Form No.
Revision History Revision Date Description -- 2008 Initial Issue. A 2012 Updated Hydraulic chapter. B 03/2018 Added revision history. © THE TORO COMPANY 2018 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content.
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
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Part No. 08161SL (Rev. B) Service Manual (Model 30412) GroundsmasterR 4000--D 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 OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. For reference, insert a copy of the Operator’s Manual and Parts Catalog for your machine into Chapter 2 of this service manual.
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Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 -2 -2 -2 -- 1 1 2 3 Chapter 3 -- Kubota Diesel Engine General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 3 Service and Repairs . .
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Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
General Safety Instructions The GROUNDSMASTER 4000-D is tested and certified by Toro for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.
1. Before servicing or making adjustments, lower decks, stop engine, apply parking brake and remove key from the switch. 10.Do not overspeed the engine by changing governor setting. To assure safety and accuracy, check maximum engine speed. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 11. Shut engine off before checking or adding oil to the crankcase. 3.
Jacking Instructions CAUTION When changing attachments, tires or performing other service, use correct jacks and supports. 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. Always chock or block wheels. Use jack stands to support the raised machine.
Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 4000--D. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog.
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Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 0.
Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size # 6 -- 32 UNC Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in--lb in--lb N--cm 10 + 2 13 + 2 147 + 23 # 6 -- 40 UNF # 8 -- 32 UNC 13 + 2 25 + 5 282 + 56 # 8 -- 36 UNF # 10 -- 24 UNC 18 + 2 30 + 5 339 + 56 # 10 -- 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger N
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series) Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in--lb 644 + 68 N--cm 78 + 8 in--lb 881 + 90 N--cm M6 X 1.0 96 + 10 in--lb 1085 + 113 N--cm 133 + 14 in--lb 1503 + 158 N--cm M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 28 + 3 ft--lb 38 + 4 N--m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3 ft--lb 1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb Recommended Torque** 7/16 -- 20 UNF Grade 5 65 + 10 ft--lb 88 + 14 N--m 1/2 -- 20 UNF Grade 5 80 + 10 ft--lb 108 + 14 N--m M12 X 1.25 Class 8.
Chapter 3 Kubota Diesel Engine Table of Contents Groundsmaster 4000--D Page 3 -- 1 Kubota Diesel Engine GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Air Filter System . . . . . . . . . . . . . . . . . .
General Information This Chapter gives information about specifications and repair of the diesel engine used in the Groundsmaster 4000--D. General maintenance procedures are described in your Operator’s Manual. Information on engine troubleshooting, testing, disassembly and reassembly is identified in the Kubota Workshop Manual, Diesel Engine, V2403--M--T--E3B that is included at the end of this section. Most repairs and adjustments require tools which are commonly available in many service shops.
Specifications Item Description Make / Designation Kubota Model V2403--M--T--E3B: 4--Cycle, 4 Cylinder, Water Cooled, Turbocharged, Diesel Engine 3.43” (87.0 mm) Stroke 4.031” (102.4 mm) Total Displacement 148.5 in3 (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 23.
Service and Repairs Air Filter System 7 RIGHT FRONT 1 9 12 to 15 in--lb (1.4 to 1.6 N--m) 11 6 12 13 14 4 15 8 2 10 5 11 16 17 VACUATOR DIRECTION 3 Figure 1 1. 2. 3. 4. 5. 6. Air cleaner hose Hose clamp Air cleaner assembly Indicator Air cleaner strap Lock nut (2 used) Kubota Diesel Engine 7. 8. 9. 10. 11. 12. Hose clamp Air cleaner hose Hose clamp Cap screw (2 used) Flat washer (4 used) Spring (2 used) Page 3 -- 4 13. 14. 15. 16. 17.
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 4 2. Raise and support hood. 1 3. Remove air cleaner components as needed using Figure 1 as a guide. 3 Installation (Fig. 1) 1. Assemble air cleaner system using Figure 1 as a guide. 5 Figure 2 1. Air cleaner housing 2. Safety filter element 3. Air filter element 4. Air cleaner cover 5. Vacuator valve A.
Exhaust System 16 to 22 ft--lb (21 to 29 N--m) 11 12 1 16 to 22 ft--lb (21 to 29 N--m) 11 14 3 2 15 16 4 16 to 22 ft--lb (21 to 29 N--m) 7 5 8 13 ft--lb (17.6 N--m) 9 8 7 6 8 13 6 8 RIGHT 10 FRONT 16 to 22 ft--lb (21 to 29 N--m) Figure 5 1. 2. 3. 4. 5. 6. Muffler Muffler bracket Exhaust pipe Flange head screw (4 used) Exhaust gasket Lock nut (2 used) Kubota Diesel Engine 7. 8. 9. 10. 11.
Removal (Fig. 5) CAUTION B The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the muffler. E C 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. A 3. Remove exhaust system components from the engine as necessary using Figure 5 as a guide. Figure 6 Installation (Fig.
Fuel System 38 39 37 36 35 34 29 26 27 28 23 24 25 41 2 30 22 31 33 1 21 14 3 4 5 40 6 32 20 7 RIGHT FRONT 19 18 17 1615 7 8 9 10 12 11 13 135 to 165 ft--lb (183 to 223 N--m) 60 to 80 in--lb (7 to 9 N--m) Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
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 fuel tank to the frame from 60 to 80 in--lb (7 to 9 N--m). 2. Install two (2) tank covers to ROPS assembly. 3. Connect fuel hose to the standpipe and venting hoses to the elbow fittings. 4. Connect electrical wiring to the sending unit. A. Connect white wire to the center terminal and black wire to any of the screws that secure the fuel sender to the fuel tank.
Radiator RIGHT 20 16 18 22 19 28 51 23 53 FRONT 17 62 24 25 1 27 52 46 12 9 45 50 8 54 6 61 21 49 41 25 7 30 28 26 59 4 38 29 5 11 55 37 49 10 60 57 56 32 13 41 15 14 42 44 35 2 34 48 39 47 33 3 45 58 28 31 43 58 36 40 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Removal (Fig. 8) Installation (Fig. 8) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 1. Remove all plugs placed during the removal procedure. 2. Open and support hood. CAUTION 2. Carefully position radiator to the support frame. Secure radiator to the support frame with cap screws and flange nuts. 3. Position lower radiator shroud and fan motor bracket assembly to the radiator.
Engine 27 1 RIGHT FRONT 26 25 24 2 3 4 23 5 22 6 21 11 13 12 7 14 20 13 13 9 10 15 9 16 19 28 to 32 ft--lb (38 to 43 N--m) 18 8 17 Loctite #242 29 to 33 ft--lb (40 to 44 N--m) 28 to 32 ft--lb (38 to 43 N--m) Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. Engine Cap screw (4 used) LH engine mount Lock washer Cap screw Lock washer (5 used) Cap screw (5 used) Engine support (4 used) Flange nut (12 used) 10. 11. 12. 13. 14. 15. 16. 17. 18.
CAUTION 2 Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Ethylene--glycol antifreeze is poisonous. Dispose of coolant properly or store it in a properly labeled container away from children and pets. 1 4. Drain coolant from the radiator into a suitable container (see Radiator Removal in this section). Disconnect upper and lower hoses from the radiator. Figure 10 CAUTION 1. Dual temp switch 2. Temperature sender 3.
11. Remove fan hub and fan from hydraulic fan motor (Fig. 14). 1 3 2 4 5 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. 8 B. Use suitable puller to remove fan hub (with fan attached) from fan motor shaft taking care to not damage fan. Remove fan hub and fan from machine. 6 7 12.Remove transport cylinder assembly from engine mount (Fig. 15). It is not necessary to remove the hydraulic hose from the cylinder.
12.Install air cleaner assembly to the engine (see Air Filter System Installation in this section). One person should operate lift or hoist while another person guides the engine into the machine. IMPORTANT: Make sure not to damage the engine, fuel and hydraulic lines, electrical harness or other parts while installing the engine. 13.Install exhaust system to machine (see Exhaust System Installation in this section). 14.Connect coolant hoses to the radiator. Make sure radiator drain is shut.
Spring Coupler RIGHT FRONT 21 20 1 2 19 18 17 4 9 16 15 14 13 12 11 5 10 7 Loctite #242 3 2 29 to 33 ft--lb (40 to 44 N--m) 6 28 to 32 ft--lb (38 to 43 N--m) 8 Figure 16 1. 2. 3. 4. 5. 6. 7. Spring coupler Washer (14 used) Cap screw (6 used) Flywheel plate Cap screw (4 used) LH engine mount Cap screw (2 used) Kubota Diesel Engine 8. 9. 10. 11. 12. 13. 14.
Coupler Removal (Fig. 16) NOTE: The hydraulic pump assembly needs to be removed 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, engine mounts and spring coupler. 1 Coupler Installation (Fig. 16) 1.
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Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 3 Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic Hose and Tube Installation . . . . . . . . . .
Specifications Item Description Piston (Traction) Pump Eaton Variable Displacement Piston Pump (Model 72400) 4000 PSI (274 bar) 5000 PSI (343 bar) 250 PSI (17 bar) System Relief Pressure: Forward System Relief Pressure: Reverse Charge Pressure Front Wheel Motors Eaton Fixed Displacement Piston Motors (Model 74318) Rear Axle Motor Eaton Fixed Displacement Piston Motor (Model 74315) Gear Pump Section P1/P2 Displacement (per revolution) Section P3/P4 Displacement (per revolution) Casappa 4 Section, Po
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. If it becomes necessary to tow (or push) the machine, tow (or push) in a forward direction only and at a speed below 3 mph.
Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions or mishandling during operation and maintenance. These conditions can cause hose damage and deterioration. Some hoses are more susceptible to these conditions than others.
Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The markings on the nut and fitting body will verify that the connection has been properly tightened. 2.
Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port) Non--Adjustable Fitting (Fig. 6) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.) method. 2.
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 recommended that the O--ring be replaced any time the connection is opened. Lock Nut 3. Lightly lubricate the O--ring with clean hydraulic oil. Fitting threads should be clean with no lubricant applied. Back--up Washer 4. Turn back the lock nut as far as possible.
Hydraulic System Page 4 -- 8 M2 M1 M2 M1 M2 M1 LC2 RV1 LC2 RV1 LC2 OR RV2 RV1 RH PTO MANIFOLD OR RV2 LH PTO MANIFOLD RV2 FRONT PTO MANIFOLD S S S LC1 LC1 LC1 P2 P1 P2 P1 P2 P1 NOTE: A larger hydraulic schematic is included in Chapter 9: Foldout Drawings P1 M1 M2 T ST P2 FAN DRIVE MANIFOLD L BYPASS VALVE FILTER MANIFOLD TRACTION MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD Hydraulic Schematic Groundsmaster 4000--D
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Hydraulic System Page 4 -- 10 M2 M1 M2 M1 M2 M1 LC2 OR LC2 RV2 OR LC2 RH PTO MANIFOLD RV2 LH PTO MANIFOLD RV2 FRONT PTO MANIFOLD RV1 RV1 RV1 S S S LC1 LC1 LC1 P2 P1 P2 P1 P2 P1 Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4000--D Traction Circuit (4WD Forward Shown) P1 M1 M2 T ST P2 L FAN DRIVE MANIFOLD TRACTION MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD Hydraulic Flow Diagrams Groundsmaster 4000--D
Traction Circuit: 4WD (Mow) Traction circuit pressure (forward and reverse) can be measured at test ports on the sides of the machine. The traction circuit pump and motors use a small amount of hydraulic fluid for internal lubrication. Fluid is designed to leak across traction pump and motor components into the case drain. This leakage results in the loss of hydraulic fluid from the closed loop traction circuit that must be replaced. The charge circuit is designed to replace this traction circuit leakage.
Hydraulic System Page 4 -- 12 Groundsmaster 4000--D M2 M1 M2 M1 M2 M1 LC2 OR LC2 RV2 OR LC2 RH PTO MANIFOLD RV2 LH PTO MANIFOLD RV2 FRONT PTO MANIFOLD RV1 RV1 RV1 S S S LC1 LC1 LC1 P2 P1 P2 P1 P2 P1 Working Pressure Low Pressure (Charge) Return or Suction Flow P1 M1 M2 Groundsmaster 4000--D Traction Circuit (Transport Forward Shown) T ST P2 L FAN DRIVE MANIFOLD TRACTION MANIFOLD 4WD MANIFOLD (energized) (extended) (shifted) (shifted) COUNTERBALANCE MANIFOLD
Traction Circuit: Transport (2WD) Traction circuit pressure (forward and reverse) can be measured at test ports on the sides of the machine. The traction circuit pump and motors use a small amount of hydraulic fluid for internal lubrication. Fluid is designed to leak across traction pump and motor components into the case drain. This leakage results in the loss of hydraulic fluid from the closed loop traction circuit that must be replaced.
Hydraulic System Page 4 -- 14 Groundsmaster 4000--D M2 M1 M2 M1 M2 M1 LC2 OR LC2 RV2 OR LC2 RH PTO MANIFOLD RV2 LH PTO MANIFOLD RV2 FRONT PTO MANIFOLD RV1 RV1 RV1 S S S LC1 LC1 LC1 P2 P1 P2 P1 P2 P1 Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4000--D Lower Cutting Unit (LH Deck Shown) P1 M1 M2 T ST P2 L FAN DRIVE MANIFOLD TRACTION MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD
Lower Cutting Deck When the cutting decks are in a stationary position, flow from the gear pump is by--passed through the lift/lower control valve, counterbalance manifold, oil filter and traction charge circuit. To lower a side cutting deck, the appropriate lift lever on the lift/lower control valve is pushed to allow valve shift in the lift/lower control valve. This valve change causes a valve shift in the counterbalance manifold and oil flow to the rod end of the lift cylinder.
Hydraulic System Page 4 -- 16 Groundsmaster 4000--D M2 M1 M2 M1 M2 M1 LC2 OR LC2 RV2 OR LC2 RH PTO MANIFOLD RV2 LH PTO MANIFOLD RV2 FRONT PTO MANIFOLD RV1 RV1 RV1 S S S LC1 LC1 LC1 P2 P1 P2 P1 P2 P1 Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4000--D Raise Cutting Unit (LH Deck Shown) M1 P1 M2 T ST P2 FAN DRIVE MANIFOLD L TRACTION MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD
Raise Cutting Deck When the cutting decks are in a stationary position, flow from the gear pump is by--passed through the lift/lower control valve, counterbalance manifold, oil filter and traction charge circuit. To raise a side cutting deck, the appropriate lift lever on the lift/lower control valve is pulled to allow valve shift in the lift/lower control valve.
Hydraulic System Page 4 -- 18 Groundsmaster 4000--D M2 M1 M2 M1 M2 M1 LC2 OR LC2 RV2 OR LC2 RH PTO MANIFOLD RV2 LH PTO MANIFOLD RV2 FRONT PTO MANIFOLD RV1 RV1 RV1 S S S LC1 LC1 LC1 Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4000--D Mow (Front Deck Shown) P2 P1 P2 P1 P2 P1 P1 M1 M2 T ST P2 L FAN DRIVE MANIFOLD TRACTION MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD
Mow Hydraulic flow for the mow circuit is supplied by two sections of the gear pump. The gear pump section closest to the piston (traction) pump supplies hydraulic flow to the side cutting decks, while the next gear pump section supplies the front cutting deck. Maximum mow circuit pressure is limited at each deck by a relief valve (RV1) in the hydraulic manifold. The front and left deck relief valves are set at 3000 PSI (207 bar) and the right deck relief valve is set at 2000 PSI (137 bar).
PTO Mow Circuit Cutting Deck Blade Braking When the operator turns the PTO switch OFF or if a deck is raised with the PTO switch ON, PTO control manifold solenoid valve (S) is de--energized causing logic cartridge (LC1) to shift (refer to information in PTO Mow Circuit in this section). This shifted cartridge allows oil return out manifold port P2.
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Hydraulic System Page 4 -- 22 Groundsmaster 4000--D M2 M1 M2 M1 M2 M1 LC2 OR LC2 RV2 OR LC2 RH PTO MANIFOLD RV2 LH PTO MANIFOLD RV2 FRONT PTO MANIFOLD RV1 RV1 RV1 S S S LC1 LC1 LC1 Working Pressure Low Pressure (Charge) Return or Suction Flow P2 P1 P2 P1 P2 P1 Groundsmaster 4000--D Steering Circuit (Left Turn Shown) P1 M1 M2 T ST P2 L FAN DRIVE MANIFOLD TRACTION MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD
Steering Circuit A four section gear pump is coupled to the piston (traction) pump. The third gear pump section supplies hydraulic flow to the steering control valve and the lift/lower control valve. Pump hydraulic flow is delivered to the two circuits through a proportional flow divider located in the fan drive manifold. The gear pump takes its suction from the hydraulic reservoir. Steering circuit pressure is limited to 1350 PSI (93 bar) by a relief valve located in the steering control.
Hydraulic System Page 4 -- 24 Groundsmaster 4000--D M2 M1 M2 M1 M2 M1 LC2 OR LC2 RV2 OR LC2 RH PTO MANIFOLD RV2 LH PTO MANIFOLD RV2 FRONT PTO MANIFOLD RV1 RV1 RV1 S S S LC1 LC1 LC1 P2 P1 P2 P1 P2 P1 Working Pressure Low Pressure (Charge) Return or Suction Flow P1 M1 M2 T ST P2 L FAN DRIVE MANIFOLD Groundsmaster 4000--D Engine Cooling Fan Circuit (Forward Direction Shown) TRACTION MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD
Engine Cooling Fan Circuit The fan drive manifold controls the operation of the hydraulic motor that drives the engine cooling fan in addition to including the flow divider for the steering and lift circuits. The electronically controlled proportional relief valve (PRV) in the manifold controls the oil flow to the fan motor. The fan drive manifold controls the speed and direction of the fan motor based on electrical output from the TEC--5002 controller. runs in the reverse direction.
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. Contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges. Use gauges as recommended in the Testing section of this chapter.
Hydraulic Test Fitting Kit This kit includes a variety of O--ring Face Seal fittings to enable you to connect test gauges into the system. TORO TEST FITTING KIT (NO. TOR4079) The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Toro Part Number: TOR4079 Figure 18 Measuring Container Hydraulic System Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only).
Troubleshooting The charts that follow contain suggestions to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the Testing section of this Chapter for precautions and specific test procedures. NOTE: When troubleshooting traction problems on the Groundsmaster 4000--D, if a problem exists in both 4WD and transport speeds, consider a faulty component that affects the entire traction circuit (e.g.
Problem Possible Causes Traction power is lost or unit will not operate in either direction. Hydraulic reservoir oil level is low. 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. Electrical problem exists (see Chapter 5 -- Electrical System). Solenoid valve (SV) in 4WD hydraulic manifold is faulty. Cartridge valve(s) in 4WD manifold is faulty.
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. Gear pump section for lift/lower control valve is inefficient. Cutting decks raise, but will not stay up. NOTE: Lift cylinders cannot provide an absolutely perfect seal.
Testing Before Performing Hydraulic Tests IMPORTANT: All obvious areas such as oil supply, filter, binding linkages, loose fasteners or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem. Precautions for Hydraulic Testing CAUTION Failure to use gauges with recommended pressure (PSI) rating as listed in test procedures could result in damage to the gauge and possible personal injury from leaking hot oil.
Traction Circuit Charge Pressure (Using Pressure Gauge) FROM COUNTERBALANCE MANIFOLD 4WD MANIFOLD FROM FRONT DECK CYLINDERS FILTER MANIFOLD TRACTION MANIFOLD 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 Hydraulic System Page 4 -- 32 FROM PTO MANIFOLDS & FAN MOTOR FROM PTO MANIFOLDS TO COOLING FAN CIRCUIT Groundsmaster 4000--D
Procedure for Traction Circuit Charge Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 1 2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is applied. 3. Raise and support operator seat. CAUTION 2 Prevent personal injury and/or damage to equipment.
Traction Circuit Relief Pressure (Using Pressure Gauge) FORWARD TRACTION CIRCUIT RELIEF PRESSURE TEST SHOWN FROM COUNTERBALANCE MANIFOLD 4WD MANIFOLD FROM FRONT DECK CYLINDERS FILTER MANIFOLD TRACTION MANIFOLD 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 Hydraulic System Page 4 -- 34 FROM PTO MANIFOLDS & FAN MOTOR FROM PTO MANIFOLDS TO COOLING FAN CIRCUIT Groundsmaster 4000--D
Procedure for Traction Circuit Relief Pressure Test 2 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 1 CAUTION Move machine to an open area, away from people and obstructions. Figure 22 2. Drive machine to an open area, lower cutting decks, turn the engine off and apply the parking brake. 1. Forward traction port 2. Left front wheel 2 CAUTION Prevent personal injury and/or damage to equipment.
Hydraulic System Page 4 -- 36 FROM FRONT PTO MANIFOLD FROM RH PTO CIRCUIT FROM RH PTO MANIFOLD P1 M1 M2 T ST P2 TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT FROM PTO MANIFOLDS FAN DRIVE MANIFOLD L FILTER MANIFOLD TRACTION MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD Counterbalance Pressure (Using Pressure Gauge) PRESSURE GAUGE FROM DECK MOTORS Groundsmaster 4000--D
Procedure for Counterbalance Pressure Test 4 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 3 2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is applied. Remove console cover. CAUTION 2 1 Prevent personal injury and/or damage to equipment.
Rear Traction Circuit (RV) Relief Pressure (Using Pressure Gauge) FROM COUNTERBALANCE MANIFOLD PRESSURE GAUGE FROM FRONT DECK FILTER MANIFOLD TRACTION MANIFOLD 4WD MANIFOLD 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 & LIFT CIRCUITS Hydraulic System Page 4 -- 38 FROM PTO MANIFOLDS & FAN MOTOR FROM PTO MANIFOLDS TO COOLING FAN CIRCUIT Groundsmaster 4000--D
Procedure for Rear Traction Circuit (RV) Relief Pressure Test 1 1. Make sure hydraulic oil is at normal operating temperature 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. Make sure engine is off and the parking brake is applied. 2 CAUTION Figure 26 Prevent personal injury and/or damage to equipment.
Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge) FROM COUNTERBALANCE MANIFOLD PRESSURE GAUGE FROM FRONT DECK FILTER MANIFOLD TRACTION MANIFOLD 4WD MANIFOLD 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 & LIFT CIRCUITS Hydraulic System Page 4 -- 40 FROM PTO MANIFOLDS & FAN MOTOR FROM PTO MANIFOLDS TO COOLING FAN CIRCUIT Groundsmaster 4000--D
Procedure for Traction Circuit Reducing Valve (PR) Pressure Test 1 1. Make sure hydraulic oil is at normal operating temperature 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. Make sure engine is off and the parking brake is applied. 2 CAUTION Figure 29 Prevent personal injury and/or damage to equipment.
Hydraulic System Page 4 -- 42 OR LC2 RV2 OR LC2 RH PTO MANIFOLD RV2 RV1 RV1 RV1 S S S LC1 LC1 LC1 P2 P1 P2 P1 P2 P1 FROM COOLING FAN CIRCUIT TO COOLING FAN CIRCUIT TO STEERING & LIFT CIRCUITS FILTER MANIFOLD FROM REAR AXLE MOTOR CHARGE CIRCUIT FROM FRONT WHEEL MOTORS FROM 4WD MANIFOLD TRACTION CIRCUIT FLOW FRONT DECK CIRCUIT PRESSURE TEST SHOWN M2 M1 M2 M1 LC2 LH PTO MANIFOLD RV2 PRESSURE GAUGE M2 M1 FRONT PTO MANIFOLD Cutting Deck Circuit Pressure (Using Pressur
Procedure for Cutting Deck Circuit Pressure Test 1. Make sure hydraulic oil is at normal operating temperature 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. Make sure engine is off and the parking brake is applied. 1 CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.
TESTER Hydraulic System Page 4 -- 44 LC2 OR LC2 RV2 OR LC2 RH PTO MANIFOLD RV2 LH PTO MANIFOLD RV2 RV1 RV1 RV1 S S S LC1 LC1 LC1 P2 P1 P2 P1 P2 P1 FROM COOLING FAN CIRCUIT TO COOLING FAN CIRCUIT TO STEERING & LIFT CIRCUITS FILTER MANIFOLD FROM REAR AXLE MOTOR CHARGE CIRCUIT FROM FRONT WHEEL MOTORS FROM 4WD MANIFOLD TRACTION CIRCUIT FLOW FRONT PTO RELIEF PRESSURE TEST SHOWN M2 M1 M2 M1 M2 M1 FRONT PTO MANIFOLD PTO Relief Pressure (Using Tester with Pressure Gauges
Procedure for PTO Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature 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. Make sure engine is off and the parking brake is applied. 9. Disengage cutting decks. Shut off engine and record test results. If specification is not met, adjust or clean relief valve in deck manifold port (RV1).
Hydraulic System Page 4 -- 46 OR LC2 RV2 OR LC2 RV1 RV1 RH PTO MANIFOLD RV2 LC2 RV1 S S S LC1 LC1 P2 P1 P2 P1 LC1 P2 P1 FROM COOLING FAN CIRCUIT TO COOLING FAN CIRCUIT TO STEERING & LIFT CIRCUITS FILTER MANIFOLD FROM REAR AXLE MOTOR CHARGE CIRCUIT FROM FRONT WHEEL MOTORS FROM 4WD MANIFOLD TRACTION CIRCUIT FLOW FRONT CUTTING DECK MOTOR CASE DRAIN LEAKAGE TEST SHOWN M2 M1 M2 M1 RV2 LH PTO MANIFOLD M2 M1 FRONT PTO MANIFOLD Cutting Deck Motor Case Drain Leakage (Using
Procedure for Cutting Deck Motor Case Drain Leakage Test 5. Sit on seat and start the engine. Move throttle to full speed (2870 RPM). Move PTO switch to ON. NOTE: Over a period of time, a deck motor can wear internally. A worn motor may by--pass oil to its case drain causing the motor to be less efficient. Eventually, enough oil loss will cause the deck motor to stall under heavy cutting conditions.
Hydraulic System Page 4 -- 48 LC2 OR LC2 RV2 OR LC2 RH PTO MANIFOLD RV2 LH PTO MANIFOLD RV2 RV1 RV1 RV1 S S S LC1 LC1 LC1 P2 P1 P2 P1 P2 P1 FROM COOLING FAN CIRCUIT TO COOLING FAN CIRCUIT TO STEERING & LIFT CIRCUITS FILTER MANIFOLD FROM REAR AXLE MOTOR CHARGE CIRCUIT FROM FRONT WHEEL MOTORS FROM 4WD MANIFOLD TRACTION CIRCUIT FLOW FRONT DECK GEAR PUMP FLOW TEST SHOWN M2 M1 M2 M1 M2 M1 FRONT PTO MANIFOLD Cutting Deck Gear Pump Flow (Using Tester with Pressure Gauges
NOTE: Over a period of time, the gears and wear plates in the pump can wear. A worn pump will by pass oil and make the pump less efficient. Eventually, enough oil loss will occur to cause the cutting deck motors to stall under heavy cutting conditions. Continued operation with a worn, inefficient pump can generate excessive heat and cause damage to the seals and other components in the hydraulic system. 1.
Steering Circuit Relief Pressure (Using Pressure Gauge) FROM COUNTERBALANCE MANIFOLD FILTER MANIFOLD TRACTION MANIFOLD 4WD MANIFOLD FROM FRONT DECK LIFT CYLINDERS TO LIFT/LOWER CONTROL VALVE FAN DRIVE MANIFOLD P2 P1 T ST M2 M1 TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT FROM PTO MANIFOLDS L PRESSURE GAUGE Hydraulic System Page 4 -- 50 FROM RH PTO CIRCUIT FROM FRONT PTO MANIFOLD FROM RH PTO MANIFOLD FROM DECK MOTORS Groundsmaster 4000--D
Procedure for Steering Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature 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. Make sure engine is off and the parking brake is applied. 1 CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.
Hydraulic System Page 4 -- 52 FROM FRONT PTO MANIFOLD FROM RH PTO CIRCUIT FROM RH PTO MANIFOLD P1 M1 M2 T ST P2 TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT FROM PTO MANIFOLDS FAN DRIVE MANIFOLD L FILTER MANIFOLD TRACTION MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) PRESSURE GAUGE FROM DECK MOTORS Groundsmaster 4000--D
Procedure for Lift/Lower Circuit Relief Pressure Test NOTE: Before attempting to check or adjust lift pressure, make sure that counterbalance pressure is correctly adjusted. 3 1. Make sure hydraulic oil is at normal operating temperature 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. Make sure engine is off and the parking brake is applied. 4 2 CAUTION 1 Figure 41 1.
FILTER MANIFOLD TRACTION MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD Steering and Lift/Lower Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter) FAN DRIVE MANIFOLD TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT FROM PTO MANIFOLDS TESTER FROM DECK MOTORS Hydraulic System Page 4 -- 54 FROM RH PTO CIRCUIT FROM RH PTO MANIFOLD FROM FRONT PTO MANIFOLD Groundsmaster 4000--D
Procedure for Steering and Lift/Lower Gear Pump Flow Test 2 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 3 2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is applied. 4 CAUTION Prevent personal injury and/or damage to equipment.
Hydraulic System Page 4 -- 56 FROM RH PTO CIRCUIT FROM RH PTO MANIFOLD TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT FROM PTO MANIFOLDS FAN DRIVE MANIFOLD FILTER MANIFOLD TRACTION MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac) FROM DECK MOTORS FROM FRONT PTO MANIFOLD Groundsmaster 4000--D
Procedure for Engine Cooling Fan Circuit Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2 2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is applied. Raise and support hood. 3 1 CAUTION Prevent personal injury and/or damage to equipment.
FILTER MANIFOLD TRACTION MANIFOLD 4WD MANIFOLD COUNTERBALANCE MANIFOLD Engine Cooling Fan Circuit Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter) FAN DRIVE MANIFOLD TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT FROM PTO MANIFOLDS TESTER FROM DECK MOTORS Hydraulic System Page 4 -- 58 FROM RH PTO CIRCUIT FROM RH PTO MANIFOLD FROM FRONT PTO MANIFOLD Groundsmaster 4000--D
Procedure for Engine Cooling Fan Circuit Gear Pump Flow Test 2 1. Make sure hydraulic oil is at normal operating temperature 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. Make sure engine is off and the parking brake is applied. 1 4 CAUTION Prevent personal injury and/or damage to equipment.
Adjustments Adjust Front Cutting Deck Lift Flow Control The front cutting deck lift circuit is equipped with an adjustable flow control valve used to adjust the rate at which the front cutting deck lowers. Adjust flow control valve as follows: 1. Run machine to get hydraulic oil at operating temperatures. Park machine on a level surface, shut engine off and lower cutting decks to the ground. 2 1 2. Locate flow control valve under front of machine (Fig. 46). 3.
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 system, park machine on a level surface, apply parking brake, lower cutting decks or attachments and stop engine. Remove key from the ignition switch. 1. Check oil level in the hydraulic reservoir and add correct oil if necessary.
Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky, black or contains metal particles). 1. Park machine on a level surface. Lower cutting decks to the ground, stop engine and apply parking brake. Remove key from the ignition switch. CAUTION 9. Turn ignition key switch and engage starter for ten (10) seconds to prime hydraulic pumps. Repeat this step again. 10.
Charge Hydraulic System IMPORTANT: Change hydraulic oil filters whenever hydraulic components are repaired or replaced. 11. After the hydraulic system starts to show signs of fill, actuate lift control lever until the lift cylinder rod moves in and out several times. If the cylinder rod does not move after 10 to 15 seconds, or the pump emits abnormal sounds, shut the engine off immediately and determine cause or problem. Inspect for the following: A. Loose filter or suction lines. 1.
Hydraulic Reservoir 25 19 18 9 23 10 9 13 12 14 11 27 7 15 1 6 24 17 5 16 3 2 30 to 40 in--lb (3.4 to 4.5 N--m) (minimum) 21 4 8 20 31 28 30 22 26 RIGHT NOTE: HYDRAULIC COMPONENTS ATTACHED TO FRONT FRAME ARE NOT SHOWN IN ILLUSTRATION FRONT 29 Figure 47 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Hydraulic reservoir Petcock O--ring Strap Felt strap (2 used) Bushing (2 used) Bushing Strap Stand pipe (2 used) Hose clamp (2 used) Screen filter Hydraulic System 12. 13. 14. 15. 16. 17. 18. 19.
Removal (Fig. 47) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove front cutting deck (see Front Cutting Deck Removal in the Service and Repairs section of Chapter 8 -- Cutting Decks). Inspection 1. Clean hydraulic reservoir and suction strainer with solvent. 2. Inspect reservoir for leaks, cracks or other damage. Installation (Fig. 47) 1.
Hydraulic Oil Cooler 8 5 9 4 RIGHT 6 7 8 10 3 FRONT 9 10 2 11 12 1 13 14 15 16 12 17 18 12 ft--lb (16 N--m) Figure 48 1. 2. 3. 4. 5. 6. Radiator RH radiator support Top radiator support Knob (2 used) Oil cooler bracket Retaining ring (2 used) Hydraulic System 7. 8. 9. 10. 11. 12. Carriage screw (2 used) O--ring 90o hydraulic fitting (2 used) O--ring Cap screw (2 used) Lock washer (6 used) Page 4 -- 66 13. 14. 15. 16. 17. 18.
Removal (Fig. 48) CAUTION CAUTION The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool before working on the oil cooler. 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
Gear Pump 1 11 10 23 15 11 20 32 14 14 33 24 103 to 118 ft--lb (140 to 160 N--m) 4 34 3 2 24 22 21 31 22 30 19 8 17 27 6 7 18 RIGHT 5 16 13 12 79 to 84 ft--lb (108 to 113 N--m) 25 26 9 28 FRONT 79 to 84 ft--lb (108 to 113 N--m) 29 Figure 49 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Removal (Fig. 49) Installation (Fig. 49) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 1. If fittings were removed from gear pump, lubricate and place new O--rings onto fittings. Install fittings into pump openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 3.
Gear Pump Service 18 6 9 12 10 13 14 15 17 16 5 3 19 4 11 24 21 9 11 1 2 7 8 21 26 25 23 22 33 ft--lb (45 N--m) 22 20 Figure 50 1. 2. 3. 4. 5. 6. 7. 8. 9. Dust seal Retaining ring Flange washer Shaft seal Front cover Dowel pin (16 used) Pressure seal Back--up gasket Thrust plate (8 used) 10. 11. 12. 13. 14. 15. 16. 17. 18. Seal (8 used) Idler gear Drive shaft Back--up gasket Pressure seal Front body Splined connecting shaft (3 used) Flange Drive gear 19. 20. 21. 22. 23. 24. 25.
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 assembly. 5. Remove pump from vise and remove fasteners. 6. Support the pump assembly and gently tap the pump case with a soft face hammer to loosen the pump sections. Be careful to not drop parts or disengage gear mesh. IMPORTANT: Mark the relative positions of the gear teeth and the thrust plates so they can be reassembled in the same position.
Traction Circuit 9 6 10 RIGHT FRONT 8 1 2 5 7 3 4 Figure 52 1. 2. 3. 4. Piston (traction) pump Gear pump LH front wheel motor Traction manifold 5. RH front wheel motor 6. 4WD manifold 7. Filter manifold 8. Rear axle motor 9. Cooling fan motor 10. Check valve Figure 52 illustrates the components that are used in the Groundsmaster 4000--D traction circuit. Procedures for removal, installation and disassembly/assembly of these components are provided on the following pages of this section.
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Piston (Traction) Pump 1 11 10 23 15 11 20 32 14 14 33 24 103 to 118 ft--lb (140 to 160 N--m) 4 34 3 2 24 22 21 31 22 30 19 8 17 27 6 7 18 RIGHT 5 16 13 12 79 to 84 ft--lb (108 to 113 N--m) 25 26 9 28 FRONT 79 to 84 ft--lb (108 to 113 N--m) 29 Figure 53 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 3. Install gear pump to piston pump (see Gear Pump Installation). 4. Position traction rod to control arm on piston pump by installing cap screw, spacer and lock nut (Fig. 54). 2. To prevent contamination of hydraulic system during removal, thoroughly clean exterior of pump assembly. 5. Connect wire harness connector to neutral switch on traction pump. 3.
Piston (Traction) Pump Service 100 to 110 ft--lb (136 to 149 N--m) 27 to 31 ft--lb (37 to 42 N--m) 16 20 150 to 160 in--lb (17 to 18 N--m) 38 18 100 to 110 ft--lb (136 to 149 N--m) 15 4 to 6 ft--lb (5 to 8 N--m) 14 1 29 26 4 22 45 10 33 28 23 17 8 30 7 5 27 40 to 48 in--lb (4.5 to 5.4 N--m) 34 43 35 31 32 44 36 11 40 to 48 in--lb (4.5 to 5.4 N--m) 37 19 42 41 40 6 25 to 28 ft--lb (34 to 38 N--m) 31 5 39 37 21 12 40 to 48 in--lb (4.5 to 5.
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Rear Axle Motor 2 Arrow on side of motor case points up 15 3 12 1 2 17 18 13 14 11 16 10 5 9 4 6 19 20 7 59 to 73 ft--lb (80 to 99 N--m) 21 8 RIGHT FRONT Figure 56 1. 2. 3. 4. 5. 6. 7. Axle motor 90o hydraulic fitting (2 used) Hydraulic fitting Cap screw (2 used) Flat washer (2 used) O--ring External snap ring (2 used) Hydraulic System 8. 9. 10. 11. 12. 13. 14. Pinion gear External snap ring (2 used) Gear Needle bearing O--ring O--ring O--ring Page 4 -- 78 15. 16. 17. 18. 19. 20. 21.
Removal (Fig. 56) Installation (Fig. 56) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 1. If fittings were removed from motor, lubricate and place new O--rings onto fittings. Install fittings into port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter).
Front Wheel Motor 2 3 11 2 8 13 12 16 14 15 9 5 4 10 1 14 11 Arrow on side of motor case points up 19 7 6 1 11 14 10 16 18 2 15 RIGHT FRONT 15 8 75 to 85 ft--lb (101 to 115 N--m) 17 3 2 5 16 12 22 21 20 Figure 57 1. 2. 3. 4. 5. 6. 7. 8. Front wheel motor Internal retaining ring Splined brake shaft RH brake assembly Planetary assembly Cap screw (2 used per side) Flat washer (2 used per side) O--ring Hydraulic System 9. 10. 11. 12. 13. 14. 15.
Removal (Fig. 57) Installation (Fig. 57) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 1. If fittings were removed from motor, lubricate and place new O--rings onto fittings. Install fittings into port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter).
Rear Axle and Front Wheel Motor Service 15 to 18 ft--lb (20 to 24 N--m) 9 10 13 10 9 7 2 1 11 18 8 6 14 15 16 12 4 5 3 17 Figure 58 1. 2. 3. 4. 5. 6. Drive shaft Backplate (front motor shown) Housing assembly Rotating assembly Cam plate insert Retaining ring 7. 8. 9. 10. 11. 12. Cap screw (6 used) Shaft seal Retaining ring Thrust race O--ring Valve plate NOTE: The front wheel motors are identical. The rear axle motor has some differences from the front motors.
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4WD Manifold 2 5 18 12 3 6 7 9 17 16 RIGHT 4 8 11 9 10 13 12 7 FRONT 4 15 5 10 14 1 19 Figure 59 1. 2. 3. 4. 5. 6. 7. Frame assembly 4WD manifold 90o hydraulic fitting O--ring O--ring Quick fitting O--ring 8. 9. 10. 11. 12. 13. Fitting cap Hydraulic fitting O--ring O--ring 90o hydraulic fitting O--ring 14. 15. 16. 17. 18. 19.
Removal (Fig. 59) Installation (Fig. 59) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 1. If fittings were removed from manifold, lubricate and place new O--rings onto fittings. Install fittings into manifold openings using marks made during the removal process to properly orientate fittings.
4WD Manifold Service 13 35 ft--lb (47 N--m) 25 ft--lb (34 N--m) 10 13 REAR DOWN 11 10 6 50 ft--lb (67 N--m) 1 4 10 11 8 7 1 13 2 5 9 13 10 UP FRONT 3 20 ft--lb (27 N--m) 11 PLUG TORQUE #4 Zero Leak: 20 ft--lb (27 N--m) #6 Zero Leak: 25 ft--lb (34 N--m) #8 Zero Leak: 50 ft--lb (67 N--m) 5 ft--lb (6.7 N--m) 10 11 12 Figure 60 1. 2. 3. 4. 5. 4WD manifold body Solenoid valve (port SV) Solenoid coil Check valve (port CV) Nut 6. 7. 8. 9.
1. Make sure the manifold is clean before removing the valve. 2. If cartridge is solenoid operated, remove nut securing solenoid to the cartridge valve. Carefully slide solenoid off the valve. IMPORTANT: Use care when handling the valve cartridge. Slight bending or distortion of the stem tube can cause binding and malfunction. 3. Remove cartridge valve with a deep socket wrench. Note correct location for O--rings, sealing rings and backup rings. Remove and discard seal kit. 4.
Traction (Flow Divider) Manifold 16 9 8 15 10 7 17 14 18 11 12 13 19 2 8 1 2 3 5 4 6 RIGHT 5 FRONT Figure 61 1. 2. 3. 4. 5. 6. 7. Traction manifold O--ring Hydraulic fitting Bracket Flange nut Cap screw (2 used) Hydraulic hose 8. 9. 10. 11. 12. 13. O--ring 90o hydraulic elbow O--ring Hydraulic hose Hydraulic fitting O--ring 14. 15. 16. 17. 18. 19.
Removal (Fig. 61) Installation (Fig. 61) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 1. If fittings were removed from manifold, lubricate and place new O--rings onto fittings. Install fittings into manifold openings using marks made during the removal process to properly orientate fittings.
Traction (Flow Divider) Manifold Service 50 ft--lb (67 N--m) 50 ft--lb (67 N--m) FRONT 1 20 ft--lb (27 N--m) UP 5 2 4 198 in--lb (22.4 N--m) 40 ft--lb (54 N--m) 6 20 ft--lb (27 N--m) 10 5 ft--lb (6.7 N--m) 20 ft--lb (27 N--m) 9 5 198 in--lb (22.4 N--m) 7 8 10 20 ft--lb (27 N--m) 3 5 10 6 198 in--lb (22.4 N--m) 40 ft--lb (54 N--m) Figure 62 1. 2. 3. 4. Flow divider valve Piloted directional valve Orifice (0.020) Traction manifold 5. Check valve 6. Plug with O--ring (SAE #8) 7.
Traction Manifold Service (Fig. 62) Hydraulic System For cartridge valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 62 for traction (flow divider) manifold cartridge valve and plug installation torque.
Filter Manifold 8 9 18 20 6 10 11 2 21 4 11 12 19 6 5 22 1 23 14 17 6 3 7 11 13 RIGHT 15 FRONT 24 16 25 Figure 63 1. 2. 3. 4. 5. 6. 7. 8. 9. Filter manifold 45o hydraulic fitting Test nipple Dust cap O--ring O--ring O--ring Cap screw (3 used) Flat washer (3 used) 10. 11. 12. 13. 14. 15. 16. 17. Hydraulic fitting O--ring O--ring 90o hydraulic fitting Hydraulic hose O--ring O--ring 90o hydraulic fitting 18. 19. 20. 21. 22. 23. 24. 25.
Removal (Fig. 63) Installation (Fig. 63) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 1. If fittings were removed from manifold, lubricate and place new O--rings onto fittings. Install fittings into manifold openings using marks made during the removal process to properly orientate fittings.
Filter Manifold Service 5 25 ft--lb (34 N--m) UP FRONT 25 ft--lb (34 N--m) 1 6 25 ft--lb (34 N--m) 30 ft--lb (41 N--m) 5 7 4 3 2 50 ft--lb (67 N--m) 30 ft--lb (41 N--m) UP FRONT 3 Figure 64 1. Filter manifold 2. Check valve (reservoir return) 3. Oil filter element 4. Check valve (filter bypass) 5. Plug (Zero Leak #6) 6. Charge relief valve 7. Plug (Zero Leak #8) NOTE: The ports on the manifold are marked for easy identification of components.
Filter Manifold Service (Fig. 64) Hydraulic System For cartridge valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 64 for filter manifold cartridge valve and plug installation torque.
Steering and Cooling Fan Circuits RIGHT 4 FRONT 3 2 1 5 Figure 65 1. Gear pump 2. Steering control valve 3. Fan drive manifold 4. Fan motor 5. Steering cylinder 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 following pages of this section.
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Steering Valve 24 23 1 3 2 22 29 4 28 27 25 5 12 26 6 8 21 20 19 18 16 to 20 ft--lb (22 to 27 N--m) 7 17 16 15 RIGHT 9 10 11 9 12 13 11 14 FRONT Figure 66 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Hex nut Flat washer Steering wheel Foam collar Steering seal External snap ring Steering shaft assembly Steering tower cover O--ring 90o hydraulic fitting Hydraulic System 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Removal (Fig. 66) Installation (Fig. 66) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 1. If fittings were removed from steering valve, lubricate and place new O--rings onto fittings. Install fittings into port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 2.
Steering Valve Service 8 1 3 24 2 4 5 20 19 23 6 7 19 22 21 150 in--lb (17 N--m) 9 10 13 12 11 140 to 160 in--lb (16 to 18 N--m) 14 18 17 16 15 Figure 67 1. 2. 3. 4. 5. 6. 7. 8. Steering valve housing Dust seal O--ring Spool Spring retaining ring Pin Sleeve Centering springs/spacers 9. 10. 11. 12. 13. 14. 15. 16. Cap screw (7 used) End cap O--ring Seal ring O--ring Geroter O--ring Spacer NOTE: Cleanliness is extremely important when repairing hydraulic components.
8. Put the thrust bearing and races into the housing. The thrust bearing goes between the two races (Fig. 68). The centering springs are under tension. Remove the retaining ring carefully. IMPORTANT: Do not damage the dust or quad seals when installing the spool and sleeve assembly. 10.Remove the spring retaining ring and centering springs from the spool. 9. Apply a light coating of clean hydraulic fluid to the spool and sleeve assembly and slide carefully the assembly into the housing. Assembly (Fig.
Steering Cylinder 7 6 9 4 7 9 1 8 5 2 4 3 10 See text for tightening procedure 12 13 14 11 RIGHT See text for tightening procedure FRONT Figure 69 1. 2. 3. 4. 5. Steering cylinder Ball joint Ball joint Retaining ring Grease fitting Hydraulic System 6. 7. 8. 9. 10. Grease fitting 90o hydraulic fitting O--ring O--ring Drive axle assembly Page 4 -- 102 11. 12. 13. 14.
Removal (Fig. 69) Installation (Fig. 69) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 1. If removed, install ball joints into steering cylinder. 3. To prevent contamination of hydraulic system during cylinder removal, thoroughly clean exterior of cylinder and fittings. NOTE: To ease installation, tag the hydraulic hoses to show their correct position on the steering cylinder. 4.
Steering Cylinder Service 12 9 11 10 2 7 8 5 4 1 6 3 45 to 55 ft--lb (62 to 74 N--m) Figure 70 1. 2. 3. 4. Tube assembly Rod Piston assembly Head Hydraulic System 5. 6. 7. 8. Retaining ring Backup ring O--ring Cap seal Page 4 -- 104 9. 10. 11. 12.
Disassembly (Fig. 70) Assembly (Fig. 70) 1. Pump oil out of cylinder into a drain pan by SLOWLY moving rod and piston in and out of cylinder bore. Plug ports and clean outside of cylinder. 1. Use a complete repair kit when rebuilding the cylinder. Put a coating of clean hydraulic oil on all new seals and O--rings. IMPORTANT: To prevent damage when clamping cylinder in a vise, clamp only on pivotal ends. Use of a vise with soft jaws is recommended. 2.
Engine Cooling Fan Motor 4 3 2 1 5 27 to 33 ft--lb (37 to 44 N--m) 21 6 20 7 8 2 9 4 5 19 18 13 14 15 16 17 12 11 12 to 14 ft--lb (17 to 18 N--m) 10 RIGHT FRONT Figure 71 1. 2. 3. 4. 5. 6. 7. Hydraulic fan motor O--ring Bracket 45o hydraulic fitting O--ring Hydraulic hose Fan hub Hydraulic System 8. 9. 10. 11. 12. 13. 14. Washer Hex nut Engine Cap screw (4 used) Washer (4 used) Fan Lock nut (2 used) Page 4 -- 106 15. 16. 17. 18. 19. 20. 21.
1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3. Unlatch and raise hood. 4. Remove air cleaner hose and upper radiator shroud to allow easier access to hydraulic fan motor (Fig. 72). CAUTION The radiator and oil cooler may be hot.
Engine Cooling Fan Motor Service 11 10 15 6 3 1 14 7 16 9 8 12 8 5 4 14 33 ft--lb (45 N--m) 9 2 13 Figure 73 1. 2. 3. 4. 5. 6. Flange washer O--ring Front flange Dust seal Retaining ring Front wear plate 7. 8. 9. 10. 11. Shaft seal Backup gasket Pressure seal Rear wear plate Body 12. 13. 14. 15. 16. Idler gear Cap screw (4 used) Dowel (2 used) Drive gear Washer (4 used) Disassembly (Fig. 73) MARKER LINE 1. Plug motor ports and clean the outside of the motor thoroughly.
8. Remove and discard back--up gaskets and pressure seals from wear plates. 2 1 3 4 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. 75). Discard seals. Figure 75 1. Dust seal 2. Retaining ring Inspection 3. Flange washer 4. Shaft seal 1.
4. Install the pressure seals, flat side outward, into the grooves in the wear plates. Follow by carefully placing the backup gaskets, flat side outward, between the pressure seals and the grooves in the wear plate. 5. Apply a light coating of petroleum jelly to the exposed side of the front flange. 6. Lubricate the drive gear shaft with clean hydraulic oil.
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Fan Drive Manifold 4 3 6 7 5 2 8 1 9 25 4 5 10 10 5 26 7 27 7 11 23 7 22 7 21 7 5 14 20 19 7 18 17 16 15 5 12 13 14 RIGHT FRONT 24 Figure 77 1. 2. 3. 4. 5. 6. 7. 8. 9. Fan drive manifold O--ring Test fitting Dust cap (2 used) O--ring 45o hydraulic fitting (2 used) O--ring Hydraulic hose Hydraulic hose 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 77) Installation (Fig. 77) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 1. If fittings were removed from manifold, lubricate and place new O--rings onto fittings. Install fittings into manifold openings using marks made during the removal process to properly orientate fittings.
Fan Drive Manifold Service 5 ft--lb (6.7 N--m) 5 ft--lb (6.7 N--m) UP FRONT 6 25 ft--lb (34 N--m) 50 ft--lb (67 N--m) 10 7 7 2 5 20 ft--lb (27 N--m) 1 25 ft--lb (34 N--m) 8 9 4 2 25 ft--lb (34 N--m) 25 ft--lb (34 N--m) B 2 4 3 25 ft--lb (34 N--m) 20 ft--lb (27 N--m) FRONT 20 ft--lb (27 N--m) UP Figure 78 1. 2. 3. 4. Fan drive manifold #4 zero leak plug (3 used) Check valve #6 zero leak plug (2 used) 5. Flow divider valve 6. Nut 7. Solenoid coil (2 used) 8.
Fan Drive Manifold Service (Fig. 78) Hydraulic System For cartridge valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 78 for fan drive manifold cartridge valve and plug installation torque.
PTO Circuit RIGHT 9 FRONT 2 4 1 6 5 8 3 7 Figure 79 1. Gear pump 2. RH cutting deck motor 3. LH cutting deck motor 4. RH PTO manifold 5. Front cutting deck motor 6. LH PTO manifold 7. Front PTO manifold 8. Filter manifold 9. Oil cooler Figure 79 illustrates the components that are used in the Groundsmaster 4000--D PTO circuits. Procedures for removal, installation and disassembly/assembly of these components are provided on the following pages of this section.
Cutting Deck Motor 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3. Thoroughly clean exterior of deck motor and fittings. Disconnect hydraulic lines from motor. Put caps or plugs on fittings and hoses to prevent contamination.
Cutting Deck Motor Service 9 15 12 10 10 13 15 9 14 1 8 7 15 6 5 11 8 4 33 to 40 ft--lb (45 to 55 N--m) 2 3 Figure 82 1. 2. 3. 4. 5. Rear cover Drive gear Seal Woodruff key Nut 6. 7. 8. 9. 10. Tab washer Spider hub Pressure seal Back--up ring O--ring Disassembly (Fig. 82) 1. Plug motor ports and clean the outside of the motor thoroughly. After cleaning, remove plugs and drain any oil out of the motor. 11. 12. 13. 14. 15.
IMPORTANT: Mark the relative positions of the gear teeth and the bearing blocks so they can be reassembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. 1 7. Place the motor on its side and push on the rear bearing block to remove the bearing block and gear set (Fig. 84). 8. Carefully remove and discard O--rings, pressure seals and back--up rings (Fig. 85) from motor. Do not cause any damage to the machined grooves during the removal process.
Assembly (Fig. 82) 8. Install dowel pins in body. NOTE: When assembling the motor, check the identification marks made during disassembly to make sure the parts are properly aligned during assembly. IMPORTANT: Do not dislodge O--rings, pressure seals or back--up rings during final assembly. 1. Lubricate O--rings, pressure seals, back--up gaskets and seal grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic oil. 2.
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PTO Manifold 23 5 22 12 18 19 7 16 2 4 15 25 3 11 24 8 21 17 6 26 25 21 27 5 8 6 8 6 6 8 5 9 14 11 3 8 2 21 12 7 12 2 3 4 4 19 18 21 20 19 18 23 19 1 7 13 10 21 RIGHT FRONT Figure 87 1. 2. 3. 4. 5. 6. 7. 8. 9. Hydraulic PTO manifold (front deck) Quick fitting (1 used per manifold) Flange nut O--ring Hydraulic fitting O--ring O--ring O--ring Hydraulic adapter 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 87) Installation (Fig. 87) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 1. If fittings were removed from manifold, lubricate and place new O--rings onto fittings. Install fittings into manifold openings using marks made during the removal process to properly orientate fittings.
PTO Manifold Service 20 ft--lb (27 N--m) 8 5 ft--lb (6.7 N--m) 7 9 25 ft--lb (34 N--m) 20 ft--lb (27 N--m) 10 6 11 5 25 ft--lb (34 N--m) 20 ft--lb (27 N--m) 1 50 ft--lb (67 N--m) 20 ft--lb (27 N--m) 4 2 RH DECK PTO MANIFOLD SHOWN 3 Figure 88 1. 2. 3. 4. PTO manifold body NWD SAE #4 plug with O--ring Orifice (0.063) (port OR) #8 zero leak plug with O--ring 5. 6. 7. 8. Relief valve (port RV2) Solenoid valve (port S) Solenoid coil Nut 9. Relief valve (port RV1) 10.
PTO Manifold Service (Fig. 88) Hydraulic System 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.
Lift/Lower Circuit 1 2 RIGHT FRONT 4 5 3 7 6 8 7 Figure 89 1. Counterbalance manifold 2. RH lift cylinder 3. LH lift cylinder 4. Fan drive manifold 5. Lift control valve 6. Front deck flow control valve 7. Front lift cylinder 8. Oil filter Figure 89 illustrates the components that are used in the Groundsmaster 4000--D cutting deck lift and lower circuits. Procedures for removal, installation and disassembly/assembly of these components are provided on the following pages of this section.
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Lift/Lower Control Valve 28 RIGHT 29 24 22 25 19 FRONT 17 16 18 18 17 14 20 27 26 17 23 1 2 13 21 22 12 11 10 9 8 7 6 5 15 4 3 Figure 90 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Control valve assembly Valve bracket Isolator (6 used) Cap screw Lock nut (2 used) Pivot bracket LH lever assembly Lever link (3 used) Center lever assembly Cotter pin (6 used) Hydraulic System 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Removal (Fig. 90) Installation (Fig. 90) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 1. If fittings were removed from control valve, lubricate and place new O--rings onto fittings. Install fittings into port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 2.
Lift/Lower Control Valve Service 6 32 20 34 13 14 15 31 10 7 11 23 27 21 22 24 17 18 35 3 36 28 5 33 4 25 1 11 8 16 19 2 12 26 20 to 25 ft--lb (27 to 33 N--m) 9 30 29 Figure 91 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Poppet Spacer Wiper Seat O--ring Plug Ring Bushing Cap Relief valve poppet O--ring Retaining ring Hydraulic System 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Disassembly (Fig. 91) Assembly (Fig. 91) 1. Plug all ports and thoroughly clean outside of control valve. 1. Thoroughly clean and dry all parts. Apply a light coating of clean hydraulic oil to parts prior to assembly. 2. Remove caps (item 9). Do not remove retaining rings (item 12) from spools unless spring (item 19) is broken. NOTE: All O--rings, back--up washers, wiper seals and nylon poppets should be replaced with new items. NOTE: Spools and spool bores are matched sets.
Side Deck Lift Cylinder 12 11 9 10 8 6 7 4 3 RIGHT 5 2 1 FRONT Figure 92 1. 2. 3. 4. Lift arm assembly (LH shown) Shoulder screw Pin assembly Lift cylinder Hydraulic System 5. 6. 7. 8. Flange locking nut 90o hydraulic fitting (2 used) O--ring O--ring Page 4 -- 132 9. 10. 11. 12.
Removal (Fig. 92) Installation (Fig. 92) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 1. If fittings were removed from lift cylinder, lubricate and place new O--rings onto fittings. Install fittings into port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 3.
Front Deck Lift Cylinder 9 11 1 3 2 12 RIGHT 10 9 11 FRONT 5 1 4 6 8 6 7 Figure 93 1. 2. 3. 4. Lift cylinder Upper lift pin Cotter pin Pin assembly Hydraulic System 5. 6. 7. 8. Cap screw Flat washer Lock nut Lift arm assembly (LH shown) Page 4 -- 134 9. 10. 11. 12.
Removal (Fig. 93) Installation (Fig. 93) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 1. If fittings were removed from lift cylinder, lubricate and place new O--rings onto fittings. Install fittings into port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 3.
Lift Cylinder Service 100 to 120 ft--lb (136 to 162 N--m) 1 13 12 11 10 9 16 15 SIDE DECK LIFT CYLINDER 7 6 2 5 8 3 13 14 4 Figure 94 1. 2. 3. 4. 5. 6. Barrel with clevis Retaining ring Shaft with clevis Dust seal Rod seal O--ring 7. 8. 9. 10. 11. Back--up ring Head O--ring Wear ring Piston 12. 13. 14. 15. 16. Lock nut Grease fitting Bushing O--ring Seal 30 to 35 ft--lb (41 to 47 N--m) 12 11 13 8 4 3 1 2 10 9 FRONT DECK LIFT CYLINDER 5 6 7 Figure 95 1. 2. 3. 4. 5.
Disassembly (Figs. 94 and 95) Assembly (Figs. 94 and 95) 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 1. Make sure all cylinder components are clean before assembly. 2. Mount lift cylinder securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft jaws is recommended. 3. Loosen head from barrel: A.
Counterbalance Manifold 12 16 15 10 13 9 5 14 1 RIGHT 2 FRONT 10 11 10 8 9 3 4 7 6 5 Figure 96 1. 2. 3. 4. 5. 6. Counterbalance manifold Valve plate Flat washer (2 used) Cap screw (2 used) Isolator (4 used) Flat washer (2 used) 7. 8. 9. 10. 11. Lock nut (2 used) Hydraulic fitting (2 used) O--ring O--ring 90o hydraulic fitting (4 used) 12. 13. 14. 15. 16.
Removal (Fig. 96) Installation (Fig. 96) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 1. If fittings were removed from manifold, lubricate and place new O--rings onto fittings. Install fittings into manifold openings using marks made during the removal process to properly orientate fittings.
Counterbalance Manifold Service 35 to 40 ft--lb (47 to 54 N--m) 2 35 to 40 ft--lb (47 to 54 N--m) 4 35 to 40 ft--lb (47 to 54 N--m) 2 3 5 3 1 UP FRONT Figure 97 1. Manifold body 2. Pilot valve 3. Seal kit 4. Relief valve (counterbalance) NOTE: The ports on the manifold are marked for easy identification of components.
Chapter 5 Electrical System Table of Contents Groundsmaster 4000--D Audio Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow and Power Relays . . . . . . . . . . . . . . . . . . . . . Start, Engine Shutdown, Seat, PTO, PTO Over-temp, Alarm and Over Temperature Relays . . Hydraulic Valve Solenoids . . . . . . . . . . . . . . . . . . . TEC--5002 Controller . . . . . . . . . . . . . . . . . . . . . . . Fuel Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 harness drawings for the Groundsmaster 4000--D are located in Chapter 9 -- Foldout Drawings.
Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. 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 meter in the voltage mode will make sure that excess current is not allowed through the meter.
Battery Terminal Protector 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. Obtain this tool locally.
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Chapter 9 -Foldout Drawings). CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Also, disconnect the battery cables unless the test requires battery voltage. If the machine has any interlock switches by--passed, reconnect the switches for safety and efficient troubleshooting.
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). Starter cranks, but should not, when the traction pedal is depressed. The traction neutral switch is out of adjustment. The traction neutral switch or circuit wiring is faulty.
Cutting Deck Operating Problems The cutting decks remain engaged, but should not, with no operator in the seat. The seat switch or circuit wiring is faulty. Cutting decks run, but should not, when raised. Decks shut off with PTO switch. The deck position switch or circuit wiring is faulty. Cutting decks run, but should not, when raised. Decks do not shut off with the PTO switch. The deck position switch or circuit wiring and PTO switch or circuit wiring are faulty.
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Set multimeter to the DC volts setting. The battery should be at a temperature of 60o to 100oF (16o to 38oC). The ignition key should be off and all accessories turned off. Connect the positive (+) meter lead to the positive battery post and the negative (--) meter lead to the negative battery post. Voltage Measured Battery Charge Level 12.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before checking continuity on the switch). NOTE: For engine component testing information, see the Kubota Workshop Manual, Diesel Engine, V2403--M--T--E3B Series at the end of Chapter 3 -- Kubota Diesel Engine.
Fuses The fuse blocks are located under the operator control panel. 10A 15A OPT B 10A 5A 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. 10A A 10A Identification, Function and Wiring Fuse F1 (5 amp) (fuseblock location A1): Supplies power to the seat switch and seat relay. Fuse F4 (10 amp) (fuseblock location A4): Supplies power to the starter solenoid. 1 7.
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 pressure drops below 7 PSI (0.5 kg/cm2). 3 2 If oil pressure light does not come on when the ignition switch is in the ON position with the engine not running: 1. Locate oil pressure switch on engine and disconnect green harness wire from switch. 4 1 2.
PTO Switch The PTO switch is used to engage or disengage the cutting 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 below. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each position. Verify continuity between switch terminals.
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 circuitry of the switches is shown in the chart below. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each position.
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 position, cooling fan operation is controlled by the TEC--5002 controller.
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 traction system or PTO switch is engaged when the operator raises out of the seat, the engine will stop. Testing of the switch can be done without seat removal by disconnecting the seat wire from the machine wiring harness (Fig. 23). 2 Testing 1 1. Make sure the engine is off. 2.
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. When the parking brake is applied, the parking brake pawl is positioned away from the switch plunger so the switch is in its normal, open state. Testing 1. Make sure the engine is off. Locate parking brake switch for testing. 2.
Hour Meter The hour meter is located on the control console next to the operator seat. 1 Testing 1. Disconnect wire harness connector from hour meter. 3 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 (6) minutes. 4. Disconnect voltage source from the hour meter. Reconnect harness connector to hour meter. 4 2 Figure 25 1. Top view 2. Bottom view 3. Positive (+) terminal 4.
Glow and Power Relays The Groundsmaster 4000--D uses two (2) identical relays 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 control panel under the console housing. The glow relay supplies electrical power for the engine glow plugs when energized. The start relay is energized by the glow plug controller.
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. 1 Testing 1. Make sure that ignition switch is OFF. 2 2. Remove console cover and locate relay. Disconnect the machine wire harness connector from the relay. Remove relay from machine if necessary.
Hydraulic Valve Solenoids 5 RIGHT 1 6 FRONT 2 4 3 Figure 30 1. 4WD manifold 2. LH PTO manifold 3. Traction manifold 4. Front PTO manifold There are several hydraulic valve solenoids on the Groundsmaster 4000--D (Fig. 30). Testing of these solenoids can be done with the solenoid on the hydraulic valve. Testing 5. Fan drive manifold 6. RH PTO manifold 3. Install new solenoid if necessary. Torque solenoid nut to 5 ft--lb (6.7 N--m).
TEC--5002 Controller Groundsmaster 4000--D machines use a Toro Electronic Controller (TEC) to control the operation of the hydraulic cooling fan. The controller is attached to the operator platform under the console housing cover (Fig. 32). 1 Logic power is provided to the controller as long as the battery cables are connected to the battery. A 2 amp fuse in a fuse holder near the battery provides circuit protection for this logic power to the controller.
Fuel Sender The fuel sender is located on top of the fuel tank. Testing 1. Remove white wire and black ground wire from the sender. 2. Remove screws and lock washers that secure the sender to the fuel tank. FULL POSITION EMPTY POSITION 3. Remove sender and gasket from the fuel tank. Clean all fuel from the sender. NOTE: Before taking small resistance readings with a digital multimeter, short meter test leads together. The meter will display a small resistance value.
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 before connecting it to the electrical circuit to avoid electrical shock and prevent damaging the gauge. VARIABLE RESISTANCE 14 VDC + 0.01 VDC 1. Connect fuel gauge to the variable resistance and DC voltage source (Fig. 34).
Fuel Pump The fuel pump is attached to the frame above the fuel water separator (Fig. 36). 3 2 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. 3. Disconnect fuel hose (pump discharge) from the fuel water separator. 4. Make sure fuel hoses attached to the fuel pump are free of obstructions. 5.
Glow Controller The glow controller is located under the console cover (Fig. 37). 1 NOTE: Refer to electrical schematic and circuit drawings in Chapter 9 -- Foldout Drawings when troubleshooting the glow controller. 2 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. 2.
Temperature Sender The temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 39). The resistance of the temperature sender reduces as the engine coolant temperature increases. There is a gray harness wire attached to the terminal of the switch. 1 Testing 1. Lower coolant level in the engine and remove the temperature sender from water flange. 2 2. Suspend sender in a container of oil with a thermometer and slowly heat the oil (Fig. 40).
Dual Temperature Switch The dual temperature switch is attached to the engine near the alternator on the water flange attached to the engine cylinder head (Fig. 41). Two (2) electrical harness wires (a blue wire and a yellow wire) are attached to the switch. The terminal on the switch is used to activate the engine over temperature warning (Fig. 42). The warning illuminates the overtemp warning light and also causes the PTO to disengage. The wire harness blue wire attaches to the switch terminal. B.
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 before connecting variable resistance to the electrical circuit to avoid electrical shock and to prevent damaging the gauge. VARIABLE RESISTANCE 14 VDC + 0.01 VDC 1. Connect temperature gauge to the variable resistance and DC voltage source (Fig. 44).
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 across the two switch terminals.
Diode Circuit Board The circuit board contains four diodes (Fig. 48) and is located under the console housing. The diodes are used for circuit protection from inductive voltage spikes that occur when a hydraulic valve solenoid is de--energized. Diode D1 is in the left cutting deck circuit, D2 is in the Transport/Mow circuit, D3 is in the front cutting deck circuit and D4 is in the right cutting deck circuit.
Fusible Link Harness The Groundsmaster 4000--D uses five (5) fusible links for circuit protection. Three (3) of these fusible links are located in a harness that connects the starter B+ terminal to the wire harness (Fig. 49). An additional fusible link is used that connects the starter B+ terminal to the alternator B+ terminal (Fig. 50). The remaining fusible link is included in the wire harness and connects the starter terminal to the engine run solenoid pull coil.
Cutting Deck Position Switch The cutting deck position switches on the Groundsmaster 4000--D are located on the traction unit frame (Fig. 51 and 52). The position switch is a normally open, powered proximity switch that incorporates an internal reed switch and relay (see schematic in Figure 53). The sensing plate is located on the cutting deck lift arm. The switches for front and side decks are the same although their operation depends on deck location.
Engine Coolant and Hydraulic Oil Temperature Senders The Groundsmaster 4000--D uses two (2) temperature senders as inputs for the TEC--5002 to identify if either the engine coolant or hydraulic oil temperature has reached an excessive level. These senders are identical. The coolant temperature sender threads into the radiator (Fig. 54). The hydraulic oil temperature sender is attached to the hydraulic hydraulic tube on the left side of the machine (Fig. 55). 6.
Service and Repairs NOTE: For engine component repair information, see the Kubota Workshop Manual, Diesel Engine, V2403--M--T--E3B Series at the end of Chapter 3 -- Kubota Diesel Engine. Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery and charge it fully (see Battery Service in this section). 2. Either store battery on a shelf or on the machine. 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5.
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. 2 CAUTION When working with batteries, use extreme caution to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries. 1 3 Electrolyte Specific Gravity Fully charged: 1.
A. Measure the specific gravity of each cell with a hydrometer. Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm-up the hydrometer. At the same time take the temperature of the cell. A. Check the voltage across the battery terminals prior to testing the battery. If the voltage is less than 12.4 VDC, charge the battery before performing a load test. B. If the battery has been charged, apply a 150 amp load for 15 seconds to remove the surface charge.
Battery Charging CAUTION Follow the manufacturer’s instructions when using a battery charger. NOTE: Using specific gravity of the battery cells is the most accurate method of determining battery condition. 1. Determine the battery charge level from either its specific gravity or open circuit voltage. Battery Charge Level Specific Gravity Open Circuit Voltage 100% 1.265 12.68 75% 1.225 12.45 50% 1.190 12.24 25% 1.155 12.06 0% 1.120 11.89 2.
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Chapter 6 Axles, Planetaries and Brakes Table of Contents Axles, Planetaries and Brakes SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Brake Inspection and Repair . . . . . . . . . . . . . . . . . .
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 System gear lube capacity (each wheel) SAE 85W--140 wt. gear lube 16 fl. oz. (0.47 liters) Rear axle lubricant System gear lube capacity SAE 85W--140 wt. gear lube 80 fl. oz. (2.37 liters) Rear axle gear box lubricant System gear lube capacity SAE 85W--140 wt. gear lube 16 fl. oz. (0.
General Information Operator’s Manual Axles, Planetaries and Brakes 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.
Service and Repairs Brake Assembly 16 17 85 to 100 ft--lb (115 to 135 N--m) 2 3 2 5 15 1 18 4 6 14 7 13 5 8 12 RIGHT FRONT 75 to 85 ft--lb (101 to 115 N--m) 2 3 2 11 1 75 to 85 ft--lb (101 to 115 N--m) 6 9 10 18 Figure 1 1. 2. 3. 4. 5. 6. Planetary assembly Retaining ring Splined brake shaft Brake assembly (RH) O--ring Hydraulic wheel motor 7. 8. 9. 10. 11. 12.
3. Chock rear wheels and jack up front of machine (see Jacking Instructions in Chapter 1 -- Safety). Support machine with jack stands. 4. Remove front wheel assembly. 5. Remove hydraulic wheel motor (see Front Wheel Motors in the Service and Repairs section of Chapter 4 -- Hydraulic System). 6. Disconnect brake cable from pull rod on brake assembly. 8. Make sure drain plug is installed in bottom of brake assembly (Fig. 3). Fill planetary wheel drive/brake assembly with SAE 85W--140 gear lube.
Brake Inspection and Repair 3 2 1 4 5 6 7 8 9 15 14 10 13 12 11 Figure 5 1. 2. 3. 4. 5. Brake housing (LH shown) Seal Pull rod Clevis pin (2 used) Link 6. 7. 8. 9. 10. Hitch pin (2 used) Stationary disc (4 used) Rotating disc (3 used) Retaining ring Gasket 11. 12. 13. 14. 15. Rotating actuator Extension spring (3 used) Ball (3 used) Plug O--ring Brake Inspection and Repair (Fig. 5) 6. Remove seal (item 2) from brake housing. 1.
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Planetary Wheel Drive Assembly 13 14 85 to 100 ft--lb (115 to 135 N--m) 2 3 2 5 12 1 11 4 75 to 85 ft--lb (101 to 115 N--m) 6 7 5 8 2 3 2 RIGHT 1 FRONT 75 to 85 ft--lb (101 to 115 N--m) 6 9 10 11 Figure 6 1. 2. 3. 4. 5. Planetary assembly Retaining ring Splined brake shaft Brake assembly (RH) O--ring Axles, Planetaries and Brakes 6. 7. 8. 9. 10.
NOTE: The planetary wheel drive assembly can be serviced with the planetary installed to machine (see Planetary Wheel Drive Service in this section). Use the following procedure to remove and install planetary wheel drive assembly from machine. Removal (Fig. 6) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch. 2. Drain oil from planetary wheel drive/brake assembly. CAUTION When removing front wheel, use correct jacks and supports.
Planetary Wheel Drive Service 2 24 3 9 ft--lb (12 N--m) 19 20 6 7 1 8 21 9 4 10 11 5 23 18 17 12 16 15 21 14 22 13 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. Spindle Boot seal Inner bearing cone Inner bearing cup Wheel stud (8 used) Housing Outer bearing cup Outer bearing cone Axles, Planetaries and Brakes 9. 10. 11. 12. 13. 14. 15. 16. Thrust washer Retaining ring (external) Ring gear Retaining ring (internal) Plug (2 used) End cap Thrust plug Thrust washer Page 6 -- 10 17. 18. 19. 20. 21. 22.
NOTE: The planetary wheel drive assembly can be serviced 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 section. 3 1 2 24 4 7 19 20 8 12 21 11 Disassembly (Figs. 8 and 9) 14 1. If planetary wheel drive assembly is installed on machine: 15 17 A. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch. 16 B.
F. Lightly oil bearing journals on spindle shaft. Slide housing onto spindle (item 1) taking care to not damage seal or spindle. Make sure that bearing in housing fully seats against spindle shaft shoulder. 3. Install carrier assembly (item 18) making sure that carrier gear teeth align with ring gear and spline on spindle shaft. G. Install outer bearing cone (item 8) onto spindle. 4. Install drive shaft (item 17) making sure that drive shaft spline aligns with carrier gears.
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Rear Axle Assembly 18 17 19 2 4 16 RIGHT 4 FRONT 15 7 2 15 14 13 12 11 2 3 4 1 5 6 10 9 See text for tightening procedure 8 Figure 10 1. 2. 3. 4. 5. 6. 7. Frame assembly Cap screw (10 used) Lock washer (6 used) Flat washer (16 used) Support frame Thrust washer (thick) Grease fitting 8. 9. 10. 11. 12. 13. Rear axle assembly Thrust washer (thin) Washer head screw Pivot pin Rear axle mount Washer Removal (Fig. 10) 1.
8. Remove cap screw and flange nut that secures front corner of 4WD hydraulic manifold to rear axle mount. 1 2 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. Use a ball joint fork and remove the tie rod ends from the axle steering arms. 3 10.Support rear axle to prevent it from falling. Remove six (6) cap screws, flat washers and flange nuts that secure rear axle mount to equipment frame.
8. Install steering cylinder to axle assembly (see Steering Cylinder Installation in the Service and Repairs section of Chapter 4 -- Hydraulic System). 9. Install hydraulic motor to axle assembly (see Rear Axle Motor Installation in the Service and Repairs section of Chapter 4 -- Hydraulic System). 2 1 WARNING Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury. Figure 14 10.Install wheels to axle. 11. Lower machine to ground.
Bevel Gear Case and Axle Case The following procedures assume the rear axle assembly has been removed from the machine (see Rear Axle Assembly Removal in this section). 35 to 41 ft--lb (47 to 56 N--m) Bevel Gear Case and Axle Case Removal 1 1. Remove the mounting screws, nuts and lock washers. Remove the bevel gear case/axle case assembly and O-ring from the axle support (Fig. 15). 4 2. Mark both right and left bevel gear case/axle case assemblies.
5. Remove the knuckle pin mounting bolts and the knuckle pin. Remove the gasket and any remaining gasket material from both mating surfaces (Fig. 18). 6. While holding the bevel gear case, tap the upper end of the bevel gear shaft out of the upper bearing and upper bevel gear. 2 1 17 to 20 ft--lb (23 to 27 N--m) 3 4 Threadlocking Compound 7. Pull the bevel gear case from the axle case and remove the upper bevel gear and collar from the gear case. 5 8.
Bevel Gear Case and Axle Case Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 20). 3 2 1 Figure 20 1. Axle case 2. Bevel gear case 2. Install the lower bevel gear and bevel gear shaft in the axle case cover. Coat a new O-ring with grease and install the axle case cover (Fig. 21). Tighten cover screws from 17 to 20 ft-lb (23 to 27 N--m). 7 8 3. Slide the bevel gear case over the bevel gear shaft and install the bevel gear and collar.
5. Determine necessary quantity of support shims. 4 A. Lubricate the axle case support bushing with a thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during disassembly between axle case support and axle case. Install mounting screws into axle case. Slowly tighten screws while frequently checking for clearance (vertical endplay) between axle case support and knuckle pin.
9. Remove the bevel gear case/axle case assembly from the axle support. Coat a new O-ring with grease and temporarily install the axle cover assembly. Position a dial indicator at the tooths center. Prevent the axle from turning and measure the lower bevel gear to axle gear backlash (Fig. 24). LOWER BEVEL GEAR BACKLASH: 0.004 to 0.016 in. (0.10 to 0.40 mm) 11. Tighten axle cover screws from 17 to 20 ft-lb (23 to 27 N--m). 12.
Differential Shafts The following procedures assume the rear axle assembly has been removed from the machine (see Rear Axle Assembly Removal in this section). 35 to 41 ft--lb (47 to 56 N--m) 1 Differential Shaft Removal 6 5 IMPORTANT: Do not interchange right and left differential shaft assemblies. 4 1. Remove the mounting screws, nuts and lock washers. Remove the bevel gear case/axle case assembly and O-ring from the axle support (Fig. 25). 3 4. Drive the differential shaft out of the bearings.
Axle Shafts The following procedures assume the rear axle assembly has been removed from the machine (see Rear Axle Assembly Removal in this section). 17 to 20 ft--lb (23 to 27 N--m) 1 4 Axle Shaft Removal 3 1. Remove the axle cover mounting bolts. Remove the axle cover from the axle case as an assembly (Fig. 27). 2. Use a bearing puller to remove the bearing and bevel gear as shown (Fig. 28). 3. Remove the shims, spacer and retaining ring. Drive the axle out of the bearing and cover.
Input Shaft/Pinion Gear 1 35 to 41 ft--lb (47 to 56 N--m) 9 7 8 6 5 3 2 18 17 4 18 15 10 9 16 14 10 13 35 to 41 ft--lb (47 to 56 N--m) 11 12 Figure 30 1. 2. 3. 4. 5. 6. Nut (2 used) Lock washer (2 used) Stud (2 used) Lock nut Stake washer Oil seal 7. 8. 9. 10. 11. 12. O-ring Seal collar Bearing O-ring Input shaft/Pinion gear Bearing case The following procedures assume the rear axle assembly has been removed from the machine (see Rear Axle Assembly Removal in this section).
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 surface of the bearing case. Subtract the “Design Cone Center Distance” from this distance to determine initial shim thickness (Fig. 32). 0.040 in. (1.0 mm) 2 DESIGN CONE CENTER DISTANCE (distance from mating surface of axle support to end face of pinion gear): 1.870 + 0.002 in. (47.5 + 0.05 mm) 1 NOTE: Bearing case shims are available in 0.004 in. (0.
Differential Gear The following procedures assume the rear axle assembly has been removed from the machine (see Rear Axle Assembly Removal in this section). 35 to 41 ft--lb (47 to 56 N--m) 5 2 6 Differential Gear Removal 1 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual). IMPORTANT: Do not interchange right and left differential shafts assemblies. 7 4 3 2. Mark and pull the differential shaft assemblies from the axle support. 3.
Differential Gear Inspection 1. Measure the differential side gear O.D. and the differential 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) 1 SIDE GEAR O.D. (Factory Spec.): 1.335 to 1.337 in. (33.91 to 33.95 mm) DIFFERENTIAL CASE I.D. (Factory Spec.): 1.339 to 1.341 in. (34.00 to 34.06 mm) 2 2. Measure the differential pinion shaft O.D. and the pinion gear I.D.
Differential Gear Installation 3 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 1 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. 3. Install the side gear shims and side gears in their original location in the differential case. 4.
Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using the gear contact pattern method as described in the following procedure. PROFILE TOP LAND GEAR TOOTH DEFINITIONS (Fig. 41): Toe -- the portion of the tooth surface at the end towards the center. TOE HEEL Heel -- the portion of the gear tooth at the outer end. LENGTHWISE BEARING ARC Top Land -- top surface of tooth. 1.
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. Install thicker or additional bearing case shim(s) to move pinion shaft toward ring gear. Figure 44 B. Install thinner or remove differential bearing shim(s) to move ring gear backward. C.
Chapter 7 Chassis Table of Contents GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 1 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 2 Steering Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Front Deck Lift Arm . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Side Deck Lift Arm . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Side Deck Rear Arm Assembly . . . . . . . . . . .
Service and Repairs Steering Tower 39 25 1 3 24 2 23 26 27 22 33 34 35 36 37 4 5 6 7 21 40 8 28 41 9 10 29 30 31 11 12 13 14 32 16 to 20 ft--lb (22 to 27 N--m) 41 15 16 17 18 19 38 20 21 RIGHT FRONT Figure 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Hex nut Flat washer Steering wheel Foam collar Steering seal External snap ring (2 used) Knob Steering tower cover Steering shaft Compression spring Cap Rod assembly Extension spring Tilt rod Chassis 15. 16. 17. 18. 19. 20. 21. 22.
Disassembly (Fig. 1) Assembly (Fig. 1) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 1. Assemble steering tower using Figure 1 as a guide. B. If steering wheel was removed, torque hex nut that secures steering wheel from 16 to 20 ft--lb (22 to 27 N--m). Chassis 2. Disassemble steering tower as needed using Figure 1 as a guide. A.
Front Deck Lift Arm 38 16 15 37 RIGHT 33 FRONT 60 to 70 ft--lb (81 to 94 N--m) 34 35 36 32 31 30 90 to 100 ft--lb (123 to 135 N--m) 12 150 to 175 ft--lb (203 to 237 N--m) 39 28 29 27 26 25 19 18 1 20 21 22 23 2 13 17 14 11 24 8 7 6 5 10 9 4 3 28 Figure 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Removal (Fig. 2) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove front cutting deck (see Front Cutting Deck Removal in Chapter 8 -- Cutting Decks). CAUTION 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” to 2.390” (56.1 to 60.7 mm) (Fig. 4). Make sure that ball joint is horizontal and that stud is centered in ball joint.
Side Deck Lift Arm 16 17 19 18 16 17 12 11 14 13 20 10 23 17 21 27 15 4 24 25 28 29 5 FRONT 22 34 36 36 35 7 8 9 10 35 Anti--seize Lubricant 77 to 96 ft--lb (105 to 130 N--m) 34 3 6 5 2 RIGHT Loctite #242 32 32 31 26 1 37 30 33 38 37 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Lift arm (LH shown) Shoulder screw Lift cylinder pin Lift cylinder Thrust washer Flange nut Pivot hub Lift arm pivot shaft Thrust washer Cap screw Spring pin Cylinder pin Rivet (2 per bumper) 14.
Removal (Fig. 5) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove side deck from lift arm (see Side Cutting Deck Removal in Chapter 8 -- Cutting Decks). 3. Remove side deck rear arm assembly from pivot hub (see Side Deck Rear Arm Assembly Removal in this section). 4. Remove lift cylinder pin (item 3) that secures lift cylinder to lift arm. 5.
Side Deck Rear Arm Assembly 16 27 34 26 24 25 22 17 Thread locking Compound 39 29 28 44 43 33 40 41 19 35 36 31 30 18 34 35 32 35 270 to 330 in--lb (31 to 37 N--m) 15 21 42 38 23 20 14 13 FRONT 13 12 5 RIGHT 37 11 4 3 6 9 2 8 45 10 1 7 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Rear Arm Removal (Fig. 8) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove hair pin and clevis pin that connects damper link to cutting deck (Fig. 9). 10.Thoroughly pack spring with grease. Install spring shaft assembly into housing and secure plate with four (4) cap screws and lock nuts. 11. Thread rod end (item 8) with jam nut (item 9) into end of spring shaft. Do not tighten jam nut at this time. 3.
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. Secure pivot shaft with lock washer and lock nut. 3. Connect damper link to cutting deck with clevis pin and hair pin (Fig. 9). 4. Position spacers on both sides of rod end of rear arm assembly. Secure rod end of rear arm assembly to deck mount with cap screw and lock nut. Figure 10 5. Lubricate rear arm grease fittings. 6.
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Lift Arm Joint Yoke 150 to 180 ft--lb (203 to 244 N--m) 14 13 12 17 11 11 RIGHT FRONT 9 10 1 20 18 18 5 19 6 8 3 16 2 4 15 7 Figure 11 1. 2. 3. 4. 5. 6. 7. Side cutting deck (LH shown) Deck mount (LH shown) Retaining ring (2 used per deck) Lock nut Plate Rubber plate Cap screw 8. 9. 10. 11. 12. 13. 14. Flat washer (8 used per mount) Joint yoke Spacer Thrust washer Hardened washer Cotter pin Slotted hex nut Removal (Fig. 11) 1.
IMPORTANT: Support yoke when removing cross and bearings to prevent yoke damage. 5. Install retaining rings to yoke and deck mount to secure bearings in place. 2. Use a press to remove yoke from deck mount: 6. Make sure that assembled joint yoke moves without binding. Slight binding can usually be eliminated by lightly rapping the yoke lugs with a soft faced hammer. If binding continues, disassemble joint yoke and deck mount to identify and eliminate source of binding. A.
Operator Seat 1 7 9 17 8 10 14 2 5 11 6 3 13 15 2 18 12 8 16 21 22 20 23 24 4 25 26 RIGHT 19 FRONT Figure 12 1. 2. 3. 4. 5. 6. 7. 8. 9. Seat assembly Flat washer (5 used) Seat belt Cap screw (4 used) Seat platform Flange nut (4 used) Seat belt buckle Cap screw (2 used) R--clamp (2 used) Chassis 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 12) 1 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2 2. Remove seat from seat suspension: A. Disconnect seat electrical connectors from machine wire harness (Fig. 13). 3 B. Remove four (4) Torx head screws that secure seat to seat suspension (Fig. 14). Note that the screw near the seat adjustment handle is longer than the other three screws. C. Lift seat from seat suspension and remove from machine.
Operator Seat Service 7 6 21 1 2 13 5 28 12 21 22 26 25 30 29 16 18 19 20 11 4 14 17 24 3 23 9 8 27 10 15 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Backrest cushion Seat cushion Armrest cover LH armrest Bushing (2 used) Backrest Plug (2 used) Cable tie (3 used) LH adjustment rail Bumper (2 used) Chassis 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Washer Cap screw (2 used) Seat Nut Spring (2 used) Magnet Seat switch Rivet (4 used) Mounting plate Return spring Page 7 -- 16 21. 22. 23.
Assembly (Fig. 15) 1. Disassemble operator seat as necessary using Figure 15 as a guide. 1. Assemble operator seat using Figure 15 as a guide. Chassis Disassembly (Fig.
Operator Seat Suspension RIGHT 16 17 FRONT 24 22 25 23 5 18 2 19 21 33 1 20 3 39 14 12 7 35 28 30 6 15 38 27 13 31 4 36 8 29 9 10 26 33 11 34 32 37 Figure 16 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Cover Cover Level control Air control valve Shock absorber Air spring Air tube assembly Wire harness Compressor Bellows Stop Bumper set (2 used) Roller (4 used) Chassis 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
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) requires removal, the seat suspension base will have to be removed from the seat platform. 1 2 Disassembly (Fig. 16) 1. Remove operator seat from seat suspension (see Operator Seat Removal in this section). 3 2.
Hood 13 2 41 12 1 40 24 43 39 38 23 4 37 36 5 6 29 25 28 42 11 3 7 10 14 33 27 32 31 9 25 30 35 15 46 45 17 47 16 18 19 26 RIGHT 8 20 25 FRONT 22 23 44 15 48 34 21 Figure 18 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Removal 4 4 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 3 2. Remove hood using Figure 18 as a guide. 1 Installation 3 2 1. Install hood using Figure 18 as a guide. 2. Align hood to machine to allow correct operation of hood latch and dust seals: Figure 19 1. Shim location (LH) 2. Shim location (RH) 3. Hood pivot 4. Screen pivot A.
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Chapter 8 Cutting Decks Table of Contents Cutting Decks SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Castor Wheel Tire Pressure . . . . . . . . . . . . . . . . . . 3 Blade Stopping Time . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications MOUNTING: Cutting decks are supported by lift arms controlled with individual hydraulic lift levers. CONSTRUCTION: Deck chamber is welded 12 gauge steel construction reinforced with channels and plates. HEIGHT--OF--CUT RANGE: 1” to 5” (25.4 mm to 127 mm) in 1/2” (12.7 mm) increments. Front deck height-of--cut adjustment is achieved by changing spacers on castor wheels and adjusting length of deck support chains.
General Information CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine 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. Refer to that publication for additional information when servicing and adjusting the cutting decks on your Groundsmaster.
Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, uneven ground conditions, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the machine. Remember that the “effective” or actual height--of--cut depends on cutting deck weight, tire pressures, hydraulic counterbalance settings and turf conditions.
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Service and Repairs CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine and remove key from ignition switch first. Front Cutting Deck 38 16 15 37 RIGHT 33 FRONT 60 to 70 ft--lb (81 to 94 N--m) 34 35 36 32 31 30 90 to 100 ft--lb (123 to 135 N--m) 12 150 to 175 ft--lb (203 to 237 N--m) 39 28 29 27 26 25 19 18 1 20 21 22 23 2 13 17 14 11 24 8 7 6 5 10 9 4 3 28 Figure 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Removal (Fig. 1) 1. Position machine on a clean, level surface. Lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2 NOTE: Removal of clevis pin from deck and height--of-cut chain is easier if deck is lifted slightly. 1 2. Remove hairpin and clevis pin that secure the height--of--cut chain to the rear of the cutting deck (Fig. 2). 3.
Side Cutting Deck 16 27 34 26 24 25 22 17 Thread locking Compound 39 29 28 44 43 33 40 41 19 35 36 31 30 18 34 35 32 35 270 to 330 in--lb (31 to 37 N--m) 15 21 42 38 23 20 14 13 RIGHT 37 13 12 5 11 4 FRONT 3 6 1 9 2 8 45 10 46 7 48 47 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Removal (Fig. 5) 1. Position machine on a clean, level surface. Lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 7. Lubricate grease fittings on cutting deck and lift arm assembly. 2. Remove hydraulic motor from cutting deck (see Cutting Deck Motor Removal in the Service and Repairs Section of Chapter 4 -- Hydraulic System). 3 IMPORTANT: Do not change the length of the damper link (Fig. 7). 1 1 3.
Idler Assembly 18 17 16 22 15 RIGHT FRONT 19 14 20 5 21 7 20 19 13 8 11 1 23 18 10 24 6 12 9 8 25 7 5 4 2 19 3 22 2 4 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. Front deck Flange nut Flange nut Adjusting screw Idler pulley Driven spindle (double pulley) Flat washer Lock washer Socket head screw 10. 11. 12. 13. 14. 15. 16. 17. Stop bolt Flange nut Cap screw Spacer Shoulder bolt Spring Lock nut Idler arm 18. 19. 20. 21. 22. 23. 24. 25.
Removal (Fig. 8) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove deck covers from top of cutting deck. CAUTION Be careful when removing idler spring. The spring is under heavy load and may cause personal injury. 3. Use spring hook tool to unhook the idler spring (item 15) from the adjusting screw (item 4). 4. Remove drive belt(s) from deck pulleys. 5.
Blade Spindles 6 6 2 3 5 4 5 5 4 4 6 6 1 RIGHT FRONT 6 6 Figure 10 1. 2. Front cutting deck RH cutting deck Cutting Decks 3. 4. LH cutting deck Drive spindle Page 8 -- 12 5. 6.
Removal (Figs. 10 and 11) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove covers from cutting deck to allow access to blade spindle. 3. If drive spindle is to be serviced, remove hydraulic motor from cutting deck (see Cutting Deck Motor Removal in the Service and Repairs Section of Chapter 4 -- Hydraulic Systems). Position motor away from spindle. 3.
Blade Spindle Service 2 1 130 to 150 ft--lb (176 to 203 N--m) 3 130 to 150 ft--lb (176 to 203 N--m) 7 1 8 9 2 6 10 5 11 12 9 8 13 DRIVE SPINDLE 4 Figure 12 1. 2. 3. 4. 5. Lock nut Hardened washer Driven pulley (single shown) Spindle shaft Drive pulley 6. 7. 8. 9. Hydraulic motor mount O--ring Oil seal Bearing cup and cone 10. 11. 12. 13. Spacer set Spindle housing Grease fitting Spindle shaft spacer Disassembly (Fig. 12) Assembly (Fig. 12) 1.
2. Install outer bearing spacer into top of spindle housing. The spacer should fit against the snap ring. 1 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. Make sure that the assembly is correct by supporting the first bearing cup and pressing the second cup against it (Fig 14). 2 1 Figure 13 1. Bearing 2. Spacer ring 3.
Castor Forks and Wheels FRONT CUTTING DECK SIDE CUTTING DECK 34 14 13 12 16 1 11 20 6 7 19 10 9 8 31 5 15 2 10 32 17 21 22 33 7 60 to 80 ft--lb (81 to 108 N--m) 6 5 18 3 4 CASTOR WHEEL 4 28 23 60 to 80 ft--lb (81 to 108 N--m) 24 29 30 23 25 26 27 Figure 16 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Castor arm (front deck) Cap screw (5 used) Castor fork Cap screw Lock nut Castor spacer Thrust washer Flange nut (5 used) Grease fitting Flange bushing Retaining ring Cap washer 13.
Chapter 9 Foldout Drawings Table of Contents Groundsmaster 4000--D Page 9 - 1 Foldout Drawings Foldout Drawings HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL SCHEMATICS Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CIRCUIT DIAGRAMS Glow Plug Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Crank Circuits . . . . . . . . . . . . . . . . . . . . . .
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COUNTERBALANCE MANIFOLD FRONT PTO MANIFOLD M1 P1 RV1 RV2 LC1 S LC2 M2 P2 LH PTO MANIFOLD M1 P1 RV1 TRACTION MANIFOLD RV2 LC1 S LC2 M2 4WD MANIFOLD P2 OR M1 M2 ST L RH PTO MANIFOLD M1 BYPASS VALVE P1 RV1 RV2 LC1 S P1 LC2 M2 T P2 FAN DRIVE MANIFOLD P2 OR FILTER MANIFOLD Groundsmaster 4000--D Hydraulic Schematic Page 9 - 3
CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) FRONT DECK PTO SOLENOID LEFT DECK PTO SOLENOID 2WD SOLENOID RIGHT DECK PTO SOLENOID (UNOCCUPIED) PTO OVERTEMP SHUTDOWN RELAY SOLENOID CONTINUES TO SHEET 2 Groundsmaster 4000--D Electrical Schematic Sheet 1 of 2 All relays and solenoids are shown as de-- energized.
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.
CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (IGNITION SWITCH IN RUN) (OPTIONAL CRUISE CONTROL KIT) FRONT DECK PTO SOLENOID LEFT DECK PTO SOLENOID 2WD SOLENOID RIGHT DECK PTO SOLENOID (UNOCCUPIED) PTO OVERTEMP SHUTDOWN RELAY SOLENOID CONTINUES TO SHEET 2 Groundsmaster 4000--D Glow Plug Circuits Power Current Control Current Indication Current Page 9 - 6
CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (IGNITION SWITCH IN START) (OPTIONAL CRUISE CONTROL KIT) FRONT DECK PTO SOLENOID LEFT DECK PTO SOLENOID 2WD SOLENOID RIGHT DECK PTO SOLENOID (UNOCCUPIED) PTO OVERTEMP SHUTDOWN RELAY SOLENOID CONTINUES TO SHEET 2 Groundsmaster 4000--D Crank Circuits Power Current Control Current Indication Current Page 9 - 7
CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (OPTIONAL CRUISE CONTROL KIT) (IGNITION SWITCH IN RUN) FRONT DECK PTO SOLENOID (DISENGAGED) (NOT IN NEUTRAL) LEFT DECK PTO SOLENOID 2WD SOLENOID RIGHT DECK PTO SOLENOID (OCCUPIED) (IN TRANSPORT) PTO OVERTEMP SHUTDOWN RELAY SOLENOID CONTINUES TO SHEET 2 Groundsmaster 4000--D Run (Transport) Circuits Power Current
WHEN THE PTO SWITCH IS MOVED TO THE ENGAGE POSITION, PTO SWITCH CONTINUES TO SHEET 2 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. DIODES D1-- B, D1-- C AND D1-- D WILL THEN CREATE A LATCHING CIRCUIT TO KEEP THE PTO RELAY ENERGIZED WHEN THE PTO CONTINUES TO SHEET 2 SWITCH IS IN THE ON POSITION.
CONTINUES TO SHEET 2 o o 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 ENERGIZES THE PTO OVERTEMP SHUTDOWN RELAY. THIS ENERGIZED RELAY CONTINUES TO SHEET 2 (OPTIONAL CRUISE CONTROL KIT) CAUSES THE PTO RELAY TO DE-- ENERGIZE AND SHUT OFF ELECTRICAL TO THE DECK PTO SOLENOIDS.
o o 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 CONTINUES TO SHEET 2 SHUTTING OFF THE ENGINE.
(STARTER) (STARTER) (STARTER) Groundsmaster 4000--D Engine Wire Harness Page 9 - 12
RED/BLACK FUSIBLE LINK RED BLACK BLACK RED RED WHITE RED/BLACK RED/BLACK PINK ORANGE BLUE WHITE GRAY GREEN YELLOW BLACK YELLOW BLACK WHITE/BLACK YELLOW BROWN BLUE ORANGE WHITE ORANGE VIOLET/BLACK YELLOW/BLACK GREEN BROWN/WHITE YELLOW/WHITE BLACK RED BLACK BLACK BLACK BLACK GREEN BLACK BLACK YELLOW/BLACK YELLOW/BLACK YELLOW/BLACK BLACK VIOLET/BLACK BLACK VIOLET/BLACK BLACK BLACK ORANGE VIOLET/BLACK ORANGE Groundsmaster 4000--D Engine Wire Harness Page 9 - 13
FLOW DIVIDER SOLENOID Groundsmaster 4000--D Front Wire Harness Page 9 - 14
PINK BLACK WHITE FLOW DIVIDER SOLENOID PINK BROWN YELLOW PINK PINK GRAY PINK PINK PINK GREEN/BLACK TAN TAN BLACK BLACK GRAY TAN GREEN WHITE BLUE ORANGE VIOLET/BLACK BLACK BLACK GREEN/BLACK GREEN/BLACK BLACK GREEN/BLACK BLACK YELLOW/BLACK ORANGE ORANGE BLUE ORANGE BLACK TAN Groundsmaster 4000--D Front Wire Harness Page 9 - 15
(ENGINE SHUTDOWN DELAY) COOLING FAN SWITCH FLOW DIVIDER SWITCH TRANSPORT/4WD SWITCH Groundsmaster 4000--D Console Wire Harness Page 9 - 16 (PTO SHUTDOWN DELAY)
TRANSPORT/4WD YELLOW/BLACK VIOLET WHITE TO SHEET 2 YELLOW TO SHEET 2 YELLOW TAN BLACK BLUE BLACK WHITE YELLOW/BLACK YELLOW YELLOW YELLOW BLUE TAN RED/BLACK YELLOW YELLOW YELLOW YELLOW GRAY YELLOW YELLOW ORANGE BLACK PINK PINK BLACK PINK PINK PINK BLACK PINK WHITE YELLOW GREEN BLUE PT0 SHUTDOWN ENGINE SHUTDOWN DELAY DELAY WHITE ORANGE FLOW DIVIDER SWITCH YELLOW YELLOW YELLOW TAN TAN GREEN TAN GRAY BLACK RED BLACK GRAY WHITE GRAY TAN BLACK YELLOW TAN TO SHEET 2 BLAC
Groundsmaster 4000--D Console Wire Harness Sheet 2 of 2 Page 9 - 18 YELLOW/WHITE WHITE/BLACK WHITE/GREEN TAN/BLACK BLACK ORANGE/BLACK TO SHEET 1 TO SHEET 1 TO SHEET 1 TO SHEET 1 RED BROWN/WHITE BLUE/BLACK BLACK YELLOW BLACK BLACK GREEN/BLACK VIOLET YELLOW TAN/BLACK RED YELLOW/GREEN TAN/BLACK BLACK VIOLET TO SHEET 1 BLACK BLUE/BLACK BLACK COOLING FAN SWITCH TO SHEET 1 TO SHEET 1 BLACK YELLOW/GREEN BLACK BLACK WHITE/GREEN RED TAN/BLACK RED RED RED GREEN/BLACK TAN/BLACK B
