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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: Service Manual , Operator's Manual
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 (Model 30412).
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.
Groundsmaster
AND
ADJUSTMENT
E The Toro Company - - 2008, 2012

Service Manual

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.
Part No. 08161SL (Rev. A)
(Model 30412)
R
4000- -D

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  • Page 1: Service Manual

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

  • Page 5: General Safety Instructions 1

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

  • Page 6: General Safety Instructions

    General Safety Instructions The GROUNDSMASTER 4000-D is tested and certified by Toro for compliance with existing safety standards WARNING and specifications. Although hazard control and acci- dent prevention partially are dependent upon the design To reduce the potential for injury or death, and configuration of the machine, these factors are also comply with the following safety instructions.

  • Page 7: Maintenance And Service

    Toro replacement parts and 6. Before disconnecting or performing any work on the accessories. Replacement parts and accessories made...

  • Page 8: 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 9: Safety And Instruction Decals

    Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 4000--D. If any decal becomes illeg- ible or damaged, install a new decal. Decal part num- bers are listed in your Parts Catalog. Groundsmaster 4000--D Safety Page 1 - - 5...
  • Page 10 This page is intentionally blank. Safety Groundsmaster 4000--D Page 1 - - 6...

  • Page 11: Product Records

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

  • Page 12: Equivalents And Conversions

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

  • Page 13: 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 14 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 15 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 Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...
  • Page 16 Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size 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...

  • Page 17: General Information

    Chapter 3 Kubota Diesel Engine Table of Contents GENERAL INFORMATION ..... Operator’s Manual ......Stopping the Engine .

  • Page 18: General Information

    Kubota Workshop Manual, Diesel Engine, Service and repair parts for Kubota engines are sup- V2403--M--T--E3B that is included at the end of this sec- plied through your Authorized Toro Distributor. If no tion. parts list is available, be prepared to provide your distrib- utor with the Toro model and serial number.

  • Page 19: Specifications

    Specifications Item Description Make / Designation Kubota Model V2403--M--T--E3B: 4--Cycle, 4 Cylinder, Water Cooled, Turbocharged, Diesel Engine Bore 3.43” (87.0 mm) Stroke 4.031” (102.4 mm) Total Displacement 148.5 in (2434 cc) Firing Order 1 (closest to gear case end) -- 3 -- 4 (closest to flywheel end) -- 2 Combustion Chamber Spherical Type (E--TVCS) Compression Ratio...

  • Page 20: Air Filter System

    Service and Repairs Air Filter System RIGHT FRONT 12 to 15 in- -lb (1.4 to 1.6 N- -m) 13 14 16 17 VACUATOR DIRECTION Figure 1 1. Air cleaner hose 7. Hose clamp 13. Flat washer (2 used) 2. Hose clamp 8.
  • Page 21 Removal (Fig. 1) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Raise and support hood. 3. Remove air cleaner components as needed using Figure 1 as a guide. Installation (Fig.

  • Page 22: Exhaust System

    Exhaust System 16 to 22 ft- -lb 16 to 22 ft- -lb (21 to 29 N- -m) (21 to 29 N- -m) 16 to 22 ft- -lb (21 to 29 N- -m) 13 ft- -lb (17.6 N- -m) RIGHT FRONT 16 to 22 ft- -lb (21 to 29 N- -m) Figure 5...
  • Page 23 Removal (Fig. 5) CAUTION The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and ex- haust system to cool before working on the muf- fler. 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch.

  • Page 24: Fuel System

    Fuel System 27 28 RIGHT 18 17 16 135 to 165 ft- -lb FRONT (183 to 223 N- -m) 60 to 80 in- -lb (7 to 9 N- -m) Figure 7 1. Fuel tank 15. Retaining ring (2 used) 29. Fuel hose 2.

  • Page 25: Check Fuel Lines And Connections

    Fuel Tank Installation (Fig. 7) DANGER 1. Install fuel tank using Figure 7 as a guide. A. Torque two (2) flange nuts (item 7) that secure the Because diesel fuel is highly flammable, use cau- fuel tank to the frame from 60 to 80 in- -lb (7 to 9 tion when storing or handling it.

  • Page 26: Radiator

    Radiator RIGHT FRONT Figure 8 1. Radiator cap 22. Carriage screw (2 used) 43. Coolant reservoir 2. Foam strip (2 used) 23. 90 hydraulic fitting (2 used) 44. Tank bracket 3. Foam strip (2 used) 24. Cap screw (6 used) 45.
  • Page 27 Removal (Fig. 8) Installation (Fig. 8) 1. Park machine on a level surface, lower cutting 1. Remove all plugs placed during the removal proce- decks, stop engine, apply parking brake and remove dure. key from the ignition switch. 2. Carefully position radiator to the support frame. Se- 2.

  • Page 28: Engine

    Engine RIGHT FRONT Loctite #242 29 to 33 ft- -lb 28 to 32 ft- -lb (40 to 44 N- -m) 28 to 32 ft- -lb (38 to 43 N- -m) (38 to 43 N- -m) Figure 9 1. Engine 10. Rebound washer (4 used) 19.
  • Page 29 CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot cool- ant can escape and cause burns. Ethylene- -glycol antifreeze is poisonous. Dis- pose of coolant properly or store it in a properly labeled container away from children and pets.

  • Page 30: Engine Installation

    11. Remove fan hub and fan from hydraulic fan motor (Fig. 14). A. Remove hex nut (item 9) and washer (item 8) that secure fan hub and fan assembly to fan motor. NOTE: The fan motor shaft is tapered. B. Use suitable puller to remove fan hub (with fan at- tached) from fan motor shaft taking care to not dam- age fan.
  • Page 31 12.Install air cleaner assembly to the engine (see Air Fil- CAUTION ter System Installation in this section). 13.Install exhaust system to machine (see Exhaust Sys- One person should operate lift or hoist while tem Installation in this section). another person guides the engine into the ma- chine.

  • Page 32: Spring Coupler

    Spring Coupler RIGHT FRONT Loctite #242 29 to 33 ft- -lb (40 to 44 N- -m) 28 to 32 ft- -lb (38 to 43 N- -m) Figure 16 1. Spring coupler 8. Carriage screw (2 used) 15. Retaining ring 2. Washer (14 used) 9.
  • Page 33 Coupler Removal (Fig. 16) NOTE: The hydraulic pump assembly needs to be re- moved from engine before coupler can be removed. Engine Side Hydraulic Pump Side 1. If engine is in machine, support engine from below to prevent it from shifting while removing hydraulic pump assembly (see Piston (Traction) Pump Removal in the Service and Repairs section of Chapter 4 -- Hydraulic System), transport cylinder assembly, flywheel plate,...
  • Page 34 This page is intentionally blank. Kubota Diesel Engine Page 3 - - 18 Groundsmaster 4000--D...

  • Page 35: Hydraulic Schematic 4

    Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......Flush Hydraulic System .

  • Page 36: Specifications

    Specifications Item Description Piston (Traction) Pump Eaton Variable Displacement Piston Pump (Model 72400) System Relief Pressure: Forward 4000 PSI (274 bar) System Relief Pressure: Reverse 5000 PSI (343 bar) Charge Pressure 250 PSI (17 bar) Front Wheel Motors Eaton Fixed Displacement Piston Motors (Model 74318) Rear Axle Motor Eaton Fixed Displacement Piston Motor...

  • Page 37: 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. Towing Traction Unit IMPORTANT: If towing limits are exceeded, severe damage to the piston pump may occur.

  • Page 38: Hydraulic Hoses

    Tube Installation in this section). If the hose has an el- bow 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 39: 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 40 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 41 Adjustable Fitting (Fig. 8) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is rec- ommended that the O--ring be replaced any time the connection is opened.

  • Page 42: Hydraulic Schematic

    Hydraulic Schematic Hydraulic System Page 4 - - 8 Groundsmaster 4000--D...
  • Page 43 This page is intentionally blank. Groundsmaster 4000--D Page 4 - - 9 Hydraulic System...

  • Page 44: Hydraulic Flow Diagrams

    Hydraulic Flow Diagrams Hydraulic System Page 4 - - 10 Groundsmaster 4000--D...

  • Page 45: Traction Circuit: 4Wd (Mow)

    Traction Circuit: 4WD (Mow) The traction circuit piston pump is a variable displace- Forward Direction ment pump that is directly coupled to the engine fly- When the transport/4WD switch is in the 4WD (mow) wheel. Pushing the traction pedal engages a hydraulic position and the traction pedal is pushed in the forward servo valve which controls the variable displacement direction, oil from the piston pump passes through the...
  • Page 46 Hydraulic System Page 4 - - 12 Groundsmaster 4000--D...

  • Page 47: Traction Circuit: Transport (2Wd)

    Traction Circuit: Transport (2WD) The traction circuit piston pump is a variable displace- Forward Direction ment pump that is directly coupled to the engine fly- With the transport/4WD switch in the transport position, wheel. Pushing the traction pedal engages a hydraulic solenoid valve (SV) in the 4WD control manifold is ener- servo valve which controls the variable displacement gized.
  • Page 48 Hydraulic System Page 4 - - 14 Groundsmaster 4000--D...

  • Page 49: Lower Cutting Deck

    Lower Cutting Deck A four section gear pump is coupled to the piston (trac- To lower the front cutting deck, the center lift lever on the tion) pump. The third gear pump section supplies hy- lift/lower control valve is pushed to allow valve shift in the draulic flow to both the lift/lower control valve and the lift/lower control.
  • Page 50 Hydraulic System Page 4 - - 16 Groundsmaster 4000--D...

  • Page 51: Raise Cutting Deck

    Raise Cutting Deck A four section gear pump is coupled to the piston (trac- To raise the front cutting deck, the center lift lever on the tion) pump. The third gear pump section supplies hy- lift/lower control valve is pulled to allow valve shift in the draulic flow to the lift/lower control valve and the steering lift/lower control valve.
  • Page 52 Hydraulic System Page 4 - - 18 Groundsmaster 4000--D...

  • Page 53: Mow

    Hydraulic flow for the mow circuit is supplied by two sec- Return oil from the deck motors is directed to the oil cool- tions of the gear pump. The gear pump section closest er and oil filter. Deck motor case drain leakage returns to the piston (traction) pump supplies hydraulic flow to to the hydraulic reservoir.

  • Page 54: Pto Mow Circuit Cutting Deck Blade Braking

    PTO Mow Circuit Cutting Deck Blade Braking When the operator turns the PTO switch OFF or if a deck PTO MANIFOLD is raised with the PTO switch ON, PTO control manifold solenoid valve (S) is de--energized causing logic car- tridge (LC1) to shift (refer to information in PTO Mow Cir- cuit in this section).
  • Page 55 This page is intentionally blank. Groundsmaster 4000--D Page 4 - - 21 Hydraulic System...
  • Page 56 Hydraulic System Page 4 - - 22 Groundsmaster 4000--D...

  • Page 57: Steering Circuit

    Steering Circuit A four section gear pump is coupled to the piston (trac- that the oil flow to the cylinder is proportional to the tion) pump. The third gear pump section supplies hy- amount of the turning on the steering wheel. Fluid leav- draulic flow to the steering control valve and the lift/lower ing the cylinder flows back through the spool valve then control valve.
  • Page 58 Hydraulic System Page 4 - - 24 Groundsmaster 4000--D...

  • Page 59: Engine Cooling Fan Circuit

    Engine Cooling Fan Circuit A four section gear pump is coupled to the piston (trac- runs in the reverse direction. A lower PWM signal is sent tion) pump. The gear pump section farthest from the pis- to the PRV valve allowing oil flow to return to the fan mo- ton pump supplies hydraulic flow for the fan drive tor but in the reverse direction causing the motor and manifold and hydraulic engine cooling fan motor (Fig.

  • Page 60: Special Tools

    Special Tools Order these 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.

  • Page 61: Hydraulic Test Fitting Kit

    Hydraulic Test Fitting Kit This kit includes a variety of O--ring Face Seal fittings to TORO TEST FITTING KIT (NO. TOR4079) enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings.

  • Page 62: Troubleshooting

    Troubleshooting The charts that follow contain suggestions to assist in NOTE: When troubleshooting traction problems on the troubleshooting. There may possibly be more than one Groundsmaster 4000--D, if a problem exists in both cause for a machine malfunction. 4WD and transport speeds, consider a faulty compo- nent that affects the entire traction circuit (e.g.
  • Page 63 Problem Possible Causes Traction power is lost or unit will not Hydraulic reservoir oil level is low. operate in either direction. Piston pump by--pass valve is open or damaged. Charge pressure is low. Traction circuit pressure is low. Front wheel motor couplers are damaged. Four wheel drive will not engage.
  • Page 64 Problem Possible Causes Cutting decks will not raise. Engine RPM is too low. Hydraulic oil level in reservoir is low. Lift arm pivots are binding. Relief valve in lift/lower control valve is stuck. Pilot valve in lift/lower control valve is damaged or sticking. Lift cylinder(s) is (are) damaged.

  • Page 65: Testing

    Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment WARNING such as pressure gauges and flow meters in the circuits during various operational checks (See the Special Before disconnecting or performing any work Tools section in this Chapter).

  • Page 66: Traction Circuit Charge Pressure

    Traction Circuit Charge Pressure (Using Pressure Gauge) FROM COUNTERBALANCE MANIFOLD FROM FRONT DECK CYLINDERS PRESSURE GAUGE FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT TO STEERING & LIFT CIRCUITS TO COOLING FAN CIRCUIT Hydraulic System Page 4 - - 32...
  • Page 67 Procedure for Traction Circuit Charge Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off.

  • Page 68: Traction Circuit Relief Pressure

    Traction Circuit Relief Pressure (Using Pressure Gauge) FORWARD TRACTION CIRCUIT RELIEF PRESSURE TEST SHOWN FROM COUNTERBALANCE MANIFOLD FROM FRONT DECK CYLINDERS PRESSURE GAUGE FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT TO STEERING &...
  • Page 69 Procedure for Traction Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. CAUTION Move machine to an open area, away from people and obstructions.

  • Page 70: Counterbalance Pressure

    Counterbalance Pressure (Using Pressure Gauge) PRESSURE GAUGE FROM DECK MOTORS FROM FRONT PTO MANIFOLD Hydraulic System Page 4 - - 36 Groundsmaster 4000--D...
  • Page 71 Procedure for Counterbalance Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off.

  • Page 72: Rear Traction Circuit (Rv) Relief Pressure

    Rear Traction Circuit (RV) Relief Pressure (Using Pressure Gauge) FROM COUNTERBALANCE MANIFOLD PRESSURE GAUGE FROM FRONT DECK CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT TO STEERING &...
  • Page 73 Procedure for Rear Traction Circuit (RV) Relief Pres- sure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off.

  • Page 74: Traction Circuit Reducing Valve (Pr) Pressure

    Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge) FROM COUNTERBALANCE MANIFOLD PRESSURE GAUGE FROM FRONT DECK CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT TO STEERING &...
  • Page 75 Procedure for Traction Circuit Reducing Valve (PR) Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off.

  • Page 76: Cutting Deck Circuit Pressure

    Cutting Deck Circuit Pressure (Using Pressure Gauge) FRONT DECK CIRCUIT PRESSURE TEST SHOWN TRACTION CIRCUIT FLOW PRESSURE GAUGE Hydraulic System Page 4 - - 42 Groundsmaster 4000--D...
  • Page 77 Procedure for Cutting Deck Circuit Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off.

  • Page 78: Pto Relief Pressure

    PTO Relief Pressure (Using Tester with Pressure Gauges and Flow Meter) FRONT PTO RELIEF PRESSURE TEST SHOWN TRACTION CIRCUIT FLOW Hydraulic System Page 4 - - 44 Groundsmaster 4000--D...
  • Page 79 Procedure for PTO Relief Pressure Test 9. Disengage cutting decks. Shut off engine and record test results. If specification is not met, adjust or clean re- 1. Make sure hydraulic oil is at normal operating tem- lief valve in deck manifold port (RV1). Adjust relief valve perature by operating the machine for approximately 10 as follows: minutes.

  • Page 80: Cutting Deck Motor Case Drain Leakage

    Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauges and Flow Meter) FRONT CUTTING DECK MOTOR CASE DRAIN LEAKAGE TEST SHOWN TRACTION CIRCUIT FLOW TESTER MEASURING CONTAINER Hydraulic System Page 4 - - 46 Groundsmaster 4000--D...
  • Page 81 Procedure for Cutting Deck Motor Case Drain 5. Sit on seat and start the engine. Move throttle to full Leakage Test speed (2870 RPM). Move PTO switch to ON. NOTE: Over a period of time, a deck motor can wear in- 6.

  • Page 82: Cutting Deck Gear Pump Flow

    Cutting Deck Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter) FRONT DECK GEAR PUMP FLOW TEST SHOWN TRACTION CIRCUIT FLOW TESTER Hydraulic System Page 4 - - 48 Groundsmaster 4000--D...
  • Page 83 Procedure for Cutting Deck Gear Pump Flow Test 8. Flow indication should be approximately 14 GPM (53 LPM). NOTE: Over a period of time, the gears and wear plates in the pump can wear. A worn pump will by pass oil and 9.

  • Page 84: Steering Circuit Relief Pressure

    Steering Circuit Relief Pressure (Using Pressure Gauge) FROM COUNTERBALANCE MANIFOLD FROM FRONT DECK LIFT CYLINDERS TO LIFT/LOWER CONTROL VALVE PRESSURE GAUGE FROM DECK MOTORS FROM FRONT PTO MANIFOLD Hydraulic System Page 4 - - 50 Groundsmaster 4000--D...
  • Page 85 Procedure for Steering Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off.

  • Page 86: Lift/Lower Circuit Relief Pressure

    Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) PRESSURE GAUGE FROM DECK MOTORS FROM FRONT PTO MANIFOLD Hydraulic System Page 4 - - 52 Groundsmaster 4000--D...
  • Page 87 Procedure for Lift/Lower Circuit Relief Pressure Test NOTE: Before attempting to check or adjust lift pres- sure, make sure that counterbalance pressure is cor- rectly adjusted. 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes.

  • Page 88: Steering And Lift/Lower Gear Pump Flow

    Steering and Lift/Lower Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter) TESTER FROM DECK MOTORS FROM FRONT PTO MANIFOLD Hydraulic System Page 4 - - 54 Groundsmaster 4000--D...
  • Page 89 Procedure for Steering and Lift/Lower Gear Pump Flow Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off.

  • Page 90: Engine Cooling Fan Circuit

    Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac) FROM DECK MOTORS FROM FRONT PTO MANIFOLD Hydraulic System Page 4 - - 56 Groundsmaster 4000--D...
  • Page 91 Procedure for Engine Cooling Fan Circuit Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off.

  • Page 92: Engine Cooling Fan Circuit Gear Pump Flow

    Engine Cooling Fan Circuit Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter) TESTER FROM DECK MOTORS FROM FRONT PTO MANIFOLD Hydraulic System Page 4 - - 58 Groundsmaster 4000--D...
  • Page 93 Procedure for Engine Cooling Fan Circuit Gear Pump Flow Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off.

  • Page 94: Adjustments

    Adjustments Adjust Front Cutting Deck Lift Flow Control The front cutting deck lift circuit is equipped with an ad- justable flow control valve used to adjust the rate at which the front cutting deck lowers. Adjust flow control valve as follows: 1.

  • Page 95: 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 96: Flush Hydraulic System

    Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time 9. Turn ignition key switch and engage starter for ten there is a severe component failure or the system is (10) seconds to prime hydraulic pumps. Repeat this contaminated (oil appears milky, black or contains step again.

  • Page 97: Charge Hydraulic System

    Charge Hydraulic System NOTE: When initially starting the hydraulic system with 11. After the hydraulic system starts to show signs of fill, new or rebuilt components such as motors, pumps or lift actuate lift control lever until the lift cylinder rod moves cylinders, it is important that the hydraulic system be in and out several times.

  • Page 98: Hydraulic Reservoir

    Hydraulic Reservoir 30 to 40 in- -lb (3.4 to 4.5 N- -m) (minimum) RIGHT NOTE: HYDRAULIC COMPONENTS FRONT ATTACHED TO FRONT FRAME ARE NOT SHOWN IN ILLUSTRATION Figure 47 1. Hydraulic reservoir 12. Dipstick 22. Lock nut (3 used) 2. Petcock 13.
  • Page 99 NOTE: The front frame needs to be lowered from the Inspection main frame to allow clearance to remove the hydraulic 1. Clean hydraulic reservoir and suction strainer with reservoir from the machine. solvent. Removal (Fig. 47) 2. Inspect reservoir for leaks, cracks or other damage. 1.

  • Page 100: Hydraulic Oil Cooler

    Hydraulic Oil Cooler RIGHT FRONT 12 ft- -lb (16 N- -m) Figure 48 1. Radiator 7. Carriage screw (2 used) 13. Oil cooler 2. RH radiator support 8. O- -ring 14. Flange nut (2 used) 3. Top radiator support 9. 90 hydraulic fitting (2 used) 15.
  • Page 101 Removal (Fig. 48) CAUTION CAUTION Use eye protection such as goggles when using compressed air. The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling 2. Dry inside of oil cooler using compressed air in the systems to cool before working on the oil cooler.

  • Page 102: Gear Pump

    Gear Pump 103 to 118 ft- -lb (140 to 160 N- -m) 79 to 84 ft- -lb (108 to 113 N- -m) RIGHT 79 to 84 ft- -lb (108 to 113 N- -m) FRONT Figure 49 1. Hydraulic T fitting 13.
  • Page 103 Removal (Fig. 49) Installation (Fig. 49) 1. Park machine on a level surface, lower cutting 1. If fittings were removed from gear pump, 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 104: Gear Pump Service

    Gear Pump Service 33 ft- -lb (45 N- -m) Figure 50 1. Dust seal 10. Seal (8 used) 19. Body 2. Retaining ring 11. Idler gear 20. Body 3. Flange washer 12. Drive shaft 21. Drive gear 4. Shaft seal 13.
  • Page 105 IMPORTANT: Use caution when clamping gear 8. Clean all parts. Check all components for burrs, pump in a vise to avoid distorting any pump compo- scoring, nicks and other damage. nents. 9. Replace the entire pump assembly if parts are ex- 3.

  • Page 106: Traction Circuit

    Traction Circuit RIGHT FRONT Figure 52 1. Piston (traction) pump 5. RH front wheel motor 8. Rear axle motor 2. Gear pump 6. 4WD manifold 9. Cooling fan motor 3. LH front wheel motor 7. Filter manifold 10. Check valve 4.
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  • Page 108: Piston (Traction) Pump

    Piston (Traction) Pump 103 to 118 ft- -lb (140 to 160 N- -m) 79 to 84 ft- -lb (108 to 113 N- -m) RIGHT 79 to 84 ft- -lb (108 to 113 N- -m) FRONT Figure 53 1. Hydraulic T fitting 13.
  • Page 109 Removal (Fig. 53) 3. Install gear pump to piston pump (see Gear Pump Installation). 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove 4. Position traction rod to control arm on piston pump key from the ignition switch.

  • Page 110: Piston (Traction) Pump Service

    Piston (Traction) Pump Service 100 to 110 ft- -lb 27 to 31 ft- -lb (136 to 149 N- -m) (37 to 42 N- -m) 100 to 110 ft- -lb (136 to 149 N- -m) 150 to 160 in- -lb (17 to 18 N- -m) 4 to 6 ft- -lb (5 to 8 N- -m) 40 to 48 in- -lb...
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  • Page 112: Rear Axle Motor

    Rear Axle Motor Arrow on side of motor case points up 59 to 73 ft- -lb (80 to 99 N- -m) RIGHT FRONT Figure 56 1. Axle motor 8. Pinion gear 15. O- -ring 2. 90 hydraulic fitting (2 used) 9.
  • Page 113 Removal (Fig. 56) Installation (Fig. 56) 1. Park machine on a level surface, lower cutting 1. If fittings were removed from motor, lubricate and decks, stop engine, apply parking brake and remove place new O--rings onto fittings. Install fittings into port key from the ignition switch.

  • Page 114: Front Wheel Motor

    Front Wheel Motor Arrow on side of motor case points up RIGHT 75 to 85 ft- -lb (101 to 115 N- -m) FRONT Figure 57 1. Front wheel motor 9. Flange head screw (6 used per side) 16. O- -ring 2.
  • Page 115 Removal (Fig. 57) Installation (Fig. 57) 1. Park machine on a level surface, lower cutting 1. If fittings were removed from motor, lubricate and decks, stop engine, apply parking brake and remove place new O--rings onto fittings. Install fittings into port key from the ignition switch.

  • Page 116: Rear Axle And Front Wheel Motor Service

    Rear Axle and Front Wheel Motor Service 15 to 18 ft- -lb (20 to 24 N- -m) Figure 58 1. Drive shaft 7. Cap screw (6 used) 13. Thrust bearing 2. Backplate (front motor shown) 8. Shaft seal 14. Roll pin (3 used) 3.
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  • Page 118: 4Wd Manifold

    4WD Manifold RIGHT FRONT Figure 59 1. Frame assembly 8. Fitting cap 14. Hydraulic fitting 2. 4WD manifold 9. Hydraulic fitting 15. Adapter 3. 90 hydraulic fitting 10. O- -ring 16. Hydraulic fitting 4. O- -ring 11. O- -ring 17. O- -ring 5.
  • Page 119 Removal (Fig. 59) Installation (Fig. 59) 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 120: Wd Manifold Service

    4WD Manifold Service 35 ft- -lb REAR 50 ft- -lb (47 N- -m) (67 N- -m) DOWN 25 ft- -lb (34 N- -m) FRONT 20 ft- -lb (27 N- -m) PLUG TORQUE #4 Zero Leak: 20 ft- -lb (27 N- -m) 5 ft- -lb #6 Zero Leak: 25 ft- -lb (34 N- -m) (6.7 N- -m)
  • Page 121 4WD Manifold Service (Fig. 60) 7. The 4WD control manifold includes three (3) orifice fittings (items 9 and 13). The 0.030 orifice (item 9) is 1. Make sure the manifold is clean before removing the positioned in the SV port under the solenoid cartridge valve.

  • Page 122: Traction (Flow Divider) Manifold

    Traction (Flow Divider) Manifold RIGHT FRONT Figure 61 1. Traction manifold 8. O- -ring 14. O- -ring 2. O- -ring 9. 90 hydraulic elbow 15. 90 hydraulic elbow 3. Hydraulic fitting 10. O- -ring 16. O- -ring 4. Bracket 11. Hydraulic hose 17.
  • Page 123 Removal (Fig. 61) Installation (Fig. 61) 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 124: Traction (Flow Divider) Manifold Service

    Traction (Flow Divider) Manifold Service 50 ft- -lb 50 ft- -lb (67 N- -m) (67 N- -m) FRONT 20 ft- -lb (27 N- -m) 40 ft- -lb (54 N- -m) 198 in- -lb (22.4 N- -m) 20 ft- -lb (27 N- -m) 5 ft- -lb (6.7 N- -m) 20 ft- -lb...
  • Page 125 Traction Manifold Service (Fig. 62) For cartridge valve service procedures, see 4WD Man- ifold Service in this section. Refer to Figure 62 for trac- tion (flow divider) manifold cartridge valve and plug installation torque. Groundsmaster 4000--D Page 4 - - 91 Hydraulic System...

  • Page 126: Filter Manifold

    Filter Manifold RIGHT FRONT Figure 63 1. Filter manifold 10. Hydraulic fitting 18. Hydraulic hose 2. 45 hydraulic fitting 11. O- -ring 19. Hydraulic tee fitting 3. Test nipple 12. O- -ring 20. 90 hydraulic fitting 4. Dust cap 13. 90 hydraulic fitting 21.
  • Page 127 Removal (Fig. 63) Installation (Fig. 63) 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 128 Filter Manifold Service 25 ft- -lb (34 N- -m) FRONT 25 ft- -lb (34 N- -m) 25 ft- -lb (34 N- -m) 30 ft- -lb (41 N- -m) 50 ft- -lb (67 N- -m) 30 ft- -lb (41 N- -m) FRONT Figure 64 1.
  • Page 129 Filter Manifold Service (Fig. 64) For cartridge valve service procedures, see 4WD Man- ifold Service in this section. Refer to Figure 64 for filter manifold cartridge valve and plug installation torque. Groundsmaster 4000--D Page 4 - - 95 Hydraulic System...

  • Page 130: Steering And Cooling Fan Circuits

    Steering and Cooling Fan Circuits RIGHT FRONT Figure 65 1. Gear pump 3. Fan drive manifold 5. Steering cylinder 2. Steering control valve 4. Fan motor Figure 65 illustrates the components that are used in the Groundsmaster 4000--D steering and cooling fan circuit. Procedures for removal, installation and disassembly/ assembly of these components are provided on the fol- lowing pages of this section.
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  • Page 132: Steering Valve

    Steering Valve 16 to 20 ft- -lb (22 to 27 N- -m) RIGHT FRONT Figure 66 1. Hex nut 11. O- -ring 21. Steering column assembly 2. Flat washer 12. Flange head screw 22. Flange bushing 3. Steering wheel 13. Hydraulic adapter (4 used) 23.
  • Page 133 Removal (Fig. 66) Installation (Fig. 66) 1. Park machine on a level surface, lower cutting 1. If fittings were removed from steering valve, 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 134: Steering Valve Service

    Steering Valve Service 150 in- -lb (17 N- -m) 140 to 160 in- -lb (16 to 18 N- -m) Figure 67 1. Steering valve housing 9. Cap screw (7 used) 17. Geroter drive 2. Dust seal 10. End cap 18. Wear plate 3.
  • Page 135 8. Put the thrust bearing and races into the housing. CAUTION The thrust bearing goes between the two races (Fig. 68). IMPORTANT: Do not damage the dust or quad seals The centering springs are under tension. Re- when installing the spool and sleeve assembly. move the retaining ring carefully.

  • Page 136: Steering Cylinder

    Steering Cylinder See text for tightening procedure RIGHT See text for tightening FRONT procedure Figure 69 1. Steering cylinder 6. Grease fitting 11. Ball joint spacer 2. Ball joint 7. 90 hydraulic fitting 12. Axle washer 3. Ball joint 8. O- -ring 13.
  • Page 137 Removal (Fig. 69) Installation (Fig. 69) 1. Park machine on a level surface, lower cutting 1. If removed, install ball joints into steering cylinder. decks, stop engine, apply parking brake and remove 2. If fittings were removed from steering cylinder, lubri- key from the ignition switch.

  • Page 138: Steering Cylinder Service

    Steering Cylinder Service 45 to 55 ft- -lb (62 to 74 N- -m) Figure 70 1. Tube assembly 5. Retaining ring 9. Rod seal 2. Rod 6. Backup ring 10. O- -ring 3. Piston assembly 7. O- -ring 11. O- -ring 4.
  • Page 139 Disassembly (Fig. 70) Assembly (Fig. 70) 1. Pump oil out of cylinder into a drain pan by SLOWLY 1. Use a complete repair kit when rebuilding the cylin- moving rod and piston in and out of cylinder bore. Plug der. Put a coating of clean hydraulic oil on all new seals ports and clean outside of cylinder.

  • Page 140: Engine Cooling Fan Motor

    Engine Cooling Fan Motor 27 to 33 ft- -lb (37 to 44 N- -m) 16 17 12 to 14 ft- -lb (17 to 18 N- -m) RIGHT FRONT Figure 71 1. Hydraulic fan motor 8. Washer 15. Hydraulic hose 2. O- -ring 9.
  • Page 141 Removal (Fig. 71) IMPORTANT: Make sure to not damage the radiator, oil cooler or other machine components while 1. Park machine on a level surface, lower cutting installing the fan motor. decks, stop engine, apply parking brake and remove key from the ignition switch. 2.

  • Page 142: Engine Cooling Fan Motor Service

    Engine Cooling Fan Motor Service 33 ft- -lb (45 N- -m) Figure 73 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 143 8. Remove and discard back--up gaskets and pressure seals from wear plates. 9. Turn front flange over, with seal side up. 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.
  • Page 144 4. Install the pressure seals, flat side outward, into the 10.Install locating dowels in body. Align marker line on grooves in the wear plates. Follow by carefully placing the body and front flange. the backup gaskets, flat side outward, between the IMPORTANT: Do not dislodge seals during installa- pressure seals and the grooves in the wear plate.
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  • Page 146: Fan Drive Manifold

    Fan Drive Manifold RIGHT FRONT Figure 77 1. Fan drive manifold 10. Hydraulic fitting 19. 90 hydraulic fitting 2. O- -ring 11. Hydraulic hose 20. Hydraulic hose 3. Test fitting 12. Hydraulic hose 21. Hydraulic hose 4. Dust cap (2 used) 13.
  • Page 147 Removal (Fig. 77) Installation (Fig. 77) 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 148: Fan Drive Manifold Service

    Fan Drive Manifold Service 5 ft- -lb (6.7 N- -m) 5 ft- -lb (6.7 N- -m) FRONT 25 ft- -lb 50 ft- -lb (34 N- -m) (67 N- -m) 20 ft- -lb (27 N- -m) 25 ft- -lb (34 N- -m) 25 ft- -lb 25 ft- -lb (34 N- -m)
  • Page 149 Fan Drive Manifold Service (Fig. 78) For cartridge valve service procedures, see 4WD Man- ifold Service in this section. Refer to Figure 78 for fan drive manifold cartridge valve and plug installation torque. Groundsmaster 4000--D Page 4 - - 115 Hydraulic System...

  • Page 150: Pto Circuit

    PTO Circuit RIGHT FRONT Figure 79 1. Gear pump 4. RH PTO manifold 7. Front PTO manifold 2. RH cutting deck motor 5. Front cutting deck motor 8. Filter manifold 3. LH cutting deck motor 6. LH PTO manifold 9. Oil cooler Figure 79 illustrates the components that are used in the Groundsmaster 4000--D PTO circuits.

  • Page 151: Cutting Deck Motor

    Cutting Deck Motor Removal 5. Secure motor to cutting deck with two (2) flange head screws (Fig. 80). 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove 6. Remove caps or plugs from fittings and hoses. Con- key from the ignition switch.

  • Page 152: Cutting Deck Motor Service

    Cutting Deck Motor Service 33 to 40 ft- -lb (45 to 55 N- -m) Figure 82 1. Rear cover 6. Tab washer 11. Body 2. Drive gear 7. Spider hub 12. Idler gear 3. Seal 8. Pressure seal 13. Cap screw (4 used) 4.
  • Page 153 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 154 Assembly (Fig. 82) 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 156: Pto Manifold

    PTO Manifold 18 19 19 18 19 18 RIGHT FRONT Figure 87 1. Hydraulic PTO manifold (front deck) 10. Straight fitting 19. O- -ring 2. Quick fitting (1 used per manifold) 11. Cap screw (2 used per manifold) 20. 90 hydraulic fitting 3.
  • Page 157 Removal (Fig. 87) Installation (Fig. 87) 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 158: Pto Manifold Service

    PTO Manifold Service 20 ft- -lb 5 ft- -lb (27 N- -m) (6.7 N- -m) 25 ft- -lb 20 ft- -lb (34 N- -m) (27 N- -m) 25 ft- -lb (34 N- -m) 20 ft- -lb (27 N- -m) 50 ft- -lb (67 N- -m) 20 ft- -lb (27 N- -m)
  • Page 159 PTO Manifold Service (Fig. 88) For solenoid and control valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 88 for PTO manifold cartridge valve and plug installation torque. Groundsmaster 4000--D Page 4 - - 125 Hydraulic System...
  • Page 160 Lift/Lower Circuit RIGHT FRONT Figure 89 1. Counterbalance manifold 4. Fan drive manifold 7. Front lift cylinder 2. RH lift cylinder 5. Lift control valve 8. Oil filter 3. LH lift cylinder 6. Front deck flow control valve Figure 89 illustrates the components that are used in the Groundsmaster 4000--D cutting deck lift and lower cir- cuits.
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  • Page 162: Lift/Lower Control Valve

    Lift/Lower Control Valve RIGHT FRONT Figure 90 1. Control valve assembly 11. RH lever assembly 21. Hydraulic fitting 2. Valve bracket 12. Spacer 22. O- -ring 3. Isolator (6 used) 13. Cap screw (2 used) 23. Flat washer (3 used) 4.
  • Page 163 Removal (Fig. 90) Installation (Fig. 90) 1. Park machine on a level surface, lower cutting 1. If fittings were removed from control valve, 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 164: Lift/Lower Control Valve Service

    Lift/Lower Control Valve Service 20 to 25 ft- -lb (27 to 33 N- -m) Figure 91 1. Poppet 13. Washer 25. O- -ring 2. Spacer 14. Washer 26. Backup washer 3. Wiper 15. Washer 27. Disc 4. Seat 16. Washer 28.
  • Page 165 Disassembly (Fig. 91) Assembly (Fig. 91) 1. Plug all ports and thoroughly clean outside of control 1. Thoroughly clean and dry all parts. Apply a light coat- valve. ing of clean hydraulic oil to parts prior to assembly. 2. Remove caps (item 9). Do not remove retaining rings NOTE: All O--rings, back--up washers, wiper seals and (item 12) from spools unless spring (item 19) is broken.
  • Page 166 Side Deck Lift Cylinder RIGHT FRONT Figure 92 1. Lift arm assembly (LH shown) 5. Flange locking nut 9. Cylinder pin 2. Shoulder screw 6. 90 hydraulic fitting (2 used) 10. Spring pin 3. Pin assembly 7. O- -ring 11. Lock nut 4.
  • Page 167 Removal (Fig. 92) Installation (Fig. 92) 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 168 Front Deck Lift Cylinder RIGHT FRONT Figure 93 1. Lift cylinder 5. Cap screw 9. O- -ring 2. Upper lift pin 6. Flat washer 10. Straight hydraulic fitting 3. Cotter pin 7. Lock nut 11. O- -ring 4. Pin assembly 8.
  • Page 169 Removal (Fig. 93) Installation (Fig. 93) 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 170: Lift Cylinder Service

    Lift Cylinder Service 100 to 120 ft- -lb (136 to 162 N- -m) SIDE DECK LIFT CYLINDER Figure 94 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 171 Disassembly (Figs. 94 and 95) Assembly (Figs. 94 and 95) 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.

  • Page 172: Counterbalance Manifold

    Counterbalance Manifold RIGHT FRONT Figure 96 1. Counterbalance manifold 7. Lock nut (2 used) 12. Cap screw (2 used) 2. Valve plate 8. Hydraulic fitting (2 used) 13. 90 hydraulic fitting 3. Flat washer (2 used) 9. O- -ring 14. O- -ring 4.
  • Page 173 Removal (Fig. 96) Installation (Fig. 96) 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 174: Counterbalance Manifold Service

    Counterbalance Manifold Service 35 to 40 ft- -lb 35 to 40 ft- -lb (47 to 54 N- -m) (47 to 54 N- -m) 35 to 40 ft- -lb (47 to 54 N- -m) FRONT Figure 97 1. Manifold body 3. Seal kit 5.

  • Page 175: Electrical System Quick Checks 5

    Chapter 5 Electrical System Table of Contents GENERAL INFORMATION ..... Audio Alarm ....... Operator’s Manual .

  • Page 176: 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. Electrical Drawings The electrical schematic, circuit diagrams and wire har- ness drawings for the Groundsmaster 4000--D are lo- cated in Chapter 9 -- Foldout Drawings.

  • Page 177: Special Tools

    Multimeter The meter can test electrical components and circuits 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 178 Aerosol spray that should be used on battery terminals to reduce corrosion problems. Apply terminal protector after the battery cable has been secured to the battery terminal. Toro Part Number: 107- -0392 Figure 4 Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte.

  • Page 179: Troubleshooting

    Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and CAUTION components used on this machine (see Chapter 9 -- Foldout Drawings). Remove all jewelry, especially rings and If the machine has any interlock switches by--passed, watches, before doing any electrical trouble- shooting or testing.
  • Page 180 Problem Possible Causes Engine cranks, but does not start. Engine is not cranking fast enough. The engine fuel run solenoid or circuit wiring is faulty. The fuel pump or circuit wiring is faulty. An engine problem exists (see Chapter 3 -- Kubota Engine).

  • Page 181: Cutting Deck Operating Problems

    Cutting Deck Operating Problems The cutting decks remain engaged, but should not, The seat switch or circuit wiring is faulty. with no operator in the seat. Cutting decks run, but should not, when raised. Decks The deck position switch or circuit wiring is faulty. shut off with PTO switch.

  • Page 182: Electrical System Quick Checks

    Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level battery terminals. 12.68 V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery 12.45 V 75% charged should be at a temperature of 60...

  • Page 183: Component Testing

    Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the CAUTION circuit (e.g. unplug the ignition switch connector before checking continuity on the switch). When testing electrical components for continu- NOTE: For engine component testing information, see ity with a multimeter (ohms setting), make sure the Kubota Workshop Manual, Diesel Engine, that power to the circuit has been disconnected.

  • Page 184: Fuses

    Fuses The fuse blocks are located under the operator control panel. Identification, Function and Wiring The fuses are held in three (3) fuse blocks. Use Figures 9 and 10 to identify each individual fuse and its correct amperage. Each fuse has the following functions. Fuse F1 (5 amp) (fuseblock location A1): Supplies power to the seat switch and seat relay.

  • Page 185: Warning Lights

    Warning Lights Engine Oil Pressure Light The oil pressure light should illuminate when the ignition switch is in the ON position with the engine not running. Also, it should light with the engine running if the oil pres- sure drops below 7 PSI (0.5 kg/cm If oil pressure light does not come on when the ignition switch is in the ON position with the engine not running: 1.

  • Page 186: Pto Switch

    PTO Switch The PTO switch is used to engage or disengage the cut- ting decks. The PTO switch is attached to the control console next to the operator seat (Fig. 13). Testing The switch terminals are marked as shown in Figure 14. The circuitry of the PTO switch is shown in the chart be- low.

  • Page 187: Transport / 4Wd Switch

    Transport / 4WD Switch The transport/4WD switch is used to set the machine traction speed for transport or mow. The transport/4WD rocker switch is located on the control console next to the operator seat (Fig. 17). Testing The switch terminals are shown in Figure 18. The circuit- ry of the switches is shown in the chart below.

  • Page 188: Cooling Fan Switch

    Cooling Fan Switch The cooling fan switch is used to control the operation of the hydraulic cooling fan and is located on the control console (Fig. 21). This switch has three (3) positions: Reverse, Auto and Forward. When the cooling fan switch is in the normal Auto posi- tion, cooling fan operation is controlled by the TEC--5002 controller.

  • Page 189: Seat Switch

    Seat Switch The seat switch is normally open and closes when the operator is on the seat. 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, the engine will stop.

  • Page 190: Parking Brake Switch

    Parking Brake Switch The switch used for the parking brake is a normally open switch that is located under the steering tower cover (Fig. 24). When the parking brake is not applied, the parking brake pawl depresses the switch plunger to close the switch.

  • Page 191: Hour Meter

    Hour Meter The hour meter is located on the control console next to the operator seat. Testing 1. Disconnect wire harness connector from hour meter. 2. Correctly connect 12VDC source to the hour meter terminals (Fig. 25). 3. The hour meter should move a 1/10 of an hour in six Figure 25 (6) minutes.

  • Page 192: Glow And Power Relays

    Glow and Power Relays The Groundsmaster 4000--D uses two (2) identical re- lays to control electrical power circuits. The glow relay is attached to the the right side of the fuel tank support under the hood. The power relay is attached to the con- trol panel under the console housing.

  • Page 193: Start, Engine Shutdown, Seat, Pto, Pto Over

    Start, Engine Shutdown, Seat, PTO, PTO Overtemp, Alarm and Over Temperature Relays These seven (7) relays are located under the console housing cover (Fig. 28). The wiring harness is tagged to identify each relay. Testing 1. Make sure that ignition switch is OFF. 2.

  • Page 194: Hydraulic Valve Solenoids

    Hydraulic Valve Solenoids RIGHT FRONT Figure 30 1. 4WD manifold 3. Traction manifold 5. Fan drive manifold 2. LH PTO manifold 4. Front PTO manifold 6. RH PTO manifold There are several hydraulic valve solenoids on the 3. Install new solenoid if necessary. Torque solenoid Groundsmaster 4000--D (Fig.

  • Page 195: Tec--5002 Controller

    TEC- -5002 Controller Groundsmaster 4000--D machines use a Toro Electron- ic Controller (TEC) to control the operation of the hy- draulic cooling fan. The controller is attached to the operator platform under the console housing cover (Fig. 32). Logic power is provided to the controller as long as the battery cables are connected to the battery.

  • Page 196: Fuel Sender

    240 to 260 ohms. 5. Replace sender as necessary. Install sender into fuel tank. 6. Connect wires to fuel sender. Apply skin--over grease (Toro Part No. 505--165) to sender terminals. Electrical System Page 5 - - 22 Groundsmaster 4000--D...

  • Page 197: Fuel Gauge

    Fuel Gauge The fuel gauge can be tested using a new gauge as a substitute or with the use of a DC voltage source and a variable resistance box. CAUTION Make sure the voltage source is turned OFF be- fore connecting it to the electrical circuit to avoid VARIABLE electrical shock and prevent damaging the RESISTANCE...

  • Page 198: Specifications 6

    Fuel Pump The fuel pump is attached to the frame above the fuel water separator (Fig. 36). Operational Test 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake. 2. Disconnect wire harness electrical connector from the fuel stop solenoid to prevent the engine from firing.

  • Page 199: Glow Controller

    Glow Controller The glow controller is located under the console cover (Fig. 37). NOTE: Refer to electrical schematic and circuit draw- ings in Chapter 9 -- Foldout Drawings when trouble- shooting the glow controller. Glow Controller Operation 1. When the ignition switch is placed in the ON position, the controller energizes the glow plugs and lights up the glow lamp for approximately 10 seconds.

  • Page 200: Temperature Sender

    B. Screw sender into the water flange. Torque send- er from 16 to 20 ft- -lb (22 to 27 N- -m). C. Reconnect gray harness wire to sender. Apply skin--over grease (Toro Part No. 505--165) to sender terminal. 5. Fill engine cooling system.

  • Page 201: Dual Temperature Switch

    Dual Temperature Switch The dual temperature switch is attached to the engine B. Screw switch into the cylinder head and torque near the alternator on the water flange attached to the switch from 22 to 28 ft- -lb (29.4 to 39.2 N- -m). engine cylinder head (Fig.

  • Page 202: Temperature Gauge

    Temperature Gauge The temperature gauge can be tested using a new gauge as a substitute or by the use of a DC voltage source and a variable resistance box. CAUTION Make sure the voltage source is turned OFF be- fore connecting variable resistance to the elec- VARIABLE trical circuit to avoid electrical shock and to pre- RESISTANCE...

  • Page 203: Traction Neutral Switch

    Traction Neutral Switch The traction neutral switch is closed when the traction pedal is in the neutral position and opens when the pedal is depressed in either direction. The switch is located on the right side of the piston (traction) pump (Fig. 46). Testing Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester...

  • Page 204: Diode Circuit Board

    DIODE DIAGRAM be replaced. Figure 48 Apply dielectric grease (Toro part number 107--0342) to circuit board contacts whenever the circuit board is installed into the wire harness. Red Lead (+)

  • Page 205: Fusible Link Harness

    Fusible Link Harness The Groundsmaster 4000--D uses five (5) fusible links for circuit protection. Three (3) of these fusible links are FUSIBLE LINK located in a harness that connects the starter B+ termi- FUSIBLE LINK FUSIBLE LINK nal to the wire harness (Fig. 49). An additional fusible link is used that connects the starter B+ terminal to the alternator B+ terminal (Fig.

  • Page 206: Cutting Deck Position Switch

    Cutting Deck Position Switch The cutting deck position switches on the Groundsmas- ter 4000--D are located on the traction unit frame (Fig. 51 and 52). The position switch is a normally open, pow- ered proximity switch that incorporates an internal reed switch and relay (see schematic in Figure 53).

  • Page 207: Engine Coolant And Hydraulic Oil Temperature Senders

    Engine Coolant and Hydraulic Oil Temperature Senders The Groundsmaster 4000--D uses two (2) temperature 6. Check and fill system (coolant or hydraulic) to proper senders as inputs for the TEC--5002 to identify if either level. the engine coolant or hydraulic oil temperature has reached an excessive level.

  • Page 208: Service And Repairs

    (+) cable first. Coat battery posts and cable are explosive, keep open flames and electrical connectors with battery terminal protector (Toro Part No. sparks away from the battery; do not smoke. 107--0392) or petroleum jelly to prevent corrosion.

  • Page 209: 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 210 A. Measure the specific gravity of each cell with a A. Check the voltage across the battery terminals hydrometer. Draw electrolyte in and out of the prior to testing the battery. If the voltage is less than hydrometer barrel prior to taking a reading to warm-- 12.4 VDC, charge the battery before performing a up the hydrometer.
  • Page 211 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.
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  • Page 213: General Information 6

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

  • Page 214: Specifications

    Specifications Item Specification Tire pressure (front and rear) 25 to 30 PSI (172 to 207 kPa) Rear wheel toe--in 0.125 in (3.18 mm) Planetary gear drive oil SAE 85W--140 wt. gear lube System gear lube capacity (each wheel) 16 fl. oz. (0.47 liters) Rear axle lubricant SAE 85W--140 wt.

  • Page 215: 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 Page 6 - - 3 Axles, Planetaries and Brakes...

  • Page 216: Service And Repairs

    Service and Repairs Brake Assembly 85 to 100 ft- -lb (115 to 135 N- -m) 75 to 85 ft- -lb (101 to 115 N- -m) RIGHT FRONT 75 to 85 ft- -lb (101 to 115 N- -m) Figure 1 1. Planetary assembly 7.
  • Page 217 3. Chock rear wheels and jack up front of machine (see 8. Make sure drain plug is installed in bottom of brake Jacking Instructions in Chapter 1 -- Safety). Support ma- assembly (Fig. 3). Fill planetary wheel drive/brake as- chine with jack stands. sembly with SAE 85W--140 gear lube.

  • Page 218: Brake Inspection And Repair

    Brake Inspection and Repair Figure 5 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 220: Planetary Wheel Drive Assembly

    Planetary Wheel Drive Assembly 85 to 100 ft- -lb (115 to 135 N- -m) 75 to 85 ft- -lb (101 to 115 N- -m) RIGHT 75 to 85 ft- -lb FRONT (101 to 115 N- -m) Figure 6 1. Planetary assembly 6.
  • Page 221 NOTE: The planetary wheel drive assembly can be ser- 2. Install brake assembly (see Brake Assembly Instal- viced with the planetary installed to machine (see Plane- lation in this section). tary Wheel Drive Service in this section). Use the 3. Install hydraulic wheel motor (see Front Wheel Mo- following procedure to remove and install planetary tors in the Service and Repairs section of Chapter 4 -- wheel drive assembly from machine.

  • Page 222: Planetary Wheel Drive Service

    Planetary Wheel Drive Service 9 ft- -lb (12 N- -m) Figure 8 1. Spindle 9. Thrust washer 17. Drive shaft 2. Boot seal 10. Retaining ring (external) 18. Carrier assembly 3. Inner bearing cone 11. Ring gear 19. Socket head screw (16 used) 4.
  • Page 223 NOTE: The planetary wheel drive assembly can be ser- viced with the planetary installed to machine. If the spindle (item 1) needs to be removed from machine, see Planetary Wheel Drive Assembly Removal in this sec- tion. Disassembly (Figs. 8 and 9) 1.
  • Page 224 F. Lightly oil bearing journals on spindle shaft. Slide 3. Install carrier assembly (item 18) making sure that housing onto spindle (item 1) taking care to not dam- carrier gear teeth align with ring gear and spline on age seal or spindle. Make sure that bearing in hous- spindle shaft.
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  • Page 226: Rear Axle Assembly

    Rear Axle Assembly RIGHT FRONT See text for tightening procedure Figure 10 1. Frame assembly 8. Rear axle assembly 14. Lock nut 2. Cap screw (10 used) 9. Thrust washer (thin) 15. Flange nut (10 used) 3. Lock washer (6 used) 10.
  • Page 227 8. Remove cap screw and flange nut that secures front corner of 4WD hydraulic manifold to rear axle mount. 9. If required, remove tie rod ends from steering arms on rear axle (Fig. 12). Remove the cotter pins and castle nuts from the tie rod ball joints.
  • Page 228 8. Install steering cylinder to axle assembly (see Steer- ing Cylinder Installation in the Service and Repairs sec- tion of Chapter 4 -- Hydraulic System). 9. Install hydraulic motor to axle assembly (see Rear Axle Motor Installation in the Service and Repairs sec- tion of Chapter 4 -- Hydraulic System).

  • Page 229: 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 (see Rear Axle (47 to 56 N- -m) Assembly Removal in this section). Bevel Gear Case and Axle Case Removal 1.
  • Page 230 5. Remove the knuckle pin mounting bolts and the knuckle pin. Remove the gasket and any remaining gas- ket material from both mating surfaces (Fig. 18). 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 231 Bevel Gear Case and Axle Case Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 20). Figure 20 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 232 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 233 9. Remove the bevel gear case/axle case assembly NOTE: Axle bearing shims are available in 0.008 in. from the axle support. Coat a new O-ring with grease (0.2 mm), 0.012 in. (0.3 mm) and 0.020 in. (0.5 mm) and temporarily install the axle cover assembly. Position thickness.

  • Page 234: Differential Shafts

    Differential Shafts The following procedures assume the rear axle assem- 35 to 41 ft- -lb bly has been removed from the machine (see Rear Axle (47 to 56 N- -m) Assembly Removal in this section). Differential Shaft Removal IMPORTANT: Do not interchange right and left dif- ferential shaft assemblies.

  • Page 235: Axle Shafts

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

  • Page 236: 11. 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 30 1. Nut (2 used) 7. O-ring 13. Shim 2. Lock washer (2 used) 8. Seal collar 14.
  • Page 237 7. Secure the lock nut with the stake washer. 8. Use a depth gauge to measure the distance from the end face of the input shaft/pinion gear to the mating sur- face of the bearing case. Subtract the “Design Cone Center Distance”...

  • Page 238: Differential Gear

    Differential Gear The following procedures assume the rear axle assem- 35 to 41 ft- -lb bly has been removed from the machine (see Rear Axle (47 to 56 N- -m) Assembly Removal in this section). Differential Gear Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual).
  • Page 239 Differential Gear 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. 37). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 in. (0.05 to 0.30 mm) SIDE GEAR O.D.
  • Page 240 Differential Gear 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 241: 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. 41): Toe -- the portion of the tooth surface at the end to- LENGTHWISE wards the center.
  • Page 242 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. 44): A.

  • Page 243: General Information

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

  • Page 244: Steering Tower

    Service and Repairs Steering Tower 16 to 20 ft- -lb (22 to 27 N- -m) RIGHT FRONT Figure 1 1. Hex nut 15. Lock nut (2 used) 29. Cap screw (2 used) 2. Flat washer 16. Parking brake switch 30. Pivot hub (2 used) 3.
  • Page 245 Disassembly (Fig. 1) Assembly (Fig. 1) 1. Park machine on a level surface, lower cutting 1. Assemble steering tower using Figure 1 as a guide. decks, stop engine, apply parking brake and remove A. Thrust washer(s) (item 24) on steering column key from the ignition switch.

  • Page 246: Front Deck Lift Arm

    Front Deck Lift Arm RIGHT FRONT 60 to 70 ft- -lb (81 to 94 N- -m) 90 to 100 ft- -lb (123 to 135 N- -m) 150 to 175 ft- -lb (203 to 237 N- -m) Figure 2 1. Flange bushing 14.
  • Page 247 Removal (Fig. 2) 6. If removed, install ball joint to lift arm. Distance from end of lift arm to center of ball joint should be from 2.210” 1. Park machine on a level surface, lower cutting to 2.390” (56.1 to 60.7 mm) (Fig. 4). Make sure that ball decks, stop engine, apply parking brake and remove joint is horizontal and that stud is centered in ball joint.

  • Page 248: Side Deck Lift Arm

    Side Deck Lift Arm 16 17 19 18 Loctite #242 9 10 Anti- -seize Lubricant 77 to 96 ft- -lb (105 to 130 N- -m) RIGHT 30 33 FRONT Figure 5 1. Lift arm (LH shown) 14. Rubber bumper 27. Lock nut (2 per switch) 2.
  • Page 249 Removal (Fig. 5) 5. Install side deck rear arm assembly (see Side Deck Rear Arm Assembly Installation in this section). 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove 6. Position and install side cutting deck to machine (see key from the ignition switch.

  • Page 250: Side Deck Rear Arm Assembly

    Side Deck Rear Arm Assembly Thread locking Compound 24 25 35 36 270 to 330 in- -lb (31 to 37 N- -m) RIGHT FRONT Figure 8 1. Cutting deck (LH shown) 16. Lock nut (2 per arm) 31. Damper rod end (2 per damper) 2.
  • Page 251 Rear Arm Removal (Fig. 8) 10.Thoroughly pack spring with grease. Install spring shaft assembly into housing and secure plate with four 1. Park machine on a level surface, lower cutting (4) cap screws and lock nuts. decks, stop engine, apply parking brake and remove key from the ignition switch.
  • Page 252 Rear Arm Installation (Fig. 8) 1. Position rear arm assembly to cutting deck and frame. 2. Slide pivot shaft through rear arm clevis and hub. Se- cure pivot shaft with lock washer and lock nut. 3. Connect damper link to cutting deck with clevis pin and hair pin (Fig.
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  • Page 254: Lift Arm Joint Yoke

    Lift Arm Joint Yoke 150 to 180 ft- -lb (203 to 244 N- -m) RIGHT FRONT Figure 11 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 255 IMPORTANT: Support yoke when removing cross 5. Install retaining rings to yoke and deck mount to se- and bearings to prevent yoke damage. cure bearings in place. 2. Use a press to remove yoke from deck mount: 6. Make sure that assembled joint yoke moves without binding.

  • Page 256: Operator Seat

    Operator Seat RIGHT FRONT Figure 12 1. Seat assembly 10. Manual tube 19. Clevis pin (2 used) 2. Flat washer (5 used) 11. Screw 20. Spring 3. Seat belt 12. Lock nut 21. Latch shaft 4. Cap screw (4 used) 13.
  • Page 257 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. Remove seat from seat suspension: A. Disconnect seat electrical connectors from ma- chine wire harness (Fig. 13). B.

  • Page 258: Operator Seat Service

    Operator Seat Service Figure 15 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 259 Disassembly (Fig. 15) Assembly (Fig. 15) 1. Disassemble operator seat as necessary using Fig- 1. Assemble operator seat using Figure 15 as a guide. ure 15 as a guide. Groundsmaster 4000--D Page 7 - - 17 Chassis...

  • Page 260: Operator Seat Suspension

    Operator Seat Suspension RIGHT FRONT Figure 16 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 261 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 262: Hood

    Hood RIGHT FRONT Figure 18 1. Rear screen 17. Flange nut (4 used) 33. Screw (2 used) 2. Top screen 18. Latch 34. Washer head screw (2 used) 3. Screen assembly 19. Latch cover 35. Cable tie 4. Bulb seal 20.
  • Page 263 Removal 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove hood using Figure 18 as a guide. Installation 1. Install hood using Figure 18 as a guide. Figure 19 2.
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  • Page 265: Troubleshooting 8

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

  • Page 266: Specifications

    Specifications MOUNTING: Cutting decks are supported by lift arms WIDTH OF CUT: Front deck provides 62” (1575 mm) controlled with individual hydraulic lift levers. 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 12 gauge mm) overlap.

  • Page 267: 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 268: 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.
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  • Page 270: 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. Front Cutting Deck RIGHT FRONT 60 to 70 ft- -lb (81 to 94 N- -m) 90 to 100 ft- -lb (123 to 135 N- -m)
  • Page 271 Removal (Fig. 1) 1. Position machine on a clean, level surface. Lower cutting decks, stop engine, apply parking brake and re- move key from the ignition switch. NOTE: Removal of clevis pin from deck and height--of-- cut chain is easier if deck is lifted slightly. 2.

  • Page 272: Side Cutting Deck

    Side Cutting Deck Thread locking Compound 24 25 35 36 270 to 330 in- -lb (31 to 37 N- -m) RIGHT FRONT Figure 5 1. Cutting deck (LH shown) 17. Cap screw (2 per arm) 33. Link tube 2. Deck mount (LH shown) 18.
  • Page 273 Removal (Fig. 5) 7. Lubricate grease fittings on cutting deck and lift arm assembly. 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 274: Idler Assembly

    Idler Assembly RIGHT FRONT Figure 8 Front deck 10. Stop bolt 18. Retaining ring Flange nut 11. Flange nut 19. Thrust washer Flange nut 12. Cap screw 20. Bushing (2 used per idler) Adjusting screw 13. Spacer 21. Grease fitting Idler pulley 14.
  • Page 275 Removal (Fig. 8) 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 276: Blade Spindles

    Blade Spindles RIGHT FRONT Figure 10 Front cutting deck LH cutting deck Driven spindle RH cutting deck Drive spindle Grease fitting location Page 8 - - 12 Cutting Decks Groundsmaster 4000--D...
  • Page 277 Removal (Figs. 10 and 11) 3. 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 4. Install drive belt to spindle pulleys and idler pulley. key from the ignition switch.

  • Page 278: 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 12 Lock nut Hydraulic motor mount 10. Spacer set Hardened washer O- -ring 11. Spindle housing Driven pulley (single shown) Oil seal 12.
  • Page 279 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 280: Castor Forks And Wheels

    Castor Forks and Wheels FRONT CUTTING DECK 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 16 Castor arm (front deck) 13.

  • Page 281: Hydraulic Schematic

    Chapter 9 Foldout Drawings Table of Contents HYDRAULIC SCHEMATIC ..... ELECTRICAL SCHEMATICS Sheet 1 of 2 ....... . Sheet 2 of 2 .
  • Page 282 This page is intentionally blank. Page 9 - 2 Foldout Drawings Groundsmaster 4000--D...

  • Page 283: Hydraulic Schematic

    COUNTERBALANCE MANIFOLD FRONT PTO MANIFOLD LH PTO MANIFOLD TRACTION MANIFOLD MANIFOLD RH PTO MANIFOLD BYPASS VALVE FAN DRIVE MANIFOLD FILTER MANIFOLD Groundsmaster 4000--D Hydraulic Schematic Page 9 - 3...

  • Page 284: Sheet 1 Of 2

    CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 (OPTIONAL CRUISE (OPTIONAL CRUISE CONTROL KIT) CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE FRONT DECK CONTROL KIT) PTO SOLENOID LEFT DECK PTO SOLENOID 2WD SOLENOID RIGHT DECK PTO SOLENOID...

  • Page 285: Sheet 2 Of 2

    CONTINUES FROM SHEET 1 CONTINUES FROM SHEET 1 COOLING FAN SWITCH POWER RELAY CONTINUES FROM SHEET 1 CONTINUES FROM SHEET 1 Groundsmaster 4000--D Electrical Schematic Sheet 2 of 2 All relays and solenoids are shown as de- - energized. All ground wires are black. Page 9 - 5...

  • Page 286: Glow Plug Circuits

    CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 (OPTIONAL CRUISE (OPTIONAL CRUISE CONTROL KIT) CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE FRONT DECK CONTROL KIT) (IGNITION SWITCH IN RUN) PTO SOLENOID LEFT DECK PTO SOLENOID 2WD SOLENOID...
  • Page 287 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 (OPTIONAL CRUISE (OPTIONAL CRUISE CONTROL KIT) CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE FRONT DECK CONTROL KIT) (IGNITION SWITCH IN START) PTO SOLENOID LEFT DECK PTO SOLENOID 2WD SOLENOID...

  • Page 288: Run (Transport) Circuits

    CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 (OPTIONAL CRUISE (OPTIONAL CRUISE CONTROL KIT) CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE FRONT DECK CONTROL KIT) PTO SOLENOID (IGNITION SWITCH IN RUN) (DISENGAGED) (NOT IN NEUTRAL) LEFT DECK...

  • Page 289: Run (Mow) Circuits

    CONTINUES TO SHEET 2 WHEN THE PTO SWITCH IS MOVED TO THE ENGAGE POSITION, PTO SWITCH TERMINALS 4 & 5 ARE MOMENTARILY CONNECTED ALLOWING A CURRENT PATH TO ENERGIZE THE PTO RELAY, THE DECK POSITION SWITCHES AND CONTINUES TO SHEET 2 THE PTO SOLENOIDS.

  • Page 290: High Temperature Warning Circuits

    CONTINUES TO SHEET 2 IF THE ENGINE COOLANT TEMPERATURE RISES TO 220 F (105 C), THE DUAL CONTINUES TO SHEET 2 TEMPERATURE WARNING SWITCH CLOSES. THIS CLOSED SWITCH CAUSES THE OVER TEMPERATURE WARNING LIGHT TO ILLUMINATE AND ALSO CONTINUES TO SHEET 2 ENERGIZES THE PTO OVERTEMP SHUTDOWN RELAY.

  • Page 291: Over Temperature Shutdown Circuits

    IF THE ENGINE COOLANT TEMPERATURE RISES TO 240 F (115 C), THE DUAL TEMPERATURE SHUTDOWN SWITCH CLOSES. THIS CLOSED SWITCH CAUSES CONTINUES TO SHEET 2 THE OVER TEMPERATURE SHUTDOWN RELAY TO ENERGIZE AND REMOVES ELECTRICAL POWER FROM THE ENGINE RUN SOLENOID AND FUEL PUMP SHUTTING OFF THE ENGINE.

  • Page 292: Engine Wire Harness

    (STARTER) (STARTER) (STARTER) Groundsmaster 4000--D Engine Wire Harness Page 9 - 12...
  • Page 293 BLACK BLACK WHITE RED/BLACK RED/BLACK PINK ORANGE BLUE WHITE GRAY GREEN YELLOW WHITE/BLACK YELLOW BROWN BLUE WHITE ORANGE VIOLET/BLACK YELLOW/BLACK GREEN BROWN/WHITE YELLOW/WHITE BLACK BLACK BLACK GREEN BLACK BLACK BLACK ORANGE Groundsmaster 4000--D Engine Wire Harness Page 9 - 13...

  • Page 294: Front Wire Harness

    FLOW DIVIDER SOLENOID Groundsmaster 4000--D Front Wire Harness Page 9 - 14...
  • Page 295 FLOW DIVIDER SOLENOID BROWN YELLOW PINK GRAY BLACK PINK GREEN/BLACK GRAY GREEN WHITE BLUE ORANGE VIOLET/BLACK BLACK ORANGE ORANGE BLACK Groundsmaster 4000--D Front Wire Harness Page 9 - 15...

  • Page 296: Console Wire Harness

    (ENGINE SHUTDOWN DELAY) COOLING (PTO SHUTDOWN DELAY) SWITCH FLOW DIVIDER SWITCH TRANSPORT/4WD SWITCH Groundsmaster 4000--D Console Wire Harness Page 9 - 16...
  • Page 297 TRANSPORT/4WD PT0 SHUTDOWN ENGINE SHUTDOWN DELAY DELAY WHITE YELLOW ORANGE GRAY FLOW DIVIDER YELLOW/BLACK SWITCH VIOLET YELLOW SHEET 2 WHITE YELLOW SHEET 2 YELLOW YELLOW YELLOW GREEN GRAY BLACK GRAY WHITE GRAY BLACK YELLOW BLACK BLACK ORANGE BLUE BLACK BLACK WHITE ORANGE YELLOW...
  • Page 298 COOLING FAN SWITCH SHEET 1 YELLOW YELLOW/GREEN SHEET 1 BLACK BLACK WHITE/GREEN BLACK TAN/BLACK TAN/BLACK GREEN/BLACK BLACK ORANGE/BLACK BLACK GRAY Groundsmaster 4000--D Console Wire Harness Sheet 2 of 2 Page 9 - 18...

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