Toro 30603 manual

(Models 30603, 30605, 30607 and 30609) Part No. 13202SL Service Manual Groundsmaster R 4000 - - D & 4010 - - D Preface The pur pose of t his public ation is to pr ovide the serv ice technic ian with i nfor mati on for tr oubleshooting, t est ing and repair of maj or syst ems and co mponents on the Gr oundsmas ter 4000- - D (Models 30605 and 306[...]

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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 ec ords and Mainte nance Produc t Records 2 - - 1 ....................[...]

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Gr oundsmas ter 4000 - - D/ 4010 - - D T able Of Contents (Continued) Chap ter 9 - - O p erato r Cab Gener al Inf orm ation 9 - - 2 ........................ Servic e and Repairs 9 - - 3 ........................ SANDEN SD COMPRESSOR SER VICE G UIDE Cha pter 1 0 - - Foldout Dra wings Elect rical Drawing Des ignations 10 - - 2 ............. Hydraulic [...]

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

Groundsmaster 4000- - D/4010 - -D Page 1 - - 2 Safe ty General Safety Instructions The Groundsmaster 4000-D and 4010 - - D are tested and certified by T oro for complia nce with existing safety standards and specificatio ns. Al though hazard control and accident prevention partially are depende nt upon the design and configuration of the machine, t[...]

Groundsmaster 4000- - D/4010 - -D Page 1 - - 3 Safet y While Operating 1. Sit on the seat when st arting an d operating th e ma- chine. 2. Before starting the eng ine: A. Apply the parking br ake. B. Make sure traction pedal is in neutral a nd the PTO switch is OFF (dise ngaged). 3. After engine is start ed, release pa rking brake and keep foot off[...]

Groundsmaster 4000- - D/4010 - -D Page 1 - - 4 Safe ty Maintenance and Service 1. Before servicing or making adjustments, lowe r decks, stop engine, apply parking brake and remov e key from the ignition switch. 2. Make sure machine is in safe ope rating condit ion by keeping all nuts, bolts and scre ws tight. 3. Never store the m achine or fue l co[...]

Groundsmaster 4000- - D/4010 - -D Page 1 - - 5 Safet y Jacking Instructions CAUTION When changing attachments, tires or perform- ing other servic e, use corre ct jacks and sup- ports. Make sure machine is park ed on a solid, level surface such as a concre te floor . Prior to raising machine, remove any attac hments that may interfere with the safe [...]

Groundsmaster 4000- - D/4010 - -D Page 1 - - 6 Safe ty Safety and Instruction Decals Numerous safe ty and instruction decals are af fixed to your Groundsmaster mach ine. If any decal becomes il- legible or damaged, install a new deca l. Decal part num- bers are listed in your P arts Catalog.[...]

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

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 Recor ds and Maintenance T or que Specifications Recommended fastener torque values are listed in t he following tables. For critical applications, as determined by T oro, either the recommended tor que or a torque that is unique to the application is clearly iden tified and spe- cified in this[...]

Groundsmaster 4000- - D/4010 - -D Page 2 - - 4 Product Records and Maintenance Standard T orque for Dry , Zinc Plate d a nd Steel Fasteners (Inch Ser ies) Thread Size Grade 1, 5 & 8w i t hT h i n Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Hei ght Nuts (SAE J995 G rade 2 or St ronger Nuts) SAE Grade 5 Bol ts, Scr ews, S[...]

Groundsmaster 4000- - D/4010 - -D Page 2 - - 5 Product Recor ds and Maintenance Standard T orque f or Dry , Zinc Plated a nd Steel Fasteners (Metric Series) Thre ad Siz e Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X [...]

Groundsmaster 4000- - D/4010 - -D Page 2 - - 6 Product Records and Maintenance Other T orque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended T orque Square Head Hex Soc ket 1/4 - - 2 0 UNC 14 0 + 20 in - - lb 73 + 12 in - -lb 5/16 - - 18 UNC 215 + 35 in - - lb 145 + 20 in - -lb 3/8 - - 1 6 UNC 35 + 10 ft - - lb 18 + 3f t - - l b[...]

Groundsmaster 4000- - D/4010 - -D Page 3 - - 1 Y anmar Diesel Engine Chapter 3 Y anmar Diesel Engine T able o f Contents SPECIFICA TIONS 2 ............................ Models 30603 an d 30605 2 .................... Models 30607 an d 30609 3 .................... GENERAL INFORMA TION 5 ..................... Operator ’s Manu als 5 ..................[...]

Groundsmaster 4000- - D/4010 - -D Page 3 - - 2 Y anmar Diesel Engine Specifications (Models 30603 and 30605) Item Description Make / Designation Y anmar Model 4TNV84T- - ZMTR: 4 - - Cycle, 4 Cylinder , W ater Cooled, Turbo charged, Tier 4i Diesel Engin e Bore 3.307 in (84 mm) Stroke 3.543 in (90 mm) T ot al Dis placem ent 121.7 in 3 (19 95 cc) Firi[...]

Groundsmaster 4000- - D/4010 - -D Page 3 - - 3 Y anmar Diese l Engine Specifications (Models 30607 and 30609) Item Description Make / Designation Y anmar Model 4TNV86CT- - DTR: 4 - - Cycle, 4 Cylinder , W ater Cooled, T urbocharged, T ier 4 Diesel Engine Bore 3.386 in (86 mm) Stroke 3.543 in (90 mm) T otal Displacement 127 .5 in 3 (2090 cc) Firing [...]

Groundsmaster 4000- - D/4010 - -D Page 3 - - 4 Y anmar Diesel Engine This page is intentionally blank.[...]

Groundsmaster 4000- - D/4010 - -D Page 3 - - 5 Y anmar Diesel Engine General Information This Chapter gives information about specifications an d repair of the diesel engine used in Grou ndsmaster 4000 - - D and 4010 - - D machines. General maintenance procedure s are described in your Operator ’s Man ual. Information on engine troubl eshoot- ing[...]

Groundsmaster 4000- - D/4010 - -D Page 3 - - 6 Y anmar Diesel Engine Engine Elec tronic Control Unit (ECU ) The Y anmar engine that powers your Groundsmaster uses an electron ic control unit (ECU) fo r engine man- agement an d also to commu nicate with the machin e TEC controllers and the operator Info Center display on the machine. All wire harnes[...]

Groundsmaster 4000- - D/4010 - -D Page 3 - - 7 Y anmar Diese l Engine Y anm ar Engine: Models 30603 and 30605 The engine used on Groundsmaster models 30603 and 30605 is a Y anmar TNV Series, turbocharged, diese l engine that complies with EP A interim T ier 4 emission regulations. Eng ine features include an electr onic con- trol unit (ECU) control[...]

Groundsmaster 4000- - D/4010 - -D Page 3 - - 8 Y anmar Diesel Engine Y anma r Engine: Models 30607 and 30609 The engine u sed on Groundsmaster mode ls 30607 and 30609 is a Y anmar TNV Series , turbochar ged, diesel engine that complies with EP A Tier 4 emission regula- tions. Engine features incl ude an electronic control unit (ECU) that controls a[...]

Groundsmaster 4000- - D/4010 - -D Page 3 - - 9 Y anmar Diese l Engine Station ary regene ration is requested by the engine ECU if the assist and reset regenerations do not return the DPF p articulate level to an acceptable level. Du ring the stationary regen eration, the engine ECU contr ols engine speed, load and air/fuel mixture to perform a cont[...]

Groundsmaster 4000- - D/4010 - -D Page 3 - - 10 Y anmar Diesel Engine Service and Repairs Air Cleaner Sy stem Figure 6 FRONT RIGHT 1. Air cleaner assembly 2. T ank support 3. Indicator 4. Adapter 5. Air cleaner strap 6. Flat washer (4 used) 7. Cap s crew (2 used ) 8. Lock nut (2 used) 9. Flat washer (2 used) 10. Lock nut (2 used) 1 1. S pring (2 us[...]

Groundsmaster 4000- - D/4010 - -D Page 3 - - 1 1 Y anmar Diesel Engine Removal (Fig. 6) 1. Park machine on a level s urface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Raise and support h ood. 3. Remove air clea ner components as needed using Figure 6 as a guide. Installation (Fig. 6) IMPORT A[...]

Groundsmaster 4000- - D/4010 - -D Page 3 - - 12 Y anmar Diesel Engine Fuel System Figure 9 1. Car riage s crew (2 u sed) 2. Retaining ring (2 used) 3. Flat washer (2 used) 4. Flange nut (6 used) 5. V ent hose 6. Fuel tank 7. Hose clamp (2 used) 8. Elbow fitting (2 used) 9. Stan d pipe 10. Grommet (3 used) 11 . H o s e c l a m p 12. Lock washer (5 u[...]

Groundsmaster 4000- - D/4010 - -D P age 3 - - 13 Y anmar Diesel E ngine DANGER Because diesel fuel is f lammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while en - gine is running, hot or when m achine is in an en - closed area. Always fill fu el tank outsi de and wipe up any spilled[...]

Groundsmaster 4000- - D/4010 - -D Page 3 - - 14 Y anmar Diesel Engine Radiator and Oil Cooler Assem bly Figure 1 1 FRONT RIGHT 2 3 6 8 9 10 11 1 5 7 4 24 25 3 26 27 28 29 30 31 32 33 34 35 Thread Sealant 1. LH radiator support 2. Cap s crew (2 used ) 3. Flange nut (12 used) 4. Hose clamp (3 used) 5. Hose 6. Flange nut (6 used) 7. Foam plug (2 used)[...]

Groundsmaster 4000- - D/4010 - -D P age 3 - - 15 Y anmar Diesel E ngine Removal (Fig. 1 1) 1. Park machine on a level s urface, lower cutting decks, stop engine, apply parking brake and remove key from the ignitio n switch. Open and suppo rt hood. CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot c[...]

Groundsmaster 4000- - D/4010 - -D Page 3 - - 16 Y anmar Diesel Engine Installation (Fig. 1 1) 1. Inspect seal s (items 7, 10, 27 and 34) around radiat- or location for wear or damage. Replace seal s if neces- sary . 2. Remove all plugs plac ed during the r emoval proce - dure. 3. If hydraulic fittings (items 29 and 31) were removed from oil cooler [...]

Groundsmaster 4000- - D/4010 - -D P age 3 - - 17 Y anmar Diesel E ngine This page is intentionally blank. Ya n m a r Diesel Engine[...]

Groundsmaster 4000- - D/4010 - -D Page 3 - - 18 Y anmar Diesel Engine Engine Figure 15 1. Engine (model 30603 show n) 2. Cap s crew (4 used ) 3. Reb ound w asher ( 4 used) 4. Flange nut (12 used) 5. Engine mount (4 used) 6. Cap s crew (2 used p er moun t) 7. Engine mount bracket (2 used) 8. Lock washer 9. Engine mount bracket (2 used) 10. Cap screw[...]

Groundsmaster 4000- - D/4010 - -D P age 3 - - 19 Y anmar Diesel E ngine Engine Removal (Fig. 15) 1. Park machine on a level s urface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Disconnect neg ative battery cable from battery ter- minal and then disconnect positive cable from battery (see Batte[...]

Groundsmaster 4000- - D/4010 - -D Page 3 - - 20 Y anmar Diesel Engine 1 1. On machines with a T ier 4 compliant engine (m odels 30607 and 306 09): A . R e m o v ef u e lt a n kt oa l l o we n g i n et ob er a i s e d f r o mm a c h i n e( s e eF u e lS y s t e mi nt h i ss e c t i o n ) . B. Install lift b racket to front of engine cylinder head (i[...]

Groundsmaster 4000- - D/4010 - -D P age 3 - - 21 Y anmar Diesel E ngine CAUTION One person should operate lift or hoist while a second person guides the engine out of the ma- chine. IMPORT ANT : Make sure to not damage the engine, radiator assembly , fuel lines, hydraulic lines, elec- trical wire harness or other components while re- moving the eng[...]

Groundsmaster 4000- - D/4010 - -D Page 3 - - 22 Y anmar Diesel Engine 15. Connect coo lant hoses to the radiator . Make sure ra - diator draincock is close d. Fill radiator and coolant reservoir with coolant. 16. Secure the wire harness, fuel lines and hydraulic hoses to the engine w ith cable ties as noted durin g en- gine removal. 17. Check posit[...]

Groundsmaster 4000- - D/4010 - -D P age 3 - - 23 Y anmar Diesel E ngine This page is intentionally blank. Ya n m a r Diesel Engine[...]

Groundsmaster 4000- - D/4010 - -D Page 3 - - 24 Y anmar Diesel Engine Spring Coupler Figure 21 1. Cap s crew (8 used ) 2. W asher (8 used) 3. Flyw heel pl ate 4. Cap screw (8 used) 5. W asher (8 used) 6. Spring coupler 7. Engine (model 30603/30605 shown) FRONT RIGHT 29 to 33 ft - - lb ( 4 0t o4 4N - - m ) 28 to 32 ft - - lb (38 to 43 N - - m) 1 2 3[...]

Groundsmaster 4000- - D/4010 - -D P age 3 - - 25 Y anmar Diesel E ngine Coupler Removal (Fig. 21) NOTE: The hydraulic pump assembly ne eds to be re- moved from engine befor e coupler can be removed. 1. If engine is in machine, remove hydrau lic pump as- sembly from machine ( see Piston (T raction) Pump Re- moval in the Service and Re pairs section [...]

Groundsmaster 4000- - D/4010 - -D Page 3 - - 26 Y anmar Diesel Engine Exhaust System (Mod els 30607 and 30609) Figure 23 1. Gasket 2. Exhaust assembly stay 3. Exhaust assembly stay 4. Exhaust assembly stay 5. Exhaust assembly stay 6. Nut 7. DOC t emp senso r (inle t) 8. DOC temp sensor (outlet) 9. Nut ( 4 used) 10. DOC assembly 1 1. Nut (3 used) 12[...]

Groundsmaster 4000- - D/4010 - -D P age 3 - - 27 Y anmar Diesel E ngine Groundsmaster models that are powered by a diesel en- gine that complies with EP A Tier 4 emissi on regulations are equipped with an exhau st system that includes a diesel oxidation catalyst (DOC) and a diesel p articulate filter (DPF). These exhau st components require service[...]

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

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Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 3 Specifications Item Description Piston (T raction) Pump Sauer - - Danfoss V ariable Displacement Axial Piston Pump Maximum Displacement (per revolution) 2.75 in 3 (45 cc) System Relief Pressure: Forward 4350 PSI (300 bar) System Relief Pressure: Reverse 5000 PSI (345 bar) Char ge Pres [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 4 General Information Operator ’ s Manual The Operator’s Manual provi des information regard ing the operation, general maintenance and maintenance intervals for your G roundsmaster machine. R efer to that publication for additional informati on when servicing the machine. Check Hydr[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 5 T owing T raction Unit IMPORT ANT : If towing limits are exceeded, severe damage to the piston (traction) pump may occur . If it becomes necessary to tow (or push ) the machine, tow (or pu sh) in a forward direction only and at a speed below 3 mph (5 kph) . The piston (traction) pump r[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 6 Hydraulic Hoses Hydraulic hoses are subject to extre me conditions such as pressure d iffe rentials during op eration and exposure to weather , sun, c hemicals, very war m storage con di- tions or mishandling during operation and mainte nance. These conditions can ca use hose damage an[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 7 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, scratch es or any foreign material. 2. As a preventative measure aga inst leakage, it is rec- ommended that t he fa[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 8 Hydraulic Fitting Installation (SAE S traight Thread O - - Ring Fitting into Component Port) Non - - Adjustable Fitting (Fig. 6) 1. Make sure al l threads and sealing surfa ces of fitting and component port are free of burrs, nicks, scratches or any foreign m aterial. 2. As a prevent a[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 9 Adjustable Fitting (Fi g. 8) 1. Make sure all thr eads and sealing surfaces o f fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure aga inst leakage, it is rec- ommended that the O- -ring be replaced any time the connecti[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 10 Hydraulic Schematic NOTE: A larger hydraulic schematic is included in Chapte r 10: Foldout Drawings S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 1600 PSI S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 OR7 .070 T 2SP CH3 G2 G4 CV4 PR[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 1 1 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 12 Hydraulic Flow Diagrams T raction Circuit: LOW Spee d (Mow) (Forward Shown) Wo rking Pre ssure Low Pressure (Charge) Return or Suction Flow S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 13 T racti on Circuit: LOW Speed (Mow) The traction circuit piston pump is a variabl e displace- ment pump that is directly coupled to the engine fly- wheel. This pump utilizes an in tegral electro - -hydraulic servo piston assembly that co ntrols the rate and direc- tion of hydraulic fl[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 14 T raction Circuit: HI Speed (T ransport) (Forward Shown) Working Pressure Low Pr ess ure (C harge) Return or Suction Flow S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 OR7 .070 T 2SP CH3[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 15 T racti on Circuit: HI Spe ed (T rans port) The traction circuit piston pump is a variabl e displace- ment pump that is directly coupled to the engine fly- wheel. This pump utilizes an in tegral electro - -hydraulic servo piston assembly that co ntrols the rate and direc- tion of hydr[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 16 Lower Cutting Deck (LH Deck Shown) Working Pressure Low Pressure ( Charge) Return or Suction Flow S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 OR7 .070 T 2SP CH3 G2 G4 CV4 PR G1 G3 3250[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 17 Lower Cutting Deck Circuit A four section gear pump is coupled to the piston (trac- tion) pump . The third gea r pump sectio n supplies hy - draulic flow to the lift/lower c ircuit, the engine cooling fan circuit and the traction charg e circuit. Each of the cuttin g decks (cen ter , [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 18 Raise Cutting Deck (LH Deck Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 OR7 .070 T 2SP CH3 G2 G4 CV4 PR G1 G3 3250 [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 19 Raise Cut ting Deck Circ uit A four section gear pump is coupled to the piston (trac- tion) pump (Fig. 10). The th ird gear pump section sup- plies hydraulic flow to the lif t/lower circui t, the engine cooling fan circuit and the tra ction charge circuit. A relief valve (R V2) locate[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 20 Mow (Front Deck Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 OR7 .070 T 2SP CH3 G2 G4 CV4 PR G1 G3 3250 PSI 1350 PSI[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 21 Mow Circuit A four section gear pump is coupled to the piston (trac- tion) pump. Hydraulic flow f or 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 cutting decks, while[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 22 Mow Circuit Cutting Deck Blade Braking When the operator turns th e PTO switch OFF or if a deck is raised with the PTO switch ON, P TO manifold propor- tional relief valve ( PRV) is de - - energized causing logic valve (LC1) to shift (refer t o information in Mow Circuit in this secti[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 23 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 24 Steering Circuit (Right T urn S hown) Working Pressure Low Pressure (Charge) Return or Suction Flow S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 OR7 .070 T 2SP CH3 G2 G4 CV4 PR G1 G3 32[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 25 Steering Circuit A four section gear pump is coupled to the piston (trac- tion) pump. The fourth g ear pump section (farthest from the piston pump) supplies hyd raulic flow to the steering circuit, the engine cooling fan circuit and th e traction charge circuit. Priority hydrauli c fl[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 26 Engine Cooling Fan Circuit (Forward Direction Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 OR7 .070 T 2SP CH3 G2 G4 [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 27 Engine Cooling Fan Circuit A four section gear pump is coupled to the piston (trac- tion) pump (Fig. 14). The f ourth gear pump section (farthes t from th e piston pum p) supplies hydra ulic flow to the steering circuit, the engin e cooling fan circuit and the traction charge circu it[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 28 Special T ools Order speci al tools from your T oro Distributor . Hydraulic Pressure T est Kit Use to take various pressure read ings for diagnostic tests. Quick disconnect fitti ngs provided attach directly to mating fittings on machine test ports without tools. A high pressure ho se[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 29 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 chapte r . This tester include s the following: 1. LOAD V AL VE: A s imulated working load is created in the circu[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 30 High Flow Hydraulic Filter Kit The high flow hydraulic filt er kit is designed with large flow (40 GPM/150 LPM) and high pre ssure (5000 PSI/345 bar) capabilities. This kit provides for bi - - direc- tional filtration whi ch prevents filtered debris from being allowed back into the ci[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 31 Hydraulic T est Fitting Kit This kit includes a variety of O - - ring Face Seal fittin gs to enable you to co nnect test gauges into th e system. The kit includes: tee’ s, unions, reducers, plugs, caps and male test fittings. T oro Part Number: TOR 407 9 Figure 21 TORO TEST FITTING [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 32 Remote Starter Switch After flushing the hydraulic system or replacing a hy- draulic component (e.g. gear pump, pi ston pump, wheel motor), it is nec essary to pr ime the hydr aulic pumps. A remote starter switch (Fig. 24) can be used for this pur- pose. Obtain a remo te starter switc[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 33 T roubleshooting The charts that follow contain suggestions th at can be used to assist in diagnosing hyd raulic system perfor- mance issues. The suggestions are not al l - -inclusive. Also, consider that ther e may be more than one cause for a machine pr oblem. Review the hydraulic s[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 34 T raction C ircuit Problems Problem Possible Cause M a c h i n eo p e r a t e si no n ed i r e c t i o n only . Piston (traction) pump by- -pass valve is open or damaged. T r action relief valve is leaking or faulty . Piston (traction) pump servo contro l valve orifices or scr eens ar[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 35 Mow Circuit Problems Problem Possible Cause None of the cutting decks w ill oper- ate. NOTE: T o engage the mow circuit, t h es e a tm u s tb eo c c u p i e d ,t h ec u t - ting deck(s) must be fully lowered, the traction speed m ust be in the LOW (mow) position and the PT O switch mu[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 36 Lift Circuit Problems Problem Possible Cause Cutting decks will not raise. NOTE: Seat must be occ upied in or - der to raise cutting decks. Engine RPM is too low . Hydraulic oil level in reservoir is low (NOTE : Other hydraulic systems are affected a s well). Solenoid valve (S1) in c [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 37 Steering Circui t Problems Problem Possible Cause Steering inoperative or sluggish Steering components (e.g. tie r ods, steering cylinder ends) are worn or binding. Steering cylinder is b inding. Oil level in hydraulic reservoir is low (NOTE: Other hydraulic sys- tems are af fected as[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 38 Engine Cooling Fan Cir cuit Problems Problem Possible Cause Cooling fan runs on ly in forward di- r e c t i o n( f a nd o e sn o tr u ni nr e v e r s e direction). Solenoid cartridge valve (S10) in combination contro l manifold is faulty . Electrical problem exists that prev ents comb[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 39 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 40 Te s t i n g The most effective method for isol ating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flo w meters in the circuits during variou s operationa l checks (see the S pecial T ools section in this Chapter). IMPORT ANT : All [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 41 Which Hydraulic T ests Are Necessary? Before begin ning any hydra ulic test, i dentify if t he prob - lem is related to the traction circui t, cutting (mow) circuit, lift/lower circuit, steering circuit o r engine cooling fan cir- cuit. Once the faulty system has been i dentified, p e[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 42 T raction Circ uit Charge Pressure (Us ing Pressure Gauge) 3.3 GPM 4.4 GPM 14.3 GPM 14.3 GPM P1 16.8 GPM 13.7 GPM PR 380 PSI RV 650 PSI .050 CV T P2 M8 CH OR1 250 PSI 2.14 CID / 1.16 CID 200 PSI 4350 PSI 5000 PSI M1 OR M3 CH1 FRONT CH2 .063 CV1 CV2 HFD .0315 .0315 0.4 CID 0.3 1.29 1.2[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 43 The traction charge circui t is designed to replace loss of hydraulic fluid from the close d loop traction circuit. This test is used to ma ke sure that tr action char ge pressure is correct. Procedure for T rac tion Circuit Charge Pressure Te s t CAUTION Prevent personal injury and/o[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 44 T racti on Circuit Relief Pressur e (Using Pressure Gauge) 3.3 GPM 4.4 GPM 14.3 GPM 14.3 GPM P1 16.8 GPM 13.7 GPM PR 380 PSI RV 650 PSI .050 CV T P2 M8 CH OR1 250 PSI 2.14 CID / 1.16 CID 200 PSI 4350 PSI 5000 PSI M1 OR M3 CH1 FRONT CH2 .063 CV1 CV2 HFD .0315 .0315 0.4 CID 0.3 1.29 1. [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 45 Procedure for T raction Circuit R elief Pressure Te s t NOTE: T h et r a c t i o nc h a r g ec i r c u i ti sd e s i g n e dt or e - place loss of hydraulic fluid fro m the closed loop traction circuit. CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 46 Counterbalance P ressure (Using Pressure Ga uge) PRESSURE GAUGE S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 OR7 .070 T 2SP CH3 G2 G4 CV4 PR G1 G3 3250 PSI 1350 PSI 4P S I 4P S I .030 O[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 47 Procedure for Counter balance Pressure Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre - cautions for Hydraulic T esting at the beginning of this section. 1. Park machine on a level surface with the cutting decks lowered and of[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 48 Reverse T raction Circu it Reducin g V alve (PR) Pressure (Using Pressure Gau ge) 3.3 GPM 4.4 GPM 14.3 GP M 14.3 GPM P1 16.8 GPM 13.7 GPM PR 380 PSI RV 650 PSI .050 CV T P2 M8 CH OR1 250 PSI 2.14 CID / 1.16 CID 200 PSI 4350 PSI 5000 PSI M1 OR M3 CH1 FRONT CH2 .063 CV1 CV2 HFD .0315 .0[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 49 Procedure for Revers e T raction Circuit Reducing Va l v e ( P R ) P r e s s u r e Te s t NOTE: When in reverse, pressure reducing valve (P R) limits the pressure to the rear axle motor to 380 PSI (26 bar) so the rear wheels will no t scuff the turf. CAUTION Prevent personal injury an[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 50 Rear T raction Circuit Relief V alve (R V) Pressure (Using Pressure Gauge) 3.3 GPM 4.4 GPM 14.3 GPM 14.3 GPM P1 16.8 GPM 13.7 GPM PR 380 PSI RV 650 PSI .050 CV T P2 M8 CH OR1 250 PSI 2.14 CID / 1.16 CID 200 PSI 4350 PSI 5000 PSI M1 OR M3 CH1 FRONT CH2 .063 CV1 CV2 HFD .0315 .0315 0.4 [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 51 Procedure for Rear T raction Circuit Relief V alve (R V) Pressure Te s t NOTE: Adjustable relief valve (RV) in the rear traction control manifo ld reduces rear axle m otor pressure created in down hill, dynamic braking conditions to pre- vent rear wheel lock up. CAUTION Prevent person[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 52 Piston (T raction) Pump Flow T est (Using T ester with Pressure Gaug e and Flow Meter) 3.3 GPM 4.4 GPM 14.3 GPM 14.3 GPM P1 16.8 GPM 13.7 GPM PR 380 PSI RV 650 PSI .050 CV T P2 M8 CH OR1 250 PSI 2.14 CID / 1.16 CID 200 PSI 4350 PSI 5000 PSI M1 OR M3 CH1 FRONT CH2 .063 CV1 CV2 HFD .031[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 53 Procedure for Piston (T raction) Pump Flow Te s t This test me asures pisto n (tractio n) pump outp ut (flow) . During this tes t, pump load is creat ed at the flow meter using the adjustable loa d valve on the tester . NOTE: Before perfor ming piston pum p flow test, make sure that t[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 54 Cutting Deck Circuit Pressure (Using Pressu re Gauge) FRONT DECK CIRCUIT PRESSURE TEST SHOWN PRESSURE GAUGE 3.3 GPM 14.3 GPM 14.3 GPM 1.17 CID 3000 PSI P1 P1 P1 P2 P2 P2 M1 M2 LC1 PRV PD CD RV 2000 PSI M1 M2 LC1 PRV PD RV 3000 PSI M1 M2 LC1 PRV PD RV CD CD LEFT DECK CENTER DECK RIGHT [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 55 Procedure for Cutting Deck Circuit Pressure Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre - cautions for Hydraulic T esting at the beginning of this section. 1. Park machine on a level surface with the cutting decks lowered a[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 56 PTO Relief Pr essure (Using T ester with Pressure Gauge and Flow Meter) FRONT PTO RELIEF PRESSURE TEST SHO WN 3.3 GPM 14.3 GPM 14.3 GP M 1.17 CID 3000 PSI P1 P1 P1 P2 P2 P2 M1 M2 LC1 PRV PD CD RV 2000 PSI M1 M2 LC1 PRV PD RV 3000 PSI M1 M2 LC1 PRV PD RV CD CD LEFT DECK CENTER DECK RIG[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 57 The PTO circuit relief pressure test should be performed to make sure that the PTO ci rcuit relief pressures are correct. Procedure for PTO Relief Press ure Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre - cautions for Hydraul[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 58 Cutting Deck Motor Case Drain Leakage (Using T ester with Pressure Gauge and Flow Meter) CENTER CUTTING DECK MOTOR CASE DRAIN LEAKAGE TEST SHOWN 1.17 CID 3000 PSI P1 P1 P2 P2 M1 M2 LC1 PRV PD CD RV 2000 PSI M1 M2 LC1 PRV PD RV 3000 PSI M1 M2 LC1 PRV PD RV CD CD LEFT DECK CENTER DECK R[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 59 Procedure for Cutting Deck Motor Case Drain Leakage Te s t NOTE: Over a period of time, a de ck 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 unde[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 60 Lift/Lower Circuit Relief Press ure (Using P ressure Gauge) S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 OR7 .070 T 2SP CH3 G2 G4 CV4 PR G1 G3 3250 PSI 1350 PSI 3.3 GPM 4.4 GPM 14.3 GPM[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 61 The lift/lower circuit relief pressure test should be per- formed to make sure that the cutting unit lift and lower circuit relief pressure is correct. Procedure for Lift/Lower Circuit Relief Pressure Te s t NOTE: Before attempting to check or adjust lift/lower circuit relief pr essur[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 62 Steering Cir cuit Relief Pressure (Using Pr essure Gauge) S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 1600 PSI S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 OR7 .070 T 2SP CH3 G2 G4 CV4 PR G1 G3 3250 PSI 1350 PSI 3.3 GPM 4.4 GPM 1[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 63 The steering circuit relief pressure test shou ld be per- formed to make sure that the ste ering circuit relief pres- sure is correct. Procedure for Steering Circuit Relief Pressure Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and P[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 64 Steeri ng Cylinder Internal Le akage 6.1 CID E P L R T STEERING CYLINDER 2.00” BORE 4.20” STROKE 0.625” ROD STEERING CONTROL VA LV E STEERING WHEEL TURNED FOR RIGHT TURN CYLINDER FULL Y EXTENDED LOOK FOR LEAKAGE STEEL CAP FROM COMBINA TIO N MANIFOLD FROM COMBINA TION MANIFOLD TO[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 65 The steering cy linder intern al leakage test should be performed if a steering problem is identified. This test will determine if the steering cylinder is faulty . Procedure for Steering Cylinder Inter nal Leakage Te s t NOTE: Steering circuit operat ion will be affected by rear tire[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 66 Engine Cool ing Fan Circuit (Us ing Pressur e Gauge and Phototac) S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 1600 PSI S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 OR7 .070 T 2SP CH3 G2 G4 CV4 PR G1 G3 3250 PSI 1350 PSI 3.3 GPM 4[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 67 The cooling fan circuit test shoul d be performed to make sure that the e ngine cooling fan circuit ha s the correct system pressure and fan spee d. Procedure for Engine Cooling Fan Circuit T est CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTION[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 68 Gear Pump Flow (Using T ester with Pressure Gauge and Flow Meter) SECOND GEAR PUMP SECTION FLOW TEST SHOWN 3.3 GPM 14.3 GPM 14.3 GPM 250 PSI 4350 PSI 5000 PSI .0315 .0315 0.4 CID 0.3 1.29 1.29 CID CID CID 2.75 CID ENGINE 30.5 GPM G G G G TO COMBINATION MANIFOLD FROM COMBINA TION MANIF[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 69 Procedure for Gear Pump Flow Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre - cautions for Hydraulic T esting at the beginning of this section. 1. Park machine on a level surface with the cutting decks lowered and off. Make su[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 70 Adjustments Adjust Control Ma nifold Relie f V alves Several of the hydraulic control manifolds on your Groundsmaster include a djustable relief valves. The fol- lowing procedure can be used to adjust th ese relief valves. Refer to the T esting sectio n of this chapter for in- formati[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 71 Service and Repairs General Precautions for R emoving and In stalling Hydraulic System Components Before Repair or Re placement of Components 1. Before removing any pa rts from the hydraulic sys- tem, park machine on a level surface, apply pa rking brake, lowe r cutting decks or at ta[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 72 Check Hydraulic Li nes and Hoses WA R N I N G Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use pape r or cardboard, not hands, to search fo r leaks. Hydraulic f luid escapi ng und er pressure can h ave suff icient fo rce to pe[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 73 Flush Hydraulic Sy stem IMPORT ANT : Flush the hydraulic system any time there is a sever e component failure or t he 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 trac[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 74 Filtering Closed - - L oop T raction Circuit Filtering of a closed - - loop hydraulic system after a major component failure (e.g. traction (piston) pu mp 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 Hydraul ic System NOTE: When initially starting the hydraulic syst em 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 cha nce of component da[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 76 Hydraulic Reservoir 1. Hydraulic reservoir 2. Cap screw 3. Recess bumper (2 used) 4. Thin spacer 5. Flange nut 6. Breather 7. Bushing (3 used) 8. Stand pipe (3 used) 9. Hose clamp 10. Reservoir cap 11 . O - - r i n g 12. Dipstick 13. Screen filter 14. T ank strainer 15. Cap screw 16. [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 77 NOTE: The operator platform needs to be raised from the main frame so that the hydraulic reservoir can be re- moved from the machine (se e Operato r Platform in the Service and Repairs se ction of Chapter 6 - - Chassis). Removal (Fig. 52) 1. Park machine on a level s urface, lower cut[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 78 Radiator and Oil Cooler Assem bly 1. LH radiator support 2. Cap screw (2 used) 3. Flange nut (12 used) 4. Hose clamp (3 used) 5. Hose 6. Flange nut (6 used) 7. Foam plug (2 used) 8. Flange head screw (6 used) 9. Flange head screw (9 used) 10. Foam strip 1 1. Hose bracket 12. R - - cla[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 79 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 80 Gear Pump 1. Hose clamp (3 used) 2. Hose clamp (2 used) 3. Hydraulic hose 4. Suction hose 5. T ee fitting 6. Straight hydraulic fitting 7. Plug 8. Cap screw (2 used) 9. Flat washer (4 used) 10. Gea r pump 11 . O - - r i n g 12. Hydraulic fitting 13. 45 o hydraulic fitt ing 14. Hydraul[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 81 Removal (Fig. 55) 1. Park machine on a level s urface, 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 o f the machine. 3. Drain the hydr aulic reservoir . IMPOR[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 82 10. Replace hydrau lic filters a nd fill hydraulic reservoir with new hydraulic oil. 1 1. Prime hydraulic pumps (see Priming Hydrau lic Pumps in this section ). 12. Properly fill hydraulic system (see Charge Hydraulic System in this sect ion). 13. Stop engine and check for hydraulic o[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 83 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 84 Gear Pump Se rvice 1. Front cover 2. Dowel pin (4 used) 3. Pressure seal 4. Back - - up gasket 5. Front thrust plate 6. Seal (8 used) 7. Front body 8. Idler gear 9. Drive shaft 10. Thrust plate (7 used) 1 1. Dowel pin (6 used) 12. Spl ined co nnect ing s haft ( 3 used ) 1 3 . F l a n [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 85 IMPORT ANT : Use caution when clamping gear pump in a vise to avoid distorting any pump compo- nents . 3 . S e c u r et h ef r o n tc o v e ro ft h ep u m pi nav i s ew i t ht h e drive shaft pointing down. 4. Loosen the four (4) cap screws that se cure pump as- sembly . 5. Remove pum[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 86 Piston (T raction) P ump Figure 61 FRONT RIGHT 1. Hose clamp (3 used) 2. Hose clamp (2 used) 3. Hydraulic hose 4. Suct ion ho se 5. T ee fi ttin g 6. Straight hydraulic fitting 7. Plug 8. Cap s crew (2 used ) 9. Flat washer (4 used) 10. Gear pump 11 . O - - r i n g 12. Hydraulic fitti[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 87 Removal (Fig. 61) 1. Park machine on a level surface, lower cu tting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. T o prevent contamination of hydraulic system during removal, thoroughly clean exterio r of pump assembly . 3. Raise and supp ort m[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 88 Installation (Fig. 61) 1. If fittings were removed from pi ston pump, lubricate and place new O - - rings onto fittings. Install fittings into pump openings using marks made during the remova l process to properly orientate f ittings. Tighten fittings (see Hydraulic Fitting Installati[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 89 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 90 Piston (T raction) Pump Serv ice Figure 65 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 2 3 10 7 25 10 29 33 34 36 37 38 39 40 41 46 47 42 43 48 49 44 45 41 42 42 55 42 44 45 46 50 51 52 53 10 54[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 91 1. Scre en (2 used ) 2. Plug with O - - r ing (2 used) 3. Plug with O - - r ing (2 used) 4. Cylinder block assembly 5. V alve pla te 6. Serv o piston 7. Scre w (4 used ) 8 . O r i f i c e( 2u s e d ) 9. Scre w (4 used ) 10. Plug with O - - ring (4 used) 1 1. Screw (2 used) 12. Plug 13[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 92 Rear Axle Motor 1. Rear axle motor 2. 90 o hydraulic fitting (2 used) 3. 90 o hydraulic fitting 4. Straight hydraulic fitting 5. 90 o hydraulic fitting 6. T emperature sender 7. Cap screw (2 used) 8. Flat washer (2 used) 9. O - - ri ng 10. External snap ring (2 used) 11 . P i n i o n [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 93 Removal (Fig. 66) 1. Park machine on a level s urface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Drain lubr icant from rear axle gearbox. 3. Read the General Pre cautions for Removing and Installing Hydraulic System Components a[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 94 Front Wheel Motors 1. Front wheel motor 2. Internal retaining ring 3. Splined brake shaft 4. RH brake assembly 5. Planetary assembly (2 used) 6. Cap s crew (2 used p er moto r) 7. Flat washer (2 used per motor) 8. O - - ri ng 9. LH brake assembly 10. Hydraulic tee fitting 11 . 9 0 o h[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 95 Removal (Fig. 67) 1. Park machine on a level s urface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Read the General Pre cautions 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 - - 96 Rear Axle and Front Wheel Motor Service Figure 68 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 23 21 25 1. Plug w ith O - - ring 2. Minimum angle stop 3. Bias spring 4. Serv o piston 5. O - - ri ng 6. O - - ri ng 7. Socket head screw (5 used) 8. Endcap 9. Dowel 10. D owel [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 97 NOTE: The front wheel motors on yo ur Groundsmaster are identical (Fig. 68). The rear axle motor includes a flushing valve for cooling of the clo sed loop traction cir - cuit and therefore has some dif ferences from the front motors (Fig. 69). Se rvice of the wheel and axle motors use[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 98 Rear T r action Manifold 1. Front frame 2. PTO manifold (center deck) 3. Front traction manifold 4. Rear traction manifold 5. Cap screw (2 used) 6. Flange nut (2 used) 7. 90 o hydraulic fitting 8. O - - ri ng 9. 45 o hydraulic fitting 10. O - - rin g 11 . O - - r i n g 12. Str aight f[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 99 Removal (Fig. 70) 1. Read the General Pre cautions 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, thoroughl y clean exterior of ma[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic Syst em Page 4 - - 1 00 Rear T r action Manifold Service 1. Rear traction manifold body 2. Relief valve (port RV) 3. Pressure reducing valve (port PR) 4. #4 ze ro leak p lug wi th O - - ri ng 5. #6 ze ro leak p lug wi th O - - ri ng 6. Check valve (port CV) 7. Orifice (0.050) (port OR1) Figure 71 25 ft - [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 101 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic Syst em Page 4 - - 1 02 Front T racti on Manifold 1. Front frame 2. PTO manifold (center deck) 3. Rear traction manifold 4. Front traction manifold 5. Cap screw (2 used) 6. Flange nut (2 used) 7. O - - ring 8. Check fi tting 9. O - - ri ng 10. Hydraulic straight fitting 11 . O - - r i n g 12. 90 o hydraul[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 103 Removal (Fig. 72) 1. Read the General Pre cautions 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, thoroughl y clean exterior of m[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic Syst em Page 4 - - 1 04 Front T racti on Manifold Service 1. Flow divider valve (port HFD) 2. SAE #4 plug with O - - ring 3. Orifice (0.063) (port OR) 4. Front traction manifold 5. Check valve (ports CV1 and CV 2) 6. SAE #6 plug with O - - ring 7. #4 ze ro leak p lug wi th O - - ri ng Figure 73 1 2 3 4 5 [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 105 Front T raction Manifold Service (Fig. 73) For front traction manifold cartridge va lve service proce- dures, see Control Manifold Cartridge V a lve Service in this section. Refer to Figure 73 for front traction manifol d cartridge va lve and plug installat ion torque. IMPORT ANT : A[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic Syst em Page 4 - - 1 06 Combination Ma nifold 1. Combination manifold 2. Flange nut (3 used) 3. Flat washer (3 used) 4. Mount (3 used) 5. Spacer (3 used) Figure 74 FRONT RIGHT 2 3 1 5 4 NOTE: The ports on the combi nation manifold are marked for easy ident ification of com ponents. Exa mple: P 3a n dP 4a [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 107 Removal (Fig. 74) 1. Read the General Pre cautions 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 o f [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic Syst em Page 4 - - 1 08 Combination Manifo ld Service 1. Combination manifold 2. #6 zero leak plug with O - - ring 3. Check valve (CV3) 4. #4 zero leak plug with O - - ring 5. Solenoid valve (S4, S6 and S9) 6. Solenoid valve (S5) 7. Relief valve (RV2) 8. Solenoid valve (S2, S3, S7 a nd S8) 9. Solenoid val[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 109 NOTE: The ports on the combina tion manifold are marked for easy identification of components. Example: P4 is the gear pump connection port, S 1 is the lift/lower solenoid valve and SV10 is the engine cooling fan solen- oid valve (see Hydraulic Schematic in Chapter 10 - - Foldout Dra[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 1 10 Control Manifold Cartri dge V alve Ser vice 1. Make sure the c ontrol manifold is clean befo re re- moving the cartridge valve from th e control manifold. 2. If cartridge v alve is solenoid oper ated, remove nut securing solenoid coil to th e cartridge valve. Carefully s l i d ec o [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 1 1 1 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 1 12 Steering Contro l V alve 1. Steering wheel cover 2. Hex nut 3. Flat washer 4. Steering wheel 5. Foam collar 6. Steering seal 7. External snap ring (2 used) 8. Steering shaft 9. Flange bushing 10. Thrust washer (as needed) 1 1. Cap screw ( 4 used) 12. W asher ( 4 used) 13. W asher ( [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 1 13 Removal (Fig. 79) 1. Park machine on a level s urface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Remove steering tower cover to allow access to steering control valve. 3. Read the General Pre cautions for Removing and Installi[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 1 14 Steering Contro l V alve Service 1. Steering valve housing 2. Dust seal 3. O - - ring 4. Spool 5. Spring retaining ring 6. Pin 7. Sleeve 8. Centering springs/spacers 9. Cap s crew (7 used ) 10. End c ap 11 . O - - r i n g 12. Seal ring 13. O - - rin g 14. Gero ter 15. O - - rin g 16[...]

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Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 1 16 Steer ing Cylinder 1. Steering cylinder 2. Ball joint 3. Ball joint 4. Retaining ring (2 used) 5. Grease fitting 6. Grease fi tting 7. 90 o hydraulic fitting (2 used) 8. Drive axle assembly 9. Ball joint spacer 10. Axle washer 1 1. Slotted hex nut (2 used) 12. Cotter pin (2 used) 13[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 1 17 Removal (Fig. 83) 1. Park machine on a level s urface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Read the General Pre cautions 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 - - 1 18 Steering Cylinder Service 1. Barrel 2. Rod 3. Piston 4. Head 5. Inte rnal co llar 6. Backup ring 7. O - - ri ng 8. Dust seal 9. Rod seal 10. O - - rin g 1 1. Piston seal 12. Lock nut Figure 85 40 ft - - lb (54 N - - m) 1 6 7 3 9 10 4 11 2 8 5 12 1 6 7 3 9 8 10 4 11 2 5 12[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 1 19 Disassembly (Fig. 85) 1. Pump oil ou t of steering cylinde r into a drain pan by slowly moving rod in an d out of cylinder bore. After oil has been removed from cylinder , plug ports and clean outside of cylinder . IMPORT ANT : Prevent damage when clamping the cylinder in a vise, cl[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic Syst em Page 4 - - 1 20 Engine Cooling Fan Motor 1. Hydraulic fan motor 2. O - - ring 3. Fan bracket 4. Hydraulic fitting (2 used) 5. O - - ring 6. Radiator/oil cooler assembly 7. Fan hub 8. W asher 9. Hex nut 10. Lower radiator shroud 1 1. Cap screw (4 used) 12. Washer (4 used ) 13. Fan 14. Lock nut (2 u[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 121 Removal (Fig. 86) 1. Park machine on a level s urface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Unlatch and raise ho od. CAUTION The radiator and oil cooler may be hot. T o avoid possible burns, allow the engine and cooling sy[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic Syst em Page 4 - - 1 22 4. Position fan hub on to motor shaft and secure with washer (item 8) and hex n ut (item 9). IMPORT ANT : Make sure to not damage the radiator or other machine components while installing the fan motor and bracket as sembly . 5. Carefully positio n fan mo tor and bra cket assembly [...]

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Groundsmaster 4000- - D/4010 - -D Hydraulic Syst em Page 4 - - 1 24 Engine Cooling Fan Motor S ervice 1. Flange washer 2. O - - ring 3. Front flange 4. Dust seal 5. Retaining ring 6. Front wear plate 7. Shaf t seal 8. Backup gasket 9. Pressure seal 10. Rear wear plate 11 . B o d y 12. Idler gear 13. Cap sc rew ( 4 used) 14. Dowel (2 used) 15. Dri v[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 125 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 ring, flange washer and shaft seal from the front flange (Fig. 90). Note orienta tion of seal lip s during rem oval. Discar d re[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic Syst em Page 4 - - 1 26 3. Place f ront flange, seal side down, on a flat surface. 4. Install the pressure se als, flat side outward, into the grooves in the wear plates. Follow by carefully placing t h eb a c k u pg a s k e t s ,f l a ts i d eo u t w a r d ,b e t w e e nt h e pressure seals and the g roo[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 127 Cutting Deck Motors Removal 1. Park machine on a level s urface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Read the General Pre cautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic Syst em Page 4 - - 1 28 Cutting Deck Motor Service (Sau er - - Danfoss) 1. Rear cover 2. Drive gear 3. Seal 4. Woodruff key 5. Nut 6. T ab washer 7. Spid er hub 8. Pressure seal 9. Back - - up ring 10. O - - rin g 1 1. Body 12. Idler gear 13. Cap sc rew ( 4 used) 14. Front flange 15. Dowel pin Figure 94 8[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 129 IMPORT ANT : Mark the relative positions of the gear teeth an d the b earing b locks so t hey can be re - assembled in the same position. Do not touch the gear surfaces as re sidue on hands may be corrosiv e to gear finish. 7. Place the motor on its side and p ush on the rear bear- i[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic Syst em Page 4 - - 1 30 Assembly (Fig. 94) NOTE: When assembling the motor , check the i dentifi- cation marks made during d isassembly to make sure the parts are proper ly aligned during assembly . 1. Lubricate O- - rings, pressure seals, back- -up gaskets and seal grooves with a thi n coat of petroleum [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 131 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic Syst em Page 4 - - 1 32 Cutting Deck Motor Service (Casappa) (45 to 55 N - - m) 33 to 40 ft - - lb 8 7 4 3 2 6 9 10 11 9 12 13 8 14 16 15 14 1 1. Flange washer 2. O - - ri ng 3. Front flange 4. Dust seal 5. Retaining ring 6. Front wear plate 7. Sh aft seal 8. Backup gasket 9. Pressure seal 10. Rear wear p[...]

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

Groundsmaster 4000- - D/4010 - -D Hydraulic Syst em Page 4 - - 1 34 PTO Manifold 1. Hydraulic PTO manifold (center deck) 2. Quick fitting (1 used per manifo ld) 3. Flange screw (2 used per manifold) 4. O - - ring 5. Hydraulic tee fitting 6. O - - ring 7. O - - ring 8. O - - ri ng 9. Hydraulic adapter 10. Str aight f itti ng 1 1. Flange screw (2 u s[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 135 Removal (Fig. 101) 1. Read the General Pre cautions 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 re moval, tho roughly clea n exterior o[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic Syst em Page 4 - - 1 36 PT O Manifold Service 1. PTO manifold body 2. NWD SAE #4 plug with O - - ring 3. Orifice (0.025) (port OR) 4. #6 zero leak plug with O - - ring 5. Relief valve (port RV1) 6. Proportional relief valve (port PRV) 7. Solenoid coil 8. Nut 9. Logic cartridge valve (port LC1) 10. Pilot d[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 137 The manif olds for the three (3 ) cutting d ecks are v ery similar . The front and right side PT O manifolds are identical. The left side P TO manifold use s the same cart- ridges and plugs a s the front and right side manifol ds but also includes an additional orifice that threads i[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic Syst em Page 4 - - 1 38 Side Deck Lift Cylinders 1. Lift arm assembly (LH shown) 2. Shoulder screw 3. Flange nut 4. Pin assembly 5. Lock nut 6. Flat w asher 7. Cylinde r pin 8. Spring pin 9. Lift cylinder 10. 90 o hydraulic fitting 11 . 9 0 o hydraulic f itting Figure 105 FRONT RIGHT 2 3 6 8 9 10 11 1 5 7[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 139 Removal (Fig. 105) 1. Park machine on a level s urface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Read the General Pre cautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repai[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic Syst em Page 4 - - 1 40 Center Deck Lift Cylinders 1. Front frame 2. Flange head screw 3. Flange nut 4. Pin assembly 5. Grease fi tting 6. Cotter pin (2 used per pin) 7. Flat washer (4 used per pin) 8. Cle vis pin 9. Lift cylinder (2 used) 10. RH lift arm assembly 1 1. LH lift arm assembly Figure 106 FRON[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 141 Removal (Fig. 106) 1. Park machine on a level s urface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Read the General Pre cautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repai[...]

Groundsmaster 4000- - D/4010 - -D Hydraulic Syst em Page 4 - - 1 42 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 - - ri ng 10. W ear ring 11 . P i s t o n 12. Lock nut 13. Grease fitting 14. Bushing 15. O - - rin g 16. Seal Figure 108 SIDE [...]

Groundsmaster 4000- - D/4010 - -D Hydraulic System Page 4 - - 143 Disassembly (Figs . 108 and 109) 1. Remove oil fro m lift cylinder into a drain pan by sl owly pumping th e cylinder s haft. Plug both ports and clean the outside of the cy linder . IMPORT ANT : Prevent damage when clamping the cylinder in a vise; clamp on the clevis only . 2. Mount [...]

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Groundsmaster 4000- - D/4010 - -D Page 5 - - 1 Electrical S ystem Chapter 5 Electrical System T able o f Contents GENERAL INFORMA TION 2 ..................... Operator ’s Manu al 2 ....... ................... T o ro Electronic Cont rollers (TEC) 2 ............. Y a nmar Engine Electronic Co ntrol Unit (ECU) 3 ... Y anmar Engine Electrical Compone[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 2 Electrical S ystem General Information Operator ’ s Manual The Operator’s Manual provi des information regard ing the operation, general maintenance and maintenance intervals for your G roundsmaster machine . Refer to th at publication for additional informati on when servicing the machine. T oro E[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 3 Electrical S ystem Y anmar E ngine Electronic Control Uni t (ECU) The Y anmar eng ine that powers the Grou ndsmaster 4000 - -D and 4010 - -D uses an electronic control unit (ECU) for engine management and a lso to communi- cate with the TEC controller s and the InfoCenter Display on the machi ne. All e[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 4 Electrical S ystem CAN - - bus Communications The two (2) TEC controllers, the Y anmar engine elec- tronic control unit and the I nfoCenter Display used on the Groundsmaster 4000- -D and 4010 - - D communicate with each other on a CAN - - bus system. Using this sys- tem allows the traction unit to full[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 5 Electrical S ystem This page is intentionally blank. Electrical System[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 6 Electrical S ystem Special T ools Order special tools from your T oro Distributor . Some tools may also be available from a local supplier . Multimet er The multimeter can test ele ctrical components a nd cir- cuits for current, re sistance or voltage. NOTE: T or o recommen ds the use of a DIGIT AL V o[...]

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

Groundsmaster 4000- - D/4010 - -D Page 5 - - 8 Electrical S ystem InfoCenter Display The InfoCenter Display us ed on your Groundsmaster is a LCD device that is located on the consol e. The Info- Center provides information f or the machine operator during machine operation, p rovides elec trical system diagnostic assistance for technicians an d all[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 9 Electrical S ystem Main Information Scr een The two (2) InfoCenter main information scre ens (Figs. 10 and 1 1) are displayed afte r the initial sp lash screen has been displayed for se veral seconds. Dur ing normal machine operation, the ma in information screens provide machine informatio n for the o[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 10 Electrical S ystem Main Menu Screen The main menu screen can be accessed from the Info- Center main information by pressing and releasing the menu/back b utton (left button ) on the dis play . Once to the main menu scr een (Fig. 12) , navigation to the five (5) diffe rent menu items can occur . Pressi[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 1 1 Electri cal System Service Screen The service scree n (Fig. 13 ) contains m achine oper a- tional information including hours and counts. V alues listed for these service menu items cannot be changed. If the machin e PIN has been en tered to allow acce ss to protected menu item s in the settings scre[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 12 Electrical S ystem Diagnos tics Scree n The diagnostics scr een (Fig. 16 ) lists the vario us states of machine electrical com ponents. The diagnostics screen should be used to check operation of machi ne controls and to v erify t hat switches and circuit wiring a re functioning correctly . For each o[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 13 Electri cal System Settings Screen The settings screen iden tifies the I nfoCenter language and units (English or Metric). The settings screen also allows the operator to customize the backlight (bright- ness) and contrast settings for the I nfoCenter display . If either the backligh t (brigh tness) o[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 14 Electrical S ystem About Screen The about scree n (Fig. 17) i dentifies the ma chine model number , serial numbe r and software revisions for the TEC controllers, In foCenter and engine electr onic con- trol unit (if available). The about screen also lists the CAN - - bus sta tus. Additiona l informa [...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 15 Electri cal System T roubleshooting CAUTION Remove all jewelr y , especially r ings and watches, before doing any elec trical trouble- shooting or testing. Also, disconnect the battery cables unless the tes t requires batter y voltage. For effective troublesho oting and repairs, you must have a good u[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 16 Electrical S ystem Fault Codes The list below identifies the fault codes that are gen er- ated by the TEC controller to identify an electrical sys- tem malfunction (fault) that occurred during ma chine operation. Use the InfoCenter Disp lay for fault retrieval. NOTE: The following list of fault codes [...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 17 Electri cal System Fault Code Fault Description 31 Brake/RH turn light output ha s open or short to ground 32 Brake/LH tu rn light output has open or sho rt to ground 33 Forward piston (traction) pump outpu t has open or short to ground 34 Reverse piston (traction) pump outp ut has open or short to gr[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 18 Electrical S ystem Starting Pr oblems NOTE: Check InfoCenter Display for possi ble operator advisories or faults whenever diagno sing machine elec- trical pr oblems. Problem Possible Causes No electrical power to machine. The battery is discharged. The battery cables are l oose or corroded. F u s eF -[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 19 Electri cal System Starting Problems (C ontinued) Problem Possible Causes Starter cranks, but shoul d not, when the traction peda l is depressed. T raction pedal position sensor is out of adjustment. T raction pedal position sensor or circuit wiring is faulty . Engine cranks, but do es not start. The [...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 20 Electrical S ystem General Run a nd T ransport Pr oblems NOTE: Check InfoCenter Display for possi ble operator advisories or faults whenever diagno sing machine elec- trical pr oblems. Problem Possible Causes Engine conti nues to run, but should no t, when the ignition switch is turned of f. The ignit[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 21 Electri cal System Cutting Deck Operating Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine ele c- trical p roblems. NOTE: T o engage the mow circuit, the operator must be in the operator seat, the t raction speed must be in the LOW speed (m[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 22 Electrical S ystem Cutting Deck Operating Pr oblems (Continued) Problem Possible Causes Cutting decks run, but s hould not, when lower ed with PTO swi tch in the OFF (diseng age) position. The PTO switch or circuit wiring is faulty . The TEC controller is faulty . Cutting deck(s) do not operate. The o[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 23 Electri cal System Cutting Deck Lift/Lower Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine ele c- trical p roblems. NOTE: T ol o w e ra c u t t i n gd e c k ,t h eo p e r a t o rm u s tb ei n the operator seat and the traction speed must b[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 24 Electrical S ystem Cutting Deck Lift/Lower Problems (Continued) Problem Possible Causes Right side cutting deck will not raise or lower , but the center and left side cutti ng decks will raise and lower . The RH deck lift switch or circuit wiring is faulty . Fuse is faulty . Combination control manifo[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 25 Electri cal System Adjustments Cutting Deck Position Switch Adjustment 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 fr om 0.07 0” to 0.130?[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 26 Electrical S ystem T raction Pedal Adjustment The traction pedal includes a neutral asse mbly that is used to adjust the traction neutral position (Fig. 20). T r action pedal ad justment ma y be necessary to mak e sure that traction pe dal movement provides the correct full reverse and full forward po[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 27 Electri cal System 6. After any adju stment of the spring shaft and rod end bearing, use the InfoCenter Display Diagnostics menu (see InfoCenter Display in this chap ter) to obtain and se- lect the T raction Pedal me nu item. Choose O utputs and the InfoCenter display will identify the traction pedal [...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 28 Electrical S ystem T raction Pedal Position Sensor Calibration IMPORT ANT : A properly installed and calibrated traction pedal position sensor is critical to accurate traction system respons e and for reliable sensor life. Use care when rem oving, installing and cali- brating the traction pedal positi[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 29 Electri cal System Electrical System Quick Checks Battery T est (Open Circuit) Use a multimeter to measure the voltage between th e battery terminals. Set multimeter t o the DC volts settin g. The batt ery should be at a tempera ture of 60 o to 100 o F( 1 6 o to 38 o C). The ignition key sho uld be of[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 30 Electrical S ystem Component T esting For accurate resistance and/or continuity checks, elec - trically disconne ct the component being tested from the circuit (e.g. unplug the ignition switch connector b efore checking continuity on the switch). NOTE: For engine component testing informatio n, see th[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 31 Electri cal System Fuses The fuse block is located unde r the controller cover next to the operator seat (Fig. 28). In addition to the fuses in the fuse block, a 60 Amp fuse is included in the wire harness to protect the power cir- cuit for the operator cab. This fuse reside s in a fuse hold- er near [...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 32 Electrical S ystem Operator Cab Fuses (Groundsmaster 4010 - - D) The operator cab fuse blocks a re located in the cab headliner (Fig. 30). Identification and Function (Figs. 30 and 31) Fuse F1 - -2 (15 Amp) protects the cab fan circuit. Fuse F1 - - 3 (30 Amp) pr otects the air cond itioner circuit. Fu[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 33 Electri cal System Fusible Link Harnes s Y our Groundsmaster uses two (2) fusible links for circuit protection . These fusible links are located in a harness that connects the starter B+ terminal to the wire harness (Fig. 33). If either of these links should fail, current to the protected circu its wi[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 34 Electrical S ystem PTO Switch T h eP T Os w i t c hi s l o c a t e do nt h ec o n t r o la r m( F i g .3 5 ) . The PTO switch is pull ed up to engage the PTO and pushed in to diseng age the PTO. The TEC controller monitor s the position of the PT O switch (up or down). Using inputs from the PT O switc[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 35 Electri cal System HI/LOW Speed, Engine Speed and Cutting Deck Lift Switches The HI/LOW , engine speed an d cutting deck lift switches are all identical momenta ry switches. These switches are loc ated on the control arm (Fi g. 37). The HI/LOW speed switch is used as an input f or the TEC controller t[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 36 Electrical S ystem Cruise Control Switch The cruise control switch is u sed as an input for the TEC controller to maintain gr ound speed when engaged . The cruise control function is enabled when the switch is in the ON (center) position. Pressing the front of the switch to the momentary position sets[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 37 Electri cal System Seat Switch The seat switch is normally open and close s when the operator is on the seat. This switch is used a s an input for the TEC controller . The sea t switch and its electrical connector are located in t he seat assembly . If the trac- tion system or PTO switch is engaged wh[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 38 Electrical S ystem Parking Brake Switch The switch used for the par king brake is a normal ly open proximity switch that is located unde r the steering tower cover (Fig. 42). The parki ng brake switch is an input fo r the TEC controller . When the parking brake is not ap- plied, a tab on the br ake ro[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 39 Electri cal System Service Brake Switches The two (2) switc hes used for th e service brak es are nor- mally open switches that are located under the footrest panel (Fig. 43). The service brake switches provide in- puts for the TEC controller . When a brake pe dal is not depressed, the brake pedal ass[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 40 Electrical S ystem Headlight Switch (Groundsmaster 4010 - - D) The Groundsma ster 4010 - - D headlight switch is a two (2) position rocker switch tha t is located on the inside of the control arm. The headlight switch allows the head- lights and taillights to be turned on and off. T esting 1. Make sur[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 41 Electri cal System Windshiel d Wiper/W asher Sw itch (Groundsmaster 4010 - - D) The windshield wiper/washer switch is used to control operation of the windshield w iper and washer pump on the Groundsmaster 4010- -D. The windshield wiper/wa- sher switch is located in the cab headliner (Fig. 46). Te s t[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 42 Electrical S ystem Air Conditioning S witch (Groundsmaster 4010 - - D) The air conditioning switch is used to control operation of the air conditioning syst em on the G roundsmaster 4010 - - D. The switch is located in the cab headliner (Fig. 48). T esting 1. Make sure ignition switch is OFF . Remove [...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 43 Electri cal System T urn Signal Switch (Gr oundsmaster 4010 - - D) On Groundsmaster 4010- -D machines, the turn signal switch is used as an input for the TEC controller to pro- vide power for the tur n signals. The switch is located on the steering t ower (Fig. 50). Te s t i n g 1. Before disconnec ti[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 44 Electrical S ystem Flasher Switch (Groundsmaste r 4010 - - D) On Groun dsmast er 4010 - - D machin es, the f lasher switch is used as an input for the TEC contro ller to pro- vide power for the fou r way flashers. The swi tch is lo- cated on the stee ring tower (Fig. 52). T esting 1. Before disconnect[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 45 Electri cal System T raction P edal Position Sensor The traction pedal position sensor is connected to the traction peda l assembly (Fig. 54). This position senso r determines the neutra l band for the traction peda l, the direction of travel desired by th e operator and the trac- tion speed. The posi[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 46 Electrical S ystem Relays with Four (4) T erminals Y our Groundsmaster uses a number of electrical relays that have four (4) terminals. A tag near the wire h arness relay connector can be u sed to identify each relay . The main power r elay is used to pro vide current to most of the fuse protected ci [...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 47 Electri cal System 5. Using a multimeter , verify that coil resistance be- tween terminals 86 and 85 is approximately 72 ohms. 6. Connect multimeter (ohms setting ) leads to relay ter- minals 30 and 87. Ground terminal 86 an d apply +12 VDC to terminal 8 5. The relay should make and break continuity b[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 48 Electrical S ystem Relays with Five (5) T erminals Y our Groundsmaster uses a number of electrical relays that have five (5 ) termin als. A tag near the wire harness relay connector can be u sed to identify each relay . The air conditioning rel ay is used to control the air c ondi- tioning electrical [...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 49 Electri cal System 8. Connect multimeter (ohms setting ) leads to relay ter- minals 30 and 87A. Appl y +12 VDC to terminal 85. The relay should make and break continuity between termi- nals 30 and 87A as +12 VDC is applied an d removed from terminal 85. 9. After testing, discon nect voltage and mul ti[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 50 Electrical S ystem T oro Electronic Controllers (TE C) Groundsmaster 4000 - - D and 4010 - - D machines use two (2) T oro Electronic Controllers (TEC) to control electrical system operation. The controllers are attached to the operator platform under the co ntroller cover (Figs. 64 and 65). Logic powe[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 51 Electri cal System IMPORT ANT : When testing for wire harness con- tinuity at the connector for the TEC controller , tak e care to not damage the connector pins with multi- meter test leads. If connector pins are enlar ged or damaged during testing, connector repair will be necessary for pr oper machi[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 52 Electrical S ystem Hydraulic Solenoid V alve Coils Figure 66 1. Front PTO manifold 2. RH P TO manifo ld 3. LH PTO manifold 4. Combination manifold FRONT RIGHT 2 3 1 4 Several hydraulic solenoid v a l v ec o i l sa r eu s e do nt h e hydraulic control manifol ds of Groundsmaster 4000- -D and 4010 - - D[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 53 Electri cal System Te s t i n g 1. Park machine on a level surface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Locate hydraulic solenoid valve coil to be tested (Fig. 66). Disconnect wire harness co nnector from coil. 3. Identify coil resistanc[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 54 Electrical S ystem Piston (T raction) Pump Control Solenoid Coils The piston (tract ion) pump us es an electronic con trol as- sembly for swash p late rotation. Electrical outputs from the machine TEC controller are p rovided to two (2) solenoid coils for pump control. The piston pump control assembly[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 55 Electri cal System CAN - - bus T ermination Resistor System communication between electrical comp onents on Groundsmaster 40 00 - -D and 4010 - - D machines is accomplished on a CAN - - bus communication system. T wo (2) specially designed, twisted wires form the bus for the network used on the machin[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 56 Electrical S ystem Diode Assemblies The Groundsmaster engine wire ha rness contains a diode assembly that i s used for circuit protection from voltage spikes when the en gine starter solenoid is de - - energized . Groundsmaster models 30607 an d 30609 use an addi- tional diode assembly in the engi ne [...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 57 Electri cal System Fuel Sender The fuel sender is attached to the top of the fuel tank. The resistance of the fue l sender increases as the fuel level in the fuel tank decreases. The TEC contr oller uses the fuel sender as an in put to generate an ou tput for the InfoCente r fuel gauge. T wo (2) style[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 58 Electrical S ystem Fuel Pump (Models 30603 and 30605) The fuel pump is atta ched to the fuel tank sup port above the fuel water separator (Fig . 76). Operational T est 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake. Raise hood to access fuel pump. 2. Disco[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 59 Electri cal System Fuel Pump (Models 30607 and 30609) The fuel pump is atta ched to the fuel t ank support abo ve the fuel water se parator (Fig. 78). Operatio nal T est 1. Park machine on a level surface, lower cu tting decks, stop engine and apply parking brake. Raise hood to access fu el pump. 2. D[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 60 Electrical S ystem Cutting Deck Position Switches Three (3) cutting dec k position switches are used on the Groundsmaster 4000 - - D and 4010 - -D. These switches are located on t he traction un it frame (Figs . 80 and 81). The position switches are powered proximity switches that incorporate an inter[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 61 Electri cal System Hydraulic Oil T emperature Sender The Groun dsmas ter 4000 - -D and 4 010 - - D use a tempe r- ature sender as an input for the TEC controlle r to identify if the hydraulic o il temperat ure has reac hed an exces - sive level. The hydrauli c oil temperature sen der is at- tached to [...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 62 Electrical S ystem Audio Alarm The audio al arm sounds to notify the operator when a machine problem exists. Electrical curr ent for the alarm is provided as an output fro m the TEC controller . The alarm is attached to the control arm next to the operator seat. T esting 1. Make sure ignition switch i[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 63 Electri cal System Service and Repairs NOTE: For engine component re pair information (e.g. starter motor), refer to the Y anmar Work shop Manual that is correct fo r your Groundsmas ter model. Battery Care 1. The top of the batte ry must be kept clean. lf the ma- c h i n ei ss t o r e di nal o c a t [...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 64 Electrical S ystem Battery Service The battery is the heart of th e electrical system. With regular and proper service, battery life can be e xtended. Additiona lly , battery and electri cal component failure can be prevented. CAUTION When working with batter ies, use extreme cau- tion to avoid splash[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 65 Electri cal System Battery T esting 1. Perform a high- - discharge test with an adjustable load tester . T his is one of the most reliable m eans of test - ing a battery as it simulates the cold - - cranking test. A commercial battery load tester is required to perform this test. CAUTION Follow the ma[...]

Groundsmaster 4000- - D/4010 - -D Page 5 - - 66 Electrical S ystem Battery Charging T o minimize possible damage to the battery and allow the battery to be fully charged, th e slow charging meth- od is presented h ere. This char ging method ca n be ac- complished with a constant current battery charger which is readily available. CAUTION Follow the[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 1 Axles, Planet aries and Brake s Chapter 6 Axles, Planetaries and Brakes T able o f Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TION 3 ..................... Operator ’s Manu al 3 ....... ................... ADJUSTMENTS 4 .............................. Planetary Wheel Drive [...]

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 . 2 5 0i n( 6m m ) Planetary gear drive oil SAE 85W - - 140 wt. gear lube System gear lube capacity (each wheel) 22 fl. oz. (0.65 liters) Rear axle lubri[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 3 Axles, Planet aries and Brake s General Information Operator ’ s Manual The Operator ’s Manu al provides informa tion regarding the operation, general main tenance and maintenance intervals for your Ground smaster machine. Refer to that publication for additional information when servicing the mach[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 4 Axles, Planetaries and Brakes Adjustments Planetar y Wheel Driv e Assembly E ndplay A front planetary wheel drive assembly that is properly operating should have no en dplay . Any endpla y in a planetary assembly indicates tha t there are potential problems with the planetary . Check planetary endplay [...]

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Groundsmaster 4000- - D/4010 - -D Page 6 - - 6 Axles, Planetaries and Brakes Service and Repairs Brake Assembly Figure 1 FRONT RIGHT 75 to 85 ft - - lb (101 to 1 15 N - - m) 85 to 100 ft - - lb (1 15 to 135 N - - m) 75 to 85 ft - - lb (101 to 1 15 N - - m) 2 3 6 8 9 11 13 1 5 7 12 14 15 4 10 1 6 7 8 13 1. Front wheel motor 2. Internal retaining rin[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 7 Axles, Planet aries and Brake s Removal (Fig. 1) 1. Park machine on a level s urface, lower cutting decks, stop engine and remove key from the ignition switch. 2. Drain oil from planetary wheel drive/bra ke assembly (Fig. 2). CAUTION When remo ving f ront wh eel, u se corre ct jacks and supports. Make [...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 8 Axles, Planetaries and Brakes 2. Apply g asket sealant to sealing surfaces of new gas- ket (item 18). Apply gasket to brake assembly . 3. Install brake assembly onto machine, aligning splined brake shaf t with input shaft on planet ary wheel drive. Make sure th at brake pull rod is orientated toward re[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 9 Axles, Planet aries and Brake s This page is intentionally blank.[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 10 Axles, Planetaries and Brakes Brake Inspection and Repair 1. Brake housing (LH show n) 2. Seal 3. Pull rod 4. Clevis pin (2 used) 5. Link (2 used) 6. Hit ch pin ( 2 used) 7. Stationary disc (4 used) 8. Rotating disc (3 use d) 9. Retaining ring 10. Gask et 1 1. Rotat ing act uator 12. Extension spring [...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 1 1 Axles, Planetaries and Brakes This page is intentionally blank.[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 12 Axles, Planetaries and Brakes Planetary Wheel Drive Assembly Figure 7 FRONT RIGHT 75 to 85 ft - - lb (101 to 1 15 N - - m) 85 to 100 ft - - lb (1 15 to 135 N - - m) 75 to 85 ft - - lb (101 to 1 15 N - - m) 2 3 6 8 9 11 13 1 5 7 12 14 15 4 10 1 6 7 8 13 16 17 18 19 20 21 1. Front wheel motor 2. Interna[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 13 Axles, Planetaries and Brakes Removal (Fig. 7) 1. Park machine on a level s urface, lower cutting decks, stop engine and remove key from the ignition switch. 2. Drain oil from planetary wheel drive/bra ke assembly (Fig. 8). CAUTION When remo ving f ront wh eel, u se corre ct jacks and supports. Make s[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 14 Axles, Planetaries and Brakes Planetary Wheel Drive Service 1. Spindle 2. Boot seal 3. Oil seal 4. Inner bearing cone 5. Inner bearing cup 6. Whee l stud (8 use d) 7. Socket head screw (16 used) 8. Lock washer (16 used) 9. Housing 10. Dowel pin (2 used) 1 1. O uter bearing cup 12. Outer bearing cone 1[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 15 Axles, Planetaries and Brakes NOTE: The planetary wheel drive assem bly can be ser- viced with the p lanetary installed to machine. If the spindle (item 1) needs to be re moved from mach ine, see Planetary Wheel Drive A ssembly in this section. Disassembly (Figs . 10 and 1 1) 1. If plane tary wheel dr[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 16 Axles, Planetaries and Brakes F . Lightly oil bearing journals on spindle shaft. Slide housing assembly onto spindle (item 1) taking care to not damage seal or spindle. Make sure that inner bearing in housing fully seats against spin dle shaft shoulder . G. Install outer bearing cone (item 12) onto sp[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 17 Axles, Planetaries and Brakes This page is intentionally blank.[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 18 Axles, Planetaries and Brakes Rear Axle Assembly 1. Plug with O - - ring 2. Lug nut (5 used per wheel) 3. Rear wheel assembly (2 used) 4. Cap screw (2 used) 5. Flat washer (8 used) 6. Rear axle motor 7. O - - ring 8. Steering cylinder 9. Spacer 10. Cotter pin (2 used) 1 1. Slotted hex nut (2 used) 12.[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 19 Axles, Planetaries and Brakes Removal (Fig. 12) 1. Park machine on a level s urface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Drain oil from rear axle and axle gearbo x (Figs. 13 and 14). 3. Chock front wheels and jack up rear of machine (see J[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 20 Axles, Planetaries and Brakes 2. Secure rear axle to re ar axle mount. A. Slide rear axle pin through rear axle mount and rear axle. Ins tall washer and lock nut onto rear a xle pin. B. Secure pivot pin to axle mount with washer head screw (Fig. 16). C. T orque lock nut from 135 to 165 ft - - lb (184 [...]

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Groundsmaster 4000- - D/4010 - -D Page 6 - - 22 Axles, Planetaries and Brakes Rear Axle Service Figure 19 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 64 22[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 23 Axles, Planetaries and Brakes 1. LH axle support 2. Flange bushing (2 used) 3. Axle vent 4. Filter 5. V ent extension 6. Cap screw (4 used per gear case) 7. Shi m set 8. Seal washer 9. Plug 10. Lock nut 1 1. Lock washer 12. Grease fitting 13. Bal l bear ing 14. Screw (2 used per steering arm) 15. Axle[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 24 Axles, Planetaries and Brakes Bevel Gear Case and Axle Case The following proce dures assume the rear axle assem- bly has been re moved from the machine. Removal 1. Remove the moun ting screws, nuts and lock wash- ers. Remove th e bevel ge ar case/axle case assembly and O-ring from the ax le support ([...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 25 Axles, Planetaries and Brakes 5. Remove the knuckl e pin mounting screws and the knuckle pin. Remove the g asket and any remaining gas- ket mater ial from either m ating surface (Fig. 23). 6. While hol ding the bevel gear case , tap the upper end of the bevel gear shaft o ut of the upper bearing and u[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 26 Axles, Planetaries and Brakes Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 25). 1. Axle case 2. Bevel gear case 3. Sh aft seal Figure 25 1 2 3 2. Install the lower beve l gear and bevel gear shaft in the axle case cover . Coat a new O-ring with grease and ins[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 27 Axles, Planetaries and Brakes 5. Determine necessary qu antity of support shims. A . L u b r i c a t et h ea x l ec a s es u p p o r tb u s h i n gw i t ha thin coat of grease and slide axle case suppo rt onto knuckle pin. B. Position support shims that were removed during disassembly between axle cas[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 28 Axles, Planetaries and Brakes 9. Remove th e bevel gear case/ax le case assembly from the axle suppo rt. Coat a new O-rin g with grease and temporar ily install the ax le cover assembly . Position a dial indica tor at the tooths center . Preve nt the axle from turning and measure the lower bevel ge ar[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 29 Axles, Planetaries and Brakes Axle Shafts The following p rocedure s assume t he rear a xle assem- bly has been removed fr om 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. 32). 2. Use a bea ring puller t[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 30 Axles, Planetaries and Brakes Input Shaft/Pinion Gea r Figure 35 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. Beari ng 10. O -ring 1 1. Input shaft/pinion gear 12. Bearing case 13. Shim 14. Screw (2 used) 15. Gea r case [...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 31 Axles, Planetaries and Brakes 5. Instal l a new stake washer . Install the lo ck nut finger tight. 6. Set the beari ng 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 un til 4 to 6[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 32 Axles, Planetaries and Brakes Differentia l Gear The following proce dures assume the rear axle assem- bly has been re moved 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 - - 33 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 ca se clearance (Fig. 42) . Replace components as necessa ry . SIDE GEAR TO CASE CLEARANCE: 0 . 0 0 2t o0 . 0 1 2i n c h( 0 . 0 5t o0 . 3 0m m ) SIDE GEAR[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 34 Axles, Planetaries and Brakes Installation 1. If the r ing gear was removed from the dif ferential case, use medium strength Loctite thread locker and tighten the mountin g screws from 22 to 25 ft -lb (30 to 34 N - - m) . 2. Apply molybdenum disul fide lubricant (Three Bond 1901 or equivalent ) to the[...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 35 Axles, Planetaries and Brakes Pinion Gear to Ring Gear Engagement The final position o f the pinion gear is verified b y using the gear contact pattern method as de scribed in the fol- lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 46): To e - - th e portion of the too th surface at the end to- wards [...]

Groundsmaster 4000- - D/4010 - -D Page 6 - - 36 Axles, Planetaries and Brakes Gear Patter n Movement Summar y Every gear has a characteristic pattern. The il lustrations show typical patte rns only and exp lain how patt erns shift as gear location is chan ged. 1. If contact is toward the heel or base of the g ear (Fig. 49): A. Install thick er or a[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 1 Chassis Chapter 7 Chassis T able o f Contents GENERAL INFORMA TION 1 ..................... Operator ’s Manu al 1 ....... ................... SERVICE AND REP AIRS 2 ...................... Steeri ng T o wer 2 .......... ................... Center Deck Lift Arms 4 ........... ............ Side Deck Lift[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 2 Chassis Service and Repairs Steering T o wer Figure 1 FRONT RIGHT 27 to 33 ft - - l b ( 3 7t o4 4N - - m ) 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 7 10 20 to 26 ft - - lb ( 2 8t o3 5N - - m ) 20 19 1. Steer ing wh eel co ver 2. Hex n ut 3. Flat w asher 4. Steer ing wh eel 5. Foam collar 6. S[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 3 Chassis Disassembly (Fig. 1) 1. Park machine on a level s urface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Remove steering tower covers to access ste ering tower components (Fig. 2). 3. Disassemble steering tower as needed u sing Figure 1 as a g[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 4 Chassis Center Deck Lift Arms 1. Center deck assembly 2. Grease fitting 3. Bal l joint s eal 4. Hydraulic deck motor 5. Flange head screw 6. RH lift arm 7. LH lift arm 8. Lift cylinder (2 used) 9. Pin (2 used) 10. Flange nut (2 used) 1 1. Jam nut (LH threads) (2 used) 12. Ball joint (LH threads) (2 use[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 5 Chassis Removal (Fig. 3) 1. Park machine on a level s urface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Remove center cutting deck (see Ce nter Cutting Deck Removal in Chapter 8 - - Cutting Decks). CAUTION When changing attachments, tires or perf[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 6 Chassis 7. Install ball joi nt mount to ball joint with slotted hex nut. T or que nut f rom 90 t o 100 ft - - lb (123 t o 135 N - - m) while aligning cotte r pin holes. Install cotter pin . 8. Install center cuttin g deck (see Center Cutting Deck Installation in Chapte r 8 - - Cutting Decks). 9. If bal[...]

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

Groundsmaster 4000- - D/4010 - -D Page 7 - - 8 Chassis Side Deck Lift Arms 1. Lift cylinder pin 2. Slotted roll pin 3. Flange head screw 4. Rubber bumper 5. Rivet (2 per bumper) 6. Cap screw 7. Thrust washer 8. Lift ar m pivot sh aft 9. Pivot hub 10. Thrust washer (as needed) 1 1. Spring pin 12. T apped block 13. Flat washer (5 used per side) 14. F[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 9 Chassis Removal (Fig. 6) 1. Park machine on a level s urface, 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 - - 10 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. Straight bushing 12. Spring shaft 13. Flat washer 14. Compression spring 15. Plastic bearing 16. Pl[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 1 1 Chassis Rear Arm Rem oval (Fig. 9) 1. Park machine on a level s urface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Remove hair pin (item 6) and clevis pin (item 5 ) that connect damper link to cutting d eck. 3. Remove cap screw (item 3) and lock[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 12 Chassis Rear Arm Installation (Fig. 9) 1. Position rear arm assembly to cutting de ck and frame. 2. Slide pivot shaft throu gh rear arm clevis and hub. Se- cure pivot shaft with lock washer (item 24) an d lock nut (item 25). 3. Connect damper link to cutting deck with cl evis pin (item 5) and hair pin[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 13 Chassis This page is intentionally blank. Chassis[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 14 Chassis Lift Arm Joint Y oke 1. Side cutting deck (LH show n) 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. Join t yoke 10. Spacer 1 1. Thrust w asher (0.125” thickness) 12. Hardened washer 13. Co[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 15 Chassis Joint Y oke Dis assembly 1. Remove retaining rings from yoke and deck mount. IMPORT ANT : Support yoke when removing cross and bea rings to pr event yo ke damage. 2. Use a pre ss to remove yoke from deck moun t: A. Place a small so cket against on e bearing in the deck mou nt and a large socke[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 16 Chassis Control Arm 1. Flange nut (3 used) 2. Flange head screw (2 used) 3. W asher head screw (10 used) 4. LH cover 5. Lock nut 6. Control arm panel 7. Igni tio n swit ch 8. InfoCenter display 9. R - - clamp 10. Audio alarm 11 . P T O s w i t c h 12. Nut 13. Bracket 14. U - - nut (5 used) 15. Clip (2[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 17 Chassis Disassembly (Fig. 15) 1. Park machi ne on a level sur face, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 2. Remove two (2) flan ge head screw s (item 27) and then cover plate (ite m 26) from outside of co ntrol arm. Locate and retrieve two (2) spa[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 18 Chassis Tr a c t i o n P e d a l 1. Carriage bolt (6 used) 2. T raction pedal 3. Bushing 4. Operator platform 5. Cap screw 6. Rod end bearing 7. Hex nut 8. Flange nut ( 10 used) 9. T raction pedal shaft 10. Roll pin 1 1. Cap screw (2 used) 12. Clamp block (2 used) 13. Lock nut 14. Cap screw 15. Flange[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 19 Chassis IMPORT ANT : A properly installed and calibrated traction pedal position sensor is critic al to accurate traction system response a nd for reliable sensor life. Use care w hen removing, installing and cali- brating the traction pedal position s ensor . Disassembly (Fig. 17) 1. Park machine on [...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 20 Chassis Operator Platform 1. Operator platform 2. Cap screw (2 used) 3. Flat washer (4 used) 4. Center mount (4 u sed) 5. Plain washer (4 used) 6. Lock nut (4 used) 7. Cap screw (2 used) Figure 19 FRONT RIGHT 3 2 1 4 5 6 7 3 4 5 6 95 to 1 15 ft - - lb (129 to 155 N - - m)[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 21 Chassis Some service procedures (e.g. removing the hydraulic reservoir) require the operator platform to be raised. The f o l l o w i n gs t e p sc a nb eu s e dt or a i s et h ep l a t f o r m . Disassembly (Fig. 19) 1. Park machine on a level s urface, lower cutting decks, stop engine, apply parking[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 22 Chassis Assembly (Fig. 19) 1. Make sure that al l machine components are installed below operator platfo rm before platform is lowered to frame. IMPORT ANT : Make sure to not damage the elect ric- al wire harness or other components while lowering the operator platform . 2. Carefully lower ope rator p[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 23 Chassis This page is intentionally blank. Chassis[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 24 Chassis Operator Seat 1. Carriage screw (5 used) 2. Support channel 3. Support bracket 4. Flange nut (6 used) 5. Cap screw 6. Flat washer (4 used) 7. Arm support 8. Screw 9. Coupler nut 10. Spacer 1 1. Flange nut (4 used) 12. Seat belt 13. Cap screw 14. Seat latch 15. Locking cotter pin 16. Latch rod [...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 25 Chassis Removal (Fig. 24) 1. Park machine on a level s urface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Disconnect seat electrical connector from machine wire harness (Fi g. 25). 3. Support c ontrol arm assembly to p revent it from shift- ing. [...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 26 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) 11 . W a s h e r 12. Cap screw (2 used) 13. Seat 14. Nut 15. Spring (2 used) 16. Magnet 17. [...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 27 Chassis Disassembly (Fig. 27) 1. Disassemble operator sea t as necessary using Fig- ures 27 and 28 as gu ides. Assembly (Fig. 27) 1. Assemble operator seat using Figures 27 and 28 as guides. 1. Operator seat 2. R - - clamp ( 2 used) 3. Scre w (2 used ) 4. Manu al tube 5. Flat washer 6. Seat belt 7. Ca[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 28 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. W asher ( 2 used) 15. T ether 16. Rivet (2 used) 17. W as[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 29 Chassis NOTE: Most of the seat suspension com ponents can be serviced with the seat suspension base mounte d to the frame platform. If the air spring assembly (ite m 6) re- quires removal, the seat su spension base will have to be removed from the seat platform. Disassembly (Fig. 29) 1. Remove operato[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 30 Chassis Hood 1. Hood 2. Screen assembly 3. Bulb seal 4. Flange nut (2 used) 5. Screen pivot (2 used) 6. Hair pin (2 used) 7. Hood support 8. Plastite screw (4 used) 9. Door handle (2 used) 10. Bulb seal 1 1. Hood pivot (2 used) 12. Flexible draw latch (2 used) 13. Corner screen seal (2 used) 14. Screw[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 31 Chassis Removal 1. Park machine on a level s urface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Remove hood asse mbly from machine: A. Remove hair pins (item 6) that retain screen pivots to hood pi vots. B. Slide hood assembly to disengage screen[...]

Groundsmaster 4000- - D/4010 - -D Page 7 - - 32 Chassis This page is intentionally blank.[...]

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

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

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

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

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. Center Cutting Deck Figure 1 FRON T RIGHT 150 to 175 ft - - lb (203 to 237 N - - m) 90 to 100 ft - - lb (123 to 135 [...]

Groundsmaster 4000- - D/4010 - -D Cutting Decks Page 8 - - 7 Removal (Fig. 1) 1. Position machine on a cl ean, level surface. Lower cutting decks, stop engine, a pply parking brake and re- move key from the ignition switch. 2. Remove spring pin (item 32 ) that secures damper (item 30) to cutting deck. Position damper away from cutting deck . NOTE: [...]

Groundsmaster 4000- - D/4010 - -D Cutting Decks Page 8 - - 8 Side Cutting Decks 1. Cutting deck (LH shown) 2. Flange head screw (2 used) 3. Hydraulic deck motor 4. Spider 5. Cle vis pin 6. Hai r pin 7. Deck mount (LH shown) 8. Cap s crew (8 used p er moun t) 9. Lock washer (8 used per mou nt) 10. Flat w asher (8 us ed per mount ) 1 1. Lift arm (LH [...]

Groundsmaster 4000- - D/4010 - -D Cutting Decks Page 8 - - 9 Removal (Fig. 5) 1. Position machine on a cl ean, level surface. Lower cutting decks, stop engine, a pply 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 - - 10 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. Cut ting d eck (fr ont sh own ) 2. Flange nut 3. Flange nut 4. Adjusting screw 5. Idler pulley 6. Driven spindle (double pulley s hown) 7. Flat w asher 8. Lock washer 9. Socket head screw 10. Idl[...]

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

Groundsmaster 4000- - D/4010 - -D Cutting Decks Page 8 - - 12 Blade Spindle As semblies 1. Center cutting deck 2. RH cutting deck 3. LH cutting deck 4. Drive spindle assembly 5. Driven spindle assembly 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 s urface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Remove covers from cutting deck to allow access to spindle assemblies. 3. If drive spindle assembly is to be serviced, remov [...]

Groundsmaster 4000- - D/4010 - -D Cutting Decks Page 8 - - 14 Blade Spindle Ser vice 1. Lock nut 2. Hardened washer 3. Driven pulley (single shown) 4. Spindle shaft 5. Drive pulley 6. Hydraulic motor mount 7. O - - ri ng 8. Oil seal 9. Bear ing cu p and co ne 10. Spac er set 1 1. Spindle housing 12. Grease fitting 13. Spindle shaft spacer Figure 13[...]

Groundsmaster 4000- - D/4010 - -D Cutting Decks Page 8 - - 15 2. Instal l 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 th e top and bottom of the spindle housin g. The top bearing cup must contact the outer bearing s pacer previously installed, a[...]

Groundsmaster 4000- - D/4010 - -D Cutting Decks Page 8 - - 16 Castor Forks and Wheels 1. Castor arm (center deck shown) 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[...]

Groundsmaster 4010- - D Operator Cab Page 9 - - 1 Chapter 9 Operator Cab T able o f Contents GENERAL INFORMA TION 2 ..................... Operator ’s Manu al 2 ....... ................... Electrical Components an d Schematic 2 ......... Air Conditioning S ystem 2 ..................... Cab Heater System 2 ............. ............ SERVICE AND REP[...]

Groundsmaster 401 0 - -D Operator Cab Page 9 - - 2 General Information The information in this ch apter pertains to the operator cab on the Groundsmaster 4010- - D. Operator ’ s Manual The Operator’s Manual provi des information regard ing the operation, general maintenance and maintenance intervals for your Groundsmaster . Refer to the Opera- [...]

Groundsmaster 4010- - D Operator Cab Page 9 - - 3 Service and Repairs General Precautions for R emoving and Inst alling Ai r 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 com pletely discharged by a certified A/C service te[...]

Groundsmaster 401 0 - -D Operator Cab Page 9 - - 4 Air Conditioning Compressor Figure 1 FRONT RIGHT 1. Cap s crew (2 used ) 2. Flat washer (4 used) 3. Lock washer (6 used) 4. Hex nut (2 used) 5. Conduit 6. O - - ri ng (2 u sed) 7. 90 o fitting 8. O - - ring 9. A/C compressor 10. Cap screw (4 used) 1 1. Cap scr ew ( 2 used) 12. A/C compressor mount [...]

Groundsmaster 4010- - D Operator Cab Page 9 - - 5 7. Read the General Pre cautions for Removing and Installing Air Conditioning System Components at the beginning of the Service and Repairs section of this chapter . CAUTION The air conditioning system is under high pres- sure. Do not loosen any system fitting or compo- nent until after the system h[...]

Groundsmaster 401 0 - -D Operator Cab Page 9 - - 6 Roof Assem bly 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) 11 . H e a d l i n e r 12. Front spacer (2 used) 13. Fro nt fa stener (2 use d) 14. Rubbe[...]

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

Groundsmaster 401 0 - -D Operator Cab Page 9 - - 8 Air Conditioning Condenser As sembly 1. Condenser cover 2. Lock nut (4 used) 3. Condenser fan 4. Condenser coil assembly 5. Car riage s crew (2 u sed) 6. Flat washer (8 used) 7. Roof 8. Bus hing ( 4 used) 9. Moun ting st rap 10. But ton hea d screw (4 use d) Figure 5 2 1 3 4 7 8 5 9 6 2 6 8 10 6 6 [...]

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

Groundsmaster 401 0 - -D Operator Cab Page 9 - - 10 Heater/Evapor ator Assembly 1. Heater/evaporator assembly 2. T op cover 3. Flange head screw (2 used) 4. Drier - - receiver mount 5. Bottom cover 6. Hose clamp (2 used) 7. Speed n ut (8 us ed) 8. Panel nut (4 used) 9. Drier - - receiver assembly 10. Screw (8 used) 1 1. Screw (4 used) 12. Blower fa[...]

Groundsmaster 4010- - D Operator Cab Page 9 - - 1 1 7. Loosen hose c lamp that secures air duct hose to heater/evaporator assemb ly covers. Slide hose from covers. 8. Remove screws that se cure top cover to bottom cov- er . Remove top cover to access heater/evaporator as- sembly . 9. Disassemble heater/eva porator assembly using Fig. 7 as a guide. [...]

Groundsmaster 401 0 - -D Operator Cab Page 9 - - 12 Windshiel d Wiper 1. Wiper motor 2. Gasket 3. Linkage bracket 4. Lock washer 5. Cap screw 6. Cap (2 use d) 7. W asher 8. Nut 9. Flange nu t (2 used) 10. Cover (2 used) 1 1. Wiper arm assembly 12. Wi per b lade 13. Screw (2 used) Figure 10 2 3 6 8 9 10 11 13 1 5 7 12 4[...]

Groundsmaster 4010- - D Operator Cab Page 9 - - 13 Disassembly (Fig. 10) 1. Park machine on a level s urface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. If access to wiper motor is necessary , remove fasten- ers that secure roof in place. Ra ise and support roof to allow access to condenser a[...]

Groundsmaster 401 0 - -D Operator Cab Page 9 - - 14 This page is intentionally blank.[...]

Groundsmaster 4000- - D/4010 - -D Foldout Drawings Page 10 - - 1 Chapter 10 Foldout Drawings T able o f Contents ELECTRICAL DRA WING DESIGNA TIONS 2 ....... HYDRAULIC SCHEMA TIC 3 ............... ...... ELECTRICAL SCHEMA TICS Models 3060 5 and 30603 4 .............. ...... Models 3060 9 and 30607 5 .............. ...... Operator Cab 6 .............[...]

Groundsmaster 4000- - D/4010 - -D Foldout Drawings Page 10 - - 2 Electrical Drawing Designations The following a bbreviations are used fo r wire harness colors on the electrical sch ematics and wire harness drawings in this chapter . ABBREVIA TION COLOR BK BLACK BR or BN BROWN BU BLUE GN GREEN GY GRA Y OR ORANGE PK PINK Ro rR D R E D TT A N VIO VIO[...]

Page 10 - - 3 Hydr aulic Sc hema tic Groundsmaster 4000 - - D/4010 - - D S10 RV1 CV1 S2 S4 S5 PRV P4 CH2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV2 1600 PSI S7 S9 S8 C6 M1 M2 CH1 CV3 CH4 OR2 .063 OR6 .063 OR3 .070 OR7 .070 T 2SP CH3 G2 G4 CV4 PR G1 G3 3250 PSI 1350 PSI 3.3 GPM 4.4 GPM 14.3 GPM 4 PSI 4 PSI .030 OR9 S1 3300 PSI RV3 S12 1[...]

Page 10 - - 4 Models 30605 and 30603 Groundsmaster 4000 - - D/4010 - - D All r elays and so lenoids are shown as de - - energized. All gr ound wir es are black. Ele ct ric al Sc h ema t ic 1 2 3 4 5 CAB, A REFERE NCE NUMBER W ILL BE LISTED. THE CAB S CHEMA TIC W ILL ALSO INCLUDE THE REFERENCE NUMBER. NOTE: WHEN A W IRE FROM THIS SCHEMA TIC CONTINUE[...]

Page 10 - - 5 Models 30609 and 30607 Groundsmaster 4000 - - D/4010 - - D All r elays and so lenoids are shown as de - - energized. All gr ound wir es are black. Electr ical Schematic 5 2 4 3 1 CAB, A REFERE NCE NUMBER W ILL BE LISTED. THE CAB S CHEMA TIC W ILL ALSO INCLUDE THE REFERENCE NUMBER. NOTE: WHEN A W IRE FROM THIS SCHEMA TIC CONTINUES TO T[...]

Page 10 - - 6 TO GROUND BLOCK PLA TFORM WIRE HARNES S FROM OPE RA TOR PLA TFORM WIRE HARNES S TO OPERA TOR Operator Cab (shown with l ights for US model) Groundsmaster 4010 - - D All r elays and so lenoids are shown as de - - energized. All gr ound wir es are black. Ele ct ric al Sc h ema ti c 1 2 3 4 TO CAB WIRE HARNES S SCHEMA TIC FOR THE AP PROP[...]

Page 10 - - 7 Electr ical Schematic Groundsmaster 4010 - - D All r elays and so lenoids are shown as de - - energized. All gr ound wir es are black. International Light Ki ts 2 3 4 5 PLA TFORM WIRE HARNES S FROM OPE RA TOR PLA TFORM WIRE HARNES S TO OPERA TOR TO CAB WIRE HARNES S PLA TFORM WIRE HARNES S TO OPERA TOR SCHEMA TIC FOR THE AP PROPRIA TE[...]

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

Page 10 - - 9 Groundsmaster 4000 - - D/4010 - - D Pla tf o rm Wi re H arn e ss Dra wi n g AB CD 1 2 3 4 5[...]

Pag e 10 - - 10 Groundsmaster 4000 - - D/4010 - - D Pla tf o rm Wire Ha rn es s Di ag ra m Sheet 1 of 2 REFERENCE NUMBE R WILL BE IDENTIFIED. NOTE: T HE PLA TFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO ( 2) SHEE TS. WHEN A CONDUCTOR CONTINUES ON ANOTHER S HEET , A DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AN[...]

Page 10 - - 1 1 Groundsmaster 4000 - - D/4010 - - D Pla tf o rm Wire Ha rn es s Di ag ra m Sheet 2 of 2 REFERENCE NUMBE R WILL BE IDENTIFIED. NOTE: T HE PLA TFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO ( 2) SHEE TS. WHEN A CONDUCTOR CONTINUES ON ANOTHER S HEET , A DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AN[...]

Pag e 10 - - 12 Groundsmaster 4000 - - D/4010 - - D Rear W ire Har n ess Drawing[...]

Pag e 10 - - 13 Groundsmaster 4000 - - D/4010 - - D Rear Wire Harness Diagram DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION.[...]

Pag e 10 - - 14 Groundsmaster 4000 - - D/4010 - - D Models 30609 and 30607 Engi ne Wir e Har ness Dr awing[...]

Pag e 10 - - 15 Models 30609 and 30607 Engi ne Wir e Har ness Di agra m DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION. Groundsmaster 4000 - - D/4010 - - D[...]

Pag e 10 - - 16 Models 30605 and 30603 Engi ne Wir e Har ness Dr awing Groundsmaster 4000 - - D/4010 - - D[...]

Pag e 10 - - 17 Models 30605 and 30603 Engi ne Wir e Har ness Di agra m DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION. Groundsmaster 4000 - - D/4010 - - D[...]

Pag e 10 - - 18 Groundsmaster 4010 - - D Operator Cab Wir e Harness Drawing[...]

Pag e 10 - - 19 Groundsmaster 4010 - - D Operator Cab Wire Harness Diagram DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION.[...]

Pag e 10 - - 20 Groundsmaster 4010 - - D Operator Cab Interconnect Wir e Harness DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION.[...]