Toro 4100 D Users Manual Gm4100 0

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2015-01-21

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Part No. 08162SL (Rev. A)

Service Manual
(Model 30413)

GroundsmasterR 4100--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 30413).
REFER TO THE OPERATOR’S MANUAL FOR OPERATING, 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 available on the internet at www.Toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.

This safety symbol means DANGER, WARNING
or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or repair of the machine.
IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the
machine.

E The Toro Company - 2008, 2012

This page is intentionally blank.

Groundsmaster 4100--D

Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions . . . . . . . . . . . . . . . .
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . .

2 -2 -2 -2 --

1
1
2
3

Chapter 3 -- Kubota Diesel Engine
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 4
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
V2403--M--T--E3B SERIES

Chapter 6 -- Axles, Planetaries and Brakes
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 4
Chapter 7 -- Chassis
General Information . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 1
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 2

Chapter 4 -- Hydraulic System

Chapter 8 -- Cutting Deck

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 3
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 8
Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . 4 -- 10
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 26
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 28
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 31
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 60
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 -- 61
EATON MODEL 72400 SERVO CONTROLLED PISTON PUMP REPAIR INFORMATION
EATON MODEL 74318 and 74348 PISTON MOTORS:
FIXED DISPLACEMENT, VALVE PLATE DESIGN
REPAIR INFORMATION

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . .

8 -8 -8 -8 --

2
3
4
6

Chapter 9 -- Foldout Drawings

Groundsmaster 4100--D

Foldout
Drawings

Cutting Deck

Chassis

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 3
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 4
Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 6
Wire Harness Drawings . . . . . . . . . . . . . . . . . . . . 9 -- 12

Product Records
and Maintenance

Chapter 2 -- Product Records and Maintenance

Kubota
Diesel Engine

General Information . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 5
Electrical System Quick Checks . . . . . . . . . . . . . . 5 -- 8
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 9
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 11
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 -- 37

Hydraulic
System

General Safety Instructions . . . . . . . . . . . . . . . . . . 1 -- 2
Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 4
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 -- 5

Electrical
System

Chapter 5 -- Electrical System

Axles, Planetaries
and Brakes

Chapter 1 -- Safety

Safety

Table Of Contents

This page is intentionally blank.

Groundsmaster 4100--D

Safety
Table of Contents
GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . .
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . .
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Service . . . . . . . . . . . . . . . . . . . .
JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . .
Jacking the Front End . . . . . . . . . . . . . . . . . . . . . . . .
Jacking the Rear End . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY AND INSTRUCTION DECALS . . . . . . . . . .

Groundsmaster 4100--D

2
2
2
3
4
4
4
5

Page 1 -- 1

Safety

Chapter 1

General Safety Instructions
The GROUNDSMASTER 4100-D was 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 factors
are also dependent upon the awareness, concern and
proper training of the personnel involved in the operation, transport, maintenance and storage of the machine. 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 Operator’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.

4. Since diesel fuel is highly flammable, handle it carefully:
A. Use an approved fuel container.
B. Do not remove fuel tank cap while engine is hot or
running.

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 machine. Also tighten any loose nuts, bolts or screws to ensure machine is in safe operating condition.

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.

3. Assure interlock switches are adjusted correctly so
engine cannot be started unless traction pedal is in
NEUTRAL and cutting deck is DISENGAGED.

While Operating
1. Sit on the seat when starting and operating the machine.

5. Before getting off the seat:

2. Before starting the engine:

A. Ensure that traction pedal is in neutral.
B. Apply parking brake.

A. Apply the parking brake.
B. Make sure traction pedal is in neutral and the
PTO switch is OFF (disengaged).
C. After engine is started, release parking brake and
keep foot off traction pedal. Machine must not move.
If movement is evident, the traction pedal linkage is
adjusted incorrectly; therefore, shut engine off and
adjust linkage until machine does not move when
traction pedal is released.
3. Do not run engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.

C. Disengage cutting deck and wait for blades to
stop.
D. Stop engine and remove key from switch.
E. 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 lift circuit and eliminates the risk of the cutting deck unexpectedly lowering to the ground.
F. Do not park on slopes unless wheels are chocked
or blocked.

4. 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.
Safety

Page 1 -- 2

Groundsmaster 4100--D

1. Before servicing or making adjustments, lower deck,
stop engine, apply parking brake and remove key from
the switch.

10.Do not overspeed the engine by changing governor
setting. To assure safety and accuracy, check maximum
engine speed.

2. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.

11. Shut engine off before checking or adding oil to the
crankcase.

3. Never store the machine or fuel container inside
where there is an open flame, such as near a water heater or furnace.

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.

4. Make sure all hydraulic line connectors are tight and
all hydraulic hoses and lines are in good condition before applying pressure to the system.
5. Keep body and hands away from pin hole leaks in hydraulic 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 doctor familiar with this form of injury or gangrene may result.
6. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be relieved by stopping engine and lowering cutting deck to
the ground.
7. If major repairs are ever needed or assistance is desired, 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 moving parts. Keep bystanders away.

Groundsmaster 4100--D

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 optimum performance and continued safety certification of
the machine, use genuine Toro replacement parts and
accessories. Replacement parts and accessories made
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 blocks, hoists and jacks.
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).

Page 1 -- 3

Safety

Maintenance and Service

Jacking Instructions
CAUTION
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 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.

1
2

2
Figure 1
1. Frame jacking point

2. Front tire

Jacking the Front End (Fig. 1)
1. Set parking brake and chock both rear tires to prevent the machine from moving.
2. Position jack securely under the frame, just to the inside 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 (Fig. 2)
1. Place jack securely under the center of rear axle.

1
Figure 2

1. Rear axle jacking point

2. Rear tire

2. Chock both front tires. Jack rear of machine off the
ground.
3. Once the machine is raised, use suitable jack stands
under the rear axle to support the machine.

Safety

Page 1 -- 4

Groundsmaster 4100--D

Safety

Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
the Groundsmaster 4100--D. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog.

Groundsmaster 4100--D

Page 1 -- 5

Safety

This page is intentionally blank.

Safety

Page 1 -- 6

Groundsmaster 4100--D

Chapter 2
Product Records
and Maintenance

Product Records and Maintenance
Table of Contents
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . .
Decimal and Millimeter Equivalents . . . . . . . . . . . .
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . .
Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Using a Torque Wrench with an Offset Wrench . .
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Inch Series) . . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Metric) . . . . . . . . . . . . . . . . . . . .
Other Torque Specifications . . . . . . . . . . . . . . . . . .
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
2
2
2
3
3
3
4
5
6
6

Product Records
Insert Operator’s Manual and Parts Catalog for your
Groundsmaster 4100--D at the end of this chapter. Refer
to Operator’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 intervals for the Groundsmaster 4100--D are covered in
the Operator’s Manual. Refer to that publication when
performing regular equipment maintenance. Several
maintenance procedures have break--in intervals identified in the Operator’s Manual. Refer to the Engine Operator’s Manual for additional engine specific
maintenance procedures.

Groundsmaster 4100--D

Page 2 -- 1 Rev. A

Product Records and Maintenance

Equivalents and Conversions

0.09375

Product Records and Maintenance

Page 2 -- 2

Groundsmaster 4100--D

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 specified 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 Service 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 engagement, etc.
The standard method of verifying torque shall be performed 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
the lines match up.

Fastener Identification

Grade 1

Grade 5

Grade 8

Class 8.8

Inch Series Bolts and Screws

Class 10.9

Metric Bolts and Screws

Figure 1

Figure 2

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 recommendation 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 recommendation.

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.
Offset wrench

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”.

Torque wrench

B
(effective length of torque
wrench + offset wrench)

TORQUE CONVERSION FACTOR = A / B

The calculated torque conversion factor for this torque
wrench with this offset wrench would be 18 / 19 = 0.947.
Groundsmaster 4100--D

(effective length of
torque wrench)
A

Page 2 -- 3 Rev. A

Figure 3
Product Records and Maintenance

Product Records
and Maintenance

Torque Specifications

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)

Thread Size

# 6 -- 32 UNC

Grade 1, 5 &
8 with Thin
Height Nuts

SAE Grade 1 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)

in--lb

N--cm

10 + 2

13 + 2

147 + 23

# 6 -- 40 UNF
# 8 -- 32 UNC

13 + 2

25 + 5

282 + 56

# 8 -- 36 UNF
# 10 -- 24 UNC

18 + 2

30 + 5

339 + 56

# 10 -- 32 UNF

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

N--cm

in--lb

N--cm

15 + 2

169 + 23

23 + 3

262 + 34

17 + 2

192 + 23

25 + 3

282 + 34

29 + 3

328 + 34

41 + 5

463 + 56

31 + 4

350 + 45

43 + 5

486 + 56

42 + 5

475 + 56

60 + 6

678 + 68

48 + 5

542 + 56

68 + 7

768 + 79

1/4 -- 20 UNC

48 + 7

53 + 7

599 + 79

100 + 10

1130 + 113

140 + 15

1582 + 169

1/4 -- 28 UNF

53 + 7

65 + 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

N--m

ft--lb

N--m

ft--lb

N--m

3/8 -- 16 UNC

16 + 2

22 + 3

30 + 3

41 + 4

43 + 5

58 + 7

3/8 -- 24 UNF

17 + 2

18 + 2

24 + 3

35 + 4

47 + 5

50 + 6

68 + 8

7/16 -- 14 UNC

27 + 3

37 + 4

50 + 5

68 + 7

70 + 7

95 + 9

7/16 -- 20 UNF

29 + 3

39 + 4

55 + 6

75 + 8

77 + 8

104 + 11

1/2 -- 13 UNC

30 + 3

48 + 7

65 + 9

75 + 8

102 + 11

105 + 11

142 + 15

1/2 -- 20 UNF

32 + 4

53 + 7

72 + 9

85 + 9

115 + 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.
Product Records and Maintenance

NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.

Page 2 -- 4

Groundsmaster 4100--D

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 + 6 in--lb

644 + 68 N--cm

78 + 8 in--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 + 2 ft--lb

26 + 3 N--m

28 + 3 ft--lb

38 + 4 N--m

M10 X 1.5

38 + 4 ft--lb

52 + 5 N--m

54 + 6 ft--lb

73 + 8 N--m

M12 X 1.75

66 + 7 ft--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: 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.

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.

Groundsmaster 4100--D

Page 2 -- 5

Product Records and Maintenance

Product Records
and Maintenance

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)

Other Torque Specifications
SAE Grade 8 Steel Set Screws

Wheel Bolts and Lug Nuts

Recommended Torque

Thread Size

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 + 3 ft--lb

1/2 -- 13 UNC

75 + 15 ft--lb

50 + 10 ft--lb

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)
Type 1, Type 23 or Type F
Thread Size

Baseline Torque*

No. 6 -- 32 UNC

20 + 5 in--lb

No. 8 -- 32 UNC

Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size

Threads per Inch

Baseline Torque*

Type A

Type B

No. 6

20 + 5 in--lb

30 + 5 in--lb

No. 8

30 + 5 in--lb

No. 10 -- 24 UNC

38 + 7 in--lb

No. 10

38 + 7 in--lb

1/4 -- 20 UNC

85 + 15 in--lb

No. 12

85 + 15 in--lb

5/16 -- 18 UNC

110 + 20 in--lb

3/8 -- 16 UNC

200 + 100 in--lb

* Hole size, material strength, material thickness and finish must be considered when determining specific
torque values. All torque values are based on non--lubricated fasteners.

Conversion Factors
in--lb X 11.2985 = N--cm
ft--lb X 1.3558 = N--m

Product Records and Maintenance

N--cm X 0.08851 = in--lb
N--m X 0.7376 = ft--lb

Page 2 -- 6

Groundsmaster 4100--D

Chapter 3

Kubota Diesel Engine
Table of Contents

Groundsmaster 4100--D

Page 3 -- 1

Kubota
Diesel Engine

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4
Air Filter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Check Fuel Lines and Connections . . . . . . . . . . . 9
Empty and Clean Fuel Tank . . . . . . . . . . . . . . . . . 9
Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . 9
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . 14
Spring Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
V2403--M--T--E3B SERIES

Kubota Diesel Engine

General Information
This Chapter gives information about specifications and
repair of the diesel engine used in the Groundsmaster
4100--D.
General maintenance procedures are described in your
Operator’s Manual. Information on engine troubleshooting, testing, disassembly and reassembly is identified in
the Kubota Workshop Manual, Diesel Engine,
V2403--M--T--E3B that is included at the end of this section.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special

tools are described in the Kubota Workshop Manual,
Diesel Engine, V2403--M--T--E3B. The use of some specialized test equipment is explained. However, the cost
of the test equipment and the specialized nature of
some repairs may dictate that the work be done at an engine repair facility.
Service and repair parts for Kubota engines are supplied through your Authorized Toro Distributor. If no
parts list is available, be prepared to provide your distributor with the Toro model and serial number of your machine.

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.

Stopping the Engine
IMPORTANT: Before stopping the engine after
mowing or full load operation, cool the turbo-charger by allowing the engine to run at low idle speed
for 5 minutes. Failure to do so may lead to turbocharger trouble.

Kubota Diesel Engine

Page 3 -- 2

Groundsmaster 4100--D

Specifications
Item

Description

Make / Designation

Kubota Model V2403--M--T--E3B: 4--Cycle, 4 Cylinder,
Water Cooled, Turbocharged, Diesel Engine
3.43” (87.0 mm)

Stroke

4.031” (102.4 mm)

Total Displacement cc (cu. in.)

148.5 in3 (2434 cc)

Firing Order

1 (closest to gear case end) -- 3 -- 4 (closest to flywheel end) -- 2

Combustion Chamber

Spherical Type (E--TVCS)

Compression Ratio

23.0:1

Direction of Rotation

Counterclockwise (viewed from flywheel)

Fuel

Diesel or Biodiesel (up to B20) Fuel with Low or Ultra Low
Sulfur Content

Fuel Capacity

19.0 U.S. gallons (72 liters)

Fuel Injection Pump

Denso PFR 4M Type Mini Pump

Injection Nozzle

Denso OPD Mini Nozzle

Governor

Centrifugal Mechanical

Low Idle (no load)

1450 + 50 RPM

High Idle (no load)

2870 +50/--120 RPM

Engine Oil

API CH--4, CI--4 or higher

Engine Oil Viscosity

See Operator’s Manual

Crankcase Oil Capacity

10.0 U.S. Quarts (9.5 Liters) with Filter

Oil Pump

Trochoid Type

Coolant Capacity

13 U.S. Quarts (12.3 Liters)

Starter

12 VDC, 2.0 kW

Alternator/Regulator
Standard Alternator
Optional Alternator

12 VDC
40 amp
90 amp

Engine Dry Weight

Groundsmaster 4100--D

419 U.S. pounds (190 kg)

Page 3 -- 3

Kubota Diesel Engine

Kubota
Diesel Engine

Bore

Service and Repairs
Air Filter System

RIGHT
FRONT

12 to 15 in--lb
(1.4 to 1.6 N--m)

6 12

13 14

4
15
8

2
10

16 17

VACUATOR
DIRECTION

Figure 1
1.
2.
3.
4.
5.
6.

Air cleaner hose
Hose clamp
Air cleaner assembly
Indicator
Air cleaner strap
Lock nut (2 used)

Kubota Diesel Engine

7.
8.
9.
10.
11.
12.

Hose clamp
Air cleaner hose
Hose clamp
Cap screw (2 used)
Flat washer (4 used)
Spring (2 used)

Page 3 -- 4

13.
14.
15.
16.
17.

Flat washer (2 used)
Cap screw (2 used)
Adapter
Lock nut (2 used)
Flat washer (2 used)

Groundsmaster 4100--D

Removal (Fig. 1)
1. Park machine on a level surface, lower cutting deck,
stop engine, apply parking brake and remove key from
the ignition switch.

2
4

2. Raise and support hood.

3. Remove air cleaner components as needed using
Figure 1 as a guide.
3

Installation (Fig. 1)

1. Assemble air cleaner system using Figure 1 as a
guide.

Figure 2
1. Air cleaner housing
2. Safety filter element
3. Air filter element

4. Air cleaner cover
5. Vacuator valve

A. If service indicator (item 8) and adapter (item 9)
were removed from air cleaner housing, apply thread
sealant to adapter threads before installing adapter
and indicator to housing. Install adapter so that
grooves in adapter hex and adapter filter element are
installed toward service indicator (Fig. 3). Torque indicator from 12 to 15 in--lb (1.4 to 1.6 N--m).

2
3

2. When installing air cleaner hose (8) between air
cleaner and turbo--charger (Fig. 4):

A. Make sure that hose does not contact engine
valve cover. To ensure clearance, move and/or rotate air cleaner body in air cleaner strap.
B. Position hose to allow maximum clearance between air cleaner hose and muffler bracket.

Figure 3
1. Air cleaner assembly
2. Service indicator

3. Adapter

3. Lower and secure hood.

2
Figure 4
1. Air cleaner hose
2. Engine valve cover
3. Air cleaner strap

Groundsmaster 4100--D

Page 3 -- 5

4. Air cleaner slots
5. Muffler bracket

Kubota Diesel Engine

Kubota
Diesel Engine

IMPORTANT: Any leaks in the air filter system will
cause serious engine damage. Make sure that all air
cleaner components are in good condition and are
properly secured during assembly.

Exhaust System
16 to 22 ft--lb
(21 to 29 N--m)

16 to 22 ft--lb
(21 to 29 N--m)

14
3

2
15
16

16 to 22 ft--lb
(21 to 29 N--m)

13 ft--lb
(17.6 N--m)

6
8

RIGHT

FRONT

16 to 22 ft--lb
(21 to 29 N--m)

Figure 5
1.
2.
3.
4.
5.
6.

Muffler
Muffler bracket
Exhaust pipe
Flange head screw (4 used)
Exhaust gasket
Lock nut (2 used)

Kubota Diesel Engine

7.
8.
9.
10.
11.

Cap screw (2 used)
Flat washer (4 used)
Spacer (2 used)
Rubber hanger
Flange nut (4 used)

Page 3 -- 6

12.
13.
14.
15.
16.

Flange head screw (2 used)
Engine mount
Muffler clamp
Exhaust mount
Flange head screw (2 used)

Groundsmaster 4100--D

Removal (Fig. 5)

CAUTION

The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the engine and exhaust system to cool before working on the muffler.

E
C

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.
A

3. Remove exhaust system components from the engine as necessary using Figure 5 as a guide.

Figure 6

Installation (Fig. 5)
IMPORTANT: If exhaust studs were removed from
engine cylinder head, thoroughly clean threads in
head and apply Loctite #277 (or equivalent) to stud
threads before installing studs into head.
NOTE: Make sure muffler flange and exhaust manifold
sealing surfaces are free of debris or damage that may
prevent a tight seal.
1. Install new exhaust gasket if original gasket is damaged or torn.
IMPORTANT: Failure to follow the suggested muffler fastener sequence may result in premature muffler failure.
2. Install exhaust system components to the engine using Figure 5 as a guide. Hand tighten exhaust system
fasteners and then torque in the sequence shown in Fig.
6 as follows:
A. Torque lock nuts used on rubber hanger cap
screws from 16 to 22 ft--lb (21 to 29 N--m).
B. Torque flange nuts that secure muffler to muffler
bracket from 16 to 22 ft--lb (21 to 29 N--m).
C. Torque flange head screws that secure muffler
flange to engine from 16 to 22 ft--lb (21 to 29 N--m).
D. Torque flange nuts that secure muffler bracket to
engine from 16 to 22 ft--lb (21 to 29 N--m).
E. Torque flange screws that secure exhaust mount
to engine to 13 ft--lb (17.6 N--m).
3. Tailpipe should have equal clearance between frame
and engine after installation.
4. Lower and secure hood.
Groundsmaster 4100--D

Page 3 -- 7

Rev. A

Kubota Diesel Engine

Kubota
Diesel Engine

Fuel System

38
39
37

RIGHT

36 35
34

FRONT

26 27 28
25

41
2

30 31

33
1
21

3
4
5
40
6

20
7

19
18 17 1615

12
11

60 to 80 in--lb
(7 to 9 N--m)

135 to 165 ft--lb
(183 to 223 N--m)

Figure 7
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Fuel tank
Fuel tank bracket
Air breather
Female hose barb
Tank support assembly
Fuel hose
Flange nut
Cap screw (4 used)
Flat washer
Cap screw (4 used)
Carriage screw (2 used)
Washer
Battery strap
Battery

Kubota Diesel Engine

15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.

Retaining ring (2 used)
Battery cover
Flat washer (2 used)
Knob (2 used)
Battery plate
Negative battery cable
Positive battery cable
Carriage screw (2 used)
Gasket
Bushing (3 used)
Stand pipe
Fuel sender
Lock washer (5 used)
Phillips head screw (5 used)

Page 3 -- 8

29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.

Fuel hose
Hose clamp
Elbow fitting
Fuel cap
Locking flange nut
Speed nut
Tank cover (2 used)
Phillips head screw
Vent tube
Insulated clip (3 used)
Washer head screw (3 used)
Hose clamp
ROPS assembly

Groundsmaster 4100--D

Fuel Tank Installation (Fig. 7)

DANGER

1. Install fuel tank using Figure 7 as a guide.
A. Torque two (2) flange nuts that secure the fuel
tank to the frame from 60 to 80 in--lb (7 to 9 N--m).
2. Install two (2) tank covers to ROPS assembly.
3. Connect fuel hose to the standpipe and venting
hoses to the elbow fittings.
4. Connect electrical wiring to the fuel sender.
A. Connect white wire to the center terminal and
black wire to any of the screws that secure the fuel
sender to the fuel tank.

Check Fuel Lines and Connections
Check fuel lines and connections periodically as recommended in the Operator’s Manual. Check lines for deterioration, damage, leaks or loose connections. Replace
hoses, clamps and connections as necessary.

B. Apply skin--over grease to the wire terminal connections.

CAUTION

Empty and Clean Fuel Tank
Empty and clean the fuel tank periodically as recommended in the Operator’s Manual. Also, empty and
clean the fuel tank if the fuel system becomes contaminated or if the machine is to be stored for an extended
period.

Connecting battery cables to the wrong battery
post could result in personal injury and/or damage to the electrical system.

To clean fuel tank, flush tank out with clean diesel fuel.
Make sure tank is free of contaminates and debris.

5. Position battery in machine. Connect positive battery
cable first and then negative battery cable. Install battery strap and cover.

Fuel Tank Removal (Fig. 7)

6. Lower seat and hood.

1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.

7. Fill fuel tank.

2. Raise and support seat and hood.
3. Remove battery cover and strap. Disconnect negative battery cable first and then positive battery cable.
Remove battery from machine.
4. Use a fuel transfer pump to remove fuel from the fuel
tank and into a suitable container.
5. Disconnect electrical wiring from the fuel sender on
the fuel tank.
6. Disconnect fuel hose from the standpipe and venting
hoses from elbow fittings in top of tank.
7. Remove phillips head screws that secure two (2)
tank covers to ROPS assembly. Remove tank covers.
8. Remove fuel tank using Figure 7 as a guide.

Groundsmaster 4100--D

Page 3 -- 9

Kubota Diesel Engine

Kubota
Diesel Engine

Because diesel fuel is highly flammable, use caution when storing or handling it. Do not smoke
while filling the fuel tank. Do not fill fuel tank
while engine is running, hot or when machine is
in an enclosed area. 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.

Radiator

RIGHT

FRONT

24
25

50
8

54
6
61

49
41
25

59
4
38

11
55

49
10
60
57

32
13

42
44

35
2

34
48
39

47
33
3

Figure 8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

Radiator cap
Foam strip (2 used)
Foam strip (2 used)
Lower radiator hose
Upper radiator hose
Clamp (4 used)
Lower radiator shroud
Temperature sender
Radiator
Hose clamp (3 used)
Hose (2 used)
Screw (4 used)
Rubber grommet
Flange nut (4 used)
Retaining ring (2 used)
Knob (2 used)
Bulb seal
Top radiator support
Retaining ring (2 used)
Oil cooler bracket
Oil cooler

Kubota Diesel Engine

22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.

Carriage screw (2 used)
90o hydraulic fitting (2 used)
Cap screw (6 used)
Lock washer (6 used)
Oil cooler mount plate (2 used)
Upper radiator shroud
Flange nut (10 used)
Foam plug (2 used)
Lock nut (6 used)
Foam strip
Base bracket
Flange head screw (6 used)
Bulb seal (2 used)
Grommet (2 used)
Cover
Flange head screw (4 used)
Plate (2 used)
Flat washer (2 used)
Knob (2 used)
Cap screw (6 used)
Cable tie

Page 3 -- 10

43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.

Coolant reservoir
Tank bracket
Flat washer (10 used)
Foam pad
Cap screw (7 used)
Foam seal
Cap screw (3 used)
LH radiator support
RH radiator support
Flange nut (6 used)
Cap screw (6 used)
Fan motor bracket
Grommet (2 used)
Grommet
Harness clip
R--clamp (2 used)
Foam pad
Reservoir cap
Air cleaner hose
Plug

Groundsmaster 4100--D

Removal (Fig. 8)

Installation (Fig. 8)

1. Park machine on a level surface, lower cutting deck,
stop engine, apply parking brake and remove key from
the ignition switch.

1. Remove all plugs placed during the removal procedure.

2. Open and support hood.

CAUTION

2. Carefully position radiator to the support frame. Secure radiator to the support frame with cap screws and
flange nuts.
3. Position lower radiator shroud and fan motor bracket
assembly to the radiator.

Ethylene--glycol antifreeze is poisonous. Dispose of coolant properly or store it in a properly
labeled container away from children and pets.

4. Secure fan motor bracket to radiator with six (6)
flange head screws and flange nuts.
5. Position upper radiator shroud to lower radiator
shroud to radiator. Secure shrouds with removed fasteners.

3. Drain radiator into a suitable container using the radiator drain. The radiator drain hose is located near the
engine oil filter.

6. Attach radiator shroud assembly to the radiator with
cap screws and flat washers. Make sure that clearance
between shroud and cooling fan is at least 0.180” (4.6
mm) at all points.

4. Disconnect upper and lower radiator hoses from the
radiator.

7. Connect reservoir hose to the vent tube near the radiator cap.

5. Remove air cleaner hose (item 61).

8. Connect upper and lower radiator hoses to the radiator.

6. Disconnect reservoir hose from the vent tube near
the radiator cap.

9. Reinstall air cleaner hose (item 61).

7. Detach upper radiator shroud from the radiator and
lower radiator shroud. Remove upper shroud from machine.

10.Make sure radiator drain is closed. Fill radiator with
coolant.
11. Close and secure hood.

8. Remove fasteners that secure lower radiator shroud
to radiator.
9. Remove six (6) flange head screws and flange nuts
that secure fan motor bracket to radiator.
10.Position lower radiator shroud and fan motor bracket
assembly away from radiator.
11. Remove cap screws and flange nuts securing the radiator to the support frame. Carefully pull radiator from
the machine.
12.Plug all radiator or hose openings to prevent contamination.

Groundsmaster 4100--D

Page 3 -- 11

Kubota Diesel Engine

Kubota
Diesel Engine

Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.

Engine

RIGHT
FRONT
26
25
24
2

3
4

5
22
6

21
11
13

8
9

16
19

28 to 32 ft--lb
(38 to 43 N--m)

Loctite #242

28 to 32 ft--lb
(38 to 43 N--m)

29 to 33 ft--lb
(40 to 44 N--m)

Figure 9
1.
2.
3.
4.
5.
6.
7.
8.
9.

Engine
Cap screw (4 used)
LH engine mount
Lock washer
Cap screw
Lock washer (5 used)
Cap screw (5 used)
Engine support (4 used)
Flange nut (12 used)

Kubota Diesel Engine

10.
11.
12.
13.
14.
15.
16.
17.
18.

Rebound washer (4 used)
Cap screw (8 used)
Spring coupler
Washer (14 used)
Cap screw (6 used)
Flywheel plate
Cap screw (4 used)
Cap screw (2 used)
Lock washer (2 used)

Page 3 -- 12

19.
20.
21.
22.
23.
24.
25.
26.
27.

LH engine mount
Cap screw (4 used)
RH engine mount
Cap screw (PTO manifold)
Lock washer
Ground cable
Cap screw
Lock washer
RH engine mount

Groundsmaster 4100--D

Engine Removal (Fig. 9)
1. Park machine on a level surface, lower cutting deck,
stop engine, apply parking brake and remove key from
the ignition switch.

2. Remove battery cover and strap. Disconnect negative battery cable first and then positive battery cable.
Remove battery from machine.
1

3. Open and support hood.

CAUTION
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.

Figure 10
1. Dual temperature switch
2. Temperature sender

3. Alternator

Ethylene--glycol antifreeze is poisonous. Dispose 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 container (see Radiator Removal in this section). Disconnect upper and lower hoses from the radiator.

CAUTION
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the exhaust system
to cool before working on or near the muffler.

Figure 11
1. Glow plug wire
2. Glow plug lead

3. Cylinder #4 glow plug

5. Remove exhaust system from engine (see Exhaust
System Removal in this section).
6. Remove air cleaner system from engine (see Air Filter System Removal in this section).

7. Note location of cable ties used to secure wire harness to the machine. Disconnect wires and/or electrical
connections from the following electrical components:

A. The dual temperature switch, temperature sender and alternator (Fig 10).
B. The glow plug lead (Fig. 11).
C. The engine run solenoid (Fig. 12).

Figure 12

D. Battery, frame and wire harness ground at the engine block.

1. Engine run solenoid
2. Alternator belt

3. Throttle cable

E. The electric starter and low oil pressure switch
(on RH side of engine).
8. Disconnect fuel supply hose from injection pump
(Fig. 13).
Groundsmaster 4100--D

Page 3 -- 13

Kubota Diesel Engine

Kubota
Diesel Engine

9. Disconnect throttle cable from the speed control lever by removing the flat washer and lock nut (Fig. 14).
Loosen jam nut and separate cable from cable support.
Position cable away from engine.

10.Remove fasteners that secure the upper radiator
shroud to the lower shroud and radiator (see Radiator
Removal in this section). Position coolant reservoir and
bracket away from the radiator. Remove upper radiator
shroud from machine.

11. Remove fan hub and fan from hydraulic fan motor
(Fig. 15).

A. Remove hex nut (item 9) and washer (item 8) that
secure fan hub and fan assembly to fan motor.
NOTE: The fan motor shaft is tapered.

Figure 13
1. Fuel pump
2. Fuel supply hose

B. Use suitable puller to remove fan hub (with fan attached) from fan motor shaft taking care to not damage fan. Remove fan hub and fan from machine.

3. Throttle cable

IMPORTANT: The hydraulic pump assembly can remain in machine during engine removal. To prevent
pump from shifting or falling, make sure to support
pump assembly before mounting fasteners are removed.

8
6
7

12.Support hydraulic pump assembly. Remove fasteners that secure pump assembly to engine (see Pump
Assembly Removal in the Service and Repairs section
of Chapter 4 -- Hydraulic System).

9
10

13.Make sure all cable ties securing the wiring harness,
fuel lines or hydraulic hoses to the engine are removed.

Figure 14

14.Connect hoist or lift to the lift tabs on engine.
15.Remove flange nuts, rebound washers and cap
screws securing the engine mounts to the engine supports.

1.
2.
3.
4.
5.
6.

Lock nut
Flat washer
Throttle lever
Lock nut
Flange head screw
Cap screw

7.
8.
9.
10.
11.
12.

Flange head screw
Spring washer (2 used)
Ball joint
Cap screw (2 used)
Throttle cable
Cable support

Engine Installation (Fig. 9)

CAUTION
One person should operate lift or hoist while
another person guides the engine out of the machine.

1. If removed, install engine mounts to the engine using
Figure 9 as a guide.
2. Connect hoist or lift to the engine lift tabs.

IMPORTANT: Make sure not to damage the engine,
fuel and hydraulic lines, electrical harness or other
components while removing the engine.
16.Slowly remove engine assembly from the machine.
17.If necessary, remove engine mounts from the engine
using Figure 9 as a guide.

Kubota Diesel Engine

CAUTION
One person should operate lift or hoist while
another person guides the engine into the machine.
IMPORTANT: Make sure not to damage the engine,
fuel and hydraulic lines, electrical harness or other
parts while installing the engine.

Page 3 -- 14

Groundsmaster 4100--D

3. Slowly lower engine into the machine.
27 to 33 ft--lb
(37 to 44 N--m)

5. Secure hydraulic pump assembly to engine (see
Pump Assembly Installation in the Service and Repairs
section of Chapter 4 -- Hydraulic System).

1
10

6. Thoroughly clean tapered surfaces of fan motor
shaft and fan hub. Position fan hub (with fan attached)
onto motor shaft and secure with washer and hex nut
(Fig. 15). Torque nut from 27 to 33 ft--lb (37 to 44 N--m).
7. Position upper radiator shroud and coolant reservoir
with bracket to the radiator. Secure shroud and reservoir
bracket to the radiator and lower radiator bracket with
removed fasteners (see Radiator Installation in this section). Make sure that clearance between shroud and fan
is at least 0.180” (4.6 mm) at all points.
8. Connect throttle cable to the speed control lever with
washer and lock nut (Fig. 14). Secure cable to cable
support. Adjust throttle cable.
9. Connect fuel line to the injection pump.
10.Connect wires and/or electrical connections to the
following electrical components:
A. The dual temperature switch, temperature sender and alternator (Fig 10).

5
6
7

12 to 14 ft--lb
(17 to 18 N--m)

Figure 15
1.
2.
3.
4.
5.
6.

Fan motor
Cap screw (2 used)
Flat washer (2 used)
Fan motor bracket
Lock nut (2 used)
Washer (4 used)

7.
8.
9.
10.
11.

Cap screw (4 used)
Hex nut
Washer
Fan hub
Fan

13.Connect coolant hoses to the radiator. Make sure radiator drain is shut. Fill radiator and reservoir with coolant.
14.Check position of wires, fuel lines, hydraulic hoses
and cables for proper clearance with rotating, high temperature and moving components.

B. The engine run solenoid and fuel pump (Fig. 13).

15.Position battery to machine. Connect positive battery cable first and then negative battery cable. Secure
battery to machine with strap and cover.

C. The glow plug (Fig. 11).

16.Check and adjust engine oil as needed.

D. Battery, frame and wire harness ground to the engine block.

17.Check and adjust hydraulic oil as needed.

E. The starter and low oil pressure switch (near
starter).
11. Install air cleaner assembly to the engine (see Air Filter System Installation in this section).
12.Install exhaust system to machine (see Exhaust System Installation in this section).

Groundsmaster 4100--D

18.Bleed fuel system.
19.Start engine and operate hydraulic controls to properly fill hydraulic system (see Charge Hydraulic System
in Chapter 4 -- Hydraulic System).
20.Close and secure hood.

Page 3 -- 15

Kubota Diesel Engine

Kubota
Diesel Engine

4. Align engine to the engine supports and hydraulic
pump input shaft. Secure engine to engine supports with
cap screws, rebound washers and flange nuts.

Spring Coupler

RIGHT
FRONT

8
2

1
2

2
4
5
7

Loctite #242

29 to 33 ft--lb
(40 to 44 N--m)

6
28 to 32 ft--lb
(38 to 43 N--m)

Figure 16
1. Spring coupler
2. Washer (14 used)
3. Cap screw (6 used)

Kubota Diesel Engine

4. Flywheel plate
5. Cap screw (4 used)
6. LH engine mount

Page 3 -- 16

7. Cap screw (2 used)
8. RH engine mount

Groundsmaster 4100--D

Coupler Removal (Fig. 16)
NOTE: The hydraulic pump assembly needs to be removed from engine before coupler can be removed.

Engine Side

Hydraulic
Pump Side

1. If engine is in machine, support engine from below to
prevent it from shifting while removing hydraulic pump
assembly (see Piston (Traction) Pump Removal in the
Service and Repairs section of Chapter 4 -- Hydraulic
System), transport cylinder assembly, flywheel plate,
engine mounts and spring coupler.

2. Remove flywheel plate and spring coupler from engine using Figure 16 as a guide.
Coupler Installation (Fig. 16)
1. Position spring coupler to engine flywheel and align
mounting holes. Make sure that coupler hub is away
from engine flywheel (Fig. 17).
2. Apply Loctite #242 (or equivalent) to threads of cap
screws (item 3). Secure coupler to flywheel with six (6)
cap screws and washers. Torque cap screws in a crossing pattern from 29 to 33 ft--lb (40 to 44 N--m).

2
Figure 17
1. Spring coupler
2. Engine flywheel

3. Coupler hub

3. Position flywheel plate to engine and engine mounts.
Secure flywheel plate and mounts with cap screws
(items 5 and 7) and washers using 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 assembly (see Piston (Traction) Pump Installation in the
Service and Repairs section of Chapter 4 -- Hydraulic
System).

Groundsmaster 4100--D

Page 3 -- 17

Kubota Diesel Engine

Kubota
Diesel Engine

This page is intentionally blank.

Kubota Diesel Engine

Page 3 -- 18

Groundsmaster 4100--D

Chapter 4

Hydraulic System
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 3
Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Hose and Tube Installation . . . . . . . . . . 5
Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 6
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 8
HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . 10
Traction Circuit: 4WD (Mow) . . . . . . . . . . . . . . . . . 10
Traction Circuit: Transport (2WD) . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . 28
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Traction Circuit Charge Pressure . . . . . . . . . . . . . 32
Traction Circuit Relief Pressure . . . . . . . . . . . . . . 34
Counterbalance Pressure . . . . . . . . . . . . . . . . . . . 36
Rear Traction Circuit (RV) Relief Pressure . . . . . 38
Traction Circuit Reducing Valve (PR)
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Cutting Deck Circuit Pressure . . . . . . . . . . . . . . . . 42
PTO Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . 44
Cutting Deck Gear Pump Flow . . . . . . . . . . . . . . . 46
Cutting Deck Motor Case Drain Leakage . . . . . . 48
Steering Circuit Relief Pressure . . . . . . . . . . . . . . 50
Lift/Lower Circuit Relief Pressure . . . . . . . . . . . . . 52
Steering and Lift/Lower Gear Pump Flow . . . . . . 54
Engine Cooling Fan Circuit . . . . . . . . . . . . . . . . . . 56
Engine Cooling Fan Circuit Gear Pump Flow . . . 58
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Adjust Cutting Deck Flow Control Valve . . . . . . . 60
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 61
General Precautions for Removing and
Installing Hydraulic System Components . . . . 61
Check Hydraulic Lines and Hoses . . . . . . . . . . . . 61
Flush Hydraulic System . . . . . . . . . . . . . . . . . . . . . 62

Groundsmaster 4100--D

Charge Hydraulic System . . . . . . . . . . . . . . . . . . . 63
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . 64
Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . 66
Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Gear Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . 70
Traction Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Piston (Traction) Pump . . . . . . . . . . . . . . . . . . . . . . 74
Piston (Traction) Pump Service . . . . . . . . . . . . . . 76
Rear Axle Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Front Wheel Motors . . . . . . . . . . . . . . . . . . . . . . . . 80
Rear Axle and Front Wheel Motor Service . . . . . 82
4WD Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4WD Manifold Service . . . . . . . . . . . . . . . . . . . . . . 86
Filter Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Filter Manifold Service . . . . . . . . . . . . . . . . . . . . . . 90
Steering and Cooling Fan Circuits . . . . . . . . . . . . 92
Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Steering Valve Service . . . . . . . . . . . . . . . . . . . . . . 96
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Steering Cylinder Service . . . . . . . . . . . . . . . . . . 100
Engine Cooling Fan Motor . . . . . . . . . . . . . . . . . . 102
Engine Cooling Fan Motor Service . . . . . . . . . . . 104
Fan Drive Manifold . . . . . . . . . . . . . . . . . . . . . . . . 108
Fan Drive Manifold Service . . . . . . . . . . . . . . . . . 110
Mow Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Cutting Deck Motor . . . . . . . . . . . . . . . . . . . . . . . . 113
Cutting Deck Motor Service . . . . . . . . . . . . . . . . . 114
Deck Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Deck Manifold Service . . . . . . . . . . . . . . . . . . . . . 120
Lift/Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Lift/Lower Control Valve . . . . . . . . . . . . . . . . . . . . 124
Lift/Lower Control Valve Service . . . . . . . . . . . . . 126
Front Deck Lift Cylinder . . . . . . . . . . . . . . . . . . . . 128
Wing Deck Lift Cylinder . . . . . . . . . . . . . . . . . . . . 130
Deck Lift Cylinder Service . . . . . . . . . . . . . . . . . . 132
Counterbalance Manifold . . . . . . . . . . . . . . . . . . . 134
Counterbalance Manifold Service . . . . . . . . . . . . 136
EATON MODEL 72400 SERVO CONTROLLED PISTON PUMP REPAIR INFORMATION
EATON MODEL 74318 and 74348 PISTON MOTORS:
FIXED DISPLACEMENT, VALVE PLATE DESIGN
REPAIR INFORMATION

Page 4 -- 1

Hydraulic System

Hydraulic
System

Table of Contents

Specifications
Item

Description

Piston (Traction) Pump

Eaton Variable Displacement Piston Pump
(Model 72400)
4000 PSI (274 bar)
5000 PSI (343 bar)
250 PSI (17 bar)

System Relief Pressure: Forward
System Relief Pressure: Reverse
Charge Pressure
Front Wheel Motors

Eaton Fixed Displacement Piston Motors
(Model 74328)

Rear Axle Motor

Eaton Fixed Displacement Piston Motor
(Model 74315)

Gear Pump
Section P1/P2 Displacement (per revolution)
Section P3/P4 Displacement (per revolution)

Casappa 4 section, positive displacement gear type pump
1.37 Cubic Inches (22.46 cc)
0.56 Cubic Inches (9.16 cc)

Steering Control Valve

Eaton Steering Unit, Series 5

Steering Relief Pressure

1350 PSI (93 bar)

Lift/Lower Relief Pressure

2525 PSI (174 bar)

Cutting Deck Motors

Sauer Danfoss Gear Motor

Cutting Deck Circuit Relief Pressure
Center and Left Side
Right Side

3000 PSI (207 bar)
2000 PSI (137 bar)

Engine Cooling Fan Motor
Displacement (per revolution)

Casappa Gear Motor
0.50 Cubic Inches (8.3 cc)

Engine Cooling Fan Circuit Relief Pressure

3000 PSI (207 bar)

Hydraulic Filters
In--line Suction Strainer

Spin--on cartridge type
100 mesh (in reservoir)

Hydraulic Reservoir

8 U.S. Gallons (30.3 Liters)

Hydraulic Oil

Hydraulic System

See Operator’s Manual

Page 4 -- 2

Groundsmaster 4100--D

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.

Towing Traction Unit
IMPORTANT: If towing limits are exceeded, severe
damage to the piston 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. The piston (traction) pump is
equipped with a by--pass valve that needs to be turned
90o for towing. See Operator’s Manual for Towing Procedures.

Hydraulic
System

Figure 1
1. By--pass valve location

Check Hydraulic Fluid
The Groundsmaster 4100--D hydraulic system is designed to operate on anti--wear hydraulic fluid. The reservoir holds approximately 8 gallons (30.3 liters) of
hydraulic fluid. Check level of hydraulic fluid daily.
See Operator’s Manual for fluid level checking procedure and hydraulic oil recommendations.

Figure 2
1. Hydraulic reservoir cap

Groundsmaster 4100--D

Page 4 -- 3

Hydraulic System

Hydraulic Hoses
Hydraulic hoses are subject to extreme conditions such
as pressure differentials during operation and exposure
to weather, sun, chemicals, very warm storage conditions or mishandling during operation and maintenance.
These conditions can cause hose damage and deterioration. 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; hold the hose straight with
one wrench and tighten the hose swivel nut onto the fitting with the other wrench (See Hydraulic Hose and
Tube Installation in this section). 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.

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 injected into the skin, it must be surgically removed within a few hours by a doctor familiar
with this type of injury. Gangrene may result from
such an injury.

For additional hydraulic hose information, refer to Toro
Service Training Book, Hydraulic Hose Servicing (Part
Number 94813SL).

Hydraulic System

Page 4 -- 4

Groundsmaster 4100--D

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.

C. Use a second wrench to tighten the nut to the correct 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.

2. As a preventative measure against leakage, it is recommended 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.

Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)

3. Place the hose/tube against the fitting body so that
the flat face of the hose/tube sleeve fully contacts the O-ring in the fitting.

Swivel Nut

1/2 to 3/4
1/2 to 3/4
1/2 to 3/4
1/2 to 3/4
1/3 to 1/2
1/3 to 1/2

Fitting Body

O--ring

Hydraulic
System

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
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).

Tube or Hose

Figure 3

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 Resistance (F.F.W.R.) method (Fig. 2).

Mark Nut
and Fitting
Body

A. Using a wrench, tighten the swivel nut onto the fitting until light wrench resistance is reached (approximately 30 in--lb).
B. Mark the swivel nut and fitting body. Hold the
hose/tube with a wrench to prevent it from turning.

F.F.W.R.

Final
Position

Initial
Position

Extend Line
AT WRENCH RESISTANCE

AFTER TIGHTENING

Figure 4

Fitting Dash Size

Hose/Tube Side Thread Size

Installation Torque

9/16 -- 18

18 to 22 ft--lb (25 to 29 N--m)

11/16 -- 16

27 to 33 ft--lb (37 to 44 N--m)

13/16 -- 16

37 to 47 ft--lb (51 to 63 N--m)

1 -- 14

60 to 74 ft--lb (82 to 100 N--m)

1 3/16 -- 12

85 to 105 ft--lb (116 to 142 N--m)

1 7/16 -- 12

110 to 136 ft--lb (150 to 184 N--m)

1 11/16 -- 12

140 to 172 ft--lb (190 to 233 N--m)
Figure 5

Groundsmaster 4100--D

Page 4 -- 5

Hydraulic System

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.

5. If a torque wrench is not available, or if space at the
port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.)
method.

2. As a preventative measure against leakage, it is recommended 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.

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 fitting to 60% of listed F.F.F.T.
Size

IMPORTANT: Before installing fitting into port, determine 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 recommended installation torque shown in Figure 7.

F.F.F.T.

4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)

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
Using a Torque Wrench with an Offset Wrench in the
Torque Specifications section of Chapter 2 -- Product
Records and Maintenance to determine necessary conversion information.

1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25

Fitting

O--ring

Figure 6

Fitting
Dash Size

Fitting Port Side
Thread Size

Installation Torque Into
Steel Port

Installation Torque Into
Aluminum Port

7/16 -- 20

15 to 19 ft--lb (21 to 25 N--m)

9 to 11 ft--lb (13 to 15 N--m)

1/2 -- 20

18 to 22 ft--lb (25 to 29 N--m)

11 to 15 ft--lb (15 to 20 N--m)

9/16 -- 18

34 to 42 ft--lb (47 to 56 N--m)

20 to 26 ft--lb (28 to 35 N--m)

3/4 -- 16

58 to 72 ft--lb (79 to 97 N--m)

35 to 43 ft--lb (48 to 58 N--m)

7/8 -- 14

99 to 121 ft--lb (135 to 164 N--m)

60 to 74 ft--lb (82 to 100 N--m)

1 1/16 -- 12

134 to 164 ft--lb (182 to 222 N--m)

81 to 99 ft--lb (110 to 134 N--m)

1 3/16 -- 12

160 to 196 ft--lb (217 to 265 N--m)

96 to 118 ft--lb (131 to 160 N--m)

1 5/16 -- 12

202 to 248 ft--lb (274 to 336 N--m)

121 to 149 ft--lb (165 to 202 N--m)

1 5/8 -- 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

Page 4 -- 6

Groundsmaster 4100--D

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 recommended that the O--ring be replaced any time the
connection is opened.

Lock Nut

3. Lightly lubricate the O--ring with clean hydraulic oil.
Fitting threads should be clean with no lubricant applied.

Back--up Washer

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
as possible (Step 1 in Figure 9).

O--ring

Figure 8

IMPORTANT: Before installing fitting into port, determine port material. If fitting is to be installed into
an aluminum port, installation torque is reduced.

6. To put the fitting in the desired position, unscrew it by
the required amount, but no more than one full turn
(Step 3).
7. Hold the fitting in the desired position with a wrench
and use a torque wrench to tighten the fitting 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).

Step 1

Step 3

Step 2

Step 4

Hydraulic
System

5. Install the fitting into the port and tighten finger tight
until the washer contacts the face of the port (Step 2).

Figure 9

8. If a torque wrench is not available, or if space at the
port prevents use of a torque wrench, an alternate method 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
with a second wrench to the listed F.F.F.T (Step 4). If port
material is aluminum, tighten fitting to 60% of listed
F.F.F.T.
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)

Groundsmaster 4100--D

F.F.F.T.
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25

Page 4 -- 7

Hydraulic System

RH WING DECK
MANIFOLD

LH WING DECK
MANIFOLD

CENTER DECK
MANIFOLD

NOTE: A larger hydraulic schematic is
included in Chapter 9: Foldout Drawings

FAN DRIVE
MANIFOLD

FILTER
MANIFOLD

4WD
MANIFOLD

COUNTERBALANCE
MANIFOLD

Hydraulic Schematic

Page 4 -- 8

Groundsmaster 4100--D

Hydraulic
System

This page is intentionally blank.

Groundsmaster 4100--D

Page 4 -- 9

Hydraulic System

RV2

Page 4 -- 10

RV2

RH WING DECK
MANIFOLD

LH WING DECK
MANIFOLD

CENTER DECK
MANIFOLD

LC2

RV1

LC1

Working Pressure
Low Pressure (Charge)
Return or Suction
Flow

Groundsmaster 4100--D
Traction Circuit (4WD Forward Shown)

FAN DRIVE
MANIFOLD

4WD
MANIFOLD

COUNTERBALANCE
MANIFOLD

Hydraulic Flow Diagrams

Groundsmaster 4100--D

Traction Circuit: 4WD (Mow)

Traction circuit pressure (forward and reverse) can be
measured at test ports on the sides of the machine.
The traction circuit pump and motors use a small
amount of hydraulic fluid 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 hydraulic fluid from the closed loop traction circuit
that must be replaced. The charge circuit is designed to
replace this traction circuit leakage.
The gear pump section that supplies oil to the steering
and lift/lower circuits also provides oil for the charge circuit. This gear pump is driven directly off the traction
pump. It provides a constant supply of charge oil to
make up for oil that is lost due to internal leakage in the
traction pump and motors.
Pump flow for the charge circuit is directed through the
oil filter and to the low pressure side of the closed loop
traction circuit. A filter bypass valve allows charge oil
flow to the closed loop if the filter becomes plugged.
Charge pressure is limited to 250 PSI (17 bar) by a relief
valve located in the oil filter manifold. Charge pressure
can be measured at the charge circuit pressure test port
on the oil filter manifold.

Groundsmaster 4100--D

Forward Direction
When the transport/4WD switch is in the 4WD (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 4WD manifold. Oil flow to the front
wheel motors drives the motors in the forward direction
and then returns to the hydrostat. Oil flow to the 4WD
manifold enters the P1 port and then is directed to the
PD1 cartridge and out of the manifold M1 port to drive
the rear axle motor in the forward direction. Oil returning
from the rear motor re--enters the 4WD manifold at the
M2 port. Flow passes through the PD2 cartridge,
through the CV check valve, out manifold port P2 and
back to the hydrostat.
When going down a hill, the tractor becomes an over-running load that drives the wheel and 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 hydrostat. To prevent rear wheel lock up, an
adjustable relief valve (RV) in the 4WD manifold reduces rear axle motor pressure created in down hill, dynamic braking conditions.
Reverse Direction
The traction circuit operates essentially the same in reverse 4WD (mow) as it does in the forward direction.
However, the flow through the circuit is reversed. Oil flow
from the hydrostat is directed to the front wheel motors
and also to the 4WD manifold. The oil to the front wheel
motors drives them in the reverse direction and then returns to the hydrostat. The oil to the 4WD manifold enters the manifold at port P2 and flows through pressure
reducing valve (PR) which limits the down stream pressure to the rear axle motor to 650 PSI (45 bar) so the rear
wheels will not scuff the turf during reverse operation.
This reduced pressure flows through the PD2 cartridge
and out port M2 to the rear axle motor. Return oil from
the rear motor re--enters the 4WD manifold at port M1,
flows through the PD1 cartridge, exits the manifold at
port P1 and returns to the hydrostat.

Page 4 -- 11

Hydraulic System

Hydraulic
System

The traction circuit piston pump is a variable displacement pump that is directly coupled to the engine flywheel. Pushing the traction pedal engages a hydraulic
servo valve which controls the variable displacement
piston pump swash plate to create a flow of oil. This oil
is directed to the 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 fixed displacement wheel and axle motors. As the load increases, circuit pressure can increase to relief valve settings: 4000 PSI (274 bar) in
forward and 5000 PSI (343 bar) in reverse. If pressure
exceeds the relief setting, oil flows through the relief
valve to the low pressure side of the closed loop traction
circuit. The traction circuit provides operation in either
4WD (mow) or transport (2WD).

Hydraulic System

Page 4 -- 12

Groundsmaster 4100--D

RV2

RH WING DECK
MANIFOLD

LH WING DECK
MANIFOLD

CENTER DECK
MANIFOLD

LC2

RV1

LC1

Working Pressure
Low Pressure (Charge)
Return or Suction
Flow

Groundsmaster 4100--D
Traction Circuit (Transport Forward Shown)

FAN DRIVE
MANIFOLD

4WD
MANIFOLD

(energized)

(shifted)

COUNTERBALANCE
MANIFOLD

Traction Circuit: Transport (2WD)

Traction circuit pressure (forward and reverse) can be
measured at test ports on the sides of the machine.
The traction circuit pump and motors use a small
amount of hydraulic fluid 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 hydraulic fluid from the closed loop traction circuit
that must be replaced. The charge circuit is designed to
replace this traction circuit leakage.
The gear pump section that supplies oil to the steering
and lift/lower circuits also provides charge oil for the
traction circuit. This gear pump is driven directly off the
traction pump. It provides a constant supply of charge oil
to the traction circuit to make up for oil that is lost due to
internal leakage in the traction pump and motors.
Charge pump flow is directed through the oil filter and to
the low pressure side of the closed loop traction circuit.
A filter bypass valve allows charge oil flow to the closed
loop if the filter becomes plugged. Charge pressure is limited to 250 PSI (17 bar) by a relief valve located in the
oil filter manifold. Charge pressure can be measured at
the charge circuit pressure test port on the oil filter manifold.

Groundsmaster 4100--D

Forward Direction
With the transport/4WD switch in the transport position,
solenoid valve (SV) in the 4WD control manifold is energized. The solenoid valve spool shifts to direct charge
pressure that shifts the PD1 and PD2 control valve
spools. The shifted PD1 valve prevents hydraulic flow
from the piston pump to the rear axle motor. With flow
blocked to the rear axle motor, all pump flow is directed
to the front wheel motors to allow a higher transport
speed in the forward direction.
Without flow to the rear axle motor, the rotating rear
wheels drive the axle motor so it acts like a pump. Inlet
oil to the axle motor is provided by a check valve that allows charge oil into the rear axle motor circuit. Oil leaving the axle motor enters the 4WD control manifold at
port M2 and is directed back to the axle motor through
the shifted PD1 cartridge and manifold port M1. To allow
for rear wheel loop cooling when in forward transport operation, a small amount of oil exits through the shifted
PD1 and PD2 cartridges that returns to the reservoir.
Reverse Direction
The traction circuit operates essentially the same in reverse transport (2WD) as it does in the forward direction.
However, the flow through the circuit is reversed. The
shifted solenoid valve (SV) and directional valves PD1
and PD2 in the 4WD manifold prevent oil flow from the
rear axle motor. Oil flow from the hydrostat is therefore
directed to only the front wheel motors. This oil drives
the front wheel motors in the reverse direction and then
returns to the hydrostat. Oil circulation through the rear
axle motor loop is the same as in the transport (2WD)
forward direction.

Page 4 -- 13

Hydraulic System

Hydraulic
System

Hydraulic System

Page 4 -- 14

Groundsmaster 4100--D

RV2

RH WING DECK
MANIFOLD

LH WING DECK
MANIFOLD

CENTER DECK
MANIFOLD

LC2

RV1

LC1

Working Pressure
Low Pressure (Charge)
Return or Suction
Flow

Groundsmaster 4100--D
Lower Cutting Deck (LH Deck Shown)

FAN DRIVE
MANIFOLD

4WD
MANIFOLD

COUNTERBALANCE
MANIFOLD

Lower Cutting Deck

When the cutting deck is in a stationary position, flow
from the gear pump is by--passed through the lift/lower
control valve, counterbalance manifold, oil filter and
traction charge circuit.
To lower the cutting deck, the center lift lever on the lift/
lower control valve is pushed to allow valve shift in the
lift/lower control. This valve change allows a passage for
oil flow from the rod end of the front deck lift cylinders.
The weight of the cutting deck causes the lift cylinders
to extend, and lower the cutting deck. Oil from the rod
end of the cylinders is allowed to return to the traction
charge circuit. When the lift lever is released, the lift cylinders and cutting deck is held in position.

Groundsmaster 4100--D

The drop speed of the front cutting deck is regulated by
an adjustable flow control valve that is located in the hydraulic lines between the lift/lower control valve and the
deck lift cylinders.
To lower a wing deck, the appropriate lift lever on the lift/
lower control valve is pushed to allow valve shift in the
lift/lower control valve. This valve change causes a
valve shift in the counterbalance manifold and oil flow to
the barrel end of the lift cylinder. Higher hydraulic pressure against the barrel end of the cylinder causes the
cylinder shaft to extend, and lower the wing deck. Oil
from the piston end of the cylinder returns to the traction
charge circuit. When the lift lever is released, the lift cylinder and wing deck is held in position.
An adjustable counterbalance valve (CB) in the counterbalance manifold maintains back pressure on the deck
lift cylinders to allow some of the cutting deck weight to
be transferred to the traction unit to improve traction. A
relief valve located in the lift/lower control valve limits lift/
lower circuit pressure to 1500 PSI (103 bar). Excess circuit flow is routed to the oil filter and then to the traction
charge circuit.

Page 4 -- 15

Hydraulic System

Hydraulic
System

A four section gear pump is coupled to the piston (traction) pump. The third gear pump section supplies hydraulic flow to both the lift/lower control valve and the
steering control valve. Hydraulic flow from this pump
section is delivered to the steering and lift/lower circuits
through a proportional flow divider that is located in the
fan drive manifold. This pump section takes its suction
from the hydraulic reservoir.

Hydraulic System

Page 4 -- 16

Groundsmaster 4100--D

RV2

RH WING DECK
MANIFOLD

LH WING DECK
MANIFOLD

CENTER DECK
MANIFOLD

LC2

RV1

LC1

Working Pressure
Low Pressure (Charge)
Return or Suction
Flow

Groundsmaster 4100--D
Raise Cutting Deck (LH Deck Shown)

FAN DRIVE
MANIFOLD

4WD
MANIFOLD

COUNTERBALANCE
MANIFOLD

Raise Cutting Deck

When the cutting deck is in a stationary position, flow
from the gear pump is by--passed through the lift/lower
control valve, counterbalance manifold, oil filter and
traction charge circuit.
To raise the cutting deck, the center lift lever on the lift/
lower control valve is pulled to allow valve shift in the lift/
lower control valve. This valve change allows hydraulic
pressure to the rod end of the front deck lift cylinders,
causing the cylinders to retract. As the cylinders retract,
the cutting deck raises. Oil from the piston end of the cylinders returns to the hydraulic reservoir. When the lift lever is released, the lift cylinders and cutting deck is held
in position.

Groundsmaster 4100--D

To raise a wing deck, the appropriate lift lever on the lift/
lower control valve is pulled to allow valve shift in the lift/
lower control valve. This valve change allows hydraulic
pressure to the piston end of the wing deck lift cylinder
and causes the cylinder shaft to retract, raising the wing
deck. Oil from the rod end of the cylinder flows to the
traction charge circuit. When the lift lever is released, the
lift cylinder and wing deck is held in position.
An adjustable counterbalance valve (CB) in the counterbalance manifold maintains back pressure on the deck
lift cylinders to allow some of the cutting deck weight to
be transferred to the traction unit to improve traction. A
relief valve located in the lift/lower control valve limits lift/
lower circuit pressure to 1500 PSI (103 bar). Excess circuit flow is routed to the oil filter and then to the traction
charge circuit.

Page 4 -- 17

Hydraulic
System

A four section gear pump is coupled to the piston (traction) pump. The third gear pump section supplies hydraulic flow to the lift/lower control valve and the steering
control valve. Hydraulic flow from this pump section is
delivered to the two circuits through a proportional flow
divider. The gear pump takes its suction from the hydraulic reservoir.

Hydraulic System

Page 4 -- 18

Groundsmaster 4100--D

RV2

RH WING DECK
MANIFOLD

LH WING DECK
MANIFOLD

CENTER DECK
MANIFOLD

LC2

RV1

LC1

Working Pressure
Low Pressure (Charge)
Return or Suction
Flow

Groundsmaster 4100--D
Mow Circuit (All Deck Motors Rotating)

FAN DRIVE
MANIFOLD

4WD
MANIFOLD

COUNTERBALANCE
MANIFOLD

Mow Circuit
Hydraulic flow for the mow circuit is supplied by two sections of the gear pump. The gear pump section closest
to the piston (traction) pump supplies hydraulic flow to
the wing decks, while the next gear pump section supplies the center deck.

Return oil from the deck motors is directed to the oil cooler and oil filter. Deck motor case drain leakage returns
to the hydraulic reservoir.
Maximum mow circuit pressure is limited at each deck
by a relief valve (RV1) in the hydraulic manifold. The
front and left deck relief valves are set at 3000 PSI (207
bar) and the right deck relief valve is set at 2000 PSI (137
bar).
Circuit pressure can be measured at port (G) of the hydraulic manifold for each cutting deck.

Hydraulic
System

Each cutting deck is controlled by a hydraulic manifold
equipped with a solenoid control valve (S), bypass cartridge (LC1), brake cartridge (LC2) and relief cartridge
(RV1). When the the deck solenoid valve (S) is not energized (PTO switch OFF), hydraulic flow by--passes the
deck motor through the bypass cartridge (LC1). When
the PTO switch is turned ON, the solenoid valve (S) energizes, causing a shift of the by--pass cartridge (LC1)
and allowing hydraulic flow to the deck motor. Brake cartridge (LC2) and relief cartridge (RV2) control the stopping rate of the blade when the solenoid control valve is
de--energized as the PTO switch is turned OFF.

The solenoid valve (S) for each wing deck is de--energized any time the wing deck is raised.

Groundsmaster 4100--D

Page 4 -- 19

Hydraulic System

Mow Circuit Cutting Deck Blade Braking
When the operator turns the PTO switch OFF or if a deck
is raised with the PTO switch ON, deck control manifold
solenoid valve (S) is de--energized causing logic cartridge (LC1) to shift (refer to information in PTO Mow Circuit in this section). This shifted cartridge allows oil
return out manifold port P2. At the same time, solenoid
valve (S) in its neutral position prevents any sense line
flow through the spool which causes the logic cartridge
LC2 to shift to its neutral position blocking return flow
from the deck motor and slowing the cutting blades (Fig.
10).
The inertia of the rotating cutting blades, however, effectively turns the deck motor into a pump causing an increase in pressure as the flow from the motor comes up
against the closed logic cartridge (LC2). When this pressure builds to approximately 600 PSI (41 bar), relief
valve (RV2) opens which allows a small amount of hydraulic flow to return to tank through a manifold sensing
line (Fig. 11). This flow causes a pressure increase that
shifts logic cartridge LC2 to once again allow oil flow
from the motor (Fig. 12). When motor return pressure
drops below 600 PSI (41 bar), relief valve (RV2) reseats
and causes LC2 to close again blocking return flow from
the deck motor to further slow the cutting blades. This
action of the brake relief valve opening and the logic cartridge shifting occurs several times in a very short time
frame as the blades finally come to a stop. Once the
blades have stopped, logic cartridge LC2 remains in the
neutral position to keep the deck motor from rotating.

DECK MANIFOLD

RV1

RV2

LC1

DECK
MOTOR
S
M2

LC2
P2

Figure 10
DECK MANIFOLD

RV1

RV2

LC1
DECK
MOTOR
S
M2

LC2
P2

Figure 11
DECK MANIFOLD

RV1

RV2

LC1

DECK
MOTOR
S
M2

LC2
P2

Figure 12

Hydraulic System

Page 4 -- 20

Groundsmaster 4100--D

Hydraulic
System

This page is intentionally blank.

Groundsmaster 4100--D

Page 4 -- 21

Hydraulic System

Page 4 -- 22

Groundsmaster 4100--D

LC2

RV2

LC2

RH PTO
MANIFOLD

RV2

LH PTO
MANIFOLD

RV2

FRONT PTO
MANIFOLD

RV1

LC1

Working Pressure
Low Pressure (Charge)
Return or Suction
Flow

Groundsmaster 4100--D
Steering Circuit (Left Turn Shown)

FAN DRIVE
MANIFOLD

4WD
MANIFOLD

COUNTERBALANCE
MANIFOLD

Steering Circuit
A four section gear pump is coupled to the piston (traction) pump. The third gear pump section supplies hydraulic flow to the steering control valve and the lift/lower
control valve. Pump hydraulic flow is delivered to the two
circuits through a proportional flow divider located in the
fan drive manifold. The gear pump takes its suction from
the hydraulic reservoir. Steering circuit pressure is limited to 1350 PSI (93 bar) by a relief valve located in the
steering control.

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 spool valve then
through the T port and to the hydraulic reservoir.
The steering control valve returns to the neutral position
when turning is completed.

With the steering wheel in the neutral position and the
engine running, flow enters the steering control valve at
the P port and goes through the steering control spool
valve, by--passing the rotary meter (V1) and steering
cylinder. Flow leaves the control valve through the PB
port to the oil filter and traction charge circuit.

When a right turn is made with the engine running, the
turning of the steering wheel positions the spool valve so
that flow goes through the bottom of the spool. Flow entering the steering control valve at the P port goes
through the spool and is routed to two places. As in a left
turn, most of the flow through the valve is by--passed out
the PB port back to the oil filter and traction charge circuit. Also like a left turn, the remainder of the flow is
drawn through rotary meter (V1) but goes out port R.
Pressure extends the steering cylinder piston 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
steering wheel. Fluid leaving the cylinder flows back
through the spool valve then through the T port and to
the hydraulic reservoir.

Left Turn
When a left turn is made with the engine running, the
turning of the steering wheel positions the spool valve so
that flow goes through the top of the spool. Flow entering
the steering control valve at the P port goes through the
spool and is routed to two places. First, most of the flow
through the valve is by--passed out the PB port back to
the oil filter and traction charge circuit. Second, the remainder of the flow is drawn through the rotary meter
(V1) and out the L port. Pressure contracts the steering
cylinder piston for a left turn. The rotary meter ensures

The steering control valve returns to the neutral position
when turning is completed.

STEERING CYLINDER

NO PISTON MOVEMENT

PISTON MOVEMENT

1350
PSI
T

1350
PSI
STEERING
CONTROL

NEUTRAL POSITION

1350
PSI
STEERING
CONTROL

LEFT TURN

STEERING
CONTROL

RIGHT TURN

Figure 13

Groundsmaster 4100--D

Page 4 -- 23

Hydraulic System

Hydraulic
System

Right Turn

Hydraulic System

Page 4 -- 24

Groundsmaster 4100--D

LC2

RV2

LC2

RH PTO
MANIFOLD

RV2

LH PTO
MANIFOLD

RV2

FRONT PTO
MANIFOLD

RV1

LC1

Working Pressure
Low Pressure (Charge)
Return or Suction
Flow

Groundsmaster 4100--D
Engine Cooling Fan Circuit (Forward Direction Shown)

FAN DRIVE
MANIFOLD

4WD
MANIFOLD

COUNTERBALANCE
MANIFOLD

Engine Cooling Fan Circuit

The fan drive manifold controls the operation of the hydraulic motor that drives the engine cooling fan in addition to including the flow divider for the steering and lift
circuits. The electronically controlled proportional relief
valve (PRV) in the manifold controls the oil flow to the fan
motor. The fan drive manifold controls the speed and direction of the fan motor based on electrical output from
the TEC--5002 controller.

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
cooling fan to run in reverse. The controller determines
the length of time that the fan should be run in reverse
before fan rotation is returned to the forward direction.
2

Oil flow from the gear pump to the cooling fan motor is
controlled by the proportional relief valve (PRV) in the
fan drive manifold. This valve adjusts fan circuit pressure and flow based on a PWM (Pulse Width Modulation) signal from the TEC--5002 controller. The controller
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 cooling fan.
If the fan motor is stalled for any reason, the manifold
proportional relief valve (PRV) has a secondary function
as a circuit relief to limit fan motor pressure to 3000 PSI
(207 bar).
When the engine is shut off, the over--running inertia
load of the fan blades keeps driving the fan motor and
turns it into a pump. The check valve (CV) in the fan drive
manifold will open to keep the motor circuit full of oil so
the fan motor will not cavitate.

Hydraulic
System

A four section gear pump is coupled to the piston (traction) pump. The gear pump section farthest from the piston pump supplies hydraulic flow for the fan drive
manifold and hydraulic engine cooling fan motor (Fig.
14).

1
Figure 14
1. Gear pump

2. Fan drive manifold

REVERSE DIRECTION SHOWN
TO RESERVOIR
TO STEERING
CIRCUIT

Forward Direction Fan Operation

TO LIFT/LOWER
CIRCUIT

Oil flow from the gear pump is sent through the de--energized solenoid valve (S1) to rotate the cooling fan motor.
Return flow from the motor re--enters the manifold (port
M2), through the de--energized solenoid valve (S1), out
of the manifold (port T) and then is routed through the oil
cooler and oil filter.
Reverse Direction Fan Operation (Fig. 15)
The TEC--5002 controller can reverse the cooling fan to
clean debris from the radiator, oil cooler and 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 pump oil flow to the reservoir. The controller then
energizes solenoid valve (S1) in the fan drive manifold
to reverse cooling fan motor oil flow so that the motor

Groundsmaster 4100--D

Page 4 -- 25

FAN DRIVE
MANIFOLD

FROM GEAR PUMP
TO OIL COOLER

Figure 15

Hydraulic System

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 Testing section of this chapter.
Toro Part Number: TOR47009

Figure 16

Hydraulic Tester (Pressure and Flow)
This tester requires O--ring Face Seal (ORFS) adapter
fittings for use on this machine (see Hydraulic Test Fitting Kit -- TOR4079 in this section).
1. INLET HOSE: Hose connected from the system circuit 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. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI
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 (5 to 55 LPM).

Figure 17

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 included with this kit.
Toro Part Number: TOR214678

Hydraulic System

Page 4 -- 26 Rev. A

Groundsmaster 4100--D

Hydraulic Test Fitting Kit
This kit includes a variety of O--ring Face Seal fittings to
enable you to connect test gauges into the system.

TORO TEST FITTING KIT (NO. TOR4079)

The kit includes: tee’s, unions, reducers, plugs, caps
and male test fittings.
Toro Part Number: TOR4079

Figure 18

Measuring Container
Hydraulic
System

Use this container for doing hydraulic motor efficiency
testing (motors with case drain lines only). Measure efficiency 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 20 provides gallons per minute
(GPM) conversion for measured milliliter or ounce motor
case drain leakage.
Toro Part Number: TOR4077
Figure 19

Figure 20

Groundsmaster 4100--D

Page 4 -- 27

Hydraulic System

Troubleshooting
The charts that follow contain suggestions to assist in
troubleshooting. There may possibly be more than one
cause for a machine malfunction.
Refer to the Testing section of this Chapter for precautions and specific test procedures.

NOTE: When troubleshooting traction problems on the
Groundsmaster 4100--D, if a problem exists in both
4WD and transport speeds, consider a faulty component that affects the entire traction circuit (e.g. charge
circuit, relief valves, piston pump, front wheel motors).
If the problem exists in 4WD but not in transport, consider a problem in the 4WD traction system (e.g. rear axle
motor, 4WD manifold).

Problem

Possible Cause

Hydraulic system operates hot.

Engine RPM is too low.

NOTE: An indication that the hydraulic system is operating at excessive temperatures would be frequent
reversing of the cooling fan and a
normal engine coolant temperature.

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) or motor(s) are damaged.

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.

Machine operates in one direction
only.

Traction control linkage is faulty.

Traction pedal is sluggish.

Traction control linkage is stuck or binding.

Traction relief valve is defective.

Charge pressure is low.
Piston (traction) pump servo control valve orifices are plugged or
damaged.
4WD manifold PD1 and PD2 pilot directional valves seals are leaking
or damaged.
Machine travels too far before stopping when the traction pedal is released.

Traction linkage is out of adjustment.
Charge pressure is low.
Piston (traction) pump servo control valve orifices are plugged or damaged.
Traction pedal does not return to neutral.

Hydraulic System

Page 4 -- 28

Groundsmaster 4100--D

Problem

Possible Causes

Traction power is lost or unit will not
operate in either direction.

Hydraulic reservoir oil level is low.
Piston pump by--pass valve is open or damaged.
Charge pressure is low.
Traction circuit pressure is low.
Front wheel motor couplers are damaged.

Four wheel drive will not engage.

Electrical problem exists (see Chapter 5 -- Electrical System).
Solenoid valve (SV) in 4WD hydraulic manifold is faulty.
Cartridge valve(s) in 4WD manifold is faulty.
Drive gear on rear axle motor or driven gear for rear axle is loose or
damaged.

Four wheel drive will not disengage.

Electrical problem exists (see Chapter 5 -- Electrical System).
Solenoid valve (SV) in 4WD hydraulic manifold is faulty.
Cartridge valve in 4WD manifold is damaged or sticking.

No cutting decks will operate.

Electrical problem exists (see Chapter 5 -- Electrical System).
Gear pump or its coupler is damaged (Note: other hydraulic circuits
impacted as well).

One cutting deck will not operate.

Electrical problem exists (see Chapter 5 -- Electrical System).
System pressure to the affected deck is low.
Woodruff key on affected deck motor is damaged.
Solenoid valve (S) in deck manifold is faulty.
Cartridge valve in deck manifold is damaged or sticking.
Deck motor or gear pump section is damaged.

All cutting decks operate slowly.

Engine RPM is low.
Deck motor or gear pump sections are damaged.

Cutting deck stops under load.

Relief valve in deck manifold is by--passing.
Deck motor has internal leakage (by--passing oil).
Cutting deck gear pump section is inefficient.

Groundsmaster 4100--D

Page 4 -- 29

Hydraulic System

Hydraulic
System

Rear axle motor is damaged.

Problem

Possible Causes

Cutting deck (or wing decks) will not
raise.

Engine RPM is too low.
Hydraulic oil level in reservoir is low.
Lift arm pivots are binding.
Relief valve in lift/lower control valve is stuck.
Pilot valve in lift/lower control valve is damaged or sticking.
Lift cylinder(s) is (are) damaged.
Gear pump section for lift/lower control valve is inefficient.

Cutting deck (or wing decks) raise,
but will not stay up.
NOTE: Lift cylinders cannot provide
an absolutely perfect seal. The cutting deck will eventually lower if left
in the raised position during storage.

Lift circuit lines or fittings are leaking.
Lift cylinder is damaged.
Detents in lift/lower control valve are worn.

Front cutting deck drops too fast or
too slow.

Flow control valve is not adjusted properly.

Cutting deck (or wing decks) will not
lower.

Lift arm pivots are binding.
Counterbalance pressure is excessive.
Pilot valve in lift/lower control valve is damaged or sticking.
Lift cylinder is damaged.
Lift/lower control valve is worn or damaged.

Hydraulic System

Page 4 -- 30

Groundsmaster 4100--D

Testing

Before Performing Hydraulic Tests
IMPORTANT: All obvious areas such as oil supply,
filter, binding linkages, loose fasteners or improper
adjustments must be checked before assuming that
a hydraulic component is the source of the problem.
Precautions for Hydraulic Testing

CAUTION
Failure to use gauges with recommended pressure (PSI) rating as listed in test procedures
could result in damage to the gauge and possible
personal injury from leaking hot oil.

CAUTION
All testing should be performed by two (2)
people. One person should be in the seat to operate the machine and the other should read and
record test results.

CAUTION
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the
ignition switch in OFF. Remove key from the ignition switch.

WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved and all rotating machine parts must be stopped. Stop engine;
lower or support attachments.
1. Clean machine thoroughly before disconnecting or
disassembling any hydraulic components. Always keep
in mind the need for cleanliness when working on hydraulic equipment. Contamination will cause excessive
wear of hydraulic components.
2. Put metal caps or plugs on any hydraulic lines left
open or exposed during testing or removal of components.
3. The engine must be in good operating condition. Use
a phototac when performing a hydraulic test. Engine
speed can affect the accuracy of the tester readings.
Check actual speed of the pump when performing flow
testing.
4. The inlet and the outlet hoses for tester with pressure
and flow capabilities must be properly connected and
not reversed to prevent damage to the hydraulic tester
or components.
5. When using hydraulic tester with pressure and flow
capabilities, open load valve completely in the tester to
minimize the possibility of damaging components.
6. Install fittings finger tight and far enough to make
sure that they are not cross--threaded before tightening
them with a wrench.
7. Position tester hoses to prevent rotating machine
parts from contacting and damaging the hoses or tester.
8. Check oil level in the hydraulic reservoir. After connecting test equipment, make sure tank is full.

WARNING
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Do not use hands to search for
leaks; use paper or cardboard. Hydraulic fluid
escaping under pressure can have sufficient
force to penetrate the skin and cause serious
injury. If fluid is injected into the skin, it must
be surgically removed within a few hours by a
doctor familiar with this type of injury. Gangrene may result from such an injury.
Groundsmaster 4100--D

9. Check control linkages for improper adjustment,
binding or broken parts.
10.After installing test gauges, run engine at low speed
and check for any hydraulic oil leaks.
11. All hydraulic tests should be made with the hydraulic
oil at normal operating temperature.
12.Before returning machine to use, make sure that hydraulic reservoir has correct fluid level. Also, check for
hydraulic leaks after test equipment has been removed
from hydraulic system.

Page 4 -- 31

Hydraulic System

Hydraulic
System

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).

Traction Circuit Charge Pressure (Using Pressure Gauge)

FROM COUNTERBALANCE
MANIFOLD

4WD
MANIFOLD

FROM FRONT DECK
CYLINDERS

FILTER
MANIFOLD

PRESSURE
GAUGE

FROM STEERING VALVE PORT PB
FROM STEERING VALVE PORT T
FROM FRONT PTO MANIFOLD
TO MOW CIRCUIT
TO MOW CIRCUIT
TO STEERING & LIFT CIRCUITS

Hydraulic System

Page 4 -- 32

FROM DECK MANIFOLDS AND FAN MOTOR

FROM DECK MANIFOLDS

TO COOLING FAN CIRCUIT

Groundsmaster 4100--D

Procedure for Traction Circuit Charge Pressure Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
1

2. Park machine on a level surface with the cutting deck
lowered and off. Make sure engine is off and the parking
brake is engaged. Raise and support operator seat.

CAUTION
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning
of this section.

3. Connect a 1000 PSI (70 bar) gauge onto charge
pressure test port (Fig. 21) under operator seat.

2. Filter manifold

5. Operate the engine at full engine speed (2870 RPM)
with no load on the hydraulic system.
GAUGE READING TO BE 200 to 300 PSI (13.8 to
20.6 bar).
6. Stop engine and record test results.
7. If there is no pressure, or pressure is low, check for
restriction in pump intake line. Also, inspect charge relief
valve located in filter manifold (see Hydraulic Manifold
Service: Filter Manifold in the Service and Repairs section of this chapter). If necessary, check for internal damage or worn parts in gear pump.
8. Also, 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 full engine speed (2870 RPM).
Apply the brakes and push the traction pedal forward,
then reverse.
GAUGE READING TO BE 200 to 300 PSI (13.8 to
20.6 bar).
9. If charge pressure is good under no load, but consistently drops below specification when under traction
load, the piston (traction) pump and/or traction motor(s)
should be suspected of wear and inefficiency. When the
pump and/or traction motor(s) are worn or damaged, the
charge pump is not able to keep up with internal leakage
in traction circuit components.
10.When testing is completed, disconnect pressure
gauge from test port.
Groundsmaster 4100--D

Page 4 -- 33

Hydraulic System

Hydraulic
System

4. After installing pressure gauge, start engine and run
at idle speed. Check for hydraulic leakage and correct
before proceeding with test.

Figure 21
1. Charge pressure port

Traction Circuit Relief Pressure (Using Pressure Gauge)

FORWARD TRACTION CIRCUIT RELIEF PRESSURE TEST SHOWN

FROM COUNTERBALANCE
MANIFOLD

4WD
MANIFOLD

FROM FRONT DECK
CYLINDERS

FILTER
MANIFOLD

PRESSURE
GAUGE

FROM STEERING VALVE PORT PB
FROM STEERING VALVE PORT T
FROM FRONT PTO MANIFOLD
TO MOW CIRCUIT
TO MOW CIRCUIT

FROM DECK MANIFOLDS

TO COOLING FAN CIRCUIT

Hydraulic System

Page 4 -- 34

FROM DECK MANIFOLDS AND FAN MOTOR

TO STEERING & LIFT CIRCUITS

Groundsmaster 4100--D

Procedure for Traction Circuit Relief Pressure Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.

9. When testing is completed, disconnect pressure
gauge from test port.

CAUTION
1

Move machine to an open area, away from people
and obstructions.
2. Drive machine to an open area, lower cutting deck,
turn the engine off and engage the parking brake.

Figure 22
1. Forward traction port

2. LH front tire

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning
of this section.

Hydraulic
System

3. Connect a 10,000 PSI (700 bar) gauge to traction circuit test port for function to be checked (Forward or Reverse: Fig. 22 or 23).
4. After installing pressure gauge, start engine and run
at idle speed. Check for hydraulic leakage and correct
before proceeding with test.

Figure 23
1. Reverse traction port

5. Operate the engine at full speed (2870 RPM). Make
sure that transport/4WD switch is in the transport position.

RIGHT
FRONT

6. Sit on seat, apply brakes fully and slowly depress the
traction pedal in the appropriate direction. While pushing traction pedal, look at pressure reading on gauge:

2. RH front tire

GAUGE READING TO BE:
Forward: 3750 to 4250 PSI (259 to 293 bar)
Reverse: 4750 to 5250 PSI (328 to 362 bar)

7. Release traction pedal and stop engine. Record test
results.
8. If traction pressure is too low, inspect traction pump
relief valves (Fig. 24). Clean or replace 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.

Figure 24
1. Forward relief valve
2. Reverse relief valve

3. Traction pump

NOTE: Seal leakage across pilot directional valves
PD1 and PD2 in 4WD manifold can also cause low forward traction pressure with reverse pressure meeting
specifications.
Groundsmaster 4100--D

Page 4 -- 35

Hydraulic System

Page 4 -- 36

FROM FRONT DECK MANIFOLD

FROM RH DECK
CIRCUIT

FROM RH DECK
MANIFOLD

TO MOW CIRCUIT

FROM DECK MANIFOLDS

FAN DRIVE
MANIFOLD

FILTER
MANIFOLD

4WD
MANIFOLD

COUNTERBALANCE
MANIFOLD

Counterbalance Pressure (Using Pressure Gauge)

PRESSURE
GAUGE

FROM DECK MOTORS

Groundsmaster 4100--D

Procedure for Counterbalance Pressure Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
2. Park machine on a level surface with the cutting deck
lowered and off. Make sure engine is off and the parking
brake is engaged. Remove console cover.

CAUTION

C. To decrease pressure setting, turn the adjustment screw on the valve in a counterclockwise direction. A 1/8 turn on the screw will make a measurable
change in counterbalance pressure.
D. Tighten locknut to secure adjustment. After adjustment, recheck counterbalance pressure. Readjust as needed.
9. When testing is completed, disconnect pressure
gauge from test port.
4

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning
of this section.

4. Connect a 1000 PSI (70 bar) gauge to counterbalance test port on manifold under console (Fig. 25).

5. After installing pressure gauge, start engine and run
at idle speed. Check for hydraulic leakage and correct
before proceeding with test.
6. Operate the engine at full engine speed (2870 RPM)
with no load on the system. Do not engage the cutting
deck.

Hydraulic
System

3. Determine system charge pressure (see Traction
Circuit Charge Pressure in this chapter).

Figure 25
1. Counterbalance test port
2. Counterbalance valve

3. Locknut
4. Adjusting screw

GAUGE READING TO BE 225 PSI (15.5 bar) over
system charge pressure (e.g. if charge pressure is
250 PSI (17.2 bar), counterbalance pressure should
be 475 PSI (32.7 bar)).
7. Stop the engine and record test results.
8. Adjustment of the counterbalance valve can be performed as follows:
NOTE: Do not remove the counterbalance valve
from the hydraulic manifold for adjustment.
A. Loosen locknut on counterbalance valve (Fig.
25).
B. To increase pressure setting, turn the adjustment screw on the valve in a clockwise direction. A
1/8 turn on the screw will make a measurable change
in counterbalance pressure.

Groundsmaster 4100--D

Page 4 -- 37

Hydraulic System

Rear Traction Circuit (RV) Relief Pressure (Using Pressure Gauge)

FROM COUNTERBALANCE
MANIFOLD

PRESSURE
GAUGE

FROM FRONT DECK

FILTER
MANIFOLD

4WD
MANIFOLD

CYLINDERS

FROM STEERING VALVE PORT PB
FROM STEERING VALVE PORT T
FROM FRONT PTO MANIFOLD
TO MOW CIRCUIT
TO MOW CIRCUIT
TO STEERING & LIFT CIRCUITS

Hydraulic System

Page 4 -- 38

FROM DECK MANIFOLDS AND FAN MOTOR

FROM DECK MANIFOLDS

TO COOLING FAN CIRCUIT

Groundsmaster 4100--D

Procedure for Rear Traction Circuit (RV) Relief Pressure Test

8. When testing is completed, disconnect pressure
gauge from test port.

1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.

2. Park machine on a level surface with the cutting deck
lowered and off. Make sure engine is off and the parking
brake is engaged.

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning
of this section.

Figure 26
1. 4WD control manifold
2. Relief valve test port

3. Connect a 1000 PSI (70 bar) gauge to test port on
4WD control manifold under radiator (Fig. 26).

Hydraulic
System

4. After installing pressure gauge, start engine and run
at idle speed. Check for hydraulic leakage and correct
before proceeding with test.
5. Operate the engine at full engine speed (2870 RPM).
6. Operate the machine in 4WD (not transport speed)
with the cutting deck lowered. Drive down a slope in a
forward direction, decrease pressure on the traction
pedal and monitor the pressure gauge. Pressure should
increase until the relief valve (RV) lifts. Record test results.

1
Figure 27
1. Manifold: lower side

2. Relief valve (RV)

GAUGE READING TO BE 750 PSI (52 bar)
(approximate).
7. Relief valve (RV) is located on the lower, front side
of the 4WD control manifold (Fig. 27). Adjustment of the
relief valve can be performed as follows:
1

NOTE: Do not remove the relief valve from the hydraulic manifold for adjustment.
A. To increase relief pressure setting, remove cap
on relief valve and turn the adjustment socket on the
relief valve in a clockwise direction. A 1/8 turn on the
socket will make a measurable change in relief pressure (Fig. 28).
2

B. To decrease pressure setting, remove cap on relief valve and turn the adjustment socket on the relief
valve in a counterclockwise direction. A 1/8 turn on
the socket will make a measurable change in relief
pressure (Fig. 28).
C. Recheck relief pressure and readjust as needed.

Figure 28
1.

Groundsmaster 4100--D

Page 4 -- 39

Relief valve cap

Adjustment socket

Hydraulic System

Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge)

FROM COUNTERBALANCE
MANIFOLD

PRESSURE
GAUGE

FROM FRONT DECK

FILTER
MANIFOLD

4WD
MANIFOLD

CYLINDERS

FROM STEERING VALVE PORT PB
FROM STEERING VALVE PORT T
FROM FRONT PTO MANIFOLD
TO MOW CIRCUIT
TO MOW CIRCUIT
TO STEERING & LIFT CIRCUITS

Hydraulic System

Page 4 -- 40

FROM DECK MANIFOLDS AND FAN MOTOR

FROM DECK MANIFOLDS

TO COOLING FAN CIRCUIT

Groundsmaster 4100--D

Procedure for Traction Circuit Reducing Valve (PR)
Pressure Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.

C. Recheck reducing valve (PR) pressure setting
and readjust as needed.
9. Disconnect pressure gauge from test port.
1

2. Park machine on a level surface with the cutting deck
lowered and off. Make sure engine is off and the parking
brake is engaged.

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning
of this section.

Figure 29

3. Connect a 1000 PSI (70 bar) gauge to test port on
4WD control manifold under radiator (Fig. 29).
4. After installing pressure gauge, start engine and run
at idle speed. Check for hydraulic leakage and correct
before proceeding with test.

Hydraulic
System

1. 4WD control manifold
2. Pressure test port

5. Operate the engine at full engine speed (2870 RPM).
Make sure that transport/4WD switch is in the 4WD position.

6. Sit on seat, apply brakes fully and slowly depress the
traction pedal in the reverse direction. While pushing
traction pedal, look at pressure reading on gauge:
GAUGE READING TO BE 650 PSI (45 bar)
(approximate).

Figure 30
1. Manifold: front side

2. Reducing valve (PR)

7. Stop engine and record test results.
8. Pressure reducing valve (PR) is located on the front
side of the 4WD control manifold (Fig. 30). Adjustment
of this valve can be performed as follows:
NOTE: Do not remove the pressure reducing valve
from the hydraulic manifold for adjustment.
A. To increase pressure setting, remove cap on reducing valve and turn the adjustment socket on the
valve in a clockwise direction. A 1/8 turn on the socket will make a measurable change in pressure setting.
B. To decrease pressure setting, remove cap on reducing valve and turn the adjustment socket on the
valve in a counterclockwise direction. A 1/8 turn on
the socket will make a measurable change in pressure setting.

Groundsmaster 4100--D

Page 4 -- 41

Hydraulic System

Page 4 -- 42

LC2

RV1

RV2

LC2

RV1

RH WING DECK
MANIFOLD

RV2

LC1

FROM COOLING
FAN CIRCUIT

TO COOLING FAN CIRCUIT

TO STEERING & LIFT CIRCUITS

FILTER
MANIFOLD

FROM REAR AXLE MOTOR

CHARGE CIRCUIT

FROM FRONT WHEEL MOTORS

FROM 4WD MANIFOLD

TRACTION CIRCUIT FLOW

NOTE: CENTER DECK PRESSURE TEST SHOWN

LC2

RV1

LH WING DECK
MANIFOLD

RV2

PRESSURE
GAUGE

CENTER DECK
MANIFOLD

Cutting Deck Circuit Pressure (Using Pressure Gauge)

Groundsmaster 4100--D

Procedure for Cutting Deck Circuit Pressure Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
2. Park machine on a level surface with the cutting deck
lowered and off. Make sure engine is off and the parking
brake is engaged.

CAUTION

2
1

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning
of this section.

Figure 31
1. Center deck hydraulic manifold
2. Center deck circuit pressure test port

Hydraulic
System

3. Install 5000 PSI (350 bar) pressure gauge with hydraulic hose attached to deck manifold test port for the
deck to be tested (Fig. 31, 32 and 33).
4. After installing pressure gauge, start engine and run
at idle speed. Check for hydraulic leakage and correct
before proceeding with test.
1

CAUTION
Keep away from deck during test to prevent personal injury from the cutting blades.
5. Operate engine at full speed (2870 RPM). Engage
the cutting deck.

Figure 32
1. Right wing deck circuit pressure test port

6. Watch pressure gauge carefully while mowing with
the machine.
7. 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)
RH Wing Deck: 1000 to 2000 PSI (69 to 137 bar)
8. Disengage cutting deck and shut off engine. Record
test results.
1

9. When testing is completed, disconnect test gauge
with hose from manifold test port.
Figure 33

1. Left wing deck circuit pressure test port

Groundsmaster 4100--D

Page 4 -- 43

Hydraulic System

TESTER

Hydraulic System

Page 4 -- 44

LC2

RV2

LC2

RH WING DECK
MANIFOLD

RV2

RV1

LH WING DECK
MANIFOLD

RV2

LC1

FROM COOLING
FAN CIRCUIT

TO COOLING FAN CIRCUIT

TO STEERING & LIFT CIRCUITS

FILTER
MANIFOLD

FROM REAR AXLE MOTOR

CHARGE CIRCUIT

FROM FRONT WHEEL MOTORS

FROM 4WD MANIFOLD

TRACTION CIRCUIT FLOW

CENTER DECK PTO RELIEF PRESSURE TEST SHOWN

CENTER DECK
MANIFOLD

PTO Relief Pressure (Using Tester with Pressure Gauges and Flow Meter)

Groundsmaster 4100--D

1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
2. Park machine on a level surface with the cutting deck
lowered and off. Make sure engine is off and the parking
brake is engaged.

CAUTION
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning
of this section.
3. Locate deck manifold to be tested (Fig. 34). Disconnect hydraulic hose at deck manifold port (M1).
NOTE: An alternative to using manifold port (M1) would
be to disconnect the inlet hydraulic hose at deck motor.

11. If specification is not met, adjust or clean relief valve
in deck manifold port (RV1). Adjust relief valve as follows:
NOTE: Do not remove valve from the hydraulic
manifold for adjustment.
A. Remove cap on relief valve with an allen wrench.
B. To increase pressure setting, turn the adjustment screw on the valve in a clockwise direction. A
1/8 turn on the screw will make a measurable change
in relief pressure.
C. To decrease pressure setting, turn the adjustment screw on the valve in a counterclockwise direction. A 1/8 turn on the screw will make a measurable
change in relief pressure.
D. Install and tighten cap to secure adjustment. Recheck relief pressure and readjust as needed.
12.Disconnect tester from manifold and hose. Reconnect hydraulic hose that was disconnected for test procedure.

4. Install tester with pressure gauges and flow meter in
series with the the disconnected hose and hydraulic
manifold port (M1) (or motor inlet if hose was disconnected at deck motor).

TO OIL COOLER

RIGHT
FRONT

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

CAUTION
Keep away from deck during test to prevent personal injury from the cutting blades.
7. Operate engine at full speed (2870 RPM). Engage
the cutting deck.

Figure 34
1. Center deck manifold
2. LH wing deck manifold

3. RH wing deck manifold

FRONT DECK MANIFOLD SHOWN
1

8. Watch pressure gauge carefully while slowly closing
the flow control valve to fully closed.
9. As the relief valve lifts, system pressure should be
approximately:

2900 to 3100 PSI (200 to 213 bar) for the center
deck and LH wing deck
1900 to 2100 PSI (131 to 144 bar) for the RH wing
deck

1. Deck manifold
2. Relief valve

10.Disengage cutting deck. Shut off engine and record
test results.
Groundsmaster 4100--D
Page 4 -- 45

Figure 35

3. Relief valve cap

Hydraulic System

Hydraulic
System

Procedure for Cutting Deck Manifold Relief
Pressure Test

Hydraulic System

Page 4 -- 46

LC2

RV1

LC2

RV1

RV2

LC2

RV1

RH WING DECK
MANIFOLD

RV2

LH WING DECK
MANIFOLD

RV2

LC1

FROM COOLING
FAN CIRCUIT

TO COOLING FAN CIRCUIT

TO STEERING & LIFT CIRCUITS

FILTER
MANIFOLD

FROM REAR AXLE MOTOR

CHARGE CIRCUIT

FROM FRONT WHEEL MOTORS

FROM 4WD MANIFOLD

TRACTION CIRCUIT FLOW

NOTE: CENTER GEAR PUMP
SECTION FLOW TEST SHOWN

CENTER DECK
MANIFOLD

Cutting Deck Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter)

TESTER

Groundsmaster 4100--D

Procedure for Cutting Deck Gear Pump Flow Test
NOTE: Over a period of time, the gears and wear plates
in the gear pump can wear. A worn pump will by--pass
oil and make the pump less efficient. Eventually, enough
oil loss will occur to cause the cutting deck motors to stall
under heavy cutting conditions. Continued operation
with a worn, inefficient pump can generate excessive
heat and cause damage to the seals and other components in the hydraulic system.
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
2. Park machine on a level surface with the cutting deck
lowered and off. Make sure engine is off and the parking
brake is engaged.

CAUTION

IMPORTANT: Do not fully restrict oil flow through
tester. In this test, the flow tester is positioned before the relief valve. Pump damage can occur if the
oil flow is fully restricted.
8. Watch pressure gauge carefully while slowly closing
the flow control valve until 2000 PSI is obtained. Verify
with a phototac that the engine speed is 2400 RPM.
9. For a normal pump, gear pump flow should be
approximately 14 GPM. Shut off engine. Record test results.
10.If measured flow is less than 12 GPM or if a pressure
of 2000 PSI cannot be obtained, check for restriction in
the pump intake line. If line is not restricted, remove gear
pump and repair or replace as necessary.
11. Disconnect flow tester from hydraulic hose and manifold port. Reconnect hose to the manifold.

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning
of this section.

TO OIL COOLER

RIGHT
FRONT

3. Locate deck manifold for gear pump section to be
tested. Disconnect hydraulic hose at deck manifold port
(P1) (Fig. 36).
3

4. Install tester with pressure gauges and flow meter in
series with the the disconnected hose and hydraulic
manifold port (P1).

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

Figure 36
1. Center deck manifold
2. Hyd. hose to front P1

3. LH wing deck manifold
4. Hyd. hose to side P1

IMPORTANT: Do not run engine at full speed during
testing. At full engine speed, cutting deck gear
pump output can exceed 15 GPM and cause tester
damage.
7. Using a phototac, adjust engine speed to 2400 RPM.
Do not engage the cutting deck.

Groundsmaster 4100--D

Page 4 -- 47

Hydraulic System

Hydraulic
System

12.Repeat test for second pump section if required.

Hydraulic System

Page 4 -- 48

LC2

RV2

LC2

RV1

RH WING DECK
MANIFOLD

RV2

LC2

RV1

LC1

FROM COOLING
FAN CIRCUIT

TO COOLING FAN CIRCUIT

TO STEERING & LIFT CIRCUITS

FILTER
MANIFOLD

FROM REAR AXLE MOTOR

CHARGE CIRCUIT

FROM FRONT WHEEL MOTORS

FROM 4WD MANIFOLD

TRACTION CIRCUIT FLOW

CENTER CUTTING DECK MOTOR
CASE DRAIN LEAKAGE TEST SHOWN

RV2

LH WING DECK
MANIFOLD

CENTER DECK
MANIFOLD

Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauges and Flow
Meter)

TRACTION CIRCUIT FLOW

TESTER

MEASURING
CONTAINER

CAP

Groundsmaster 4100--D

Procedure for Cutting Deck Motor Case Drain
Leakage Test

6. Sit on seat and operate the engine at full speed (2870
RPM). Move PTO switch to ON.

NOTE: Over a period of time, a deck motor can wear internally. 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 hydraulic system and affect quality of cut.

7. While watching pressure gauge, slowly close flow
control valve on tester until a pressure of 1200 PSI (83
bar) is obtained.

8. Have another person measure flow from the case
drain line for 15 seconds, then move the PTO switch to
OFF. Open the tester flow control valve and stop the engine. Record test results.
TEST RESULTS: Flow less than 22.2 ounces (662
ml).
9. If flow is more than 22.2 ounces (662 ml), the motor
is worn or damaged and should be repaired or replaced.
10.After testing is completed, disconnect tester from
motor and hose. Reconnect hose to the deck motor. Remove cap from machine fitting and reconnect case drain
hose.
11. If required, repeat test procedure for other deck motors.

CAUTION
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning
of this section.

NOTE: The wing deck motors are connected in series.
To isolate a faulty motor, both motors in the circuit may
have to be tested by starting with the left side motor first.
3. Disconnect return hose from the motor to be tested
(Fig. 37). Install flow tester in series with the motor and
the disconnected return hose. Make sure the flow control valve on tester is fully open.
4. Disconnect the motor case drain hose (small diameter hose) where it connects to the machine (not at the
motor). Put a steel cap on the fitting; leave the case drain
hose open (Fig. 38).

Figure 37
1. Deck motor (RH shown)
2. Return hose

3. Case drain hose

5. After installing flow tester, start engine and run at idle
speed. Check for hydraulic leakage and correct before
proceeding with test.

CAUTION
Cutting deck blades will rotate with PTO switch
in ON position. Keep away from cutting deck during test to prevent personal injury from rotating
blades. Do not stand in front of the machine.
Groundsmaster 4100--D

Page 4 -- 49 Rev. A

Figure 38
Hydraulic System

Hydraulic
System

NOTE: One method to find a failing or malfunctioning
deck motor is to have another person observe the machine while mowing in dense turf. A bad deck motor will
run slower, produce fewer clippings and may cause a
different appearance on the turf.

NOTE: Use a graduated container, special tool
TOR4077, to measure case drain leakage (Fig. 38).

Steering Circuit Relief Pressure (Using Pressure Gauge)

FROM COUNTERBALANCE MANIFOLD

FILTER
MANIFOLD

4WD
MANIFOLD

FROM FRONT DECK LIFT CYLINDERS

TO LIFT/LOWER CONTROL VALVE

FAN DRIVE
MANIFOLD
P2
P1

ST
M2
M1

TO MOW CIRCUIT

FROM DECK MANIFOLDS

PRESSURE
GAUGE

Hydraulic System

Page 4 -- 50

FROM RH DECK
CIRCUIT

FROM FRONT DECK MANIFOLD

FROM RH DECK
MANIFOLD

FROM DECK MOTORS

Groundsmaster 4100--D

Procedure for Steering Circuit Relief Pressure Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
2. Park machine on a level surface with the cutting deck
lowered and off. Make sure engine is off and the parking
brake is engaged.
1

CAUTION
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning
of this section.

Figure 39

1. Steering circuit pressure test port

4. After installing pressure gauge, start engine and run
at idle speed. Check for hydraulic leakage and correct
before proceeding with test.

Hydraulic
System

3. Connect a 5000 PSI (350 bar) gauge onto steering
circuit pressure test port (Fig. 39).
1

5. Operate the engine at full engine speed (2870 RPM).
IMPORTANT: Hold steering wheel at full lock only
long enough to get a system pressure reading.
Holding the steering wheel against the stop for an
extended period will damage the steering motor.
2

6. Turn steering all the way in one direction and momentarily hold the steering wheel against resistance.
GAUGE READING TO BE 1300 to 1400 PSI (90 to
96 bar).
Figure 40

7. Stop the engine and record test results.

1. Steering tower

2. Steering relief valve

8. If pressure is incorrect, inspect steering relief valve
in control valve (Fig. 40). If steering relief valve is operating properly and if lift/lower problems also exist, gear
pump should be suspected of wear and inefficiency. If
steering wheel continues to turn at end of cylinder travel
(with lower than normal effort), steering cylinder or
steering valve should be suspected of wear or damage.
9. When testing is completed, disconnect pressure
gauge from test port.

Groundsmaster 4100--D

Page 4 -- 51

Hydraulic System

Page 4 -- 52

FROM FRONT DECK MANIFOLD

FROM RH DECK
CIRCUIT

FROM RH DECK
MANIFOLD

TO MOW CIRCUIT

FROM DECK MANIFOLDS

FAN DRIVE
MANIFOLD

FILTER
MANIFOLD

4WD
MANIFOLD

COUNTERBALANCE
MANIFOLD

Lift/Lower Circuit Relief Pressure (Using Pressure Gauge)

PRESSURE
GAUGE

FROM DECK MOTORS

Groundsmaster 4100--D

Procedure for Lift/Lower Circuit Relief Pressure
Test

NOTE: Before attempting to check or adjust lift pressure, make sure that counterbalance pressure is correctly adjusted.

4
1
Figure 41
1. Fan drive manifold
2. Lift circuit test port

3. Lift control valve
4. Relief valve

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning
of this section.

Hydraulic
System

CAUTION

3. Raise seat to gain access to hydraulic test fitting.
Connect a 5,000 PSI (345 bar) gauge to lift circuit test
port (Fig. 41). Route gauge hose to allow seat to be safely lowered.

4
5

4. After installing pressure gauge, start engine and run
at idle speed. Check for hydraulic leakage and correct
before proceeding with test.

5. Sit on the seat and operate the engine at full speed
(2870 RPM).
6. While sitting on the seat, pull lift lever back to raise
the cutting deck. Momentarily hold the lever with the lift
cylinder fully retracted (deck fully raised) while looking
at the gauge.
GAUGE READING TO BE 2500 to 2550 PSI (173 to
175 bar).

Figure 42
1. Control valve assembly
2. Relief valve assembly
3. Washers

4. Spring
5. Poppet

7. Stop the engine and record test results.
8. If pressure is too high, adjust relief valve in lift control
valve by rotating counterclockwise (Figure 42). If pressure is too low, check for restriction in pump intake line.
Check the lift cylinder for internal leakage. If cylinder is
not leaking, adjust the relief valve by rotating clockwise.
If pressure is still too low, pump or lift cylinder(s) should
be suspected of wear, damage or inefficiency.
9. When testing is completed, disconnect pressure
gauge from test port.

Groundsmaster 4100--D

Page 4 -- 53

Hydraulic System

FILTER
MANIFOLD

4WD
MANIFOLD

COUNTERBALANCE
MANIFOLD

Steering and Lift/Lower Gear Pump Flow (Using Tester with Pressure Gauges and Flow
Meter)

M2
M1

TO MOW CIRCUIT

FROM DECK MANIFOLDS

P2 FAN DRIVE
MANIFOLD

TESTER

Hydraulic System

Page 4 -- 54

FROM RH DECK
CIRCUIT

FROM FRONT DECK MANIFOLD

FROM RH DECK
MANIFOLD

FROM DECK MOTORS

Groundsmaster 4100--D

Procedure for Steering and Lift/Lower Gear Pump
Flow Test

5. Start the engine and move throttle to full speed (2870
RPM). DO NOT engage the cutting deck.

Output from the steering and lift/lower gear pump section is equally divided by a proportional valve to provide
flow to the steering circuit and the lift circuit. To test gear
pump flow, testing of both steering and lift/lower circuits
is required. Total gear pump flow is the combined flow
from the two circuits.

6. While watching pressure gauges, slowly close flow
control valve until 1000 PSI (69 bar) is obtained on
gauge. Verify engine speed continues to be 2870 RPM.

1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.

7. Stop engine and record test results.

2. Park machine on a level surface with the cutting deck
lowered and off. Make sure engine is off and the parking
brake is engaged. Raise seat.

GAUGE READING TO BE: Flow approximately 7
GPM (26.3 LPM) at 1000 PSI (69 bar).

8. If a pressure of 1000 PSI (69 bar) could not be obtained or flow is lower than 6 GPM (22.3 LPM) (85% of
expected flow), check for restriction in pump intake line.
If intake line is not restricted, consider that gear pump is
worn or damaged.

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning
of this section.

IMPORTANT: Make sure that the oil flow indicator
arrow on the flow gauge is showing that the oil will
flow from the pump section, through the tester and
into the hydraulic hose.

3. With the engine off and cutting deck lowered, disconnect the hydraulic hose from the 90o fitting in the third
gear pump section which supplies the steering and lift/
lower circuits (Fig. 43).
4. Install tester in series between the fitting and the disconnected hose. Make sure the tester flow control valve
is OPEN.
IMPORTANT: The pump is a positive displacement
type. If pump flow is completely restricted or
stopped, damage to the pump, tester or other components could occur.

Groundsmaster 4100--D

1
Figure 43
1. Gear pump
2. Fan drive manifold

Page 4 -- 55

3. Steering/lift hose
4. 90o fitting

Hydraulic System

Hydraulic
System

9. When testing is complete, remove tester and reconnect hose to pump fitting.

Hydraulic System

Page 4 -- 56

FROM RH PTO
CIRCUIT

FROM RH PTO
MANIFOLD

FROM FRONT PTO MANIFOLD

TO MOW MANIFOLD

FROM DECK MANIFOLDS

P2 FAN DRIVE
MANIFOLD

FILTER
MANIFOLD

4WD
MANIFOLD

COUNTERBALANCE
MANIFOLD

Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac)

FROM DECK MOTORS

Groundsmaster 4100--D

Procedure for Engine Cooling Fan Circuit Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.

2. Park machine on a level surface with the cutting
decks lowered and off. Make sure engine is off and the
parking brake is applied. Raise and support hood.

CAUTION
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning
of this section.

3. Test port

Hydraulic
System

3. Raise seat to gain access to cooling fan circuit test
port at the fan drive manifold (Fig. 44). Connect a 5,000
PSI (345 bar) gauge with hydraulic hose attached to test
port on top of manifold.

Figure 44
1. Fan drive manifold
2. PRV solenoid

4. Start the engine. Move throttle to full speed (2870
RPM).
5. While monitoring the pressure gauge and using a
phototac to identify the cooling fan speed, disconnect
the wire harness connector (white/green and black
wires) from the PRV solenoid on fan drive manifold. Both
fan speed and pressure should increase and stabilize
after the solenoid is disconnected.
PRESSURE GAUGE READING TO BE approximately 3000 PSI (207 bar).
PHOTOTAC READING TO BE: fan speed approximately 2800 RPM.
6. Stop engine and record test results.
7. If pressure rises to approximately 3000 PSI (207
bar) but fan speed is low, consider that the fan motor is
worn or damaged. If pressure and fan speed are both
low, consider that the gear pump is worn or damaged
(see Engine Cooling Circuit Gear Pump Flow Test).
NOTE: If pressure and fan speed are both low and gear
pump flow proves to be correct, suspect that seals in fan
drive manifold are leaking or faulty (see Fan Drive Manifold Service in the Service and Repairs section of this
chapter).
8. When testing is complete, remove pressure gauge
and reconnect wire harness to PRV solenoid.

Groundsmaster 4100--D

Page 4 -- 57

Hydraulic System

FILTER
MANIFOLD

4WD
MANIFOLD

COUNTERBALANCE
MANIFOLD

Engine Cooling Fan Circuit Gear Pump Flow (Using Tester with Pressure Gauges and
Flow Meter)

P2 FAN DRIVE
MANIFOLD
T

M2
M1

TO MOW MANIFOLD

FROM DECK MANIFOLDS

TESTER

Hydraulic System

Page 4 -- 58

FROM RH PTO
CIRCUIT

FROM FRONT PTO MANIFOLD

FROM RH PTO
MANIFOLD

FROM DECK MOTORS

Groundsmaster 4100--D

Procedure for Engine Cooling Fan Circuit Gear
Pump Flow Test

CAUTION
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning
of this section.

Figure 45
1. Gear pump
2. Fan drive manifold

3. Engine cooling hose
4. 90o fitting

Hydraulic
System

IMPORTANT: Make sure that the oil flow indicator
arrow on the flow gauge is showing that the oil will
flow from the pump section, through the tester and
into the hydraulic hose.

3. With the engine off and cutting deck lowered, disconnect the hydraulic hose from the 90o fitting in the last
gear pump section which supplies the engine cooling
circuit (Fig. 43).
4. Install tester in series between the fitting and the disconnected hose. Make sure the tester flow control valve
is OPEN.
IMPORTANT: The pump is a positive displacement
type. If pump flow is completely restricted or
stopped, damage to the pump, tester or other components could occur.
5. Start the engine and move throttle to full speed (2870
RPM). DO NOT engage the cutting deck.
6. While watching tester pressure gauges, slowly close
flow control valve until 1000 PSI (69 bar) is obtained on
pressure gauge. Verify engine speed continues to be
2870 RPM.
GAUGE READING TO BE: Flow approximately 7
GPM (26.3 LPM) at 1000 PSI (69 bar).
7. Stop engine and record test results.
8. If a pressure of 1000 PSI (69 bar) could not be obtained or flow is lower than 6 GPM (22.3 LPM) (85% of
expected flow), check for restriction in pump intake line.
If intake line is not restricted, consider that gear pump is
worn or damaged.
9. When testing is complete, remove tester and reconnect hose to pump fitting.
Groundsmaster 4100--D

Page 4 -- 59

Hydraulic System

Adjustments
Adjust Cutting Deck Flow Control Valve
The cutting deck lift circuit is equipped with an adjustable flow control valve used to adjust the rate at which
the cutting deck lowers. The control valve is located under the front platform.

Adjust flow control valve as follows:
1. Run machine to get hydraulic oil at operating temperatures. Park machine on a level surface, shut engine off
and lower cutting deck to the ground.
2. Locate valve under front of machine (Fig. 46).

3. Loosen set screw on valve and rotate valve clockwise to slow drop rate of cutting deck.
4. Verify adjustment by raising and lowering cutting
deck several times. Readjust as required.

Figure 46
1. Cutting deck lift flow control valve
2. Front deck hydraulic manifold

5. After desired drop rate is attained, tighten set screw
on flow control valve to secure adjustment.

Hydraulic System

Page 4 -- 60

Groundsmaster 4100--D

Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Before Repair or Replacement of Components

After Repair or Replacement of Components

1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking
brake, lower cutting deck or attachments and stop engine. Remove key from the ignition switch.

1. Check oil level in the hydraulic reservoir and add correct oil if necessary. Drain and refill hydraulic system
reservoir and change oil filter if component failure was
severe or system is contaminated (see Flush Hydraulic
System in this section).

CAUTION
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the
ignition switch in RUN and the engine OFF. Make
sure all electrically operated control valves are
actuated. Return ignition switch to OFF when
pressure has been relieved. Remove key from
the ignition switch.
3. Put caps or plugs on any hydraulic lines, hydraulic fittings and components left open or exposed to prevent
contamination.
4. Put labels on disconnected hydraulic lines and
hoses for proper installation after repairs are completed.

2. Lubricate O--rings and seals with clean hydraulic oil
before installing hydraulic components.
3. Make sure all caps or plugs are removed from hydraulic tubes, hydraulic fittings and components before
reconnecting.
4. Use proper tightening methods when installing hydraulic hoses and fittings (see Hydraulic Fitting Installation in the General Information section of this chapter).
5. After repairs, check control linkages or cables for
proper adjustment, binding or broken parts.
6. After disconnecting or replacing any hydraulic components, operate machine functions slowly until air is
out of system (see Charge Hydraulic System in this section).
7. Check for hydraulic oil leaks. Shut off engine and correct leaks if necessary. Check oil level in hydraulic reservoir and add correct oil if necessary.

5. Note the position of hydraulic fittings (especially elbow fittings) on hydraulic components before removal.
Mark parts if necessary to make sure they will be aligned
properly when reinstalling hydraulic hoses and tubes.

Check Hydraulic Lines and Hoses

WARNING
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 injected into the skin, it must be surgically removed within a few hours by a doctor familiar
with this type of injury. Gangrene may result from
such an injury.
Groundsmaster 4100--D

IMPORTANT: Check hydraulic lines and hoses daily
for leaks, kinked lines, loose mounting supports,
wear, loose fittings or deterioration. Make all necessary repairs before operating.

Page 4 -- 61

Hydraulic System

Hydraulic
System

2. Clean machine before disconnecting, removing or
disassembling any hydraulic components. Make sure
hydraulic components, hoses connections and fittings
are cleaned thoroughly. Always keep in mind the need
for cleanliness when working on hydraulic equipment.

Flush Hydraulic System
IMPORTANT: Flush the hydraulic system any time
there is a severe component failure or the system is
contaminated (oil appears milky, black or contains
metal particles).

7. Fill hydraulic reservoir with new hydraulic fluid.

1. Park machine on a level surface. Lower cutting deck
to the ground, stop engine and engage parking brake.
Remove key from the ignition switch.

9. Turn ignition key switch and engage starter for ten
(10) seconds to prime hydraulic pumps. Repeat this
step again.

8. Disconnect wire harness connector from engine run
solenoid.

10.Connect wire harness connector to engine run solenoid.

CAUTION
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hydraulic oil.
IMPORTANT: Make sure to clean around any hydraulic connections that will be disconnected for
draining.
2. Drain hydraulic reservoir.
3. Drain hydraulic system. Drain all hoses, tubes and
components while the system is warm.
4. Change and replace both hydraulic oil filters.

11. Start engine and let it run at low idle (1450 RPM) for
a minimum of 2 minutes. Increase engine speed to high
idle (2870 RPM) for a minimum of 1 minute under no
load.
12.Raise and lower cutting deck several times. Turn
steering wheel fully left and right several times.
13.Shut off engine and check for hydraulic oil leaks.
Check oil level in hydraulic reservoir and add correct
amount of oil if necessary.
14.Operate machine for 2 hours under normal operating
conditions.

5. Inspect and clean hydraulic reservoir (see Hydraulic
Reservoir Inspection in this section).

15.Check condition of hydraulic oil. If the new fluid
shows any signs of contamination, repeat steps 1
through 14 again until oil is clean.

6. Connect all hydraulic hoses, tubes and components
that were disconnected while draining system.

16.Assume normal operation and follow recommended
maintenance intervals.

NOTE: Use only hydraulic fluids specified in the Operator’s Manual. Other fluids may cause system damage.

Hydraulic System

Page 4 -- 62

Groundsmaster 4100--D

Charge Hydraulic System

IMPORTANT: Change hydraulic oil filter whenever
hydraulic components are repaired or replaced.

11. After the hydraulic system starts to show signs of fill,
actuate lift control lever until the lift cylinder rod moves
in and out several times. If the cylinder rod does not
move after fifteen (15) seconds or the pump emits abnormal sounds, shut the engine off immediately and determine cause or problem. Inspect for the following:
A. Loose filter or suction lines.

1. Park machine on a level surface. Lower cutting deck
to the ground, stop engine and engage parking brake.
Remove key from the ignition switch.

B. Blocked suction line.

2. Make sure all hydraulic connections, lines and components are tight.

D. Faulty gear pump.

3. If component failure was severe or the system is contaminated, flush and refill hydraulic system and reservoir (see Flush Hydraulic System in this section).
4. Make sure hydraulic reservoir is full. Add correct hydraulic oil if necessary.

C. Faulty charge relief valve.

12.If cylinder does move in 15 seconds, proceed to
step 13.
13.Operate the traction pedal in the forward and reverse
directions. The wheels off the ground should rotate in
the proper direction.

5. Check control rod to the piston (traction) pump for
proper adjustment, binding or broken parts.

A. If the wheels rotate in the wrong direction, stop
engine and check for proper hose connections at
traction pump and motors. Correct as needed.

6. Disconnect wire harness connector from engine run
solenoid to prevent the engine from starting.

B. If the wheels rotate in the proper direction, stop
engine.

7. Make sure traction pedal and lift control lever are in
the neutral position. Turn ignition key switch and engage
starter for ten (10) seconds to prime the traction and
gear pumps. Repeat this step again.
8. Connect wire harness connector to engine run solenoid.

WARNING
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 -- Safety.
9. Raise one front and one rear wheel off the ground
and place support blocks under the frame. Chock remaining wheels to prevent movement of the machine.

14.Adjust traction pedal to the neutral position.
15.Check operation of the traction interlock switch.
16.Remove blocks from frame and lower machine to the
ground. Remove chocks from remaining wheels.
17.If the piston (traction) pump or a wheel or axle motor
was replaced or rebuilt, run the machine so all wheels
turn slowly for 10 minutes.
18.Operate machine by gradually increasing it’s work
load to full over a 10 minute period.
19.Stop the machine. Check hydraulic reservoir and fill
if necessary. Check hydraulic components for leaks and
tighten any loose connections.

10.Make sure traction pedal and lift control lever are in
neutral. Start engine and run it at low idle (1400 RPM).
The charge pump should pick up oil and fill the hydraulic
system. If there is no indication of fill in 30 seconds, stop
the engine and determine the cause.

Groundsmaster 4100--D

Page 4 -- 63

Hydraulic System

Hydraulic
System

NOTE: When initially starting the hydraulic system with
new or rebuilt components such as motors, pumps or lift
cylinders, it is important that the hydraulic system be
charged properly. Air must be purged from the system
and its components to reduce the chance of damage.

Hydraulic Reservoir

9 23

10 9

13
12

14
11

1
6

3
2

30 to 40 in--lb
(3.4 to 4.5 N--m)
(minimum)

21
4
8

20
31
28

RIGHT
NOTE: HYDRAULIC COMPONENTS
ATTACHED TO FRONT FRAME ARE
NOT SHOWN IN ILLUSTRATION

FRONT
29

Figure 47
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Hydraulic reservoir
Petcock
O--ring
Strap
Felt strap (2 used)
Bushing (2 used)
Bushing
Strap
Stand pipe (2 used)
Hose clamp (2 used)
Screen filter

Hydraulic System

12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

Dipstick
O--ring
Reservoir cap
Suction hose
Tank strainer
Hose clamp
Hose
Hose clamp
Cap screw
Socket head screw (3 used)

Page 4 -- 64

22.
23.
24.
25.
26.
27.
28.
29.
30.
31.

Lock nut (3 used)
Hose
Hose
Elbow fitting
Flange nut
O--ring
Flat washer (4 used)
Front frame
Flange nut (4 used)
Cap screw (4 used)

Groundsmaster 4100--D

Removal (Fig. 47)
1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.
2. Remove front cutting deck (see Cutting Deck Removal in the Service and Repairs section of Chapter 8
-- Cutting Deck).

Inspection
1. Clean hydraulic reservoir and suction strainer with
solvent.
2. Inspect for leaks, cracks or other damage.
Installation (Fig. 47)
1. Using a wrench, turn tank strainer into port at least
1--1/2 to 2 full turns beyond finger tight.
2. Position reservoir to machine.

3. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.

3. Carefully raise front frame assembly to main frame.
Align frame mounting holes and support front frame to
prevent it from moving.

4. Drain reservoir into a suitable container.

4. Secure front frame to main frame with cap screws
(item 31), flat washers (item 28) and flange nuts (item
30).

5. Disconnect hydraulic hoses from reservoir. Label
disconnected hydraulic lines for proper installation.
6. Remove straps (items 4 and 8) that secure reservoir
to front frame. Remove felt straps (item 3) from between
straps and reservoir.
7. To allow front frame to be lowered for reservoir removal, remove hydraulic tubes that connect hydraulic
components on front frame (wheel motors and front
deck PTO manifold) to components on main frame. Put
caps or plugs on open hydraulic lines and fittings.
8. Chock rear wheels to prevent the machine from moving. Use jack or hoist to raise front of machine and support machine with jackstands.
9. Support front frame to prevent it from moving.
10.Remove cap screws (item 31), flat washers (item 28)
and flange nuts (item 30) that secure front frame to main
frame.
11. Carefully lower front frame assembly to allow clearance for reservoir removal. Once lowered, support front
frame to prevent it from shifting.

5. Lower machine to ground.
6. Position felt straps (item 3) between straps and reservoir. Secure reservoir to front frame with straps (items
4 and 8).
7. Remove caps and plugs from hydraulic lines and fittings that were placed during the removal process. Using labels placed during removal, connect hydraulic
hoses and tubes to fittings on reservoir, wheel motors
and hydraulic manifold (see Hydraulic Hose and Tube
Installation in the General Information section of this
chapter).
8. Install front cutting deck (see Cutting Deck Installation in the Service and Repairs section of Chapter 8 -Cutting Deck).
9. Fill reservoir with new hydraulic fluid to proper level.
10.Properly fill hydraulic system (see Charge Hydraulic
System in this section).
11. Stop engine and check for hydraulic oil leaks. Check
hydraulic reservoir oil level.

12.Carefully remove hydraulic reservoir from machine.

Groundsmaster 4100--D

Page 4 -- 65

Hydraulic System

Hydraulic
System

NOTE: The front frame needs to be lowered from the
main frame to allow clearance to remove the hydraulic
reservoir from the machine.

Hydraulic Oil Cooler
8
5

9
4

RIGHT

FRONT

9
10
2

11
12

13
14
15
16
12
17
18
12 ft--lb
(16 N--m)

Figure 48
1.
2.
3.
4.
5.
6.

Radiator
RH radiator support
Top radiator support
Knob (2 used)
Oil cooler bracket
Retaining ring (2 used)

Hydraulic System

7.
8.
9.
10.
11.
12.

Carriage screw (2 used)
O--ring
90o hydraulic fitting (2 used)
O--ring
Cap screw (2 used)
Lock washer (6 used)

Page 4 -- 66

13.
14.
15.
16.
17.
18.

Oil cooler
Flange nut (2 used)
Cap screw(2 used)
Oil cooler mount plate (2 used)
Cap screw (4 used)
LH radiator support

Groundsmaster 4100--D

Removal (Fig. 48)

CAUTION
CAUTION

The radiator and oil cooler may be hot. To avoid
possible burns, allow the engine and cooling
systems to cool before working on the oil cooler.
1. Park machine on a level surface, lower cutting deck,
stop engine, apply parking brake and remove key from
the ignition switch.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.

Use eye protection such as goggles when using
compressed air.
2. Dry inside of oil cooler using compressed air in the
opposite direction of the oil flow.
3. Plug both ends of oil cooler. Clean exterior of cooler.
Make sure fins are clear of dirt and debris.
4. The oil cooler should be free of corrosion, cracked
tubes and excessive pitting of tubes.
Installation (Fig. 48)
1. Install oil cooler using Figures 48 as a guide.

Inspection

2. Fill reservoir with hydraulic fluid as required.
Hydraulic
System

3. Remove oil cooler using Figures 48 as a guide.

1. Back flush oil cooler with cleaning solvent. After cooler is clean, make sure all solvent is drained from the
cooler.

Groundsmaster 4100--D

Page 4 -- 67

Hydraulic System

Gear Pump

15
11

33
24

103 to 118 ft--lb
(140 to 160 N--m)

24
22
21

22
30

19
8

17
27

RIGHT

79 to 84 ft--lb
(108 to 113 N--m)

25
26

9
28

FRONT

79 to 84 ft--lb
(108 to 113 N--m)

Figure 49
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Hydraulic tee fitting
Roll pin
90o hydraulic fitting
Piston pump
Flat washer (2 used)
Cap screw (2 used)
Hydraulic fitting (2 used)
90o hydraulic fitting
Hydraulic fitting
Hydraulic hose
O--ring
Pump spacer

Hydraulic System

13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.

O--ring (2 used)
O--ring
90o hydraulic fitting (2 used)
Pump coupler
O--ring
Flat washer (2 used)
Cap screw (2 used)
Engine
Gear pump
O--ring
Hydraulic hose

Page 4 -- 68

24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.

O--ring
Hose clamp
Hydraulic hose
O--ring
Hose clamp
Hydraulic hose
O--ring
O--ring
Hydraulic hose
Hydraulic hose
Hydraulic fitting

Groundsmaster 4100--D

Removal (Fig 49)

Installation (Fig 49)

1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.

1. Lubricate new O--rings with clean hydraulic oil and
position on pump.

3. Drain the hydraulic reservoir.
4. To prevent contamination of hydraulic system during
pump removal, thoroughly clean exterior of pump and
fittings.
5. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of this section.
6. Disconnect hydraulic lines from gear pump and put
caps or plugs on open hydraulic lines and fittings. Label
disconnected hydraulic lines for proper installation.
7. Support gear pump assembly to prevent it from falling.
8. Remove two (2) cap screws and washers that secure
gear pump to piston pump. Remove gear pump, coupler, spacer and O--rings from machine through the seat
opening.

2. Slide coupler onto the piston pump output shaft.
3. Position O--rings and spacer to gear pump. Align
gear teeth and slide gear pump input shaft into coupler.
Secure gear pump to piston pump with two (2) cap
screws and washers. Torque cap screws from 79 to 84
ft--lb (108 to 113 N--m).
4. Remove caps or plugs from hydraulic lines and fittings. Install hydraulic lines to gear pump.
5. Replace hydraulic filter and fill hydraulic reservoir
with new hydraulic oil.
6. Disconnect engine run solenoid electrical connector
to prevent engine from starting. Prime the hydraulic
pump by turning the ignition key switch to start and crank
the engine for ten (10) seconds. Wait 15 seconds and repeat cranking procedure again.
7. Connect engine run solenoid electrical connector,
start the engine and check for proper operation.
8. Properly fill hydraulic system (see Charge Hydraulic
System in this section).
9. Stop engine and check for hydraulic oil leaks. Check
hydraulic reservoir oil level.

Groundsmaster 4100--D

Page 4 -- 69

Hydraulic System

Hydraulic
System

2. Raise seat and secure it with prop rod to gain access
to gear pump.

Gear Pump Service
18

5
3

21
9
11
1

21
26
25
23

33 ft--lb
(45 N--m)

Figure 50
1.
2.
3.
4.
5.
6.
7.
8.
9.

Dust seal
Retaining ring
Flange washer
Shaft seal
Front cover
Dowel pin (16 used)
Pressure seal
Back--up gasket
Thrust plate (8 used)

10.
11.
12.
13.
14.
15.
16.
17.
18.

Seal (8 used)
Idler gear
Drive shaft
Back--up gasket
Pressure seal
Front body
Splined connecting shaft (3 used)
Flange
Drive gear

19.
20.
21.
22.
23.
24.
25.
26.

Body
Body
Drive gear
Idler gear
Rear body
Rear cover
Cap screw (4 used)
Washer (4 used)

Disassembly (Fig. 50)
NOTE: The gear pump must be replaced as a complete
assembly. Individual gears, housings and thrust plates
are not available separately. Disassemble gear pump
for cleaning, inspection and seal replacement only.

DIAGONAL LINE

IMPORTANT: Keep bodies, gears, flanges and
thrust plates for each pump section together; do not
mix parts between pump sections.
1. Plug pump ports and thoroughly clean exterior of
pump with cleaning solvent. Make sure work area is
clean.
2. Use a marker to make a diagonal line across the
gear pump for assembly purposes (Fig. 51).
Hydraulic System

Page 4 -- 70

Figure 51
Groundsmaster 4100--D

3. Secure the front cover of the pump in a vise with the
drive shaft pointing down.
4. Loosen the four (4) cap screws that secure pump assembly.
5. Remove pump from vise and remove fasteners.
6. Support the pump assembly and gently tap the pump
case with a soft face hammer to loosen the pump sections. Be careful to not drop parts or disengage gear
mesh.
IMPORTANT: Mark the relative positions of the gear
teeth and the thrust plates so they can be reassembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear
finish.
7. Remove the thrust plates and seals from each pump
section. Before removing each gear set, apply marking
dye to mating teeth to retain ”timing”. Pump efficiency
may be affected if the teeth are not installed in the same
position during assembly. Keep the parts for each pump
section together; do not mix parts between sections.

Groundsmaster 4100--D

8. Clean all parts. Check all components for burrs,
scoring, nicks and other damage.
9. Replace the entire pump assembly if parts are excessively worn or scored.
Assembly (Fig. 50)
1. Apply clean hydraulic oil to all parts before assembling.
NOTE: Pressure seals and back--up gaskets fit in
grooves machined into thrust plates. Body seals fit in
grooves machined in body faces.
2. Assemble pump sections starting at front cover end.
Apply grease or petroleum jelly to new section seals to
hold them in position during gear pump assembly.
3. After pump has been assembled, tighten cap screws
and nuts by hand. Rotate the drive shaft to check for
binding. Protect the shaft if using a pliers to rotate shaft.
4. Tighten the four (4) cap screws evenly in a crossing
pattern to a torque of 33 ft--lb (45 N--m).

Page 4 -- 71

Hydraulic System

Hydraulic
System

IMPORTANT: Use caution when clamping gear
pump in a vise to avoid distorting any pump components.

Traction Circuit

9
4

RIGHT

FRONT

Figure 52
1. Piston (traction) pump
2. Gear pump
3. LH front wheel motor

4. Check valve
5. RH front wheel motor
6. 4WD manifold

7. Filter manifold
8. Rear axle motor
9. Cooling fan motor

Figure 52 illustrates the components that are used in the
Groundsmaster 4100--D traction circuit. Procedures for
removal, installation and disassembly/assembly of
these components are provided on the following pages
of this section.

Hydraulic System

Page 4 -- 72

Groundsmaster 4100--D

Hydraulic
System

This page is intentionally blank.

Groundsmaster 4100--D

Page 4 -- 73

Hydraulic System

Piston (Traction) Pump

15
11

33
24

103 to 118 ft--lb
(140 to 160 N--m)

24
22
21

22
30

19
8

17
27

RIGHT

79 to 84 ft--lb
(108 to 113 N--m)

25
26

9
28

FRONT

79 to 84 ft--lb
(108 to 113 N--m)

Figure 53
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Hydraulic T fitting
Roll pin
90o hydraulic fitting
Piston pump
Flat washer (2 used)
Cap screw (2 used)
Hydraulic fitting (2 used)
90o hydraulic fitting
Hydraulic fitting
Hydraulic hose
O--ring
Pump spacer

Hydraulic System

13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.

O--ring (2 used)
O--ring
90o hydraulic fitting (2 used)
Pump coupler
O--ring
Flat washer (2 used)
Cap screw (2 used)
Engine
Gear pump
O--ring
Hydraulic hose

Page 4 -- 74

24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.

O--ring
Hose clamp
Hydraulic hose
O--ring
Hose clamp
Hydraulic hose
O--ring
O--ring
Hydraulic hose
Hydraulic hose
Hydraulic fitting

Groundsmaster 4100--D

1. Park machine on a level surface, lower cutting deck,
stop engine, apply parking brake and remove key from
the ignition switch.

3. Install gear pump to piston pump (see Gear Pump
Installation).
4. Position traction rod to control arm on piston pump
by installing cap screw, spacer and lock nut (Fig. 54).

2. To prevent contamination of hydraulic system during
removal, thoroughly clean exterior of pump assembly.

5. Connect wire harness connector to neutral switch on
traction pump.

3. Remove traction rod from control arm on piston
pump by removing lock nut, spacer and cap screw (Fig.
54).

6. Remove plugs or caps from disconnected hydraulic
hoses and open ports of the pump assembly. Install fittings and hoses to correct location on gear and piston
pumps.

4. Disconnect wire harness connector from neutral
switch on piston pump.
5. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
6. For installation purposes, label all hydraulic lines that
connect to gear pump and piston pump.
7. Put a drain pan below the pump assembly. Remove
hydraulic hoses and fittings connected to piston and
gear pumps. Put plugs or caps on disconnected hydraulic hoses to prevent contamination of the system. Put
plugs in open ports of pumps.
NOTE: If fuel tank is loosened and raised from the machine, the gear pump and piston pump can be removed
as a complete assembly.

7. Install new filter and fill hydraulic reservoir with correct oil.
8. Disconnect engine run solenoid electrical connector
to prevent engine from starting. Prime pumps by turning
ignition key switch to crank engine for 10 seconds. Repeat cranking procedure again.
9. Connect engine run solenoid electrical connector,
start the engine and check for proper operation.
10.Properly fill hydraulic system (see Charge Hydraulic
System in this section).
11. Stop engine and check for hydraulic oil leaks. Check
hydraulic reservoir oil level.
5

8. Remove gear pump from machine (see Gear Pump
Removal in this section).

3
2

9. Support the piston pump to prevent it from falling
while removing two (2) cap screws and washers retaining pump assembly to engine flywheel plate. Carefully
pull pump assembly from flywheel plate and raise it out
of the machine.
8

Installation (Fig. 53)
1. Carefully lower piston pump into the machine, align
pump input shaft to spring coupler on engine and position it to the engine flywheel plate. Support pump to prevent it from producing any side load into coupler and
also to align pilot diameter of pump to flywheel plate
bore.
2. While maintaining pump alignment with spring coupler and flywheel plate, install two (2) cap screws and
washers to secure piston pump to engine flywheel plate.
Torque screws from 79 to 84 ft--lb (108 to 113 N--m).

Groundsmaster 4100--D

Figure 54
1.
2.
3.
4.

Page 4 -- 75

Piston pump
Cap screw
Pump control arm
Spacer

5.
6.
7.
8.

Lock nut
Jam nut
Traction rod
Rod end

Hydraulic System

Hydraulic
System

Removal (Fig. 53)

Piston (Traction) Pump Service
100 to 110 ft--lb
(136 to 149 N--m)

27 to 31 ft--lb
(37 to 42 N--m)

16
20

150 to 160 in--lb
(17 to 18 N--m)

100 to 110 ft--lb
(136 to 149 N--m)

15
14

40 to 48 in--lb
(4.5 to 5.4 N--m)

45
10
33

17
8

7
5

4 to 6 ft--lb
(5 to 8 N--m)

40 to 48 in--lb
(4.5 to 5.4 N--m)

37
19

25 to 28 ft--lb
(34 to 38 N--m)

31
5

39
37

40 to 48 in--lb
(4.5 to 5.4 N--m)

13
24
2

Figure 55
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Jam nut
Retaining ring
Retaining ring
Seal washer
Socket head screw
Rotating kit assembly
Servo piston assembly
Piston follower
Cover plate
Cover plate
Camplate assembly
Thrust race
Thrust bearing
Bypass valve
Cap screw

16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.

Relief valve (Reverse)
Socket head screw
Valve plate
Pump housing
Backplate assembly
Drive shaft
Nut
Lock washer
Washer
Shaft seal
Relief valve (Forward)
Control arm
Servo control assembly
Washer
Orifice plate (3 used)

31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.

Flat washer
Housing gasket
Cover plate gasket
Control assembly gasket
Plug
O--ring
Seal sub--assembly
Roll pin
Bearing
Dowel bushing
Cradle sub--assembly
Cap screw
Button head cap screw
Bushing
Bearing

NOTE: For service of the piston (traction) pump (including the servo control (item 28), see the Eaton Model
72400 Servo Controlled Piston Pump Repair Information at the end of this chapter.
Hydraulic System

Page 4 -- 76

Groundsmaster 4100--D

Hydraulic
System

This page is intentionally blank.

Groundsmaster 4100--D

Page 4 -- 77

Hydraulic System

Rear Axle Motor
2
Arrow on side of
motor case points up

3
12

1
2

17
18

13
14

11
16

19
20
7

59 to 73 ft--lb
(80 to 99 N--m)

RIGHT
FRONT

Figure 56
1.
2.
3.
4.
5.
6.
7.

Axle motor
90o hydraulic fitting (2 used)
Hydraulic fitting
Cap screw (2 used)
Flat washer (2 used)
O--ring
External snap ring (2 used)

Hydraulic System

8.
9.
10.
11.
12.
13.
14.

Pinion gear
External snap ring (2 used)
Gear
Needle bearing
O--ring
O--ring
O--ring

Page 4 -- 78

15.
16.
17.
18.
19.
20.
21.

O--ring
Drive axle assembly
Cap screw (6 used)
Lock washer (6 used)
Dowel pin (2 used)
Cover plate
Gasket

Groundsmaster 4100--D

Removal (Fig. 56)

Installation (Fig. 56)

1. Park machine on a level surface, lower cutting deck,
stop engine, apply parking brake and remove key from
the ignition switch.

1. If fittings were removed from motor, lubricate and
place new O--rings onto fittings. Install fittings into port
openings using marks made during the removal process
to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information
section of this chapter).

NOTE: To ease installation, tag the hydraulic hoses to
show their correct position on the axle motor.
3. Disconnect hydraulic hoses from motor. Put caps or
plugs on motor ports and hose openings to prevent contamination.
IMPORTANT: Support axle motor to prevent motor
from falling during removal.
4. Remove motor from rear axle using Figure 56 as a
guide.
5. If hydraulic fittings are to be removed from motor,
mark fitting orientation to allow correct assembly. Remove fittings from motor and discard O--rings.

Groundsmaster 4100--D

2. If removed, install pinion gear to axle motor.
3. Install O--ring onto motor. Position motor to rear axle
assembly making sure that arrows on the side of motor
case point upward. Align gear teeth and slide motor into
place.
4. Secure motor to axle with cap screws and flat washers. Torque screws from 59 to 73 ft--lb (80 to 99 N--m).
5. Remove plugs from motor ports and hose openings.
Attach hydraulic hoses to axle motor.
6. Fill reservoir with hydraulic fluid as required.
7. After assembly is completed, verify that hydraulic
hoses and fittings do not contact anything.

Page 4 -- 79

Hydraulic System

Hydraulic
System

2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.

Front Wheel Motors

12 16

15
19

4
8

16
14

Arrow on side of
motor case points up

10
15
12

Arrow on side of
motor case points up

15
16
1

RIGHT

75 to 85 ft--lb
(101 to 115 N--m)

16
17

13
9

FRONT

Figure 57
1.
2.
3.
4.
5.
6.
7.

Front wheel motor
Internal retaining ring
Splined brake shaft
RH brake assembly
Planetary assembly
Cap screw (2 used per motor)
Flat washer (2 used per motor)

Hydraulic System

8.
9.
10.
11.
12.
13.
14.

O--ring
Hex head plug
90o hydraulic fitting
90o hydraulic fitting
O--ring
O--ring
Hydraulic fitting

Page 4 -- 80

15.
16.
17.
18.
19.
20.

O--ring
O--ring
Hydraulic tee fitting
O--ring
O--ring
LH brake assembly

Groundsmaster 4100--D

Removal (Fig. 57)

Installation (Fig. 57)

1. Park machine on a level surface, lower cutting deck,
stop engine, apply parking brake and remove key from
the ignition switch.

NOTE: To ease installation, tag the hydraulic hoses to
show their correct position on the wheel motor.
3. Disconnect hydraulic hoses and tubes from wheel
motor. Put caps or plugs on motor ports and hose openings to prevent contamination.
IMPORTANT: Before loosening fasteners, support
wheel motor to prevent motor from falling during removal.
4. Remove wheel motor using Figure 57 as a guide.
5. If hydraulic fittings are to be removed from motor,
mark fitting orientation to allow correct assembly. Remove fittings from motor and discard O--rings.

Groundsmaster 4100--D

2. Position wheel motor to brake assembly making sure
that arrows on the side of motor case point upward.
3. Align splines on motor shaft and splined brake shaft.
Slide motor into brake assembly.
4. Secure motor to brake assembly with cap screws
and flat washers. Tighten cap screws from 75 to 85 ft--lb
(101 to 115 N--m).
5. Remove plugs from wheel motor ports and hose
openings. Attach hydraulic hoses and tubes to wheel
motor.
6. Fill reservoir with hydraulic fluid as required.

Page 4 -- 81

Hydraulic System

Hydraulic
System

2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.

Rear Axle and Front Wheel Motor Service
15 to 18 ft--lb
(20 to 24 N--m)

7
2

1
11
18
8
6

14
15
16
12
4

5
3
17

Figure 58
1.
2.
3.
4.
5.
6.

Drive shaft
Backplate (front motor shown)
Housing assembly
Rotating assembly
Cam plate insert
Retaining ring

7.
8.
9.
10.
11.
12.

Cap screw (6 used)
Shaft seal
Retaining ring
Thrust race
O--ring
Valve plate

NOTE: The front wheel motors are identical. The rear
axle motor has some differences from the front motors.
Service of the front and rear motors requires the same
procedures.

Hydraulic System

13.
14.
15.
16.
17.
18.

Thrust bearing
Roll pin (3 used)
Roll pin
Bearing
Bearing
Washer

NOTE: For service of the wheel motors, see the Eaton
Model 74318 and 74348 Piston Motors: Fixed Displacement, Valve Plate Design Repair Information at the end
of this chapter.

Page 4 -- 82

Groundsmaster 4100--D

Hydraulic
System

This page is intentionally blank.

Groundsmaster 4100--D

Page 4 -- 83

Hydraulic System

4WD Manifold
2

4
5

11
9

10
10
17
16

11
7
4

13
12

14
15

RIGHT

FRONT
18

Figure 59
1.
2.
3.
4.
5.
6.
7.

Frame assembly
4 wheel drive manifold
90o hydraulic fitting
O--ring
O--ring
Quick fitting
O--ring

Hydraulic System

8.
9.
10.
11.
12.
13.

Fitting cap
Hydraulic fitting
O--ring
O--ring
90o hydraulic fitting
O--ring

Page 4 -- 84

14.
15.
16.
17.
18.
19.

O--ring
Hydraulic fitting
Adapter
Plug (SAE #4)
Flange nut (2 used)
Cap screw (2 used)

Groundsmaster 4100--D

Removal (Fig. 59)

Installation (Fig. 59)

NOTE: The ports on the manifold are marked for easy
identification of components. Example: P1 is a piston
pump connection port and SV is the location for the solenoid valve (See Hydraulic Schematic in Chapter 9 -Foldout Drawings to identify the function of the hydraulic
lines and cartridge valves at each port).

1. Install hydraulic manifold to the frame using Figure
59 as guide.
2. Remove caps and plugs from fittings and hoses.
Properly connect hydraulic lines to manifold.
3. Connect electrical connector to the solenoid valve.

1. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of this section.
2. To prevent contamination of hydraulic system during
manifold removal, thoroughly clean exterior of manifold
and fittings.
3. Disconnect electrical connector from the solenoid
valve.

Hydraulic
System

4. Disconnect hydraulic lines from manifold and put
caps or plugs on open hydraulic lines and fittings. Label
disconnected hydraulic lines for proper installation.
5. Remove hydraulic manifold from the frame using
Figure 59 as guide.

Groundsmaster 4100--D

Page 4 -- 85

Hydraulic System

4WD Manifold Service

35 ft--lb
(47 N--m)
25 ft--lb
(34 N--m)

10
13

REAR
DOWN

50 ft--lb
(67 N--m)

8
7

1
13

UP
FRONT

3
20 ft--lb
(27 N--m)

PLUG TORQUE
#4 Zero Leak: 20 ft--lb (27 N--m)
#6 Zero Leak: 25 ft--lb (34 N--m)
#8 Zero Leak: 50 ft--lb (67 N--m)

5 ft--lb
(6.7 N--m)

10
11
12

Figure 60
1.
2.
3.
4.
5.

Manifold body
Solenoid valve (port SV)
Solenoid coil
Check valve (port CV)
Nut

6.
7.
8.
9.

Directional valve (ports PD1 & PD2)
Pressure reducing valve (port PR)
Relief valve (port RV)
Orifice (0.030) (port SV)

10.
11.
12.
13.

#4 zero leak plug with O--ring
#6 zero leak plug with O--ring
Orifice (0.050) (ports OR1 and OR2)
#8 zero leak plug with O--ring

Hydraulic System

Page 4 -- 86

Groundsmaster 4100--D

4WD Manifold Service (Fig. 60)

8. Reinstall the cartridge valve:

2. If cartridge is solenoid operated, remove nut securing solenoid to the cartridge valve. Carefully slide solenoid off the valve.
IMPORTANT: Use care when handling the valve cartridge. Slight bending or distortion of the stem tube
can cause binding and malfunction.
3. Remove cartridge valve with a deep socket wrench.
Note correct location for O--rings, sealing rings and
backup rings. Remove and discard seal kit.

A. Lubricate new seal kit components with clean hydraulic oil and install on valve. The O--rings, sealing
rings and backup rings must be arranged properly on
the cartridge valve for proper operation and sealing.
IMPORTANT: Use care when handling the valve
cartridge. Slight bending or distortion of the
stem tube can cause binding and malfunction.
B. Thread cartridge valve carefully into manifold
port. The valve should go in easily without binding.
C. Torque cartridge valve using a deep socket to value identified in manifold illustration.

4. Visually inspect the port in the manifold for damage
to the sealing surfaces, damaged threads or contamination.

D. If cartridge is solenoid operated, carefully install
solenoid coil to the cartridge valve. Torque nut to value identified in manifold illustration.

5. Visually inspect cartridge valve for damaged sealing
surfaces and contamination.

9. If problems still exist, remove valve and clean again
or replace valve.

A. Contamination may cause valves to stick or hang
up. Contamination can become lodged in small valve
orifices or seal areas causing malfunction.
B. If valve sealing surfaces appear pitted or damaged, the hydraulic system may be overheating or
there may be water in the system.

CAUTION
Use eye protection such as goggles when using
compressed air.
6. Clean cartridge valve using clean mineral spirits.
Submerge valve in clean mineral spirits to flush out contamination. Particles as fine as talcum powder can affect
the operation of high pressure hydraulic valves. If cartridge design allows, use a wood or plastic probe to push
the internal spool in and out 20 to 30 times to flush out
contamination. Be extremely careful not to damage cartridge. Use compressed air for cleaning.
7. The 4WD control manifold includes three (3) orifice
fittings (items 9 and 13). The 0.030 orifice (item 9) is
positioned in the SV port under the solenoid cartridge
valve. The 0.050 orifices (item 13) thread into the manifold in ports OR1 and OR2. Before removing or installing the orifice in OR1, removal of the #6 plug in the
bottom of the manifold is necessary.

Groundsmaster 4100--D

Page 4 -- 87

Hydraulic System

Hydraulic
System

1. Make sure the manifold is clean before removing the
valve.

Filter Manifold

21
4
11

19
6

5
22
1
23

17
6

3
7

11
13

RIGHT
15

FRONT

Figure 61
1.
2.
3.
4.
5.
6.
7.
8.
9.

Filter manifold
45o hydraulic fitting
Test nipple
Dust cap
O--ring
O--ring
O--ring
Cap screw (3 used)
Flat washer (3 used)

10.
11.
12.
13.
14.
15.
16.
17.

Hydraulic fitting
O--ring
O--ring
90o hydraulic fitting
Hydraulic hose
O--ring
O--ring
90o hydraulic fitting

18.
19.
20.
21.
22.
23.
24.
25.

Hydraulic hose
Hydraulic tee fitting
90o hydraulic fitting
O--ring
Hose clamp
Filter hose
Barb fitting
Oil filter

NOTE: The ports on the manifold are marked for easy
identification of components. Example: P2 is the gear
pump connection port and T is the connection for the hydraulic reservoir return port (See Hydraulic Schematic
in Chapter 9 -- Foldout Drawings to identify the function
of the hydraulic lines and cartridge valves at each port).

Hydraulic System

Page 4 -- 88

Groundsmaster 4100--D

Removal (Fig. 61)

Installation (Fig. 61)

1. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.

1. If fittings were removed from manifold, lubricate and
place new O--rings onto fittings. Install fittings into manifold openings using marks made during the removal
process to properly orientate fittings. Tighten fittings
(see Hydraulic Fitting Installation in the General Information section of this chapter).

2. To prevent contamination of hydraulic system during
manifold removal, thoroughly clean exterior of manifold
and fittings.
3. Disconnect hydraulic lines from manifold and put
caps or plugs on open hydraulic lines and fittings. Label
disconnected hydraulic lines for proper reassembly.
4. Remove filter manifold from the frame using Figure
61 as guide.

2. Install filter manifold to the frame using Figure 61 as
guide.
3. Remove caps and plugs from fittings and hoses. Using labels placed during manifold removal, properly connect hydraulic lines to manifold.

Hydraulic
System

5. If hydraulic fittings are to be removed from manifold,
mark fitting orientation to allow correct assembly. Remove fittings from manifold and discard O--rings.

Groundsmaster 4100--D

Page 4 -- 89

Hydraulic System

Filter Manifold Service
5
25 ft--lb
(34 N--m)

UP
FRONT

25 ft--lb
(34 N--m)
1
6

25 ft--lb
(34 N--m)
30 ft--lb
(41 N--m)
5

7
4

3
2
50 ft--lb
(67 N--m)
30 ft--lb
(41 N--m)

UP
FRONT
3

Figure 62
1. Filter manifold
2. Check valve (reservoir return)
3. Oil filter element

4. Check valve (filter bypass)
5. Plug (Zero Leak #6)

6. Charge relief valve
7. Plug (Zero Leak #8)

Hydraulic System

Page 4 -- 90

Groundsmaster 4100--D

Filter Manifold Service (Fig. 62)

Hydraulic
System

For cartridge valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 62 for filter
manifold cartridge valve and plug installation torque.

Groundsmaster 4100--D

Page 4 -- 91

Hydraulic System

Steering and Cooling Fan Circuits

RIGHT

FRONT
3

Figure 63
1. Gear pump
2. Steering control valve

3. Fan drive manifold
4. Fan motor

5. Steering cylinder

Figure 63 illustrates the components that are used in the
Groundsmaster 4100--D steering and cooling fan circuit.
Procedures for removal, installation and disassembly/
assembly of these components are provided on the following pages of this section.

Hydraulic System

Page 4 -- 92

Groundsmaster 4100--D

Hydraulic
System

This page is intentionally blank.

Groundsmaster 4100--D

Page 4 -- 93

Hydraulic System

Steering Valve
24
23

22
29

28
27
25

21
12

16 to 20 ft--lb
(22 to 27 N--m)

19
18

RIGHT

9
10
11
9
12
13
11

FRONT

Figure 64
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Hex nut
Flat washer
Steering wheel
Foam collar
Steering seal
External snap ring
Steering shaft assembly
Steering tower cover
O--ring
90o hydraulic fitting

Hydraulic System

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

O--ring
Flange head screw
Hydraulic adapter (4 used)
Steering valve assembly
Nut insert
Steering tower
Flange locking nut (2 used)
Flange head screw (4 used)
Pivot hub (2 used)
Cap screw (2 used)

Page 4 -- 94

21.
22.
23.
24.
25.
26.
27.
28.
29.

Steering column assembly
Flange bushing
Thrust washer
Steering wheel cover
In port (P)
Right turn port (R)
Load sensing port (PB)
Left turn port (L)
Out port (T)

Groundsmaster 4100--D

Removal (Fig. 64)

Installation (Fig. 64)

1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.

1. If fittings were removed from steering valve, lubricate
and place new O--rings onto fittings. Install fittings into
port openings using marks made during the removal
process to properly orientate fittings. Tighten fittings
(see Hydraulic Fitting Installation in the General Information section of this chapter).

2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of this section.
3. To prevent contamination of hydraulic system during
steering valve removal, thoroughly clean exterior of
steering valve and fittings.

2. Install steering valve using Figure 64 as a guide.
3. Make sure hydraulic tank is full. Add correct oil if necessary before returning machine to service.

4. Remove steering valve from machine using Figure
64 as a guide.

Hydraulic
System

5. If hydraulic fittings are to be removed from steering
valve, mark fitting orientation to allow correct assembly.
Remove fittings from valve and discard O--rings.

Groundsmaster 4100--D

Page 4 -- 95

Hydraulic System

Steering Valve Service

8
1

3
24

2
4

5
20

22
21

150 in--lb
(17 N--m)

9
10

14
18

11
140 to 160 in--lb
(16 to 18 N--m)

Figure 65
1.
2.
3.
4.
5.
6.
7.
8.

Steering valve housing
Dust seal
O--ring
Spool
Spring retaining ring
Pin
Sleeve
Centering springs/spacers

9.
10.
11.
12.
13.
14.
15.
16.

Cap screw (7 used)
End cap
O--ring
Seal ring
O--ring
Geroter
O--ring
Spacer

Disassembly (Fig. 65)
NOTE: Cleanliness is extremely important when
repairing steering control units. Work in a clean area.
Before disconnecting the hydraulic lines, clean the port
area of the steering valve assembly. Before disassembly, drain the oil, then plug the ports and thoroughly
clean the exterior. During repairs, always protect
machined surfaces.
1. Remove the seven (7) cap screws from the steering
valve assembly.
2. Remove end cap, geroter, spacer, geroter drive,
wear plate, seal ring and O--rings from housing.
3. Remove the plug and relief valve.

Hydraulic System

17.
18.
19.
20.
21.
22.
23.
24.

Geroter drive
Wear plate
Bearing race
Thrust bearing
Plug
O--ring
Relief valve
Quad seal

4. Slide the spool and sleeve assembly from the housing.
5. Remove the thrust bearing and bearing races (2).
6. Remove the quad seal.
7. Use a small blade screwdriver to carefully pry the
dust seal from the housing. Be careful to not damage the
dust seal seat in the housing.
8. Remove the pin that holds the spool and sleeve together.
9. Carefully slide the spool out of the sleeve. The centering springs and spring retaining ring will stay with the
spool as it is removed.

Page 4 -- 96

Groundsmaster 4100--D

8. Put the thrust bearing and races into the housing.
The thrust bearing goes between the two races
(Fig. 66).

The centering springs are under tension. Remove the retaining ring carefully.

IMPORTANT: Do not damage the dust or quad seals
when installing the spool and sleeve assembly.

10.Remove the spring retaining ring and centering
springs from the spool.

9. Apply a light coating of clean hydraulic fluid to the
spool and sleeve assembly and carefully slide the assembly into the housing.

Reassembly (Fig. 65)
Check all mating surfaces. Replace any parts with
scratches or burrs that could cause leakage. Wash all
metal parts in clean solvent. Blow them dry with pressurized air. Do not wipe parts dry with paper towels or cloth
as lint in a hydraulic system will cause damage.
NOTE: Always use new seals and O--rings when assembling the steering valve.

10.Clamp the housing in a vise. Use only enough clamping force to hold the housing securely.
11. Lubricate and install a new O-ring seal in the groove
in the housing.
12.Install the wear plate and align screw holes in the
wear plate with threaded holes in the housing.
NOTE: The holes in the wear plate are symmetrical.

IMPORTANT: During assembly, lubricate the new
seals with petroleum jelly. Also, lubricate machined
surfaces and bearings with clean hydraulic fluid.

13.Install the geroter drive, making sure the slot in the
drive engages the pin.

1. Install the quad seal (Fig. 66):

14.Lubricate and install new O-ring in wear plate
groove.

A. Put one of the bearing races and sleeve into the
housing.
B. Together, the housing and bearing race create a
groove into which the quad seal will be installed.
C. Hold the bearing race tightly against the input end
of the housing by pushing on the gerotor end of the
sleeve.
D. Fit the quad seal into its seat through the input end
of the housing. Be sure the seal is not twisted.
E. Remove the sleeve and bearing race.

15.Install the gerotor and align the screw holes.
16.Lubricate and install new O-ring in gerotor ring
groove.
17.Lubricate and install new O-ring and seal ring in gerotor star groove.
18.Install the spacer.
19.Install the end cap and seven (7) cap screws. Tighten
the cap screws, in a crossing pattern, from 140 to 160
in-lb (16 to 18 N--m).
20.Remove the steering valve from the vise.

2. Lubricate and install the dust seal.
3. Install the centering springs in the spool. It is best to
install the two flat pieces first. Next, install the curved
pieces, three at a time.

21.Install the relief valve and plug. Tighten the plug to
150 in-lb (17 N--m).

4. Fit the retaining ring over the centering springs.
5. Apply a light coating of clean hydraulic fluid to the
spool and slide it into the sleeve. Be sure the centering
springs fit into the notches in the sleeve.
6. Install the pin.

Quad Seal

7. Apply a light coating of petroleum jelly to the inner
edge of the dust and quad seals.

Groundsmaster 4100--D

Thrust Bearing
and Race (2)

Dust Seal

Page 4 -- 97

Figure 66

Hydraulic System

Hydraulic
System

CAUTION

Steering Cylinder
9

6
4

7
9

4
3

10
See text for
tightening
procedure

13
14
11

RIGHT
See text for
tightening
procedure

FRONT

Figure 67
1.
2.
3.
4.
5.

Steering cylinder
Ball joint
Ball joint
Retaining ring
Grease fitting

Hydraulic System

6.
7.
8.
9.
10.

Grease fitting
90o hydraulic fitting
O--ring
O--ring
Drive axle assembly

Page 4 -- 98

11.
12.
13.
14.

Ball joint spacer
Axle washer
Hex slotted nut
Cotter pin

Groundsmaster 4100--D

Removal (Fig. 67)

Installation (Fig. 67)

1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.

1. If removed, install ball joints into steering cylinder.

3. To prevent contamination of hydraulic system during
steering cylinder removal, thoroughly clean exterior of
cylinder and fittings.
NOTE: To ease installation, label the hydraulic hoses to
show their correct position on the steering cylinder.
4. Remove hydraulic hoses from steering cylinder.
5. Remove cotter pins, hex slotted nuts, axle washer
and ball joint spacer from the threaded ends of ball joints
(Fig. 67). Remove steering cylinder with ball joints from
machine.
6. If hydraulic fittings are to be removed from steering
cylinder, mark fitting orientation to allow correct assembly. Remove fittings from cylinder and discard O--rings.

3. Slide ram end ball joint through hole on steering arm.
Secure with axle washer and hex slotted nut. Slide fixed
end of cylinder through hole on axle. Secure with slotted
hex nut. Torque slotted hex nuts to 100 ft--lbs (135 N--m)
and then continue tightening the nut until hex nut groove
aligns with cotter pin hole in ball joint. Install cotter pin
to nut and ball joint.
4. Install hydraulic hoses to steering cylinder.
5. Fill reservoir with hydraulic fluid as required.
6. After assembly is completed, operate steering cylinder to verify that hydraulic hoses and fittings are not contacted by anything.

7. If needed, remove ball joints from steering cylinder.

Groundsmaster 4100--D

Page 4 -- 99

Hydraulic System

Hydraulic
System

2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of this section.

2. If fittings were removed from steering cylinder, lubricate and place new O--rings onto fittings. Install fittings
into port openings using marks made during the removal
process to properly orientate fittings. Tighten fittings
(see Hydraulic Fitting Installation in the General Information section of this chapter).

Steering Cylinder Service

12
9
11
10

7
8
5
4

1
6
3

45 to 55 ft--lb
(62 to 74 N--m)

Figure 68
1.
2.
3.
4.

Tube assembly
Rod
Piston assembly
Head

Hydraulic System

5.
6.
7.
8.

Retaining ring
Backup ring
O--ring
Cap seal

Page 4 -- 100

9.
10.
11.
12.

Rod seal
O--ring
O--ring
Wiper

Groundsmaster 4100--D

1. Pump oil out of cylinder into a drain pan by SLOWLY
moving rod and piston in and out of cylinder bore. Plug
ports and clean outside of cylinder.
IMPORTANT: To prevent damage when clamping
cylinder in a vise, clamp only on pivotal ends. Use
of a vise with soft jaws is recommended.
2. Mount cylinder in a vise so rod end of cylinder is tilted
up slightly. Do not close vise so firmly that cylinder tube
could become distorted.
3. Loosen head from tube:
A. Use a spanner wrench to rotate head clockwise
until the edge of the retaining ring appears in the tube
opening.
B. Insert a screwdriver under the beveled edge of
the retaining ring to start the retaining ring through
the opening.
C. Rotate the head counter--clockwise to remove retaining ring from tube and head.
4. Grasp end of piston rod and use a twisting and pulling motion to carefully extract piston, piston rod and
head from cylinder tube.
IMPORTANT: Do not clamp vise jaws against piston
rod surface; the piston rod will become damaged.
5. Securely mount piston, piston rod and head into vise
and remove piston. Remove head from rod.
6. Remove and discard all seals and O--rings from
head and piston.

Groundsmaster 4100--D

7. Wash parts in clean solvent. Dry parts with compressed air. Do not wipe parts dry with paper towels or
cloth. Lint in a hydraulic system will cause damage.
8. Carefully inspect internal surface of barrel for damage (deep scratches, out--of--round, etc.). Replace entire cylinder if barrel is damaged. Inspect rod and piston
for evidence of excessive scoring, pitting or wear. Replace any damaged parts.
Assembly (Fig. 68)
1. Use a complete repair kit when rebuilding the cylinder. Put a coating of clean hydraulic oil on all new seals
and O--rings.
2. Install new O--rings and seals to the piston and head.
3. Lubricate shaft with clean hydraulic oil. Slide head
onto shaft. Install and tighten head. Torque head from 45
to 55 ft--lb (62 to 74 N--m).
4. Put a coating of clean hydraulic oil on all cylinder
parts to ease assembly.
5. Slide rod assembly into cylinder tube.
6. Mount steering cylinder in a vise with soft jaws. Secure head in barrel:
A. Align retaining ring hole in the head with the access slot in the tube.
B. Insert the retaining ring hook into the hole and rotate head clockwise until the retaining ring is completely pulled into the tube and the ring ends are
covered.
C. Apply silicone sealer to tube access slot.

Page 4 -- 101

Hydraulic System

Hydraulic
System

Disassembly (Fig. 68)

Engine Cooling Fan Motor

4
27 to 33 ft--lb
(37 to 44 N--m)

2
1

7
8

5
19

16 17

12
11
12 to 14 ft--lb
(17 to 18 N--m)

RIGHT
FRONT

Figure 69
1.
2.
3.
4.
5.
6.
7.

Hydraulic fan motor
O--ring
Bracket
45o hydraulic fitting
O--ring
Hydraulic hose
Fan hub

Hydraulic System

8.
9.
10.
11.
12.
13.
14.

Washer
Hex nut
Engine
Cap screw (4 used)
Washer (4 used)
Fan
Lock nut (2 used)

Page 4 -- 102

15.
16.
17.
18.
19.
20.
21.

Hydraulic hose
O--ring
Hydraulic fitting
O--ring
Hydraulic hose
Cap screw (2 used)
Flat washer (2 used)

Groundsmaster 4100--D

1. Park machine on a level surface, lower cutting deck,
stop engine, apply parking brake and remove key from
the ignition switch.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
3. Unlatch and raise hood.
4. Remove air cleaner hose and upper radiator shroud
to allow easier access to hydraulic fan motor (Fig. 70).

CAUTION
The radiator and oil cooler may be hot. To avoid
possible burns, allow the engine and cooling
systems to cool before removing fan motor.
IMPORTANT: Make sure to not damage the radiator,
fan or other machine components while loosening
and removing the fan motor.

IMPORTANT: Make sure to not damage the radiator,
oil cooler or other machine components while
installing the fan motor.
2. Carefully position fan motor to fan motor bracket.
Loosely attach motor to bracket with cap screws (item
20), flat washers (item 21) and lock nuts (item 14).
3. Remove caps or plugs placed during removal to prevent contamination. Connect hydraulic hoses to cooling
fan motor (see Hydraulic Hose and Tube Installation in
the General Information section of this chapter).
4. Tighten fasteners to secure fan motor to bracket.
5. Thoroughly clean tapered surfaces of fan motor
shaft and fan hub. Position fan hub (with fan attached)
onto motor shaft and secure with washer (item 8) and
hex nut (item 9). Torque nut from 27 to 33 ft--lb (37 to
44 N--m).
6. Install upper radiator shroud and air cleaner hose
(Fig. 70). Make sure that clearance between shroud and
cooling fan is at least 0.180” (4.6 mm) at all points.
7. Lower and secure hood.

5. Remove hex nut (item 9) and washer (item 8) that secure fan hub and fan assembly to fan motor.

1
2

6. Use suitable puller to remove fan hub (with fan attached) from fan motor shaft taking care to not damage
fan. Position fan assembly away from fan motor.
7. To prevent contamination of hydraulic system during
fan motor removal, thoroughly clean exterior of motor
and fittings.

3
4
5

8. Disconnect hydraulic hoses from cooling fan motor.
Put caps or plugs on fittings and hoses to prevent contamination. Tag hydraulic lines for proper assembly.
9. Support fan motor to prevent it from falling. Remove
two (2) cap screws (item 20), flat washers (item 21) and
lock nuts (item 14) that secure fan motor to fan motor
bracket.
10.Carefully lower fan motor and remove from machine.
11. If hydraulic fittings are to be removed from fan motor,
mark fitting orientation to allow correct assembly. Remove fittings from motor and discard O--rings.

4
4

Figure 70
1.
2.
3.
4.

Radiator
Upper radiator shroud
Screw (4 used)
Flat washer

5. Air cleaner hose
6. Flange nut (4 used)
7. Cap screw

Installation (Fig. 69)
1. If fittings were removed from fan motor, lubricate and
place new O--rings onto fittings. Install fittings into port
openings using marks made during the removal process
to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information
section of this chapter).
Groundsmaster 4100--D

Page 4 -- 103

Hydraulic System

Hydraulic
System

Removal (Fig. 69)

Engine Cooling Fan Motor Service
11
10
15
6

16
9

8
12

8
5
4

33 ft--lb
(45 N--m)

Figure 71
1.
2.
3.
4.
5.
6.

Flange washer
O--ring
Front flange
Dust seal
Retaining ring
Front wear plate

7.
8.
9.
10.
11.

Shaft seal
Backup gasket
Pressure seal
Rear wear plate
Body

12.
13.
14.
15.
16.

Idler gear
Cap screw (4 used)
Dowel (2 used)
Drive gear
Washer (4 used)

Disassembly (Fig. 71)
MARKER LINE

1. Plug motor ports and clean the outside of the motor
thoroughly. After cleaning, remove plugs and drain any
oil out of the motor.
2. Use a marker to make a diagonal line across the
front flange and body for assembly purposes (Fig. 72).
IMPORTANT: Prevent damage when clamping the
fan motor into a vise; clamp on the front flange only.
Also, use a vise with soft jaws.
3. Clamp front flange of motor in a vise with soft jaws
with the shaft end down.

Figure 72

4. Loosen cap screws from the rear cover.
5. Remove motor from the vise. Turn motor so that the
shaft end is facing down. Remove cap screws.
6. Carefully remove body. Lift body straight up to remove. Make sure the rear wear plate remains on the
drive and idler gear shafts. Remove and discard O-rings from the body. Locate and retrieve dowel pins.
Hydraulic System

IMPORTANT: Note position of the open and closed
side of the wear plates before removing. Also, identify wear plates (front and rear) with a marker for
proper assembly.
7. Carefully remove rear wear plate, idler gear, drive
gear and front wear plate from the front flange.

Page 4 -- 104

Groundsmaster 4100--D

8. Remove and discard back--up gaskets and pressure
seals from wear plates.

9. Turn front flange over, with seal side up.
2

IMPORTANT: Make sure not to damage the front
flange counter bore when removing the seals from
the front flange.
10.Carefully remove dust seal, retaining ring, flange
washer and shaft seal from the front flange (Fig. 74).
Discard seals.

Inspection

1. Remove any nicks and burrs from all parts with
emery cloth.

1.
2.

Gear shaft spline
Gear shaft

CAUTION

Figure 73
3.
4.

Gear teeth
Gear face edge

Hydraulic
System

Use eye protection such as goggles when using
compressed air.
2. Clean all parts with solvent. Dry all parts with compressed air.
3. Inspect drive gears and idler gears for the following
(Fig. 73):

Figure 74

A. Gear shafts should be free of rough surfaces and
excessive wear at bushing points and sealing areas.
Scoring, rough surfaces or wear on gear shafts indicates need for replacement.

Assembly (Fig. 71)

B. Gear teeth should be free of excessive scoring
and wear. Any broken or nicked gear teeth must be
replaced.

NOTE: When assembling the motor, check the marker
line on each part to make sure the parts are properly
aligned during assembly.

C. Inspect gear face edge for sharpness. Sharp
edges of gears will mill into wear plates and, thus,
must be replaced.

1. Lubricate O--rings, pressure seals, back--up gaskets
and wear plate grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic oil.

4. Inspect wear plates for the following:

3. Flange washer
4. Shaft seal

2. Install new seals into front flange (Fig. 74):

A. Bearing areas should not have excessive wear or
scoring.
B. Face of wear plates that are in contact with gears
should be free of wear, roughness or scoring.
C. Thickness of wear plates should be equal.
5. Inspect front flange and rear cover for damage or
wear.

Groundsmaster 4100--D

1. Dust seal
2. Retaining ring

A. Press shaft seal into front flange until it reaches
the bottom of the bore.
B. Install flange washer into front flange and then
install retaining ring into the groove of the front
flange.
C. Install new dust seal into front flange.
3. Place front flange, seal side down, on a flat surface.

Page 4 -- 105

Hydraulic System

4. Install the pressure seals, flat side outward, into the
grooves in the wear plates. Follow by carefully placing
the backup gaskets, flat side outward, between the
pressure seals and the grooves in the wear plate.
5. Apply a light coating of petroleum jelly to the exposed
side of the front flange.
6. Lubricate the drive gear shaft with clean hydraulic oil.
Insert the drive end of the drive shaft through the wear
plate with the pressure seal side down and the open side
of the pressure seal pointing to the inlet side of the motor. Carefully install shaft into front flange.
7. Lubricate the idler gear shaft with clean hydraulic oil.
Install idler gear shaft into the remaining position in the
front wear plate. Apply a light coating of clean hydraulic
oil to gear faces.
8. Install rear wear plate with pressure seal side up and
open side of the pressure seal pointing to the inlet side
of the motor.
9. Apply a light coating of petroleum jelly to new O-rings and O--ring grooves in the body. Install new O-rings to the body.

Hydraulic System

10.Install locating dowels in body. Align marker line on
the body and front flange.
IMPORTANT: Do not dislodge seals during installation.
11. Gently slide the body onto the assembly. Firm hand
pressure should be sufficient to engage the dowels.
12.Install the four (4) cap screws with washers and hand
tighten.
IMPORTANT: Prevent damage when clamping the
fan motor into a vise; clamp on the front flange only.
Also, use a vise with soft jaws.
13.Place front flange of the motor into a vise with soft
jaws and alternately torque the cap screws 33 ft--lb (45
N--m).
14.Remove motor from vise.
15.Place a small amount of clean hydraulic oil in the inlet
of the motor and rotate the drive shaft away from the inlet
one revolution. If any binding is noted, disassemble the
motor and check for assembly problems.

Page 4 -- 106

Groundsmaster 4100--D

Hydraulic
System

This page is intentionally blank.

Groundsmaster 4100--D

Page 4 -- 107

Hydraulic System

Fan Drive Manifold
4

10 5 26
7
27

7
11

23
7
22
7
21

14
20
19

7
18
17

12
13

RIGHT
FRONT

Figure 75
1.
2.
3.
4.
5.
6.
7.
8.
9.

Fan drive manifold
O--ring
Test fitting
Dust cap (2 used)
O--ring
45o hydraulic fitting (2 used)
O--ring
Hydraulic hose
Hydraulic hose

10.
11.
12.
13.
14.
15.
16.
17.
18.

Hydraulic fitting
Hydraulic hose
Hydraulic hose
90o hydraulic fitting
90o hydraulic fitting (2 used)
Cap screw (2 used)
Lock washer (2 used)
Hydraulic hose
O--ring

19.
20.
21.
22.
23.
24.
25.
26.
27.

90o hydraulic fitting
Hydraulic hose
Hydraulic hose
Hydraulic tee fitting
Hydraulic test fitting
Oil filter assembly
Cap screw (2 used)
Flat washer (2 used)
Manifold mount

NOTE: The ports on the manifold are marked for easy
identification of components. Example: P1 and P2 are
gear pump connection ports and S1 is the solenoid valve
port (See Hydraulic Schematic in Chapter 9 -- Foldout
Drawings to identify the function of the hydraulic lines
and cartridge valves at each port).
Hydraulic System

Page 4 -- 108

Groundsmaster 4100--D

Removal (Fig. 75)

Installation (Fig. 75)

1. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.

2. To prevent contamination of hydraulic system during
manifold removal, thoroughly clean exterior of manifold
and fittings.
3. Disconnect wire harness connectors from the solenoid valve coils.
4. Disconnect hydraulic lines from manifold and put
caps or plugs on open hydraulic lines and fittings. Label
disconnected hydraulic lines for proper reassembly.
5. Remove hydraulic manifold from the frame using
Figure 75 as guide.

2. Install hydraulic manifold to the frame using Figure
75 as guide.
3. Remove caps and plugs from fittings and hoses. Using labels placed during manifold removal, properly connect hydraulic lines to manifold.
4. Connect wire harness connectors to the solenoid
valve coils.

Groundsmaster 4100--D

Page 4 -- 109

Hydraulic
System

6. If hydraulic fittings are to be removed from manifold,
mark fitting orientation to allow correct assembly. Remove fittings from manifold and discard O--rings.

Hydraulic System

Fan Drive Manifold Service
5 ft--lb
(6.7 N--m)

5 ft--lb
(6.7 N--m)

UP
FRONT

25 ft--lb
(34 N--m)

50 ft--lb
(67 N--m)

7
7

5
20 ft--lb
(27 N--m)

1
25 ft--lb
(34 N--m)

4
2

25 ft--lb
(34 N--m)

2
4

25 ft--lb
(34 N--m)
20 ft--lb
(27 N--m)

FRONT
20 ft--lb
(27 N--m)

Figure 76
1.
2.
3.
4.

Fan drive manifold
#4 zero leak plug (3 used)
Check valve
#6 zero leak plug (2 used)

5. Flow divider valve
6. Nut
7. Solenoid coil (2 used)

8. Proportional relief valve
9. Solenoid valve
10. Nut

Hydraulic System

Page 4 -- 110

Groundsmaster 4100--D

Fan Drive Manifold Service (Fig. 76)

Hydraulic
System

For cartridge valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 76 for fan
drive manifold cartridge valve and plug installation
torque.

Groundsmaster 4100--D

Page 4 -- 111

Hydraulic System

Mow Circuit

RIGHT
FRONT

2
6

8
7

5
3

Figure 77
1. Gear pump
2. RH wing deck motor
3. LH wing deck motor

4. RH Wing Deck manifold
5. Front cutting deck motor
6. LH Wing Deck manifold

7. Front Deck manifold
8. Filter manifold
9. Oil cooler

Figure 77 illustrates the components that are used in the
Groundsmaster 4100--D mow circuits. Procedures for
removal, installation and disassembly/assembly of
these components are provided on the following pages
of this section.

Hydraulic System

Page 4 -- 112

Groundsmaster 4100--D

Cutting Deck Motor
Removal
1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of this section.

5. Remove caps or plugs from fittings and hoses. Connect hydraulic hoses to deck motor.
6. After assembly is completed, verify that hydraulic
hoses and fittings are not contacted by moving components through full range of deck movement.
1

3. To prevent contamination of hydraulic system during
motor removal, thoroughly clean exterior of motor and
fittings.

4. Disconnect hydraulic lines from deck motor. Put
caps or plugs on fittings and hoses to prevent contamination. Label hydraulic lines for proper installation.

6. Carefully remove hydraulic motor from cutting deck
taking care not to damage spider hub attached to motor.
Locate and remove spider and mounting shim(s) (if
present) from the deck.
7. If required, remove spider hub from motor shaft.
Straighten tab washer and remove nut, spider and
woodruff key.

Figure 78
1. Cutting deck motor
2. Flange head screw
3. Inlet hose

1. If spider hub was removed from motor shaft, thoroughly clean tapered surfaces of hub and shaft. Install
spider hub to motor shaft with tab washer and nut.
Torque nut from 27 to 33 ft--lb (37 to 45 N--m). Bend
small tab of washer into keyway and large tab against
nut.

IMPORTANT: For proper hydraulic hose routing,
make sure cutting deck is fully lowered before
installing hoses to deck motor.
Groundsmaster 4100--D

7
8
9
6
12
13
14

10
11

2. Check for proper clearance between spider hub and
spindle pulley. Install motor to cutting deck without placing the spider in the spindle pulley. The clearance between hub and pulley valleys should be from 0.830” to
0.930” (21.1 to 23.6 mm). If required, use mounting
shims between motor and motor mount to adjust clearance.

4. Secure motor to cutting deck with two (2) flange head
screws (Fig. 78).

4. Return hose
5. Case drain hose

Installation

3. Position spider in spindle pulley. Place mounting
shim(s) (if required) on deck. Carefully install hydraulic
motor to the cutting deck taking care not to damage spider hub attached to motor.

Hydraulic
System

5. Remove two (2) flange head screws that secure hydraulic motor to motor mount (Fig. 78).

27 to 33 ft--lb
(37 to 45 N--m)

Figure 79
1.
2.
3.
4.
5.
6.
7.
8.

Page 4 -- 113

Cutting deck motor
O--ring
Hydraulic adapter
O--ring
Flange head screw (2)
O--ring
90o hydraulic fitting
O--ring

9.
10.
11.
12.
13.
14.
15.
16.

90o hydraulic fitting
Woodruff key
Shim (if required)
Spider hub
Tab washer
Nut
Spider
Cutting deck

Hydraulic System

Cutting Deck Motor Service

15
12

27 to 33 ft--lb
(37 to 45 N--m)

9
10

10
14

9
1
8

7
6

33 to 40 ft--lb
(45 to 55 N--m)

Figure 80
1.
2.
3.
4.
5.

Rear cover
Drive gear
Seal
Woodruff key
Nut

6.
7.
8.
9.
10.

Tab washer
Spider hub
Pressure seal
Back--up ring
O--ring

11.
12.
13.
14.
15.

Body
Idler gear
Cap screw (4 used)
Front flange
Dowel pin

Disassembly (Fig. 80)

6. Take motor from the vise and remove cap screws.

1. Plug motor ports and clean the outside of the motor
thoroughly. After cleaning, remove plugs and drain any
oil out of the motor.

7. Remove front flange from the body, then remove rear
cover. Locate and remove dowel pins from body.

2. Straighten tabs on tab washer to allow removal of nut
from motor shaft. Remove tab washer, spider hub and
woodruff key from motor.

DIAGONAL MARK

3. Use a marker to make a diagonal mark across the
front flange, body and rear cover for assembly purposes
(Fig. 81).
IMPORTANT: Prevent damage when clamping the
deck motor into a vise; clamp on the front flange
only. Also, use a vise with soft jaws.
4. Clamp front flange of motor in a vise equipped with
soft jaws with the shaft end down.

Figure 81

5. Loosen cap screws that secure the rear cover.
Hydraulic System

Page 4 -- 114

Groundsmaster 4100--D

IMPORTANT: Mark the relative positions of the gear
teeth and the bearing blocks so they can be reassembled in the same position. Do not touch the
gear surfaces as residue on hands may be corrosive
to gear finish.

8. Place the motor on its side and push on the rear bearing block to remove the bearing block and gear set (Fig.
82).
9. Carefully remove and discard O--rings, pressure
seals and back--up rings (Fig. 83) from motor. Do not
cause any damage to the machined grooves during the
removal process.
IMPORTANT: Make sure not to damage the counter
bore when removing the shaft seal from the front
plate.

2
Figure 82
1. Motor body

2. Bearing block & gear set

10.Position front flange with seal side up. Remove shaft
seal.
Hydraulic
System

Inspection
1. Remove any nicks and burrs from all motor components with emery cloth.

CAUTION
Use eye protection such as goggles when using
compressed air.
Figure 83

2. Clean all motor components with solvent. Dry all
parts with compressed air.
3. Inspect drive gear, idler gear and bearing blocks
(Fig. 84) for the following:
A. Gear shafts should be free of rough surfaces and
excessive wear at bushing points and sealing areas.
Scoring, rough surfaces or wear on gear shafts indicates need for replacement.

B. Gear teeth should be free of excessive scoring
and wear. Any broken or nicked gear teeth must be
replaced.

C. Inspect gear face edge for sharpness. Sharp
edges of gears will mill into bearing blocks and, thus,
must be replaced.
D. Bearing areas of bearing blocks should not have
excessive wear or scoring.
E. Face of bearing blocks that are in contact with
gears should be free of wear, roughness or scoring.
4. Inspect front flange and rear cover for damage or
wear.
Groundsmaster 4100--D

3
Figure 84
1. Drive gear
2. Idler gear

Page 4 -- 115

3. Bearing block

Hydraulic System

Assembly (Fig. 80)
NOTE: When assembling the motor, check the identification marks made during disassembly to make sure
the parts are properly aligned during assembly.
1. Lubricate O--rings, pressure seals, back--up gaskets
and seal grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic
oil.
2. Install new shaft seal into front flange.
3. Install lubricated pressure seals into the grooves in
the front flange and rear cover. Follow by carefully placing the back--up rings into the grooves.
4. Install new O--rings to the body.
5. Lubricate gear faces and bearing surfaces of drive
gear, idler gear and bearing blocks with clean hydraulic
oil. Carefully assemble bearing blocks and gears noting
identification marks made during disassembly.
6. Position the motor body on its side. Carefully slide
bearing block and gear assembly into the body cavity
using identification marks made during disassembly.
7. Remove any excess lubrication from mating surfaces of body, rear cover and front flange. Make sure
that these surfaces are clean and dry.
8. Install dowel pins in body.

9. Gently slide the rear cover onto the assembly using
marker or scribe mark for proper location. Firm hand
pressure should be sufficient to engage the dowel pins.
10.Position the motor with rear cover downwards. Carefully slide the front flange onto the assembly using marker line for proper location.
11. Install the four (4) cap screws and hand tighten.
IMPORTANT: Prevent damage when clamping the
deck motor into a vise; clamp on the front flange
only. Also, use a vise with soft jaws.
12.Place motor front flange in a vise and alternately
torque the screws from 33 to 40 ft--lb (45 to 55 N--m).
13.Put a small amount of hydraulic oil in port on motor
and rotate driveshaft one revolution. Protect the shaft if
using a pliers. If drive shaft binds, disassemble motor
and repeat assembly process.
14.Make sure that tapered surface of motor shaft and
spider hub are thoroughly clean.
15.Place woodruff key in motor shaft slot. Install spider
hub and tab washer on shaft. Secure spider hub to shaft
with nut. Torque nut from 27 to 33 ft--lb (37 to 45 N--m).
16.Secure nut to motor shaft by bending small tab of tab
washer into keyway and large tab against nut.
17.Remove motor from vise.

IMPORTANT: Do not dislodge O--rings, pressure
seals or back--up rings during final assembly.

Hydraulic System

Page 4 -- 116

Groundsmaster 4100--D

Hydraulic
System

This page is intentionally blank.

Groundsmaster 4100--D

Page 4 -- 117

Hydraulic System

Deck Manifolds
16
4

10
25
8

20
2

11 14

13
12

14
21

18
6
17

6 2

16
6

17
13
10

4
18
24

6 11
13
12
4

14
8

9 8

10 1

15
14

RIGHT
FRONT

Figure 85
1.
2.
3.
4.
5.
6.
7.
8.
9.

Center deck manifold
O--ring
Hydraulic adapter
O--ring
Straight hydraulic fitting
O--ring
90o hydraulic fitting
O--ring
Hydraulic tee fitting

Hydraulic System

10.
11.
12.
13.
14.
15.
16.
17.

O--ring
O--ring
Dust cap
Quick fitting
Flange nut
LH wing deck manifold
45o hydraulic fitting
Cap screw (2 used per manifold)

Page 4 -- 118

18.
19.
20.
21.
22.
23.
24.
25.

O--ring
Hydraulic tee fitting
RH wing deck manifold
Hose
90o hydraulic fitting
Hydraulic fitting
Hydraulic adapter
90o hydraulic fitting

Groundsmaster 4100--D

Removal (Fig. 85)

Installation (Fig. 85)

NOTE: The ports on the manifold are marked for easy
identification of components. Example: SV1 is the deck
solenoid valve and P1 is a gear pump connection port.
(See Hydraulic Schematic in Chapter 9 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port).

The control manifolds for the three (3) cutting deck sections are very similar.

2. Install hydraulic manifold to the frame using Figure
85 as guide.

IMPORTANT: When servicing the deck control manifolds, DO NOT interchange parts from one control
manifold to another.

3. Remove caps and plugs from fittings and hoses.
Properly connect hydraulic lines to manifold.

1. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of this section.

4. Connect electrical connector to the solenoid valve.

Hydraulic
System

2. To prevent contamination of hydraulic system during
manifold removal, thoroughly clean exterior of manifold
and fittings.
3. Disconnect electrical connector from the solenoid
valve.
4. Disconnect hydraulic lines from manifold and put
caps or plugs on open hydraulic lines and fittings. Label
disconnected hydraulic lines for proper installation.
5. Remove hydraulic manifold from the frame using
Figure 85 as guide.
6. If hydraulic fittings are to be removed from manifold,
mark fitting orientation to allow correct assembly. Remove fittings from manifold and discard O--rings.

Groundsmaster 4100--D

Page 4 -- 119

Hydraulic System

Deck Manifold Service
20 ft--lb
(27 N--m)

5 ft--lb
(6.7 N--m)
7

9
25 ft--lb
(34 N--m)

20 ft--lb
(27 N--m)

25 ft--lb
(34 N--m)

20 ft--lb
(27 N--m)
1

50 ft--lb
(67 N--m)
20 ft--lb
(27 N--m)

4
2

RH WING DECK PTO MANIFOLD SHOWN

Figure 86
1.
2.
3.
4.

Manifold body
NWD SAE #4 plug with O--ring
Orifice (0.063) (port OR)
#8 zero leak plug with O--ring

5.
6.
7.
8.

Relief valve (port RV2)
Solenoid valve (port S)
Solenoid coil
Nut

9. Relief valve (port RV1)
10. Spool logic cartridge (port LC2)
11. Spool logic cartridge (port LC1)

NOTE: The ports on the manifold are marked for easy
identification of components. Example: S is the deck solenoid valve and P1 is the gear pump connection port.
(See Hydraulic Schematic in Chapter 9 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port location).
The control manifolds for the three (3) cutting deck sections are very similar. The front deck control manifold
does not include an orifice (item 3).
IMPORTANT: When servicing the deck control manifolds, DO NOT interchange parts from one control
manifold to another.

Hydraulic System

Page 4 -- 120

Groundsmaster 4100--D

PTO Manifold Service (Fig. 86)

Hydraulic
System

For solenoid and control valve service procedures, see
4WD Manifold Service in this section. Refer to Figure 86
for PTO manifold cartridge valve and plug installation
torque.

Groundsmaster 4100--D

Page 4 -- 121

Hydraulic System

Lift/Lower Circuit

RIGHT

FRONT

4
8

Figure 87
1. Counterbalance manifold
2. RH wing deck lift cylinder
3. LH wing deck lift cylinder

4. Fan drive manifold
5. Lift control valve
6. Front deck flow control valve

7. Front lift cylinder
8. Oil filter

Figure 87 illustrates the components that are used in the
Groundsmaster 4100--D cutting deck lift and lower circuits. Procedures for removal, installation and disassembly/assembly of these components are provided on
the following pages of this section.

Hydraulic System

Page 4 -- 122

Groundsmaster 4100--D

Hydraulic
System

This page is intentionally blank.

Groundsmaster 4100--D

Page 4 -- 123

Hydraulic System

Lift/Lower Control Valve

13
17
16
14

1
2

17
20
17
21
22

RIGHT
FRONT

11
10

6
8 7

4
3

Figure 88
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Control valve assembly
Valve bracket
Isolator (6 used)
Cap screw
Lock nut (2 used)
Pivot bracket
LH lever assembly
Lever link (3 used)
Center lever assembly
Cotter pin (6 used)

Hydraulic System

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

RH lever assembly
Spacer
Flange head screw (2 used)
Knob (3 used)
Lock nut (4 used)
90o hydraulic fitting (2 used)
O--ring
O--ring
Cap screw (2 used)
Hydraulic fitting (3 used)

Page 4 -- 124

21.
22.
23.
24.
25.
26.
27.
28.
29.

Hydraulic fitting
O--ring
Flat washer (3 used)
Cap screw (3 used)
Control panel
Spring bracket
Extension spring
Lock nut (2 used)
R--clamp

Groundsmaster 4100--D

Removal (Fig. 88)

Installation (Fig. 88)

1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.

1. If fittings were removed from control valve, lubricate
and place new O--rings onto fittings. Install fittings into
port openings using marks made during the removal
process to properly orientate fittings. Tighten fittings
(see Hydraulic Fitting Installation in the General Information section of this chapter).

3. To prevent contamination of hydraulic system during
control valve removal, thoroughly clean exterior of control valve and fittings.
4. Remove lift/lower control valve using Figure 88 as a
guide.
5. If hydraulic fittings are to be removed from control
valve, mark fitting orientation to allow correct assembly.
Remove fittings from valve and discard O--rings.

2. Install lift/lower control valve using Figure 88 as a
guide.
A. If valve bracket (item 2) was removed, tighten cap
screw (item 24) only until the washer (item 23) begins
to seat against the isolator (item 3). The isolator
should not be deformed.
3. After installation, check operation of cutting deck
raise and lower switches (see Cutting Deck Raise and
Lower Switches in the Adjustment section of Chapter 5
-- Electrical System).
4. Make sure hydraulic tank is full. Add correct oil if necessary before returning machine to service.

Groundsmaster 4100--D

Page 4 -- 125

Hydraulic System

Hydraulic
System

2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of this section.

Lift/Lower Control Valve Service

34
13
14
15
31
10

7
11

28
5

4
25
1

11
8
16
19
2
12

20 to 25 ft--lb
(27 to 33 N--m)

30
29

Figure 89
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Poppet
Spacer
Wiper seal
Seat
O--ring
Plug (3 used)
O--ring
Bushing
Spool cap (3 used)
Relief valve poppet
O--ring
Retaining ring

Hydraulic System

13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.

Washer
Washer
Washer
Washer
Plug
O--ring
Spool spring
Backup washer
Detent spring
Detent plunger
Detent plug (3 used)
O--ring

Page 4 -- 126

25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.

O--ring
Backup washer
Disc
Plunger (2 used)
Plug assembly (3 used)
Lockout spring
Relief valve spring
Relief plug assembly
Plunger
O--ring
Spool
Control valve body

Groundsmaster 4100--D

Disassembly (Fig. 89)

Assembly (Fig. 89)

1. Plug all ports and clean outside of valve thoroughly.

1. Thoroughly clean and dry all parts. Apply a light coating of clean hydraulic oil to all control valve parts prior to
assembly.

NOTE: Spools and spool bores are matched sets. Be
sure each spool is identified with the correct valve body
spool bore.
3. Remove spools (item 35) from valve body (item 36).
4. Remove bushings (item 8) and O--rings (item 11)
from spools.
5. Remove plugs (item 6).
IMPORTANT: Check location and positioning of
plungers when removing from body to assure proper assembly.
6. Remove plugs (item 29), lockout springs (item 30),
poppets (item 1), seats (item 4) and plungers (items 28
and 33).
7. Remove plug (item 17).
8. Remove detent plug (item 23), disc (item 27), detent
spring (item 21) and detent plunger (item 22).
9. Remove relief plug assembly (item 32), washers
(items 13, 14 and 15), relief valve spring (item 31) and
relief valve poppet (item 10).
10.Remove all O--rings and back--up rings from all plugs
and seats.
11. Discard all removed O--rings, back--up washers,
wiper seals and nylon poppets.
Inspection
1. Remove all nicks and burns from parts and inspect
for excessive wear.
2. Inspect all plungers and poppet seats for burrs or
roughness.
3. Inspect spool springs (item 19), relief valve spring
(item 31), lockout springs (item 30) and detent spring
(item 21) for breakage.

NOTE: All O--rings, back--up washers, wiper seals and
nylon poppets should be replaced as new items.
2. Install new O--rings (item 11) in proper grooves in
spool bores.
3. Install relief valve components (items 13, 14, 15, 31
and 10) with new O--ring (item 34) on plug assembly
(item 32).
4. Install plugs (item 6) with new back--up washers
(item 20) and new O--rings (item 7).
5. Install plungers (items 33 and 28).
IMPORTANT: Check location and positioning of
plungers during installation.
6. Install new O--rings (item 5) on seats (item 4). Install
new back--up washers (item 26) and O--rings (item 25)
on plugs (item 29).
7. Install seats (item 4), new poppets (item 1) and plugs
(item 29).
8. Install plug (item 17) with new O--ring (item 18).
9. Install detent plunger (item 22), spring (item 21), disc
(item 27) and plug (item 23) with new O--ring (item 24).
10.If retaining ring (item 12) has been removed to replace spool spring (item 19), install washer (item 16),
spring (item 19) and spacer (item 2) on spool. Secure
with retaining ring (item 12).
11. Slide bushings (item 8) over spools. Slide new O-rings (item 11) over spools and position next to bushings. Dip spools in clean hydraulic oil and install spool
assemblies into proper location of valve body.
12.Install spool caps (item 9) and tighten from 20 to 25
ft--lb (27 to 33 N--m).
13.Install new wiper seals (item 3).

4. If spools (item 35) have excessive wear, the control
valve becomes non--serviceable as the spools and
spool bores are matched. Damaged spools cannot be
replaced individually.
5. Inspect relief valve poppet (item 10) for breakage or
wear.
Groundsmaster 4100--D

Page 4 -- 127

Hydraulic System

Hydraulic
System

2. Remove spool caps (item 9). Do not remove retaining rings (item 12) from spools unless spool spring (item
19) is broken.

Front Deck Lift Cylinder
10 9
7
8

RIGHT

11
9

FRONT

6
13
5

4
2

Figure 90
1.
2.
3.
4.
5.

Lift cylinder (2 used)
Lift arm (LH shown)
Lock nut
Pin
Flange head screw

Hydraulic System

6.
7.
8.
9.

Grease fitting
O--ring
90o hydraulic fitting
O--ring

Page 4 -- 128

10.
11.
12.
13.

Hydraulic fitting
Pivot pin
Cotter pin
Grease fitting

Groundsmaster 4100--D

Removal (Fig. 90)

Installation (Fig. 90)

1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.

1. If fittings were removed from lift cylinder, lubricate
and place new O--rings onto fittings. Install fittings into
port openings using marks made during the removal
process to properly orientate fittings. Tighten fittings
(see Hydraulic Fitting Installation in the General Information section of this chapter).

3. To prevent contamination of hydraulic system during
lift cylinder removal, thoroughly clean exterior of cylinder and fittings.

2. Position cylinder barrel clevis to frame and insert upper lift pin into frame and clevis. Secure lift pin with cotter
pin.

NOTE: To ease installation, label the hydraulic hoses to
show their correct position on the lift cylinder.

3. Insert pin through lift arm and cylinder shaft clevis.
Secure pin to lift arm with flange head screw and lock
nut.

4. Disconnect hydraulic hoses from lift cylinder.

4. Attach hydraulic hoses to lift cylinder.

5. Remove flange head screw and lock nut that secure
the pin to the lift arm. Remove pin from lift arm and cylinder shaft clevis which will free lift cylinder from lift arm.

5. Fill reservoir with hydraulic fluid as required.

6. Remove one cotter pin from upper lift pin. Pull upper
lift pin from frame and cylinder barrel clevis.

6. After assembly is completed, operate lift cylinder to
verify that hydraulic hoses and fittings are not contacted
by anything.

7. Remove lift cylinder from machine.
8. If hydraulic fittings are to be removed from lift cylinder, mark fitting orientation to allow correct assembly. Remove fittings from cylinder and discard O--rings.

Groundsmaster 4100--D

Page 4 -- 129

Hydraulic System

Hydraulic
System

2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of this section.

Wing Deck Lift Cylinder
2

160 to 180 ft--lb
(217 to 244 N--m)
8

30 to 40 ft--lb
(41 to 54 N--m)

12
6
13

5
4
2

160 to 180 ft--lb
(217 to 244 N--m)

3
9
10

RIGHT
FRONT

Figure 91
1.
2.
3.
4.
5.

Center deck
Grease fitting
Tapered stud
Spherical bearing
Flange nut

Hydraulic System

6.
7.
8.
9.

Retaining ring
Wing deck lift cylinder
Lock nut
Flat washer

Page 4 -- 130

10.
11.
12.
13.

Lock nut
Pilot spacer
Cap screw
Wing deck (RH shown)

Groundsmaster 4100--D

Removal (Fig. 91)

Installation (Fig. 91)

1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.

1. If removed, install spherical bearings into lift cylinder
clevis ends.

3. Remove deck covers as needed to allow access to
lift cylinder hoses and fasteners.
4. To prevent contamination of hydraulic system during
lift cylinder removal, thoroughly clean exterior of cylinder and fittings.
NOTE: To ease installation, label the hydraulic hoses to
show their correct position on the lift cylinder.
5. Disconnect hydraulic hoses from lift cylinder.
6. Remove cap screw and lock nut that secure the lift
cylinder clevis to the wing deck.
7. Remove lock nut and flat washer from the tapered
stud on the barrel end of the lift cylinder.

B. On barrel clevis, install spherical bearing on tapered stud and secure with flange nut. Torque flange
nut from 30 to 40 in--lb (41 to 54 N--m). Install stud
with spherical bearing into clevis and secure with retaining ring.
2. Thoroughly clean tapered surfaces of lift cylinder
stud and mounting boss on deck.
3. Position lift cylinder to cutting deck. Insert tapered
stud into deck mounting boss. Secure stud with flat
washer and lock nut. Torque flange nut from 160 to 180
ft--lb (217 to 244 N--m).
4. Insert cap screw from the front of the deck through
the deck brackets and cylinder shaft clevis. Secure cap
screw with lock nut. Torque lock nut from 160 to 180 ft-lb (217 to 244 N--m).
5. Attach hydraulic hoses to lift cylinder.

8. Remove lift cylinder from deck assembly.
9. Remove spherical bearings from lift cylinder clevis
ends, if required.
A. On shaft clevis, remove retaining ring and then
press spherical bearing from clevis.
B. On barrel clevis, remove retaining ring and then
press tapered stud with spherical bearing and flange
nut from clevis. Remove flange nut and then spherical bearing from stud.

Groundsmaster 4100--D

A. On shaft clevis, press spherical bearing into clevis and secure with retaining ring.

6. Install any removed deck covers.
7. Fill reservoir with hydraulic fluid as required.
8. After assembly is completed, operate lift cylinder to
verify that hydraulic hoses and fittings are not contacted
by anything.

Page 4 -- 131

Hydraulic System

Hydraulic
System

2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of this section.

Deck Lift Cylinder Service
100 to 120 ft--lb
(136 to 162 N--m)

FRONT DECK LIFT CYLINDER

11
3
8

1
13
10

Figure 92
1.
2.
3.
4.
5.

Barrel with clevis
Retaining ring
Shaft with clevis
Dust seal
Rod seal

6.
7.
8.
9.

O--ring
Back--up ring
Head
O--ring

10.
11.
12.
13.

60 to 75 ft--lb
(82 to 101 N--m)

Wear ring
Piston
Locking nut
Seal with loader

WING DECK LIFT CYLINDER

11
8
2

1
10

Figure 93
1.
2.
3.
4.

Barrel with clevis
Retaining ring
Shaft with clevis
Dust seal

Hydraulic System

5.
6.
7.
8.

Rod seal
O--ring
Back--up ring
Head

Page 4 -- 132

9.
10.
11.
12.

O--ring
Seal with O--ring
Piston
Lock nut

Groundsmaster 4100--D

Disassembly (Figs. 92 and 93)

Assembly (Figs. 92 and 93)

1. Remove oil from lift cylinder into a drain pan by slowly
pumping the cylinder shaft. Plug both ports and clean
the outside of the cylinder.

1. Make sure all cylinder components are clean before
assembly.

2. Mount lift cylinder securely in a vise by clamping on
the clevis end of the barrel. Use of a vise with soft jaws
is recommended.
3. Loosen head from barrel:
A. Use a spanner wrench to rotate head clockwise
until the edge of the retaining ring appears in the barrel opening.
B. Insert a screwdriver under the beveled edge of
the retaining ring to start the retaining ring through
the opening.
C. Rotate the head counter--clockwise to remove retaining ring from barrel and head.
4. Extract shaft with head and piston by carefully twisting and pulling on the shaft.
IMPORTANT: Do not clamp vise jaws against the
shaft surface. Protect shaft surface before mounting in a vise.

2. Coat new seal kit components with clean hydraulic
oil.
A. Install new seals and O--rings to the piston.
B. Install new seals, O--ring and back--up ring to the
head.
IMPORTANT: Do not clamp vise jaws against the
shaft surface. Protect shaft surface before mounting in a vise.
3. Mount shaft securely in a vise by clamping on the clevis of the shaft.
A. Coat shaft with clean hydraulic oil.
B. Carefully slide head and piston onto the shaft.
Secure piston to shaft with lock nut.
C. Torque lock nut to specification in Figure 92 (front
deck cylinder) or Figure 93 (wing cylinder).
4. Lubricate head and piston with hydraulic oil. Carefully slide shaft assembly into cylinder barrel.
IMPORTANT: Prevent damage when clamping the
cylinder’s barrel into a vise; clamp on the clevis
only. Do not close vise enough to distort the barrel.

5. Mount shaft securely in a vise by clamping on the clevis of the shaft. Remove lock nut and piston from the
shaft. Slide head off the shaft.

5. Mount lift cylinder in a vise with soft jaws. Secure
head in barrel:

6. Remove and discard all seals and O--rings from the
piston and the head.

A. Align retaining ring hole in the head with the access slot in the barrel.

7. Wash parts in clean solvent. Dry parts with compressed air. Do not wipe parts dry with paper towels or
cloth. Lint in a hydraulic system will cause damage.

B. Insert the retaining ring hook into the hole and rotate head clockwise until the retaining ring is completely pulled into the barrel and the ring ends are
covered.

8. Carefully inspect internal surface of barrel for damage (deep scratches, out--of--round, etc.). Replace entire cylinder if barrel is damaged. Inspect piston rod and
piston for evidence of excessive scoring, pitting or wear.
Replace any damaged parts.

Groundsmaster 4100--D

C. Apply silicone sealer to barrel access slot.

Page 4 -- 133

Hydraulic System

Hydraulic
System

IMPORTANT: Prevent damage when clamping the
cylinder in a vise; clamp on the clevis only. Do not
close vise enough to distort the barrel.

Counterbalance Manifold

16
15
10
13

14
1

RIGHT

FRONT

3
4
7 6

Figure 94
1.
2.
3.
4.
5.
6.

Counterbalance hydraulic manifold
Valve plate
Flat washer (2 used)
Cap screw (2 used)
Isolator (4 used)
Flat washer (2 used)

7.
8.
9.
10.
11.

Lock nut (2 used)
Hydraulic fitting (2 used)
O--ring
O--ring
90o hydraulic fitting (4 used)

12.
13.
14.
15.
16.

Cap screw (2 used)
90o hydraulic fitting
O--ring
Test nipple
Dust cap

NOTE: The ports on the manifold are marked for easy
identification of components. Example: C1 is the connection port from the LH deck lift cylinder and CHG is the
charge circuit connection (See Hydraulic Schematic in
Chapter 9 -- Foldout Drawings to identify the function of
the hydraulic lines and cartridge valves at each port).

Hydraulic System

Page 4 -- 134

Groundsmaster 4100--D

Removal (Fig. 94)

Installation (Fig. 94)

1. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.

2. Install hydraulic manifold to the frame using Figure
94 as guide.

5. If hydraulic fittings are to be removed from manifold,
mark fitting orientation to allow correct assembly. Remove fittings from manifold and discard O--rings.

3. Remove caps and plugs from fittings and hoses. Using labels placed during manifold removal, properly connect hydraulic lines to manifold.

Hydraulic
System

4. Remove hydraulic manifold from the frame using
Figure 94 as guide.

A. If valve plate (item 2) was removed, tighten lock
nut (item 7) until washer begins to seat in isolator
(item 5). Do not cause isolator to be deformed during
valve plate installation.

Groundsmaster 4100--D

Page 4 -- 135

Hydraulic System

Counterbalance Manifold Service

35 to 40 ft--lb
(47 to 54 N--m)

UP
FRONT

Figure 95
1. Manifold body
2. Pilot valve

3. Seal kit
4. Relief valve (counterbalance)

Hydraulic System

5. Seal kit

Counterbalance Manifold Service (Fig. 95)
For cartridge valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 95 for counterbalance manifold cartridge valve installation torque.

Page 4 -- 136

Groundsmaster 4100--D

Chapter 5

Electrical System
Table of Contents

Groundsmaster 4100--D

Audio Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow and Power Relays . . . . . . . . . . . . . . . . . . . . .
Start, Engine Shutdown, Seat, Alarm, PTO, PTO
Overtemp, Down Latching and Over
Temperature Relays . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Valve Solenoids . . . . . . . . . . . . . . . . . . .
TEC--5002 Controller . . . . . . . . . . . . . . . . . . . . . . .
Fuel Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . .
Dual Temperature Switch . . . . . . . . . . . . . . . . . . . .
Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . .
Traction Neutral Switch . . . . . . . . . . . . . . . . . . . . .
Diode Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . .
Diode Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . .
Fusible Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wing Deck Position Switches . . . . . . . . . . . . . . . .
Cutting Deck Raise and Lower Switches . . . . . .
Engine Coolant and Hydraulic Oil Temperature
Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . .
Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 5 -- 1

19
20
21
22
23
24
25
26
27
28
29
30
31
31
32
33
34
35
36
37
37
37
38

Electrical System

Electrical
System

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 5
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Run & Transport Problems . . . . . . . . . . . . 6
Cutting Deck Operating Problems . . . . . . . . . . . . . 7
ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . . 8
Battery Test (Open Circuit Test) . . . . . . . . . . . . . . . 8
Charging System Test . . . . . . . . . . . . . . . . . . . . . . . 8
Check Operation of Interlock Switches . . . . . . . . . 8
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Wing Deck Position Switches . . . . . . . . . . . . . . . . . 9
Cutting Deck Raise and Lower Switches . . . . . . 10
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . 11
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Alarm Silence and Temperature Override
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Transport/4WD Switch . . . . . . . . . . . . . . . . . . . . . . 15
Cooling Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . 16
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . 18
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Electrical Drawings
The electrical schematic, circuit diagrams and wire harness drawings for the Groundsmaster 4100--D are located in Chapter 9 -- Foldout Drawings.

Electrical System

Page 5 -- 2

Groundsmaster 4100--D

Special Tools
Order special tools from your Toro Distributor. Some
tools may also be available from a local supplier.

Multimeter
The meter can test electrical components and circuits
for current, resistance or voltage.
NOTE: Toro recommends the use of a DIGITAL Volt-Ohm--Amp multimeter when testing electrical circuits.
The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter. This excess
current can cause damage to circuits not designed to
carry it.

Figure 1

Skin--Over Grease
Electrical
System

Special non--conductive grease which forms a light protective skin to help waterproof electrical switches and
contacts.
Toro Part Number: 505--165

Figure 2

Deck Proximity Switch Adjustment Tool
The Deck Proximity Switch Adjustment Tool is designed
to assist in the adjustment of the cutting deck position
switches for cutting blade shutdown during deck lift.
Toro Part Number: TOR4095

Figure 3

Groundsmaster 4100--D

Page 5 -- 3

Electrical System

Dielectric Gel
Dielectric gel should be used to prevent corrosion of
connection terminals. To ensure complete coating of terminals, liberally apply gel to both component and wire
harness connector, plug connector to component, unplug connector, reapply gel to both surfaces and reconnect harness connector to component. Connectors
should be thoroughly packed with gel for effective results.
Toro Part Number: 107--0342
Figure 4

Battery Terminal Protector
Aerosol spray that should be used on battery terminals
to reduce corrosion problems. Apply terminal protector
after the battery cable has been secured to the battery
terminal.
Toro Part Number: 107--0392

Figure 5

Battery Hydrometer
Use the Battery Hydrometer when measuring specific
gravity of battery electrolyte. Obtain this tool locally.

Figure 6

Electrical System

Page 5 -- 4

Groundsmaster 4100--D

Troubleshooting
For effective troubleshooting and repairs, there must be
a good understanding of the electrical circuits and components used on this machine (see electrical schematic
and circuit diagrams in Chapter 9 -- Foldout Drawings).

CAUTION
Remove all jewelry, especially rings and
watches, before doing any electrical troubleshooting or testing. Disconnect the battery
cables unless the test requires battery voltage.

If the machine has any interlock switches by--passed,
connect the switches for proper troubleshooting and
safety.

Starting Problems
Problem

Possible Causes

All electrical power is dead, including gauges.

The traction pedal is not in the neutral position.
The battery is discharged.
Fuse F2 (10 amp) to the ignition switch is faulty.
A bad ground connection exists on machine.
The ignition switch or circuit wiring is faulty.
The neutral switch or circuit wiring is faulty.

Starter solenoid clicks, but starter will not crank.
NOTE: If the solenoid clicks, the problem is not in the
interlock circuit.

The battery is discharged.
The battery cables are loose or corroded.
A ground wire or cable is loose or corroded.
Wiring at the starter motor is faulty.
The starter solenoid is faulty.
The starter is faulty.

Nothing happens when start attempt is made. Control
panel lights and gauges operate with the ignition
switch in ON.

The traction pedal is not in neutral position.
The traction neutral switch or circuit wiring is faulty.
The ignition switch or circuit wiring is faulty.
The start relay or circuit wiring is faulty.
The starter solenoid is faulty.
The starter is faulty.

Engine starts, but stops when the ignition switch is
released from the START position.

The engine run solenoid is out of adjustment or circuit
wiring is faulty.
The high temperature shutdown switch or circuit wiring
is faulty.

Groundsmaster 4100--D

Page 5 -- 5

Electrical System

Electrical
System

The fusible link from the battery is faulty.

Problem

Possible Causes

Engine cranks, but does not start.

Engine is not cranking fast enough.
The engine run solenoid or circuit wiring is faulty.
The fuel pump is faulty.
An engine problem exists (see Chapter 3 -- Kubota
Engine).

Starter cranks, but should not when the traction pedal
is depressed.

The traction neutral switch is out of adjustment.
The traction neutral switch or circuit wiring is faulty.

General Run and Transport Problems
Engine continues to run, but should not, when the
ignition switch is turned off.

The engine run solenoid is stuck or is faulty.

Engine continues to run, but should not, when the
traction pedal is engaged with no operator in the seat.

The seat switch or circuit wiring is faulty.

The engine stops during operation, but is able to
restart.

The operator is lifting off the seat switch.

The ignition switch or circuit wiring is faulty.

The traction neutral switch or circuit wiring is faulty.

The seat switch or circuit wiring is faulty.
The engine shutdown delay is faulty.
The ignition switch or circuit wiring is faulty.

The engine kills when the traction pedal is depressed.

The operator is lifting off the seat as the pedal is
depressed.
The seat switch or circuit wiring is faulty.

Battery does not charge.

Loose, corroded or broken wire(s).
The fusible link to the battery is faulty.
The charge indicator lamp is faulty or burned out.
The charge indicator lamp wiring is loose, corroded or
damaged.
The battery is faulty.
The alternator is faulty.

Electrical System

Page 5 -- 6

Groundsmaster 4100--D

Cutting Deck Operating Problems
The cutting deck remains engaged, but should not,
with no operator in the seat.

The seat switch or circuit wiring is faulty.

Cutting deck runs, but should not, when raised. Deck
shuts off with PTO switch.

The deck position switch or circuit wiring is faulty.

Cutting deck runs, but should not, when raised. Deck
does not shut off with the PTO switch.

The deck position switch or circuit wiring and PTO
switch or circuit wiring are faulty.
A hydraulic problem exists (see Troubleshooting
section of Chapter 4 -- Hydraulic System).

Cutting deck runs, but should not, when lowered with
PTO switch in the OFF (disengage) position.

The PTO switch or circuit wiring is faulty.

Cutting deck does not operate.

The operator is lifting off the seat switch.
Traction circuit is in transport mode.
The seat switch, relay or circuit wiring is faulty.
The PTO switch, relay or circuit wiring is faulty.
The deck position switch or circuit wiring is faulty.

The transport/4WD switch or circuit wiring is faulty.
Hydraulic valve solenoid(s) or circuit wiring is faulty.
A hydraulic problem exists (see Troubleshooting
section of Chapter 4 -- Hydraulic System).
Cutting deck shut off when PTO switch is released
from the engage position.

Diode circuit board or circuit wiring is faulty.

PTO fuse blows when engaging cutting deck.

Hydraulic valve solenoid coil is shorted.
Deck position switch is faulty.

Groundsmaster 4100--D

Page 5 -- 7

Electrical System

Electrical
System

Center lift lever position switch is out of adjustment or
faulty.

Electrical System Quick Checks
Battery Test (Open Circuit Test)
Use a multimeter to measure the voltage between the
battery terminals.
Set multimeter to the DC volts setting. The battery
should be at a temperature of 60oF to 100oF (16oC to
38oC). The ignition key should be off and all accessories
turned off. Connect the positive (+) meter lead to the
positive battery post and the negative (--) meter lead to
the negative battery post.

Voltage Measured

Battery Charge Level

12.68 V (or higher)

Fully charged (100%)

12.45 V

75% charged

12.24 V

50% charged

12.06 V

25% charged

11.89 V

0% charged

NOTE: This test provides a relative condition of the battery. Load testing of the battery will provide additional
and more accurate information.

Charging System Test
This is a simple test used to determine if a charging system is functioning. It will tell you if the charging system
has an output, but not its capacity.

Start the engine and run at high idle (2870 RPM). Allow
the battery to charge for at least 3 minutes. Record the
battery voltage.

Use a digital multimeter set to DC volts. Connect the
positive (+) multimeter lead to the positive battery post
and the negative (--) multimeter lead to the negative battery post. Keep the test leads connected to the battery
posts and record the battery voltage.

After running the engine for at least 3 minutes, battery
voltage should be at least 0.50 volt higher than initial battery voltage.

NOTE: Upon starting the engine, the battery voltage
will drop and then should increase once the engine is
running.
NOTE: Depending upon the condition of the battery
charge and battery temperature, the battery voltage will
increase at different rates as the battery charges.

An example of a charging system that is functioning:
At least 0.50 volt over initial battery voltage.
Initial Battery Voltage

= 12.30 v

Battery Voltage after 3 Minute Charge

= 12.85 v

Difference

= +0.55 v

Check Operation of Interlock Switches

CAUTION
Do not disconnect safety switches. They are for
the operator’s protection. Check the operation of
the interlock switches daily for proper operation.
Replace any malfunctioning switches before operating the machine.

Electrical System

Interlock switch operation is described in the Operator’s
Manual. Testing of interlock switches and relays is included in the Component Testing section of this Chapter.

Page 5 -- 8

Groundsmaster 4100--D

Adjustments
Wing Deck Position Switches
Adjustment
5

1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.
2. Remove switch cover from deck to allow access to
position switch that requires adjustment.
NOTE: Use Deck Proximity Switch Adjustment Tool
(TOR4095) to assist with switch adjustment (see Special Tools).

3. Loosen two (2) lock nuts that secure switch bracket
to center cutting deck (Fig. 7).

3
2

4. When adjusting switch location, the target surface of
position switch should be approximately 0.188” (4.8
mm) from actuator tab on wing deck link (Fig. 8).

6. For switch testing information, see Wing Deck Position Switches in the Component Testing section of this
chapter.

Figure 7
1.
2.
3.
4.

Position switch
Lock nut (2 used)
Flat washer (2 used)
Switch bracket

5. Carriage screw (2 used)
6. Center cutting deck
7. Screw (2 used)

0.188”
(4.8 mm)

2
3

Figure 8
1. Position switch
2. Actuator tab

Groundsmaster 4100--D

Page 5 -- 9

3. Wing deck link

Electrical System

Electrical
System

5. When wing deck position switch is properly adjusted,
hydraulic motor on wing deck should turn off when wing
deck is raised and wing deck latch opens.

Cutting Deck Raise and Lower Switches
Adjustment (Fig. 9)

1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch. Remove console housing.

3
5

2. The cutting deck raise and lower switches can be adjusted for correct operation by repositioning the
switch(es).

A. The distance between switches should be from
0.595” to 0.655” (15.2 to 16.6 mm) (Fig. 10).
B. The lever bracket (item 4) should be parallel with
the center deck lift/lower lever. If lever bracket adjustment is needed, loosen flange bolts (item 6) and
reposition lever bracket.
C. Switch surfaces need to be parallel to each other
and also to the switch actuator on center lift/lower lever (item 9). If necessary, switch plate (item 3) can be
rotated after loosening flange nut (item 5).

3. After any switch adjustment, unplug switch connector from machine harness and check for correct switch
operation using a multimeter:
A. The raise switch should be closed (continuity)
when the center deck lift/lower lever is in the neutral
position. As the lift/lower lever is slowly pulled back,
the raise switch should open (no continuity) after the
lever has removed all free play (with no spool movement in lift/lower control valve) but before the deck is
lifted.

Figure 9
1.
2.
3.
4.
5.

Deck lower switch
Deck raise switch
Switch plate
Lever bracket
Flange nut

6.
7.
8.
9.
10.

Flange bolt (2 used)
Tab plate
Deck lift/lower lever
Switch actuator
Lock nut (2 used)

B. The lower switch should be open (no continuity)
when the center deck lift/lower lever is in the neutral
position. As the lift/lower lever is slowly pushed forward, the lower switch should close (continuity) before the lever reaches full forward travel.
4. If switch operation is too sensitive, increase distance
between switches by repositioning one or both
switches. If switch operation is not sensitive enough, decrease distance between switches by repositioning one
or both switches. Recheck operation of switches after
repositioning.
5. If switches cannot be adjusted for correct operation,
exchange position of switches. Recheck operation of
switches.
NOTE: If correct switch operation cannot be achieved,
replace one or both switches. Recheck switch operation
after replacement.

Electrical System

0.595” to 0.655”
(15.2 to 16.6 mm)

Figure 10
1. Deck lower switch

Page 5 -- 10

2. Deck raise switch

Groundsmaster 4100--D

Component Testing
For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the
circuit (e.g. unplug the ignition switch connector before
doing a continuity check).
NOTE: For engine component testing information, see
the Kubota Workshop Manual, Diesel Engine,
V2403--M--T--E3B Series at the end of Chapter 3 -- Kubota Diesel Engine.

CAUTION
When testing electrical components for continuity with a multimeter (ohms setting), make sure
that power to the circuit has been disconnected.

Ignition Switch
The ignition (key) switch has three positions: OFF, ON/
PREHEAT and START (Fig. 11). The terminals are
marked as shown in Figure 12. The circuit wiring of the
ignition switch is shown in the chart. With the use of a
multimeter (ohms setting), the switch functions may be
tested to determine whether continuity exists between
the various terminals for each position. Verify continuity
between switch terminals.

START

ON / PREHEAT

45 °
START

NONE
Figure 11

B + I + A, X + Y

Electrical
System

ON / PREHEAT

45 °

CIRCUIT

POSITION
OFF

OFF

B+I+S

Y
X

I
Figure 12

Groundsmaster 4100--D

Page 5 -- 11

Electrical System

Fuses
The fuse blocks are located under the operator’s control
console.
10A

10A

15A
OPT

10A

The fuses are held in three (3) fuse blocks. Use Figures
13 and 14 to identify each individual fuse and its correct
amperage. Each fuse holder has the following functions
and wire connected to it.

Identification, Function and Wiring

Fuse F1 (5 amp) (fuseblock location A1): Supplies
power to the seat switch and seat relay.

Fuse F3 (10 amp) (fuseblock location A3): Supplies power to the PTO switch.
Fuse F4 (10 amp) (fuseblock location A4): Supplies power to the starter solenoid.

7.5A

10A

Fuse F2 (10 amp) (fuseblock location A2): Supplies power to ignition switch terminal B.

Figure 13

Fuse F5 (when optional lighting is installed) (15
amp) (fuseblock location B4): Supplies power for
optional light kit.
Fuse F8 (10 amp) (fuseblock location B1): Supplies power to the power point outlet.
Fuse F9 (7.5 amp) (fuseblock location C4): Supplies power for engine cooling fan operation
(TEC--5002 controller).
Fuse F10 (10 amp) (fuseblock location C3): Supplies power for seat operation.
In addition to the fuses in the fuse blocks, a 2 amp fuse
is included in the wire harness to protect the logic power
circuit for the TEC--5002 controller. This fuse resides in
a fuse holder near the battery.

Electrical System

Page 5 -- 12

Figure 14

Groundsmaster 4100--D

Warning Lights
Engine Oil Pressure Light
The oil pressure light should come on when the ignition
switch is in the ON position with the engine not running.
Also, it should light with the engine running if the engine
oil pressure drops below 7 PSI (0.5 kg/cm2).

1. Disconnect green wire from the oil pressure switch
on the engine (located near the starter motor).

2. Ground green wire to the engine block.

3. Turn ignition switch to ON; the oil pressure light
should come on indicating correct operation of the electrical wiring to the oil pressure switch.
4. Turn ignition switch to OFF. Reconnect green wire to
the oil pressure switch. Apply skin--over grease (Toro
Part No. 505--165) to switch terminal.
High Temperature Warning Light

NOTE: If the PTO is engaged when the dual temperature switch terminal closes, the PTO will disengage.
To test the high temperature warning light and its circuit
wiring, ground the blue wire attached to dual temperature switch on engine water flange. The high temperature warning light should illuminate.

Figure 15
1. Charge indicator
2. Engine oil pressure

3. High temp warning
4. Glow plug indicator

Glow Plug Indicator Light
The glow plug indicator light should come on when the
ignition switch is placed in ON prior to placing the ignition
switch in START. The light should stay lit for approximately 10 seconds while the ignition switch is left in ON.
Charge Indicator Light
The charge indicator light should come on when the ignition switch is in ON with the engine not running or with
an improperly operating charging circuit while the engine is running.

1A (+)

2A (+)

Testing Warning Lights
1. Apply 12 VDC to terminals 1A and 2A.
2. Ground terminals 1B and 2B.

Figure 16
1. Charge indicator
2. Engine oil pressure
3. High temp shutdown

4. Glow plug indicator
5. Warning light back

3. Both indicator lights should light.

Groundsmaster 4100--D

Page 5 -- 13

Electrical System

Electrical
System

If the coolant temperature rises to approximately 220oF
(105oC), the high temperature warning light should illuminate as the dual temperature switch terminal closes.

PTO Switch
The PTO switch is used to engage or disengage the cutting deck. The PTO switch is attached to the control console next to the operator seat (Fig. 17).

2
1

The switch terminals are marked as shown in Figure 18.
The circuitry of the PTO switch is shown in the chart below. With the use of a multimeter (ohms setting), the
switch functions may be tested to determine whether
continuity exists between the various terminals for each
position. Verify continuity between switch terminals.
NOTE: The PTO ENGAGE position requires lifting and
pushing the lever toward the switch keyway. The PTO
OFF position occurs when the lever is pushed opposite
the keyway.
SWITCH
POSITION

NORMAL
CIRCUITS

OTHER
CIRCUITS

PTO ENGAGE

1+2

4+5

CENTER (ON)

1+2

NONE

PTO OFF

NONE

Figure 17
1. PTO switch

2. Control console

BACK OF PTO SWITCH
Figure 18

Alarm Silence and Temperature Override Switches
The alarm silence and temperature override rocker
switches are located on the control console next to the
operator seat (Fig. 19). These switches are identical.

Testing
The switch terminals are shown in Figure 20. The circuitry of the switches is shown in the chart below. With the
use of a multimeter (ohms setting), the switch functions
may be tested to determine whether continuity exists
between the various terminals for each position. Verify
continuity between switch terminals.
SWITCH
POSITION

NORMAL
CIRCUITS

OTHER
CIRCUITS

2+3

5+6

OFF

1+2

4+5

Figure 19
1. Control console
2. Alarm silence switch

NOTE: Terminals 7 (--) and 8 (+) on alarm silence and
temperature override switches are for the switch light.

3. Temp. override switch

BACK OF ALARM SILENCE AND
TEMPERATURE OVERRIDE SWITCHES
Figure 20
Electrical System

Page 5 -- 14

Groundsmaster 4100--D

Transport / 4WD Switch
The transport/4WD switch is used to set the machine
traction speed for transport or mow. The transport/4WD
rocker switch is located on the control console next to
the operator seat (Fig. 21).

Testing
The switch terminals are shown in Figure 22. The circuitry of the switches is shown in the chart below. With the
use of a multimeter (ohms setting), the switch functions
may be tested to determine whether continuity exists
between the various terminals for each position. Verify
continuity between switch terminals.

2
Figure 21
1. Control console

SWITCH
POSITION

NORMAL
CIRCUITS

OTHER
CIRCUITS

TRANSPORT

2+3

5+6

MOW

1+2

4+5

2. Transport/4WD switch

BACK OF TRANSPORT / 4WD SWITCH

Groundsmaster 4100--D

Page 5 -- 15

Electrical
System

Figure 22

Electrical System

Cooling Fan Switch
The cooling fan switch is used to control the operation
of the hydraulic cooling fan and is located on the control
console (Fig. 23). This switch has three (3) positions:
Reverse, Auto and Forward.
When the cooling fan switch is in the normal Auto position, cooling fan operation is controlled by the
TEC--5002 controller. In this switch position, if either engine coolant or hydraulic oil temperature is excessive,
the fan will stop and then reverse direction to allow automatic debris cleaning of the radiator, oil cooler and rear
intake screen. The controller determines the length of
time that the fan should be run in reverse before fan rotation is returned to the forward direction.

Figure 23
1. Control console

If the operator depresses the cooling fan switch to the
Reverse position, a fan reverse cycle that is controlled
by the TEC--5002 controller is initiated. The switch automatically returns to the Auto position and fan operation
returns to the forward direction after the reverse cycle is
completed.
If the cooling fan switch is placed in the Forward position, the engine cooling fan will run only in the forward
direction.
Testing

2. Cooling fan switch

BACK OF COOLING FAN SWITCH
Figure 24

The switch terminals are shown in Figure 24. The circuitry of the switch is shown in the chart below. With the use
of a multimeter (ohms setting), the switch functions may
be tested to determine whether continuity exists between the various terminals for each position. Verify
continuity between switch terminals.
SWITCH
POSITION

NORMAL
CIRCUITS

OTHER
CIRCUITS

NORMAL

2+3

NONE

REVERSE

2+3

5+6

FORWARD

NONE

Electrical System

Page 5 -- 16

Groundsmaster 4100--D

Seat Switch
The seat switch is normally open and closes when the
operator is on the seat. The seat switch and its electrical
connector are located in the seat assembly. If the traction system or PTO switch is engaged when the operator
raises out of the seat, the engine will stop. Testing of the
switch can be done without seat removal by disconnecting the seat wire from the machine wiring harness (Fig.
25).

Testing

1. Make sure the engine is off.
2. Disconnect wire harness electrical connector for the
seat switch.
3. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the connector terminals.

Figure 25
1. Seat switch electrical connector
2. Operator seat

4. With no pressure on the seat, there should be no
continuity between the seat switch terminals.

Electrical
System

5. Press directly onto the seat switch through the seat
cushion. There should be continuity as the seat cushion
approaches the bottom of its travel.
6. If testing determines that seat switch is faulty, replace seat switch (see Operator Seat Service in the Service and Repairs section of Chapter 7 -- Chassis).
7. Connect seat switch to harness connector after testing is complete.

Groundsmaster 4100--D

Page 5 -- 17

Electrical System

Parking Brake Switch
The switch used for the parking brake is a normally open
switch that is located under the steering tower cover
(Fig. 26). When the parking brake is not applied, the
parking brake pawl depresses the switch plunger to
close the switch. When the parking brake is applied, the
parking brake pawl is positioned away from the switch
plunger so the switch is in its normal, open state.
Testing
1. Make sure the engine is off. Locate parking brake
switch for testing.
2. Disconnect wire harness connector from the switch.
3. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the connector terminals.

4. When the switch plunger is extended there should
not be continuity between the switch terminals.
3

5. When the switch plunger is depressed, there should
be continuity between the switch terminals.
6. After testing, connect switch connector to wire harness.

Electrical System

Figure 26
1. Parking brake switch
2. Parking brake rod

Page 5 -- 18

3. Parking brake pawl

Groundsmaster 4100--D

Hour Meter
The hour meter is located on the control console next to
the operator seat.
Testing
1. Disconnect wire harness connector from hour meter.
2. Connect the positive (+) terminal of a 12 VDC source
to the positive (+) terminal of the hour meter.
1

3. Connect the negative (--) terminal of the voltage
source to the other terminal of the hour meter.
4. The hour meter should move a 1/10 of an hour in six
(6) minutes.

Figure 27
1. Positive (+) terminal

2. Negative (--) terminal

5. Disconnect voltage source from the hour meter. Reconnect harness connector to hour meter.

Audio Alarm
The audio alarm for low engine oil pressure or high engine coolant temperature is attached to the control console next to the operator seat.

Electrical
System

Testing
1. Disconnect wire harness connector from alarm.
IMPORTANT: Make sure to observe polarity on the
alarm terminals when testing. Damage to the alarm
may result from an improper connection.
2. Correctly connect 12VDC source to the alarm terminals (Fig. 28).

Figure 28
1. Top view
2. Bottom view

3. Positive (+) terminal
4. Negative (--) terminal

3. Alarm should sound. Remove voltage source from
the alarm.
4. Reconnect harness connector to alarm.

Groundsmaster 4100--D

Page 5 -- 19

Electrical System

Glow and Power Relays
The Groundsmaster 4100--D uses two (2) identical relays to control electrical power circuits. The glow relay
is attached to the the right side of the fuel tank support
under the hood. The power relay is attached to the control panel under the console housing.
The glow relay supplies electrical power for the engine
glow plugs when energized. The start relay is energized
by the glow plug controller.
The power relay supplies electrical power for fuses F9
(TEC--5002 outputs), F10, F11 and F12. The main power relay is energized when the ignition switch is in the
START or RUN position.

30
85

86
87

Figure 29

Testing
1. Park machine on a level surface, lower cutting deck,
stop engine, apply parking brake and remove key from
ignition switch.
2. Open hood to gain access to relay.
3. Locate relay and disconnect the machine wire harness connector from the relay. Remove relay from machine for easier testing.
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this value from from the measured value of the component you
are testing.
4. Verify coil resistance between terminals 85 and 86
with a multimeter (ohms setting) (Fig. 29). Resistance
should be approximately 72 ohms.
5. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should have continuity between terminals 30 and 87 as +12 VDC is applied to terminal 85. The relay should not have continuity between
terminals 30 and 87 as +12 VDC is removed from terminal 85.
6. After testing is complete, install relay to frame and
connect wire harness to relay.
7. Close and secure hood.

Electrical System

Page 5 -- 20

Groundsmaster 4100--D

Start, Engine Shutdown, Seat, Alarm, PTO, PTO Overtemp, Down Latching and Over
Temperature Relays
These eight (8) relays are located under the console
housing cover (Fig. 30). The wiring harness is tagged to
identify each relay.

Testing
1. Make sure that ignition switch is OFF.
2

2. Locate relay and disconnect the machine wire harness connector from the relay. Remove relay from machine if necessary.
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this value from the measured value of the component you are
testing.

Figure 30
1. Control panel

2. Relay location

3. Using a multimeter (ohms setting), measure coil resistance between terminals 85 and 86 (Fig. 31). Resistance should be between 70 and 90 ohms.

5. Disconnect voltage and multimeter leads from the
relay terminals.

87A

Figure 31

6. Connect multimeter (ohms setting) leads to relay terminals 30 and 87A. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should not have continuity
between terminals 30 and 87A as +12 VDC is applied to
terminal 85. The relay should have continuity between
terminals 30 and 87A as +12 VDC is removed from terminal 85.
7. Disconnect voltage and multimeter leads from the
relay terminals.
8. Secure relay to machine if removed. Connect machine wire harness connector to relay.

Groundsmaster 4100--D

Page 5 -- 21

Electrical System

Electrical
System

4. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should have continuity between terminals 30 and 87 as +12 VDC is applied to terminal 85. The relay should not have continuity between
terminals 30 and 87 as +12 VDC is removed from terminal 85.

Hydraulic Valve Solenoids

3
5

RIGHT
FRONT

Figure 32
1. 4WD manifold
2. LH deck manifold

3. RH deck manifold
4. Front deck manifold

There are several hydraulic valve solenoids on the
Groundsmaster 4100--D (Fig. 32). Testing of these solenoids can be done with the solenoid on the hydraulic
valve.
Testing

5. Fan drive manifold

3. Install new solenoid if necessary. Torque solenoid
nut to 5 ft--lb (6.7 N--m). Over--tightening may damage
the solenoid or cause the cartridge valve to malfunction.
4. When testing is complete, connect wire harness connector to the solenoid.

NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this value from from the measured value of the component you
are testing.

1
2

1. Make sure engine is off. Disconnect wire harness
connector from the solenoid (Fig. 33).
2. Measure resistance between the two (2) solenoid
connector terminals. The resistance for any solenoid
coil used on the Groundsmaster 4100--D should be
approximately 8.7 ohms.

Electrical System

Page 5 -- 22

3
Figure 33
1. Manifold (RH deck manifold shown)
2. Valve solenoid
3. Solenoid connector

Groundsmaster 4100--D

TEC--5002 Controller
Groundsmaster 4100--D machines use a Toro Electronic Controller (TEC) to control the operation of the hydraulic cooling fan. The controller is attached to the
operator platform under the console housing cover (Fig.
34).

Logic power is provided to the controller as long as the
battery cables are connected to the battery. A 2 amp
fuse in a fuse holder near the battery provides circuit
protection for this logic power to the controller.

The TEC--5002 controller monitors the states of the following components as inputs: ignition switch, hydraulic
temperature sender, engine coolant temperature sender and cooling fan switch.
The TEC--5002 controller controls electrical output to
the engine cooling fan hydraulic valve solenoid coils
(speed and direction). Circuit protection for TEC--5002
outputs is provided by fuse F9 (7.5 amp).

Figure 34
1. Fuses

2. TEC location

Groundsmaster 4100--D

Page 5 -- 23

Electrical
System

Because of the solid state circuitry built into the TEC,
there is no method to test the controller directly. The controller may be damaged if an attempt is made to test it
with an electrical test device (e.g. digital multimeter or
test light).

Electrical System

Fuel Sender
The fuel sender is located on top of the fuel tank.
Testing
1. Remove white wire and black ground wire from the
sender.

CAUTION

FULL POSITION

EMPTY POSITION

If testing circuit wiring and fuel gauge, make sure
wire connections are secure before turning ignition switch ON to prevent an explosion or fire
from sparks.

Figure 35

2. To test the circuit wiring and fuel gauge, connect
white and black wires and turn ignition switch to ON.
Fuel gauge needle should point to the right edge of the
green area (full). Turn ignition switch OFF and continue
testing fuel sender if circuit wiring and gauge are acceptable.
3. Remove screws and lock washers that secure the
sender to the fuel tank.
4. Remove sender and gasket from the fuel tank. Clean
any fuel from the sender.
NOTE: Before taking small resistance readings with a
digital multimeter, short meter test leads together. The
meter will display a small resistance value. This internal
resistance of the meter and test leads should be subtracted from the measured value of the component.

CAUTION
Make sure sending unit is completely dry (no fuel
on it) before testing. Perform test away from the
tank to prevent an explosion or fire from sparks.
5. Check resistance of the sender with a multimeter
(Fig. 35).
A. Resistance with the float in the full position should
be 27.5 to 39.5 ohms.
B. Resistance with the float in the empty position
should be 240 to 260 ohms.
6. Replace sender as necessary. Reinstall sender into
fuel tank.
7. Reconnect wires to fuel sender. Apply skin--over
grease (Toro Part No. 505--165) to sender terminals.
Electrical System

Page 5 -- 24

Groundsmaster 4100--D

Fuel Gauge
The fuel gauge can be tested using a new gauge as a
substitute or with the use of a DC voltage source and a
variable resistance box (see Fuel Sender Testing in this
section for additional information).
Testing

CAUTION
Make sure the voltage source is turned OFF before connecting it to the electrical circuit to avoid
electrical shock and prevent damaging the
gauge.

VARIABLE
RESISTANCE

14 VDC + 0.01 VDC
--

1. Connect fuel gauge to the variable resistance and
DC voltage source (Fig. 36).
NOTE: When reading the gauge test point, there are
two white dots on the gauge face below the edge of the
glass cover for each test point. For each variable resistance setting, the needle must be pointed between the
two white dots.

Figure 36

Electrical
System

2. Take test point readings (Fig. 37).
IMPORTANT: Allow circuit to warm up for at least 5
minutes before taking test readings.
A. Set variable resistance to 240 ohms. Apply a 14 +
0.01 VDC to the circuit. The needle should point to
the left edge of the red area (empty).
B. Set variable resistance to 33 ohms. The needle
should point to the right edge of the green area (full).
3

3. Turn off the voltage source. Disconnect voltage
source, gauge and variable resistance.
Figure 37
1. Empty position
2. Full position

Groundsmaster 4100--D

Page 5 -- 25

3. Glass face edge

Electrical System

Fuel Pump
The fuel pump is attached to the frame above the fuel
water separator (Fig. 38).

Operational Test
1. Park machine on a level surface, lower cutting deck,
stop engine and apply parking brake.
2. Disconnect wire harness electrical connector from
the fuel stop solenoid to prevent the engine from firing.
3. Disconnect fuel hose (pump discharge) from the fuel
water separator.
4. Make sure fuel hoses attached to the fuel pump are
free of obstructions.
5. Place fuel hose (pump discharge) into a large, graduated cylinder sufficient enough to collect 1 quart (0.95
liter).
6. Collect fuel in the graduated cylinder by turning ignition switch to the ON position. Allow pump to run for 15
seconds, then turn switch to OFF.

1
4
Figure 38
1. Fuel water separator
2. Fuel pump

3. Pump inlet hose
4. Pump discharge hose

Fuel Pump Specifications
Pump Capacity

7. The amount of fuel collected in the graduated cylinder should be approximately 16 fl oz (475 ml) after 15
seconds.

Pressure
Current Draw

64 fl oz/min (1.9 l/min)
7 PSI (48.3 kPa)
2.0 amp

8. Replace fuel pump as necessary. Install fuel hose to
the water separator.
9. Connect wire harness electrical connector to the fuel
stop solenoid.
10.Prime fuel system.

Electrical System

Page 5 -- 26

Groundsmaster 4100--D

Glow Controller
The glow controller is located under the console cover
(Fig. 39).

NOTE: Refer to electrical schematic and circuit drawings in Chapter 9 -- Foldout Drawings when troubleshooting the glow controller.

Glow Controller Operation
1. When the ignition switch is placed in the ON position,
the controller energizes the glow plugs and lights up the
glow lamp for approximately 10 seconds.
2. When the ignition switch is held in the START position, the glow plugs will energize and the glow lamp will
not light.
3. When the ignition switch is released from START to
ON, the glow plugs will deenergize and the glow lamp
will remain off.

Figure 39
1. Control panel

2. Controller location

1. Make sure there is power from the battery.
2. Disconnect electrical connector to the engine run solenoid to prevent the engine from starting.
3. Place ignition switch in the ON position. Verify the following while in the ON position:

2
VIOLET
ORANGE

C. Glow plugs are energized.

YELLOW

D. Glow indicator lamp goes out and glow plugs de-energize after approximately 10 seconds.
4. Place ignition switch in the START position. Verify
the following while in the START position:
A. Glow indicator lamp is not illuminated.
B. Glow relay is energized.

CONTROLLER
CONNECTIONS

A. Glow indicator lamp is illuminated.
B. Glow relay is energized.

START 1

TEMP (not used)

LAMP 2

GLOW

+12V 3

GROUND

BROWN
BLACK

Figure 40
1. Glow controller end view

2. Controller side view

5. If any of the conditions in step 3 are not met or power
to terminal 1 exists and any of the other conditions in
step 4 are not met:
A. Verify continuity of the circuitry from the battery to
the glow relay and glow plugs (see electrical schematic in Chapter 9 -- Foldout Drawings).

C. Glow plugs are energized.
D. Power exists at terminal 1 of the glow controller.
NOTE: If there is no power at terminal 1 of the glow controller, verify continuity of the circuitry from the ignition
switch to the controller and perform step 4 again (see
electrical schematic in Chapter 9 -- Foldout Drawings).

B. Verify continuity of the circuitry from the battery to
ignition switch, glow controller, glow lamp, glow relay
and ground (see electrical schematic in Chapter 9 -Foldout Drawings).
C. Replace parts as necessary.
6. Connect electrical connector to the run solenoid.

Groundsmaster 4100--D

Page 5 -- 27

Electrical System

Electrical
System

Glow Controller Checks

Temperature Sender
The temperature sender is located near the alternator
on the water flange attached to the engine cylinder head
(Fig. 41). The resistance of the temperature sender reduces as the engine coolant temperature increases.
There is a gray harness wire attached to the terminal of
the switch.

Testing
1. Lower coolant level in the engine and remove the
temperature sender from water flange.

2. Suspend sender in a container of oil with a thermometer and slowly heat the oil (Fig. 42).
Figure 41

CAUTION

1. Temperature sender

2. Alternator

Handle the hot oil with extreme care to prevent
personal injury or fire.
NOTE: Prior to taking resistance readings with a digital
multi meter, short the meter test leads together. The meter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value
from from the measured value of the component you are
testing.
3. Check resistance of the sender with a multimeter
(ohms setting) as the temperature increases. Replace
sender if specifications are not met.
COOLANT TEMP

Figure 42

TEMP SENDER RESISTANCE

100oF

(38oC)

460 ohms (approximate)

160oF

(71oC)

140 ohms (approximate)

200oF

(93oC)

54 to 78 ohms

221oF

(105oC)

50 ohms (approximate)

4. After testing is complete, install sender to the water
flange.
A. Thoroughly clean threads of water flange and
sender. Apply thread sealant to the threads of the
sender.
B. Screw sender into the water flange. Torque sender from 16 to 20 ft--lb (22 to 27 N--m).
C. Reconnect gray harness wire to sender. Apply
skin--over grease (Toro Part No. 505--165) to sender
terminal.
5. Fill engine cooling system.
Electrical System

Page 5 -- 28

Groundsmaster 4100--D

Dual Temperature Switch
The dual temperature switch is attached to the engine
near the alternator on the water flange attached to the
engine cylinder head (Fig. 43). Two (2) electrical harness wires (a blue wire and a yellow wire) are attached
to the switch.
The terminal on the switch is used to activate the engine
over temperature warning. The warning illuminates the
overtemp warning light and also causes the PTO to disengage. The wire harness blue wire attaches to the
switch terminal.

B. Screw switch into the cylinder head and torque
switch from 22 to 28 ft--lb (29.4 to 39.2 N--m).
C. Connect harness wires to switch.
6. Fill engine cooling system.

The wire lead on the switch is used to shutdown the engine. The wire harness yellow wire attaches to the
switch lead.

Testing
2

CAUTION
Make sure engine is cool before removing the
temperature switch.

2. Put switch in a container of oil with a thermometer
and slowly heat the oil (Fig. 45).

2. Alternator

CAUTION

Handle the hot oil with extreme care to prevent
personal injury or fire.
3. Check continuity of the switch with a multimeter
(ohms setting). Both circuits of the temperature switch
are normally open and should close at the following temperatures:

Figure 44
1. Dual temperature switch
2. Terminal (warning)

3. Wire lead (shutdown)

A. The warning terminal should close from 214o to
226o F (101 to 108o C).
B. The shutdown wire lead should close from 234o
to 246o F (112 to 119o C).
4. Replace switch if necessary.
5. Install switch to the water flange.
A. Clean threads of cylinder head and switch thoroughly. Apply thread sealant to the threads of the
switch.

Groundsmaster 4100--D

Page 5 -- 29 Rev. A

Figure 45

Electrical System

Electrical
System

1. Lower coolant level in the engine and remove the
dual temperature switch from the engine water flange.

Figure 43
1. Dual temp switch

Temperature Gauge
The temperature gauge can be tested using a new
gauge as a substitute or with the use of a DC voltage
source and a variable resistance box.
Testing

CAUTION
Make sure the voltage source is turned OFF before connecting variable resistance to the electrical circuit to avoid electrical shock and to prevent damaging the gauge.

VARIABLE
RESISTANCE

14 VDC + 0.01 VDC

1. Connect temperature gauge to the variable resistance and DC voltage source (Fig. 46).

Figure 46

NOTE: When reading the gauge test point, there are
two white dots on the gauge face below the edge of the
glass cover for each test point. For each variable resistance setting, the needle must be pointed between the
two white dots.

1
2

2. Take test point readings (Fig. 47).
IMPORTANT: Allow circuit to warm up for at least 5
minutes before taking test readings.
A. Set variable resistance to 71 ohms. Apply a 14 +
0.01 VDC to the circuit. The needle should point to
the middle of the green area (80oC).
B. Set variable resistance to 38 ohms. The needle
should point between the green and red area
(105oC).
3. Turn off the voltage source. Disconnect voltage
source, gauge and variable resistance.
3
Figure 47
1. Middle position
2. High temp. position

Electrical System

Page 5 -- 30

3. Edge of glass cover

Groundsmaster 4100--D

Traction Neutral Switch
The traction neutral switch is closed when the traction
pedal is in the neutral position and opens when the pedal
is depressed in either direction. The switch is located on
the right side of the piston (traction) pump (Fig. 48).
Testing
Test the switch by disconnecting the wires from the
switch terminals and connecting a continuity tester
across the two switch terminals. With the engine turned
off, slowly push the traction pedal in a forward or reverse
direction while watching the continuity tester. There
should be indications that the traction neutral switch is
opening and closing. Allow the traction pedal to return
to the neutral position. There should be continuity
across the switch terminals when the traction pedal is in
the neutral position.

1
Figure 48
1. Piston pump (bottom)

2. Neutral switch

See the Eaton Model 72400 Servo Controlled Piston
Pump Repair Information at the end of Chapter 4 -- Hydraulic System for disassembly and assembly procedures for the neutral switch.

The Groundsmaster 4100--D electrical system includes
several diode assemblies (Fig. 49) that are used for circuit protection and circuit logic control. The diodes plug
into the wiring harness at various locations on the machine.

The diodes D2, D4, D5 and D6 are used for circuit
protection from inductive voltage spikes that occur when
a hydraulic valve solenoid is de--energized. Diode D2 is
in the Transport/Mow circuit, D4 is in the left cutting deck
circuit, D5 is in the front cutting deck circuit and D6 is in
the right cutting deck circuit.
Diode D9 provides logic for the high temperature warning system.
Diode D3 provides a latching circuit for the cutting deck
when in the lowered position.
If the machine is equipped with the optional cruise control kit, two (2) additional diodes are used. Diode D7 in
this kit is used for circuit protection that occur when a hydraulic valve solenoid is de--energized. Diode D8 provides a latching circuit to keep the cruise relay
energized.

3
1

Figure 49
1. Diode
2. Male terminal

3. Female terminal

Multimeter
Red Lead (+)
on Terminal

Multimeter
Black Lead (--)
on Terminal

Continuity

Female

Male

YES

Male

Female

Testing
The diodes can be individually tested using a digital
multimeter (diode test or ohms setting) and the table to
the right.
Groundsmaster 4100--D

Page 5 -- 31

Electrical System

Electrical
System

Diode Assemblies

Diode Circuit Board
The diode circuit board (Fig. 50) contains four (4) diodes
and is located under the console housing. Diode D1--A
provides logic for the interlock system. Diodes D1--B
(right wing deck), D1--C (front deck) and D1--D (left wing
deck) provide latching circuits for the PTO relay.

D1--A
D1--C
D1--D

D1--A

The diodes can be individually tested using a digital
multimeter (ohms setting) and the table to the right. If
any of the diodes are damaged, the diode circuit board
must be replaced.

D1--C

D1--B

Testing

D
C
B
A

CIRCUIT BOARD

Apply dielectric grease (Toro part number 107--0342) to
circuit board contacts whenever the circuit board is
installed into the wire harness.

Electrical System

D1--D

DIODE DIAGRAM

Figure 50
Red Lead (+)
on
Terminal

Black Lead (--)
on
Terminal

Continuity

YES

Page 5 -- 32

Groundsmaster 4100--D

Fusible Links
The Groundsmaster 4100--D uses five (5) fusible links
for circuit protection. Three (3) of these fusible links are
located in a harness that connects the starter B+ terminal to the wire harness (Fig. 51). An additional fusible
link is used that connects the starter B+ terminal to the
alternator B+ terminal (Fig. 52). The remaining fusible
link is included in the wire harness and connects the
starter terminal to the engine run solenoid pull coil. If any
of these links should fail, current to the protected circuit
will cease. Refer to the Electrical Schematic and Circuit
Diagrams in Chapter 9 -- Foldout Diagrams for additional circuit information.

FUSIBLE LINK
FUSIBLE LINK
FUSIBLE LINK

Figure 51

Testing
J1

Make sure that ignition switch is OFF. Disconnect negative battery cable from battery terminal and then disconnect positive cable from battery (see Battery Service in
the Service and Repairs section of this chapter). Locate
and unplug fusible link connector. Use a multimeter to
make sure that continuity exists between the fusible link
terminals. If a fusible link is open, replace the link.

STARTER
B+

RED

SP1

J2
ALTERNATOR
B+
J2

Figure 52

Groundsmaster 4100--D

Page 5 -- 33

Electrical
System

After testing is complete, make sure that fusible link is
securely attached to engine component and wire harness. Connect positive battery cable to battery terminal
first and then connect negative cable to battery.

Electrical System

Wing Deck Position Switches
The wing deck position switches on the Groundsmaster
4100--D are attached to the center deck housing (Fig.
53) and are normally open. The wing deck position
switch is a powered proximity switch that incorporates
an internal reed switch and relay (see schematic in Figure 54). The actuator for the position switch is bolted to
the wing deck link (Fig. 55).
When a wing deck is lowered, the actuator tab on the
wing deck link is positioned close to the position switch
causing the switch to close. The closed switch allows
current flow to the wing deck hydraulic valve solenoid
and allows that wing deck to operate.
When a wing deck is raised, the actuator tab is moved
away from the position switch and the switch opens. The
open switch prevents current flow to the wing deck hydraulic valve solenoid and keeps that wing deck from operating.

3
1
2

Figure 53
1. Switch cover
2. Position switch

3. Switch bracket

Testing

BLUE
WHITE

1. Park machine on a level surface, lower cutting deck
and raise wing decks. Stop engine, engage parking
brake and remove key from the ignition switch.

BLACK
RED

2. Remove switch cover from deck to allow access to
switch that requires testing. Disconnect switch from wiring harness.

CONNECTOR

POSITION SWITCH

Figure 54

NOTE: Deck Proximity Switch Adjustment Tool
(TOR4095) can be used for switch testing and adjustment.

0.188”
(4.8 mm)

3. Ground switch connector terminal for black wire and
apply 12 VDC to switch connector terminal for red wire.
4. Using a multimeter, verify that switch connector terminal for blue wire has 12 VDC and terminal for white
wire has 0 VDC.

2
3

5. Place a metal object near sensing area of switch (opposite end from wires). Ground switch connector terminal for black wire and apply 12 VDC to switch connector
terminal for red wire.
6. Using a multimeter, verify that switch connector terminal for blue wire has 0 VDC and terminal for white wire
has 12 VDC.

Figure 55
1. Position switch
2. Actuator tab

3. Wing deck link

7. Replace switch as needed. For switch adjustment
procedure, see Wing Deck Position Switches in the Adjustments section of this chapter.
8. Install switch cover to deck.

Electrical System

Page 5 -- 34

Groundsmaster 4100--D

Cutting Deck Raise and Lower Switches
The deck raise and lower switches are normally open
proximity switches that are located under the console
housing (Fig. 56). These identical switches are mounted
in opposite directions so their circuit logic differs. The actuator for the switches is on the center deck lift/lower lever. The raise and lower switches are used in
conjunction with the down latching relay to provide current to the PTO switch.

3
5

6
7

The deck raise switch is closed when the center deck lift/
lower lever is either in the neutral (center) position or
pushed to the lower (forward) position. If the center deck
lift/lower lever is pulled to the raise (rear) position, the
deck raise switch opens.

Once the down latching relay is energized by lowering
the cutting deck, the cutting deck raise switch and diode
D3 provide a latching circuit to keep the relay energized.

Testing
1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.
2. Remove console cover and locate cutting deck raise
or lower switch to be tested. Disconnect switch connector from machine wiring harness.

Figure 56
1.
2.
3.
4.
5.

Deck lower switch
Deck raise switch
Switch plate
Lever bracket
Flange nut

6.
7.
8.
9.
10.

Flange bolt (2 used)
Tab plate
Deck lift/lower lever
Switch actuator
Lock nut (2 used)

3. Check switch continuity by connecting a multimeter
(ohms setting) across the switch connector terminals.
4. The raise switch should be closed (continuity) when
the center deck lift/lower lever is in the neutral position.
As the lift/lower lever is slowly pulled back, the raise
switch should open (no continuity) after the lever has removed all free play (with no spool movement in lift/lower
control valve) but before the deck is lifted.
5. The lower switch should be open (no continuity)
when the center deck lift/lower lever is in the neutral
position. As the lift/lower lever is slowly pushed forward,
the lower switch should close (continuity) before the lever reaches full forward travel.
6. For switch adjustment procedure, see Cutting Deck
Raise and Lower Switches in the Adjustments section of
this chapter.
7. Connect switch to wiring harness. Install console
cover to machine.
Groundsmaster 4100--D

Page 5 -- 35

Electrical System

Electrical
System

The deck lower switch is closed when the center deck
lift/lower lever is pushed to the lower (forward) position.
If the center deck lift/lower lever is in either the neutral
(center) position or the raise (rear) position, the deck
lower switch remains open.

Engine Coolant and Hydraulic Oil Temperature Senders
The Groundsmaster 4100--D uses two (2) temperature
senders as inputs for the TEC--5002 to identify if either
the engine coolant or hydraulic oil temperature has
reached an excessive level. These senders are identical. The coolant temperature sender threads into the radiator (Fig. 57). The hydraulic oil temperature sender is
attached to the hydraulic hydraulic tube on the left side
of the machine (Fig. 58).

6. Check and fill system (coolant or hydraulic) to proper
level.

Testing
1. Locate temperature sender that is to be tested. Disconnect wire harness connector from sender.

2. Thoroughly clean area around temperature sender
and remove sender.
3. Put sensing end of sender in a container of oil with
a thermometer and slowly heat the oil (Fig. 59).

Figure 57
1. Radiator

2. Coolant temp sender

CAUTION
Handle the hot oil with extreme care to prevent
personal injury or fire.
NOTE: Prior to taking resistance readings with a digital
multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value
from from the measured value of the component you are
testing.

1
2

4. Check resistance of the sender with a multimeter
(ohms setting) as the oil temperature increases.
A. The meter should indicate from 11.6 to 13.5 kilo
ohms at 68oF (20oC).

Figure 58
1. Hydraulic tube

2. Oil temp sender

B. The meter should indicate from 2.3 to 2.5 kilo
ohms at 140oF (60oC).
C. The meter should indicate from 605 to 669 ohms
at 212 oF (100oC).
D. Replace sender if specifications are not met.
5. After allowing the sender to cool, install sender:
A. Install new O--ring on sender.
B. Install sender into port and torque from 9 to 11 ft-lb (12.3 to 14.9 N--m).
Figure 59

C. Reconnect harness wire to sender.
Electrical System

Page 5 -- 36 Rev. A

Groundsmaster 4100--D

Service and Repairs
NOTE: For engine component repair information, see
the Kubota Workshop Manual, Diesel Engine,
V2403--M--T--E3B Series at the end of Chapter 3 -- Kubota Diesel Engine.

Battery Storage
If the machine will be stored for more than 30 days:
1. Remove the battery and charge it fully (see Battery
Service in this section).
2. Either store battery on a shelf or on the machine.

4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge.
5. To help prevent the battery from freezing, make sure
it is fully charged (see Battery Service in this section).

3. Leave cables disconnected if the battery is stored on
the machine.

Battery Care
3. Battery cables must be tight on terminals to provide
good electrical contact.

WARNING
Connecting cables to the wrong post could result in personal injury and/or damage to the electrical system.

WARNING
Wear safety goggles and rubber gloves when
working with electrolyte. Charge battery in a
well ventilated place so gasses produced
while charging can dissipate. Since the gases
are explosive, keep open flames and electrical
sparks away from the battery; do not smoke.
Nausea may result if the gases are inhaled. Unplug charger from electrical outlet before connecting or disconnecting charger leads to or
from battery posts.
IMPORTANT: Do not remove fill caps while cleaning.

4. If corrosion occurs at terminals, disconnect cables.
Always disconnect negative (--) cable first. Clean
clamps and terminals separately. Connect cables with
positive (+) cable first. Coat battery posts and cable connectors with terminal protector (Toro Part No.
107--0392) or petroleum jelly to prevent corrosion.
5. Check electrolyte level every 25 operating hours and
every 30 days if machine is in storage.
6. Maintain cell level with distilled water. Do not fill cells
above the fill line.

2. Check battery condition weekly or after every 50
hours of operation. Keep terminals and entire battery
case clean because a dirty battery will discharge slowly.
A. Clean battery by washing entire case with a solution of baking soda and water. Rinse with clear water.
B. Coat battery posts and cable connectors with terminal protector (Toro Part No. 107--0392) or petroleum jelly to prevent corrosion.

Groundsmaster 4100--D

Page 5 -- 37

Electrical System

Electrical
System

1. Battery electrolyte level must be properly maintained. The top of the battery must be kept clean. lf the
machine is stored in a location where temperatures are
extremely high, the battery will discharge more rapidly
than if the machine is stored in a location where temperatures are cool.

Battery Service
The battery is the heart of the electrical system. With
regular and proper service, battery life can be extended.
Additionally, battery and electrical component failure
can be prevented.

CAUTION
1

When working with batteries, use extreme caution to avoid splashing or spilling electrolyte.
Electrolyte can destroy clothing and burn skin or
eyes. Always wear safety goggles and a face
shield when working with batteries.

Electrolyte Specific Gravity
Fully charged: 1.265 corrected to 80oF (26.7oC)
Discharged: less than 1.240

Figure 60
1. Negative (--) cable
2. Positive (+) cable

Battery Specifications
BCI Group Size 24
650 CCA at 0o F (--17.8o C)
Reserve Capacity of 110 minutes at 80oF (26.7oC)

3. Battery strap

Battery Inspection, Maintenance and Testing

Dimensions (including terminal posts and caps)
Length
10.2 inches (259 mm)
Width
6.6 inches (167 mm)
Height
9.0 inches (228 mm)

1. Perform following inspections and maintenance:
A. Check for cracks. Replace battery if cracked or
leaking.

Battery Removal and Installation (Fig. 60)
1. Raise and support operator seat. Remove battery
access panel.
2. Loosen and remove negative cable from battery. After negative cable is removed, loosen and remove positive cable.
3. Loosen battery strap that secures battery to machine.
4. Carefully remove battery from machine.
5. Install battery in reverse order making sure to connect and tighten positive cable to battery before connecting negative cable.
NOTE: Before connecting the negative (ground) cable
to the battery, connect a digital multimeter (set to DC
Amps) between the negative battery post and the negative (ground) cable connector. The reading should be
less than 0.1 amp. If the reading is 0.1 amp or more, the
machine’s electrical system should be tested for short
circuits or faulty components and repaired.

B. Check battery terminal posts for corrosion. Use
wire brush to clean corrosion from posts.
IMPORTANT: Before cleaning the battery, tape
or block vent holes to the filler caps and make
sure the caps are on tightly.
C. Check for signs of wetness or leakage on the top
of the battery which might indicate a loose or missing
filler cap, overcharging, loose terminal post or overfilling. Also, check battery case for dirt and oil. Clean
the battery with a solution of baking soda and water,
then rinse it with clean water.
D. Check that the cover seal is not broken away. Replace the battery if the seal is broken or leaking.
E. Check the electrolyte level in each cell. If the level
is below the tops of the plates in any cell, fill all cells
with distilled water between the minimum and maximum fill lines. Charge at 15 to 25 amps for 15 minutes to allow sufficient mixing of the electrolyte.

6. Secure battery with battery strap. Install battery access panel. Lower and secure operator seat.

Electrical System

Page 5 -- 38

Groundsmaster 4100--D

2. Conduct a hydrometer test of the battery electrolyte.
IMPORTANT: Make sure the area around the cells is
clean before opening the battery caps.
A. Measure the specific gravity of each cell with a
hydrometer. Draw electrolyte in and out of the
hydrometer barrel prior to taking a reading to warm-up the hydrometer. At the same time take the temperature of the cell.
B. Temperature correct each cell reading. For each
10oF (5.5oC) above 80oF (26.7oC) add 0.004 to the
specific gravity reading. For each 10oF (5.5oC) below 80oF (26.7oC) subtract 0.004 from the specific
gravity reading.
Example: Cell Temperature
100oF
Cell Gravity
1.245
100oF minus 80oF equals 20oF
(37.7oC minus 26.7oC equals 11.0oC)
20oF multiply by 0.004/10oF equals 0.008
(11oC multiply by 0.004/5.5oC equals 0.008)
ADD (conversion above)
0.008
Correction to 80oF (26.7oC)
1.253

B. If the battery has recently been charged, apply a
150 amp load for 15 seconds to remove the surface
charge. Use a battery load tester following the
manufacturer’s instructions.
C. Make sure battery terminals are free of corrosion.
D. Measure the temperature of the center cell.
E. Connect a battery load tester to the battery terminals following the manufacturer’s instructions.
Connect a digital multimeter to the battery terminals.
F. Apply a test load of 325 amps (one half the battery
cold cranking amp rating) for 15 seconds.
G. Take a battery voltage reading at 15 seconds,
then remove the load.
H. Using the table below, determine the minimum
voltage for the cell temperature reading:

C. If the difference between the highest and lowest
cell specific gravity is 0.050 or greater or the lowest
cell specific gravity is less than 1.225, charge the battery. Charge at the recommended rate and time given in Charging or until all cells specific gravity is
1.225 or greater with the difference in specific gravity
between the highest and lowest cell less than 0.050.
If these charging conditions can not be met, replace
the battery.
3. Perform a high--discharge test with an adjustable
load tester.
This is one of the most reliable means of testing a battery
as it simulates the cold--cranking test. A commercial battery load tester is required to perform this test.

Battery Electrolyte
Temperature

9.6

70oF (and up)

21.1oC (and up)

9.5

60oF

15.6oC

9.4

50oF

10.0oC

9.3

40oF

4.4oC

9.1

30oF

--1.1oC

8.9

20oF

--6.7oC

8.7

10oF

--12.2oC

8.5

0 oF

--17.8oC

I. If the test voltage is below the minimum, replace
the battery. If the test voltage is at or above the minimum, return the battery to service.

CAUTION
Follow the manufacturer’s instructions when using a battery tester.
A. Check the voltage across the battery terminals
prior to testing the battery. If the voltage is less than
12.4 VDC, charge the battery before continuing with
load testing procedure.

Groundsmaster 4100--D

Page 5 -- 39

Electrical System

Electrical
System

Minimum
Voltage

Battery Charging
To minimize possible damage to the battery and allow
the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger
which is readily available locally.

CAUTION
Follow the manufacturer’s instructions when using a battery charger.
NOTE: Using specific gravity of the battery cells is the
most accurate method of determining battery condition.
1. Determine the battery charge level from either its
specific gravity or open circuit voltage.
Battery Charge
Level

Specific
Gravity

Open Circuit
Voltage

100%

1.265

12.68

75%

1.225

12.45

50%

1.190

12.24

25%

1.155

12.06

1.120

11.89

2. Determine the charging time and rate using the battery charger manufacturer’s instructions or the following table.
Battery
Reserve
Capacity
(Minutes)

CAUTION
Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to
60oF (15.5o C) before connecting to a charger.
Charge the battery in a well--ventilated place to
dissipate gases produced from charging. These
gases are explosive; keep open flame and electrical spark away from the battery. Do not smoke.
Nausea may result if the gases are inhaled. Unplug the charger from the electrical outlet before
connecting or disconnecting the charger leads
from the battery posts.
3. Following the battery charger manufacturer’s
instructions, connect the charger cables to the battery.
Make sure a good connection is made.
4. Charge the battery following the battery charger
manufacturer’s instructions.
5. Occasionally check the temperature of the battery
electrolyte. If the temperature exceeds 125oF (51.6oC)
or the electrolyte is violently gassing or spewing, the
charging rate must be lowered or temporarily stopped.
6. Three hours prior to the end of the charging, measure the specific gravity of a battery cell once per hour.
The battery is fully charged when the cells are gassing
freely at a low charging rate and there is less than a
0.003 change in specific gravity for three consecutive
readings.

Battery Charge Level
(Percent of Fully Charged)
75%

50%

25%

80 or less

3.8 hrs
@
3 amps

7.5 hrs
@
3 amps

11.3 hrs
@
3 amps

15 hrs
@
3 amps

81 to 125

5.3 hrs
@
4 amps

10.5 hrs 15.8 hrs
@
@
4 amps 4 amps

21 hrs
@
4 amps

126 to
170

5.5 hrs
@
5 amps

11 hrs
@
5 amps

16.5 hrs
@
5 amps

22 hrs
@
5 amps

171 to
250

5.8 hrs
@
6 amps

11.5 hrs
@
6 amps

17.3 hrs
@
6 amps

23 hrs
@
6 amps

above
250

6 hrs
12 hrs
18 hrs
24 hrs
@
@
@
@
10 amps 10 amps 10 amps 10 amps

Electrical System

Page 5 -- 40

Groundsmaster 4100--D

Chapter 6

Axles, Planetaries and Brakes
Table of Contents

Axles, Planetaries
and Brakes

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4
Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Brake Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Planetary Wheel Drive Assembly . . . . . . . . . . . . . . 8
Planetary Wheel Drive Service . . . . . . . . . . . . . . . 10
Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . 14
Bevel Gear Case and Axle Case . . . . . . . . . . . . . 17
Differential Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Axle Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Input Shaft/Pinion Gear . . . . . . . . . . . . . . . . . . . . . 24
Differential Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Pinion Gear to Ring Gear Engagement . . . . . . . . 29

Groundsmaster 4100--D

Page 6 -- 1

Axles, Planetaries and Brakes

Specifications
Item

Specification

Tire pressure (front and rear)

25 to 30 PSI (172 to 207 kPa)

Rear wheel toe--in

0.125 in (3.18 mm)

Planetary gear drive oil
System gear lube capacity (each wheel)

SAE 85W--140 wt. gear lube
16 fl. oz. (0.47 liters)

Rear axle lubricant
System gear lube capacity

SAE 85W--140 wt. gear lube
80 fl. oz. (2.37 liters)

Rear axle gear box lubricant
System gear lube capacity

SAE 85W--140 wt. gear lube
16 fl. oz. (0.47 liters)

Wheel lug nut torque

85 to 100 ft--lb (115 to 135 N--m), front and rear

Steering cylinder bolt torque

100 to 125 ft--lb (139 to 169 N--m)

Planetary, brake housing and front wheel motor
mounting screw torque

Axles, Planetaries and Brakes

75 to 85 ft--lb (101 to 115 N--m)

Page 6 -- 2

Groundsmaster 4100--D

General Information
Operator’s Manual

Axles, Planetaries
and Brakes

The Operator’s Manual provides information regarding
the operation, general maintenance and maintenance
intervals for your Groundsmaster machine. Refer to that
publication for additional information when servicing the
machine.

Groundsmaster 4100--D

Page 6 -- 3

Axles, Planetaries and Brakes

Service and Repairs
Brake Assembly
85 to 100 ft--lb
(115 to 135 N--m)

12
6

75 to 85 ft--lb
(101 to 115 N--m)

3
11

16
5

7
8

RIGHT

15
3

FRONT

6
9

75 to 85 ft--lb
(101 to 115 N--m)

1.
2.
3.
4.
5.
6.

Planetary assembly
Retaining ring
Splined brake coupler
Brake assembly (RH)
O--ring
Hydraulic wheel motor

1
10

7.
8.
9.
10.
11.
12.

Figure 1

Flat washer
Cap screw (2 used per side)
Flange head screw (4 used per side)
Brake assembly (LH)
Gasket
Flange head screw (6 used per side)

13.
14.
15.
16.
17.
18.

Tire and wheel assembly
Lug nut (8 used per wheel)
Jam nut
Compression spring
Spring plate
Brake cable

Removal (Fig. 1)
1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.
2. Drain oil from planetary wheel drive/brake assembly.

Axles, Planetaries and Brakes

CAUTION
When removing front wheel, use correct jacks
and supports. 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.

Page 6 -- 4

Groundsmaster 4100--D

3. Chock rear wheels and jack up front of machine (see
Jacking Instructions in Chapter 1 -- Safety). Support machine with suitable jack stands.
4. Remove front wheel assembly.
5. Remove hydraulic wheel motor (see Front Wheel
Motors in Service and Repairs section of Chapter 4 -Hydraulic System).
6. Disconnect brake cable from pull rod on brake assembly.

8. Make sure drain plug is installed in bottom of brake
assembly (Fig. 3). Fill planetary wheel drive/brake assembly with SAE 85W--140 gear lube. Capacity is
approximately 16 fl. oz. (0.47 liters) per wheel.
9. Check and adjust brake cables for proper brake operation. If necessary, adjust brake cable jam nuts at
frame bracket so that pull rod jam nut is positioned from
0.470” to 0.530” (12.0 to 13.4 mm) from brake casting
surface when brakes are disengaged (Fig. 4).

7. Support brake assembly to prevent it from falling.
8. Remove four (4) flange head screws (item 9) securing brake assembly to machine. Remove brake assembly taking care to not drop splined brake coupler as
brake assembly is removed.

9. Remove splined brake coupler.
10.Complete brake inspection and repair (see Brake Inspection and Repair in this section).

Figure 2
1. Brake coupler step
2. Hydraulic motor end

3. Planetary assembly end

Installation (Fig. 1)
1. Slide splined brake coupler into brake assembly.
NOTE: The stepped end of the coupler must be installed
toward the hydraulic wheel motor (Fig. 2).

1
2

2. Position brake assembly to frame, aligning splined
brake coupler with input shaft on planetary wheel drive.

4. Install brake cable to pull rod on brake assembly.
Brake cable end should be completely threaded onto
pull rod.
5. Install new O--ring on hydraulic wheel motor. Install
wheel motor and torque cap screws from 75 to 85 ft--lb
(101 to 115 N--m).

Axles, Planetaries
and Brakes

3. Install four (4) flange head screws to secure brake
assembly to frame. Torque screws in a crossing pattern
from 75 to 85 ft--lb (101 to 115 N--m).
3
Figure 3
1. Brake housing
2. Check plug

3. Drain plug

0.470” to 0.530”
(12.0 to 13.4 mm)

6. Install wheel assembly.

WARNING
Failure to maintain proper torque could result in
failure or loss of wheel and may result in personal injury.
7. Lower machine to ground. Torque lug nuts from 85
to 100 ft--lb (115 to 135 N--m).

Groundsmaster 4100--D

Figure 4
1. Pull rod jam nut
2. Brake cable end

Page 6 -- 5

3. Cable jam nut
4. Brake cable

Axles, Planetaries and Brakes

Brake Service
3

2
1

5
5

8
7
8
7

13
12

8
9

1.
2.
3.
4.
5.

Brake housing (LH shown)
Seal
Pull rod
Clevis pin (2 used)
Link

6.
7.
8.
9.
10.

Figure 5

Hitch pin (2 used)
Stationary disc (4 used)
Rotating disc (3 used)
Retaining ring
Gasket

11.
12.
13.
14.
15.

Rotating actuator
Extension spring (3 used)
Ball (3 used)
Plug
O--ring

Brake Inspection and Repair (Fig. 5)

6. Remove seal (item 2) from brake housing.

1. Scrape gasket material (item 10) from brake housing
and planetary wheel drive mounting surfaces.

7. Wash parts in cleaning solvent. Inspect components
for wear or damage.

2. Remove retaining ring (item 9).
3. Remove four (4) stationary discs (item 7) and three
(3) rotating discs (item 8).

A. The stack of four (4) stationary and three (3) rotating discs should have a minimum thickness of 0.440”
(11.2 mm).

4. Remove three (3) extension springs (item 12).

8. Reverse steps 2 -- 6 to assemble brakes, installing
new parts as necessary. Install a new seal (item 2).

5. Remove actuator assembly (items 11, 6, 5, 4 and 3)
and balls (item 13).

9. Use a new gasket (item 10) when installing brake assembly to machine.

Axles, Planetaries and Brakes

Page 6 -- 6

Groundsmaster 4100--D

Axles, Planetaries
and Brakes

This page is intentionally blank.

Groundsmaster 4100--D

Page 6 -- 7

Axles, Planetaries and Brakes

Planetary Wheel Drive Assembly
85 to 100 ft--lb
(115 to 135 N--m)

13
14

12
6

75 to 85 ft--lb
(101 to 115 N--m)

3
11

5
5

7
8

3
6

RIGHT
FRONT

9
10
75 to 85 ft--lb
(101 to 115 N--m)

2
1

Figure 6
1.
2.
3.
4.
5.

Planetary assembly
Retaining ring
Splined brake coupler
Brake assembly (RH)
O--ring

Axles, Planetaries and Brakes

6.
7.
8.
9.
10.

Hydraulic wheel motor
Flat washer
Cap screw (2 used per side)
Flange head screw (4 used per side)
Brake assembly (LH)

Page 6 -- 8

11.
12.
13.
14.

Gasket
Flange head screw (6 used per side)
Tire and wheel assembly
Lug nut (8 used per wheel)

Groundsmaster 4100--D

Removal (Fig. 6)
1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.

4. Secure hydraulic wheel motor to planetary assembly
with two (2) cap screws. Torque screws from 75 to 85 ft-lb (101 to 115 N--m).
5. Install wheel assembly.

2. Drain oil from planetary wheel drive/brake assembly.

WARNING

Failure to maintain proper torque could result in
failure or loss of wheel and may result in personal injury.
6. Lower machine from jack stands. Torque lug nuts
from 85 to 100 ft--lb (115 to 135 N--m).
7. Make sure drain plug is installed in bottom of brake
assembly (Fig. 7). Fill planetary wheel drive/brake assembly with SAE 85W--140 gear lube. Capacity is
approximately 16 fl. oz. (0.47 l) per wheel.
8. Check for proper brake operation.

3. Chock rear wheels and jack up front of machine (see
Jacking Instructions in Chapter 1 -- Safety). Support machine with suitable jack stands.

4. Remove front wheel assembly.
5. Remove four (4) flange head screws that secure
brake assembly to planetary assembly (see Brake Assembly Removal in this Chapter).
4

7. Support planetary assembly to prevent it from falling.
Loosen and remove flange head screws that secure
planetary assembly to frame. Remove planetary assembly from machine.
Installation (Fig. 6)
1. Inspect gasket between brake and planetary assemblies. Replace as needed.

Figure 7
1. Brake housing
2. Wheel motor cap screw
3. Brake flange screw

4. Planetary flange screw
5. Brake drain plug

2. Position planetary assembly to machine. Install
flange head screws that secure planetary assembly to
frame. Torque screws from 75 to 85 ft--lb (101 to 115
N--m).
3. Secure brake assembly to planetary assembly with
four (4) flange head screws (see Brake Assembly Installation in this Chapter). Torque screws from 75 to 85 ft--lb
(101 to 115 N--m).

Groundsmaster 4100--D

Page 6 -- 9

Axles, Planetaries and Brakes

Axles, Planetaries
and Brakes

6. Support hydraulic wheel motor to prevent it from falling. Remove two (2) cap screws that secure wheel motor to planetary assembly.

Planetary Wheel Drive Service

2
24

9 ft--lb
(12 N--m)

19
20
6
7

8
21
9
4

10
11

18
17
12

16
15

Figure 8
1.
2.
3.
4.
5.
6.
7.
8.

Spindle
Boot seal
Bearing cone
Bearing cup
Wheel stud (8 used)
Housing
Bearing cup
Bearing cone

Axles, Planetaries and Brakes

9.
10.
11.
12.
13.
14.
15.
16.

Thrust washer
Retaining ring (external)
Ring gear
Retaining ring (internal)
Plug (2 used)
End cap
Thrust plug
Thrust washer

Page 6 -- 10

17.
18.
19.
20.
21.
22.
23.
24.

Drive shaft
Carrier assembly
Socket head screw (16 used)
Lock washer (16 used)
O--ring
O--ring
Dowel pin (2 used)
Seal

Groundsmaster 4100--D

NOTE: The planetary wheel drive assembly can be serviced with the planetary installed to machine. If the
spindle (item 1) needs to be removed from machine, see
Planetary Wheel Drive Assembly Removal in this section.

3
1

19
20

Disassembly (Figs. 8 and 9)

1. If planetary wheel drive assembly is installed on machine:

A. Park machine on a level surface, lower cutting
decks, stop engine and remove key from the ignition
switch.
16

B. Drain oil from planetary wheel drive/brake assembly.

C. Chock rear wheels and jack up front of machine
(see Jacking Instructions in Chapter 1 -- Safety).
Support machine with jack stands.

D. Remove front wheel assembly.

Figure 9

2. Remove retaining ring (item 12).

4. Remove drive shaft assembly (items 17).

Assembly (Figs. 8 and 9)
1. Thoroughly clean parts in solvent and dry completely
after cleaning. Inspect parts for damage or excessive
wear and replace as necessary.

5. Remove carrier assembly (item 18).

NOTE: Use new seal and shim kits when assembling
planetary wheel drive.

6. If wheel stud (item 5) removal is necessary, use
press to extract stud(s) from housing.

2. If spindle and housing were separated:

NOTE: Steps 6 through 10 are necessary only if inspecting or replacing bearings and/or seals.

A. Press bearing cups (items 4 and 7) into housing.
Cups should be pressed fully to shoulder of the housing bore.

IMPORTANT: Do not reuse retaining ring (item 10)
after it has been removed.

B. Set inner bearing cone (item 3) into bearing cup
(item 4) that is installed in housing.

7. Remove retaining ring (item 10) and thrust washer
(item 9). Discard retaining ring.

C. Make sure that seal bore in housing is thoroughly
cleaned. If OD of seal (item 24) is not rubber or does
not have a sealant coating, apply light coating of silicone sealant to seal bore in housing. Install seal into
housing so it is flush with housing face. Lightly
grease seal lips.

8. Remove housing (item 6) from spindle (item 1). Remove outer bearing cone (item 8).
9. Remove and discard all seals and O--rings (items 2,
21 and 24).
10.If bearings will be replaced, remove inner bearing
cone (item 3) from housing. Remove bearing cups
(items 4 and 7) from housing.
11. If necessary, remove socket head screws (item 19)
with lock washers (item 20) that secure ring gear (item
11) to housing. Remove ring gear and two (2) dowel pins
(item 23) from housing.

Groundsmaster 4100--D

Page 6 -- 11

D. Pack boot seal (item 2) with grease and install on
housing.
E. If ring gear was removed from housing, place
dowel pins (item 23) in housing. Secure ring gear to
housing with lock washers (item 20) and socket head
screws (item 19). Torque socket head screws to 9 ft-lb (12 N--m).

Axles, Planetaries and Brakes

Axles, Planetaries
and Brakes

3. Remove end cap (item 14). Thrust plug (item 15) and
thrust washer (item 16) usually remain in end cap bore
and should be removed for cleaning and inspection.

F. Lightly oil bearing journals on spindle shaft. Slide
housing onto spindle (item 1) taking care to not damage seal or spindle. Make sure that bearing in housing fully seats against spindle shaft shoulder.

3. Install carrier assembly (item 18) making sure that
carrier gear teeth align with ring gear and spline on
spindle shaft.

G. Install outer bearing cone (item 8) onto spindle.

4. Install drive shaft (item 17) making sure that drive
shaft spline aligns with carrier gears.

NOTE: The planetary shim kit includes the retaining
ring and several thrust washers with thickness in incremental steps of 0.004 in. (0.10 mm).

5. Install thrust plug (item 15) and thrust washer (item
16) into end cap (item 14). Make sure that thrust plug
and thrust washer are captive on inside of end cap.

H. Measure thickness of thrust washer (item 9) that
was removed during disassembly. Choose new
thrust washer of equal thickness or the next available
thickness from thrust washers in the shim kit.

6. Install new O--ring (item 21) to end cap (item 14) and
then install end cap. Secure cap with retaining ring (item
12).

I. Apply a light coating of oil to spindle shaft, thrust
washer and retaining ring. Install thrust washer onto
spindle shaft.

WARNING
If retaining ring (item 10) is not fully installed in
spindle groove, loss of wheel and personal injury may result.
J. Carefully install new retaining ring (item 10) into
the spindle shaft groove taking care to not distort
ring. If the proper thrust washer has been installed,
the retaining ring should fit tightly between the thrust
washer and spindle groove. Tap the OD of the retaining ring starting in the center and working out toward each end to ensure that the retaining ring is
properly seated into the spindle groove. After correct
assembly, make sure that retaining ring ID is fully
seated to spindle shaft groove.

7. Check operation of planetary wheel drive. With a
constant turning force applied, rotation of the planetary
should be consistent. If there is more drag at certain
points, gears are not rolling freely and the planetary
should be examined for improper assembly or damaged
components.
8. If planetary wheel drive assembly is installed on machine:
A. Install wheel assembly.

WARNING
Failure to maintain proper wheel lug nut torque
could result in failure or loss of wheel and may
result in personal injury.

K. After retaining ring is installed, make sure that
there is no endplay in assembly. If required, remove
retaining ring and install a thrust washer of different
thickness to adjust endplay.

B. Lower machine from jack stands. Torque lug nuts
from 85 to 100 ft--lb (115 to 135 N--m).
C. Make sure drain plug is installed in bottom of
brake assembly. Fill planetary wheel drive/brake assembly with SAE 85W--140 gear lube. Capacity is
approximately 16 fl. oz. (0.47 liters) per wheel.

L. Install new O--ring (item 21) to housing.

Axles, Planetaries and Brakes

Page 6 -- 12

Groundsmaster 4100--D

Axles, Planetaries
and Brakes

This page is intentionally blank.

Groundsmaster 4100--D

Page 6 -- 13

Axles, Planetaries and Brakes

Rear Axle Assembly
18
17
16
2
3

See text for
tightening
procedure

RIGHT
FRONT

19
7

13
12
5

11
10

4
9

Figure 10
1.
2.
3.
4.
5.
6.
7.

Frame
Cap screw (6 used)
Flat washer
Bulkhead lock nut (2 used)
Washer
Thrust washer (thick)
Grease fitting (2 used)

8.
9.
10.
11.
12.
13.

Rear axle assembly
Thrust washer (thin)
Washer head screw
Pivot pin
Rear frame mount
Washer

Removal (Fig. 10)
1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.

14.
15.
16.
17.
18.
19.

Lock nut
Flange nut
Rear bumper
Hydraulic manifold (4WD)
Cap screw (2 used)
Flange nut (2 used)

2. Chock front wheels and jack up rear of machine (see
Jacking Instructions in Chapter 1 -- Safety). Support machine with suitable jack stands.
3. Drain oil from rear axle and axle gearbox.
4. Remove both wheels from rear axle.

Axles, Planetaries and Brakes

5. Remove hydraulic motor from rear axle assembly
(see Rear Axle Motor in the Service and Repairs section
of Chapter 4 -- Hydraulic System).
6. Remove steering cylinder from rear axle (see Steering Cylinder in the Service and Repairs section of Chapter 4 -- Hydraulic System).
7. Disconnect both steering cylinder hydraulic hoses
from hydraulic tubes at rear frame mount (Fig. 11). Remove bulkhead locknuts and washers that secure steering cylinder hydraulic tubes to rear frame mount.
Separate tubes from frame mount.

Page 6 -- 14

Groundsmaster 4100--D

8. Remove cap screw and flange nut that secures front
corner of 4WD hydraulic manifold to rear frame mount.

2
3

9. If required, remove tie rod ends from steering arms
on rear axle (Fig. 12). Remove the cotter pins and castle
nuts from the tie rod ball joints. Use a ball joint fork and
remove the tie rod ends from the axle steering arms.
10.Support rear axle to prevent it from falling. Remove
six (6) cap screws, flat washers and flange nuts that secure rear frame mount to equipment frame. Lower rear
axle and rear frame mount from machine.

11. Remove lock nut and washer from pivot pin that attaches rear axle to rear frame mount. Remove washer
head screw that secures flange of pivot pin to frame
mount (Fig. 13).

Figure 11
1. Hydraulic hose
2. Hydraulic hose
3. Hydraulic tube

Installation (Fig. 10)

1. Position rear frame mount to axle. Install thrust
washers between axle boss and frame mount. The thinner thrust washer should be installed on the hydraulic
motor end of the axle (toward the rear of the machine).
With washers installed, there should be from 0.002” to
0.020” (0.05 mm to 0.51 mm) clearance between rear
frame mount and axle mounting boss. Add thrust washers if needed to adjust clearance.
2. Install axle pivot pin to secure axle to rear frame
mount. Tighten lock nut and then loosen it slightly to allow the axle pin to pivot freely. Secure pivot pin to frame
mount with washer head screw (Fig. 13).
3. If removed, install the tie rod to rear axle (Fig. 12).
Tighten ball joint castle nuts and install new cotter pins.

4. Hydraulic tube
5. Rear frame mount

5
1

1. Tie rod
2. Dust cover
3. Cotter pin

4. Position axle and rear mount under machine with a
jack. Raise assembly to machine frame and align
mounting holes of rear mount and machine frame.

5. Secure rear mount to frame with six (6) cap screws,
flat washers and flange nuts.

Figure 12

4. Castle nut
5. Tie rod end
6. Steering arm (LH)

6. Install cap screw and flange nut that secures front
corner of 4WD hydraulic manifold to rear frame mount.
7. Attach steering cylinder hydraulic tubes to rear frame
mount with washers and bulkhead lock nuts (Fig. 11).
Install steering cylinder hoses to hydraulic tubes.

Groundsmaster 4100--D

Figure 13
1. Pivot pin

Page 6 -- 15

2. Washer head screw

Axles, Planetaries and Brakes

Axles, Planetaries
and Brakes

12.Remove pivot pin. Separate rear frame mount from
rear axle. Note location of thrust washers on both ends
of axle mounting boss.

8. Install steering cylinder to axle assembly (see Steering Cylinder Installation in the Service and Repairs section of Chapter 4 -- Hydraulic System).
9. Install hydraulic motor to axle assembly (see Rear
Axle Motor Installation in the Service and Repairs section of Chapter 4 -- Hydraulic System).

2
1

10.Install wheels to axle.

WARNING
Failure to maintain proper wheel lug nut torque
could result in failure or loss of wheel and may result in personal injury.
11. Lower machine to ground. Torque wheel lug nuts
from 85 to 100 ft--lb (115 to 135 N--m).

Figure 14
1. Steering stop bolt

2. Bevel gear case (LH)

12.Fill axle and input gearbox with SAE 85W--140
weight gear lube. Lubricant capacity is approximately 80
fl. oz. (2.37 liters) for the axle and 16 fl. oz. (0.47 liters)
for the gearbox.
13.Check rear wheel toe--in and adjust if necessary.
14.Check steering stop bolt adjustment. When the
steering cylinder is fully extended (right turn), a gap of
1/16” (1.6 mm) should exist between bevel gear case
casting and stop bolt on left axle case. Figure 14 shows
stop bolt location.

Axles, Planetaries and Brakes

Page 6 -- 16

Groundsmaster 4100--D

Bevel Gear Case and Axle Case
The following procedures assume the rear axle assembly has been removed from the machine (see Rear Axle
Assembly Removal in this section).

35 to 41 ft--lb
(47 to 56 N--m)
1

Bevel Gear Case and Axle Case Removal
1. Remove the mounting screws, nuts and lock washers. Remove the bevel gear case/axle case assembly
and O-ring from the axle support (Fig. 15).

2
3

2. Mark both right and left bevel gear case/axle case
assemblies.

35 to 41 ft--lb
(47 to 56 N--m)

IMPORTANT: Do not interchange right and left bevel gear case/axle case assemblies.
1.
2.
3.
4.

Figure 15

Cap screw (4 used)
Lock nut (2 used)
Lock washer (2 used)
Axle support

5. Bevel gear case/axle
case assembly
6. O-ring

3. Remove the axle cover mounting screws. Remove
the axle cover from the axle case as an assembly
(Fig. 16).

17 to 20 ft--lb
(23 to 27 N--m)
1

Figure 16

1. Axle case
2. Axle cover assembly

4. Remove the axle case support mounting screws, the
axle case support and the support shims (Fig. 17).

3. Mounting screw (6 used)
4. O-ring

Threadlocking
Compound

57 to 67 ft--lb
(77 to 91 N--m)
4
1

1. Axle case
2. Axle case support

Groundsmaster 4100--D

Page 6 -- 17

Figure 17

3. Mounting screw (2 used)
4. Support shim

Axles, Planetaries and Brakes

Axles, Planetaries
and Brakes

5. Remove the knuckle pin mounting screws and the
knuckle pin. Remove the gasket and any remaining gasket material from either mating surface (Fig. 18).
6. While holding the bevel gear case, tap the upper end
of the bevel gear shaft out of the upper bearing and upper bevel gear.

17 to 20 ft--lb
(23 to 27 N--m)

Threadlocking
Compound

7. Pull the bevel gear case from the axle case and remove the upper bevel gear and collar from the gear
case.

8. Remove the axle case cover screws, cover and the
O-ring from the axle case.

9. Remove the plug and sealing washer from the center
of the axle case cover. While holding the axle case cover, lightly tap the lower end of the bevel gear shaft out of
the lower bearing and lower bevel gear.

10.Remove and discard bevel gear shaft seal from axle
case (Fig. 18).
13

12
10
17 to 20 ft--lb
(23 to 27 N--m)

1.
2.
3.
4.
5.
6.
7.
8.

Figure 18

Knuckle pin
Mounting screw (4 used)
O--ring
Bevel gear case
Upper bearing
Bevel gear shaft
Collar
Upper bevel gear

9.
10.
11.
12.
13.
14.
15.

Lower bevel gear
Lower bearing
Axle case
Axle case cover
O-ring
Shaft seal
Bushing

Bevel Gear Case and Axle Case Inspection
1. Measure the knuckle pin O.D. and the axle case support bushing I.D. to determine the bushing to pin clearance (Fig. 19). Replace components as necessary.

1
2

BUSHING TO PIN CLEARANCE:
0.002 to 0.016 in. (0.05 to 0.40 mm)
KNUCKLE PIN O.D. (Factory Spec.):
0.982 to 0.983 in. (24.95 to 24.98 mm)
AXLE CASE SUPPORT BUSHING I.D.
(Factory Spec.):
0.984 to 0.987 in. (25.00 to 25.08 mm)
2. Inspect all gears, shafts, bearings, cases and covers
for damage and wear. Replace components as necessary.

Axles, Planetaries and Brakes

1. Knuckle pin

Page 6 -- 18

Figure 19

2. Axle case support

Groundsmaster 4100--D

Bevel Gear Case and Axle Case Installation
1. Coat new shaft seal with grease and install in axle
case as shown (Fig. 20).
3
2

1. Axle case
2. Bevel gear case

2. Install the lower bevel gear and bevel gear shaft in
the axle case cover. Coat a new O-ring with grease and
install the axle case cover (Fig. 21). Tighten cover
screws from 17 to 20 ft-lb (23 to 27 N--m).

3. Shaft seal

7
8

3. Slide the bevel gear case over the bevel gear shaft
and install the bevel gear and collar. Make sure the bevel
gear shaft is completely seated in the upper and lower
bearings (Fig. 21).
4. Install the knuckle pin. Use medium strength Loctite
thread locker and tighten the knuckle pin mounting
screws from 17 to 20 ft-lb (23 to 27 N--m).

Figure 20

2
1
4

Figure 21
1.
2.
3.
4.

Groundsmaster 4100--D

Page 6 -- 19

Axle case cover
Lower bevel gear
Bevel gear shaft
Lower bearing

5.
6.
7.
8.

Upper bevel gear
Collar
Upper bearing
Knuckle pin

Axles, Planetaries and Brakes

Axles, Planetaries
and Brakes

5. Determine necessary quantity of support shims.
4

A. Lubricate the axle case support bushing with a
thin coat of grease and slide axle case support onto
knuckle pin.
B. Position support shims that were removed during
disassembly between axle case support and axle
case. Install mounting screws into axle case. Slowly
tighten screws while frequently checking for clearance (vertical endplay) between axle case support
and knuckle pin. If binding of components is noted
before screws are fully tightened, add additional support shims. Torque screws from 57 to 67 ft--lb (77 to
91 N--m).
C. Use dial indicator to measure vertical endplay of
axle case (Fig. 22).
AXLE CASE ASSEMBLY ENDPLAY:
0.001 to 0.008 in. (0.02 to 0.20 mm)

57 to 67 ft--lb
(77 to 91 N--m)
1

VERTICAL
ENDPLAY

1. Axle case support
2. Axle case
3. Bevel gearcase

D. Adjust endplay by increasing or reducing number
of axle case support shims.

Figure 22

4. Dial indicator
5. Knuckle pin
6. Support shim location

NOTE: Axle case support shims are available in
0.004 in. (0.1 mm), 0.008 in. (0.2 mm) and 0.016 in.
(0.4 mm) thickness.

6. After correct support shims have been determined,
remove mounting screws, apply heavy strength thread-locking compound to screw threads, reinstall screws
and torque from 57 to 67 ft--lb (77 to 91 N--m).
5

IMPORTANT: Correct engagement between bevel
gears is critical to axle performance and durability.
7. Temporarily install the bevel gear case/axle case assembly on the axle support. Position a dial indicator at
the tooths center. Prevent the axle from turning and
measure the upper bevel gear to differential shaft gear
backlash (Fig. 23).

Figure 23

1. Axle support
2. Upper bevel gear
3. Differential shaft gear

UPPER BEVEL GEAR BACKLASH:
0.004 to 0.016 in. (0.10 to 0.40 mm)

4. Dial indicator
5. Axle bearing shims

5
1

8. Adjust backlash by increasing or reducing axle bearing shim thickness (see Differential Shafts in this section
of this manual).
NOTE: Axle bearing shims are available in 0.004 in.
(0.1 mm), 0.008 in. (0.2 mm) and 0.020 in. (0.5 mm)
thickness.

Figure 24

1. Axle cover assembly
2. Lower bevel gear
3. Axle gear

Axles, Planetaries and Brakes

Page 6 -- 20

4. Dial indicator
5. Axle bearing shims

Groundsmaster 4100--D

9. Remove the bevel gear case/axle case assembly
from the axle support. Coat a new O-ring with grease
and temporarily install the axle cover assembly. Position
a dial indicator at the tooths center. Prevent the axle
from turning and measure the lower bevel gear to axle
gear backlash (Fig. 24).
LOWER BEVEL GEAR BACKLASH:
0.004 to 0.016 in. (0.10 to 0.40 mm)

11. Tighten axle cover screws from 17 to 20 ft-lb (23 to
27 N--m).
12.Coat a new O-ring with grease and install the bevel
gear case/axle case assembly on the axle support.
Tighten mounting screws and nuts from 35 to 41 ft-lb
(47 to 56 N--m) (Fig. 15).

Axles, Planetaries
and Brakes

10.Adjust backlash by increasing or reducing axle bearing shim thickness (see Axle Shafts in this section of this
manual).

NOTE: Axle bearing shims are available in 0.008 in.
(0.2 mm), 0.012 in. (0.3 mm) and 0.020 in. (0.5 mm)
thickness.

Groundsmaster 4100--D

Page 6 -- 21

Axles, Planetaries and Brakes

Differential Shafts
The following procedures assume the rear axle assembly has been removed from the machine (see Rear Axle
Assembly Removal in this section).

35 to 41 ft--lb
(47 to 56 N--m)
1

Differential Shaft Removal

IMPORTANT: Do not interchange right and left differential shaft assemblies.
4

1. Remove the mounting screws, nuts and lock washers. Remove the bevel gear case/axle case assembly
and O-ring from the axle support (Fig. 25).

4. Drive the differential shaft out of the bearings. Remove the bearings and bearing shims.

35 to 41 ft--lb
(47 to 56 N--m)

2. Mark and pull the differential shaft assembly from the
axle support.
3. Remove the retaining ring and bevel gear (Fig 26).

1.
2.
3.
4.

Figure 25

Cap screw (4 used)
Lock nut (2 used)
Lock washer (2 used)
Axle support

5. Bevel gear/axle case
assembly
6. O-ring
7. Stud (2 used)

5. Inspect all gears, shafts, bearings and cases for
damage and wear. Replace components as necessary.
Differential Shaft Installation
6

1. Press bearings onto differential shaft. Place correct
combination of bearing shims in axle support and drive
differential shaft and bearing assembly into axle support.

3
5
4

2. Install bevel gear and retaining ring.
3. Coat new O-ring with grease. Align differential shaft
splines with differential gear assembly and slide differential shaft assembly onto axle support.
4. Install bevel gear case/axle case assembly (see
Bevel Gear Case/Axle Case Assembly in this section of
this manual).

Axles, Planetaries and Brakes

1. Retaining ring
2. Bevel gear
3. Differential shaft

Page 6 -- 22

Figure 26

4. Bearing
5. Bearing shims
6. O-ring

Groundsmaster 4100--D

Axle Shafts
The following procedures assume the rear axle assembly has been removed from the machine (see Rear Axle
Assembly Removal in this section).

17 to 20 ft--lb
(23 to 27 N--m)
1

Axle Shaft Removal

1. Remove the axle cover mounting screws. Remove
the axle cover from the axle case as an assembly
(Fig. 27).
2. Use a bearing puller to remove the bearing and bevel
gear as shown (Fig. 28).
3. Remove the shims, spacer and retaining ring. Drive
the axle out of the bearing and cover. Remove and discard the axle shaft seal.

Figure 27

1. Axle case
2. Axle cover assembly

3. Mounting screw (6 used)
4. O-ring

4. Inspect all gears, shafts, bearings, spacers and
cases for damage and wear. Replace components as
necessary.

Axle Shaft Installation
2

1. Coat new axle shaft seal with grease and install in
axle cover as shown (Fig. 29).
4

2. Press the axle cover and bearing assembly onto the
axle shaft. Press only on the inner race of the cover
bearing (Fig. 29).

4. Coat a new O-ring with grease and install the axle
cover assembly. Tighten axle cover screws from 17 to
20 ft-lb (23 to 27 N--m).

1. Bearing
2. Bevel gear
3. Bearing shims

Figure 28

4. Spacer
5. Retaining ring

1
4
2

1. Axle shaft seal
2. Axle cover

Groundsmaster 4100--D

Page 6 -- 23

Figure 29

3. Bearing
4. Axle shaft

Axles, Planetaries and Brakes

Axles, Planetaries
and Brakes

3. Install retaining ring, spacer and correct combination
of bearing shims. Install bevel gear and bearing.

Input Shaft/Pinion Gear
1

35 to 41 ft--lb
(47 to 56 N--m)

18
15

10
13

35 to 41 ft--lb
(47 to 56 N--m)

11
12

Figure 30
1.
2.
3.
4.
5.
6.

Nut (2 used)
Lockwasher (2 used)
Stud (2 used)
Locknut
Stake washer
Oil seal

7.
8.
9.
10.
11.
12.

O-ring
Seal collar
Bearing
O-ring
Input shaft/pinion gear
Bearing case

The following procedures assume the rear axle assembly has been removed from the machine (see Rear Axle
Assembly Removal in this section).
Removal (Fig. 30)
1. Remove the cover plate, gasket and gear case assembly from the axle assembly. Remove the gasket and
any remaining gasket material.
2. Remove the retaining rings and the driven gear from
the input shaft/pinion gear.
3. Remove input shaft/pinion gear assembly from the
gear case. Remove the shims and bearing case Orings.
4. Release the stake washer and remove the locknut.
Remove and discard the stake washer.
5. Drive the input shaft/pinion gear out from the outer
bearing cone and bearing case. Remove and discard
the oil seal and O-ring.
6. Inspect all gears, shafts, bearings, spacers and
cases for damage and wear. Replace components as
necessary.
NOTE: Replacement input shaft/pinion gears are only
available in matched ring and pinion sets.
Axles, Planetaries and Brakes

13.
14.
15.
16.
17.
18.

Shim
Screw (2 used)
Gear case
Gasket
Cover plate
Dowel pin

Installation (Fig. 30)
NOTE: When installing new bearing cones, press only
on the inner race of the bearing cone.
1. If the inner bearing cone was removed, press a new
bearing cone all the way onto the input shaft/pinion gear.
2. Place the shaft and bearing assembly in the bearing
case and install the outer bearing cone.
NOTE: The bearings must be completely seated.
There should be no input shaft/pinion gear end play.
3. Coat a new oil seal with grease and install as shown
(Fig. 31). The seal should be installed with the garter
spring towards the hydraulic motor.
4. Coat new O-ring with grease. Install O-ring in the oil
seal collar and install the collar.
5. Install a new stake washer. Install the lock nut finger
tight.
6. Set the bearing preload by securing the bearing case
in a vise. Thread a M12 x 1.5 hex head cap screw into
the splined end of the input shaft/pinion gear and slowly
tighten the locknut until 4 to 6 in-lb (0.4 to 0.7 N--m) of
force is required to rotate the input shaft/pinion gear in
the bearing case.

Page 6 -- 24

Groundsmaster 4100--D

7. Secure the lock nut with the stake washer.
8. Use a depth gauge to measure the distance from the
end face of the input shaft/pinion gear to the mating surface of the bearing case. Subtract the “Design Cone
Center Distance” from this distance to determine initial
shim thickness (Fig. 32).

0.040 in. (1.0 mm)
2

DESIGN CONE CENTER DISTANCE (distance
from mating surface of axle support to end face of
pinion gear):
1.870 + 0.002 in. (47.5 + 0.05 mm)

NOTE: Bearing case shims are available in 0.004 in.
(0.1 mm) and 0.008 in. (0.2 mm) thickness.
9. Coat new O-rings with grease and install the bearing
case in the gear case. Place shims on the gear case and
temporarily install gear case assembly into axle case.
Tighten mounting nuts and screws from 35 to 41 ft-lb
(47 to 56 N--m).

1. Oil seal
2. Bearing case

10.Insert a screwdriver through the drain plug hole to
hold ring gear and measure the pinion gear to ring gear
backlash (Fig. 33).

Figure 31

3. Seal garter spring

1
Design
Cone Center
Distance

PINION GEAR TO RING GEAR BACKLASH:
0.004 to 0.016 in. (0.10 to 0.40 mm)
11. Adjust backlash by increasing or reducing gear case
shim thickness.

13.Place the correct combination of shims on the gear
case. Tighten mounting nuts and screws from 35 to 41
ft-lb (47 to 56 N--m).

Axles, Planetaries
and Brakes

12.Check pinion gear to ring gear engagement (see Pinion Gear to Ring Gear Engagement in this section of this
manual).
Figure 32

1. Input shaft/pinion gear

2. Bearing case

14.Install retaining rings and driven gear on input shaft/
pinion gear.

15.If the drive gear (on drive motor shaft) was removed,
install the retaining rings and drive gear on the motor
shaft.
16.Use a new gasket and install the cover plate.

1. Axle case
2. Screwdriver

Groundsmaster 4100--D

Page 6 -- 25

Figure 33

3. Dial indicator
4. Input shaft/pinion gear

Axles, Planetaries and Brakes

Differential Gear
The following procedures assume the rear axle assembly has been removed from the machine (see Rear Axle
Assembly Removal in this section).

35 to 41 ft--lb
(47 to 56 N--m)

Differential Gear Removal

1. Remove bevel gear case/axle case assemblies (see
Bevel Gear Case/Axle Case Assembly in this section of
this manual).
IMPORTANT: Do not interchange right and left differential shafts assemblies.

7
4
3

2. Mark and pull the differential shaft assemblies from
the axle support.
3. Remove input shaft/pinion gear assembly, shims
and O-ring from the axle support (Fig. 34).
4. Remove the axle support case screws. Separate the
axle support halves and remove the O-ring.

35 to 41 ft--lb
(47 to 56 N--m)
1.
2.
3.
4.

Gear Case
Pinion Gear
Axle support (left)
Axle support (right)

Figure 34

5. Case screw (8 used)
6. Differential gear
7. O-ring

5. Remove the differential gear assembly, bearings and
adjusting shims from the axle case.

2
1

6. Drive the spring pin from the differential case with a
punch and hammer. Discard the spring pin (Fig. 35).
NOTE: Mark and arrange all components so they can
be reassembled in their original position.
7. Remove the differential pinion shaft, pinion gears
and pinion washers. Remove the differential side gears
and side gear shims. Remove the ring gear only if it will
be replaced (Fig. 36).
NOTE: Replacement ring gears are only available in
matched ring and pinion sets.

Figure 35

1. Differential case

2. Spring pin

1
3
2
5
22 to 25 ft--lb
(30 to 34 N--m)

8
Threadlocking
Compound
7

1.
2.
3.
4.

Axles, Planetaries and Brakes

Page 6 -- 26

Figure 36

Differential pinion shaft
Pinion gear
Pinion washer
Side gear

5.
6.
7.
8.

Side gear shims
Ring gear
Differential case
Bolt/washer (8 used)

Groundsmaster 4100--D

Differential Gear Inspection
1. Measure the differential side gear O.D. and the differential case I.D. to determine the side gear to case
clearance (Fig. 37). Replace components as necessary.
SIDE GEAR TO CASE CLEARANCE:
0.002 to 0.012 in. (0.05 to 0.30 mm)
1

SIDE GEAR O.D. (Factory Spec.):
1.335 to 1.337 in. (33.91 to 33.95 mm)
DIFFERENTIAL CASE I.D. (Factory Spec.):
1.339 to 1.341 in. (34.00 to 34.06 mm)
2

2. Measure the differential pinion shaft O.D. and the
pinion gear I.D. to determine the pinion shaft to pinion
gear clearance (Fig. 38). Replace components as necessary.
PINION SHAFT TO PINION GEAR CLEARANCE:
0.001 to 0.010 in. (0.03 to 0.25 mm)
PINION SHAFT O.D. (Factory Spec.):
0.550 to 0.551 in. (13.97 to 13.10 mm)

1. Side gear

PINION GEAR I.D. (Factory Spec.):
0.551 to 0.552 in. (13.10 to 14.02 mm)

Figure 37

2. Differential case

Axles, Planetaries
and Brakes

3. Inspect all gears, shafts, bearings, cases and covers
for damage and wear. Replace components as necessary.

1. Pinion shaft

Groundsmaster 4100--D

Page 6 -- 27

Figure 38

2. Pinion gear

Axles, Planetaries and Brakes

Differential Gear Installation

1. If the ring gear was removed, use medium strength
thread locking compound and tighten the mounting
screws from 22 to 25 ft-lb (30 to 34 N--m).

2
1

2. Apply molybdenum disulfide grease to the splines
and bearing surfaces of the differential pinion gears, pinion washers and side gears.
3. Install the side gear shims and side gears in their
original location in the differential case.
4. Place the differential pinion gears and pinion washers in their original location in the differential case. Temporarily install the differential pinion shaft.
5. Secure the differential case in a vise. Position a dial
indicator at the tooths center and measure the differential pinion gear to side gear backlash (Fig. 39).

Figure 39

1. Vise
2. Differential gear case

3. Dial indicator

More than 35% total tooth contact

PINION GEAR TO SIDE GEAR BACKLASH:
0.004 to 0.016 in. (0.10 to 0.40 mm)
6. Adjust backlash by increasing or reducing side gear
shim thickness.
NOTE: Side gear shims are available in 0.043 in. (1.1
mm), 0.047 in. (1.2 mm) and 0.051 in. (1.3 mm) thickness.
7. Apply gear marking compound, such as DyKemR
Steel Blue lightly over several gear teeth.
8. While applying a light load to either side gear, rotate
either pinion gear until the side gears have made one
complete revolution.
9. Ideal tooth contact should cover more than 35% of
each tooth surface. The contact area should be in the
center of each tooth and extend 1/3 to 1/2 way across
each tooth from the toe (small) end (Fig. 40).
10.Adjust side gear shims if necessary to correct tooth
contact. Recheck differential pinion gear to side gear
backlash if any changes are made.
11. After backlash and tooth contact have been adjusted, align the hole in the differential pinion shaft with
the hole in the differential case and install a new spring
pin.

Axles, Planetaries and Brakes

1/3 to 1/2 of entire width
from small end of tooth

Figure 40
12.Install differential gear assembly in right side axle
support half.
13.Coat a new O-ring with grease and install left side
axle support half. Tighten axle support case screws from
35 to 41 ft-lb (47 to 56 N--m).
14.Install input shaft/pinion gear assembly (see Input
shaft/Pinion in this section of this manual).
15.Coat new O-rings with grease, align differential shaft
splines with differential gear assembly and slide differential shaft assemblies onto axle support.
16.Install bevel gear case/axle case assemblies (see
Bevel Gear Case/Axle Case Assembly in this section of
this manual).

Page 6 -- 28

Groundsmaster 4100--D

Pinion Gear to Ring Gear Engagement
The final position of the pinion gear is verified by using
the gear contact pattern method as described in the following procedure.

PROFILE

TOP LAND

GEAR TOOTH DEFINITIONS (Fig. 41):
Toe -- the portion of the tooth surface at the end towards the center.

TOE

HEEL

Heel -- the portion of the gear tooth at the outer end.

LENGTHWISE
BEARING
ARC

Top Land -- top surface of tooth.
1. Paint the teeth of the ring gear, both drive and coast
side, with a gear marking compound, such as DyKemR
Steel Blue.

ROOT

Figure 41

2. Install the input shaft/pinion gear assembly into axle
case.

More than 35% total tooth contact

3. While applying a light load to the ring gear, rotate the
pinion gear in the direction of forward travel until the ring
gear has made one complete revolution.
Ideal tooth contact observed on the ring gear should
cover more than 35% of each tooth surface. The contact
area should be in the center of each tooth and extend 1/3
to 1/2 way across each tooth from the toe end (Fig. 42).

1/3 to 1/2 of entire width
from small end of tooth

Axles, Planetaries
and Brakes

Figure 42

Adjustments to the gear contact position are made by
moving the input shaft/pinion gear (bearing case shims)
or by moving the differential gear case (differential bearing shims) (Fig. 43).

NOTE: Bearing case shims are available in 0.004 in.
(0.10 mm) and 0.008 in. (0.20 mm) thickness.
NOTE: Differential bearing shims are available in
0.004 in. (0.10 mm), 0.008 in. (0.20 mm) and 0.016 in.
(0.40 mm) thickness.
Study the different contact patterns (Figs. 44 and 45)
and correct gear engagement as necessary.
2

NOTE: When making changes, note that two variables
are involved (see Gear Pattern Movement Summary in
this section of this manual).
Example: If the pinion gear to ring gear backlash is set
correctly to specifications and the bearing case shim is
changed to adjust tooth contact, it may be necessary to
readjust backlash to the correct specification before
checking the contact pattern.

Groundsmaster 4100--D

Figure 43

1. Input shaft/pinion gear
2. Bearing case shims
3. Differential gear case

Page 6 -- 29

4. Differential bearing
shims

Axles, Planetaries and Brakes

Gear Pattern Movement Summary

Heel Contact

Base Contact

Every gear has a characteristic pattern. The illustrations
show typical patterns only and explain how patterns shift
as gear location is changed.
1. If contact is toward the heel or base of the gear (Fig.
44):
A. Install thicker or additional bearing case shim(s)
to move pinion shaft toward ring gear.

Figure 44

B. Install thinner or remove differential bearing
shim(s) to move ring gear backward.
C. Repeat until proper tooth contact and pinion gear
to ring gear backlash are correct.

Toe Contact

Tip Contact

2. If contact is toward the toe or tip of the gear (Fig. 45):
A. Install thinner or remove bearing case shim(s) to
move pinion shaft away from ring gear.
B. Install thicker or additional differential bearing
shim(s) to move ring gear forward.

Figure 45

C. Repeat until proper tooth contact and pinion gear
to ring gear backlash are correct.

Axles, Planetaries and Brakes

Page 6 -- 30

Groundsmaster 4100--D

Chapter 7

Chassis
Table of Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 1
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 2
Steering Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cutting Deck Lift Arms . . . . . . . . . . . . . . . . . . . . . . . 4
Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operator Seat Service . . . . . . . . . . . . . . . . . . . . . . . 8
Operator Seat Suspension . . . . . . . . . . . . . . . . . . 10
Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

General Information
Operator’s Manual

Chassis

Groundsmaster 4100--D

Page 7 -- 1

Chassis

Service and Repairs
Steering Tower

39
24
25

23
26

33
34
35
36
37

4
5
6
41

21
40

9
10

29
30
31

11
12
13
14

16 to 20 ft--lb
(22 to 27 N--m)

41
15
16
17

18
19

38
20

RIGHT
FRONT

Figure 1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Hex nut
Flat washer
Steering wheel
Foam collar
Steering seal
External snap ring (2 used)
Knob
Steering tower cover
Steering shaft
Compression spring
Cap
Rod assembly
Extension spring
Tilt rod

Chassis

15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.

Lock nut (2 used)
Parking brake switch
Cotter pin
Brake pawl
Cotter pin
Lock nut (2 used)
Nut insert (10 used)
Flange head screw (10 used)
Flange bushing (2 used)
Thrust washer (as needed)
Temperature gauge
Warning lamp (temp/glow plug)
Warning lamp (charge/oil pressure)
Steering column

Page 7 -- 2

29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.

Cap screw (2 used)
Pivot hub(2 used)
Flange head screw (4 used)
Switch bracket
Flange nut (2 used)
Cap screw (2 used)
Steering tower
Phillips head screw (2 used)
Clevis pin
Steering valve
Steering wheel cover
Front wire harness
Snap ring location

Groundsmaster 4100--D

Disassembly (Fig. 1)

Assembly (Fig. 1)

1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.

1. Assemble steering tower using Figure 1 as a guide.

B. If steering wheel was removed, torque hex nut
(item 1) from 16 to 20 ft lb (22 to 27 N--m).

Chassis

2. Disassemble steering tower as needed using Figure
1 as a guide.

A. Thrust washer(s) (item 24) on steering column
are used as needed to remove end play of steering
shaft.

Groundsmaster 4100--D

Page 7 -- 3

Chassis

Cutting Deck Lift Arms
8
38
Loctite 242
on threads

60 to 70 ft--lb
(81 to 94 N--m)

10
11

RIGHT

30 to 40 ft--lb
(41 to 54 N--m)

12
14
15
16
17
18
19
20 21
22

FRONT

11
36

16
32

35
33

24
25 16

2
1

30
28

34
155 to 185 ft--lb
(211 to 251 N--m)

16
37

75 to 85 ft--lb
(102 to 115 N--m)

Figure 2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Lift cylinder
Clevis pin
Cap screw
Grease fitting
Lift arm pin
Slotted roll pin
Lock nut
Cotter pin
Pivot pin
Hair pin
Spherical rod end
Damper
Yoke spacer

14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.

Flange nut
Lock nut
Flat washer
Grease fitting
Flange head screw
Lift cylinder pin
Flange nut
Spherical bearing
Tapered stud
Retaining ring
Cap screw
Grease fitting
Support hub

27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.

Clevis pin
Hair pin
Flat washer
Flange nut
Height--of--cut chain
U--bolt
Nut
Lock nut
Flange bushing (2 per lift arm)
Lift arm (LH)
Lock nut
Lift arm (RH)

Removal (Fig. 2)
1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.
2. Remove front cutting deck (see Cutting Deck Removal in Chapter 8 -- Cutting Deck).

Chassis

Page 7 -- 4

Groundsmaster 4100--D

E. Thoroughly clean tapered surfaces of stud and
mounting boss of support hub. Secure support hub
(position slotted hole in hub toward rear of deck) to
tapered stud with flat washer and flange nut. Tighten
flange nut from 155 to 185 ft--lb (211 to 251 N--m).

CAUTION
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 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.
3. Chock rear wheels and jack up front of machine.
Support machine on jack stands. Remove front wheel
next to lift arm that is being removed.
4. Remove flange head screw and lock nut that secure
lift cylinder pin to lift arm. Remove pin and separate lift
cylinder from lift arm.
5. Remove lock nut that secures lift arm pin. Support lift
arm and slide pin from frame and lift arm. Remove lift
arm from frame.

2. Position lift arm to frame and insert lift arm pin. Engage roll pin into frame slots and install lock nut on pin.
Torque lock nut from 60 to 70 ft--lb (81 to 94 N--m).
3. Align lift cylinder with lift arm. Slide lift cylinder pin
through lift arm and cylinder end. Secure pin with flange
head screw and lock nut.
4. Install front wheel assembly. Lower machine to the
ground.
5. Install cutting deck (see Cutting Deck Installation in
Chapter 8 -- Cutting Deck).
6. Lubricate lift arm grease fittings.
7. After assembly is completed, raise and lower the cutting deck to verify that hydraulic hoses and fittings do not
contact anything.
8. Check height--of--cut and deck pitch adjustment.

6. As needed, disassemble lift arm:

0.750”
(19.1 mm)

A. Remove height--of--cut chain and damper assembly.
B. Press flange bearings from lift arm.
C. Remove flange nut, flat washer and support hub
from tapered stud. Remove tapered stud with spherical bearing from lift arm after removing retaining ring
from lift arm. Remove flange nut and spherical bearing from stud.

1
Figure 3
1. Lift arm

2. U--bolt threads

1. If removed, install components to lift arm.
A. Assemble height--of--cut chain u--bolt so that
threaded portion of u--bolt extends 0.750” (19.1 mm)
above mounting plate on lift arm (Fig. 3).
B. If rod ends were removed from damper, apply
Loctite #242 to threads and install on damper. Install
damper assembly to lift arm with damper rod end toward deck (Fig. 4).

3
1

C. Press flange bearings into lift arm.
D. Install spherical bearing on tapered stud and secure with flange nut. Torque flange nut from 30 to 40
ft--lb (41 to 54 N--m). Install stud with spherical bearing into lift arm and secure with retaining ring.
Groundsmaster 4100--D

Figure 4
1. Lift arm
2. Deck castor arm

Page 7 -- 5

3. Support hub
4. Damper

Chassis

Installation (Fig. 2)

Operator Seat

9
17
8

14
2
5

3
13

12
8

16
21

RIGHT
19

FRONT

Figure 5
1.
2.
3.
4.
5.
6.
7.
8.

Seat assembly
Flat washer (5 used)
Seat belt
Cap screw (4 used)
Seat platform
Flange nut (4 used)
Seat belt buckle
Cap screw (2 used)

Chassis

9.
10.
11.
12.
13.
14.
15.
16.

R--clamp (2 used)
Manual tube
Screw
Lock nut
Seat belt mount
Lock washer (2 used)
R--clamp (2 used)
Wire harness seat switch lead

Page 7 -- 6

17.
18.
19.
20.
21.
22.
23.
24.

Screw (2 used)
Hair pin (2 used)
Clevis pin (2 used)
Spring
Latch shaft
Cotter pin (2 used)
Latch
Prop rod

Groundsmaster 4100--D

Removal (Fig. 5)
1

1. Park machine on a level surface, lower cutting deck,
stop engine, apply parking brake and remove key from
the ignition switch.

2. Remove seat from seat suspension:
A. Disconnect seat electrical connectors from machine wire harness (Fig. 6).

B. Remove four (4) Torx head screws that secure
seat to seat suspension (Fig. 7). Note that the screw
near the seat adjustment handle is longer than the
other three (3) screws.
C. Lift seat from seat suspension and remove from
machine.
NOTE: Most of the seat suspension components can
be serviced with the seat suspension base mounted to
the frame platform.

Figure 6
1. Operator seat
2. Seat switch connector

3. Suspension connector

3. If necessary, remove seat suspension from seat platform:
1

A. Tilt seat to gain access to mounting fasteners.
Support seat suspension to prevent it from falling.
B. Remove four (4) cap screws and flange nuts that
secure seat suspension to seat plate. Note that two
(2) r--clamps that retain wire harness are secured
with seat suspension fasteners.
3

C. Lift seat suspension from machine.
Installation (Fig. 5)

1. If removed, install seat suspension to seat platform:
18 ft--lb
(25 N--m)

B. Secure seat suspension and two (2) wire harness
r--clamps to seat platform with four (4) cap screws
and flange nuts.

Figure 7
1. Seat
2. Suspension assembly

C. Lower seat plate and suspension.

3. Screw (M8x12) (3 used)
4. Screw (M8x16)

2. Install seat to seat suspension:
A. Carefully position seat to seat suspension.
B. Secure seat to seat suspension with four (4) Torx
head screws (Fig. 7). Make sure that longer screw is
positioned near the seat adjustment handle.
C. Torque screws 18 ft--lb (25 N--m).
3. Connect seat electrical connectors to machine wire
harness (Fig. 6).

Groundsmaster 4100--D

Page 7 -- 7

Chassis

A. Position seat suspension onto seat plate.

Operator Seat Service

13
5

22
26
25
30

16
18
19

24
23

10
15

Figure 8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Backrest cushion
Seat cushion
Armrest cover
LH armrest
Bushing (2 used)
Backrest
Plug (2 used)
Cable tie (3 used)
LH adjustment rail
Bumper (2 used)

Chassis

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Washer
Cap screw (2 used)
Seat
Nut
Spring (2 used)
Magnet
Seat switch
Rivet (4 used)
Mounting plate
Return spring

Page 7 -- 8

21.
22.
23.
24.
25.
26.
27.
28.
29.
30.

Torx screw (5 used)
RH adjustment rail
Rail stop
Torx screw
Torx screw (3 used)
Washer (3 used)
Handle
Nut
Support bracket
Cap screw

Groundsmaster 4100--D

Assembly (Fig. 8)

1. Disassemble operator seat as necessary using Figure 8 as a guide.

1. Assemble operator seat using Figure 8 as a guide.

Chassis

Disassembly (Fig. 8)

Groundsmaster 4100--D

Page 7 -- 9

Chassis

Operator Seat Suspension

RIGHT
17

FRONT
24

2
19
21

33
1

3
39

14
12

4
30

6
15

36
8

26
33
11
34

Figure 9
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Cover
Cover
Level control
Air control valve
Shock absorber
Air spring
Air tube assembly
Wire harness
Compressor
Bellows
Stop
Bumper set (2 used)
Roller (4 used)

Chassis

14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.

Washer (2 used)
Tether
Rivet (2 used)
Washer (4 used)
C--clip (4used)
Pin (2 used)
Rivet (2 used)
Washer (3 used)
Screw (2 used)
Washer
Housing support (4 used)
Spacer (4 used)
Hose nipple

Page 7 -- 10

27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.

Clamp (2 used)
Hose nipple
Screw
Handle
Bumper
Nut
Plastic plug (23 used)
Screw (2 used)
Roller (2 used)
Screw (4 used)
Base plate
Suspension frame
Upper plate

Groundsmaster 4100--D

NOTE: Most of the seat suspension components can
be serviced with the seat suspension base mounted to
the frame platform. If the air spring assembly (item 6) requires removal, the seat suspension base will have to be
removed from the seat platform.

1
2

Disassembly (Fig. 9)
1. Remove operator seat from seat suspension (see
Operator Seat Removal in this section).

2. If the air spring assembly (item 6) or base plate (item
37) requires removal, remove seat suspension from
seat platform (see Operator Seat Removal in this section).
3. Remove seat suspension components as needed
using Figure 9 as a guide.
Assembly (Fig. 9)

Figure 10
1. Operator seat
2. Seat switch connector

3. Suspension connector

1. Install all removed seat suspension components using Figure 9 as a guide.
2. Install seat suspension if it was removed from seat
platform (see Operator Seat Installation in this section):
3. Install operator seat to seat suspension (see Operator Seat Installation in this section).

Chassis

4. Make sure that seat electrical connectors are secured to machine wire harness (Fig. 10).

Groundsmaster 4100--D

Page 7 -- 11

Chassis

Hood

RIGHT

FRONT

37
42

13
29

7
38

3
40
41

9
25

11
10
12

4
30
14
47

3
32

15
16
18

17
19
21
46
22
45

Figure 11
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

Rear screen
Top screen
Cap screw (22 used)
Screen assembly
Bulb seal
Flange nut (2 used)
Bulb seal
Screen corner seal (2 used)
Hair pin (2 used)
Screw (8 used)
Hood pivot (2 used)
Pivot bracket (2 used)
Hood
Handle (2 used)
Flange head screw (4 used)
Oil filter deflector

Chassis

17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.

Flange nut (4 used)
Latch cover
Latch
Hood latch bracket
Washer head screw (2 used)
LH latch bracket
Latch bracket (2 used)
Screw (4 used)
Fuel tank support
Screw (4 used)
Screw (2 used)
Hood support
R--clamp (2 used)
Hair pin (2 used)
Clevis pin (2 used)
Hood rod (2 used)

Page 7 -- 12

33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.

RH screen mount
LH screen mount
Carriage bolt (2 used)
Flange nut (2 used)
Plastic plug (24 used)
Pop rivet (22 used)
Flat washer (22 used)
Lock nut (20 used)
Flat washer (21 used)
Foam seal (2 used)
RH latch bracket
Latch handle (2 used)
Latch keeper (2 used)
Flange head screw (4 used)
Flange nut (4 used)

Groundsmaster 4100--D

Removal
1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.

2. Remove hood using Figure 11 as a guide.
Installation
2

1. Install hood using Figure 11 as a guide.
2. Align hood to machine to allow correct operation of
hood latches and dust seals:
A. Place shim that is 3/8” to 7/16” (9.5 to 11.1 mm)
thick on top of frame (both RH and LH sides) near the
sides of oil cooler (Figs. 12 and 13).
B. Close hood so that it rests on shims and fasten
the hood latches.

Figure 12
1. LH shim location
2. LH hood pivot

C. Loosen hood pivots at frame to adjust vertical
placement of pivots. Re--tighten hood pivot fasteners.

3. LH pivot bracket

D. Loosen pivot brackets to allow hood latches to
pull hood against radiator support. Re--tighten pivot
bracket fasteners.
3. After hood is assembled to machine, check for the
following:

A. Check that bulb seals are equally compressed at
all contact points with hood.

B. Hood should open and close without contacting
oil cooler hardware.

Figure 13
3. RH pivot bracket

Chassis

1. RH shim location
2. RH hood pivot

Groundsmaster 4100--D

Page 7 -- 13

Chassis

This page is intentionally blank.

Chassis

Page 7 -- 14

Groundsmaster 4100--D

Chapter 8

Cutting Deck
Table of Contents

Cutting Deck

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Castor Wheel Tire Pressure . . . . . . . . . . . . . . . . . . 3
Blade Stopping Time . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4
Factors That Can Affect Quality of Cut . . . . . . . . . 4
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 6
Cutting Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wing Deck Service . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cutting Deck Link Service . . . . . . . . . . . . . . . . . . . 13
Wing Deck Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Blade Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Blade Spindle Service . . . . . . . . . . . . . . . . . . . . . . 18
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Castor Forks and Wheels . . . . . . . . . . . . . . . . . . . 22
Deck Rollers and Skids . . . . . . . . . . . . . . . . . . . . . 24

Groundsmaster 4100--D

Page 8 -- 1

Cutting Deck

Specifications

MOUNTING: Cutting deck is supported by lift arms controlled with hydraulic lift levers.
CONSTRUCTION: Deck chamber is welded 12 gauge
steel construction reinforced with channels and plates.
HEIGHT--OF--CUT RANGE: 1” to 5” (25.4 mm to 127
mm) adjustable in 1/2” (12.7 mm) increments. Center
deck height--of--cut adjustment is achieved by changing
spacers on castor wheels and adjusting length of deck
support chains. Wing deck adjustment achieved by
changing spacers on castor wheels, re--positioning the
castor wheel axles in the castor forks and securing the
castor wheel bracket to the correct height--of--cut bracket holes.
DECK DRIVE: Closed loop hydraulic system operates
hydraulic motor on each cutting deck section. Motor
drives one spindle directly with remaining deck section
spindle(s) driven by B section kevlar v--belt(s). Blade
spindles are 1--1/4” (31.7 mm) shafts supported by
greaseable, tapered roller bearings.

Cutting Deck

CUTTING BLADE: Cutting blade dimensions are 19”
(483 mm) long, 2.5” (64 mm) wide and 0.250” (6.4 mm)
thick. Anti--scalp cup installed on each cutting blade.
Center deck includes three blades and each wing deck
includes two blades.
WIDTH OF CUT: Front deck provides 54” (1372 mm)
width of cut. Each side deck has 37” (940 mm) width of
cut. Total width of cut is 124” (3150 mm).
DISCHARGE: Clippings are discharged from the rear of
the cutting deck.
SUSPENSION SYSTEM: A fully floating suspension
with hydraulic counterbalance. Front deck suspended
from lift arms and has six castor wheels, two adjustable
skids and five anti--scalp rollers.

Page 8 -- 2

Groundsmaster 4100--D

General Information
CAUTION
Never install or work on the cutting deck or lift
arms with the engine running. Always stop engine and remove ignition key first.

Operator’s Manual
The Operator’s Manual provides information regarding
the operation, general maintenance, adjustments and
maintenance intervals for your Groundsmaster cutting
deck. Refer to that publication for additional information
when servicing the machine.

Castor Wheel Tire Pressure
Castor tires on the cutting deck should be inflated to 50
PSI (345 kPa).

Blade Stopping Time
The blades of the cutting deck should come to a complete stop in approximately (5) seconds after the cutting
deck engagement switch is shut down.

Cutting Deck

NOTE: Make sure the deck is lowered onto a clean section of turf or hard surface to avoid dust and debris.

To verify blade stopping stopping time, have a second
person stand back from the deck at least 20 feet and
watch one of the cutting deck blades. Have the operator
shut the cutting deck down and record the time it takes
for the blades to come to a complete stop. If this stopping
time is excessive, the braking valve(s) (RV2) on the hydraulic deck control manifold(s) may need adjustment.

Groundsmaster 4100--D

Page 8 -- 3

Cutting Deck

Troubleshooting
There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf
conditions. Turf conditions such as excessive thatch,
uneven ground conditions, “sponginess” or attempting
to cut off too much grass height may not always be overcome by adjusting the machine.

Remember that the “effective” or actual height--of--cut
depends on cutting deck weight, tire pressures, hydraulic counterbalance settings and turf conditions. Effective
height--of--cut will be different than the bench set height-of--cut.

Factors That Can Affect Quality of Cut
Factor

Possible Problem/Correction

1. Maximum governed engine speed.

Check maximum governed engine speed. Adjust
speed to specifications if necessary (see Chapter 3 -Kubota Diesel Engine).

2. Blade speed.

All deck blades should rotate at the same speed.
See items in Troubleshooting Section of Chapter 4 -Hydraulic System.

3. Tire pressure.

Check air pressure of each tire including castor tires.
Adjust to pressures specified in Operator’s Manual.

4. Blade condition.

Sharpen blades if their cutting edges are dull or nicked.
Inspect blade sail for wear or damage. Replace blade if
needed.

5. Mower housing condition.

Make sure that cutting chambers are in good condition.
Keep underside of deck clean. Debris buildup will
reduce cutting performance.

6. Height--of--cut.

Make sure all deck height--of--cut adjustments are the
same. Adjust deck as specified in the Operator’s
Manual.

7. Cutting deck alignment and ground following.

Check lift arms and cutting deck pivot linkages for
wear, damage or binding. Also, inspect for bent or
damaged pivot shafts.

8. Roller and castor wheel condition.

All rollers and caster wheels should rotate freely.
Replace bearings if worn or damaged.

9. Grass conditions.

Mow when grass is dry for best cutting results. Also,
remove only 1” (25 mm) or 1/3 of the grass blade when
cutting.

Cutting Deck

Page 8 -- 4

Groundsmaster 4100--D

Cutting Deck

This page is intentionally blank.

Groundsmaster 4100--D

Page 8 -- 5

Cutting Deck

Service and Repairs
CAUTION
Never install or work on the cutting deck or lift
arms with the engine running. Always stop engine and remove ignition key first.

Cutting Deck

RIGHT
8

FRONT

7
6

10
11

4
1

3
2

14
18
16

15
12

75 to 85 ft--lb
(102 to 115 N--m)

Figure 1
1.
2.
3.
4.
5.
6.

Cutting deck
Cap screw
Lift arm (LH shown)
Flange nut
Spacer
Damper

Cutting Deck

7.
8.
9.
10.
11.
12.

Damper rod end (2 per damper)
Hair pin
Clevis pin
Cap screw
Flange nut
Hair pin

Page 8 -- 6

13.
14.
15.
16.
17.
18.

Hex nut
U--bolt
Height of cut chain
Support hub
Clevis pin
Flat washer

Groundsmaster 4100--D

Removal (Fig. 1)
1. Position machine on a clean, level surface. Lower
cutting deck, stop engine, engage parking brake and remove key from the ignition switch.

2
1

NOTE: Removal of clevis pins from deck and height-of--cut chains is easier if deck is lifted slightly.
2. Remove hairpins and clevis pins that secure the
height--of--cut chains to the rear of the cutting deck (Fig.
2).
3. Remove hydraulic motors from cutting deck (see
Cutting Deck Motor Removal in the Service and Repairs
Section of Chapter 4 -- Hydraulic System). Position motors away from cutting deck.

Figure 2
1. Hairpin and clevis pin

2. Height--of--cut chain

4. Remove hairpins and clevis pins that secure dampers to lift arms (Fig. 3). Rotate dampers and place on cutting deck.

5. Remove hydraulic hoses from wing deck lift cylinders (Fig. 4):
A. Remove deck covers to allow access to wing
deck lift cylinders.

B. Thoroughly clean exterior of cylinder and fittings.
For assembly purposes, label hydraulic hoses to
show their correct position on the lift cylinder.
C. Disconnect hydraulic hoses from wing deck lift
cylinders. Cap hoses and fittings to prevent contamination.

Figure 3
1. Lift arm
2. Castor arm

6. Disconnect cutting deck wire harness from main machine harness (Fig. 5).

3. Support hub
4. Damper

6
6

7. Remove cap screws, flat washers and flange nuts
that secure support hubs to cutting deck castor arms
(Fig. 3).

160 to 180 ft--lb
(217 to 244 N--m)

5
4

8. Slide the cutting deck away from the traction unit.

Installation (Fig. 1)

Cutting Deck

1. Position machine on a clean, level surface. Lower lift
arms, stop engine, engage parking brake and remove
key from the ignition switch.
2. Position the cutting deck to the lift arms.
3. Align support hub to cutting deck castor arms and secure with cap screws, flat washers and flange nuts (Fig.
3). Torque flange nuts from 75 to 85 ft--lb (102 to 115
N--m).

Groundsmaster 4100--D

Figure 4
1. Wing deck lift cylinder
2. Flat washer
3. Lock nut

Page 8 -- 7

4. Lock nut
5. Cap screw
6. Spacer

Cutting Deck

NOTE: Installation of clevis pins to deck and height--of-cut chains is easier if deck is lifted slightly.
4. Install clevis pins and hairpins that secure the
height--of--cut chains to the rear of the cutting deck (Fig.
2).
5. Remove plugs from hydraulic hoses and fittings on
wing deck lift cylinders. Attach hydraulic hoses to lift cylinders.

6. Connect cutting deck wire harness to main machine
wire harness (Fig. 5).
7. Position dampers to lift arms. Install clevis pins and
hairpins to secure dampers to lift arms (Fig. 3).
8. Install any removed cutting deck covers.

Figure 5
1. Cutting deck wire harness connection

9. Install hydraulic motors to cutting deck (see Cutting
Deck Motor Installation in the Service and Repairs Section of Chapter 4 -- Hydraulic System).
10.Lubricate grease fittings on cutting deck and lift assemblies.
11. Fill reservoir with hydraulic fluid as required.

Cutting Deck

Page 8 -- 8

Groundsmaster 4100--D

Cutting Deck

This page is intentionally blank.

Groundsmaster 4100--D

Page 8 -- 9

Cutting Deck

Wing Deck Service

30 to 40 ft--lb
(41 to 54 N--m)

160 to 180 ft--lb
(217 to 244 N--m)
43

48
49
37
1

41
24
4

44
7

RIGHT

39
21

8
52

FRONT

52
53

23
39
36

24
5

27
26

17 13

Figure 6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

Wing deck (RH shown)
Skid (RH shown)
Flange screw (2 used per skid)
Flange nut (2 used per skid)
Cap screw
Roller (2 used)
Lock nut
Pivot latch (2 used)
Flat washer
Retaining ring (2 used per latch)
Cap screw (3 used per latch)
Lock nut (3 used per latch)
Spring support
Compression spring
Lug nut
Lock roller (2 used per latch)
Bushing (3 used per latch)
Pivot pin (4 used)

Cutting Deck

19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.

Flange nut (front links)
Grease fitting
Link assembly (4 used)
Cap screw (front links)
Thrust washer (0.030” thick)
Flat washer (4 used)
Lock nut (4 used)
Carriage bolt (4 used)
Latch pin
Flat washer (2 used)
Cap screw (4 used)
Cap screw (rear links)
Hex jam nut (rear links)
Washer head screw (12 used)
Wing strap (2 used)
Flex shield (2 used)
Shield strap (center deck)
Switch tab (front links)

Page 8 -- 10

37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.

Tapered stud
Hose guide
Hardened spacer (0.120” thick)
Plug
Grease fitting
Foam washer (4 used)
Link skid (2 used)
Link skid (2 used)
Flat washer
Flange nut
Dust cap
Retaining ring
Spherical bearing
Switch shield (RH shown)
Center deck
Flange bushing
Grease fitting
Washer head screw (2 per shield)

Groundsmaster 4100--D

Removal (Fig. 6)

1. Position machine on a clean, level surface. Lower
cutting deck and engage parking brake.
2. Fully raise wing deck, stop engine and remove key
from the ignition switch. Remove three (3) washer head
screws and shield strap that secure flex shield to wing
deck. Lower wing deck.

3. Remove hydraulic motor from wing deck (see Cutting Deck Motor Removal in the Service and Repairs
Section of Chapter 4 -- Hydraulic System).
4. Remove cap screw and lock nut that secure lift cylinder clevis to the wing deck (Fig. 7).
5. Remove switch shield (item 50) from center deck.

2
Figure 7

1. Hydraulic motor
2. Flange head screw

6. Support wing deck to prevent it from falling as links
are removed.

3. Lift cylinder clevis

Front of center deck

7. Remove cap screw (item 29) from pivot pin on upper
end of both links. Cap screw on rear link also uses a flat
washer (item 28).
NOTE: When removing pivot pins from deck, note location of thrust washers (item 6) and hardened spacers
(item 42).

0.060” to 0.090”
(1.5 to 2.2 mm)
(wing lowered & latched)

8. Remove flange nut (item 19) from carriage bolt (item
26) and pull pivot pins (item 18) from deck. Locate and
retrieve thrust washers (item 6) and hardened spacers
(item 42) from between links and deck brackets.
9. Slide the wing deck away from the center deck.
Wing opens this way

10.If required, remove link(s) from wing deck by removing lock nut and flat washer that secure tapered stud to
deck. Press tapered stud from deck to remove link assembly. Remove foam washer (item 42) and link skid.

Figure 8

Installation (Fig. 6)
1. Park machine on a clean, level surface. Stop engine,
engage parking brake and remove key from the ignition
switch.

0.380” to 0.620”
(9.7 to 15.7 mm)

NOTE: Pivot latches (item 8) may need to be manually
opened prior to wing deck installation. If necessary, use
a pry bar to carefully open latch.

2
Figure 9
1. Wing deck blade

2. Center deck blade

3. Position the wing deck to the center deck.

Groundsmaster 4100--D

Page 8 -- 11

Cutting Deck

2. If links were removed from wing deck, thoroughly
clean tapered stud on link and mounting boss of wing
deck. Place foam washer on tapered stud and insert
stud into deck mounting boss. Position link skid to stud
and secure with flat washer and lock nut. Torque lock nut
from 160 to 180 ft--lb (217 to 244 N--m).

4. Position upper end of links to center cutting deck
brackets.
5. Align upper end of links with mounting holes in center
deck. While installing pivot pins to center deck and links,
insert spacers and washers as follows:
A. Place a hardened spacer (item 42) on each side
of the front link. Use one or two thrust washers on
rear side of assembly so that link is snug between
deck brackets.
B. Place a thrust washer (item 6) on each side of
rear link.
6. Secure pins with carriage screw and flange head
screw.
7. Install cap screw (item 29) to pivot pin on both links.
Cap screw on rear link uses a flat washer (item 28). Cap
screw on front link also secures hose guide (item 38).
8. Position lift cylinder to the wing deck (Fig. 7). Secure
cylinder with cap screw and lock nut.
9. Install hydraulic motor to cutting deck (see Cutting
Deck Motor Installation in the Service and Repairs Section of Chapter 4 -- Hydraulic System).

11. Lower wing deck and inspect deck latch assembly to
insure that front link is locked when the wing deck is in
the lowered position. There should be a gap from 0.060”
to 0.090” (1.5 to 2.2 mm) between the arm latch actuator
and the latch pivot (Fig. 8). If gap is incorrect, adjust link
position by repositioning the location of the hardened
spacers (item 42) and thrust washers (item 6). At a minimum, there must be a hardened spacer positioned to
the rear of the front link.
12.Lubricate grease fittings on cutting deck and lift components.
13.Check distance between inner deck blade on wing
deck and outer deck blade on center deck. Distance between blades should be 0.380” to 0.620” (9.7 to 15.7
mm) (Fig. 9). If blade distance is incorrect, loosen hex
jam nut (item 32) on rear link assembly and adjust cap
screw (item 31). Tighten jam nut when blade distance is
correct.
14.Check operation of wing deck position switch. Adjust
if necessary (see Wing Deck Position Switches in the
Adjustments section of Chapter 5 -- Electrical System).
15.Secure switch shield (item 50) to center deck.

10.Fully raise wing deck, stop engine and remove key
from the ignition switch. Secure flex shield to wing deck
with shield strap and three (3) washer head screws.
Lower wing deck.

Cutting Deck

Page 8 -- 12

Groundsmaster 4100--D

Cutting Deck Link Service
Disassembly (Fig. 10)
1. Press bushings from top of link.

30 to 40 ft--lb
(41 to 54 N--m)

2. Remove dust cap and retaining ring from link.
3. Press tapered stud with spherical bearing, flat washers and flange nut from link.

6 7

4. Remove flange nut and press spherical bearing from
tapered stud.
Assembly (Fig. 10)
1. Install new spherical bearing onto tapered stud. Secure bearing with flange nut. Torque nut from 30 to 40
ft--lb (41 to 54 N--m).

Figure 10
1.
2.
3.
4.

Link
Bushing (2 used)
Tapered stud
Spherical bearing

5.
6.
7.
8.

Flat washer (2 used)
Retaining ring
Flange nut
Dust cap

2. Position flat washer in both sides of spherical bearing.
3. Press tapered stud with spherical bearing, flat washers and flange nut into link. Secure spherical bearing
into link with retaining ring.
4. Press bushings into top bore of link.

1.625”
(41.3 mm)

5. If cap screw and jam nut were removed from rear
link, install cap screw to allow 1.625” (41.3 mm) between
the head of the screw and the side of the link (Fig. 11).

6. After link is installed on deck, check distance between center deck blade and wing deck blade. Readjust
cap screw and jam nut on rear link if needed (see Wing
Deck Service in this Chapter).

3
Figure 11
3. Hex jam nut

Cutting Deck

1. Rear link
2. Cap screw

Groundsmaster 4100--D

Page 8 -- 13

Cutting Deck

Wing Deck Latch
Disassembly (Fig. 12)
9

1. Raise wing deck to transport position. Carefully rotate latch to closed position.

2. Loosen lug nut to release compression spring tension.
3. Remove retaining ring and flat washer from bottom
of latch pin. Rotate lug nut enough to allow latch pin to
be removed from latch.

14
5

4. Remove lug nut from spring support. Remove latch
assembly from deck.
5. Disassemble latch (items 1 through 8) using Figure
12 as a guide.

4
6

Assembly (Fig. 12)

1. Assemble latch (items 1 through 8) using Figure 12
as a guide.
2. Slide spring onto spring support and insert end of
spring support into hole located on underside of center
deck. Start lug nut (tapered side towards plate on deck)
onto spring support.
3. Tighten lug nut until holes in front of deck align with
bushings in latch. Insert latch pin with retaining ring
down through deck and latch. Secure latch pin on underside of deck with flat washer and retaining ring.

Figure 12
1.
2.
3.
4.
5.
6.
7.

Latch
Grease fitting
Lock roller
Bushing
Flange bushing
Cap screw (3 used)
Spring support

8.
9.
10.
11.
12.
13.
14.

Lock nut (3 used)
Retaining ring
Flat washer
Compression spring
Lug nut
Latch pin
Center deck

4. Carefully rotate latch to the open position. Lower
wing deck to allow link to engage latch.
5. Lubricate latch grease fitting.

Cutting Deck

Page 8 -- 14

Groundsmaster 4100--D

Cutting Deck

This page is intentionally blank.

Groundsmaster 4100--D

Page 8 -- 15

Cutting Deck

Blade Spindle

11
12

1
6
8

RIGHT
FRONT

88 to 108 ft--lb
(119 to 146 N--m)

Figure 13
1.
2.
3.
4.

Cutting deck
Drive spindle: single pulley (2 used)
Low driven spindle (3 used)
Drive spindle: double pulley (1 used)

5.
6.
7.
8.

Flange head screw
Flange nut
Blade bolt
Cutting blade (7 used)

Removal (Fig. 13)
1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.
2. If drive spindle is to be serviced, remove hydraulic
motor from cutting deck (see Cutting Deck Motor Removal in the Service and Repairs Section of Chapter 4
-- Hydraulic System). Position motor away from spindle.
3. Remove belt covers from top of cutting deck. Loosen
idler pulley to release belt tension (see Idler Assembly
Removal in this section). Remove drive belt from spindle
to be serviced.

9.
10.
11.
12.

Anti--scalp cup
High driven spindle (1 used)
Flat washer
Cap screw

5. Remove cutting blade, anti--scalp cup and blade bolt
from spindle to be serviced.
6. Remove spindle housing assembly from deck:
A. For driven spindle assemblies, remove eight (8)
flange head screws with flange nuts that secure
spindle to deck.
B. For drive spindle assemblies, loosen and remove
four (4) flange head screws with flange nuts that secure spindle to deck. Then, remove four (4) cap
screws with flat washers that secure spindle and motor mount to deck.

4. Start the engine and raise the cutting deck. Stop engine and remove key from the ignition switch. Latch or
block up the cutting deck so it cannot fall accidentally.

Cutting Deck

Page 8 -- 16

Groundsmaster 4100--D

Installation (Fig. 13)
1. Position spindle on cutting deck noting orientation of
grease fitting (Fig. 15). Secure spindle assembly to deck
with removed fasteners.
1

2. Install cutting blade, anti--scalp cup and blade bolt.
Tighten blade bolt from 88 to 108 ft--lb (119 to 146
N--m).
3. Slowly rotate cutting blades to verify that blades do
not contact any deck component(s).

2
1

4. Install drive belt and adjust belt tension (see Idler Assembly Installation in this section).

Figure 14
1. Flange head screw

5. If drive spindle was removed, install hydraulic motor
to cutting deck (see Cutting Deck Motor Installation in
the Service and Repairs Section of Chapter 4 -- Hydraulic System).

2. Hydraulic motor

6. Install belt covers to cutting deck.
1

1
5

5
5

3
5

Driven spindle
Driven spindle (high pulley)

Groundsmaster 4100--D

3.
4.

Drive spindle (wing deck)
Drive spindle (center deck)

Page 8 -- 17

Spindle grease fitting location

Cutting Deck

Figure 15
1.
2.

Blade Spindle Service
DRIVEN SPINDLE

10
11

130 to 150 ft--lb
(176 to 203 N--m)

DRIVE SPINDLE

15
1

2
9

5
16

6
4

Figure 16
1.
2.
3.
4.
5.
6.

Lock nut
Flat washer
Driven pulley
Spindle shaft
Drive pulley (single shown)
Hydraulic motor mount

7.
8.
9.
10.
11.
12.

O--ring
Oil seal
Bearing cup and cone
Outer bearing spacer
Inner bearing spacer
Spacer ring

13.
14.
15.
16.
17.

Snap ring
Grease fitting
Spindle housing
Spindle shaft spacer
Spindle shaft

Disassembly (Fig. 16)

Assembly (Fig. 16)

1. Loosen and remove lock nut from top of spindle
shaft. Remove hardened washer and pulley from
spindle. For drive spindle, remove hydraulic motor
mount.

NOTE: A replacement spindle bearing set contains two
(2) bearings, a spacer ring and a large snap ring (items
1, 2 and 3 in Fig. 17). These parts cannot be purchased
separately. Also, do not mix bearing set components
from one deck spindle to another.

2. Remove the spindle shaft from the spindle housing
which may require the use of an arbor press. The spindle
shaft spacer should remain on the spindle shaft as the
shaft is being removed.
3. Carefully remove oil seals from spindle housing taking care to not damage seal bore in housing.
4. Allow the bearing cones, inner bearing spacer and
spacer ring to drop out of the spindle housing (Fig. 17).
5. Using an arbor press, remove both of the bearing
cups and the outer bearing spacer from the housing.
6. The large snap ring can remain inside the spindle
housing. Removal of this snap ring is very difficult.

Cutting Deck

NOTE: A replacement bearing spacer set includes the
inner spacer and outer spacer (items 4 and 5 in Fig. 17).
Do not mix bearing spacers from one deck spindle to
another.
IMPORTANT: If new bearings are installed into a
used spindle housing, it may not be necessary to replace the original large snap ring. If the original
snap ring is in good condition with no evidence of
damage (e.g. spun bearing), leave the snap ring in
the housing and discard the snap ring that comes
with the new bearings. If the large snap ring is found
to be damaged, replace the snap ring.
1. If large snap ring was removed from spindle housing,
install snap ring into housing groove. Make sure snap
ring is fully seated in housing groove.

Page 8 -- 18

Groundsmaster 4100--D

2. Install outer bearing spacer into top of spindle housing. The spacer should fit against the snap ring.

3. Using an arbor press, push the bearing cups into the
top and bottom of the spindle housing. The top bearing
cup must contact the outer bearing spacer previously
installed, and the bottom bearing cup must contact the
snap ring. Make sure that the assembly is correct by
supporting the first bearing cup and pressing the second
cup against it (Fig 18).

1
Figure 17
1. Bearing
2. Spacer ring
3. Large snap ring

6. Slide spacer ring and inner bearing spacer into
spindle housing, then install upper bearing cone and oil
seal into top of housing. Note: The upper seal must have
the lip facing in (down) (Fig. 19). Also, upper seal should
be flush or up to 0.060” (1.5 mm) recessed into housing.

8. Install spindle shaft spacer onto shaft. Place thin
sleeve or tape on spindle shaft splines to prevent seal
damage during shaft installation.

4. Inner bearing spacer
5. Outer bearing spacer

PRESS

IMPORTANT: If bearings are being replaced, make
sure to use the spacer ring that is included with new
bearing set (Fig. 17).

7. Inspect the spindle shaft and shaft spacer to make
sure there are no burrs or nicks that could possibly damage the oil seals. Lubricate the shaft and spacer with
grease.

4. Pack the bearing cones with grease. Apply a film of
grease on lips of oil seals and O--ring.
5. Install lower bearing cone and oil seal into bottom of
spindle housing. Note: The bottom seal must have the
lip facing out (down) (Fig. 19). This seal installation allows grease to purge from the spindle during the lubrication process.

Figure 18
1. Bearing cups
2. Large snap ring
3. Large outer spacer

4. Arbor press
5. Support
6. Arbor press base

9. Carefully slide spindle shaft with spacer up through
spindle housing. The bottom oil seal and spindle spacer
fit together when the spindle is fully installed.
10.Install O--ring to top of spindle shaft. For drive
spindle, position hydraulic motor mount to top of spindle.
11. Install pulley (hub down), hardened washer and lock
nut to spindle shaft. Tighten lock nut from 130 to 150 ft-lb (176 to 203 N--m).

Cutting Deck

IMPORTANT: Pneumatic grease guns can produce
air pockets when filling large cavities and therefore,
are not recommended to be used for proper greasing of spindle housings.
12.Attach a hand pump grease gun to grease fitting on
housing and fill housing cavity with grease until grease
starts to come out of lower seal.

Figure 19
1. Bottom seal installation

2. Upper seal installation

13.Rotate spindle shaft to make sure that it turns freely.
Groundsmaster 4100--D

Page 8 -- 19

Cutting Deck

Idler Assembly
24
17

20
21

14
9

18
19

8
12
11

1
5
RIGHT
4
FRONT

Figure 20
1.
2.
3.
4.
5.
6.
7.
8.

Center deck
Flange nut
Flange nut
Adjusting screw
Idler pulley
High driven pulley
Flat washer
Lock washer

9.
10.
11.
12.
13.
14.
15.
16.

Socket head screw
Stop bolt
Flange nut
Cap screw
Spacer
Shoulder bolt
Spring
Lock nut

17.
18.
19.
20.
21.
22.
23.
24.

Idler arm
Retaining ring
Thrust washer (4 used per idler)
Bushing (2 used per idler)
Grease fitting
Low driven pulley
Flange head screw
Drive belt

NOTE: The center deck is shown in Figure 20. The idler
assemblies used on the wing decks use the same idler
components.

Cutting Deck

Page 8 -- 20

Groundsmaster 4100--D

Removal (Fig. 20)
1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.
2. Remove deck covers from top of cutting deck.

CAUTION
Be careful when removing idler spring. The
spring is under heavy load and may cause personal injury.
3. Use spring hook tool to unhook the idler spring (item
15) from the adjusting screw (item 4).
4. Remove drive belt(s) from deck pulleys.
5. Loosen flange nuts (item 11) that secure idler stop
bolt (item 10) to cutting deck to allow clearance between
idler arm and stop bolt.

CAUTION
Be careful when installing the idler spring. The
spring is under heavy load and may cause personal injury.
3. Use spring hook tool to attach the idler spring (item
15) onto the adjusting screw (item 4) and shoulder bolt
on idler arm. With the idler arm tensioning the drive belt,
the spring hook to hook length should be from 3.250” to
3.750” (82.6 to 95.2 mm) (Fig. 21). If necessary, disconnect spring and change position of adjusting screw.
When idler spring is the correct length, tighten second
flange nut to secure adjustment.
4. Adjust location of idler stop bolt (item 10) so that the
clearance between idler arm and idler stop bolt head is
from 0.125” to 0.185” (3.2 to 4.6 mm) (Fig. 21).
5. Install deck covers to cutting deck.

6. Remove idler components as needed using Figure
20 as a guide. Note location of washers, idler spacer and
screw as idler assemblies are being removed.
Installation (Fig. 20)
1. Install removed idler components using Figure 20 as
a guide.
A. Make sure that one (1) thrust washer (item 19) is
placed below the idler arm and three (3) thrust washers are placed between the idler and retaining ring
location.
B. Secure idler arm assembly to cutting deck with
snap ring.

3.250” to 3.750”
(82.6 to 95.2 mm)

0.125” to 0.185”
(3.2 to 4.6 mm)

Figure 21

C. If idler stop bolt (item 10) was removed from deck,
make sure that it is installed in the hole that allows the
stop bolt head to align with the idler arm.

Cutting Deck

2. Install drive belt to pulleys.

Groundsmaster 4100--D

Page 8 -- 21

Cutting Deck

Castor Forks and Wheels
DECK CASTOR ARM

WING DECK CASTOR FORK
14
13

17
20

60 to 80 ft--lb
(81 to 108 N--m)
7

4
18
22
16
23

CASTOR WHEEL
8
15

33
28
29

60 to 80 ft--lb
(81 to 108 N--m)

Figure 22
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Castor arm (wing deck shown)
Cap screw (6 per arm)
Castor fork
Castor wheel bolt
Lock nut
Castor spacer
Thrust washer
Flange lock nut
Grease fitting
Flange bushing
Retaining ring
Cap washer

Cutting Deck

13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.

Compression spring
Cap
Flat washer (6 per arm)
Clevis pin (2 used per fork)
Lock nut
Carriage screw (3 used per fork)
Castor fork bracket
Shim
Castor fork bracket
Hairpin
Cutting deck (LH shown)

Page 8 -- 22

24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.

Decal
Flat washer
Tension rod
Bearing
Inner bearing spacer
Wheel hub
Wheel rim half
Castor tire
Wheel rim half
Plate
Flange nut (4 used per wheel)

Groundsmaster 4100--D

Disassembly (Fig. 22)

Assembly (Fig. 22)

1. Park machine on a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.

1. Assemble castor forks and wheels using Figure 22
as a guide.

2. Disassemble castor forks and wheels using Figure
22 as a guide.

2. Torque castor wheel lock nut from 60 to 80 ft--lb (81
to 108 N--m).
3. If castor fork was removed, lubricate grease fitting.

Cutting Deck

4. See Operator’s Manual for castor wheel adjustment.

Groundsmaster 4100--D

Page 8 -- 23

Cutting Deck

Deck Rollers and Skids

6
5

7
6

RIGHT

4
3

FRONT

2
1

Figure 23
1.
2.
3.
4.

Roller
Flange head screw
Roller shaft
Flange nut

5.
6.
7.

Lock nut
Roller
Cap screw

8. Flange nut
9. Skid (RH shown)
10. Flange head screw

Removal (Fig. 23)

Installation (Fig. 23)

1. Remove skids and rollers from deck using Figure 23
as a guide.

1. Install skids to deck using Figure 23 as a guide. Make
sure to install skids in the same mounting hole height
position (lower or upper).
2. When installing roller (item 6), install cap screw with
the threads orientated toward the centerline of the deck.
Install and tighten lock nut until roller will not rotate, then
loosen lock nut only enough to allow roller to rotate freely. Make sure to install all deck rollers in the same mounting hole height position (lower or upper).

Cutting Deck

Page 8 -- 24

Groundsmaster 4100--D

Chapter 9

Foldout Drawings
Table of Contents

Foldout
Drawings

HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 3
ELECTRICAL SCHEMATIC
Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CIRCUIT DIAGRAMS
Glow Plug Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Crank Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Run (Transport) Circuits . . . . . . . . . . . . . . . . . . . . . . 8
Run (Mow) Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . 9
High Temperature Warning Circuits . . . . . . . . . . . 10
Over Temperature Shutdown Circuits . . . . . . . . . 11
WIRE HARNESS DRAWINGS
Console Wire Harness . . . . . . . . . . . . . . . . . . . . . . 12
Front Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine Wire Harness . . . . . . . . . . . . . . . . . . . . . . . 17
Jumper Wire Harness . . . . . . . . . . . . . . . . . . . . . . . 19
Cutting Deck Wire Harness . . . . . . . . . . . . . . . . . . 20

Groundsmaster 4100--D

Page 9 - 1

Foldout Drawings

This page is intentionally blank.

Foldout Drawings

Page 9 - 2

Groundsmaster 4100--D

CENTER DECK
MANIFOLD

COUNTERBALANCE
MANIFOLD

LH WING DECK
MANIFOLD

4WD
MANIFOLD

RH WING DECK
MANIFOLD

FAN DRIVE
MANIFOLD

FILTER
MANIFOLD

Groundsmaster 4100--D
Hydraulic Schematic
Page 9 - 3

CONTINUES TO SHEET 2

CONTINUES TO SHEET 2
(OPTIONAL CRUISE
CONTROL KIT)

(OPTIONAL CRUISE
CONTROL KIT)

2WD SOLENOID

PTO OVERTEMP
SHUTDOWN RELAY

CONTINUES TO SHEET 2

Groundsmaster 4100--D
Electrical Schematic
Sheet 1 of 2
All relays and solenoids
are shown as de-- energized.
All ground wires are black.

Page 9 - 4

CONTINUES FROM SHEET 1

COOLING FAN
SWITCH

POWER
RELAY
CONTINUES FROM SHEET 1
CONTINUES FROM SHEET 1

Groundsmaster 4100--D
Electrical Schematic
Sheet 2 of 2
All relays and solenoids
are shown as de-- energized.
All ground wires are black.

Page 9 - 5

CONTINUES TO SHEET 2

(OPTIONAL CRUISE
CONTROL KIT)

(OPTIONAL CRUISE
CONTROL KIT)
(OPTIONAL CRUISE
CONTROL KIT)

(IGNITION SWITCH IN RUN)

(OPTIONAL CRUISE
CONTROL KIT)

FRONT DECK
PTO SOLENOID

2WD SOLENOID

LEFT DECK
PTO SOLENOID

RIGHT DECK
PTO SOLENOID
(UNOCCUPIED)

PTO OVERTEMP
SHUTDOWN RELAY

CONTINUES TO SHEET 2

Groundsmaster 4100--D
Glow Plug Circuits
Power Current
Control Current
Indication Current

Page 9 - 6

CONTINUES TO SHEET 2

(OPTIONAL CRUISE
CONTROL KIT)

(OPTIONAL CRUISE
CONTROL KIT)
(OPTIONAL CRUISE
CONTROL KIT)

(IGNITION SWITCH IN START)

(OPTIONAL CRUISE
CONTROL KIT)

FRONT DECK
PTO SOLENOID

2WD SOLENOID

LEFT DECK
PTO SOLENOID

RIGHT DECK
PTO SOLENOID
(UNOCCUPIED)

PTO OVERTEMP
SHUTDOWN RELAY

CONTINUES TO SHEET 2

Groundsmaster 4100--D
Crank Circuits
Power Current
Control Current
Indication Current

Page 9 - 7

CONTINUES TO SHEET 2

(OPTIONAL CRUISE
CONTROL KIT)

(OPTIONAL CRUISE
CONTROL KIT)
(OPTIONAL CRUISE
CONTROL KIT)

(OPTIONAL CRUISE
CONTROL KIT)

(IGNITION SWITCH IN RUN)

FRONT DECK
PTO SOLENOID

(DISENGAGED)

(NOT IN NEUTRAL)

2WD SOLENOID

LEFT DECK
PTO SOLENOID

RIGHT DECK
PTO SOLENOID
(OCCUPIED)
(IN TRANSPORT)

PTO OVERTEMP
SHUTDOWN RELAY

CONTINUES TO SHEET 2

Groundsmaster 4100--D
Run (Transport) Circuits
Power Current
Control Current
Indication Current

Page 9 - 8

CONTINUES TO SHEET 2

WHEN THE PTO SWITCH IS MOVED TO THE ENGAGE POSITION, PTO SWITCH
TERMINALS 4 & 5 ARE MOMENTARILY CONNECTED ALLOWING A CURRENT

CONTINUES TO SHEET 2

PATH TO ENERGIZE THE PTO RELAY, THE DECK POSITION SWITCHES AND
THE PTO SOLENOIDS. DIODES D1-- B, D1-- C AND D1-- D WILL THEN CREATE

CONTINUES TO SHEET 2

A LATCHING CIRCUIT TO KEEP THE PTO RELAY ENERGIZED WHEN THE PTO
SWITCH IS IN THE ON POSITION.
(OPTIONAL CRUISE
CONTROL KIT)

(OPTIONAL CRUISE
CONTROL KIT)

(OPTIONAL CRUISE
CONTROL KIT)
(OPTIONAL CRUISE
CONTROL KIT)

(OPTIONAL CRUISE
CONTROL KIT)

(IGNITION SWITCH IN RUN)

FRONT DECK
PTO SOLENOID

(DISENGAGED)

(NOT IN NEUTRAL)

2WD SOLENOID

LEFT DECK
PTO SOLENOID
(DECK LOWERED)

RIGHT DECK
PTO SOLENOID
(OCCUPIED)
(IN 4WD)

(DECK LOWERED)

PTO OVERTEMP
SHUTDOWN RELAY

CONTINUES TO SHEET 2

WHEN THE CUTTING DECK LIFT LEVER IS MOVED TO LOWER THE DECK,
THE DECK LOWER SWITCH CLOSES TO ENERGIZE THE DOWN LATCHING
RELAY. THIS PROVIDES A CURRENT PATH FOR THE PTO SWITCH. THE DECK
RAISE SWITCH AND DIODE D3 CREATE A LATCHING CIRCUIT TO KEEP THE
DOWN LATCHING RELAY ENERGIZED. IF THE LIFT LEVER IS MOVED TO RAISE
THE DECK, THE DOWN LATCHING RELAY IS DE-- ENERGIZED PREVENTING
AVAILABLE CURRENT FOR THE PTO CIRCUIT.

Groundsmaster 4100--D
Run (Mow) Circuits
Power Current
Control Current
Indication Current

Page 9 - 9

CONTINUES TO SHEET 2

IF THE ENGINE COOLANT TEMPERATURE RISES TO 220F (105 C), THE DUAL
TEMPERATURE WARNING SWITCH CLOSES. THIS CLOSED SWITCH CAUSES

CONTINUES TO SHEET 2

THE OVER TEMPERATURE WARNING LIGHT TO ILLUMINATE AND ALSO
ENERGIZES THE PTO OVERTEMP SHUTDOWN RELAY. THIS ENERGIZED RELAY

CONTINUES TO SHEET 2

CAUSES THE PTO RELAY TO DE-- ENERGIZE AND SHUT OFF ELECTRICAL
TO THE DECK PTO SOLENOIDS.
(OPTIONAL CRUISE
CONTROL KIT)

(OPTIONAL CRUISE
CONTROL KIT)

(OPTIONAL CRUISE
CONTROL KIT)
(OPTIONAL CRUISE
CONTROL KIT)

(OPTIONAL CRUISE
CONTROL KIT)

(IGNITION SWITCH IN RUN)

FRONT DECK
PTO SOLENOID

(DISENGAGED)

(NOT IN NEUTRAL)

2WD SOLENOID

LEFT DECK
PTO SOLENOID
(DECK LOWERED)

RIGHT DECK
PTO SOLENOID
(OCCUPIED)
(IN 4WD)

(DECK LOWERED)

PTO OVERTEMP
SHUTDOWN RELAY

CONTINUES TO SHEET 2

Groundsmaster 4100--D
High Temperature Warning Circuits
Power Current
Control Current
Indication Current

Page 9 - 10

IF THE ENGINE COOLANT TEMPERATURE RISES TO 240 F (115 C), THE DUAL
TEMPERATURE SHUTDOWN SWITCH CLOSES. THIS CLOSED SWITCH CAUSES
THE OVER TEMPERATURE SHUTDOWN RELAY TO ENERGIZE AND REMOVES
ELECTRICAL POWER FROM THE ENGINE RUN SOLENOID AND FUEL PUMP

CONTINUES TO SHEET 2

SHUTTING OFF THE ENGINE.
NOTE: IN THIS OVER TEMPERATURE CONDITION, THE ENGINE CAN BE STARTED

CONTINUES TO SHEET 2

BY DEPRESSING THE OVERRIDE SWITCH WHICH DE-- ENERGIZES THE OVER

CONTINUES TO SHEET 2

TEMPERATURE SHUTDOWN RELAY RETURNING POWER TO THE ENGINE RUN
SOLENOID AND FUEL PUMP.
(OPTIONAL CRUISE
CONTROL KIT)

(OPTIONAL CRUISE
CONTROL KIT)

(OPTIONAL CRUISE
CONTROL KIT)
(OPTIONAL CRUISE
CONTROL KIT)

(OPTIONAL CRUISE
CONTROL KIT)

(IGNITION SWITCH IN RUN)

FRONT DECK
PTO SOLENOID

(DISENGAGED)

(NOT IN NEUTRAL)

2WD SOLENOID

LEFT DECK
PTO SOLENOID
(DECK LOWERED)

RIGHT DECK
PTO SOLENOID
(OCCUPIED)
(IN 4WD)

(DECK LOWERED)

PTO OVERTEMP
SHUTDOWN RELAY

CONTINUES TO SHEET 2

Groundsmaster 4100--D
Over Temperature Shutdown Circuits
Power Current
Control Current
Indication Current

Page 9 - 11

(ENGINE SHUTDOWN DELAY)
COOLING
FAN
SWITCH

FLOW
DIVIDER
SWITCH

TRANSPORT/4WD
SWITCH

Groundsmaster 4100--D
Console Wire Harness
Page 9 - 12

(PTO SHUTDOWN DELAY)

TRANSPORT/4WD

YELLOW/BLACK
VIOLET
WHITE

TO SHEET 2

YELLOW

TO SHEET 2

YELLOW

TAN

BLACK

BLUE

BLACK

WHITE

YELLOW/BLACK

YELLOW
YELLOW
YELLOW

BLUE

TAN

RED/BLACK

YELLOW
YELLOW

YELLOW

YELLOW
GRAY

YELLOW

ORANGE
BLACK

PINK

BLACK

PINK

PINK
PINK

BLACK

PINK

WHITE

YELLOW

GREEN
BLUE

PT0 SHUTDOWN ENGINE SHUTDOWN
DELAY
DELAY

WHITE
ORANGE
FLOW DIVIDER
SWITCH

YELLOW
YELLOW

YELLOW

TAN
TAN

GREEN

TAN
GRAY
BLACK

RED

BLACK
GRAY

WHITE
GRAY
TAN
BLACK

YELLOW
TAN

TO SHEET 2

BLACK

ORANGE

BLUE

BLACK

RED

BLACK

RED
ORANGE

WHITE

YELLOW
RED
BLACK
GREEN

TO SHEET 2
YELLOW

ORANGE
VIOLET
VIOLET
YELLOW
YELLOW

TAN
BLACK
TO SHEET 2

BLACK

TO SHEET 2

RED

BLACK

VIOLET/BLACK

ORANGE

GREEN/BLACK

BLACK
GRAY

VIOLET

PINK

BLUE

GREEN

GRAY

GREEN

WHITE

GREEN

YELLOW/WHITE

GREEN
BROWN/WHITE

VIOLET/BLACK
YELLOW/BLACK

ORANGE

BLUE
WHITE

BROWN

WHITE/BLACK

GREEN

WHITE

PINK

BLUE

RED

BLUE

TO SHEET 2

Groundsmaster 4100--D
Console Wire Harness
Sheet 1 of 2
Page 9 - 13

Groundsmaster 4100--D
Console Wire Harness
Sheet 2 of 2

Page 9 - 14
YELLOW/WHITE

WHITE/GREEN

TO SHEET 1

RED

WHITE/BLACK

TAN/BLACK

BLACK

ORANGE/BLACK

BLACK

BROWN/WHITE

BLUE/BLACK

BLACK

YELLOW

BLACK

GREEN/BLACK

VIOLET

YELLOW

TAN/BLACK

RED

YELLOW/GREEN

TAN/BLACK

BLACK

VIOLET

BLACK

BLUE/BLACK

BLACK

TO SHEET 1

COOLING FAN SWITCH

TO SHEET 1
TO SHEET 1
BLACK
YELLOW/GREEN

BLACK

BLACK
WHITE/GREEN

RED
TAN/BLACK

RED

RED
GREEN/BLACK

TAN/BLACK
BLACK

ORANGE/BLACK

GRAY

FLOW DIVIDER
SOLENOID

Groundsmaster 4100--D
Front Wire Harness
Page 9 - 15

PINK

BLACK

WHITE

FLOW DIVIDER
SOLENOID

PINK

BROWN

YELLOW

PINK

GRAY

PINK

GREEN/BLACK

TAN

BLACK

GRAY
TAN
GREEN
WHITE
BLUE
ORANGE
VIOLET/BLACK

BLACK

Groundsmaster 4100--D
Front Wire Harness
Page 9 - 16

GREEN/BLACK

BLACK

GREEN/BLACK

BLACK

YELLOW/BLACK

ORANGE

BLUE

ORANGE

BLACK

TAN

BLACK

(STARTER)

Groundsmaster 4000--D
Engine Wire Harness
Page 9 - 17

RED/BLACK

FUSIBLE LINK

RED
BLACK

BLACK
RED

RED
WHITE
RED/BLACK

RED/BLACK
PINK
ORANGE
BLUE
WHITE
GRAY
GREEN
YELLOW

BLACK

YELLOW

BLACK

WHITE/BLACK

YELLOW
BROWN
BLUE
ORANGE

WHITE
ORANGE
VIOLET/BLACK
YELLOW/BLACK
GREEN
BROWN/WHITE
YELLOW/WHITE

BLACK

RED

BLACK
BLACK
BLACK

BLACK

GREEN
BLACK

BLACK

Page 9 - 18

YELLOW/BLACK

BLACK

YELLOW/BLACK

VIOLET/BLACK
BLACK

VIOLET/BLACK

BLACK
BLACK

ORANGE

Groundsmaster 4000--D
Engine Wire Harness

VIOLET/BLACK

ORANGE

VIOLET

BLUE

GRAY
BLUE

BLUE
GRAY

GRAY

VIOLET

YELLOW

BLACK

Groundsmaster 4100--D
Jumper Wire Harness
Page 9 - 19

P15

ORANGE

VIOLET/BLACK

BLACK

YELLOW/BLACK

ORANGE

Groundsmaster 4100--D
Cutting Deck Wire Harness
Page 9 - 20

ORANGE

BLACK

DECK LIFT
SENSOR (LH)

DECK LIFT
SENSOR (RH)

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