Toro 4014-D - 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...

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). C. 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 -- 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 CONVER...

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 Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 U...

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

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

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

Groundsmaster 4000--D/4010--D Page 3 -- 4 Kubota Diesel Engine Service and Repairs Air Filter System Figure 1 1. Air cleaner hose 2. Hose clamp 3. Air cleaner assembly 4. Indicator 5. Air cleaner strap 6. Lock nut (2 used) 7. Hose clamp 8. Air cleaner hose 9. Hose clamp 10. Cap screw (2 used) 11. Fl...

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

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

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

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

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

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

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

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

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 3 General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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. 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...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 116 Steering Cylinder Service 1. Tube assembly 2. Rod 3. Piston assembly 4. Head 5. Retaining ring 6. Backup ring 7. O--ring 8. Cap seal 9. Rod seal 10. O--ring 11. O--ring 12. Wiper Figure 88 45 to 55 ft--lb (62 to 74 N--m) 1 6 7 3 9 10 4 11 ...

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 118 Engine Cooling Fan Motor 1. Hydraulic fan motor 2. O--ring 3. Bracket 4. 45 o hydraulic fitting 5. O--ring 6. Hydraulic hose 7. Fan hub 8. Washer 9. Hex nut 10. Engine 11. Cap screw (4 used) 12. Washer (4 used) 13. Fan 14. Lock nut (2 used...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Groundsmaster 4000--D/4010--D Hydraulic System Page 4 -- 148 Lift Cylinder Service 1. Barrel with clevis 2. Retaining ring 3. Shaft with clevis 4. Dust seal 5. Rod seal 6. O--ring 7. Back--up ring 8. Head 9. O--ring 10. Wear ring 11. Piston 12. Lock nut 13. Grease fitting 14. Bushing 15. O--ring 16....

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 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 -- 5 Electrical System Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally. Figure 7 Electrical System

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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 Service and Repairs Brake Assembly 1. Planetary assembly 2. Retaining ring 3. Splined brake shaft 4. Brake assembly (RH) 5. O--ring 6. Hydraulic wheel motor 7. Flat washer (2 used per side) 8. Cap screw (2 used per side) 9. Flan...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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 1. Hex nut 2. Flat washer 3. Steering wheel 4. Foam collar 5. Steering seal 6. External snap ring (2 used) 7. Knob 8. Steering tower cover 9. Steering shaft 10. Compression spring 11. Cap 12. Rod assembly 13. Extens...

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

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

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

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

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

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

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

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

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

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

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. Front Cutting Deck 1. Flange bushing 2. Ball joint 3. Lock nut (2 per m...

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

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 Spindles 1. Front cutting deck 2. RH cutting deck 3. LH cutting deck 4. Drive spindle 5. Driven spindle 6. Grease fitting location Figure 11 FRONT RIGHT 1 2 3 4 5 6 4 4 5 5 6 6 6 6 6

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 (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...

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 (3 used) 2. Lock washer (8 used) 3. Pulley 4. V--belt 5. Lower radiator hose 6. Hose clamp (2 used) 7. Lower radiator hose 8. Cap screw (3 used) 9. Alternator plate 10. Carriage screw 11. Fla...

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

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

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

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

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

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

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

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

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

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