Toro 30603 - Manual

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

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

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

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

Groundsmaster 4000--D/4010--D Page 1 -- 5 Safety Jacking Instructions CAUTION When changing attachments, tires or perform- ing other service, use correct jacks and sup-ports. Make sure machine is parked on a solid,level surface such as a concrete floor. Prior to raising machine, remove any attachmen...

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

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

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

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

Groundsmaster 4000--D/4010--D Page 2 -- 6 Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended Torque 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 f...

Groundsmaster 4000--D/4010--D Page 3 -- 1 Yanmar Diesel Engine Chapter 3 Yanmar Diesel Engine Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Models 30603 and 30605 2 . . . . . . . . . . . . . . . . . . . . Models 30607 and 30609 3 . . . . . . . . . . . . ....

Groundsmaster 4000--D/4010--D Page 3 -- 3 Yanmar Diesel Engine Specifications (Models 30607 and 30609) Item Description Make / Designation Yanmar Model 4TNV86CT--DTR: 4--Cycle, 4 Cylinder, Water Cooled, Turbocharged, Tier 4 Diesel Engine Bore 3.386 in (86 mm) Stroke 3.543 in (90 mm) Total Displaceme...

Groundsmaster 4000--D/4010--D Page 3 -- 5 Yanmar Diesel Engine General Information This Chapter gives information about specifications and repair of the diesel engine used in Groundsmaster 4000--D and 4010--D machines. General maintenance procedures are described in your Operator’s Manual. Informati...

Groundsmaster 4000--D/4010--D Page 3 -- 10 Yanmar Diesel Engine Service and Repairs Air Cleaner System Figure 6 FRONT RIGHT 1. Air cleaner assembly 2. Tank support 3. Indicator 4. Adapter 5. Air cleaner strap 6. Flat washer (4 used) 7. Cap screw (2 used) 8. Lock nut (2 used) 9. Flat washer (2 used) ...

Groundsmaster 4000--D/4010--D Page 3 -- 12 Yanmar Diesel Engine Fuel System Figure 9 1. Carriage screw (2 used) 2. Retaining ring (2 used) 3. Flat washer (2 used) 4. Flange nut (6 used) 5. Vent hose 6. Fuel tank 7. Hose clamp (2 used) 8. Elbow fitting (2 used) 9. Stand pipe 10. Grommet (3 used) 11. ...

Groundsmaster 4000--D/4010--D Page 3 -- 13 Yanmar Diesel Engine DANGER Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while en- gine is running, hot or when machine is in an en- closed area. Always fill fuel ...

Groundsmaster 4000--D/4010--D Page 3 -- 14 Yanmar Diesel Engine Radiator and Oil Cooler Assembly Figure 11 FRONT RIGHT 2 3 6 8 9 10 11 1 5 7 4 24 25 3 26 27 28 29 30 31 32 33 34 35 Thread Sealant 1. LH radiator support 2. Cap screw (2 used) 3. Flange nut (12 used) 4. Hose clamp (3 used) 5. Hose 6. F...

Groundsmaster 4000--D/4010--D Page 3 -- 15 Yanmar Diesel Engine Removal (Fig. 11) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. Open and support hood. CAUTION Do not open radiator cap or drain coolant if the radiato...

Groundsmaster 4000--D/4010--D Page 3 -- 18 Yanmar Diesel Engine Engine Figure 15 1. Engine (model 30603 shown) 2. Cap screw (4 used) 3. Rebound washer (4 used) 4. Flange nut (12 used) 5. Engine mount (4 used) 6. Cap screw (2 used per mount) 7. Engine mount bracket (2 used) 8. Lock washer 9. Engine m...

Groundsmaster 4000--D/4010--D Page 3 -- 19 Yanmar Diesel Engine Engine Removal (Fig. 15) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Disconnect negative battery cable from battery ter- minal and then disconnect...

Groundsmaster 4000--D/4010--D Page 3 -- 24 Yanmar Diesel Engine Spring Coupler Figure 21 1. Cap screw (8 used) 2. Washer (8 used) 3. Flywheel plate 4. Cap screw (8 used) 5. Washer (8 used) 6. Spring coupler 7. Engine (model 30603/30605 shown) FRONT RIGHT 29 to 33 ft--lb (40 to 44 N--m) 28 to 32 ft--...

Groundsmaster 4000--D/4010--D Page 3 -- 25 Yanmar Diesel Engine Coupler Removal (Fig. 21) NOTE: The hydraulic pump assembly needs to be re- moved from engine before coupler can be removed. 1. If engine is in machine, remove hydraulic pump as- sembly from machine (see Piston (Traction) Pump Re- moval...

Groundsmaster 4000--D/4010--D Page 3 -- 27 Yanmar Diesel Engine Groundsmaster models that are powered by a diesel en- gine that complies with EPA Tier 4 emission regulations are equipped with an exhaust system that includes a diesel oxidation catalyst (DOC) and a diesel particulate filter (DPF). The...

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

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 3 Specifications Item Description Piston (Traction) Pump Sauer--Danfoss Variable Displacement Axial Piston Pump Maximum Displacement (per revolution) 2.75 in 3 (45 cc) System Relief Pressure: Forward 4350 PSI (300 bar) System Relief Pressure: ...

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

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 6 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 ...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 10 Hydraulic Schematic NOTE: A larger hydraulic schematic is in clud ed in Ch ap te r 10 :Fold ou tD ra wing s S1 0 RV 1 CV 1 S2 S4 S5 PR V P4 CH 2 P3 EC CF LS S3 OR 1 C3 OR 4 .040 S6 OR 5 .070 C4 C2 C5 RV 2 16 00 PSI S7 S9 S8 C6 M1 M2 CH 1 CV...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 12 Hydraulic Flow Diagrams Tr ac tion Cir cuit: LOW S pee d (Mow) (For war d S hown) W orki ng P re ss ure Lo w P res su re (Charge) Re tu rn or Su ct io n Fl ow S1 0 RV 1 CV1 S2 S4 S5 PR V P4 CH 2 P3 EC CF LS S3 OR 1 C3 OR4 .040 S6 OR5 .070 C...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 13 Traction Circuit: LOW Speed (Mow) The traction circuit piston pump is a variable displace- ment pump that is directly coupled to the engine fly- wheel. This pump utilizes an integral electro--hydraulic servo piston assembly that controls th...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 17 Lower Cutting Deck 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 lift/lower circuit, the engine cooling fan circuit and the traction charge circuit....

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 19 Raise Cutting Deck Circuit A four section gear pump is coupled to the piston (trac- tion) pump (Fig. 10). The third gear pump section sup- plies hydraulic flow to the lift/lower circuit, the engine cooling fan circuit and the traction charg...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 21 Mow Circuit A four section gear pump is coupled to the piston (trac- tion) pump. Hydraulic flow for the mow circuit is supplied by two sections of the gear pump. The gear pump sec- tion closest to the piston (traction) pump supplies hy- dra...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 22 Mow Circuit Cutting Deck Blade Braking When the operator turns the PTO switch OFF or if a deck is raised with the PTO switch ON, PTO manifold propor- tional relief valve (PRV) is de--energized causing logic valve (LC1) to shift (refer to in...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 25 Steering Circuit A four section gear pump is coupled to the piston (trac- tion) pump. The fourth gear pump section (farthest from the piston pump) supplies hydraulic flow to the steering circuit, the engine cooling fan circuit and the tract...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 27 Engine Cooling Fan Circuit A four section gear pump is coupled to the piston (trac- tion) pump (Fig. 14). The fourth gear pump section (farthest from the piston pump) supplies hydraulic flow to the steering circuit, the engine cooling fan c...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 28 Special Tools Order special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test port...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 29 40 GPM Hydraulic Tester (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter. This tester includes the following: 1. LOAD VALVE: A simulated...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 30 High Flow Hydraulic Filter Kit The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi--direc- tional filtration which prevents filtered deb...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 31 Hydraulic Test Fitting Kit This kit includes a variety of O--ring Face Seal fittings to enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Toro Part Number: TOR4...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 32 Remote Starter Switch After flushing the hydraulic system or replacing a hy- draulic component (e.g. gear pump, piston pump, wheel motor), it is necessary to prime the hydraulic pumps. A remote starter switch (Fig. 24) can be used for this ...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 33 Troubleshooting The charts that follow contain suggestions that can be used to assist in diagnosing hydraulic system perfor- mance issues. The suggestions are not all--inclusive. Also, consider that there may be more than one cause for a ma...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 34 Traction Circuit Problems Problem Possible Cause Machine operates in one direction only. Piston (traction) pump by--pass valve is open or damaged. Traction relief valve is leaking or faulty. Piston (traction) pump servo control valve orific...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 35 Mow Circuit Problems Problem Possible Cause None of the cutting decks will oper- ate. NOTE: To engage the mow circuit, the seat must be occupied, the cut- ting deck(s) must be fully lowered, the traction speed must be in the LOW (mow) posit...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 36 Lift Circuit Problems Problem Possible Cause Cutting decks will not raise. NOTE: Seat must be occupied in or- der to raise cutting decks. Engine RPM is too low. Hydraulic oil level in reservoir is low (NOTE: Other hydraulic systems are affe...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 37 Steering Circuit Problems Problem Possible Cause Steering inoperative or sluggish Steering components (e.g. tie rods, steering cylinder ends) are worn or binding. Steering cylinder is binding. Oil level in hydraulic reservoir is low (NOTE: ...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 38 Engine Cooling Fan Circuit Problems Problem Possible Cause Cooling fan runs only in forward di- rection (fan does not run in reverse direction). Solenoid cartridge valve (S10) in combination control manifold is faulty. Electrical problem ex...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 42 Traction Circuit Charge Pressure (Using Pressure Gauge) 3. 3 G P M 4. 4 G PM 14 .3 GP M 14. 3 G PM P1 16. 8 G PM 13. 7 G PM PR 38 0 P S I RV 650 PSI .05 0 CV T P2 M8 CH OR 1 25 0 PSI 2. 14 CID / 1. 16 CI D 20 0 P S I 4350 PSI 50 00 PSI M1 O...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 43 The traction charge circuit is designed to replace loss of hydraulic fluid from the closed loop traction circuit. This test is used to make sure that traction charge pressure is correct. Procedure for Traction Circuit Charge Pressure Test C...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 44 Traction Circuit Relief Pressure (Using Pressure Gauge) 3. 3 G PM 4.4 G P M 14 .3 G P M 14 .3 G P M P1 16 .8 G P M 13 .7 G P M PR 38 0 P SI RV 65 0 P S I .050 CV T P2 M8 CH OR1 25 0 PSI 2.14 C ID / 1.16 CID 20 0 PSI 435 0 P S I 50 00 PSI M1...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 46 Counterbalance Pressure (Using Pressure Gauge) PRESSURE GAUGE S1 0 RV 1 CV 1 S2 S4 S5 PR V P4 CH2 P3 EC CF LS S3 OR1 C3 OR 4 .040 S6 OR 5 .07 0 C4 C2 C5 RV 2 S7 S9 S8 C6 M1 M2 CH 1 CV 3 CH 4 OR2 .0 63 OR6 .063 OR 3 .0 70 OR 7 .0 70 T 2S P C...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 50 Rear Traction Circuit Relief Valve (RV) Pressure (Using Pressure Gauge) 3. 3 G P M 4.4 G P M 14 .3 G P M 14 .3 G P M P1 16.8 G P M 13 .7 G P M PR 38 0 P S I RV 65 0 P S I .05 0 CV T P2 M8 CH OR1 25 0 P S I 2.14 C ID / 1.16 C ID 20 0 P S I 4...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 52 Piston (Traction) Pump Flow Test (Using Tester with Pressure Gauge and Flow Meter) 3.3 G P M 4.4 G P M 14.3 G P M 14.3 G P M P1 16.8 G P M 13 .7 G P M PR 38 0 P S I RV 65 0 P S I .050 CV T P2 M8 CH OR1 25 0 P S I 2.14 CID / 1. 16 C ID 20 0 ...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 54 Cutting Deck Circuit Pressure (Using Pressure Gauge) FRONT DECK CIRCUIT PRESSURE TEST SHOWN PRESSURE GAUGE 3.3 G P M 14 .3 G P M 14 .3 G P M 1.17 C ID 30 00 P S I P1 P1 P1 P2 P2 P2 M1 M2 LC 1 PR V PD CD RV 20 00 PSI M1 M2 LC 1 PR V PD RV 30...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 58 Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauge and Flow Meter) CENTER CUTTING DECK MOTOR CASE DRAIN LEAKAGE TEST SHOWN 1.17 CID 3000 PSI P1 P1 P2 P2 M1 M2 LC1 PRV PD CD RV 2000 PSI M1 M2 LC1 PRV PD RV 3000 PSI M1 M2...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 60 Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) S1 0 RV 1 CV 1 S2 S4 S5 PR V P4 CH 2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR5 .070 C4 C2 C5 RV 2 S7 S9 S8 C6 M1 M2 CH 1 CV 3 CH 4 OR2 .063 OR 6 .063 OR3 .070 OR 7 .0 70 T 2SP CH 3 G2 G4...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 62 Steering Circuit Relief Pressure (Using Pressure Gauge) S1 0 RV 1 CV1 S2 S4 S5 PR V P4 CH 2 P3 EC CF LS S3 OR 1 C3 OR4 .040 S6 OR 5 .07 0 C4 C 2 C5 RV 2 16 00 PSI S7 S9 S8 C6 M1 M2 CH 1 CV3 CH 4 OR 2 .0 63 OR 6 .0 63 OR 3 .07 0 OR7 .070 T 2...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 64 Steering Cylinder Internal Leakage 6.1 CID E P L R T STEERING CYLINDER 2.00” BORE 4.20” STROKE 0.625” ROD STEERING CONTROL VALVE STEERING WHEEL TURNED FOR RIGHT TURN CYLINDER FULLY EXTENDED LOOK FOR LEAKAGE STEEL CAP FROM COMBINATION MANIFO...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 66 Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac) S1 0 RV 1 CV 1 S2 S4 S5 PR V P4 CH 2 P3 EC CF LS S3 OR1 C3 OR4 .040 S6 OR 5 .0 70 C4 C 2 C5 RV 2 160 0 PS I S7 S9 S8 C6 M1 M2 CH 1 CV 3 CH 4 OR 2 .063 OR 6 .0 63 OR 3 .0 70 OR 7...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 68 Gear Pump Flow (Using Tester with Pressure Gauge and Flow Meter) SECOND GEAR PUMP SECTION FLOW TEST SHOWN 3. 3 G P M 14 .3 G P M 14 .3 G P M 25 0 PSI 435 0 P S I 50 00 P S I .031 5 .03 15 0.4 CI D 0. 3 1.29 1.29 CI D C ID C ID 2. 75 CI D EN...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 70 Adjustments Adjust Control Manifold Relief Valves Several of the hydraulic control manifolds on your Groundsmaster include adjustable relief valves. The fol- lowing procedure can be used to adjust these relief valves. Refer to the Testing s...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 71 Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- tem, park machine on a level surface, apply park...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 72 Check Hydraulic Lines and Hoses WARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under highpressure. Use paper or cardboard, not hands, tosearch for leaks. Hydraulic fluid escaping under pressure ca...

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

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

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 76 Hydraulic Reservoir 1. Hydraulic reservoir 2. Cap screw 3. Recess bumper (2 used) 4. Thin spacer 5. Flange nut 6. Breather 7. Bushing (3 used) 8. Stand pipe (3 used) 9. Hose clamp 10. Reservoir cap 11. O--ring 12. Dipstick 13. Screen filter...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 78 Radiator and Oil Cooler Assembly 1. LH radiator support 2. Cap screw (2 used) 3. Flange nut (12 used) 4. Hose clamp (3 used) 5. Hose 6. Flange nut (6 used) 7. Foam plug (2 used) 8. Flange head screw (6 used) 9. Flange head screw (9 used) 10...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 80 Gear Pump 1. Hose clamp (3 used) 2. Hose clamp (2 used) 3. Hydraulic hose 4. Suction hose 5. Tee fitting 6. Straight hydraulic fitting 7. Plug 8. Cap screw (2 used) 9. Flat washer (4 used) 10. Gear pump 11. O--ring 12. Hydraulic fitting 13....

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 84 Gear Pump Service 1. Front cover 2. Dowel pin (4 used) 3. Pressure seal 4. Back--up gasket 5. Front thrust plate 6. Seal (8 used) 7. Front body 8. Idler gear 9. Drive shaft 10. Thrust plate (7 used) 11. Dowel pin (6 used) 12. Splined connec...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 91 1. Screen (2 used) 2. Plug with O --ring (2 used) 3. Plug with O --ring (2 used) 4. Cylinder block assembly 5. Valve plate 6. Servo piston 7. Screw (4 used) 8. Orifice (2 used) 9. Screw (4 used) 10. Plug with O --ring (4 used) 11. Screw (2 ...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 92 Rear Axle Motor 1. Rear axle motor 2. 90 o hydraulic fitting (2 used) 3. 90 o hydraulic fitting 4. Straight hydraulic fitting 5. 90 o hydraulic fitting 6. Temperature sender 7. Cap screw (2 used) 8. Flat washer (2 used) 9. O--ring 10. Exter...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 94 Front Wheel Motors 1. Front wheel motor 2. Internal retaining ring 3. Splined brake shaft 4. RH brake assembly 5. Planetary assembly (2 used) 6. Cap screw (2 used per motor) 7. Flat washer (2 used per motor) 8. O--ring 9. LH brake assembly ...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 96 Rear Axle and Front Wheel Motor Service Figure 68 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 23 21 25 1. Plug with O --ring 2. Minimum angle stop 3. Bias spring 4. Servo piston 5. O--ring 6. O--ring 7. Socket head screw (5 use...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 97 NOTE: The front wheel motors on your Groundsmaster are identical (Fig. 68). The rear axle motor includes a flushing valve for cooling of the closed loop traction cir- cuit and therefore has some differences from the front motors (Fig. 69). ...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 98 Rear Traction Manifold 1. Front frame 2. PTO manifold (center deck) 3. Front traction manifold 4. Rear traction manifold 5. Cap screw (2 used) 6. Flange nut (2 used) 7. 90 o hydraulic fitting 8. O--ring 9. 45 o hydraulic fitting 10. O--ring...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 100 Rear Traction Manifold Service 1. Rear traction manifold body 2. Relief valve (port RV) 3. Pressure reducing valve (port PR) 4. #4 zero leak plug with O --ring 5. #6 zero leak plug with O --ring 6. Check valve (port CV) 7. Orifice (0.050) ...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 102 Front Traction Manifold 1. Front frame 2. PTO manifold (center deck) 3. Rear traction manifold 4. Front traction manifold 5. Cap screw (2 used) 6. Flange nut (2 used) 7. O--ring 8. Check fitting 9. O--ring 10. Hydraulic straight fitting 11...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 104 Front Traction Manifold Service 1. Flow divider valve (port HFD) 2. SAE #4 plug with O--ring 3. Orifice (0.063) (port OR) 4. Front traction manifold 5. Check valve (ports CV1 and CV2) 6. SAE #6 plug with O --ring 7. #4 zero leak plug with ...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 106 Combination Manifold 1. Combination manifold 2. Flange nut (3 used) 3. Flat washer (3 used) 4. Mount (3 used) 5. Spacer (3 used) Figure 74 FRONT RIGHT 2 3 1 5 4 NOTE: The ports on the combination manifold are marked for easy identification...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 108 Combination Manifold Service 1. Combination manifold 2. #6 zero leak plug with O--ring 3. Check valve (CV3) 4. #4 zero leak plug with O--ring 5. Solenoid valve (S4, S6 and S9) 6. Solenoid valve (S5) 7. Relief valve (RV2) 8. Solenoid valve ...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 110 Control Manifold Cartridge Valve Service 1. Make sure the control manifold is clean before re- moving the cartridge valve from the control manifold. 2. If cartridge valve is solenoid operated, remove nut securing solenoid coil to the cartr...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 112 Steering Control Valve 1. Steering wheel cover 2. Hex nut 3. Flat washer 4. Steering wheel 5. Foam collar 6. Steering seal 7. External snap ring (2 used) 8. Steering shaft 9. Flange bushing 10. Thrust washer (as needed) 11. Cap screw (4 us...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 114 Steering Control 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. Ge...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 116 Steering Cylinder 1. Steering cylinder 2. Ball joint 3. Ball joint 4. Retaining ring (2 used) 5. Grease fitting 6. Grease fitting 7. 90 o hydraulic fitting (2 used) 8. Drive axle assembly 9. Ball joint spacer 10. Axle washer 11. Slotted he...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 118 Steering Cylinder Service 1. Barrel 2. Rod 3. Piston 4. Head 5. Internal collar 6. Backup ring 7. O--ring 8. Dust seal 9. Rod seal 10. O--ring 11. Piston seal 12. Lock nut Figure 85 40 ft--lb (54 N--m) 1 6 7 3 9 10 4 11 2 8 5 12 1 6 7 3 9 ...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 120 Engine Cooling Fan Motor 1. Hydraulic fan motor 2. O--ring 3. Fan bracket 4. Hydraulic fitting (2 used) 5. O--ring 6. Radiator/oil cooler assembly 7. Fan hub 8. Washer 9. Hex nut 10. Lower radiator shroud 11. Cap screw (4 used) 12. Washer ...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 124 Engine Cooling Fan Motor Service 1. Flange washer 2. O--ring 3. Front flange 4. Dust seal 5. Retaining ring 6. Front wear plate 7. Shaft seal 8. Backup gasket 9. Pressure seal 10. Rear wear plate 11. Body 12. Idler gear 13. Cap screw (4 us...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 125 IMPORTANT: Make sure not to damage the front flange counter bore when removing the seals from the front flange. 10.Carefully remove dust seal, retaining ring, flange washer and shaft seal from the front flange (Fig. 90). Note orientation o...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 127 Cutting Deck Motors 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 Com...

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

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 136 PTO Manifold Service 1. PTO manifold body 2. NWD SAE #4 plug with O --ring 3. Orifice (0.025) (port OR) 4. #6 zero leak plug with O--ring 5. Relief valve (port RV1) 6. Proportional relief valve (port PRV) 7. Solenoid coil 8. Nut 9. Logic c...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 138 Side Deck Lift Cylinders 1. Lift arm assembly (LH shown) 2. Shoulder screw 3. Flange nut 4. Pin assembly 5. Lock nut 6. Flat washer 7. Cylinder pin 8. Spring pin 9. Lift cylinder 10. 90 o hydraulic fitting 11. 90 o hydraulic fitting Figure...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 139 Removal (Fig. 105) 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...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 140 Center Deck Lift Cylinders 1. Front frame 2. Flange head screw 3. Flange nut 4. Pin assembly 5. Grease fitting 6. Cotter pin (2 used per pin) 7. Flat washer (4 used per pin) 8. Clevis pin 9. Lift cylinder (2 used) 10. RH lift arm assembly ...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 141 Removal (Fig. 106) 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...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 142 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....

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

Groundsmaster 4000--D/4010--D Page 5 -- 3 Electrical System Yanmar Engine Electronic Control Unit (ECU) The Yanmar engine that powers the Groundsmaster 4000--D and 4010--D uses an electronic control unit (ECU) for engine management and also to communi- cate with the TEC controllers and the InfoCente...

Groundsmaster 4000--D/4010--D Page 5 -- 4 Electrical System CAN--bus Communications The two (2) TEC controllers, the Yanmar engine elec- tronic control unit and the InfoCenter Display used on the Groundsmaster 4000--D and 4010--D communicate with each other on a CAN--bus system. Using this sys- tem ...

Groundsmaster 4000--D/4010--D Page 5 -- 6 Electrical System Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The multimeter can test electrical components and cir- cuits for current, resistance or voltage. NOTE: Toro rec...

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

Groundsmaster 4000--D/4010--D Page 5 -- 8 Electrical System InfoCenter Display The InfoCenter Display used on your Groundsmaster is a LCD device that is located on the console. The Info- Center provides information for the machine operator during machine operation, provides electrical system diagnos...

Groundsmaster 4000--D/4010--D Page 5 -- 9 Electrical System Main Information Screen The two (2) InfoCenter main information screens (Figs. 10 and 11) are displayed after the initial splash screen has been displayed for several seconds. During normal machine operation, the main information screens pr...

Groundsmaster 4000--D/4010--D Page 5 -- 10 Electrical System Main Menu Screen The main menu screen can be accessed from the Info- Center main information by pressing and releasing the menu/back button (left button) on the display. Once to the main menu screen (Fig. 12), navigation to the five (5) di...

Groundsmaster 4000--D/4010--D Page 5 -- 11 Electrical System Service Screen The service screen (Fig. 13) contains machine opera- tional information including hours and counts. Values listed for these service menu items cannot be changed. If the machine PIN has been entered to allow access to protect...

Groundsmaster 4000--D/4010--D Page 5 -- 12 Electrical System Diagnostics Screen The diagnostics screen (Fig. 16) lists the various states of machine electrical components. The diagnostics screen should be used to check operation of machine controls and to verify that switches and circuit wiring are ...

Groundsmaster 4000--D/4010--D Page 5 -- 13 Electrical System Settings Screen The settings screen identifies the InfoCenter language and units (English or Metric). The settings screen also allows the operator to customize the backlight (bright- ness) and contrast settings for the InfoCenter display. ...

Groundsmaster 4000--D/4010--D Page 5 -- 14 Electrical System About Screen The about screen (Fig. 17) identifies the machine model number, serial number and software revisions for the TEC controllers, InfoCenter and engine electronic con- trol unit (if available). The about screen also lists the CAN-...

Groundsmaster 4000--D/4010--D Page 5 -- 15 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...

Groundsmaster 4000--D/4010--D Page 5 -- 16 Electrical System Fault Codes The list below identifies the fault codes that are gener- ated by the TEC controller to identify an electrical sys- tem malfunction (fault) that occurred during machine operation. Use the InfoCenter Display for fault retrieval....

Groundsmaster 4000--D/4010--D Page 5 -- 18 Electrical System Starting Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical problems. Problem Possible Causes No electrical power to machine. The battery is discharged. The battery c...

Groundsmaster 4000--D/4010--D Page 5 -- 20 Electrical System General Run and Transport Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical problems. Problem Possible Causes Engine continues to run, but should not, when the ignit...

Groundsmaster 4000--D/4010--D Page 5 -- 21 Electrical System Cutting Deck Operating Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical problems. NOTE: To engage the mow circuit, the operator must be in the operator seat, the tr...

Groundsmaster 4000--D/4010--D Page 5 -- 22 Electrical System Cutting Deck Operating Problems (Continued) Problem Possible Causes Cutting decks run, but should not, when lowered with PTO switch in the OFF (disengage) position. The PTO switch or circuit wiring is faulty. The TEC controller is faulty. ...

Groundsmaster 4000--D/4010--D Page 5 -- 23 Electrical System Cutting Deck Lift/Lower Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical problems. NOTE: To lower a cutting deck, the operator must be in the operator seat and the ...

Groundsmaster 4000--D/4010--D Page 5 -- 25 Electrical System Adjustments Cutting Deck Position Switch Adjustment Adjustment 1. Park machine on a level surface with front cutting deck raised and side cutting decks lowered. Stop en- gine, engage parking brake and remove key from the ignition switch. 2...

Groundsmaster 4000--D/4010--D Page 5 -- 26 Electrical System Traction Pedal Adjustment The traction pedal includes a neutral assembly that is used to adjust the traction neutral position (Fig. 20). Traction pedal adjustment may be necessary to make sure that traction pedal movement provides the corr...

Groundsmaster 4000--D/4010--D Page 5 -- 28 Electrical System Traction Pedal Position Sensor Calibration IMPORTANT: A properly installed and calibrated traction pedal position sensor is critical to accurate traction system response and for reliable sensor life. Use care when removing, installing and ...

Groundsmaster 4000--D/4010--D Page 5 -- 29 Electrical System Electrical System Quick Checks Battery Test (Open Circuit) 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...

Groundsmaster 4000--D/4010--D Page 5 -- 30 Electrical System Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before checking continuity on the switch). NOTE: For engin...

Groundsmaster 4000--D/4010--D Page 5 -- 31 Electrical System Fuses The fuse block is located under the controller cover next to the operator seat (Fig. 28). In addition to the fuses in the fuse block, a 60 Amp fuse is included in the wire harness to protect the power cir- cuit for the operator cab. ...

Groundsmaster 4000--D/4010--D Page 5 -- 33 Electrical System Fusible Link Harness Your Groundsmaster uses two (2) fusible links for circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the wire harness (Fig. 33). If either of these links should fa...

Groundsmaster 4000--D/4010--D Page 5 -- 34 Electrical System PTO Switch The PTO switch is located on the control arm (Fig. 35). The PTO switch is pulled up to engage the PTO and pushed in to disengage the PTO. The TEC controller monitors the position of the PTO switch (up or down). Using inputs from...

Groundsmaster 4000--D/4010--D Page 5 -- 35 Electrical System HI/LOW Speed, Engine Speed and Cutting Deck Lift Switches The HI/LOW, engine speed and cutting deck lift switches are all identical momentary switches. These switches are located on the control arm (Fig. 37). The HI/LOW speed switch is use...

Groundsmaster 4000--D/4010--D Page 5 -- 36 Electrical System Cruise Control Switch The cruise control switch is used as an input for the TEC controller to maintain ground speed when engaged. The cruise control function is enabled when the switch is in the ON (center) position. Pressing the front of ...

Groundsmaster 4000--D/4010--D Page 5 -- 37 Electrical System Seat Switch The seat switch is normally open and closes when the operator is on the seat. This switch is used as an input for the TEC controller. The seat switch and its electrical connector are located in the seat assembly. If the trac- t...

Groundsmaster 4000--D/4010--D Page 5 -- 38 Electrical System Parking Brake Switch The switch used for the parking brake is a normally open proximity switch that is located under the steering tower cover (Fig. 42). The parking brake switch is an input for the TEC controller. When the parking brake is...

Groundsmaster 4000--D/4010--D Page 5 -- 39 Electrical System Service Brake Switches The two (2) switches used for the service brakes are nor- mally open switches that are located under the footrest panel (Fig. 43). The service brake switches provide in- puts for the TEC controller. When a brake peda...

Groundsmaster 4000--D/4010--D Page 5 -- 45 Electrical System Traction Pedal Position Sensor The traction pedal position sensor is connected to the traction pedal assembly (Fig. 54). This position sensor determines the neutral band for the traction pedal, the direction of travel desired by the operat...

Groundsmaster 4000--D/4010--D Page 5 -- 52 Electrical System Hydraulic Solenoid Valve Coils Figure 66 1. Front PTO manifold 2. RH PTO manifold 3. LH PTO manifold 4. Combination manifold FRONT RIGHT 2 3 1 4 Several hydraulic solenoid valve coils are used on the hydraulic control manifolds of Groundsm...

Groundsmaster 4000--D/4010--D Page 5 -- 54 Electrical System Piston (Traction) Pump Control Solenoid Coils The piston (traction) pump uses an electronic control as- sembly for swash plate rotation. Electrical outputs from the machine TEC controller are provided to two (2) solenoid coils for pump con...

Groundsmaster 4000--D/4010--D Page 5 -- 57 Electrical System Fuel Sender The fuel sender is attached to the top of the fuel tank. The resistance of the fuel sender increases as the fuel level in the fuel tank decreases. The TEC controller uses the fuel sender as an input to generate an output for th...

Groundsmaster 4000--D/4010--D Page 5 -- 60 Electrical System Cutting Deck Position Switches Three (3) cutting deck position switches are used on the Groundsmaster 4000--D and 4010--D. These switches are located on the traction unit frame (Figs. 80 and 81). The position switches are powered proximity...

Groundsmaster 4000--D/4010--D Page 5 -- 61 Electrical System Hydraulic Oil Temperature Sender The Groundsmaster 4000--D and 4010--D use a temper- ature sender as an input for the TEC controller to identify if the hydraulic oil temperature has reached an exces- sive level. The hydraulic oil temperatu...

Groundsmaster 4000--D/4010--D Page 5 -- 62 Electrical System Audio Alarm The audio alarm sounds to notify the operator when a machine problem exists. Electrical current for the alarm is provided as an output from the TEC controller. The alarm is attached to the control arm next to the operator seat....

Groundsmaster 4000--D/4010--D Page 5 -- 63 Electrical System Service and Repairs NOTE: For engine component repair information (e.g. starter motor), refer to the Yanmar Workshop Manual that is correct for your Groundsmaster model. Battery Care 1. The top of the battery must be kept clean. lf the ma-...

Groundsmaster 4000--D/4010--D Page 5 -- 64 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,...

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

Groundsmaster 4000--D/4010--D Page 6 -- 3 Axles, Planetaries and Brakes General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional inf...

Groundsmaster 4000--D/4010--D Page 6 -- 4 Axles, Planetaries and Brakes Adjustments Planetary Wheel Drive Assembly Endplay A front planetary wheel drive assembly that is properly operating should have no endplay. Any endplay in a planetary assembly indicates that there are potential problems with th...

Groundsmaster 4000--D/4010--D Page 6 -- 6 Axles, Planetaries and Brakes Service and Repairs Brake Assembly Figure 1 FRONT RIGHT 75 to 85 ft--lb (101 to 115 N--m) 85 to 100 ft--lb (115 to 135 N--m) 75 to 85 ft--lb (101 to 115 N--m) 2 3 6 8 9 11 13 1 5 7 12 14 15 4 10 1 6 7 8 13 1. Front wheel motor 2...

Groundsmaster 4000--D/4010--D Page 6 -- 7 Axles, Planetaries and Brakes Removal (Fig. 1) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch. 2. Drain oil from planetary wheel drive/brake assembly (Fig. 2). CAUTION When removing front wheel, u...

Groundsmaster 4000--D/4010--D Page 6 -- 8 Axles, Planetaries and Brakes 2. Apply gasket sealant to sealing surfaces of new gas- ket (item 18). Apply gasket to brake assembly. 3. Install brake assembly onto machine, aligning splined brake shaft with input shaft on planetary wheel drive. Make sure tha...

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

Groundsmaster 4000--D/4010--D Page 6 -- 12 Axles, Planetaries and Brakes Planetary Wheel Drive Assembly Figure 7 FRONT RIGHT 75 to 85 ft--lb (101 to 115 N--m) 85 to 100 ft--lb (115 to 135 N--m) 75 to 85 ft--lb (101 to 115 N--m) 2 3 6 8 9 11 13 1 5 7 12 14 15 4 10 1 6 7 8 13 16 17 18 19 20 21 1. Fron...

Groundsmaster 4000--D/4010--D Page 6 -- 14 Axles, Planetaries and Brakes Planetary Wheel Drive Service 1. Spindle 2. Boot seal 3. Oil seal 4. Inner bearing cone 5. Inner bearing cup 6. Wheel stud (8 used) 7. Socket head screw (16 used) 8. Lock washer (16 used) 9. Housing 10. Dowel pin (2 used) 11. O...

Groundsmaster 4000--D/4010--D Page 6 -- 18 Axles, Planetaries and Brakes Rear Axle Assembly 1. Plug with O --ring 2. Lug nut (5 used per wheel) 3. Rear wheel assembly (2 used) 4. Cap screw (2 used) 5. Flat washer (8 used) 6. Rear axle motor 7. O--ring 8. Steering cylinder 9. Spacer 10. Cotter pin (2...

Groundsmaster 4000--D/4010--D Page 6 -- 22 Axles, Planetaries and Brakes Rear Axle Service Figure 19 3 2 4 5 6 7 8 9 10 14 13 12 11 15 1 10 11 8 9 8 13 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 20 41 42 43 50 44 45 46 47 48 49 51 54 55 56 57 58 59 52 53 60 61 62 63 64 2...

Groundsmaster 4000--D/4010--D Page 6 -- 23 Axles, Planetaries and Brakes 1. LH axle support 2. Flange bushing (2 used) 3. Axle vent 4. Filter 5. Vent extension 6. Cap screw (4 used per gear case) 7. Shim set 8. Seal washer 9. Plug 10. Lock nut 11. Lock washer 12. Grease fitting 13. Ball bearing 14. ...

Groundsmaster 4000--D/4010--D Page 6 -- 24 Axles, Planetaries and Brakes Bevel Gear Case and Axle Case The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove the mounting screws, nuts and lock wash- ers. Remove the bevel gear case/axle case asse...

Groundsmaster 4000--D/4010--D Page 6 -- 25 Axles, Planetaries and Brakes 5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gas- ket material from either mating surface (Fig. 23). 6. While holding the bevel gear case, tap the upper end of the bevel gea...

Groundsmaster 4000--D/4010--D Page 6 -- 27 Axles, Planetaries and Brakes 5. Determine necessary quantity of support shims. A. Lubricate the axle case support bushing with a thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during disassembl...

Groundsmaster 4000--D/4010--D Page 6 -- 28 Axles, Planetaries and Brakes 9. Remove the bevel gear case/axle case assembly from the axle support. Coat a new O-ring with grease and temporarily install the axle cover assembly. Position a dial indicator at the tooths center. Prevent the axle from turnin...

Groundsmaster 4000--D/4010--D Page 6 -- 29 Axles, Planetaries and Brakes Axle Shafts The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig. 32). 2. Use...

Groundsmaster 4000--D/4010--D Page 6 -- 30 Axles, Planetaries and Brakes Input Shaft/Pinion Gear Figure 35 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...

Groundsmaster 4000--D/4010--D Page 6 -- 32 Axles, Planetaries and Brakes Differential Gear The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of thi...

Groundsmaster 4000--D/4010--D Page 6 -- 33 Axles, Planetaries and Brakes Inspection 1. Measure the differential side gear O.D. and the dif- ferential case I.D. to determine the side gear to case clearance (Fig. 42). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 inch (0...

Groundsmaster 4000--D/4010--D Page 6 -- 35 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. 46): Toe -- the portion of t...

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

Groundsmaster 4000--D/4010--D Page 7 -- 2 Chassis Service and Repairs Steering Tower Figure 1 FRONT RIGHT 27 to 33 ft--lb (37 to 44 N--m) 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 7 10 20 to 26 ft--lb (28 to 35 N--m) 20 19 1. Steering wheel cover 2. Hex nut 3. Flat washer 4. Steering wheel ...

Groundsmaster 4000--D/4010--D Page 7 -- 4 Chassis Center Deck Lift Arms 1. Center deck assembly 2. Grease fitting 3. Ball joint seal 4. Hydraulic deck motor 5. Flange head screw 6. RH lift arm 7. LH lift arm 8. Lift cylinder (2 used) 9. Pin (2 used) 10. Flange nut (2 used) 11. Jam nut (LH threads) (...

Groundsmaster 4000--D/4010--D Page 7 -- 8 Chassis Side Deck Lift Arms 1. Lift cylinder pin 2. Slotted roll pin 3. Flange head screw 4. Rubber bumper 5. Rivet (2 per bumper) 6. Cap screw 7. Thrust washer 8. Lift arm pivot shaft 9. Pivot hub 10. Thrust washer (as needed) 11. Spring pin 12. Tapped bloc...

Groundsmaster 4000--D/4010--D Page 7 -- 9 Chassis Removal (Fig. 6) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove side deck from lift arm (see Side Cutting Deck Removal in Chapter 8 -- Cutting Decks). 3. Re...

Groundsmaster 4000--D/4010--D Page 7 -- 10 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. Co...

Groundsmaster 4000--D/4010--D Page 7 -- 14 Chassis Lift Arm Joint Yoke 1. Side cutting deck (LH shown) 2. Deck mount (LH shown) 3. Retaining ring (2 used per deck) 4. Lock nut 5. Plate 6. Rubber plate 7. Cap screw 8. Flat washer (8 used per mount) 9. Joint yoke 10. Spacer 11. Thrust washer (0.125” t...

Groundsmaster 4000--D/4010--D Page 7 -- 16 Chassis Control Arm 1. Flange nut (3 used) 2. Flange head screw (2 used) 3. Washer head screw (10 used) 4. LH cover 5. Lock nut 6. Control arm panel 7. Ignition switch 8. InfoCenter display 9. R--clamp 10. Audio alarm 11. PTO switch 12. Nut 13. Bracket 14. ...

Groundsmaster 4000--D/4010--D Page 7 -- 20 Chassis Operator Platform 1. Operator platform 2. Cap screw (2 used) 3. Flat washer (4 used) 4. Center mount (4 used) 5. Plain washer (4 used) 6. Lock nut (4 used) 7. Cap screw (2 used) Figure 19 FRONT RIGHT 3 2 1 4 5 6 7 3 4 5 6 95 to 115 ft--lb (129 to 15...

Groundsmaster 4000--D/4010--D Page 7 -- 24 Chassis Operator Seat 1. Carriage screw (5 used) 2. Support channel 3. Support bracket 4. Flange nut (6 used) 5. Cap screw 6. Flat washer (4 used) 7. Arm support 8. Screw 9. Coupler nut 10. Spacer 11. Flange nut (4 used) 12. Seat belt 13. Cap screw 14. Seat...

Groundsmaster 4000--D/4010--D Page 7 -- 26 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. ...

Groundsmaster 4000--D/4010--D Page 7 -- 27 Chassis Disassembly (Fig. 27) 1. Disassemble operator seat as necessary using Fig- ures 27 and 28 as guides. Assembly (Fig. 27) 1. Assemble operator seat using Figures 27 and 28 as guides. 1. Operator seat 2. R--clamp (2 used) 3. Screw (2 used) 4. Manual tu...

Groundsmaster 4000--D/4010--D Page 7 -- 28 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) ...

Groundsmaster 4000--D/4010--D Page 7 -- 30 Chassis Hood 1. Hood 2. Screen assembly 3. Bulb seal 4. Flange nut (2 used) 5. Screen pivot (2 used) 6. Hair pin (2 used) 7. Hood support 8. Plastite screw (4 used) 9. Door handle (2 used) 10. Bulb seal 11. Hood pivot (2 used) 12. Flexible draw latch (2 use...

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

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

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

Groundsmaster 4000--D/4010--D Cutting Decks Page 8 -- 6 Service and Repairs CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop en- gine and remove key from ignition switch first. Center Cutting Deck Figure 1 FRONT RIGHT 150 to 175 ft--lb (203 to 237 ...

Groundsmaster 4000--D/4010--D Cutting Decks Page 8 -- 8 Side Cutting Decks 1. Cutting deck (LH shown) 2. Flange head screw (2 used) 3. Hydraulic deck motor 4. Spider 5. Clevis pin 6. Hair pin 7. Deck mount (LH shown) 8. Cap screw (8 used per mount) 9. Lock washer (8 used per mount) 10. Flat washer (...

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

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

Groundsmaster 4000--D/4010--D Cutting Decks Page 8 -- 12 Blade Spindle Assemblies 1. Center cutting deck 2. RH cutting deck 3. LH cutting deck 4. Drive spindle assembly 5. Driven spindle assembly 6. Grease fitting location Figure 11 FRONT RIGHT 1 2 3 4 5 6 4 4 5 5 6 6 6 6 6

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

Groundsmaster 4000--D/4010--D Cutting Decks Page 8 -- 16 Castor Forks and Wheels 1. Castor arm (center deck shown) 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 wa...

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

Groundsmaster 4010--D Operator Cab Page 9 -- 4 Air Conditioning Compressor Figure 1 FRONT RIGHT 1. Cap screw (2 used) 2. Flat washer (4 used) 3. Lock washer (6 used) 4. Hex nut (2 used) 5. Conduit 6. O--ring (2 used) 7. 90 o fitting 8. O --ring 9. A/C compressor 10. Cap screw (4 used) 11. Cap screw ...

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

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

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

Groundsmaster 4010--D Operator Cab Page 9 -- 12 Windshield Wiper 1. Wiper motor 2. Gasket 3. Linkage bracket 4. Lock washer 5. Cap screw 6. Cap (2 used) 7. Washer 8. Nut 9. Flange nut (2 used) 10. Cover (2 used) 11. Wiper arm assembly 12. Wiper blade 13. Screw (2 used) Figure 10 2 3 6 8 9 10 11 13 1...

Groundsmaster 4000--D/4010--D Foldout Drawings Page 10 -- 1 Chapter 10 Foldout Drawings Table of Contents ELECTRICAL DRAWING DESIGNATIONS 2 . . . . . . . HYDRAULIC SCHEMATIC 3 . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SCHEMATICS Models 30605 and 30603 4 . . . . . . . . . . . . . . . . . ....

Groundsmaster 4000--D/4010--D Foldout Drawings Page 10 -- 2 Electrical Drawing Designations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. ABBREVIATION COLOR BK BLACK BR or BN BROWN BU BLUE GN GREEN GY GRAY OR ORAN...

Page 10 -- 4 Models 30605 and 30603 Groundsmaster 4000--D/4010--D All relays and solenoids are shown as de-- energized.All ground wires are black. Electrical Schematic 1 2 3 4 5 CAB, A REFERENCE NUMBER WILL BE LISTED. THE CAB SCHEMATIC WILL ALSO INCLUDE THE REFERENCE NUMBER. NOTE: WHEN A WIRE FROM T...

Page 10 -- 6 TO GROUNDBLOCK PLATFORM WIRE HARNESS FROM OPERATOR PLATFORM WIRE HARNESS TO OPERATOR Operator Cab (shown with lights for US model) Groundsmaster 4010--D All relays and solenoids are shown as de-- energized.All ground wires are black. Electrical Schematic 1 2 3 4 TO CAB WIRE HARNESS SCHE...

Page 10 -- 7 Electrical Schematic Groundsmaster 4010--D All relays and solenoids are shown as de-- energized.All ground wires are black. International Light Kits 2 3 4 5 PLATFORM WIRE HARNESS FROM OPERATOR PLATFORM WIRE HARNESS TO OPERATOR TO CAB WIRE HARNESS PLATFORM WIRE HARNESS TO OPERATOR SCHEMA...

Page 10 -- 9 Groundsmaster 4000--D/4010--D Platform Wire Harness Drawing A B C D 12345

Page 10 -- 10 Groundsmaster 4000--D/4010--D Platform Wire Harness Diagram Sheet 1 of 2 REFERENCE NUMBER WILL BE IDENTIFIED. NOTE: THE PLATFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, A DRAWING DESIGNATIONS IN THIS CHAPTER NOTE: THIS DRAWING IDENT...

Page 10 -- 12 Groundsmaster 4000--D/4010--D Rear Wire Harness Drawing

Page 10 -- 13 Groundsmaster 4000--D/4010--D Rear Wire Harness Diagram DRAWING DESIGNATIONS IN THIS CHAPTER NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIONAL INFORMATION.

Page 10 -- 14 Groundsmaster 4000--D/4010--DModels 30609 and 30607 Engine Wire Harness Drawing

Page 10 -- 15 Models 30609 and 30607 Engine Wire Harness Diagram DRAWING DESIGNATIONS IN THIS CHAPTER NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIONAL INFORMATION. Groundsmaster 4000--D/4010--D

Page 10 -- 18 Groundsmaster 4010--D Operator Cab Wire Harness Drawing

Page 10 -- 19 Groundsmaster 4010--D Operator Cab Wire Harness Diagram DRAWING DESIGNATIONS IN THIS CHAPTER NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIONAL INFORMATION.

Page 10 -- 20 Groundsmaster 4010--D Operator Cab Interconnect Wire Harness DRAWING DESIGNATIONS IN THIS CHAPTER NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIONAL INFORMATION.