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Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky, black or contains metal particles). 1. Park machine on a level surface. Lower cutting deck to the ground, stop engine and engage parking brake. Remove key from the ignition switch. CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. IMPORTANT: Make sure to clean around any hydraulic connections that will be disconnected for draining. 2. Drain hydraulic reservoir. 3. Drain hydraulic system. Drain all hoses, tubes and components while the system is warm. 4. Change and replace both hydraulic oil filters. 5. Inspect and clean hydraulic reservoir (see Hydraulic Reservoir Inspection in this section). 6. Connect all hydraulic hoses, tubes and components that were disconnected while draining system. 7. Fill hydraulic reservoir with new hydraulic fluid. 8. Disconnect wire harness connector from engine run solenoid. 9. Turn ignition key switch and engage starter for ten (10) seconds to prime hydraulic pumps. Repeat this step again. 10.Connect wire harness connector to engine run solenoid. 11.Start engine and let it run at low idle (1450 RPM) for a minimum of 2 minutes. Increase engine speed to high idle (2870 RPM) for a minimum of 1 minute under no load. 12.Raise and lower cutting deck several times. Turn steering wheel fully left and right several times. 13.Shut off engine and check for hydraulic oil leaks. Check oil level in hydraulic reservoir and add correct amount of oil if necessary. 14.Operate machine for 2 hours under normal operating conditions. 15.Check condition of hydraulic oil. If the new fluid shows any signs of contamination, repeat steps 1 through 14 again until oil is clean. 16.Assume normal operation and follow recommended maintenance intervals. NOTE: Use only hydraulic fluids specified in the Operator’s Manual. Other fluids may cause system damage. Hydraulic System Page 4 - 62 Groundsmaster 4100--D
Charge Hydraulic System NOTE: When initially starting the hydraulic system with new or rebuilt components such as motors, pumps or lift cylinders, it is important that the hydraulic system be charged properly. Air must be purged from the system and its components to reduce the chance of damage. IMPORTANT: Change hydraulic oil filter whenever hydraulic components are repaired or replaced. 1. Park machine on a level surface. Lower cutting deck to the ground, stop engine and engage parking brake. Remove key from the ignition switch. 2. Make sure all hydraulic connections, lines and components are tight. 3. If component failure was severe or the system is contaminated, flush and refill hydraulic system and reservoir (see Flush Hydraulic System in this section). 4. Make sure hydraulic reservoir is full. Add correct hydraulic oil if necessary. 5. Check control rod to the piston (traction) pump for proper adjustment, binding or broken parts. 6. Disconnect wire harness connector from engine run solenoid to prevent the engine from starting. 7. Make sure traction pedal and lift control lever are in the neutral position. Turn ignition key switch and engage starter for ten (10) seconds to prime the traction and gear pumps. Repeat this step again. 8. Connect wire harness connector to engine run solenoid. WARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 - Safety. 9. Raise one front and one rear wheel off the ground and place support blocks under the frame. Chock remaining wheels to prevent movement of the machine. 10.Make sure traction pedal and lift control lever are in neutral. Start engine and run it at low idle (1400 RPM). The charge pump should pick up oil and fill the hydraulic system. If there is no indication of fill in 30 seconds, stop the engine and determine the cause. 11.After the hydraulic system starts to show signs of fill, actuate lift control lever until the lift cylinder rod moves in and out several times. If the cylinder rod does not move after fifteen (15) seconds or the pump emits abnormal sounds, shut the engine off immediately and determine cause or problem. Inspect for the following: A. Loose filter or suction lines. B. Blocked suction line. C. Faulty charge relief valve. D. Faulty gear pump. 12.If cylinder does move in 15 seconds, proceed to step 13. 13.Operate the traction pedal in the forward and reverse directions. The wheels off the ground should rotate in the proper direction. A. If the wheels rotate in the wrong direction, stop engine and check for proper hose connections at traction pump and motors. Correct as needed. B. If the wheels rotate in the proper direction, stop engine. 14.Adjust traction pedal to the neutral position. 15.Check operation of the traction interlock switch. 16.Remove blocks from frame and lower machine to the ground. Remove chocks from remaining wheels. 17.If the piston (traction) pump or a wheel or axle motor was replaced or rebuilt, run the machine so all wheels turn slowly for 10 minutes. 18.Operate machine by gradually increasing it’s work load to full over a 10 minute period. 19.Stop the machine. Check hydraulic reservoir and fill if necessary. Check hydraulic components for leaks and tighten any loose connections. Hydraulic System Groundsmaster 4100--D Page 4 - 63 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
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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
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: Service and Repairs General Precaut
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
Page 135 and 136: Disassembly (Fig. 68) 1. Pump oil o
Page 139 and 140: 8. Remove and discard back--up gask
Page 143 and 144: Removal (Fig. 75) 1. Read the Gener
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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Removal (Fig. 88) 1. Park machine o
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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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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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