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-
draulic flow to the wings of the cutting deck, while the
next gear pump section supplies the center section of
the cutting deck.
Each cutting deck section is controlled by a hydraulic
manifold equipped with a proportional relief valve
(PRV), a pilot directional valve (PD), a logic valve (LC1)
and a relief valve (RV). The proportional relief valve is
a solenoid operated valve that also functions as the cir-
cuit relief valve when energized. Circuit pressure can be
measured at port (G) of the hydraulic manifold for each
cutting deck.
NOTE: To engage the mow circuit, the operator must
be in the operator seat, the traction speed must be in the
LOW speed (mow) position, the PTO switch must be ON
and the wing decks must be fully lowered and in float.
PTO Not Engaged
When the PTO switch is OFF or if the deck or wing deck
is raised with the PTO switch ON, the PTO manifold pro-
portional relief valve (PRV) is not energized which al-
lows a small amount of hydraulic flow through the valve.
As this hydraulic flow returns to the hydraulic reservoir,
a circuit pressure increase shifts logic valve LC1. The
pump flow is routed through shifted LC1 and out man-
ifold port P2 bypassing the cutting deck motors. Pilot dir-
ection valve PD and relief valve RV remain in the
unshifted position to prevent any return flow from the
deck motor which keeps the deck section motor and cut-
ting blades from rotating.
Return flow from the center and right PTO manifolds is
routed through the oil cooler, oil filter and then to the gear
pump input. Return flow from the left PTO manifold pro-
vides supply for the right deck.
PTO Engaged
When the PTO switch is turned ON and the deck is low-
ered, the PTO manifold proportional relief valve (PRV)
is energized by the TEC controller. This shifted solenoid
valve prevents any flow through the valve which allows
the logic valve LC1 to be in its neutral position directing
circuit flow toward the cutting deck motors. Gear pump
flow entering the manifold is routed out manifold port M1
and to the cutting deck motor to cause the motor and cut-
ting blades to rotate. As circuit pressure increases, pilot
direction valve PD shifts to provide a return path for cir-
cuit flow. The return flow from the deck motor re--enters
manifold port M2, is routed through shifted PD, out man-
ifold port P2, through the oil cooler and filter and then is
routed to the gear pump input. The deck motor contin-
ues to rotate as long as proportional relief valve (PRV)
is energized.
Deck motor case drain leakage returns to the hydraulic
reservoir.
PTO Circuit Relief
Maximum mow circuit pressure is limited for each deck
section by proportional relief valve (PRV) in the PTO
manifold. The center and left wing deck relief valves are
set at 3000 PSI (207 bar) and the right wing deck relief
valve is set at 2000 PSI (138 bar).
Proportional relief valve (PRV) and logic valve (LC1)
work together as a two stage circuit relief. When in-
creased circuit resistance is met (e.g. a cutting blade
strikes an object), the pressure increase is felt at the pro-
portional relief valve. If the pressure should exceed the
relief valve setting, the relief valve will open, allowing a
small amount of hydraulic flow through the valve. This
flow causes a pressure increase that shifts logic valve
LC1 and diverts circuit flow away from the deck motor to
manifold port P2 (Fig. 11). When circuit pressure lowers,
proportional relief valve (PRV) closes which returns lo-
gic valve LC1 back to its neutral position allowing flow
to return to the deck section motor.
Figure 11
PRV ENERGIZED
PRV AND LC1 SHIFTED
DECK MOTOR STALLED
P1
P2
M1
M2
LC1
PRV
PD
RV
3000 PSI
CD RIGHT DECK
1.17 CID
600 PSI
.025
PUMP
RETURN
FLOW
RETURN
G
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic 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 information in Mow Cir-
cuit in this section). This shifted cartridge directs oil re-
turn out of manifold port P2. As circuit pressure
decreases, pilot direction valve PD is shifted to it’s neut-
ral position, preventing return flow from the deck motor
and slows the cutting blades (Fig. 12).
The inertia of the rotating cutting blades, however, effec-
tively turns the deck motor into a pump causing an in-
crease in pressure as the flow from the motor comes up
against the closed relief valve (RV). When this pressure
builds to approximately 600 PSI (41 bar), relief valve
(RV) opens which allows hydraulic flow to flow from the
motor (Fig. 13). When return pressure drops below 600
PSI (41 bar), relief valve (RV) reseats to once again
block return flow from the deck motor to further slow the
cutting blades. This action of the brake relief valve open-
ing occurs several times in a very short time frame as the
blades finally come to a stop. Once the deck section
blades have stopped, relief valve (RV) remains seated
to keep the deck motor from rotating.
Figure 12
P1
P2
M1
M2
LC1
PRV
PD
RV
3000 PSI
CD RIGHT DECK
1.17 CID
600 PSI
.025
PUMP
RETURN
FLOW
RETURN
PRV NOT ENERGIZED
LC1 SHIFTED
PTO SWITCH OFF
G
Figure 13
P1
P2
M1
M2
LC1
PRV
PD
RV
3000 PSI
CD RIGHT DECK
1.17 CID
600 PSI
.025
PUMP
RETURN
FLOW
RETURN
PRV NOT ENERGIZED
LC1 AND RV SHIFTED
PTO SWITCH OFF
G
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 4 -- 21
This page is intentionally blank.
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 22
Steering Circuit (Right Turn Shown)
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundsmaster 4100--D/4110--D
S10
RV1
CV1
S2
S4
S5
PRV
P4 CH2 P3
EC
CF
LS
S3
OR1
C3
OR4
.040
S6
OR5
.070
C4 C2 C5
RV2
S7
S9
S8
C6
M1 M2
CH1
CV3
CH4
OR2
.063
OR6
.063
OR3
.070
OR7
.070
T2SPCH3
G2
G4
CV4
PR
G1
G3
3250
PSI
1350
PSI
3.3 GPM
4.4 GPM
4 PSI
4PSI
.030
OR9
S1
3300 PSI
RV3 S12
S11
CV2
4 PSI
1.17 CID 3000 PSI
P1
P1
P1
P2
P2
P2
M1
M2
LC1
PRV
PD
CD
RV
2000 PSI
M1
M2
LC1
PRV
PD
RV
3000 PSI
M1
M2
LC1
PRV
PD
RV
CD
CD
LEFT DECK
CENTER DECK
RIGHT DECK
50 PSI
1.17 CID
1.17 CID
6.1 CID
EP
LR
T
STEERING
CYLINDER 0.51 CID
PR
380 PSI
RV
650 PSI
.050
CV
T
P2
M8
CH
OR1
250 PSI
2.14 CID /
1.16 CID
600 PSI
600 PSI
600 PSI
.030”
200 PSI
4350 PSI
5000 PSI
.025
.025
.025
.0315 .0315
0.4
CID
0.3 1.37 1.37
CID CID CID
2.75
CID
REAR
TRACTION
MANIFOLD
ENGINE
30.5
GPM
80
PSI 60
PSI
310
PSI
1.50” BORE
3.08” STROKE
RAM CYLINDERS
CENTER DECK
2.00” BORE
4.20” STROKE
0.625” ROD
GG
G
GG
G
COMBINATION MANIFOLD
STEERING
CONTROL
VALVE
EXTENDING
G
G
G
2500 PSI
15.2 GPM
1.4 CID/
0.79 CID
15.2 GPM
1.4 CID/
0.79 CID
1.125” ROD
2.50” BORE
6.50” STROKE
WING DECK
RIGHT
1.125” ROD
2.50” BORE
6.50” STROKE
WING DECK
LEFT
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 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 traction
charge circuit. Priority hydraulic flow from this gear
pump section is provided to the steering circuit by the
pressure compensator valve (EC) located in the com-
bination manifold.
NOTE: The hydraulic schematic symbol for the pres-
sure compensator valve (EC) appears to be a two (2) po-
sition valve. In operation, this valve will direct the gear
pump section flow to the steering circuit as priority de-
pending on steering input. The remainder of the gear
pump section flow will be directed to the charge and en-
gine cooling fan circuits. If there is no steering input, the
compensator valve (EC) directs all gear pump section
flow to the charge and engine cooling fan circuits.
The combination manifold controls the operation of the
steering control valve, the engine cooling fan motor and
the cutting deck lift cylinders. The pressure compensat-
or valve (EC) in the manifold controls the oil flow to the
steering control valve which is a closed center, load
sensing valve. The steering control valve senses the oil
flow that is needed for steering and the compensator
valve (EC) will supply the correct amount. Oil flow not
needed for the steering circuit is provided to the engine
cooling fan motor and then to the traction charge circuit.
With the steering wheel in the neutral, at rest position
and the engine running, hydraulic oil from the final gear
pump section enters the combination manifold port P4,
flows through the pressure compensator valve (EC) and
to the steering control valve where it dead heads at the
steering control spool. Oil is also sent to both ends of the
compensator valve (EC) spool. On one end of the spool,
oil is directed to the steering relief valve (RV1) and also
is directed through the OR1 orifice and out the LS man-
ifold port to the steering control valve. This flow provides
steering load sense pressure and is directed through a
small passage in the steering control valve spool and
sleeve before returning to the hydraulic reservoir. While
this load sense pressure is returning to the reservoir, the
compensator valve (EC) spool shifts to direct pump flow
to the engine cooling fan motor circuit and then to the
traction charge circuit. Without steering input, no oil is
flowing through the steering control valve to the steering
cylinder.
Right Turn
When a right turn is made with the engine running, the
turning of the steering wheel positions the steering con-
trol valve spool so that the load sense flow is blocked off.
Without load sense flow, pressures on the ends of man-
ifold compensator valve (EC) start to equalize causing
(EC) to move toward its neutral position which allows the
needed oil flow to the steering control valve. Oil is routed
out manifold port CF, into steering valve port P, through
the steering control spool, is drawn through the rotary
meter section and out the R port to the steering cylinder.
Pressure extends the steering cylinder for a right turn.
The rotary meter ensures that the oil flow to the cylinder
is proportional to the amount of the turning on the steer-
ing wheel. Fluid leaving the cylinder flows back through
the steering valve L port, the spool valve, out the T port
and then returns to the hydraulic reservoir.
The steering control valve returns to the neutral position
when turning is completed.
Left Turn
When a left turn is made with the engine running, the
turning of the steering wheel positions the steering con-
trol valve spool so that the load sense flow is blocked off.
Without load sense flow, pressures on the ends of man-
ifold compensator valve (EC) start to equalize causing
(EC) to move toward its neutral position which allows the
needed oil flow to the steering control valve. Oil is routed
out manifold port CF, into steering valve port P, through
the steering control spool, is drawn through the rotary
meter section and out the L port to the steering cylinder.
Pressure retracts the steering cylinder for a left turn. The
rotary meter ensures that the oil flow to the cylinder is
proportional to the amount of the turning on the steering
wheel. Fluid leaving the cylinder flows back through the
steering valve R port, the spool valve, out the T port and
then returns to the hydraulic reservoir.
The steering control valve returns to the neutral position
when turning is completed.
Steering Relief Operation
When the steering cylinder reaches the end of its stroke
or if a rear wheel should encounter an obstruction (e.g.
a curb) while steering, the pressure in the steering circuit
will rise. Relief valve (RV1) in the combination manifold
senses this pressure increase. When steering circuit
pressure builds to approximately 1350 PSI (93 bar), re-
lief valve (RV1) opens and allows hydraulic flow to return
to the hydraulic reservoir. This action causes flow
across the relief valve side orifice of compensator valve
(EC) which shifts the spool in (EC) to send oil away from
the steering circuit to the fan motor circuit. Relief valve
(RV1) controls the action of compensator valve (EC)
and allows the compensator valve to divert only enough
oil flow to the steering circuit to maintain relief pressure.
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 24
Engine Cooling Fan Circuit (Forward Direction Shown)
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundsmaster 4100--D/4110--D
S10
RV1
CV1
S2
S4
S5
PRV
P4 CH2 P3
EC
CF
LS
S3
OR1
C3
OR4
.040
S6
OR5
.070
C4 C2 C5
RV2
2500 PSI
S7
S9
S8
C6
M1 M2
CH1
CV3
CH4
OR2
.063
OR6
.063
OR3
.070
OR7
.070
T2SPCH3
G2
G4
CV4
PR
G1
G3
3250
PSI
1350
PSI
3.3 GPM
4.4 GPM
4 PSI
4PSI
.030
OR9
S1
3300 PSI
RV3 S12
S11
CV2
4 PSI
1.17 CID 3000 PSI
P1
P1
P1
P2
P2
P2
M1
M2
LC1
PRV
PD
CD
RV
2000 PSI
M1
M2
LC1
PRV
PD
RV
3000 PSI
M1
M2
LC1
PRV
PD
RV
CD
CD
LEFT DECK
CENTER DECK
RIGHT DECK
50 PSI
1.17 CID
1.17 CID
6.1 CID
EP
LR
T
STEERING
CYLINDER
0.51 CID
PR
380 PSI
RV
650 PSI
.050
CV
T
P2
M8
CH
OR1
250 PSI
2.14 CID /
1.16 CID
600 PSI
600 PSI
600 PSI
.030”
200 PSI
4350 PSI
5000 PSI
.025
.025
.025
.0315 .0315
0.4
CID
0.3 1.37 1.37
CID CID CID
2.75
CID
REAR
TRACTION
MANIFOLD
ENGINE
30.5
GPM
80
PSI 60
PSI
310
PSI
1.50” BORE
3.08” STROKE
RAM CYLINDERS
CENTER DECK
2.00” BORE
4.20” STROKE
0.625” ROD
G
GG
G
GG
G
COMBINATION MANIFOLD
STEERING
CONTROL
VALVE
G
G
1.4 CID/
0.79 CID
15.2 GPM
1.4 CID/
0.79 CID
15.2 GPM
1.125” ROD
2.50” BORE
6.50” STROKE
WING DECK
RIGHT
1.125” ROD
2.50” BORE
6.50” STROKE
WING DECK
LEFT
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 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 circuit and
the traction charge circuit. The third gear pump section
supplies hydraulic flow to the engine cooling fan circuit,
the lift/lower circuit and the traction charge circuit.
So that there is sufficient oil flow for the engine cooling
fan circuit, oil flow from either or both of the third or fourth
gear pump section is used to drive the hydraulic cooling
fan motor depending on what other machine functions
are being used (steering, lift/lower). If additional oil flow
is needed for cooling fan operation in extreme condi-
tions (e.g. high ambient temperatures, cutting very
heavy grass), the TEC controller can allow flow from the
twopumpsectionstobecombined.
Oil flow from the third gear pump section is routed to the
combination manifold (port P3) where it is available
either for the lift/lower circuit or the engine cooling fan
circuit. When the lift/lower circuit is not being used (all lift
switches in the neutral position), solenoid valve (S1) in
the combination manifold is not energized and gear
pump section oil flow is directed toward the engine cool-
ing fan motor.
Priority oil flow from the fourth gear pump section is
provided to the steering circuit. All excess flow from this
gear pump section is normally routed to the traction
charge circuit by energized solenoid valve (S11). This
valve is energized by the TEC controller as long as the
lift/lower function is not being used and the hydraulic oil
and engine coolant temperatures are within normal
ranges. If inputs to the TEC controller suggest additional
oil flow is necessary for the cooling fan (e.g. lift/lower cir-
cuit is engaged or engine coolant temperature is elev-
ated), solenoid valve (S11) will be de--energized
allowing excess pump section oil flow to be directed to-
wardtheenginecoolingfanmotor.
Oil flow from the gear pump section(s) to the cooling fan
motor is controlled by the proportional relief valve (PRV)
in the combination manifold. This valve adjusts fan cir-
cuit pressure and flow based on a PWM (Pulse Width
Modulation) signal from the TEC controller. The control-
ler uses engine coolant and hydraulic oil temperatures
as inputs to determine the proper PWM signal for the
(PRV) valve. The fan circuit flow determines the speed
of the cooling fan motor and thus, the speed of the cool-
ing fan.
If the fan motor is stalled for any reason during machine
operation, the manifold proportional relief valve (PRV)
has a secondary function as a circuit relief to limit fan
motor pressure to 3250 PSI (224 bar).
When the engine is shut off, the over--running inertia
load of the engine cooling fan blades keeps driving the
fan motor and turns it into a pump. The check valve
(CV1) in the combination manifold will open to keep the
motor circuit full of oil so the fan motor will not cavitate.
Forward Direction Fan Operation
During normal, forward direction fan operation, circuit oil
flow is sent through the de--energized solenoid valve
(S10) in the combination manifold to rotate the cooling
fan motor. Return flow from the motor re--enters the
manifold (port M2), through the de--energized solenoid
valve (S10), to the oil filter and then out of the manifold
(port CH2). After exiting the manifold, circuit oil is routed
to the traction charge circuit.
Reverse Direction Fan Operation
The TEC controller can reverse the cooling fan to clean
debris from the rear intake screen. If hydraulic oil and/or
engine coolant temperatures increase to an unsuitable
level, a high PWM signal is sent to the (PRV) valve to
slow the cooling fan and direct all pump oil flow to the
traction charge circuit. The controller then energizes so-
lenoid valve (S10) in the combination manifold to re-
verse cooling fan motor oil flow so that the motor runs in
the reverse direction. A lower PWM signal is sent to the
(PRV) valve allowing oil flow to return to the fan motor
but in the reverse direction causing the motor and cool-
ing fan to run in reverse. The controller determines the
length of time that the fan should be run in reverse be-
fore fan rotation is returned to the forward direction.
NOTE: The operator can manually cause the cooling
fan to reverse by simultaneously pressing the right and
left buttons on the InfoCenter display.
1. Piston (traction) pump
2. 4th gear pump section
3. 3rd gear pump section
Figure 14
2
3
1
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic 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 test ports without tools. A
high pressure hose is provided for remote readings.
Contains one each: 1000 PSI (70 bar), 5000 PSI (350
bar) and 10000 PSI (700 bar) gauges. Use gauges as
recommended in the Testing section of this chapter.
Toro Part Number: TOR47009
Figure 15
15 GPM Hydraulic Tester Kit (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. INLET HOSE: Hose connected from the system cir-
cuit to the inlet side of the hydraulic tester.
2. LOAD VALVE: A simulated working load is created
in the circuit by turning the valve to restrict flow.
3. PRESSUREGAUGE:Glycerinefilled0to5000PSI
gauge to provide operating circuit pressure.
4. FLOW METER: This meter measures actual oil flow
in the operating circuit with a gauge rated from 1 to 15
GPM(5to55LPM).
5. OUTLET HOSE: A hose from the outlet side of the
hydraulic tester connects to the hydraulic system circuit.
6. FITTINGS: An assortment of hydraulic fittings are in-
cluded with this kit.
Toro Part Number: TOR214678
Figure 16
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 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 working load is created
in the circuit by turning the valve to restrict flow.
2. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI
gauge to provide operating circuit pressure.
3. FLOW METER: This meter measures actual oil flow
intheoperatingcircuitwithagaugeratedfrom4to40
GPM (20 to 150 LPM).
Toro Part Number: AT40002
NOTE: This tester does not include hydraulic hoses
(see Hydraulic Hose Kit TOR6007 below).
Figure 17
Hydraulic Hose Kit
This kit includes hydraulic fittings and hoses needed to
connect 40 GPM hydraulic tester (AT40002) or high flow
hydraulic filter kit (TOR6011) to machine hydraulic trac-
tion system components.
Toro Part Number: TOR6007
Figure 18
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic 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 debris from being
allowed back into the circuit regardless of flow direction.
If a component failure occurs in the closed loop traction
circuit, contamination from the failed part will remain in
the circuit until removed. When connecting hydraulic
test gauges in order to test traction circuit components
or after replacing a failed traction circuit component (e.g.
piston pump or wheel motor), the high flow hydraulic fil-
ter can be installed in the traction circuit. The filter will
ensure that contaminates are removed from the closed
loop and thus, do not cause additional component dam-
age.
Toro Part Number: TOR6011
NOTE: This kit does not include hydraulic hoses (see
Hydraulic Hose Kit TOR6007 above).
NOTE: Replacement filter element is Toro part number
TOR6012. Filter element cannister tightening torque is
25 ft--lb (34 N--m).
Figure 19
O--Ring Kit
The O--ring kit includes O--rings in a variety of sizes for
face seal and port seal hydraulic connections. It is rec-
ommended that O--rings be replaced whenever a hy-
draulic connection is loosened.
Toro Part Number: 117--2727
Figure 20
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 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: TOR4079
Figure 21
TORO TEST FITTING KIT (TOR4079)
Measuring Container
Use this container for doing hydraulic motor efficiency
testing (motors with case drain lines only). Measure effi-
ciency of a hydraulic motor by restricting the outlet flow
from the motor and measuring leakage from the case
drain line while the motor is pressurized by the hydraulic
system.
The table in Figure 23 provides gallons per minute
(GPM) conversion for measured milliliter or ounce motor
case drain leakage.
Toro Part Number: TOR4077
Figure 22
Figure 23
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic 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 pur-
pose. Obtain a remote starter switch locally.
IMPORTANT: When using a remote starter switch, it
is highly recommended to include a 20 amp inline
fuse between the battery and switch connector for
circuit protection.
A remote stater switch can also be constructed using
Toro switch #106--2027, a length of 14 gauge wire, a 20
amp in--line fuse, two (2) alligator clips and necessary
connectors. Connecting the wire to switch terminals 1
and 2 will allow the momentary switch contacts to be
used for the remote starter switch (Fig. 25).
NOTE: For information on using the remote starter
switch to prime the hydraulic pumps, see Flush Hydraul-
ic System in the Service and Repairs section of this
chapter.
Figure 24
Figure 25
TORO SWITCH
(#106--2027)
BATTERY
MACHINE
SOLENOID
STARTER
STARTER
MACHINE
20 AMP
FUSE
1. Starter motor
2. Starter solenoid
3. B+ terminal
Figure 26
1
2
3
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 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 machine problem.
Review the hydraulic schematic and information on hy-
draulic system operation in the Hydraulic Flow Dia-
grams section of this Chapter. This information will be
useful during the hydraulic troubleshooting process.
Refer to the Testing section of this Chapter for precau-
tions and specific hydraulic test procedures.
General Hydraulic System Problems
Problem Possible Cause
Hydraulic oil leaks from machine Fitting(s), hose(s) or tube(s) is (are) loose or damaged.
O--ring(s) or seal(s) is (are) missing or damaged.
Hydraulic system operates hot.
NOTE: An indication that the hy-
draulic system is operating at exces-
sive temperatures would be frequent
reversing of the cooling fan and a
normal engine coolant temperature.
Engine RPM is too low.
Brakes are applied or sticking.
Hydraulic reservoir oil level is low.
Hydraulic oil is contaminated or the wrong type.
Piston pump by--pass valve is open or damaged.
Cooling system is not operating properly.
Charge pressure is low.
Traction circuit pressure is incorrect.
Pump(s)ormotor(s)aredamaged.
Hydraulic oil in reservoir foams. Hydraulic reservoir oil level is low.
Wrong type of oil is in the hydraulic system.
Air is leaking into a pump suction line.
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 32
Traction Circuit Problems
Problem Possible Cause
Machineoperatesinonedirection
only.
Piston (traction) pump by--pass valve is open or damaged.
Traction relief valve is leaking or faulty.
Piston (traction) pump servo control valve orifices or screens are
plugged or damaged.
Problem with TEC output to piston (traction) pump servo control
exists (see Chapter 5 -- Electrical System).
Traction pedal response is sluggish. Traction pedal components are stuck or binding.
Traction charge pressure is low.
Piston (traction) pump servo control valve orifices are plugged or
damaged.
Machinetravelstoofarbeforestop-
ping when the traction pedal is re-
leased.
Traction pedal components are stuck or binding.
Traction charge pressure is low.
Adjustment of relief valve (RV) in rear traction manifold is incorrect.
Piston (traction) pump servo control valve orifices are plugged or
damaged.
Traction power is lost or machine will
not operate in either direction.
Hydraulic reservoir oil level is low (NOTE: Other hydraulic systems
are affected as well).
Piston (traction) pump by--pass valve is open or damaged.
Traction charge pressure is low.
Traction circuit pressure is low.
Traction pedal position sensor is not plugged in or is faulty (see
Chapter 5 -- Electrical System).
Problem with TEC output to piston (traction) pump servo control
exists (see Chapter 5 -- Electrical System).
LOW traction speed (mow) will not
engage.
NOTE: LOW (mow) will not engage
when the cutting deck is lowered.
Electrical problem exists that prevents solenoid valve S12 from be-
ing de--energized (see Chapter 5 -- Electrical System).
Solenoid valve (S12) in combination manifold is faulty.
LOW traction speed (mow) will not
disengage.
Electrical problem exists that prevents solenoid valve S12 from be-
ing energized (see Chapter 5 -- Electrical System).
Solenoid valve (S12) in combination manifold is faulty.
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 4 -- 33
Mow Circuit Problems
Problem Possible Cause
None of the cutting deck sections
will operate.
NOTE: To engage the mow circuit,
theseatmustbeoccupied,thecut-
ting deck(s) must be fully lowered,
the traction speed must be in the
LOW (mow) position and the PTO
switch must be ON.
Electrical problem exists that prevents PRV solenoid valve in PTO
manifolds from being energized (see Chapter 5 -- Electrical Sys-
tem).
Front two (2) gear pump sections for mow circuits are worn or dam-
aged.
One cutting deck section will not op-
erate.
Electrical problem (e.g. solenoid coil in PTO manifold, cutting deck
position switch) exists (see Chapter 5 -- Electrical System).
Cutting deck section problem exists (e.g. drive belt, deck spindle).
System pressure to the affected cutting deck section is low.
Woodruff key on affected deck section motor is damaged.
Proportional relief valve (PRV) in PTO manifold for affected deck sec-
tion is faulty.
Cartridge valve in PTO manifold for affected deck section is damaged
or sticking.
Deck motor for affected deck section is damaged (NOTE: if appropri-
ate, transfer a suspected damaged motor to another cutting deck. If
problem follows the motor, motor is faulty and needs repair or re-
placement).
Gear pump section for affected deck section is worn or damaged.
All cutting deck sections operate
slowly.
Engine RPM is low.
All deck motors are worn or damaged.
Front two (2) gear pump sections for mow circuits are worn or dam-
aged.
Cutting deck section stops under
load.
Proportional relief valve in PTO manifold for affected deck section
is by--passing.
Deck motor has internal leakage (by--passing oil).
Gear pump section for affected deck section is worn or damaged.
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic 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 systems
are affected as well).
Solenoid valve (S1) in combination manifold is faulty.
Electrical problem exists (see Chapter 5 -- Electrical System).
Lift arm pivots are binding.
Relief valve in combination manifold is stuck.
Lift cylinder(s) is (are) damaged.
Gear pump section for lift/lower circuit is worn or damaged (NOTE: A
worn or damaged gear pump section will also affect the steering, en-
gine cooling fan motor and traction charge circuits).
Cutting deck (or wing decks) raise,
but will not stay up.
NOTE: Lift cylinders cannot provide
an absolutely perfect seal. The cut-
ting deck will eventually lower if left
in the raised position during storage.
Lift circuit hydraulic lines or fittings are leaking.
Cartridge valve(s) in combination manifold has damaged seals or is
faulty.
Lift cylinder for affected deck section is damaged.
Cutting deck (or wing decks) will not
lower.
NOTE: To lower cutting deck (or
wing deck), the seat must be occu-
pied and the traction speed must be
in the Low (4WD) position.
Lift arm pivots are binding.
Electrical problem exists (see Chapter 5 -- Electrical System).
Solenoid valve (S1) in combination manifold is faulty.
Counterbalance pressure is excessive.
Lift cylinder for affected deck section is damaged.
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 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 (NOTE: other hydraulic sys-
tems are affected as well).
Steering relief valve (RV1) in combination manifold is stuck or dam-
aged.
The pressure compensator valve (EC) in combination manifold is
stuck or damaged.
Steering cylinder leaks internally.
Steering control valve is worn or damaged.
Gear pump section is worn or damaged (NOTE: A worn or dam-
aged gear pump section will also affect the lift/lower, engine cooling
fan motor and traction charge circuits).
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 36
Engine Cooling Fan Circuit Problems
Problem Possible Cause
Cooling fan runs only in forward di-
rection(fandoesnotruninreverse
direction).
Solenoid cartridge valve (S10) in combination control manifold is
faulty.
Electrical problem exists that prevents combination control manifold
solenoid valve (S10) operation (see Chapter 5 -- Electrical System).
Cooling fan does not rotate. Cooling fan motor is worn or damaged.
Proportional relief valve (PRV) in combination manifold is stuck or
damaged.
Gear pump section for engine cooling fan circuit is worn or damaged
(NOTE: A worn or damaged gear pump section will also affect the
steering, lift/lower and traction charge circuits).
Cooling fan always rotates at slow
speed.
Combination manifold cartridge valve seals are leaking.
Check valve in combination manifold is not seating.
Proportional relief valve (PRV) in combination manifold is stuck or
damaged.
Hydraulic fan motor is worn or damaged.
Cooling fan always rotates at fast
speed.
Proportional relief valve (PRV) in combination manifold is faulty.
Electrical problem exists that prevents correct operation of combin-
ation manifold proportional relief valve (PRV) (see Chapter 5 --
Electrical System).
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 4 -- 37
This page is intentionally blank.
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 38
Testing
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
Tools section in this Chapter).
IMPORTANT: All obvious areas such as hydraulic
oil supply, oil filters, binding components, loose
fasteners or improper adjustments must be
checked before assuming that a hydraulic compo-
nent is the source of the problem.
CAUTION
Failure to use gauges with recommended pres-
sure (PSI/bar) rating as listed in test procedures
could result in damage to the gauge and possible
personal injury from leaking hot oil.
WARNING
Keep body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pres-
sure. Do not use hands to search for leaks; use
paper or cardboard. Hydraulic fluid escaping un-
der pressure can have sufficient force to pene-
trate the skin and cause serious injury. If fluid is
injected into the skin, it must be surgically re-
moved within a few hours by a doctor familiar
with this type of injury. Gangrene may result from
such an injury.
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the sys-
tem must be relieved. See Relieving Hydraulic
System Pressure in the General Information sec-
tion in this chapter.
CAUTION
All testing should be performed by two (2)
people. One person should be in the seat to oper-
ate the machine, and the second person should
read test instruments and record test results.
Precautions for Hydraulic Testing
1. Clean machine thoroughly before disconnecting or
disassembling any hydraulic components. Always keep
in mind the need for cleanliness when working on hy-
draulic equipment. Contamination will cause excessive
wear of components.
2. Before conducting a hydraulic test, make sure hy-
draulic oil is at normal operating temperature by operat-
ing the machine under load for approximately ten (10)
minutes.
3. Put metal caps or plugs on any hydraulic lines left
open or exposed during testing or removal of compo-
nents.
4. Theenginemustbeingoodoperatingcondition.Use
a phototac to determine engine speed when performing
a hydraulic test. Engine speed will affect the accuracy of
the tester readings. See Chapter 3 -- Yanmar Diesel En-
gine for engine speed specifications.
5. When using the hydraulic tester with flow and pres-
sure capabilities, the inlet and the outlet hoses must be
properly connected and not reversed to prevent dam-
age to the hydraulic tester or components.
6. When using the hydraulic tester with flow and pres-
sure capabilities, completely open flow control valve on
tester before starting the engine to minimize the possi-
bility of damaging components.
7. Install fittings finger tight and far enough to make
sure that they are not cross--threaded before tightening
them with a wrench.
8. Position tester hoses to prevent rotating machine
parts from contacting and damaging the hoses or tester.
9. Check oil level in the hydraulic reservoir. After con-
necting test equipment, make sure tank is full.
10.Check control linkages for improper adjustment,
binding or broken parts.
11. After installing test gauges, run engine at low idle
speed and check for any hydraulic oil leaks. Correct any
leaks before proceeding with test procedure.
12.Before returning machine to use, make sure that hy-
draulic reservoir has correct fluid level.
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 4 -- 39
Which Hydraulic Tests Are Necessary?
Before beginning any hydraulic test, identify if the prob-
lem is related to the traction circuit, cutting (mow) circuit,
lift/lower circuit, steering circuit or engine cooling fan cir-
cuit. Once the faulty system has been identified, perform
tests that relate to that circuit.
1. If a traction circuit problem exists, consider perform-
ing one or more of the following tests: Traction Circuit
Charge Pressure, Traction Circuit Relief Pressure,
Counterbalance Pressure, Reverse Traction Circuit Re-
ducing Valve (PR) Pressure, Rear Traction Circuit Relief
Valve (RV) Pressure, Piston (Traction) Pump Flow and/
or Gear Pump Flow Tests.
IMPORTANT: Refer to Traction Circuit Component
Failure in the General Information section of this
chapter for information regarding the importance of
removing contamination from the traction circuit.
2. If a cutting (mow) circuit problem exists, consider
performing one or more of the following tests: Cutting
Deck Circuit Pressure, PTO Relief Pressure, Cutting
Deck Motor Case Drain Leakage and/or Gear Pump
Flow Tests.
3. If a lift/lower circuit problem exists, consider perform-
ing one or more of the following tests: Lift/Lower Circuit
Relief Pressure and/or Gear Pump Flow Tests.
4. If a steering circuit problem exists, consider perform-
ing one or more of the following tests: Steering Circuit
Relief Pressure, Steering Cylinder Internal Leakage
and/or Gear Pump Flow Tests.
5. If a engine cooling fan circuit problem exists, consid-
er performing one or more of the following tests: Engine
Cooling Fan Circuit and/or Gear Pump Flow Tests.
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 40
Traction Circuit Charge Pressure (Using Pressure Gauge)
3.3 GPM
4.4 GPM
14.3 GPM
14.3 GPM
PR
380 PSI
RV
650 PSI
.050
CV
T
P2
M8
CH
OR1
250 PSI
2.14 CID /
1.16 CID
200 PSI
4350 PSI
5000 PSI
.0315 .0315
0.4
CID
0.3 1.29 1.29
CID CID CID
2.75
CID
REAR
TRACTION
MANIFOLD
ENGINE
30.5 GPM
1.2 CID /
0.64 CID
1.2 CID /
0.64 CID
G
G
G
G
FROM COMBINATION MANIFOLD
TO
COMBINATION
MANIFOLD
FROM
FROM
COMBINATION
MANIFOLD
PTO MANIFOLD
CENTER DECK
FROM
OIL FILTER
TO
PTO MANIFOLD
LEFT DECK
TO
PTO MANIFOLD
CENTER DECK
TO COMBINATION MANIFOLD
PRESSURE
GAUGE
TO
COMBINATION
MANIFOLD
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 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
CAUTION
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
1. Park machine on a level surface with the cutting deck
lowered and off. Make sure hydraulic oil is at normal op-
erating temperature, engine is off and the parking brake
is applied.
2. Raise and support operator seat.
3. Connect a 1000 PSI (70 bar) pressure gauge to test
fitting attached to tee fitting in final section of gear pump
(Fig. 27).
NOTE: Make sure that steering wheel is not turned dur-
ing charge pressure testing. Also, if engine coolant tem-
perature is elevated, gear pump flow from the final pump
section might be directed to the cooling fan motor which
may affect charge pressure testing results.
4. Start engine and increase engine speed to high idle
speed with no load on the hydraulic system.
GAUGE READING TO BE 200 to 300 PSI (13.8 to
20.6 bar).
5. Stop engine and record test results.
6. If there is no pressure or pressure is low, check for
restriction in gear pump intake line. Also, inspect charge
relief valve located in piston (traction) pump (see Piston
(Traction) Pump Service in the Service and Repairs sec-
tion of this chapter). A worn or damaged gear pump sec-
tioncouldalsobeconsidered(seeGearPumpFlowTest
in this section).
NOTE: If the gear pump section that supplies the
charge circuit is worn or damaged, charge, steering, lift/
lower and engine cooling fan circuits may all be affected.
7. Next, with the pressure gauge still connected to the
charge pressure test port, take a gauge reading while
operating the machine in forward and reverse. Start the
engine and put throttle at high idle speed. Apply the
brakes and push the traction pedal forward while moni-
toring the pressure gauge. Repeat for reverse direction.
Stop engine and record test results.
8. If charge pressure meets specifications under no
load conditions (step 5 above), but consistently drops
more than 15% when under traction load, the piston
(traction) pump and/or traction motor(s) should be sus-
pected of wear and inefficiency. When the pump or mo-
tors are worn or damaged, the charge pump is not able
to keep up with internal leakage in the traction system
components.
9. When testing is completed, disconnect pressure
gauge from test fitting. Secure dust cap to test fitting.
10.Lower and secure operator seat.
1. Piston (traction) pump
2. Gear pump
3. Charge pressure port
Figure 27
1
2
3
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 42
Traction Circuit Relief Pressure (Using Pressure Gauge)
3.3 GPM
4.4 GPM
14.3 GPM
14.3 GPM
PR
380 PSI
RV
650 PSI
.050
CV
T
P2
M8
CH
OR1
250 PSI
2.14 CID /
1.16 CID
200 PSI
4350 PSI
5000 PSI
.0315 .0315
0.4
CID
0.3 1.29 1.29
CID CID CID
2.75
CID
REAR
TRACTION
MANIFOLD
ENGINE
30.5 GPM
1.2 CID /
0.64 CID
1.2 CID /
0.64 CID
GG
G
G
FROM COMBINATION MANIFOLD
TO
COMBINATION
MANIFOLD
FROM
COMBINATION
MANIFOLD
TO
COMBINATION
MANIFOLD
FROM
PTO MANIFOLD
CENTER DECK
FROM
OIL FILTER
TO
PTO MANIFOLD
LEFT DECK
TO
PTO MANIFOLD
CENTER DECK
TO COMBINATION MANIFOLD
PRESSURE
GAUGE
FORWARD TRACTION CIRCUIT
RELIEF PRESSURE TEST SHOWN
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 4 -- 43
Procedure for Traction Circuit Relief Pressure Test
CAUTION
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
1. Park machine on a level surface with the cutting deck
lowered and off. Make sure hydraulic oil is at normal op-
erating temperature, engine is off and the parking brake
is applied.
When performing the traction circuit relief pres-
sure test, move machine to an open area, away
from people and obstructions.
CAUTION
2. Drive machine to an open area, lower cutting deck,
turn the engine off and apply the parking brake.
3. Connect a 10,000 PSI (700 bar) pressure gauge to
traction circuit test port for function to be checked (Fig.
28 or 29).
4. Start engine and increase engine speed to high idle
speed. Release parking brake. Make sure that HI/LOW
speed switch is in the HI (transport) position.
NOTE: If possible, turn off Smart PowerTM by using the
InfoCenter display protected menu. Machines with TEC
software above revision level G will allow Smart
PowerTM to be disabled for testing. Check software revi-
sion level using the InfoCenter About screen.
5. Sit on seat, apply brakes fully and slowly depress the
traction pedal in the appropriate direction (forward or re-
verse). While pushing traction pedal, look at pressure
reading on gauge:
GAUGE READING TO BE:
Forward: 4100 to 4600 PSI (283 to 317 bar)
Reverse: 4750 to 5250 PSI (328 to 362 bar)
6. Release traction pedal and stop engine. Record test
results.
7. If traction pressure is too low, inspect traction pump
relief valves (Fig. 28 or 29). Clean or replace relief
valves as necessary. These cartridge type valves are
factory set, and are not adjustable. If relief valves are in
good condition, traction pump or wheel motors should
be suspected of wear and inefficiency.
8. When testing is completed, disconnect pressure
gauge from test port. Secure dust cap to test fitting.
1. Forward traction port 2. Forward relief valve
Figure 28
FRONT
1
2
1. Reverse traction port 2. Reverse relief valve
Figure 29
FRONT
RIGHT
1
2
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 44
Counterbalance Pressure (Using Pressure Gauge)
PRESSURE
GAUGE
S10
RV1
CV1
S2
S4
S5
PRV
P4 CH2 P3
EC
CF
LS
S3
OR1
C3
OR4
.040
S6
OR5
.070
C4 C2 C5
RV2
S7
S9
S8
C6
M1 M2
CH1
CV3
CH4
OR2
.063
OR6
.063
OR3
.070
OR7
.070
T2SPCH3
G2
G4
CV4
PR
G1
G3
3250
PSI
1350
PSI
4PSI
4PSI
.030
OR9
S1
3300 PSI
RV3 S12
S11
CV2
4PSI
0.51 CID
1.125” ROD
.030”
80
PSI
60
PSI
310
PSI
2.50” BORE
6.50” STROKE
1.50” BORE
3.08” STROKE
RAM CYLINDERS
CENTER DECK
1.125” ROD
2.50” BORE
6.50” STROKE
GG
COMBINATION MANIFOLD
RIGHT DECK
LEFT DECK
TO FRONT
TO RESERVOIR TO STEERING
CONTROL VALVE
TO STEERING
CONTROL VALVE
FROM GEAR PUMP
TRACTION
VALVE
TO PISTON
PUMP
TO RESERVOIR TO WHEEL/AXLE
MOTORS
FROM GEAR PUMP
2500 PSI
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 4 -- 45
Procedure for Counterbalance Pressure Test
CAUTION
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
1. Park machine on a level surface with the cutting deck
lowered and off. Make sure hydraulic oil is at normal op-
erating temperature, engine is off and the parking brake
is applied.
2. Raise and support operator seat to gain access to
combination manifold.
3. Connect a 1000 PSI (70 bar) pressure gauge to test
port G1 on combination manifold (Fig. 30).
NOTE: The cutting deck need to be in the float position
when checking counterbalance pressure. Also, make
sure that all of the cutting deck castor wheels are on the
ground when testing or adjusting counterbalance pres-
sure.
IMPORTANT: While testing counterbalance pres-
sure, DO NOT raise the cutting deck. If deck is
raised, system pressure increase will damage pres-
sure gauge.
4. Start engine and increase engine speed to high idle
speed with no load on the hydraulic system. Do not en-
gage the cutting deck.
GAUGE READING TO BE approximately 325 PSI
(22.4 bar).
NOTE: The recommended counterbalance pressure is
325 PSI (22.4 bar).
5. Stop engine and record test results.
6. The pressure reducing valve on the combination
manifold is used to set the counterbalance pressure
(Fig. 31). If necessary, adjust pressure reducing valve:
NOTE: Because of valve design, the pressure reducing
valve can be adjusted with the engine running. Do not
remove the pressure reducing valve from the hydraulic
manifold for adjustment.
A. Locate pressure reducing valve on combination
manifold (Fig. 31). Loosen lock nut on pressure redu-
cing valve.
B. Start engine and increase engine speed to high
idle speed with no load on the hydraulic system. Do
not engage the cutting deck.
C. To increase pressure setting, turn the adjust-
ment screw on the valve in a clockwise direction. A
1/8 turn on the screw will make a measurable change
in counterbalance pressure.
D. To decrease pressure setting, turn the adjust-
ment screw on the valve in a counterclockwise direc-
tion. A 1/8 turn on the screw will make a measurable
change in counterbalance pressure.
E. Tighten lock nut to secure adjustment. Check
counterbalance pressure and readjust as needed.
7. When testing is completed, disconnect pressure
gauge from manifold test port. Secure dust cap to test
fitting. Lower operator seat.
1. Combination manifold
2. Test port G1
3. Pressure reducing valve
Figure 30
2
1
3
1. Combination manifold
2. Pressure reducing valve
3. Adjustment screw
Figure 31
2
3
1
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 46
Reverse Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge)
3.3 GPM
4.4 GPM
14.3 GPM
14.3 GPM
PR
380 PSI
RV
650 PSI
.050
CV
T
P2
M8
CH
OR1
250 PSI
2.14 CID /
1.16 CID
200 PSI
4350 PSI
5000 PSI
.0315 .0315
0.4
CID
0.3 1.29 1.29
CID CID CID
2.75
CID
REAR
TRACTION
MANIFOLD
ENGINE
30.5 GPM
1.2 CID /
0.64 CID
1.2 CID /
0.64 CID
GG
G
G
FROM COMBINATION MANIFOLD
TO
COMBINATION
MANIFOLD
FROM
COMBINATION
MANIFOLD
FROM
PTO MANIFOLD
CENTER DECK
FROM
OIL FILTER
TO
PTO MANIFOLD
LEFT DECK
TO
PTO MANIFOLD
CENTER DECK
TO COMBINATION MANIFOLD
PRESSURE
GAUGE
TO
COMBINATION
MANIFOLD
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 4 -- 47
Procedure for Reverse Traction Circuit Reducing
Valve (PR) Pressure Test
CAUTION
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
1. Park machine on a level surface with the cutting deck
lowered and off. Make sure hydraulic oil is at normal op-
erating temperature, engine is off and the parking brake
is applied.
NOTE: The #6 zero leak plug on the inside of rear trac-
tion manifold is a zero leak plug that has a tapered seal-
ing surface on the plug head. Lightly rap the plug head
using a punch and hammer before using an allen
wrench to remove the plug: the impact will allow plug re-
moval with less chance of damage to the socket head of
the plug.
2. Locate rear traction manifold that is attached to the
front frame next to the left side front wheel (Fig. 32). Re-
move #6 zero leak plug on the inside of rear traction
manifold and install diagnostic fitting (Toro part number
59--7410) into manifold port.
3. Connect a 1000 PSI (70 bar) pressure gauge with hy-
draulic hose attached to installed diagnostic fitting.
4. Start engine and increase engine speed to high idle
speed. Make sure that HI/LOW speed switch is in the
LOW speed (mow) position and release parking brake.
5. Sit on seat, apply brakes fully and slowly depress the
traction pedal in the reverse direction. While pushing
traction pedal, carefully monitor the pressure gauge to
identify the opening pressure of the pressure reducing
(PR) valve:
GAUGE READING TO BE approximately 380 PSI
(26 bar) when the pressure reducing (PR) valve
opens.
6. Stop engine and record test results.
7. The pressure reducing (PR) valve is located on the
rear side of the rear traction manifold (Figs. 32 and 33).
If test pressure is incorrect, adjust pressure reducing
(PR) valve (see Adjust Control Manifold Relief Valves in
the Adjustments section of this chapter). Recheck pres-
sure reducing valve pressure after any adjustment.
NOTE: The rear traction circuit relief valve (RV) pres-
sure test uses the same pressure gauge position as
used to measure reverse traction circuit reducing valve
(PR) pressure. If necessary, conduct the rear traction
circuit relief valve (RV) pressure test before removing
pressure gauge from rear traction manifold.
8. When testing is completed, disconnect pressure
gauge from the installed diagnostic fitting. Remove
diagnostic fitting from manifold and install removed plug
into manifold. Torque plug to 25 ft--lb (34 N--m).
1. Rear traction manifold
2. #6 zero leak plug
3. Relief(RV)valve
4. Reducing (PR) valve
Figure 32
2
1
3
4
1. Rear traction manifold
2. #6 zero leak plug
3. Relief(RV)valve
4. Reducing (PR) valve
Figure 33
1
2
3
4
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 48
Rear Traction Circuit Relief Valve (RV) Pressure (Using Pressure Gauge)
3.3 GPM
4.4 GPM
14.3 GPM
14.3 GPM
PR
380 PSI
RV
650 PSI
.050
CV
T
P2
M8
CH
OR1
250 PSI
2.14 CID /
1.16 CID
200 PSI
4350 PSI
5000 PSI
.0315 .0315
0.4
CID
0.3 1.29 1.29
CID CID CID
2.75
CID
REAR
TRACTION
MANIFOLD
ENGINE
30.5 GPM
1.2 CID /
0.64 CID
1.2 CID /
0.64 CID
GG
G
G
FROM COMBINATION MANIFOLD
TO
COMBINATION
MANIFOLD
FROM
COMBINATION
MANIFOLD
FROM
PTO MANIFOLD
CENTER DECK
FROM
OIL FILTER
TO
PTO MANIFOLD
LEFT DECK
TO
PTO MANIFOLD
CENTER DECK
TO COMBINATION MANIFOLD
PRESSURE
GAUGE
TO
COMBINATION
MANIFOLD
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 4 -- 49
Procedure for Rear Traction Circuit Relief Valve (RV)
Pressure Test
CAUTION
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
1. Park machine on a level surface with the cutting deck
lowered and off. Make sure hydraulic oil is at normal op-
erating temperature, engine is off and the parking brake
is applied.
NOTE: This test uses the same pressure gauge posi-
tion as used to measure reverse traction circuit reducing
valve (PR) pressure.
NOTE: The #6 zero leak plug on the inside of rear trac-
tion manifold is a zero leak plug that has a tapered seal-
ing surface on the plug head. Lightly rap the plug head
using a punch and hammer before using an allen
wrench to remove the plug: the impact will allow plug re-
moval with less chance of damage to the socket head of
the plug.
2. Locate rear traction manifold that is attached to the
front frame next to the left side front wheel (Fig. 34). Re-
move #6 zero leak plug on inside of rear traction mani-
fold and install diagnostic fitting (Toro part number
59--7410) into manifold port.
3. Connect a 1000 PSI (70 bar) pressure gauge with hy-
draulic hose attached to installed diagnostic fitting.
4. Start engine and increase engine speed to high idle
speed. Make sure that HI/LOW switch is in the LOW
(mow) position and release the parking brake.
5. OperatethemachineinLOWspeed(mow)withthe
cutting deck lowered. Drive down a slope in a forward di-
rection, decrease pressure on the traction pedal and
monitor the pressure gauge. Pressure should increase
until the rear traction circuit relief valve lifts.
GAUGE READING TO BE approximately 650 PSI
(45 bar) when the rear traction relief valve (RV)
opens.
6. Stop engine and record test results.
NOTE: If the rear traction circuit reducing valve (PR)
pressure is excessive, operation of the rear traction re-
lief valve (RV) may be affected. Before adjusting rear
traction relief valve (RV), make sure that pressure redu-
cing valve (PR) pressure is correct.
7. The rear traction circuit relief valve (RV) is located on
the rear side of the rear traction manifold (Figs. 34 and
35). If test pressure is incorrect, adjust relief valve (RV)
(see Adjust Control Manifold Relief Valves in the Adjust-
ments section of this chapter).
8. When testing is completed, disconnect pressure
gauge from the installed diagnostic fitting. Remove
diagnostic fitting from manifold and install removed plug
into manifold. Torque plug to 25 ft--lb (34 N--m).
1. Rear traction manifold
2. #6 zero leak plug
3. Relief(RV)valve
4. Reducing (PR) valve
Figure 34
2
1
3
4
1. Rear traction manifold
2. #6 zero leak plug
3. Relief(RV)valve
4. Reducing (PR) valve
Figure 35
1
2
3
4
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 50
Piston (Traction) Pump Flow (Using Tester with Flow meter and Pressure Gauge)
3.3 GPM
4.4 GPM
14.3 GPM
14.3 GPM
PR
380 PSI
RV
650 PSI
.050
CV
T
P2
M8
CH
OR1
250 PSI
2.14 CID /
1.16 CID
200 PSI
4350 PSI
5000 PSI
.0315 .0315
0.4
CID
0.3 1.29 1.29
CID CID CID
2.75
CID
REAR
TRACTION
MANIFOLD
ENGINE
30.5 GPM
1.2 CID /
0.64 CID
1.2 CID /
0.64 CID
GG
G
G
FROM COMBINATION MANIFOLD
TO
COMBINATION
MANIFOLD
FROM
COMBINATION
MANIFOLD
TO
COMBINATION
MANIFOLD
FROM
PTO MANIFOLD
CENTER DECK
FROM
OIL FILTER
TO
PTO MANIFOLD
LEFT DECK
TO
PTO MANIFOLD
CENTER DECK
TO COMBINATION MANIFOLD
TESTER
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 4 -- 51
Procedure for Piston (Traction) Pump Flow Test
This test measures piston (traction) pump output (flow).
During this test, pump load is created at the flow meter
using the adjustable load valve on the tester.
NOTE: Before performing piston pump flow test, make
sure that traction speed is set to 100% using the In-
foCenter settings menu.
IMPORTANT: Traction circuit flow for the
Groundsmaster 4100--D/4110--D is approximately 30
GPM(113.5LPM).Use40GPMHydraulicTester
#AT40002 (pressure and flow) for this test (see Spe-
cial Tools in this chapter).
CAUTION
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
1. Park machine on a level surface with the cutting deck
lowered and off. Make sure hydraulic oil is at normal op-
erating temperature, engine is off and the parking brake
is applied.
CAUTION
All wheels will be off the ground and rotating dur-
ing this test. Make sure machine is supported so
it will not move and accidentally fall to prevent in-
juring anyone near the machine.
2. Raise and support machine so all wheels are off the
ground (see Jacking Instructions in Chapter 1 -- Safety).
3. Thoroughly clean junction of hydraulic hose and
right side fitting on bottom of piston pump (forward port)
(Fig. 36). Disconnect hose from right side pump fitting.
4. Install tester with pressure gauge and flow meter in
series between piston pump fitting and disconnected
hosetoallowflowfromtractionpumptotester.Usehy-
draulic hose kit (see Special Tools in this chapter) to con-
nect tester to machine. Make sure that fitting and hose
connections are properly tightened. Also, make sure the
flow control valve on tester is fully open.
5. Start engine and increase engine speed to high idle
speed.
NOTE: If possible, turn off Smart PowerTM by using the
InfoCenter display protected menu. Machines with TEC
software above revision level G will allow Smart
PowerTM to be disabled for testing. Check software revi-
sion level using the InfoCenter About screen.
6. Slowly push traction pedal to fully forward position.
Keep pedal fully depressed in the fully forward position.
7. Have second person watch pressure gauge on test-
er carefully while slowly closing the flow control valve
until 1000 PSI (69 bar) is obtained. Verify with the In-
foCenter display that the engine speed is still at the cor-
rect high idle speed.
NOTE: If engine speed drops during testing, pump flow
will decrease and flow test results will be inaccurate.
8. Observe flow gauge. Flow indication should be
approximately 30 GPM (113 LPM).
9. Release traction pedal to neutral, open flow control
valveontesterandshutoffengine. Record test results.
10.If flow is less than 24 GPM (91 LPM), consider the
following:
A. The traction pedal is not calibrated correctly (see
Traction Pedal Calibration in the Adjustments sec-
tion of Chapter 5 -- Electrical System).
B. The piston pump swash plate is not being rotated
fully (e.g. traction speed is not set to 100%).
C. The forward traction relief valve is leaking or
faulty.
D.Thepistonpumpneedstoberepairedorre-
placed as necessary.
11. Make necessary repairs before performing any addi-
tional traction circuit tests.
12.When testing is complete, disconnect tester from
pump fitting and machine hydraulic hose. Reconnect
hose to pump fitting. Lower machine to ground.
1. Piston (traction) pump 2. Forward direction hose
Figure 36
FRONT
1
2
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 52
Cutting Deck Circuit Pressure (Using Pressure Gauge)
CENTER DECK CIRCUIT PRESSURE TEST SHOWN
PRESSURE
GAUGE
3.3 GPM
14.3 GPM
14.3 GPM
1.17 CID 3000 PSI
P1
P1
P1
P2
P2
P2
M1
M2
LC1
PRV
PD
CD
RV
2000 PSI
M1
M2
LC1
PRV
PD
RV
3000 PSI
M1
M2
LC1
PRV
PD
RV
CD
CD
LEFT DECK
CENTER DECK
RIGHT DECK
50 PSI
1.17 CID
1.17 CID
250 PSI
600 PSI
600 PSI
600 PSI
4350 PSI
5000 PSI
.025
.025
.025
.0315 .0315
0.4
CID
0.3 1.29 1.29
CID CID CID
2.75
CID
ENGINE
30.5
GPM
G
GG
G
G
CONTROL VALVE
FROM STEERING
TO COMBINATION MANIFOLD
TO
COMBINATION
MANIFOLD
FROM
COMBINATION
MANIFOLD
TO WHEEL
MOTORS
TO RESERVOIR
FROM MANIFOLD
AND FAN MOTOR
FROM REAR
TRACTION
MANIFOLD
FROM CENTER
DECK MANIFOLD
FROM REAR AXLE MOTOR
G
G
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 4 -- 53
Procedure for Cutting Deck Circuit Pressure Test
CAUTION
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
1. Park machine on a level surface with the cutting deck
lowered and off. Make sure hydraulic oil is at normal op-
erating temperature, engine is off and the parking brake
is applied.
2. Install 5000 PSI (350 bar) pressure gauge with hy-
draulic hose attached to manifold test port (G) for the
deck to be tested (Fig. 37).
CAUTION
Cutting deck blades will rotate when cutting
deck is lowered with PTO switch in ON position.
Keep away from deck during test to prevent per-
sonal injury from rotating blades. Do not stand in
front of the machine.
3. Start engine and increase engine speed to high idle
speed. Release the parking brake.
4. Watch pressure gauge carefully while mowing with
the machine.
5. Cutting deck circuit pressure should be as follows
and will vary depending on mowing conditions:
LH Wing Deck: 1000 to 3000 PSI (69 to 207 bar)
Center Deck: 1000 to 3000 PSI (69 to 207 bar)
RHWingDeck:1000to2000PSI(69to137bar)
6. Disengage cutting deck. Shut off engine and record
test results.
7. When testing is completed, disconnect pressure
gauge with hose from manifold test fitting. Secure dust
captotestfitting.
1. PTO manifold (front) 2. Manifold test port
Figure 37
1
2
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 54
PTO Relief Pressure (Using Tester with Pressure Gauge and Flow Meter)
CENTER DECK PTO RELIEF PRESSURE TEST SHOWN
3.3 GPM
14.3 GPM
14.3 GPM
1.17 CID 3000 PSI
P1
P1
P1
P2
P2
P2
M1
M2
LC1
PRV
PD
CD
RV
2000 PSI
M1
M2
LC1
PRV
PD
RV
3000 PSI
M1
M2
LC1
PRV
PD
RV
CD
CD
LEFT DECK
CENTER DECK
RIGHT DECK
50 PSI
1.17 CID
1.17 CID
250 PSI
600 PSI
600 PSI
600 PSI
4350 PSI
5000 PSI
.025
.025
.025
.0315 .0315
0.4
CID
0.3 1.29 1.29
CID CID CID
2.75
CID
ENGINE
G
G
G
GG
G
G
CONTROL VALVE
FROM STEERING
TO COMBINATION MANIFOLD
TO
COMBINATION
MANIFOLD
FROM
COMBINATION
MANIFOLD
TO RESERVOIR
FROM MANIFOLD
AND FAN MOTOR
FROM REAR
TRACTION
MANIFOLD
FROM CENTER
DECK MANIFOLD
FROM REAR AXLE MOTOR
TESTER
TO TRACTION
MOTORS
30.5 GPM
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 4 -- 55
The PTO circuit relief pressure test should be performed
to make sure that the PTO circuit relief pressures are
correct.
Procedure for PTO Relief Pressure Test
CAUTION
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
1. Park machine on a level surface with the cutting deck
lowered and off. Make sure hydraulic oil is at normal op-
erating temperature, engine is off and the parking brake
is applied.
2. Locate PTO (deck) manifold to be tested (Fig. 38).
Disconnect hydraulic hose at PTO manifold port (M1).
NOTE: An alternative to using manifold port (M1) would
be to disconnect the inlet hydraulic hose to the deck mo-
tor.
3. Install tester (flow and pressure) in series with the
disconnected hose and PTO manifold port (M1) (or mo-
tor inlet if hose was disconnected at deck motor). Make
sure the flow control valve on tester is fully open.
CAUTION
Cutting deck blades will rotate when cutting
deck is lowered with PTO switch in ON position.
Keep away from cutting deck during test to pre-
vent personal injury from rotating blades. Do not
stand in front of the machine.
4. Start engine and increase engine speed to high idle
speed. Release the parking brake.
5. Watch pressure gauge carefully while slowly closing
the tester flow control valve to fully closed.
6. As the PTO relief valve lifts, system pressure should
be approximately:
2900 to 3100 PSI (200 to 213 bar) for the center and
left wing decks
1900 to 2100 PSI (131 to 144 bar) for the right wing
deck
7. Fully open tester flow control valve and disengage
cutting deck. Shut off engine and record test results.
8. If relief pressure is incorrect, remove PRV valve on
mow manifold and clean or replace valve (see PTO
Manifold Service in the Service and Repairs section of
this chapter). Also, if pressure is still low after PRV valve
service, check for restriction in pump intake line. The
front gear pump section (center cutting deck circuit) and/
or the second gear pump section (side cutting deck cir-
cuits) could also be suspected of wear, damage or
inefficiency (see Gear Pump Flow Test in this section).
9. When relief pressure testing is complete, disconnect
tester from PTO manifold and hydraulic hose. Recon-
nect hydraulic hose that was disconnected for test pro-
cedure.
1. Center PTO manifold
2. LH PTO manifold
3. RH PTO manifold
Figure 38
FRONT
RIGHT
1
3
2
1. PTO manifold 2. PRV valve
Figure 39
1
2
LEFT PTO MANIFOLD SHOWN
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic 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
LC1
PRV
PD
RV
CD
CD
LEFT DECK
CENTER DECK
RIGHT DECK
1.17 CID
1.17 CID
600 PSI
600 PSI
600 PSI
.025
.025
.025
G
G
CONTROL VALVE
FROM STEERING
TO RESERVOIR
TESTER
TO RESERVOIR
FROM SECOND
GEAR PUMP SECTION
FROM FRONT
GEAR PUMP SECTION
MEASURING
CONTAINER
CAP
G
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 4 -- 57
Procedure for Cutting Deck Motor Case Drain
Leakage Test
NOTE: Over a period of time, a deck motor can wear in-
ternally. A worn motor may by--pass oil to its case drain
causing the motor to be less efficient. Eventually,
enough oil loss will cause the deck motor to stall under
heavy cutting conditions. Continued operation with a
worn, inefficient motor can generate excessive heat,
cause damage to seals and other components in the hy-
draulic system and affect quality of cut.
NOTE: Onemethodtofindafailingormalfunctioning
deck motor is to have another person observe the ma-
chine while mowing in dense turf. A bad motor will run
slower, produce fewer clippings and may cause a differ-
ent appearance on the turf.
CAUTION
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
1. Park machine on a level surface with the cutting deck
lowered and off. Make sure hydraulic oil is at normal op-
erating temperature, engine is off and the parking brake
is applied.
NOTE: The wing deck motors are connected in series.
To isolate a faulty wing deck motor, both motors in the
circuit may have to be tested by starting with the left side
motor first.
2. Disconnect hose from return of the motor to be
tested (Fig. 40). Install tester (flow and pressure) in se-
ries with the motor and disconnected return hose. Make
sure the flow control valve on tester is fully open.
3. Disconnect the motor case drain hose (small diame-
ter hose) where it connects to hydraulic manifold tee fit-
ting (not at the motor). Put a steel cap on the fitting at the
tee fitting; leave the case drain hose open.
CAUTION
Cutting deck blades will rotate when cutting
deck is lowered with PTO switch in ON position.
Keep away from cutting deck during test to pre-
vent personal injury from rotating blades. Do not
stand in front of the machine.
4. Sit on seat and start the engine. With engine running,
increase engine speed to high idle speed and release
the parking brake. Engage the cutting deck.
5. While watching pressure gauge, slowly close flow
control valve on tester until a pressure of 1200 PSI (83
bar) is obtained.
NOTE: Use a graduated container, special tool
TOR4077, to measure case drain leakage (Fig. 41).
6. Have a second person collect the flow from the case
drain line for 15 seconds, then move the PTO switch to
OFF and stop the engine (Fig. 41). Record test results.
TEST RESULTS: Flow less than 22.4 ounces (662
ml) (0.7 GPM/2.6 LPM) of hydraulic fluid in 15 sec-
onds.
7. If flow is more than 22.4 ounces (662 ml) (0.7
GPM/2.6 LPM) in 15 seconds, the motor is worn or dam-
aged and should be repaired or replaced.
8. After testing is completed, disconnect tester from
motor and hose. Reconnect hose to the deck motor. Re-
move cap from tee fitting and reconnect case drain hose
to tee fitting.
1. Deck motor (RH shown)
2. Return hose
3. Case drain hose
Figure 40
1
3
2
Figure 41
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 58
Lift/Lower Circuit Relief Pressure (Using Pressure Gauge)
S10
RV1
CV1
S2
S4
S5
PRV
P4 CH2 P3
EC
CF
LS
S3
OR1
C3
OR4
.040
S6
OR5
.070
C4 C2 C5
RV2
S7
S9
S8
C6
M1 M2
CH1
CV3
CH4
OR2
.063 OR6
.063
OR3
.070
OR7
.070
T2SPCH3
G2
G4
CV4
PR
G1
G3
3250
PSI
1350
PSI
3.3 GPM
4.4 GPM
14.3 GPM
4PSI
4 PSI
.030
OR9
S1
3300 PSI
RV3 S12
14.3 GPM
S11
CV2
4PSI
6.1 CID
EP
LR
T
STEERING
CYLINDER
0.51 CID
1.125” ROD
PR
380 PSI
RV
650 PSI
.050
CV
T
P2
M8
CH
OR1
250 PSI
2.14 CID /
1.16 CID
.030”
200 PSI
4350 PSI
5000 PSI
.0315 .0315
0.4
CID
0.3 1.29 1.29
CID CID CID
2.75
CID
REAR
TRACTION
MANIFOLD
ENGINE
30.5
GPM
1.2 CID /
0.64 CID
1.2 CID /
0.64 CID
80
PSI 60
PSI
310
PSI
2.50” BORE
6.50” STROKE 1.50” BORE
3.08” STROKE
RAM CYLINDERS
CENTER DECK
1.125” ROD
2.50” BORE
6.50” STROKE
2.00” BORE
4.20” STROKE
0.625” ROD
GG
G
GG
G
COMBINATION MANIFOLD
STEERING
CONTROL
VALVE
RIGHT DECK
LEFT DECK
EXTENDED
PRESSURE
GAUGE
FROM
PTO MANIFOLD
CENTER DECK
FROM
OIL FILTER
TO
PTO MANIFOLD
LEFT DECK
TO
PTO MANIFOLD
CENTER DECK
FROM LEFT AND
PTO MANIFOLDS
RIGHT DECK
TO
PTO MANIFOLD
CENTER DECK
LEFT WING DECK LIFT SWITCH PRESSED IS SHOWN
FULLY
2500 PSI
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 4 -- 59
The lift/lower circuit relief pressure test should be per-
formed to make sure that the cutting unit lift and lower
circuit relief pressure is correct.
Procedure for Lift/Lower Circuit Relief Pressure
Test
NOTE: Before attempting to check or adjust lift/lower
circuit relief pressure, make sure that counterbalance
pressure is correctly adjusted (see Counterbalance
Pressure Test in this section).
CAUTION
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
1. Park machine on a level surface with the cutting deck
lowered and off. Make sure hydraulic oil is at normal op-
erating temperature, engine is off and the parking brake
is applied.
2. Raise and support operator seat.
3. Connect a 5,000 PSI (345 bar) pressure gauge to
test fitting attached to tee fitting in third section of gear
pump (Fig. 42).
4. Sit on the seat and start the engine. With engine run-
ning, increase engine speed to high idle speed.
5. While sitting on the seat, depress the rear of one of
the lift switches to fully raise the cutting deck section.
Momentarily hold the switch with the deck section fully
raised while watching the pressure gauge.
GAUGE READING TO BE approximately 2450 to
2550 PSI (170 to 175 bar).
6. Release the lift switch,stoptheengineandrecord
test results.
7. If specification is not met, clean or adjust relief valve
RV2 located in the combination control manifold (see
Combination Manifold Service in the Service and Re-
pairs section of this chapter).
A. If relief pressure is too high, adjust relief valve
RV2 to reduce lift/lower circuit relief pressure (see
Adjust Control Manifold Relief Valves in the Adjust-
ments section of this chapter).
B. If relief pressure is too low, check for restriction in
gear pump intake line. Check the lift cylinders for in-
ternal leakage. If pump intake line is not restricted
and lift cylinders are not leaking, adjust relief valve
RV2 to increase lift/lower circuit relief pressure (see
Adjust Control Manifold Relief Valves in the Adjust-
ments section of this chapter).
C. If pressure is still too low after relief valve adjust-
ment, lift cylinder(s) or the third section of the gear
pump should be suspected of wear or damage.
8. When relief pressure testing is completed, discon-
nect pressure gauge from test fitting. Secure dust cap to
test fitting.
9. Lower and secure operator seat.
1. Gear pump
2. Third section test fitting
3. Combination manifold
4. Relief valve RV2
Figure 42
2
3
4
1
1. Combination manifold 2. Relief valve RV2
Figure 43
2
1
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 60
Steering Circuit Relief Pressure (Using Pressure Gauge)
S10
RV1
CV1
S2
S4
S5
PRV
P4 CH2 P3
EC
CF
LS
S3
OR1
C3
OR4
.040
S6
OR5
.070
C4 C2 C5
RV2
2500 PSI
S7
S9
S8
C6
M1 M2
CH1
CV3
CH4
OR2
.063
OR6
.063
OR3
.070
OR7
.070
T2SPCH3
G2
G4
CV4
PR
G1
G3
3250
PSI
1350
PSI
3.3 GPM
4.4 GPM
14.3 GPM
4PSI
4PSI
.030
OR9
S1
3300 PSI
RV3 S12
14.3 GPM
S11
CV2
4 PSI
1.17 CID 3000 PSI
P1
P1
P1
P2
P2
P2
M1
M2
LC1
PRV
PD
CD
RV
2000 PSI
M1
M2
LC1
PRV
PD
RV
3000 PSI
M1
M2
LC1
PRV
PD
RV
CD
CD
LEFT DECK
CENTER DECK
RIGHT DECK
50 PSI
1.17 CID
1.17 CID
6.1 CID
EP
LR
T
STEERING
CYLINDER 0.51 CID
1.125” ROD
PR
380 PSI
RV
650 PSI
.050
CV
T
P2
M8
CH
OR1
250 PSI
2.14 CID /
1.16 CID
600 PSI
600 PSI
600 PSI
.030”
200 PSI
4350 PSI
5000 PSI
.025
.025
.025
.0315 .0315
0.4
CID
0.3 1.29 1.29
CID CID CID
2.75
CID
REAR
TRACTION
MANIFOLD
ENGINE
30.5
GPM
1.2 CID /
0.64 CID
1.2 CID /
0.64 CID
80
PSI 60
PSI
310
PSI
2.50” BORE
6.50” STROKE
1.50” BORE
3.08” STROKE
RAM CYLINDERS
CENTER DECK
1.125” ROD
2.50” BORE
6.50” STROKE
2.00” BORE
4.20” STROKE
0.625” ROD
G
G
G
GG
G
GG
G
COMBINATION MANIFOLD
STEERING
CONTROL
VALVE
RIGHT DECK
LEFT DECK
EXTENDED
FULLY
PRESSURE
GAUGE
Groundsmaster 4100--D/4110--D Hydraulic SystemPage 4 -- 61
The steering circuit relief pressure test should be per-
formed to make sure that the steering circuit relief pres-
sure is correct.
Procedure for Steering Circuit Relief Pressure Test
CAUTION
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
1. Park machine on a level surface with the cutting deck
lowered and off. Make sure hydraulic oil is at normal op-
erating temperature, engine is off and the parking brake
is applied.
2. Raise and support operator seat.
3. Connect a 5000 PSI (350 bar) pressure gauge to test
fitting attached to tee fitting in final section of gear pump
(Fig. 44).
4. Start engine and increase engine speed to high idle
speed.
IMPORTANT: Hold steering wheel at full lock only
long enough to get a system relief pressure reading.
Holding the steering wheel against the stop for an
extended period can damage the steering control
valve.
5. Turn steering all the way in one direction and mo-
mentarily hold the steering wheel against resistance.
GAUGE READING TO BE 1300 to 1400 PSI (90 to
96 bar).
6. Stop the engine and record test results.
7. If pressure is incorrect, inspect steering relief valve
in steering control valve (see Steering Control Valve in
the Service and Repairs section of this chapter). If relief
valve is operating properly and if lift/lower problems also
exist, flow divider in fan manifold and/or gear pump
(third section) should be suspected of wear and ineffi-
ciency. If steering wheel continues to turn at end of cylin-
der travel (with lower than normal effort), steering
cylinder or steering control valve should be suspected
of wear or damage.
8. When testing is completed, disconnect pressure
gauge from test fitting. Secure dust cap to test fitting.
9. Lower and secure operator seat.
1. Piston (traction) pump
2. Gear pump
3. Test fitting
Figure 44
1
2
3
Hydraulic
System
Groundsmaster 4100--D/4110--DHydraulic System Page 4 -- 62
Steering Cylinder Internal Leakage
6.1 CID
EP
LR
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
MANIFOLD
FROM COMBINATION
MANIFOLD
TO RESERVOIR