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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. 2 CAUTION When working with batteries, use extreme <strong>caution</strong> 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. 3 1 Electrolyte Specific Gravity Fully charged: 1.265 corrected to 80 o F (26.7 o C) Discharged: less than 1.240 Battery Specifications BCI Group Size 24 650 CCA at 0 o F (--17.8 o C) Reserve Capacity of 110 minutes at 80 o F (26.7 o C) 1. Negative ( -) cable 2. Positive (+) cable Figure 60 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) 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. 1. Perform following inspections and maintenance: A. Check for cracks. Replace battery if cracked or leaking. 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 10 o F(5.5 o C) above 80 o F (26.7 o C) add 0.004 to the specific gravity reading. For each 10 o F(5.5 o C) below 80 o F (26.7 o C) subtract 0.004 from the specific gravity reading. Example: Cell Temperature 100 o F Cell Gravity 1.245 100 o F minus 80 o F equals 20 o F (37.7 o C minus 26.7 o C equals 11.0 o C) 20 o F multiply by 0.004/10 o F equals 0.008 (11 o C multiply by 0.004/5.5 o C equals 0.008) ADD (conversion above) 0.008 Correction to 80 o F (26.7 o C) 1.253 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. 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: Minimum Voltage Battery Electrolyte Temperature 9.6 70 o F (and up) 21.1 o C (and up) 9.5 60 o F 15.6 o C 9.4 50 o F 10.0 o C 9.3 40 o F 4.4 o C 9.1 30 o F -- 1.1 o C 8.9 20 o F -- 6.7 o C 8.7 10 o F --12.2 o C 8.5 0 o F --17.8 o C 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. Electrical System 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
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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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Removal (Fig. 8) 1. Park machine on
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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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Removal (Fig. 53) 1. Park machine o
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Removal (Fig. 59) NOTE: The ports o
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4WD Manifold Service (Fig. 60) 1. M
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Removal (Fig. 61) 1. Read the Gener
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Filter Manifold Service (Fig. 62) F
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CAUTION The centering springs are u
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Disassembly (Fig. 68) 1. Pump oil o
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8. Remove and discard back--up gask
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Removal (Fig. 75) 1. Read the Gener
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Fan Drive Manifold Service (Fig. 76
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Cutting Deck Motor Removal 1. Park
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IMPORTANT: Mark the relative positi
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Removal (Fig. 85) NOTE: The ports o
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PTO Manifold Service (Fig. 86) For
Page 157 and 158: Hydraulic System This page is inten
Page 159 and 160: Removal (Fig. 88) 1. Park machine o
Page 161 and 162: Disassembly (Fig. 89) 1. Plug all p
Page 167 and 168: Disassembly (Figs. 92 and 93) 1. Re
Page 169 and 170: Removal (Fig. 94) 1. Read the Gener
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: Service and Repairs NOTE: For engin
Page 211 and 212: Chapter 6 Axles, Planetaries and Br
Page 213 and 214: General Information Operator’s Ma
Page 215 and 216: 3. Chock rear wheels and jack up fr
Page 217 and 218: This page is intentionally blank. A
Page 219 and 220: Removal (Fig. 6) 1. Park machine on
Page 221 and 222: NOTE: The planetary wheel drive ass
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Page 225 and 226: 8. Remove cap screw and flange nut
Page 227 and 228: Bevel Gear Case and Axle Case The f
Page 229 and 230: Bevel Gear Case and Axle Case Insta
Page 231 and 232: 9. Remove the bevel gear case/axle
Page 233 and 234: Axle Shafts The following procedure
Page 235 and 236: 7. Secure the lock nut with the sta
Page 237 and 238: Differential Gear Inspection 1. Mea
Page 239 and 240: Pinion Gear to Ring Gear Engagement
Page 241 and 242: Chapter 7 Chassis Table of Contents
Page 243 and 244: Disassembly (Fig. 1) 1. Park machin
Page 245 and 246: CAUTION When changing attachments,
Page 247 and 248: Removal (Fig. 5) 1. Park machine on
Page 249 and 250: Disassembly (Fig. 8) 1. Disassemble
Page 251 and 252: NOTE: Most of the seat suspension c
Page 253 and 254: Removal 1. Park machine on a level
Page 255 and 256: Chapter 8 Cutting Deck Table of Con
Page 257 and 258: General Information CAUTION Never i
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This page is intentionally blank. C
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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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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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