Toro 4000-D manuale d’uso

(Models 30448 and 30446) Part No. 10176S L (Rev . A) Service Manual Groundsmaster R 4000 - - D & 4010 - - D Preface The pur pose of this public ation is to pr ovide t he service technic ian with inf orm ation f or t roubles hooting, test ing and repair of maj or syst ems and co mponents on the Gr oundsmas ter 4000- - D (Model 30448) and 4010- -[...]

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Gr oundsmas ter 4000 - - D/ 4010 - - D T able Of Contents Chapter 1 - - Safety Gener al Safet y I nst ruc tions 1 - - 2 .................. Jackin g Instructions 1 - - 5 ......................... Safet y and I nst ruc tion Dec als 1 - - 6 ................ Cha pter 2 - - Product R ecor ds and Maint enanc e Produc t Records 2 - - 1 ...................[...]

Gr oundsmas ter 4000 - - D/ 4010 - - D This page is intent ionall y blank .[...]

Gr oundsmas ter 4000 - - D/ 4010 - - D T able Of Contents (Continued) Chap ter 9 - - O perat or Cab Gener al Inf orm ation 9 - - 2 ........................ Serv ice and Repairs 9 - - 3 ........................ SANDEN SD COMPRESSOR SER VI CE GUIDE Cha pter 1 0 - - Foldout Dr awings Hydraulic S chemat ic 10 - - 3 ....................... Elect rical S[...]

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Groundsmaster 4000 - - D/4010 - - D Page 1 - - 1 Safety Chapter 1 Safety T able of Contents GENERAL SAFETY INSTRUCTIONS 2 ............ Before Operating 2 ............................ While Operating 3 ............................. Maintenance and Service 4 .................... JACKING INSTRUCTIONS 5 ..................... SAFETY AND INSTRUCTION DECA[...]

Groundsmaster 4000 - - D/4010 - - D Page 1 - - 2 Safety General Safety Instructions The Groundsmaster 4000-D and 4010 - - D are tested and certified by T oro for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, thes[...]

Groundsmaster 4000 - - D/4010 - - D Page 1 - - 3 Safety While Operating 1. Sit on the seat when starting and operating the ma- chine. 2. Before starting the engine: A. Apply the parking brake. B. Make sure traction pedal is in neutral and the PTO switch is OFF (disengaged). C. After engine is started, release parking brake and keep foot off tractio[...]

Groundsmaster 4000 - - D/4010 - - D Page 1 - - 4 Safety Maintenance and Service 1. Before servicing or making adjustments, lower decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 3. Never store the machine or fuel containe[...]

Groundsmaster 4000 - - D/4010 - - D Page 1 - - 5 Safety Jacking Instructions CAUTION When changing attachments, tires or perform- ing other service, use correct jacks and sup - ports. 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[...]

Groundsmaster 4000 - - D/4010 - - D Page 1 - - 6 Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to your Groundsmaster machine. If any decal becomes il- legible or damaged, install a new decal. Decal part num- bers are listed in your Parts Catalog.[...]

Groundsmaster 4000 - - D/4010 - - D Page 2 - - 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance T able of Contents PRODUCT RECORDS 1 ......................... MAINTENANCE 1 ............................... EQUIV ALENTS AND CONVERSIONS 2 ........... Decimal and Millimeter Equivalents 2 ............ U.S. to Metric Conversion[...]

0.09375 Groundsmaster 4000 - - D/4010 - - D Page 2 - - 2 Product Records and Maintenance Equivalents and Conversions[...]

Groundsmaster 4000 - - D/4010 - - D Page 2 - - 3 Product Records and Maintenance T orque Specifications Recommended fastener torque values are listed in the following tables. For critical applications, as determined by T oro, either the recommended torque or a torque that is unique to the application is clearly identified and spe- cified in this Se[...]

Groundsmaster 4000 - - D/4010 - - D Page 2 - - 4 Product Records and Maintenance Standard T orque for Dry , Zinc Plated and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 & 8w i t hT h i n Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) SAE Grade 5 Bolts, Screws, Studs &[...]

Groundsmaster 4000 - - D/4010 - - D Page 2 - - 5 Product Records and Maintenance Standard T orque for Dry , Zinc Plated and Steel Fasteners (Metric Series) T h r e a d S i z e Class 8.8 Bolts, Screws and Studs with R e g u l a r H e i g h t N u t s Class 10.9 Bolts, Screws and Studs with R e g u l a r H e i g h t N u t s Thread Size Regular Height [...]

Groundsmaster 4000 - - D/4010 - - D Page 2 - - 6 Product Records and Maintenance Other T orque Specifications SAE Grade 8 Steel Set Screws T h r e a d S i z e Recommended T orque Thread Size Square Head Hex Socket 1/4 - - 20 UNC 140 + 20 in - - lb 73 + 12 in - - lb 5/16 - - 18 UNC 215 + 35 in - - lb 145 + 20 in - - lb 3/8 - - 16 UNC 35 + 10 ft - - [...]

Groundsmaster 4000 - - D/4010 - - D Page 3 - - 1 Kubota Diesel Engine Chapter 3 Kubota Diesel Engine T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ..................... Operator ’s Manual 3 .......................... Stopping the Engine 3 ......................... SERVICE AND REP AIRS 4 ................[...]

Groundsmaster 4000 - - D/4010 - - D Page 3 - - 2 Kubota Diesel Engine Specifications Item Description Make / Designation Kubota Model V2403 - - M - - T - - E3B: 4- - Cycle, 4 Cylinder , W ater Cooled, Turbocharged, Diesel Engine Bore 3.43 in (87.0 mm) Stroke 4.031 in (102.4 mm) T otal Displacement 148.5 in 3 (2434 cc) Firing Order 1 (closest to gea[...]

Groundsmaster 4000 - - D/4010 - - D Page 3 - - 3 Kubota Diesel Engine General Information This Chapter gives information about specifications and repair of the diesel engine used in Groundsmaster 4000 - - D and 4010 - - D machines. General maintenance procedures are described in your Operator ’s Manual. Information on engine troubleshoot- ing, te[...]

Groundsmaster 4000 - - D/4010 - - D Page 3 - - 4 Kubota Diesel Engine Service and Repairs Air Filter System Figure 1 1. Air cleaner hose 2. Hose clamp 3. Air cleaner assembly 4. Indicator 5. Air cleaner strap 6. Lock nut (2 used) 7. Hose clamp 8. Air cleaner hose 9. Hose clamp 10. Cap screw (2 used) 1 1. Flat washer (4 used) 12. Spring (2 used) 13.[...]

Groundsmaster 4000 - - D/4010 - - D Page 3 - - 5 Kubota Diesel Engine Removal (Fig. 1) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Raise and support hood. 3. Remove air cleaner components as needed using Figure 1 as a guide. Installation (Fig. 1) IMPORT ANT : [...]

Groundsmaster 4000 - - D/4010 - - D Page 3 - - 6 Kubota Diesel Engine Exhaust System Figure 5 1. Muffler 2. Muffler bracket 3. Exhaust pipe 4. Flange head screw (4 used) 5. Exhaust gasket 6. Lock nut (2 used) 7. Cap screw (2 used) 8. Flat washer (4 used) 9. Spacer (2 used) 10. Rubber hanger 1 1. Flange nut (4 used) 12. Flange head screw (2 used) 13[...]

Rev . A Groundsmaster 4000- - D/4010 - - D Page 3 - - 7 Kubota Diesel Engine Removal (Fig. 5) CAUTION The muffler and exhaust pipe may be hot. T o avoid possible burns, allow the e ngine and ex - haust system to cool befor e working on the muf- fler . 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remo[...]

Groundsmaster 4000 - - D/4010 - - D Page 3 - - 8 Kubota Diesel Engine Fuel System Figure 7 1. Fuel tank 2. Fuel tank bracket 3. ROPS assembly 4. W asher head screw (3 used) 5. T ank support assembly 6. Insulated clip (3 used) 7. Flange nut (6 used) 8. Cap screw (4 used) 9. Flat washer (4 used) 10. Cap screw (4 used) 1 1. Carriage screw (2 used) 12.[...]

Groundsmaster 4000 - - D/4010 - - D Page 3 - - 9 Kubota Diesel Engine DANGER Because diesel fuel is highly flammable, use cau - tion when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled d[...]

Groundsmaster 4000 - - D/4010 - - D Page 3 - - 1 0 Kubota Diesel Engine Radiator Figure 9 1. Radiator cap 2. Foam strip (2 used) 3. Foam strip (2 used) 4. Lower radiator hose 5. Upper radiator hose 6. Clamp (4 used) 7. Lower radiator shroud 8. T emperature sender 9. Radiator 10. Hose clamp (3 used) 1 1 . H o s e( 2u s e d ) 12. Screw (4 used) 13. R[...]

Groundsmaster 4000 - - D/4010 - - D Page 3 - - 1 1 Kubota Diesel Engine Removal (Fig. 9) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Open and support hood. CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coo[...]

Groundsmaster 4000 - - D/4010 - - D Page 3 - - 1 2 Kubota Diesel Engine Engine Figure 10 1. Engine 2. Cap screw (4 used) 3. LH engine mount 4. Lock washer 5. Cap screw 6. Lock washer (5 used) 7. Cap screw (5 used) 8. Engine support (4 used) 9. Flange nut (12 used) 10. Rebound washer (4 used) 1 1. Cap screw (8 used) 12. Spring coupler 13. Washer (14[...]

Groundsmaster 4000 - - D/4010 - - D Page 3 - - 13 Kubota Diesel Engine Engine Removal (Fig. 10) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove battery from machine (see Battery Service in the Service and Repairs section of Chapter 5 - - Electri- cal System[...]

Groundsmaster 4000 - - D/4010 - - D Page 3 - - 1 4 Kubota Diesel Engine 8. Disconnect fuel supply hose from injection pump (Fig. 13). 9. Remove throttle cable from engine (Figs. 13 and 14): A. Remove lock nut that secures throttle cable swiv- el to speed control lever . B. Loosen cable clamp and remove throttle c able from under clamp. C. Position [...]

Groundsmaster 4000 - - D/4010 - - D Page 3 - - 15 Kubota Diesel Engine 15. Make sure all cable ties securing the wiring harness, fuel lines or hydraulic hoses to the engine are removed. 16. Connect hoist or lift to the lift tabs on engine. 17. Remove flange nuts, rebound washers and cap screws securing the engine mounts to the engine sup- ports. CA[...]

Groundsmaster 4000 - - D/4010 - - D Page 3 - - 1 6 Kubota Diesel Engine 7. Install fan motor and fan assembly (Fig. 15). A. Carefully position fan motor , fan and motor brack- et assembly to radiator . B. Secure fan motor bracket to radiator with six (6) cap screws and flange nuts. C. Remove caps and plugs placed in hoses and fit- tings during remo[...]

Groundsmaster 4000 - - D/4010 - - D Page 3 - - 17 Kubota Diesel Engine This page is intentionally blank. Kubota Diesel Engine[...]

Groundsmaster 4000 - - D/4010 - - D Page 3 - - 1 8 Kubota Diesel Engine Spring Coupler Figure 18 1. Spring coupler 2. W asher (14 used) 3. Cap screw (6 used) 4. Flywheel plate 5. Cap screw (4 used) 6. LH engine mount 7. Cap screw (2 used) 8. Carriage screw (2 used) 9. Cylinder spacer 10. T ransport cylinder 1 1. Lock nut (2 used) 12. Cylinder pisto[...]

Groundsmaster 4000 - - D/4010 - - D Page 3 - - 19 Kubota Diesel Engine Coupler Removal (Fig. 18) NOTE: The hydraulic pump assembly needs to be re- moved from engine before coupler can be removed. 1. If engine is in machine, support engine from below to prevent it from shifting. Remove the following: A. Remove hydraulic pump assembly from machine (s[...]

Groundsmaster 4000 - - D/4010 - - D Page 3 - - 2 0 Kubota Diesel Engine This page is intentionally blank.[...]

Rev . A Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 1 Chapter 4 Hydraulic System T able o f Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TION 3 ..................... Operator ’s Manu al 3 .......................... Check Hydraulic Fluid 3 ....................... T owing Traction Unit 3 ...............[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 2 Specifications Item Description Piston (T raction) Pump Eaton V ariable Displacement Piston Pump (Model 72400) Maximum Displacement (per revolution) 2.48 in 3 (40.6 cc) System Relief Pressure: Forward 4000 PSI (274 bar) System Relief Pressure: Reverse 5000 PSI (343 bar) Charge Pressu[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 3 General Information Operator ’s Manual The Operator ’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Check Hydraul[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 4 Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hy- draulic system, all pressure in the hydraulic system must be relieved. Park machine on a level surface, make sure that PTO switch is OFF , lower cutting decks fully , stop engine and engage par[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 5 Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather , sun, chemicals, very warm storage condi- tions or mishandling during operation and maintenance. These conditions can cause hose damage and deter[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 6 Hydraulic Hose and T ube Installation (O - - Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is rec- ommended that the fac[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 7 Hydraulic Fitting Installation (SAE Straight Thread O - - Ring Fitting into Component Port) Non - - Adjustable Fitting (Fig. 6) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventativ[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 8 Adjustable Fitting (Fig. 8) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is rec- ommended that the O - - ring be replaced any time the connecti[...]

Rev . A Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 9 Hydraulic Schematic NOTE: A larger hydraulic schematic is included in Chapte r 10: Foldout Drawings FRONT PTO MANIFOLD FA N D R I V E MANIFOLD RH PTO MANIFOLD 4WD MANIFOLD LH PTO MANIFOLD TRACTION MANIFOLD FIL TER MANIFOLD S1 S2 S3 S4 S5 S7 S6 S8 RV1 RV2 S9 LIFT/LOWER MANIFOLD[...]

Rev . A Groundsmaster 4000 - - D/4010 - - D Hy draulic System Page 4 - - 10 Hydraulic Flow Diagrams T raction Circuit: Low Speed (4WD) (Forward Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow FRONT PTO MANIFOLD FA N D R I V E MANIFOLD RH PTO MANIFOLD 4WD MANIFOLD LH PTO MANIFOLD TRACTION MANIFOLD FIL TER MANIFOLD S1 S2 S3 S4 S5[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 1 1 T raction Circ uit: Low Speed (4WD) The traction circuit piston pump is a variabl e displace- ment pump that is directly coupled to the engine fly- wheel. Pushing the traction pedal engages a hyd raulic servo valv e which contr ols the va riable displa cement piston pump swash plate[...]

Rev . A Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 12 T raction Circuit: Hi Speed (2WD) (Forward Shown) Wo rking Pressure Low Pressure (Charge) Return or Suction Flow FRONT PTO MANIFOLD FAN D R I V E MANIFOLD RH PTO MANIFOLD 4WD MANIFOLD LH PTO MANIFOLD TRACTION MANIFOLD FIL TER MANIFOLD S1 S2 S3 S4 S5 S7 S6 S8 RV1 RV2 S9 LIFT/[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 13 T ractio n Circuit: Hi Speed (2 WD) The traction circuit piston pump is a variabl e displace- ment pump that is directly coupled to the engine fly- wheel. Pushing the traction pedal engages a hyd raulic servo valv e which contr ols the va riable displa cement piston pump swash plate [...]

Rev . A Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 14 Lower Cutting Deck (LH Deck Shown) Working Pressure Low Pressure ( Charge) Return or Suction Flow FRONT PTO MANIFOLD FAN D R I V E MANIFOLD RH PTO MANIFOLD 4WD MANIFOLD LH PTO MANIFOLD TRACTION MANIFOLD FIL TER MANIFOLD S1 S2 S3 S4 S5 S7 S6 S8 RV1 RV2 S9 LIFT/LOWER MANIFOLD [...]

Rev . A Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 15 Lower Cutting Deck A four section gear pump is cou pled to the piston (trac- tion) pump . The third gea r pump sectio n supplies hy - draulic flow to both the steer ing and lift/lower circuits. Hydraulic flow from this pump section is delivered to the two circuits through a p[...]

Rev . A Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 16 Raise Cutting Deck (LH Deck Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow FRONT PTO MANIFOLD FAN D R I V E MANIFOLD RH PTO MANIFOLD 4WD MANIFOLD LH PTO MANIFOLD TRACTION MANIFOLD FIL TER MANIFOLD S1 S2 S3 S4 S5 S7 S6 S8 RV1 RV 2 S9 LIFT/LOWER MANIFOLD [...]

Rev . A Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 17 Raise Cut ting Deck A four section gear pump is cou pled to the piston (trac- tion) pump . The third gea r pump sectio n supplies hy - draulic flow to both the steer ing and lift/lower circuits. Hydraulic flow from this pump section is delivered to the two circuits through a [...]

Rev . A Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 18 Mow (Front Deck Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow FRONT PTO MANIFOLD FAN D R I V E MANIFOLD RH PTO MANIFOLD 4WD MANIFOLD LH PTO MANIFOLD TRACTION MANIFOLD FIL TER MANIFOLD S1 S2 S3 S4 S5 S7 S6 S8 RV1 RV2 S9 LIFT/LOWER MANIFOLD BYPASS VAL V [...]

Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 19 Mow A four section gear pump is cou pled to the piston (trac- tion) pump. Hydraulic flow for the mow circuit is supplied by two sections of the gear pump. The gear pump sec- tion closest to the piston (tra ction) pump supp lies hy- draulic flow to the side cutt ing decks, while the n[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic S ystem Page 4 - - 20 Mow Circuit Cutting Deck Blade Braking When the operator turns the PTO switch OFF or if a deck is raised with the PTO swit ch ON, PTO manifold sole- noid valve (S) is de - - energized causing bypass cartridge (LC1) to shift (refer to information in Mow Circuit in this section). T hi[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 21 This page is intentionally blank. Hydraulic System[...]

Rev . A Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 22 Steering Circuit (Left T urn Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow FRONT PTO MANIFOLD FAN D R I V E MANIFOLD RH PTO MANIFOLD 4WD MANIFOLD LH PTO MANIFOLD TRACTION MANIFOLD FIL TER MANIFOLD BYPASS VAL V E M1 M2 ST L T P1 P2 S1 S2 S3 S4 S5 S7 S6 [...]

Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 23 Steering Circuit A four section gear pump is cou pled to the piston (trac- tion) pump . The third gea r pump sectio n supplies hy - draulic flow to both the steer ing and lift/lower circuits. Hydraulic flow from this pump section is delivered to the two circuits through a proportiona[...]

Rev . A Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 24 Engine Cooling Fan Circuit (Forward Direction Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow FRONT PTO MANIFOLD FAN D R I V E MANIFOLD RH PTO MANIFOLD 4WD MANIFOLD LH PTO MANIFOLD TRACTION MANIFOLD FIL TER MANIFOLD S1 S2 S3 S4 S5 S7 S6 S8 RV1 RV2 S9 LIF[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 25 Engine Cooling Fan Circuit A four section gear pump is coupled to the piston (trac- tion) pump. The gear pump section farthest from the pis- ton pump supplies hydraulic flow for the engine cooling fan circuit (Fig. 15). The fan drive manifold controls the operation of the hy- drauli[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 26 Special T ools Order special tools from your T oro Distributor . Hydraulic Pressure T est Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose i[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 27 40 GPM Hydraulic T ester (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the T esting section of this chapter . This tester includes the following: 1. LOAD V AL VE: A simulated working load is created in the circui[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 28 High Flow Hydraulic Filter Kit The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi - - direc- tional filtration which prevents filtered debris from being allowed back into the cir[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 29 Hydraulic T est Fitting Kit This kit includes a variety of O - - r ing Face Seal fittings to enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. T oro Part Number: TOR4079 Figure 23 TORO TEST FITTING KIT[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 30 T roubleshooting The charts that follow contain suggestions that can be used to assist in diagnosing hydraulic system perfor- mance issues. The suggestions are not all - - inclusive. Also, consider that there may be more than one cause for a machine problem. Review the hydraulic sch[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 31 T raction Circuit Problems Problem Possible Cause Machine operates in one direction only . T raction control linkage is faulty . T raction relief valve is faulty . T raction pedal is sluggish. T raction control linkage is stuck or binding. Charge pressure is low . Piston (traction) [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 32 Mow Circuit Problems Problem Possible Cause No cutting decks will operate. NOTE: T o engage the mow circuit, the seat must be occupied, the cut- ting deck(s) must be fully lowered, the traction speed must be in the Low (4WD) position and the PTO switch must be ON. Electrical problem[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 33 Lift Circuit Problems Problem Possible Cause Cutting decks will not raise. NOTE: Seat must be occupied in or- der to raise cutting decks. Engine RPM is too low . Hydraulic oil level in reservoir is low . Solenoid valve (S1) in lift/lower manifold is faulty . Electrical problem exist[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 34 Steering Circuit Problems Problem Possible Cause Steering inoperative or sluggish Steering components (e.g. tie rods, steering cylinder ends) are worn or binding. Steering cylinder is binding. Oil level in hydraulic reservoir is low (NOTE: ot her hydraulic sys- tems are affected as [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 35 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 36 T esting The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (see the Special T ools section in this Chapter). Before Performing Hydrau[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 37 Which Hydraulic T ests Are Necessary? Before beginning any hydraulic test, identify if the prob- lem is r elated to the traction circuit, cutting (mow) circuit, lift circuit, steering circuit or engine cooling fan circuit. Once the faulty system has been identified, perform tests th[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 38 T raction Circuit Charge Pressure (Using Pressure Gauge) 4WD MANIFOLD TRACTION MANIFOLD FIL TER MANIFOLD TO COOLING F AN CIRCUIT TO STEERING & LIFT CIRCUITS TO PT O (MOW) CIRCUIT FROM FRONT DECK FROM LIFT CONTROL MANIFOLD FROM PTO MANIFOLDS TO PT O (MOW) CIRCUIT CYLINDERS FROM F[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 39 Procedure for T raction C ircuit Charge Pressure T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine under load for approximately ten (10) minutes. Make sure the hydrau- lic tank is full. 2. Park machine on a level surface with the cutting [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 40 T raction Circuit Relief Pressure (Using Pressure Gauge) FORW ARD TRACTION CIRCUIT RELIEF PRESSURE TEST SHOWN 4WD MANIFOLD TRACTION MANIFOLD FIL TER MANIFOLD TO COOLING F AN CIRCUIT TO STEERING & LIFT CIRCUITS TO PT O (MOW) CIRCUIT FROM FRONT DECK FROM LIFT CONTROL MANIFOLD FROM[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 41 Procedure for T raction Circuit Relief Pressure T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine under load for approximately ten (10) minutes. Make sure the hydrau- lic tank is full. Move machine to an open area, away from people and ob[...]

Rev . A Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 42 Counterbalance P ressure (Using Pressure Gauge) FA N D R I V E MANIFOLD 4WD MANIFOLD TRACTION MANIFOLD FIL TER MANIFOLD S1 S2 S3 S4 S5 S7 S6 S8 RV1 RV2 S9 LIFT MANIFOLD TO PTO (M OW) CIRCUIT FROM PT O MANIFOLD S TO PTO (M OW) CIRCUIT FROM FRONT PTO MANIFOLD FROM DECK MOT ORS[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 43 Procedure for Counter balance Pressure T est 1. Make sure hydrau lic oil is at normal operating tem- perature by opera ting the machine under load for approximately ten (10) minutes. Make sure the hydrau- lic tank is full. 2. Park machine on a level surface with the cutting decks low[...]

Rev . A Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 44 T raction Circuit Reducing V alve (PR) Pressur e (Using Pressure Gauge) 4WD MANIFOLD TRACTION MANIFOLD FIL TER MANIFOLD TO COOLING F AN CIRCUIT TO STEERING & LI FT CIRCUITS TO PT O (MOW) CIRCUIT FROM FR ONT DECK FROM LIFT CONTROL MANIFOLD FROM PTO MANIFOLDS TO PT O (MOW)[...]

Rev . A Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 45 Procedure for T raction Circuit Reduc ing V alve (PR) Pressure T est 1. Make sure hydrau lic oil is at normal operating tem- perature by opera ting the machine under load for approximately ten (10) minutes. Make sure the hydrau- lic tank is full. 2. Park machine on a level su[...]

Rev . A Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 46 Rear T raction Circuit (R V) Relief Pressure (Using Pressure Gauge) 4WD MANIFOLD TRACTION MANIFOLD FIL TER MANIFOLD TO COOLING F AN CIRCUIT TO STEERING & LI FT CIRCUITS TO PT O (MOW) CIRCUIT FROM FR ONT DECK FROM LIFT CONTROL MANIFOLD FROM PTO MANIFOLDS TO PT O (MOW) CIR[...]

Rev . A Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 47 Procedure for Rear T raction Circuit (RV) Relief Pres - sure T est 1. Make sure hydrau lic oil is at normal operating tem- perature by opera ting the machine under load for approximately ten (10) minutes. Make sure the hydrau- lic tank is full. 2. Park machine on a level surf[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic S ystem Page 4 - - 48 Piston (T raction) Pump Flow T est (Using T e ster with Flow meter and Pressure Gauge) 4WD MANIFOLD TRACTION MANIFOLD FIL TER MANIFOLD TO COOLING F AN CIRCUIT TO STEERING & LIFT CIRCUITS TO PT O (MOW) CIRCUI T FROM FRONT DECK FROM LIFT CONTROL MANIFOLD FROM PTO MANIFOLDS TO PT O[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 49 Procedure for Piston (T raction) Pump Flow Te s t This test me asures pisto n (tractio n) pump output (f low). During this tes t, pump load is creat ed at the flow meter using the adjustable loa d valve on the tester . IMPORT ANT : T raction circuit flow for the Groundsmaster 4000/40[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic S ystem Page 4 - - 50 Cutting Deck Circuit Pressure (Using Pressure Gau ge) FRONT DECK CIRCUIT PRESSURE TEST SHOWN TO COOL ING FAN CIRCUI T FROM REAR AXLE MOT OR TO STEE RING & LIFT CIRCUITS TRACTION CIR CUIT FLOW CHARGE CIRCUIT FROM FRONT WHEEL MOTORS FROM 4WD MANIFOLD TRACTION CIRCUI T FLOW FROM CO[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 51 Procedure for Cutting Deck Circuit Pressure T est 1. Make sure hydrau lic oil is at normal operating tem- perature by opera ting the machine under load for approximately ten (10) minutes. Make sure the hydrau- lic tank is full. 2. Park machine on a level surface with the cutting deck[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic S ystem Page 4 - - 52 PTO Relief Pr essure (Using T ester with Pressure Gauge and Flow Meter) FRONT PTO RELIEF PRES SURE TEST SHOWN TO COOLING FAN CIRCUIT FROM REAR AXLE MOTOR TO STEERING & LIFT CIRCUITS TRACTION CIRCUI T FLOW CHARGE CIRCUI T FROM FRONT WHEE L MOTORS FROM 4W D MANIFOLD TRACTION CIRCU[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 53 Procedure for PT O Relief Pressure T est 1. Make sure hydrau lic oil is at normal operating tem- perature by opera ting the machine under load for approximately ten (10) minutes. Make sure the hydrau- lic tank is full. 2. Park machine on a level surface with the cutting decks lowered[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic S ystem Page 4 - - 54 Cutting Deck Motor Case Drain Leakage (Using T ester with Pressure Gauge and Flow Meter) FRONT CUTTING DECK MOTOR CASE DRAIN LEAKAGE TEST SHOWN TO COOL ING F AN CIRCUIT FROM REAR AXLE MOTOR TO STEERING & LI FT CIRCUITS TRACTION CI RCUIT FLOW CHARGE CIRCU IT FROM FRONT WH EEL MOT[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 55 Procedure for Cutting Deck Motor Case Drain Leakage T est NOTE: Over a period of time, a deck motor can wear in- ternally . A worn motor may by - -pass oil to its case drain causing the motor to be less efficien t. Eventually , enough oil loss will cause the deck motor to stall un de[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic S ystem Page 4 - - 56 Cutting Deck Gear Pump Flow (Using T ester with Pressure Gauge and Flow Meter) FRONT DECK GEAR PUMP FLOW TE ST SHOWN TO COOL ING F AN CIRCUIT FROM REAR AXLE MOT OR TO STEERING & LI FT CIRCUITS TRACTION CIRCUI T FLOW CHARGE CIRCU IT FROM FRONT W HEEL MOTORS FROM 4WD MANIFOLD TRAC[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 57 Procedure for Cutting Deck Gea r Pump Flow T est NOTE: Over a period o f time, the gears and wear plates in the pump can wear . A worn pump will by pass oil and make the pump less efficient. Eventually , enough oil loss will occur to cause the cutting deck motors to stall under heavy[...]

Rev . A Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 58 Lift/Lower Circuit Relief Press ure (Us ing Pressure Gauge) FA N D R I V E MANIFOLD 4WD MANIFOLD TRACTION MANIFOLD FIL TER MANIFOLD S1 S2 S3 S4 S5 S7 S6 S8 RV1 RV2 S9 LIFT MANIFOLD TO PTO (MOW) CIRCUIT FROM P TO MANI FOLD S TO PTO (MOW) CIRCUIT FROM FRONT PT O MANIFOLD FROM [...]

Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 59 Procedure for Lift/Lower Circuit Relief Pr essure Te s t NOTE: Before attempting to check or adjust lift/lower circuit relief pr essure, make sure that counterbalance pressure is correctly adjusted (see Co unterbalance Pressure T est in this section). 1. Make sure hydrau lic oil is a[...]

Rev . A Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 60 Steering Cir cuit Relief Pressure (Using Pressure Gauge) FAN DRIVE MANIFOLD 4WD MANIFOLD TRACTION MANIFOLD FIL TER MANIFOLD S1 S2 S3 S4 S5 S7 S6 S8 RV1 RV2 S9 LIFT MANIFOLD TO PT O (MOW) CIRCUIT FROM P TO MANIF OLD S TO PT O (MOW) CIRCUIT FROM FRONT PTO MANIFOLD FROM DECK MO[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 61 Procedure for Steering Circuit Relief Pressure T est 1. Make sure hydrau lic oil is at normal operating tem- perature by opera ting the machine under load for approximately ten (10) minutes. Make sure the hydrau- lic tank is full. 2. Park machine on a level surface with the cutting d[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic S ystem Page 4 - - 62 Steer ing Cylinder Internal Leakage 1350 PSI PB STEERING CYLINDER STEERING CONTROL T R P L CYLINDER FULL Y EXTENDED STEEL CAP LOOK FOR LEAKAGE STEERING WHEE L TURNED FOR RIGHT TURN[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 63 Procedure for Steering Cylinder Internal Lea kage Te s t NOTE: Steering circuit operat ion will be affected by rear tire pressure, binding of steering cylinder , extra weight on the vehicle and/or binding of rear axle steering components. Make sure tha t these items are checked befor[...]

Rev . A Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 64 Steering a nd Lift/Lower Gear Pump Fl ow (U sing T ester with Pressu re Gauge and Flow Meter) FA N D R I V E MANIFOLD 4WD MANIFOLD TRACTION MANIFOLD FIL TER MANIFOLD S1 S2 S3 S4 S5 S7 S6 S8 RV1 RV2 S9 LIFT MANIFOLD TO PTO (MOW) CIRCUIT FROM P TO MANIF OLD S TO PTO (MOW) CIRC[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 65 Procedure for Steering and Lift/Lower Gear Pump Flow T est NOTE: Output from the steering and lift/lower gear pump section is equally d ivided by a proportional valve to provide flow to the steering circuit and the lift circuit. The proportional valve is in the fan drive manifo ld. N[...]

Rev . A Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 66 Engine Cool ing Fan Circuit (Using P ressure Gauge and P hototac) FA N D R I V E MANIFOLD 4WD MANIFOLD TRACTION MANIFOLD FIL TER MANIFOLD S1 S2 S3 S4 S5 S7 S6 S8 RV1 RV 2 S9 LIFT MANIFOLD TO PTO (M OW) CIRCUIT FROM PT O MANIFOLD S TO PTO (M OW) CIRCUIT FROM FRONT PTO MANIFOL[...]

Groundsmaster 4000- - D/4010 - - D Hydraulic System Page 4 - - 67 Procedure for Engine Cooling Fan Circuit T est 1. Make sure hydrau lic oil is at normal operating tem- perature by opera ting the machine under load for approximately ten (10) minutes. Make sure the hydrau- lic tank is full. 2. Park machine on a level surface with the cutting decks l[...]

Rev . A Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 68 Engine Cooling Fan Cir cuit Gear Pump Flow (Using T ester with Press ure Gauge and Flow Meter) FA N D R I V E MANIFOLD 4WD MANIFOLD TRACTION MANIFOLD FIL TER MANIFOLD S1 S2 S3 S4 S5 S7 S6 S8 RV1 RV2 S9 LIFT MANIFOLD TO PTO (MOW) CIRCUIT FROM P TO MANIF OLD S TO PTO (MOW) CIR[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 69 Procedure for Engine Cooling Fan Circuit Gear Pump Flow T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine under load for approximately ten (10) minutes. Make sure the hydrau- lic tank is full. 2. Park machine on a level surface with the c[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 70 Adjustments T raction Linkage Adjustment 1. T raction pedal 2. Cap screw (4 used) 3. Hex nut 4. Pedal stop 5. W asher head screw (2 used) 6. Pedal bracket 7. Lock nut (4 used) 8. T raction rod 9. Slotted roll pin 10. Lock nut 1 1. Flat washer 12. Compression spring 13. Spring retain[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 71 4. With ignition switch in the ON position (engine not running), use Diagnostic Display to make sure that neu- tral switch is closed when traction pedal is released to the neutral detent position (see Diagnostic Display in the T roubleshooting section of Chapter 5 - - Electrical Sys[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 72 Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- tem, park machine on a level surface, apply parking brake, lower cutting decks or attachmen[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 73 Flush Hydraulic System IMPORT ANT : Flush the hydraulic system any time there is a severe component failure or the system is contaminated. Contaminated oil may appear milky or black or may contain metal particles. IMPORT ANT : If a component failure occurred in the closed loop tract[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 74 Filtering Closed - - Loop T raction Circuit Filtering of a closed - - loop hydraulic system after a major component failure (e.g. traction (piston) pump or front wheel motor) is a requirement to prevent debris from transmitting throughout the system. If a closed - - loop hy- draulic[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 75 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 to reduce the chance of component dam[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 76 Hydraulic Reservoir 1. Hydraulic reservoir 2. Petcock 3. O - - ring 4. Strap 5. Felt strap (2 used) 6. Bushing (2 used) 7. Bushing 8. Strap 9. Stand pipe (2 used) 10. Hose clamp (2 used) 1 1. Screen filter 12. Dipstick 13. O - - ring 14. Reservoir cap 15. Suction hose 16. T ank stra[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 77 NOTE: The front frame needs to be lowered from the main frame to allow clearance to remove the hydraulic reservoir from the machine. Removal (Fig. 59) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 78 Hydraulic Oil Cooler 1. Radiator 2. RH radiator support 3. T op radiator support 4. Knob (2 used) 5. Oil cooler bracket 6. Retaining ring (2 used) 7. Carriage screw (2 used) 8. O - - ring 9. 90 o hydraulic fitting (2 used) 10. O - - ring 1 1. Cap screw (2 used) 12. Lock washer (6 us[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 79 Removal (Fig. 60) CAUTION The radiator and oil cooler may be hot. T o avoid possible burns, allow the engine and cooling systems t o cool before working on the oil cooler . 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 80 Gear Pump 1. Hydraulic T fitting 2. Roll pin 3. 90 o hydraulic fitting 4. Piston pump 5. Flat washer (2 used) 6. Cap screw (2 used) 7. Hydraulic fitting (2 used) 8. 90 o hydraulic fitting 9. Hydraulic fitting 10. Hydraulic hose 11 . O - - r i n g 12. Pump spacer 13. O - - ring (2 us[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 81 Removal (Fig. 61) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Raise and support machine to gain access to gear pump from the underside of the machine. 3. Drain the hydraulic reservoir . 4. T o [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 82 Gear Pump Service 1. Dust seal 2. Retaining ring 3. Flange washer 4. Shaft seal 5. Front cover 6. Dowel pin (16 used) 7. Pressure seal 8. Back - - up gasket 9. Thrust plate (8 used) 10. Seal (8 used) 1 1. Idler gear 12. Drive shaft 13. Back - - up gasket 14. Pressure seal 15. Front [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 83 IMPORT ANT : Use caution when clamping gear pump in a vise to avoid distorting any pump c ompo- nents. 3. Secure the front cover of t he pump in a vise with the drive shaft pointing down. 4. Loosen the four (4) cap screws that secure pump as- sembly . 5. Remove pump from vise and re[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 84 T raction Circuit 1. Piston (traction) pump 2. Gear pump 3. LH front wheel motor 4. T raction manifold 5. RH front wheel motor 6. 4WD manifold 7. Filter manifold 8. Rear axle motor 9. Cooling fan motor 10. Check valve 1 1. Forward traction pressure port 12. Hydraulic temperature sen[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 85 T ransport Cylinder A transport cylinder is included in the traction circuit to reduce traction pump control arm movement when op- erating in Hi speed (2WD). This reduced control arm movement limits pump swash plate rotation to prevent excessive transport speed. The transport cylind[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 86 Piston (T raction) Pump 1. Hydraulic T fitting 2. Roll pin 3. 90 o hydraulic fitting 4. Piston pump 5. Flat washer (2 used) 6. Cap screw (2 used) 7. Hydraulic fitting (2 used) 8. 90 o hydraulic fitting 9. Hydraulic fitting 10. Hydraulic hose 11 . O - - r i n g 12. Pump spacer 13. O [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 87 5. Disconnect wire harness connector from neutral switch on piston pump. 6. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter . 7. For installation purposes, label all hydraulic [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 88 Piston (T raction) Pump Service 1. Drive shaft 2. Retaining ring 3. Shaft seal 4. W asher 5. Retaining ring 6. Thrust bearing race 7. Thrust bearing 8. Bearing 9. Housing 10. Seal set 1 1. S ervo piston 12. Gasket 13. Cover plate 14. Flat washer (4 used per cover) 15. Socket head sc[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 89 Piston (T raction) Pump Service (Fig. 70) For service of the piston (traction) pump (including the servo control (item 28) assembly), see the Eaton Model 72400 Servo Controlled Piston Pump Repair Informa- tion at the end of this chapter . Hydraulic System[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 90 Rear Axle Motor 1. Axle motor 2. 90 o hydraulic fitting (2 used) 3. Hydraulic fitting 4. Cap screw (2 used) 5. Flat washer (2 used) 6. O - - ring 7. External snap ring (2 used) 8. Gear (45T) 9. External snap ring (2 used) 10. Pinion gear (27T) 1 1. Needle bearing 12. O - - ring 13. [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 91 Removal (Fig. 71) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 92 Front Wheel Motor 1. Front wheel motor 2. Internal retaining ring 3. Splined brake shaft 4. RH brake assembly 5. Planetary assembly 6. Cap screw (2 used per side) 7. Flat washer (2 used per side) 8. O - - ring 9. Flange head screw (6 used per side) 10. 90 o hydraulic fitting 11 . 9 [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 93 Removal (Fig. 72) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 94 Rear Axle and Front Wheel Motor Service 1. Drive shaft 2. Backplate (front motor shown) 3. Housing assembly 4. Rotating assembly 5. Cam plate insert 6. Retaining ring 7. Cap screw (6 used) 8. Shaft seal 9. Retaining ring 10. Thrust race 11 . O - - r i n g 12. V alve plate 13. Thrust[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 95 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 96 4WD Manifold 1. Frame assembly 2. 4WD manifold 3. 90 o hydraulic fitting 4. O - - ring 5. O - - ring 6. Quick fitting 7. O - - ring 8. Dust cap 9. Hydraulic fitting 10. O - - ring 11 . O - - r i n g 12. 90 o hydraulic fitting 13. O - - ring 14. Hydraulic fitting 15. Adapter 16. Hydr[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 97 Removal (Fig. 74) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter . NOTE: Removal of the radiator (see Radiator Removal in the Service and Repairs section of Chapter 3 - - K[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 98 4WD Manifold Service 1. 4WD manifold body 2. Solenoid valve (port SV) 3. Solenoid coil 4. Check valve (port CV) 5. Nut 6. Directional valve (ports PD1 & PD2) 7. Pressure reducing valve (port PR) 8. Relief valve (port RV) 9. Orifice (0.030) (port SV) 10. #4 zero leak plug with O [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 99 4WD Manifold Service (Fig. 75) 1. Make sure the manifold is clean before removing any of the cartridge valves. 2. If cartridge valve is solenoid operated, remove nut securing solenoid to the cartridge valve. Carefully slide solenoid off the valve. IMPORT ANT : Use care when removing[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 100 T raction (Flow Divider) Manifold 1. T raction manifold 2. O - - ring 3. Hydraulic fitting 4. Bracket 5. Flange nut 6. Cap screw (2 used) 7. Hydraulic hose 8. O - - ring 9. 90 o hydraulic elbow 10. O - - ring 1 1. Hydraulic hose 12. Hydraulic fitting 13. O - - ring 14. O - - ring 1[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 101 Removal (Fig. 76) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter . 2. T o prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of m[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 102 T raction (Flow Divider) Manifold Service 1. Flow divider valve 2. Pilot directional valve 3. Orifice (0.020) 4. T raction manifold 5. Check valve 6. SAE #8 plug with O - - ring 7. Solenoid coil 8. Nut 9. Solenoid cartridge valve 10. SAE #6 plug with O - - ring Figure 77 7 9 1 2 3 [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 103 T raction Manifold Service (Fig. 77) NOTE: If the check valve (item 5) next to the pilot direc- tional valve (item 2) needs to be removed from manifold, remove directional valve first. When installing this check valve, install and torque check valve before installing di- rectional [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 104 Filter Manifold 1. Filter manifold 2. 45 o hydraulic fitting 3. T est nipple 4. Dust cap 5. O - - ring 6. O - - ring 7. O - - ring 8. Cap screw (3 used) 9. Flat washer (3 used) 10. Hydraulic fitting 11 . O - - r i n g 12. O - - ring 13. 90 o hydraulic fitting 14. Hydraulic hose 15.[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 105 Removal (Fig. 78) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter . 2. T o prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of f[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 106 Filter Manifold Service 1. Filter manifold 2. Check valve (reservoir return) 3. Oil filter element 4. Check valve (filter bypass) 5. #6 zero leak plug with O - - ring 6. Charge relief valve 7. #8 zero leak plug with O - - ring Figure 79 FRONT UP 6 7 1 5 5 4 2 FRONT UP 3 3 25 ft - -[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 107 Filter Manifold Service (Fig. 79) For filter manifold cartridge valve service procedures, see 4WD Manifold Service in this section. Refer to Fig- ure 79 for filter manifold cartridge valve and plug instal- lation torque. Hydraulic System[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 108 Steering and Engine Cooling Fan Circuits 1. Gear pump 2. Steering control valve 3. Fan drive manifold 4. Fan motor 5. Steering cylinder 6. Steering circuit test port (GM4000) 7. Fan circuit test port Figure 80 FRONT RIGHT 2 1 5 4 3 6 7 GROUNDSMASTER 4000 - - D[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 109 Figure 80 illustrates the components that are used in the Groundsmaster 4000 - - D steering and engine cooling fan circuits. The steering control valve hydraulic lines used on the Groundsmaster 4010 - - D are slightly differ- ent and are shown in Figure 81. Procedures for r emoval,[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 1 10 Steering Control V alve 1. Hex nut 2. Flat washer 3. Steering wheel 4. Foam collar 5. Steering seal 6. External snap ring (2 used) 7. Knob 8. Steering tower cover 9. Steering shaft 10. Compression spring 11 . C a p 12. Rod assembly 13. Extension spring 14. Tilt rod 15. Lock nut (2[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System P a g e 4 - - 111 Removal (Fig. 82) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repa[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 1 12 Steering Control V alve Service 1. Steering control valve housing 2. Dust seal 3. O - - ring 4. Spool 5. Spring retaining ring 6. Pin 7. Sleeve 8. Centering springs/spacers 9. Cap screw (7 used) 10. End cap 11 . O - - r i n g 12. Seal ring 13. O - - ring 14. Geroter 15. O - - ring[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 1 13 CAUTION The centering springs are under tension. Re- move the retaining ring carefully . 10. Remove the spring retaining ring and centering springs from the spool. Assembly (Fig. 85) Check all mating surfaces. Replace any parts with scratches or burrs that could cause leakage. W a[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 1 14 Steering Cylinder 1. Steering cylinder 2. Ball joint 3. Ball joint 4. Retaining ring 5. Grease fitting 6. Grease fitting 7. 90 o hydraulic fitting 8. O - - ring 9. O - - ring 10. Drive axle assembly 1 1. Ball joint spacer 12. Axle washer 13. Slotted hex nut 14. Cotter pin 15. Hydr[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 1 15 Removal (Fig. 87) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repair[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 1 16 Steering Cylinder Service 1. T ube assembly 2. Rod 3. Piston assembly 4. Head 5. Retaining ring 6. Backup ring 7. O - - ring 8. Cap seal 9. Rod seal 10. O - - ring 11 . O - - r i n g 12. Wiper Figure 88 45 to 55 ft - - lb ( 6 2t o7 4N - - m ) 1 6 7 3 9 10 4 11 2 8 5 12[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 1 17 Disassembly (Fig. 88) 1. Pump oil out of cylinder into a drain pan by SLOWL Y moving rod and piston in and out of cylinder bore. Plug ports and clean outside of cylinder . IMPORT ANT : T o prevent damage when c lamping cylinder in a vise, clamp only on pivotal ends. Use of a vise [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 1 18 Engine Cooling Fan Motor 1. Hydraulic fan motor 2. O - - ring 3. Bracket 4. 45 o hydraulic fitting 5. O - - ring 6. Hydraulic hose 7. Fan hub 8. W asher 9. Hex nut 10. Engine 1 1. Cap screw (4 used) 12. Washer (4 used) 13. Fan 14. Lock nut (2 used) 15. Hydraulic hose 16. O - - rin[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 1 19 5. Remove four (4) cap screws (item 1 1) and washers used to secure fan to fan hub. Remove fan. IMPORT ANT : Make sure to not damage the radiator or other machine components while loosening and removing the fan motor and bracket assembly . 6. Remove cooling fan motor and bracket a[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 120 Engine Cooling Fan Motor Service 1. Flange washer 2. O - - ring 3. Front flange 4. Dust seal 5. Retaining ring 6. Front wear plate 7. Shaft seal 8. Backup gasket 9. Pressure seal 10. Rear wear plate 1 1. Body 12. Idler gear 13. Cap screw (4 used) 14. Dowel (2 used) 15. Drive gear 1[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 121 8. Remove and discard back - - up gaskets and pressure seals from wear plates. 9. T urn front flange over , with seal side up. IMPORT ANT : Make sure not to damage the front flange counter bore when removing the seals from the front flange. 10. Carefully remove dust seal, retaining[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 122 3. Place front flange, seal side down, on a flat surface. 4. Install the pressure seals, flat side outward, into the grooves in the wear plates. Follow by carefully placing the backup gaskets, flat side outward, between the pressure seals and the grooves in the wear plate. 5. Apply[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 123 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 124 Fan Drive Manifold 1. Fan drive manifold 2. O - - ring 3. T est fitting 4. Dust cap (2 used) 5. O - - ring 6. 45 o hydraulic fitting (2 used) 7. O - - ring 8. Hydraulic hose 9. Hydraulic hose 10. Hydraulic fitting 1 1. Hydraulic hose 12. Hydraulic hose 13. 90 o hydraulic fitting 14[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 125 Removal (Fig. 95) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Raise and support operator seat to allow access to fan drive manifold (Fig. 96). 3. Read the General Precautions for Removing and [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 126 Fan Drive Manifold Service 1. Fan drive manifold body 2. #4 zero leak plug with O - - ring (3 used) 3. Check valve (port CV) 4. #6 zero leak plug with O - - ring (2 used) 5. Flow divider valve (port FD) 6. Nut 7. Solenoid coil (2 used) 8. Proportional relief valve (port TS) 9. Sole[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 127 Fan Drive Manifold Service (Fig. 97) For fan drive manifold cartridge valve service proce- dures, see 4WD Manifold Service in this section. Refer to Figure 97 for fan drive manifold cartridge valve and plug installation torque. Hydraulic System[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 128 PT O Circuit 1. Gear pump 2. RH cutting deck motor 3. LH cutting deck motor 4. RH PTO manifold 5. Front cutting deck motor 6. LH PTO manifold 7. Front PTO manifold 8. Filter manifold 9. Oil cooler Figure 98 FRONT RIGHT 2 1 5 4 3 7 6 8 9 Figure 98 illustrates the components that are[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 129 Cutting Deck Motor Removal 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service an[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 130 Cutting Deck Motor Service 1. Rear cover 2. Drive gear 3. Seal 4. Woodruff key 5. Nut 6. T ab washer 7. Spider hub 8. Pressure seal 9. Back - - up ring 10. O - - ring 1 1. Body 12. Idler gear 13. Cap screw (4 used) 14. Front flange 15. Dowel pin Figure 101 8 7 4 3 1 2 5 6 9 10 11 1[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 131 IMPORT ANT : Mark the relative positions of the gear teeth and the bearing blocks so they can be re- assembled in the same position. Do not touch t he gear surfaces as residue on hands may be corrosive to gear finish. 7. Place the motor on its side and push on the rear bear- ing bl[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 132 Assembly (Fig. 101) NOTE: When assembling the motor , check the identifi- cation marks made during disassembly to make sure the parts are properly aligned during assembly . 1. Lubricate O - - rings, pressure seals, back - - up gaskets and seal grooves with a thin coat of petroleum [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 133 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 134 PT O Manifold 1. Hydraulic PTO manifold (front deck) 2. Quick fitting (1 used per manifold) 3. Flange nut 4. O - - ring 5. Hydraulic fitting 6. O - - ring 7. O - - ring 8. O - - ring 9. Hydraulic adapter 10. Straight fitting 1 1. Cap screw (2 used per manifold) 12. Dust cap 13. Hyd[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 135 Removal (Fig. 106) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter . 2. T o prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 136 PT O Manifold Service 1. PTO manifold body 2. NWD SAE #4 plug with O - - ring 3. Orifice (0.063) (port OR) 4. #8 zero leak plug with O - - ring 5. Relief valve (port RV2) 6. Solenoid valve (port S) 7. Solenoid coil 8. Nut 9. Relief valve (port RV1) 10. Spool logic cartridge (port L[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 137 PTO Manifold Service (Fig. 107) For PTO manifold solenoid and control valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 107 for PTO manifold cartridge valve and plug installation torque. Hydraulic System[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 138 Cutting Deck Lift/Lower Circuit 1. Front lift cylinder (2 used) 2. RH lift cylinder 3. LH lift cylinder 4. Fan drive manifold 5. Lift/lower manifold 6. Oil filter Figure 108 FRONT RIGHT 2 1 5 4 3 6 1 Figure 108 illustrates the components that are used in the Groundsmaster 4000 - - [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 139 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 140 Lift/Lower Manifold 1. Lift/lower manifold 2. Flange head screw (2 used) 3. W asher head screw (2 used) 4. Splash shield Figure 109 FRONT RIGHT 2 4 3 1 Removal (Fig. 109) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from t[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 141 6. Disconnect hydraulic lines from manifold and put caps or plugs on open hydraulic lines and fittings. Label disconnected hydraulic lines for proper installation. 7. Remove lift/lower manifold using Figure 109 as a guide. IMPORT ANT : The fitting in manifold port C2 in - cludes a [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 142 Lift/Lower Manifold Service 1. Lift/lower manifold body 2. Solenoid valve (S4, S6 & S9) 3. Solenoid coil (5 used) 4. Nut (8 used) 5. Relief valve (RV2) 6. Relief valve (RV1) 7. Solenoid valve (S1) 8. Nut 9. Solenoid coil (4 used) 10. Solenoid valve (S2, S3, S7 & S8) 1 1. #4[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 143 Lift/Lower Manifold Service (Fig. 1 12) W ARNING If lift/lower manifold is attached to machine, make sure that cutting decks are fully lowered before loosening hydraulic lines, cartridge valves or plugs from lift/lower manifold. If decks are not fully lowered when manifold componen[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 144 Side Deck Lift Cylinder 1. Lift arm assembly (LH shown) 2. Shoulder screw 3. Pin assembly 4. Lift cylinder 5. Flange locking nut 6. 90 o hydraulic fitting (2 used) 7. O - - ring 8. O - - ring 9. Cylinder pin 10. Spring pin 1 1. Lock nut 12. Flat washer Figure 1 13 11 12 9 10 3 2 4 [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 145 Removal (Fig. 1 13) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repai[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 146 Front Deck Lift Cylinder 1. Lift cylinder 2. Pivot pin 3. Cotter pin (2 used per pin) 4. Pin assembly 5. Cap screw 6. Flat washer 7. Lock nut 8. LH lift arm assembly 9. O - - ring 10. Straight hydraulic fitting 11 . O - - r i n g 12. 90 o hydraulic fitting 13. RH lift arm assembly [...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 147 Removal (Fig. 1 14) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repai[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 148 Lift Cylinder Service 1. Barrel with clevis 2. Retaining ring 3. Shaft with clevis 4. Dust seal 5. Rod seal 6. O - - ring 7. Back - - up ring 8. Head 9. O - - ring 10. Wear ring 11 . P i s t o n 12. Lock nut 13. Grease fitting 14. Bushing 15. O - - ring 16. Seal Figure 1 15 SIDE DE[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 149 Disassembly (Figs. 1 15 and 1 16) 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder . IMPORT ANT : Prevent damage when clamping the cylinder in a vise; clamp on the clevis only . 2. Mount li[...]

Groundsmaster 4000 - - D/4010 - - D Hydraulic System Page 4 - - 150 This page is intentionally blank.[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 1 Electrical System Chapter 5 Electrical System T able of Contents GENERAL INFORMA TION 2 ..................... Operator ’s Manual 2 .......................... T oro Electronic Controllers (TEC) 2 .............. CAN - - bus Communications 2 ................... Electrical Drawings 2 ..................[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 2 Electrical System General Information Operator ’s Manual The Operator ’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. T oro Electr[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 3 Electrical System Special T ools Order special tools from your T oro Distributor . Some tools may also be available from a local supplier . Multimeter The multimeter can test electrical components and cir- cuits for current, resistance or voltage. NOTE: T oro recommends the use of a DIGIT AL V olt - [...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 4 Electrical System Diagnostic Display The D iagnostic Display (Fig. 4) can be connected to the wiring harness communication connector located under the controller cover to verify correct electrical functions of the machine. T oro Electronic Controller (TEC) inputs and outputs can be checked using the [...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 5 Electrical System Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally . Figure 7 Electrical System[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 6 Electrical System T roubleshooting CAUTION Remove all jewelry , especially rings and watches, before doing any electrical trouble- shooting or testing. Also, disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting and repairs, you must have a good underst[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 7 Electrical System 4. T urn the ignition switch to the ON position, but do not start machine. NOTE: The red text on the Diagnostic Display overlay decal refers to input switches and the green text refers to TEC outputs. 5. Make sure that the “INPUTS DISPLA YED” L ED, on lower right column of the D[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 8 Electrical System Diagnostic Display TEC - - 5002 Master Inputs Diagnostic Display LED Operation P BRAKE OFF Parking brake released: LED ON Parking brake applied: LED OFF NEUTRAL T raction pedal in neutral: LED ON T raction pedal in forward or reverse: LED OFF SEA T SWITCH Operator seat occupied: LED[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 9 Electrical System Diagnostic Display TEC - - 5001 Slave Inputs Diagnostic Display LED Operation CD E C K RAISE Cutting deck lift switch for center deck in RAISE position: LED ON Lift switch for center deck NOT in RAISE position: LED OFF CD E C K LOWER Cutting deck lift switch for center deck in LOWER[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 1 0 Electrical System V erify Diagnostic Display Output Functions The Diagnostic Display also has the ability to detect which output solenoids or relays are energized by the TEC controllers. This is a quick way to determine if a ma- chine malfunction is electrical or hydraulic. NOTE: An open output (e.[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 1 1 Electrical System Starting Problems Problem Possible Causes No electrical power to machine (including gauges). The battery is discharged. The battery cables are loose or corroded. Fuse F3 - - 1 (2 amp) to the ignition switch is faulty . Bad ground connection on machine. The ignition switch or circu[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 1 2 Electrical System Starting Problems (Continued) Problem Possible Causes Engine cranks, but does not start. The fuel tank is empty . The engine is not cranking fast enough. Fuse F5 - - 1 (30 amp) is faulty preventing engine run solenoid pull coil from being energized. Fuse M1 (60 amp) is faulty prev[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 13 Electrical System General Run and T ransport Problems Engine continues to run, but should not, when the ignition switch is turned off. The engine run solenoid is faulty . The ignition switch or circuit wiring is faulty . Engine continues to run, but should not, when the traction pedal is depressed w[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 1 4 Electrical System Cutting Deck Operating Problems The cutting decks remain engaged, but should not, with no operator in the seat. The seat switch or circuit wiring is faulty . The TEC - - 5001 controller is faulty . Cutting deck runs, but should not, when raised. Decks shut off with PT O switch. Th[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 15 Electrical System Cutting Deck Lift/Lower Problems Problem Possible Causes None of the cutting decks will lower . The Hi/Low speed switch is in the Hi speed position. Operator is not fully depressing the seat switch. TEC - - 5001 fuse(s) (F4 - - 1, F4 - - 2, F4 - - 3, F4 - - 4) are faulty . The seat[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 1 6 Electrical System Cutting Deck Lift/Lower Problems (Continued) Problem Possible Causes RH wing cutting deck will not raise or lower , but the front and LH wing cutting decks will raise and lower . The RH deck lift switch or circuit wiring is faulty . Fuse F4 - - 3 is faulty . Lift control manifold [...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 17 Electrical System Adjustments Cutting Deck Position Switches Adjustment 1. Park machine on a level surface with front cutting deck raised and side cutting decks lowered. Stop en- gine, engage parking brake and remove key from the ignition switch. 2. There should be from 0.070” to 0.130” (1.8 to [...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 1 8 Electrical System Electrical System Quick Checks Battery T est (Open Circuit T est) Use a multimeter to measure the voltage between the battery terminals. Set multimeter to the DC volts setting. The battery should be at a temperature of 60 o to 100 o F( 1 6 o to 38 o C). The ignition key should be [...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 19 Electrical System Check Operation of Interlock Switches CAUTION Do not disconnect safety switches. They are for the operator ’ s protection. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before op- erating the machine. Interlock switc[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 2 0 Electrical System Component T esting For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before checking continuity on the switch). NOTE: For engine component testing information, see the [...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 21 Electrical System Fuses The fuse blocks are located in the power center under the hood on the right side of the machine (Fig. 17). In addition to the fuses in the fuse blocks, a 40 amp fuse (F5 - - 1) is included in the wire harness to protect the pull coil circuit for the engine run solenoid. This [...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 2 2 Electrical System Operator Cab Fuses (Groundsmaster 4010 - - D) The cab fuse blocks are located in the cab headliner (Fig. 19). Identification and Function (Figs. 19 and 20) Fuse F1 - - 2 (15 Amp) protects the cab fan circuit. Fuse F1 - - 3 (30 Amp) protects the air conditioner circuit. Fuse F2 - -[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 23 Electrical System W arning Lights Charge Indicator Light The charge indicator light should come on w hen the igni- tion switch is in ON with the engine not running or with an improperly operating charging circuit while the en- gine is running. T o test the c harge indicator light and circuit w iring[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 2 4 Electrical System PT O Switch The PT O switch is located on the console arm (Fig. 23). The PTO switch is pulled up to engage the PTO and pushed in to disengage the PTO. The TEC - - 5001 controller monitors the position of the PTO switch (up or down). Using inputs from the PT O switch and other swit[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 25 Electrical System Cutting Deck Lift Switches The cutting deck lift switches are used as inputs for the TEC - - 5001 controller to raise or lower the cutting decks. When the front of a lift switch is depressed and held, the controlled decks will lower . When the rear of a lift switch is depressed and[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 2 6 Electrical System Hi/Low Speed and Headlight (Groundsmaster 4010 - - D) Switches The Hi/Low speed and headlight switches (Ground- smaster 4010 - - D) are identical, two (2) position rocker switches that are located on the control console. The Hi/Low speed switch (Fig. 27) is used as an input for th[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 27 Electrical System Flow Divider and Engine Cooling Fan Switches The flow divider and engine cooling fan switches are identical, two (2) position rocker switches that are lo- cated on the control console (Fig. 29). These switches have a normal and a momentary position. The flow divider switch is used [...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 2 8 Electrical System Seat Switch The seat switch is normally open and closes when the operator is on the seat. This switch is used as an input for the TEC - - 5002 controller . The seat switch and its electrical connector are located in the seat assembly . If the traction system or PTO switch is engag[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 29 Electrical System Parking Brake Switch The switch used for the parking brake is a normally open switch that is located under the steering tower cover (Fig. 32). The brake switch is used as an input for the TEC - - 5002 controller . When the parking brake is not ap- plied, the parking brake pawl depr[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 3 0 Electrical System Windshield Wiper/W asher Switch (Groundsmaster 4010 - - D) The windshield wiper/washer switch is used to control operation of the windshield wiper and washer pump on the Groundsmaster 4010 - - D. The windshield wiper/wa- sher switch is located in the cab headliner (Fig. 33). T est[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 31 Electrical System Air Conditioning Switch (Groundsmaster 4010 - - D) The air conditioning switch is used to control operation of the air conditioning system on the Groundsmaster 4010 - - D. The s witch is located in the cab headliner (Fig. 35). T esting 1. Make sure igniti on switch is OFF . Remove [...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 3 2 Electrical System Hour Meter The hour meter is located on the outside of the c onsole arm. T esting 1. Make sure igniti on switch is OFF . Remove key from ignition switch. 2. Disassemble console arm to gain access to the hour meter (see Console Arm Disassembly in the Service and Repairs section of [...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 33 Electrical System Main Power , Glow and Operator Cab Power (Groundsmaster 4010 - - D) Relays The main power , glow and operator cab power relays are located at the power center behind the operator seat (Fig. 39). The wire harness is attached to these relays with a four (4) wire connector (Fig. 40). [...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 3 4 Electrical System Start and Air Conditioning (G roundsmaster 4010 - - D) Relays When energized by the TEC - - 5002 controller , the start relay is used to provide current to the engine starter mo- tor solenoid. The start relay is located at the power cen- ter behind the operator seat (Fig. 41). An [...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 35 Electrical System T oro Electronic Controllers (TEC) Groundsmaster 4000 - - D and 4010 - - D machines use two T oro Electronic C ontrollers (TEC) to control electrical system operation. The controllers are attached to the operator platform under the controller cover (Figs. 43 and 44). Logic power is[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 3 6 Electrical System Hydraulic V alve Solenoids Figure 45 1. 4WD manifold 2. LH PTO manifold 3. T raction manifold 4. Front PTO manifold 5. Fan drive manifold 6. RH PTO manifold 7. Lift/lower manifold FRONT RIGHT 1 2 3 4 5 6 7 Several hydraulic solenoid valve coils are used on the hydraulic control ma[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 37 Electrical System T esting 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Locate hydraulic valve solenoid coil to be tested (Fig. 45). Disconnect wire harness connector from coil. 3. Identify coil resistance spec[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 3 8 Electrical System T raction Neutral Switch The traction neutral switch is closed when the traction pedal is in the neutral position and opens when the pedal is depressed in either direction (forward or reverse). The neutral switch is used as an input to the TEC - - 5002 con- troller . The switch is[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 39 Electrical System Fuel Sender The fuel sender is located on top of the fuel tank. T esting 1. Make sure igniti on switch is OFF . Remove key from ignition switch. 2. Remove white (+) wire and black (- - ) wire from the fuel sender . CAUTION If testing circuit wiring and fuel gauge, make sure wire co[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 4 0 Electrical System Fuel Gauge The fuel gauge can be tested using a new gauge as a substitute or with the use of a DC voltage source and a variable resistance box. T esting 1. Make sure igniti on switch is OFF . Remove key from ignition switch. 2. Locate fuel gauge for testing (see Steering T ower Di[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 41 Electrical System Fuel Pump The fuel pump is attached to the frame above the fuel water separator (Fig. 54). Operational T est 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake. 2. Remove fuse F1- - 1 (20 amp) (Fig. 55) from fuse block to prevent the engine[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 4 2 Electrical System T emperature Sender The temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 56). The resistance of the temperature sender re- duces as the engine coolant temperature increases. There is a gray harness wire attached to th[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 43 Electrical System T emperature Gauge The temperature gauge on the control panel indicates engine coolant temperature level during machine op- eration ( Fig. 58). The changing resistance of the engine temperature sender signals the temperature gauge. The temperature gauge should display the first gre[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 4 4 Electrical System Cutting Deck Position Switches Three (3) cutting deck position switches are used on the Groundsmaster 4000 - - D and 4010 - - D. These switches are located on the traction unit frame (Figs. 59 and 60). The position switches are powered proximity switches that incorporate an intern[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 45 Electrical System B. Make sure that ignition switch is OFF and discon- nect the switch connector from wire harness. C. Using a multimeter , verify that wire harness con- nector terminal for pink wire has 12 VDC when the ignition switch is ON. D. Make sure that clearance between end of posi- tion swi[...]

Rev . A Groundsmaster 4000- - D/4010 - - D Page 5 - - 4 6 Elect rical System Engine Coolant and Hydraulic Oil T emperature Senders The Groundsmaster 4000- - D and 4010 - - D use two (2) temperature senders as inputs for the TEC- - 5002 to identify if either the engine coolant or hydraulic oil tem- perature has reached an excessive level. These send[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 47 Electrical System Service and Repairs NOTE: For engine component repair information (e.g. starter motor), see the Kubota Workshop Manual, Die- sel Engine, 03 - - M - - E3B Series at the end of Chapter 3 - - Kubota Diesel Engine. Battery Storage If the machine will be stored for more than 30 days: 1.[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 4 8 Electrical System Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally , battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid splashing[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 49 Electrical System Battery T esting 1. Conduct a hydrometer test of the battery electrolyte. IMPORT ANT : Make sure the area around the cells is clean before opening the battery caps. A. Measure the specific gravity of each cell with a hydrometer . Draw electrolyte in and out of the hydrometer barrel[...]

Groundsmaster 4000 - - D/4010 - - D Page 5 - - 5 0 Electrical System Battery Charging T o minimize possible damage to the battery and allow the battery to be fully charged, the slow charging meth- od is presented here. This charging method can be ac- complished with a constant current battery charger which is readily available. CAUTION Follow the m[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 1 Axles, Planetaries and Brakes Chapter 6 Axles, Planetaries and Brakes T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ..................... Operator ’s Manual 3 .......................... SERVICE AND REP AIRS 4 ...................... Brake Assembly 4 ......[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 2 Axles, Planetaries and Brakes Specifications Item Specification T ire pressure (front and rear) 25 to 30 PSI (172 to 207 kPa) Rear wheel toe - - in 0.125 in (3.18 mm) Planetary gear drive oil SAE 85W - - 140 wt. gear lube System gear lube capacity (each wheel) 16 fl. oz. (0.47 liters) Rear axle lubri[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 3 Axles, Planetaries and Brakes General Information Operator ’s Manual The Operator ’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. [...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 4 Axles, Planetaries and Brakes Service and Repairs Brake Assembly 1. Planetary assembly 2. Retaining ring 3. Splined brake shaft 4. Brake assembly (RH) 5. O - - ring 6. Hydraulic wheel motor 7. Flat washer (2 used per side) 8. Cap screw (2 used per side) 9. Flange head screw (4 used per side) 10. Brak[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 5 Axles, Planetaries and Brakes Removal (Fig. 1) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch. 2. Drain oil from planetary wheel drive/brake assembly . CAUTION When removing front wheel, use correct jacks and supports. Make sure machine is[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 6 Axles, Planetaries and Brakes 2. Apply gasket sealant to sealing surfaces of new gas- ket (item 18). Apply gasket to brake assembly . 3. Install brake assembly onto machine, aligning splined brake shaft with input shaft on planetary wheel drive. 4. Secure brake assembly to planetary assembly with fou[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 7 Axles, Planetaries and Brakes This page is intentionally blank. Axles, Planetaries and Brakes[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 8 Axles, Planetaries and Brakes Brake Inspection and Repair 1. Brake housing (LH shown) 2. Seal 3. Pull rod 4. Clevis pin (2 used) 5. Link (2 used) 6. Hitch pin (2 used) 7. Stationary disc (4 used) 8. Rotating disc (3 used) 9. Retaining ring 10. Gasket 1 1. Rotating actuator 12. Extension spring (3 use[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 9 Axles, Planetaries and Brakes This page is intentionally blank. Axles, Planetaries and Brakes[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 1 0 Axles, Planetaries and Brakes Planetary Wheel Drive Assembly 1. Planetary assembly 2. Retaining ring 3. Splined brake shaft 4. Brake assembly (RH) 5. O - - ring 6. Hydraulic wheel motor 7. Flat washer (2 used per side) 8. Cap screw (2 used per side) 9. Flange head screw (4 used per side) 10. Brake [...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 1 1 Axles, Planetaries and Brakes NOTE: The planetary wheel drive assembly can be ser- viced with the planetary installed to machine (see Plane- tary Wheel Drive Service in this section). Use the following procedure to remove and install planetary wheel drive assembly from machine. Removal (Fig. 7) 1. [...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 1 2 Axles, Planetaries and Brakes Planetary Wheel Drive Service 1. Spindle 2. Boot seal 3. Inner bearing cone 4. Inner bearing cup 5. Wheel stud (8 used) 6. Housing 7. Outer bearing cup 8. Outer bearing cone 9. Thrust washer 10. Retaining ring (external) 1 1. Ring gear 12. Retaining ring (internal) 13.[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 13 Axles, Planetaries and Brakes NOTE: The planetary wheel drive assembly can be ser- viced with the planetary installed to machine. If the spindle (item 1) needs to be removed from machine, see Planetary Wheel Drive Assembly Removal in this sec- tion. Disassembly (Figs. 9 and 10) 1. If planetary wheel[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 1 4 Axles, Planetaries and Brakes F . Lightly oil bearing journals on spindle shaft. Slide housing onto spindle (item 1) taking care to not dam- age seal or spindle. Make sure that bearing in hous- ing fully seats against spindle shaft shoulder . G. Install outer bearing cone (item 8) onto spindle. NOT[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 15 Axles, Planetaries and Brakes This page is intentionally blank. Axles, Planetaries and Brakes[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 1 6 Axles, Planetaries and Brakes Rear Axle Assembly 1. Frame assembly 2. Cap screw (10 used) 3. Lock washer (6 used) 4. Flat washer (16 used) 5. Support frame 6. Thrust washer (thick) 7. Grease fitting 8. Rear axle assembly 9. Thrust washer (thin) 10. Washer head screw 1 1. P ivot pin 12. Rear axle mo[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 17 Axles, Planetaries and Brakes 8. Remove cap screw and flange nut that secures front corner of 4WD hydraulic manifold to rear axle mount bracket. 9. If required, remove tie rod ends from steering arms on rear axle (Fig. 13). Remove the cotter pins and castle nuts from the tie rod ball joints. Use a b[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 1 8 Axles, Planetaries and Brakes 8. Install steering cylinder to axle assembly (see Steer- ing Cylinder Installation in the Service and Repairs sec- tion of Chapter 4 - - Hydraulic System). 9. Install hydraulic motor to axle assembly (see Rear Axle Motor Installation in the Service and Repairs sec- ti[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 19 Axles, Planetaries and Brakes This page is intentionally blank. Axles, Planetaries and Brakes[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 2 0 Axles, Planetaries and Brakes Rear Axle Service Figure 16 3 2 4 5 6 7 8 9 10 14 13 12 11 15 1 10 11 8 9 8 13 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 20 41 42 43 50 44 45 46 47 48 49 51 54 55 56 57 58 59 52 53 60 61 62 63 22 9[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 21 Axles, Planetaries and Brakes 1. LH axle support 2. Flange bushing (2 used) 3. Axle vent 4. O - - ring 5. V ent extension 6. Cap screw (4 used per gear case) 7. Shim set 8. Seal washer 9. Plug 10. Lock nut 1 1. Lock washer 12. Grease fitting 13. Ball bearing 14. Screw (2 used per steering arm) 15. A[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 2 2 Axles, Planetaries and Brakes Bevel Gear Case and Axle Case The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove the mounting screws, nuts and lock wash- ers. Remove the bevel gear case/axle case assembly and O-ring from the axle support (Fig[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 23 Axles, Planetaries and Brakes 5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gas- ket material from either mating surface (Fig. 20). 6. While holding the bevel gear case, tap the upper end of the bevel gear shaft out of the upper bearing and up- pe[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 2 4 Axles, Planetaries and Brakes Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 22). 1. Axle case 2. Bevel gear case 3. Shaft seal Figure 22 1 2 3 2. Install the lower bevel gear and bevel gear shaft in the axle case cover . Coat a new O-ring with grease and in[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 25 Axles, Planetaries and Brakes 5. Determine necessary quantity of support shims. A. Lubricate the axle case support bushing with a thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during disassembly between axle case support and axle case. [...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 2 6 Axles, Planetaries and Brakes 9. Remove the bevel gear case/axle case assembly from the axle support. Coat a new O-ring with grease and temporarily install the axle cover assembly . Position a dial indicator at the tooths center . Prevent the axle from turning and measure the lower bevel gear to ax[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 27 Axles, Planetaries and Brakes Axle Shafts The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove the axle cover mounting screws. Remove t h ea x l ec o v e rf r o mt h ea x l ec a s ea sa na s s e m b l y (Fig. 29). 2. Use a bearing puller to re[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 2 8 Axles, Planetaries and Brakes Input Shaft/Pinion Gear Figure 32 1 1. Nut (2 used) 2. Lock washer (2 used) 3. Stud (2 used) 4. Lock nut 5. Stake washer 6. Oil seal 7. O-ring 8. Seal collar 9. Bearing 10. O-ring 1 1. I nput shaft/pinion gear 12. Bearing case 13. Shim 14. Screw (2 used) 15. Gear case [...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 29 Axles, Planetaries and Brakes 5. Install a new stake washer . Install the lock nut finger tight. 6. Set the bearing preload by securing the bearing case in a vise. Thread a M12 x 1.5 hex head cap screw into the splined end of the input shaft/pinion gear and slowly tighten the lock nut until 4 to 6 i[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 3 0 Axles, Planetaries and Brakes Differential Gear The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual). IMPORT ANT : Do not interchange[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 31 Axles, Planetaries and Brakes Inspection 1. Measure the dif ferential side gear O.D. and the dif- ferential case I.D. to determine the side gear to case clearance (Fig. 39). Replace components as necessary . SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 in. (0.05 to 0.30 mm) SIDE GEAR O.D. (Factory Sp[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 3 2 Axles, Planetaries and Brakes Installation 1. If the ring gear was removed from the differential case, use medium strength Loctite thread locker and tighten the mounting screws from 22 to 25 ft-lb (30 to 34 N - - m) . 2. Apply molybdenum disulfide lubricant (Three Bond 1901 or equivalent) to the sp[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 33 Axles, Planetaries and Brakes Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using the gear contact pattern method as described in the fol- lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 43): To e - - the portion of the tooth surface at the end to- wards the[...]

Groundsmaster 4000 - - D/4010 - - D Page 6 - - 3 4 Axles, Planetaries and Brakes Gear Pattern Movement Summary Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as gear location is changed. 1. If contact is toward t he heel or base of the gear (Fig. 46): A. Install thicker or additi[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 1 Chassis Chapter 7 Chassis T able of Contents GENERAL INFORMA TION 1 ..................... Operator ’s Manual 1 .......................... SERVICE AND REP AIRS 2 ...................... Steering T ower 2 .............................. Front Deck Lift Arm 4 .......................... Side Deck Lift Ar[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 2 Chassis Service and Repairs Steering T ower 1. Hex nut 2. Flat washer 3. Steering wheel 4. Foam collar 5. Steering seal 6. External snap ring (2 used) 7. Knob 8. Steering tower cover 9. Steering shaft 10. Compression spring 11 . C a p 12. Rod assembly 13. Extension spring 14. Tilt rod 15. Lock nut (2[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 3 Chassis Disassembly (Fig. 1) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Disassemble steering tower as needed using Figure 1 as a guide. Assembly (Fig. 1) 1. Assemble steering tower using Figure 1 as a guide. A.[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 4 Chassis Front Deck Lift Arm 1. Flange bushing 2. Ball joint 3. Lock nut (2 per mount) 4. Clevis pin 5. Height - - of - - cut chain 6. U - - bolt 7. Hex nut (2 per u - - bolt) 8. Flat washer (4 per u - - bolt) 9. Lock nut (2 per u - - bolt) 10. Lock nut 1 1. Grease fitting (45 o ) 12. Grease fitting 1[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 5 Chassis CAUTION When changing attachments, tires or perform- ing other service, use correct jacks and sup - ports. 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 t[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 6 Chassis Side Deck Lift Arm 1. Lift arm (LH shown) 2. Shoulder screw 3. Lift cylinder pin 4. Lift cylinder 5. Thrust washer 6. Flange nut 7. Pivot hub 8. Lift arm pivot shaft 9. Thrust washer 10. Cap screw 1 1. Spring pin 12. Cylinder pin 13. Rivet (2 per bumper) 14. Rubber bumper 15. Slotted roll pin[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 7 Chassis Removal (Fig. 5) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove side deck from lift arm (see Side Cutting Deck Removal in Chapter 8 - - Cutting Decks). 3. Remove side deck rear arm assembly from pivo[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 8 Chassis Side Deck Rear Arm Assembly 1. Cutting deck (LH shown) 2. Deck mount (LH shown) 3. Cap screw 4. Lock nut 5. Clevis pin 6. Hair pin 7. Spacer 8. Rod end 9. Jam nut 10. Cap screw (4 per arm) 1 1. S traight bushing 12. Spring shaft 13. Flat washer 14. Compression spring 15. Plastic bearing 16. L[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 9 Chassis Rear Arm Removal (Fig. 8) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove hair pin and clevis pin that connects damper link to cutting deck (Fig. 9). 3. Remove cap screw and lock nut that secures rod [...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 1 0 Chassis Rear Arm Installation (Fig. 8) 1. Position rear arm assembly to cutting deck and frame. 2. Slide pivot shaft through rear arm clevis and hub. Se- cure pivot shaft with lock washer and lock nut. 3. Connect damper link to cutting deck with clevis pin and hair pin (Fig. 9). 4. Position spacers[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 1 1 Chassis This page is intentionally blank. Chassis[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 1 2 Chassis Lift Arm Joint Y oke 1. Side cutting deck (LH shown) 2. Deck mount (LH shown) 3. Retaining ring (2 used per deck) 4. Lock nut 5. Plate 6. Rubber plate 7. Cap screw 8. Flat washer (8 used per mount) 9. Joint yoke 10. Spacer 1 1. Thrust washer (0.125” thickness) 12. Hardened washer 13. Cott[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 13 Chassis Joint Y oke Disassembly 1. Remove retaining rings from yoke and deck mount. IMPORT ANT : S upport yoke when removing cross and bearings to prevent yoke damage. 2. Use a press to remove yoke from deck mount: A. Place a small socket against one bearing in the deck mount and a large socket on t[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 1 4 Chassis Console Arm 1. Flange nut (3 used) 2. Flange head screw (2 used) 3. Foam seal 4. W asher head screw (10 used) 5. LH cover 6. Hi - - low speed switch 7. Lock nut (3 used) 8. Throttle control 9. Control arm 10. Diagnostic light 1 1. I gnition switch 12. Button plug 13. Screw (2 used) 14. Warn[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 15 Chassis Disassembly (Fig. 13) 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 2. Remove two (2) flange head screws (item 40) and then cover plate (item 39) from outside of console arm. Locate and retrieve two (2) spacers[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 1 6 Chassis Operator Seat 1. Platform 2. Clevis pin (2 used) 3. Hair pin (2 used) 4. Seat plate 5. Grommet 6. Cotter pin (2 used) 7. Latch shaft 8. Cap screws (4 used) 9. Latch 10. T orsion spring 11 . P r o p r o d 12. Flange nut (4 used) 13. Cotter pin (2 used) 14. Flat washer (2 used) 15. Flat washe[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 17 Chassis Removal (Fig. 15) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Disconnect seat electrical connector from machine wire harness (Fig. 16). 3. Support console arm assembly to prevent it from shifting. 4. Re[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 1 8 Chassis Operator Seat Service 1. Backrest cushion 2. Seat cushion 3. Armrest cover 4. LH armrest 5. Bushing (2 used) 6. Backrest 7. Plug (2 used) 8. Cable tie (3 used) 9. LH adjustment rail 10. Bumper (2 used) 1 1. W asher 12. Cap screw (2 used) 13. Seat 14. Nut 15. Spring (2 used) 16. Magnet 17. S[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 19 Chassis Disassembly (Fig. 18) 1. Disassemble operator seat as necessary using Fig- ures 18 and 19 as guides. Assembly (Fig. 18) 1. Assemble operator seat using Figures 18 and 19 as guides. 1. Operator seat 2. R - - clamp 3. Screw 4. Manual tube 5. Button head screw 6. Seat belt 7. Flat washer 8. Loc[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 2 0 Chassis Operator Seat Suspension 1. Cover 2. Cover 3. Level control 4. Air control valve 5. Shock absorber 6. Air spring 7. Air tube assembly 8. Wire harness 9. Compressor 10. Bellows 11 . S t o p 12. Bumper set (2 used) 13. Roller (4 used) 14. Washer (2 used) 15. T ether 16. Rivet (2 used) 17. Was[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 21 Chassis NOTE: Most of the seat suspension components can be serviced with the seat suspension base mounted to the frame platform. If the air spring assembly (item 6) re- quires removal, the seat suspension base will have to be removed from the seat platform. Disassembly (Fig. 20) 1. Remove operator [...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 2 2 Chassis Hood 1. Rear screen 2. T op screen 3. Screen assembly 4. Bulb seal 5. Bulb seal 6. Corner screen seal (2 used) 7. Hair pin (2 used) 8. Screw (8 used) 9. Screen pivot (2 used) 10. Hood pivot (2 used) 1 1. Hood 12. Carriage bolt (2 used) 13. Flange nut (2 used) 14. Door handle (2 used) 15. Fl[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 23 Chassis Removal 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove hood using Figure 23 as a guide. Installation 1. Install hood using Figure 23 as a guide. 2. Align hood to machine to allow correct operation o[...]

Groundsmaster 4000 - - D/4010 - - D Page 7 - - 2 4 Chassis This page is intentionally blank.[...]

Groundsmaster 4000 - - D/4010 - - D Cutting Decks Page 8 - - 1 Chapter 8 Cutting Decks T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ..................... Operator ’s Manual 3 .......................... Castor Wheel T ire Pressure 3 .................. Blade Stopping T ime 3 ........................ TROU[...]

Groundsmaster 4000 - - D/4010 - - D Cutting Decks Page 8 - - 2 Specifications MOUNTING: Cutting decks are supported by lift arms controlled with individual lift switches. CONSTRUCTION: Deck chamber is welded 12 gauge steel construction reinforced with channels and plates. HEIGHT - - OF - - CUT RANGE: 1” to 5” (25.4 mm to 127 mm) in 1/2” (12.7[...]

Groundsmaster 4000 - - D/4010 - - D Cutting Decks Page 8 - - 3 General Information CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop en- gine and remove key first. Operator ’s Manual The Operator ’s Manual provides information regarding the operation, general maintenance and maintenance interva[...]

Groundsmaster 4000 - - D/4010 - - D Cutting Decks Page 8 - - 4 T roubleshooting There are a number of factors that can contribute to un- satisfactory quality of cut, some of which may be turf conditions. T urf conditions such as excessive thatch, uneven ground conditions, “sponginess” or attempting to cut off too much grass height may not alway[...]

Groundsmaster 4000 - - D/4010 - - D Cutting Decks Page 8 - - 5 This page is intentionally blank. Cutting Decks[...]

Groundsmaster 4000 - - D/4010 - - D Cutting Decks Page 8 - - 6 Service and Repairs CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop en- gine and remove key from ignition switch first. Front Cutting Deck 1. Flange bushing 2. Ball joint 3. Lock nut (2 per mount) 4. Clevis pin 5. Height - - of - - cu[...]

Groundsmaster 4000 - - D/4010 - - D Cutting Decks Page 8 - - 7 Removal (Fig. 1) 1. Position machine on a clean, level surface. Lower cutting decks, stop engine, apply parking brake and re- move key from the ignition switch. NOTE: Removal of clevis pin from deck and height - - of - - cut chain is easier if deck is lifted slightly . 2. Remove hairpin[...]

Groundsmaster 4000 - - D/4010 - - D Cutting Decks Page 8 - - 8 Side Cutting Deck 1. Cutting deck (LH shown) 2. Deck mount (LH shown) 3. Cap screw 4. Lock nut 5. Clevis pin 6. Hair pin 7. Spacer 8. Rod end 9. Jam nut 10. Cap screw (4 per arm) 1 1. S traight bushing 12. Spring shaft 13. Flat washer 14. Compression spring 15. Plastic bearing 16. Lock [...]

Groundsmaster 4000 - - D/4010 - - D Cutting Decks Page 8 - - 9 Removal (Fig. 5) 1. Position machine on a clean, level surface. Lower cutting decks, stop engine, apply parking brake and re- move key from the ignition switch. 2. Remove hydraulic motor from cutting deck (see Cut- ting Deck Motor Removal in the Service and Repairs Section of Chapter 4 [...]

Groundsmaster 4000 - - D/4010 - - D Cutting Decks Page 8 - - 1 0 Idler Assembly FRONT RIGHT 6 7 8 9 10 11 12 15 16 13 14 17 18 19 1 2 4 3 5 20 23 21 24 22 1. Cutting deck (front shown) 2. Flange nut 3. Flange nut 4. Adjusting screw 5. Idler pulley 6. Driven spindle (double pulley shown) 7. Flat washer 8. Lock washer 9. Socket head screw 10. Idler s[...]

Groundsmaster 4000 - - D/4010 - - D Cutting Decks Page 8 - - 1 1 Removal (Fig. 9) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove deck covers from top of cutting deck. CAUTION Be careful when removing idler spring. The spring is under heavy load and may cau[...]

Groundsmaster 4000 - - D/4010 - - D Cutting Decks Page 8 - - 1 2 Blade Spindles 1. Front cutting deck 2. RH cutting deck 3. LH cutting deck 4. Drive spindle 5. Driven spindle 6. Grease fitting location Figure 1 1 FRONT RIGHT 1 2 3 4 5 6 4 4 5 5 6 6 6 6 6[...]

Groundsmaster 4000 - - D/4010 - - D Cutting Decks Page 8 - - 13 Removal (Figs. 1 1 and 12) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove covers from cut ting deck to allow access to blade spindle. 3. If drive spindle is to be serviced, remove hydraulic mo[...]

Groundsmaster 4000 - - D/4010 - - D Cutting Decks Page 8 - - 1 4 Blade Spindle Service 1. Lock nut 2. Hardened washer 3. Driven pulley (single shown) 4. Spindle shaft 5. Drive pulley 6. Hydraulic motor mount 7. O - - ring 8. Oil seal 9. Bearing cup and cone 10. Spacer set 1 1. S pindle housing 12. Grease fitting 13. Spindle shaft spacer Figure 13 1[...]

Groundsmaster 4000 - - D/4010 - - D Cutting Decks Page 8 - - 15 2. Install outer bearing spacer into top of spindle hous- ing. The spacer should fit against the snap ring. 3. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the outer bearing spacer previously installed, and[...]

Groundsmaster 4000 - - D/4010 - - D Cutting Decks Page 8 - - 1 6 Castor Forks and Wheels 1. Castor arm (front deck) 2. Cap screw (5 used) 3. Castor fork 4. Cap screw 5. Lock nut 6. Castor spacer 7. Thrust washer 8. Flange nut (5 used) 9. Grease fitting 10. Flange bushing 1 1. Retaining ring 12. Cap washer 13. Compression spring 14. Cap 15. Flat was[...]

Groundsmaster 4010 - - D Operator Cab Page 9 - - 1 Chapter 9 Operator Cab T able of Contents GENERAL INFORMA TION 2 ..................... Operator ’s Manual 2 .......................... Electrical Components and Schematic 2 ......... Air Conditioning System 2 ...................... Cab Heater System 2 .......................... SERVICE AND REP AI[...]

Groundsmaster 4010 - - D Operator Cab Page 9 - - 2 General Information The information in this chapter pertains to the operator cab on the Groundsmaster 4010 - - D. Operator ’s Manual The Operator ’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster . Refer to the Opera- to[...]

Groundsmaster 4010 - - D Operator Cab Page 9 - - 3 Service and Repairs General Precautions for Removing and Installing Air Conditioning System Components CAUTION The air conditioning system is under high pres - sure. Do not loosen any system fitting or compo - nent until after the system has been completely discharged by a certified A/C service tec[...]

Groundsmaster 4010 - - D Operator Cab Page 9 - - 4 Air Conditioning Compressor Figure 1 FRONT RIGHT 1. Cap screw (3 used) 2. Lock washer (8 used) 3. Pulley 4. V - - belt 5. Lower radiator hose 6. Hose clamp (2 used) 7. Lower radiator hose 8. Cap screw (3 used) 9. Alternator plate 10. Carriage screw 1 1. Flat washer 12. Idler pulley 13. Idler plate [...]

Groundsmaster 4010 - - D Operator Cab Page 9 - - 5 5. Disconnect compressor electrical connector from machine wire harness. 6. Read the General Precautions for Removing and Installing Air Conditioning System Components at t he beginning of the Service and Repairs section of this chapter . CAUTION The air conditioning system is under high pres - sur[...]

Groundsmaster 4010 - - D Operator Cab Page 9 - - 6 Roof Assembly 1. Roof 2. Screw (2 used) 3. Flat washer (6 used) 4. Bushing (10 used) 5. Rear fastener (2 used) 6. Rear spacer (2 used) 7. Panel nut 8. Roof mount 9. Flange nut (2 used) 10. Flange nut (4 used) 1 1. Headliner 12. Front spacer (2 used) 13. Front fastener (2 used) 14. Rubber washer 15.[...]

Groundsmaster 4010 - - D Operator Cab Page 9 - - 7 T o gain access to the heater core and air conditioning components that are located under the cab roof, the roof panel can be loosened, raised and supported. Removal (Fig. 3) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition [...]

Groundsmaster 4010 - - D Operator Cab Page 9 - - 8 Air Conditioning Condenser Assembly 1. Condenser cover 2. Lock nut (4 used) 3. Condenser fan 4. Condenser coil assembly 5. Carriage screw (2 used) 6. Flat washer (8 used) 7. Roof 8. Bushing (4 used) 9. Mounting strap 10. Button head screw (4 used) Figure 5 2 1 3 4 7 8 5 9 6 2 6 6 8 10 Removal (Fig.[...]

Groundsmaster 4010 - - D Operator Cab Page 9 - - 9 8. Label and remove hoses from condenser coil. Imme- diately cap hoses and fittings to prevent moisture and contaminants from entering the system. 9. Remove condenser coil from roof using Figure 6 as a guide. NOTE: The replacement of the drier - - receiver is recom- mended whenever the air conditio[...]

Groundsmaster 4010 - - D Operator Cab Page 9 - - 10 Heater/Evaporator Assembly 1. Heater/evaporator assembly 2. T op cover 3. Flange head screw (2 used) 4. Drier - - r eceiver mount 5. Bottom cover 6. Hose clamp (2 used) 7. Speed nut (8 used) 8. Panel nut (4 used) 9. Drier - - receiver assembly 10. Screw (8 used) 1 1. S crew (5 used) Figure 7 2 1 3[...]

Groundsmaster 4010 - - D Operator Cab Page 9 - - 1 1 CAUTION The air conditioning system is under high pres - sure. Do not loosen any system fitting or compo - nent until after the system has been completely discharged by a certified A/C service technician. 5. Have refrigerant evacuated from air conditioning system by a certified A/C service techni[...]

Groundsmaster 4010 - - D Operator Cab Page 9 - - 12 This page is intentionally blank.[...]

Groundsmaster 4000 - - D/4010 - - D Foldout Drawings Page 10 - - 1 Chapter 10 Foldout Drawings T able of Contents HYDRAULIC SCHEMA TIC 3 ..................... ELECTRICAL SCHEMA TICS Sheet 1 of 3 4 ................................ Sheet 2 of 3 5 ................................ Sheet 3 of 3 6 ................................ Operator Cab 7 .........[...]

Groundsmaster 4000 - - D/4010 - - D Foldout Drawings Page 10 - - 2 This page is intentionally blank.[...]

Rev . A Page 10 - - 3 Hydr aulic S chem atic Groundsmaster 4000 - - D/4010 - - D FRON T PTO MANI F OLD FAN DRIVE MANI F OLD RH PTO MANI F OLD 4WD MANI F OLD LH PTO MANI F OLD TRACTIO N MANI F OLD FIL TER MANI F OLD S1 S2 S3 S4 S5 S7 S6 S8 RV1 RV2 S9 LIFT/LO WER MANI F OLD BYPASS VAL V E M1 M2 S T L T P1 P2 .035 .063 .063 .070[...]

Page 10 - - 4 Ele ct ric al Sc h ema ti c Groundsmaster 4000 - - D/4010 - - D All r elays and so lenoid s are shown as de - - energized. All gr ound wir es are black. Sheet 1 of 3 WHEN A CONDUCTOR CONTINUES ON ANOTHER S HEE T , THE SHE ET NUMBER W ILL BE IDENTIFIED. NOTE: THE ELECTRICAL SCHEMA TIC IS S HOWN ON THREE (3) SHEETS . ST ANDARD ON GM4010[...]

Page 10 - - 5 Ele ct ric al Sc h ema ti c Groundsmaster 4000 - - D/4010 - - D All r elays and so lenoid s are shown as de - - energized. All gr ound wir es are black. She et 2 o f 3 WHEN A CONDUCTOR CONTINUES ON ANOTHER S HEE T , THE SHE ET NUMBER W ILL BE IDENTIFIED. NOTE: THE ELECTRICAL SCHEMA TIC IS S HOWN ON THREE (3) SHEETS . (NOT IN NEUTRAL) [...]

Page 10 - - 6 Electr ical Schematic Groundsmaster 4000 - - D/4010 - - D All r elays and so lenoid s are shown as de - - energized. All gr ound wir es are black. Sheet 3 of 3 WHEN A CONDUCTOR CONTINUES ON ANOTHER S HEE T , THE SHE ET NUMBER W ILL BE IDENTIFIED. NOTE: THE ELECTRICAL SCHEMA TIC IS S HOWN ON THREE (3) SHEETS .[...]

Page 10 - - 7 Electr ical Schematic Groundsmaster 4010 - - D All r elays and so lenoid s are shown as de - - energized. All gr ound wir es are black. Operator Cab 1 2 BK 1F 1 R R R PK VIO 4 3 L H Y OR VIO VIO W/BK OR BU GN BK OR/B K 05- - B 05- - A BK/W BU W R/W VIO W/BK GN P05- - G BK/W OR/B K PWR GND P1 1 - - 4 P1 1 - - 1 BU W PWR VIO GY VIO VIO [...]

Page 10 - - 8 This page is intenti onally bl ank.[...]

Page 10 - - 9 Groundsmaster 4000 - - D/4010 - - D Pla tf o rm Wire H arn e ss D raw in g NOTE CLOCK POSITION NOTE CLOCK POSITION (NOT USED) (OP TION AL KIT) (OP TION AL KIT) (OP TION AL KIT) (OP TION AL KIT) A / CC L U T C H& WS WASHER PUMP TO REAR HARNESS TO REAR HARNESS TO REAR HARNESS TO REAR HARNESS TEC- - 5001 COMM PORT[...]

Pag e 10 - - 10 Groundsmaster 4000 - - D/4010 - - D Pla tf o rm Wire H arn e ss D ia g ram Sheet 1 of 2 VIOLET BLACK GRA Y BLACK BLACK VIOLET VIOLET BLACK BLACK WHITE/ YELLOW GRA Y RED/WHI TE BLACK/WHI TE 641 171 272 BLACK 168 RED/WHI TE BLACK/WHI TE BLACK BLACK BLACK 246 636 BLACK BLACK RED/GREEN VIOLET 635 BLACK/WHI TE RED/WHI TE BLACK BLACK PINK[...]

Page 10 - - 1 1 Groundsmaster 4000 - - D/4010 - - D Pla tf o rm Wire H arn e ss D ia g ram Sheet 2 of 2 289 175 728 172 GRA Y/ BLUE BLACK PINK GRA Y BLACK BLACK PINK PINK/ GREEN YELLOW VIOLET PINK PINK 166 167 165 155 747 BLACK BLACK WHITE PINK PINK BLUE/WHI TE BLACK BROWN WHITE GREEN PINK YELLOW/BLUE 270 YELLOW YELLOW ORANGE GRA Y YELLOW RED GREEN[...]

Pag e 10 - - 12 Groundsmaster 4000 - - D/4010 - - D Rear W ire Har ness Drawing FUSEBLOCKS MAXI FUSES TO PLA TFORM HARNESS TO PLA TFORM HARNESS TO PLA TFORM HARNESS TO PLA TFORM HARNESS[...]

Pag e 10 - - 13 Groundsmaster 4000 - - D/4010 - - D Rear Wire Harness Diagram WHITE BLACK PINK RED BLACK BLACK RED BROWN/BLACK GRA Y/ BLA CK PINK/B LACK WHITE/ORANGE WHITE/BLACK T AN/BLACK BLUE WHITE YELLO W PINK VIOLET BLACK RED RED RED PINK GRA Y/ BLA CK BROWN/BLACK RED/GREEN PINK WHITE/YELL OW BROWN RED/BL UE WHITE/BLACK T AN/BLACK BLACK YELLOW/[...]

Pag e 10 - - 14 Groundsmaster 4010 - - D Cab Wire H arness Drawing FUSEBLOCKS TO CAB HARNESS INTERCONNECT[...]

Pag e 10 - - 15 Groundsmaster 4010 - - D Cab Wire Harness Diagram VIO LET GRAY ORA NGE RED WHIT E/ BLACK BLUE WHIT E/BLACK RED/WHITE RED RED RED RED BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK ORA NGE VIO LET VIO LET ORA NGE GRAY BLUE VIO LET BRO WN VIO LET BLACK RED BLACK BLACK WHIT E VIO LET BLACK BLACK VIO LET BRO WN VIO LET BLACK VIO [...]

Pag e 10 - - 16 Groundsmaster 4010 - - D Cab Interconnect Wire Har ness BLACK BLUE WHITE RED BLACK[...]