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Spring Coupler RIGHT FRONT 21 20 19 18 17 4 3 2 1 Loctite #242 16 15 14 12 13 11 10 9 8 7 6 5 2 28 to 32 ft -lb (38to43N-m) 29 to 33 ft -lb (40to44N-m) 1. Spring coupler 2. Washer (14 used) 3. Cap screw (6 used) 4. Flywheel plate 5. Cap screw (4 used) 6. LH engine mount 7. Cap screw (2 used) Figure 16 8. Carriage screw (2 used) 9. Cylinder shim 10. Transport cylinder 11. Lock nut (2 used) 12. Cylinder piston 13. O -ring (2 used) 14. Backup ring (2 used) 15. Retaining ring 16. Seal 17. O -ring 18. Hydraulic fitting 19. O -ring 20. Hydraulic hose 21. RH engine mount Kubota Diesel Engine Page 3 - 16 Groundsmaster 4000--D
Coupler Removal (Fig. 16) NOTE: The hydraulic pump assembly needs to be removed from engine before coupler can be removed. 1. If engine is in machine, support engine from below to prevent it from shifting while removing hydraulic pump assembly (see Piston (Traction) Pump Removal in the Service and Repairs section of Chapter 4 -- Hydraulic System), transport cylinder assembly, flywheel plate, engine mounts and spring coupler. 2. Remove flywheel plate and spring coupler from engine using Figure 16 as a guide. Engine Side Hydraulic Pump Side 1 Coupler Installation (Fig. 16) 1. Position spring coupler to engine flywheel and align mounting holes. Make sure that coupling hub is away from engine flywheel (Fig. 17). 2. Apply Loctite #242 (or equivalent) to threads of cap screws (item 3). Secure coupler to flywheel with six (6) cap screws and washers. Torque cap screws in a crossing pattern from 29 to 33 ft -lb (40 to 44 N -m). 3. Position flywheel plate to engine and engine mounts. Secure flywheel plate and mounts with cap screws (items 5 and 7) and washers using a crossing pattern tightening procedure. Torque cap screws in a crossing pattern from 28 to 32 ft -lb (38 to 43 N -m). 4. Install transport cylinder assembly to engine mount. 5. If engine is in machine, install hydraulic pump assembly (see Piston (Traction) Pump Installation in the Service and Repairs section of Chapter 4 -- Hydraulic System). Figure 17 1. Coupler 2. Engine flywheel 2 Kubota Diesel Engine Groundsmaster 4000--D Page 3 - 17 Kubota Diesel Engine
Page 1 and 2: Part No. 08161SL (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 Product Records and Maint
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: CAUTION Do not open radiator cap or
Page 31: CAUTION One person should operate l
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 Hydraulic flow for the mow circ
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 PTO Relief Pressure T
Page 81 and 82: Procedure for Cutting Deck Motor Ca
Page 83 and 84:
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
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Removal (Fig. 49) 1. Park machine o
Page 105 and 106:
IMPORTANT: Use caution when clampin
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Hydraulic System This page is inten
Page 109 and 110:
Page 111 and 112:
Page 113 and 114:
Page 115 and 116:
Page 117 and 118:
Page 119 and 120:
Removal (Fig. 59) 1. Read the Gener
Page 121 and 122:
4WD Manifold Service (Fig. 60) 1. M
Page 123 and 124:
Page 125 and 126:
Traction Manifold Service (Fig. 62)
Page 127 and 128:
Page 129 and 130:
Filter Manifold Service (Fig. 64) F
Page 131 and 132:
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Page 135 and 136:
CAUTION The centering springs are u
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Disassembly (Fig. 70) 1. Pump oil o
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8. Remove and discard back--up gask
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Page 147 and 148:
Page 149 and 150:
Fan Drive Manifold Service (Fig. 78
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Cutting Deck Motor Removal 1. Park
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IMPORTANT: Mark the relative positi
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Page 159 and 160:
PTO Manifold Service (Fig. 88) For
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Disassembly (Fig. 91) 1. Plug all p
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Disassembly (Figs. 94 and 95) 1. Re
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Page 175 and 176:
Chapter 5 Electrical System Table o
Page 177 and 178:
Special Tools Order special tools f
Page 179 and 180:
Troubleshooting CAUTION Remove all
Page 181 and 182:
Cutting Deck Operating Problems The
Page 183 and 184:
Component Testing For accurate resi
Page 185 and 186:
Warning Lights Engine Oil Pressure
Page 187 and 188:
Transport / 4WD Switch The transpor
Page 189 and 190:
Seat Switch The seat switch is norm
Page 191 and 192:
Hour Meter The hour meter is locate
Page 193 and 194:
Start, Engine Shutdown, Seat, PTO,
Page 195 and 196:
TEC -5002 Controller Groundsmaster
Page 197 and 198:
Fuel Gauge The fuel gauge can be te
Page 199 and 200:
Glow Controller The glow controller
Page 201 and 202:
Dual Temperature Switch The dual te
Page 203 and 204:
Traction Neutral Switch The tractio
Page 205 and 206:
Fusible Link Harness The Groundsmas
Page 207 and 208:
Engine Coolant and Hydraulic Oil Te
Page 209 and 210:
Battery Service The battery is the
Page 211 and 212:
Battery Charging To minimize possib
Page 213 and 214:
Chapter 6 Axles, Planetaries and Br
Page 215 and 216:
General Information Operator’s Ma
Page 217 and 218:
3. Chock rear wheels and jack up fr
Page 219 and 220:
This page is intentionally blank. A
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NOTE: The planetary wheel drive ass
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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
Page 233 and 234:
9. Remove the bevel gear case/axle
Page 235 and 236:
Axle Shafts The following procedure
Page 237 and 238:
7. Secure the lock nut with the sta
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Differential Gear Inspection 1. Mea
Page 241 and 242:
Pinion Gear to Ring Gear Engagement
Page 243 and 244:
Chapter 7 Chassis Table of Contents
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Disassembly (Fig. 1) 1. Park machin
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Removal (Fig. 2) 1. Park machine on
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Page 251 and 252:
Rear Arm Removal (Fig. 8) 1. Park m
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This page is intentionally blank. C
Page 255 and 256:
IMPORTANT: Support yoke when removi
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Page 259 and 260:
Disassembly (Fig. 15) 1. Disassembl
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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 Decks Table of Co
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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. 5) 1. Position machin
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Removal (Figs. 10 and 11) 1. Park m
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2. Install outer bearing spacer int
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Chapter 9 Foldout Drawings Table of
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COUNTERBALANCE MANIFOLD FRONT PTO M
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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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Groundsmaster 4000--D Engine Wire H
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PINK Groundsmaster 4000--D Front Wi
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YELLOW GRAY YELLOW/BLACK VIOLET WHI
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