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Toro Groundsmaster 4000-D, Service Manual

The Toro Groundsmaster 4000-D Service Manual is a comprehensive and invaluable resource for maintaining and repairing your Groundsmaster 4000-D efficiently. Download the manual for free from our website to access step-by-step instructions and diagrams, enabling you to keep your equipment running smoothly all year round.

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Groundsmaster 4000--D

Engine Wire Harness

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Summary of Contents for Groundsmaster 4000-D

Page 1: ...s of the Operator s Manual and Parts Catalog are avail able on the internet at www Toro com The Toro Company reserves the right to change product specifications or this publication without notice This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal...

Page 2: ...Groundsmaster 4000 D This page is intentionally blank ...

Page 3: ...ONTROLLED PIS TON PUMP REPAIR INFORMATION EATON MODEL 74318 and 74348 PISTON MOTORS FIXED DISPLACEMENT VALVE PLATE DESIGN REPAIR INFORMATION Chapter 5 Electrical System General Information 5 2 Special Tools 5 3 Troubleshooting 5 5 Electrical System Quick Checks 5 8 Component Testing 5 9 General Information 5 34 Chapter 6 Axles Planetaries and Brakes Specifications 6 2 General Information 6 3 Servi...

Page 4: ...Groundsmaster 4000 D This page is intentionally blank ...

Page 5: ...r 4000 D Page 1 1 Safety Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS 2 Before Operating 2 While Operating 2 Maintenance and Service 3 JACKING INSTRUCTIONS 4 SAFETY AND INSTRUCTION DECALS 5 Safety ...

Page 6: ...al is in NEUTRAL and cutting decks are DISENGAGED 4 Since diesel fuel is highly flammable handle it care fully A Use an approved fuel container B Do not remove fuel tank cap while engine is hot or running C Do not smoke while handling fuel D Fill fuel tank outdoors and only to within an inch of the top of the tank not the filler neck Do not overfill E Wipe up any spilled fuel While Operating 1 Sit...

Page 7: ... cutting decks and other moving parts Keep bystanders away 10 Do not overspeed the engine by changing governor setting To assure safety and accuracy check maximum engine speed 11 Shut engine off before checking or adding oil to the crankcase 12 Disconnect battery before servicing the machine Disconnect negative cable first and positive cable last If battery voltage is required for troubleshooting ...

Page 8: ...l which may result in personal injury Jacking the Front End Fig 1 1 Set parking brake and chock both rear tires to pre vent the machine from moving 2 Position jack securely under the frame just to the in side of the front tire Jack front wheel off the ground 3 Once the machine is raised position jack stand un der the frame as close to the wheel as possible to sup port the machine Jacking the Rear ...

Page 9: ...ety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 4000 D If any decal becomes illeg ible or damaged install a new decal Decal part num bers are listed in your Parts Catalog Safety ...

Page 10: ...Groundsmaster 4000 D Page 1 6 Safety This page is intentionally blank ...

Page 11: ...inc Plated and Steel Fasteners Metric 5 Other Torque Specifications 6 Conversion Factors 6 Product Records Insert Operator s Manuals and Parts Catalogs for your Groundsmaster at the end of this chapter Additionally if any optional equipment or accessories have been installed to your machine insert the Installation Instruc tions Operator s Manuals and Parts Catalogs for those options at the end of ...

Page 12: ...0 09375 Groundsmaster 4000 D Page 2 2 Product Records and Maintenance Equivalents and Conversions ...

Page 13: ...er head or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Fastener Identification Figure 1 Grade 1 Grade 5 Grade 8 Inch Series Bolts and Screws Figure 2 Class 8 8 Class 10 9 Metric Bolts and Screws Using a Torque Wrench with an Offset Wrench Use of an offset wrench e g crowfoot wrench will affect torque wrench c...

Page 14: ...16 2 22 3 30 3 41 4 43 5 58 7 3 8 24 UNF 17 2 18 2 24 3 35 4 47 5 50 6 68 8 7 16 14 UNC 27 3 27 3 37 4 50 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 6 75 8 77 8 104 11 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 11 142 15 1 2 20 UNF 32 4 53 7 72 9 85 9 115 12 120 12 163 16 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 21 285 28 5 8 18 UNF 75 10 95 15 129 20 170 18 230 24 240 24 325 33 3 4 10 U...

Page 15: ...b 90 10 N m 93 10 ft lb 126 14 N m M16 X 2 0 166 17 ft lb 225 23 N m 229 23 ft lb 310 31 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610 62 N m NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite NOTE Torque values may have to be reduced whe...

Page 16: ...n lb Wheel Bolts and Lug Nuts Thread Size 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 8 80 10 ft lb 108 14 N m M12 X 1 5 Class 8 8 80 10 ft lb 108 14 N m For steel wheels and non lubricated fasteners Thread Cutting Screws Zinc Plated Steel Thread Size Threads per Inch Baseline Torque Size Type A Type B Baseline Torque No...

Page 17: ...e 2 SPECIFICATIONS 3 SERVICE AND REPAIRS 4 Air Filter System 4 Exhaust System 6 Fuel System 8 Check Fuel Lines and Connections 9 Empty and Clean Fuel Tank 9 Fuel Tank Removal 9 Fuel Tank Installation 9 Radiator 10 Engine 12 Engine Removal 12 Engine Installation 14 Spring Coupler 16 KUBOTA WORKSHOP MANUAL DIESEL ENGINE V2403 M T E3B SERIES Kubota Diesel Engine ...

Page 18: ...est equipment is explained However the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an en gine repair facility Service and repair parts for Kubota engines are sup plied through your Authorized Toro Distributor If no parts listis available be prepared to provide your distrib utor with the Toro model and serial number Operator s Manual Th...

Page 19: ...Diesel or Biodiesel up to B20 Fuel with Low or Ultra Low Sulfur Content Fuel Capacity 19 0 U S Gallons 72 Liters Fuel Injection Pump Denso PFR 4M Type Mini Pump Injection Nozzle Denso OPD Mini Nozzle Governor Centrifugal Mechanical Low Idle no load 1425 50 RPM High Idle no load 2870 50 120 RPM Engine Oil API CH 4 CI 4 or higher Engine Oil Viscosity See Operator s Manual Crankcase Oil Capacity 10 0...

Page 20: ... 4 Indicator 5 Air cleaner strap 6 Lock nut 2 used 7 Hose clamp 8 Air cleaner hose 9 Hose clamp 10 Cap screw 2 used 11 Flat washer 4 used 12 Spring 2 used 13 Flat washer 2 used 14 Cap screw 2 used 15 Adapter 16 Lock nut 2 used 17 Flat washer 2 used VACUATOR DIRECTION FRONT RIGHT 8 1 3 4 5 6 9 7 10 2 11 11 12 13 14 15 16 17 12 to 15 in lb 1 4 to 1 6 N m ...

Page 21: ...installing adapter and indicator to housing Install adapter so that grooves in adapter hex and adapter filter elementare installed toward service indicator Fig 3 Torque in dicator from 12 to 15 in lb 1 4 to 1 6 N m 2 When installing air cleaner hose 8 between air cleaner and turbo charger Fig 4 A Make sure that hose does not contact engine valve cover To ensure clearance move and or ro tate air cl...

Page 22: ...screw 2 used 8 Flat washer 4 used 9 Spacer 2 used 10 Rubber hanger 11 Flange nut 4 used 12 Flange head screw 2 used 13 Engine mount 14 Muffler clamp 15 Exhaust mount 16 Flange head screw 2 used 16 to 22 ft lb 21 to 29 N m 16 to 22 ft lb 21 to 29 N m 16 to 22 ft lb 21 to 29 N m FRONT RIGHT 1 14 3 4 7 5 8 8 7 6 9 13 11 2 12 10 16 11 8 8 6 15 16 to 22 ft lb 21 to 29 N m 13 ft lb 17 6 N m ...

Page 23: ...ay prevent a tight seal 1 Install new exhaust gasket if original gasket is dam aged or torn IMPORTANT Failure to follow the suggested muf fler fastener sequence may result in premature muf fler failure 2 Install exhaust system components to the engine us ing Figure 5 as a guide Hand tighten exhaust system fasteners and then torque in the sequence shown in Fig 6 as follows A Torque lock nuts used o...

Page 24: ... plate 20 Negative cable 21 Positive cable 22 Carriage screw 23 Gasket 24 Bushing 3 used 25 Stand pipe 26 Fuel sender 27 Lock washer 5 used 28 Phillips head screw 5 used 29 Fuel hose 30 Hose clamp 31 Elbow fitting 2 used 32 Fuel cap 33 Locking flange nut 2 used 34 Speed nut 35 Tank cover 2 used 36 Phillips head screw 4 used 37 Vent tube 38 Insulated clip 3 used 39 Washer head screw 3 used 40 Hose ...

Page 25: ...on switch 2 Raise and support operator seat and hood 3 Remove battery cover and strap Disconnect nega tive battery cable first and then positive battery cable Remove battery from machine 4 Use a fuel transfer pump to remove fuel from the fuel tank and into a suitable container 5 Disconnect electrical wiring from the sending unit 6 Disconnect fuel hose from the standpipe and venting hoses from elbo...

Page 26: ...ge nut 10 used 29 Foam plug 2 used 30 Lock nut 6 used 31 Foam strip 32 Base bracket 33 Flange head screw 6 used 34 Bulb seal 2 used 35 Grommet 2 used 36 Cover 37 Flange head screw 4 used 38 Plate 2 used 39 Flat washer 2 used 40 Knob 2 used 41 Cap screw 6 used 42 Cable tie 43 Coolant reservoir 44 Tank bracket 45 Flat washer 10 used 46 Foam pad 47 Cap screw 7 used 48 Foam seal 49 Cap screw 3 used 50...

Page 27: ...cure fan motor bracket to radiator 10 Position lower radiator shroud and fan motor bracket assembly away from radiator 11 Remove cap screws and flange nuts securing the ra diator to the support frame Carefully pull radiator from the machine 12 Plug allradiator or hose openings to preventcontam ination Installation Fig 8 1 Remove all plugs placed during the removal proce dure 2 Carefully position r...

Page 28: ...ap screw 4 used 21 RH engine mount 22 Cap screw PTO manifold 23 Lock washer 24 Ground cable 25 Cap screw 26 Lock washer 27 RH engine mount FRONT RIGHT 1 2 3 6 5 4 7 26 8 9 10 11 14 15 12 13 16 17 18 20 21 19 24 23 22 25 27 9 13 13 Loctite 242 29 to 33 ft lb 40 to 44 N m 28 to 32 ft lb 38 to 43 N m 28 to 32 ft lb 38 to 43 N m Engine Removal Fig 9 1 Park machine on a level surface lower cutting deck...

Page 29: ...hine Disconnect wires and or electrical connections from the following electrical components A The dual temperature switch temperature sen der and alternator Fig 10 B The glow plugs Fig 11 C The engine run solenoid Fig 12 D Battery frame and wire harness ground at the en gine block E The electric starter and low oil pressure switch near electric starter 8 Disconnect fuel line from injection pump 9...

Page 30: ...rness fuel lines or hydraulic hoses to the engine are removed 15 Connect hoist or lift to the lift tabs on engine 16 Remove flange nuts rebound washers and cap screws securing the engine mounts to the engine sup ports CAUTION One person should operate lift or hoist while another person guides the engine out of the ma chine IMPORTANT Make sure not to damage the engine fuel and hydraulic lines elect...

Page 31: ...ter plate Fig 15 Make sure that removed shim s are positioned between transport cylinder and engine mount 11 Connect wires and or electrical connections to the following electrical components A The dual temperature switch temperature send er and alternator Fig 10 B The glow plug Fig 11 C The engine run solenoid Fig 12 D Battery frame and wire harness ground to the en gine block E The starter and l...

Page 32: ...screw 2 used 8 Carriage screw 2 used 9 Cylinder shim 10 Transport cylinder 11 Lock nut 2 used 12 Cylinder piston 13 O ring 2 used 14 Backup ring 2 used 15 Retaining ring 16 Seal 17 O ring 18 Hydraulic fitting 19 O ring 20 Hydraulic hose 21 RH engine mount 1 2 3 6 5 4 7 2 8 9 10 11 14 15 12 13 16 17 18 20 21 19 FRONT RIGHT Loctite 242 29 to 33 ft lb 40 to 44 N m 28 to 32 ft lb 38 to 43 N m ...

Page 33: ...nting holes Make sure that coupling hub is away from engine flywheel Fig 17 2 Apply Loctite 242 or equivalent to threads of cap screws item 3 Secure coupler to flywheel with six 6 cap screws and washers Torque cap screws in a cross ing pattern from 29 to 33 ft lb 40 to 44 N m 3 Position flywheel plate to engine and engine mounts Secure flywheel plate and mounts with cap screws items 5 and 7 and wa...

Page 34: ...Groundsmaster 4000 D Page 3 18 Kubota Diesel Engine This page is intentionally blank ...

Page 35: ...MENTS 60 Adjust Front Cutting Deck Lift Flow Control 60 SERVICE AND REPAIRS 61 General Precautions for Removing and Installing Hydraulic System Components 61 Check Hydraulic Lines and Hoses 61 Flush Hydraulic System 62 Charge Hydraulic System 63 Hydraulic Reservoir 64 Hydraulic Oil Cooler 66 Gear Pump 68 Gear Pump Service 70 Traction Circuit 72 Piston Traction Pump 74 Piston Traction Pump Service ...

Page 36: ...on 1 16 Cubic Inches 19 09 cc Section P3 P4 Displacement per revolution 0 56 Cubic Inches 9 16 cc Steering Control Valve Eaton Steering Unit Series 5 Steering Circuit Relief Pressure 1350 PSI 93 bar Lift Lower Circuit Relief Pressure 1500 PSI 103 bar Cutting Deck Motors Sauer Danfoss Gear Motor PTO Circuit Relief Pressure Front and Left Side 3000 PSI 207 bar Right Side 2000 PSI 137 bar Engine Cool...

Page 37: ...the machine tow or push in a forward direction only and at a speed below 3 mph The piston traction pump is equipped with a by pass valve that needs to be turned 90o one quarter turn for towing Refer to your Opera tor s Manual for additional towing instructions 1 By pass valve location Figure 1 1 Check Hydraulic Fluid The Groundsmaster 4000 D hydraulic system is de signed to operate on anti wear hy...

Page 38: ... the hose Use two wrenches hold the hose straight with one wrench and tighten the hose swivel nut onto the fit ting with the other wrench See Hydraulic Hose and Tube Installation in this section If the hose has an el bow at one end tighten the swivel nut on that end before tightening the nut on the straight end of the hose For additional hydraulic hose information refer to Toro Service Training Bo...

Page 39: ...in the Torque Specifica tions section of Chapter 2 Product Records and Main tenance 5 If a torque wrench is not available or if space at the swivel nut prevents use of a torque wrench an alternate method of assembly is the Flats From Wrench Resist ance F F W R method Fig 2 A Using a wrench tighten the swivel nut onto the fit ting until light wrench resistance is reached approxi mately 30 in lb B M...

Page 40: ...Records and Maintenance to determine necessary con version information 5 If a torque wrench is not available or if space at the port prevents use of a torque wrench an alternate meth od of assembly is the Flats From Finger Tight F F F T method A Install the fitting into the port and tighten it down full length until finger tight B If port material is steel tighten the fitting to the listed F F F T...

Page 41: ...n with a wrench and use a torque wrench to tighten the fitting to the rec ommended installation torque shown in Figure 7 This tightening process will require the use of an offset wrench e g crowfoot wrench Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using a torque wrench with an offset wrench will be l...

Page 42: ... MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD TRACTION MANIFOLD COUNTERBALANCE MANIFOLD FILTER MANIFOLD M1 M2 ST L P1 P2 T RV1 RV2 LC2 LC1 S P1 P2 M1 M2 RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR BYPASS VALVE NOTE A larger hydraulic schematic is included in Chapter 9 Foldout Drawings ...

Page 43: ...Groundsmaster 4000 D Hydraulic System Page 4 9 This page is intentionally blank Hydraulic System ...

Page 44: ...g Pressure Low Pressure Charge Return or Suction Flow Groundsmaster 4000 D FAN DRIVE MANIFOLD RH PTO MANIFOLD 4WD MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD TRACTION MANIFOLD COUNTERBALANCE MANIFOLD M1 M2 ST L P1 P2 T P1 P2 P1 P2 P1 P2 LC2 LC1 RV1 RV2 RV1 RV2 M1 M2 M1 M2 S LC2 LC1 OR OR S M1 M2 RV1 RV2 LC2 LC1 S ...

Page 45: ...rator can momentarily engage this flow divider when low traction situations could lead to wheel spin Depressing the flow divider switch energizes the sole noid valve in the traction manifold This energized sole noid valve causes traction pump hydraulic flow to split between the front wheel motors approximately 45 and rear axle motor approximately 55 to reduce the chance that excessive flow goes to...

Page 46: ...arge Return or Suction Flow Groundsmaster 4000 D FAN DRIVE MANIFOLD RH PTO MANIFOLD 4WD MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD TRACTION MANIFOLD COUNTERBALANCE MANIFOLD M1 M2 ST L P1 P2 T P1 P2 P1 P2 P1 P2 LC2 LC1 RV1 RV2 RV1 RV2 M1 M2 M1 M2 S LC2 LC1 OR OR S M1 M2 RV1 RV2 LC2 LC1 S extended energized shifted shifted ...

Page 47: ...ure is li mited to 250 PSI 17 bar by a relief valve located in the oil filter manifold Charge pressure can be measured at the charge circuit pressure test port on the oil filter man ifold Forward Direction With the transport 4WD switch in the transport position solenoid valve SV in the 4WD control manifold is ener gized The solenoid valve spool shifts to direct charge pressure that shifts the PD1 ...

Page 48: ...w Pressure Charge Return or Suction Flow Groundsmaster 4000 D FAN DRIVE MANIFOLD RH PTO MANIFOLD 4WD MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD TRACTION MANIFOLD COUNTERBALANCE MANIFOLD M1 M2 ST L P1 P2 T RV1 RV2 LC2 LC1 S P1 P2 M1 M2 RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR ...

Page 49: ...nd of the cylinder returns to the traction charge circuit When the lift lever is released the lift cyl inder and side cutting deck are held in position To lower the front cutting deck the center lift lever on the lift lower controlvalveis pushedtoallow valveshiftinthe lift lower control This valve change allows a passagefor oil flow from the rod end of the front deck lift cylinders The weight of t...

Page 50: ...w Pressure Charge Return or Suction Flow Groundsmaster 4000 D FAN DRIVE MANIFOLD RH PTO MANIFOLD 4WD MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD TRACTION MANIFOLD COUNTERBALANCE MANIFOLD M1 M2 ST L P1 P2 T RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR RV1 RV2 LC2 LC1 S P1 P2 M1 M2 RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR ...

Page 51: ... cutting deck Oil from the rod end of the cylinder flows to the tractionchargecircuit When theliftleveris released the lift cylinder and cutting deck are held in position To raise the front cutting deck the center lift lever on the lift lower control valve is pulled to allow valve shift in the lift lower control valve This valve change allows hy draulic pressure to the rod end of the front deck li...

Page 52: ...sure Charge Return or Suction Flow Groundsmaster 4000 D FAN DRIVE MANIFOLD RH PTO MANIFOLD 4WD MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD TRACTION MANIFOLD COUNTERBALANCE MANIFOLD M1 M2 ST L P1 P2 T RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR RV1 RV2 LC2 LC1 S P1 P2 M1 M2 RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR ...

Page 53: ...idge LC1 When the PTO switch is turned ON the solenoid valve S en ergizes causing a shift of the by pass cartridge LC1 and allowing hydraulic flow to the deck motor Brake car tridge LC2 and relief cartridge RV2 control the stop ping rate of the blade when the solenoid control valve is de energized as the PTO switch is turned OFF Return oil from the deck motors is directed to the oilcool er and oil...

Page 54: ...against the closed logic cartridge LC2 When this pres sure builds to approximately 600 PSI 41 bar relief valve RV2 opens which allows a small amount of hy draulic flow to return to tank through a manifold sensing line Fig 11 This flow causes a pressure increase that shifts logic cartridge LC2 to once again allow oil flow from the motor Fig 12 When return pressure drops below 600 PSI 41 bar relief ...

Page 55: ...Groundsmaster 4000 D Hydraulic System Page 4 21 This page is intentionally blank Hydraulic System ...

Page 56: ...w Pressure Charge Return or Suction Flow Groundsmaster 4000 D FAN DRIVE MANIFOLD RH PTO MANIFOLD 4WD MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD TRACTION MANIFOLD COUNTERBALANCE MANIFOLD M1 M2 ST L P1 P2 T RV1 RV2 LC2 LC1 S P1 P2 M1 M2 RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR ...

Page 57: ...the steering cylinder piston for a left turn The rotary meter ensures that the oil flow to the cylinder is proportional to the amount of the turning on the steering wheel Fluid leav ing the cylinder flows back through the spool valve then through the T port and to the hydraulic reservoir The steering control valve returns to the neutral position when turning is completed Right Turn When a right tu...

Page 58: ...essure Low Pressure Charge Return or Suction Flow Groundsmaster 4000 D FAN DRIVE MANIFOLD RH PTO MANIFOLD 4WD MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD TRACTION MANIFOLD COUNTERBALANCE MANIFOLD M1 M2 ST L P1 P2 T RV1 RV2 LC2 LC1 S P1 P2 M1 M2 RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR ...

Page 59: ...ut off the over running inertia load of the fan blades keeps driving the fan motor and turns itinto a pump The check valve CV in the fan drive manifold will open to keep the motor circuit full of oil so the fan motor will not cavitate Forward Direction Fan Operation Oil flow from the gear pump is sent through the de ener gized solenoid valve S1 to rotate the cooling fan motor Return flow from the ...

Page 60: ... Hydraulic Tester Pressure and Flow This tester requires O ring Face Seal ORFS adapter fittings for use on this machine 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 PRESSURE GAUGE Glycerine filled 0 to 5000 PSI gauge to provide operating circuit ...

Page 61: ...ING KIT NO TOR4079 Measuring Container Use this container for doing hydraulic motor efficiency testing motors with case drain lines only Measure effi ciency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydraulic system The table in Figure 20 provides gallons per minute GPM conversion formeasu...

Page 62: ...nt temperature Engine RPM is too low Brakes are applied or sticking Hydraulic reservoir oil level is low Hydraulic oil is contaminated or the wrong type Piston pump by pass valve is open or damaged Cooling system is not operating properly Charge pressure is low Traction circuit pressure is incorrect Pump s or motor s are damaged Hydraulic oil in reservoir foams Hydraulic reservoir oil level is low...

Page 63: ...cal System Solenoid valve SV in 4WD hydraulic manifold is faulty Cartridge valve in 4WD manifold is damaged or sticking No cutting decks will operate Electrical problem exists see Chapter 5 Electrical System Gear pump or its coupler is damaged NOTE other hydraulic circuits impacted as well One cutting deck will not operate Electrical problem exists see Chapter 5 Electrical System System pressure t...

Page 64: ...ecks raise but will not stay up NOTE Lift cylinders cannot provide an absolutely perfect seal The cut ting deck will eventually lower if left in the raised position during storage Lift circuit lines or fittings are leaking Lift cylinder is damaged Detents in lift lower control valve are worn Front cutting deck drops too fast or too slow Flow control valve is not adjusted properly Cutting decks wil...

Page 65: ...rk on the hydraulic system all pressure in the system must be relieved and all rotating ma chine parts must be stopped Stop engine lower or support attachments WARNING 1 Clean machine thoroughly before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hy draulic equipment Contamination will cause excessive wear of components 2 Put ...

Page 66: ...TRACTION MANIFOLD FILTER MANIFOLD TO COOLING FAN CIRCUIT TO STEERING LIFT CIRCUITS TO PTO MOW CIRCUIT FROM FRONT DECK FROM COUNTERBALANCE MANIFOLD FROM PTO MANIFOLDS TO PTO MOW CIRCUIT CYLINDERS FROM FRONT PTO MANIFOLD FROM STEERING VALVE PORT T FROM STEERING VALVE PORT PB FROM PTO MANIFOLDS FAN MOTOR PRESSURE GAUGE ...

Page 67: ...pressure is low check for restriction in pump intake line Also inspect charge relief valve located in filter manifold see Hydraulic Manifold Service Filter Manifold in the Service and Repairs sec tion ofthischapter Ifnecessary checkfor internaldam age or worn parts in gear pump 8 Also with the pressure gauge still connected to the charge pressure test port take a gauge reading while operating the ...

Page 68: ...ANIFOLD TO COOLING FAN CIRCUIT TO STEERING LIFT CIRCUITS TO PTO MOW CIRCUIT FROM FRONT DECK FROM COUNTERBALANCE MANIFOLD FROM PTO MANIFOLDS TO PTO MOW CIRCUIT CYLINDERS FROM FRONT PTO MANIFOLD FROM STEERING VALVE PORT T FROM STEERING VALVE PORT PB FROM PTO MANIFOLDS FAN MOTOR FORWARD TRACTION CIRCUIT RELIEF PRESSURE TEST SHOWN PRESSURE GAUGE ...

Page 69: ...ly brakes fully and slowly depress the traction pedal in the appropriate direction While pushing traction pedal look at pressure reading on gauge GAUGE READING TO BE Forward 3750 to 4250 PSI 259 bar to 293 bar Reverse 4750 to 5250 PSI 328 to 362 bar 6 Release traction pedal and stop engine Record test results 7 If traction pressure is too low inspect traction pump relief valves Fig 24 Clean or rep...

Page 70: ... Pressure Gauge FAN DRIVE MANIFOLD 4WD MANIFOLD TRACTION MANIFOLD FILTER MANIFOLD TO PTO MOW CIRCUIT FROM PTO MANIFOLDS TO PTO MOW CIRCUIT FROM FRONT PTO MANIFOLD FROM DECK MOTORS FROM RH PTO MANIFOLD FROM RH PTO CIRCUIT PRESSURE GAUGE COUNTERBALANCE MANIFOLD M1 M2 ST L P1 P2 T ...

Page 71: ...ngage the cutting decks GAUGE READING TO BE 220 PSI 15 2 bar over system charge pressure e g if charge pressure is 250 PSI 17 2 bar counterbalance pressure should be 470 PSI 32 4 bar 6 Stop engine and record test results 7 Adjustment of the counterbalance valve can be per formed as follows NOTE Do not remove the valve from the hydraulic manifold for adjustment A Loosen lock nut on counterbalance v...

Page 72: ...OLD TRACTION MANIFOLD FILTER MANIFOLD TO COOLING FAN CIRCUIT TO STEERING LIFT CIRCUITS TO PTO MOW CIRCUIT FROM FRONT DECK FROM COUNTERBALANCE MANIFOLD FROM PTO MANIFOLDS TO PTO MOW CIRCUIT CYLINDERS FROM FRONT PTO MANIFOLD FROM STEERING VALVE PORT T FROM STEERING VALVE PORT PB FROM PTO MANIFOLDS FAN MOTOR PRESSURE GAUGE ...

Page 73: ...onitor the pressure gauge Pressure should increase until the relief valve lifts GAUGE READING TO BE 750 PSI 52 bar approx imate 6 Stop engine and record test results 7 Relief valve RV is located on the lower front side of the 4WD control manifold Fig 27 Adjustment of the relief valve RV can be performed as follows NOTE Do not remove the valve from the hydraulic manifold for adjustment A To increas...

Page 74: ...FOLD TRACTION MANIFOLD FILTER MANIFOLD TO COOLING FAN CIRCUIT TO STEERING LIFT CIRCUITS TO PTO MOW CIRCUIT FROM FRONT DECK FROM COUNTERBALANCE MANIFOLD FROM PTO MANIFOLDS TO PTO MOW CIRCUIT CYLINDERS FROM FRONT PTO MANIFOLD FROM STEERING VALVE PORT T FROM STEERING VALVE PORT PB FROM PTO MANIFOLDS FAN MOTOR PRESSURE GAUGE ...

Page 75: ...ction While pushing traction pedal look at pressure reading on gauge GAUGE READING TO BE approximately 650 PSI 45 bar 6 Stop engine and record test results 7 Pressure reducing valve PR is located on the front side of the 4WD control manifold Fig 30 Adjustment of this valve can be performed as follows NOTE Do not remove the pressure reducing valve from the hydraulic manifold for adjustment A To inc...

Page 76: ...R MANIFOLD TO COOLING FAN CIRCUIT FROM REAR AXLE MOTOR TO STEERING LIFT CIRCUITS TRACTION CIRCUIT FLOW CHARGE CIRCUIT FROM FRONT WHEEL MOTORS FROM 4WD MANIFOLD TRACTION CIRCUIT FLOW FROM COOLING FAN CIRCUIT FRONT DECK CIRCUIT PRESSURE TEST SHOWN PRESSURE GAUGE RV1 RV2 LC2 LC1 S P1 P2 M1 M2 RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR ...

Page 77: ...port for the deck to be tested Figs 31 32 and 33 CAUTION Keep away from decks during test to prevent per sonal injury from the cutting blades 4 Start engine and move throttle to full speed 2870 RPM Engage the cutting decks 5 Watch pressure gauge carefully while mowing with the machine 6 Cutting deck circuit pressure should be as follows and will vary depending on mowing conditions LH Deck 1000 to ...

Page 78: ...MANIFOLD FILTER MANIFOLD TO COOLING FAN CIRCUIT FROM REAR AXLE MOTOR TO STEERING LIFT CIRCUITS TRACTION CIRCUIT FLOW CHARGE CIRCUIT FROM FRONT WHEEL MOTORS FROM 4WD MANIFOLD TRACTION CIRCUIT FLOW FROM COOLING FAN CIRCUIT FRONT PTO RELIEF PRESSURE TEST SHOWN TESTER RV1 RV2 LC2 LC1 S P1 P2 M1 M2 RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR ...

Page 79: ...PM Engage the cutting decks 7 Watch pressure gauge carefully while slowly closing the flow control valve to fully closed 8 As the relief valve lifts system pressure should be approximately 2900 to 3100 PSI 200 to 213 bar for the front and left decks 1900 to 2100 PSI 131 to 144 bar for the right deck 9 Disengage cutting decks Shut off engine and record test results If specification is not met adjus...

Page 80: ...TER MANIFOLD TO COOLING FAN CIRCUIT FROM REAR AXLE MOTOR TO STEERING LIFT CIRCUITS TRACTION CIRCUIT FLOW CHARGE CIRCUIT FROM FRONT WHEEL MOTORS FROM 4WD MANIFOLD TRACTION CIRCUIT FLOW FROM COOLING FAN CIRCUIT FRONT CUTTING DECK MOTOR CASE DRAIN LEAKAGE TEST SHOWN MEASURING CONTAINER CAP TESTER RV1 RV2 LC2 LC1 S P1 P2 M1 M2 RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR ...

Page 81: ...left side motor first 3 Disconnect hose from return of the motor to be tested Fig 36 Install flow tester in series with the mo tor and disconnected return hose Make sure the flow control valve on tester is fully open Fig 37 4 Disconnect the motor case drain hose small diame ter hose where it connects to hydraulic manifold tee fit ting not at the motor Put a steel cap on the fitting at the tee fitt...

Page 82: ...PTO MANIFOLD FILTER MANIFOLD TO COOLING FAN CIRCUIT FROM REAR AXLE MOTOR TO STEERING LIFT CIRCUITS TRACTION CIRCUIT FLOW CHARGE CIRCUIT FROM FRONT WHEEL MOTORS FROM 4WD MANIFOLD TRACTION CIRCUIT FLOW FROM COOLING FAN CIRCUIT FRONT DECK GEAR PUMP FLOW TEST SHOWN TESTER RV1 RV2 LC2 LC1 S P1 P2 M1 M2 RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR ...

Page 83: ...ect hydraulic hose at deck manifold port P1 Fig 38 4 Install tester in series with the the disconnected hose and hydraulic manifold port P1 5 Make sure the flow control valve on the tester is fully open 6 Start engine and move throttle to full speed 2870 RPM Do not engage the cutting decks IMPORTANT Do not fully restrict oil flow through tester In this test the flow tester is positioned be fore th...

Page 84: ...ANIFOLD 4WD MANIFOLD TRACTION MANIFOLD FILTER MANIFOLD TO PTO MOW CIRCUIT FROM PTO MANIFOLDS TO PTO MOW CIRCUIT FROM FRONT PTO MANIFOLD TO LIFT LOWER CONTROL VALVE FROM FRONT DECK LIFT CYLINDERS FROM COUNTERBALANCE MANIFOLD FROM DECK MOTORS FROM RH PTO MANIFOLD FROM RH PTO CIRCUIT PRESSURE GAUGE M1 M2 ST L P1 P2 T ...

Page 85: ...ull lock only long enough to get a system pressure reading Holding the steering wheel against the stop for an extended period can damage the steering valve 5 Turn steering all the way in one direction and mo mentarily hold the steering wheel against resistance GAUGE READING TO BE 1300 to 1400 PSI 90 to 96 bar 6 Stop the engine and record test results 7 If pressure is incorrect inspect steering rel...

Page 86: ... Using Pressure Gauge FAN DRIVE MANIFOLD 4WD MANIFOLD TRACTION MANIFOLD FILTER MANIFOLD TO PTO MOW CIRCUIT FROM PTO MANIFOLDS TO PTO MOW CIRCUIT FROM FRONT PTO MANIFOLD FROM DECK MOTORS FROM RH PTO MANIFOLD FROM RH PTO CIRCUIT PRESSURE GAUGE COUNTERBALANCE MANIFOLD M1 M2 ST L P1 P2 T ...

Page 87: ...Sit on the seat and start the engine Move throttle to full speed 2870 RPM 5 While sitting on the seat pull lift lever back to raise the cutting decks Momentarily hold the lever with the lift cylinder at full extension while looking at the gauge GAUGE READING TO BE 1500 to 1600 PSI 104 to 110 bar 6 Stop the engine and record test results 7 If pressure is too high adjust relief valve in lift control...

Page 88: ...w Using Tester with Pressure Gauges and Flow Meter FAN DRIVE MANIFOLD 4WD MANIFOLD TRACTION MANIFOLD FILTER MANIFOLD TO PTO MOW CIRCUIT FROM PTO MANIFOLDS TO PTO MOW CIRCUIT FROM FRONT PTO MANIFOLD FROM DECK MOTORS FROM RH PTO MANIFOLD FROM RH PTO CIRCUIT COUNTERBALANCE MANIFOLD TESTER ...

Page 89: ...g and lift lower circuits Fig 43 4 Install tester in series between the fitting and the dis connected hose Make sure the tester flow control valve is OPEN IMPORTANT The pump is a positive displacement type If pump flow is completely restricted or stopped damage to the pump tester or other com ponents could occur 5 Start the engine and move throttle to full speed 2870 RPM DO NOT engage the cutting ...

Page 90: ...ircuit Using Pressure Gauge and Phototac FAN DRIVE MANIFOLD 4WD MANIFOLD TRACTION MANIFOLD FILTER MANIFOLD TO PTO MOW CIRCUIT FROM PTO MANIFOLDS TO PTO MOW CIRCUIT FROM FRONT PTO MANIFOLD FROM DECK MOTORS FROM RH PTO MANIFOLD FROM RH PTO CIRCUIT COUNTERBALANCE MANIFOLD ...

Page 91: ...hototac to identify the cooling fan speed disconnect the wire harness connector white green and black wires fromthe PRVsolenoid on fan drive manifold Both fan speed and pressure should increase and stabilize after the solenoid is disconnected PRESSURE GAUGE READING TO BE approxi mately 3000 PSI 207 bar PHOTOTAC READING TO BE fan speed approxi mately 2800 RPM 6 Stop engine and record test results 7...

Page 92: ...low Using Tester with Pressure Gauges and Flow Meter FAN DRIVE MANIFOLD 4WD MANIFOLD TRACTION MANIFOLD FILTER MANIFOLD TO PTO MOW CIRCUIT FROM PTO MANIFOLDS TO PTO MOW CIRCUIT FROM FRONT PTO MANIFOLD FROM DECK MOTORS FROM RH PTO MANIFOLD FROM RH PTO CIRCUIT COUNTERBALANCE MANIFOLD TESTER ...

Page 93: ...e cooling circuit Fig 43 4 Install tester in series between the fitting and the dis connected hose Make sure the tester flow control valve is OPEN IMPORTANT The pump is a positive displacement type If pump flow is completely restricted or stopped damage to the pump tester or other com ponents could occur 5 Start the engine and move throttle to full speed 2870 RPM DO NOT engage the cutting decks 6 ...

Page 94: ...oilat operating temper atures Park machine on a level surface shut engine off and lower cutting decks to the ground 2 Locate flow controlvalve under frontof machine Fig 46 3 Loosen set screw on valve and rotate valve clock wise to slow down drop rate of front cutting deck 4 Verify adjustment by raising and lowering cutting deck several times Readjust as required 5 After desired drop rate is attain...

Page 95: ...oil filter if component failure was severe or system is contaminated see Flush Hydraulic System in this section 2 Lubricate O rings and seals with clean hydraulic oil before installing hydraulic components 3 Make sure caps or plugs are removed from the hy draulic tubes hydraulic fittings and components before reconnecting 4 Use proper tightening methods when installing hy draulic hoses and fitting...

Page 96: ...e disconnected while draining system NOTE Use only hydraulic fluids specified in the Opera tor s Manual Other fluids may cause system damage 7 Fill hydraulic reservoir with new hydraulic fluid 8 Disconnect electrical connector from engine run so lenoid 9 Turn ignition key switch and engage starter for ten 10 seconds to prime hydraulic pumps Repeat this step again 10 Connect electrical connector to...

Page 97: ...ke sure traction pedal and lift control lever are in neutral Start engine and run it at low idle 1450 rpm The charge pump should pick up oil and fill the hydraulic system If there is no indication of fill in thirty 30 se conds stop the engine and determine the cause 11 After the hydraulic system starts to show signs of fill actuate lift control lever until the lift cylinder rod moves in and out se...

Page 98: ...n hose 16 Tank strainer 17 Hose clamp 18 Hose 19 Hose clamp 20 Cap screw 21 Socket head screw 3 used 22 Lock nut 3 used 23 Hose 24 Hose 25 Elbow fitting 26 Flange nut 27 O ring 28 Flat washer 4 used 29 Front frame 30 Flange nut 4 used 31 Cap screw 4 used Figure 47 FRONT RIGHT 1 2 6 8 7 9 11 12 13 14 21 22 20 5 15 16 3 18 19 10 17 4 23 9 26 24 25 27 30 to 40 in lb 3 4 to 4 5 N m minimum 28 31 30 29...

Page 99: ...ts item 30 that secure front frame to main frame 11 Carefully lower front frame assembly to allow clear ance for reservoir removal Once lowered support front frame to prevent it from shifting 12 Carefully remove hydraulic reservoir from machine Inspection 1 Clean hydraulic reservoir and suction strainer with solvent 2 Inspect reservoir for leaks cracks or other damage Installation Fig 47 1 Using a...

Page 100: ... Retaining ring 2 used 7 Carriage screw 2 used 8 O ring 9 90o hydraulic fitting 2 used 10 O ring 11 Cap screw 2 used 12 Lock washer 6 used 13 Oil cooler 14 Flange nut 2 used 15 Cap screw 2 used 16 Oil cooler mount plate 2 used 17 Cap screw 4 used 18 LH radiator support Figure 48 1 2 5 8 7 9 3 10 4 6 15 16 17 18 11 12 13 14 12 FRONT RIGHT 8 9 10 12 ft lb 16 N m ...

Page 101: ...n of this chapter 3 Remove oil cooler using Figures 48 as a guide Inspection 1 Back flush oilcooler with cleaning solvent After cool er is clean make sure all solvent is drained from the cooler CAUTION Use eye protection such as goggles when using compressed air 2 Dry inside of oil cooler using compressed air in the opposite direction of the oil flow 3 Plug both ends of oil cooler Clean exterior o...

Page 102: ...draulic fitting 2 used 16 Pump coupler 17 O ring 18 Flat washer 2 used 19 Cap screw 2 used 20 Engine 21 Gear pump 22 O ring 23 Hydraulic hose 24 O ring 25 Hose clamp 26 Hydraulic hose 27 O ring 28 Hose clamp 29 Hydraulic hose 30 O ring 31 O ring 32 Hydraulic hose 33 Hydraulic hose 34 Hydraulic fitting Figure 49 FRONT RIGHT 79 to 84 ft lb 108 to 113 N m 1 9 7 15 14 12 4 8 10 6 3 13 5 2 11 16 17 18 ...

Page 103: ...emoval process to properly orientate fittings Tighten fittings see Hydraulic Fitting Installation in the General Infor mation section of this chapter A If 90o hydraulic suction fitting item 8 was re moved torque fitting nut from 103 to 118 ft lb 140 to 160 N m 2 Lubricate new O rings item 13 with clean hydraulic oil Position O rings on gear pump and pump spacer flanges 3 Slide coupler onto the pis...

Page 104: ... Figure 50 10 11 8 15 5 3 19 20 21 22 23 24 9 7 25 26 6 1 2 16 17 18 4 14 13 12 9 33 ft lb 45 N m 11 22 21 Disassembly Fig 50 NOTE The gear pump must be replaced as a complete assembly Individual gears housings and thrust plates are not available separately Disassemble gear pump for cleaning inspection and seal replacement only IMPORTANT Keep bodies gears flanges and thrust plates for each pump se...

Page 105: ...arking dye to mating teeth to retain timing Pump efficiency may be affected if the teeth are not installed in the same position during assembly Keep the parts for each pump section together do not mix parts between sections 8 Clean all parts Check all components for burrs scoring nicks and other damage 9 Replace the entire pump assembly if parts are ex cessively worn or scored Assembly Fig 50 1 Ap...

Page 106: ...otor 6 4WD manifold 7 Filter manifold 8 Rear axle motor 9 Cooling fan motor 10 Check valve Figure 52 FRONT RIGHT 2 1 5 4 3 7 6 8 9 10 Figure 52 illustrates the components that are used in the Groundsmaster 4000 D traction circuit Procedures for removal installation and disassembly assembly of these components are provided on the following pages of this section ...

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Page 108: ...0o hydraulic fitting 2 used 16 Pump coupler 17 O ring 18 Flat washer 2 used 19 Cap screw 2 used 20 Engine 21 Gear pump 22 O ring 23 Hydraulic hose 24 O ring 25 Hose clamp 26 Hydraulic hose 27 O ring 28 Hose clamp 29 Hydraulic hose 30 O ring 31 O ring 32 Hydraulic hose 33 Hydraulic hose 34 Hydraulic fitting Figure 53 FRONT RIGHT 79 to 84 ft lb 108 to 113 N m 1 9 7 15 14 12 4 8 10 6 3 13 5 2 11 16 1...

Page 109: ...on pump into the machine align pump input shaft to spring coupler on engine and posi tion it to the engine flywheel plate Support pump to pre vent it from producing any side load into coupler and also to align pilot diameter of pump to flywheel plate bore 2 While maintaining pump alignment with spring cou pler and flywheel plate install two 2 cap screws and washers to secure piston pump to engine ...

Page 110: ...ng gasket 33 Cover plate gasket 34 Control assembly gasket 35 Plug 36 O ring 37 Seal sub assembly 38 Roll pin 39 Bearing 40 Dowel bushing 41 Cradle sub assembly 42 Cap screw 43 Button head cap screw 44 Bushing 45 Bearing Figure 55 20 8 32 6 7 31 5 18 11 9 33 19 33 10 1 29 4 3 12 13 24 3 21 31 25 2 34 30 28 23 27 22 17 14 26 15 16 36 35 37 38 39 40 41 42 43 44 45 37 100 to 110 ft lb 136 to 149 N m ...

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Page 112: ...ernal snap ring 2 used 8 Pinion gear 9 External snap ring 2 used 10 Gear 11 Needle bearing 12 O ring 13 O ring 14 O ring 15 O ring 16 Drive axle assembly 17 Cap screw 6 used 18 Lock washer 6 used 19 Dowel pin 2 used 20 Cover plate 21 Gasket Figure 56 FRONT RIGHT Arrow on side of 16 11 10 5 4 3 9 7 8 6 1 2 15 14 13 12 motor case points up 59 to 73 ft lb 80 to 99 N m 18 21 19 17 20 2 ...

Page 113: ...ngs from motor and discard O rings Installation Fig 56 1 If fittings were removed from motor lubricate and place new O rings onto fittings Install fittings into port openingsusingmarksmadeduringthe removalprocess to properly orientate fittings Tighten fittings see Hy draulic Fitting Installation in the General Information section of this chapter 2 If removed install pinion gear to axle motor 3 Ins...

Page 114: ...Flange head screw 6 used per side 10 90o hydraulic fitting 11 90o hydraulic fitting 12 O ring 13 O ring 14 Hydraulic fitting 15 O ring 16 O ring 17 Hydraulic fitting 18 O ring 19 O ring 20 LH brake assembly 21 Flange head screw 4 used per side 22 Hex plug Figure 57 FRONT RIGHT 5 2 3 2 4 8 1 14 11 10 6 17 21 22 20 7 12 13 12 16 15 18 19 15 16 10 9 11 11 14 14 75 to 85 ft lb 101 to 115 N m 15 16 Arr...

Page 115: ... mark fitting orientation to allow correct assembly Re move fittings from motor and discard O rings Installation Fig 57 1 If fittings were removed from motor lubricate and place new O rings onto fittings Install fittings into port openingsusingmarksmadeduringthe removalprocess to properly orientate fittings Tighten fittings see Hy draulic Fitting Installation in the General Information section of ...

Page 116: ...st bearing 14 Roll pin 3 used 15 Roll pin 16 Bearing 17 Bearing 18 Washer Figure 58 6 8 1 9 10 13 7 2 11 14 3 17 15 16 12 4 5 9 10 18 15 to 18 ft lb 20 to 24 N m NOTE The front wheel motors are identical The rear axle motor has some differences from the front motors Service of the front and rear motors requires the same procedures NOTE For service of the wheel motors see the Eaton Model 74318 and ...

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Page 118: ...5 Adapter 16 Hydraulic fitting 17 O ring 18 Cap screw 2 used 19 Flange nut 2 used Figure 59 FRONT RIGHT 1 15 16 2 18 3 14 9 12 8 6 10 10 11 7 4 5 4 5 7 17 13 12 9 19 NOTE The ports on the manifold are marked for easy identification of components Example P1 is a piston pump connection port and SV is the location for the sole noid valve See Hydraulic Schematic in Chapter 9 Foldout Drawings to identi...

Page 119: ...lic fittings are to be removed from manifold mark fitting orientation to allow correct assembly Re move fittings from manifold and discard O rings Installation Fig 59 1 If fittings were removed from manifold lubricate and place new O rings onto fittings Install fittings into man ifold openings using marks made during the removal process to properly orientate fittings Tighten fittings see Hydraulic...

Page 120: ...lug with O ring Figure 60 25 ft lb 34 N m 35 ft lb 47 N m 20 ft lb 27 N m 50 ft lb 67 N m 5 ft lb 6 7 N m FRONT UP 7 13 10 8 2 3 1 11 9 4 5 13 13 11 10 10 6 12 11 13 10 1 11 10 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 DOWN REAR NOTE The ports on the manifold are marked for easy identification of components Example P1 is a piston pump connectio...

Page 121: ...der can affect the operation of high pressure hydraulic valves If car tridge design allows use a wood or plastic probe to push the internal spool in and out 20 to 30 times to flush out contamination Be extremely careful not to damage car tridge Use compressed air for cleaning 7 The 4WD control manifold includes three 3 orifice fittings items 9 and 13 The 0 030 orifice item 9 is positioned in the S...

Page 122: ... 15 90o hydraulic elbow 16 O ring 17 Cap screw 18 O ring 19 Hydraulic fitting Figure 61 FRONT RIGHT 13 10 8 9 19 1 17 2 3 18 14 4 16 12 15 7 11 5 6 5 2 8 NOTE The ports on the manifold are marked for easy identification of hydraulic line connections Example P is the traction pump connection port and M1 is the con nection for the front traction motors See Hydraulic Schematic in Chapter 9 Foldout Dr...

Page 123: ...ic fittings are to be removed from manifold mark fitting orientation to allow correct assembly Re move fittings from manifold and discard O rings Installation Fig 61 1 If fittings were removed from manifold lubricate and place new O rings onto fittings Install fittings into man ifold openings using marks made during the removal process to properly orientate fittings Tighten fittings see Hydraulic ...

Page 124: ...m 198 in lb 22 4 N m 5 5 10 10 6 5 ft lb 6 7 N m 20 ft lb 27 N m 40 ft lb 54 N m 40 ft lb 54 N m 20 ft lb 27 N m 20 ft lb 27 N m 20 ft lb 27 N m 50 ft lb 67 N m 198 in lb 22 4 N m 198 in lb 22 4 N m FRONT UP NOTE The ports on the manifold are marked for easy identification of components Example P2 is the gear pump connection port and CD is the connection for the case drain from the deck motors See...

Page 125: ...Page 4 91 Traction Manifold Service Fig 62 For cartridge valve service procedures see 4WD Man ifold Service in this section Refer to Figure 62 for trac tion flow divider manifold cartridge valve and plug installation torque Hydraulic System ...

Page 126: ...se 19 Hydraulic tee fitting 20 90o hydraulic fitting 21 O ring 22 Hose clamp 23 Filter hose 24 Barb fitting 25 Oil filter Figure 63 FRONT RIGHT 13 10 8 9 19 1 17 2 3 20 23 18 14 4 21 16 12 15 7 11 5 6 22 24 25 6 11 11 6 NOTE The ports on the manifold are marked for easy identification of components Example P2 is the gear pump connection port and T is the connection for the hy draulic reservoir ret...

Page 127: ...fittings are to be removed from manifold mark fitting orientation to allow correct assembly Re move fittings from manifold and discard O rings Installation Fig 63 1 If fittings were removed from manifold lubricate and place new O rings onto fittings Install fittings into man ifold openings using marks made during the removal process to properly orientate fittings Tighten fittings see Hydraulic Fit...

Page 128: ...P 6 7 1 5 5 4 2 FRONT UP 3 3 25 ft lb 34 N m 30 ft lb 41 N m 50 ft lb 67 N m 25 ft lb 34 N m 25 ft lb 34 N m 30 ft lb 41 N m NOTE The ports on the manifold are marked for easy identification of components Example P2 is the gear pump connection port and T is the connection for the hy draulic reservoir return port See Hydraulic Schematic in Chapter 9 Foldout Drawings to identify the function of the ...

Page 129: ...c System Page 4 95 Filter Manifold Service Fig 64 For cartridge valve service procedures see 4WD Man ifold Service in this section Refer to Figure 64 for filter manifold cartridge valve and plug installation torque Hydraulic System ...

Page 130: ...Fan drive manifold 4 Fan motor 5 Steering cylinder Figure 65 FRONT RIGHT 2 1 5 4 3 Figure 65 illustrates the components that are used in the Groundsmaster4000 Dsteeringandcoolingfancircuit Procedures for removal installation and disassembly assembly of these components are provided on the fol lowing pages of this section ...

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Page 132: ...dapter 4 used 14 Steering valve assembly 15 Nut insert 16 Steering tower 17 Flange locking nut 2 used 18 Flange head screw 4 used 19 Pivot hub 2 used 20 Cap screw 2 used 21 Steering column assembly 22 Flange bushing 23 Thrust washer 24 Steering wheel cover 25 In port P 26 Right turn port R 27 Load sensing port PB 28 Left turn port L 29 Out port T Figure 66 1 2 3 4 5 6 7 23 22 8 17 21 20 19 12 16 1...

Page 133: ...from machine using Figure 66 as a guide 5 If hydraulic fittings are to be removed from steering valve mark fitting orientation to allow correct assembly Remove fittings from valve and discard O rings Installation Fig 66 1 Iffittings were removed fromsteering valve lubricate and place new O rings onto fittings Install fittings into port openings using marks made during the removal process to proper...

Page 134: ...ea Before disassembly drain the oil then plug the ports and thoroughly clean the exterior During repairs always protect machined surfaces Disassembly Fig 67 1 Remove the seven 7 cap screws from the steering valve assembly 2 Remove end cap geroter spacer geroter drive wear plate seal ring and O rings from housing Fig 67 3 Remove the plug and relief valve 4 Slide the spool and sleeve assembly from t...

Page 135: ... springs 5 Apply a light coating of clean hydraulic fluid to the spool and slide it into the sleeve Be sure the centering springs fit into the notches in the sleeve 6 Install the pin 7 Apply a light coating of petroleum jelly to the inner edge of the dust and quad seals 8 Put the thrust bearing and races into the housing The thrust bearing goes between the two races Fig 68 IMPORTANT Do not damage ...

Page 136: ... 4 Retaining ring 5 Grease fitting 6 Grease fitting 7 90o hydraulic fitting 8 O ring 9 O ring 10 Drive axle assembly 11 Ball joint spacer 12 Axle washer 13 Slotted hex nut 14 Cotter pin Figure 69 6 4 1 2 10 5 4 3 12 14 11 13 7 8 9 9 FRONT RIGHT See text for tightening procedure See text for tightening procedure 7 ...

Page 137: ...rd O rings 7 If needed remove ball joints from steering cylinder Installation Fig 69 1 If removed install ball joints into steering cylinder 2 If fittings were removed from steering cylinder lubri cate and place new O rings onto fittings Install fittings into portopenings using marks made during theremoval process to properly orientate fittings Tighten fittings see Hydraulic Fitting Installation i...

Page 138: ...Page 4 104 Steering Cylinder Service 1 Tube assembly 2 Rod 3 Piston assembly 4 Head 5 Retaining ring 6 Backup ring 7 O ring 8 Cap seal 9 Rod seal 10 O ring 11 O ring 12 Wiper Figure 70 45 to 55 ft lb 62 to 74 N m 1 6 7 3 9 10 4 11 2 8 5 12 ...

Page 139: ...d O rings from head and piston 7 Wash parts in clean solvent Dry parts with com pressed air Do not wipe parts dry with paper towels or cloth Lint in a hydraulic system will cause damage 8 Carefully inspect internal surface of barrel for dam age deep scratches out of round etc Replace en tire cylinder if barrel is damaged Inspect rod and piston for evidence of excessive scoring pitting or wear Re p...

Page 140: ...ose 7 Fan hub 8 Washer 9 Hex nut 10 Engine 11 Cap screw 4 used 12 Washer 4 used 13 Fan 14 Lock nut 2 used 15 Hydraulic hose 16 O ring 17 Hydraulic fitting 18 O ring 19 Hydraulic hose 20 Cap screw 2 used 21 Flat washer 2 used Figure 71 37 to 44 N m 27 to 33 ft lb 17 to 18 N m 12 to 14 ft lb 3 5 6 4 7 1 2 8 9 10 11 12 13 14 15 16 17 4 2 5 18 19 20 21 FRONT RIGHT ...

Page 141: ...otor bracket 10 Carefully lower fan motor and remove from machine 11 If hydraulic fittings are to be removed from fan motor mark fitting orientation to allow correct assembly Re move fittings from motor and discard O rings Installation Fig 71 1 If fittings were removed from fan motor lubricate and place new O rings onto fittings Install fittings into port openingsusingmarksmadeduringthe removalpro...

Page 142: ...s Fig 74 IMPORTANT Prevent damage when clamping the fan motor into a vise clamp on the front flange only Also use a vise with soft jaws 3 Clamp front flange of motor in a vise with soft jaws with the shaft end down 4 Loosen cap screws from the rear cover 5 Remove motor from the vise Turn motor so that the shaft end is facing down Remove cap screws 6 Carefully remove body Lift body straight up to r...

Page 143: ...harp edges of gears will mill into wear plates and thus must be replaced 4 Inspect wear plates for the following A Bearing areas should not have excessive wear or scoring B Face of wear plates that are in contact with gears should be free of wear roughness or scoring C Thickness of wear plates should be equal 5 Inspect front flange and rear cover for damage or wear 1 Dust seal 2 Retaining ring 3 F...

Page 144: ...rear wear plate with pressure seal side up and open side of the pressure seal pointing to the inlet side of the motor 9 Apply a light coating of petroleum jelly to new O rings and O ring grooves in the body Install new O rings to the body 10 Install locating dowels in body Align marker line on the body and front flange IMPORTANT Do not dislodge seals during installa tion 11 Gently slide the body o...

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Page 146: ...0o hydraulic fitting 20 Hydraulic hose 21 Hydraulic hose 22 Hydraulic tee fitting 23 Hydraulic test fitting 24 Oil filter assembly 25 Cap screw 2 used 26 Flat washer 2 used 27 Manifold mount Figure 77 7 9 1 2 3 4 8 6 5 10 5 5 5 5 7 7 7 7 7 7 10 11 12 15 16 13 14 17 18 19 20 14 21 22 23 24 25 26 4 27 FRONT RIGHT NOTE The ports on the manifold are marked for easy identification of components Example...

Page 147: ...lic fittings are to be removed from manifold mark fitting orientation to allow correct assembly Re move fittings from manifold and discard O rings Installation Fig 77 1 If fittings were removed from manifold lubricate and place new O rings onto fittings Install fittings into man ifold openings using marks made during the removal process to properly orientate fittings Tighten fittings see Hydraulic...

Page 148: ...5 2 2 4 7 9 8 6 10 7 20 ft lb 27 N m 20 ft lb 27 N m 20 ft lb 27 N m 50 ft lb 67 N m 25 ft lb 34 N m 25 ft lb 34 N m 25 ft lb 34 N m 25 ft lb 34 N m 25 ft lb 34 N m 5 ft lb 6 7 N m 5 ft lb 6 7 N m FRONT UP NOTE The ports on the manifold are marked for easy identification of components Example P1 and P2 are gearpumpconnectionportsandS1isthe solenoidvalve port See Hydraulic Schematic in Chapter 9 Fo...

Page 149: ...stem Page 4 115 Fan Drive Manifold Service Fig 78 For cartridge valve service procedures see 4WD Man ifold Service in this section Refer to Figure 78 for fan drive manifold cartridge valve and plug installation torque Hydraulic System ...

Page 150: ...tting deck motor 6 LH PTO manifold 7 Front PTO manifold 8 Filter manifold 9 Oil cooler Figure 79 FRONT RIGHT 2 1 5 4 3 7 6 8 9 Figure 79 illustrates the components that are used in the Groundsmaster 4000 D PTO circuits Procedures for removal installation and disassembly assembly of these components are provided on the following pages of this section ...

Page 151: ...ulic Fitting Installation in the General Information section of this chapter 2 If removed install spider hub on motor shaft Secure with tab washer and nut Torque nut from 27 to 33 ft lb 37 to 44 N m Bend small tab of washer into keyway and large tab against nut 3 Check for proper clearance between spider hub and spindle pulley Install motor to cutting deck without plac ing the spider in the spindl...

Page 152: ... of the motor thoroughly After cleaning remove plugs and drain any oil out of the motor 2 Use a marker or scribe to make a diagonal mark across the front flange body and rear cover for reas sembly purposes Fig 83 IMPORTANT Prevent damage when clamping the deck motor into a vise clamp on the front flange only Also use a vise with soft jaws 3 Clamp mounting flange of motor in a vise with the shaft e...

Page 153: ...s with emery cloth CAUTION Use eye protection such as goggles when using compressed air 2 Clean all motor components with solvent Dry all parts with compressed air 3 Inspect drive gear idler gear and bearing blocks Fig 86 for the following A Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas Scoring rough surfaces or wear on gear shafts indi cates n...

Page 154: ...dentification marks made during disassembly 7 Remove any excess lubrication from mating sur faces of body rear cover and front flange Make sure that these surfaces are clean and dry 8 Install dowel pins in body IMPORTANT Do not dislodge O rings pressure seals or back up rings during final assembly 9 Gently slide the rear cover onto the assembly using marker or scribe mark for proper location Firm ...

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Page 156: ...Hydraulic adapter 19 O ring 20 90o hydraulic fitting 21 O ring 22 R clamp 23 O ring 24 Hydraulic tee fitting 25 O ring 26 Hydraulic fitting 27 45o hydraulic fitting Figure 87 FRONT RIGHT 12 1 2 3 4 5 8 6 9 11 10 7 20 19 18 17 25 26 22 23 27 24 7 16 14 12 13 15 3 3 6 6 6 7 5 8 8 8 2 4 21 21 21 5 2 19 18 19 19 18 23 4 21 12 11 21 25 8 NOTE The ports on the manifold are marked for easy identification...

Page 157: ...ulic fittings are to be removed from manifold mark fitting orientation to allow correct assembly Re move fittings from manifold and discard O rings Installation Fig 87 1 If fittings were removed from manifold lubricate and place new O rings onto fittings Install fittings into man ifold openings using marks made during the removal process to properly orientate fittings Tighten fittings see Hydrauli...

Page 158: ... ft lb 34 N m 20 ft lb 27 N m 20 ft lb 27 N m 20 ft lb 27 N m RH DECK PTO MANIFOLD SHOWN NOTE The ports on the manifold are marked for easy identification of components Example S is the deck so lenoid valve and P1 is the gear pump connection port See Hydraulic Schematic in Chapter 9 Foldout Draw ings to identify the function ofthe hydraulic lines and car tridge valves at each port location The con...

Page 159: ...ystem Page 4 125 PTO Manifold Service Fig 88 For solenoid and control valve service procedures see 4WD Manifold Service in this section Refer to Figure 88 for PTO manifold cartridge valve and plug installation torque Hydraulic System ...

Page 160: ...ol valve 6 Front deck flow control valve 7 Front lift cylinder 8 Oil filter Figure 89 FRONT RIGHT 2 1 5 4 3 7 6 8 7 Figure 89 illustrates the components that are used in the Groundsmaster 4000 D cutting deck lift and lower cir cuits Procedures for removal installation and disas sembly assembly of these components are provided on the following pages of this section ...

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Page 162: ...n 6 used 11 RH lever assembly 12 Spacer 13 Cap screw 2 used 14 Knob 3 used 15 Lock nut 5 used 16 90o hydraulic fitting 2 used 17 O ring 18 O ring 19 Cap screw 2 used 20 Hydraulic fitting 4 used 21 Hydraulic fitting 22 O ring 23 Flat washer 3 used 24 Cap screw 3 used 25 Control panel 26 Lock nut 2 used 27 R clamp 28 Hydraulic fitting 29 O ring Figure 90 10 7 8 9 11 14 2 23 24 5 4 3 16 19 21 20 1 18...

Page 163: ...valve mark fitting orientation to allow correct assembly Remove fittings from valve and discard O rings Installation Fig 90 1 If fittings were removed from control valve lubricate and place new O rings onto fittings Install fittings into port openings using marks made during the removal process to properly orientate fittings Tighten fittings see Hydraulic Fitting Installation in the General Infor ...

Page 164: ...r 14 Washer 15 Washer 16 Washer 17 Plug 18 O ring 19 Spring 20 Backup washer 21 Detent spring 22 Plunger 23 Plug 24 O ring 25 O ring 26 Backup washer 27 Disc 28 Plunger 29 Plug assembly 30 Lockout spring 31 Spring 32 Relief plug assembly 33 Plunger 34 O ring 35 Spool 36 Body Figure 91 33 29 30 1 4 5 28 23 27 21 22 24 17 18 7 20 32 34 13 14 15 31 10 3 8 16 19 2 12 9 6 11 11 26 25 35 20 to 25 ft lb ...

Page 165: ...res are matched Damaged spools cannot be replaced 5 Inspect relief valve poppet item 10 for breakage or wear Assembly Fig 91 1 Thoroughly clean and dry all parts Apply a light coat ing of clean hydraulic oil to parts prior to assembly NOTE All O rings back up washers wiper seals and nylon poppets should be replaced with new items 2 Install new O rings item 11 in proper grooves in spool bores 3 Ins...

Page 166: ...ft Cylinder 1 Lift arm assembly LH shown 2 Shoulder screw 3 Pin assembly 4 Lift cylinder 5 Flange locking nut 6 90o hydraulic fitting 2 used 7 O ring 8 O ring 9 Cylinder pin 10 Spring pin 11 Lock nut 12 Flat washer Figure 92 11 12 9 10 3 2 4 5 1 6 7 8 FRONT RIGHT ...

Page 167: ...nder from machine 8 If hydraulic fittings are to be removed from lift cylind er mark fitting orientation to allow correct assembly Re move fittings from cylinder and discard O rings Installation Fig 92 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 fitt...

Page 168: ...Cylinder 1 Lift cylinder 2 Upper lift pin 3 Cotter pin 4 Pin assembly 5 Cap screw 6 Flat washer 7 Lock nut 8 Lift arm assembly LH shown 9 O ring 10 Straight hydraulic fitting 11 O ring 12 90o hydraulic fitting Figure 93 8 5 4 1 3 2 7 6 10 11 9 12 11 9 6 1 FRONT RIGHT ...

Page 169: ...vis 7 Remove lift cylinder from machine 8 If hydraulic fittings are to be removed from lift cylind er mark fitting orientation to allow correct assembly Re move fittings from cylinder and discard O rings Installation Fig 93 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 p...

Page 170: ...Lock nut 13 Grease fitting 14 Bushing 15 O ring 16 Seal Figure 94 SIDE DECK LIFT CYLINDER 12 11 9 10 7 6 5 8 4 3 2 15 14 13 13 100 to 120 ft lb 136 to 162 N m 1 16 1 Barrel with clevis 2 Seal 3 Shaft with clevis 4 Dust seal 5 Rod seal 6 O ring 7 Back up ring 8 Head 9 O ring 10 Wear ring 11 Piston 12 Lock nut 13 Retaining ring Figure 95 FRONT DECK LIFT CYLINDER 1 12 10 11 6 5 7 8 4 3 2 9 30 to 35 f...

Page 171: ...ydraulic system will cause damage 8 Carefully inspect internal surface of barrel for dam age deep scratches out of round etc Replace en tire cylinder if barrel is damaged Inspect piston rod and piston for evidence of excessive scoring pitting or wear Replace any damaged parts Assembly Figs 94 and 95 1 Make sure all cylinder components are clean before assembly 2 Coat new seal kit components with c...

Page 172: ...4 used 12 Cap screw 2 used 13 90o hydraulic fitting 14 O ring 15 Test nipple 16 Dust cap Figure 96 2 11 8 4 3 1 13 14 10 10 10 9 9 16 15 12 7 6 5 5 FRONT RIGHT NOTE The ports on the manifold are marked for easy identification of components Example C1 is the con nection port from the LH deck lift cylinder and CHG is the charge circuit connection See Hydraulic Schematic in Chapter 9 Foldout Drawings...

Page 173: ...mbly Re move fittings from manifold and discard O rings Installation Fig 96 1 If fittings were removed from manifold lubricate and place new O rings onto fittings Install fittings into man ifold openings using marks made during the removal process to properly orientate fittings Tighten fittings see Hydraulic Fitting Installation in the General Infor mation section of this chapter 2 Install hydraul...

Page 174: ...manifold are marked for easy identification of components Example C1 is the con nection port from the LH deck lift cylinder and CHG is the charge circuit connection See Hydraulic Schematic in Chapter 9 Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port Counterbalance Manifold Service Fig 97 For cartridge valve service procedures see 4WD Man ifold Ser...

Page 175: ...ide Switches 12 Transport 4WD Switch 13 Flow Divider Switch 13 Cooling Fan Switch 14 Seat Switch 15 Parking Brake Switch 16 Hour Meter 17 Audio Alarm 17 Glow and Power Relays 18 Start Engine Shutdown Seat PTO PTO Over temp Alarm and Over Temperature Relays 19 Hydraulic Valve Solenoids 20 TEC 5002 Controller 21 Fuel Sender 22 Fuel Gauge 23 Fuel Pump 24 Glow Controller 25 Temperature Sender 26 Dual ...

Page 176: ...ding the operation general maintenance and maintenance intervals for your Groundsmaster machine Refer to that publication for additional information when servicing the machine Electrical Drawings The electrical schematic circuit diagrams and wire har ness drawings for the Groundsmaster 4000 D are lo cated in Chapter 9 Foldout Drawings ...

Page 177: ... meter This excess current can cause damage to circuits not designed to carry it Figure 1 Skin Over Grease Special non conductive grease which forms a light pro tective skin which helps waterproof electrical switches and contacts Toro Part Number 505 165 Figure 2 Dielectric Gel Dielectric gel should be used to prevent corrosion of connection terminals To ensure completecoating ofter minals liberal...

Page 178: ...o the battery terminal Toro Part Number 107 0392 Figure 4 Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte Obtain this tool locally Figure 5 Deck Proximity Switch Adjustment Tool The Deck Proximity Switch Adjustment Tool is designed to assist in the adjustment of the cutting deck position switches for cutting blade shutdown during deck lift Toro ...

Page 179: ...s faulty The neutral switch or circuit wiring is faulty The fusible link from the battery is faulty Starter solenoid clicks but starter will not crank NOTE If the solenoid clicks the problem is not in the in terlock circuit The battery is discharged The battery cables are loose or corroded A ground wire or cable is loose or corroded Wiring at the starter motor is faulty The starter solenoid is fau...

Page 180: ...it wiring is faulty Engine continues to run but should not when the traction pedal is engaged with no operator in the seat The seat switch or circuit wiring is faulty The traction neutral switch or circuit wiring is faulty Engine stops during operation but is able to restart The operator is lifting off the seat switch The seat switch or circuit wiring is faulty The engine shutdown delay is faulty ...

Page 181: ...ld not when lowered with PTO switch in the OFF disengage position The PTO switch or circuit wiring is faulty Cutting deck s do not operate The operator is lifting off the seat switch Traction circuit is in transport mode The seat switch or circuit wiring is faulty The PTO switch or circuit wiring is faulty The deck position switch or circuit wiring is faulty The transport 4WD switch or circuit wir...

Page 182: ...eter lead to the negative bat tery post Keep the test leads connected to the battery posts and record the battery voltage NOTE Upon starting the engine the battery voltage will drop and then should increase once the engine is running NOTE Depending upon the condition of the battery charge and battery temperature the battery voltage will increase at different rates as the battery charges Start the ...

Page 183: ...ts for continu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected Ignition Switch The ignition key switch has three 3 positions OFF ON PREHEAT and START Fig 7 The terminals are marked as shown in Figure 8 The circuit wiring of the ignition switch is shown in the chart below With the use of a multimeter ohms setting the switch functions may be tested to det...

Page 184: ... the PTO switch Fuse F4 10 amp fuseblock location A4 Sup plies power to the starter solenoid Fuse F5 when optional lighting is installed 15 amp fuseblock location B4 Supplies power for optional light kit Fuse F8 10 amp fuseblock location B1 Sup plies power to the power point outlet Fuse F9 7 5 amp fuseblock location C4 Sup plies power for engine cooling fan operation TEC 5002 controller Fuse F10 1...

Page 185: ... switch terminal closes NOTE If the PTO is engaged when the dual tempera ture switch terminal closes the PTO will disengage To test the high temperature warning light and its circuit wiring ground the blue wire attached to dual tempera ture switch on engine water flange The high tempera ture warning light should illuminate Glow Plug Indicator Light The glow plug indicator light should illuminate w...

Page 186: ... NORMAL CIRCUITS OTHER CIRCUITS PTO ENGAGE 1 2 4 5 PTO ON 1 2 NONE PTO OFF NONE NONE 1 PTO switch 2 Control console Figure 13 1 2 Figure 14 1 2 4 5 BACK OF PTO SWITCH Alarm Silence and Temperature Override Switches The alarm silence and temperature override rocker switches are located on the control console next to the operator seat Fig 15 These switches are identical Testing The switch terminals ...

Page 187: ...switch is used to energize the solenoid valve in the hydraulic traction manifold When the flow divider switch is depressed traction pump hydraulic flow is split between the front wheel motors approxi mately 45 and rear axle motor approximately 55 to reduce the chance that excessive flow goes to a spin ning wheel The flow divider switch only functions when the machine transport 4WD switch is in the...

Page 188: ...ction If the operator depresses the cooling fan switch to the Reverse position a fan reverse cycle that is controlled by the TEC 5002 controller is initiated The switch auto matically returns to the Auto position and fan operation returns to the forward direction after the reverse cycle is completed If the cooling fan switch is placed in the Forward posi tion the engine cooling fan will run only i...

Page 189: ...harness electrical connector for the seat switch 3 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals 4 With no pressure on the seat there should be no continuity between the seat switch terminals 5 Press directly onto the seat switch through the seat cushion There should be continuity as the seat cushion approaches the bottom of its travel 6...

Page 190: ... switch is in its normal open state Testing 1 Make sure the engine is off Locate parking brake switch for testing 2 Disconnect wire harness connector from the switch 3 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals 4 When the switch plunger is extended there should not be continuity between the switch terminals 5 When the switch plunger i...

Page 191: ...Positive terminal 4 Negative terminal 1 2 3 4 Audio Alarm The audio alarm for low engine oil pressure or high en gine coolant temperature is attached to the control con sole next to the operator seat Testing IMPORTANT Make sure to observe polarity on the alarm terminals when testing Damage to the alarm may result from an improper connection 1 Disconnect wire harness connector from alarm 2 Correctl...

Page 192: ...t the machine wire har ness connector from the relay Remove relay from ma chine for easier testing NOTE Prior to taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measur...

Page 193: ...nals 85 and 86 Fig 29 Resist ance should be between 70 and 90 ohms 4 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal85 The relay should have continuity be tween terminals 30 and 87 as 12 VDC is applied to ter minal 85 The relay should not have continuity between terminals 30 and 87 as 12 VDC is removed from termi nal 85 5 Disconne...

Page 194: ...rt the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measured value of the component you are testing 2 Measure resistance between the two 2 solenoid connectorterminals Theresistance forallsolenoidcoils used on the Groundsmaster 4000 D...

Page 195: ...controller The TEC 5002 controller monitors the states of the fol lowing components as inputs ignition switch hydraulic temperature sender engine coolant temperature send er and cooling fan switch The TEC 5002 controller controls electrical output to the engine cooling fan hydraulic valve solenoid coils speed and direction Circuit protection for TEC 5002 outputs is provided by fuse F9 7 5 amp Beca...

Page 196: ...alue This internal resistance of the meter and test leads should be sub tracted from the measured value of the component CAUTION Make sure sending unit is completely dry no fuel on it before testing Perform test away from the tank to prevent an explosion or fire from sparks 4 Check resistance of the sender with a multimeter Fig 33 A Resistance with the floatin the full position should be 27 5 to 3...

Page 197: ...e edge of the glass cover for the each test point For each variable re sistance setting the needle must be pointed between the two white dots 2 Take test point readings Fig 35 IMPORTANT Allow circuit to warm up for at least 5 minutes before taking test readings A Set variable resistance to 240 ohms Apply a 14 0 01 VDC to the circuit The needle should point to the left edge of the red area empty B ...

Page 198: ...p discharge into a large grad uated cylinder sufficient enough to collect 1 quart 0 95 liter 6 Collect fuel in the graduated cylinder by turning igni tion switch to the ON position Allow pump to run for 15 seconds then turn switch to OFF 7 The amount of fuel collected in the graduated cylin der should be approximately 16 fl oz 475 ml after 15 seconds 8 Replace fuel pump as necessary Install fuel h...

Page 199: ...after approximately 10 seconds 4 Place ignition switch in the START position Verify the following while in the START position A Glow indicator lamp is not illuminated B Glow relay is energized C Glow plugs are energized D Power exists at terminal 1 of the glow controller NOTE If there is no power at terminal 1 of the glow con troller verify continuity of the circuitry from the ignition switch to t...

Page 200: ...small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing 3 Check resistance of the sender with a multimeter ohms setting as the temperature increases Replace sender if specifications are not met COOLANT TEMP TEMP SENDER RESISTANCE 100oF 38oC 460 oh...

Page 201: ...mperature switch from the engine water flange 2 Put switch in a container of oil with a thermometer and slowly heat the oil Fig 43 CAUTION Handle the hot oil with extreme care to prevent personal injury or fire 3 Check continuity of the switch with a multimeter ohms setting Both circuits of the temperature switch are normally open and should close at the following tem peratures A The warning termi...

Page 202: ...ts on the gauge face below the edge of the glass cover for the each test point For each variable re sistance setting the needle must be pointed between the two white dots 2 Take test point readings Fig 45 IMPORTANT Allow circuit to warm up for at least 5 minutes before taking test readings A Set variable resistance to 71 ohms Apply a 14 0 01 VDC to the circuit The needle should point to the middle...

Page 203: ...itch Figure 46 1 2 Diode Assemblies The Groundsmaster 4000 D electrical system includes several diode assemblies Fig 47 that are used for cir cuit protection and circuit logic control The diodes plug into the wiring harness at various locations on the ma chine The diodes D2 D4 D5 and D6 are used for circuit protectionfrominductivevoltage spikesthatoccurwhen a hydraulic valve solenoid is de energiz...

Page 204: ...the front cutting deck cir cuit and D4 is in the right cutting deck circuit Testing The diodes can be individually tested using a digital multimeter ohms setting and the table to the right If any of the diodes are faulty the diode circuit board must be replaced Apply dielectric grease Toro part number 107 0342 to circuit board contacts whenever the circuit board is installed into the wire harness ...

Page 205: ...nd Circuit Diagrams in Chapter 9 Foldout Diagrams for addition al circuit information Testing Make sure that ignition switch is OFF Disconnect nega tive battery cable from battery terminal and then discon nect positive cable from battery see Battery Service in the Service and Repairs section of this chapter Locate and unplug fusible link connector Use a multimeter to make sure that continuity exis...

Page 206: ...ly parking brake and remove key from the ignition switch 2 Locate switch that requires testing and disconnect switch connector from machine wiring harness 3 Ground switch connector terminal for black wire and apply 12 VDC to switch connector terminal for red wire 4 Using a multimeter verify that switch connector ter minal for blue wire has 12 VDC and terminal for white wire has 0 VDC 5 Place metal...

Page 207: ...NOTE Prior to taking resistance readings with a digital multimeter short the meter test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing 4 Check resistance of the sender with a multimeter ohms settin...

Page 208: ...ses are explosive keep open flames and electrical sparks away from the battery do not smoke Nausea may result if the gases are inhaled Un plug charger from electrical outlet before con necting or disconnecting charger leads to or from battery posts IMPORTANT Do not remove fill caps while clean ing 2 Check battery condition weekly or after every 50 hours of operation Keep terminals and entire batte...

Page 209: ...battery post and the nega tive ground cable connector The reading should be less than 0 1 amp If the reading is 0 1 amp or more the machine s electrical system should be tested for short circuits or faulty components and repaired 6 Secure battery with battery strap Install battery ac cess panel Lower and secure operator seat 1 Negative cable 2 Positive cable 3 Battery strap Figure 57 1 2 3 Battery...

Page 210: ...d tester This is one ofthe mostreliable means oftesting a battery as itsimulates the cold cranking test A commercialbat tery load tester is required to perform this test CAUTION Follow the manufacturer s instructions when us ing a battery load tester 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 performi...

Page 211: ...8 hrs 6 amps 11 5 hrs 6 amps 17 3 hrs 6 amps 23 hrs 6 amps above 250 6 hrs 10 amps 12 hrs 10 amps 18 hrs 10 amps 24 hrs 10 amps CAUTION Do not charge a frozen battery because it can ex plode and cause injury Let the battery warm to 60oF 15 5o C before connecting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are explosive keep open ...

Page 212: ...Groundsmaster 4000 D Page 5 38 Electrical System This page is intentionally blank ...

Page 213: ...rator s Manual 3 SERVICE AND REPAIRS 4 Brake Assembly 4 Brake Inspection and Repair 6 Planetary Wheel Drive Assembly 8 Planetary Wheel Drive Service 10 Rear Axle Assembly 14 Bevel Gear Case and Axle Case 17 Differential Shafts 22 Axle Shafts 23 Input Shaft Pinion Gear 24 Differential Gear 26 Pinion Gear to Ring Gear Engagement 29 Axles Planetaries and Brakes ...

Page 214: ...acity each wheel 16 fl oz 0 47 liters Rear axle lubricant SAE 85W 140 wt gear lube System gear lube capacity 80 fl oz 2 37 liters Rear axle gear box lubricant SAE 85W 140 wt gear lube System gear lube capacity 16 fl oz 0 47 liters Wheel lug nut torque 85 to 100 ft lb 115 to 135 N m front and rear Steering cylinder bolt torque 100 to 125 ft lb 139 to 169 N m Planetary brake housing and front wheel ...

Page 215: ...tion 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 Axles Planetaries and Brakes ...

Page 216: ...ONT RIGHT 75 to 85 ft lb 101 to 115 N m 17 85 to 100 ft lb 115 to 135 N m 18 18 3 2 2 75 to 85 ft lb 101 to 115 N m Removal Fig 1 1 Park machine on a level surface lower cutting decks stop engine and remove key from the ignition switch 2 Drain oil from planetary wheel drive brake assembly CAUTION When removing front wheel use correct jacks and supports Make sure machine is parked on a solid level ...

Page 217: ...hten screws in a crossing pattern to a torque from 75 to 85 ft lb 101 to 115 N m 4 Install brake cable to pull rod on brake assembly Brake cable end should be completely threaded onto pull rod before tightening jam nut 5 Install new O ring on hydraulic wheel motor Install wheel motor and torque cap screws from 75 to 85 ft lb 101 to 115 N m WARNING Failure to maintain proper wheel lug nut torque co...

Page 218: ...ction and Repair Fig 5 1 Scrape gasket material item 10 from brake housing and planetary wheel drive mounting surfaces 2 Remove retaining ring item 9 3 Remove stationary discs item 7 and rotating discs item 8 4 Remove extension springs item 12 5 Remove actuator assembly items 11 6 5 4 and 3 and balls item 13 6 Remove seal item 2 from brake housing 7 Wash parts in cleaning solvent Inspect component...

Page 219: ...Groundsmaster 4000 D Page 6 7 Axles Planetaries and Brakes This page is intentionally blank Axles Planetaries and Brakes ...

Page 220: ...aulic wheel motor 7 Flat washer 2 used per side 8 Cap screw 2 used per side 9 Flange head screw 4 used per side 10 Brake assembly LH 11 Gasket 12 Flange head screw 6 used per side 13 Wheel assembly 14 Lug nut 8 used per side Figure 6 1 2 3 2 4 5 6 8 6 9 10 12 13 7 5 1 FRONT RIGHT 75 to 85 ft lb 101 to 115 N m 14 85 to 100 ft lb 115 to 135 N m 11 11 3 75 to 85 ft lb 101 to 115 N m 2 2 ...

Page 221: ...wheel motor see Front Wheel Motors in the Service and Repairs section of Chapter 4 Hydraulic System 6 Remove brake assembly see Brake Assembly Re moval in this section 7 Support planetary assembly to prevent it from falling Loosen and remove flange head screws that secure planetary assembly to frame Remove planetary as sembly from machine Installation Fig 6 1 Position planetary assembly to machine...

Page 222: ...ring cup 8 Outer bearing cone 9 Thrust washer 10 Retaining ring external 11 Ring gear 12 Retaining ring internal 13 Plug 2 used 14 End cap 15 Thrust plug 16 Thrust washer 17 Drive shaft 18 Carrier assembly 19 Socket head screw 16 used 20 Lock washer 16 used 21 O ring 22 O ring 23 Dowel pin 2 used 24 Seal Figure 8 9 ft lb 12 N m 1 2 3 4 19 20 6 7 8 9 10 23 5 11 13 14 15 16 12 17 21 18 24 22 21 ...

Page 223: ...ove outer bearing cone item 8 9 Remove and discard all seals and O rings items 2 21 and 24 10 If bearings will be replaced remove inner bearing cone item 3 from housing Remove bearing cups items 4 and 7 from housing 11 If necessary remove socket head screws item 19 with lock washers item 20 that secure ring gear item 11 to housing Remove ring gear and two 2 dowel pins item 23 from housing Figure 9...

Page 224: ...aining ring ID is fully seated to spindle shaft groove K After retaining ring is installed make sure that there is no endplay in assembly If required remove retaining ring and install a thrust washer of different thickness to adjust endplay L Install new O ring item 21 to housing 3 Install carrier assembly item 18 making sure that carrier gear teeth align with ring gear and spline on spindle shaft...

Page 225: ...Groundsmaster 4000 D Page 6 13 Axles Planetaries and Brakes This page is intentionally blank Axles Planetaries and Brakes ...

Page 226: ...ace 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 orblock wheels Use jack stands to support the raised machine If the machine is not properly supported by jack stands the machine may move or fall which may result in personal injury 2 Chock front wheels and jack up rear of machine see Jacking ...

Page 227: ... installed there should be from 0 002 to 0 020 0 05 mm to 0 51 mm clearance between rear axle mount and axle mounting boss Add thrust washers if needed to adjust clearance 2 Install axle pivot pin to secure axle to rear axle mount Install washer and lock nut onto pivot pin Tight en lock nut and then loosen it slightly to allow the axle pin to pivot freely Secure pivot pin to axle mount with washer...

Page 228: ...heel and may result in personal injury 10 Install wheels to axle 11 Lower machine to ground Torque wheel lug nuts from 85 to 100 ft lb 115 to 135 N m 12 Fill axle with SAE 85W 140 weight gear lube Lubri cant capacity is approximately 80 fl oz 2 37 liters for the axle and 16 fl oz 0 47 liters for the gearbox 13 Check rear wheel toe in and adjust if necessary 14 Check steering stop bolt adjustment W...

Page 229: ...and left bev el gear case axle case assemblies 1 2 3 4 5 6 1 Cap screw 4 used 2 Lock nut 2 used 3 Lock washer 2 used 4 Axle support 5 Bevel gear case axle case assembly 6 O ring Figure 15 35 to 41 ft lb 47 to 56 N m 35 to 41 ft lb 47 to 56 N m 3 Remove the axle cover mounting bolts Remove the axle cover from the axle case as an assembly Fig 16 1 Axle case 2 Axle cover assembly 3 Bolt 6 used 4 O ri...

Page 230: ...discard bevel gear shaft seal from axle case Fig 18 1 Knuckle pin 2 Bolt 4 used 3 O ring 4 Bevel gear case 5 Upper bearing 6 Bevel gear shaft 7 Collar 8 Upper bevel gear 9 Lower bevel gear 10 Lower bearing 11 Axle case 12 Axle case cover 13 O ring 14 Shaft seal 15 Bushing Figure 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 to 20 ft lb 23 to 27 N m 17 to 20 ft lb 23 to 27 N m Threadlocking Compound Be...

Page 231: ...cover Fig 21 Tighten cover screws from 17 to 20 ft lb 23 to 27 N m 3 Slide the bevel gear case over the bevel gear shaft andinstallthebevelgear andcollar Makesurethebevel gear shaft is completely seated in the upper and lower bearings Fig 21 4 Install the knuckle pin Use medium strength Loctite thread locker and tighten the knuckle pin mounting bolts from 17 to 20 ft lb 23 to 27 N m 1 Axle case co...

Page 232: ...een determined remove mounting screws apply heavy strength thread locking compound to screw threads reinstall screws and torque from 57 to 67 ft lb 77 to 91 N m IMPORTANT Correct engagement between bevel gears is critical to axle performance and durability 7 Temporarily install the bevel gear case axle case as sembly on the axle support Position a dial indicator at the tooths center Prevent the ax...

Page 233: ...OWER BEVEL GEAR BACKLASH 0 004 to 0 016 in 0 10 to 0 40 mm 10 Adjust backlash by increasing or reducing axle bear ing shim thickness see Axle Shafts in this section of this manual NOTE Axle bearing shims are available in 0 008 in 0 2 mm 0 012 in 0 3 mm and 0 020 in 0 5 mm thickness 11 Tighten axle cover screws from 17 to 20 ft lb 23 to 27 N m 12 Coat a new O ring with grease and install the bevel ...

Page 234: ... bearings and cases for damage and wear Replace components as necessary Differential Shaft Installation 1 Press bearings onto differential shaft Place correct combination of bearing shims in axle support and drive differential shaft and bearing assembly into axle sup port 2 Install bevel gear and retaining ring 3 Coat new O ring with grease Align differential shaft splines with differential gear a...

Page 235: ... for damage and wear Replace components as necessary Axle Shaft Installation 1 Coat new axle shaft seal with grease and install in axle cover as shown Fig 29 2 Press the axle cover and bearing assembly onto the axle shaft Press only on the inner race of the cover bearing Fig 29 3 Install retaining ring spacer and correct combination of bearing shims Install bevel gear and bearing 4 Coat a new O ri...

Page 236: ... and bearing case Remove and discard the oil seal and O ring 6 Inspect all gears shafts bearings spacers and cases for damage and wear Replace components as necessary NOTE Replacement input shaft pinion gears are only available in matched ring and pinion sets Installation Fig 30 NOTE When installing new bearing cones press only on the inner race of the bearing cone 1 If the inner bearing cone was ...

Page 237: ...rewdriver through the drain plug hole to hold ring gear and measure the pinion gear to ring gear backlash Fig 33 PINION GEAR TO RING GEAR BACKLASH 0 004 to 0 016 in 0 10 to 0 40 mm 11 Adjust backlash by increasing or reducing gear case shim thickness 12 Check pinion gear to ring gear engagement see Pin ion Gear to Ring Gear Engagement in this section of this manual 13 Place the correct combination...

Page 238: ...adjusting shims from the axle case 6 Drive the spring pin from the differential case with a punch and hammer Discard the spring pin Fig 35 NOTE Mark and arrange all components so they can be reassembled in their original position 7 Remove the differential pinion shaft pinion gears and pinion washers Remove the differential side gears and side gear shims Remove the ring gear only if it will be repl...

Page 239: ... 341 in 34 00 to 34 06 mm 2 Measure the differential pinion shaft O D and the pinion gear I D to determine the pinion shaft to pinion gear clearance Fig 38 Replace components as nec essary PINION SHAFT TO PINION GEAR CLEARANCE 0 001 to 0 010 in 0 03 to 0 25 mm PINION SHAFT O D Factory Spec 0 550 to 0 551 in 13 97 to 13 10 mm PINION GEAR I D Factory Spec 0 551 to 0 552 in 13 10 to 14 02 mm 3 Inspec...

Page 240: ... lightly over several gear teeth 8 While applying a light load to either side gear rotate either pinion gear until the side gears have made one complete revolution 9 Ideal tooth contact should cover more than 35 of each tooth surface The contact area should be in the center of each tooth and extend 1 3 to 1 2 way across each tooth from the toe small end Fig 40 10 Adjust side gear shims if necessar...

Page 241: ...Adjustments to the gear contact position are made by moving the input shaft pinion gear bearing case shims or by moving the differential gear case differential bear ing shims Fig 43 NOTE Bearing case shims are available in 0 004 in 0 10 mm and 0 008 in 0 20 mm thickness NOTE Differential bearing shims are available in 0 004 in 0 10 mm 0 008 in 0 20 mm and 0 016 in 0 40 mm thickness Study the diffe...

Page 242: ...rd ring gear B Install thinner or remove differential bearing shim s to move ring gear backward C Repeat until proper tooth contact and pinion gear to ring gear backlash are correct 2 If contact is toward the toe or tip of the gear Fig 45 A Install thinner or remove bearing case shim s to move pinion shaft away from ring gear B Install thicker or additional differential bearing shim s to move ring...

Page 243: ...Side Deck Rear Arm Assembly 8 Lift Arm Joint Yoke 12 Operator Seat 14 Operator Seat Service 16 Operator Seat Suspension 18 Hood 20 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 Chassis...

Page 244: ...lange head screw 10 used 23 Flange bushing 2 used 24 Thrust washer as needed 25 Temperature gauge 26 Warning lamp temp glow plug 27 Warning lamp charge oil pressure 28 Steering column 29 Cap screw 2 used 30 Pivot hub 2 used 31 Flange head screw 4 used 32 Switch bracket 33 Flange nut 2 used 34 Cap screw 2 used 35 Steering tower 36 Phillips head screw 2 used 37 Clevis pin 38 Steering valve 39 Steeri...

Page 245: ...e ignition switch 2 Disassemble steering tower as needed using Figure 1 as a guide Assembly Fig 1 1 Assemble steering tower using Figure 1 as a guide A Thrust washer s item 24 on steering column are used as needed to remove end play of steering shaft 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 ...

Page 246: ... 21 Cap screw 22 Flat washer 2 per pin 23 Lift arm LH shown 24 Jam nut 25 Hair pin 26 Ball joint mount 27 Cotter pin 28 Washer 4 per mount 29 Cap screw 2 per mount 30 Lock nut 31 Flat washer 2 per plate 32 Sensing plate 33 Carriage screw 2 per plate 34 Lock nut 2 per switch 35 Flat washer 2 per switch 36 Sensing switch 37 Spacer 38 Carriage screw 2 per switch 39 Slotted hex nut Figure 2 14 13 1 23...

Page 247: ...rm to frame and insert lift arm pin En gage roll pin into frame slots and install lock nut on pin Torque lock nut from 60 to 70 ft lb 81 to 94 N m 2 Align lift cylinder with lift arm Slide pin through lift arm and cylinder end Secure pin with cap screw wash ers and lock nut 3 Install front wheel assembly 4 Lower machine to the ground 5 If height of cut chain u bolt was removed from lift arm assemb...

Page 248: ...ate 32 Flange bushing 33 Lock nut 2 per plate 34 Grease fitting 35 Flange bushing 36 Flange bushing 37 Bushing 38 Grease fitting Figure 5 21 16 19 18 16 17 12 11 14 13 3 2 32 4 6 5 1 35 34 7 36 8 9 10 15 5 20 10 17 35 23 26 24 25 28 31 29 30 33 17 27 36 22 34 FRONT RIGHT 32 37 38 37 Anti seize Lubricant Loctite 242 77 to 96 ft lb 105 to 130 N m NOTE There are not bushings in the frame to support t...

Page 249: ...ove lift arm from machine Installation Fig 5 1 Apply anti seize lubricant to lift arm pivot shaft 2 Position liftarm to frame with thrust washers properly placed Fig 5 Slide pivot shaft into frame and lift arm until roll pin holes in shaft and frame align 3 Install new roll pin to secure lift arm pivot shaft 4 If pivot hub was removed from pivot shaft slide pivot hub onto shaft Apply Loctite 242 o...

Page 250: ... LH shown 23 Lock nut 2 per damper 24 Lock washer 25 Lock nut 26 Bumper pad 5 per arm 27 Bumper bracket 28 Cap screw 29 Bell crank LH shown 30 Damper 31 Damper rod end 2 per damper 32 Cap screw 2 per damper 33 Link tube 34 Lock nut 35 Flat washer 36 Bushing 37 Damper spring 38 Lock nut 4 per arm 39 Carriage screw 2 per arm 40 Grease fitting 41 Jam nut 42 Lock nut 2 per arm 43 Jam nut 2 per arm 44 ...

Page 251: ...g with two 2 cap screws and lock nuts Grasp end of spring shaft Push inward and pull outward on shaft to determine endplay in assembly IMPORTANT All endplay must be removed from as sembly to allow proper operation and ensure long life 7 Loosen jam nut 1 2 turn at a time until all endplay in shaft is removed 8 Remove two 2 cap screws and nuts securing plate to rear arm housing Remove spring shaft a...

Page 252: ...C Measure from the inset bead of the rim not the outer edge of the rim to the straight edge at two loca tions as indicated in Figure 10 Rim and paint irregu larities make the rim outer edge an unreliable point of measure These two measurements should be the same within a tolerance of 1 8 3 mm D Rotate spring shaft item 12 in rear arm assem bly until correct dimension is attained Shaft should rotat...

Page 253: ...Groundsmaster 4000 D Page 7 11 Chassis This page is intentionally blank Chassis ...

Page 254: ...ng decks stop engine apply parking brake and remove key from the ignition switch 2 Remove cap screw item 19 and lock nut item 20 that secures rod end of rear arm assembly to cutting deck Locate and remove spacer item 18 from each side of rod end 3 Remove eight 8 cap screws lock washers and flat washers that secure deck mount to cutting deck 4 Remove cotter pin from joint yoke shaft Make sure that ...

Page 255: ... and yoke C Hold cross in alignment and press bearing in until it hits the yoke D Carefully place second bearing into yoke bore and onto cross shaft Press bearing into yoke 4 Use a press and the above process to install deck mount to yoke 5 Install retaining rings to yoke and deck mount to se cure bearings in place 6 Make sure that assembled joint yoke moves without binding Slight binding can usua...

Page 256: ...used 9 R clamp 2 used 10 Manual tube 11 Screw 12 Lock nut 13 Seat belt mount 14 Lock washer 2 used 15 R clamp 2 used 16 Wire harness seat switch lead 17 Screw 2 used 18 Hair pin 2 used 19 Clevis pin 2 used 20 Spring 21 Latch shaft 22 Cotter pin 2 used 23 Latch 24 Prop rod 25 Cotter pin 26 Washer Figure 12 FRONT RIGHT 2 3 1 4 5 6 8 9 7 12 13 14 15 17 18 20 23 21 22 19 11 10 16 2 8 24 25 26 ...

Page 257: ...ove four 4 cap screws and flange nuts that secure seat suspension to seat plate Note that two 2 r clamps that retain wire harness are secured with seat suspension fasteners C Lift seat suspension from machine Installation Fig 12 1 If removed install seat suspension to seat platform A Position seat suspension onto seat plate B Secure seat suspension and two 2 wireharness r clamps to seat platform w...

Page 258: ... 10 Bumper 2 used 11 Washer 12 Cap screw 2 used 13 Seat 14 Nut 15 Spring 2 used 16 Magnet 17 Seat switch 18 Rivet 4 used 19 Mounting plate 20 Return spring 21 Torx screw 5 used 22 RH adjustment rail 23 Rail stop 24 Torx screw 25 Torx screw 3 used 26 Washer 3 used 27 Handle 28 Nut 29 Support bracket 30 Cap screw Figure 15 8 10 6 5 7 4 3 2 1 11 14 12 13 9 15 16 17 18 19 20 21 21 23 24 25 26 22 27 28...

Page 259: ...Groundsmaster 4000 D Page 7 17 Chassis Disassembly Fig 15 1 Disassemble operator seat as necessary using Fig ure 15 as a guide Assembly Fig 15 1 Assemble operator seat using Figure 15 as a guide Chassis ...

Page 260: ...used 17 Washer 4 used 18 C clip 4 used 19 Pin 2 used 20 Rivet 2 used 21 Washer 3 used 22 Screw 2 used 23 Washer 24 Housing support 4 used 25 Spacer 4 used 26 Hose nipple 27 Clamp 2 used 28 Hose nipple 29 Screw 30 Handle 31 Bumper 32 Nut 33 Plastic plug 23 used 34 Screw 2 used 35 Roller 2 used 36 Screw 4 used 37 Base plate 38 Suspension frame 39 Upper plate Figure 16 FRONT RIGHT 11 8 7 30 10 15 6 1...

Page 261: ...equires removal remove seat suspension from seat platform see Operator Seat Removal in this sec tion 3 Remove seat suspension components as needed using Figure 16 as a guide Assembly Fig 16 1 Install all removed seat suspension components us ing Figure 16 as a guide 2 Install seat suspension if it was removed from seat platform see Operator Seat Installation in this section 3 Install operator seat...

Page 262: ...Plastic plug 24 used 25 Cap screw 26 used 26 Taptite screw 4 used 27 Plastite screw 4 used 28 Hood support 29 R clamp 2 used 30 Hood rod 2 used 31 Clevis pin 2 used 32 Hair pin 2 used 33 Screw 2 used 34 Washer head screw 2 used 35 Cable tie 36 Flat washer 20 used 37 Lock nut 20 used 38 Pop rivet 22 used 39 Flat washer 22 used 40 RH screen mount 41 LH screen mount 42 RH latch bracket 43 Foam seal 2...

Page 263: ... sides of oil cooler Fig 19 B Close hood so that it rests on shims and fasten the hood latches C Loosen hood pivots at frame to adjust vertical placement of pivots Re tighten hood pivot fasten ers D Loosen screen pivots to allow hood latches to pull hood against radiator support Re tighten screen pivot fasteners 3 After hood is assembled to machine check for the following A Check that bulb and foa...

Page 264: ...Groundsmaster 4000 D Page 7 22 Chassis This page is intentionally blank ...

Page 265: ...L INFORMATION 3 Operator s Manual 3 Castor Wheel Tire Pressure 3 Blade Stopping Time 3 TROUBLESHOOTING 4 Factors That Can Affect Quality of Cut 4 SERVICE AND REPAIRS 6 Front Cutting Deck 6 Side Cutting Deck 8 Idler Assembly 10 Blade Spindles 12 Blade Spindle Service 14 Castor Forks and Wheels 16 Cutting Decks ...

Page 266: ...ble ta pered roller bearings CUTTING BLADE Cutting blade dimensions are 21 750 552 mm long 2 500 64 mm wide and 0 250 6 4 mm thick Anti scalp cup installed on each cutting blade Three 3 blades on front deck and two 2 blades on each side deck WIDTH OF CUT Front deck provides 62 1575 mm width of cut Each side deck has 42 1067 mm width of cut Total width of cut is 132 3353 mm with 7 128 mm overlap DI...

Page 267: ... on the front and side decks should be in flated to 50 PSI 345 kPa Blade Stopping Time The blades of the cutting deck are to come to a complete stop in approximately five 5 seconds after the cutting deck engagement switch is shut down NOTE Make sure the decks are lowered onto a clean section of turf or hard surface to avoid dust and debris To verify this stopping time have a second person stand ba...

Page 268: ...d See items in Troubleshooting Section of Chapter 4 Hydraulic System 3 Tire pressure Check air pressure of each tire including castor tires Adjust to pressures specified in Operator s Manual 4 Blade condition Sharpen blades if their cutting edges are dull or nicked Inspect blade sail for wear or damage Replace blade if needed 5 Mower housing condition Make sure that cutting chambers are in good co...

Page 269: ...Groundsmaster 4000 D Cutting Decks Page 8 5 This page is intentionally blank Cutting Decks ...

Page 270: ...in 15 Cotter pin 16 Upper lift pin 17 Grease fitting 18 Lift cylinder 19 Lock nut 20 Pin 21 Cap screw 22 Flat washer 2 per pin 23 Lift arm LH shown 24 Jam nut 25 Hair pin 26 Ball joint mount 27 Cotter pin 28 Washer 4 per mount 29 Cap screw 2 per mount 30 Lock nut 31 Flat washer 2 per plate 32 Sensing plate 33 Carriage screw 2 per plate 34 Lock nut 2 per switch 35 Flat washer 2 per switch 36 Sensin...

Page 271: ...llation Fig 1 1 Position machine on a clean level surface Lower lift arms stop engine apply parking brake and remove key from the ignition switch 2 Position the front deck to the lift arms 3 Align ball joint mounts to front deck castor arms and secure with cap screws washers and lock nuts Fig 4 NOTE Installation of clevis pin to deck and height of cut chain is easier if deck is lifted slightly 4 I...

Page 272: ...ock washer 25 Lock nut 26 Bumper pad 5 per arm 27 Bumper bracket 28 Cap screw 29 Bell crank LH shown 30 Damper 31 Damper rod end 2 per damper 32 Cap screw 2 per damper 33 Link tube 34 Lock nut 35 Flat washer 36 Bushing 37 Damper spring 38 Lock nut 4 per arm 39 Carriage screw 2 per arm 40 Grease fitting 41 Jam nut 42 Lock nut 2 per arm 43 Jam nut 2 per arm 44 Rod end 2 per arm 45 Plate 46 Cap screw...

Page 273: ...Fig 5 1 Position machine on a clean level surface Stop engine apply parking brake and remove key from the ignition switch 2 Position the side cutting deck to the lift arm and deck mount 3 Lower lift arm while aligning deck mount to cutting deck 4 Install deck mount to cutting deck with 8 cap screws lock washers and flat washers Fig 6 Tighten fasteners IMPORTANT The length of the damper link should...

Page 274: ...her 8 Lock washer 9 Socket head screw 10 Stop bolt 11 Flange nut 12 Cap screw 13 Spacer 14 Shoulder bolt 15 Spring 16 Lock nut 17 Idler arm 18 Retaining ring 19 Thrust washer 20 Bushing 2 used per idler 21 Grease fitting 22 Washer 23 Flange head screw 24 Drive belt 25 Driven spindle single pulley Figure 8 2 4 5 7 8 18 19 19 20 22 25 NOTE The front deck is shown in Figure 8 The idler assemblies use...

Page 275: ...depends on whether the idler pulley mounts on the bottomside ofthe idler arm or on the top of the idler arm B Secure idler arm assembly to cutting deck with retaining ring C If idler stop bolt item 10 was removed fromdeck make sure thatitis installed in the hole that allows the stop bolt head to align with the idler arm 2 Install drive belt to pulleys CAUTION Be careful when installing the idler s...

Page 276: ... 4000 D Cutting Decks Page 8 12 Blade Spindles 1 Front cutting deck 2 RH cutting deck 3 LH cutting deck 4 Drive spindle 5 Driven spindle 6 Grease fitting location Figure 10 FRONT RIGHT 1 2 3 4 5 6 4 4 5 5 6 6 6 6 6 ...

Page 277: ...o deck B For drive spindle assemblies removefour 4 cap screws with washers that secure spindle and hy draulic motor mount to deck Remove motor mount Then remove four 4 flange head screws with flan ge nuts that secure spindle to deck C Lift spindle assembly from deck Installation Figs 10 and 11 1 Position spindle on cutting deck noting orientation of grease fitting Fig 10 Secure spindle assembly to...

Page 278: ...ng Fig 13 5 Using an arbor press remove both of the bearing cups and the outer bearing spacer from the housing 6 The large snap ring can remain inside the spindle housing Removal of this snap ring is very difficult Assembly Fig 12 NOTE A replacement spindle bearing set contains two 2 bearings a spacer ring and a large snap ring items 1 2 and 3 in Fig 13 These parts cannot be purchased separately A...

Page 279: ...ng 7 Inspect the spindle shaft and shaft spacer to make sure there are no burrs or nicks that could possibly dam age the oil seals Lubricate the shaft and spacer with grease 8 Install spindle shaft spacer onto shaft Place thin sleeve or tape on spindle shaft splines to prevent seal damage during shaft installation 9 Carefully slide spindle shaft with spacer up through spindle housing The bottom oi...

Page 280: ...n 22 Cutting deck RH shown 23 Bearing 24 Inner bearing spacer 25 Wheel hub 26 Wheel rim half 27 Castor tire 28 Wheel rim half 29 Plate 30 Flange nut 31 Flat washer 32 Tension rod 33 Flange nut 34 Clevis pin Figure 16 1 2 3 4 7 8 5 10 9 6 11 12 13 14 7 6 20 34 21 17 18 16 19 22 23 24 25 26 27 28 29 30 23 4 5 60 to 80 ft lb 81 to 108 N m 60 to 80 ft lb 81 to 108 N m FRONT CUTTING DECK SIDE CUTTING D...

Page 281: ...L SCHEMATICS Sheet 1 of 2 4 Sheet 2 of 2 5 CIRCUIT DIAGRAMS Glow Plug Circuits 6 Crank Circuits 7 Run Transport Circuits 8 Run Mow Circuits 9 High Temperature Warning Circuits 10 Over Temperature Shutdown Circuits 11 WIRE HARNESS DRAWINGS Engine Wire Harness 12 Front Wire Harness 14 Console Wire Harness 16 Foldout Drawings ...

Page 282: ...Groundsmaster 4000 D Foldout Drawings Page 9 2 This page is intentionally blank ...

Page 283: ...E MANIFOLD RH PTO MANIFOLD 4WD MANIFOLD LH PTO MANIFOLD FRONT PTO MANIFOLD TRACTION MANIFOLD COUNTERBALANCE MANIFOLD FILTER MANIFOLD M1 M2 ST L P1 P2 T RV1 RV2 LC2 LC1 S P1 P2 M1 M2 RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR RV1 RV2 LC2 LC1 S P1 P2 M1 M2 OR BYPASS VALVE ...

Page 284: ...UES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 UNOCCUPIED 2WD SOLENOID RIGHT DECK FRONT DECK PTO SOLENOID LEFT DECK PTO SOLENOID PTO SOLENOID SOLENOID OPTIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT PTO OVERTEMP SHUTDOWN RELAY ...

Page 285: ...roundsmaster 4000 D All relays and solenoids are shown as de energized All ground wires are black Sheet 2 of 2 CONTINUES FROM SHEET 1 CONTINUES FROM SHEET 1 CONTINUES FROM SHEET 1 CONTINUES FROM SHEET 1 COOLING FAN SWITCH POWER RELAY ...

Page 286: ... 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 UNOCCUPIED 2WD SOLENOID RIGHT DECK FRONT DECK PTO SOLENOID LEFT DECK PTO SOLENOID PTO SOLENOID SOLENOID OPTIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT IGNITION SWITCH IN RUN PTO OVERTEMP SHUTDOWN RELAY ...

Page 287: ...CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 UNOCCUPIED 2WD SOLENOID RIGHT DECK FRONT DECK PTO SOLENOID LEFT DECK PTO SOLENOID PTO SOLENOID SOLENOID OPTIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT IGNITION SWITCH IN START PTO OVERTEMP SHUTDOWN RELAY ...

Page 288: ...HEET 2 CONTINUES TO SHEET 2 OCCUPIED 2WD SOLENOID RIGHT DECK FRONT DECK PTO SOLENOID LEFT DECK PTO SOLENOID PTO SOLENOID SOLENOID OPTIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT NOT IN NEUTRAL IGNITION SWITCH IN RUN DISENGAGED IN TRANSPORT PTO OVERTEMP SHUTDOWN RELAY ...

Page 289: ...TIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT NOT IN NEUTRAL IGNITION SWITCH IN RUN DISENGAGED IN 4WD DECK LOWERED DECK LOWERED DECK LOWERED SWITCH IS IN THE ON POSITION WHEN THE PTO SWITCH IS MOVED TO THE ENGAGE POSITION PTO SWITCH TERMINALS 4 5 ARE MOMENTARILY CONNECTED ALLOWING A CURRENT PATH TO ENERGIZE THE PTO RELAY THE DECK POSITION SWITCHES AND THE PTO SO...

Page 290: ...ROL KIT OPTIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT OPTIONAL CRUISE CONTROL KIT NOT IN NEUTRAL IGNITION SWITCH IN RUN DISENGAGED IN 4WD DECK LOWERED DECK LOWERED DECK LOWERED IF THE ENGINE COOLANT TEMPERATURE RISES TO 220 TEMPERATURE WARNING SWITCH CLOSES THIS CLOSED SWITCH CAUSES THE OVER TEMPERATURE WARNING LIGHT TO ILLUMINATE AND ALSO ENERGIZES THE PTO OVERTEMP SHUTDOWN RELAY THIS E...

Page 291: ...RUISE CONTROL KIT NOT IN NEUTRAL IGNITION SWITCH IN RUN DISENGAGED IN 4WD DECK LOWERED DECK LOWERED DECK LOWERED PTO OVERTEMP SHUTDOWN RELAY IF THE ENGINE COOLANT TEMPERATURE RISES TO 240 TEMPERATURE SHUTDOWN SWITCH CLOSES THIS CLOSED SWITCH CAUSES THE OVER TEMPERATURE SHUTDOWN RELAY TO ENERGIZE AND REMOVES ELECTRICAL POWER FROM THE ENGINE RUN SOLENOID AND FUEL PUMP SHUTTING OFF THE ENGINE o o C T...

Page 292: ...Page 9 12 Groundsmaster 4000 D Engine Wire Harness STARTER STARTER STARTER ...

Page 293: ...OLET BLACK BLACK VIOLET BLACK BLACK BLACK BLACK VIOLET BLACK BLACK YELLOW BLACK ORANGE YELLOW BLACK BLACK YELLOW BLACK GREEN BLACK BLACK RED BLACK BLACK BROWN WHITE YELLOW BLACK ORANGE BLUE YELLOW YELLOW WHITE GREEN VIOLET BLACK WHITE BROWN BLACK RED RED PINK BLUE GRAY YELLOW RED BLACK ORANGE WHITE GREEN WHITE BLACK FUSIBLE LINK ...

Page 294: ...Page 9 14 Groundsmaster 4000 D Front Wire Harness FLOW DIVIDER SOLENOID ...

Page 295: ...WHITE PINK PINK PINK BLACK GREEN BLACK GRAY TAN BLACK BROWN YELLOW PINK ORANGE WHITE TAN PINK PINK TAN TAN BLACK BLACK ORANGE ORANGE BLACK YELLOW BLACK GREEN BLACK GREEN BLACK GREEN BLACK BLACK ORANGE BLUE BLACK GRAY GREEN BLUE VIOLET BLACK FLOW DIVIDER SOLENOID ...

Page 296: ...Page 9 16 Groundsmaster 4000 D Console Wire Harness FLOW SWITCH TRANSPORT 4WD PTO SHUTDOWN DELAY DIVIDER SWITCH ENGINE SHUTDOWN DELAY COOLING FAN SWITCH ...

Page 297: ...BLACK WHITE YELLOW TAN BLUE YELLOW BLACK YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW RED BLACK YELLOW YELLOW PINK PINK PINK PINK PINK BLACK BLACK ORANGE BLACK BLACK PINK WHITE BLUE GREEN YELLOW BLUE RED RED BLACK PINK WHITE GREEN WHITE BLACK GREEN WHITE GREEN YELLOW WHITE BROWN WHITE GREEN YELLOW BLACK VIOLET BLACK ORANGE WHITE BLUE BROWN BLUE GREEN GRAY PINK BLACK GRAY ORANGE GREEN BL...

Page 298: ...ACK TAN BLACK BLACK ORANGE BLACK YELLOW WHITE WHITE GREEN WHITE BLACK BLUE BLACK BROWN WHITE GRAY TAN BLACK BLACK BLACK BLACK Groundsmaster 4000 D Console Wire Harness Sheet 2 of 2 TO SHEET 1 TO SHEET 1 TO SHEET 1 TO SHEET 1 TO SHEET 1 TO SHEET 1 TO SHEET 1 WHITE GREEN YELLOW GREEN GREEN BLACK BLACK ORANGE BLACK BLUE BLACK VIOLET COOLING FAN SWITCH ...

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