Form No.
Revision History Revision Date Description -- 2010 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. 10176SL (Rev. B) Service Manual (Models 30448 and 30446) GroundsmasterR 4000--D & 4010--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 30448) and 4010--D (Model 30446). REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.
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Chapter 2 -- Product Records and Maintenance 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 . . . . . . . . . . . . . . . . . . . . . . .
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Table Of Contents (Continued) Chapter 10 -- Foldout Drawings Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . 10 -- 3 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 10 -- 4 Wire Harness Drawings . . . . . . . . . . . . . . . . . . . . 10 -- 9 Groundsmaster 4000--D/4010--D Foldout Drawings General Information . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 2 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 and 4010--D are 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.
While Operating 5. Before getting off the seat: 2. Before starting the engine: A. Ensure that traction pedal is in neutral. B. Apply the parking brake. A. Apply the parking brake. B. Make sure traction pedal is in neutral and the PTO switch is OFF (disengaged). C. After engine is started, release parking brake and keep foot off traction pedal. Machine must not move.
Maintenance and Service 1. Before servicing or making adjustments, lower decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 3. Never store the machine or fuel container inside where there is an open flame, such as near a water heater or furnace. 4.
Jacking Instructions 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 and Instruction Decals Numerous safety and instruction decals are affixed to your Groundsmaster machine. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog.
Chapter 2 Product Records and Maintenance Table of Contents 1 1 2 2 2 3 3 3 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.
Torque Specifications 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. The following factors shall be considered when applying torque: cleanliness of the fastener, use of a thread sealant (e.g. Loctite), degree of lubrication on the fastener, presence of a prevailing torque feature (e.g.
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 + 30 # 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/4010--D Page 3 -- 1 Kubota Diesel Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Air Filter System . . . . . . . . . . . . . .
Specifications Item Description Make / Designation Kubota Model V2403--M--T--E3B: 4--Cycle, 4 Cylinder, Water Cooled, Turbocharged, Diesel Engine Bore 3.43 in (87.0 mm) Stroke 4.031 in (102.4 mm) 148.5 in3 (2434 cc) Total Displacement Firing Order 1 (closest to gear case end) -- 3 -- 4 (closest to flywheel end) -- 2 Combustion Chamber Spherical Type (E--TVCS) Compression Ratio 23.
General Information This Chapter gives information about specifications and repair of the diesel engine used in Groundsmaster 4000--D and 4010--D machines. General maintenance procedures are described in your Operator’s Manual. Information on engine troubleshooting, testing, disassembly and reassembly is identified in the Kubota Workshop Manual, Diesel Engine, 03--M--E3B that is included at the end of this section.
Service and Repairs Air Filter System 7 RIGHT 1 FRONT 9 11 6 12 12 to 15 in--lb (1.4 to 1.6 N--m) 13 14 4 15 8 11 2 5 16 17 10 18 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. 18.
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 8 RIGHT FRONT 13 6 10 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 C 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 B 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. D 2. Raise and support hood. Installation (Fig.
Fuel System 6 4 37 38 40 39 26 29 27 30 25 24 36 35 34 3 29 2 31 22 28 23 33 1 21 32 5 14 20 7 19 RIGHT 18 17 1615 FRONT 7 8 9 10 12 11 135 to 165 ft--lb (183 to 223 N--m) 13 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. Check Fuel Lines and Connections 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 supply hose to the standpipe and vent and overflow hoses to the elbow fittings (Fig. 8). Secure hoses with clamps. 4. Connect wire harness connections to the fuel sender. A.
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 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Removal (Fig. 9) Installation (Fig. 9) 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. CAUTION 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.
Engine 27 26 RIGHT 1 FRONT 28 25 24 2 3 4 23 5 22 6 21 11 12 7 13 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 28 to 32 ft--lb (38 to 43 N--m) 29 to 33 ft--lb (40 to 44 N--m) Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 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) Rebound washer (4 used) Kubota Diesel Engine 11. 12. 13. 14. 15. 16. 17. 18. 19.
Engine Removal (Fig. 10) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2 2. Remove battery from machine (see Battery Service in the Service and Repairs section of Chapter 5 -- Electrical System). 1 3. Raise and support hood. CAUTION Figure 11 1. Alternator 2. Temperature sender Kubota Diesel Engine Do not open radiator cap or drain coolant if the radiator or engine is hot.
8. Disconnect fuel supply hose from injection pump (Fig. 13). 9. Remove throttle cable from engine (Figs. 13 and 14): A. Remove lock nut that secures throttle cable swivel to speed control lever. B. Loosen cable clamp and remove throttle cable from under clamp. IMPORTANT: The hydraulic pump assembly can remain in machine during engine removal. To prevent pump from shifting or falling, make sure to support pump assembly before mounting fasteners are removed. 14.Support hydraulic pump assembly.
15.Make sure all cable ties securing the wiring harness, fuel lines or hydraulic hoses to the engine are removed. 13 3 14 RIGHT 16.Connect hoist or lift to the lift tabs on engine. FRONT 17.Remove flange nuts, rebound washers and cap screws securing the engine mounts to the engine supports. 12 11 1 10 CAUTION 2 One person should operate lift or hoist while another person guides the engine out of the machine. 18.Carefully remove engine assembly from machine. 19.
7. Install fan motor and fan assembly (Fig. 15). A. Carefully position fan motor, fan and motor bracket assembly to radiator. 13.Connect wires and/or electrical connections to the following electrical components: A. The temperature sender and alternator (Fig 11). B. Secure fan motor bracket to radiator with six (6) cap screws and flange nuts. B. The glow plug (Fig. 12). C. The engine run solenoid. C. Remove caps and plugs placed in hoses and fittings during removal to prevent contamination. D.
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Spring Coupler RIGHT FRONT 21 10 20 1 2 19 18 4 17 9 16 22 23 15 14 13 12 11 6 24 25 5 7 8 Loctite #242 29 to 33 ft--lb (40 to 44 N--m) 3 2 Loctite #242 28 to 32 ft--lb (38 to 43 N--m) Figure 18 1. 2. 3. 4. 5. 6. 7. 8. 9. Spring coupler Washer (14 used) Cap screw (6 used) Flywheel plate Cap screw (4 used) LH engine mount Cap screw (2 used) Carriage screw (2 used) Cylinder spacer Kubota Diesel Engine 10. 11. 12. 13. 14. 15. 16. 17.
Coupler Removal (Fig. 18) 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. Remove the following: 1 A. Remove hydraulic pump assembly from machine (see Piston (Traction) Pump Removal in the Service and Repairs section of Chapter 4 -- Hydraulic System). B. Remove transport cylinder assembly from engine mount.
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Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 3 Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 3 Relieving Hydraulic System Pressure . . . . . . . . . . 4 Traction Circuit Component Failure . . . . . . . . . . . .
Specifications Item Description Piston (Traction) Pump Eaton Variable Displacement Piston Pump (Model 72400) 2.48 in3 (40.6 cc) 4000 PSI (274 bar) 5000 PSI (343 bar) 250 PSI (17 bar) Maximum Displacement (per revolution) System Relief Pressure: Forward System Relief Pressure: Reverse Charge Pressure Front Wheel Motors Eaton Fixed Displacement Piston Motors (Model 74318) 2.48 in3 (40.6 cc) Displacement (per revolution) Rear Axle Motor Eaton Fixed Displacement Piston Motor (Model 74315) 2.01 in3 (32.
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Check Hydraulic Fluid The Groundsmaster hydraulic system is designed to operate on anti--wear hydraulic fluid. The hydraulic reservoir located beneath the operator seat holds approximately 8 U.S. gallons (30.3 liters) of hydraulic fluid.
Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hydraulic system, all pressure in the hydraulic system must be relieved. Park machine on a level surface, make sure that PTO switch is OFF, lower cutting decks fully, stop engine and engage parking brake. Wait for all moving parts to come to a complete stop. To relieve hydraulic pressure in lift circuit, start engine and fully lower the cutting decks. Turn key switch to OFF and remove key from the ignition switch.
Hydraulic Hoses Hard, cracked, cut, abraded, charred, leaking or otherwise damaged hose. Kinked, crushed, flattened or twisted hose. Blistered, soft, degraded or loose hose cover. Cracked, damaged or badly corroded hose fittings. When replacing a hydraulic hose, be sure that the hose is straight (not twisted) before tightening the fittings. This can be done by observing the imprint (layline) on the hose.
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) 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.
Groundsmaster 4000--D/4010--D Page 4 -- 9 Rev. A RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD NOTE: A larger hydraulic schematic is included in Chapter 10: Foldout Drawings P1 M1 M2 T ST P2 FAN DRIVE MANIFOLD L RV1 LIFT/LOWER MANIFOLD S1 S6 S5 S3 S4 S2 .035 .
Hydraulic System Page 4 -- 10 Rev. A RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow P1 M1 M2 T ST P2 Traction Circuit: Low Speed (4WD) (Forward Shown) FAN DRIVE MANIFOLD L RV1 LIFT/LOWER MANIFOLD S1 S5 S2 S3 S6 S4 .035 .
Traction Circuit: Low Speed (4WD) Traction circuit pressure (forward and reverse) can be measured at test ports in hydraulic tubes. The forward traction port is on the left side of the machine and the reverse traction port is on the right side 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.
Hydraulic System Page 4 -- 12 Rev. A Groundsmaster 4000--D/4010--D RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow P1 M1 M2 T ST Traction Circuit: Hi Speed (2WD) (Forward Shown) P2 FAN DRIVE MANIFOLD L RV1 LIFT/LOWER MANIFOLD S1 S5 S2 S3 S6 S4 .035 .
Traction Circuit: Hi Speed (2WD) Traction circuit pressure (forward and reverse) can be measured at test ports in hydraulic tubes. The forward traction port is on the left side of the machine and the reverse traction port is on the right side 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.
Hydraulic System Page 4 -- 14 Rev. A Groundsmaster 4000--D/4010--D RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow Lower Cutting Deck (LH Deck Shown) P1 M1 M2 T ST P2 FAN DRIVE MANIFOLD L RV1 S9 S7 RV2 S8 SOLENIDS S1, S3 AND S4 ENERGIZED LIFT/LOWER MANIFOLD S1 S6 S5 S3 S4 S2 .035 .
Lower Cutting Deck A relief valve (RV1) located in the lift/lower manifold limits lift/lower circuit pressure to 1600 PSI (110 bar). An adjustable valve (RV2) in the lift/lower manifold maintains back pressure (counterbalance) on the deck lift cylinders to allow some of the cutting deck weight to be transferred to the traction unit to improve traction. Each of the cutting decks (center, right and left) can be lowered independently with the use of three (3) switches on the armrest console.
Hydraulic System Page 4 -- 16 Rev. A Groundsmaster 4000--D/4010--D RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow Raise Cutting Deck (LH Deck Shown) P1 M1 M2 T ST P2 FAN DRIVE MANIFOLD L S4 S2 RV1 S6 S1 S5 S9 S7 RV2 S8 LIFT/LOWER MANIFOLD SOLENIDS S1 AND S2 ENERGIZED S3 .035 .
Raise Cutting Deck A relief valve (RV1) located in the lift/lower manifold limits lift/lower circuit pressure to 1600 PSI (110 bar). An adjustable valve (RV2) in the lift/lower manifold maintains back pressure (counterbalance) on the deck lift cylinders to allow some of the cutting deck weight to be transferred to the traction unit to improve traction. Each of the cutting decks (center, right and left) can be raised independently with the use of three (3) switches on the armrest console.
Hydraulic System Page 4 -- 18 Rev. A Groundsmaster 4000--D/4010--D RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow Mow (Front Deck Shown) P1 M1 M2 T ST P2 FAN DRIVE MANIFOLD L RV1 LIFT/LOWER MANIFOLD S1 S9 S7 S6 S5 S3 S4 S2 .035 .
Mow NOTE: To engage the mow circuit, the operator must be in the operator seat, the cutting deck(s) must be fully lowered and the traction speed must be in the Low speed (4WD) position. PTO Not Engaged When the PTO switch is OFF or if the deck is raised with the PTO switch ON, the PTO manifold solenoid valve (S) is not energized and the solenoid spool is in the neutral position.
Mow Circuit Cutting Deck Blade Braking RETURN PTO MANIFOLD PUMP FLOW Figure 11 RETURN The inertia of the rotating cutting blades, however, effectively turns the deck motor into a pump causing an increase in pressure as the flow from the motor comes up against the closed brake cartridge (LC2). When this pressure builds to approximately 600 PSI (41 bar), relief valve (RV2) opens which allows a small amount of hydraulic flow to return to tank through a manifold sensing line (Fig. 12).
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Hydraulic System Page 4 -- 22 Rev. A Groundsmaster 4000--D/4010--D RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow Steering Circuit (Left Turn Shown) P1 M1 M2 T ST P2 RETRACTING FAN DRIVE MANIFOLD L RV1 LIFT/LOWER MANIFOLD S1 S5 S2 S3 S6 S4 .035 .
Steering Circuit A four section gear pump is coupled to the piston (traction) pump. The third gear pump section supplies hydraulic flow to both the steering and lift/lower circuits. Hydraulic flow from this pump section is delivered to the two circuits through a proportional flow divider that is located in the fan drive manifold. This flow divider splits pump flow approximately 50% for the steering circuit and 50% for the lift/lower circuit. (V1) and out the L port.
Hydraulic System Page 4 -- 24 Rev. A Groundsmaster 4000--D/4010--D RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow P1 M1 M2 T ST P2 Engine Cooling Fan Circuit (Forward Direction Shown) FAN DRIVE MANIFOLD L RV1 LIFT/LOWER MANIFOLD S1 S9 S7 S6 S5 S3 S4 S2 .035 .
Engine Cooling Fan Circuit A four section gear pump is coupled to the piston (traction) pump. The gear pump section farthest from the piston pump supplies hydraulic flow for the engine cooling fan circuit (Fig. 15). 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/lower circuits.
Special Tools Order special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Kit contains one each: 1000 PSI (70 bar), 5000 PSI (350 bar) and 10000 PSI (700 bar) gauges. Use gauges as recommended in the Testing section of this chapter.
40 GPM Hydraulic Tester (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter. This tester includes the following: 1. LOAD VALVE: A simulated working load is created in the circuit by turning the valve to restrict flow. 2. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure. 3.
High Flow Hydraulic Filter Kit The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi--directional filtration which prevents filtered debris from being allowed back into the circuit regardless of flow direction. If a component failure occurs in the closed loop traction circuit, contamination from the failed part will remain in the circuit until removed.
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 (TOR4079) The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Toro Part Number: TOR4079 Figure 23 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 that can be used to assist in diagnosing hydraulic system performance issues. The suggestions are not all--inclusive. Also, consider that there may be more than one cause for a machine problem. Review the hydraulic schematic and information on hydraulic system operation in the Hydraulic Flow Diagrams section of this Chapter. This information will be useful during the hydraulic troubleshooting process.
Traction Circuit Problems Problem Possible Cause Machine operates in one direction only. Traction control linkage is faulty. Traction pedal is sluggish. Traction control linkage is stuck or binding. Traction relief valve is faulty. Charge pressure is low. Piston (traction) pump servo control valve orifices are plugged or damaged. 4WD manifold PD1 and PD2 pilot directional valves seals are leaking or damaged. Machine travels too far before stopping when the traction pedal is released.
Mow Circuit Problems Problem Possible Cause No cutting decks will operate. Electrical problem exists (see Chapter 5 -- Electrical System). NOTE: To engage the mow circuit, the seat must be occupied, the cutting deck(s) must be fully lowered, the traction speed must be in the Low (4WD) position and the PTO switch must be ON. Gear pump is damaged (NOTE: other hydraulic circuits impacted as well). One cutting deck will not operate. Electrical problem exists (see Chapter 5 -- Electrical System).
Lift Circuit Problems Problem Possible Cause Cutting decks will not raise. Engine RPM is too low. NOTE: Seat must be occupied in order to raise cutting decks. Hydraulic oil level in reservoir is low. Solenoid valve (S1) in lift/lower manifold is faulty. Electrical problem exists (see Chapter 5 -- Electrical System). Lift arm pivots are binding. Relief valve in lift/lower manifold is stuck. Lift cylinder(s) is (are) damaged.
Steering Circuit Problems Problem Possible Cause Steering inoperative or sluggish Steering components (e.g. tie rods, steering cylinder ends) are worn or binding. Steering cylinder is binding. Oil level in hydraulic reservoir is low (NOTE: other hydraulic systems are affected as well). Steering relief valve in steering control valve is stuck or damaged. Steering cylinder leaks internally. Steering control valve is worn or damaged.
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Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (see the Special Tools section in this Chapter). 1. Clean machine thoroughly before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. Contamination will cause excessive wear of components.
Which Hydraulic Tests Are Necessary? Before beginning any hydraulic test, identify if the problem is related to the traction circuit, cutting (mow) circuit, lift circuit, steering circuit or engine cooling fan circuit. Once the faulty system has been identified, perform tests that relate to that circuit. 1.
Traction Circuit Charge Pressure (Using Pressure Gauge) TRACTION MANIFOLD 4WD MANIFOLD FROM LIFT CONTROL MANIFOLD FROM FRONT DECK CYLINDERS FILTER 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 -- 38 FROM PTO MANIFOLDS & FAN MOTOR FROM PTO MANIFOLDS TO COOLING FAN CIRCUIT Groundsmaster 4000--D/4010--D
Procedure for Traction Circuit Charge Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (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. 3. Raise and support operator seat. CAUTION Prevent personal injury and/or damage to equipment.
Traction Circuit Relief Pressure (Using Pressure Gauge) FORWARD TRACTION CIRCUIT RELIEF PRESSURE TEST SHOWN 4WD MANIFOLD FROM LIFT CONTROL MANIFOLD TRACTION MANIFOLD PRESSURE GAUGE FILTER MANIFOLD FROM FRONT DECK CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT TO STEERING & LIFT CIRCUITS Hydraulic System Page 4 -- 40 FROM PTO MANIFOLDS & FAN MOTOR FROM PTO MANIFOLDS TO COOLING FAN CIRCUIT Groundsmaster 4000--D/4
Procedure for Traction Circuit Relief Pressure Test 2 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full. CAUTION 1 Move machine to an open area, away from people and obstructions. 2. Drive machine to an open area, lower cutting decks, turn the engine off and apply the parking brake. Figure 27 1. Forward traction port CAUTION 2.
LIFT MANIFOLD S7 RV2 RV1 S9 S6 S5 S1 PRESSURE GAUGE FAN DRIVE MANIFOLD S2 S4 S3 .035 .070 S8 FILTER MANIFOLD 4WD MANIFOLD TRACTION MANIFOLD Counterbalance Pressure (Using Pressure Gauge) FROM PTO MANIFOLDS TO PTO (MOW) CIRCUIT Hydraulic System Page 4 -- 42 Rev.
Procedure for Counterbalance Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full. D. Tighten lock nut to secure adjustment. Check counterbalance pressure and readjust as needed. 9. When testing is completed, disconnect pressure gauge from manifold test port. Install controller cover. 2. Park machine on a level surface with the cutting decks lowered and off.
Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge) FROM LIFT CONTROL MANIFOLD TRACTION MANIFOLD 4WD MANIFOLD PRESSURE GAUGE FILTER MANIFOLD FROM FRONT DECK CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT TO STEERING & LIFT CIRCUITS Hydraulic System Page 4 -- 44 Rev.
Procedure for Traction Circuit Reducing Valve (PR) Pressure Test 1 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (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. CAUTION 2 Figure 32 1. 4WD manifold Prevent personal injury and/or damage to equipment.
Rear Traction Circuit (RV) Relief Pressure (Using Pressure Gauge) FROM LIFT CONTROL MANIFOLD TRACTION MANIFOLD 4WD MANIFOLD PRESSURE GAUGE FILTER MANIFOLD FROM FRONT DECK CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT TO STEERING & LIFT CIRCUITS Hydraulic System Page 4 -- 46 Rev.
Procedure for Rear Traction Circuit (RV) Relief Pressure Test B. To increase relief pressure setting, rotate adjustment socket in a clockwise direction. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full. C. To decrease pressure setting, rotate adjustment socket in a counterclockwise direction. 2. Park machine on a level surface with the cutting decks lowered and off.
Piston (Traction) Pump Flow Test (Using Tester with Flow meter and Pressure Gauge) TRACTION MANIFOLD 4WD MANIFOLD FROM LIFT CONTROL MANIFOLD TESTER FILTER MANIFOLD FROM FRONT DECK CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT TO STEERING & LIFT CIRCUITS Hydraulic System Page 4 -- 48 FROM PTO MANIFOLDS & FAN MOTOR FROM PTO MANIFOLDS TO COOLING FAN CIRCUIT Groundsmaster 4000--D/4010--D
This test measures piston (traction) pump output (flow). During this test, pump load is created at the flow meter using the adjustable load valve on the tester. IMPORTANT: Traction circuit flow for the Groundsmaster 4000/4010 is approximately 30 GPM (113.5 LPM). Use 40 GPM Hydraulic Tester #AT40002 (pressure and flow) for this test (see Special Tools in this chapter). 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes.
Hydraulic System Page 4 -- 50 RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD FROM COOLING FAN CIRCUIT TO STEERING & LIFT CIRCUITS TO COOLING FAN CIRCUIT FILTER MANIFOLD FRONT DECK CIRCUIT PRESSURE TEST SHOWN FROM REAR AXLE MOTOR CHARGE CIRCUIT FROM FRONT WHEEL MOTORS FROM 4WD MANIFOLD TRACTION CIRCUIT FLOW Cutting Deck Circuit Pressure (Using Pressure Gauge) TRACTION CIRCUIT FLOW PRESSURE GAUGE Groundsmaster 4000--D/4010--D
Procedure for Cutting Deck Circuit Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (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 Figure 38 Prevent personal injury and/or damage to equipment.
TESTER Hydraulic System Page 4 -- 52 FROM COOLING FAN CIRCUIT TO STEERING & LIFT CIRCUITS TO COOLING FAN CIRCUIT FILTER MANIFOLD FROM REAR AXLE MOTOR CHARGE CIRCUIT FROM 4WD MANIFOLD FROM FRONT WHEEL MOTORS TRACTION CIRCUIT FLOW FRONT PTO RELIEF PRESSURE TEST SHOWN RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD PTO Relief Pressure (Using Tester with Pressure Gauge and Flow Meter) TRACTION CIRCUIT FLOW Groundsmaster 4000--D/4010--D
1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (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. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 3. Locate deck manifold to be tested (Fig.
FROM REAR AXLE MOTOR CHARGE CIRCUIT FROM 4WD MANIFOLD FROM COOLING FAN CIRCUIT RH PTO MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD TO STEERING & LIFT CIRCUITS TO COOLING FAN CIRCUIT FILTER MANIFOLD TRACTION CIRCUIT FLOW FROM FRONT WHEEL MOTORS FRONT CUTTING DECK MOTOR CASE DRAIN LEAKAGE TEST SHOWN TRACTION CIRCUIT FLOW Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauge and Flow Meter) TESTER CAP MEASURING CONTAINER Hydraulic System Page 4 -- 54 Groundsmaster 4000--D/401
Procedure for Cutting Deck Motor Case Drain Leakage Test 5. Sit on seat and start the engine. Move throttle to high idle 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 -- 56 FROM COOLING FAN CIRCUIT FILTER MANIFOLD FROM REAR AXLE MOTOR CHARGE CIRCUIT FROM 4WD MANIFOLD FROM FRONT WHEEL MOTORS TRACTION CIRCUIT FLOW FRONT DECK GEAR PUMP FLOW TEST SHOWN RH PTO MANIFOLD TO STEERING & LIFT CIRCUITS TO COOLING FAN CIRCUIT TESTER LH PTO MANIFOLD FRONT PTO MANIFOLD Cutting Deck Gear Pump Flow (Using Tester with Pressure Gauge and Flow Meter) TRACTION CIRCUIT FLOW Groundsmaster 4000--D/4010--D
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.
RV2 FAN DRIVE MANIFOLD PRESSURE GAUGE LIFT MANIFOLD S1 S3 RV1 S5 S2 S7 S6 S4 .035 .070 S9 S8 FILTER MANIFOLD 4WD MANIFOLD TRACTION MANIFOLD Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) FROM PTO MANIFOLDS TO PTO (MOW) CIRCUIT FROM DECK MOTORS TO PTO (MOW) CIRCUIT Hydraulic System Page 4 -- 58 Rev.
Procedure for Lift/Lower Circuit Relief Pressure Test NOTE: Before attempting to check or adjust lift/lower circuit relief pressure, make sure that counterbalance pressure is correctly adjusted (see Counterbalance Pressure Test in this section). 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off.
RV2 FAN DRIVE MANIFOLD LIFT MANIFOLD RV1 PRESSURE GAUGE S3 S1 S5 S2 S7 S6 S4 .035 .070 S9 S8 FILTER MANIFOLD 4WD MANIFOLD TRACTION MANIFOLD Steering Circuit Relief Pressure (Using Pressure Gauge) FROM PTO MANIFOLDS TO PTO (MOW) CIRCUIT FROM DECK MOTORS TO PTO (MOW) CIRCUIT Hydraulic System Page 4 -- 60 Rev.
Procedure for Steering Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (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. 7.
Steering Cylinder Internal Leakage STEERING CYLINDER CYLINDER FULLY EXTENDED L R LOOK FOR LEAKAGE STEEL CAP STEERING WHEEL TURNED FOR RIGHT TURN 1350 PSI T Hydraulic System PB P STEERING CONTROL Page 4 -- 62 Groundsmaster 4000--D/4010--D
Procedure for Steering Cylinder Internal Leakage Test NOTE: Steering circuit operation will be affected by rear tire pressure, binding of steering cylinder, extra weight on the vehicle and/or binding of rear axle steering components. Make sure that these items are checked before proceeding with steering cylinder internal leakage test. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2.
RV2 S1 TESTER FAN DRIVE MANIFOLD LIFT MANIFOLD S3 RV1 S5 S2 S7 S6 S4 .035 .070 S9 S8 FILTER MANIFOLD 4WD MANIFOLD TRACTION MANIFOLD Steering and Lift/Lower Gear Pump Flow (Using Tester with Pressure Gauge and Flow Meter) FROM PTO MANIFOLDS TO PTO (MOW) CIRCUIT FROM DECK MOTORS TO PTO (MOW) CIRCUIT Hydraulic System Page 4 -- 64 Rev.
Procedure for Steering and Lift/Lower Gear Pump Flow Test 5. Start the engine and move throttle to high idle speed (2870 RPM). DO NOT engage the cutting decks. NOTE: Output from the steering and lift/lower gear pump section is equally divided by a proportional valve to provide flow to the steering circuit and the lift circuit. The proportional valve is in the fan drive manifold. 6. While watching pressure gauge on tester, slowly close flow control valve until 1000 PSI (69 bar) is obtained on gauge.
RV2 FAN DRIVE MANIFOLD LIFT MANIFOLD S3 RV1 S1 S5 S2 S7 S6 S4 .035 .070 S9 S8 FILTER MANIFOLD 4WD MANIFOLD TRACTION MANIFOLD Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac) FROM PTO MANIFOLDS PRESSURE GAUGE TO PTO (MOW) CIRCUIT FROM DECK MOTORS TO PTO (MOW) CIRCUIT Hydraulic System Page 4 -- 66 Rev.
Procedure for Engine Cooling Fan Circuit Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (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. 1 CAUTION Prevent personal injury and/or damage to equipment.
RV2 S1 LIFT MANIFOLD TESTER FAN DRIVE MANIFOLD S3 RV1 S5 S2 S7 S6 S4 .035 .070 S9 S8 FILTER MANIFOLD 4WD MANIFOLD TRACTION MANIFOLD Engine Cooling Fan Circuit Gear Pump Flow (Using Tester with Pressure Gauge and Flow Meter) FROM PTO MANIFOLDS TO PTO (MOW) CIRCUIT FROM DECK MOTORS TO PTO (MOW) CIRCUIT Hydraulic System Page 4 -- 68 Rev.
1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (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. Raise and support seat to gain access to the gear pump. CAUTION Prevent personal injury and/or damage to equipment.
Adjustments Traction Linkage Adjustment 22 15 16 28 18 19 23 17 19 25 8 20 14 27 21 10 24 19 10 29 6 9 24 20 12 13 5 11 17 18 7 26 1 4 3 RIGHT 2 FRONT Figure 55 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Traction pedal Cap screw (4 used) Hex nut Pedal stop Washer head screw (2 used) Pedal bracket Lock nut (4 used) Traction rod Slotted roll pin Lock nut 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
4. With ignition switch in the ON position (engine not running), use Diagnostic Display to make sure that neutral switch is closed when traction pedal is released to the neutral detent position (see Diagnostic Display in the Troubleshooting section of Chapter 5 -- Electrical System). 7. Shut engine off. Adjustments with Engine Running 9. Lower machine to ground. 8.
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. Contaminated oil may appear milky or black or may contain metal particles. IMPORTANT: If a component failure occurred in the closed loop traction circuit (e.g. piston pump or wheel motor), filtering the traction circuit is recommended. See Filtering Closed--Loop Traction Circuit in this section. 1. Park machine on a level surface.
Filtering Closed--Loop Traction Circuit Filtering of a closed--loop hydraulic system after a major component failure (e.g. traction (piston) pump or front wheel motor) is a requirement to prevent debris from transmitting throughout the system. If a closed--loop hydraulic system filtering tool is not used to ensure system cleanliness, repeat failures, as well as subsequent damage to other hydraulic components in the affected system, will occur.
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 a lift switch 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 7 25 19 18 9 23 9 10 24 12 14 13 11 27 15 1 6 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 59 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. 59) 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. 59) 1.
Hydraulic Oil Cooler 8 9 4 RIGHT 19 19 5 10 3 6 8 7 FRONT 9 10 2 11 12 1 13 14 15 16 12 17 18 12 ft--lb (16 N--m) Figure 60 1. 2. 3. 4. 5. 6. 7. Radiator RH radiator support Top radiator support Knob (2 used) Oil cooler bracket Retaining ring (2 used) Carriage screw (2 used) Hydraulic System 8. 9. 10. 11. 12. 13. O--ring 90o hydraulic fitting (2 used) O--ring Cap screw (2 used) Lock washer (6 used) Oil cooler Page 4 -- 78 14. 15. 16. 17. 18. 19.
Removal (Fig. 60) 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 10 1 11 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 19 8 7 13 12 17 27 6 31 22 18 RIGHT 5 16 30 Loctite #242 79 to 84 ft--lb (108 to 113 N--m) Loctite #242 79 to 84 ft--lb (108 to 113 N--m) 25 26 9 35 FRONT 30 to 40 in--lb (3.4 to 4.5 N--m) 28 29 Figure 61 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. 2. Raise and support machine to gain access to gear pump from the underside of the machine. 3. Drain the hydraulic reservoir. 4. To prevent contamination of hydraulic system during removal, thoroughly clean exterior of pump and fittings. 5.
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 25 22 26 23 33 ft--lb (45 N--m) 22 20 Figure 62 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.
IMPORTANT: Use caution when clamping gear pump in a vise to avoid distorting any pump components. NOTE: Pressure seals and back--up gaskets fit in grooves machined into thrust plates. Body seals fit in grooves machined in body faces. 3. Secure the front cover of the pump in a vise with the drive shaft pointing down. 2. Assemble pump sections starting at front cover end. Apply grease or petroleum jelly to new section seals to hold them in position during gear pump assembly. 4.
Traction Circuit NOTE: Arrow on check valve points toward rear of machine RIGHT 10 FRONT 6 9 8 1 2 13 5 7 11 12 4 3 Figure 65 1. 2. 3. 4. 5. Piston (traction) pump Gear pump LH front wheel motor Traction manifold RH front wheel motor 6. 7. 8. 9. 4WD manifold Filter manifold Rear axle motor Cooling fan motor 10. 11. 12. 13.
Transport Cylinder A transport cylinder is included in the traction circuit to reduce traction pump control arm movement when operating in Hi speed (2WD). This reduced control arm movement limits pump swash plate rotation to prevent excessive transport speed. The transport cylinder is attached to the forward, right side engine mount (Fig. 66). 13 3 14 RIGHT FRONT 12 11 Disassembly (Fig. 66) 1 10 1.
Piston (Traction) Pump 10 11 1 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 19 8 6 31 22 18 7 13 12 Loctite #242 79 to 84 ft--lb (108 to 113 N--m) 30 17 27 RIGHT 5 16 Loctite #242 79 to 84 ft--lb (108 to 113 N--m) 25 26 9 35 FRONT 30 to 40 in--lb (3.4 to 4.5 N--m) 28 29 Figure 68 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
5. Disconnect wire harness connector from neutral switch on piston pump. 6. Connect wire harness connector to neutral switch on traction pump. 6. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 7. Remove plugs or caps from disconnected hydraulic hoses and open ports of the pump assembly.
Piston (Traction) Pump Service 40 to 48 in--lb (4.5 to 5.4 N--m) 4 to 6 ft--lb (5 to 8 N--m) 40 to 48 in--lb (4.5 to 5.
Piston (Traction) Pump Service (Fig. 70) Hydraulic System For service of the piston (traction) pump (including the servo control (item 28) assembly), see the Eaton Model 72400 Servo Controlled Piston Pump Repair Information at the end of this chapter.
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 71 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. Gear (45T) External snap ring (2 used) Pinion gear (27T) Needle bearing O--ring O--ring O--ring Page 4 -- 90 15. 16. 17. 18.
Removal (Fig. 71) Installation (Fig. 71) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. IMPORTANT: Refer to Traction Circuit Component Failure in the General Information section of this chapter for information regarding the importance of removing contamination from the traction circuit. NOTE: To ease installation, label the hydraulic hoses to show their correct position on the axle motor. 3.
Front Wheel Motor 2 3 11 2 8 13 12 16 5 14 15 9 18 4 19 1 14 11 Arrow on side of motor case points up 10 1 7 11 14 23 6 16 24 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 72 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. 16.
Removal (Fig. 72) Installation (Fig. 72) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. IMPORTANT: If 90o fitting (item 10) was removed from backplate of RH wheel motor, make sure that straight fittings (item 14) are installed and correctly torqued before installing 90o fitting. NOTE: To ease installation, label the hydraulic hoses to show their correct position on the wheel motor. 3.
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 73 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 4 6 3 RIGHT 8 11 9 17 FRONT 10 9 7 13 12 16 7 4 15 5 10 14 1 19 Figure 74 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. Dust cap Hydraulic fitting O--ring O--ring 90o hydraulic fitting O--ring 14. 15. 16. 17. 18. 19.
Removal (Fig. 74) Installation (Fig. 74) 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 75 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 any of the cartridge valves. 2. If cartridge valve is solenoid operated, remove nut securing solenoid to the cartridge valve. Carefully slide solenoid off the valve. IMPORTANT: Use care when removing cartridge valves. Slight bending or distortion of the stem tube can cause binding and malfunction. Make sure that deep well socket fully engages the valve base. 3. Remove cartridge valve with a deep well socket.
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 76 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. 76) Installation (Fig. 76) 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 77 1. 2. 3. 4. Flow divider valve Pilot directional valve Orifice (0.020) Traction manifold 5. Check valve 6. SAE #8 plug with O--ring 7.
Traction Manifold Service (Fig. 77) NOTE: If the check valve (item 5) next to the pilot directional valve (item 2) needs to be removed from manifold, remove directional valve first. When installing this check valve, install and torque check valve before installing directional valve. Hydraulic System For traction manifold cartridge valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 77 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 78 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. 78) Installation (Fig. 78) 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 79 1. Filter manifold 2. Check valve (reservoir return) 3. Oil filter element 4. Check valve (filter bypass) 5. #6 zero leak plug with O--ring NOTE: The ports on the filter manifold are marked for easy identification of components.
Filter Manifold Service (Fig. 79) Hydraulic System For filter manifold cartridge valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 79 for filter manifold cartridge valve and plug installation torque.
Steering and Engine Cooling Fan Circuits 4 GROUNDSMASTER 4000--D RIGHT FRONT 3 7 1 2 5 6 Figure 80 1. Gear pump 2. Steering control valve 3. Fan drive manifold Hydraulic System 4. Fan motor 5. Steering cylinder Page 4 -- 108 6. Steering circuit test port (GM4000) 7.
Figure 80 illustrates the components that are used in the Groundsmaster 4000--D steering and engine cooling fan circuits. The steering control valve hydraulic lines used on the Groundsmaster 4010--D are slightly different and are shown in Figure 81. Procedures for removal, installation and disassembly/assembly of these components are provided on the following pages of this section. GROUNDSMASTER 4010--D 4 3 5 1 2 Figure 81 4. Fan circuit test port 5. Steering test port Hydraulic System 1.
Steering Control Valve 39 45 25 7 33 34 35 36 37 26 4 5 6 21 40 43 42 2 23 44 41 1 3 24 22 8 28 9 10 29 30 31 11 12 13 14 32 27 16 to 20 ft--lb (22 to 27 N--m) 27 15 16 17 18 19 38 20 21 RIGHT FRONT Figure 82 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Removal (Fig. 82) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. GROUNDSMASTER 4000--D 1 3 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. To prevent contamination of hydraulic system during steering control valve removal, thoroughly clean exterior of control valve and fittings.
Steering Control Valve Service 8 1 3 24 2 4 5 6 7 19 20 19 23 22 21 150 in--lb (17 N--m) 9 11 13 12 140 to 160 in--lb (16 to 18 N--m) 14 18 16 17 10 15 Figure 85 1. 2. 3. 4. 5. 6. 7. 8. Steering control 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. 86). CAUTION 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.
Steering Cylinder 15 7 6 9 7 4 1 16 9 8 2 5 4 3 10 See text for tightening procedure 12 13 14 11 RIGHT See text for tightening procedure FRONT Figure 87 1. 2. 3. 4. 5. 6. Steering cylinder Ball joint Ball joint Retaining ring Grease fitting Grease fitting Hydraulic System 7. 8. 9. 10. 11. 90o hydraulic fitting O--ring O--ring Drive axle assembly Ball joint spacer Page 4 -- 114 12. 13. 14. 15. 16.
Removal (Fig. 87) Installation (Fig. 87) 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 88 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 -- 116 9. 10. 11. 12.
Disassembly (Fig. 88) Assembly (Fig. 88) 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 2 3 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) Loctite #242 10 RIGHT FRONT Figure 89 1. 2. 3. 4. 5. 6. 7. Hydraulic fan motor O--ring Bracket 45o hydraulic fitting O--ring Hydraulic hose Fan hub 8. 9. 10. 11. 12. 13. 14. Washer Hex nut Engine Cap screw (4 used) Washer (4 used) Fan Lock nut (2 used) 15. 16. 17. 18. 19. 20. 21. Removal (Fig. 89) 1.
IMPORTANT: Make sure to not damage the radiator or other machine components while loosening and removing the fan motor and bracket assembly. 6. Remove cooling fan motor and bracket assembly. A. To prevent contamination of hydraulic system, thoroughly clean exterior of fan motor and fittings. B. Disconnect hydraulic hoses from fan motor. Put caps or plugs on fittings and hoses to prevent contamination. Label hydraulic lines for proper assembly.
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 91 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. 91) 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. 1 4 3 2 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. 93). Note orientation of seal lips during removal. Discard removed seals. Inspection 1. Remove any nicks and burrs from all parts with emery cloth. Figure 93 1.
3. Place front flange, seal side down, on a flat surface. 4. Install the pressure seals, flat side outward, into the grooves in the wear plates. Follow by carefully placing the backup gaskets, flat side outward, between the pressure seals and the grooves in the wear plate. 5. Apply 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 95 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. 95) Installation (Fig. 95) 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 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. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 2.
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 97 1. 2. 3. 4. Fan drive manifold body #4 zero leak plug with O--ring (3 used) Check valve (port CV) #6 zero leak plug with O--ring (2 used) 5. Flow divider valve (port FD) 6. Nut 7.
Fan Drive Manifold Service (Fig. 97) Hydraulic System For fan drive manifold cartridge valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 97 for fan drive manifold cartridge valve and plug installation torque.
PTO Circuit RIGHT 9 FRONT 2 4 1 6 5 8 3 7 Figure 98 1. Gear pump 2. RH cutting deck motor 3. LH cutting deck motor 4. RH PTO manifold 5. Front cutting deck motor 6. LH PTO manifold 7. Front PTO manifold 8. Filter manifold 9. Oil cooler Figure 98 illustrates the components that are used in the Groundsmaster 4000--D and 4010--D PTO circuit. 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 10 12 10 15 14 13 9 8 7 15 6 1 33 to 40 ft--lb (45 to 55 N--m) 2 11 5 8 4 3 Figure 101 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 11. 12. 13. 14. 15. Body Idler gear Cap screw (4 used) Front flange Dowel pin Disassembly (Fig. 101) 1. Plug motor ports and clean the outside of the motor thoroughly. After cleaning, remove plugs and drain any oil out of the motor. 2.
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. 103). 8. Carefully remove and discard O--rings, pressure seals and back--up rings (Fig. 104) from motor. Do not cause any damage to the machined grooves during the removal process.
Assembly (Fig. 101) 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 22 12 18 23 5 19 2 4 21 6 9 5 11 24 8 6 15 25 3 8 7 16 17 6 26 25 21 11 5 8 8 27 8 6 14 12 2 3 3 4 19 18 2 21 19 1 7 13 12 7 10 21 4 21 20 19 18 23 RIGHT FRONT Figure 106 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. 106) Installation (Fig. 106) 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 107 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.
PTO Manifold Service (Fig. 107) Hydraulic System For PTO manifold solenoid and control valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 107 for PTO manifold cartridge valve and plug installation torque.
Cutting Deck Lift/Lower Circuit RIGHT 5 2 FRONT 4 3 1 6 1 Figure 108 1. Front lift cylinder (2 used) 2. RH lift cylinder 3. LH lift cylinder 4. Fan drive manifold Figure 108 illustrates the components that are used in the Groundsmaster 4000--D and 4010--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. Hydraulic System 5. Lift/lower manifold 6.
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Lift/Lower Manifold RIGHT FRONT 1 4 3 2 Figure 109 1. Lift/lower manifold 2. Flange head screw (2 used) 3. Washer head screw (2 used) 4. Splash shield Removal (Fig. 109) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. Raise and support operator seat. 2. Remove controller cover and then support bracket from the right side of the operator seat (Fig. 110). 3.
6. Disconnect hydraulic lines from manifold and put caps or plugs on open hydraulic lines and fittings. Label disconnected hydraulic lines for proper installation. 2 1 3 7. Remove lift/lower manifold using Figure 109 as a guide. 4 IMPORTANT: The fitting in manifold port C2 includes a .070 orifice to control the lowering speed of the front deck. If this fitting is removed from the manifold, label its position for assembly purposes. 8.
Lift/Lower Manifold Service 25 ft--lb (34 N--m) 5 ft--lb (6.7 N--m) 20 ft--lb (27 N--m) 4 5 5 ft--lb (6.7 N--m) 8 4 3 7 6 3 9 3 UP 10 2 12 10 20 ft--lb (27 N--m) 20 ft--lb (27 N--m) 25 ft--lb (34 N--m) 1 20 ft--lb (27 N--m) 2 11 11 20 ft--lb (27 N--m) Figure 112 1. 2. 3. 4. Lift/lower manifold body Solenoid valve (S4, S6 & S9) Solenoid coil (5 used) Nut (8 used) 5. 6. 7. 8.
Lift/Lower Manifold Service (Fig. 112) WARNING If lift/lower manifold is attached to machine, make sure that cutting decks are fully lowered before loosening hydraulic lines, cartridge valves or plugs from lift/lower manifold. If decks are not fully lowered when manifold components are loosened, decks may drop unexpectedly. Hydraulic System For lift/lower manifold solenoid and control valve service procedures, see 4WD Manifold Service in this section.
Side Deck Lift Cylinder 12 11 9 10 6 8 7 6 4 3 RIGHT 5 2 1 FRONT Figure 113 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 -- 144 9. 10. 11. 12.
Removal (Fig. 113) Installation (Fig. 113) 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). 2.
Front Deck Lift Cylinder 10 RIGHT 11 FRONT 3 2 1 12 9 13 10 15 10 9 1 11 14 4 5 6 8 7 6 Figure 114 1. 2. 3. 4. 5. Lift cylinder Pivot pin Cotter pin (2 used per pin) Pin assembly Cap screw Hydraulic System 6. 7. 8. 9. 10. Flat washer Lock nut LH lift arm assembly O--ring Straight hydraulic fitting Page 4 -- 146 11. 12. 13. 14. 15.
Removal (Fig. 114) Installation (Fig. 114) 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). 2.
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 115 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 116 1. 2. 3. 4. 5.
Disassembly (Figs. 115 and 116) Assembly (Figs. 115 and 116) 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.
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Chapter 5 Electrical System Table of Contents Groundsmaster 4000--D/4010--D Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . Windshield Wiper/Washer Switch (Grounds-master 4010--D) . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning Switch (Groundsmaster 4010--D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. Toro Electronic Controllers (TEC) Groundsmaster 4000--D and 4010--D machines use two (2) Toro Electronic Controllers (TEC) to manage machine electrical functions.
Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The multimeter 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.
Diagnostic Display The Diagnostic Display (Fig. 4) can be connected to the wiring harness communication connector located under the controller cover to verify correct electrical functions of the machine. Toro Electronic Controller (TEC) inputs and outputs can be checked using the Diagnostic Display.
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 10 -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.
4. Turn the ignition switch to the ON position, but do not start machine. NOTE: The red text on the Diagnostic Display overlay decal refers to input switches and the green text refers to TEC outputs. TEC--5002 MASTER OVERLAY 5. Make sure that the “INPUTS DISPLAYED” LED, on lower right column of the Diagnostic Display, is illuminated. If “OUTPUTS DISPLAYED” LED is illuminated, press the toggle button on the Diagnostic Display to change to “INPUTS DISPLAYED” LED. 6.
Diagnostic Display TEC--5002 Master Inputs Diagnostic Display LED Operation P BRAKE OFF Parking brake released: LED ON Parking brake applied: LED OFF NEUTRAL Traction pedal in neutral: LED ON Traction pedal in forward or reverse: LED OFF SEAT SWITCH Operator seat occupied: LED ON Operator seat empty: LED OFF HI RANGE Hi/Lo speed switch in HI range: LED ON Hi/Lo speed switch in LO range: LED OFF OIL PRESSURE LOW Engine not running OR low engine oil pressure: LED ON Engine oil pressure OK: LED OFF
Diagnostic Display TEC--5001 Slave Inputs Diagnostic Display LED Operation C DECK RAISE Cutting deck lift switch for center deck in RAISE position: LED ON Lift switch for center deck NOT in RAISE position: LED OFF C DECK LOWER Cutting deck lift switch for center deck in LOWER position: LED ON Lift switch for center deck NOT in LOWER position: LED OFF L DECK RAISE Cutting deck lift switch for left deck in RAISE position: LED ON Lift switch for left deck NOT in RAISE position: LED OFF L DECK LOWER Cu
Verify Diagnostic Display Output Functions B. If the output LED’s are on as specified, but the machine does not function properly, suspect a failed electrical component, an open in the tested circuit or a non-electrical problem (e.g. hydraulic component problem). Repair as necessary. The Diagnostic Display also has the ability to detect which output solenoids or relays are energized by the TEC controllers. This is a quick way to determine if a machine malfunction is electrical or hydraulic. C.
Starting Problems Problem Possible Causes No electrical power to machine (including gauges). The battery is discharged. The battery cables are loose or corroded. Fuse F3--1 (2 amp) to the ignition switch is faulty. Bad ground connection on machine. The ignition switch or circuit wiring is faulty. Starter solenoid clicks, but starter will not crank. The battery is discharged. NOTE: If the solenoid clicks, the problem is not in the in- The battery cables are loose or corroded. terlock circuit.
Starting Problems (Continued) Problem Possible Causes Engine cranks, but does not start. The fuel tank is empty. The engine is not cranking fast enough. Fuse F5--1 (30 amp) is faulty preventing engine run solenoid pull coil from being energized. Fuse M1 (60 amp) is faulty preventing glow plug operation. The glow relay or circuit wiring is faulty preventing glow plug operation. Glow plug(s) is faulty. The engine run solenoid or circuit wiring is faulty. The fuel pump or circuit wiring is faulty.
General Run and Transport Problems Engine continues to run, but should not, when the ignition switch is turned off. The engine run solenoid is faulty. Engine continues to run, but should not, when the traction pedal is depressed with no operator in the seat. The seat switch or circuit wiring is faulty. Engine stops during operation, but is able to restart. The operator is lifting off the seat switch.
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 deck runs, 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. Both the deck position switch or circuit wiring and PTO switch or circuit wiring are faulty.
Cutting Deck Lift/Lower Problems Problem Possible Causes None of the cutting decks will lower. The Hi/Low speed switch is in the Hi speed position. Operator is not fully depressing the seat switch. TEC--5001 fuse(s) (F4--1, F4--2, F4--3, F4--4) are faulty. The seat switch or circuit wiring is faulty. The Hi/Low speed switch or circuit wiring is faulty. Lift control manifold solenoid coil S1 or circuit wiring is faulty.
Cutting Deck Lift/Lower Problems (Continued) Problem Possible Causes RH wing cutting deck will not raise or lower, but the front and LH wing cutting decks will raise and lower. The RH deck lift switch or circuit wiring is faulty. Fuse F4--3 is faulty. Lift control manifold solenoid coils S7, S8 or S9 or circuit wiring is faulty. A hydraulic problem exists (see Troubleshooting section of Chapter 4 - Hydraulic System). The TEC--5001 controller is faulty.
Adjustments Cutting Deck Position Switches Adjustment 1. Park machine on a level surface with front cutting deck raised and side cutting decks lowered. Stop engine, engage parking brake and remove key from the ignition switch. 2. There should be from 0.070” to 0.130” (1.8 to 3.3 mm) clearance between the target surface end of position switch and the sensing plate on lift arm. 2 1 3.
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 (+) multimeter lead to the positive battery post and the negative (--) multimeter lead to the negative battery post. The multimeter will display battery voltage.
Check Operation of Interlock Switches CAUTION NOTE: Use the Diagnostic Display (see Special Tools in this chapter) to test Toro Electronic Controller inputs and outputs before further troubleshooting of an electrical problem on your Groundsmaster. Electrical System Do not disconnect safety switches. They are for the operator’s protection. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before operating the machine.
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, 03--M--E3B Series at the end of Chapter 3 -- Kubota Diesel Engine.
Fuses The fuse blocks are located in the power center under the hood on the right side of the machine (Fig. 17). In addition to the fuses in the fuse blocks, a 40 amp fuse (F5--1) is included in the wire harness to protect the pull coil circuit for the engine run solenoid. This fuse resides in a fuse holder near the starter motor (Fig. 17). Fuse Identification and Function Use Figure 18 to identify each individual fuse and its correct amperage in the fuse block. The fuses have the following functions.
Operator Cab Fuses (Groundsmaster 4010--D) The cab fuse blocks are located in the cab headliner (Fig. 19). Identification and Function (Figs. 19 and 20) 1 2 Fuse F1--2 (15 Amp) protects the cab fan circuit. Fuse F1--3 (30 Amp) protects the air conditioner circuit. Fuse F2--1 (15 Amp) protects the windshield wiper/ washer circuit. Fuse F2--2 (15 Amp) protects the cab dome light circuit. Fuses F1--1, F1--4, F2--3 and F2--4 are available for optional equipment. Testing Figure 19 1.
Warning Lights Charge Indicator Light 3. Apply 12 VDC to terminals 1A and 2A (Fig. 22). The charge indicator light should come on when the ignition switch is in ON with the engine not running or with an improperly operating charging circuit while the engine is running. 4. Ground terminals 1B and 2B (Fig. 22). To test the charge indicator light and circuit wiring, ground the white wire attached to alternator.
PTO Switch The PTO switch is located on the console arm (Fig. 23). The PTO switch is pulled up to engage the PTO and pushed in to disengage the PTO. The TEC--5001 controller monitors the position of the PTO switch (up or down). Using inputs from the PTO switch and other switches in the interlock system, the TEC--5001 controller controls the energizing of the hydraulic solenoid valves used to drive the cutting deck motors.
Cutting Deck Lift Switches 7. After testing is completed, connect wire harness connector to the lift switch. 8. Assemble console arm (see Console Arm Assembly in the Service and Repairs section of Chapter 7 -- Chassis). 3 NOTE: To lower the cutting decks, traction speed has to be in low range (4WD). Also, to raise or lower the decks, the operator seat has to be occupied. 2 Testing 1.
Hi/Low Speed and Headlight (Groundsmaster 4010--D) Switches The Hi/Low speed and headlight switches (Groundsmaster 4010--D) are identical, two (2) position rocker switches that are located on the control console. The Hi/Low speed switch (Fig. 27) is used as an input for the TEC--5002 controller to set the machine traction speed for Hi speed (2WD) or Low speed (4WD). 6. After testing is completed, connect wire harness connector to the switch. 7.
Flow Divider and Engine Cooling Fan Switches The flow divider and engine cooling fan switches are identical, two (2) position rocker switches that are located on the control console (Fig. 29). These switches have a normal and a momentary position. 6. If switch tests correctly and circuit problem still exists, check wire harness (see Electrical Schematics and Wire Harness Drawings in Chapter 10 -- Foldout Drawings).
Seat Switch The seat switch is normally open and closes when the operator is on the seat. This switch is used as an input for the TEC--5002 controller. The seat switch and its electrical connector are located in the seat assembly. If the traction system or PTO switch is 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 switch wire from the machine wire harness (Fig. 31). Testing 2 1 1.
Parking Brake Switch The switch used for the parking brake is a normally open switch that is located under the steering tower cover (Fig. 32). The brake switch is used as an input for the TEC--5002 controller. When the parking brake is not 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.
Windshield Wiper/Washer Switch (Groundsmaster 4010--D) The windshield wiper/washer switch is used to control operation of the windshield wiper and washer pump on the Groundsmaster 4010--D. The windshield wiper/washer switch is located in the cab headliner (Fig. 33). 2 Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 2. Remove switch plate from cab headliner. 3. Locate windshield wiper/washer switch and unplug wire harness connector from switch. 4.
Air Conditioning Switch (Groundsmaster 4010--D) The air conditioning switch is used to control operation of the air conditioning system on the Groundsmaster 4010--D. The switch is located in the cab headliner (Fig. 35). Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 2. Remove switch plate from cab headliner. 2 3. Locate air conditioning switch and unplug wire harness connector from switch. 4. The switch terminals are marked as shown in Figure 36.
Hour Meter The hour meter is located on the outside of the console arm. Testing 7. Assemble console arm (see Console Arm Assembly in the Service and Repairs section of Chapter 7 -- Chassis). 1. Make sure ignition switch is OFF. Remove key from ignition switch. Hobbs QUARTZ 2. Disassemble console arm to gain access to the hour meter (see Console Arm Disassembly in the Service and Repairs section of Chapter 7 -- Chassis). 00001 HOURS 3.
Main Power, Glow and Operator Cab Power (Groundsmaster 4010--D) Relays The main power, glow and operator cab power relays are located at the power center behind the operator seat (Fig. 39). The wire harness is attached to these relays with a four (4) wire connector (Fig. 40). 8. Secure relay to mounting bracket and connect wire harness connector to relay. Secure power center to tank support if it was removed. Install cover (item 1) and heat shield (item 11) to power center.
Start and Air Conditioning (Groundsmaster 4010--D) Relays When energized by the TEC--5002 controller, the start relay is used to provide current to the engine starter motor solenoid. The start relay is located at the power center behind the operator seat (Fig. 41). An identical relay is used to control the air conditioning electrical power circuit on the Groundsmaster 4010--D. When energized by the air conditioning switch, the relay provides current for the air conditioning components.
Toro Electronic Controllers (TEC) Logic power is provided to the controllers as long as the battery cables are connected to the battery. A pair of 2 amp fuses (F3--1 and F4--1) provide circuit protection for this logic power to the controllers. IMPORTANT: Before performing welding on the machine, disconnect both positive and negative battery cables from the battery, disconnect wire harness connector from both of the TEC controllers and disconnect the terminal connector from the alternator.
Hydraulic Valve Solenoids 7 1 6 5 RIGHT FRONT 2 4 3 Figure 45 1. 4WD manifold 2. LH PTO manifold 3. Traction manifold 4. Front PTO manifold 5. Fan drive manifold Several hydraulic solenoid valve coils are used on the hydraulic control manifolds of Groundsmaster 4000--D and 4010--D machines. When energized by the TEC controller, these coils provide hydraulic circuit control. Solenoid valve coils with two (2) different resistance specifications are used on the 4000--D and 4010--D.
Testing 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Locate hydraulic valve solenoid coil to be tested (Fig. 45). Disconnect wire harness connector from coil. 3. Identify coil resistance specification by measuring the coil diameter and coil height (Fig. 46). COIL DIAMETER NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together.
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 (forward or reverse). The neutral switch is used as an input to the TEC--5002 controller. The switch is located on the right side of the piston (traction) pump (Fig. 48).
Fuel Sender The fuel sender is located on top of the fuel tank. 7. Replace sender as necessary. Install sender into fuel tank. Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 8. Connect wires to fuel sender. Apply skin--over grease (see Special Tools in this chapter) to sender terminals. 2. Remove white (+) wire and black (--) wire from the fuel sender.
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. Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 2. Locate fuel gauge for testing (see Steering Tower Disassembly in the Service and Repairs section of Chapter 7 -- Chassis). VARIABLE RESISTANCE 14 VDC + 0.
Fuel Pump The fuel pump is attached to the frame above the fuel water separator (Fig. 54). Operational Test 3 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake. 2 2. Remove fuse F1--1 (20 amp) (Fig. 55) from fuse block to prevent the engine from cranking. 3. Disconnect fuel hose (pump discharge) from the fuel water separator. 4 1 4. Make sure fuel hoses attached to the fuel pump are free of obstructions. Figure 54 5.
Temperature Sender The temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 56). The resistance of the temperature sender reduces as the engine coolant temperature increases. There is a gray harness wire attached to the terminal of the switch. 1 Testing 2 1. Lower coolant level in the engine and remove the temperature sender from water flange. 2. Suspend sender in a container of oil with a thermometer and slowly heat the oil (Fig. 57).
Temperature Gauge The temperature gauge on the control panel indicates engine coolant temperature level during machine operation (Fig. 58). The changing resistance of the engine temperature sender signals the temperature gauge. The temperature gauge should display the first green segment when the ignition switch is turned to ON. The first yellow segment on the gauge should display when engine coolant temperature is approximately 212oF (100oC).
Cutting Deck Position Switches Three (3) cutting deck position switches are used on the Groundsmaster 4000--D and 4010--D. These switches are located on the traction unit frame (Figs. 59 and 60). The position switches are powered proximity switches that incorporate an internal reed switch and a LED. The deck position switches are used as inputs for the TEC--5001 controller to prevent deck operation when a cutting deck is raised. The switch sensing plates are attached to the cutting deck lift arms.
B. Make sure that ignition switch is OFF and disconnect the switch connector from wire harness. C. Using a multimeter, verify that wire harness connector terminal for pink wire has 12 VDC when the ignition switch is ON. 1 2 D. Make sure that clearance between end of position switch and sensing plate is from 0.070” and 0.130” (1.8 to 3.3 mm). If necessary, adjust position switch (see Cutting Deck Position Switches in the Adjustments section of this chapter). Recheck switch operation after adjustment. E.
Engine Coolant and Hydraulic Oil Temperature Senders The Groundsmaster 4000--D and 4010--D use two (2) temperature senders as inputs for the TEC--5002 to identify if either the engine coolant or hydraulic oil temperature has reached an excessive level. These senders are identical. The coolant temperature sender threads into the radiator (Fig. 62). The hydraulic oil temperature sender is attached to the hydraulic hydraulic tube on the left side of the machine (Fig. 63). 6.
Service and Repairs NOTE: For engine component repair information (e.g. starter motor), see the Kubota Workshop Manual, Diesel Engine, 03--M--E3B Series at the end of Chapter 3 -- Kubota Diesel Engine. Battery Storage If the machine will be stored for more than 30 days: 1. 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 1 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. Electrolyte Specific Gravity Fully charged: 1.
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. Battery Testing 1. Conduct a hydrometer test of the battery electrolyte. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. B. If the battery has been charged, apply a 150 amp load for fifteen (15) seconds to remove the surface charge. Use a battery load tester following the manufacturer’s instructions.
Battery Charging To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which is readily available. 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.
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 85 to 100 ft--lb (115 to 135 N--m) 16 17 2 3 2 5 15 1 18 4 75 to 85 ft--lb (101 to 115 N--m) 14 6 7 11 5 8 2 3 2 RIGHT FRONT 12 13 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 Axles, Planetaries and Brakes 7. 8. 9. 10. 11. 12.
Removal (Fig. 1) 24 25 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch. 6 23 21 22 2. Drain oil from planetary wheel drive/brake assembly. 5 CAUTION 20 When removing front wheel, 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.
2. Apply gasket sealant to sealing surfaces of new gasket (item 18). Apply gasket to brake assembly. 3. Install brake assembly onto machine, aligning splined brake shaft with input shaft on planetary wheel drive. 4. Secure brake assembly to planetary assembly with four (4) flange head screws (item 9). Tighten screws in a crossing pattern to a torque from 75 to 85 ft--lb (101 to 115 N--m). 5. Secure brake link assembly to pull rod on brake assembly, frame bracket and brake lever (Fig. 2).
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Brake Inspection and Repair 2 1 3 4 5 6 7 8 9 15 10 14 13 12 11 Figure 6 1. 2. 3. 4. 5. Brake housing (LH shown) Seal Pull rod Clevis pin (2 used) Link (2 used) 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. 6) 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 7 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. 7) 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 9 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 -- 12 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. 9 and 10) 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 RIGHT 20 FRONT 17 19 16 4 4 15 2 15 7 14 13 12 11 10 9 2 1 3 4 5 6 See text for tightening procedure 8 Figure 11 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. 14. Rear axle assembly Thrust washer (thin) Washer head screw Pivot pin Rear axle mount Washer Lock nut Removal (Fig. 11) 1.
8. Remove cap screw and flange nut that secures front corner of 4WD hydraulic manifold to rear axle mount bracket. 1 2 3 9. If required, remove tie rod ends from steering arms on rear axle (Fig. 13). Remove the cotter pins and castle nuts from the tie rod ball joints. Use a ball joint fork and remove the tie rod ends from the axle steering arms. 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 15 10.Install wheels to axle. 11. Lower machine to ground.
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Rear Axle Service 10 11 22 21 24 17 23 20 18 19 8 2 9 25 15 3 13 12 5 26 43 14 16 1 6 33 7 27 44 45 28 29 8 61 62 9 46 47 10 37 22 50 41 60 52 4 42 36 11 48 63 39 59 9 38 40 53 8 35 30 31 49 13 34 32 58 57 54 51 56 55 Figure 16 Axles, Planetaries and Brakes Page 6 -- 20 Groundsmaster 4000--D/4010--D
Figure 16 (Continued) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. LH axle support Flange bushing (2 used) Axle vent O--ring Vent extension Cap screw (4 used per gear case) Shim set Seal washer Plug Lock nut Lock washer Grease fitting Ball bearing Screw (2 used per steering arm) Axle case support (LH shown) Bolt (2 used) Stud (2 used) Shim set Differential assembly O--ring Plug 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42.
Bevel Gear Case and Axle Case The following procedures assume the rear axle assembly has been removed from the machine. 35 to 41 ft--lb (47 to 56 N--m) Removal 1 6 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. 17). 4 5 2 2. Mark both right and left bevel gear case/axle case assemblies. 3 35 to 41 ft--lb (47 to 56 N--m) IMPORTANT: Do not interchange right and left bevel gear case/axle case assemblies.
5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gasket material from either mating surface (Fig. 20). 6. While holding the bevel gear case, tap the upper end of the bevel gear shaft out of the upper bearing and upper bevel gear. 2 1 17 to 20 ft--lb (23 to 27 N--m) 3 4 Thread--locking 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.
Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 22). 3 2 1 Figure 22 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. 23). Tighten cover screws from 17 to 20 ft-lb (23 to 27 N--m). 3. Shaft seal 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. 26). LOWER BEVEL GEAR BACKLASH: 0.004 to 0.016 in. (0.10 to 0.40 mm) 10.Adjust backlash by increasing or reducing axle bearing shim thickness (see Axle Shafts in this section of this manual).
Axle Shafts The following procedures assume the rear axle assembly has been removed from the machine. 17 to 20 ft--lb (23 to 27 N--m) 1 Removal 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig. 29). 4 3 2. Use a bearing puller to remove the bearing and bevel gear as shown (Fig. 30). 3. Remove the shims, spacer and retaining ring. Drive the axle out of the bearing and cover. Remove and discard the axle shaft seal. 4.
Input Shaft/Pinion Gear 35 to 41 ft--lb (47 to 56 N--m) 1 3 2 18 20 19 9 8 7 6 5 17 4 18 16 15 10 14 10 9 13 11 35 to 41 ft--lb (47 to 56 N--m) 12 Figure 32 1. 2. 3. 4. 5. 6. 7. Nut (2 used) Lock washer (2 used) Stud (2 used) Lock nut Stake washer Oil seal O-ring 8. 9. 10. 11. 12. 13. 14. Seal collar Bearing O-ring Input shaft/pinion gear Bearing case Shim Screw (2 used) The following procedures assume the rear axle assembly has been removed from the machine. Removal (Fig. 32) 1.
5. Install a new stake washer. Install the lock nut finger tight. 6. Set the bearing preload by securing the bearing case in a vise. Thread a M12 x 1.5 hex head cap screw into the splined end of the input shaft/pinion gear and slowly tighten the lock nut until 4 to 6 in-lb (0.4 to 0.7 N--m) of force is required to rotate the input shaft/pinion gear in the bearing case. 0.040 in. (1.0 mm) 2 1 7. Secure the lock nut with the stake washer. 8.
Differential Gear The following procedures assume the rear axle assembly has been removed from the machine. 35 to 41 ft--lb (47 to 56 N--m) 1 Removal 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. 2. Mark and pull the differential shaft assemblies from the axle support. 3. Remove input shaft/pinion gear assembly, shims and O-ring from the axle support (Fig.
Inspection 1. Measure the differential side gear O.D. and the differential case I.D. to determine the side gear to case clearance (Fig. 39). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 in. (0.05 to 0.30 mm) 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.
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. 43): 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. 46): A. Install thicker or additional bearing case shim(s) to move pinion shaft toward ring gear. Figure 46 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 RIGHT FRONT 25 1 3 24 2 23 7 26 4 5 6 21 40 22 33 34 35 36 37 8 28 27 9 10 29 30 31 11 12 13 14 32 16 to 20 ft--lb (22 to 27 N--m) 27 15 16 17 18 19 38 20 21 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 33 35 RIGHT 16 34 15 FRONT 37 60 to 70 ft--lb (81 to 94 N--m) 36 30 32 31 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 18 1 20 21 22 23 2 13 17 38 19 40 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. 14.
7. Install ball joint mount to ball joint with slotted hex nut. Torque nut from 90 to 100 ft--lb (123 to 135 N--m) while aligning cotter pin holes. Install cotter pin. 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.
Side Deck Lift Arm 16 17 19 18 16 17 12 11 14 13 20 10 23 17 21 24 25 4 27 40 28 5 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 29 15 Loctite #242 39 6 5 2 32 32 31 RIGHT 26 1 37 30 33 FRONT 38 37 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 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. Drive out slotted roll pin (item 15) that retains lift arm pivot shaft.
Side Deck Rear Arm Assembly 17 39 26 Loctite #271 34 27 16 24 22 29 25 44 43 33 28 49 40 31 34 35 35 36 31 37 30 41 18 19 RIGHT 35 32 15 21 42 38 23 20 270 to 330 in--lb (31 to 37 N--m) 14 13 13 5 FRONT 12 4 11 3 6 1 9 2 8 45 10 46 7 48 47 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
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) 13 14 12 21 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 (0.125” thickness) Hardened washer Cotter pin Slotted hex nut Removal (Fig. 11) 1.
Joint Yoke Disassembly 1. Remove retaining rings from yoke and deck mount. IMPORTANT: Support yoke when removing cross and bearings to prevent yoke damage. 2. Use a press to remove yoke from deck mount: 5. Install retaining rings to yoke and deck mount to secure bearings in place. 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.
Console Arm 40 32 39 38 37 31 30 29 34 1 28 27 35 1 18 19 25 17 43 6 13 12 36 14 33 15 23 24 16 22 2 21 26 11 10 9 RIGHT 42 8 7 FRONT 20 41 5 4 3 44 7 45 Figure 13 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Disassembly (Fig. 13) 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 2. Remove two (2) flange head screws (item 40) and then cover plate (item 39) from outside of console arm. Locate and retrieve two (2) spacers (item 38). 3. At front of console arm, remove screw (item 43) and lock nut (item 7) that secure console arm covers to each other. 9 3 1 1 5 12 5 13 11 10 5. Remove console arm covers from machine.
Operator Seat 37 36 39 35 33 27 38 20 34 26 20 25 32 5 18 19 32 31 30 20 29 29 28 24 4 21 22 6 23 3 7 17 1 9 10 12 11 13 14 RIGHT FRONT 16 2 8 15 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Platform Clevis pin (2 used) Hair pin (2 used) Seat plate Grommet Cotter pin (2 used) Latch shaft Cap screws (4 used) Latch Torsion spring Prop rod Flange nut (4 used) Cotter pin (2 used) Chassis 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Removal (Fig. 15) B. Secure console arm support (item 35) to coupler nut (item 38) with cap screw (item 37). 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. C. Place flat washer (item 20), seat belt latch (item 39) and spacer (item 36) between seat and console arm support (item 35). Secure with cap screw (item 33) and second flat washer (item 20). 2. Disconnect seat electrical connector from machine wire harness (Fig.
Operator Seat Service 7 6 21 1 2 13 5 28 12 21 22 26 25 30 29 4 16 18 19 20 11 24 14 17 3 23 9 8 27 10 15 Figure 18 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 -- 18 21. 22. 23.
Disassembly (Fig. 18) 2 1. Disassemble operator seat as necessary using Figures 18 and 19 as guides. 3 Assembly (Fig. 18) 1. Assemble operator seat using Figures 18 and 19 as guides. 1 4 5 7 11 6 7 10 8 9 Figure 19 Operator seat R--clamp Screw Manual tube Button head screw Seat belt 7. 8. 9. 10. 11. Flat washer Lock nut Cap screw Lock washer Seat belt mount Chassis 1. 2. 3. 4. 5. 6.
Operator Seat Suspension RIGHT 16 17 FRONT 24 22 25 23 5 18 2 19 21 33 1 20 3 39 14 12 7 13 35 28 30 6 15 38 27 31 4 36 8 29 9 10 26 33 11 34 37 32 Figure 20 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. 20) 1. Remove operator seat from seat suspension (see Operator Seat Removal in this section). 2. Disconnect seat suspension connector from machine wire harness (Fig. 21). 3 3.
Hood 49 12 13 41 1 2 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 21 48 34 Figure 23 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Removal 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 23 as a guide. Installation 1 1. Install hood using Figure 23 as a guide. 2. Align hood to machine to allow correct operation of hood latch and dust seals: A. Place shim that is from 3/8” to 7/16“ (9.5 to 11.1 mm) thick on top of frame (both RH and LH sides) near the sides of oil cooler (Figs. 24 and 25). B.
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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 lift switches. CONSTRUCTION: Deck chamber is welded 12 gauge steel construction reinforced with channels and plates. HEIGHT--OF--CUT RANGE: 1” to 5” (25.4 mm to 127 mm) in 1/2” (12.7 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 34 33 35 16 15 RIGHT 37 FRONT 60 to 70 ft--lb (81 to 94 N--m) 36 30 32 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 31 18 1 20 21 22 23 2 13 17 38 19 40 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. 14.
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 17 39 26 34 Thread locking Compound 27 16 24 22 29 25 44 43 33 28 49 40 41 270 to 330 in--lb (31 to 37 N--m) 15 14 13 13 5 FRONT 37 32 35 21 42 38 19 23 20 RIGHT 35 36 31 30 18 34 35 12 4 11 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. 17.
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. 3 2. Remove hydraulic motor from cutting deck (see Cutting Deck Motor Removal in the Service and Repairs Section of Chapter 4 -- Hydraulic System). IMPORTANT: Do not change the length of the damper link (Fig. 8). 1 1 3. Remove hairpin and clevis pin that secure the damper link to the rear of the cutting deck (Fig. 8). 4.
Idler Assembly RIGHT FRONT 18 17 16 22 15 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 10 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. Cutting deck (front shown) Flange nut Flange nut Adjusting screw Idler pulley Driven spindle (double pulley shown) Flat washer Lock washer Socket head screw 10. 11. 12. 13. 14. 15. 16. 17. Idler stop bolt Flange nut Cap screw Spacer Shoulder bolt Idler spring Lock nut Idler arm 18. 19. 20. 21. 22. 23. 24. 25.
Removal (Fig. 9) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove deck covers from top of cutting deck. CAUTION Be careful when removing idler spring. The spring is under heavy load and may 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 6 4 6 1 RIGHT FRONT 6 6 Figure 11 1. Front cutting deck 2. RH cutting deck Cutting Decks 3. LH cutting deck 4. Drive spindle Page 8 -- 12 5. Driven spindle 6.
Removal (Figs. 11 and 12) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove covers from 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. 4.
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 13 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. 13) Assembly (Fig. 13) 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 15). 2 1 Figure 14 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 17 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 Operator Cab Operator Cab Table of Contents GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical Components and Schematic . . . . . . . . . 2 Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . 2 Cab Heater System . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
General Information The information in this chapter pertains to the operator cab on the Groundsmaster 4010--D. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster. Refer to the Operator’s Manual for additional information when servicing the machine.
Service and Repairs 5. Put labels on disconnected lines and hoses for proper installation after repairs are completed. CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. WARNING Always wear safety goggles or a face shield when working with air conditioning system components.
Air Conditioning Compressor FRONT RIGHT 31 29 27 4 34 23 22 9 3 22 23 26 28 2 17 8 5 2 24 35 15 16 17 6 1 17 7 14 32 8 11 12 2 13 10 25 30 33 2 18 15 19 20 21 22 23 22 Figure 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Cap screw (3 used) Lock washer (8 used) Pulley V--belt Lower radiator hose Hose clamp (2 used) Lower radiator hose Cap screw (3 used) Alternator plate Carriage screw Flat washer Idler pulley 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
6. Read the General Precautions for Removing and Installing Air Conditioning System Components at the beginning of the Service and Repairs section of this chapter. CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. 7. Have refrigerant evacuated from air conditioning system by a certified A/C service technician. 8. Label and remove hoses from compressor.
Roof Assembly FRONT 16 16 1 3 3 15 4 4 2 3 4 14 5 13 7 6 12 4 8 4 9 11 4 10 3 2 9 10 Figure 3 1. 2. 3. 4. 5. 6. Roof Screw (2 used) Flat washer (6 used) Bushing (10 used) Rear fastener (2 used) Rear spacer (2 used) Operator Cab 7. 8. 9. 10. 11. Panel nut Roof mount Flange nut (2 used) Flange nut (4 used) Headliner Page 9 -- 6 12. 13. 14. 15. 16.
To gain access to the heater core and air conditioning components that are located under the cab roof, the roof panel can be loosened, raised and supported. 2 1 Removal (Fig. 3) 6 4 10 2. Remove screw (item 2), flat washer (item 3) and bushing (item 4) that secure the rear of the roof to the roof mount. 3. Remove the cap screw (item 15) and rubber washer (item 14) that secure the front of the roof. 4.
Air Conditioning Condenser Assembly 1 2 6 10 3 8 2 6 4 8 7 6 9 5 Figure 5 1. 2. 3. 4. Condenser cover Lock nut (4 used) Condenser fan Condenser coil assembly 5. Carriage screw (2 used) 6. Flat washer (8 used) 7. Roof Removal (Fig. 5) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 6.
8. Label and remove hoses from condenser coil. Immediately cap hoses and fittings to prevent moisture and contaminants from entering the system. 12 2 13 1 9. Remove condenser coil from roof using Figure 6 as a guide. Installation (Fig. 5) 11 3 4 10 9 1. Install condenser coil to roof using Figure 6 as a guide. 4. Secure condenser fan to condenser coil with button head screws (item 10). 5. Connect wire harness connector to condenser fan motor. 16 5 6 2.
Heater/Evaporator Assembly 10 10 2 10 10 4 3 9 1 6 5 8 8 11 11 7 Figure 7 1. 2. 3. 4. Heater/evaporator assembly Top cover Flange head screw (2 used) Drier--receiver mount 5. 6. 7. 8. Bottom cover Hose clamp (2 used) Speed nut (8 used) Panel nut (4 used) Removal (Fig. 7) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove fasteners that secure roof in place.
The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. 5. Have refrigerant evacuated from air conditioning system by a certified A/C service technician. 9. Operate the heater system to make sure that no engine coolant leaks exist. 10.Lower and secure roof assembly (see Roof Assembly Installation in this section). 6.
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Chapter 10 Foldout Drawings Table of Contents Groundsmaster 4000--D/4010--D Page 10 -- 1 Foldout Drawings HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL SCHEMATICS Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.070 .063 .035 S4 S2 S3 .063 S6 S9 S5 S7 S8 FRONT PTO MANIFOLD S1 RV1 RV2 LIFT/LOWER MANIFOLD TRACTION MANIFOLD LH PTO MANIFOLD M1 M2 ST L BYPASS VALVE 4WD MANIFOLD P1 T P2 FAN DRIVE MANIFOLD FILTER MANIFOLD RH PTO MANIFOLD Groundsmaster 4000--D/4010--D Hydraulic Schematic Page 10 -- 3 Rev.
STANDARD ON GM4010--D (OPTIONAL ON GM4000--D) Groundsmaster 4000--D/4010--D Electrical Schematic Sheet 1 of 3 All relays and solenoids are shown as de-- energized. All ground wires are black. NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON THREE (3) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER WILL BE IDENTIFIED.
(BRAKE APPLIED) (NOT IN NEUTRAL) (SEAT UNOCCUPIED) ENGINE OIL PRESSURE (OPTIONAL KIT) ALTERNATOR (OPTIONAL KIT) Groundsmaster 4000--D/4010--D Electrical Schematic Sheet 2 of 3 All relays and solenoids are shown as de-- energized. All ground wires are black. NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON THREE (3) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER WILL BE IDENTIFIED.
Groundsmaster 4000--D/4010--D Electrical Schematic Sheet 3 of 3 All relays and solenoids are shown as de-- energized. All ground wires are black. NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON THREE (3) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER WILL BE IDENTIFIED.
1F 3 30 A A/C BU BN VIO 1F 2 15 A HEATER PK L 2 B 3 --2 OR --7 OR --8 BK --5 BK --6 RESISTOR 2 --3 OR BK/W --4 BK/W FREEZE SWITCH PWR R GND 5 4 H C OR Y 2 1 3 5 4 6 BU OR 30 85 87a 87 86 BK/W OR/BK BK BINARY SWITCH AIR CONDITIONING (PRESSURE SWITCH) P05--H W W 56--E W BU 56--D BU LINE 38 LINE 39 R 1F 1 15 A WORK LIGHTS P05--G BU BK W/BK 2 3 GN R 6 BU GN R W/BK BK P11--1 P11--2 P11--3 P11--4 P11--5 VIO PWR WINDSHIELD WASHER/WIPER LOW SPEED HIGH SPEED
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TO REAR HARNESS (OPTIONAL KIT) (OPTIONAL KIT) A/C CLUTCH & WS WASHER PUMP (OPTIONAL KIT) (OPTIONAL KIT) NOTE CLOCK POSITION NOTE CLOCK POSITION TO REAR HARNESS TEC--5001 COMM PORT (NOT USED) TO REAR HARNESS TO REAR HARNESS Groundsmaster 4000--D/4010--D Platform Wire Harness Drawing Page 10 -- 9
Page 10 -- 10 (OPTIONAL KIT) Groundsmaster 4000--D/4010--D Platform Wire Harness Diagram Sheet 1 of 2 NOTE: THE PLATFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, A REFERENCE NUMBER WILL BE IDENTIFIED.
TO REAR HARNESS TO REAR HARNESS BLACK BLACK BLACK BLACK BLACK BLUE PINK/BLACK WHITE/ORANGE PINK PINK BLACK WHITE YELLOW YELLOW BLUE BROWN ORANGE GRAY YELLOW RED GREEN BLACK YELLOW BLACK BLACK WHITE PINK PINK WHITE PINK GREEN BLUE/WHITE BLACK BROWN 265 728 175 VIOLET YELLOW PINK PINK BLACK GRAY/BLUE BLACK GRAY PINK (NOT USED) 197 747 641 166 BLACK 635 165 167 636 PINK/GREEN 270 172 YELLOW/BLUE PINK 154 269 GREEN/BLACK ORANGE/BLACK BLACK WHITE/BLUE BLACK ORANGE/
FUSEBLOCKS MAXI FUSES TO PLATFORM HARNESS TO PLATFORM HARNESS TO PLATFORM HARNESS TO PLATFORM HARNESS Groundsmaster 4000--D/4010--D Rear Wire Harness Drawing Page 10 -- 12
BLACK RED/BLACK BLUE BLACK PINK WHITE RED RED PINK RED RED RED BLACK RED VIOLET RED BLACK BLUE BLACK WHITE/BLACK TO PLATFORM HARNESS BROWN/BLACK TAN/BLACK GRAY/BLACK BLUE PINK/BLACK RED BLACK WHITE WHITE/ORANGE TO PLATFORM HARNESS YELLOW RED PINK VIOLET ORANGE BLACK BLACK WHITE/YELLOW RED/BLACK BLACK BROWN PINK RED/BLUE RED/GREEN WHITE/BLACK BLACK BLACK BROWN/BLACK TAN/BLACK GRAY/BLACK BLACK PINK BLACK PINK YELLOW/BLUE BLACK BLACK BLACK BLACK BLACK RED RED RED RED RE
FUSEBLOCKS TO CAB INTERCONNECT HARNESS Groundsmaster 4010--D Cab Wire Harness Drawing Page 10 -- 14
BLACK/WHITE ORANGE/BLACK ORANGE WHITE/ BLACK RED YELLOW GRAY ORANGE BROWN VIOLET PINK ORANGE/BLACK BLUE BLACK BLUE BLACK ORANGE ORANGE ORANGE BLACK BLACK WHITE/BLACK ORANGE/BLACK RED VIOLET RED/WHITE RED RED BLACK BLACK GREEN RED WHITE/BLACK RED BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK VIOLET WHITE VIOLET ORANGE VIOLET GRAY BROWN BROWN BLUE BLUE VIOLET BLACK VIOLET VIOLET BLUE VIOLET BROWN VIOLET BLACK VIOLET BLACK TO CAB INTERCONNECT HARNESS BLACK
RED BLACK WHITE Groundsmaster 4010--D Cab Interconnect Wire Harness Page 10 -- 16 BLACK BLUE
