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Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauges and Flow Meter) CENTER CUTTING DECK MOTOR CASE DRAIN LEAKAGE TEST SHOWN FROM REAR AXLE MOTOR TRACTION CIRCUIT FLOW M1 M2 M1 M2 CENTER DECK MANIFOLD M1 RV2 M2 LC2 LH WING DECK MANIFOLD RV1 RH WING DECK MANIFOLD TO STEERING & LIFT CIRCUITS TO COOLING FAN CIRCUIT FILTER MANIFOLD TRACTION CIRCUIT FLOW FROM 4WD MANIFOLD FROM FRONT WHEEL MOTORS RV2 CHARGE CIRCUIT LC2 OR RV1 RV2 LC2 OR RV1 S S S LC1 LC1 LC1 P1 P2 P1 P2 P1 P2 FROM COOLING FAN CIRCUIT TESTER CAP MEASURING CONTAINER Hydraulic System Page 4 - 48 Groundsmaster 4100--D
Procedure for Cutting Deck Motor Case Drain Leakage Test 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. NOTE: Onemethodtofindafailingormalfunctioning 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. 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 Pre<strong>caution</strong>s for Hydraulic Testing at the beginning of this section. 6. Sit on seat and operate the engine at full speed (2870 RPM). Move PTO switch to ON. 7. While watching pressure gauge, slowly close flow control valve on tester until a pressure of 1200 PSI (83 bar) is obtained. NOTE: Use a graduated container, special tool TOR4077, to measure case drain leakage (Fig. 38). 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),themotor 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. 1 3 Hydraulic System 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). 5. After installing flow tester, start engine and run at idle speed. Check for hydraulic leakage and correct before proceeding with test. 2 Figure 37 1. Deck motor (RH shown) 3. Case drain hose 2. Return hose 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. Figure 38 Groundsmaster 4100--D Page 4 - 49 Rev. A 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
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 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: Procedure for Cutting Deck Gear Pum
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 109 and 110: Removal (Fig. 53) 1. Park machine o
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
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Removal (Fig. 67) 1. Park machine o
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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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Hydraulic System This page is inten
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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
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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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Removal (Fig. 94) 1. Read the Gener
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Chapter 5 Electrical System Table o
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Special Tools Order special tools f
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Troubleshooting CAUTION Remove all
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Cutting Deck Operating Problems The
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Adjustments Wing Deck Position Swit
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Component Testing For accurate resi
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Warning Lights Engine Oil Pressure
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Transport / 4WD Switch The transpor
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Seat Switch The seat switch is norm
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Hour Meter The hour meter is locate
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Start, Engine Shutdown, Seat, Alarm
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TEC -5002 Controller Groundsmaster
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Fuel Gauge The fuel gauge can be te
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Glow Controller The glow controller
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Dual Temperature Switch The dual te
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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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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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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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