Toro 30410 - Manual

Groundsmaster 4000−D Page 1 − 2 Safety General Safety Instructions The GROUNDSMASTER 4000-D was tested and certi-fied by TORO for compliance with the B71.4-1999 speci-fications of the American National Standards Institute.Although hazard control and accident prevention par-tially are dependent upon ...

Groundsmaster 4000−D Page 1 − 3 Safety Maintenance and Service 1. Before servicing or making adjustments, lowerdecks, stop engine, set parking brake, and remove keyfrom the switch. 2. Make sure machine is in safe operating condition bykeeping all nuts, bolts and screws tight. 3. Never store the mach...

Groundsmaster 4000−D Page 1 − 4 Safety Jacking Instructions CAUTION When changing attachments, tires, or perform-ing other service, use correct blocks, hoists,and jacks. Make sure machine is parked on asolid level surface such as a concrete floor.Prior to raising machine, remove any attach-ments tha...

Groundsmaster 4000−D Page 1 − 5 Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 4000−D. If any decal becomes illegible ordamaged, install a new decal. Part numbers are listed in your Parts Catalog. Safety

Rev. E Groundsmaster 4000−D Page 2 − 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS 1 . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS...

0.09375 Rev. E Groundsmaster 4000−D Page 2 − 2 Product Records and Maintenance Equivalents and Conversions

Groundsmaster 4000−D Page 2 − 3 Product Records and Maintenance Torque Specifications Recommended fastener torque values are listed in thefollowing tables. For critical applications, as determinedby Toro, either the recommended torque or a torque thatis unique to the application is clearly identifie...

Groundsmaster 4000−D Page 2 − 4 Product Records and Maintenance Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) SAE ...

Groundsmaster 4000−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 UNC 35 + 10 ft−lb ...

Groundsmaster 4000−D Page 3 − 1 Kubota Diesel Engine (Rev. B) Chapter 3 Kubota Diesel Engine Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Stopping the Engine 2 . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS 3 . . . . . . . . . . . . . . . . . . ...

Groundsmaster 4000−D Page 3 − 2 Kubota Diesel Engine (Rev. B) General Information This Chapter gives information about specifications andrepair of the diesel engine used in the Groundsmaster4000−D. General maintenance procedures are described in yourOperator’s Manual. Information on engine troublesh...

Groundsmaster 4000−D Page 3 − 3 Kubota Diesel Engine (Rev. B) Specifications Item Description Make / Designation Kubota, 4−Cycle, 4 Cylinder, Water Cooled, Turbocharged, Diesel Engine Horse Power 58 HP (43.3 kW) @ 2600 RPM Bore mm (in.) 83.0 (3.27) Stroke mm (in.) 92.4 (3.64) Total Displacement cc (...

Groundsmaster 4000−D Page 3 − 4 Kubota Diesel Engine (Rev. B) Adjustments Run Solenoid 1. When ignition switch is in the RUN position, the runsolenoid should energize and position the fuel stop leverto within 1/16” (1.6 mm) of stop on the injection pump. 2. If adjustment is needed, loosen lock nut a...

Groundsmaster 4000−D Page 3 − 6 Kubota Diesel Engine (Rev. B) Service and Repairs Air Filter System Figure 3 1. Air cleaner hose2. Hose clamp 3. Air cleaner assembly4. Indicator 5. Air cleaner strap6. Lock nut 7. Hose clamp 8. Air cleaner hose 9. Hose clamp 10. Cap screw11. Flat washer 8 1 3 4 5 6 9...

Groundsmaster 4000−D Page 3 − 7 Kubota Diesel Engine (Rev. B) Removal 1. Remove air cleaner components as needed usingFigure 3 as a guide. Installation IMPORTANT: Any leaks in the air filter system willcause serious engine damage. Make sure daily thatall air cleaner components are in good conditiona...

Groundsmaster 4000−D Page 3 − 8 Kubota Diesel Engine (Rev. B) Exhaust System Figure 5 1. Muffler2. Muffler bracket 3. Exhaust pipe 4. Flange head screw5. Exhaust gasket 6. Lock nut 7. Cap screw 8. Flat washer 9. Spacer10. Rubber hanger 11. Flange nut12. Flange head screw13. Engine mount14. Muffler c...

Rev. F Groundsmaster 4000--D Page 3 -- 9 Kubota Diesel Engine (Rev. B) Removal 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 units, stop engine...

Groundsmaster 4000−D Page 3 − 10 Kubota Diesel Engine (Rev. B) Fuel System Figure 7 1. Fuel tank 2. Fuel tank bracket3. Air breather 4. Female hose barb5. Tank support assembly6. Fuel hose 7. Locking flange nut8. Cap screw 9. Flat washer 10. Cap screw11. Carriage screw12. Washer13. Battery strap14. ...

Rev. E Groundsmaster 4000−D Page 3 − 11 Kubota Diesel Engine (Rev. B) DANGER Because diesel fuel is highly flammable, use cau-tion when storing or handling it. Do not smokewhile filling the fuel tank. Do not fill fuel tankwhile engine is running, hot, or when machine isin an enclosed area. Always fi...

Groundsmaster 4000−D Page 3 − 12 Kubota Diesel Engine (Rev. B) Radiator Figure 8 1. Radiator cap 2. Foam strip 3. Foam strip 4. Lower radiator hose5. Upper radiator hose6. Hose clamp 7. Radiator shroud 8. Lock nut 9. Radiator10. Hose clamp11. Reservoir hose12. Flange head screw13. Grommet14. Flange ...

Groundsmaster 4000−D Page 3 − 13 Kubota Diesel Engine (Rev. B) Removal 1. Park machine on a level surface, lower cutting units,stop engine, engage parking brake, and remove keyfrom the ignition switch. 2. Open engine hood on the machine. CAUTION Do not open radiator cap or drain coolant if theradiat...

Groundsmaster 4000−D Page 3 − 14 Kubota Diesel Engine (Rev. B) Engine Figure 9 1. Engine2. Engine mount bracket (RH shown)3. Lock washer 4. Cap screw 5. Barb fitting 6. Hose clamp 7. Hose8. Fuel line 9. Fuel filter 10. Fuel line11. Coolant drain hose12. Hose clamp13. Cap screw14. Barb fitting (femal...

Groundsmaster 4000−D Page 3 − 15 Kubota Diesel Engine (Rev. B) Engine Removal 1. Park machine on a level surface, lower cutting units,stop engine, engage parking brake, and remove keyfrom the ignition switch. 2. Remove battery cover and strap. Disconnect nega-tive battery cable first and then positi...

Groundsmaster 4000−D Page 3 − 16 Kubota Diesel Engine (Rev. B) 8. Disconnect fuel line from injection pump (Fig. 11). 9. Disconnect throttle cable from the speed control le-ver by removing the washer and lock nut. Loosen jamnut and take cable from mounting bracket (Fig. 11). 10. Remove coolant reser...

Groundsmaster 4000−D Page 3 − 17 Kubota Diesel Engine (Rev. B) Coupling Disassembly 1. Remove adapter plate, spring coupling, and cou-pling spacer from engine using Figure 9 as a guide. Coupling Assembly 1. Position coupling spacer to engine and align mount-ing holes. Use two shoulder bolts and lock...

Groundsmaster 4000−D Page 3 − 18 Kubota Diesel Engine (Rev. B) following electrical components: A. The temperature sender and alternator (Fig 10). B. The engine run solenoid and fuel pump (Fig. 12). C. The high temperature shutdown switch and glowplug (Fig. 13). D. Battery, frame, and wire harness g...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 1 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Hydraulic Hoses 3 . . . . . . . . . . . . . . . . . . . ...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 3 General Information 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 o...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 5 Towing Traction Unit IMPORTANT: If towing limits are exceeded, severe damage to the piston pump may occur. If it becomes necessary to tow (or push) the machine, tow (or push) in a forward direction only and at a speed below 3 mph . The pist...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 6 Hydraulic Schematics Hydraulic Schematic Groundsmaster 4000 --D T P1 G P2 1.50 BO RE 4.00 ST RO KE .750 RO D CHG M1 T R ANSPO R T CYLINDER G G G G G G G G GA GE CYL PD2 CV PR CHG 8 3 5B 7 2 5A SV PD1 RV 5 CD CD RV 14 G P M 14 G P M 2.50 BO ...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 8 Hydraulic Flow Diagrams Traction C ircuit (Forward/Mow Shown) W ork in g P res su re Low Pressure (Charge) Return or Suction Fl ow Groundsmaster 4000 --D T P1 G P2 1.50 BO RE 4.00 ST RO KE .750 RO D CHG M1 T R ANSPO R T CYLINDER G G G G G G...

Rev. E Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 9 Traction Circuit The traction circuit piston pump is a variable displace- ment pump that is directly coupled to the engine fly- wheel. Pushing the top of the traction pedal engages a hydraulic servo valve which controls the variable ...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 11 Lower Cutting Unit A three section gear pump is coupled to the piston (trac- tion) pump. The gear pump section farthest from the pis- ton pump supplies hydraulic flow to both the lift/lower control valve and the steering control valve. Hyd...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 13 Raise Cutting Unit A three section gear pump is coupled to the piston (trac- tion) pump. The gear pump section farthest from the pis- ton pump supplies hydraulic flow to the lift/lower control valve and the steering control valve. Hydrauli...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 15 Mow Hydraulic flow for the mow circuit is supplied by two sec- tions of the gear pump. The gear pump section closest to the piston (traction) pump supplies hydraulic flow to the side cutting units, while the next gear pump section supplies...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 17 Steering Circuit A three section gear pump is coupled to the piston (trac- tion) pump. The gear pump section farthest from the pis- ton pump supplies hydraulic flow to the steering control valve and the lift/lower control valve. Pump hydra...

Rev. E Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 18 Special Tools Order these tools from your Toro Distributor. Hydraulic Pressure Test Kit -- TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 20 Troubleshooting The charts that follow contain information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the Testing section of this Chapter for precau- tions and specific test ...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 25 Procedure for Traction Circuit Charge Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level sur...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 29 Procedure for Cutting Deck Circuit Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surfac...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 30 TEST NO. 4: Cutting Deck Gear Pump Flow (Front Deck Shown) (Using Tester with Pressure Gauges and Flow Meter) Working PressureLow PressureReturn or Suction Flow T P1 P2 G G G CD 1.2 1.17 40 PSI 1.2 RH DECK MO TO R LH DECK MO TO R 1.17 MP P...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 34 TEST NO. 6: Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauges and Flow Meter) Working PressureLow PressureReturn or Suction Flow T P1 P2 G G G CD 1.2 1.17 40 PSI 1.2 RH DECK MO TO R LH DECK MO TO R 1.17 MP P1 PSI R1B...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 48 Adjustments Adjust Front Cutting Unit Lift Flow Control The front cutting unit lift circuit is equipped with an ad- justable flow control valve used to adjust the rate at which the front deck lowers. Adjust flow control valve as follows: 1...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 49 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, engage pa...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 50 Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky, black, or contains metal particles). IMPORTANT: Flush hydraulic system when chang- ...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 51 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 ...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 52 Gear Pump 1. 90 o hydraulic fitting 2. O--ring 3. O--ring 4. 90 o hydraulic fitting 5. O--ring 6. O--ring 7. Hydraulic fitting 8. O--ring 9. Hydraulic fitting 10. O--ring 11. Clamp 12. Hydraulic T fitting 13. O--ring 14. Hydraulic fitting ...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 54 Gear Pump Service 1. Shaft seal 2. Washer 3. Cap screw 4. O--ring 5. Washer 6. Proportional valve 7. Plug 8. Plug 9. O--ring 10. Front body 11. Drive gear assembly 12. Wear plate 13. Pressure seal 14. Backup gasket 15. Front plate assembly...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 56 Reassembly It is important that the relationship of the backplate, adapter plates, bodies, wear plates and front plate is correct. The two half moon cavities in the bodies must face away from the front plate or adapter plate. The smaller h...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 64 Piston Pump Control Assembly 1. Plug 2. O--ring 3. Retaining ring 4. Spring retainer 5. Spring 6. Spool valve 7. Control housing 8. Input shaft 9. O--ring 10. Wiper seal 11. O--ring 12. Adaptor 13. Ball 14. Pin 15. Neutral switch 16. O--ri...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 66 Hydraulic Control Manifold: 4 Wheel Drive 1. Frame assembly 2. Manifold 3. 90 o hydraulic fitting 4. O--ring 5. O--ring 6. Quick fitting 7. O--ring 8. Fitting cap 9. Hydraulic fitting 10. O--ring 11. O--ring 12. 90 o hydraulic fitting 13. ...

Rev. E Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 68 Hydraulic Control Manifold Service: 4 Wheel Drive 1. Manifold body 2. Solenoid valve (port 2) 3. Seal kit 4. Check valve (port 3) 5. Seal kit 6. Control valve (ports 5A & 5B) 7. Seal kit 8. Relief valve (port 7) 9. Seal kit 10. ...

Rev. E Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 69 5. Visually inspect cartridge valve for damaged sealing surfaces and contamination. A. Contamination may cause valves to stick or hang up. Contamination can become lodged in small valve orifices or seal areas causing malfunction. B....

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 70 Hydraulic Control Manifold: Deck Drive 1. Hydraulic manifold (front deck) 2. Quick fitting 3. Flange nut 4. O--ring 5. Hydraulic fitting 6. O--ring 7. O--ring 8. 45 o hydraulic fitting 9. Adapter 10. O--ring 11. Cap screw 12. Fitting cap 1...

Rev. F Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 71 Hydraulic Control Manifold Service: Deck Drive 1. Manifold body 2. Spool logic cartridge (port BY1) 3. Seal kit 4. Spool logic cartridge (port BR1) 5. Seal kit 6. Relief valve (port R1BY) 7. Seal kit 8. Solenoid valve (port SV1) 9. ...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 72 Hydraulic Control Manifold: Cutting Deck Lift/Lower 1. Lift/lower hydraulic manifold 2. Valve plate 3. Flat washer 4. Cap screw 5. Grommet 6. Flat washer 7. Lock nut 8. Hydraulic fitting 9. O--ring 10. O--ring 11. 90 o hydraulic fitting 12...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 73 Hydraulic Control Manifold Service: Cutting Deck Lift/Lower 1. Manifold body 2. Pilot valve 3. Seal kit 4. Relief valve (Counterbalance) 5. Seal kit 6. Plug (SAE #2) 7. O--ring Figure 55 2 6 7 1 2 3 5 4 3 35 to 40 ft--lb (47 to 54 N--m) 35...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 74 Hydraulic Manifold: Filter Manifold 1. Filter manifold 2. 45 o hydraulic elbow 3. Test nipple 4. Fitting cap 5. O--ring 6. O--ring 7. O--ring 8. Cap screw 9. Flat washer 10. Hydraulic fitting 11. O--ring 12. O--ring 13. Hydraulic fitting 1...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 75 Hydraulic Manifold Service: Filter Manifold 1. Filter manifold assembly 2. Check valve (Reservoir return) 3. Seal kit 4. Check valve (Filter bypass) 5. Seal kit 6. Check valve (Charge pressure) 7. Seal kit 8. Plug (SAE #4) 9. O--ring 10. P...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 76 Hydraulic Manifold: Flow Divider 1. Hydraulic manifold 2. O--ring 3. Hydraulic fitting 4. Bracket 5. Flange nut 6. Cap screw (2 used) 7. Hydraulic hose 8. O--ring 9. 90 o hydraulic elbow 10. O--ring 11. Hydraulic hose 12. Hydraulic fitting...

Rev. E Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 77 Hydraulic Manifold Service: Flow Divider 1. Flow divider valve 2. Piloted directional valve 3. Seal kit 4. Hydraulic manifold 5. O--ring 6. Plug (SAE #8) 7. Plug (not serviced) 8. Seal kit 9. Solenoid cartridge valve 10. Solenoid co...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 78 Rear Axle Motor 1. Wheel motor 2. 90 o hydraulic fitting 3. Hydraulic fitting 4. Cap screw 5. Flat washer 6. O--ring 7. External snap ring 8. Pinion gear 9. External snap ring 10. Gear 11. Needle bearing 12. O--ring 13. O--ring 14. O--ring...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 80 Front Wheel Motors 1. Front wheel motor 2. Internal retaining ring 3. Splined brake shaft 4. RH brake assembly 5. Planetary assembly 6. Cap screw 7. Flat washer 8. O--ring 9. Flange head screw 10. 90 o hydraulic fitting 11. 90 o hydraulic ...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 82 Rear Axle/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 8. Shaft seal 9. Retaining ring 10. Thrust race 11. O--ring 12....

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 85 Cutting Deck Motor Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Co...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 86 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 14. Front flange 15. Dowel pin 16. Snap r...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 90 Lift/Lower Control Valve 1. Control valve assembly 2. Valve bracket 3. Grommet 4. Cap screw 5. Lock nut 6. Pivot bracket 7. LH lever assembly 8. Lever link 9. Center lever assembly 10. Cotter pin 11. RH lever assembly 12. Spacer 13. Cap sc...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 92 Lift/Lower Control Valve Service 1. Poppet 2. Spacer 3. Wiper 4. Seat 5. O--ring 6. Plug 7. Ring 8. Bushing 9. Cap 10. Relief valve poppet 11. O--ring 12. Retaining ring 13. Washer 14. Washer 15. Washer 16. Washer 17. Plug 18. O--ring 19. ...

Rev. E Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 94 Steering Valve 1. Hex nut 2. Flat washer 3. Steering wheel 4. Foam collar 5. Steering seal 6. External snap ring 7. Steering shaft assembly 8. Steering tower cover 9. O--ring 10. 90 o hydraulic fitting 11. O--ring 12. Flange head sc...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 96 Steering Valve Service 1. Steering 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 10. End cap 11. O--ring 12. Seal ring 13. O--ring 14. Geroter 15. O--ring...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 98 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 7. O--ring 8. O--ring 9. Cylinder pin 10. Spring pin 11. Lock nut 12. Flat washer Fi...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 100 Front Deck Lift 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. 90 o hydraulic fit...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 102 Lift Cylinder Service 1. Barrel with clevis 2. Collar 3. Shaft with clevis 4. Dust seal 5. Rod seal 6. O--ring 7. Back--up ring 8. Head 9. O--ring 10. Uni--ring 11. Piston 12. Lock nut 13. Grease fitting 14. Bushing Figure 78 2 1 3 4 5 6 ...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 104 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. Ball joint spacer 11. Ball joint spacer 12. Axle washer 13. Hex s...

Rev. E Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 106 Steering Cylinder Service 1. Butt and tube assembly 2. Shaft 3. Piston rod assembly 4. Gland (head) 5. Lock nut 6. O--ring 7. PTFE seal 8. O--ring 9. O--ring 10. U--cup 11. Wiper Figure 82 1 6 7 3 9 10 4 11 2 8 5

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 108 Hydraulic Reservoir 1. Hydraulic reservoir 2. Petcock 3. O--ring 4. Strap 5. Felt strap 6. Bushing 7. Bushing 8. Hydraulic fitting 9. Stand pipe 10. Hose clamp 11. Screen filter 12. Dipstick 13. O--ring 14. Reservoir cap 15. Suction hose ...

Groundsmaster 4000--D Hydraulic System (Rev. B) Page 4 -- 110 Hydraulic Oil Cooler Removal CAUTION The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool before working on the oil cooler. 1. Park machine on a level surface, lower cutting units, ...

Groundsmaster 4000−D Page 5 − 1 Electrical System Chapter 5 Electrical System Table of Contents ELECTRICAL SCHEMATIC, CIRCUIT DIAGRAMS, AND WIRE HARNESS DRAWINGS 2 . . . . . . . . . . . . SPECIAL TOOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 4 . . . . . . . . . . ...

Rev. E Groundsmaster 4000−D Page 5 − 3 Electrical System Special Tools Order special tools from your Toro Distributor. Sometools may also be available from a local supplier. Multimeter The meter can test electrical components and circuitsfor current, resistance, or voltage. NOTE: Toro recommends the...

Groundsmaster 4000−D Page 5 − 4 Electrical System Troubleshooting CAUTION Remove all jewelry, especially rings andwatches, before doing any electrical trouble-shooting or testing. Disconnect the batterycables unless the test requires battery voltage. For effective troubleshooting and repairs, you mu...

Groundsmaster 4000−D Page 5 − 5 Electrical System Problem Possible Causes Engine cranks, but does not start. Engine is not cranking fast enough. Engine fuel stop solenoid, circuit wiring, or fuel pump isfaulty. The problem is not electrical (see Chapter 3 − KubotaEngine). Starter cranks, but should ...

Groundsmaster 4000−D Page 5 − 6 Electrical System Cutting Unit Operating Problems The cutting units remain engaged, but should not, withno operator in the seat. The seat switch or circuit wiring is faulty. Cutting units run, but should not, when raised. Unitsshut off with PTO switch. The deck positi...

Rev. E Groundsmaster 4000−D Page 5 − 7 Electrical System Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between thebattery terminals. Set multimeter to the DC volts setting. The batteryshould be at a temperature of 60 to 100 o F (16 to 38 o C)...

Groundsmaster 4000−D Page 5 − 8 Electrical System Component Testing For accurate resistance and/or continuity checks, elec-trically disconnect the component being tested from thecircuit (e.g. unplug the ignition switch connector beforedoing a continuity check). NOTE: For engine component testing inf...

Groundsmaster 4000−D Page 5 − 9 Electrical System Fuses The fuse blocks are located under the operator’s controlpanel. Identification, Function, and Wiring The fuses are held in two fuse blocks. Use Figure 7 toidentify each individual fuse and its correct amperage.Each fuse holder has the following ...

Groundsmaster 4000−D Page 5 − 10 Electrical System Warning Lights Testing Warning Lights 1. Apply 12 VDC to terminals 1A and 2A. 2. Ground terminals 1B and 2B. 3. Both indicator lights should light. Engine Oil Pressure Light The oil pressure light should come on when the ignitionswitch is in the ON ...

Groundsmaster 4000−D Page 5 − 11 Electrical System PTO Switch The PTO switch is attached to the control console nextto the operator seat (Fig. 11). The switch terminals are marked as shown in Figure 12.The circuitry of the PTO switch is shown in the chart be-low. With the use of a multimeter (ohms s...

Groundsmaster 4000−D Page 5 − 12 Electrical System Transport, Alarm Silence, and Temperature Override Switches The transport, alarm silence, and temperature overriderocker switches are located on the control console (Fig.13). These switches have common switching logic. The switch terminals are marke...

Groundsmaster 4000−D Page 5 − 13 Electrical System Seat Switch The seat switch is normally open and closes when theoperator is on the seat. If the traction system or PTOswitch is engaged when the operator raises out of theseat, the engine will stop. The seat switch and its electri-cal connector are ...

Groundsmaster 4000−D Page 5 − 14 Electrical System Hour Meter The hour meter is located on the control console next tothe operator seat. 1. Connect the positive (+) terminal of a 12 VDC sourceto the positive (+) terminal of the hour meter. 2. Connect the negative (−) terminal of the voltagesource to...

Groundsmaster 4000−D Page 5 − 16 Electrical System Hydraulic Valve Solenoids There are four hydraulic valve solenoids on the Ground-smaster 4000−D (Fig. 23). Testing of these solenoidscan be done with the solenoid on the hydraulic valve. NOTE: Prior to taking small resistance readings with adigital ...

Groundsmaster 4000−D Page 5 − 17 Electrical System Engine Run Solenoid The engine run solenoid must be energized for the en-gine to run. It is mounted on the engine block near theinjection pump. In Place Testing NOTE: Prior to taking small resistance readings with adigital multimeter, short the mete...

Groundsmaster 4000−D Page 5 − 18 Electrical System Fuel Sender The fuel sender is located on top of the fuel tank. 1. Remove white wire and black ground wire from thesender. 2. Remove screws and lock washers that secure thesender to the fuel tank. 3. Remove sender and gasket from the fuel tank. Clea...

Groundsmaster 4000−D Page 5 − 19 Electrical System Fuel Gauge The fuel gauge can be tested using a new gauge as asubstitute or with the use of a DC voltage source and avariable resistance box. CAUTION Make sure the voltage source is turned OFF be-fore connecting it to the electrical circuit to avoid...

Rev. E Groundsmaster 4000−D Page 5 − 20 Electrical System Fuel Pump The fuel pump is attached to the frame above the fuelwater separator. Operational Test 1. Park machine on a level surface, lower cutting units,stop engine, and engage parking brake. 2. Disconnect electrical connector from the fuel s...

Groundsmaster 4000−D Page 5 − 21 Electrical System Glow Controller The glow controller is located under the console cover. NOTE: Refer to Chapter 9 − Electrical Schematics andDiagrams when troubleshooting the controller. Controller Operation 1. When the ignition switch is placed in the ON position,t...

Rev. E Groundsmaster 4000−D Page 5 − 22 Electrical System Temperature Sender The temperature sender is located near the alternatoron the water flange attached to the engine cylinder head(Fig. 31). There is a gray wire attached to the terminalof the switch. 1. Lower coolant level in the engine and re...

Groundsmaster 4000−D Page 5 − 23 Electrical System High Temperature Shutdown Switch The high temperature shutdown switch is located nearthe glow plug connection on the engine cylinder head(Fig. 33). There is a blue wire attached to the switch. CAUTION Make sure engine is cool before removing thetemp...

Groundsmaster 4000−D Page 5 − 24 Electrical System Temperature Gauge The temperature gauge can be tested using a newgauge as a substitute or by the use of a DC voltagesource and a variable resistance box. CAUTION Make sure the voltage source is turned OFF be-fore connecting variable resistance to th...

Groundsmaster 4000−D Page 5 − 25 Electrical System Traction Neutral Switch The traction neutral switch is closed when the tractionpedal is in the neutral position and opens when the pedalis depressed in either direction. The switch is located onthe right side of the piston (traction) pump. Test the ...

Groundsmaster 4000−D Page 5 − 26 Electrical System Diode Circuit Board The circuit board contains four diodes (Fig. 39) and is lo-cated under the console housing. The diodes are usedfor circuit protection from inductive voltage spikes thatoccur when a hydraulic valve solenoid is de−energized.Diode D...

Rev. E Groundsmaster 4000−D Page 5 − 27 Electrical System Cutting Deck Position Switch The cutting deck position switches on the Groundsmas-ter 4000−D are located on the traction unit frame (Fig.40 and 41) and are normally open. The position switchis a powered proximity switch that incorporates an i...

Rev. E Groundsmaster 4000−D Page 5 − 28 Electrical System Service and Repairs NOTE: For more component repair information, seethe Kubota Workshop Manual, Diesel Engine, V2003−TSeries at the end of Chapter 3 − Kubota Diesel Engine. Battery Storage If the machine will be stored for more than 30 days: ...

Groundsmaster 4000−D Page 5 − 29 Electrical System Battery Service The battery is the heart of the electrical system. Withregular and proper service, battery life can be extended.Additionally, battery and electrical component failurecan be prevented. CAUTION When working with batteries, use extreme ...

Groundsmaster 4000−D Page 5 − 30 Electrical System C. If the difference between the highest and lowestcell specific gravity is 0.050 or greater or the lowestcell specific gravity is less than 1.225, charge the bat-tery. Charge at the recommended rate and time giv-en in Charging or until all cells sp...

Groundsmaster 4000−D Page 5 − 31 Electrical System Charging To minimize possible damage to the battery and allowthe battery to be fully charged, the slow charging meth-od is presented here. This charging method can be ac-complished with a constant current battery chargerwhich is available in most sh...

Groundsmaster 4000−D Page 6 − 4 Axles, Planetaries, and Brakes (Rev. B) Service and Repairs Brake Assembly 1. Planetary assembly 2. Retaining ring 3. Splined brake shaft4. Brake assembly (RH)5. O−ring6. Hydraulic wheel motor 7. Flat washer 8. Cap screw 9. Flange head screw10. Brake assembly (LH)11. ...

Groundsmaster 4000−D Page 6 − 5 Axles, Planetaries, and Brakes (Rev. B) CAUTION When changing attachments, tires, or perform-ing other service, use correct blocks, hoists,and jacks. Make sure machine is parked on asolid, level surface such as a concrete floor.Prior to raising machine, remove any att...

Groundsmaster 4000−D Page 6 − 6 Axles, Planetaries, and Brakes (Rev. B) Brake Inspection and Repair 1. Brake housing (LH shown)2. Seal3. Pull rod 4. Clevis pin 5. Link 6. Hitch pin 7. Stationary disc 8. Rotating disc 9. Retaining ring 10. Gasket 11. Rotating actuator12. Extension spring13. Ball14. P...

Groundsmaster 4000−D Page 6 − 8 Axles, Planetaries, and Brakes (Rev. B) Planetary Wheel Drive Assembly 1. Planetary assembly 2. Retaining ring 3. Splined brake shaft4. Brake assembly (RH)5. O−ring 6. Hydraulic wheel motor7. Flat washer 8. Cap screw 9. Flange head screw10. Brake assembly (LH) 11. Gas...

Groundsmaster 4000−D Page 6 − 9 Axles, Planetaries, and Brakes (Rev. B) Planetary Wheel Drive Removal 1. Park machine on a level surface, lower cutting units,stop engine, engage parking brake, and remove keyfrom the ignition switch. 2. Drain oil from planetary wheel drive/brake assembly(see Operator...

Groundsmaster 4000−D Page 6 − 10 Axles, Planetaries, and Brakes (Rev. B) Planetary Wheel Drive Service 1. Spindle2. Seal3. Bearing cone 4. Bearing cup 5. Wheel stud 6. Housing7. Bearing cup 8. Bearing cone 9. Thrust washer 10. Retaining ring (external)11. Ring gear12. Retaining ring (internal)13. Pl...

Groundsmaster 4000−D Page 6 − 12 Axles, Planetaries, and Brakes (Rev. B) Rear Axle Assembly 1. Frame assembly 2. Cap screw 3. Lock washer 4. Flat washer 5. Support frame 6. Thrust washer (thick)7. Grease fitting 8. Rear axle assembly9. Thrust washer (thin)10. Washer head screw11. Pivot pin12. Rear f...

Groundsmaster 4000−D Page 6 − 13 Axles, Planetaries, and Brakes (Rev. B) 8. Remove cap screw and flange nut that secures frontcorner of 4WD hydraulic manifold to rear frame mount. 9. If required, remove tie rod ends from steering armson rear axle (Fig. 10). Remove the cotter pins and castlenuts from...

Groundsmaster 4000−D Page 6 − 15 Axles, Planetaries, and Brakes (Rev. B) 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 assem...

Groundsmaster 4000−D Page 6 − 16 Axles, Planetaries, and Brakes (Rev. B) 5. Remove the knuckle pin mounting screws and theknuckle pin. Remove the gasket and any remaining gas-ket material from either mating surface (Fig. 16). 6. While holding the bevel gear case, tap the upper endof the bevel gear s...

Groundsmaster 4000−D Page 6 − 18 Axles, Planetaries, and Brakes (Rev. B) 5. Determine necessary quantity of support shims. A. Lubricate the axle case support bushing with athin coat of grease and slide axle case support ontoknuckle pin. B. Position support shims that were removed duringdisassembly b...

Groundsmaster 4000−D Page 6 − 19 Axles, Planetaries, and Brakes (Rev. B) 9. Remove the bevel gear case/axle case assemblyfrom the axle support. Coat a new O-ring with greaseand temporarily install the axle cover assembly. Positiona dial indicator at the tooths center. Prevent the axlefrom turning an...

Groundsmaster 4000−D Page 6 − 20 Axles, Planetaries, and Brakes (Rev. B) Differential Shafts The following procedures assume the rear axle assem-bly has been removed from the machine. Removal IMPORTANT: Do not interchange right and left dif- ferential shaft assemblies. 1. Remove the mounting screws,...

Groundsmaster 4000−D Page 6 − 21 Axles, Planetaries, and Brakes (Rev. B) 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. Removethe axle cover from the axle case as an assembly(Fig. 25). 2. Use a ...

Groundsmaster 4000−D Page 6 − 22 Axles, Planetaries, and Brakes (Rev. B) Input Shaft/Pinion Gear Figure 28 1 1. Nut2. Lockwasher3. Stud4. Locknut5. Stake washer 6. Oil seal 7. O-ring8. Seal collar 9. Bearing10. O-ring11. Input shaft/Pinion gear12. Bearing case 13. Shim14. Screw15. Gear case16. Gaske...

Groundsmaster 4000−D Page 6 − 24 Axles, Planetaries, and Brakes (Rev. B) 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 (seeBevel Gear Case/Axle Case Assembly in this section ofthis m...

Groundsmaster 4000−D Page 6 − 25 Axles, Planetaries, and Brakes (Rev. B) Inspection 1. Measure the differential side gear O.D. and the dif-ferential case I.D. to determine the side gear to caseclearance (Fig. 35). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 in. (0.05...

Rev. E Groundsmaster 4000−D Page 6 − 26 Axles, Planetaries, and Brakes (Rev. B) Installation 1. If the ring gear was removed from the differentialcase, use medium strength Loctite thread locker andtighten the mounting screws from 22 to 25 ft-lb (30 to34 N−m). 2. Apply molybdenum disulfide lubricant ...

Rev. E Groundsmaster 4000−D Page 6 − 27 Axles, Planetaries, and Brakes (Rev. B) Pinion Gear to Ring Gear Engagement (4 Wheel Drive Axle) The final position of the pinion gear is verified by usingthe gear contact pattern method as described in the fol-lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 39...

Rev. E Groundsmaster 4000−D Page 6 − 28 Axles, Planetaries, and Brakes (Rev. B) Gear Pattern Movement Summary Every gear has a characteristic pattern. The illustrationsshow typical patterns only and explain how patterns shiftas gear location is changed. 1. If contact is toward the heel or base of th...

Groundsmaster 4000−D Page 7 − 1 Chassis Chapter 7 Chassis Table of Contents SERVICE AND REPAIRS 2 . . . . . . . . . . . . . . . . . . . . . . Steering Tower 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Deck Lift Arm 4 . . . . . . . . . . . . . . . . . . . . . . . . . . Side Deck...

Rev. E Groundsmaster 4000−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. Knob8. Steering tower cover9. Steering shaft 10. Compression spring11. Cap12. Rod assembly13. Extension sprin...

Groundsmaster 4000−D Page 7 − 4 Chassis Front Deck Lift Arm 1. Flange bushing 2. Ball joint 3. Lock nut 4. Clevis pin 5. Height−of−cut chain 6. U−bolt7. Hex nut 8. Flat washer 9. Lock nut 10. Lock nut11. Grease fitting (45 o ) 12. Grease fitting13. Slotted roll pin 14. Lift arm pin15. Cotter pin16. ...

Groundsmaster 4000−D Page 7 − 6 Chassis Side Deck Lift Arm 1. Lift arm (LH shown)2. Shoulder screw 3. Lift cylinder pin4. Lift cylinder 5. Thrust washer 6. Flange nut 7. Pivot hub 8. Lift arm pivot shaft9. Thrust washer 10. Cap screw11. Spring pin12. Cylinder pin13. Rivet 14. Rubber bumper15. Slotte...

Groundsmaster 4000−D Page 7 − 7 Chassis Removal 1. Park machine on a level surface, lower cutting units,stop engine, engage parking brake, and remove keyfrom the ignition switch. 2. Remove side deck from lift arm (see Side CuttingUnit in Chapter 8 − Cutting Units). 3. Remove side deck rear arm assem...

Groundsmaster 4000−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. Spacer8. Rod end 9. Jam nut 10. Cap screw11. Straight bushing12. Spring shaft13. Flat washer14. Compression spring15. Plastic be...

Groundsmaster 4000−D Page 7 − 9 Chassis Disassembly 1. Disassemble rear arm assembly using Figure 7 as aguide. Note: early models use rear arm components asshown in Figure 9. On these models, roll pin removal willallow coupler to be separated from spring shaft. Assembly (Figure 7) 1. Slide large fla...

Groundsmaster 4000−D Page 7 − 10 Chassis Installation 1. Position rear arm assembly to cutting deck andframe. 2. Slide pivot shaft through rear arm clevis and hub. Se-cure pivot shaft with lock washer and locknut. 3. Connect damper link to cutting deck with clevis pinand hair pin (Fig. 8). 4. Positi...

Groundsmaster 4000−D Page 7 − 12 Chassis Lift Arm Yoke Joint 1. Side cutting deck (LH shown)2. Deck mount (LH shown)3. Shim4. Base mount 5. Plate6. Rubber pad 7. Cap screw 8. Flat washer 9. Yoke joint 10. Spacer11. Thrust washer12. Hardened washer 13. Cotter pin14. Slotted hex nut15. Flange head scr...

Groundsmaster 4000−D Page 7 − 13 Chassis Yoke Joint Assembly 1. Apply a coating of grease to bearing bores of yoke. 2. Press one bearing partially into yoke. 3. Insert cross into yoke and bearing. 4. Hold cross in alignment and press bearing in until ithits the yoke. 5. Install snap ring to secure i...

Groundsmaster 4000−D Page 7 − 14 Chassis Hood 1. Hood2. Latch bracket (RH)3. Screen assembly 4. Bulb seal 5. Bulb seal 6. Screen seal corner7. Hair pin 8. Flange head screw9. Screen pivot 10. Hood pivot 11. Clevis pin12. Hood rod13. Hair pin14. Door handle15. Flange head screw16. Oil filter deflecto...

Groundsmaster 4000−D Page 7 − 15 Chassis Removal 1. Park machine on a level surface, lower cutting units,stop engine, engage parking brake, and remove keyfrom the ignition switch. 2. Remove hood using Figure 13 as a guide. Installation 1. Install hood using Figure 13 as a guide. 2. Align hood to mac...

Groundsmaster 4000−D Cutting Units Page 8 − 1 Chapter 8 Cutting Units Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 3 . . . . . . . . . . . . . . . . . . . . . . . . . Factors That Can Affect Quality of Cut 3 . . . . . . . . . ADJUSTMENTS ...

Groundsmaster 4000−D Cutting Units Page 8 − 3 Troubleshooting There are a number of factors that can contribute to un-satisfactory quality of cut, some of which may be turfconditions. Turf conditions such as excessive thatch,uneven ground conditions, “sponginess” or attemptingto cut off too much gra...

Groundsmaster 4000−D Cutting Units Page 8 − 4 Adjustments CAUTION Never install or work on the cutting units or liftarms with the engine running. Always stop en-gine and remove key first. See Operator’s Manual for adjustment procedures forthe cutting units on the Groundsmaster 4000−D. Castor Wheel T...

Groundsmaster 4000−D Cutting Units Page 8 − 6 Service and Repairs CAUTION Never install or work on the cutting units or liftarms with the engine running. Always stop en-gine and remove key first. Front Cutting Unit 1. Spider2. Mounting shim (if required)3. Hydraulic deck motor4. Cap screw 5. Washer6...

Groundsmaster 4000−D Cutting Units Page 8 − 7 Removal 1. Position machine on a clean, level surface. Lowercutting units, stop engine, engage parking brake, andremove key from the ignition switch. NOTE: Removal of clevis pin from deck and height−of−cut chain is easier if deck is lifted slightly. 2. R...

Groundsmaster 4000−D Cutting Units Page 8 − 8 Side Cutting Unit 1. Side cutting deck (LH shown)2. Deck mount (LH shown)3. Flange head screw4. Flat washer 5. Lock nut 6. Clevis pin 7. Hair pin 8. Jam nut 9. Rod end 10. Damper link tube Figure 5 6 8 FRONT RIGHT 10 9 7 1 8 9 2 3 4 5

Groundsmaster 4000−D Cutting Units Page 8 − 9 Removal 1. Position machine on a clean, level surface. Lowercutting units, stop engine, engage parking brake, andremove key from the ignition switch. 2. Remove hydraulic motor from cutting deck (see Cut-ting Deck Motor Removal in the Service and RepairsS...

Rev. E Groundsmaster 4000−D Cutting Units Page 8 − 10 Blade Spindle Service Disassembly 1. Park machine on a level surface, lower cutting units,stop engine, engage parking brake, and remove keyfrom the ignition switch. 2. Remove belt covers from top of cutting deck. Loosenidler pulley to release bel...

Rev. E Groundsmaster 4000−D Cutting Units Page 8 − 11 Assembly IMPORTANT: If new bearings are installed into aused spindle housing, it may not be necessary to re-place the original large snap ring. If the originalsnap ring is in good condition with no evidence ofdamage (e.g. spun bearing), leave the...

Groundsmaster 4000−D Cutting Units Page 8 − 12 Castor Forks and Wheels 1. Castor arm (front deck)2. Flange head screw3. Castor fork 4. Cap screw 5. Lock nut 6. Castor spacer 7. Thrust washer 8. Flange lock nut9. Grease fitting 10. Flange bushing 11. Retaining ring12. Cap washer13. Compression spring...

Groundsmaster 4000−D Electrical Diagrams (Rev. B) Page 9 - 1 Chapter 9 Electrical Diagrams Table of Contents ELECTRICAL SCHEMATICS 3 . . . . . . . . . . . . . . . . . . . Electrical Schematic (S/N below 220999999) 3 . . . Electrical Schematic (S/N above 230000001) 4 . . . CIRCUIT DIAGRAMS 5 . . . . ...

Page 9 - 3 Electrical Schematic Groundsmaster 4000−D All relays and solenoids are shown as de−energized. F 8 W POWER POINT R R OPTIONAL FUSEBLOCK F 6 F 7 R R VIO PK F 1 F 3 SEAT SWITCH F 2 Y 10 A 10 A 5 A Y GN NEUTRAL SWITCH(IN NEUTRAL) F 5 6500 MFD (−) (+) S B A Y X I IGNITION SWITCH PTO SHUTDOWN D...

Page 9 - 5 F 8 W POWER POINT R R OPTIONAL FUSEBLOCK F 6 F 7 R R VIO PK F 1 F 3 SEAT SWITCH F 2 Y 10 A 10 A 5 A Y GN NEUTRAL SWITCH(IN NEUTRAL) F 5 6500 MFD (−) (+) S B A Y X I IGNITION SWITCH PTO SHUTDOWN DELAY PK GN W OR BK R VIO START 4 5 6 1 2 3 KUBOTA GLOW PLUG CONTROLLER LAMP + 12V GND GLOW THE...

Page 9 - 6 F 8 W POWER POINT R R OPTIONAL FUSEBLOCK F 6 F 7 R R VIO PK F 1 F 3 SEAT SWITCH F 2 Y 10 A 10 A 5 A Y GN NEUTRAL SWITCH (IN NEUTRAL) F 5 6500 MFD (−) (+) S B A Y X I IGNITION SWITCH PTO SHUTDOWN DELAY PK GN W OR BK R VIO START 4 5 6 1 2 3 KUBOTA GLOW PLUG CONTROLLER LAMP + 12V GND GLOW TH...

Page 9 - 15 Groundsmaster 4000−D PINK BLACK FRONT PTO CONNECTOR WHITE GREEN GRAY BLUE GREEN/BLACK ORANGE FRONT DECK POSITION SWITCH INTERCONNECT INTERCONNECT P2 P1 LEFT SIDE SERVICE BRAKE P4 B A GRAY BROWN SP1 GRA Y ground ign. A TEMP GAUGE LIGHT B A TEMP GAUGE 2 G 1 I S 3 P3 J1 D C B A nc no + gnd ...