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Jacking Instructions CAUTION When changing attachments, tires or performing other service, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands to support the raised machine. If the machine is not properly supported by jack stands, the machine may move or fall, which may result in personal injury. 2 1 Figure 1 1. Frame jacking point 2. Front tire 1 2 Jacking the Front End (Fig. 1) 1. Set parking brake and chock both rear tires to prevent the machine from moving. 2. Position jack securely under the frame, just to the inside of the front tire. Jack front wheel off the ground. 3. Once the machine is raised, position suitable jack stand under the frame as close to the wheel as possible to support the machine. Jacking the Rear End (Fig. 2) 1. Place jack securely under the center of rear axle. 2. Chock both front tires. Jack rear of machine off the ground. 3. Once the machine is raised, use suitable jack stands under the rear axle to support the machine. 2 1 2 Figure 2 1. Rear axle jacking point 2. Rear tire Safety Page 1 - 4 Groundsmaster 4100--D
Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 4100--D. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog. Safety Groundsmaster 4100--D Page 1 - 5 Safety
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: Maintenance and Service 1. Before s
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
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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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Page 115 and 116:
Page 117 and 118:
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Removal (Fig. 59) NOTE: The ports o
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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:
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Page 131 and 132:
CAUTION The centering springs are u
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Page 135 and 136:
Disassembly (Fig. 68) 1. Pump oil o
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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
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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:
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Disassembly (Fig. 89) 1. Plug all p
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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
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NOTE: The planetary wheel drive ass
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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
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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
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
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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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