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Page 3 - Table Of Contents; Chapter 2 -- Product Records and Maintenance
Groundsmaster 4000--D Table Of Contents Chapter 1 -- Safety General Safety Instructions 1 -- 2 . . . . . . . . . . . . . . . . . . Jacking Instructions 1 -- 4 . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals 1 -- 5 . . . . . . . . . . . . . . . . Chapter 2 -- Product R...
Page 5 - Chapter 1; Safety; Table of Contents; Safety
Groundsmaster 4000--D Page 1 -- 1 Safety Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS 2 . . . . . . . . . . . . Before Operating 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Ser...
Page 6 - General Safety Instructions; To reduce the potential for injury or death,; Before Operating
Groundsmaster 4000--D Page 1 -- 2 Safety General Safety Instructions The GROUNDSMASTER 4000-D is tested and certified by Toro for compliance with existing safety standards and specifications. Although hazard control and acci- dent prevention partially are dependent upon the design and configuration ...
Page 7 - Maintenance and Service
Groundsmaster 4000--D Page 1 -- 3 Safety Maintenance and Service 1. Before servicing or making adjustments, lower decks, stop engine, apply parking brake and remove key from the switch. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 3. Never store th...
Page 9 - Safety and Instruction Decals; Numerous safety and instruction decals are affixed to
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 illeg- ible or damaged, install a new decal. Decal part num- bers are listed in your Parts Catalog. Safety
Page 11 - Chapter 2; Product Records and Maintenance
Rev. A 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 CONVERSIO...
Page 12 - Equivalents and Conversions
0.09375 Groundsmaster 4000--D Page 2 -- 2 Product Records and Maintenance Equivalents and Conversions
Page 13 - Torque Specifications; reduced by 25% for lubricated fasteners; Fastener Identification
Rev. A Groundsmaster 4000--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 clear...
Page 16 - Other Torque Specifications; Grade 5; Conversion Factors
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 + ...
Page 17 - Chapter 3; Kubota Diesel Engine; Kubota
Groundsmaster 4000--D Page 3 -- 1 Kubota Diesel Engine Chapter 3 Kubota Diesel Engine Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping the Engine 2 . . . . . . . . . . . . . . . . . . . ...
Page 18 - General Information; Operator’s Manual; IMPORTANT: Before stopping the engine after
Groundsmaster 4000--D Page 3 -- 2 Kubota Diesel Engine General Information This Chapter gives information about specifications and repair of the diesel engine used in the Groundsmaster 4000--D. General maintenance procedures are described in your Operator’s Manual. Information on engine troubleshoot...
Page 19 - Specifications
Groundsmaster 4000--D Page 3 -- 3 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” (87.0 mm) Stroke 4.031” (102.4 mm) Total Displacement 148.5 in 3 (2434 cc) Firing Order ...
Page 20 - Service and Repairs; Air Filter System; Figure 1; VACUATOR; FRONT
Groundsmaster 4000--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. Flat washe...
Page 22 - Exhaust System; Figure 5
Groundsmaster 4000--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 (4 used)...
Page 23 - CAUTION
Rev. A Groundsmaster 4000--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, stop engine...
Page 24 - Fuel System; Figure 7
Groundsmaster 4000--D Page 3 -- 8 Kubota Diesel Engine Fuel System Figure 7 1. Fuel tank 2. Fuel tank bracket 3. Air breather 4. Female hose barb 5. Tank support assembly 6. Fuel hose 7. Flange nut (6 used) 8. Cap screw (4 used) 9. Flat washer (4 used) 10. Cap screw (4 used) 11. Carriage screw (2 us...
Page 26 - Radiator; Figure 8
Groundsmaster 4000--D Page 3 -- 10 Kubota Diesel Engine Radiator Figure 8 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 (2 used)...
Page 27 - Do not open radiator cap or drain coolant if the
Groundsmaster 4000--D Page 3 -- 11 Kubota Diesel Engine Removal (Fig. 8) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Open and support hood. CAUTION Do not open radiator cap or drain coolant if the radiator or e...
Page 28 - Engine
Groundsmaster 4000--D Page 3 -- 12 Kubota Diesel Engine Engine Figure 9 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 (8 used) 1...
Page 32 - Spring Coupler
Groundsmaster 4000--D Page 3 -- 16 Kubota Diesel Engine Spring Coupler Figure 16 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 shim 10. Transport cylinder 11. Lock nu...
Page 35 - Chapter 4; Hydraulic System; Hydraulic System
Groundsmaster 4000--D Hydraulic System Page 4 -- 1 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 3 . . . . . . . . . . . . . . . . . . . . . . ....
Page 38 - Hydraulic Hoses; WARNING
Groundsmaster 4000--D Hydraulic System Page 4 -- 4 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 conditio...
Page 42 - Hydraulic Schematic
Groundsmaster 4000--D Hydraulic System Page 4 -- 8 Hydraulic Schematic FA N DRIVE MANIF O LD RH PT O MANIF O LD 4WD MANIF O LD LH PT O MANIF O LD FRONT P TO MANIF O LD TRA C TION MANIF O LD COUNTE R BALANCE MANIF O LD FIL T E R MANIF O LD M1 M2 ST L P1 P2 T RV 1 RV 2 LC2 LC1 S P1 P2 M1 M2 RV 1 RV 2 ...
Page 44 - Hydraulic Flow Diagrams; Traction; Groundsmaster
Groundsmaster 4000--D Hydraulic System Page 4 -- 10 Hydraulic Flow Diagrams Traction C ircuit (4WD Forward Shown) W ork in g P res su re Low Pressure (Charge) Return or Suction Fl ow Groundsmaster 4000 --D FA N DRIVE MA N IFOLD RH PT O MA N IFOLD 4W D MA N IFOLD LH P TO MA N IFOLD FR O N T P TO MA N...
Page 49 - Lower Cutting Deck
Groundsmaster 4000--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 lift/lower control valve and the steering control valve. Hydraulic flow from this pump section...
Page 51 - Raise Cutting Deck
Groundsmaster 4000--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 the lift/lower control valve and the steering control valve. Hydraulic flow from this pump section is d...
Page 53 - Mow
Groundsmaster 4000--D Hydraulic System Page 4 -- 19 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 decks, while the next gear pump section supplies the fron...
Page 54 - PTO Mow Circuit Cutting Deck Blade Braking
Groundsmaster 4000--D Hydraulic System Page 4 -- 20 PTO Mow Circuit Cutting Deck Blade Braking When the operator turns the PTO switch OFF or if a deck is raised with the PTO switch ON, PTO control manifold solenoid valve (S) is de--energized causing logic car- tridge (LC1) to shift (refer to informa...
Page 57 - Steering Circuit; Left Turn
Groundsmaster 4000--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 the steering control valve and the lift/lower control valve. Pump hydraulic flow is delivered to the two ...
Page 59 - Engine Cooling Fan Circuit; Forward Direction Fan Operation; REVERSE DIRECTION SHOWN
Groundsmaster 4000--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 fan drive manifold and hydraulic engine cooling fan motor (Fig. 14...
Page 60 - Special Tools; Hydraulic Pressure Test Kit
Rev. A Groundsmaster 4000--D Hydraulic System Page 4 -- 26 Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test...
Page 61 - Hydraulic Test Fitting Kit
Groundsmaster 4000--D Hydraulic System Page 4 -- 27 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: TOR4079 Figu...
Page 62 - Troubleshooting; Problem
Groundsmaster 4000--D Hydraulic System Page 4 -- 28 Troubleshooting The charts that follow contain suggestions to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the Testing section of this Chapter for precau- tions and specific test procedure...
Page 66 - Traction Circuit Charge Pressure (Using Pressure Gauge)
Groundsmaster 4000--D Hydraulic System Page 4 -- 32 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 COUNTERBALANCE MANIFOLD FRO M PT O M ...
Page 67 - Prevent personal injury and/or damage to equip-
Groundsmaster 4000--D Hydraulic System Page 4 -- 33 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 surface with...
Page 68 - Traction Circuit Relief Pressure (Using Pressure Gauge); FORWARD TRACTION CIRCUIT RELIEF PRESSURE TEST SHOWN
Groundsmaster 4000--D Hydraulic System Page 4 -- 34 Traction Circuit Relief 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 COUNTERBALANCE MANIFOLD FRO M PT O M ...
Page 70 - Counterbalance Pressure (Using Pressure Gauge)
Groundsmaster 4000--D Hydraulic System Page 4 -- 36 Counterbalance Pressure (Using Pressure Gauge) FA N DRIVE MANIF O LD 4WD MANIF O LD TRA C TION MANIF O LD FIL T E R MANIF O LD TO P TO (MOW) CIRCUIT FROM PT O M ANIFOLDS TO P TO (MOW) CIRCUIT FROM FRONT PTO MANIFOLD FROM DECK MOTORS FROM RH PT O MA...
Page 76 - Cutting Deck Circuit Pressure (Using Pressure Gauge); FRONT DECK CIRCUIT PRESSURE TEST SHOWN
Groundsmaster 4000--D Hydraulic System Page 4 -- 42 Cutting Deck Circuit Pressure (Using Pressure Gauge) RH PT O MANIF O LD LH PT O MANIF O LD FRONT P TO MANIF O LD FIL T E R MANIF O LD TO COOLING FAN CIRCUIT FROM RE AR AX LE MOT O R TO S TE E R ING & LIFT CIRCUITS TRACTION CIRCUIT FLOW CHARGE C...
Page 78 - FRONT PTO RELIEF PRESSURE TEST SHOWN
Groundsmaster 4000--D Hydraulic System Page 4 -- 44 PTO Relief Pressure (Using Tester with Pressure Gauges and Flow Meter) RH PT O MANIF O LD LH PT O MANIF O LD FRONT P TO MANIF O LD FIL T E R MANIF O LD TO COOLING FAN CIRCUIT FROM RE AR AX LE MOT O R TO S TE E R ING & LIFT CIRCUITS TRACTION CIR...
Page 80 - FRONT CUTTING DECK MOTOR
Groundsmaster 4000--D Hydraulic System Page 4 -- 46 Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauges and Flow Meter) RH PT O MANIF O LD LH PT O MANIF O LD FRONT P TO MANIF O LD FIL T E R MANIF O LD TO COOLING FAN CIRCUIT FROM RE AR AX LE MOT O R TO S TE E R ING & LIFT CIR...
Page 81 - Hydrauli
Rev. A Groundsmaster 4000--D Hydraulic System Page 4 -- 47 Procedure for Cutting Deck Motor Case Drain Leakage Test NOTE: Over a period of time, a deck motor can wear in- ternally. A worn motor may by--pass oil to its case drain causing the motor to be less efficient. Eventually, enough oil loss wil...
Page 82 - FRONT DECK GEAR PUMP FLOW TEST SHOWN
Groundsmaster 4000--D Hydraulic System Page 4 -- 48 Cutting Deck Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter) RH PT O MANIF O LD LH PT O MANIF O LD FRONT P TO MANIF O LD FIL T E R MANIF O LD TO COOLING FAN CIRCUIT FROM RE AR AX LE MOT O R TO S TE E R ING & LIFT CIRCUITS TRAC...
Page 84 - Steering Circuit Relief Pressure (Using Pressure Gauge)
Groundsmaster 4000--D Hydraulic System Page 4 -- 50 Steering Circuit Relief Pressure (Using Pressure Gauge) FA N DRIVE MANIF O LD 4WD MANIF O LD TRA C TION MANIF O LD FIL T E R MANIF O LD TO P TO (MOW) CIRCUIT FROM PT O M ANIFOLDS TO P TO (MOW) CIRCUIT FROM FRONT PTO MANIFOLD TO LIFT/LOWER CONTROL V...
Page 90 - Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac)
Groundsmaster 4000--D Hydraulic System Page 4 -- 56 Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac) FA N DRIVE MANIF O LD 4WD MANIF O LD TRA C TION MANIF O LD FIL T E R MANIF O LD TO P TO (MOW) CIRCUIT FROM PT O M ANIFOLDS TO P TO (MOW) CIRCUIT FROM FRONT PTO MANIFOLD FROM DECK MOTORS...
Page 94 - Adjustments; Adjust Front Cutting Deck Lift Flow Control
Groundsmaster 4000--D Hydraulic System Page 4 -- 60 Adjustments Adjust Front Cutting Deck Lift Flow Control The front cutting deck lift circuit is equipped with an ad- justable flow control valve used to adjust the rate at which the front cutting deck lowers. Adjust flow control valve as follows: 1....
Page 95 - Check Hydraulic Lines and Hoses
Groundsmaster 4000--D Hydraulic System Page 4 -- 61 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 parking brak...
Page 96 - Flush Hydraulic System
Groundsmaster 4000--D Hydraulic System Page 4 -- 62 Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky, black or contains metal particles). 1. Park machine on a level surface. Lower cutting decks ...
Page 97 - Charge Hydraulic System
Groundsmaster 4000--D Hydraulic System Page 4 -- 63 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 system to ...
Page 98 - Hydraulic Reservoir
Groundsmaster 4000--D Hydraulic System Page 4 -- 64 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 cap 15....
Page 100 - Hydraulic Oil Cooler
Groundsmaster 4000--D Hydraulic System Page 4 -- 66 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 screw (2 ...
Page 102 - Gear Pump
Groundsmaster 4000--D Hydraulic System Page 4 -- 68 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 12. Pump...
Page 104 - Gear Pump Service; thrust plates for each pump section together do not
Groundsmaster 4000--D Hydraulic System Page 4 -- 70 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 gasket ...
Page 106 - Traction Circuit
Groundsmaster 4000--D Hydraulic System Page 4 -- 72 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 Figure 52 FRONT RIGHT 2 1 5 4 3 ...
Page 110 - 2400 Servo Controlled Piston Pump Repair Informa-
Groundsmaster 4000--D Hydraulic System Page 4 -- 76 Piston (Traction) Pump Service 1. Jam nut 2. Retaining ring 3. Retaining ring 4. Seal washer 5. Socket head screw 6. Rotating kit assembly 7. Servo piston assembly 8. Piston follower 9. Cover plate 10. Cover plate 11. Camplate assembly 12. Thrust r...
Page 112 - Rear Axle Motor
Groundsmaster 4000--D Hydraulic System Page 4 -- 78 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. Pinion gear 9. External snap ring (2 used) 10. Gear 11. Needle bearing ...
Page 114 - Front Wheel Motor
Groundsmaster 4000--D Hydraulic System Page 4 -- 80 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 side) 10...
Page 116 - Rear Axle and Front Wheel Motor Service; The front wheel motors are identical. The rear
Groundsmaster 4000--D Hydraulic System Page 4 -- 82 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. O--ring...
Page 118 - WD Manifold
Groundsmaster 4000--D Hydraulic System Page 4 -- 84 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. Fitting cap 9. Hydraulic fitting 10. O--ring 11. O--ring 12. 90 o hydraulic fitting 13. O--ring 14. Hydraulic fitting 15. ...
Page 120 - WD Manifold Service
Groundsmaster 4000--D Hydraulic System Page 4 -- 86 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 (0.030) (por...
Page 125 - For cartridge valve service procedures, see 4WD Man-
Groundsmaster 4000--D Hydraulic System Page 4 -- 91 Traction Manifold Service (Fig. 62) For cartridge valve service procedures, see 4WD Man- ifold Service in this section. Refer to Figure 62 for trac- tion (flow divider) manifold cartridge valve and plug installation torque. Hydraulic System
Page 126 - Filter Manifold
Groundsmaster 4000--D Hydraulic System Page 4 -- 92 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 14. Hydr...
Page 128 - Filter Manifold Service
Groundsmaster 4000--D Hydraulic System Page 4 -- 94 Filter Manifold Service 1. Filter manifold 2. Check valve (reservoir return) 3. Oil filter element 4. Check valve (filter bypass) 5. Plug (Zero Leak #6) 6. Charge relief valve 7. Plug (Zero Leak #8) Figure 64 FRONT UP 6 7 1 5 5 4 2 FRONT UP 3 3 25 ...
Page 130 - Steering and Cooling Fan Circuits
Groundsmaster 4000--D Hydraulic System Page 4 -- 96 Steering and Cooling Fan Circuits 1. Gear pump 2. Steering control valve 3. Fan drive manifold 4. Fan motor 5. Steering cylinder Figure 65 FRONT RIGHT 2 1 5 4 3 Figure 65 illustrates the components that are used in the Groundsmaster 4000--D steerin...
Page 132 - Steering Valve
Groundsmaster 4000--D Hydraulic System Page 4 -- 98 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 screw 13. Hydrauli...
Page 134 - Steering Valve Service
Groundsmaster 4000--D Hydraulic System Page 4 -- 100 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 (7 used) 10. End cap 11. O--ring 12. Seal ring 13. O--ring 14. Geroter 15. O--rin...
Page 136 - Steering Cylinder
Groundsmaster 4000--D Hydraulic System Page 4 -- 102 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. Slotted hex ...
Page 138 - Steering Cylinder Service
Groundsmaster 4000--D Hydraulic System Page 4 -- 104 Steering Cylinder Service 1. Tube assembly 2. Rod 3. Piston assembly 4. Head 5. Retaining ring 6. Backup ring 7. O--ring 8. Cap seal 9. Rod seal 10. O--ring 11. O--ring 12. Wiper Figure 70 45 to 55 ft--lb (62 to 74 N--m) 1 6 7 3 9 10 4 11 2 8 5 12
Page 140 - Engine Cooling Fan Motor
Groundsmaster 4000--D Hydraulic System Page 4 -- 106 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) 15. Hy...
Page 142 - Engine Cooling Fan Motor Service
Groundsmaster 4000--D Hydraulic System Page 4 -- 108 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 used) 14. ...
Page 143 - Use eye protection such as goggles when using
Groundsmaster 4000--D Hydraulic System Page 4 -- 109 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.Carefully ...
Page 146 - Fan Drive Manifold
Groundsmaster 4000--D Hydraulic System Page 4 -- 112 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 hose 13. 9...
Page 148 - Fan Drive Manifold Service
Groundsmaster 4000--D Hydraulic System Page 4 -- 114 Fan Drive Manifold Service 1. Fan drive manifold 2. #4 zero leak plug (3 used) 3. Check valve 4. #6 zero leak plug (2 used) 5. Flow divider valve 6. Nut 7. Solenoid coil (2 used) 8. Proportional relief valve 9. Solenoid valve 10. Nut Figure 78 FRO...
Page 150 - PTO Circuit
Groundsmaster 4000--D Hydraulic System Page 4 -- 116 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 79 FRONT RIGHT 2 1 5 4 3 7 6 8 9 Figure 79 i...
Page 151 - Cutting Deck Motor; Removal
Groundsmaster 4000--D Hydraulic System Page 4 -- 117 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 Components a...
Page 152 - Cutting Deck Motor Service; diagonal
Groundsmaster 4000--D Hydraulic System Page 4 -- 118 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 Figure 82...
Page 156 - PTO Manifold
Groundsmaster 4000--D Hydraulic System Page 4 -- 122 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 manifold)...
Page 158 - PTO Manifold Service; DO NOT
Groundsmaster 4000--D Hydraulic System Page 4 -- 124 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 RV1) 10. S...
Page 159 - For solenoid and control valve service procedures, see
Groundsmaster 4000--D Hydraulic System Page 4 -- 125 PTO Manifold Service (Fig. 88) For solenoid and control valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 88 for PTO manifold cartridge valve and plug installation torque. Hydraulic System
Page 162 - Lift/Lower Control Valve
Groundsmaster 4000--D Hydraulic System Page 4 -- 128 Lift/Lower Control Valve 1. Control valve assembly 2. Valve bracket 3. Isolator (6 used) 4. Cap screw 5. Lock nut (2 used) 6. Pivot bracket 7. LH lever assembly 8. Lever link (3 used) 9. Center lever assembly 10. Cotter pin (6 used) 11. RH lever a...
Page 164 - Lift/Lower Control Valve Service
Groundsmaster 4000--D Hydraulic System Page 4 -- 130 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. Spring 2...
Page 166 - Side Deck Lift Cylinder
Groundsmaster 4000--D Hydraulic System Page 4 -- 132 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 washer F...
Page 168 - Front Deck Lift Cylinder
Groundsmaster 4000--D Hydraulic System Page 4 -- 134 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 fitting Figu...
Page 170 - Lift Cylinder Service; SIDE DECK LIFT CYLINDER; FRONT DECK LIFT CYLINDER
Groundsmaster 4000--D Hydraulic System Page 4 -- 136 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. Seal Fi...
Page 172 - Counterbalance Manifold
Groundsmaster 4000--D Hydraulic System Page 4 -- 138 Counterbalance Manifold 1. Counterbalance manifold 2. Valve plate 3. Flat washer (2 used) 4. Cap screw (2 used) 5. Isolator (4 used) 6. Flat washer (2 used) 7. Lock nut (2 used) 8. Hydraulic fitting (2 used) 9. O--ring 10. O--ring 11. 90 o hydraul...
Page 174 - Counterbalance Manifold Service
Groundsmaster 4000--D Hydraulic System Page 4 -- 140 Counterbalance Manifold Service 1. Manifold body 2. Pilot valve 3. Seal kit 4. Relief valve (counterbalance) 5. Seal kit Figure 97 2 1 2 3 5 4 3 35 to 40 ft--lb (47 to 54 N--m) 35 to 40 ft--lb (47 to 54 N--m) 35 to 40 ft--lb (47 to 54 N--m) FRONT ...
Page 175 - Chapter 5; Electrical System; Electrical System
Groundsmaster 4000--D Page 5 -- 1 Electrical System Chapter 5 Electrical System Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Drawings 2 . . . . . . . . . . . . . . . . . . . . . . ...
Page 176 - The Operator’s Manual provides information regarding; Electrical Drawings; The electrical schematic, circuit diagrams and wire har-
Groundsmaster 4000--D Page 5 -- 2 Electrical System 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 servic...
Page 177 - Multimeter
Groundsmaster 4000--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 meter can test electrical components and circuits for current, resistance or voltage. NOTE: Toro recommends the use...
Page 178 - Battery Terminal Protector
Groundsmaster 4000--D Page 5 -- 4 Electrical System Battery Terminal Protector Aerosol spray that should be used on battery terminals to reduce corrosion problems. Apply terminal protector after the battery cable has been secured to the battery terminal. Toro Part Number: 107--0392 Figure 4 Battery ...
Page 179 - Starting Problems
Groundsmaster 4000--D Page 5 -- 5 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 and repa...
Page 180 - General Run and Transport Problems
Groundsmaster 4000--D Page 5 -- 6 Electrical System Problem Possible Causes Engine cranks, but does not start. Engine is not cranking fast enough. The engine fuel run solenoid or circuit wiring is faulty. The fuel pump or circuit wiring is faulty. An engine problem exists (see Chapter 3 -- Kubota En...
Page 181 - Cutting Deck Operating Problems
Groundsmaster 4000--D Page 5 -- 7 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. Cutting decks run, but should not, when raised. Decks shut off with PTO switch. The deck po...
Page 182 - Electrical System Quick Checks; Charging System Test
Groundsmaster 4000--D Page 5 -- 8 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 to 38 o C...
Page 183 - Component Testing; When testing electrical components for continu-; Ignition Switch
Groundsmaster 4000--D Page 5 -- 9 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 engine compone...
Page 184 - Fuses; Identification, Function and Wiring
Groundsmaster 4000--D Page 5 -- 10 Electrical System Fuses The fuse blocks are located under the operator control panel. Identification, Function and Wiring The fuses are held in three (3) fuse blocks. Use Figures 9 and 10 to identify each individual fuse and its correct amperage. Each fuse has the ...
Page 185 - Warning Lights; Engine Oil Pressure Light
Groundsmaster 4000--D Page 5 -- 11 Electrical System Warning Lights Engine Oil Pressure Light The oil pressure light should illuminate when the ignition switch is in the ON position with the engine not running. Also, it should light with the engine running if the oil pres- sure drops below 7 PSI (0....
Page 187 - Transport / 4WD Switch; Flow Divider Switch; Testing; BACK OF FLOW DIVIDER SWITCH
Groundsmaster 4000--D Page 5 -- 13 Electrical System Transport / 4WD Switch The transport/4WD switch is used to set the machine traction speed for transport or mow. The transport/4WD rocker switch is located on the control console next to the operator seat (Fig. 17). Testing The switch terminals are...
Page 188 - Cooling Fan Switch; BACK OF COOLING FAN SWITCH
Groundsmaster 4000--D Page 5 -- 14 Electrical System Cooling Fan Switch The cooling fan switch is used to control the operation of the hydraulic cooling fan and is located on the control console (Fig. 21). This switch has three (3) positions: Reverse, Auto and Forward. When the cooling fan switch is...
Page 189 - Seat Switch
Groundsmaster 4000--D Page 5 -- 15 Electrical System Seat Switch The seat switch is normally open and closes when the operator is on the seat. The seat switch and its electrical connector are located in the seat assembly. If the trac- tion system or PTO switch is engaged when the operator raises out...
Page 190 - Parking Brake Switch
Groundsmaster 4000--D Page 5 -- 16 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. 24). When the parking brake is not applied, the parking brake pawl depresses the switch plunger to close the ...
Page 192 - Glow and Power Relays
Groundsmaster 4000--D Page 5 -- 18 Electrical System Glow and Power Relays The Groundsmaster 4000--D uses two (2) identical re- lays to control electrical power circuits. The glow relay is attached to the the right side of the fuel tank support under the hood. The power relay is attached to the con-...
Page 194 - Hydraulic Valve Solenoids
Groundsmaster 4000--D Page 5 -- 20 Electrical System Hydraulic Valve Solenoids Figure 30 1. 4WD manifold 2. LH PTO manifold 3. Traction manifold 4. Front PTO manifold 5. Fan drive manifold 6. RH PTO manifold FRONT RIGHT 1 2 3 4 5 6 There are several hydraulic valve solenoids on the Groundsmaster 400...
Page 196 - Fuel Sender; Make sure sending unit is completely dry (no fuel
Groundsmaster 4000--D Page 5 -- 22 Electrical System Fuel Sender The fuel sender is located on top of the fuel tank. Testing 1. Remove white wire and black ground wire from the sender. 2. Remove screws and lock washers that secure the sender to the fuel tank. 3. Remove sender and gasket from the fue...
Page 197 - Fuel Gauge
Groundsmaster 4000--D Page 5 -- 23 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. CAUTION Make sure the voltage source is turned OFF be- fore connecting it to the electrical circuit to ...
Page 198 - Fuel Pump; Operational Test; Fuel Pump Specifications
Groundsmaster 4000--D Page 5 -- 24 Electrical System Fuel Pump The fuel pump is attached to the frame above the fuel water separator (Fig. 36). Operational Test 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake. 2. Disconnect wire harness electrical connect...
Page 199 - Glow Controller; Glow Controller Operation
Groundsmaster 4000--D Page 5 -- 25 Electrical System Glow Controller The glow controller is located under the console cover (Fig. 37). NOTE: Refer to electrical schematic and circuit draw- ings in Chapter 9 -- Foldout Drawings when trouble- shooting the glow controller. Glow Controller Operation 1. ...
Page 200 - Temperature Sender; Handle the hot oil with extreme care to prevent
Groundsmaster 4000--D Page 5 -- 26 Electrical System Temperature Sender The temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 39). The resistance of the temperature sender re- duces as the engine coolant temperature increases. There is a...
Page 201 - Dual Temperature Switch; Make sure engine is cool before removing the; Elec
Rev. A Groundsmaster 4000--D Page 5 -- 27 Electrical System Dual Temperature Switch The dual temperature switch is attached to the engine near the alternator on the water flange attached to the engine cylinder head (Fig. 41). Two (2) electrical har- ness wires (a blue wire and a yellow wire) are att...
Page 202 - Temperature Gauge
Groundsmaster 4000--D Page 5 -- 28 Electrical System Temperature Gauge The temperature gauge can be tested using a new gauge as a substitute or by the use of a DC voltage source and a variable resistance box. CAUTION Make sure the voltage source is turned OFF be- fore connecting variable resistance ...
Page 204 - Diode Circuit Board
Groundsmaster 4000--D Page 5 -- 30 Electrical System Diode Circuit Board The circuit board contains four diodes (Fig. 48) and is lo- cated under the console housing. The diodes are used for circuit protection from inductive voltage spikes that occur when a hydraulic valve solenoid is de--energized. ...
Page 205 - Fusible Link Harness
Groundsmaster 4000--D Page 5 -- 31 Electrical System Fusible Link Harness The Groundsmaster 4000--D uses five (5) fusible links for circuit protection. Three (3) of these fusible links are located in a harness that connects the starter B+ termi- nal to the wire harness (Fig. 49). An additional fusib...
Page 206 - Cutting Deck Position Switch
Groundsmaster 4000--D Page 5 -- 32 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. 51 and 52). The position switch is a normally open, pow- ered proximity switch that incorporates an interna...
Page 207 - Engine Coolant and Hydraulic Oil Temperature Senders
Rev. A Groundsmaster 4000--D Page 5 -- 33 Electrical System Engine Coolant and Hydraulic Oil Temperature Senders The Groundsmaster 4000--D uses two (2) temperature senders as inputs for the TEC--5002 to identify if either the engine coolant or hydraulic oil temperature has reached an excessive level...
Page 208 - Battery Storage
Groundsmaster 4000--D Page 5 -- 34 Electrical System Service and Repairs NOTE: For engine component repair information, see the Kubota Workshop Manual, Diesel Engine, V2403--M--T--E3B Series at the end of Chapter 3 -- Ku- bota Diesel Engine. Battery Storage If the machine will be stored for more tha...
Page 209 - Battery Service
Groundsmaster 4000--D Page 5 -- 35 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, use ext...
Page 213 - Chapter 6; Axles, Planetaries and Brakes
Groundsmaster 4000--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 216 - Brake Assembly
Groundsmaster 4000--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. Flange head ...
Page 217 - Failure to maintain proper wheel lug nut torque
Groundsmaster 4000--D Page 6 -- 5 Axles, Planetaries and Brakes 3. Chock rear wheels and jack up front of machine (see Jacking Instructions in Chapter 1 -- Safety). Support ma- chine with jack stands. 4. Remove front wheel assembly. 5. Remove hydraulic wheel motor (see Front Wheel Motors in the Serv...
Page 218 - Brake Inspection and Repair
Groundsmaster 4000--D Page 6 -- 6 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 6. Hitch pin (2 used) 7. Stationary disc (4 used) 8. Rotating disc (3 used) 9. Retaining ring 10. Gasket 11. Rotating actuator 12...
Page 220 - Planetary Wheel Drive Assembly; Figure 6
Groundsmaster 4000--D Page 6 -- 8 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 head scre...
Page 222 - Planetary Wheel Drive Service
Groundsmaster 4000--D Page 6 -- 10 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. Ring gear ...
Page 226 - Rear Axle Assembly
Groundsmaster 4000--D Page 6 -- 14 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 head scre...
Page 229 - Bevel Gear Case and Axle Case; Bevel Gear Case and Axle Case Removal
Groundsmaster 4000--D Page 6 -- 17 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 (see Rear Axle Assembly Removal in this section). Bevel Gear Case and Axle Case Removal 1. Remove the mounting scr...
Page 230 - Bevel Gear Case and Axle Case Inspection
Groundsmaster 4000--D Page 6 -- 18 Axles, Planetaries and Brakes 5. Remove the knuckle pin mounting bolts and the knuckle pin. Remove the gasket and any remaining gas- ket material from both mating surfaces (Fig. 18). 6. While holding the bevel gear case, tap the upper end of the bevel gear shaft ou...
Page 234 - Differential Shafts; Differential Shaft Removal
Groundsmaster 4000--D Page 6 -- 22 Axles, Planetaries and Brakes Differential Shafts The following procedures assume the rear axle assem- bly has been removed from the machine (see Rear Axle Assembly Removal in this section). Differential Shaft Removal IMPORTANT: Do not interchange right and left di...
Page 235 - Axle Shafts; Axle Shaft Removal
Groundsmaster 4000--D Page 6 -- 23 Axles, Planetaries and Brakes Axle Shafts The following procedures assume the rear axle assem- bly has been removed from the machine (see Rear Axle Assembly Removal in this section). Axle Shaft Removal 1. Remove the axle cover mounting bolts. Remove the axle cover ...
Page 236 - Input Shaft/Pinion Gear
Groundsmaster 4000--D Page 6 -- 24 Axles, Planetaries and Brakes Input Shaft/Pinion Gear Figure 30 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. Shim 1...
Page 238 - Differential Gear; Differential Gear Removal
Groundsmaster 4000--D Page 6 -- 26 Axles, Planetaries and Brakes Differential Gear The following procedures assume the rear axle assem- bly has been removed from the machine (see Rear Axle Assembly Removal in this section). Differential Gear Removal 1. Remove bevel gear case/axle case assemblies (se...
Page 239 - ferential case I.D. to determine the side gear to case
Groundsmaster 4000--D Page 6 -- 27 Axles, Planetaries and Brakes Differential Gear 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. 37). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.0...
Page 241 - Pinion Gear to Ring Gear Engagement; Toe
Groundsmaster 4000--D Page 6 -- 29 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. 41): Toe -- the portion of the tooth...
Page 243 - Chapter 7; Chassis; Chassis
Groundsmaster 4000--D Page 7 -- 1 Chassis Chapter 7 Chassis Table of Contents GENERAL INFORMATION 1 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 1 . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE AND REPAIRS 2 . . . . . . . . . . . . . . . . . . . . . . Steering Tower 2 . ....
Page 244 - Steering Tower
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. Knob 8. Steering tower cover 9. Steering shaft 10. Compression spring 11. Cap 12. Rod assembly 13. Extension spri...
Page 246 - Front Deck Lift Arm; Figure 2
Groundsmaster 4000--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 o ) 12. ...
Page 248 - Side Deck Lift Arm
Groundsmaster 4000--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 bumper) 14. ...
Page 250 - Side Deck Rear Arm Assembly
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. Spacer 8. Rod end 9. Jam nut 10. Cap screw (4 per arm) 11. Straight bushing 12. Spring shaft 13. Flat washer 14. Compression...
Page 254 - Lift Arm Joint Yoke; Joint Yoke Disassembly
Groundsmaster 4000--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 12. Hardened wash...
Page 256 - Operator Seat
Groundsmaster 4000--D Page 7 -- 14 Chassis Operator Seat 1. Seat assembly 2. Flat washer (5 used) 3. Seat belt 4. Cap screw (4 used) 5. Seat platform 6. Flange nut (4 used) 7. Seat belt buckle 8. Cap screw (2 used) 9. R--clamp (2 used) 10. Manual tube 11. Screw 12. Lock nut 13. Seat belt mount 14. L...
Page 258 - Operator Seat Service
Groundsmaster 4000--D Page 7 -- 16 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. Nut 15. ...
Page 259 - Disassemble operator seat as necessary using Fig-
Groundsmaster 4000--D Page 7 -- 17 Chassis Disassembly (Fig. 15) 1. Disassemble operator seat as necessary using Fig- ure 15 as a guide. Assembly (Fig. 15) 1. Assemble operator seat using Figure 15 as a guide. Chassis
Page 260 - Operator Seat Suspension
Groundsmaster 4000--D Page 7 -- 18 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) 15. Teth...
Page 262 - Hood
Groundsmaster 4000--D Page 7 -- 20 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 (2 used)...
Page 265 - Chapter 8; Cutting Decks; Cutting
Groundsmaster 4000--D Cutting Decks Page 8 -- 1 Chapter 8 Cutting Decks Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 3 . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 267 - Never install or work on the cutting decks or lift
Groundsmaster 4000--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, general mainte...
Page 268 - Factors That Can Affect Quality of Cut; Factor
Groundsmaster 4000--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 off too mu...
Page 270 - Front Cutting Deck
Groundsmaster 4000--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 mount) 4....
Page 272 - Side Cutting Deck
Groundsmaster 4000--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. Compression spr...
Page 274 - Idler Assembly
Groundsmaster 4000--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. Front deck 2. Flange nut 3. Flange nut 4. Adjusting screw 5. Idler pulley 6. Driven spindle (double pulley) 7. Flat washer 8. Lock washer 9. Socket head screw...
Page 275 - Be careful when removing idler spring. The; Be careful when installing the idler spring. The
Groundsmaster 4000--D Cutting Decks Page 8 -- 11 Removal (Fig. 8) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove deck covers from top of cutting deck. CAUTION Be careful when removing idler spring. The spri...
Page 276 - Blade Spindles
Groundsmaster 4000--D Cutting Decks Page 8 -- 12 Blade Spindles 1. Front cutting deck 2. RH cutting deck 3. LH cutting deck 4. Drive spindle 5. Driven spindle 6. Grease fitting location Figure 10 FRONT RIGHT 1 2 3 4 5 6 4 4 5 5 6 6 6 6 6
Page 278 - Blade Spindle Service
Groundsmaster 4000--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 13. Spi...
Page 280 - Castor Forks and Wheels; Disassemble castor wheel as needed using Figure
Groundsmaster 4000--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. Compre...
Page 281 - Chapter 9; Foldout Drawings; Foldout Drawings
Groundsmaster 4000--D Foldout Drawings Page 9 - 1 Chapter 9 Foldout Drawings Table of Contents HYDRAULIC SCHEMATIC 3 . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SCHEMATICS Sheet 1 of 2 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sheet 2 of 2 5 . . . . . . . . . . . . ....
Page 284 - Electrical Schematic
Page 9 - 4 Electrical Schematic Groundsmaster 4000--D All relays and solenoids are shown as de-- energized.All ground wires are black. Sheet 1 of 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 (UNOCCUPIED) 2WD SOLENOID RIGHT DECK FRONT DECK PTO SOLENOID LEFT DE...
Page 286 - Glow Plug Circuits
Page 9 - 6 Glow Plug Circuits Power CurrentControl CurrentIndication Current Groundsmaster 4000--D CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 (UNOCCUPIED) 2WD SOLENOID RIGHT DECK FRONT DECK PTO SOLENOID LEFT DECK PTO SOLENOID PTO SOLENOID SOLENOID (OPTIONAL C...
Page 287 - Crank Circuits
Page 9 - 7 Crank Circuits Power CurrentControl CurrentIndication Current Groundsmaster 4000--D CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 (UNOCCUPIED) 2WD SOLENOID RIGHT DECK FRONT DECK PTO SOLENOID LEFT DECK PTO SOLENOID PTO SOLENOID SOLENOID (OPTIONAL CRUIS...
Page 290 - High Temperature Warning Circuits
Page 9 - 10 High Temperature Warning Circuits Power CurrentControl CurrentIndication Current Groundsmaster 4000--D CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 (OCCUPIED) 2WD SOLENOID RIGHT DECK FRONT DECK PTO SOLENOID LEFT DECK PTO SOLENOID PTO SOLENOID SOLENO...
Page 291 - Over Temperature Shutdown Circuits
Page 9 - 11 Over Temperature Shutdown Circuits Power CurrentControl CurrentIndication Current Groundsmaster 4000--D CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 (OCCUPIED) 2WD SOLENOID RIGHT DECK FRONT DECK PTO SOLENOID LEFT DECK PTO SOLENOID PTO SOLENOID SOLEN...
Page 292 - Engine Wire Harness
Page 9 - 12 Groundsmaster 4000--D Engine Wire Harness (STARTER) (STARTER) (STARTER)
Page 294 - Front Wire Harness
Page 9 - 14 Groundsmaster 4000--D Front Wire Harness FLOW DIVIDER SOLENOID
Page 296 - Console Wire Harness
Page 9 - 16 Groundsmaster 4000--D Console Wire Harness FLOW SWITCH TRANSPORT/4WD (PTO SHUTDOWN DELAY) DIVIDER SWITCH (ENGINE SHUTDOWN DELAY) COOLING FAN SWITCH
