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This page is intentionally blank. Groundsmaster 4100--D
Table of Contents GENERAL SAFETY INSTRUCTIONS ............ 2 Before Operating ............................ 2 While Operating ............................. 2 Maintenance and Service .................... 3 JACKING INSTRUCTIONS ..................... 4 Jacking the Front End ........................ 4 Jacking the Rear End ........................ 4 SAFETY AND INSTRUCTION DECALS .......... 5 Chapter 1 Safety Safety Groundsmaster 4100--D Page 1 - 1 Safety
Page 1 and 2: Part No. 08162SL (Rev. A) Service M
Page 3: Table Of Contents Chapter 1 - Safet
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 and 28: Removal (Fig. 8) 1. Park machine on
Page 29 and 30: Engine Removal (Fig. 9) 1. Park mac
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
Page 81 and 82:
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
Page 93 and 94:
Procedure for Engine Cooling Fan Ci
Page 95 and 96:
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
Page 103 and 104:
Removal (Fig 49) 1. Park machine on
Page 105 and 106:
IMPORTANT: Use caution when clampin
Page 107 and 108:
Page 109 and 110:
Removal (Fig. 53) 1. Park machine o
Page 111 and 112:
Page 113 and 114:
Page 115 and 116:
Page 117 and 118:
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 127 and 128:
Page 129 and 130:
Page 131 and 132:
CAUTION The centering springs are u
Page 133 and 134:
Page 135 and 136:
Disassembly (Fig. 68) 1. Pump oil o
Page 137 and 138:
Page 139 and 140:
8. Remove and discard back--up gask
Page 141 and 142:
Page 143 and 144:
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 151 and 152:
Page 153 and 154:
Removal (Fig. 85) NOTE: The ports o
Page 155 and 156:
PTO Manifold Service (Fig. 86) For
Page 157 and 158:
Page 159 and 160:
Page 161 and 162:
Disassembly (Fig. 89) 1. Plug all p
Page 163 and 164:
Page 165 and 166:
Page 167 and 168:
Disassembly (Figs. 92 and 93) 1. Re
Page 169 and 170:
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
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
Page 223 and 224:
This page is intentionally blank. A
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
Page 259 and 260:
This page is intentionally blank. C
Page 261 and 262:
Removal (Fig. 1) 1. Position machin
Page 263 and 264:
Page 265 and 266:
Removal (Fig. 6) 1. Position machin
Page 267 and 268:
Cutting Deck Link Service Disassemb
Page 269 and 270:
Page 271 and 272:
Installation (Fig. 13) 1. Position
Page 273 and 274:
2. Install outer bearing spacer int
Page 275 and 276:
Page 277 and 278:
Disassembly (Fig. 22) 1. Park machi
Page 279 and 280:
Chapter 9 Foldout Drawings Table of
Page 281 and 282:
CENTER DECK MANIFOLD COUNTERBALANCE
Page 283 and 284:
CONTINUES FROM SHEET 1 CONTINUES FR
Page 285 and 286:
CONTINUES TO SHEET 2 CONTINUES TO S
Page 287 and 288:
CONTINUES TO SHEET 2 WHEN THE PTO S
Page 289 and 290:
CONTINUES TO SHEET 2 CONTINUES TO S
Page 291 and 292:
YELLOW GRAY YELLOW/BLACK VIOLET WHI
Page 293 and 294:
FLOW DIVIDER SOLENOID Groundsmaster
Page 295 and 296:
(STARTER) (STARTER) (STARTER) Groun
Page 297 and 298:
BLUE GRAY VIOLET BLACK YELLOW GRAY
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