Toro 4014-D - Manuals - manualsarea.com

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Groundsmaster 4000--D/4010--D This page is intentionally blank.

Page 3 - Table Of Contents; Chapter 2 -- Product Records and Maintenance

Groundsmaster 4000--D/4010--D Table Of Contents Chapter 1 -- Safety General Safety Instructions 1 -- 2 . . . . . . . . . . . . . . . . . . Jacking Instructions 1 -- 5 . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals 1 -- 6 . . . . . . . . . . . . . . . . Chapter 2 -- P...

Page 5 - erat; Cab

Groundsmaster 4000--D/4010--D Table Of Contents (Continued) Chapter 9 -- Operator Cab General Information 9 -- 2 . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs 9 -- 3 . . . . . . . . . . . . . . . . . . . . . . . . SANDEN SD COMPRESSOR SERVICE GUIDE Chapter 10 -- Foldout Drawing...

Page 7 - Chapter 1; Safety; Table of Contents; Safety

Groundsmaster 4000--D/4010--D Page 1 -- 1 Safety Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS 2 . . . . . . . . . . . . Before Operating 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance...

Page 8 - General Safety Instructions; To reduce the potential for injury or death,; Before Operating

Groundsmaster 4000--D/4010--D Page 1 -- 2 Safety General Safety Instructions The Groundsmaster 4000-D and 4010--D are tested and certified by Toro for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design...

Page 9 - While Operating

Groundsmaster 4000--D/4010--D Page 1 -- 3 Safety While Operating 1. Sit on the seat when starting and operating the ma- chine. 2. Before starting the engine: A. Apply the parking brake. B. Make sure traction pedal is in neutral and the PTO switch is OFF (disengaged). C. After engine is started, rele...

Page 10 - Maintenance and Service

Groundsmaster 4000--D/4010--D Page 1 -- 4 Safety Maintenance and Service 1. Before servicing or making adjustments, lower decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. ...

Page 12 - Safety and Instruction Decals; Numerous safety and instruction decals are affixed to

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

Page 13 - Chapter 2; Product Records and Maintenance

Groundsmaster 4000--D/4010--D Page 2 -- 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS 1 . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVER...

Page 14 - Equivalents and Conversions

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

Page 15 - Torque Specifications; reduced by 25% for lubricated fasteners; Fastener Identification

Groundsmaster 4000--D/4010--D Page 2 -- 3 Product Records and Maintenance Torque Specifications Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clea...

Page 18 - Other Torque Specifications; Grade 5; Conversion Factors

Groundsmaster 4000--D/4010--D Page 2 -- 6 Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended Torque Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 U...

Page 19 - Chapter 3; Kubota Diesel Engine; Kubota

Groundsmaster 4000--D/4010--D Page 3 -- 1 Kubota Diesel Engine Chapter 3 Kubota Diesel Engine Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 3 . . . . . . . . . . . . . . ....

Page 20 - Specifications

Groundsmaster 4000--D/4010--D Page 3 -- 2 Kubota Diesel Engine Specifications Item Description Make / Designation Kubota Model V2403--M--T--E3B: 4--Cycle, 4 Cylinder, Water Cooled, Turbocharged, Diesel Engine Bore 3.43 in (87.0 mm) Stroke 4.031 in (102.4 mm) Total Displacement 148.5 in 3 (2434 cc) F...

Page 21 - General Information; Operator’s Manual; IMPORTANT: Before stopping the engine after

Groundsmaster 4000--D/4010--D Page 3 -- 3 Kubota Diesel Engine General Information This Chapter gives information about specifications and repair of the diesel engine used in Groundsmaster 4000--D and 4010--D machines. General maintenance procedures are described in your Operator’s Manual. Informati...

Page 22 - Service and Repairs; Air Filter System; Figure 1; VACUATOR; FRONT

Groundsmaster 4000--D/4010--D Page 3 -- 4 Kubota Diesel Engine Service and Repairs Air Filter System Figure 1 1. Air cleaner hose 2. Hose clamp 3. Air cleaner assembly 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. Fl...

Page 24 - Exhaust System; Figure 5

Groundsmaster 4000--D/4010--D Page 3 -- 6 Kubota Diesel Engine Exhaust System Figure 5 1. Muffler 2. Muffler bracket 3. Exhaust pipe 4. Flange head screw (4 used) 5. Exhaust gasket 6. Lock nut (2 used) 7. Cap screw (2 used) 8. Flat washer (4 used) 9. Spacer (2 used) 10. Rubber hanger 11. Flange nut ...

Page 25 - CAUTION

Rev. A Groundsmaster 4000--D/4010--D Page 3 -- 7 Kubota Diesel Engine Removal (Fig. 5) CAUTION The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and ex- haust system to cool before working on the muf- fler. 1. Park machine on a level surface, lower cutting decks, sto...

Page 26 - Fuel System; Figure 7

Groundsmaster 4000--D/4010--D Page 3 -- 8 Kubota Diesel Engine Fuel System Figure 7 1. Fuel tank 2. Fuel tank bracket 3. ROPS assembly 4. Washer head screw (3 used) 5. Tank support assembly 6. Insulated clip (3 used) 7. Flange nut (6 used) 8. Cap screw (4 used) 9. Flat washer (4 used) 10. Cap screw ...

Page 28 - Radiator; Figure 9

Groundsmaster 4000--D/4010--D Page 3 -- 10 Kubota Diesel Engine Radiator Figure 9 1. Radiator cap 2. Foam strip (2 used) 3. Foam strip (2 used) 4. Lower radiator hose 5. Upper radiator hose 6. Clamp (4 used) 7. Lower radiator shroud 8. Temperature sender 9. Radiator 10. Hose clamp (3 used) 11. Hose ...

Page 29 - Do not open radiator cap or drain coolant if the

Groundsmaster 4000--D/4010--D Page 3 -- 11 Kubota Diesel Engine Removal (Fig. 9) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Open and support hood. CAUTION Do not open radiator cap or drain coolant if the radia...

Page 30 - Engine

Groundsmaster 4000--D/4010--D Page 3 -- 12 Kubota Diesel Engine Engine Figure 10 1. Engine 2. Cap screw (4 used) 3. LH engine mount 4. Lock washer 5. Cap screw 6. Lock washer (5 used) 7. Cap screw (5 used) 8. Engine support (4 used) 9. Flange nut (12 used) 10. Rebound washer (4 used) 11. Cap screw (...

Page 36 - Spring Coupler

Groundsmaster 4000--D/4010--D Page 3 -- 18 Kubota Diesel Engine Spring Coupler Figure 18 1. Spring coupler 2. Washer (14 used) 3. Cap screw (6 used) 4. Flywheel plate 5. Cap screw (4 used) 6. LH engine mount 7. Cap screw (2 used) 8. Carriage screw (2 used) 9. Cylinder spacer 10. Transport cylinder 1...

Page 39 - Chapter 4; Hydraulic System; Hydrauli

Rev. A Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 1 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 3 . . . . . . . . . . . . . . . . ...

Page 41 - Check level of hydraulic fluid daily.; Towing Traction Unit; IMPORTANT: If towing limits are exceeded, severe

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 3 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...

Page 42 - Relieving Hydraulic System Pressure

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 4 Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hy- draulic system, all pressure in the hydraulic system must be relieved. Park machine on a level surface, make sure that PTO switch is OFF, lower cuttin...

Page 43 - Hydraulic Hoses; WARNING

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 5 Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage condi- tions or mishandling during operation and maintenance. These ...

Page 47 - Hydraulic Schematic

Rev. A Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 9 Hydraulic Schematic NOTE: A larger hydraulic schematic is in clud ed in Ch ap te r 10 :Fold ou tD ra wing s FRONT P TO MA N IF O LD FA N D R IV E MA N IF O LD RH PT O MA NIF O LD 4WD MAN IF O LD LH P TO MA NIF O LD TR A C TIO N MAN IF...

Page 48 - Hydraulic Flow Diagrams

Rev. A Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 10 Hydraulic Flow Diagrams Tr action C irc u it: L ow Spe ed (4WD) (F or war d Shown) W ork ing P res su re Low P ressu re (C ha rg e) Return or Suction Fl ow FRONT P TO MA N IF O LD FA N D R IV E MA N IF O LD RH PT O MA NIF O LD 4W D M...

Page 53 - Lower Cutting Deck; Lower Center Cutting Deck

Rev. A Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 15 Lower Cutting Deck A four section gear pump is coupled to the piston (trac- tion) pump. The third gear pump section supplies hy- draulic flow to both the steering and lift/lower circuits. Hydraulic flow from this pump section is deli...

Page 55 - Raise Cutting Deck; Raise Center Cutting Deck

Rev. A Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 17 Raise Cutting Deck A four section gear pump is coupled to the piston (trac- tion) pump. The third gear pump section supplies hy- draulic flow to both the steering and lift/lower circuits. Hydraulic flow from this pump section is deli...

Page 57 - Mow; PTO Not Engaged

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 19 Mow A four section gear pump is coupled to the piston (trac- tion) pump. Hydraulic flow for the mow circuit is supplied by two sections of the gear pump. The gear pump sec- tion closest to the piston (traction) pump supplies hy- draulic flo...

Page 58 - Mow Circuit Cutting Deck Blade Braking

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 20 Mow Circuit Cutting Deck Blade Braking When the operator turns the PTO switch OFF or if a deck is raised with the PTO switch ON, PTO manifold sole- noid valve (S) is de--energized causing bypass cartridge (LC1) to shift (refer to informatio...

Page 61 - Steering Circuit; Left Turn

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 23 Steering Circuit A four section gear pump is coupled to the piston (trac- tion) pump. The third gear pump section supplies hy- draulic flow to both the steering and lift/lower circuits. Hydraulic flow from this pump section is delivered to ...

Page 63 - Engine Cooling Fan Circuit; Forward Direction Fan Operation; REVERSE DIRECTION SHOWN

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 25 Engine Cooling Fan Circuit A four section gear pump is coupled to the piston (trac- tion) pump. The gear pump section farthest from the pis- ton pump supplies hydraulic flow for the engine cooling fan circuit (Fig. 15). The fan drive manifo...

Page 64 - Special Tools; Hydraulic Pressure Test Kit

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 26 Special Tools Order special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test port...

Page 65 - 0 GPM Hydraulic Tester (Pressure and Flow)

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 27 40 GPM Hydraulic Tester (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter. This tester includes the following: 1. LOAD VALVE: A simulated...

Page 66 - High Flow Hydraulic Filter Kit

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 28 High Flow Hydraulic Filter Kit The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi--direc- tional filtration which prevents filtered deb...

Page 67 - Hydraulic Test Fitting Kit

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 29 Hydraulic Test Fitting Kit This kit includes a variety of O--ring Face Seal fittings to enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Toro Part Number: TOR4...

Page 68 - Troubleshooting; General Hydraulic System Problems; Problem

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 30 Troubleshooting The charts that follow contain suggestions that can be used to assist in diagnosing hydraulic system perfor- mance issues. The suggestions are not all--inclusive. Also, consider that there may be more than one cause for a ma...

Page 69 - Traction Circuit Problems

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 31 Traction Circuit Problems Problem Possible Cause Machine operates in one direction only. Traction control linkage is faulty. Traction relief valve is faulty. Traction pedal is sluggish. Traction control linkage is stuck or binding. Charge p...

Page 70 - Mow Circuit Problems

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 32 Mow Circuit Problems Problem Possible Cause No cutting decks will operate. NOTE: To engage the mow circuit, the seat must be occupied, the cut- ting deck(s) must be fully lowered, the traction speed must be in the Low (4WD) position and the...

Page 71 - Lift Circuit Problems

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 33 Lift Circuit Problems Problem Possible Cause Cutting decks will not raise. NOTE: Seat must be occupied in or- der to raise cutting decks. Engine RPM is too low. Hydraulic oil level in reservoir is low. Solenoid valve (S1) in lift/lower mani...

Page 72 - Steering Circuit Problems; Engine Cooling Fan Circuit Problems

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 34 Steering Circuit Problems Problem Possible Cause Steering inoperative or sluggish Steering components (e.g. tie rods, steering cylinder ends) are worn or binding. Steering cylinder is binding. Oil level in hydraulic reservoir is low (NOTE: ...

Page 76 - Traction Circuit Charge Pressure (Using Pressure Gauge)

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 38 Traction Circuit Charge Pressure (Using Pressure Gauge) 4WD MANIF O LD TRA C TION MANIF O LD FIL T E R MANIF O LD TO COOLING FAN CIRCUIT TO STEERING & LIFT CIRCUITS TO PTO (MOW) CIRCUIT FROM FRONT DECK FROM LIFT CONTROL MANIFOLD FRO M P...

Page 77 - Prevent personal injury and/or damage to equip-

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 39 Procedure for Traction Circuit Charge Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine under load for approximately ten (10) minutes. Make sure the hydrau- lic tank is full. 2. Park mach...

Page 78 - Traction Circuit Relief Pressure (Using Pressure Gauge); FORWARD TRACTION CIRCUIT RELIEF PRESSURE TEST SHOWN

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 40 Traction Circuit Relief Pressure (Using Pressure Gauge) FORWARD TRACTION CIRCUIT RELIEF PRESSURE TEST SHOWN 4WD MANIF O LD TRA C TION MANIF O LD FIL T E R MANIF O LD TO COOLING FAN CIRCUIT TO STEERING & LIFT CIRCUITS TO PTO (MOW) CIRCUI...

Page 80 - Counterbalance Pressure (Using Pressure Gauge)

Rev. A Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 42 Counterbalance Pressure (Using Pressure Gauge) FA N D R IV E MA NIF O LD 4W D MA NIF O LD TR A C TIO N MAN IF O LD FI LT ER MAN IF O LD S1 S2 S3 S4 S5 S7 S6 S8 RV 1 RV 2 S9 LI F T MA NIF O LD TO PTO (MOW) CIRCUIT FROM PTO MANIFOLDS T...

Page 88 - Cutting Deck Circuit Pressure (Using Pressure Gauge); FRONT DECK CIRCUIT PRESSURE TEST SHOWN

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 50 Cutting Deck Circuit Pressure (Using Pressure Gauge) FRONT DECK CIRCUIT PRESSURE TEST SHOWN TO CO O L ING FAN CI RCUI T F R O M REAR AXL E M O TO R TO S T E E R IN G & LI FT CI R CUI TS TRACTION CIRCUIT FLOW CHAR G E CIR CUI T FR O M FR...

Page 98 - Steering Circuit Relief Pressure (Using Pressure Gauge)

Rev. A Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 60 Steering Circuit Relief Pressure (Using Pressure Gauge) FA N DRIV E MA NIF O LD 4W D MA NIF O LD TR A C TIO N MAN IF O LD FI LT ER MAN IF O LD S1 S2 S3 S4 S5 S7 S6 S8 RV 1 RV 2 S9 LIF T MA N IF O LD TO PTO (MOW) CIRCUIT FROM PTO MANI...

Page 100 - Steering Cylinder Internal Leakage

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 62 Steering Cylinder Internal Leakage 1350PSI PB STEERING CYLINDER STEERING CONTROL T R P L CYLINDER FULLY EXTENDED STEEL CAP LOOK FOR LEAKAGE STEERING WHEEL TURNED FOR RIGHT TURN

Page 104 - Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac)

Rev. A Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 66 Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac) FA N D R IV E MA NIF O LD 4W D MA NIF O LD TRAC TI ON MA N IF O LD FI LT ER MAN IF O LD S1 S2 S 3 S4 S5 S7 S6 S8 RV 1 RV 2 S9 LIF T MAN IF O LD TO PTO (MOW) CIRCUIT FROM ...

Page 108 - Adjustments; Traction Linkage Adjustment; Assembly Adjustments

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 70 Adjustments Traction Linkage Adjustment 1. Traction pedal 2. Cap screw (4 used) 3. Hex nut 4. Pedal stop 5. Washer head screw (2 used) 6. Pedal bracket 7. Lock nut (4 used) 8. Traction rod 9. Slotted roll pin 10. Lock nut 11. Flat washer 12...

Page 110 - Check Hydraulic Lines and Hoses

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 72 Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- tem, park machine on a level surface, apply park...

Page 111 - Flush Hydraulic System

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 73 Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated. Contaminated oil may appear milky or black or may contain metal particles. IMPORTANT: If a component fa...

Page 113 - Charge Hydraulic System

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 75 Charge Hydraulic System NOTE: When initially starting the hydraulic system with new or rebuilt components such as motors, pumps or lift cylinders, it is important that the hydraulic system be charged properly. Air must be purged from the sy...

Page 114 - Hydraulic Reservoir

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 76 Hydraulic Reservoir 1. Hydraulic reservoir 2. Petcock 3. O--ring 4. Strap 5. Felt strap (2 used) 6. Bushing (2 used) 7. Bushing 8. Strap 9. Stand pipe (2 used) 10. Hose clamp (2 used) 11. Screen filter 12. Dipstick 13. O--ring 14. Reservoir...

Page 116 - Hydraulic Oil Cooler

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 78 Hydraulic Oil Cooler 1. Radiator 2. RH radiator support 3. Top radiator support 4. Knob (2 used) 5. Oil cooler bracket 6. Retaining ring (2 used) 7. Carriage screw (2 used) 8. O--ring 9. 90 o hydraulic fitting (2 used) 10. O--ring 11. Cap s...

Page 118 - Gear Pump

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 80 Gear Pump 1. Hydraulic T fitting 2. Roll pin 3. 90 o hydraulic fitting 4. Piston pump 5. Flat washer (2 used) 6. Cap screw (2 used) 7. Hydraulic fitting (2 used) 8. 90 o hydraulic fitting 9. Hydraulic fitting 10. Hydraulic hose 11. O--ring ...

Page 120 - Gear Pump Service; thrust plates for each pump section together do not

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 82 Gear Pump Service 1. Dust seal 2. Retaining ring 3. Flange washer 4. Shaft seal 5. Front cover 6. Dowel pin (16 used) 7. Pressure seal 8. Back--up gasket 9. Thrust plate (8 used) 10. Seal (8 used) 11. Idler gear 12. Drive shaft 13. Back--up...

Page 122 - Traction Circuit

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 84 Traction Circuit 1. Piston (traction) pump 2. Gear pump 3. LH front wheel motor 4. Traction manifold 5. RH front wheel motor 6. 4WD manifold 7. Filter manifold 8. Rear axle motor 9. Cooling fan motor 10. Check valve 11. Forward traction pre...

Page 123 - Transport Cylinder

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 85 Transport Cylinder A transport cylinder is included in the traction circuit to reduce traction pump control arm movement when op- erating in Hi speed (2WD). This reduced control arm movement limits pump swash plate rotation to prevent exces...

Page 127 - 2400 Servo Controlled Piston Pump Repair Informa-

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 89 Piston (Traction) Pump Service (Fig. 70) For service of the piston (traction) pump (including the servo control (item 28) assembly), see the Eaton Model 72400 Servo Controlled Piston Pump Repair Informa- tion at the end of this chapter. Hyd...

Page 128 - Rear Axle Motor

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 90 Rear Axle Motor 1. Axle motor 2. 90 o hydraulic fitting (2 used) 3. Hydraulic fitting 4. Cap screw (2 used) 5. Flat washer (2 used) 6. O--ring 7. External snap ring (2 used) 8. Gear (45T) 9. External snap ring (2 used) 10. Pinion gear (27T)...

Page 130 - Front Wheel Motor

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 92 Front Wheel Motor 1. Front wheel motor 2. Internal retaining ring 3. Splined brake shaft 4. RH brake assembly 5. Planetary assembly 6. Cap screw (2 used per side) 7. Flat washer (2 used per side) 8. O--ring 9. Flange head screw (6 used per ...

Page 132 - Rear Axle and Front Wheel Motor Service; The front wheel motors are identical. The rear

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 94 Rear Axle and Front Wheel Motor Service 1. Drive shaft 2. Backplate (front motor shown) 3. Housing assembly 4. Rotating assembly 5. Cam plate insert 6. Retaining ring 7. Cap screw (6 used) 8. Shaft seal 9. Retaining ring 10. Thrust race 11....

Page 134 - WD Manifold

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 96 4WD Manifold 1. Frame assembly 2. 4WD manifold 3. 90 o hydraulic fitting 4. O--ring 5. O--ring 6. Quick fitting 7. O--ring 8. Dust cap 9. Hydraulic fitting 10. O--ring 11. O--ring 12. 90 o hydraulic fitting 13. O--ring 14. Hydraulic fitting...

Page 136 - WD Manifold Service

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 98 4WD Manifold Service 1. 4WD manifold body 2. Solenoid valve (port SV) 3. Solenoid coil 4. Check valve (port CV) 5. Nut 6. Directional valve (ports PD1 & PD2) 7. Pressure reducing valve (port PR) 8. Relief valve (port RV) 9. Orifice (0.0...

Page 142 - Filter Manifold

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 104 Filter Manifold 1. Filter manifold 2. 45 o hydraulic fitting 3. Test nipple 4. Dust cap 5. O--ring 6. O--ring 7. O--ring 8. Cap screw (3 used) 9. Flat washer (3 used) 10. Hydraulic fitting 11. O--ring 12. O--ring 13. 90 o hydraulic fitting...

Page 144 - Filter Manifold Service

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 106 Filter Manifold Service 1. Filter manifold 2. Check valve (reservoir return) 3. Oil filter element 4. Check valve (filter bypass) 5. #6 zero leak plug with O--ring 6. Charge relief valve 7. #8 zero leak plug with O--ring Figure 79 FRONT UP...

Page 145 - For filter manifold cartridge valve service procedures,

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 107 Filter Manifold Service (Fig. 79) For filter manifold cartridge valve service procedures, see 4WD Manifold Service in this section. Refer to Fig- ure 79 for filter manifold cartridge valve and plug instal- lation torque. Hydraulic System

Page 146 - Steering and Engine Cooling Fan Circuits

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 108 Steering and Engine Cooling Fan Circuits 1. Gear pump 2. Steering control valve 3. Fan drive manifold 4. Fan motor 5. Steering cylinder 6. Steering circuit test port (GM4000) 7. Fan circuit test port Figure 80 FRONT RIGHT 2 1 5 4 3 6 7 GRO...

Page 148 - Steering Control Valve

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 110 Steering Control Valve 1. Hex nut 2. Flat washer 3. Steering wheel 4. Foam collar 5. Steering seal 6. External snap ring (2 used) 7. Knob 8. Steering tower cover 9. Steering shaft 10. Compression spring 11. Cap 12. Rod assembly 13. Extensi...

Page 150 - Steering Control Valve Service

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 112 Steering Control Valve Service 1. Steering control valve housing 2. Dust seal 3. O--ring 4. Spool 5. Spring retaining ring 6. Pin 7. Sleeve 8. Centering springs/spacers 9. Cap screw (7 used) 10. End cap 11. O--ring 12. Seal ring 13. O--rin...

Page 152 - Steering Cylinder

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 114 Steering Cylinder 1. Steering cylinder 2. Ball joint 3. Ball joint 4. Retaining ring 5. Grease fitting 6. Grease fitting 7. 90 o hydraulic fitting 8. O--ring 9. O--ring 10. Drive axle assembly 11. Ball joint spacer 12. Axle washer 13. Slot...

Page 154 - Steering Cylinder Service

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 116 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 88 45 to 55 ft--lb (62 to 74 N--m) 1 6 7 3 9 10 4 11 ...

Page 156 - Engine Cooling Fan Motor; The radiator and oil cooler may be hot. To avoid

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 118 Engine Cooling Fan Motor 1. Hydraulic fan motor 2. O--ring 3. Bracket 4. 45 o hydraulic fitting 5. O--ring 6. Hydraulic hose 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...

Page 158 - Engine Cooling Fan Motor Service

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 120 Engine Cooling Fan Motor Service 1. Flange washer 2. O--ring 3. Front flange 4. Dust seal 5. Retaining ring 6. Front wear plate 7. Shaft seal 8. Backup gasket 9. Pressure seal 10. Rear wear plate 11. Body 12. Idler gear 13. Cap screw (4 us...

Page 159 - Use eye protection such as goggles when using

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 121 8. Remove and discard back--up gaskets and pressure seals from wear plates. 9. Turn front flange over, with seal side up. IMPORTANT: Make sure not to damage the front flange counter bore when removing the seals from the front flange. 10.Ca...

Page 162 - Fan Drive Manifold

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 124 Fan Drive Manifold 1. Fan drive manifold 2. O--ring 3. Test fitting 4. Dust cap (2 used) 5. O--ring 6. 45 o hydraulic fitting (2 used) 7. O--ring 8. Hydraulic hose 9. Hydraulic hose 10. Hydraulic fitting 11. Hydraulic hose 12. Hydraulic ho...

Page 164 - Fan Drive Manifold Service

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 126 Fan Drive Manifold Service 1. Fan drive manifold body 2. #4 zero leak plug with O--ring (3 used) 3. Check valve (port CV) 4. #6 zero leak plug with O--ring (2 used) 5. Flow divider valve (port FD) 6. Nut 7. Solenoid coil (2 used) 8. Propor...

Page 165 - For fan drive manifold cartridge valve service proce-

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 127 Fan Drive Manifold Service (Fig. 97) For fan drive manifold cartridge valve service proce- dures, see 4WD Manifold Service in this section. Refer to Figure 97 for fan drive manifold cartridge valve and plug installation torque. Hydraulic S...

Page 166 - PTO Circuit

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 128 PTO Circuit 1. Gear pump 2. RH cutting deck motor 3. LH cutting deck motor 4. RH PTO manifold 5. Front cutting deck motor 6. LH PTO manifold 7. Front PTO manifold 8. Filter manifold 9. Oil cooler Figure 98 FRONT RIGHT 2 1 5 4 3 7 6 8 9 Fig...

Page 167 - Cutting Deck Motor; Removal

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 129 Cutting Deck Motor Removal 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Comp...

Page 168 - Cutting Deck Motor Service

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 130 Cutting Deck Motor Service 1. Rear cover 2. Drive gear 3. Seal 4. Woodruff key 5. Nut 6. Tab washer 7. Spider hub 8. Pressure seal 9. Back--up ring 10. O--ring 11. Body 12. Idler gear 13. Cap screw (4 used) 14. Front flange 15. Dowel pin F...

Page 172 - PTO Manifold

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 134 PTO Manifold 1. Hydraulic PTO manifold (front deck) 2. Quick fitting (1 used per manifold) 3. Flange nut 4. O--ring 5. Hydraulic fitting 6. O--ring 7. O--ring 8. O--ring 9. Hydraulic adapter 10. Straight fitting 11. Cap screw (2 used per m...

Page 174 - PTO Manifold Service; DO NOT

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 136 PTO Manifold Service 1. PTO manifold body 2. NWD SAE #4 plug with O--ring 3. Orifice (0.063) (port OR) 4. #8 zero leak plug with O--ring 5. Relief valve (port RV2) 6. Solenoid valve (port S) 7. Solenoid coil 8. Nut 9. Relief valve (port RV...

Page 175 - For PTO manifold solenoid and control valve service

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 137 PTO Manifold Service (Fig. 107) For PTO manifold solenoid and control valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 107 for PTO manifold cartridge valve and plug installation torque. Hydraulic System

Page 176 - Cutting Deck Lift/Lower Circuit; Make sure that cutting decks are fully lowered

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 138 Cutting Deck Lift/Lower Circuit 1. Front lift cylinder (2 used) 2. RH lift cylinder 3. LH lift cylinder 4. Fan drive manifold 5. Lift/lower manifold 6. Oil filter Figure 108 FRONT RIGHT 2 1 5 4 3 6 1 Figure 108 illustrates the components t...

Page 180 - Lift/Lower Manifold Service

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 142 Lift/Lower Manifold Service 1. Lift/lower manifold body 2. Solenoid valve (S4, S6 & S9) 3. Solenoid coil (5 used) 4. Nut (8 used) 5. Relief valve (RV2) 6. Relief valve (RV1) 7. Solenoid valve (S1) 8. Nut 9. Solenoid coil (4 used) 10. S...

Page 181 - For lift/lower manifold solenoid and control valve service

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 143 Lift/Lower Manifold Service (Fig. 112) WARNING If lift/lower manifold is attached to machine, make sure that cutting decks are fully lowered before loosening hydraulic lines, cartridge valves or plugs from lift/lower manifold. If decks are...

Page 182 - Side Deck Lift Cylinder

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 144 Side Deck Lift Cylinder 1. Lift arm assembly (LH shown) 2. Shoulder screw 3. Pin assembly 4. Lift cylinder 5. Flange locking nut 6. 90 o hydraulic fitting (2 used) 7. O--ring 8. O--ring 9. Cylinder pin 10. Spring pin 11. Lock nut 12. Flat ...

Page 183 - Make sure that side cutting deck is fully lowered

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 145 Removal (Fig. 113) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components a...

Page 184 - Front Deck Lift Cylinder

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 146 Front Deck Lift Cylinder 1. Lift cylinder 2. Pivot pin 3. Cotter pin (2 used per pin) 4. Pin assembly 5. Cap screw 6. Flat washer 7. Lock nut 8. LH lift arm assembly 9. O--ring 10. Straight hydraulic fitting 11. O--ring 12. 90 o hydraulic ...

Page 185 - Make sure that front cutting deck is fully lowered

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 147 Removal (Fig. 114) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components a...

Page 186 - Lift Cylinder Service; SIDE DECK LIFT CYLINDER; FRONT DECK LIFT CYLINDER

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 148 Lift Cylinder Service 1. Barrel with clevis 2. Retaining ring 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. Grease fitting 14. Bushing 15. O--ring 16....

Page 189 - Chapter 5; Electrical System; Electrical System

Groundsmaster 4000--D/4010--D Page 5 -- 1 Electrical System Chapter 5 Electrical System Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Toro Electronic Controllers (TEC) 2 . . . . . . . . . . . ...

Page 191 - Multimeter

Groundsmaster 4000--D/4010--D Page 5 -- 3 Electrical System Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The multimeter can test electrical components and cir- cuits for current, resistance or voltage. NOTE: Toro rec...

Page 193 - Battery Hydrometer; Use the Battery Hydrometer when measuring specific

Groundsmaster 4000--D/4010--D Page 5 -- 5 Electrical System Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally. Figure 7 Electrical System

Page 194 - Diagnostic Display

Groundsmaster 4000--D/4010--D Page 5 -- 6 Electrical System Troubleshooting CAUTION Remove all jewelry, especially rings and watches, before doing any electrical trouble- shooting or testing. Also, disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting ...

Page 199 - Starting Problems

Groundsmaster 4000--D/4010--D Page 5 -- 11 Electrical System Starting Problems Problem Possible Causes No electrical power to machine (including gauges). The battery is discharged. The battery cables are loose or corroded. Fuse F3--1 (2 amp) to the ignition switch is faulty. Bad ground connection on...

Page 201 - General Run and Transport Problems

Groundsmaster 4000--D/4010--D Page 5 -- 13 Electrical System General Run and Transport Problems Engine continues to run, but should not, when the ignition switch is turned off. The engine run solenoid is faulty. The ignition switch or circuit wiring is faulty. Engine continues to run, but should not...

Page 202 - Cutting Deck Operating Problems; and

Groundsmaster 4000--D/4010--D Page 5 -- 14 Electrical System Cutting Deck Operating Problems The cutting decks remain engaged, but should not, with no operator in the seat. The seat switch or circuit wiring is faulty. The TEC--5001 controller is faulty. Cutting deck runs, but should not, when raised...

Page 203 - Cutting Deck Lift/Lower Problems

Groundsmaster 4000--D/4010--D Page 5 -- 15 Electrical System Cutting Deck Lift/Lower Problems Problem Possible Causes None of the cutting decks will lower. The Hi/Low speed switch is in the Hi speed position. Operator is not fully depressing the seat switch. TEC--5001 fuse(s) (F4--1, F4--2, F4--3, F...

Page 205 - Cutting Deck Position Switches; Adjustment

Groundsmaster 4000--D/4010--D Page 5 -- 17 Electrical System Adjustments Cutting Deck Position Switches Adjustment 1. Park machine on a level surface with front cutting deck raised and side cutting decks lowered. Stop en- gine, engage parking brake and remove key from the ignition switch. 2. There s...

Page 206 - Electrical System Quick Checks; Voltage Measured; Charging System Test; At least 0.50 volt over initial battery voltage.; Glow Plug System Test

Groundsmaster 4000--D/4010--D Page 5 -- 18 Electrical System Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Set multimeter to the DC volts setting. The battery should be at a temperature of 60 o to 100 o F (16 o ...

Page 207 - Check Operation of Interlock Switches; Do not disconnect safety switches. They are for

Groundsmaster 4000--D/4010--D Page 5 -- 19 Electrical System Check Operation of Interlock Switches CAUTION Do not disconnect safety switches. They are for the operator’s protection. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before o...

Page 208 - Ignition Switch

Groundsmaster 4000--D/4010--D Page 5 -- 20 Electrical System Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before checking continuity on the switch). NOTE: For engin...

Page 209 - Fuses; Fuse Identification and Function

Groundsmaster 4000--D/4010--D Page 5 -- 21 Electrical System Fuses The fuse blocks are located in the power center under the hood on the right side of the machine (Fig. 17). In addition to the fuses in the fuse blocks, a 40 amp fuse (F5--1) is included in the wire harness to protect the pull coil ci...

Page 211 - Warning Lights

Groundsmaster 4000--D/4010--D Page 5 -- 23 Electrical System Warning Lights Charge Indicator Light The charge indicator light should come on when the igni- tion switch is in ON with the engine not running or with an improperly operating charging circuit while the en- gine is running. To test the cha...

Page 212 - PTO Switch

Groundsmaster 4000--D/4010--D Page 5 -- 24 Electrical System PTO Switch The PTO switch is located on the console arm (Fig. 23). The PTO switch is pulled up to engage the PTO and pushed in to disengage the PTO. The TEC--5001 controller monitors the position of the PTO switch (up or down). Using input...

Page 213 - Cutting Deck Lift Switches

Groundsmaster 4000--D/4010--D Page 5 -- 25 Electrical System Cutting Deck Lift Switches The cutting deck lift switches are used as inputs for the TEC--5001 controller to raise or lower the cutting decks. When the front of a lift switch is depressed and held, the controlled decks will lower. When the...

Page 215 - Flow Divider and Engine Cooling Fan Switches

Groundsmaster 4000--D/4010--D Page 5 -- 27 Electrical System Flow Divider and Engine Cooling Fan Switches The flow divider and engine cooling fan switches are identical, two (2) position rocker switches that are lo- cated on the control console (Fig. 29). These switches have a normal and a momentary...

Page 216 - Seat Switch; Testing

Groundsmaster 4000--D/4010--D Page 5 -- 28 Electrical System Seat Switch The seat switch is normally open and closes when the operator is on the seat. This switch is used as an input for the TEC--5002 controller. The seat switch and its electrical connector are located in the seat assembly. If the t...

Page 217 - Parking Brake Switch

Groundsmaster 4000--D/4010--D Page 5 -- 29 Electrical System Parking Brake Switch The switch used for the parking brake is a normally open switch that is located under the steering tower cover (Fig. 32). The brake switch is used as an input for the TEC--5002 controller. When the parking brake is not...

Page 220 - Hour Meter; Hobbs; Audio Alarm

Groundsmaster 4000--D/4010--D Page 5 -- 32 Electrical System Hour Meter The hour meter is located on the outside of the console arm. Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 2. Disassemble console arm to gain access to the hour meter (see Console Arm Disassembly ...

Page 224 - Hydraulic Valve Solenoids

Groundsmaster 4000--D/4010--D Page 5 -- 36 Electrical System Hydraulic Valve Solenoids Figure 45 1. 4WD manifold 2. LH PTO manifold 3. Traction manifold 4. Front PTO manifold 5. Fan drive manifold 6. RH PTO manifold 7. Lift/lower manifold FRONT RIGHT 1 2 3 4 5 6 7 Several hydraulic solenoid valve co...

Page 227 - Fuel Sender

Groundsmaster 4000--D/4010--D Page 5 -- 39 Electrical System Fuel Sender The fuel sender is located on top of the fuel tank. Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 2. Remove white (+) wire and black (--) wire from the fuel sender. CAUTION If testing circuit wir...

Page 228 - Fuel Gauge

Groundsmaster 4000--D/4010--D Page 5 -- 40 Electrical System Fuel Gauge The fuel gauge can be tested using a new gauge as a substitute or with the use of a DC voltage source and a variable resistance box. Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 2. Locate fuel ga...

Page 229 - Fuel Pump; Operational Test; Fuel Pump Specifications

Groundsmaster 4000--D/4010--D Page 5 -- 41 Electrical System Fuel Pump The fuel pump is attached to the frame above the fuel water separator (Fig. 54). Operational Test 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake. 2. Remove fuse F1--1 (20 amp) (Fig. 5...

Page 230 - Temperature Sender; Handle the hot oil with extreme care to prevent

Groundsmaster 4000--D/4010--D Page 5 -- 42 Electrical System Temperature Sender The temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 56). The resistance of the temperature sender re- duces as the engine coolant temperature increases. Th...

Page 231 - Temperature Gauge

Groundsmaster 4000--D/4010--D Page 5 -- 43 Electrical System Temperature Gauge The temperature gauge on the control panel indicates engine coolant temperature level during machine op- eration (Fig. 58). The changing resistance of the engine temperature sender signals the temperature gauge. The tempe...

Page 234 - Engine Coolant and Hydraulic Oil Temperature Senders

Rev. A Groundsmaster 4000--D/4010--D Page 5 -- 46 Electrical System Engine Coolant and Hydraulic Oil Temperature Senders The Groundsmaster 4000--D and 4010--D use two (2) temperature senders as inputs for the TEC--5002 to identify if either the engine coolant or hydraulic oil tem- perature has reach...

Page 235 - Battery Storage

Groundsmaster 4000--D/4010--D Page 5 -- 47 Electrical System Service and Repairs NOTE: For engine component repair information (e.g. starter motor), see the Kubota Workshop Manual, Die- sel Engine, 03--M--E3B Series at the end of Chapter 3 -- Kubota Diesel Engine. Battery Storage If the machine will...

Page 236 - Battery Service

Groundsmaster 4000--D/4010--D Page 5 -- 48 Electrical System Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. CAUTION When working with batteries,...

Page 239 - Chapter 6; Axles, Planetaries and Brakes

Groundsmaster 4000--D/4010--D Page 6 -- 1 Axles, Planetaries and Brakes Chapter 6 Axles, Planetaries and Brakes Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 3 . . . . . ....

Page 241 - The Operator’s Manual provides information regarding

Groundsmaster 4000--D/4010--D Page 6 -- 3 Axles, Planetaries and Brakes 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 inf...

Page 242 - Brake Assembly

Groundsmaster 4000--D/4010--D Page 6 -- 4 Axles, Planetaries and Brakes Service and Repairs Brake Assembly 1. Planetary assembly 2. Retaining ring 3. Splined brake shaft 4. Brake assembly (RH) 5. O--ring 6. Hydraulic wheel motor 7. Flat washer (2 used per side) 8. Cap screw (2 used per side) 9. Flan...

Page 244 - Failure to maintain proper wheel lug nut torque

Groundsmaster 4000--D/4010--D Page 6 -- 6 Axles, Planetaries and Brakes 2. Apply gasket sealant to sealing surfaces of new gas- ket (item 18). Apply gasket to brake assembly. 3. Install brake assembly onto machine, aligning splined brake shaft with input shaft on planetary wheel drive. 4. Secure bra...

Page 246 - Brake Inspection and Repair; Figure 6

Groundsmaster 4000--D/4010--D Page 6 -- 8 Axles, Planetaries and Brakes Brake Inspection and Repair 1. Brake housing (LH shown) 2. Seal 3. Pull rod 4. Clevis pin (2 used) 5. Link (2 used) 6. Hitch pin (2 used) 7. Stationary disc (4 used) 8. Rotating disc (3 used) 9. Retaining ring 10. Gasket 11. Rot...

Page 248 - Planetary Wheel Drive Assembly

Groundsmaster 4000--D/4010--D Page 6 -- 10 Axles, Planetaries and Brakes Planetary Wheel Drive Assembly 1. Planetary assembly 2. Retaining ring 3. Splined brake shaft 4. Brake assembly (RH) 5. O--ring 6. Hydraulic wheel motor 7. Flat washer (2 used per side) 8. Cap screw (2 used per side) 9. Flange ...

Page 250 - Planetary Wheel Drive Service

Groundsmaster 4000--D/4010--D Page 6 -- 12 Axles, Planetaries and Brakes Planetary Wheel Drive Service 1. Spindle 2. Boot seal 3. Inner bearing cone 4. Inner bearing cup 5. Wheel stud (8 used) 6. Housing 7. Outer bearing cup 8. Outer bearing cone 9. Thrust washer 10. Retaining ring (external) 11. Ri...

Page 254 - Rear Axle Assembly

Groundsmaster 4000--D/4010--D Page 6 -- 16 Axles, Planetaries and Brakes Rear Axle Assembly 1. Frame assembly 2. Cap screw (10 used) 3. Lock washer (6 used) 4. Flat washer (16 used) 5. Support frame 6. Thrust washer (thick) 7. Grease fitting 8. Rear axle assembly 9. Thrust washer (thin) 10. Washer h...

Page 258 - Rear Axle Service

Groundsmaster 4000--D/4010--D Page 6 -- 20 Axles, Planetaries and Brakes Rear Axle Service Figure 16 3 2 4 5 6 7 8 9 10 14 13 12 11 15 1 10 11 8 9 8 13 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 20 41 42 43 50 44 45 46 47 48 49 51 54 55 56 57 58 59 52 53 60 61 62 63 22 9

Page 259 - Figure 16 illustrates the rear axle used on the

Groundsmaster 4000--D/4010--D Page 6 -- 21 Axles, Planetaries and Brakes 1. LH axle support 2. Flange bushing (2 used) 3. Axle vent 4. O--ring 5. Vent extension 6. Cap screw (4 used per gear case) 7. Shim set 8. Seal washer 9. Plug 10. Lock nut 11. Lock washer 12. Grease fitting 13. Ball bearing 14....

Page 260 - Bevel Gear Case and Axle Case

Groundsmaster 4000--D/4010--D Page 6 -- 22 Axles, Planetaries and Brakes Bevel Gear Case and Axle Case The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove the mounting screws, nuts and lock wash- ers. Remove the bevel gear case/axle case asse...

Page 261 - Inspection

Groundsmaster 4000--D/4010--D Page 6 -- 23 Axles, Planetaries and Brakes 5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gas- ket material from either mating surface (Fig. 20). 6. While holding the bevel gear case, tap the upper end of the bevel gea...

Page 264 - Differential Shafts

Groundsmaster 4000--D/4010--D Page 6 -- 26 Axles, Planetaries and Brakes 9. Remove the bevel gear case/axle case assembly from the axle support. Coat a new O-ring with grease and temporarily install the axle cover assembly. Position a dial indicator at the tooths center. Prevent the axle from turnin...

Page 265 - Axle Shafts

Groundsmaster 4000--D/4010--D Page 6 -- 27 Axles, Planetaries and Brakes Axle Shafts The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig. 29). 2. Use...

Page 266 - Input Shaft/Pinion Gear

Groundsmaster 4000--D/4010--D Page 6 -- 28 Axles, Planetaries and Brakes Input Shaft/Pinion Gear Figure 32 1 1. Nut (2 used) 2. Lock washer (2 used) 3. Stud (2 used) 4. Lock nut 5. Stake washer 6. Oil seal 7. O-ring 8. Seal collar 9. Bearing 10. O-ring 11. Input shaft/pinion gear 12. Bearing case 13...

Page 268 - Differential Gear

Groundsmaster 4000--D/4010--D Page 6 -- 30 Axles, Planetaries and Brakes Differential Gear The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of thi...

Page 269 - ferential case I.D. to determine the side gear to case

Groundsmaster 4000--D/4010--D Page 6 -- 31 Axles, Planetaries and Brakes Inspection 1. Measure the differential side gear O.D. and the dif- ferential case I.D. to determine the side gear to case clearance (Fig. 39). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 in. (0....

Page 271 - Pinion Gear to Ring Gear Engagement; Toe

Groundsmaster 4000--D/4010--D Page 6 -- 33 Axles, Planetaries and Brakes Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using the gear contact pattern method as described in the fol- lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 43): Toe -- the portion of t...

Page 273 - Chapter 7; Chassis; Chassis

Groundsmaster 4000--D/4010--D Page 7 -- 1 Chassis Chapter 7 Chassis Table of Contents GENERAL INFORMATION 1 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 1 . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE AND REPAIRS 2 . . . . . . . . . . . . . . . . . . . . . . Steering Tow...

Page 274 - Steering Tower

Groundsmaster 4000--D/4010--D Page 7 -- 2 Chassis Service and Repairs Steering Tower 1. Hex nut 2. Flat washer 3. Steering wheel 4. Foam collar 5. Steering seal 6. External snap ring (2 used) 7. Knob 8. Steering tower cover 9. Steering shaft 10. Compression spring 11. Cap 12. Rod assembly 13. Extens...

Page 276 - Front Deck Lift Arm

Groundsmaster 4000--D/4010--D Page 7 -- 4 Chassis Front Deck Lift Arm 1. Flange bushing 2. Ball joint 3. Lock nut (2 per mount) 4. Clevis pin 5. Height--of--cut chain 6. U--bolt 7. Hex nut (2 per u--bolt) 8. Flat washer (4 per u--bolt) 9. Lock nut (2 per u--bolt) 10. Lock nut 11. Grease fitting (45 ...

Page 278 - Side Deck Lift Arm

Groundsmaster 4000--D/4010--D Page 7 -- 6 Chassis Side Deck Lift Arm 1. Lift arm (LH shown) 2. Shoulder screw 3. Lift cylinder pin 4. Lift cylinder 5. Thrust washer 6. Flange nut 7. Pivot hub 8. Lift arm pivot shaft 9. Thrust washer 10. Cap screw 11. Spring pin 12. Cylinder pin 13. Rivet (2 per bump...

Page 280 - Side Deck Rear Arm Assembly; Figure 8

Groundsmaster 4000--D/4010--D Page 7 -- 8 Chassis Side Deck Rear Arm Assembly 1. Cutting deck (LH shown) 2. Deck mount (LH shown) 3. Cap screw 4. Lock nut 5. Clevis pin 6. Hair pin 7. Spacer 8. Rod end 9. Jam nut 10. Cap screw (4 per arm) 11. Straight bushing 12. Spring shaft 13. Flat washer 14. Com...

Page 284 - Lift Arm Joint Yoke

Groundsmaster 4000--D/4010--D Page 7 -- 12 Chassis Lift Arm Joint Yoke 1. Side cutting deck (LH shown) 2. Deck mount (LH shown) 3. Retaining ring (2 used per deck) 4. Lock nut 5. Plate 6. Rubber plate 7. Cap screw 8. Flat washer (8 used per mount) 9. Joint yoke 10. Spacer 11. Thrust washer (0.125” t...

Page 286 - Console Arm

Groundsmaster 4000--D/4010--D Page 7 -- 14 Chassis Console Arm 1. Flange nut (3 used) 2. Flange head screw (2 used) 3. Foam seal 4. Washer head screw (10 used) 5. LH cover 6. Hi--low speed switch 7. Lock nut (3 used) 8. Throttle control 9. Control arm 10. Diagnostic light 11. Ignition switch 12. But...

Page 288 - Operator Seat

Groundsmaster 4000--D/4010--D Page 7 -- 16 Chassis Operator Seat 1. Platform 2. Clevis pin (2 used) 3. Hair pin (2 used) 4. Seat plate 5. Grommet 6. Cotter pin (2 used) 7. Latch shaft 8. Cap screws (4 used) 9. Latch 10. Torsion spring 11. Prop rod 12. Flange nut (4 used) 13. Cotter pin (2 used) 14. ...

Page 290 - Operator Seat Service

Groundsmaster 4000--D/4010--D Page 7 -- 18 Chassis Operator Seat Service 1. Backrest cushion 2. Seat cushion 3. Armrest cover 4. LH armrest 5. Bushing (2 used) 6. Backrest 7. Plug (2 used) 8. Cable tie (3 used) 9. LH adjustment rail 10. Bumper (2 used) 11. Washer 12. Cap screw (2 used) 13. Seat 14. ...

Page 291 - Disassemble operator seat as necessary using Fig-

Groundsmaster 4000--D/4010--D Page 7 -- 19 Chassis Disassembly (Fig. 18) 1. Disassemble operator seat as necessary using Fig- ures 18 and 19 as guides. Assembly (Fig. 18) 1. Assemble operator seat using Figures 18 and 19 as guides. 1. Operator seat 2. R--clamp 3. Screw 4. Manual tube 5. Button head ...

Page 292 - Operator Seat Suspension

Groundsmaster 4000--D/4010--D Page 7 -- 20 Chassis Operator Seat Suspension 1. Cover 2. Cover 3. Level control 4. Air control valve 5. Shock absorber 6. Air spring 7. Air tube assembly 8. Wire harness 9. Compressor 10. Bellows 11. Stop 12. Bumper set (2 used) 13. Roller (4 used) 14. Washer (2 used) ...

Page 294 - Hood

Groundsmaster 4000--D/4010--D Page 7 -- 22 Chassis Hood 1. Rear screen 2. Top screen 3. Screen assembly 4. Bulb seal 5. Bulb seal 6. Corner screen seal (2 used) 7. Hair pin (2 used) 8. Screw (8 used) 9. Screen pivot (2 used) 10. Hood pivot (2 used) 11. Hood 12. Carriage bolt (2 used) 13. Flange nut ...

Page 297 - Chapter 8; Cutting Decks; Cutting Decks

Groundsmaster 4000--D/4010--D Cutting Decks Page 8 -- 1 Chapter 8 Cutting Decks Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 3 . . . . . . . . . . . . . . . . . . . . . ....

Page 299 - Never install or work on the cutting decks or lift

Groundsmaster 4000--D/4010--D Cutting Decks Page 8 -- 3 General Information CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop en- gine and remove key first. Operator’s Manual The Operator’s Manual provides information regarding the operation, genera...

Page 300 - Factors That Can Affect Quality of Cut; Factor

Groundsmaster 4000--D/4010--D Cutting Decks Page 8 -- 4 Troubleshooting There are a number of factors that can contribute to un- satisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, uneven ground conditions, “sponginess” or attempting to cut of...

Page 302 - Front Cutting Deck

Groundsmaster 4000--D/4010--D Cutting Decks Page 8 -- 6 Service and Repairs CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop en- gine and remove key from ignition switch first. Front Cutting Deck 1. Flange bushing 2. Ball joint 3. Lock nut (2 per m...

Page 304 - Side Cutting Deck

Groundsmaster 4000--D/4010--D Cutting Decks Page 8 -- 8 Side Cutting Deck 1. Cutting deck (LH shown) 2. Deck mount (LH shown) 3. Cap screw 4. Lock nut 5. Clevis pin 6. Hair pin 7. Spacer 8. Rod end 9. Jam nut 10. Cap screw (4 per arm) 11. Straight bushing 12. Spring shaft 13. Flat washer 14. Compres...

Page 306 - Idler Assembly

Groundsmaster 4000--D/4010--D Cutting Decks Page 8 -- 10 Idler Assembly FRONT RIGHT 6 7 8 9 10 11 12 15 16 13 14 17 18 19 1 2 4 3 5 20 23 21 24 22 1. Cutting deck (front shown) 2. Flange nut 3. Flange nut 4. Adjusting screw 5. Idler pulley 6. Driven spindle (double pulley shown) 7. Flat washer 8. Lo...

Page 307 - Be careful when removing idler spring. The; Be careful when installing the idler spring. The

Groundsmaster 4000--D/4010--D Cutting Decks Page 8 -- 11 Removal (Fig. 9) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove deck covers from top of cutting deck. CAUTION Be careful when removing idler spring. ...

Page 308 - Blade Spindles

Groundsmaster 4000--D/4010--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 11 FRONT RIGHT 1 2 3 4 5 6 4 4 5 5 6 6 6 6 6

Page 310 - Blade Spindle Service

Groundsmaster 4000--D/4010--D Cutting Decks Page 8 -- 14 Blade Spindle Service 1. Lock nut 2. Hardened washer 3. Driven pulley (single shown) 4. Spindle shaft 5. Drive pulley 6. Hydraulic motor mount 7. O--ring 8. Oil seal 9. Bearing cup and cone 10. Spacer set 11. Spindle housing 12. Grease fitting...

Page 312 - Castor Forks and Wheels; Disassemble castor wheel as needed using Figure

Groundsmaster 4000--D/4010--D Cutting Decks Page 8 -- 16 Castor Forks and Wheels 1. Castor arm (front deck) 2. Cap screw (5 used) 3. Castor fork 4. Cap screw 5. Lock nut 6. Castor spacer 7. Thrust washer 8. Flange nut (5 used) 9. Grease fitting 10. Flange bushing 11. Retaining ring 12. Cap washer 13...

Page 313 - Chapter 9; Operator Cab; Operator

Groundsmaster 4010--D Operator Cab Page 9 -- 1 Chapter 9 Operator Cab Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Components and Schematic 2 . . . . . . . . . Air Conditioning Sys...

Page 316 - Air Conditioning Compressor

Groundsmaster 4010--D Operator Cab Page 9 -- 4 Air Conditioning Compressor Figure 1 FRONT RIGHT 1. Cap screw (3 used) 2. Lock washer (8 used) 3. Pulley 4. V--belt 5. Lower radiator hose 6. Hose clamp (2 used) 7. Lower radiator hose 8. Cap screw (3 used) 9. Alternator plate 10. Carriage screw 11. Fla...

Page 318 - Roof Assembly; Figure 3

Groundsmaster 4010--D Operator Cab Page 9 -- 6 Roof Assembly 1. Roof 2. Screw (2 used) 3. Flat washer (6 used) 4. Bushing (10 used) 5. Rear fastener (2 used) 6. Rear spacer (2 used) 7. Panel nut 8. Roof mount 9. Flange nut (2 used) 10. Flange nut (4 used) 11. Headliner 12. Front spacer (2 used) 13. ...

Page 320 - Air Conditioning Condenser Assembly; The air conditioning system is under high pres-

Groundsmaster 4010--D Operator Cab Page 9 -- 8 Air Conditioning Condenser Assembly 1. Condenser cover 2. Lock nut (4 used) 3. Condenser fan 4. Condenser coil assembly 5. Carriage screw (2 used) 6. Flat washer (8 used) 7. Roof 8. Bushing (4 used) 9. Mounting strap 10. Button head screw (4 used) Figur...

Page 322 - Heater/Evaporator Assembly

Groundsmaster 4010--D Operator Cab Page 9 -- 10 Heater/Evaporator Assembly 1. Heater/evaporator assembly 2. Top cover 3. Flange head screw (2 used) 4. Drier--receiver mount 5. Bottom cover 6. Hose clamp (2 used) 7. Speed nut (8 used) 8. Panel nut (4 used) 9. Drier--receiver assembly 10. Screw (8 use...

Page 325 - Foldout Drawings

Groundsmaster 4000--D/4010--D Foldout Drawings Page 10 -- 1 Chapter 10 Foldout Drawings Table of Contents HYDRAULIC SCHEMATIC 3 . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SCHEMATICS Sheet 1 of 3 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sheet 2 of 3 5 . . . . . . . ...

Page 328 - Electrical Schematic

Page 10 -- 4 Electrical Schematic Groundsmaster 4000--D/4010--D All relays and solenoids are shown as de-- energized.All ground wires are black. Sheet 1 of 3 WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER WILL BE IDENTIFIED. NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON THREE (3) SHEETS....

Page 331 - FLASHER

Page 10 -- 7 Electrical Schematic Groundsmaster 4010--D All relays and solenoids are shown as de-- energized.All ground wires are black. Operator Cab 1 2 BK 1F 1 R R R PK VIO 4 3 L H Y OR VIO VIO W/BK OR BU GN BK OR/BK 05-- B 05-- A BK/W BU W R/W VIO W/BK GN P05-- G BK/W OR/BK PWR GND P11-- 4 P11-- ...

Page 333 - Platform Wire Harness Drawing

Page 10 -- 9 Groundsmaster 4000--D/4010--D Platform Wire Harness Drawing NOTE CLOCK POSITION NOTE CLOCK POSITION (NOT USED) (OPTIONAL KIT) (OPTIONAL KIT) (OPTIONAL KIT) (OPTIONAL KIT) A/C CLUTCH & WS WASHER PUMP TO REAR HARNESS TO REAR HARNESS TO REAR HARNESS TO REAR HARNESS TEC-- 5001COMM PORT

Page 334 - Platform Wire Harness Diagram

Page 10 -- 10 Groundsmaster 4000--D/4010--D Platform Wire Harness Diagram Sheet 1 of 2 VI O LET BLACK GRA Y BL ACK BL ACK VI O LET VIOLET BL ACK BLACK WHITE/YELLOW GRAY RED/WHITE BLACK/WHITE 641 171 272 BLACK 168 RED/WHITE BLACK/WHITE BLACK BLACK BLACK 246 636 BLACK BLACK RED/GREEN VIOLET 635 BLACK/...

Page 336 - Rear Wire Harness Drawing

Page 10 -- 12 Groundsmaster 4000--D/4010--D Rear Wire Harness Drawing FUSEBLOCKS MAXI FUSES TO PLATFORM HARNESS TO PLATFORM HARNESS TO PLATFORM HARNESS TO PLATFORM HARNESS

Page 337 - Rear Wire Harness Diagram

Page 10 -- 13 Groundsmaster 4000--D/4010--D Rear Wire Harness Diagram WH ITE BLACK PI N K RED BLACK BLACK RED BROWN/BLACK GRAY/BLACK PINK/BLACK WHITE/ORANGE WHITE/BLACK TAN/BLACK BLUE WHITE YELLOW PINK VIOLET BLACK RE D RE D RE D PI N K GRAY/BLACK BROWN/BLACK RED/GREEN PINK WHITE/YELLOW BROWN RED/BL...

Page 338 - Cab Wire Harness Drawing

Page 10 -- 14 Groundsmaster 4010--D Cab Wire Harness Drawing FUSEBLOCKS TO CAB HARNESS INTERCONNECT

Page 339 - Cab Wire Harness Diagram

Page 10 -- 15 Groundsmaster 4010--D Cab Wire Harness Diagram VI O LET GRAY ORANGE RE D WH IT E/ BL AC K BL U E WHITE/BLACK RED/WHITE RED RED RE D RED BLACK BLACK BLACK BLACK BL AC K BL AC K BL AC K BL AC K BLACK OR A N GE VIOLET VIOLET ORANGE GRAY BLUE VIOLET BROWN VIOLET BLACK RED BLACK BLACK WHITE...

Page 340 - Cab Interconnect Wire Harness

Page 10 -- 16 Groundsmaster 4010--D Cab Interconnect Wire Harness BLACK BLUE WHITE RE D BL AC K