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Lift/Lower Control Valve Service 6 32 20 7 23 27 21 22 24 17 18 11 34 13 14 15 31 10 36 35 3 28 5 4 25 1 26 30 33 11 8 16 19 2 12 9 20 to 25 ft -lb (27to33N-m) 29 1. Poppet 2. Spacer 3. Wiper seal 4. Seat 5. O -ring 6. Plug (3 used) 7. O -ring 8. Bushing 9. Spool cap (3 used) 10. Relief valve poppet 11. O -ring 12. Retaining ring Figure 89 13. Washer 14. Washer 15. Washer 16. Washer 17. Plug 18. O -ring 19. Spool spring 20. Backup washer 21. Detent spring 22. Detent plunger 23. Detent plug (3 used) 24. O -ring 25. O -ring 26. Backup washer 27. Disc 28. Plunger (2 used) 29. Plug assembly (3 used) 30. Lockout spring 31. Relief valve spring 32. Relief plug assembly 33. Plunger 34. O -ring 35. Spool 36. Control valve body Hydraulic System Page 4 - 126 Groundsmaster 4100--D
Disassembly (Fig. 89) 1. Plug all ports and clean outside of valve thoroughly. 2. Remove spool caps (item 9). Do not remove retaining rings (item 12) from spools unless spool spring (item 19) is broken. 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. 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. Assembly (Fig. 89) 1. Thoroughly clean and dry all parts. Apply a light coating of clean hydraulic oil to all control valve parts prior to assembly. 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). Hydraulic System Groundsmaster 4100--D Page 4 - 127 Hydraulic System
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Part No. 08162SL (Rev. A) Service M
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Table Of Contents Chapter 1 - Safet
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Table of Contents GENERAL SAFETY IN
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Maintenance and Service 1. Before s
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Safety and Instruction Decals Numer
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Chapter 2 Table of Contents Product
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Torque Specifications Recommended f
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Standard Torque for Dry, Zinc Plate
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Chapter 3 Kubota Diesel Engine Tabl
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Specifications Item Make / Designat
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Removal (Fig. 1) 1. Park machine on
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Removal (Fig. 5) CAUTION B The muff
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DANGER Because diesel fuel is highl
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Engine Removal (Fig. 9) 1. Park mac
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3. Slowly lower engine into the mac
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Coupler Removal (Fig. 16) NOTE: The
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Chapter 4 Hydraulic System Table of
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General Information Operator’s Ma
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Hydraulic Hose and Tube Installatio
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Adjustable Fitting (Fig. 8) 1. Make
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Hydraulic System This page is inten
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Traction Circuit: 4WD (Mow) The tra
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Traction Circuit: Transport (2WD) T
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Lower Cutting Deck A four section g
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Raise Cutting Deck A four section g
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Mow Circuit Hydraulic flow for the
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Steering Circuit A four section gea
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Engine Cooling Fan Circuit A four s
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Hydraulic Test Fitting Kit This kit
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Problem Traction power is lost or u
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Testing The most effective method f
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Procedure for Traction Circuit Char
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Procedure for Traction Circuit Reli
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Procedure for Counterbalance Pressu
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Procedure for Rear Traction Circuit
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Procedure for Traction Circuit Redu
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Procedure for Cutting Deck Circuit
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Procedure for Cutting Deck Manifold
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Procedure for Cutting Deck Gear Pum
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Procedure for Cutting Deck Motor Ca
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Procedure for Steering Circuit Reli
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Procedure for Lift/Lower Circuit Re
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Procedure for Steering and Lift/Low
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Procedure for Engine Cooling Fan Ci
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Procedure for Engine Cooling Fan Ci
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Service and Repairs General Precaut
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Charge Hydraulic System NOTE: When
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NOTE: The front frame needs to be l
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Removal (Fig. 48) CAUTION The radia
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Removal (Fig 49) 1. Park machine on
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IMPORTANT: Use caution when clampin
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Page 109 and 110: Removal (Fig. 53) 1. Park machine o
Page 111 and 112: Hydraulic System This page is inten
Page 119 and 120: Removal (Fig. 59) NOTE: The ports o
Page 121 and 122: 4WD Manifold Service (Fig. 60) 1. M
Page 123 and 124: Removal (Fig. 61) 1. Read the Gener
Page 125 and 126: Filter Manifold Service (Fig. 62) F
Page 131 and 132: CAUTION The centering springs are u
Page 135 and 136: Disassembly (Fig. 68) 1. Pump oil o
Page 139 and 140: 8. Remove and discard back--up gask
Page 145 and 146: Fan Drive Manifold Service (Fig. 76
Page 147 and 148: Cutting Deck Motor Removal 1. Park
Page 149 and 150: IMPORTANT: Mark the relative positi
Page 153 and 154: Removal (Fig. 85) NOTE: The ports o
Page 155 and 156: PTO Manifold Service (Fig. 86) For
Page 159: Removal (Fig. 88) 1. Park machine o
Page 167 and 168: Disassembly (Figs. 92 and 93) 1. Re
Page 171 and 172: Chapter 5 Electrical System Table o
Page 173 and 174: Special Tools Order special tools f
Page 175 and 176: Troubleshooting CAUTION Remove all
Page 177 and 178: Cutting Deck Operating Problems The
Page 179 and 180: Adjustments Wing Deck Position Swit
Page 181 and 182: Component Testing For accurate resi
Page 183 and 184: Warning Lights Engine Oil Pressure
Page 185 and 186: Transport / 4WD Switch The transpor
Page 187 and 188: Seat Switch The seat switch is norm
Page 189 and 190: Hour Meter The hour meter is locate
Page 191 and 192: Start, Engine Shutdown, Seat, Alarm
Page 193 and 194: TEC -5002 Controller Groundsmaster
Page 195 and 196: Fuel Gauge The fuel gauge can be te
Page 197 and 198: Glow Controller The glow controller
Page 199 and 200: Dual Temperature Switch The dual te
Page 201 and 202: Traction Neutral Switch The tractio
Page 203 and 204: Fusible Links The Groundsmaster 410
Page 205 and 206: Cutting Deck Raise and Lower Switch
Page 207 and 208: Service and Repairs NOTE: For engin
Page 209 and 210: 2. Conduct a hydrometer test of the
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Chapter 6 Axles, Planetaries and Br
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General Information Operator’s Ma
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3. Chock rear wheels and jack up fr
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This page is intentionally blank. A
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NOTE: The planetary wheel drive ass
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This page is intentionally blank. A
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8. Remove cap screw and flange nut
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Bevel Gear Case and Axle Case The f
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Bevel Gear Case and Axle Case Insta
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9. Remove the bevel gear case/axle
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Axle Shafts The following procedure
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7. Secure the lock nut with the sta
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Differential Gear Inspection 1. Mea
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Pinion Gear to Ring Gear Engagement
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Chapter 7 Chassis Table of Contents
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Disassembly (Fig. 1) 1. Park machin
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CAUTION When changing attachments,
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Disassembly (Fig. 8) 1. Disassemble
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NOTE: Most of the seat suspension c
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Removal 1. Park machine on a level
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Chapter 8 Cutting Deck Table of Con
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General Information CAUTION Never i
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Removal (Fig. 1) 1. Position machin
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Removal (Fig. 6) 1. Position machin
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Cutting Deck Link Service Disassemb
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Installation (Fig. 13) 1. Position
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2. Install outer bearing spacer int
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Removal (Fig. 20) 1. Park machine o
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Disassembly (Fig. 22) 1. Park machi
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Chapter 9 Foldout Drawings Table of
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CENTER DECK MANIFOLD COUNTERBALANCE
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CONTINUES FROM SHEET 1 CONTINUES FR
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CONTINUES TO SHEET 2 CONTINUES TO S
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CONTINUES TO SHEET 2 WHEN THE PTO S
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CONTINUES TO SHEET 2 CONTINUES TO S
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YELLOW GRAY YELLOW/BLACK VIOLET WHI
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FLOW DIVIDER SOLENOID Groundsmaster
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(STARTER) (STARTER) (STARTER) Groun
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BLUE GRAY VIOLET BLACK YELLOW GRAY
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