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Engine RIGHT 27 1 FRONT 26 25 24 2 3 23 4 5 22 21 6 11 14 13 12 8 7 20 13 19 18 17 16 13 15 Loctite #242 9 9 10 28 to 32 ft -lb (38to43N-m) 29 to 33 ft -lb 28 to 32 ft -lb (40to44N-m) (38to43N-m) 1. Engine 2. Cap screw (4 used) 3. LH engine mount 4. Lock washer 5. Cap screw 6. Lock washer (5 used) 7. Cap screw (5 used) 8. Engine support (4 used) 9. Flange nut (12 used) Figure 9 10. Rebound washer (4 used) 11. Cap screw (8 used) 12. Spring coupler 13. Washer (14 used) 14. Cap screw (6 used) 15. Flywheel plate 16. Cap screw (4 used) 17. Cap screw (2 used) 18. Lock washer (2 used) 19. LH engine mount 20. Cap screw (4 used) 21. RH engine mount 22. Cap screw (PTO manifold) 23. Lock washer 24. Ground cable 25. Cap screw 26. Lock washer 27. RH engine mount Kubota Diesel Engine Page 3 - 12 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 2. Remove battery cover and strap. Disconnect negative battery cable first and then positive battery cable. Remove battery from machine. 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. Ethylene -glycol antifreeze is poisonous. Dispose of coolant properly or store it in a properly labeled container away from children and pets. 1 1. Dual temperature switch 2. Temperature sender Figure 10 3. Alternator 3 Kubota Diesel Engine 4. Drain coolant from the radiator into a suitable container (see Radiator Removal in this section). Disconnect upper and lower hoses from the radiator. 3 1 2 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. 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). 1. Glow plug wire 2. Glow plug lead 3 Figure 11 3. Cylinder #4 glow plug 2 1 C. The engine run solenoid (Fig. 12). D. Battery, frame and wire harness ground at the engine block. 1. Engine run solenoid 2. Alternator belt Figure 12 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
Page 1 and 2: Part No. 08162SL (Rev. A) Service M
Page 3 and 4: Table Of Contents Chapter 1 - Safet
Page 5 and 6: Table of Contents GENERAL SAFETY IN
Page 7 and 8: Maintenance and Service 1. Before s
Page 9 and 10: Safety and Instruction Decals Numer
Page 11 and 12: Chapter 2 Table of Contents Product
Page 13 and 14: Torque Specifications Recommended f
Page 15 and 16: Standard Torque for Dry, Zinc Plate
Page 17 and 18: Chapter 3 Kubota Diesel Engine Tabl
Page 19 and 20: Specifications Item Make / Designat
Page 21 and 22: Removal (Fig. 1) 1. Park machine on
Page 23 and 24: Removal (Fig. 5) CAUTION B The muff
Page 25 and 26: DANGER Because diesel fuel is highl
Page 27: Removal (Fig. 8) 1. Park machine on
Page 31 and 32: 3. Slowly lower engine into the mac
Page 33 and 34: Coupler Removal (Fig. 16) NOTE: The
Page 35 and 36: Chapter 4 Hydraulic System Table of
Page 37 and 38: General Information Operator’s Ma
Page 39 and 40: Hydraulic Hose and Tube Installatio
Page 41 and 42: Adjustable Fitting (Fig. 8) 1. Make
Page 43 and 44: Hydraulic System This page is inten
Page 45 and 46: Traction Circuit: 4WD (Mow) The tra
Page 47 and 48: Traction Circuit: Transport (2WD) T
Page 49 and 50: Lower Cutting Deck A four section g
Page 51 and 52: Raise Cutting Deck A four section g
Page 53 and 54: Mow Circuit Hydraulic flow for the
Page 55 and 56: Hydraulic System This page is inten
Page 57 and 58: Steering Circuit A four section gea
Page 59 and 60: Engine Cooling Fan Circuit A four s
Page 61 and 62: Hydraulic Test Fitting Kit This kit
Page 63 and 64: Problem Traction power is lost or u
Page 65 and 66: Testing The most effective method f
Page 67 and 68: Procedure for Traction Circuit Char
Page 69 and 70: Procedure for Traction Circuit Reli
Page 71 and 72: Procedure for Counterbalance Pressu
Page 73 and 74: Procedure for Rear Traction Circuit
Page 75 and 76: Procedure for Traction Circuit Redu
Page 77 and 78: Procedure for Cutting Deck Circuit
Page 79 and 80:
Procedure for Cutting Deck Manifold
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Procedure for Cutting Deck Gear Pum
Page 83 and 84:
Procedure for Cutting Deck Motor Ca
Page 85 and 86:
Procedure for Steering Circuit Reli
Page 87 and 88:
Procedure for Lift/Lower Circuit Re
Page 89 and 90:
Procedure for Steering and Lift/Low
Page 91 and 92:
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
Page 97 and 98:
Charge Hydraulic System NOTE: When
Page 99 and 100:
NOTE: The front frame needs to be l
Page 101 and 102:
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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Hydraulic System This page is inten
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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
Page 125 and 126:
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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Page 145 and 146:
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
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Disassembly (Fig. 89) 1. Plug all p
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Disassembly (Figs. 92 and 93) 1. Re
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Chapter 5 Electrical System Table o
Page 173 and 174:
Special Tools Order special tools f
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Troubleshooting CAUTION Remove all
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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
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Fusible Links The Groundsmaster 410
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Cutting Deck Raise and Lower Switch
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Service and Repairs NOTE: For engin
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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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Removal (Fig. 6) 1. Park machine on
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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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Removal (Fig. 5) 1. Park machine on
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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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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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caution - Toro

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