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Toro Groundsmaster 4000-D Service Manual
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Toro Groundsmaster 4000-D Service Manual

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See also: Operator's Manual
Groundsmaster
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing
and repair of major systems and components on the
Groundsmaster 4000--D (Models 30605 and 30609)
and Groundsmaster 4010--D (Models 30603 and
30607).
REFER TO THE OPERATOR'S MANUAL FOR OPER-
ATING,
MAINTENANCE
INSTRUCTIONS. For reference, insert a copy of the
Operator's Manual and Parts Catalog for your machine
into Chapter 2 of this service manual. Additional copies
of the Operator's Manual and Parts Catalog are avail-
able on the internet at www.Toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.
AND
ADJUSTMENT
E The Toro Company - - 2014

Service Manual

(Models 30603, 30605, 30607 and 30609)
4000- -D & 4010- -D
R
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
Groundsmaster 4000- -D
Part No. 13202SL

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  • Page 1: Service Manual

    IMPORTANT: The IMPORTANT notice will give im- The Toro Company reserves the right to change product portant instructions which must be followed to pre- specifications or this publication without notice.
  • Page 2 This page is intentionally blank. Groundsmaster 4000--D/4010--D...

  • Page 3: Table Of Contents

    Table Of Contents Chapter 1 - - Safety Chapter 5 - - Electrical System General Safety Instructions ....1 -- 2 General Information .
  • Page 4 This page is intentionally blank. Groundsmaster 4000--D/4010--D...
  • Page 5 Table Of Contents (Continued) Chapter 9 - - Operator Cab General Information ......9 -- 2 Service and Repairs .
  • Page 6 This page is intentionally blank. Groundsmaster 4000--D/4010--D...

  • Page 7: General Safety Instructions 1

    Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS ... . Before Operating ......While Operating .

  • Page 8: General Safety Instructions

    General Safety Instructions The Groundsmaster 4000-D and 4010--D are tested and certified by Toro for compliance with existing safety WARNING standards and specifications. Although hazard control and accident prevention partially are dependent upon To reduce the potential for injury or death, com- the design and configuration of the machine, these fac- ply with the following safety instructions.
  • Page 9 D. Stop engine and remove key from switch. 3. After engine is started, release parking brake and 7. Toro recommends that anytime the machine is keep foot off traction pedal. Machine must not move. If parked (short or long term), the cutting decks should be movement is evident, there may be a problem with trac- lowered to the ground.

  • Page 10: Maintenance And Service

    5. Keep body and hands away from pin hole leaks in hy- timum performance and continued safety certification of draulic lines that eject high pressure hydraulic fluid. Use the machine, use genuine Toro replacement parts and cardboard or paper to find hydraulic leaks. Hydraulic accessories. Replacement parts and accessories made...

  • Page 11: Jacking Instructions

    Jacking Instructions CAUTION When changing attachments, tires or perform- ing other service, use correct jacks and sup- ports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine.

  • Page 12: Safety And Instruction Decals

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

  • Page 13: Product Records

    Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......MAINTENANCE ......EQUIVALENTS AND CONVERSIONS .

  • Page 14: Equivalents And Conversions

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

  • Page 15: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
  • Page 16 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
  • Page 17 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series) Class 8.8 Bolts, Screws and Studs with Class 10.9 Bolts, Screws and Studs with Thread Size Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in--lb 644 + 68 N--cm...
  • Page 18 Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Square Head Hex Socket 7/16 -- 20 UNF 65 + 10 ft--lb 88 + 14 N--m Grade 5 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb...

  • Page 19: Specifications

    Chapter 3 Yanmar Diesel Engine Table of Contents SPECIFICATIONS ......Models 30603 and 30605 .
  • Page 20 Specifications (Models 30603 and 30605) Item Description Make / Designation Yanmar Model 4TNV84T--ZMTR: 4--Cycle, 4 Cylinder, Water Cooled, Turbocharged, Tier 4i Diesel Engine Bore 3.307 in (84 mm) Stroke 3.543 in (90 mm) Total Displacement 121.7 in (1995 cc) Firing Order 1 (closest to flywheel end) -- 3 -- 4 (farthest from flywheel) -- 2 Direction of Rotation Counterclockwise (viewed from flywheel)
  • Page 21 Specifications (Models 30607 and 30609) Item Description Make / Designation Yanmar Model 4TNV86CT--DTR: 4--Cycle, 4 Cylinder, Water Cooled, Turbocharged, Tier 4 Diesel Engine Bore 3.386 in (86 mm) Stroke 3.543 in (90 mm) Total Displacement 127.5 in (2090 cc) Firing Order 1 (closest to flywheel end) -- 3 -- 4 (farthest from flywheel) -- 2 Direction of Rotation Counterclockwise (viewed from flywheel)
  • Page 22 This page is intentionally blank. Yanmar Diesel Engine Page 3 - - 4 Groundsmaster 4000--D/4010--D...

  • Page 23: Service And Repairs 3

    Authorized Toro Distributor. If no parts list is available, be prepared to provide your distrib- Most repairs and adjustments require tools which are utor with the Toro model and serial number of your ma- commonly available in many service shops. Special chine.
  • Page 24 Contact your Toro distributor for assistance in Yanmar engine troubleshooting. IMPORTANT: Do not plug or unplug the engine ECU for a period of thirty (30) seconds after the machine key switch is turned OFF.
  • Page 25 Yanmar Engine: Models 30603 and 30605 The engine used on Groundsmaster models 30603 and 30605 is a Yanmar TNV Series, turbocharged, diesel engine that complies with EPA interim Tier 4 emission regulations. Engine features include an electronic con- trol unit (ECU) controlled direct fuel injection and elec- tronic governor.
  • Page 26 Yanmar Engine: Models 30607 and 30609 The engine used on Groundsmaster models 30607 and 30609 is a Yanmar TNV Series, turbocharged, diesel engine that complies with EPA Tier 4 emission regula- tions. Engine features include an electronic control unit (ECU) that controls a common rail fuel injection system with direct injection, water--cooled exhaust gas recircu- lation (EGR), an electronic governor, an exhaust system diesel oxidation catalyst (DOC) and an exhaust diesel...
  • Page 27 Stationary regeneration is requested by the engine When the regeneration process is completed, the In- ECU if the assist and reset regenerations do not return foCenter will remove the stationary regeneration icon the DPF particulate level to an acceptable level. During and cease periodic regeneration messages.

  • Page 28: Models 30603 And 30605

    Service and Repairs Air Cleaner System RIGHT FRONT VACUATOR DIRECTION MODELS MODELS 30607 and 30603 and 30609 30605 Figure 6 1. Air cleaner assembly 7. Cap screw (2 used) 13. Socket head screw (2 used) 2. Tank support 8. Lock nut (2 used) 14.
  • Page 29 Removal (Fig. 6) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Raise and support hood. 3. Remove air cleaner components as needed using Figure 6 as a guide. Installation (Fig.
  • Page 30 Fuel System 27 28 29 24 25 RIGHT FRONT 60 to 80 in- -lb (7 to 9 N- -m) Figure 9 1. Carriage screw (2 used) 14. Fuel sender 27. Lock nut (2 used) 2. Retaining ring (2 used) 15. Gasket 28.

  • Page 31: Fuel System

    4. Disconnect wire harness connections from the fuel DANGER sender (item 14). 5. Disconnect fuel supply, vent and return hoses from Because diesel fuel is flammable, use caution elbow fittings in top of tank (Fig. 10). when storing or handling it. Do not smoke while 6.

  • Page 32: Radiator And Oil Cooler Assembly

    Radiator and Oil Cooler Assembly RIGHT FRONT Thread Sealant Figure 11 1. LH radiator support 13. Cap screw (2 used) 25. Air cleaner inlet hose 2. Cap screw (2 used) 14. Hose 26. Radiator/hydraulic oil cooler 3. Flange nut (12 used) 15.
  • Page 33 Removal (Fig. 11) MODEL 30607 (WITH TIER 4 ENGINE) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. Open and support hood. CAUTION RIGHT Do not open radiator cap or drain coolant if the FRONT radiator or engine is hot.

  • Page 34: General Information 4

    Installation (Fig. 11) 1. Inspect seals (items 7, 10, 27 and 34) around radiat- or location for wear or damage. Replace seals if neces- sary. 2. Remove all plugs placed during the removal proce- dure. 3. If hydraulic fittings (items 29 and 31) were removed from oil cooler, lubricate and place new O--rings onto fit- tings.
  • Page 35 This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 3 - - 17 Yanmar Diesel Engine...

  • Page 36: Engine

    Engine MODEL 30603 SHOWN RIGHT FRONT Figure 15 1. Engine (model 30603 shown) 9. Engine mount bracket (2 used) 16. Exhaust pipe 2. Cap screw (4 used) 10. Cap screw (14 used) 17. Wire harness bracket 3. Rebound washer (4 used) 11.
  • Page 37 Engine Removal (Fig. 15) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Disconnect negative battery cable from battery ter- minal and then disconnect positive cable from battery (see Battery Service in the Service and Repairs section of Chapter 5 -- Electrical System).

  • Page 38: Engine Removal

    11. On machines with a Tier 4 compliant engine (models 30607 and 30609): RIGHT A. Remove fuel tank to allow engine to be raised FRONT from machine (see Fuel System in this section). B. Install lift bracket to front of engine cylinder head (item 6 in Fig.

  • Page 39: Chapter 4 - - Hydraulic System

    6. Secure hydraulic pump assembly to engine (see CAUTION Pump Assembly in the Service and Repairs section of Chapter 4 -- Hydraulic System). One person should operate lift or hoist while a 7. On machines with a Tier 4 compliant engine (models second person guides the engine out of the ma- 30607 and 30609): chine.
  • Page 40 15.Connect coolant hoses to the radiator. Make sure ra- 19.Check and adjust engine oil as needed. diator draincock is closed. Fill radiator and coolant 20.Check and adjust oil level in hydraulic reservoir as reservoir with coolant. needed. 16.Secure the wire harness, fuel lines and hydraulic 21.Prime the fuel system (see Fuel System in this sec- hoses to the engine with cable ties as noted during en- tion).
  • Page 41 This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 3 - - 23 Yanmar Diesel Engine...

  • Page 42: Spring Coupler

    Spring Coupler RIGHT FRONT 28 to 32 ft- -lb (38 to 43 N- -m) 29 to 33 ft- -lb (40 to 44 N- -m) Figure 21 1. Cap screw (8 used) 4. Cap screw (8 used) 6. Spring coupler 2. Washer (8 used) 5.
  • Page 43 Coupler Removal (Fig. 21) NOTE: The hydraulic pump assembly needs to be re- Engine Side Hydraulic moved from engine before coupler can be removed. Pump Side 1. If engine is in machine, remove hydraulic pump as- sembly from machine (see Piston (Traction) Pump Re- moval in the Service and Repairs section of Chapter 4 -- Hydraulic System).

  • Page 44: Exhaust System (Models 30607 And 30609)

    Exhaust System (Models 30607 and 30609) 19 to 29 ft- -lb (25 to 40 N- -m) RIGHT FRONT Figure 23 1. Gasket 16. Bolt (20 used) 31. Hose clip (2 used) 2. Exhaust assembly stay 17. DPF lifter 32. Hose 3.
  • Page 45 C. If DPF stiffeners (items 18, 19, 20 and 21 in Fig. reconditioning process, it can be re--installed in the ex- 23) were loosened or removed, tighten fasteners haust system. Contact your Toro Distributor for informa- that secure stiffeners before tightening fasteners tion on reconditioning the DPF.
  • Page 46 This page is intentionally blank. Yanmar Diesel Engine Page 3 - - 28 Groundsmaster 4000--D/4010--D...

  • Page 47: Hydraulic Schematic 4

    Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......Check Hydraulic Lines and Hoses .
  • Page 48 This page is intentionally blank. Hydraulic System Page 4 - - 2 Groundsmaster 4000--D/4010--D...

  • Page 49: Specifications

    Specifications Item Description Piston (Traction) Pump Sauer--Danfoss Variable Displacement Axial Piston Pump Maximum Displacement (per revolution) 2.75 in (45 cc) System Relief Pressure: Forward 4350 PSI (300 bar) System Relief Pressure: Reverse 5000 PSI (345 bar) Charge Pressure 250 PSI (17 bar) Front Wheel Motors Sauer--Danfoss 2--Position Axial Piston Motors Displacement (per revolution)

  • Page 50: General Information

    General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Check Hydraulic Fluid The Groundsmaster hydraulic system is designed to op- erate on anti--wear hydraulic fluid.

  • Page 51: Towing Traction Unit

    Traction Circuit Component Failure The traction circuit on Groundsmaster 4000--D and Once the Toro high flow hydraulic filter kit has been 4010--D machines is a closed loop system that includes placed in the circuit, raise and support the machine with the piston (traction) pump, two (2) front wheel motors all wheels off the ground.

  • Page 52: Hydraulic Hoses

    If the hose has an elbow at one end, tighten the swivel nut on that end before tightening the nut on the straight end of the hose. For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL).

  • Page 53: Hydraulic Hose And Tube Installation

    Hydraulic Hose and Tube Installation (O- -Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ C. Use a second wrench to tighten the nut to the cor- tube and the fitting are free of burrs, nicks, scratches or rect Flats From Wrench Resistance (F.F.W.R.).
  • Page 54 Hydraulic Fitting Installation (SAE Straight Thread O- -Ring Fitting into Component Port) Non- -Adjustable Fitting (Fig. 6) 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate meth- 1.
  • Page 55 Adjustable Fitting (Fig. 8) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is rec- Lock Nut ommended that the O--ring be replaced any time the connection is opened.

  • Page 56: Hydraulic Schematic

    Hydraulic Schematic Hydraulic System Page 4 - - 10 Groundsmaster 4000--D/4010--D...
  • Page 57 This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 4 - - 11 Hydraulic System...

  • Page 58: Hydraulic Flow Diagrams

    Hydraulic Flow Diagrams Hydraulic System Page 4 - - 12 Groundsmaster 4000--D/4010--D...

  • Page 59: Traction Circuit: Low Speed (Mow)

    Traction Circuit: LOW Speed (Mow) The traction circuit piston pump is a variable displace- Gear pump flow for the charge circuit is directed through ment pump that is directly coupled to the engine fly- the oil filter and to the low pressure side of the closed wheel.
  • Page 60 Hydraulic System Page 4 - - 14 Groundsmaster 4000--D/4010--D...

  • Page 61: Traction Circuit: Hi Speed (Transport)

    Traction Circuit: HI Speed (Transport) The traction circuit piston pump is a variable displace- Forward Direction ment pump that is directly coupled to the engine fly- With the armrest console HI/LOW speed switch in the HI wheel. This pump utilizes an integral electro--hydraulic speed (transport) position, solenoid valve (S12) in the servo piston assembly that controls the rate and direc- combination manifold is energized.
  • Page 62 Hydraulic System Page 4 - - 16 Groundsmaster 4000--D/4010--D...

  • Page 63: Lower Cutting Deck Circuit

    Lower Cutting Deck Circuit A four section gear pump is coupled to the piston (trac- Lower Right Cutting Deck tion) pump. The third gear pump section supplies hy- To lower the right wing deck, the front of the right console draulic flow to the lift/lower circuit, the engine cooling fan lift switch is pushed as an input to the TEC controller.
  • Page 64 Hydraulic System Page 4 - - 18 Groundsmaster 4000--D/4010--D...

  • Page 65: Raise Cutting Deck Circuit

    Raise Cutting Deck Circuit A four section gear pump is coupled to the piston (trac- valves S1, S7 and S9 in the combination manifold. The tion) pump (Fig. 10). The third gear pump section sup- energized solenoid valves shift to allow a passage for plies hydraulic flow to the lift/lower circuit, the engine circuit oil flow to the barrel end of the right deck lift cylin- cooling fan circuit and the traction charge circuit.
  • Page 66 Hydraulic System Page 4 - - 20 Groundsmaster 4000--D/4010--D...

  • Page 67: Mow Circuit

    Mow Circuit A four section gear pump is coupled to the piston (trac- motor re--enters manifold port M2, is routed through tion) pump. Hydraulic flow for the mow circuit is supplied shifted PD, out manifold port P2, through the oil cooler by two sections of the gear pump.

  • Page 68: Mow Circuit Cutting Deck Blade Braking

    Mow Circuit Cutting Deck Blade Braking When the operator turns the PTO switch OFF or if a deck PUMP is raised with the PTO switch ON, PTO manifold propor- FLOW tional relief valve (PRV) is de--energized causing logic valve (LC1) to shift (refer to information in Mow Circuit 3000 PSI .025 in this section).
  • Page 69 This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 4 - - 23 Hydraulic System...
  • Page 70 Hydraulic System Page 4 - - 24 Groundsmaster 4000--D/4010--D...

  • Page 71: Steering Circuit

    Steering Circuit A four section gear pump is coupled to the piston (trac- ifold compensator valve (EC) start to equalize causing tion) pump. The fourth gear pump section (farthest from (EC) to move toward its neutral position which allows the the piston pump) supplies hydraulic flow to the steering needed oil flow to the steering control valve.
  • Page 72 Hydraulic System Page 4 - - 26 Groundsmaster 4000--D/4010--D...

  • Page 73: Engine Cooling Fan Circuit

    Engine Cooling Fan Circuit A four section gear pump is coupled to the piston (trac- When the engine is shut off, the over--running inertia tion) pump (Fig. 14). The fourth gear pump section load of the engine cooling fan blades keeps driving the (farthest from the piston pump) supplies hydraulic flow fan motor and turns it into a pump.

  • Page 74: Special Tools

    Special Tools Order special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Kit contains one each: 1000 PSI (70 bar), 5000 PSI (350 bar) and 10000 PSI (700 bar) gauges.
  • Page 75 3. FLOW METER: This meter measures actual oil flow in the operating circuit with a gauge rated from 4 to 40 GPM (20 to 150 LPM). Toro Part Number: AT40002 Figure 17 NOTE: This tester does not include hoses (see Hydrau- lic Hose Kit TOR6007 below).
  • Page 76 Toro Part Number: TOR6011 Figure 19 NOTE: This kit does not include hoses (see Hydraulic Hose Kit TOR6007 above). NOTE: Replacement filter element is Toro part number TOR6012. Filter element cannister tightening torque is 25 ft- -lb (34 N- -m). O- -Ring Kit The O--ring kit includes O--rings in a variety of sizes for face seal and port seal hydraulic connections.

  • Page 77: Measuring Container

    Hydraulic Test Fitting Kit This kit includes a variety of O--ring Face Seal fittings to TORO TEST FITTING KIT (TOR4079) enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings.
  • Page 78 Figure 24 A remote stater switch can also be constructed using Toro switch #106--2027, a length of 14 gauge wire, a 20 amp in--line fuse, two (2) alligator clips and necessary MACHINE connectors. Connecting the wire to switch terminals 1...

  • Page 79: Troubleshooting

    Troubleshooting The charts that follow contain suggestions that can be Review the hydraulic schematic and information on hy- used to assist in diagnosing hydraulic system perfor- draulic system operation in the Hydraulic Flow Dia- mance issues. The suggestions are not all--inclusive. grams section of this Chapter.

  • Page 80: Traction Circuit Problems

    Traction Circuit Problems Problem Possible Cause Machine operates in one direction Piston (traction) pump by--pass valve is open or damaged. only. Traction relief valve is leaking or faulty. Piston (traction) pump servo control valve orifices or screens are plugged or damaged. Problem with TEC output to piston (traction) pump servo control exists (see Chapter 5 -- Electrical System).
  • Page 81 Mow Circuit Problems Problem Possible Cause None of the cutting decks will oper- Electrical problem exists that prevents PRV solenoid valve in PTO ate. manifolds from being energized (see Chapter 5 -- Electrical Sys- tem). NOTE: To engage the mow circuit, the seat must be occupied, the cut- Front two (2) gear pump sections for mow circuits are worn or dam- ting deck(s) must be fully lowered,...

  • Page 82: Lift Circuit Problems

    Lift Circuit Problems Problem Possible Cause Cutting decks will not raise. Engine RPM is too low. NOTE: Seat must be occupied in or- Hydraulic oil level in reservoir is low (NOTE: Other hydraulic systems der to raise cutting decks. are affected as well). Solenoid valve (S1) in combination manifold is faulty.
  • Page 83 Steering Circuit Problems Problem Possible Cause Steering inoperative or sluggish Steering components (e.g. tie rods, steering cylinder ends) are worn or binding. Steering cylinder is binding. Oil level in hydraulic reservoir is low (NOTE: Other hydraulic sys- tems are affected as well). Steering relief valve (RV1) in combination manifold is stuck or dam- aged.
  • Page 84 Engine Cooling Fan Circuit Problems Problem Possible Cause Cooling fan runs only in forward di- Solenoid cartridge valve (S10) in combination control manifold is rection (fan does not run in reverse faulty. direction). Electrical problem exists that prevents combination control manifold solenoid valve (S10) operation (see Chapter 5 -- Electrical System).
  • Page 85 This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 4 - - 39 Hydraulic System...

  • Page 86: Testing

    Testing The most effective method for isolating problems in the Precautions for Hydraulic Testing hydraulic system is by using hydraulic test equipment 1. Clean machine thoroughly before disconnecting or such as pressure gauges and flow meters in the circuits disassembling any hydraulic components. Always keep during various operational checks (see the Special in mind the need for cleanliness when working on hy- Tools section in this Chapter).
  • Page 87 Which Hydraulic Tests Are Necessary? 2. If a cutting (mow) circuit problem exists, consider performing one or more of the following tests: Cutting Before beginning any hydraulic test, identify if the prob- Deck Circuit Pressure, PTO Relief Pressure, Cutting lem is related to the traction circuit, cutting (mow) circuit, Deck Motor Case Drain Leakage and/or Gear Pump lift/lower circuit, steering circuit or engine cooling fan cir- Flow Tests.

  • Page 88: Traction Circuit Charge Pressure

    Traction Circuit Charge Pressure (Using Pressure Gauge) PRESSURE GAUGE Hydraulic System Page 4 - - 42 Groundsmaster 4000--D/4010--D...
  • Page 89 The traction charge circuit is designed to replace loss of NOTE: If the gear pump section that supplies the hydraulic fluid from the closed loop traction circuit. This charge circuit is worn or damaged, charge, steering, lift/ test is used to make sure that traction charge pressure lower and engine cooling fan circuits may all be affected.

  • Page 90: Traction Circuit Relief Pressure

    Traction Circuit Relief Pressure (Using Pressure Gauge) FORWARD TRACTION CIRCUIT RELIEF PRESSURE TEST SHOWN PRESSURE GAUGE Hydraulic System Page 4 - - 44 Groundsmaster 4000--D/4010--D...
  • Page 91 Procedure for Traction Circuit Relief Pressure Test 6. Release traction pedal and stop engine. Record test results. NOTE: The traction charge circuit is designed to re- place loss of hydraulic fluid from the closed loop traction 7. If traction pressure is too low, inspect traction pump circuit.

  • Page 92: Counterbalance Pressure

    Counterbalance Pressure (Using Pressure Gauge) PRESSURE GAUGE TO PISTON PUMP TO STEERING TO STEERING TO RESERVOIR CONTROL VALVE CONTROL VALVE Hydraulic System Page 4 - - 46 Groundsmaster 4000--D/4010--D...

  • Page 93: Adjustments 4

    Procedure for Counterbalance Pressure Test C. To increase pressure setting, turn the adjust- ment screw on the valve in a clockwise direction. A 1/8 turn on the screw will make a measurable change CAUTION in counterbalance pressure. D. To decrease pressure setting, turn the adjust- Prevent personal injury and/or damage to equip- ment screw on the valve in a counterclockwise direc- ment.
  • Page 94 Reverse Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge) Hydraulic System Page 4 - - 48 Groundsmaster 4000--D/4010--D...
  • Page 95 (Fig. 32). Re- move #6 zero leak plug on the inside of rear traction manifold and install diagnostic fitting (Toro part number 59--7410) into manifold port. 3. Connect a 1000 PSI (70 bar) pressure gauge with hy- draulic hose attached to installed diagnostic fitting.
  • Page 96 Rear Traction Circuit Relief Valve (RV) Pressure (Using Pressure Gauge) Hydraulic System Page 4 - - 50 Groundsmaster 4000--D/4010--D...
  • Page 97 (Fig. 34). Re- move #6 zero leak plug on inside of rear traction mani- fold and install diagnostic fitting (Toro part number 59--7410) into manifold port. 3. Connect a 1000 PSI (70 bar) pressure gauge with hy- draulic hose attached to installed diagnostic fitting.
  • Page 98 Piston (Traction) Pump Flow Test (Using Tester with Pressure Gauge and Flow Meter) TESTER Hydraulic System Page 4 - - 52 Groundsmaster 4000--D/4010--D...
  • Page 99 Procedure for Piston (Traction) Pump Flow Test NOTE: If possible, turn off Smart Power by using the InfoCenter display protected menu. Machines with TEC This test measures piston (traction) pump output (flow). software above revision level G will allow Smart During this test, pump load is created at the flow meter Power to be disabled for testing.

  • Page 100: Pressure

    Cutting Deck Circuit Pressure (Using Pressure Gauge) FRONT DECK CIRCUIT PRESSURE TEST SHOWN FROM MANIFOLD AND FAN MOTOR PRESSURE GAUGE Hydraulic System Page 4 - - 54 Groundsmaster 4000--D/4010--D...
  • Page 101 Procedure for Cutting Deck Circuit Pressure Test CAUTION Prevent personal injury and/or damage to equip- ment. Read all WARNINGS, CAUTIONS and Pre- cautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting decks lowered and off.

  • Page 102: Pto Relief Pressure

    PTO Relief Pressure (Using Tester with Pressure Gauge and Flow Meter) FRONT PTO RELIEF PRESSURE TEST SHOWN FROM MANIFOLD AND FAN MOTOR TESTER Hydraulic System Page 4 - - 56 Groundsmaster 4000--D/4010--D...

  • Page 103: Service And Repairs 4

    The PTO circuit relief pressure test should be performed 7. Fully open tester flow control valve and disengage to make sure that the PTO circuit relief pressures are cutting decks. Shut off engine and record test results. correct. 8. If relief pressure is incorrect, remove PRV valve on Procedure for PTO Relief Pressure Test mow manifold and clean or replace valve (see PTO Manifold Service in the Service and Repairs section of...

  • Page 104: Cutting Deck Motor Case Drain Leakage

    Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauge and Flow Meter) CENTER CUTTING DECK MOTOR CASE DRAIN LEAKAGE TEST SHOWN 1.17 CID 3000 PSI .025 TESTER 600 PSI FROM STEERING CENTER DECK CONTROL VALVE 3000 PSI .025 1.17 CID TO RESERVOIR MEASURING...
  • Page 105 Procedure for Cutting Deck Motor Case Drain 4. Sit on seat and start the engine. With engine running, Leakage Test increase engine speed to high idle speed and release the parking brake. Engage the cutting decks. NOTE: Over a period of time, a deck motor can wear in- ternally.

  • Page 106: Lift/Lower Circuit Relief Pressure

    Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) PRESSURE GAUGE LEFT DECK LIFT SWITCH PRESSED IS SHOWN Hydraulic System Page 4 - - 60 Groundsmaster 4000--D/4010--D...
  • Page 107 The lift/lower circuit relief pressure test should be per- B. If relief pressure is too low, check for restriction in formed to make sure that the cutting unit lift and lower gear pump intake line. Check the lift cylinders for in- circuit relief pressure is correct.

  • Page 108: Steering Circuit Relief Pressure

    Steering Circuit Relief Pressure (Using Pressure Gauge) PRESSURE GAUGE Hydraulic System Page 4 - - 62 Groundsmaster 4000--D/4010--D...
  • Page 109 The steering circuit relief pressure test should be per- 7. If pressure is incorrect, inspect steering relief valve formed to make sure that the steering circuit relief pres- in steering control valve (see Steering Control Valve in sure is correct. the Service and Repairs section of this chapter).
  • Page 110 Steering Cylinder Internal Leakage STEERING CYLINDER FULLY CYLINDER EXTENDED 2.00” BORE 4.20” STROKE 0.625” ROD LOOK FOR LEAKAGE STEEL CAP STEERING CONTROL VALVE STEERING WHEEL TURNED FOR RIGHT TURN 6.1 CID TO RESERVOIR FROM COMBINATION FROM COMBINATION MANIFOLD MANIFOLD Hydraulic System Page 4 - - 64 Groundsmaster 4000--D/4010--D...
  • Page 111 The steering cylinder internal leakage test should be 4. Place a drain pan under the steering cylinder. Re- performed if a steering problem is identified. This test move hydraulic hose from the fitting on the rod end of the will determine if the steering cylinder is faulty. steering cylinder.
  • Page 112 Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac) PRESSURE GAUGE Hydraulic System Page 4 - - 66 Groundsmaster 4000--D/4010--D...
  • Page 113 The cooling fan circuit test should be performed to make 8. If circuit pressure rises to approximately 3250 PSI sure that the engine cooling fan circuit has the correct (224 bar) but fan speed is low, consider that the fan mo- system pressure and fan speed.
  • Page 114 Gear Pump Flow (Using Tester with Pressure Gauge and Flow Meter) SECOND GEAR PUMP SECTION FLOW TEST SHOWN FROM MANIFOLD AND FAN MOTOR TESTER The gear pump flow test should be performed to make NOTE: Over a period of time, the gears and wear plates sure that the mow, steering, lift/lower, cooling fan and in the gear pump can wear.
  • Page 115 Procedure for Gear Pump Flow Test 10.If a pressure of 1000 PSI (69 bar) cannot be obtained or flow was less than the minimum flow listed in Figure 48, check for restriction in the pump intake line. If line is CAUTION not restricted, consider that the tested gear pump sec- tion is worn or damaged.

  • Page 116: Adjustments

    Adjustments Adjust Control Manifold Relief Valves Several of the hydraulic control manifolds on your Groundsmaster include adjustable relief valves. The fol- lowing procedure can be used to adjust these relief valves. Refer to the Testing section of this chapter for in- formation on testing relief pressure.

  • Page 117: Service And Repairs

    Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- 1. Check oil level in the hydraulic reservoir and add cor- tem, park machine on a level surface, apply parking rect oil if necessary.

  • Page 118: Special Tools 5

    Check Hydraulic Lines and Hoses IMPORTANT: Check hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, WARNING wear, loose fittings or any hose deterioration. Make all necessary repairs before operating. Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure.
  • Page 119 Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time IMPORTANT: Follow all local codes and regulations there is a severe component failure or the system is when recycling or disposing hydraulic fluid and fil- contaminated. Contaminated oil may appear milky ters.
  • Page 120 IMPORTANT: If using a filter that is not the bi- -direc- 2. Raise and support machine so all wheels are off the tional Toro high flow filter, do not press the traction ground (see Jacking Instructions in Chapter 1 -- Safety).
  • Page 121 Charge Hydraulic System NOTE: When initially starting the hydraulic system with 8. After the hydraulic system starts to show signs of fill, new or rebuilt components such as motors, pumps or lift actuate a lift switch until the lift cylinder rod moves in and cylinders, it is important that the hydraulic system be out several times.

  • Page 122: Hydraulic Reservoir

    Hydraulic Reservoir RIGHT 80 to 88 ft- -lb (109 to 119 N- -m) FRONT Figure 52 1. Hydraulic reservoir 12. Dipstick 22. Cap screw 2. Cap screw 13. Screen filter 23. Plug 3. Recess bumper (2 used) 14. Tank strainer 24.
  • Page 123 NOTE: The operator platform needs to be raised from 2. Slide tank mount assembly (items 15, 16, 3, 17, 18 the main frame so that the hydraulic reservoir can be re- and 19) between frame and hydraulic reservoir and pos- moved from the machine (see Operator Platform in the ition bumper into slot on left side of reservoir.
  • Page 124 Radiator and Oil Cooler Assembly Thread Sealant RIGHT FRONT Figure 54 1. LH radiator support 13. Cap screw (2 used) 25. Air cleaner inlet hose 2. Cap screw (2 used) 14. Hose 26. Radiator/hydraulic oil cooler 3. Flange nut (12 used) 15.
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  • Page 126: Gear Pump

    Gear Pump RIGHT FRONT Figure 55 1. Hose clamp (3 used) 10. Gear pump 19. 90 hydraulic fitting 2. Hose clamp (2 used) 11. O- -ring 20. Test nipple (2 used) 3. Hydraulic hose 12. Hydraulic fitting 21. Straight hydraulic fitting (2 used) 4.
  • Page 127 Removal (Fig. 55) Remove plugs before installing 1. Park machine on a level surface, lower cutting gear pump to piston pump decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Raise and support machine to gain access to gear pump from the underside of the machine.
  • Page 128 10.Replace hydraulic filters and fill hydraulic reservoir with new hydraulic oil. 11. Prime hydraulic pumps (see Priming Hydraulic Pumps in this section). 12.Properly fill hydraulic system (see Charge Hydraulic System in this section). 13.Stop engine and check for hydraulic oil leaks. Check hydraulic reservoir oil level.
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  • Page 130: Gear Pump Service

    Gear Pump Service 33 ft- -lb (45 N- -m) Figure 58 1. Front cover 10. Thrust plate (7 used) 18. Body 2. Dowel pin (4 used) 11. Dowel pin (6 used) 19. Body 3. Pressure seal 12. Splined connecting shaft (3 used) 20.
  • Page 131 IMPORTANT: Use caution when clamping gear pump in a vise to avoid distorting any pump compo- nents. 3. Secure the front cover of the pump in a vise with the drive shaft pointing down. 4. Loosen the four (4) cap screws that secure pump as- sembly.
  • Page 132 Piston (Traction) Pump RIGHT FRONT Figure 61 1. Hose clamp (3 used) 10. Gear pump 19. 90 hydraulic fitting 2. Hose clamp (2 used) 11. O- -ring 20. Test nipple (2 used) 3. Hydraulic hose 12. Hydraulic fitting 21. Straight hydraulic fitting (2 used) 4.
  • Page 133 Removal (Fig. 61) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. To prevent contamination of hydraulic system during removal, thoroughly clean exterior of pump assembly. 3.
  • Page 134 Installation (Fig. 61) 7. Fill piston (traction) pump housing with new hydraul- ic oil through the case drain (90 barbed fitting) at the top 1. If fittings were removed from piston pump, lubricate of the pump (Fig. 64). This will ensure that internal pump and place new O--rings onto fittings.
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  • Page 136 Piston (Traction) Pump Service Figure 65 Hydraulic System Page 4 - - 90 Groundsmaster 4000--D/4010--D...
  • Page 137 Figure 65 (Continued) 1. Screen (2 used) 20. Bearing 38. O- -ring 2. Plug with O- -ring (2 used) 21. Screw (4 used) 39. Seal carrier 3. Plug with O- -ring (2 used) 22. Thrust plate 40. Retaining ring 4. Cylinder block assembly 23.

  • Page 138: Rear Axle Motor

    Rear Axle Motor 9 to 11 ft- -lb (12.3 to 14.9 N- -m) RIGHT FRONT Figure 66 1. Rear axle motor 8. Flat washer (2 used) 15. Dowel pin (2 used) 2. 90 hydraulic fitting (2 used) 9. O- -ring 16.
  • Page 139 Removal (Fig. 66) Installation (Fig. 66) 1. Park machine on a level surface, lower cutting IMPORTANT: Refer to Traction Circuit Component decks, stop engine, apply parking brake and remove Failure in the General Information section of this key from the ignition switch. chapter for information regarding the importance of removing contamination from the traction circuit.

  • Page 140: Front Wheel Motors

    Front Wheel Motors RIGHT FRONT Figure 67 1. Front wheel motor 6. Cap screw (2 used per motor) 11. 90 hydraulic fitting (2 used) 2. Internal retaining ring 7. Flat washer (2 used per motor) 12. Hydraulic connector 3. Splined brake shaft 8.
  • Page 141 Removal (Fig. 67) Installation (Fig. 67) 1. Park machine on a level surface, lower cutting IMPORTANT: Refer to Traction Circuit Component decks, stop engine, apply parking brake and remove Failure in the General Information section of this key from the ignition switch. chapter for information regarding the importance of removing contamination from the traction circuit.

  • Page 142: Rear Axle And Front Wheel Motor Service

    Rear Axle and Front Wheel Motor Service Figure 68 1. Plug with O- -ring 10. Dowel pin 18. Housing 2. Minimum angle stop 11. Bearing 19. Bearing 3. Bias spring 12. Gasket 20. Retaining ring 4. Servo piston 13. Valve plate 21.
  • Page 143 NOTE: The front wheel motors on your Groundsmaster REAR AXLE MOTOR FLUSHING VALVE are identical (Fig. 68). The rear axle motor includes a flushing valve for cooling of the closed loop traction cir- cuit and therefore has some differences from the front motors (Fig.
  • Page 144 Rear Traction Manifold RIGHT FRONT Figure 70 1. Front frame 7. 90 hydraulic fitting 13. O- -ring 2. PTO manifold (center deck) 8. O- -ring 14. O- -ring 3. Front traction manifold 9. 45 hydraulic fitting 15. 45 hydraulic fitting 4.
  • Page 145 Removal (Fig. 70) Installation (Fig. 70) 1. Read the General Precautions for Removing and 1. If fittings were removed from manifold, lubricate and Installing Hydraulic System Components at the begin- place new O--rings onto fittings. Install fittings into man- ning of the Service and Repairs section of this chapter. ifold openings using marks made during the removal process to properly orientate fittings.
  • Page 146 Rear Traction Manifold Service 50 ft- -lb 25 ft- -lb (67 N- -m) (34 N- -m) 20 ft- -lb (27 N- -m) 35 ft- -lb (47 N- -m) 25 ft- -lb (34 N- -m) Figure 71 1. Rear traction manifold body 4.
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  • Page 148 Front Traction Manifold RIGHT FRONT Figure 72 1. Front frame 8. Check fitting 14. O- -ring 2. PTO manifold (center deck) 9. O- -ring 15. Check adapter 3. Rear traction manifold 10. Hydraulic straight fitting 16. O- -ring 4. Front traction manifold 11.
  • Page 149 Removal (Fig. 72) Installation (Fig. 72) 1. Read the General Precautions for Removing and 1. If fittings were removed from manifold, lubricate and Installing Hydraulic System Components at the begin- place new O--rings onto fittings. Install fittings into man- ning of the Service and Repairs section of this chapter. ifold openings using marks made during the removal process to properly orientate fittings.
  • Page 150 Front Traction Manifold Service 25 ft- -lb (34 N- -m) 20 ft- -lb 120 ft- -lb (27 N- -m) (162 N- -m) 25 ft- -lb (34 N- -m) 25 ft- -lb (34 N- -m) 20 ft- -lb (27 N- -m) 25 ft- -lb (34 N- -m) 20 ft- -lb...
  • Page 151 Front Traction Manifold Service (Fig. 73) For front traction manifold cartridge valve service proce- dures, see Control Manifold Cartridge Valve Service in this section. Refer to Figure 73 for front traction manifold cartridge valve and plug installation torque. IMPORTANT: A flow control orifice is located be- neath the plug in the front traction manifold port OR.
  • Page 152 Combination Manifold RIGHT FRONT Figure 74 1. Combination manifold 3. Flat washer (3 used) 5. Spacer (3 used) 2. Flange nut (3 used) 4. Mount (3 used) NOTE: The ports on the combination manifold are marked for easy identification of components. Example: P3 and P4 are the gear pump connection ports, S1 is the location for solenoid valve S1 and OR6 is the location for orifice OR6 (see Hydraulic Schematic in Chapter 10 --...
  • Page 153 Removal (Fig. 74) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter. 2. To prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of combina- tion manifold and fittings.
  • Page 154 Combination Manifold Service 20 ft- -lb 25 ft- -lb 20 ft- -lb (27 N- -m) 25 ft- -lb (34 N- -m) (27 N- -m) 25 ft- -lb (34 N- -m) (34 N- -m) FRONT 20 ft- -lb (27 N- -m) 25 ft- -lb (34 N- -m) 20 ft- -lb...
  • Page 155 NOTE: The ports on the combination manifold are 25 ft- -lb 25 ft- -lb marked for easy identification of components. Example: (34 N- -m) (34 N- -m) P4 is the gear pump connection port, S1 is the lift/lower solenoid valve and SV10 is the engine cooling fan solen- oid valve (see Hydraulic Schematic in Chapter 10 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port).

  • Page 156: Control Manifold Cartridge Valve Service

    Control Manifold Cartridge Valve Service 1. Make sure the control manifold is clean before re- 6. Clean cartridge valve using clean mineral spirits. moving the cartridge valve from the control manifold. Submerge valve in clean mineral spirits to flush out con- tamination.
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  • Page 158: Steering Control Valve

    Steering Control Valve 27 to 33 ft- -lb 20 to 26 ft- -lb (28 to 35 N- -m) (37 to 44 N- -m) RIGHT FRONT Figure 79 1. Steering wheel cover 8. Steering shaft 15. Valve mount plate 2. Hex nut 9.
  • Page 159 Removal (Fig. 79) 1. Park machine on a level surface, 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 Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter.

  • Page 160: Steering Control Valve Service

    Steering Control Valve Service 140 to 160 in- -lb (16 to 18 N- -m) 150 in- -lb (17 N- -m) Figure 82 1. Steering valve housing 9. Cap screw (7 used) 17. Geroter drive 2. Dust seal 10. End cap 18.
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  • Page 162: Steering Cylinder

    Steering Cylinder RIGHT FRONT 79 to 84 ft- -lb (108 to 113 N- -m) Figure 83 1. Steering cylinder 6. Grease fitting 10. Axle washer 2. Ball joint 7. 90 hydraulic fitting (2 used) 11. Slotted hex nut (2 used) 3.
  • Page 163 Removal (Fig. 83) 4. Install hydraulic hoses to steering cylinder (see Hy- draulic Hose and Tube Installation in the General Infor- 1. Park machine on a level surface, lower cutting mation section of this chapter). decks, stop engine, apply parking brake and remove key from the ignition switch.

  • Page 164: Steering Cylinder Service

    Steering Cylinder Service 40 ft- -lb (54 N- -m) Figure 85 1. Barrel 5. Internal collar 9. Rod seal 2. Rod 6. Backup ring 10. O- -ring 3. Piston 7. O- -ring 11. Piston seal 4. Head 8. Dust seal 12.
  • Page 165 Disassembly (Fig. 85) Assembly (Fig. 85) 1. Pump oil out of steering cylinder into a drain pan by 1. Use a complete repair kit when rebuilding the steer- slowly moving rod in and out of cylinder bore. After oil ing cylinder. Put a coating of clean hydraulic oil on all has been removed from cylinder, plug ports and clean new seals and O--rings.

  • Page 166: Engine Cooling Fan Motor

    Engine Cooling Fan Motor RIGHT FRONT 12 to 14 ft- -lb (17 to 18 N- -m) Figure 86 1. Hydraulic fan motor 11. Cap screw (4 used) 21. Hydraulic tube 2. O- -ring 12. Washer (4 used) 22. Hydraulic tube 3.
  • Page 167 Removal (Fig. 86) 1. Park machine on a level surface, lower cutting RIGHT decks, stop engine, apply parking brake and remove FRONT key from the ignition switch. 2. Unlatch and raise hood. CAUTION The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool before removing fan motor.
  • Page 168 4. Position fan hub onto motor shaft and secure with 8. Position fan to fan hub and secure with four (4) cap washer (item 8) and hex nut (item 9). screws and washers. Torque screws from 12 to 14 ft- -lb (17 to 18 N- -m).
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  • Page 170: Engine Cooling Fan Motor Service

    Engine Cooling Fan Motor Service 33 ft- -lb (45 N- -m) Figure 88 1. Flange washer 7. Shaft seal 12. Idler gear 2. O- -ring 8. Backup gasket 13. Cap screw (4 used) 3. Front flange 9. Pressure seal 14. Dowel (2 used) 4.
  • Page 171 IMPORTANT: 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 orientation of seal lips during removal. Discard re- moved seals.
  • Page 172 3. Place front flange, seal side down, on a flat surface. 10.Install locating dowels in body. Align marker line on the body and front flange. 4. Install the pressure seals, flat side outward, into the grooves in the wear plates. Follow by carefully placing IMPORTANT: Do not dislodge seals during installa- the backup gaskets, flat side outward, between the tion.
  • Page 173 Cutting Deck Motors Removal 1. Park machine on a level surface, lower cutting 27 to 33 ft- -lb (37 to 44 N- -m) decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter.
  • Page 174 Cutting Deck Motor Service (Sauer- -Danfoss) 33 to 40 ft- -lb (45 to 55 N- -m) Figure 94 1. Rear cover 6. Tab washer 11. Body 2. Drive gear 7. Spider hub 12. Idler gear 3. Seal 8. Pressure seal 13.
  • Page 175 IMPORTANT: Mark the relative positions of the gear teeth and the bearing blocks so they can be re- assembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. 7. Place the motor on its side and push on the rear bear- ing block to remove the bearing block and gear set (Fig.
  • Page 176 Assembly (Fig. 94) 8. Install dowel pins in body. NOTE: When assembling the motor, check the identifi- IMPORTANT: Do not dislodge O- -rings, pressure cation marks made during disassembly to make sure seals or back- -up rings during final assembly. the parts are properly aligned during assembly.
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  • Page 178 Cutting Deck Motor Service (Casappa) 33 to 40 ft- -lb (45 to 55 N- -m) Figure 99 1. Flange washer 7. Shaft seal 13. Cap screw (4 used) 2. O- -ring 8. Backup gasket 14. Dowel (4 used) 3. Front flange 9.
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  • Page 180: Pto Manifold

    PTO Manifold RIGHT FRONT Figure 101 1. Hydraulic PTO manifold (center deck) 8. O- -ring 15. 90 hydraulic fitting 2. Quick fitting (1 used per manifold) 9. Hydraulic adapter 16. Hydraulic PTO manifold (RH deck) 3. Flange screw (2 used per manifold) 10.
  • Page 181 Removal (Fig. 101) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter. 2. To prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of PTO manifold and fittings.

  • Page 182: Pto Manifold Service

    PTO Manifold Service 20 ft- -lb 35 ft- -lb (27 N- -m) (47 N- -m) 25 ft- -lb (34 N- -m) 20 ft- -lb (27 N- -m) 20 ft- -lb (27 N- -m) 5 ft- -lb (6.7 N- -m) 25 ft- -lb (34 N- -m) Figure 103 1.
  • Page 183 The manifolds for the three (3) cutting decks are very similar. The front and right side PTO manifolds are identical. The left side PTO manifold uses the same cart- ridges and plugs as the front and right side manifolds but also includes an additional orifice that threads into the manifold OR2 port (Fig.
  • Page 184 Side Deck Lift Cylinders RIGHT FRONT Figure 105 1. Lift arm assembly (LH shown) 5. Lock nut 9. Lift cylinder 2. Shoulder screw 6. Flat washer 10. 90 hydraulic fitting 3. Flange nut 7. Cylinder pin 11. 90 hydraulic fitting 4.
  • Page 185 Removal (Fig. 105) Installation (Fig. 105) 1. Park machine on a level surface, lower cutting 1. If fittings were removed from lift cylinder, lubricate decks, stop engine, apply parking brake and remove and place new O--rings onto fittings. Install fittings into key from the ignition switch.
  • Page 186 Center Deck Lift Cylinders RIGHT FRONT Figure 106 1. Front frame 5. Grease fitting 9. Lift cylinder (2 used) 2. Flange head screw 6. Cotter pin (2 used per pin) 10. RH lift arm assembly 3. Flange nut 7. Flat washer (4 used per pin) 11.
  • Page 187 Removal (Fig. 106) Installation (Fig. 106) 1. Park machine on a level surface, lower cutting 1. If fitting was removed from lift cylinder, lubricate and decks, stop engine, apply parking brake and remove place new O--rings onto fitting. Install fitting into cylinder key from the ignition switch.

  • Page 188: Lift Cylinder Service

    Lift Cylinder Service 100 to 120 ft- -lb (136 to 162 N- -m) SIDE DECK LIFT CYLINDER Figure 108 1. Barrel with clevis 7. Back- -up ring 12. Lock nut 2. Retaining ring 8. Head 13. Grease fitting 3. Shaft with clevis 9.
  • Page 189 Disassembly (Figs. 108 and 109) Assembly (Figs. 108 and 109) 1. Remove oil from lift cylinder into a drain pan by slowly 1. Make sure all cylinder components are clean before pumping the cylinder shaft. Plug both ports and clean assembly.
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  • Page 191: Troubleshooting 5

    ....... Toro Electronic Controllers (TEC) ... . .

  • Page 192: General Information

    Toro Electronic Controllers (TEC) Groundsmaster 4000--D and 4010--D machines use two (2) Toro Electronic Controllers (TEC) to manage ma- chine electrical functions. The controllers are micropro- cessor controlled that sense the condition of various switches and sensors (inputs). The controllers then dir- ect electrical power to control appropriate machine func- tions (outputs) based on the input state.

  • Page 193: Yanmar Engine Electronic Control Unit (Ecu)

    Yanmar Engine Electronic Control Unit (ECU) The Yanmar engine that powers the Groundsmaster 4000--D and 4010--D uses an electronic control unit (ECU) for engine management and also to communi- cate with the TEC controllers and the InfoCenter Display on the machine. All engine ECU electrical connectors should be plugged into the controller before the machine ignition switch is moved from the OFF position to either the RUN or START position.

  • Page 194: Can--Bus Communications

    CAN- -bus Communications The two (2) TEC controllers, the Yanmar engine elec- CAN identifies the Controller Area Network that is used tronic control unit and the InfoCenter Display used on between the controllers on the Groundsmaster. Two (2) the Groundsmaster 4000--D and 4010--D communicate specially designed, twisted wires form the bus.
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  • Page 196: Special Tools

    Multimeter The multimeter can test electrical components and cir- cuits for current, resistance or voltage. NOTE: Toro recommends the use of a DIGITAL Volt-- Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
  • Page 197 Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally. Figure 7 Groundsmaster 4000--D/4010--D Page 5 - - 7 Electrical System...

  • Page 198: Infocenter Display

    InfoCenter Display The InfoCenter Display used on your Groundsmaster is Power for the InfoCenter is available when energized by a LCD device that is located on the console. The Info- the main power relay (ignition switch in the RUN or Center provides information for the machine operator START position).
  • Page 199 Main Information Screen The two (2) InfoCenter main information screens (Figs. 10 and 11) are displayed after the initial splash screen has been displayed for several seconds. During normal machine operation, the main information screens provide machine information for the operator. Toggling between the main information screens is done by press- ing the right button on the InfoCenter.

  • Page 200: Main Menu Screen

    Main Menu Screen The main menu screen can be accessed from the Info- Center main information by pressing and releasing the menu/back button (left button) on the display. Once to the main menu screen (Fig. 12), navigation to the five (5) Main Menu Faults different menu items can occur.

  • Page 201: Adjustments 5

    Service Screen The service screen (Fig. 13) contains machine opera- D Fan - - Oil identifies the number of times that hydraul- tional information including hours and counts. Values ic oil temperature caused the engine cooling fan speed listed for these service menu items cannot be changed. to change.

  • Page 202: Diagnostics Screen

    Diagnostics Screen The diagnostics screen (Fig. 16) lists the various states D PTO identifies machine requirements to allow the of machine electrical components. The diagnostics PTO to be engaged. Inputs indicate the state of the PTO screen should be used to check operation of machine switch.

  • Page 203: Settings Screen

    RUN. NOTE: The initial PIN will either be 1234 or 0000. If the PIN has been changed and is forgotten, a temporary PIN can be obtained from your Toro distributor. Protect settings allows the settings for auto idle, mow Settings...

  • Page 204: About Screen

    About Screen The about screen (Fig. 17) identifies the machine model number, serial number and software revisions for the TEC controllers, InfoCenter and engine electronic con- trol unit (if available). The about screen also lists the About CAN--bus status. Additional information is identified if Model: 30607 313000103...

  • Page 205: Troubleshooting

    Troubleshooting If the machine has any interlock switches by--passed, reconnect the switches for safety and efficient trouble- CAUTION shooting. NOTE: Check the InfoCenter Display for possible oper- Remove all jewelry, especially rings and ator advisories or faults whenever diagnosing machine watches, before doing any electrical trouble- shooting or testing.

  • Page 206: Fault Codes

    Main power relay is faulty Ignition switch was held in the START position for more than 30 seconds or the ignition switch is faulty TEC software needs to be reprogrammed (contact Toro Distributor) Alternator charging is too high Alternator charging is too low...
  • Page 207 Fault Code Fault Description Brake/RH turn light output has open or short to ground Brake/LH turn light output has open or short to ground Forward piston (traction) pump output has open or short to ground Reverse piston (traction) pump output has open or short to ground Reverse engine cooling fan output (solenoid valve S10) has open or short to ground Disable dual engine cooling fan output (solenoid valve S11) has open or short...

  • Page 208: Starting Problems

    Starting Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical problems. Problem Possible Causes No electrical power to machine. The battery is discharged. The battery cables are loose or corroded. Fuse F--D1 (2 Amp) is faulty. Fuse F--D2 (2 Amp) is faulty.
  • Page 209 Starting Problems (Continued) Problem Possible Causes Starter cranks, but should not, when the traction pedal Traction pedal position sensor is out of adjustment. is depressed. Traction pedal position sensor or circuit wiring is faulty. Engine cranks, but does not start. The fuel tank is empty.

  • Page 210: General Run And Transport Problems

    General Run and Transport Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical problems. Problem Possible Causes Engine continues to run, but should not, when the The ignition switch or circuit wiring is faulty. ignition switch is turned off.

  • Page 211: Cutting Deck Operating Problems

    Cutting Deck Operating Problems NOTE: Check InfoCenter Display for possible operator NOTE: To engage the mow circuit, the operator must advisories or faults whenever diagnosing machine elec- be in the operator seat, the traction speed must be in the trical problems. LOW speed (mow) position, the PTO switch must be ON and the cutting deck(s) must be fully lowered and in float.
  • Page 212 Cutting Deck Operating Problems (Continued) Problem Possible Causes Cutting decks run, but should not, when lowered with The PTO switch or circuit wiring is faulty. PTO switch in the OFF (disengage) position. The TEC controller is faulty. Cutting deck(s) do not operate. The operator is lifting off the seat switch.

  • Page 213: Cutting Deck Lift/Lower Problems

    Cutting Deck Lift/Lower Problems NOTE: Check InfoCenter Display for possible operator NOTE: To lower a cutting deck, the operator must be in advisories or faults whenever diagnosing machine elec- the operator seat and the traction speed must be in the trical problems.
  • Page 214 Cutting Deck Lift/Lower Problems (Continued) Problem Possible Causes Right side cutting deck will not raise or lower, but the The RH deck lift switch or circuit wiring is faulty. center and left side cutting decks will raise and lower. Fuse is faulty. Combination control manifold solenoid coils S7, S8 or S9 or circuit wiring is faulty.

  • Page 215: Adjustments

    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 from 0.070” to 0.130” (1.8 to 3.3 mm) clearance between the target surface end of posi- tion switch and the sensing plate on lift arm.

  • Page 216: Traction Pedal Adjustment

    Traction Pedal Adjustment The traction pedal includes a neutral assembly that is used to adjust the traction neutral position (Fig. 20). Traction pedal adjustment may be necessary to make sure that traction pedal movement provides the correct full reverse and full forward positions for the traction pedal position sensor.
  • Page 217 6. After any adjustment of the spring shaft and rod end bearing, use the InfoCenter Display Diagnostics menu (see InfoCenter Display in this chapter) to obtain and se- lect the Traction Pedal menu item. Choose Outputs and Traction Pedal the InfoCenter display will identify the traction pedal po- Forward Range: sition (Fig.

  • Page 218: Traction Pedal Position Sensor Calibration

    Traction Pedal Position Sensor Calibration IMPORTANT: A properly installed and calibrated traction pedal position sensor is critical to accurate traction system response and for reliable sensor life. Use care when removing, installing and cali- brating the traction pedal position sensor. Calibration of the traction pedal position sensor ensures that the TEC controller can identify the traction neutral, forward and reverse positions.

  • Page 219: Electrical System Quick Checks

    Interlock switch operation is described in the Traction Unit Operator’s Manual. Your Groundsmaster is CAUTION equipped with two (2) Toro Electronic Controllers (TEC) which monitor interlock switch operation. Testing of indi- Do not disconnect safety switches. They are for vidual interlock switches and relays is included in the the operator’s protection.

  • Page 220: Component Testing

    (3) positions: STOP, RUN and START lem still exists, check wire harness (see Electrical Sche- (Fig. 26). The Toro Electronic Controller (TEC) monitors matics and Wire Harness Drawings in Chapter 10 -- the operation of the ignition switch.

  • Page 221: Fuses

    Fuses The fuse block is located under the controller cover next Fuse Testing to the operator seat (Fig. 28). Turn ignition switch to the RUN position (do not start en- In addition to the fuses in the fuse block, a 60 Amp fuse gine).

  • Page 222: Operator Cab Fuses (Groundsmaster 4010--D)

    Operator Cab Fuses (Groundsmaster 4010- -D) The operator cab fuse blocks are 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) protects the air conditioner circuit. Fuse F2--1 (15 Amp) protects the windshield wiper/ washer circuit.

  • Page 223: Fusible Link Harness

    Fusible Link Harness Your 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 circuits will cease.

  • Page 224: Pto Switch

    PTO Switch The PTO switch is located on the control arm (Fig. 35). 6. If PTO switch tests correctly and circuit problem still The PTO switch is pulled up to engage the PTO and exists, check wire harness (see Electrical Schematics pushed in to disengage the PTO.

  • Page 225: Hi/Low Speed, Engine Speed And Cutting Deck Lift Switches

    HI/LOW Speed, Engine Speed and Cutting Deck Lift Switches The HI/LOW, engine speed and cutting deck lift SWITCH CLOSED OPEN switches are all identical momentary switches. These POSITION CIRCUITS CIRCUITS switches are located on the control arm (Fig. 37). FRONT OF 2 + 3 2 + 1 SWITCH...

  • Page 226: Cruise Control Switch

    Cruise Control Switch The cruise control switch is used as an input for the TEC 6. If switch tests correctly and circuit problem still ex- controller to maintain ground speed when engaged. The ists, check wire harness (see Electrical Schematics and cruise control function is enabled when the switch is in Wire Harness Drawings in Chapter 10 -- Foldout Draw- the ON (center) position.

  • Page 227: Seat Switch

    Seat Switch The seat switch is normally open and closes when the operator is on the seat. This switch is used as an input for the TEC controller. The seat switch and its electrical connector are located in the seat assembly. If the trac- tion system or PTO switch is engaged when the operator raises out of the seat, an operator advisory will be dis- played on the InfoCenter.

  • Page 228: Parking Brake Switch

    Parking Brake Switch The switch used for the parking brake is a normally open proximity switch that is located under the steering tower cover (Fig. 42). The parking brake switch is an input for the TEC controller. When the parking brake is not ap- plied, a tab on the brake rod is positioned near the switch sense zone which causes the switch to close (continu- ity).

  • Page 229: Service Brake Switches

    Service Brake Switches The two (2) switches used for the service brakes are nor- 13 to 17 in- -lb mally open switches that are located under the footrest (1.5 to 1.9 N- -m) panel (Fig. 43). The service brake switches provide in- puts for the TEC controller.

  • Page 230: Headlight Switch (Groundsmaster 4010--D)

    Headlight Switch (Groundsmaster 4010- -D) The Groundsmaster 4010--D headlight switch is a two (2) position rocker switch that is located on the inside of the control arm. The headlight switch allows the head- lights and taillights to be turned on and off. Testing 1.

  • Page 231: Windshield Wiper/Washer Switch

    Windshield Wiper/Washer Switch (Groundsmaster 4010- -D) The windshield wiper/washer switch is used to control operation of the windshield wiper and washer pump on the Groundsmaster 4010--D. The windshield wiper/wa- sher switch is located in the cab headliner (Fig. 46). Testing 1.

  • Page 232: Air Conditioning Switch (Groundsmaster 4010--D)

    Air Conditioning Switch (Groundsmaster 4010- -D) The air conditioning switch is used to control operation of the air conditioning system on the Groundsmaster 4010--D. The switch is located in the cab headliner (Fig. 48). Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch.

  • Page 233: Turn Signal Switch (Groundsmaster 4010--D)

    Turn Signal Switch (Groundsmaster 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 turn signals. The switch is located on the steering tower (Fig. 50). Testing 1.

  • Page 234: Flasher Switch (Groundsmaster 4010--D)

    Flasher Switch (Groundsmaster 4010- -D) On Groundsmaster 4010--D machines, the flasher switch is used as an input for the TEC controller to pro- vide power for the four way flashers. The switch is lo- cated on the steering tower (Fig. 52). Testing 1.

  • Page 235: Traction Pedal Position Sensor

    Traction Pedal Position Sensor The traction pedal position sensor is connected to the traction pedal assembly (Fig. 54). This position sensor determines the neutral band for the traction pedal, the direction of travel desired by the operator and the trac- tion speed.

  • Page 236: Relays With Four (4) Terminals

    Relays with Four (4) Terminals Your Groundsmaster uses a number of electrical relays that have four (4) terminals. A tag near the wire harness relay connector can be used to identify each relay. The main power relay is used to provide current to most of the fuse protected circuits (operator seat, InfoCenter display, power point and optional electric equipment).
  • Page 237 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 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as +12 VDC is applied and removed from terminal 85.

  • Page 238: Relays With Five (5) Terminals

    Relays with Five (5) Terminals Your Groundsmaster uses a number of electrical relays MODELS 30603 AND 30605 that have five (5) terminals. A tag near the wire harness relay connector can be used to identify each relay. The air conditioning relay is used to control the air condi- tioning electrical power circuit on the Groundsmaster 4010--D.
  • Page 239 8. Connect multimeter (ohms setting) leads to relay ter- 10.Secure all removed components to machine. minals 30 and 87A. Apply +12 VDC to terminal 85. The 11. Connect positive (+) cable first to battery and then relay should make and break continuity between termi- connect negative (--) cable to battery (see Battery Ser- nals 30 and 87A as +12 VDC is applied and removed vice in the Service and Repairs section of this chapter).

  • Page 240: Toro Electronic Controllers (Tec)

    Toro Electronic Controllers (TEC) Groundsmaster 4000--D and 4010--D machines use two (2) Toro Electronic Controllers (TEC) to control electrical system operation. The controllers are attached to the operator platform under the controller cover (Figs. 64 and 65). Logic power is provided to the controllers as long as the battery cables are connected to the battery.
  • Page 241 4000--D and 4010--D are matched for correct ma- chine operation. If either of these components are replaced for any reason, system software needs to be reprogrammed by your Toro Distributor. Figure 66 IMPORTANT: Before performing any welding on your Groundsmaster, disconnect both positive and...

  • Page 242: Hydraulic Solenoid Valve Coils

    Hydraulic Solenoid Valve Coils RIGHT FRONT Figure 66 1. Front PTO manifold 3. LH PTO manifold 4. Combination manifold 2. RH PTO manifold Several hydraulic solenoid valve coils are used on the NOTE: To assist in troubleshooting, identical solenoid hydraulic control manifolds of Groundsmaster 4000--D coils can be exchanged.
  • Page 243 Testing 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Locate hydraulic solenoid valve coil to be tested (Fig. 66). Disconnect wire harness connector from coil. 3.

  • Page 244: Piston (Traction) Pump Control Solenoid Coils

    Piston (Traction) Pump Control Solenoid Coils The piston (traction) pump uses an electronic control as- C. Slide new coil with O--rings onto the solenoid sembly for swash plate rotation. Electrical outputs from stem. the machine TEC controller are provided to two (2) D.

  • Page 245: Can--Bus Termination Resistor

    CAN- -bus Termination Resistor System communication between electrical components on Groundsmaster 4000--D and 4010--D machines is Termination accomplished on a CAN--bus communication system. Resistor Two (2) specially designed, twisted wires form the bus for the network used on the machine. These wires pro- vide the data pathways between machine components.

  • Page 246: Diode Assemblies

    Diode Assemblies The Groundsmaster engine wire harness contains a diode assembly that is used for circuit protection from voltage spikes when the engine starter solenoid is de-- energized. Groundsmaster models 30607 and 30609 use an addi- tional diode assembly in the engine wire harness that protects the engine EGR circuit from reverse polarity.

  • Page 247: Fuel Sender

    Fuel Sender The fuel sender is attached to the top of the fuel tank. 6. Using a multimeter, check resistance of the sender The resistance of the fuel sender increases as the fuel with the float in the full and empty positions. Expected level in the fuel tank decreases.

  • Page 248: Fuel Pump (Models 30603 And 30605)

    Fuel Pump (Models 30603 and 30605) The fuel pump is attached to the fuel tank support above the fuel water separator (Fig. 76). Operational Test 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake. Raise hood to access fuel pump.

  • Page 249: Fuel Pump (Models 30607 And 30609)

    Fuel Pump (Models 30607 and 30609) The fuel pump is attached to the fuel tank support above the fuel water separator (Fig. 78). Operational Test 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake. Raise hood to access fuel pump.

  • Page 250: Cutting Deck Position Switches

    Cutting Deck Position Switches Three (3) cutting deck position switches are used on the Groundsmaster 4000--D and 4010--D. These switches are located on the traction unit frame (Figs. 80 and 81). The position switches are powered proximity switches that incorporate an internal reed switch and a LED. The deck position switches are used as inputs for the TEC controller to prevent deck operation when a cutting deck is raised.

  • Page 251: Hydraulic Oil Temperature Sender

    Hydraulic Oil Temperature Sender The Groundsmaster 4000--D and 4010--D use a temper- 5. After allowing the sender to cool, install sender: ature sender as an input for the TEC controller to identify A. Install new O--ring on sender. if the hydraulic oil temperature has reached an exces- sive level.

  • Page 252: Audio Alarm

    Audio Alarm The audio alarm sounds to notify the operator when a machine problem exists. Electrical current for the alarm is provided as an output from the TEC controller. The alarm is attached to the control arm next to the operator seat.

  • Page 253: Service And Repairs

    B. Coat battery posts and cable connectors with bat- chine is stored in a location where temperatures are ex- tery terminal protector (Toro Part No. 107--0392) or tremely high, the battery will discharge more rapidly petroleum jelly to prevent corrosion.

  • Page 254: Battery Service

    Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes.
  • Page 255 Battery Testing Minimum Battery Voltage Temperature 1. Perform a high--discharge test with an adjustable F (and up) C (and up) load tester. This is one of the most reliable means of test- ing a battery as it simulates the cold--cranking test. A commercial battery load tester is required to perform this test.
  • Page 256 Battery Charging CAUTION To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging meth- od is presented here. This charging method can be ac- Do not charge a frozen battery because it can ex- complished with a constant current battery charger plode and cause injury.

  • Page 257: General Information 6

    Chapter 6 Axles, Planetaries and Brakes Table of Contents SPECIFICATIONS ......GENERAL INFORMATION .

  • Page 258: Specifications

    Specifications Item Specification Tire pressure (front and rear) 25 to 30 PSI (172 to 207 kPa) Rear wheel toe--in 0.250 in (6 mm) Planetary gear drive oil SAE 85W--140 wt. gear lube System gear lube capacity (each wheel) 22 fl. oz. (0.65 liters) Rear axle lubricant SAE 85W--140 wt.

  • Page 259: General Information

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

  • Page 260: Adjustments

    Adjustments Planetary Wheel Drive Assembly Endplay A front planetary wheel drive assembly that is properly 3. Grasp front wheel and check for endplay in the plan- operating should have no endplay. Any endplay in a etary assembly as indicated by axial wheel movement. planetary assembly indicates that there are potential Make sure that there is no endplay in assembly.
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  • Page 262: Service And Repairs

    Service and Repairs Brake Assembly 75 to 85 ft- -lb (101 to 115 N- -m) RIGHT FRONT 75 to 85 ft- -lb (101 to 115 N- -m) 85 to 100 ft- -lb (115 to 135 N- -m) Figure 1 1. Front wheel motor 9.
  • Page 263 Removal (Fig. 1) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch. 2. Drain oil from planetary wheel drive/brake assembly (Fig. 2). CAUTION When removing front wheel, use correct jacks and supports.
  • Page 264 2. Apply gasket sealant to sealing surfaces of new gas- 9. Make sure drain plugs are installed in brake and ket (item 18). Apply gasket to brake assembly. planetary drive assemblies (Fig. 2). 3. Install brake assembly onto machine, aligning 10.Fill planetary wheel drive/brake assembly with SAE splined brake shaft with input shaft on planetary wheel 85W--140 gear lube (Fig.
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  • Page 266: Brake Inspection And Repair

    Brake Inspection and Repair Figure 6 1. Brake housing (LH shown) 6. Hitch pin (2 used) 11. Rotating actuator 2. Seal 7. Stationary disc (4 used) 12. Extension spring (3 used) 3. Pull rod 8. Rotating disc (3 used) 13. Ball (3 used) 4.
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  • Page 268: Planetary Wheel Drive Assembly

    Planetary Wheel Drive Assembly 75 to 85 ft- -lb (101 to 115 N- -m) RIGHT 75 to 85 ft- -lb FRONT (101 to 115 N- -m) 85 to 100 ft- -lb (115 to 135 N- -m) Figure 7 1. Front wheel motor 8.
  • Page 269 Removal (Fig. 7) WARNING 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch. Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may 2.

  • Page 270: Planetary Wheel Drive Service

    Planetary Wheel Drive Service 118 to 144 in- -lb (13.3 to 16.3 N- -m) Figure 10 1. Spindle 11. Outer bearing cup 20. End cap 2. Boot seal 12. Outer bearing cone 21. Thrust plug 3. Oil seal 13. O- -ring 22.
  • Page 271 NOTE: The planetary wheel drive assembly can be ser- viced with the planetary installed to machine. If the spindle (item 1) needs to be removed from machine, see Planetary Wheel Drive Assembly in this section. Disassembly (Figs. 10 and 11) 1.
  • Page 272 F. Lightly oil bearing journals on spindle shaft. Slide 4. Install secondary carrier (item 28), secondary gear housing assembly onto spindle (item 1) taking care (item 27) and primary carrier (item 26) making sure that to not damage seal or spindle. Make sure that inner carrier gear teeth align with ring gear and spline on bearing in housing fully seats against spindle shaft spindle shaft.
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  • Page 274: Rear Axle Assembly

    Rear Axle Assembly RIGHT 85 to 100 ft- -lb FRONT 135 to 165 ft- -lb (115 to 135 N- -m) (184 to 223 N- -m) Figure 12 1. Plug with O- -ring 11. Slotted hex nut (2 used) 21. Rear axle mount 2.
  • Page 275 Removal (Fig. 12) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Drain oil from rear axle and axle gearbox (Figs. 13 and 14). 3. Chock front wheels and jack up rear of machine (see Jacking Instructions in Chapter 1 -- Safety).
  • Page 276 2. Secure rear axle to rear axle mount. A. Slide rear axle pin through rear axle mount and rear axle. Install washer and lock nut onto rear axle pin. B. Secure pivot pin to axle mount with washer head screw (Fig. 16). C.
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  • Page 278: Rear Axle Service

    Rear Axle Service Figure 19 Axles, Planetaries and Brakes Page 6 - - 22 Groundsmaster 4000--D/4010--D...
  • Page 279 Figure 19 (Continued) 1. LH axle support 23. RH axle support 44. Bevel gear (17 tooth) 2. Flange bushing (2 used) 24. Input shaft assembly 45. Bevel gear shaft 3. Axle vent 25. Bolt (8 used) 46. Axle case (LH shown) 4.

  • Page 280: Bevel Gear Case And Axle Case

    Bevel Gear Case and Axle Case The following procedures assume the rear axle assem- 35 to 41 ft- -lb bly has been removed from the machine. (47 to 56 N- -m) Removal 1. Remove the mounting screws, nuts and lock wash- ers.
  • Page 281 5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gas- ket material from either mating surface (Fig. 23). 6. While holding the bevel gear case, tap the upper end 17 to 20 ft- -lb (23 to 27 N- -m) of the bevel gear shaft out of the upper bearing and up- per bevel gear.
  • Page 282 Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 25). Figure 25 1. Axle case 3. Shaft seal 2. Bevel gear case 2. Install the lower bevel gear and bevel gear shaft in the axle case cover.
  • Page 283 5. Determine necessary quantity of support shims. 57 to 67 ft- -lb A. Lubricate the axle case support bushing with a (77 to 91 N- -m) thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during VERTICAL disassembly between axle case support and axle ENDPLAY...

  • Page 284: Differential Shafts

    9. Remove the bevel gear case/axle case assembly NOTE: Axle bearing shims are available in 0.008 inch from the axle support. Coat a new O-ring with grease (0.2 mm), 0.012 inch (0.3 mm) and 0.020 inch (0.5 mm) and temporarily install the axle cover assembly. Position thickness.

  • Page 285: Axle Shafts

    Axle Shafts The following procedures assume the rear axle assem- 17 to 20 ft- -lb bly has been removed from the machine. (23 to 27 N- -m) Removal 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig.

  • Page 286: Input Shaft/Pinion Gear

    Input Shaft/Pinion Gear 35 to 41 ft- -lb (47 to 56 N- -m) 35 to 41 ft- -lb (47 to 56 N- -m) Figure 35 1. Nut (2 used) 9. Bearing 17. Cover plate 2. Lock washer (2 used) 10. O-ring 18.
  • Page 287 5. Install a new stake washer. Install the lock nut finger tight. 6. Set the bearing preload by securing the bearing case in a vise. Thread a M12 x 1.5 hex head cap screw into the splined end of the input shaft/pinion gear and slowly 0.040 in.

  • Page 288: Differential Gear

    Differential Gear The following procedures assume the rear axle assem- 35 to 41 ft- -lb bly has been removed from the machine. (47 to 56 N- -m) Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual).
  • Page 289 Inspection 1. Measure the differential side gear O.D. and the dif- ferential case I.D. to determine the side gear to case clearance (Fig. 42). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 inch (0.05 to 0.30 mm) SIDE GEAR O.D.
  • Page 290 Installation 1. If the ring gear was removed from the differential case, use medium strength Loctite thread locker and tighten the mounting screws from 22 to 25 ft-lb (30 to 34 N- -m). 2. Apply molybdenum disulfide lubricant (Three Bond 1901 or equivalent) to the splines and bearing surfaces of the differential pinion gears, pinion washers and side gears.

  • Page 291: Pinion Gear To Ring Gear Engagement

    Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using PROFILE the gear contact pattern method as described in the fol- TOP LAND lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 46): Toe -- the portion of the tooth surface at the end to- LENGTHWISE wards the center.
  • Page 292 Gear Pattern Movement Summary Heel Contact Base Contact Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as gear location is changed. 1. If contact is toward the heel or base of the gear (Fig. 49): A.

  • Page 293: General Information

    Chapter 7 Chassis Table of Contents GENERAL INFORMATION ..... Operator’s Manual ......SERVICE AND REPAIRS .

  • Page 294: Service And Repairs

    Service and Repairs Steering Tower 20 to 26 ft- -lb 27 to 33 ft- -lb (28 to 35 N- -m) (37 to 44 N- -m) RIGHT FRONT Figure 1 1. Steering wheel cover 9. Flange bushing 17. Steering column 2. Hex nut 10.
  • Page 295 Disassembly (Fig. 1) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove steering tower covers to access steering tower components (Fig. 2). 3. Disassemble steering tower as needed using Figure 1 as a guide.
  • Page 296 Center Deck Lift Arms 41 42 RIGHT FRONT 90 to 100 ft- -lb (123 to 135 N- -m) 60 to 70 ft- -lb (81 to 94 N- -m) 150 to 175 ft- -lb (203 to 237 N- -m) Figure 3 1.
  • Page 297 Removal (Fig. 3) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove center cutting deck (see Center Cutting Deck Removal in Chapter 8 -- Cutting Decks). CAUTION 1.200”...

  • Page 298: Operator's Manual

    7. Install ball joint mount to ball joint with slotted hex nut. 10.Lubricate lift arm grease fittings. Torque nut from 90 to 100 ft- -lb (123 to 135 N- -m) while 11. After assembly is completed, raise and lower the cut- aligning cotter pin holes.
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  • Page 300: Side Deck Lift Arms

    Side Deck Lift Arms 33 13 Loctite #242 Antiseize Lubricant 77 to 96 ft- -lb (105 to 130 N- -m) RIGHT FRONT Figure 6 1. Lift cylinder pin 13. Flat washer (5 used per side) 25. Sensing plate 2. Slotted roll pin 14.
  • Page 301 Removal (Fig. 6) 6. Align lift cylinder with lift arm. Secure lift cylinder to lift arm with lift cylinder pin (item 28). After lift cylinder is 1. Park machine on a level surface, lower cutting secured, make sure that upper hydraulic fitting on lift cyl- decks, stop engine, apply parking brake and remove inder does not contact frame.

  • Page 302: Side Deck Rear Arm Assembly

    Side Deck Rear Arm Assembly Loctite #271 35 36 270 to 330 in- -lb (31 to 37 N- -m) RIGHT FRONT Figure 9 1. Cutting deck (LH shown) 16. Plate 30. Damper 2. Deck mount (LH shown) 17. Lock nut (2 per arm) 31.
  • Page 303 Rear Arm Removal (Fig. 9) 10.If rod ends (item 31) were removed from damper (item 30), apply Loctite #271 (or equivalent) to damper 1. Park machine on a level surface, lower cutting shaft threads before installing rod ends. Secure damper decks, stop engine, apply parking brake and remove to bellcrank and rear arm with cap screws and lock nuts.
  • Page 304 Rear Arm Installation (Fig. 9) 1. Position rear arm assembly to cutting deck and frame. 2. Slide pivot shaft through rear arm clevis and hub. Se- cure pivot shaft with lock washer (item 24) and lock nut (item 25). 3. Connect damper link to cutting deck with clevis pin (item 5) and hair pin (item 6).
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  • Page 306: Lift Arm Joint Yoke

    Lift Arm Joint Yoke 150 to 180 ft- -lb (203 to 244 N- -m) RIGHT FRONT Figure 13 1. Side cutting deck (LH shown) 8. Flat washer (8 used per mount) 15. Cap screw (8 used per mount) 2. Deck mount (LH shown) 9.
  • Page 307 Joint Yoke Disassembly 5. Install retaining rings to yoke and deck mount to se- cure bearings in place. 1. Remove retaining rings from yoke and deck mount. 6. Make sure that assembled joint yoke moves without IMPORTANT: Support yoke when removing cross binding.

  • Page 308: Control Arm

    Control Arm RIGHT FRONT Figure 15 1. Flange nut (3 used) 16. Flange head screw (6 used) 30. RH cover 2. Flange head screw (2 used) 17. Flange nut (2 used) 31. Cruise control switch 3. Washer head screw (10 used) 18.
  • Page 309 Disassembly (Fig. 15) 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 2. Remove two (2) flange head screws (item 27) and then cover plate (item 26) from outside of control arm. Locate and retrieve two (2) spacers (item 25).

  • Page 310: Traction Pedal

    Traction Pedal 13 to 17 in- -lb (1.5 to 1.9 N- -m) RIGHT FRONT Figure 17 Carriage bolt (6 used) 14. Cap screw 27. Bushing hub Traction pedal 15. Flange nut (2 used) 28. Position sensor Bushing 16. Lock washer 29.
  • Page 311 IMPORTANT: A properly installed and calibrated F. To install the traction pedal position sensor (item traction pedal position sensor is critical to accurate 28 in Fig. 17), press and hold the traction pedal in the traction system response and for reliable sensor reverse direction slightly.

  • Page 312: Operator Platform

    Operator Platform 95 to 115 ft- -lb (129 to 155 N- -m) RIGHT FRONT Figure 19 1. Operator platform 4. Center mount (4 used) 6. Lock nut (4 used) 2. Cap screw (2 used) 5. Plain washer (4 used) 7. Cap screw (2 used) 3.
  • Page 313 Some service procedures (e.g. removing the hydraulic reservoir) require the operator platform to be raised. The following steps can be used to raise the platform. Disassembly (Fig. 19) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch.
  • Page 314 Assembly (Fig. 19) 13 to 17 in- -lb 1. Make sure that all machine components are installed (1.5 to 1.9 N- -m) below operator platform before platform is lowered to frame. IMPORTANT: Make sure to not damage the electric- al wire harness or other components while lowering the operator platform.
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  • Page 316: Operator Seat

    Operator Seat RIGHT FRONT Figure 24 1. Carriage screw (5 used) 14. Seat latch 27. Flat washer (3 used) 2. Support channel 15. Locking cotter pin 28. Cotter pin (2 used) 3. Support bracket 16. Latch rod 29. Clevis pin (2 used) 4.
  • Page 317 Removal (Fig. 24) B. Secure control arm support (item 7) to coupler nut (item 9) with screw (item 8). 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove C. Place flat washer (item 6), seat belt latch (item 21) key from the ignition switch.

  • Page 318: Operator Seat Service

    Operator Seat Service Figure 27 1. Backrest cushion 11. Washer 21. Torx screw (5 used) 2. Seat cushion 12. Cap screw (2 used) 22. RH adjustment rail 3. Armrest cover 13. Seat 23. Rail stop 4. LH armrest 14. Nut 24.
  • Page 319 Disassembly (Fig. 27) 1. Disassemble operator seat as necessary using Fig- ures 27 and 28 as guides. Assembly (Fig. 27) 1. Assemble operator seat using Figures 27 and 28 as guides. Figure 28 1. Operator seat 5. Flat washer 2. R- -clamp (2 used) 6.

  • Page 320: Operator Seat Suspension

    Operator Seat Suspension RIGHT FRONT Figure 29 1. Cover 14. Washer (2 used) 27. Clamp (2 used) 2. Cover 15. Tether 28. Hose nipple 3. Level control 16. Rivet (2 used) 29. Screw 4. Air control valve 17. Washer (4 used) 30.
  • Page 321 NOTE: Most of the seat suspension components can be serviced with the seat suspension base mounted to the frame platform. If the air spring assembly (item 6) re- quires removal, the seat suspension base will have to be removed from the seat platform. Disassembly (Fig.

  • Page 322: Hood

    Hood RIGHT FRONT Figure 32 1. Hood 12. Flexible draw latch (2 used) 22. Carriage bolt (24 used) 2. Screen assembly 13. Corner screen seal (2 used) 23. Carriage bolt (2 used) 3. Bulb seal 14. Screw (8 used) 24. Plastic plug (43 used) 4.
  • Page 323 Removal 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove hood assembly from machine: A. Remove hair pins (item 6) that retain screen pivots to hood pivots. B.
  • Page 324 This page is intentionally blank. Chassis Page 7 - - 32 Groundsmaster 4000--D/4010--D...

  • Page 325: Specifications 8

    Chapter 8 Cutting Decks Table of Contents SPECIFICATIONS ......GENERAL INFORMATION ..... Operator’s Manual .

  • Page 326: Specifications

    Specifications MOUNTING: Cutting decks are supported by lift arms WIDTH OF CUT: Center deck provides 62” (1575 mm) controlled with individual lift switches. width of cut. Each side deck has 42” (1067 mm) width of cut. Total width of cut is 132” (3353 mm) with 7” (128 CONSTRUCTION: Deck chamber is welded steel mm) overlap.

  • Page 327: General Information

    General Information CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop en- gine and remove key first. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine.

  • Page 328: Troubleshooting

    Troubleshooting There are a number of factors that can contribute to un- Remember that the “effective” or actual height--of--cut satisfactory quality of cut, some of which may be turf depends on cutting deck weight, tire pressures, hydrau- conditions. Turf conditions such as excessive thatch, lic counterbalance settings and turf conditions.
  • Page 329 This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 8 - - 5 Cutting Decks...

  • Page 330: Service And Repairs

    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 RIGHT FRONT 90 to 100 ft- -lb (123 to 135 N- -m) 150 to 175 ft- -lb (203 to 237 N- -m)
  • Page 331 Removal (Fig. 1) 1. Position machine on a clean, level surface. Lower cutting decks, stop engine, apply parking brake and re- move key from the ignition switch. 2. Remove spring pin (item 32) that secures damper (item 30) to cutting deck. Position damper away from cutting deck.

  • Page 332: Side Cutting Decks

    Side Cutting Decks RIGHT FRONT Figure 5 1. Cutting deck (LH shown) 5. Clevis pin 9. Lock washer (8 used per mount) 2. Flange head screw (2 used) 6. Hair pin 10. Flat washer (8 used per mount) 3. Hydraulic deck motor 7.
  • Page 333 Removal (Fig. 5) 1. Position machine on a clean, level surface. Lower cutting decks, stop engine, apply parking brake and re- move key from the ignition switch. 2. Remove hydraulic motor from cutting deck (see Cut- ting Deck Motor Removal in the Service and Repairs Section of Chapter 4 -- Hydraulic System).

  • Page 334: Idler Assembly

    Idler Assembly RIGHT FRONT Figure 9 1. Cutting deck (front shown) 9. Socket head screw 17. Idler arm 2. Flange nut 10. Idler stop bolt 18. Retaining ring 3. Flange nut 11. Flange nut 19. Thrust washer 4. Adjusting screw 12.
  • Page 335 Removal (Fig. 9) CAUTION 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. Be careful when installing the idler spring. The spring is under heavy load and may cause per- 2.

  • Page 336: Blade Spindle Assemblies

    Blade Spindle Assemblies RIGHT FRONT Figure 11 1. Center cutting deck 3. LH cutting deck 5. Driven spindle assembly 2. RH cutting deck 4. Drive spindle assembly 6. Grease fitting location Page 8 - - 12 Cutting Decks Groundsmaster 4000--D/4010--D...
  • Page 337 Removal (Figs. 11 and 12) 4. Slowly rotate cutting blades to verify that blades do not contact any deck components. 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove 5. Install drive belt to spindle pulleys and idler pulley. key from the ignition switch.

  • Page 338: Blade Spindle Service

    Blade Spindle Service 130 to 150 ft- -lb 130 to 150 ft- -lb (176 to 203 N- -m) (176 to 203 N- -m) DRIVE SPINDLE Figure 13 1. Lock nut 6. Hydraulic motor mount 10. Spacer set 2. Hardened washer 7.
  • Page 339 2. Install outer bearing spacer into top of spindle hous- ing. The spacer should fit against the snap ring. 3. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the outer bearing spacer previously installed, and the bottom bearing cup must contact the snap ring.

  • Page 340: Castor Forks And Wheels

    Castor Forks and Wheels CASTOR FORK SIDE CUTTING DECK 60 to 80 ft- -lb (81 to 108 N- -m) CASTOR WHEEL 29 30 60 to 80 ft- -lb (81 to 108 N- -m) Figure 17 1. Castor arm (center deck shown) 13.
  • Page 341 Chapter 9 Operator Cab Table of Contents GENERAL INFORMATION ..... Operator’s Manual ......Electrical Components and Schematic .

  • Page 342: General Information

    General Information The information in this chapter pertains to the operator cab on the Groundsmaster 4010--D. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster. Refer to the Opera- tor’s Manual for additional information when servicing the machine.

  • Page 343: Service And Repairs

    Service and Repairs General Precautions for Removing and Installing Air Conditioning System Components 5. Put labels on disconnected lines and hoses for prop- CAUTION er installation after repairs are completed. 6. If compressor is removed from machine, keep com- pressor in the same orientation as the installed position. The air conditioning system is under high pres- This will prevent compressor oil from filling the compres- sure.

  • Page 344: Air Conditioning Compressor

    Air Conditioning Compressor RIGHT FRONT Figure 1 1. Cap screw (2 used) 8. O- -ring 15. Exhaust pipe 2. Flat washer (4 used) 9. A/C compressor 16. Flange nut 3. Lock washer (6 used) 10. Cap screw (4 used) 17. Carriage screw 4.
  • Page 345 7. Read the General Precautions for Removing and 2. Secure compressor to compressor mount with re- Installing Air Conditioning System Components at the moved fasteners and spacers. Do not fully tighten fas- beginning of the Service and Repairs section of this teners.

  • Page 346: Roof Assembly

    Roof Assembly FRONT Figure 3 1. Roof 7. Panel nut 12. Front spacer (2 used) 2. Screw (2 used) 8. Roof mount 13. Front fastener (2 used) 3. Flat washer (6 used) 9. Flange nut (2 used) 14. Rubber washer 4.
  • Page 347 To gain access to the heater core and air conditioning components that are located under the cab roof, the roof panel can be loosened, raised and supported. Removal (Fig. 3) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch.

  • Page 348: Air Conditioning Condenser Assembly

    Air Conditioning Condenser Assembly FRONT Figure 5 1. Condenser cover 5. Carriage screw (2 used) 8. Bushing (4 used) 2. Lock nut (4 used) 6. Flat washer (8 used) 9. Mounting strap 3. Condenser fan 7. Roof 10. Button head screw (4 used) 4.
  • Page 349 8. Label and remove hoses from condenser coil. Imme- diately cap hoses and fittings to prevent moisture and contaminants from entering the system. 9. Remove condenser coil from roof using Figure 6 as a guide. NOTE: The replacement of the drier--receiver is recom- mended whenever the air conditioning system is opened (see Heater/Evaporator in this section).

  • Page 350: Heater/Evaporator Assembly

    Heater/Evaporator Assembly Figure 7 1. Heater/evaporator assembly 7. Speed nut (8 used) 12. Blower fan assembly 2. Top cover 8. Panel nut (4 used) 13. Expansion valve 3. Flange head screw (2 used) 9. Drier- -receiver assembly 14. Freeze switch 4.
  • Page 351 7. Loosen hose clamp that secures air duct hose to heater/evaporator assembly covers. Slide hose from covers. 8. Remove screws that secure top cover to bottom cov- er. Remove top cover to access heater/evaporator as- sembly. 9. Disassemble heater/evaporator assembly using Fig. 7 as a guide.

  • Page 352: Windshield Wiper

    Windshield Wiper Figure 10 Wiper motor Cap (2 used) 10. Cover (2 used) Gasket Washer 11. Wiper arm assembly Linkage bracket 12. Wiper blade Lock washer Flange nut (2 used) 13. Screw (2 used) Cap screw Operator Cab Page 9 - - 12 Groundsmaster 4010--D...
  • Page 353 Disassembly (Fig. 10) Assembly (Fig. 10) 1. Park machine on a level surface, lower cutting 1. Assemble windshield wiper components using Fig- decks, stop engine, engage parking brake and remove ure 10 as a guide. key from the ignition switch. 2.
  • Page 354 This page is intentionally blank. Operator Cab Page 9 - - 14 Groundsmaster 4010--D...
  • Page 355 Chapter 10 Foldout Drawings Table of Contents ELECTRICAL DRAWING DESIGNATIONS ..HYDRAULIC SCHEMATIC ..... ELECTRICAL SCHEMATICS Models 30605 and 30603 .

  • Page 356: Electrical Drawing Designations

    Electrical Drawing Designations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. ABBREVIATION COLOR BLACK BR or BN BROWN BLUE GREEN GRAY ORANGE PINK R or RD VIOLET W or WH WHITE Y or YE YELLOW...

  • Page 357: Hydraulic Schematic

    COOLING FAN MOTOR LEFT DECK CENTER DECK RIGHT DECK 2.00” BORE 0.51 CID STEERING 2.50” BORE RAM CYLINDERS 2.50” BORE 4.20” STROKE CYLINDER 6.50” STROKE 6.50” STROKE 1.50” BORE 0.625” ROD 1.125” ROD 1.125” ROD 3.08” STROKE STEERING CONTROL VALVE .070 .070 .070...

  • Page 358: Models 30605 And 30603

    Groundsmaster 4000--D/4010--D Models 30605 and 30603 NOTE: WHEN A WIRE FROM THIS SCHEMATIC CONTINUES TO THE OPERATOR Electrical Schematic CAB, A REFERENCE NUMBER WILL BE LISTED. THE CAB SCHEMATIC WILL ALSO INCLUDE THE REFERENCE NUMBER. All relays and solenoids are shown as de- - energized. All ground wires are black.

  • Page 359: Models 30609 And 30607

    Groundsmaster 4000--D/4010--D Models 30609 and 30607 Electrical Schematic NOTE: WHEN A WIRE FROM THIS SCHEMATIC CONTINUES TO THE OPERATOR CAB, A REFERENCE NUMBER WILL BE LISTED. THE CAB SCHEMATIC WILL ALSO All relays and solenoids INCLUDE THE REFERENCE NUMBER. are shown as de- - energized. All ground wires are black.

  • Page 360: Operator Cab

    NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. TO OPERATOR TO GROUND FROM OPERATOR PLATFORM PLATFORM BLOCK WIRE HARNESS WIRE HARNESS TO CAB WIRE HARNESS Groundsmaster 4010--D Operator Cab (shown with lights for US model) Electrical Schematic All relays and solenoids are shown as de- - energized.

  • Page 361: International Light Kits

    NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. TO OPERATOR PLATFORM FROM OPERATOR WIRE HARNESS PLATFORM WIRE HARNESS TO OPERATOR PLATFORM WIRE HARNESS TO CAB WIRE HARNESS Groundsmaster 4010--D International Light Kits Electrical Schematic All relays and solenoids are shown as de- - energized.
  • Page 362 This page is intentionally blank. Page 10 - - 8...

  • Page 363: Platform Wire Harness Drawing

    Groundsmaster 4000--D/4010--D Platform Wire Harness Drawing Page 10 - - 9...
  • Page 364 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4000--D/4010--D Platform Wire Harness Diagram Sheet 1 of 2 NOTE: THE PLATFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2) SHEETS.
  • Page 365 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4000--D/4010--D Platform Wire Harness Diagram Sheet 2 of 2 NOTE: THE PLATFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2) SHEETS.

  • Page 366: Rear Wire Harness Drawing

    Groundsmaster 4000--D/4010--D Rear Wire Harness Drawing Page 10 - - 12...
  • Page 367 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4000--D/4010--D Rear Wire Harness Diagram Page 10 - - 13...

  • Page 368: Engine Wire Harness Drawing (Models 30609 And 30607)

    Groundsmaster 4000--D/4010--D Models 30609 and 30607 Engine Wire Harness Drawing Page 10 - - 14...
  • Page 369 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4000--D/4010--D Models 30609 and 30607 Engine Wire Harness Diagram Page 10 - - 15...

  • Page 370: Engine Wire Harness Drawing (Models 30605 And 30603)

    Groundsmaster 4000--D/4010--D Models 30605 and 30603 Engine Wire Harness Drawing Page 10 - - 16...
  • Page 371 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4000--D/4010--D Models 30605 and 30603 Engine Wire Harness Diagram Page 10 - - 17...

  • Page 372: Operator Cab Wire Harness Drawing

    Groundsmaster 4010--D Operator Cab Wire Harness Drawing Page 10 - - 18...
  • Page 373 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4010--D Operator Cab Wire Harness Diagram Page 10 - - 19...
  • Page 374 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4010--D Operator Cab Interconnect Wire Harness Page 10 - - 20...

This manual is also suitable for:

30603Groundsmaster 4010-d306053060730609

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