Home

caution

1. IARTER NEUTRAL SWITCH FUEL PUMP FUEL PUMP B G START P1 P2 J1 J2 J3 17 1 1 2 FUSIBLE _ rl xxx 2 LINK 9 5 5 aaa SP6 a mm m 88 c cc 2 RED BLACK 5 RED SP1 A 5 a RED BLACK RED BLACK J B WHITE PINK B C BLACK ORANGE BLUE p WHITE c GRAY F YELLOW BLACK 6 H 1 YELLOW WHITE 2 YELLOW 4 BROWN BLUE WHITE 0 ORANGE VIOLET BLACK YELLOW BLACK H 5 x lt 5 o m a X BLACK RED BLACK 1 9 2 YELLOW 3 5 5 1 2 z YELLOW lt EE 5 2 BROWN 5 m E o gt 9 s u SP3 ORANGE VIO BLK VIO BLK YEL BLk YEL BLK 4 lt 8 E 5 Wot BLACK BL
2. Mu 1 CRUISE CONTROL COIL 2 1 TS al fae 5 INTERCONNEC FRONT DECK biis po POSITION SW D m T H ili i H 1 c Cc WARNING LIGHT OVERTEMP CLUSTER GLOW P8 2803 2A L L14 1B INTERCONNECT P1 P11 p DIODE E H i H 10 FRONT DECK COIL J1 TEMP GAUGE LIGHT Wo P3 TEMP GAUGE Groundsmaster 4000 D Front Wire Harness Serial Numbers below 220999999 Page 9 16 IGN GROUND SENDER PTO RELAY DIODE PACK CAPACITOR SHUTDOWN POS INTERCONNECT FRONT PTO CONNECTOR CRUISE SW CRUISE RELAY OIL ALT L OT GLOW LH RH INTERCONNECT
3. RUN SOLENOID R HOLD 5 R BK s D s EMP FU PULL A BK GY GY TEMP SENDER ES w ENGINE PRESSURE BK pp e BU ENGINE OVER TEMP 110C E 55 5 EE GN FUEL PUMP BU PMN 40 gt tc GLOW PLUGS 4 amp 9 gt 5 5 874 5 lt Y 530 ALARM m BZ 0 i ainme E 8 ALARM RELAY GN __ w Y PK 8 S T epa Loose Y Y T ooo SILENCE ALARM SWITCH SERVICE BRAKE SERVICE BRAKE SWITCH OPT SWITCH OPT FRAME GROUND BATTERY LEFT SIDE RIGHT SIDE I 9 BN GY OFF NONE ON 283 ENGAGE 283 586 AE 22 30 o 874 Ww 87 2 8 prr T sg CRUISE COIL CRUISE SWITCH OPT a Wi CRUISE RELAY OPT 250156 07 O DUAL E je 55 078 frm is GN BK ENGINE SHUTDOWN DELAY 82 ae STOP jira PARKING BRAKE PH E DECK 05 START B l S x NEUTRALSWITCH x Y SWR BK FOSITION 1 BK NEUTRAL E DIEA E M TR Fm Je gt A A
4. B R li M p p mR RUN SOLENOID fs T a a R HOLD ti 09 R BK 15 d PULL w 42 BK 6 GY GY TEMP SENDER GN i ENGINE OIL PRESSURE 5 5 ENGINE OVER TEMP 110C tr b 2 FUEL PUMP am BU p 1 A gt 5 GLOW PLUGS 4 R BK 8 t 2 0 1 is 5 E 87 Y CA ALARM B E 1 1 1 2 0 EZ d BITTER quo ALARM RELAY GN a PK E Ww 1 Y FUSIBLE LINK 1 9 PK 6 Lose Y Y Y T s R n SILENCE ALARM SWITCH SERVICE BRAKE SERVICE BRAKE i SWITCH OPT SWITCH OPT FRAME GROUND BATTERY LEFT SIDE RIGHT SIDE gt BN GY OFF NONE ON 283 ENGAGE 283 586 X D8 22 p ENGINE SHUTDOWN w eB g z f L B v7 i f ABT CRUISE COIL OPT Tees CRUISE SWITCH CRUISE RELAY OPT D1 C 57
5. B R L eee ee ee RUN SOLENOID 5 Wt 1 a R HOLD Va 5 R BK 55 1 1 n P PULL 1 BK 4 0 GY GY TEMP I GN a ENGINE OIL PRESSURE w BK 9 9 D ENGINE OVER TEMP u CUELSENBER 110 gt E 5 bees 5 GN FUEL PUMP 5 w I BU pma R BK i 9 lt GLOW PLUGS 4 d rz wl gt o 2 874 oa BU 8 8 Y 30 6 ALARM 1 12 i 87178 1 lon DUO o tE koe at GN PK E g w 5 Y FUSIBLE LINK 1 PK EO 8 a o 6 29 8 Lose D Y Y z R l H SILENCE ALARM SWITCH SERVICE BRAKE SERVICE BRAKE i SWITCH OPT SWITCH OPT FRAME GROUND BATTERY x LEFT SIDE RIGHT SIDE BN GY OFF NONE ON 283 ENGAGE 283 5 amp 6 ES D8 2 PES ENGINE SHUTDOWN w i y 7 mM en ee xm CRUISE COIL a oW GY CRUISE SWITCH OPT RUISE RELAY OPT 1201 6 D7 E cos ki Y K C BK bi 8 8
6. POSI TRAC TEMP GUAGE SOLENOID TEMP GAUGE LIGHT Pid P3 JI A B 02 3 x 3 m BROWN 2 a YELLOW A PINK 8 SPI C GRAY 0 F x 2 6 a H BLACK PINK 2 amp x 9 GREEN BLACK 3 a x z z a E a A GRAY B TAN GREEN D WHITE E BLUE ORANGE 6 VIOLET BLACK H BLACK SP2 TAN SP4 ORANGE ORANGE lt SP3 x 5 x Q gt 815 m o an lt a o 3 5 8 5 m 2 a a 2 5 gt am gt gt T tt W 9 A B A B CD B A B PI3 PIS PII PIO PARKING BRAKE DECK HARNESS FRONT DECK DIODE 5 FRONT DECK POSITION SW PTO COIL P4 P5 P1 P8 P9 SERVICE BRAKE LEFT SIDE SERVICE BRAKE RIGHT SIDE DIODE 8 WARNING LIGHT CLUSTER WARNING LIGHT CLUSTER CRUISE CONTROL COIL DIODE 7 Groundsmaster 4000 D Front Wire Harness Serial Numbers above 230000000 Page 9 17 5 SERVICE BRAKE RH 6 DIODE B J2 CRUISE CONTROL COIL 0100 7 SERVICE BRAKE LH 12 FRONT DECK POSITION SW 13 PARKING BRAKE 7 10 FRONT DECK PTO COIL Sp2 8 WARNING LIGHT CLUSTER FE H P1 INTERCONNECT WARNING LIGHT CLUSTER
7. 32 2 SEAT SW P1 OPT 2 ALLE INTERCONNECT TO FRONT P2 INTERCONNECT TO FRON P17 ENGINE 1 a D SHUTDOWN RELAY grs 3 4WD SW PTO RELAY P21 2 DIODE PACK P16 P34 2 P14 16 HOUR METER POSI TRAC 36 GAUGE lt Enron GER SILENCE ALARM RELAY INTERCONNECT POWER POINT TO ENGINE ro 9 5 SP4 GM4000 SP8 m SP3 SP6 2 P3 3 INTERCONNECT p TO ENGINE PM N CONTROLLER CRUISE Sw p 5 1 d OYE OVERTEMP P15 a P28 P26 E SHUTDOWN FUEL GAUGE 23 CRUISE RELAY START RELAY Seay SILENCE ALARM PL 3 mm SW INTERCONNECT spp E ENGINE IMPLEMENTS 2 Bum LCN S 12 CRUISE RELAY TIONAL 219 5 0006 Hd 771 HIGH TEMP lt gt MEI OVER RIDE ng P6 IGNITION SW o J eodd 3 LIGHT KIT P7 P8 FUSE BLOC 298 AUDIO ALARM S B CAPACITOR 2 Ji CAPACITOR 2 h Groundsmaster 4000 D APACITOR 1 2 CAPACITOR 1 Wire Harness Serial Numbers above 230000000 9 12 ENGINE GROUND 13 HOLD ENGINE RUN SOLENOID 16 Puu ALTERNATOR GLOW PLUGS GLOW RELAY P15 J12 J11 P14 GND 87 85 86
8. P2 INTERCONNECT n TEMP GAUGE LIGHT 52 3 2 TEMP GAUGE 15 DECK HARNESS Groundsmaster 4000 D POSI TRAC SOLENOID Front Wire Harness Serial Numbers above 230000000 Page 9 18
9. E 8 3 NEUTRAL SW ITCH ABCD GLOW PLUG LG GFE INTERCONNECT GROUND P3 PL m START An STARTER i 1 ENGINE OIL PRESSURE 1 J E U P2 P15 TEMPERATURE SENDER _ _ 19 x SP6 n E H P10 RH DECK POSITION SWITCH m cule em DC GLOW RELAY e 85 P8 RH DECK PTO COIL DIODE 4 P9 Groundsmaster 4000 D Engine Wire Harness Page 9 14 CONNECTOR P2 INTERCONNECT 1 ign ground t sender pto relay diode pack capacitor shutdown cruise sw cruise relay oil alt L OT glow TEMP GAUGE TEMP GAUGE POSITION SWITCH
10. 1 lam N M ls 7 Y 4 o 203 WdOSt 9 E A 1 1 ld an zo zv en 50 l 1 ao 590 HO Ww 8 if ea 3 OHIS 059 4 3908 052 N UN ms 1 16 2 2525 o 8 3 HOLON o3d 14083 v 1 11 Rind IN Ord 1 d 2 3ATVAOH1NOO 4 5868 00 1 740 ONINSALS Groundsmaster 4000 D Page 4 8 Hydraulic System Rev B Traction Circuit The traction circuit piston pump is a variable displace ment pump that is directly coupled to the engine fly wheel Pushing the top of the traction pedal engages a hydraulic servo valve which controls the variable dis placement piston pump swash plate to create a flow of oil This oil is directed to the front wheel and rear axle motors Operating pressure on the high pressure side of the closed traction circuit loop is determined by the amount of load developed at the fixed displacement wheel and axle motors As the load increases circuit pressure can increase to relief valve settings 4000 PSI in forward and 5000 PSI in reverse If pressure exceeds the relief setting oil flows through the relief valve to the low pressur
11. Groundsmaster 4000 D Front Wire Harness P3 LIGHT ies J1 2 lt x m x 2 2 a a GRAY SERVICE BRAKE P4 EFT SIDE SP1 9 B BLACK G GRAY SERVICE BRAKE D ORANGE P5 RIGHT SIDE E GREEN BLACK I F BLUE 3 G TAN u H 1 P6 DIODE 8 2 1 oil press GREEN 1B PINK P7 WARNING LIGHT CLUSTER GRAY WHITE 2B B TAN GREEN a D WHITE 1A BLUE overtemp E BLUE 1B P8 wARNING LIGHT CLUSTER F ORANGE 2A glow ORANGE gt 2B x TAN 9 J2 CRUISE CONTROL COIL a BLACK E BLACK 1 P DIODE 7 SP2 TAN 53 es ji a a gt 5 E T a 5 x SP3 z d 9 1 lt 54 x x a a a tc a 2 13 gnd nc 11 10 12 DIODE 5 FRONT DECK PARKING BRAKE PTO COIL FRONT DECK Serial Numbers below 220999999 9 15 SERVICE BRAKE RIGHT SIDE P5 i SERVICE BRAKE LEFT SIDE CRUISE P4 DIODE 8 6 TE Ss L 75 CRUISE COIL DIODE 7 P9 PARKING BRAKE P13 S d
12. ss o E Chapter 6 Axles Planetaries and Brakes og Specifications Adjustments s Service and Repairs gu 2 E Service and Repairs Chapter 8 Cutting Units Sg 5 o gt gt Specifications Troubleshooting Adjustments Service and Repairs Chapter 9 Electrical Diagrams 5 Electrical Schematic 50 gt Circuit Diagrams Wire Harness Drawings o 5 e Sm FE x lt in 5 2 25 oD 25 6 Rev HA This is intentionally blank Groundsmaster 4000 D Chapter 1 TORO Safety Table of Contents GENERAL SAFETY INSTRUCTIONS CREE aks 2 JACKING INSTRUCTIONS 4 Before Operating 2 SAFETY AND INSTRUCTION DECALS 5 While Operating 2 Maintenance and Service 3 Groundsmaster 4000 D Page 1 1 Safety General Safety Instructions The GROUNDSMASTER 4000 D was tested and certi fied by TORO for compliance with the B71 4 1999 speci fications of the American National Standards Institute Although hazard con
13. gt on ue m ppm me cim m o 4 p LEFT DECK 85 L 54 a edd 2 1 i 586 LEFT DECK i lt 4 2 a 02 x POSITION D1 B 300 IRI 2 87 gt SEAT SWITCH PTO SHUTDOWN DELAY ITE 872 2 4 BU 1 Bo 0a 2 ue SEAT RELAY 5o 6 o B7 Y BK w 5 PK 30 m i RIGHT DECK 6900 R 0 TRANSPORT 4 WD SWITCH D 87 EM PTO Y SHOWN IN 4WD 1 PTO S eH i 5 86 PONT DEOK 1 1 pM es 3 1 PTO RELAY J gt D 10 5 Y BK p D Groundsmaster 4000 D BK 1 T CONTROLLER Glow Plug Circuit 7 W KUBOTA 1 START 1 4 THERMO Power Current OR F8 po pe GLOW _ ge i Control Current 0 12 GND sie i Indication Current OPTIONAL 04 Directi FUSEBLOCK on Logic Direction Serial Numbers below 220999999 shown Page9 5 ALTERNATOR B R L
14. Arrow on side of D motor case points up 2m 8 R S 2 5 wy 7 SS UES RIGHT 3 4 A N Q D Po 2 75 to 85 ft Ib FRONT 101 to 115 N m Figure 61 1 Front wheel motor 9 Flange head screw 16 O ring 2 Internal retaining ring 10 90 hydraulic fitting 17 Hydraulic fitting 3 Splined brake shaft 11 90 hydraulic fitting 18 O ring 4 RH brake assembly 12 O ring 19 O ring 5 Planetary assembly 13 O ring 20 LH brake assembly 6 Cap screw 14 Hydraulic fitting 21 Flange head screw 7 Flat washer 15 O ring 22 Hex plug 8 O ring Hydraulic System Rev B Page 4 80 Groundsmaster 4000 D Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter NOTE To ease reassembly tag the hydraulic hoses to show their correct position on the wheel motor 3 Disconnect hydraulic hoses and tubes from wheel motor Put caps or plugs on ports to prevent contamina tion IMPORTANT Before loosening fasteners support wheel motor to prevent motor from falling during re moval 4 Remove wheel motor using Figure 61 as a guide Groundsmaster 4000 D Page 4 81 Installation 1 Position wheel motor to brake assembly making su
15. E i 5 Lol cb on g bb ALARM RELAY FL PK 2 GN FL Cau Y Ww uf MEL FUSIBLE LINK n F A 5 7 7 8 eo 6 5 sey 2 3 ENGINE ENGINE GROUND BK Y Y 2 a pL B U SILENCE ALARM L FRAME GROUND BATTERY y BN 0 GY SERVICE BRAKE OFF NONE SWITCH SWITCH BK ON 283 LEFT SIDE RIGHT SIDE ENGAGE 283 5 amp 6 08 2 w 288 ar ENGINE SHUTDOWN rm x4 RELAY 6 22 CRUISE COIL TEEI oe aT 07 i 87 CRUISE RELAY 01 6 K E deo i 85 86 74 e 8 li T E desse oim d YY 6 0 GN BK frr PARKING BRAKE FRONT DECK ENGAGED ENGINE SHUTDOWN DELAY 4 Guo mm a po 10A Modo UE eo SERIE URS Y 6500 OR CENTER DECK DiD MFD BK POSITION 255 5 E BK 4 NEUTRAL SWITCH D1 A i 25 10AF 2 IN NEUTRAL VIO BK PK OR PK P mm 1 3 PTO OFF NONE LEFT DECK aS GN B6 2 WD ON 182 Plies PTO pa 2 gt t vi 182 LEFT DI Y IGNITION SWITCH i egr T 22 E ener POSITION SEAT SWITCH 1o i gt gt s EAFA Ol a afia UY 2 2 s 24 AAA e HC SEAT RELAY 6 ii 6500 4277 95 30
16. Figure 8 1 Frame assembly 8 Rear axle assembly 14 Lock nut 2 Cap screw 9 Thrust washer thin 15 Flange nut 3 Lock washer 10 Washer head screw 16 Rear bumper 4 Flat washer 11 Pivot pin 17 Hydraulic manifold 4WD 5 Support frame 12 Rear frame mount 18 Cap screw 6 Thrust washer thick 13 Washer 19 Flange nut 7 Grease fitting Remove Rear Axle 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch When changing attachments tires or perform ing other service use correct blocks hoists and jacks Make sure machine is parked on a solid level surface such as a concrete floor Prior to raising machine remove any attach ments that may interfere with the safe and proper raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the ma chine is not properly supported by blocks or jack stands the machine may move or fall which may result in personal injury Axles Planetaries and Brakes Rev B Page 6 12 2 Chock front wheels and jack up rear of machine see Jacking Instructions in Chapter 1 Safety Support ma chine with jack stands or solid wood blocks 3 Drain oil from rear axle and axle gearbox see Oper ator s Manual 4 Remove wheels from rear axle 5 Remove hydraulic motor from rear axle assembly see Rear Axle Motor in Servi
17. 8 8 Cutting Units Removal 1 Position machine on a clean level surface Lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove hydraulic motor from cutting deck see Cut ting Deck Motor Removal in the Service and Repairs Section of Chapter 4 Hydraulic Systems IMPORTANT Do not change the length of the damper link The length of the damper link should be 5 370 075 13 6 cm 2 cm measured between rod end cen ters 3 Remove hairpin and clevis pin that secure the damp er link to the rear of the cutting deck Fig 7 4 Remove eight flange head screws flat washers and lock nuts that secure deck mount to cutting deck Fig 6 5 Raise lift arm enough to separate deck mount from cutting deck 6 Slide the cutting deck away from the traction unit Installation 1 Position machine on a clean level surface Stop engine engage parking brake and remove key from the ignition switch 2 Position the side cutting deck to the lift arm 3 Lower lift arm while aligning deck mount to cutting deck 4 Install deck mount to cutting deck with eight flange head screws flat washers and lock nuts Fig 6 Tight en fasteners IMPORTANT Do not change the length of the damper link The length of the damper link should be 5 370 075 13 6 cm 2 cm measured between rod end cen ters 5 Install clevis pin and hairpin that secure
18. ei f 99 5 A ANO S AL OHO 2022 X m LN 590 HHO _ T vL HA HO ak T vl Q OdSNYHL 4 4 d IAS ISd ONAN HG lt 05 lt xosa AEE DIOEN nase ox 8 4 4 6 isa 4 009 0008 5 zo SS ev 7 5 dou 052 12989 NINO F9 SOULS 00 ad 027 ei eae 00 Slol l L10H1NOO ao i m _ E wot Ww E T L3 I m 1 4 H 15 059 3908 052 x Un eng i 1 ONIM H1 M x HOLLOW ZX lt B INOW 204 v A o 4 Elit X BO 16 Liga 009 M T o i L 70006 uai jq dou 29 Id IAOHLS 02 3808 002 YaMOV LAT 740 9NIH331S 9 Groundsmaster 4000 D Page4 6 Hydraulic System Rev B wia sAS 2 UMOUS 5 000000052 enas 5 000 Je1seuuspunoautc 1 230
19. 100 Lift Cylinder Service 102 Steering 104 Steering Cylinder Service 106 Hydraulic Reservoir 108 Hydraulic Oil Cooler 110 Hydraulic System Rev B 9 Ey Specifications Item Description Piston Traction Pump System Relief Pressure Forward System Relief Pressure Reverse Charge Pressure Variable displacement piston pump 4000 PSI 274 bar 5000 PSI 343 bar 250 PSI 17 bar Gear Pump Steering Relief Pressure Lift Lower Relief Pressure 3 section positive displacement gear type pump 1350 PSI 93 bar 1500 PSI 103 bar Front Wheel Motors Fixed displacement piston motors Rear Axle Motor Fixed displacement piston motor Cutting Deck Motors Relief Pressure front and left side Relief Pressure right side Gear motor 3000 PSI 207 bar 2000 PSI 137 bar Hydraulic Filters In line Suction Strainer 10 Micron spin on cartridge type 100 mesh in reservoir Hydraulic Reservoir 8 gal 30 3 Hydraulic Oil See Operator s Manual Hydraulic System Rev B Page 4 2 Groundsmaster 4000 D General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather sun chemicals very warm stora
20. 51 Gear PUMP wee 52 Gear Pump Service 54 Piston Traction 58 Piston Traction Pump Service 60 Piston Pump Control Assembly 64 Hydraulic Control Manifold 4 Wheel Drive 66 Hydraulic Control Manifold Service 4 Wheel Drive 68 Hydraulic Control Manifold Deck Drive 70 Hydraulic Control Manifold Service Deck Drive 71 Hydraulic Control Manifold Cutting Deck GLOWE mme DER aoe 72 Hydraulic Control Manifold Service Cutting Deck Lift Lower 73 Hydraulic Control Manifold Filter Manifold 74 Hydraulic Control Manifold Service Filter Manifold 75 Hydraulic Control Manifold Flow Divider 76 Hydraulic Control Manifold Service Flow Divider 77 Rear Axle Motor 78 Front Wheel Motors 80 Rear Axle Front Wheel Motor Service 82 Cutting Deck Motor 85 Cutting Deck Motor Service 86 Lift Lower Control Valve 90 Lift Lower Control Valve Service 92 Steering Valve 94 Steering Valve Service 96 Side Deck Lift 98 Front Deck Lift Cylinder
21. wx ne 21 Brake Inspection and 6 Input Shaft Pinion Gear 22 Planetary Wheel Drive Assembly 8 Differential Gear 24 Planetary Wheel Drive Service 10 Pinion Gear to Ring Gear Engagement 27 and Brakes a 5 S oa a E x lt Groundsmaster 4000 D Page 6 1 Axles Planetaries and Brakes Rev Specifications Item Specification Wheel lug nut torque 85 to 100 ft lb 115 to 135 front and rear Steering cylinder bolt torque 100 to 125 ft lb 139 to 169 Rear wheel 125 in 3 18 mm Tire pressure 25 to 30 psi 1 7 to 2 1 bar front and rear Planetary brake housing and wheel motor mounting screw torque 75 to 85 ft lb 101 to 115 N m Planetary gear drive oil System gear lube capacity each wheel SAE 85W 140 wt gear lube 16 fl oz 47 Rear axle lubricant System gear lube capacity SAE 85W 140 wt gear lube 80 fl oz 2 37 Rear axle gear box lubricant System gear lube capacity SAE 85W 140 wt gear lube 16 fl oz 47 Axles Planetaries and Brakes Rev B Page 6 2 Groundsmaster 4000 D Adjustments See Operator s Manual for adjustment procedures for Groundsmaster 4000 D axles planetaries and brakes and Brakes a 5 S a a
22. ELIET 25 T ON c s Groundsmaster 4000 D Page 4 78 Hydraulic System Rev B Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter NOTE To ease reassembly tag the hydraulic hoses to show their correct position on the axle motor 3 Disconnect hydraulic hoses from motor Put caps or plugs on ports to prevent contamination IMPORTANT Support axle motor to prevent motor from falling during removal 4 Remove motor using Figure 60 as a guide Groundsmaster 4000 D Page 4 79 Installation 1 If removed install pinion gear to axle motor 2 Install o ring onto motor Position motor to rear axle assembly making sure that arrows on the side of motor case point upward Align gear teeth and slide motor into place 3 Secure motor to axle with cap screws and flat wash ers Torque screws from 59 to 73 ft lb 80 to 99 N m 4 Remove plugs from ports Attach hydraulic hoses to axle motor 5 Fillreservoir with hydraulic fluid as required see Op erator s Manual 6 After assembly is completed verify that hydraulic hoses and fittings do not contact anything Hydraulic System Rev B 9 Oo Ey Front Wheel Motors
23. or a pressure of 2000 PSI cannot be obtained check for restriction in the pump intake line If line is not restricted remove gear pump and repair or replace as necessary Figure 21 3 Side deck manifold 4 Hyd hose to side P1 1 Front deck manifold 2 Hyd hose to front P1 Hydraulic System Rev B i 5 S 5 gt TEST 5 Cutting Deck Manifold Relief Pressure Front Deck Shown Using Tester with Pressure Gauges and Flow Meter J RACTION CIRCUIT TO LIFT LOWER CIRCUIT m TO STEERING CIRCUIT m RESERVOIR Working Pressure Low Pressure Return or Suction Groundsmaster 4000 D 4 32 Hydraulic System Rev Procedure for Cutting Deck Manifold Relief Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section 3 Locate deck manifold to be tested Fig 22 Discon nect hydraulic hose at deck manifold port MP NOTE An alter
24. 1 S om RIBK gt lt J T E GLOW PLUGS 4 1 1 on R BK a 1 8 9 95 23 9 1 Y 130 12 671 ALARM 5 LE 1 1 20 1 2 8 1 1 E APE 1 ALARM RELAY GN D 1 w Y PK D D PONES DA D 1 D D 3 T Y Y SILENCE ALARM SWITCH SERVICE BRAKE SERVICE BRAKE 1 SWITCH OPT SWITCH OPT 1 FRAME GROUND BATTERY LEFT SIDE RIGHT SIDE gN GY gt SS OFF NONE 1 283 ENGAGE 283 586 x aie gg 2 12 TM ENGINE SHUTDOWN 1 w 87 t T RELAY NN Y CRUISE COIL OPT 5 ao NE So ow E CRUISE SWITCH a 87 1 D1 C t A CRUISE RELAY OPT x x D7 bid gi em Peart g c T ENGINE SHUTDOWN DELAY Y 87 xw ae BU Peai 85 86 PARKING BRAKE 6500 FRONT DECK 05 START R Y SWITCH 1 MFD Bk SR Position TEM BK NEUTRALSWITCH ENGAGED 2 874 o IN NEUTRAL x 1 87
25. a v lt 2 XR 71 BK Iu FRONT DECK ENGINE SHUTDOWN DELAY Y STOP NONE 10A F4 18 RUN XeY 8 yO o Bae PARKING BRAKE 6500 FRONT DECK ps NEUTRALSWITCH SWITCH MFD BK DECK DOWN zs lt NOT IN NEUTRAL DISENGAGED DICA Y DECK DOWN BK 10A F2 4 8888 2 WD ON 283 ts 5 1 ENGAGE 283 586 lt IGNITION SWITCH gt 7 s 72 POSITION PTO SHUTDOWN DELAY pr gt PECK DOWN BU Woche gt y SEAT RELAY OPE i 878 a SEAT OCCUPIED 6500 TRANSPORT 4 WD SWITCH 05 p MFD SHOWN IN 4WD PTO SWITCH RIGHT DECK gt POSITION A PTO RELAY DECK DOWN y 10AF 5 3 Groundsmaster 4000 D F6 BK T gt CONTROLLER POWER POINT Y Run Mow Circuit F7 KUBOTA GLOW RELAY T B W ower Current START 4 THERMO __ 30 a 87 C ontrol Current LAMP 2 15 GLOW BN 86 85 y 12 3 e GND Indication Current Y BK BK lt KADANS OPTIONAL Logic Direction FUSEBLOGK Serial Numbers below 220999999 shown 9 8 SILENCE ALARM FUEL GAUGE HOUR METER PTO SWITCH PTO RELAY HIGH TEMP O
26. RIGHT DECK 6800 TRANSPORT 4 WD 8L fYYYA PTO 10A SHUTDOWN OR PTO SWITCH A RIGHTDECK Y Y essay POSITION 6 PTO RELAY R Bin bat Rage F5 3 Am d SN BK 27 av w FLOW DIVIDER FLOW DIVIDER mcs NTROLLER P Groundsmaster 4000 D POWER POINT pa p LOW PLUG E7 w KUBOTA Electrical Schematic f START THERMO 30 vio jae Serial Numbers above 230000000 F8 LAMP 5 GLOW samm 85 BN Y relays and solenoids 12V a 6 GND GLOW RELAY i OPTIONAL Y BK BK are shown as de energized FUSEBLOCK n All ground wires are black 9 4 ALTERNATOR B R L PK RUN SOLENOID R HOLD R BK w wi S S FU PULL Ww BK BK GY GY TEMP SENDER B GN w ENGINE OIL PRESSURE BK i cus B d a BU 1 FUEL SENDER 110C i En 5 55 1 D amp E s lt 44 x E FUEL PUMP
27. DECK DRIVE Closed loop hydraulic system operates hydraulic motor on each cutting deck Motor drives one spindle directly with remaining deck spindle s driven by B section kevlar v belt s Blade spindles are 1 1 4 8 17 cm shafts supported by greaseable tapered roll er bearings CUTTING BLADE Cutting blade dimensions are 21 75 55 2 cm long 2 5 6 4 cm wide and 25 64 cm thick Anti scalp cup installed on each cutting blade Three blades on front deck and two blades on each side deck Cutting Units Page 8 2 WIDTH OF CUT Front deck provides 62 157 5 cm width of cut Each side deck has 42 106 7 cm width of cut Total width of cut is 132 335 3 cm with 7 12 8 cm overlap DISCHARGE Clippings are discharged from the rear of the cutting decks Provided mounting holes allow at tachment of optional Guardian Recycler Kit SUSPENSION SYSTEM A fully floating suspension with hydraulic counterbalance Front deck suspended at rear from lift arms and has two castor wheels two ad justable skids and two anti scalp rollers Each side deck supported by three castor wheels and a spring damper system which connects the fourth deck corner to the traction unit There is a main lift arm that provides counterbalance to the side decks along with a rear anti rotation link which also provides bi directional impact protection Optional Guardian Recycler Kit includes one anti scalp roller on each cutting deck Groun
28. ENGINE ENGINE GROUND BK Y Y R 8 GROUND SILENCE ALARM SWITCH SERVICE BRAKE SERVICE BRAKE SWITCH OPT SWITCH OPT FRAME GROUND ERTEN LEFT SIDE RIGHT SIDE BN GY Y OFF NONE ON 283 BK ENGAGE 283 586 A D p PEEL i ENGINE SHUTDOWN 5 w 87 T RELAY un Mad zu CRUISE COIL gi Ae y CRUISESWITCH OPT 0 E i CRUISE RELAY OPT D1 C 57 E LE Y 88 IY 86 bie 7 8 ij patri nem 1 Ls 8 E 30 5 8 FK ENGINE SHUTDOWN DELAY gt 87 1 4 mit BRAKE i Es 5 t TART S 95 SWITCH MFD BK 9R POSITION BK DID NEUTRALSWITCH ENGAGED D1 A BK 10A F2 IN NEUTRAL A 87 VIO BK 9 5 OR aN PK ELTE gt LEFT DECK ts m GN B5 LLUU 86 ee Oe PTO us PTO ON 283 EPEK Y IGNITION SWITCH 87 T Beert a N pe P 227 POSITION BER ps 50 gt 87 F1 SEAT SWITCH PTO SHUTDOWN DELAY 87a 2 4 BU 3 o gt eee SSS 87 gt SEAT RELAY o Bo 87a Y BK GN w a 28 829 RIGHT DECK 85 86 6500 TRANSPORT 4 WD SWITCH SWITCH jin T BEN PTO 10A F3 SHOWN 4WD y 4 amme POSITION D6 PTO RELAY R 10AF 5 BK BK 9 gt 6 Groun
29. Temperature Sender The temperature sender is located near the alternator on the water flange attached to the engine cylinder head Fig 31 There is a gray wire attached to the terminal of the switch 1 Lower coolant level in the engine and remove the temperature sender from water flange 2 Put switch in a container of oil with a thermometer and slowly heat the oil Fig 32 caution Handle the hot oil with extreme care to prevent personal injury or fire NOTE Prior to taking resistance readings with a digital multi meter short the meter test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing 3 Check resistance of the sender with a multimeter ohms setting as the temperature increases A The meter should indicate from 54 to 78 ohms at 200 F 93 39C B Replace sender if specification is not met 4 Install sender to the water flange A Clean threads of water flange and sender thor oughly Apply thread sealant to the threads of the sender B Screw sender into the water flange and tighten Reconnect gray wire to sender Apply skin over grease Toro Part No 505 165 to sender terminal 5 Fill engine cooling system see Operator s Manual Figure 31 Temperature sender Electr
30. i PROFILE the gear contact pattern method as described in the fol SORIA lowing procedure GEAR TOOTH DEFINITIONS Fig 39 Toe the portion of the tooth surface at the end to wards the center LENGTHWISE AR Heel the portion of the gear tooth at the outer end Top Land top surface of tooth 1 Paint the teeth of the ring gear both drive and coast side with a gear marking compound such Steel Blue Figure 39 2 Install the input shaft pinion gear assembly into axle case More than 3596 total tooth contact 3 While applying a light load to the ring gear rotate the pinion gear in the direction of forward travel until the ring gear has made one complete revolution Ideal tooth contact observed on the ring gear should cover more than 3596 of each tooth surface The contact area should be in the center of each tooth and extend 1 3 1 3 to 1 2 of entire width to 1 2 way across each tooth from the toe end Fig 40 Adjustments to the gear contact position are made by moving the input shaft pinion gear bearing case shims or by moving the differential gear case differential bear ing shims Fig 41 NOTE Bearing case shims are available in 0 004 in 0 10 mm and 0 008 in 0 20 mm thickness and Brakes NOTE Differential bearing shims are available in 0 004 in 0 10 mm 0 008 in 0 20 mm and 0 016 in 0 40 mm thickness a 5 S a
31. 1 870 0 002 in 47 5 0 05 mm ai NOTE Bearing case shims are available in 0 004 0 1 mm and 0 008 in 0 2 mm thickness 9 Coat new O rings with grease and install the bearing case in the gear case Place shims on the gear case and EL m temporarily install gear case assembly into axle case In Distance Tighten mounting nuts and screws from 35 to 41 ft Ib 47 d SE to 56 N m 10 Insert a screwdriver through the drain plug hole to hold ring gear and measure the pinion gear to ring gear backlash Fig 31 PINION GEAR TO RING GEAR BACKLASH 0 004 to 0 016 in 0 10 to 0 40 mm Figure 30 11 Adjust backlash by increasing or reducing gear case 1 Input shatt pinion gear 2 Bearing case shim thickness 12 Check pinion gear to ring gear engagement see Pin ion Gear to Ring Gear Engagement in this section of this manual and Brakes a 5 S a E x lt 13 Place the correct combination of shims on the gear case Tighten mounting nuts and screws from 35 to 41 ft lb 47 to 56 14 Install retaining rings and driven gear on input shaft pinion gear 15 If the drive gear on drive motor shaft was removed install the retaining rings and drive gear on the motor shaft 16 Use a new gasket and install the cover plate Use a Figure 31 new O ring and install the drive motor i Axla case 3 Dial indicator 2 Screwdriver 4 Input s
32. 20 v 1 009 Eisa 4 S29 Id dN IMYA 1041409 00 TAO ONIH331S Groundsmaster 4000 D Page 4 12 Hydraulic System Rev B Raise Cutting Unit Athree section gear pump is coupled to the piston trac tion pump The gear pump section farthest from the pis ton pump supplies hydraulic flow to the lift lower control valve and the steering control valve Hydraulic flow from this pump section is delivered to the two circuits through a proportional flow divider The gear pump takes its suc tion from the hydraulic reservoir When the cutting units are in a stationary position flow from the gear pump is by passed through the lift lower control valve counterbalance manifold oil filter and traction charge circuit To raise a side cutting unit the appropriate lift lever on the lift lower control valve is pulled to allow valve shift in the lift lower control This valve change allows hydraulic pressure to the piston end of the lift cylinder and causes the shaft to extend raising the cutting unit Oil from the rod end of the cylinder flows to the traction charge cir cuit When the lift lever 15 released the lift cylinder is held in position Groundsmaster 4000 D Page 4 13 To raise the front cutting unit the center lift lever on the lift lower control valve is pulled to allow valve shift in the lift lower control This valve change allo
33. High Pressure Low Pressure Return or Suction gt Flow Hydraulic System Rev B Page 4 24 Groundsmaster 4000 D Procedure for Traction Circuit Charge Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section 3 Connect a 1000 PSI gauge onto charge pressure test port Fig 14 under operator seat 4 Start the engine and put throttle at full engine speed 2730 30 RPM with no load on the hydraulic system GAUGE READING TO BE 200 to 300 PSI 5 lf there is no pressure or pressure is low check for restriction in pump intake line Also inspect charge relief valve located in filter manifold see Hydraulic Manifold Service Filter Manifold in this chapter If necessary check for internal damage or worn parts in gear pump 6 Also with the pressure gauge still connected to the charge pressure test port take a gauge reading while operating the machine in forward and reverse Start the engine and put throttle at full engine speed 2730 30 RPM Apply the brakes and push the traction pedal for wa
34. Installation 1 If the ring gear was removed from the differential case use medium strength Loctite thread locker and tighten the mounting screws from 22 to 25 ft lb 30 to 34 2 Apply molybdenum disulfide lubricant Three Bond 1901 or equivalent to the splines and bearing surfaces of the differential pinion gears pinion washers and side gears 3 Install the side gear shims and side gears in their original location in the differential case 4 Place the differential pinion gears and pinion wash ers in their original location in the differential case Tem porarily install the differential pinion shaft 5 Secure the differential case in a soft jawed vise Posi tion a dial indicator on a tooth of the differential pinion gear Press the pinion and side gear against the differen tial case and measure the pinion gear to side gear back lash Fig 37 PINION GEAR TO SIDE GEAR BACKLASH 0 004 to 0 016 in 0 10 to 0 40 mm 6 Adjust backlash by increasing or reducing side gear shim thickness NOTE Side gear shims are available in 0 043 in 1 10 mm 0 047 in 1 20 mm and 0 051 in 1 30 mm thick ness 7 Apply gear marking compound such as DyKem Steel Blue lightly over several gear teeth 8 While applying a light load to either side gear rotate either pinion gear until the side gears have made one complete revolution 9 Ideal tooth contact should cover more than 35 of each tooth surface The cont
35. 15 Discard the shaft seal 25 gaskets 32 33 34 and o rings from all assemblies Replace with new seals upon reassembly Inspection 1 Inspect backplate assembly A Check the bearing 45 press fit in backplate 20 If needles remain in cage move freely and set ting is at the dimension shown in Figure 43 bearing removal is not required B Check roll pin 38 in backplate 20 If tight and settothe dimension shown in Figure 43 removal not required 173 inch 4 39 mm 090 inch 2 29 mm Figure 43 2 Check the bearing 39 press fit in pump housing 19 If needles remain in cage move freely and setting at the dimension shown in Figure 44 bearing removal is not required Flange end of housing Numbered end 1 78 mm Figure 44 Hydraulic System Rev B 2 Oo 52 3 Inspect camplate assembly A The finish on the piston shoe surfaces ofthe cam plate 11 should show no signs of scoring B Inspect camplate 11 bushing surface for wear Also inspect surface for coating transfer from bush ing 4 Inspect bushing 44 for contamination embedment within coating of bushing surface coming in contact with camplate 11 5 Inspect rotating kit Fig 45 A The pistons should move freely in the rotating kit piston block bore If they are sticky in the bore ex amine the bore for scoring or contamination B Examine the O D of the pistons for finish
36. 500 inch 12 7 mm Left Side Front flange Drive shaft end of pump Adjust to center piston Install servo piston in this direction Figure 46 5 Install new seal washer 4 washer 29 and jam nut 1 to servo piston bolt Holding servo piston bolt with hex key wrench torque jam nut from 150 to 160 17 to 18 N m Check the centering of servo piston assem bly 7 Install new cover plate gasket 33 and cover plate 9 to open side of servo piston and retain with four washers 31 and socket head screws 5 Torque screws from 40 to 48 in Ib 4 5 to 5 4 N m 6 Press dowel bushings 40 into cradle and secure bushing 44 onto cradle with button head cap screw 43 Torque button head cap screw from 14 to 16 in Ib 1 6 to 1 8 N m 7 Place cradle sub assembly 41 into housing 19 making sure dowel bushings 40 and cradle 41 are completely seated into housing Retain cradle sub as sembly with two cap screws 42 after applying Loctite 277 or equivalent to the end of threads Torque cap screws from 25 to 28 ft lb 34 to 38 N m Groundsmaster 4000 D 8 Place exterior retaining ring 3 thrust race 12 thrust bearing 13 second thrust race 12 and second retaining ring 3 onto drive shaft 21 Position washer 24 and shaft seal 25 onto shaft 9 Install shaft assembly into front of housing Seat seal 25 into position with seal driver and retain with interior retaining ring 2 10 Ins
37. 6 7 to 35 ft lb 41 to 47 N m 12 to 15 ft lb 16 to 20 N m Figure 53 1 Manifold body 8 Solenoid valve port SV1 15 O ring 2 Spool logic cartridge port BY1 9 Seal kit 16 Plug SAE 4 3 Seal kit 10 Solenoid coil 17 O ring 4 Spool logic cartridge port BR1 11 Nut 18 Plug SAE 8 5 Seal kit 12 Relief pilot cartridge port R1BR 19 O ring 6 Relief valve port R1BY 13 Seal kit 20 Orifice plug port MR 7 Seal kit 14 Plug SAE 2 NOTE The ports on the manifold are marked for easy identification of components Example SV1 is the deck solenoid valve and P 1 is the gear pump connection port See Hydraulic Schematics to identify the function ofthe hydraulic lines and cartridge valves at each port loca tion The control manifolds for the three cutting decks are very similar Note When servicing the deck control manifolds DO NOT interchange parts from one control manifold to another Groundsmaster 4000 D 4 71 Rev For solenoid and control valve service procedures see Hydraulic Control Manifold Service 4 Wheel Drive in this section Refer to Figure 53 for cartridge valve instal lation torque Hydraulic System Rev B Hydraulic Control Manifold Cutting Deck Lift Lower 12 Cap screw 13 90 hydraulic fitting 14 O ring 15 Test nipple 16 Fitting cap Figure 54 1 Lift lower hydraulic manifold 7 Lock nut 2 Valve plate 8 Hydraulic fitting 3 Flat washer 9
38. Anti seize Lubricant Figure 5 1 Lift arm LH shown 14 Rubber bumper 27 Lock nut 2 Shoulder screw 15 Slotted roll pin 28 Flat washer 3 Lift cylinder pin 16 Lock nut 29 Socket head screw 4 Lift cylinder 17 Flat washer 30 Flat washer 5 Thrust washer 18 Latch LH shown 31 Carriage screw 6 Flange nut 19 Thrust washer 32 Flange bushing 7 Pivot hub 20 Flange head screw 33 Lock nut 8 Lift arm pivot shaft 21 Plastic grip 34 Grease fitting 9 Thrust washer 22 Cam bracket 35 Flange bushing 10 Cap screw 23 Lock washer 36 Flange bushing 11 Spring pin 24 Switch spacer 37 Bushing 12 Cylinder pin 25 Sensing switch 38 Grease fitting 13 Rivet 26 Sensing plate Chassis Page 7 6 Groundsmaster 4000 D Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove side deck from lift arm see Side Cutting Unit in Chapter 8 Cutting Units 3 Remove side deck rear arm assembly from pivot hub see Side Deck Rear Arm Assembly 4 Remove lift cylinder pin that secures lift cylinder to lift arm 5 Drive out roll pin that retains lift arm pivot shaft Dis card roll pin 6 Support lift arm and pull lift arm pivot shaft from lift arm and frame Locate and remove thrust washers dur ing pivot shaft removal A If pivot shaft is difficult to remove fabricate a pull er as shown in Figure 6 Attach puller to
39. IMPORTANT Avoid using excessive clamping pressure on the pump housing to prevent distorting the housing 2 Clamp pump in vise shaft end up and remove the eight cap screws 3 Groundsmaster 4000 D 3 Remove pump from vise hold pump in hands bump shaft against wooden block to separate front pump sections Front body 10 will remain with either front plate 15 or front adapter plate 23 4 Place front idler gear 16 into gear pocket and tap with soft face hammer until the front body separates Remove idler gear from front plate or adapter plate 5 Remove plug 8 from front plate 15 6 Remove front adapter plate 23 from front body 10 by tapping on the adapter plate with a soft face hammer 7 Remove idler gear 21 slip fit gear 18 and key 17 8 Remove backplate 27 from rear body 26 by tap ping on backplate with soft face hammer 9 Remove rear idler gear 25 slip fit gear 20 and key 22 10 Remove drive gear assembly 11 from rear adapter plate 24 11 Place rear idler gear assembly 25 back into gear pocket and tap protruding end with soft face hammer to remove rear body 26 from the backplate assembly 27 or the rear adapter plate 24 IMPORTANT Note position of the open and closed side of the wear plates before removing 12 Remove the wear plates 12 and o rings 4 from front plate 15 front adapter plate 23 and rear adapt er plate 24 13 Remove backup g
40. Installation 1 Coat new shaft seal with grease and install in axle case as shown Fig 18 Figure 18 1 Axle case 3 Shaft seal 2 Bevel gear case 2 Install the lower bevel gear and bevel gear shaft in the axle case cover Coat a new O ring with grease and install the axle case cover Fig 19 Tighten cover screws from 17 to 20 ft lb 23 to 27 3 Slide the bevel gear case over the bevel gear shaft and install the bevel gear and collar Make sure the bevel gear shaft is completely seated in the upper and lower bearings Fig 19 4 Install the knuckle pin Use medium strength Loctite thread locker and tighten the knuckle pin mounting screws from 17 to 20 ft lb 23 to 27 and Brakes a 5 S a a E x lt Axle case cover 5 Upper bevel gear Lower bevel gear 6 Collar Bevel gear shaft 7 Upper bearing Lower bearing 8 Knuckle pin 1 2 3 4 Groundsmaster 4000 D Page 6 17 Axles Planetaries and Brakes Rev B 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 disassembly between axle case support and axle case Install mounting screws into axle case Slowly tighten screws while frequently checking for clear ance vertical endplay between axle case support and knuckle pin If binding of c
41. Preface The purpose of this publication is to provide the service technician with information for troubleshooting testing and repair of major systems and components on the Groundsmaster 4000 D REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR S MANUALS FOR OPERATING MAINTENANCE AND ADJUSTMENT INSTRUC TIONS Space is provided in Chapter 2 of this book to insert the Operator s Manuals and Parts Catalogs for your machine Replacement Operator s Manuals and Parts Catalogs are available on the internet atwww To ro com The Toro Company reserves the rightto change product specifications or this publication without notice PART NO 02097SL Rev F Service Manual Model 30410 Groundsmaster 4000 D This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE A NOTE will give general information aboutthe correct operation maintenance service testing or re pair of the machine IMPORTANT The IMPORTANT notice will give im portantinstructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 2002 2003 2004 2006 2007 2012 This is intentionally blank Groundsmaster 4000 D Table Of Contents Chapter 1 Safety General Safety Instructions 1 2 Jacki
42. ORANGE o 2 BLACK BLACK BLUE 3 X BLACK CRUISE BLACK 5 SWITCH TAN VIOLET BLACK GRAY G LIGHT pa YELLOW BLACK x 5 GREEN GRAY GRAY 8 98 YELLOW ale E IMPLEMENTS 1 x ds BLACK 5 a GREEN gt GRAY 2 5 pg CRUISE GREEN ui 4 E z BLACK a FUSEBLOCK 4 8 5 5 YELLOW 2 3 P25 SHUTDOWN 8 BNK RELAY 5 RED BLACK POWER pal 2 5 WHITE 9 5 d ORANGE VIOLET 2 e s pog START He ORANGE RELAY BLUE 4 L Bi ack BLACK 5 FUSEBLOCK 4 3 P7 5 lt VIOLET x ORANGE 2 2 YELLOW co x GLOW OPTIONAL pg amp BLUE BLUE 4 CONTROLLER FUSEBLOCK BROWN BLACK G WHITE 2 GREEN GREEN t GREEN P6 spa PINK BLACK r 4 ORANGE Sh YELLOW 2 IGNITION s SWITCH WHITE 3 SEAT GRAY 4 RELAY D TAN J5 YELLOW x ui GREEN BLACK d 3 d WHITE m B c e A 8 C DE F 6 gt 2 102 as cvr 2 re P32 P29 P33 P1 P30 P2 INTERCONNECT TO THE ENGINE SEAT SWITCH AUDIO ALARM SEAT SWITCH SEAT SWITCH INTERCONNECT TO THE ENGINE Spine INTERCONNECT INTERCONNECT TO FRONT OPTIONGH INTERCONNECT TO FRONT Groundsmaster 4000 D Main Wire Harness Serial Numbers below 220999999 Page9 9 32 SEAT SWITCH SEAT SWITCH OPT 2 OPT A
43. Perform following inspections and maintenance A Check for cracks Replace battery if cracked or leaking B Check battery terminal posts for corrosion Use wire brush to clean corrosion from posts IMPORTANT Before cleaning the battery tape or block vent holes to the filler caps and make sure the caps are on tightly C Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler cap overcharging loose terminal post or over filling Also check battery case for dirt and oil Clean the battery with a solution of baking soda and water then rinse it with clean water Groundsmaster 4000 D Page 5 29 Figure 43 1 Negative cable 3 Battery retainer 2 Positive cable D Check that the cover seal is not broken away Re place the battery if the seal is broken or leaking E Check the electrolyte level in each cell If the level is below the tops of the plates in any cell fill all cells with distilled water between the minimum and maxi fill lines Charge at 15 to 25 amps for 15 min utes to allow sufficient mixing of the electrolyte 2 Conduct a hydrometer test of the battery electrolyte IMPORTANT Make sure the area around the cells is clean before opening the battery caps A Measure the specific gravity of each cell with a hydrometer Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm up the hydrometer At the s
44. a 9 x Study the different contact patterns Figs 42 and 43 and correct gear engagement as necessary NOTE When making changes note that two variables are involved see Gear Pattern Movement Summary in this section of this manual Example If the pinion gear to ring gear backlash is set ue Figure 41 correctly to specifications and the bearing case shim is 1 Input shaft pinion gear 4 Differential bearing changed to adjust tooth contact it may be necessary to 2 Bearing case shims shims readjust backlash to the correct specification before 3 Differential gear case checking the contact pattern Groundsmaster 4000 D Page 6 27 Rev Axles Planetaries and Brakes Rev B Heel Contact Every gear has a characteristic pattern The illustrations show typical patterns only and explain how patterns shift as gear location is changed 1 If contact is toward the heel or base of the gear Fig 42 A Install thicker or additional bearing case shim s to move pinion shaft toward ring gear B Install thinner or remove differential bearing shim s to move ring gear backward Toe Contact C Repeat until proper tooth contact and pinion gear to ring gear backlash are correct NS 2 If contact is toward the toe or tip of the gear Fig 43 A Install thinner or remove bearing case shim s to move pinion shaft away from ring gear B Install thicker
45. cap screws 7 from the motor assembly 2 Use a soft face hammer and tap the backplate 2 to loosen and remove from housing 3 Remove valve plate 12 and O ring 11 from back plate It is not necessary to remove roll pins 14 15 in backplate Groundsmaster 4000 D 4 Remove motor from vise and remove rotating as sembly 4 from motor housing 5 Remove the camplate insert 5 from housing Use caution not to mar the finish that makes contact with pis tons 6 Remove retaining ring 6 from housing Press shaft from housing and remove shaft seal 8 and washer 18 7 Remove retaining rings 9 from shaft and remove thrust races 10 and thrust bearing 13 8 Discard the shaft seal and o ring and replace with new items upon reassembly Inspection 1 Check the condition of the needle bearing 16 in backplate 2 and replace if necessary 2 Inspectvalve plate 12 onthe bronze side next to the piston block for wear A smooth surface is required Do not lap valve plate bronze surface Replace valve plate if any wear exists 3 Inspect the piston block surface that makes contact with valve plate This surface should be smooth and free of deep scratches Do not lap piston block 4 The pistons should move freely in the piston block bore If they are sticky in the bore examine the bore for scoring or contamination 5 Examine the O D of the pistons for finish condition They should not show wear or deep
46. flush tank out with clean diesel fuel Make sure tank is free of contaminates and debris Fuel Tank Removal Fig 7 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Raise seat and hood 3 Remove battery cover and strap Disconnect nega tive battery cable first and then positive battery cable Remove battery from machine 4 Use a fuel transfer pump to remove fuel from the fuel tank and into a suitable container 5 Disconnect electrical wiring from the sending unit 6 Disconnect fuel hose from the standpipe and venting hoses from elbow fittings in top of tank 7 Remove phillips head screws that secure two 2 tank covers to ROPS assembly Remove tank covers 8 Remove fuel tank using Figure 7 as a guide Groundsmaster 4000 D 3 11 Rev E Fuel Tank Installation 1 Install fuel tank using Figure 7 as a guide A Torque two locking flange nuts that secure the fuel tank to the frame from 60 to 80 7 to 9 2 Install two 2 tank covers to ROPS assembly 3 Connect fuel hose to the standpipe and venting hoses to the elbow fittings 4 Connect electrical wiring to the sending unit A Connect white wire to the center terminal and black wire to any of the screws that secure the fuel sender to the fuel tank B Apply skin over grease to the wire terminal con nections Connecting battery cables
47. holes and install dowel pin and retaining ring 20 4 Install new o ring 9 onto input shaft Hold bell crank in position with feedback link slot and align splined hole of bell crank with input shaft cavity Install input shaft into control housing and bell crank Groundsmaster 4000 D 5 Apply Loctite 242 or equivalent to set screw 18 and install into control housing Adjust set screw until it bottoms out on input shaft and back out one quarter turn 6 Install wiper seal on input shaft 7 Install new o ring 2 onto plug and install plug Ad just plug until there is no end play in the valve spool with input shaft held stationary Secure plug in place with set screw 24 Torque set screw from 17 to 26 in Ib 2 to N m Disassembly Neutral Switch 1 Loosen set screw 17 in adapter and remove neutral switch from adapter 2 Remove adapter from control housing 3 Remove pin ball and o rings 11 amp 16 from adapt er Reassembly Neutral Switch 1 Install new o ring 11 onto adapter and new o ring 16 onto pin 2 Install ball and pin into adapter Lubricate with petro leum jelly to hold in place during installation 3 Install adapter into control housing Torque from 44 to 52 ft Ib 60 to 70 N m 4 Apply Loctite 222 or equivalentto threads of neutral switch and install switch into adapter The adjustment procedure for the switch are as follows A Install switch while moving link back
48. me 4 2 PLACES 30 n C is 1 1 ee TO FRONT P18 1 RELAY 4 33 SEAT SWITCH INTERCON 2 D POWER POINT ENGINE SHUTDOWN RELAY CRUISE RELAY 3 31 25 2L 1 2 3 AE PTO SWITCH 2 5 PLACES a L1 4 WD SWITCH FUEL GAGE 22 21 J P16 C EN SILENCE ALARM 1 0100 26 1 SEAT RELAY P5 SP1 1 pa SP7 Pa SP4 D GLOW CONTROLER 27 ug a 7 ALI 2 5 C4 x Sp 27 gt ET ian 3 6 Ph FUEL GAGE D LENCE ALARM SP9 Ee IMPLEMENTS LIGHT KIT P7 P8 P10 1 7 28 2 SHUTDOWN gt FUSEBLOCK beret 20 INTERCONNECT TO ENGINE 4 3 TYP 2 PLA
49. or nozzles that eject hydraulic fluid under high pressure Do not use hands to search for leaks use paper or cardboard Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury Gan grene may result from such an injury Groundsmaster 4000 D Page 4 23 Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved and all rotating ma chine parts must be stopped Stop engine lower or support attachments 1 Clean machine thoroughly before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hy draulic equipment Contamination will cause excessive wear of components 2 Put metal caps or plugs on any hydraulic lines left open or exposed during testing or removal of compo nents 3 Theengine must be in good operating condition Use a phototac when performing a hydraulic test Engine speed can affect the accuracy of the tester readings Check actual speed of the pump when performing flow testing 4 The inlet and the outlet hoses must be properly con nected and not reversed tester with pressure and flow capabilities to prevent damage to the hydraulic tester or components 5 When using hydraulic tester with pressu
50. ox Ld wo A Ea el L e 3 Z149 dh 5 ev 5 4 aou 052 x ajouis oov O83 Ow ot 10 3u08081 oli e ang e 9 1 Da LE ts v IOHLNOO Y3MO7 L417 lt gt Id 1 1 ISd un 1 ii HOLOW REY oaa HH SA 1 1 1 4 vNOl1HOdO8d Hae at 55 Wd vt 1 un 3 f YOLOW Gm HJ 1 1 270006 ld NINO L9 5 TOULNOO SNIH3aLs un L RA ZH 7 529 ld SOULS OZ 3408 002 gt AN3IN3AOW NOLSId TAO 15 Groundsmaster 4000 D Page 4 16 Hydraulic System Rev B Steering Circuit Athree section gear pump is coupled to the piston trac tion pump The gear pump section farthest from the pis ton pump supplies hydraulic flow to the st
51. 108 to 122 N m 0 6 e 60 to 70 ft Ib 811095 N m gt 10 80 to 90 ft Ib 108 to 122 N m 3 6 p 2 E E PSP GE 25 to 30 ft lb 35 to 40 ft lb 34 to 41 N m 47 to 54 N m jeeni E SY to 284 amp 6 to 8 N m Figure 50 1 Manifold body 9 Seal kit 17 O ring 2 Solenoid valve port 2 10 Reducing valve port 8 18 Plug SAE 6 3 Seal kit 11 Seal kit 19 O ring 4 Check valve port 3 12 Plug SAE 2 20 Plug SAE 10 5 Seal kit 13 O ring 21 O ring 6 Control valve ports 5A amp 5B 14 Plug SAE 4 22 Solenoid coil 7 Seal kit 15 O ring 23 Nut 8 Relief valve port 7 16 Plug SAE 5 NOTE The ports on the manifold are marked for easy identification of components Example P1 is a piston pump connection port and 2 is the location for the sole noid valve See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port NOTE 4WD manifolds used on Groundsmaster 4000 D machines are either Eaton Vickers Fig 50 or JEM Fig 51 Valve Cartridge Service 1 Make sure the manifold is clean before removing the valve Hydraulic System Rev B 4 68 2 If cartridge is solenoid operated remove nut secur ing solenoid to the cartridge valve Carefully slide sole noid off the valve IMPORTANT Use care when handling the valve car tridge Slight bending or distortion of the stem tube can cause
52. 5 1 Key 3 Lock washer 2 Hex nut 4 Ignition switch ON PREHEAT START Figure 6 Groundsmaster 4000 D Fuses The fuse blocks are located under the operator s control panel Identification Function and Wiring The fuses are held in two fuse blocks Use Figure 7 to identify each individual fuse and its correct amperage Each fuse holder has the following functions and wire connected to it Fuse 1 A Supplies power to the seat switch B Has green wire and red wire battery Fuse A2 A Supplies power to ignition switch terminal B B Has pink wire and red wire battery Fuse A3 A Supplies power to the PTO switch B Has yellow wire and red wire battery Fuse A4 Figure 8 6 9 Lu A Supplies power to the starter solenoid B Has orange wire and red wire battery Fuse B1 A Supplies power to the power point outlet B Has white wire and red wire battery Fuse B4 when optional lighting is installed A Supplies power for optional light kit B Has two red wires Groundsmaster 4000 D Page5 9 Electrical System Warning Lights Testing Warning Lights 1 Apply 12 VDC to terminals 1A and 2A 2 Ground terminals 1B and 2B 3 Both indicator lights should light Engine Oil Pressure Light The oil pressure light should come on when the ignition switch is
53. Lower pump so that the shaft end flange end is up Setthe rear of housing onto table with housing flat and rotating kit assembly at rest on table Hole in table for protruding shaft is required Lift and remove the housing 19 and drive shaft 21 from rotat ing kit assembly 6 and camplate assembly 11 7 Remove camplate 11 from rotating kit assembly 6 and servo piston follower 8 from camplate 11 8 Remove the four socket head screws 5 and wash ers 31 retaining each cover plate 9 amp 10 9 Remove jam nut 1 washer 29 and seal washer 4 Hold the servo piston bolt with hex key and unscrew cover plate 10 from bolt 10 Remove servo piston assembly 7 and seal sub as semblies two sets 37 from housing Note Disassem bly of servo piston assembly is not required 11 Remove retaining ring 2 from the front of pump housing 19 Press the drive shaft 21 shaft seal 25 and washer 24 from housing Remove retaining ring 3 thrust race 12 thrust bearing 13 second thrust race 12 and second retaining ring 3 from drive shaft 21 Groundsmaster 4000 D Page 4 61 12 Remove the two cap screws 42 that secure cradle sub assembly inside housing Move the cradle sub as sembly back and forth to release dowel bushings 40 and remove cradle sub assembly from housing 13 Remove button head cap screw 43 to remove bushing 44 from cradle 14 Remove remaining plugs from housing
54. O ring 4 Cap screw 10 O ring 5 Grommet 11 90 hydraulic fitting 6 Flat washer Removal NOTE The ports on the manifold are marked for easy identification of components Example C1 is the con nection port from the LH deck lift cylinder and CHG is the charge circuit connection See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port 1 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 2 Disconnect hydraulic lines from manifold and put caps or plugs on open hydraulic lines and fittings Label disconnected hydraulic lines for proper reassembly 3 Remove hydraulic manifold from the frame using Figure 54 as guide Hydraulic System Rev B Page 4 72 Installation 1 Install hydraulic manifold to the frame using Figure 54 as guide 2 Remove caps and plugs from fittings and hoses Properly connect hydraulic lines to manifold Groundsmaster 4000 D Hydraulic Control Manifold Service Cutting Deck Lift Lower 35 to 40 ft lb ___________ 2 35 to 40 ft Ib 47 to 54 N m 47 to 54 N m 35 to 40 ft Ib 47 to 54 N m 9 5 gt Figure 55 1 Manifold body 4 Relief valve Counterbalance 6 Plug SAE 2 2 Pilot valve 5 Seal kit 7 O ring 3 Seal kit NOTE The ports on the manifold are marked for easy identification of components
55. Quad Seal Figure 75 Hydraulic System Rev B 5 gt 4 gt 170 Side Deck Lift Cylinder NI 9 is sif E te 42 oP se 14 2 2 MEA SH TS poe rate Y N 0 8 7 RIGHT FRONT Figure 76 1 Lift arm assembly LH shown 5 Flange locking nut 9 Cylinder pin 2 Shoulder screw 6 90 hydraulic fitting 10 Spring pin 3 Pin assembly 7 O ring 11 Lock nut 4 Lift cylinder 8 O ring 12 Flat washer Hydraulic System Rev B Page 4 98 Groundsmaster 4000 D Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter NOTE To ease reassembly tag the hydraulic hoses to show their correct position on the lift cylinder 3 Disconnect hydraulic hoses from lift cylinder 4 Remove shoulder screw and flange locking nut that secure the pin assembly to the lift arm Remove pin as sembly from lift arm and cylinder shaft clevis 5 Remove lock nut and flat washer from the cylinder pin Remove cylinder pin with spring pin from the frame and cylinder barrel clevis 6 Remove lift cylinder from machine Groundsmaster 4000 D Page 4 99 Installation 1 Position cylinder barrel clevis to frame and insert cyl inder
56. Testing at the beginning of this section Figure 32 3 Determine system charge pressure see TEST NO 9 1 Traction Circuit Charge Pressure this chapter 1 Counterbalance test port 3 Locknut 2 Counterbalance valve 4 Adjusting screw 4 Connect a 1000 PSI gauge to counterbalance test port on manifold under console Fig 32 5 gt 5 Start the engine and put throttle at full engine speed 2730 30 RPM with no load on the system Do not en gage the cutting units GAUGE READING TO BE 220 PSI 15 2 bar over system charge pressure e g if charge pressure is 250 PSI counterbalance pressure should be 470 PSI 6 Adjustment of the counterbalance valve can be per formed as follows NOTE Do not remove the valve from the hydraulic manifold for adjustment A Loosen locknut on counterbalance valve Fig 32 B To increase pressure setting turn the adjust ment screw on the valve in a clockwise direction A 1 8turn onthe screw will make a measurable change in counterbalance pressure C To decrease pressure setting turn the adjust ment screw onthe valve in a counterclockwise direc tion A 1 8 turn on the screw will make a measurable change in counterbalance pressure D Tighten locknut to secure adjustment Check counterbalance pressure and readjust as needed Groundsmaster 4000 D Page 4 43 Hydraulic System Rev B TEST 11 Rear Traction Circuit RV5 Relief Pressure U
57. The temperature gauge can be tested using a new gauge as a substitute or by the use of a DC voltage source and a variable resistance box Make sure the voltage source is turned OFF be fore connecting variable resistance to the elec trical circuit to avoid electrical shock and to pre vent damaging the gauge VARIABLE RESISTANCE 1 Connect temperature gauge to the variable resis tance DC voltage source Fig 27 NOTE When reading the gauge test point there are two white dots on the gauge face below the edge of the Figure 35 glass cover for the each test point For each variable re sistance setting the needle must be pointed between the two white dots 2 Take test point readings Fig 28 IMPORTANT Allow circuit to warm up for at least 5 minutes before taking test readings A Set variable resistance to 71 ohms Apply a 14 0 01 VDC to the circuit The needle should point to the middle of the green area 80 C B Set variable resistance to 38 ohms The needle should point between the green and red area 105 C 3 Turn off the voltage source Disconnect voltage source gauge and variable resistance Figure 36 1 Middle position 3 Edge of glass cover 2 High temp position Electrical System Page 5 24 Groundsmaster 4000 D Traction Neutral Switch The traction neutral switch is closed when the traction pedal is in the neutral position and opens when the ped
58. Wiper seal 18 Set screw 3 Retaining ring 11 O ring 19 Pin 4 Spring retainer 12 Adaptor 20 Retaining ring 5 Spring 13 Ball 21 Feedback link 6 Spool valve 14 Pin 22 Dowel pin 7 Control housing 15 Neutral switch 23 Bell crank 8 Input shaft 16 O ring 24 Set screw Disassembly Manual Servo Control Assembly 1 Remove wiper seal with screw driver Remove set screw 18 that retains input shaft and remove input shaft from control housing Remove o ring from shaft 2 Remove set screw 24 from plug that retains valve spool Remove plug from control housing and o ring from plug 3 Remove retaining ring 20 from pin that retains feed back link and spool valve Remove pin feedback link spool valve and bell crank from control housing 4 Compress spring and remove retaining ring 3 Re move spring retainer spring and second spring retainer from spool valve 5 Clean all parts and lubricate in clean hydraulic oil for reassembly Hydraulic System Rev B Page 4 64 Reassembly Manual Servo Control Assembly 1 Install spring retainer spring and second spring re tainer onto spool valve Compress springto allow retain ing ring 3 to be installed onto spool valve 2 Install spool valve into control housing making sure that metering notches on spool valve can be seen in the metering ports 3 Position bell crank in housing Slide feedback link into position between clevis on valve spool aligning
59. and bulkhead locknuts Fig 9 Install steering cylinder hoses to hydraulic tubes Groundsmaster 4000 D Page 6 13 Axles Planetaries and Brakes Rev B 9 Install steering cylinder to axle assembly see Steer ing Cylinder in Service and Repairs section of Chapter 4 Hydraulic System 10 Install hydraulic motor to axle assembly see Rear Axle Motor in Service and Repairs section of Chapter 4 Hydraulic System Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury 11 Install wheels to axle Torque wheel lug nuts from 85 Figure 12 to 100 ft lb 115 to 135 1 Steering stop bolt 2 Bevel gear case LH 12 Lower machine to ground 13 Fill axle with SAE 85W 140 weight gear lube see Operator s Manual Lubricant capacity is approximate ly 80 fl oz 2 37 for the axle and 16 fl oz 47 for the gearbox 14 Check rear wheel toe in and adjust if necessary see Operator s Manual 15 Check steering stop bolt adjustment When the steering cylinder is fully extended right turn a gap of 1 16 1 6 mm should exist between bevel gear case casting and stop bolt on left axle case Figure 12 shows stop bolt location Axles Planetaries and Brakes Rev B Page 6 14 Groundsmaster 4000 D 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 mounti
60. burns allow the engine and cooling systems to cool before working on the oil cooler 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 3 Remove oil cooler using Figures 85 and 86 as guides Inspection 1 Back flush oil cooler with cleaning solvent After cool er is clean make sure all solvent is drained from the cooler A CAUTION Use eye protection such as goggles when using compressed air 2 Dry inside of oil cooler using compressed air in the opposite direction of the oil flow 3 Plug both ends of oil cooler Clean exterior of cooler Make sure fins are clear of dirt and debris 4 The oil cooler should be free of corrosion cracked tubes and excessive pitting of tubes Installation 1 Install oil cooler using Figures 85 and 86 as guides 2 Fillreservoir with hydraulic fluid as required see Op erator s Manual Hydraulic System Rev B Page 4 110 1 Oil cooler Oil cooler 90 hydraulic fitting O ring O ring Knob Retaining ring Figure 85 2 Radiator assembly Figure 86 7 Carriage screw 8 Clamp 9 Oil cooler bracket RH 10 Flange screw 11 Flange locking nut 12 Radiator support Groundsmast
61. control con sole next to the operator seat IMPORTANT Make sure to observe polarity on the alarm terminals when testing Damage to the alarm may result from an improper connection 1 Isolate alarm from the circuit Correctly connect 12VDC source to the terminals Fig 19 2 Alarm should sound Remove voltage source from the alarm Reconnect alarm to the circuit Glow Relay The glow relay is attached to the the right side of the fuel tank support under the hood NOTE Prior to taking small resistance readings with a digital multi meter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measured value of the component you are testing 1 Verify coil resistance between terminals 86 and 85 with a multimeter ohms setting Resistance should be from 41 to 51 ohms 2 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is applied and removed from terminal 85 3 Disconnect voltage and leads from the terminals Electrical System 5 14 Figure 18 Figure 19 3 Positive terminal 4 Negative terminal 1 Top view 2 Bottom view Figure 20 Groundsmaster 4000
62. engine and align mount ing holes Use two shoulder bolts and lockwashers in the positions shown in Figure 15 to secure the spacer to the half threaded holes in engine flywheel Torque shoulder bolts from 10 to 12 ft lb 13 6 to 16 3 2 Install four cap screws and lockwashers to coupling spacer and flywheel Torque cap screws from 17 to 21 ft lb 23 to 28 5 3 Place dowels in locating holes of coupling spacer Fig 15 4 Position spring center coupling coil springs toward engine Fig 16 over dowels Secure coupling to cou pling spacer with cap screws and lockwashers Torque cap screws from 35 to 43 47 5 to 58 3 N m 5 Install plate pins into engine casting Position pump adaptor plate to engine using plate pins as alignment points Secure adaptor plate with cap screws and lock washers using a star pattern tightening procedure Engine Installation 1 If removed install engine mount brackets to the en gine using Figure 9 as a guide 2 Connect hoist or lift to the front and rear lift tabs on engine 3 Position fan shroud around the engine fan CAUTION One person should operate lift or hoist while the other person guides the engine into the machine IMPORTANT Make sure not to damage the engine fuel and hydraulic lines electrical harness or other parts while installing the engine 4 Slowly lower engine into the machine 5 Align engine to the rubber engine mounts and secure wit
63. erating the machine Groundsmaster 4000 D Page 5 7 Rev E Voltage Measured 12 68 V or higher 12 45 V 12 24 V 50 charged 0 charged Interlock switch operation is described in the Operator s Manual Testing of interlock switches and relays is in cluded in the Component Testing section of this Chap ter Electrical System 6 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 doing a continuity check NOTE For engine component testing information see the Kubota Workshop Manual Diesel Engine V2003 T Series at the end of Chapter 3 Kubota Diesel Engine Ignition Switch The ignition key switch has three positions OFF ON PREHEAT and START The terminals are marked as shown The circuit wiring of the ignition switch is shown in the chart With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each position Verify continuity between switch terminals POSITION CIRCUIT OFF NONE ON PREHEAT B l A X Y START Electrical System Page 5 8 When testing electrical components for continu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected Figure
64. ft lb 440 45 N m 450 37 ft lb 610 50 N m on the fastener size the aluminum or base material strength length of thread engagement etc Note The nominal torque values listed above are based on 75 of the minimum proof load specified in J1199 The tolerance is approximately 10 of the nominal torque value Product Records and Maintenance Product Records 6 7 5 6 Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque 1 4 20 140 20 in Ib 73 12 in lb 5 16 18 UNC 215 35 145 20 in Ib 3 8 16 UNC 35 10 ft lb 18 3 ft lb 75 15 ft lb 50 10 ft lb 1 2 13 UNC Thread Cutting Screws Zinc Plated Steel Type 1 Type 23 or Type F Thread Size Baseline Torque No 6 32 UNC 20 5 in lb No 8 32 UNC 30 5 in lb 1 4 20 UNC 85 15 in lb 5 16 18 UNC 110 20 in Ib 3 8 16 UNC 200 100 in Ib No 10 24 UNC 38 7 in lb Conversion Factors in lb X 11 2985 N cm ft lb 1 3558 N m Product Records and Maintenance Page2 6 Wheel Bolts and Lug Nuts Thread Size Recommended Torque 88 14 N m 7 16 20 UNF 65 10 ft lb Grade 5 1 2 20 UNF 80 10 ft lb B 108 14 5 12 1 25 80 10 ft lb 108 14 Class 8 8 12 1 5 80 10 ft lb 108 14 Class 8 8 For steel wheels and non
65. head nut 4 Bulb seal 14 Door handle 24 Flat washer 5 Bulb seal 15 Flange head screw 25 Cap screw 6 Screen seal corner 16 Oil filter deflector 26 Cap screw 7T Hair pin 17 Lock nut 27 Hex flange screw 8 Flange head screw 18 Latch 28 Hood support 9 Screen pivot 19 Latch plate 29 R clamp 10 Hood pivot 20 Hood latch bracket 30 Latch keeper Chassis Page 7 14 Groundsmaster 4000 D Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove hood using Figure 13 as a guide Installation 1 Install hood using Figure 13 as a guide 2 Align hood to machine to allow correct operation of i Shim location LH Figure 5 location hood latch and dust seals 2 Shim location RH 4 Screen pivot A Place shim 3 8 to 7 16 thick on top of frame both RH and LH sides near the sides of oil cooler Fig 14 B Close hood so that it rests on shims and fasten the hood latches C Loosen hood pivots at frame to adjust vertical placement of pivots Re tighten hood pivot fasten ers D Loosen screen pivots to allow hood latches to pull hood against radiator support Re tighten screen pivot fasteners 3 After hood is assembled to machine check for the following A Check that bulb seals are equally compressed at all contact points with hood B Hood should open and close without cont
66. in the ON position with the engine not running Also it should light with the engine running when the oil pressure drops below 7 PSI 0 5 kg cm 1 Disconnect green wire from the oil pressure switch 2 Ground green wire to the engine block 3 Turn ignition switch to ON the oil pressure light should come on indicating correct operation of the elec trical wiring to the oil pressure switch 4 Turn ignition switch to OFF Reconnect green wire to the oil pressure switch High Temperature Shutdown Light If the coolant temperature rises to 2309F 1109C the high temperature light should come on as the high tem perature shutdown switch stops the engine 1 Ground the wire attached to temperature switch on flywheel end of engine Warning light and audible alarm should go on and engine should stop running 2 Depress alarm silence and alarm should turn off De press high temperature override and hold engine should start and run 3 Reconnect wire to temperature switch Glow Plug Indicator Light The glow plug indicator light should come on when the ignition switch is placed in ON prior to placing the ignition switch in START The light should stay lit for 10 seconds while the ignition switch is left in ON 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 Electric
67. includes a variety of O ring Face Seal fittings to enable you to connect test gauges into the system TORO TEST FITTING KIT NO TOR4079 TOOL NUMBER TOOL NUMBER The kit includes tee s unions reducers plugs caps and male test fittings Union 1 Toro No No 1010 No 8 0 4079 2 No 8toMo 8 TORA079 9 Reducer 1 ea Toro No Size 4 10 8 TORAOT 7 120 8 TORTS 6 Sue Toro No elsi 7 6 200RB TOR407922 14 Pipe Tha TORA079 23 Figure 11 Measuring Container TOR4077 Use this container for doing hydraulic motor efficiency testing motors with case drain lines only Measure effi ciency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydraulic system Hydraulic System The table in Figure 13 provides gallons per minute GPM conversion for measured milliliter or ounce motor case drain leakage Figure 12 Milliliters in 15 sec Ounces in 15 sec 95 3 2 189 6 4 9 6 12 8 16 0 19 2 22 4 25 6 28 8 32 0 A Figure 13 Groundsmaster 4000 0 4 19 Hydraulic System Rev Troubleshooting The charts that follow contain information to assist in Refer to the Testing section of this Chapter for precau troubleshooting
68. inner race of the bearing cone 1 Ifthe inner bearing cone was removed press a new bearing cone all the way onto the input shaft pinion gear 2 Place the shaft and bearing assembly in the bearing case and install the outer bearing cone NOTE The bearings must be completely seated There should be no input shaft pinion gear end play 3 Coat a new oil seal with grease and install as shown Fig 29 The seal should be installed with the garter spring towards the hydraulic motor 4 Coat new O ring with grease Install O ring in the oil seal collar and install the collar 5 Install a new stake washer Install the lock nut finger tight Groundsmaster 4000 D 6 Set the bearing preload by securing the bearing case a vise Thread a M12 x 1 5 hex head cap screw into the splined end of the input shaft pinion gear and slowly tighten the locknut until 4 to 6 in Ib 0 4 to 0 7 of force is required to rotate the input shaft pinion gear in the bearing case 0 04 in 1 0 mm 7 Secure the lock nut with the stake washer 8 Use a depth gauge to measure the distance from the end face of the input shaft pinion gear to the mating sur face of the bearing case Subtract the Design Cone Center Distance from this distance to determine initial shim thickness Fig 30 DESIGN CONE CENTER DISTANCE distance from mating surface of axle support to end Figure 29 face of pinion gear 1 3 Seal garter spring
69. lubricated fasteners Thread Cutting Screws Zinc Plated Steel Threads per Inch Size Baseline Torque Type A Type B No E Hole size material strength material thickness amp finish must be considered when determining specific torque values All torque values are based on non lubricated fasteners No 8 X 0 08851 in Ib N m X 0 7376 ft lb Groundsmaster 4000 D TORO Table of Contents GENERAL INFORMATION 2 Stopping the Engine 2 SPECIFICATIONS 3 ADJUSTMENTS 4 R ncSole noid gt 2e S ev eB 4 SERVICE AND REPAIRS 6 Air Filter System 6 Exhaust System 8 Fuel System 10 Check Fuel Lines and Connections 11 Drain and Clean Fuel Tank 11 Fuel Tank Removal 11 Fuel Tank Installation 11 Groundsmaster 4000 D Page 3 1 Chapter 3 Kubota Diesel Engine Radiator issues rile t cede ie ped etes 12 ri 14 Engine 15 Coupling 17 Coupling Assembly 17 Engine Installation 17 KUBOTA WORKSHOP MANUAL DIESEL ENGINE V
70. machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove battery cover and strap Disconnect nega tive battery cable first and then positive battery cable Remove battery from machine 3 Open engine hood Do not open radiator cap or drain coolant if the radiator or engine is hot Pressurized hot cool ant can escape and cause burns Ethylene glycol antifreeze is poisonous Dis pose of coolant properly or store it in a properly labeled container away from children and pets 4 Drain coolant from the radiator into a suitable con tainer see Radiator Removal Disconnect coolant hoses from the radiator The muffler and exhaust pipe may be hot To avoid possible burns allow the exhaust system to cool before working on or near the muffler 5 Remove exhaust system from engine see Muffler Removal 6 Remove air cleaner system from engine see Air Cleaner Removal 7 Note location of cable ties used to secure wires Dis connect wires and or electrical connections from the fol lowing electrical components A The temperature sender and alternator Fig 10 Note red wire attached to alternator with washer nut and boot does not have to be removed B The engine run solenoid and fuel pump Fig 12 C The high temperature shutdown switch and glow plug Fig 13 D Battery frame and wire harness ground at the engine block Fi
71. manifold test port Groundsmaster 4000 D Page 4 29 Figure 18 1 Front deck circuit pressure test port 5 gt I Figure 19 1 Right deck circuit pressure test port Figure 20 1 Left deck circuit pressure test port Hydraulic System Rev B TEST 4 Cutting Deck Gear Pump Flow Front Deck Shown Using Tester with Pressure Gauges and Flow Meter 2 ere ei TRACTION CIRCUIT A Y lt lt Anis AX CN A 89 TO LIFT LOWER CIRCUIT m TO STEERING CIRCUIT RESERVOIR HOLOW VE A HOLLOW H7 iW 21 gt Working Pressure Low Pressure Return or Suction Groundsmaster 4000 D Page 4 30 Hydraulic System Rev B Procedure for Cutting Deck Gear Pump Flow Test NOTE Overa period oftime the gears and wear plates in the pump can wear A worn pump will by pass oil and make the pumpless efficient Eventually enough oilloss will occur to cause the cutting unit motors to stall under heavy cutting conditions Continued operation with a worn inefficient pump can generate excessive heat and cause damage to the seals and other components in th
72. pin through the frame and cylinder clevis Secure pin with flat washer and lock nut 2 Insert pin assembly through the lift arm and cylinder shaft clevis Secure pin assembly to lift arm with shoul der screw and flange locking nut 3 Attach hydraulic hoses to lift cylinder 4 Fillreservoir with hydraulic fluid as required see Op erator s Manual 5 After assembly is completed operate lift cylinder to verify that hydraulic hoses and fittings are not contacted by anything Hydraulic System Rev B 9 o Ey Front Deck Lift Cylinder Figure 77 1 Lift cylinder 5 screw 9 O ring 2 Upper lift pin 6 Flat washer 10 Straight hydraulic fitting 3 Cotter pin 7 Lock nut 11 O ring 4 Pin assembly 8 Lift arm assembly LH shown 12 90 hydraulic fitting Hydraulic System Rev B Page 4 100 Groundsmaster 4000 D Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter NOTE To ease reassembly tag the hydraulic hoses to show their correct position on the lift cylinder 3 Disconnect hydraulic hoses from lift cylinder 4 Remove lock nut flat washers and cap screw that secure the pin assembly to the lift arm Remove pin as sembly
73. ports and clean outside of cylinder IMPORTANT To prevent damage when clamping cylinder barrel or rod vise clamp only on pivotal ends Use of a vise with soft jaws is recommended 2 Mount cylinder in a vise so piston rod end of cylinder is tilted up slightly Do not close vise so firmly that cylin der tube could become distorted 3 Loosen gland head from barrel A On cylinders without a retaining ring slot in the barrel Fig 82 use a spanner wrench to loosen and remove gland from barrel B On oylinders with a retaining ring Fig 83 usea spanner wrench to rotate head clockwise until the edge of the retaining ring appears in the barrel open ing Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the opening Rotate the head counter clockwise to remove retaining ring from barrel and head 4 Grasp end of piston rod and use a twisting and pull ing motion to carefully extract piston piston rod and gland from cylinder tube IMPORTANT Do not clamp vise jaws against smooth piston rod surface the piston rod will be come damaged 5 Securely mount piston piston rod and gland into vise and remove lock nut Remove piston and gland from rod 6 Remove all seals and O rings 7 Wash parts in clean solvent Dry parts with com pressed air Do not wipe parts dry with paper towels or cloth Lint in a hydraulic system will cause damage 8 Carefully inspect i
74. procedure again 7 Connect engine run solenoid electrical connector start the engine and check for proper operation 8 Properly fill hydraulic system see Charge Hydraulic System 9 Stop engine and check for hydraulic oil leaks Check hydraulic reservoir oil level Hydraulic System Rev B 9 52 Gear Pump Service 21 to 24 ft Ib 29 to 33 N m 21 to 24 1 6 29 to 33 N m 25 to 28 ft lb 34 to 38 N m Figure 40 1 Shaft seal 11 Drive gear assembly 21 Idler gear 2 Washer 12 Wear plate 22 Key 3 Cap screw 13 Pressure seal 23 Front adapter plate 4 O ring 14 Backup gasket 24 Rear adapter plate 5 Washer 15 Front plate assembly 25 Idler gear 6 Proportional valve 16 Idler gear 26 Rear body 7 Plug 17 Key 27 Backplate assembly 8 Plug 18 Gear 28 Plug 9 O ring 19 Middle body 29 O ring 10 Front body 20 Gear Disassembly Work in aclean area as cleanliness is extremely impor tant when repairing hydraulic pumps Thoroughly clean the outside of pump After cleaning remove port plugs and drain oil from pump 1 Scribe a line at an angle across front plate 15 bo dies 10 19 26 adapter plates 23 24 and backplate 27 This will assure proper reassembly Hydraulic System Rev B Page 4 54 NOTE To maintain maximum pump efficiency keep body gears and wear plates for each section together DO NOT mix parts between different sections
75. re move the upper bevel gear and collar from the gear case 8 Remove the axle case cover screws cover and the O ring from the axle case 9 Remove the plug and sealing washer from the center of the axle case cover While holding the axle case cov er lightly tap the lower end of the bevel gear shaft out of the lower bearing and lower bevel gear 10 Remove and discard bevel gear shaft seal from axle case Fig 16 Inspection 1 Measure the knuckle pin O D and the axle case sup port bushing 1 0 to determine the bushing to pin clear ance Fig 17 Replace components as necessary BUSHING TO PIN CLEARANCE 0 002 to 0 016 in 0 05 to 0 40 mm KNUCKLE PIN O D Factory Spec 0 982 to 0 983 in 24 95 to 24 98 mm AXLE CASE SUPPORT BUSHING 1 0 Factory Spec 0 984 to 0 987 in 25 00 to 25 08 mm 2 Inspect all gears shafts bearings cases and cov ers for damage and wear Replace components as nec essary Axles Planetaries and Brakes Rev B Page 6 16 ED 17 to 20 ft lb 23 to 27 N m Threadlocking Compoun 17 to 20 ft lb 7 6 23 to 27 N m Figure 16 1 Knuckle pin 9 Lower bevel gear 2 Mounting screw 10 Lower bearing 3 O ring 11 Axle case 4 Bevel gear case 12 Axle case cover 5 Upper bearing 13 O ring 6 Bevel gear shaft 14 Shaft seal 7T Collar 15 Bushing 8 Upper bevel gear Figure 17 2 Axle case support 1 Knuckle pin Groundsmaster 4000 D
76. rear lift tabs on engine 17 Remove flange head locking nuts rebound washers and cap screws securing the engine brackets to the en gine mounts M CAUTION One person should operate lift or hoist while the other person guides the engine out of the ma chine IMPORTANT Make sure not to damage the engine fuel and hydraulic lines electrical harness or other parts while removing the engine 18 Slowly remove engine from the machine 19 If necessary remove engine mount brackets from the engine using Figure 9 as a guide Figure 13 1 plug wire 3 Engine lift tab 2 High temp shutdown Figure 14 1 Battery cable 5 Alternator wire 2 Battery cable 6 Fusible link harness 3 Engine to frame ground 7 Cable tie 4 Engine wire harness Kubota Diesel Engine Rev B Page 3 16 Groundsmaster 4000 D Coupling Disassembly 1 Remove adapter plate spring coupling and cou pling spacer from engine using Figure 9 as a guide Coupling Assembly 1 Position coupling spacer to
77. ring 2 O ring 9 90 hydraulic elbow 15 90 hydraulic elbow 3 Hydraulic fitting 10 O ring 16 O ring 4 Bracket 11 Hydraulic hose 17 Cap screw 5 Flange nut 12 Hydraulic fitting 18 O ring 6 Cap screw 2 used 13 O ring 19 Hydraulic fitting 7 Hydraulic hose NOTE The hydraulic Flow Divider is included as a hy draulic system component on machines with serial num bers above 230000000 The Flow Divider was an optional kit for earlier production machines serial num bers below 220999999 Removal NOTE The ports on the manifold are marked for easy identification of hydraulic line connections Example P is the traction pump connection port and M1 is the con nection for the front traction motors See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port 1 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter Hydraulic System Rev B Page 4 76 2 Disconnect hydraulic lines from manifold and put caps or plugs on open hydraulic lines and fittings Label disconnected hydraulic lines for proper reassembly 3 Remove hydraulic manifold from the frame using Figure 58 as guide Installation 1 Install hydraulic manifold to the frame using Figure 58 as guide 2 Remove caps and plugs from fittings and hoses Properly connect hydraulic lines to manifold Groun
78. see Operator s Manual 3 Drain hydraulic system Drain all hoses tubes and components while the system is warm 4 Change and replace both hydraulic oil filters see Operator s Manual 5 Inspect and clean hydraulic reservoir see Hydraulic Reservoir Inspection Hydraulic System Rev B Page 4 50 6 Reconnect all hydraulic hoses lines and compo nents that were disconnected while draining system NOTE Use only hydraulic fluids specified in the Opera tor s Manual Other fluids may cause system damage 7 Fill hydraulic reservoir with new hydraulic fluid see Operator s Manual 8 Disconnect electrical connector from engine run so lenoid 9 Turn ignition key switch engage starter for 10 se conds to prime pump Repeat this step again 10 Connect electrical connector to engine run solenoid 11 Start engine and let it idle at low speed 1450 RPM for a minimum of 2 minutes Increase engine speed to high idle 2730 30 RPM for minimum of 1 minute un der no load 12 Raise and lower cutting units several times Turn steering wheel fully left and right several times 13 Shut off engine and check for hydraulic oil leaks Check oil level in hydraulic reservoir and add correct amount of oil if necessary 14 Operate machine for 2 hours under normal operating conditions 15 Check condition of hydraulic oil If the new fluid shows any signs of contamination repeat steps 1 through 14 again unti
79. side decks are the same al though their operation depends on deck location When a side cutting deck is raised the sensing plate is moved away from the position switch and the switch opens The open switch prevents current flow to the side deck solenoid and keeps the deck from operating When the front cutting deck is raised the sensing plate is moved near the position switch and the switch closes The closed switch prevents current flow to the front deck solenoid and keeps the deck from operating CREE d Figure 40 1 Position switch front 3 Front lift cylinder 2 Sensing plate Testing 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Locate switch that requires testing and disconnect switch connector from machine wiring harness 3 Ground switch connector terminal for black wire and apply 12 VDC to switch connector terminal for red wire 4 Using a multimeter verify that switch connector ter minal for blue wire has 12 VDC and terminal for white wire has 0 VDC 5 Place metal object near sensing area of switch op posite end from wires Ground switch connector termi nal for black wire and apply 12 VDC to switch connector terminal for red wire Figure 41 1 Position switch side 2 Sensing plate 6 Using a multimeter verify that switch connector ter minal for blue wire has 0 VDC an
80. the damper link to the rear of the cutting deck Fig 7 6 Install hydraulic motor to cutting deck see Cutting Deck Motor Installation in the Service and Repairs Sec tion of Chapter 4 Hydraulic Systems 7 Lubricate grease fittings on cutting deck and lift as sembly see Operator s Manual Figure 6 1 Flange head screw 3 Deck mount screw 2 Hydraulic motor Figure 7 1 Damper link 2 Clevis pin 2 2 5 o Groundsmaster 4000 D Page 8 9 Cutting Units Blade Spindle Service Disassembly 2 1 Park machine a level surface lower cutting units stop engine engage parking brake and remove key 130 to 150 ft Ib a from the ignition switch 176 to 203 N m TN CUM 522 iL SA es Nee ate 2 Remove belt covers from top of cutting deck Loosen idler pulley to release belt tension Remove drive belt from spindle to be serviced 3 If drive spindle is to be serviced remove hydraulic motor from cutting deck see Cutting Deck Motor Re moval in the Service and Repairs Section of Chapter 4 Hydraulic Systems 4 Start the engine and raise the cutting unit Stop en gine and remove key from the ignition switch Latch or block up the cutting unit so it cannot fall accidentally Front deck can be tilted for spindle service see Opera tor s Manual 85 to 110 ft Ib 5 Remove cutting blade anti scalp cup and bolt from 115 to 1
81. the system Put plugs in open ports of pumps 7 Remove gear pump from machine see Gear Pump Removal Note If fuel tank is loosened and raised from the machine the gear pump and piston pump can be re moved as a complete assembly 8 Support the piston pump to prevent it from falling while removing two 2 cap screws and washers retain ing pump assembly to engine adapter plate Carefully pull pump assembly from adapter plate and raise it out of the machine Groundsmaster 4000 D Page 4 59 Installation 1 Carefully lower piston pump into the machine and position it to the engine adapter plate Support pump to prevent it from falling while installing two 2 cap screws and washers securing piston pump to engine adapter plate Torque screws from 85 to 95 ft lb 115 to 128 N m 2 Install gear pump to piston pump see Gear Pump Installation 3 Position traction rod to control arm on piston pump by installing cap screw spacer and lock nut 4 Connect two wires to neutral switch on traction pump 5 Remove plugs or caps from disconnected hydraulic hoses and open ports of the pump assembly Install fit tings and hoses to correct location on gear and piston pumps 6 Install new filter and fill hydraulic reservoir with cor rect oil 7 Disconnect engine run solenoid electrical connector to prevent engine from starting Prime pumps by turning ignition key switch to crank engine for 10 seconds Re peat cranking pr
82. threads in head and apply Loctite 277 or equivalent to stud threads before installing studs into head Note Make sure muffler flange and exhaust manifold sealing surfaces are free of debris or damage that may prevent a tight seal 1 Install new gasket if original gasket is damaged or torn IMPORTANT Failure to follow the suggested muf fler fastener sequence may resultin premature muf fler failure 2 Install muffler and or muffler bracket to the engine using Figure 5 as a guide Hand tighten and then torque the following fasteners from 16 to 22 ft lb 21 to 29 N m in the sequence listed Fig 6 A Locknuts used on rubber hanger cap screws B Flange nuts that secure muffler to muffler brack et C Flange head screws thatsecure muffler flange to engine D Flange nuts that secure muffler bracket to en gine 3 Tailpipe should have equal clearance between frame and engine after installation Groundsmaster 4000 D Page3 9 Rev F Kubota Diesel Engine Rev B Fuel System Fuel tank Fuel tank bracket Air breather Female hose barb Tank support assembly Fuel hose Locking flange nut Cap screw Flat washer Cap screw Carriage screw Washer Battery strap Battery foc Io Urea ON Kubota Diesel Engine Rev y sh ON lt U A 7 Sp YY 60 to 80 in Ib 6 8 to 9 N m Figure 7 Retaining ring Battery cover
83. to 100 ft lb 115 to 135 7 Lower machine to ground 8 Make sure drain plug is installed in bottom of brake assembly Fig 3 Fill planetary wheel drive brake as sembly with SAE 85W 140 gear lube see Operator s Manual Capacity is approximately 16 oz 47 per wheel 9 Check and adjust brake cables for proper brake op eration see Operator s Manual Figure 2 1 Splined brake shaft step 3 2 Hydraulic motor end Figure 3 3 Drain plug 1 Brake housing 2 Check plug Axles Planetaries and Brakes Rev B 5 S ao x and Brakes Brake Inspection and Repair Figure 4 1 Brake housing LH shown 6 Hitch pin 11 Rotating actuator 2 Seal 7 Stationary disc 12 Extension spring 3 Pull rod 8 Rotating disc 13 Ball 4 Clevis pin 9 Retaining ring 14 Plug 5 Link 10 Gasket 15 O ring Brake Inspection and Repair Fig 4 6 Remove seal 2 from brake housing 1 Scrape gasket material 10 from brake housing and 7 Wash parts in cleaning solvent Inspect components planetary wheel drive mounting surfaces for wear or damage Remove retaining ring 9 8 Reverse steps 2 6 to assemble brakes installing new parts as necessary Install a new seal 2 9 Use a new gasket 10 when installing brake assem 2 3 Remove stationary discs 7 and rotating discs 8 4 Remove extension springs 12 bly to machine 5 Remove a
84. to the oil filter and then to the traction charge circuit Hydraulic System Rev B 2 5 5 0 20 lt 10 uunjeH einsse4g uom 331009 umous H7 esiey q 000r 4 1 5 1 ISd im H Us 99 i 4 36vo 1 3 HOLOW 21 LI J EE ex 1 4 ld Um A uM JEENE ze 872 1921 r lt 3 2 Les A NU ANOYS a 4 Jj Haqinda i T MC Cs LW ld AS 1 ESSI Wd vi z 4 L OdSNYHL Ww ONIM HH 7 AEF d 2 A HX NI L 9 d 8d 1 ONIHSSLS ao isd 90 0561 e o 541 w SZL I H E guess X kh L 77 7 iP 1 p 1 LEN e _
85. voided 16 When changing attachments tires or performing other service use correct blocks hoists and jacks Make sure machine is parked on a solid level surface such as a concrete floor Prior to raising the machine re move any attachments that may interfere with the safe and proper raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the machine is not proper ly supported by blocks or jack stands the machine may move or fall which may result in personal injury see Jacking Instructions Safety Jacking Instructions When changing attachments tires or perform ing other service use correct blocks hoists and jacks Make sure machine is parked on a solid level surface such as a concrete floor Prior to raising machine remove any attach ments that may interfere with the safe and prop er raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the machine is not properly supported by blocks or jack stands the machine may move or fall which Figure 1 may result in personal injury 1 Frame jacking point 2 Front tire Jacking the Front End Fig 1 1 Set parking brake and chock both rear tires to pre vent the machine from moving 0 t Y y SO y 2 Position jack securely under the frame just to the in side of the front tire gt 3 Position jack stands
86. 00 100 160 15 1800 170 1186 169 200 25 2250 280 300 30 3390 340 1446 192 225 25 2540 280 325 30 3670 340 6 32 UNC 6 40 UNF 8 32 UNC 8 36 UNF 10 24 UNC 10 32 UNF 1 4 20 UNC 53 7 1 4 28 65 10 5 16 18 115 15 105 17 5 16 24 UNF 138 17 128 17 A EN I 16 2 7 16 14 UNC 27 3 1 2 20 UNF 32 3 115 11 120 10 163 14 5 8 11 65 10 88 12 119 16 150 15 203 20 210 20 285 27 5 8 18 75 10 95 15 129 20 170 15 230 20 240 20 325 27 3 4 10 UNC 93 12 140 20 190 27 265 25 359 34 375 35 508 47 3 4 16 UNF 115 15 165 25 224 34 300 25 407 34 420 35 569 47 7 8 9 UNC 140 20 225 25 305 34 430 45 583 61 600 60 813 81 7 8 14 UNF 155 25 260 30 353 41 475 45 644 61 660 60 895 81 Note Reduce torque values listed in the table above on the fastener size the aluminum or base material by 25 for lubricated fasteners Lubricated fasteners strength length of thread engagement etc are defined as threads coated with a lubricant such as graphite or thread sealant such as Loctite Note The nominal torque values listed above for Grade 5 and 8 f
87. 00 D Disassembly 1 Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft Plug both ports and clean the outside of the cylinder IMPORTANT Prevent damage when clamping the cylinder in a vise clamp on the clevis only Do not close vise enough to distort the barrel 2 Mount lift cylinder securely a vise by clamping on the clevis end of the barrel Use of a vise with soft jaws is recommended 3 Loosen head from barrel A On cylinders without a retaining ring slot in the barrel Figs 78 and 79 use a spanner wrench to loosen and remove collar from barrel On cylinders with a retaining ring Fig 80 use spanner wrench to rotate head clockwise until the edge of the retaining ring appears in the barrel open ing Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the opening Rotate the head counter clockwise to remove retaining ring from barrel and head 4 Extract shaft with head and piston by carefully twist ing and pulling on the shaft IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft surface before mount ing in a vise 5 Mount shaft securely in a vise by clamping on the cle vis of the shaft Remove lock nut and piston from the shaft Slide head off the shaft 6 Remove Uni ring and O ring from the piston Re move O ring back up ring rod seal and dust seal from the head 7 Wash parts in
88. 2003 T SERIES Kubota Diesel Engine Rev B 5 2 General Information This Chapter gives information about specifications and repair of the diesel engine used in the Groundsmaster 4000 D General maintenance procedures are described in your Operator s Manual Information on engine troubleshoot ing testing disassembly and reassembly is identified in the Kubota Workshop Manual Diesel Engine 2003 that is included at the end of this section Most repairs and adjustments require tools which are commonly available in many service shops Special Stopping the Engine IMPORTANT Before stopping the engine after mowing or full load operation cool the turbo char ger by allowing the engine to idle at low speed for 5 minutes Failure to do so may lead to turbo charger trouble Kubota Diesel Engine Rev B Page 3 2 tools are described in the Kubota Workshop Manual Diesel Engine V2003 T The use of some specialized test equipment is explained However the cost of the test equipment and the specialized nature of some re pairs may dictate that the work be done at an engine re pair facility Service and repair parts for Kubota engines are sup plied through your Authorized Toro Distributor If no parts list is available be prepared to provide your distrib utor with the Toro model and serial number Groundsmaster 4000 D Specifications Item Description Make D
89. 28 IGNITION TAN 4 SWITCH J5 YELLOW By BLUE BLACK 5 5 nm BLUE oc GM4100 BLACK 35 2 D Q w amp S VIOLET 5 1 n 5 8 E g Groundsmaster 4000 D A BOC A BC DE F GH B GH 102 12 12 A 8 C DE F GH 102 A 8 C DE F A Main Wi H ain Wire Harness P3 P4 P5 P32 P29 P33 P1 P30 P2 P36 INTERCONNECT I NTERCONNECT INTERCONNECT SEAT SW AUDIO ALARM SEAT SW INTERCONNECT TO FRONT SEAT SW INTERCONNECT TO FRONT GM4000 JUMPER Serial Numbers above 230000000 TO THE ENGINE TO THE ENGINE TO THE ENGINE OPTION 2 INTERCON OPTION 1 Page 9 11 P30 SEAT SW P33 2 OPT 1 SEAT SW 2 INTERCONNECT 1
90. 4 Cotter pin Washer Cap screw Lock nut Flat washer Sensing plate Carriage screw Lock nut Flat washer Sensing switch Spacer Carriage screw Slotted hex nut Groundsmaster 4000 D When changing attachments tires or perform ing other service use correct blocks hoists and jacks Make sure machine is parked on a solid level surface such as a concrete floor Prior to raising machine remove any attach ments that may interfere with the safe and proper raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the ma chine is not properly supported by blocks or jack stands the machine may move or fall which may result in personal injury 3 Chock rear wheels and jack up front of machine Support machine on jack stands 4 Remove front wheel next to lift arm that is being re moved 5 Remove cap screw washers and lock nut that se cure lift cylinder pin to lift arm Remove pin and separate lift cylinder and lift arm 6 Remove lock nut that secures lift arm pin Support lift arm and slide pin from frame and lift arm Remove lift arm from frame 7 Remove height of cut chain ball joint mount and ball joint from removed lift arm as required Installation 1 Position lift arm to frame and insert lift arm pin En gage roll pin into frame slots and install lock nut on pin Torque lock nut from 60 to 70 ft lb 81
91. 4 Inner bearing spacer 5 Locknut 15 Clevis pin 25 Wheel hub 6 Castor spacer 16 Lock nut 26 Wheel rim half 7 Thrust washer 17 Carriage screw 27 Castor tire 8 Flange lock nut 18 Castor fork bracket 28 Wheel rim half 9 Grease fitting 19 Shim 29 Plate 10 Flange bushing 20 Castor bracket 30 Flange nut Disassembly 1 Disassemble castor wheel using Figure 12 as a guide Reassembly 1 Assemble castor wheel using Figure 12 as a guide 2 Torque castor wheel lock nut from 60 to 80 ft lb 81 to 108 N m Cutting Units Page 8 12 Groundsmaster 4000 D Chapter 9 TORO Electrical Diagrams Table of Contents ELECTRICAL SCHEMATICS 3 Electrical Schematic S N below 220999999 3 Electrical Schematic S N above 230000001 4 CIRCUIT DIAGRAMS 5 Glow Plug Circuit 5 Crank Circuit 6 Run Transport 7 Run Mow Circuit 8 WIRE HARNESS DRAWINGS 9 Wire Harness S N below 220999999 Main Wire Harness S N below 220999999 10 Main Wire Harness S N above 230000000 11 Main Wire Harness S N above 230000000 12 Engine Wire Harness 13 Engine Wire Harness 14 Front Wire Harness S N below 220999999 Front Wire Harness S N below 220999999 16 Front
92. 49 N m spindle to be serviced see Operator s Manual 6 For drive spindle assemblies Fig 8 remove flange head screws that secure spindle to deck Remove Figure 8 spindle housing assembly with motor mount from deck Lock nut 10 Spindle housing Washer 11 Grease fitting 7 For driven spindle assemblies remove flange head Pulley drive shown 12 Flange head screw screws and lock nuts that secure spindle to deck Re V ring seal if equipped n Spacer Mot t Spindle shaft move spindle housing assembly from the deck O ring if equipped 15 Blade 16 Anti scalp NOTE Early production spindle assemblies included Bearing set 17 Blade bolt seal which has been found to be unnecessary Spacer set 2 plece Discard v ring seal if found in spindle assembly 8 Loosen and remove lock nut from top of spindle shaft Remove washer pulley and v ring seal if equipped from spindle For drive spindle remove motor mount 9 Remove the spindle shaft from the spindle housing which may require the use of an arbor press The spacer should remain on the spindle shaft as the shaft is being removed 10 Remove seals from spindle housing 11 Allow the bearings inner spacer and spacer ring to 5 drop out of the spindle housing Figure 9 1 Bearing 4 12 Using a punch and hammer drive both the bearing 2 Spacer rin
93. 5 0 25 Groundsmaster 4000 D 4 3 Before disconnecting or performing any work on hydraulic system relieve all pressure in system Stop engine lower or support box and or other attachment s Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is injected into the skin it must be surgi cally removed within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Figure 1 Final Position Mark Nut and Body Initial Extend Line Position Finger Tight After Proper Tightening Figure 2 Hydraulic System Rev B Hydraulic System SAE Straight Thread O Ring Port Non adjustable 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil 4 Install the fitting into the port and tighten it down full length until finger tight 5 Tighten the fitting to the correct Flats From Finger Tight F F F T Size F F FT 4 1 4 in nominal hose or tubing 1 00 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 6 8 in 1 50 0 2
94. 5 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 SAE Straight Thread O Ring Port Adjustable 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil 4 Turn back the jam nut as far as possible Make sure the back up washer is not loose and is pushed up as far as possible Step 1 5 Install the fitting into the port and tighten finger tight until the washer contacts the face of the port Step 2 6 To put the fitting in the desired position unscrew it by the required amount but no more than one full turn Step 3 7 Hold the fitting in the desired position with a wrench and turn the jam nut with another wrench to the correct Flats From Finger Tight F F F T Step 4 Size F F F T 4 1 4 in nominal hose or tubing 1 00 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 6 8 in 1 50 0 25 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 Hydraulic System Rev B 4 4 Figure 3 Lock Nut 527 Back up Washer O Ring Figure 4 Figure 5 Groundsmaster 4000 D Towing Traction Unit IMPORTANT If towing limits are exceeded severe damage to the piston pump may occur If it becomes necessary to tow or push the machine tow or push in a forward direction only and at a speed below 3 mph T
95. 6 90 hydraulic fitting 24 Cap screw 8 Lever link 17 O ring 25 Control panel 9 Center lever assembly Hydraulic System Rev B Page 4 90 Groundsmaster 4000 D Removal Installation 1 Park machine on a level surface lower cutting units 1 Install control valve using Figure 71 as a guide stop engine engage parking brake and remove key from the ignition switch 2 sure hydraulic tank is full Add correct oil if nec essary before returning machine to service 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 3 Remove lift lower control valve using Figure 71 asa guide 2 o Ey Groundsmaster 4000 0 4 91 Hydraulic System Rev Lift Lower Control Valve Service Poppet Spacer Wiper Seat O ring Plug Ring Bushing Cap 10 Relief valve poppet 11 O ring 12 Retaining ring Hydraulic System Rev Figure 72 Washer Washer Washer Washer Plug O ring Spring Backup washer Detent spring Plunger Plug O ring Page 4 92 O ring Backup washer Disc Plunger Plug assembly Lockout spring Spring Relief plug assembly Plunger O ring Spool Body Groundsmaster 4000 D Disassembly 1 Plug all ports and clean outside of valve thoroughly 2 Remov
96. 6 Pin 14 Geroter 7 Sleeve 15 O ring 8 Centering springs spacers 16 Spacer Disassembly NOTE Cleanliness is extremely important when repairing steering control units Work in a clean area Before disconnecting the hydraulic lines clean the port area of the steering valve assembly Before disassem bly drain the oil then plug the ports and thoroughly clean the exterior During repairs always protect machined surfaces 1 Remove the seven cap screws from the steering valve assembly 2 Remove end cap geroter spacer geroter drive wear plate seal ring and o rings from housing Fig 74 3 Remove the plug and relief valve Hydraulic System Rev B Page 4 96 17 Geroter drive 18 Wear plate 19 Bearing race 20 Thrust bearing 21 Plug 22 O ring 23 Relief valve 24 Quad seal 4 Slide the spool and sleeve assembly from the hous ing 5 Remove the thrust bearing and bearing races 2 6 Remove the quad seal 7 Use a small blade screwdriver to carefully pry the dust seal from the housing Be careful to not damage the dust seal seat in the housing 8 Remove the pin that holds the spool and sleeve to gether 9 Carefully slide the spool out of the sleeve The cen tering springs and spring retaining ring will stay with the spool as it is removed Groundsmaster 4000 D The centering springs are under tension move the retaining ring carefully 10 Remove the spring retaining ri
97. 7 GN BK 1 ENGINE SHUTDOWN DELAY E FERONT DECK STOP NONE i 49 RUN Bele A X Y eue 227 START I BIS PARKING BRAKE 6500 oR FRONT DECK 05 NEUTRALSWITCH SWITCH MFD BK POSITION E NOT IN NEUTRAL DISENGAGED D1 A i 87 VIO BK A PTO OFF NONE 22 1 LEFT DECK 283 an CCP PTO ENGAGE 283 5 amp 6 LEFT DECK D1 B y IGNITION SWITCH POSITION Ne 04 PTO SHUTDOWN DELAY 2 3 130o 1 TIE SEAT SWITCH 87 fYYYA Wes ty SEAT RELAY 874 T DECK 300 SEAT OCCUPIED Msg TRANSPORT 4 WD SWITCH 8 Ps ar BL RARE UE SHOWN TRANSPORT PTO SGH i B5 86 Y 06 RELAY 10AF 5 ay BK ed Y Groundsmaster 4000 D F6 BK R CONTROLLER 1 1 POWER POINT pisi Run Transport Circuit F7 KUBOTA GLOW RELAY e R 9 ower START 4 4 THERMO Halom 80 Control Current LAMP 2 15 GLOW BN 86 85 y 12 3 16 GND ag d lt Indication Current OPTIONAL gt Logic Direction FUSEBLOCK Serial Numbers below 220999999 shown Page 9 7 ALTERNATOR
98. 7 NE BZ VIO BK frm PK TS 1 rm PTO OFF NONE p NE LEFT DECK jm GN BS ULL BE 2WD PTO 283 etiem te 5 1 lt Y SWITCH l egy 22 72 E 202 PTO ENGAGE 283 586 POSITION D1 B nm Ki 2 lcm 87 SEAT SWITCH PTO SHUTDOWN DELAY MS 2878 2 4 BU a 305 i E A em 87 fva gt SEAT RELAY 1 EN i 87a j 87 Y BK i 105 30 22 i RIGHT DECK 6500 TRANSPORT 4 WD SWITCH EU i Ear a FI SHOWN IN 4WD HO Y RR POSITION D6 PTO RELAY 0 n 10 5 1 v i Groundsmaster 4000 D F6 BK 1 R 9 CONTROLLER H 1 Crank Circuit GLOW PLUG W KUBOTA GLOW RELAY L 1 H GLOW Control Current 2 pin GLOW caine 12 GND oS eS a naication Curren ee ag I me e e Bi OPTIONAL FUSEBLOCK OR Logic Direction Serial Numbers below 220999999 shown Page9 6 ALTERNATOR
99. 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 16 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7 16 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 0 03937 0 001 0 0254 U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume C
100. 9 Stand pipe 17 Hose clamp 2 Petcock 10 Hose clamp 18 Hose 3 O ring 11 Screen filter 19 Hose clamp 4 Strap 12 Dipstick 20 Cap screw 5 Felt strap 13 O ring 21 Cap screw 6 Bushing 14 Reservoir cap 22 Lock nut 7 Bushing 15 Suction hose 23 Hose 8 Hydraulic fitting 16 Tank strainer w o ring 24 Hose Hydraulic System Rev B Page 4 108 Groundsmaster 4000 D Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 3 Drain reservoir into a suitable container see Opera tor s Manual 4 Disconnect hydraulic hoses from reservoir 5 Remove hydraulic reservoir using Figure 84 as a guide Groundsmaster 4000 D Page 4 109 Inspection 1 Clean hydraulic reservoir and suction strainer with solvent 2 Inspect for leaks cracks or other damage Installation 1 Install reservoir using Figure 84 as a guide 2 Using a wrench turn strainer into port at least 1 1 2 to 2 full turns beyond finger tight 3 Reconnect hydraulic hoses 4 Fill reservoir with hydraulic fluid as required see Op erator s Manual Hydraulic System Rev B 9 5 DM gt Hydraulic Oil Cooler Removal The radiator and oil cooler may be hot To avoid possible
101. ACK X 5 4 E 8 x SP4 5 55 9 6 am a lt a a a a a gt gt 1 0 1 2 ond no nc gnd nc D D P9 8 J9 J8 J7 J6 J5 13 12 di 1 TEMP SENDER OIL PRESSURE OVER TEMP FUEL SENDER LH DECK POSITION SW DIODE 4 LH DECK PTO COIL DECK POSITION SW 12V ground p 3 12 fuse ign B start alt L t sender oil ign glow temp fuel pto relay 5 lh pto rh pto 2 wd P6 2wocon p 2 INTERCONNECT Groundsmaster 4000 0 Engine Wire Harness Page 9 13 6 2WD COIL LH DECK PTO COIL Ex lt len P12 DIODE 4 ABCD ajelee uy H DECK 10N SWITCH 1 POSIT P13 Ji FUEL PUMP FUEL PUMP P17 OVERTEMP SW JI FUEL SENDER 5 16 P16 ENGINE RUN SOLENOID
102. AGRAMS Traction Lower Cutting Raise Cutting MOW eec ELE RC A as AME Steering Circuit SPECIAL TOOLS Hydraulic Pressure Test Kit Hydraulic Tester Pressure and Flow Hydraulic Test Fitting Measuring Container TROUBLESHOOTING TESTING Test No 1 Traction Circuit Charge Pressure Test No 2 Traction Circuit Relief Pressure Test No 3 Cutting Deck Circuit Pressure Test No 4 Cutting Deck Gear Pump Flow Test No 5 Cutting Deck Manifold Relief 55 Test No 6 Cutting Deck Motor Case Drain Leakage Test No 7 Steering Circuit Relief Pressure Test No 8 Lift Lower Circuit Relief Pressure Test No 9 Steering and Lift Lower Gear Pump Flow Test No 10 Counterbalance Pressure Test No 11 Rear Traction Circuit RV5 Relief Pressure Test 12 Traction Circuit Reducing Valve PR Pressure ADJUSTMENTS Adjust Front Cutting Unit Lift Flow Control Groundsmaster 4000 D Page 4 1 Chapter 4 Hydraulic System SERVICE AND REPAIRS 49 General Precautions for Removing and Installing Hydraulic System Components 49 Check Hydraulic Lines and Hoses 49 Flush Hydraulic System 50 Charge Hydraulic System
103. Brakes Rev B a 5 S a a E x lt Input Shaft Pinion Gear 35 to 41 ft lb 1 47 to 56 35 to 41 ft lb 47 to 56 N m Figure 28 1 Nut 7 O ring 13 Shim 2 Lockwasher 8 Seal collar 14 Screw 3 Stud 9 Bearing 15 Gear case 4 Locknut 10 O ring 16 Gasket 5 Stake washer 11 Input shaft Pinion gear 17 Cover plate 6 Oil seal 12 Bearing case 18 Dowel pin The following procedures assume the rear axle assem bly has been removed from the machine Removal 1 Remove the cover plate gasket and gear case as sembly from the axle assembly Remove the gasket and any remaining gasket material 2 Remove the retaining rings and the driven gear from the input shaft pinion gear 3 Remove input shaft pinion gear assembly from the gear case Remove the shims and bearing case O rings 4 Release the stake washer and remove the locknut Remove and discard the stake washer 5 Drive the input shaft pinion gear out from the outer bearing cone and bearing case Remove and discard the oil seal and O ring 6 Inspect all gears shafts bearings spacers and cases for damage and wear Replace components as necessary Axles Planetaries and Brakes Rev B Page 6 22 NOTE Replacement input shaft pinion gears are only available in matched ring and pinion sets Installation NOTE When installing new bearing cones press only on the
104. CES 6 3 1 5 8 4 2 T 1 273 CRUISE SWITCH 9 OPTIONAL FUSE BLOCK 2 P6 2 IGNITION SWITCH 29 P19 AUDIO ALARM HIGH TEMP OVER RIDE y CAPACITOR 2 J JA CAPACITOR 1 J2 Groundsmaster 4000 D Main Wire Harness Serial Numbers below 220999999 Page 9 10 SILENCE ALARM RELAY FUEL GAUGE OUR METER PTO SWITC TO RELAY IGH TEMP
105. D Start Engine Shutdown Seat PTO Alarm and Over Temperature Relays These six relays are located under the console housing cover The wiring harness is tagged to identify each relay NOTE The relays may be manufactured by one of two different manufacturers Verify manufacturer name and part number before performing the resistance check on the relay coil NOTE Prior to taking small resistance readings with a digital multi meter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measured value of the component you are testing 1 Verify coil resistance between terminals 85 and 86 with a multimeter ohms setting For the Potter amp Brumfield relay VF4 65F 11 resistance should be from 85 to 95 ohms Figure 21 B For the Hella Electronics relay 66211 resist ance should be from 70 to 80 ohms 2 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is applied and removed from terminal 85 3 Disconnect voltage from terminal 85 and multimeter lead from terminal 87 4 Connect multimeter ohms setting leads to relay ter mi
106. Deck Position Switch 27 Temperature Override Switches 12 SERVICE AND REPAIRS 28 Seat Switch 13 Battery Storage 28 Parking Brake Switch 13 Battery 28 Hour Meter 14 Battery Service 29 Audio Alarm 14 Groundsmaster 4000 D 5 1 Electrical System 6 9 Electrical Schematic Circuit Diagrams and Wire Harness Drawings The electrical schematic circuit diagrams and wire har ness drawings for the Groundsmaster 4000 D lo cated in Chapter 9 Electrical Diagrams Electrical System Page 5 2 Groundsmaster 4000 D Special Tools Order special tools from your Toro Distributor Some tools may also be available from a local supplier Multimeter The meter can test electrical components and circuits for current resistance or voltage NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Figure 1 Skin Over Grease Special non conductive grease Tor
107. E x lt Groundsmaster 4000 D Page 6 3 Axles Planetaries and Brakes Rev B Service and Repairs Brake Assembly 85 to 100 ft Ib 115 to 135 N m 75 to 85 ft lb 101 to 115 N m Figure 1 1 Planetary assembly 7 Flat washer 2 Retaining ring 8 Cap screw 3 Splined brake shaft 9 Flange head screw 4 Brake assembly RH 10 Brake assembly LH 5 O ring 11 Jam nut 6 Hydraulic wheel motor 12 Compression spring Remove Brake Assembly Fig 1 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Drain oil from planetary wheel drive brake assembly see Operator s Manual Axles Planetaries and Brakes Rev B 6 4 13 14 15 16 17 18 Brake cable Spring plate Flange head screw Tire and wheel assembly Lug nut Gasket Groundsmaster 4000 D When changing attachments tires or perform ing other service use correct blocks hoists and jacks Make sure machine is parked on a solid level surface such as a concrete floor Prior to raising machine remove any attach ments that may interfere with the safe and proper raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the ma chine is not properly supported by blocks or jack stands the machine may move or fall which may result in personal injury 3 Chock rear wheels and jack up
108. ERTICAL ENDPLAY Figure 20 4 Dial indicator 5 Knuckle pin 6 Support shim location Axle case support Axle case Bevel gearcase ena Figure 21 4 Dial indicator 5 Axle bearing shims Axle support Upper bevel gear Differential shaft gear oN Figure 22 4 Dial indicator 5 Axle bearing shims 1 Axle cover assembly 2 Lower bevel gear 3 Axle gear Groundsmaster 4000 D 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 turning and measure the lower bevel gear to axle gear backlash Fig 22 LOWER BEVEL GEAR BACKLASH 0 004 to 0 016 in 0 10 to 0 40 mm 10 Adjust backlash by increasing or reducing axle bear ing shim thickness see Axle Shafts in this section of this manual Groundsmaster 4000 D Page 6 19 NOTE Axle bearing shims are available in 0 008 in 0 2 mm 0 012 in 0 3 mm and 0 020 in 0 5 thickness 11 Tighten axle cover screws from 17 to 20 ft lb 23 to 27 N m 12 Coat a new O ring with grease and install the bevel gear case axle case assembly on the axle support Tighten mounting screws and nuts from 35 to 41 ft lb 47 to 56 Fig 13 Axles Planetaries and Brakes Rev B a 5 S oa a E x lt and Brakes Differential Shafts The following procedure
109. Example C1 is the con nection port from the LH deck lift cylinder and CHG is the charge circuit connection See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port For cartridge valve service procedures see Hydraulic Control Manifold Service 4 Wheel Drive in this section Refer to Figure 55 for cartridge valve installation torque Groundsmaster 4000 D Page 4 73 Hydraulic System Rev B Hydraulic Manifold Filter Manifold Figure 56 1 Filter manifold 9 Flat washer 17 90 hydraulic elbow 2 45 hydraulic elbow 10 Hydraulic fitting 18 Hydraulic hose 3 Test nipple 11 O ring 19 Hydraulic fitting 4 Fitting cap 12 O ring 20 90 hydraulic fitting 5 O ring 13 Hydraulic fitting 21 O ring 6 O ring 14 Hydraulic hose 22 Hose clamp 7 O ring 15 O ring 23 Filter hose 8 Cap screw 16 O ring Removal 2 Disconnect hydraulic lines from manifold and put NOTE The ports on the manifold are marked for easy identification of components Example P2 is the gear pump connection port and CD is the connection for the case drain from the deck motors See Hydraulic Sche matics to identify the function of the hydraulic lines and cartridge valves at each port 1 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter Hydraulic System Rev B Page 4 74 caps or plugs on op
110. Flat washer Knob Battery plate Negative cable Positive cable Carriage screw Gasket Bushing Stand pipe Fuel sender Lock washer Phillips head screw Page 3 10 135 to 165 ft lb 183 to 223 N m Fuel hose Hose clamp Elbow fitting Fuel cap Locking flange nut Speed nut Tank cover Phillips head screw Vent tube Insulated clip Washer head screw Hose clamp ROPS assembly Groundsmaster 4000 D Because diesel fuel is highly flammable use cau tion when storing or handling it Do not smoke while filling the fuel tank Do not fill fuel tank while engine is running hot or when machine is in an enclosed area Always fill fuel tank outside and wipe up any spilled diesel fuel before start ing the engine Store fuel a clean safety ap proved container and keep cap in place Use die sel fuel for the engine only not for any other purpose Check Fuel Lines and Connections Check fuel lines and connections periodically as recom mended in the Operator s Manual Check lines for dete rioration damage leaking or loose connections Replace hoses clamps and connections as necessary Drain and Clean Fuel Tank Drain and clean the fuel tank periodically as recom mended in the Operator s Manual Also drain and clean the fuel tank if the fuel system becomes contaminated or if the machine is to be stored for an extended period To clean fuel tank
111. Hydraulic System Rev Page 4 34 Groundsmaster 4000 D Procedure for Cutting Deck Motor Case Drain Leakage Test NOTE Overa period oftime a deck motor can wear in ternally A worn motor may by pass oil to its case drain causing the motor to be less efficient Eventually enough oil loss will cause the deck motor to stall under heavy cutting conditions Continued operation with a worn inefficient motor can generate excessive heat cause damage to seals and other components in the hy draulic system and affect quality of cut NOTE One method to find a failing or malfunctioning deck motor is to have another person observe the ma chine while mowing in dense turf A bad motor will run slower produce fewer clippings and may cause a differ ent appearance on the turf 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Parkmachine ona levelsurface with the cutting units lowered and off Make sure engine is offand the parking brake is engaged Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section NOTE The side deck motors are connected in series To isolate a faulty motor both motors in the circuit may have to be tested by starting with the leftside motor first 3 Disconnect hose from return of the motor to be teste
112. NIM HH e 3 Z149 ARP gv mH 25 09211999 gas NI L 9 5472 39041 00 8d 1 0 007 159 E ONIH331S EN e 1 HS Wn T Iv 390515099 3808 08 J L e 1 ONIM H1 DONIS 8808 002 H3MOYL3P1 15 LI LI LI M LI VA LI ld dn 1 65 E z 44 LI LI i LI i L l oooe 1 Id 4 D gt 1 Lom 4 1 7 000 YOLOW MOSQ LNOYS z ll NM ese ee Groundsmaster 4000 D Page 4 14 Hydraulic System Rev B Hydraulic flow for the mow circuit is supplied by two sec tions of the gear pump The gear pump section closest to the piston traction pump supplies hydraulic flow to the side cutting units while the next gear pump section supplies the front cutting unit Each cutting deck is controlled by a hydraulic manifold equipped with a solenoid control valve SV1 bypass cartridge BY1 brake cartridge BR1 and relief car tridge R1BR When the the deck solenoid valve SV1 is not energized P
113. OIR A TO CHARGE CIRCUIT V CASE DRAIN TO RESERVOIR CHARGE CIRCUIT FROM OIL lt TO LIFT LOWER CIRCUIT K TO STEERING era 1 X Hydraulic System Rev Page 4 46 FILTER Working Pressure Low Pressure Return or Suction FROM RESERVOIR Flow Groundsmaster 4000 D Procedure for Traction Circuit Reducing Valve Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Figure 36 1 2WD 4WD control manifold Prevent personal injury and or damage to equip 2 Pressure test port ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section 3 Connect a 1000 PSI gauge to test port on 2WD AWD control manifold under radiator Fig 36 4 Start the engine and put throttle at full engine speed 2730 30 RPM 5 gt 5 Sitonseat apply brakes fully and slowly depress the traction pedal in the reverse direction While pushing traction pedal look at pressure reading on gauge Figure 37 GAUGE READING BE 650 PSI approximate 1 Manifold lower side 2 Reducing val
114. OVER RIDE SW OVERTEMP SHUT DOWN DIODE PACK CAPACITOR 1 CAPACITOR 2 4 WD SWITCH P14 P15 J6 P16 P17 P18 P19 P20 P21 J1 J2 J3 J4 P22 Ioa 22273 2 2h 42524 6 T fh 4 22 AB 1 1 Pree 8 x ul z Q ilz 155 5 5 2 a Zay 3 5 d m uide ORANGE 2 gt 5 9 3 a SPT 4 y POSI TRAC YELLOW TAN 5 P34 a YELLOW T 1 WHITE 8 1 2 YELLOW 3 YELLOW YELLOW SILENCE 4 ALARM P13 SWITCH BLUE 7 BLACK m 8 Sn BLACK m 3 CRUISE TM VIOLET BLACK TAN P23 11 GRAY 1 o 2 8 m 5 GREEN BLACK 5 implements P10 9 BLACK WHITE GREEN 5 GRAY CRUISE 9 P24 Reay 4 2 5 3 ruseslock 5 l 5 6 YELLOW S 7 2 ENGINE 2 PINK 4 x BLACK 5 C BLACK a POWER POINT P31 m E 5 aa x ORANGE 2 VIOLET 2 Eu A 2 ORANGE P26 Relay 2 4 mn 3 x BLACK 5 FUSEBLOCK n SPI BLACK 7 VIOLET 8 ORANGE 2 YELLOW 3 GLOW OPTIONAL pg m P27 FUSEBLOCK m 6 WHITE 2 GREEN IGNITION SWITCH P6 PINK T 4 ORANGE GREEN GREEN YELLOW 5 2 WHITE P
115. Seal sub assembly 38 Roll pin 39 Bearing 40 Dowel bushing 41 Cradle sub assembly 42 Cap screw 43 Button head cap screw 44 Bushing 45 Bearing Groundsmaster 4000 D Disassembly 1 Position the pump into a protected jaw vise clamp ing onto the outer portion of the flange with the cap screws up Mark the relationship of the working ports for reassembly identification to the servo control as sembly with a scribe Remove the four cap screws 15 retaining backplate 20 2 Lift backplate 20 straight up off drive shaft 21 and housing 19 Remove valve plate 18 from backplate 20 or from rotating kit assembly 6 still in housing 19 3 From backplate 20 remove bypass valve 14 for ward relief valve 26 and reverse relief valve 16 Note Mark the valves in relationship to the cavity it was removed for reassembly purposes 4 Remove housing gasket 32 from housing 19 or backplate 20 5 With pump still in vise remove the six socket head screws 17 retaining the servo control assembly 28 Remove the control assembly and control housing gas ket 34 from the housing Remove orifice plates 30 noting location for reassembly Remove nut 22 lock washer 23 and control arm 27 from servo control in put shaft Note position of control arm for reassembly 6 To remove rotating kit assembly 6 from housing first remove pump from vise holding the rotating kit as sembly in position
116. TO switch OFF hydraulic flow by passes the deck motor through the bypass cartridge BY1 When the PTO switch is turned ON the solenoid valve SV1 energizes causing a shift of the by pass cartridge BY1 and allowing hydraulic flow to the deck motor Brake cartridge BR1 and relief cartridge R1BR control the stopping rate of the blade when the solenoid control valve is de energized as the PTO switch is turned OFF Groundsmaster 4000 D 4 15 Return oil from the deck motors is directed to the cool er and oil filter Deck motor case drain leakage returns to the hydraulic reservoir Maximum mow circuit pressure is limited at each deck by a relief valve R1BY in the hydraulic manifold The front and left deck relief valves are set at 3000 PSI and the right deck relief valve is set at 2000 PSI Circuit pressure can be measured at port G of the hy draulic manifold for each cutting deck Hydraulic System Rev B 2 Oo Ey lt 10 9 437 1 000 JejseuispunoJ5 3570095 1 pepe OdSNVH L 7 6 e Os ae Sas QU Use 872 88 j M P GAY SHO t RE
117. The circuitry of these switches is shown in the chart below With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each position Verify continuity between switch termi nals SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS Figure 13 1 Transport switch 3 Temp override switch 2 Alarm silence switch 4 Control console BACK OF TRANSPORT SWITCH Figure 14 BACK OF ALARM SILENCE AND TEMPERATURE OVERRIDE SWITCHES Figure 15 Electrical System 5 12 Groundsmaster 4000 D Seat Switch The seat switch is normally open and closes when the operator is on the seat If the traction system or PTO switch is engaged when the operator raises out of the seat the engine will stop The seat switch and its electri cal connector are located directly under the seat Test ing of the switch can be done without seat removal by disconnecting the seat wire from the machine wiring harness 1 Make sure the engine is off 2 Disconnect electrical connector for the seat switch 3 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals 4 With no pressure on the seat there should be no continuity between the seat switch terminals 5 Press directly onto the seat switch through the seat cushion There should be continuity as the seat cushion approaches the bottom of its trave
118. There may possibly be more than one tions and specific test procedures cause for a machine malfunction Hydraulic System Rev B Page 4 20 Groundsmaster 4000 D Hydraulic System Hydraulic System Rev B Groundsmaster 4000 D Page 4 21 Rev E Hydraulic System Rev Page 4 22 Groundsmaster 4000 D Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks See the Special Tools section in this Chapter Before Performing Hydraulic Tests IMPORTANT All obvious areas such as oil supply filter binding linkages loose fasteners or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem Precautions for Hydraulic Testing Failure to use gauges with recommended pres sure PSI rating as listed in test procedures could result in damage to the gauge and possible personal injury from leaking hot oil All testing should be performed by two 2 people One person should be in the seat to oper ate the machine and the other should read and record test results Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil Controls must be operated with the ignition switch in OFF Remove key from the igni tion switch Keep body and hands away from pin hole leaks
119. VERRIDE OVERRIDE SHUT DOWN DIODE PACK CAPACITOR 1 CAPACITOR 2 4 WD SWITCH P14 P15 J6 P16 P17 P18 P19 P20 P21 J1 J2 J3 J4 P22 2 3 25 1 02 3 22 3 475524 152 2 54 712 Ihr Bie 3 5 4 5 A B C F G H 1 E E EE TE EE EN PINK YELLOW WHITE Sif PINK PINK L BLUE 9 a E 3 WHITE YELLOW gt gt gt gt x YELLOW 3 2 5 1 SILENCE pig 5 8 a BLUE ALARM BLUE u e gt 6 gt
120. Wire Harness S N above 230000000 Front Wire Harness S N above 230000000 18 2 Eos og ua Groundsmaster 4000 D Page 9 1 Electrical Diagrams Rev B This is intentionally blank Electrical Diagrams Rev B 9 2 Groundsmaster 4000 D ALTERNATOR B R L PK RUN SOLENOID R HOLD w RBK s s I 47777 ____________ FU PULL w G G BK BK GY GY TEMP SENDER GN w 1 ENGINE OIL PRESSURE BK re BU dr co a BU FUEL SENDER 5 PrF 55 544 GN 84 FUEL PUMP 5 9 R E a T E E GLOW PLUGS 4 m m gt e 5 9 xu 5 i 87 py gt 5 5 gt Y ori ALARM 5 m N 5 GN 5 ALARM RELAY GN E W Y em FUSIBLE LINK PK V 1 zs L ogo e aoge
121. able point of measure These two measurements should be the same within a tolerance of 1 8 3 mm D Rotate spring shaft in rear arm assembly until correct dimension is attained Shaft will rotate freely inside the assembly All adjustments must be made with the rod end of the rear arm bolted to the deck E Raise and lower the deck and recheck dimen sions for correct alignment Tighten rod end jam nut to 114 ft lb 155 on the rear arm assembly NOTE Due to differences in grass conditions and the counterbalance setting of traction unit it is advised that grass be cut and appearance checked before formal cutting is started Refer to Operator s Manual for cor recting cutting unit mismatch procedures Chassis Page 7 10 Groundsmaster 4000 D This is intentionally blank Groundsmaster 4000 D Page 7 11 Chassis Lift Arm Yoke Joint 27 to 33 ft lb 37 to 44 6 7 8 150 to 180 ft Ib 14467 203 to 244 N m Figure 11 1 Side cutting deck LH shown 7 Cap screw 13 Cotter pin 2 Deck mount LH shown 8 Flat washer 14 Slotted hex nut Shim 9 Yoke joint 15 Flange head screw 4 Base mount 10 Spacer 16 Flat washer 5 Plate 11 Thrust washer 17 Lock nut 6 Rubber pad 12 Hardened washer Removal 4 Remove cap screws and flat washers that secure 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition swi
122. ace as necessary Ifthe total ofthe two flows is 7 GPM but individual circuit flow is less than 3 5 GPM e g steering circuit has 2 GPM and lift circuit has 5 GPM suspect a problem with the proportional valve in the gear pump Figure 30 1 Hydraulic tank cap 3 Steering circuit hose 2 Lift circuit hose Figure 31 3 Steering circuit 4 Proportional valve 1 Gear pump backplate 2 Lift circuit Hydraulic System Rev B 5 gt TEST 10 Counterbalance Pressure Using Pressure Gauge gt LIFT LOWER CONTROL VALVE LH WING DECK LIFT vis M p RH WING DECK LIFT Y TO RESERVOIR CHARGE CIRCUIT TO STEERING CIRCUIT RESERVOIR FROM OIL FILTER High Pressure Low Pressure Return Suction gt Hydraulic System Rev Page 4 42 Groundsmaster 4000 D Procedure for Counterbalance Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic
123. act area should be in the center of each tooth and extend 1 3 to 1 2 way across each tooth from the toe small end Fig 38 10 Adjust side gear shims if necessary to correct tooth contact Recheck differential pinion gear to side gear backlash if any changes are made 11 After backlash and tooth contact have been ad justed align the hole in the differential pinion shaft with the hole in the differential case and install a new spring pin Axles Planetaries and Brakes Rev B 6 26 Rev E Figure 37 1 Vise 3 Dial indicator 2 Differential gear case More than 35 total tooth contact eie 222 1 3 to 1 2 of entire width from small end of tooth Figure 38 12 Install differential gear assembly in right side axle support half 13 Coat a new o ring with grease and install left side axle support half Tighten axle support case screws from 35 to 41 ft lb 47 to 56 14 Install input shaft pinion gear assembly see Input Shaft Pinion Gear in this section of this manual 15 Coat new o rings with grease align differential shaft splines with differential gear assembly and slide differ ential shaft assemblies onto axle support 16 Install bevel gear case axle case assemblies see Bevel Gear Case Axle Case Assembly in this section of this manual Groundsmaster 4000 D Pinion Gear to Ring Gear Engagement 4 Wheel Drive Axle The final position of the pinion gear is verified by using
124. acting oil cooler hardware Groundsmaster 4000 D Page 7 15 Chassis This is intentionally blank Chassis Page 7 16 Groundsmaster 4000 D Chapter 8 TORO Cutting Units Table of Contents SPECIFICATIONS 2 SERVICE AND REPAIRS 6 TROUBLESHOOTING 3 Front Cutting Unit 6 Factors That Can Affect Quality of Cut 3 Side Cutting 8 ADJUSTMENTS 5 tae es 4 Blade Spindle Service 10 Castor Wheel Tire Pressure 4 Castor Forks and Wheels 12 Blade Stopping Time 4 2 E o Groundsmaster 4000 D Page 8 1 Cutting Units Specifications MOUNTING Cutting decks are supported by lift arms controlled with individual hydraulic lift levers CONSTRUCTION Deck chamber is welded 12 gauge steel construction reinforced with channels and plates HEIGHT OF CUT RANGE 1 to 5 2 54 cm to 12 7 cm in 1 2 1 27 cm increments Front deck height of cut adjustment is achieved by changing spacers on cas tor wheels and adjusting length of deck support chains Side deck adjustment requires adding or removing spacers from the castor forks re positioning the castor wheel axles in the castor forks and securing the pivot arms to the correct height of cut bracket holes
125. age 4 88 8 Install dowel pins in body IMPORTANT Do not dislodge o rings pressure seals or back up rings during final assembly 9 Gently slide the rear cover onto the assembly using marker or scribe mark for proper location Firm hand pressure should be sufficient to engage the dowel pins 10 Position the motor with rear cover downwards Care fully slide the front flange onto the assembly using mark er or scribe mark for proper location 11 Install the four cap screws and hand tighten IMPORTANT Avoid using excessive clamping pressure onthe motor housing to prevent distorting the housing 12 Place motor front flange in a vise and alternately torque the screws from 33 to 40 ft Ib 45 to 55 13 Put a small amount of hydraulic oil in port on motor and rotate driveshaft one revolution Protect the shaft if using a pliers If drive shaft binds disassemble motor and repeat assembly process 14 Remove motor from vise Groundsmaster 4000 D 9 Ey This page is intentionally blank Groundsmaster 4000 D Page 4 89 Hydraulic System Rev B Lift Lower Control Valve Figure 71 1 Control valve assembly 10 Cotter pin 18 O ring 2 Valve bracket 11 RH lever assembly 19 Cap screw 3 Grommet 12 Spacer 20 Hydraulic fitting 4 Cap screw 13 Cap screw 21 Hydraulic fitting 5 Lock nut 14 Knob 22 O ring 6 Pivot bracket 15 Lock nut 23 Flat washer 7 LH lever assembly 1
126. al is depressed in either direction The switch is located on the right side of the piston traction pump Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester across the two switch terminals With the engine turned off slowly push the traction pedal in a forward or reverse direction while watching the continuity tester There should be indications that the traction neutral switch is opening and closing Allow the traction pedal to return to the neutral position There should be continuity across the switch terminals when the traction pedal is in the neutral position See Piston Pump Control Assembly in Chapter 4 Hy draulic Systems for disassembly and reassembly proce dures for the neutral switch Diode Assemblies The diodes D2 D4 D5 and D6 Fig 38 are used for cir cuit protection that occur when a hydraulic valve sole noid is de energized Diode D2 is in the Transport Mow circuit D4 is in the left cutting deck circuit D5 is in the front cutting deck circuit and D6 is in the right cutting deck circuit The diodes plug into the wiring harness Testing The diodes can be individually tested using a digital multimeter diode test or ohms setting and the table to the right Figure 37 1 Piston pump bottom 2 Neutral switch 1 Diode 2 Male terminal Multimeter Red Lead on Terminal Female Groundsmaster 4000 D Page 5 25 Figure 38 3 Fema
127. al sparks away from the battery do not smoke Nausea may result if the gases are inhaled Un plug charger from electrical outlet before con necting or disconnecting charger leads to or from battery posts IMPORTANT Do not remove fill caps while clean ing 2 Check battery condition weekly or after every 50 hours of operation Keep terminals and entire battery case clean because a dirty battery will discharge slowly A Clean battery by washing entire case with a solu tion of baking soda and water Rinse with clear water B Coat battery posts and cable connectors with skin over grease Toro Part No 505 165 or petro leum jelly to prevent corrosion Electrical System Page5 28 4 Store battery in a cool atmosphere to avoid quick de terioration of the battery charge 5 To help prevent the battery from freezing make sure it is fully charged see Battery Service 3 Battery cables must be tight on terminals to provide good electrical contact Connecting cables to the wrong post could re sult in personal injury and or damage to the electrical system 4 If corrosion occurs at terminals disconnect cables Always disconnect negative cable first Clean clamps and terminals separately Reconnect cables with positive cable first Coat battery posts and cable connectors with skin over grease Toro Part No 505 165 or petroleum jelly to prevent corrosion 5 Check electrolyte level every 25 o
128. al System Page 5 10 Figure 9 1 Charge indicator 2 Engine oil pressure 3 High temp shutdown 4 Glow plug indicator Figure 10 1 Charge indicator 2 Engine oil pressure 3 High temp shutdown 4 Glow plug indicator 5 Warning light front 6 Warning light back Groundsmaster 4000 D PTO Switch The PTO switch is attached to the control console next to the operator seat Fig 11 The switch terminals are marked as shown in Figure 12 The circuitry of the PTO switch is shown in the chart be low With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each position Verify continuity between switch terminals NOTE The PTO ON position requires lifting and push ing the lever toward the switch keyway The PTO OFF position occurs when the lever is pushed opposite the keyway SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS PTO OFF Figure 11 1 PTO switch 2 Control console 9 4 5 6 1 2 34 BACK OF PTO SWITCH Figure 12 Groundsmaster 4000 D Page 5 11 Electrical System Transport Alarm Silence and Temperature Override Switches The transport alarm silence and temperature override rocker switches are located on the control console Fig 13 These switches have common switching logic The switch terminals are marked as shown in Figure 14 and Figure 15
129. alignment and ground following Check lift arms and cutting unit pivot linkages for wear damage or binding Also inspect for bent or damaged pivot shafts 8 Roller and castor wheel condition rollers and caster wheels should rotate freely Replace bearings if worn or damaged 9 Grass conditions Mow when grass is dry for best cutting results Also remove only 1 2 5 cm or 1 3 of the grass blade when cutting 2 2 5 o Groundsmaster 4000 D Page 8 3 Cutting Units Adjustments Never install or work on the cutting units or lift arms with the engine running Always stop en gine and remove key first See Operator s Manual for adjustment procedures for the cutting units on the Groundsmaster 4000 0 Castor Wheel Tire Pressure Castor tires on the front and side decks should be in flated to 50 psi 3 5 bar Blade Stopping Time The blades of the cutting deck are to come to a complete stop in approximately 5 seconds after the cutting deck engagement switch is shut down NOTE Make sure the decks are lowered onto a clean section of turf or hard surface to avoid dust and debris To verify this stopping time have a second person stand back from the deck at least 20 feet and watch the blades on one of the cutting decks Have the operator shut the cutting decks down and record the time it takes for the blades to come to a complete stop If this time is greater than 7 seconds the braking
130. ally blank Groundsmaster 4000 D Page 4 57 Hydraulic System Rev B Piston Traction Pump 85 to 95 ft lb 115 to 128 N m Figure 41 1 Hydraulic T fitting 11 O ring 21 Clamp 2 O ring 12 Hose connector 22 Roll pin 3 O ring 13 90 hydraulic fitting 23 Piston pump 4 90 hydraulic fitting 14 O ring 24 Gear pump 5 O ring 15 Hydraulic T fitting 25 Coupler 6 O ring 16 Hydraulic fitting 26 O ring 7 Hydraulic fitting 17 Fitting cap 27 Spacer 8 O ring 18 Hydraulic fitting 28 Cap screw 9 O ring 19 Cap screw 29 Washer 10 Hydraulic fitting 20 Flat washer Hydraulic System Rev B Page 4 58 Groundsmaster 4000 D Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 To prevent contamination of hydraulic system during removal thoroughly clean exterior of pump assembly 3 Remove traction rod from control arm on piston pump by removing lock nut spacer and cap screw 4 Disconnect two wires from neutral switch on traction pump 5 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 6 Puta drain pan below the pump assembly Remove hydraulic hoses and fittings connected to piston and gear pumps Put plugs or caps on disconnected hydrau lic hoses to prevent contamination of
131. alve in a counterclockwise direc tion A 1 8 turn on the screw will make a measurable change in relief pressure D Reinstall and tighten cap to secure adjustment Recheck relief pressure and readjust as needed 11 Disconnect tester from manifold and hose Recon nect hydraulic hose that was disconnected for test pro cedure Figure 22 1 Front deck manifold 3 RHdeck manifold 2 LH deck manifold Figure 23 3 Relief valve cap Deck manifold 2 Relief valve Hydraulic System Rev B 2 5 gt 4 gt 170 TEST 6 Cutting Deck Motor Case Drain Leakage Using Tester with Pressure Gauges and Flow Meter TRACTION CIRCUIT 94 1 2 12 248 ile LI 1 EI E TO LIFT LOWER CIRCUIT m s KAS TO STEERING CIRCUIT OIL COOLER A FROM RESERVOIR LH DECK MOTOR RH DECK 147 117 Na LIN 147 FRONT DECK MOTOR 24 Ew vA Milliliters in 15 sec Ounces in 15 sec A Y 95 3 2 6 4 MEASURING me CONTAINER 12 8 16 0 19 2 22 4 Working Pressure 25 6 Low Pressure jala 2 28 8 Return Suction 32 0 gt E
132. ame time take the tem perature of the cell B Temperature correct each cell reading For each 109F 5 59C above 809F 26 79C add 0 004 to the specific gravity reading For each 109F 5 59C be low 809F 26 79C subtract 0 004 from the specific gravity reading 1009F 1 245 Example Cell Temperature Cell Gravity 1009F minus 809F equals 209F 37 79C minus 26 79 equals 11 09C 209F multiply by 0 004 109F equals 0 008 119C multiply by 0 004 5 59 equals 0 008 ADD conversion above 0 008 Correction to 809F 26 79C 1 253 Electrical System 9 C If the difference between the highest and lowest cell specific gravity is 0 050 or greater or the lowest cell specific gravity is less than 1 225 charge the bat tery Charge at the recommended rate and time giv en in Charging or until all cells specific gravity is 1 225 or greater with the difference in specific gravity between the highest and lowest cell less than 0 050 If these charging conditions can not be met replace the battery 3 Perform a high discharge test with an adjustable load tester This is one of the most reliable means of testing a battery as it simulates the cold cranking test A commercial bat tery load tester is required to perform this test CAUTION Follow the manufacturer s instructions when us ing a battery tester A Check the voltage across the battery terminals prior to testing the battery If the voltage
133. amp is on B Glow relay is energized C Glow plugs are energized D Glow indicator lamp goes out and glow plugs deenergize after 10 seconds 4 Place ignition switch in the START position Verify the following while in the START position A Glow indicator lamp is out B Glow relay is energized C Glow plugs are energized D Power to terminal 1 of the glow controller NOTE If there is no power to terminal 1 of the glow con troller verify continuity of the circuitry from the ignition switch to the controller and perform step 4 again see Chapter 9 Electrical Schematics and Diagrams Groundsmaster 4000 D 5 21 p re OE I DEL TGCIO BA Figure 30 1 Glow controller end view 3 Controller side view 2 Controller top view 5 If any of the conditions step 3 are not met or power to terminal 1 exists and any of the other conditions in step 4 are not met A Verify continuity of the circuitry from the battery to the glow relay and glow plugs see Chapter 9 Elec trical Schematics and Diagrams B Verify continuity of the circuitry from the battery to ignition switch glow controller glow lamp glow relay and ground see Chapter 9 Electrical Sche matics and Diagrams C Replace parts as necessary 6 Connect electrical connector to the run solenoid Electrical System 6 9
134. and forth until detent action is detected Back out the switch until the detent action is very slight B Attach the leads from a test light to the switch ter minals Note A multimeter could be used instead of a test light C Move the link out of the detent position The test light will go on Screw in the switch until the light goes off Mark this as position A Fig 48 Move the link to the detent position and the test light should come back on D Leaving the link in the detent position the light will remain on Screw in the switch until the light goes off Mark this position E Unscrew the switch one third of the distance be tween and A Install and tighten the set screw 17 in one of the upper quadrants of the hex of the switch adapter Fig 48 Torque set screw from 28 to 34 in Ib 3 2 to 3 8 Groundsmaster 4000 D Page 4 65 5 Test the switch by moving the control arm to the det ent position the light should be on Move the control arm out of detent the light should go off 6 Remove test light and put servo control assembly into operation Reassembly Step 4 C Reassembly Step 4 D Reassembly Step 4 E Figure 48 Hydraulic System Rev B 2 5 gt Hydraulic Control Manifold 4 Wheel Drive Figure 49 1 Frame assembly 8 Fitting cap 14 Hydraulic fitting 2 Manifold 9 Hydrau
135. aring cone 3 from spindle Remove bearing cups 4 and 7 from housing 6 Groundsmaster 4000 D Page 6 11 Planetary Wheel Drive Assembly Figure 7 NOTE Use new seal kit when assembling planetary wheel drive 1 Clean parts in solvent Inspect parts for damage or excessive wear and replace as necessary 2 Install lip seal 2 to spindle 1 3 Press bearing cups 4 and 7 into housing 6 4 Press bearing cone 3 onto spindle 1 5 Install seal 20 to housing 6 Assemble housing 6 to spindle 1 6 Press bearing cone 8 onto spindle and secure with thrust washer 9 and retaining ring 10 7 Install o ring 21 then assemble ring gear 11 to housing 6 with cap screws 19 Torque cap screws to 9 ft lb 12 8 Install carrier assembly 18 9 Install input shaft 17 10 Install thrust washer 16 and input spacer 15 11 Install o ring 22 then install cover plate 14 Se cure cover with retaining ring 12 12 Check operation of planetary wheel drive before installing assembly on the machine With a constant turning force applied rotation of the planetary should be consistent If there is more drag at certain points gears are not rolling freely and the planetary should be ex amined for improper assembly or damaged compo nents Axles Planetaries and Brakes Rev B a 5 9 x lt and Brakes Rear Axle Assembly 70 ft lb maximum 94
136. artridge valve for proper operation and seal ing IMPORTANT Use care when handling the valve car tridge Slight bending or distortion of the stem tube can cause binding and malfunction B Thread cartridge valve carefully into manifold port The valve should go in easily without binding C Torque cartridge valve using a deep socketto val ue identified in manifold illustration D If cartridge is solenoid operated carefully install solenoid coil to the cartridge valve Apply Loctite 242 or equivalentto the threads ofthe valve Torque nut to value identified in manifold illustration 8 If problems still exist remove valve and clean again or replace valve 6 lt 50 ft Ib PLUG TORQUE 4 Zero Leak 20 ft Ib 27 N m 6 Zero Leak 25 ft Ib 34 8 Zero Leak 50 ft Ib 67 N m Directional valve ports PD1 amp PD2 10 4 zero leak plug with O ring 11 6 zero leak plug with O ring 12 Orifice 050 Figure 51 1 Manifold body 6 2 Solenoid valve port SV 7 Pressure reducing valve port PR 3 Solenoid coil 8 Relief valve port RV 4 Check valve port CV 9 Orifice 030 5 Nut Groundsmaster 4000 D 4 69 Rev 13 8 zero leak plug with O ring Hydraulic System Rev B 2 Ey Hydraulic Control Manifold Deck Drive Figure 52 1 Hydraulic manifold front deck 10 O ring 19 Elbow 90 2 Quick fitting 11 Cap screw 20 Hydraulic fi
137. askets 14 and pressure seals 13 from wear plates 15 by carefully prying out with a sharp tool IMPORTANT Do not damage the seal bore in the front plate during seal removal 14 Remove shaft seal 1 and washer 2 from front plate 15 15 Remove plug 7 and washer 9 from rear adapter plate 24 16 Remove proportional valve 6 from backplate as sembly 27 Groundsmaster 4000 D Page 4 55 Inspection 1 Clean and dry all pump components Remove nicks and burrs from all parts with emery cloth 2 Check spline drive shaft for twisted or broken teeth Also check for damaged keyway on drive shaft that drives the slip fit gears of the pump 3 Inspect both the drive gear and idler gear shafts at bushing points and seal area for rough surfaces and ex cessive wear 4 Replace gear assembly if shaft measures less than 873 inch 22 17mm in bushing area One gear assem bly may be replaced separately shafts and gears are available as assemblies only The slip fit gear is avail able separately 5 Inspect gear faces for scoring or excessive wear 6 Replace gear assembly if gear width is below 1 181 inch 30 00 mm 7 Assure that snap rings are in grooves on either side of drive and idler gears 8 If any edge of gear teeth is sharp break edge with emery cloth 9 Oil groove in bushings in front plate backplate and adapter plates should be in line with dowel pin holes and 180 degrees apart This
138. asteners are based on 75 of the mini Note Torque values may have to be reduced when mum proof load specified in SAE J429 The tolerance is installing fasteners into threaded aluminum or brass approximately 10 of the nominal torque value Thin The specific torque value should be determined based height nuts include jam nuts Product Records and Maintenance Page 2 4 Groundsmaster 4000 D Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Class 8 8 Bolts Screws and Studs with Thread Size Regular Height Nuts Class 8 or Stronger Nuts M6 X 1 0 M10 X 1 5 M12 X 1 75 M16 X 2 0 M20 X 2 5 Note Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite Note Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based Groundsmaster 4000 D 640 60 N cm 26 3 38 4 ft lb 52 5 53 5 ft lb 72 7N m Page 2 5 Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 78 7 in Ib 885 80 N cm 133 13 in Ib 96 9 in lb 1018 100 133413in b 1500 150 27 2 ft lb 36 3 N m 66 7 ft lb 90 10 92 9 ft lb 125 12 N m 166 15 ft lb 225 20 N m 229 22 ft lb 310 30 N m 325 33
139. bearing cup should be flush with the mount surface 2 Place rubber pad and plate into deck mount Make sure that tabs on plate and pad align with slots in base mount 3 Position yoke joint with base mounts to deck mounts Fig 12 and install shims Secure base mounts with cap screws and flat washers Torque screws from 27 to 33 ft lb 37 to 44 4 Place spacer washer chamfered ID side down and then thrust washer onto yoke joint shaft Insert yoke shaft up through lift arm bushings Place additional thrust washer and then hardened washer on yoke shaft and secure with slotted hex nut Torque nut from 150 to 180 ft lb 203 to 244 while aligning hole in shaft with slot in nut Install cotter pin 5 Secure deck mount to cutting deck with eight flange head screws flat washers and lock nuts 6 Grease yoke joint and lift arm bushing after installa tion on machine see Operator s Manual 7 After assembly is completed raise and lower the cut ting deck to verify that hydraulic hoses and fittings do not contact anything YY Y Y A Y 5 gt ES SS SS Ju fi Figure 12 1 Joint yoke 4 Deck mount 2 Base mount 5 Snap ring 3 Angled edge of mount Groundsmaster 4000 D Page 7 13 Chassis Hood Figure 13 1 Hood 11 Clevis pin 21 Flexible latch draw 2 Latch bracket RH 12 Hood rod 22 Latch bracket LH 3 Screen assembly 13 Hair pin 23 Flange
140. binding and malfunction 3 Remove cartridge valve with a deep socket wrench Note correct location for o rings sealing rings and backup rings Remove and discard seal kit 4 Visually inspect the port in the manifold for damage to the sealing surfaces damaged threads and contami nation Groundsmaster 4000 D 5 Visually inspect cartridge valve for damaged sealing surfaces and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in small valve orifices or seal areas causing malfunction B If valve sealing surfaces appear pitted or dam aged the hydraulic system may be overheating or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air 6 Clean cartridge valve using clean mineral spirits Submerge valve in clean mineral spirits to flush out con tamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves If car design allows use a wood or plastic probe to push the internal spool in and out 20 to 30 times to flush out contamination Be extremely careful not to damage car tridge Use compressed air for cleaning JEM MANIFOLD 35 ft Ib 47 N m 25 ft Ib 10 7 Reinstall the cartridge valve A Lubricate new seal kit components with clean hy draulic oil and install on valve The o rings sealing rings and backup rings must be arranged properly on the c
141. ce and Repairs section of Chapter 4 Hydraulic System 6 Remove steering cylinder from rear axle see Steer ing Cylinder in Service and Repairs section of Chapter 4 Hydraulic System 7 Disconnect both steering cylinder hydraulic hoses from hydraulic tubes at rear frame mount Fig 9 Re move bulkhead locknuts that secure steering cylinder hydraulic tubes to rear frame mount Separate tubes from frame mount Groundsmaster 4000 D 8 Remove screw and flange nut that secures front corner of 4WD hydraulic manifold to rear frame mount 9 If required remove tie rod ends from steering arms on rear axle Fig 10 Remove the cotter pins and castle nuts from the tie rod ball joints Use a ball joint fork and remove the tie rod ends from the axle steering arms 10 Support rear axle to prevent it from falling Remove six cap screws flat washers and flange nuts that secure rear frame mount to equipment frame Lower rear axle and rear frame mount from machine 11 Remove lock nut and washer from pivot pin that at taches rear axle to rear frame mount Remove washer head screw that secures flange of pivot pin to frame mount Fig 11 Figure 9 12 Remove pivot pin Separate rear frame mount from 1 Hydraulic hose 4 Hydraulic tube 2 Hydraulic hose 5 Rear frame mount rear axle Note location of thrust washers on both ends 3 Hydraulic tube of axle mounting boss Install Rear Axle 1 Position rear frame mount to a
142. clean solvent Dry parts with com pressed air Do not wipe parts dry with paper towels or cloth Lint in a hydraulic system will cause damage 8 Carefully inspect internal surface of barrel for dam age deep scratches out of round etc Replace en tire cylinder if barrel is damaged Inspect piston rod and piston for evidence of excessive scoring pitting or wear Replace any damaged parts Assembly 1 Make sure all parts are clean before assembly Groundsmaster 4000 D 4 103 Rev E 2 Coat new O rings Uni ring rod seal back up ring and dust seal with clean hydraulic oil A Install Uni ring and O ring to the piston B Install dust seal O ring back up ring and dust seal to the head IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft surface before mount ing in a vise 3 Mountshaft securely in a vise by clamping on the cle vis of the shaft A Coat shaft with clean hydraulic oil B If equipped install collar onto shaft C Slide head and piston onto the shaft Secure pis ton to shaft with lock nut 4 Lubricate head and piston with hydraulic oil Slide shaft assembly carefully into cylinder barrel IMPORTANT Prevent damage when clamping the cylinder s barrel into a vise clamp on the clevis only Do not close vise enough to distort the barrel 5 Mount lift cylinder in a vise with soft jaws Secure head in barrel A On cylinders without a retaining rin
143. condi tion They should not show wear or deep scratches Inspect the shoes for a snug fit on the ball end of the pistons and a flat smooth surface that comes in con tact with the camplate Do not lap piston shoes C Examine the spider for wear in the pivot area D Examine the spider pivot to insure smoothness and no signs of wear Reassembly 1 All parts should be cleaned and internal pump parts lubricated with clean hydraulic oil before reassembly 2 If necessary press new bearing into pump housing to dimension shown in Figure 44 with the numbered end of bearing outward 3 Install the two new seal sub assemblies 37 into the servo piston cavity of pump housing 19 4 Screw the cover plate 10 onto the servo piston as sembly 7 Install new cover plate gasket 33 in place on pump housing Install servo piston assembly 7 and cover plate 10 into servo piston bore in right side of housing Fig 46 Retain cover plate with four washers 31 and socket head screws 5 Torque screws from 40 to 48 in Ib 4 5 to 5 4 N m To obtain neutral centering the servo piston assembly is required Measure in from the left side and servo piston 500 in 12 7 mm from surface of housing servo bore as shown in Figure 46 NOTE Re adjustment may be required for neutral at unit start up Hydraulic System Rev B Page 4 62 Figure 45 1 Piston assemblies 4 Piston block 2 Spider 5 Retainer 3 Spider pivot
144. ction pedal and monitor the pressure gauge Pressure should increase until the re Figure 34 lief valve lifts 1 Manifold lower side 2 Relief valve RV5 GAUGE READING TO BE 750 PSI approximate 6 Relief valve RV5 is located on the lower front side of the 2WD 4WD control manifold Fig 34 Adjustment of the relief valve can be performed as follows NOTE Do not remove the valve from the hydraulic manifold for adjustment A To increase relief pressure setting remove cap on relief valve and turn the adjustment socket on the relief valve in a clockwise direction A 1 8 turn on the socket will make a measurable change in relief pres sure Fig 35 To decrease pressure setting remove cap onre lief valve and turn the adjustment socket on the relief valve in a counterclockwise direction A 1 8 turn on the socket will make a measurable change in relief pressure Fig 35 C Recheck relief pressure and readjust as needed Figure 35 1 Relief valve cap 2 Adjustment socket Groundsmaster 4000 D Page 4 45 Hydraulic System Rev B TEST 12 CIRCUIT Y P1 1 1 G FRONT 2 48 foi 2 48 N lt TO PTO MOW CIRCUIT Traction Circuit Reducing Valve PR Pressure Using Pressure Gauge lt TO RESERV
145. ctuator assembly 11 6 5 4 3 and balls 13 Axles Planetaries and Brakes Rev B Page 6 6 Groundsmaster 4000 D This is intentionally blank and Brakes a 5 S a a E x lt Groundsmaster 4000 D Page6 7 Axles Planetaries and Brakes Rev B Planetary Wheel Drive Assembly 85 to 100 ft Ib 115 to 135 N m 75 to 85 ft lb 101 to 115 Planetary assembly Retaining ring Splined brake shaft Brake assembly RH O ring 2 0 Axles Planetaries and Brakes Rev Figure 5 Hydraulic wheel motor Flat washer Cap screw Flange head screw Brake assembly LH Page 6 8 75 to 85 ft lb 101 to 115 11 Gasket 12 Flange head screw 13 Tire and wheel assembly 14 Lug nut Groundsmaster 4000 D Planetary Wheel Drive Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Drain oil from planetary wheel drive brake assembly see Operator s Manual When changing attachments tires or perform ing other service use correct blocks hoists and jacks Make sure machine is parked on a solid level surface such as a concrete floor Prior to raising machine remove any attach ments that may interfere with the safe and proper raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support the ra
146. d Fig 24 Install flow tester in series with the mo tor and disconnected return hose Make sure the flow control valve on tester is fully open Fig 25 4 Disconnectthe motor case drain hose small diame ter hose where it connects to hydraulic manifold tee fit ting notatthe motor Puta steel cap on the fitting atthe tee fitting leave the case drain hose open Fig 25 Cutting unitblades will rotate when lowered with PTO switch in ON position Keep away from cut ting units during test to prevent personal injury from rotating blades Do not stand in front of the machine Groundsmaster 4000 D 4 35 Rev F 5 Siton seat start the engine Move throttle to full speed 2730 30 RPM Move PTO switch to ON 6 While watching pressure gauge slowly close flow control valve on tester until a pressure of 1200 PSI is ob tained NOTE Use a graduated container special tool TOR 4077 to measure case drain leakage Fig 25 7 Have another person measure flow from the case drain line for 15 seconds then move the PTO switch to OFF and stop the engine TEST RESULTS Flow less than 0 7 GPM less than 22 4 ounces 662 ml of hydraulic fluid in 15 sec onds 8 Disconnecttester from motor and hose Reconnect hose to the deck motor Remove cap from tee fitting and reconnect case drain hose 9 If flow is more than 0 7 GPM the motor is worn or damaged and should be repaired or replaced Figur
147. d wire The resistance of the hold coil should be about 10 9 ohms 4 Connect solenoid to the wiring harness Electrical System Live Testing Figure 25 1 Engine run solenoid 3 White wire pull coil 2 Redwire hold coil 4 Black wire common 1 Disconnect connector from the engine run solenoid NOTE The solenoid may be removed from the engine or tested in place 2 If the solenoid is removed from the engine make sure that the solenoid linkage moves freely and is free of dirt debris and corrosion 3 Connect a positive test lead from a 12 VDC source to the pins of the red and white wires 4 Touch a negative test lead from the 12 VDC source to the pin of the black wire The solenoid should engage making an audible click 5 Remove positive voltage from the pin of the white wire The solenoid should stay engaged 6 Remove positive voltage from the pin of the red wire The solenoid should release 7 Reinstall solenoid if removed from engine 8 Reconnect the harness wire connector to the sole noid Groundsmaster 4000 D Page 5 17 Electrical System Fuel Sender The fuel sender is located on top of the fuel tank GO 1 Remove white wire and black ground wire from the sender FULL POSITION 2 Remove screws and lock washers that secure the sender to the fuel tank 3 Remove se
148. d in place 3 Install new pressure seals 13 and backup gaskets 14 into new wear plates 12 The flat section in the middle of the backup gasket must face away from the wear plate inside the seal 4 Place plug 8 into pocket of front plate 15 5 Apply athin coatof petroleum jelly to both milled gear pockets of front body 10 Position body onto front plate 15 with half moon port cavities in body facing away from front plate NOTE The small half moon port cavity must be on the pressure side of pump 6 Place wear plate 12 into the gear pocket with the pressure seal and backup gasket againstthe front plate The side with the mid section cut away must be on suc tion side of pump 7 Dip drive gear assembly 11 and idler gear assem bly 16 into clean hydraulic oil Slip both gear assem blies into gear pocket of front body 10 and into front plate bushings 8 Install front adapter plate 23 in place on front body 10 Check positioning marks for correct orientation 9 Install middle body 19 onto front adapter plate 23 Place wear plate 12 into the gear pocket with the pres sure seal and backup gasket against the front adapter plate 10 Install key 17 in slot of drive gear shaft Dip slip fit gear 18 in clean hydraulic oil and slide on shaft and into gear pocket of middle body 19 Check key for proper alignment Hydraulic System Rev B Page 4 56 11 Dip idler gear 21 in clean hydraul
149. d terminal for white wire has 12 VDC 7 Replace switch as needed Adjustment NOTE Deck Proximity Switch Adjustment Tool TOR4095 can be used for switch adjustment SWITCH CONNECTOR 1 Sensing plate on side deck lift arms should be 0 060 Figure 42 to 0 120 1 5 to 3 0 mm from target surface of position switch 2 On front deck lift arm slide sensing plate as far from the lift arm as possible Groundsmaster 4000 D Page 5 27 Rev E Electrical System Service and Repairs NOTE For more component repair information see the Kubota Workshop Manual Diesel Engine V2003 T Series at the end of Chapter 3 Kubota Diesel Engine Battery Storage If the machine will be stored for more than 30 days 1 Remove the battery and charge it fully see Battery Service 2 Either store battery on a shelf or on the machine 3 Leave cables disconnected if the battery is stored on the machine Battery Care 1 Battery electrolyte level must be properly main tained The top of the battery must be kept clean If the machine is stored in a location where temperatures are extremely high the battery will run down more rapidly than if the machine is stored in a location where temper atures are cool Wear safety goggles and rubber gloves when working with electrolyte Charge battery in a well ventilated place so gasses produced while charging can dissipate Since the gases are explosive keep open flames and electric
150. di N 230 LNOYS N e wey EE olo PSI 3 N03 3n 4 7 Hydraulic System Rev Groundsmaster 4000 D Hydraulic Flow Diagrams lt uogong JO eansseJg lt C Ln JejseuispunoJ5 1 1 HN TEMERE HOLON 271 MOA HH 0002 j SUN Y A ere lere love H 2 EZS ANOHS 7 1 lt _ tyy vi 1 1 L iHOdSNVHl II ee
151. dsmaster 4000 D Hydraulic Manifold Service Flow Divider 20 ft Ib 27 1 N m Figure 59 Flow divider valve 7 Plug not serviced Piloted directional valve 8 Seal kit Seal kit 9 Solenoid cartridge valve Hydraulic manifold 10 Solenoid coil O ring 11 Nut Plug SAE 8 NOTE The ports on the manifold marked for easy identification of components Example P2 is the gear pump connection port and CD is the connection for the case drain from the deck motors See Hydraulic Sche matics to identify the function of the hydraulic lines and cartridge valves at each port For cartridge valve service procedures see Hydraulic Control Manifold Service 4 Wheel Drive in this section Refer to Figure 59 for cartridge valve installation torque Groundsmaster 4000 D 4 77 Rev E 4 to 5 ft lb 5 4 to 6 8 N m 12 Plug SAE 6 13 O ring 14 Check valve 15 Seal kit 16 Seal kit Hydraulic System Rev B Hydraulic System Rear Axle Motor I ot 8 8 Drive axle assembly O ring O ring O 12 13 14 15 16 St T e Leese 5 9484 9 59 2 0206 am Or 06 St 26 ES 45 AN K 2 PIZ Zo 17 PT lt 2 my SY E5220 gt 50 9
152. dsmaster 4000 D Troubleshooting There are a number of factors that can contribute to un Remember that the effective or actual height of cut satisfactory quality of cut some of which may be turf depends on cutting unit weight tire pressures hydraulic conditions Turf conditions such as excessive thatch counterbalance settings and turf conditions Effective uneven ground conditions sponginess or attempting height of cut will be different than the bench set height to cut off too much grass height may not always be over of cut come by adjusting the machine Factors That Can Affect Quality of Cut 1 Maximum governed engine speed Check maximum governed engine speed Adjust speed to specifications if necessary 2 Blade speed All deck blades should rotate at the same speed See items in Troubleshooting Section of Chapter 4 Hydraulic System 3 Tire pressure Check air pressure of each tire including castor tires Adjust to pressures specified in Operator s Manual 4 Blade condition Sharpen blades if their cutting edges are dull or nicked Inspect blade sail for wear or damage Replace blade if needed 5 Mower housing condition Make sure that cutting chambers are in good condition Keep underside of deck clean Debris buildup will reduce cutting performance 6 Height of cut Make sure all cutting units are set at the same height of cut Set units as specified in the Operator s Manual 7 Cutting unit
153. dsmaster 4000 D t R CONTROLLER 3 POWER POINT pe pl E Electrical Schematic F7 KUBOTA w Serial Numbers below 220999999 START THERMO H30 o gt 87 LAMP gt a GLOW _ 85 y relays and solenoids 12V e GND are shown as de energized Y 3 BK BK OPTIONAL a All ground wires are black FUSEBLOCK 9 3 ALTERNATOR B R L PK RUN SOLENOID HOLD RIBK 9 Ul BB TEMP FU PULL 3 G G BK BK GY TEMP SENDER E GN W Ll 7 ENGINE OIL PRESSURE BK 3E BU ENGINE OVER TEMP 8 BU FUEL SENDER 8 89406 95 E 1 a W FUEL PUMP g E a BU OR om d GLOW PLUGS 4 m OR 5 rib 1 5193 E Pu STA 6 e a u
154. e ONIM a 4 Jh 3 w HAE 3 I AO Iho L e 3 zo Ev 9 an Ey 1 1 L idc rege Nous awg 9 3701 007 0 7 091 IOHINOO ONIH331S EE rr i gt 149 3 L 1 529 SOULS 0027 33098 00 c TAO 15 HOLOW 7 aoga Hy CEH 7 Id an n YOLOW Om 21 L 0008 ld Agta an ao o _ 290 _ 1 12 7 Groundsmaster 4000 D Page 4 10 Hydraulic System Rev B Lower Cutting Unit Athree section gear pump is coupled to the piston trac tion pump The gear pump section farthest from the pis ton pump supplies hydraulic flow to both the lift lower control valve and the steering control valve Hydraulic flow from this pump section is delivered to the circuits through a proportional flow divider This pump section takes its suction from the hydraulic reservoir When the cutting units are in a stationary position flow from the gear pump is by passed through the lift lower control valve counterbalance manifold oil filter and traction charge circuit To lower a side cut
155. e directions A transport cylinder is included in the traction circuit to reduce control arm movement on the piston pump when operating in two wheel drive transport This reduced arm movement limits swash plate rotation to prevent excessive transport speed On machines with serial numbers above 230000000 a flow divider is incorporated into the traction circuit When in four wheel drive the operator can momentarily engage the traction flow divider when low traction situa tions could lead to wheel spin The engaged flow divider splits traction pump flow to the front wheel motors approximately 45926 and rear axle motor 5596 to re duce the chance that excessive flow goes to a spinning wheel Hydraulic System Rev B 9 0 Ey lt 10 H1 160 000 JeiseuispunoJtc pe am ISd 042 LE 3570095 lt gt io 872 kes 9X t lt gt yy H3dIAIQ MOTH TYNOILHOdOHd tl WO tl OdSNVHL 14173930
156. e hydraulic system 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section 3 Locate deck manifold for gear pump section to be tested Disconnect hydraulic hose at deck manifold port P1 Fig 21 4 Install tester in series with the the disconnected hose and hydraulic manifold port P1 5 Make sure the flow control valve on the tester is fully open 6 Start engine and move throttle to full speed 2730 30 RPM Do not engage the cutting units IMPORTANT Do not fully restrict oil flow through tester In this test the flow tester is positioned be fore the relief valve Pump damage can occur if the flow is fully restricted 7 Watch pressure gauge carefully while slowly closing the flow control valve until 2000 PSI is obtained Verify with a phototac that the engine speed is 2730 30 RPM Groundsmaster 4000 D Page 4 31 8 Flow indication should be approximately 14 GPM 9 Shut off engine 10 Disconnectflow tester from hydraulic hose and man ifold port Reconnect hose to the manifold 11 flow was less than 14
157. e 24 1 Deck motor RH shown 3 Case drain hose 2 Return hose Figure 25 Hydraulic System Rev B TEST 7 Steering Circuit Relief Pressure Using Pressure Gauge STEERING CYL NOTE LEFT TURN SHOWN edet uses d 3 LIFT LOWER CIRCUIT CHARGE CIRCUIT lt TO PTO MOW CIRCUIT lt TRACTION 12 12 248 Kee CIRCUIT FROM gt RESERVOIR FROM OIL FILTER High Pressure Low Pressure Return or Suction gt Hydraulic System Rev Page 4 36 Groundsmaster 4000 D Procedure for Steering Circuit Relief Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Prevent personal injury and or damage to equip Figure 26 ment Read all WARNINGS CAUTIONS and Pre 1 Steering circuit pressure test port cautions for Hydraulic Testing at the beginning of this section 3 Connect a 5000 PSI gauge onto steering pressure test port 4 Start the engine and move throttle to full engine speed 2730 30 RPM Hydraulic IMPORTANT Hold steering wheel at full lock only long enough to get a system pressure reading Holdin
158. e brake as sembly with SAE 85W 140 gear lube see Operator s Manual Capacity is approximately 16 oz 47 per wheel 7 Check and adjust brake cables for proper brake op eration see Operator s Manual Figure 6 3 Drain plug 1 Brake housing 2 Check plug Axles Planetaries and Brakes Rev B 5 S a ao x lt and Brakes Planetary Wheel Drive Service Figure 7 1 Spindle 9 Thrust washer 17 Input shaft 2 Seal 10 Retaining ring external 18 Carrier assembly 3 Bearing cone 11 Ring gear 19 Cap screw 4 Bearing cup 12 Retaining ring internal 20 Seal 5 Wheel stud 13 Plug 21 O ring 6 Housing 14 Cover plate 22 O ring 7 Bearing cup 15 Input spacer 23 Dowel pin 8 Bearing cone 16 Thrust washer Axles Planetaries and Brakes Rev B Page 6 10 Groundsmaster 4000 D Planetary Wheel Drive Disassembly Figure 7 1 Remove retaining ring 12 Remove cover plate 14 Remove input spacer 15 and thrust washer 16 409 gum Remove input shaft 17 5 Remove carrier assembly 18 NOTE Steps 6 10 are necessary only if inspecting or replacing bearings and or seals 6 Remove cap screws 19 and remove ring gear 11 7 Remove retaining ring 10 and thrust washer 9 8 Use a puller to remove spindle 1 from housing 6 Remove bearing cone 8 9 Remove and discard all seals 10 If bearings will be replaced use a puller to remove be
159. e caps 9 Do not remove retaining rings 12 from spools unless spring 19 is broken NOTE Spools and spool bores are matched sets Be sure each spool is identified with the correct body spool bore 3 Remove spools 35 from body 36 4 Remove bushings 8 and O rings 11 from spools 5 Remove plugs 6 IMPORTANT Check location and positioning of plungers when removing from body to assure prop er assembly 6 Remove plugs 29 springs 80 poppets 1 seats 4 and plungers 28 and 33 7 Remove plug 17 8 Remove plug 23 disc 27 spring 21 and detent plunger 22 9 Remove relief plug assembly 32 washers 13 14 and 15 spring 31 and poppet 10 10 Remove all O rings and back up rings from all plugs and seats Inspection 1 Remove all nicks and burns from parts and inspect for excessive wear 2 Inspect all plungers and poppet seats for burrs or roughness 3 Inspect spool springs 19 relief valve spring 31 lockout springs 80 and detent spring 21 for break age 4 lf spools 35 have excessive wear the control valve becomes non serviceable as the spools and spool bores are matched Damaged spools cannot be re placed 5 Inspect relief valve poppet 10 for breakage or wear Groundsmaster 4000 D Page 4 93 Assembly 1 Thoroughly clean and dry all parts Apply a light coat ing of clean hydraulic oil to parts prior to assembly NOTE All O rings back up
160. e head screw 22 Flange bushing 3 Steering wheel 13 Hydraulic adapter 23 Thrust washer 4 Foam collar 14 Steering valve assembly 24 Steering wheel cover 5 Steering seal 15 Nut insert 25 In port P 6 External snap ring 16 Steering tower 26 Right turn port R 7 Steering shaft assembly 17 Flange locking nut 27 Load sensing port PB 8 Steering tower cover 18 Flange head screw 28 Left turn port L 9 O ring 19 Pivot hub 29 Out port T 10 90 hydraulic fitting 20 Cap screw Hydraulic System Rev B Page 4 94 Rev E Groundsmaster 4000 D Removal Installation 1 Park machine on a level surface lower cutting units 1 Install steering valve using Figure 73 as a guide stop engine engage parking brake and remove key from the ignition switch 2 Make sure hydraulic tank is full Add correct oil if nec essary before returning machine to service 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 3 Remove steering valve from machine using Figure 73 as a guide 2 o Ey Groundsmaster 4000 0 4 95 Hydraulic System Rev Steering Valve Service 150 in Ib___ gt 2 17 N m 140 to 160 in Ib 16 to 18 N m Figure 74 1 Steering valve housing 9 Cap screw 2 Dust seal 10 End cap 3 O ring 11 O ring 4 Spool 12 Seal ring 5 Spring retaining ring 13 O ring
161. e of the Figure 27 glass cover for the each test point For each variable re sistance setting the needle must be pointed between the two white dots 2 Take test point readings Fig 28 IMPORTANT Allow circuit to warm up for at least 5 minutes before taking test readings A Set variable resistance to 240 ohms Apply a 14 0 01 VDC to the circuit The needle should point to the left edge of the red area empty Electrical System B Set variable resistance to 33 ohms The needle should point to the right edge of the green area full 3 Turn off the voltage source Disconnect voltage source gauge and variable resistance Figure 28 1 Empty position 3 Glass face edge 2 Full position Groundsmaster 4000 D Page 5 19 Electrical System Fuel Pump The fuel pump is attached to the frame above the fuel water separator Operational Test 1 Park machine on a level surface lower cutting units stop engine and engage parking brake 2 Disconnect electrical connector from the fuel stop solenoid to prevent the engine from firing 3 Disconnect fuel hose pump discharge from the wa ter separator 4 Make sure fuel hoses attached to the fuel pump are free of obstructions 5 Place fuel hose pump discharge into a large grad uated cylinder sufficient enough to collect 1 quart 0 95 liter 6 Collect fuel in the graduated cylinder by turning igni tion switch to the ON position Allow pump to run f
162. e potential fire hazard keep engine area free of excessive grease grass leaves and dirt Clean protective screen on machine frequently 9 If engine must be running to perform maintenance an adjustment keep hands feet clothing and other parts of the body away from cutting units and other mov ing parts Keep bystanders away Groundsmaster 4000 D Page 1 3 10 Do not overspeed the engine by changing governor setting To assure safety and accuracy check maximum engine speed 11 Shut engine off before checking or adding oil to the crankcase 12 Disconnect battery before servicing the machine Disconnect negative cable first and positive cable last If battery voltage is required for troubleshooting or test procedures temporarily connect the battery Reconnect positive cable first and negative cable last 13 Battery acid is poisonous and can cause burns Avoid contact with skin eyes and clothing Protect your face eyes and clothing when working with a battery 14 Battery gases can explode Keep cigarettes sparks and flames away from the battery 15 At the time of manufacture the machine conformed to the safety standards for riding mowers To assure op timum performance and continued safety certification of the machine use genuine Toro replacement parts and accessories Replacement parts and accessories made by other manufacturers may result in non conformance with the safety standards and the warranty may be
163. e side of the closed loop circuit The traction circuit provides operation in either four wheel drive mowing or two wheel drive transport Traction circuit pressure forward and reverse can be measured at test ports on the sides of the machine The traction pump uses a small amount of hydraulic fluid for internal lubrication Fluid is designed to leak across pump parts into the case drain This leakage results in the loss of hydraulic fluid from the closed loop traction circuit that must be replaced The gear pump that supplies oil to the steering and lift lower circuits also provides charge oil for the traction cir cuit This gear pump is driven directly off the traction pump It provides a constant supply of charge oil to the traction circuit to make up for oil that is lost due to inter nal leakage in the traction pump and motors Groundsmaster 4000 D 4 9 Rev Charge pump flow is directed through the filter and to the low pressure side of the closed loop traction circuit A filter bypass valve allows charge oil flow to the closed loop if the filter becomes plugged Charge pressure is limited by a relief valve located in the oil filter manifold Charge pressure can be measured at the charge circuit pressure test port on the oil filter manifold Two wheel drive transport operation is controlled by a solenoid valve When in transport hydraulic flow to the rear axle motor is blocked in both forward and revers
164. e with the open end of the housing up 8 Ifroll pins were removed install to dimension shown in Figure 63 and with opening of roll pin oriented away from bearing within 5 degrees of bearing center line 9 Toreplace bearing 16 in backplate 2 Press bear ing down to the dimension shown Fig 63 protruding from backplate with numbered end of bearing facing up next to valve plate 173 in 4 39 mm Roll Pin 15 090 2 3 mm Bearing my Figure 63 10 Apply small amount of petroleum jelly to the steel side of valve plate 12 to hold in place for installation Place the valve plate in position onto the backplate 2 with steel side against backplate bronze colored side against piston block 11 Placing new o ring 11 onto backplate install back plate assembly 2 onto housing assembly Make sure valve plate stays in position 12 Insert cap screws and torque from 15 to 18 ft Ib 20 to 24 N m in a criss cross pattern 13 Fill case half full of new hydraulic oil Hydraulic System Rev B 9 Ey This page is intentionally blank Hydraulic System Rev B Page 4 84 Groundsmaster 4000 D Cutting Deck Motor Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Se
165. eals and o ring 5 Install lower bearing and seal into bottom of spindle housing Note The bottom seal must have the lip facing out down Fig 11 IMPORTANT If bearings are being replaced make sure to use the spacer ring that is included in bear ing set Fig 9 6 Slide spacer ring and inner spacer into spindle hous ing then install upper bearing and seal into top of hous ing Note The upper seal must have the lip facing in down and be recessed into the spindle housing 095 2 4 mm Fig 11 7 Inspect the spindle shaft and spindle spacer to make sure they are free of burrs or nicks that could possibly damage the seals Lubricate the shaft with grease 8 Install spindle spacer onto shaft Carefully slide spindle shaft up through spindle housing The bottom seal and spindle spacer fit together when the spindle is installed fully Install o ring if equipped onto spindle shaft 9 For drive spindle position motor mount to top of spindle assembly NOTE Early production spindle assemblies included a v ring seal which has been found to be unnecessary Do not install a v ring seal when assembling the spindle Groundsmaster 4000 D Page8 11 Rev E 10 Install pulley hub down washer and lock nut to spindle shaft Tighten lock nut from 130 to 150 ft lb 176 to 203 N m IMPORTANT Pneumatic grease guns can produce air pockets when filling large cavities and therefore are not recommended to be used for pr
166. eering control valve and the lift lower control valve Pump hydraulic flow is delivered to the two circuits through a proportion al flow divider The gear pump takes its suction from the hydraulic reservoir Steering circuit pressure is limited by a relief valve located in the steering control With the steering wheel in the neutral position rear wheels positioned straight ahead and the engine run ning flow enters the steering control valve at the P port and goes through the steering control spool valve by passing the rotary meter V1 and steering cylinder Flow leaves the control valve through the PB port to the oil filter and traction charge circuit Left Turn When a left turn is made with the engine running the turning ofthe steering wheel positions the spool valve so that flow goes through the top ofthe spool Flow entering the steering control valve at the P port goes through the spool and is routed to two places First most of the flow through the valve is by passed out the PB port back to the oil filter and traction charge circuit Second the re mainder of the flow is drawn through the rotary meter V1 and outthe L port Pressure contracts the piston for a left turn The rotary meter ensures that the oil flow to STEERING CYLINDER NO PISTON MOVEMENT STEERING CYLINDER PISTON MOVEMENT the cylinder is proportional to the amount of the turning on the steering wheel Fluid leaving the cylinder flows backthroughthe spo
167. el gear 5 Bearing shims 3 Differential shaft 6 O ring Groundsmaster 4000 D 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 25 2 Use bearing puller to remove the bearing and bevel gear as shown Fig 26 3 Remove the shims spacer and retaining ring Drive the axle out of the bearing and cover Remove and dis card the axle shaft seal 4 Inspect all gears shafts bearings spacers and cases for damage and wear Replace components as necessary Installation 1 Coat new axle shaft seal with grease and install in axle cover as shown Fig 27 2 Press the axle cover and bearing assembly onto the axle shaft Press only on the inner race of the cover bearing Fig 27 3 Install retaining ring spacer and correct combina tion of bearing shims Install bevel gear and bearing 4 Coat a new O ring with grease and install the axle cover assembly Tighten axle cover screws from 17 to 20 ft lb 23 to 27 Groundsmaster 4000 D Page 6 21 17 to 20 ft lb 23 to 27 Figure 25 3 Mounting screw 4 O ring 1 Axle case 2 Axle cover assembly Figure 26 1 Bearing 4 Spacer 2 Bevel gear 5 Retaining ring 3 Shims Figure 27 1 Axle shaft seal 3 Bearing 2 Axle cover 4 Axle shaft Axles Planetaries and
168. en hydraulic lines and fittings Label disconnected hydraulic lines for proper reassembly 3 Remove hydraulic manifold from the frame using Figure 56 as guide Installation 1 Install hydraulic manifold to the frame using Figure 56 as guide 2 Remove caps and plugs from fittings and hoses Properly connect hydraulic lines to manifold Groundsmaster 4000 D Hydraulic Manifold Service Filter Manifold 35 to 40 ft Ib 47 to 54 N m 60 to 70 ft Ib 4 6 81 to 95 N m E 9 5 gt Figure 57 1 Filter manifold assembly 7 Seal kit 12 Plug SAE 5 2 Check valve Reservoir return 8 Plug SAE 4 13 O ring 3 Seal kit 9 O ring 14 Plug SAE 10 4 Check valve Filter bypass 10 Plug SAE 6 15 O ring 5 Seal kit 11 O ring 16 Oil filter element 6 Check valve Charge pressure NOTE The ports on the manifold are marked for easy identification of components Example P2 is the gear pump connection port and CD is the connection for the case drain from the deck motors See Hydraulic Sche matics to identify the function of the hydraulic lines and cartridge valves at each port For cartridge valve service procedures see Hydraulic Control Manifold Service 4 Wheel Drive in this section Refer to Figure 57 for cartridge valve installation torque Groundsmaster 4000 D Page 4 75 Hydraulic System Rev B Hydraulic Manifold Flow Divider Figure 58 1 Hydraulic manifold 8 O ring 14 O
169. en the two connector ter minals The resistance for the solenoid coil should be about 7 2 ohms Figure 22 Manifold RH shown 3 Solenoid connector 2 Valve solenoid 2 to 5 ft Ib 3107 5 to 8 N m 2 to 5 ft lb 14 77 3107 N m 2 to 5 ft lb 3 to 7 N m Figure 23 1 Hydraulic valve solenoid decks 3 Hydraulic valve solenoid traction 4 Hydraulic manifold traction 2 Hydraulic manifold decks Electrical System Page 5 16 Groundsmaster 4000 D Engine Run Solenoid The engine run solenoid must be energized for the en gine to run It is mounted on the engine block near the injection pump In Place Testing NOTE Prior to taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measured value of the component you are testing 1 Disconnect the connector from the engine run sole Figure 24 noid Engine run solenoid 3 Injection pump 2 Solenoid connector 2 Using a digital multimeter touch one lead to the pin of the black wire and the other lead to the pin of the white wire The resistance of the pull coil should be about 0 26 ohms 3 Using a digital multimeter touch one lead to the pin of the black wire and the other lead to the pin of the re
170. end of pivot shaft with the pictured bolt and flat washer Drive piv ot shaft from lift arm and frame with hammer 7 Remove lift arm from machine Installation 1 Apply anti seize lubricant to lift arm pivot shaft 2 Position lift arm to frame with thrust washers properly placed Fig 5 Slide pivot shaft into frame and lift arm until roll pin holes align 3 Install new roll pin to secure lift arm pivot shaft 4 If pivot hub was removed from pivot shaft slide pivot hub on shaft Apply thread locking compound to cap screw and secure pivot hub with washer and cap screw 5 Install side deck rear arm assembly see Side Deck Rear Arm Assembly 6 Position and install side cutting deck to machine see Side Cutting Unit in Chapter 8 Cutting Units 7 Lubricate lift arm grease fittings after assembly is complete see Operator s Manual 8 After assembly is completed raise and lower the cut ting deck to verify that hydraulic hoses and fittings do not contact anything Groundsmaster 4000 D Page 7 7 9 16 hole 3 x 12 3 8 to 1 2 thick plate steel 1 2 13 UNC bolt Flat washer 1 to 1 1 8 Use hammer to drive pivot shaft from lift arm Figure 6 Chassis Side Deck Rear Arm Assembly 17 Thread locking Compound 32 lt 22 to 27 ft lb 30 to 37 N m Figure 7 1 Cutting deck LH shown 16 Lock nut 31 Damper rod end 2 Deck mount LH shown 17 Cap screw 32 Cap scre
171. er 4000 D Chapter 5 TORO Electrical System Table of Contents ELECTRICAL SCHEMATIC CIRCUIT DIAGRAMS Glow 14 AND WIRE HARNESS DRAWINGS 2 Start Engine Shutdown Seat PTO Alarm SPEGIAL TOOLS ees Rte 3 and Over Temperature Relays 15 TROUBLESHOOTING 4 Hydraulic Valve Solenoids 16 Starting Problems 4 Engine Run Solenoid 17 General Run amp Transport Problems 5 Fuel Sender 18 Cutting Unit Operating Problems 6 Fuel Gauge nonem 19 ELECTRICAL SYSTEM QUICK CHECKS 7 Fuel Pump 20 Battery Test Open Circuit 7 Glow Controller 21 Check Operation of Interlock Switches 7 Temperature Sender 22 COMPONENT TESTING 8 High Temperature Shutdown Switch 23 Ignition Switch 8 Temperature Gauge 24 FUSES tit tet RD eet M SLM 9 Traction Neutral Switch 25 Warning 10 Diode Assemblies 25 PTO Switch 11 Diode Circuit Board 26 Transport Alarm Silence and Cutting
172. es not contact engine valve cover To modify clearance move and or rotate air cleaner body in air cleaner strap Verify that tabs in strap mesh fully with slots in air cleaner body B Position hose to allow maximum clearance be tween air cleaner hose and muffler bracket 1 Air cleaner hose 2 Engine valve cover 3 Air cleaner strap Groundsmaster 4000 D Page 3 7 Figure 4 4 Air cleaner body 5 Muffler bracket Kubota Diesel Engine Rev B sP fe 5 Exhaust System 21 to 29 N m 16 to 22 ft lb 21 to 29 N m 16 to 22 ft lb 21 to 29 N m Figure 5 1 Muffler 6 Lock nut 11 Flange nut 2 Muffler bracket 7 Cap screw 12 Flange head screw 3 Exhaust pipe 8 Flat washer 13 Engine mount 4 Flange head screw 9 Spacer 14 Muffler clamp 5 Exhaust gasket 10 Rubber hanger Kubota Diesel Engine Rev B Page 3 8 Groundsmaster 4000 D Removal 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 1 Park machine a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove muffler and or muffler bracket from the en gine as necessary using Figure 5 as a guide 8 Y Installation Diesel Engine Figure 6 IMPORTANT If exhaust studs were removed from engine cylinder head thoroughly clean
173. esignation Kubota 4 4 Cylinder Water Cooled Turbocharged Diesel Engine Horse Power 58 HP 43 3 kW 2600 RPM Bore mm in 83 0 3 27 Stroke mm in 92 4 3 64 Total Displacement cc cu in 1999 122 12 Firing Order 1 3 4 2 Combustion Chamber Spherical Type Fuel No 2 Diesel Fuel ASTM D975 Fuel Capacity liters U S gallons 72 19 0 Fuel Injection Pump Bosch Type Mini Pump PFR Governor Centrifugal Mechanical Low Idle no load 1450 50 RPM High Idle no load 2730 30 RPM Direction of Rotation Counterclockwise Viewed from Flywheel Compression Ratio 22 0 1 Injection Nozzle Bosch Throttle Type Engine Oil SAE 10W30 10W40 Detergent API CD or higher Oil Pump Trochoid Type Crankcase Oil Capacity liters U S quarts 7 6 8 0 with Filter Starter 12 VDC 1 4 kW Alternator Regulator 12 VDC 40 AMP Coolant Capacity liters U S quarts 10 4 11 with 0 9 1 0 Reservoir Engine Dry Weight kilograms U S pounds 184 406 Groundsmaster 4000 D Page 3 3 Kubota Diesel Engine Rev B 52 e Adjustments Run Solenoid 1 When ignition switch is in the RUN position the run solenoid should energize and position the fuel stop lever to within 1 16 1 6 mm of stop on the injection
174. est Kit TOR47009 Use to take various pressure readings for diagnostic tests Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools A high pressure hose is provided for remote readings Contains one each 1000 PSI 70 Bar 5000 PSI 350 Bar and 10000 PSI 700 Bar gauges Use gauges as recommended in Testing section of this chapter Hydraulic Tester Pressure and Flow TOR214678 Figure 10 This tester requires O ring Face Seal ORFS adapter fittings for use on this machine 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 LOW PRESSURE GAUGE Low range gauge to pro vide accurate reading at low pressure 0 to 1000 PSI A protector valve cuts out when pressure is about to exceed the normal range for the gauge The cutout pressure is adjustable Hydraulic System Rev B Page 4 18 4 HIGH PRESSURE GAUGE High range gauge which accommodates pressures beyond the capacity of the low pressure gauge 0 to 5 000 PSI 5 FLOW METER This meter measures actual oil flow in the operating circuit with a gauge rated at 15 GPM 6 OUTLET HOSE A hose from the outlet side of the hydraulic tester connects to the hydraulic system circuit Groundsmaster 4000 D Hydraulic Test Fitting Kit TOR4079 This kit
175. from lift arm and cylinder shaft clevis which will free lift cylinder from lift arm 5 Remove one cotter pin from upper lift pin Pull upper lift pin from frame and cylinder barrel clevis 6 Remove lift cylinder from machine Groundsmaster 4000 D Page 4 101 Installation 1 Position cylinder barrel clevis to frame and insert up per lift pin into frame and clevis Secure lift pin with cotter pin 2 Insert pin assembly through lift arm and cylinder shaft clevis Secure pin to lift arm with cap screw flat washers and lock nut 3 Attach hydraulic hoses to lift cylinder 4 Fill reservoir with hydraulic fluid as required see Op erator s Manual 5 After assembly is completed operate lift cylinder to verify that hydraulic hoses and fittings are not contacted by anything Hydraulic System Rev B 9 o Ey Lift Cylinder Service SIDE DECK LIFT CYLINDER Figure 78 1 Barrel with clevis 6 O ring 11 Piston 2 Collar 7 Back up ring 12 Lock nut 3 Shaft with clevis 8 Head 13 Grease fitting 4 Dust seal 9 O ring 14 Bushing 5 Rod seal 10 Uni ring FRONT DECK LIFT CYLINDER Figure 79 1 Barrel with clevis 5 Rod seal 9 O ring 2 Collar 6 O ring 10 Uni ring 3 Shaft with clevis 7 Back up ring 11 Piston 4 Dust seal 8 Head 12 Lock nut Hydraulic System Rev B Page 4 102 Groundsmaster 40
176. front of machine see Jacking Instructions in Chapter 1 Safety Support ma chine with jack stands or solid wood blocks 4 Remove wheel assembly 5 Remove hydraulic wheel motor see Front Wheel Motors in Service and Repairs section of Chapter 4 Hydraulic System 6 Disconnect brake cable from pull rod on brake 7 Remove flange head capscrews 5 securing brake assembly to frame be careful not to drop splined brake shaft as brake assembly is removed 8 Remove splined brake shaft 9 Complete brake inspection and repair Install Brake Assembly Fig 1 1 Install splined brake shaft into brake assembly Note The stepped end of the splined brake shaft must be aligned toward the hydraulic wheel motor Fig 2 2 Install brake assembly onto frame aligning splined brake shaft with input shaft on planetary wheel drive 3 Install flange head screws 5 to secure brake as sembly to frame Tighten screws in a crossing pattern to a torque from 75 to 85 ft lb 101 to 115 4 Install brake cable to pull rod on brake assembly Brake cable end should be completely threaded onto pull rod 5 Install new o ring on hydraulic wheel motor Install wheel motor and torque capscrews from 75 to 85 ft lb 101 to 115 Groundsmaster 4000 D Page6 5 Failure to maintain proper torque could result in failure or loss of wheel and may result in personal injury 6 Install wheel assembly Torque lug nuts from 85
177. g 14 E The electric starter Fig 14 and low oil pressure switch near electric starter Groundsmaster 4000 D Page 3 15 Figure 10 1 Temperature sender 2 Alternator 3 Coolant hose Figure 11 4 Cable jam nut 5 Cable washer lock nut 1 Run solenoid 2 Fuel line 3 Throttle cable 3 Fuel filter 1 Run solenoid 2 Fuel pump Kubota Diesel Engine Rev B 55 3 8 Disconnect fuel line from injection pump Fig 11 9 Disconnect throttle cable from the speed control le ver by removing the washer and lock nut Loosen jam nut and take cable from mounting bracket Fig 11 10 Remove coolant reservoir and bracket from fan shroud 11 Remove four flange head screws and flat washers securing the fan shroud to the radiator 12 Remove traction cylinder assembly from engine adapter plate It is not necessary to remove the hydrau lic hose from the cylinder Locate and remove shim plate from between traction cylinder and adapter plate 13 Disconnect two wires from neutral switch on hydrau lic traction pump IMPORTANT Support hydraulic pump assembly to prevent it from falling and being damaged 14 Remove hydraulic pump assembly from engine see Pump Assembly in Chapter 4 Hydraulic Systems 15 Make sure all cable ties securing the wiring harness fuel lines or hydraulic hoses to the engine are removed 16 Connect hoist or lift to the front and
178. g 5 Outer spacer cups out of the spindle housing Remove the large outer 3 Large snap ring spacer from the housing 13 The large snap ring can remain inside the spindle housing Removal of snap ring is very difficult Cutting Units Page8 10 Rev Groundsmaster 4000 D Assembly IMPORTANT If new bearings are installed into a used spindle housing it may not be necessary to re place the original large snap ring If the original snap ring is in good condition with no evidence of damage e g spun bearing leave the snap ring in the housing and discard the snap ring that comes with the new bearings If the large snap ring is found to be damaged replace the snap ring Replacement bearings are sold only with a matched spacer ring and large snap ring Fig 9 These parts cannot be purchased separately 1 If large snap ring was removed install snap ring into spindle housing groove Make sure snap ring is seated in groove 2 Install large outer spacer into top of spindle housing The spacer should fit against the snap ring 3 Using an arbor press push the bearing cups into the top and bottom of spindle housing The top bearing cup must contact the spacer previously installed and the bottom bearing cup must contact the snap ring Make sure that the assembly is correct by supporting the first bearing cup and pressing the second against it Fig 10 4 Pack the bearing cones with grease Apply a film of grease on lips of oil s
179. g slot in the barrel Figs 78 and 79 use a spanner wrench to tighten collar into barrel On cylinders with a retaining ring Fig 80 align retaining ring hole in the head with the access slot in the barrel Insert the retaining ring hook into the hole and rotate head clockwise until the retaining ring is completely pulled into the barrel and the ring ends are covered Figure 80 1 Barrel 3 Retaining ring 2 Head Hydraulic System Rev B 2 5 gt Steering Cylinder 2 5 5 e 5 o 5 o 205 25250 lt 0 La 92450 2 gt 5529545 rrererr 2t t X o 98 rr 8 Do A 5 2 p 29 ES 5 7 9 md grees Oa00Mm 2t 1 rr 4 o 5 gt DE 99524 0 9 9 9500 m m rco 1 2 3 4 5 Groundsmaster 4000 D Page 4 104 Hydraulic System Rev B Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter NOTE To ease reassembly tag the hydraulic hoses to show their c
180. g the index pin place the valve plate 18 in posi tion onto the backplate 20 with steel side against backplate 17 Install backplate assembly 20 onto housing assem bly 19 Make sure ports are positioned correctly and that valve plate 18 and gasket 32 stay in place 18 Retain backplate 20 with four cap screws 15 Torque cap screws from 27 to 31 37 to 42 N m 19 Install control housing gasket 34 onto housing Install orifices 30 into servo control assembly 28 and retain in position with petroleum jelly Position the feed back link at 90 degrees from control housing Install manual servo control assembly 28 onto housing mak ing sure feedback link entered small groove in servo pis ton assembly 7 Groundsmaster 4000 D Page 4 63 20 Secure control assembly with six socket head screws 17 Torque screws from 40 to 48 in Ib 4 5 to 5 4 N m 21 Install control arm 27 onto control assembly input shaft Retain with lock washer 23 and nut 22 Torque nut from 4 to 6 ft lb 5 to 8 N m 22 Install remaining plugs that were removed from pump Torque 3 4 in plug from 21 to 24 ft Ib 28 to 32 N m Torque 1 1 4 in plug from 40 to 45 ft Ib 54 to 61 N m Hydraulic System Rev B 9 5 5 gt N gt N I Piston Pump Control Assembly 2 to 3 N m 44 to 52 ft Ib 60 to 70 N m 28 to 34 in Ib 3 2 to 3 8 N m Figure 47 1 Plug 9 O ring 17 Set screw 2 O ring 10
181. g the steering wheel against the stop for an extended period will damage the steering motor 5 Turn steering all the way in one direction and mo mentarily hold the steering wheel against resistance GAUGE READING TO BE 1350 50 PSI 6 Stop the engine Figure 27 7 If pressure is incorrect inspect steering relief valve Fig 27 If relief valve is operating properly and if lift 1 Steering tower 2 Steering relief valve lower problems also exist gear pump should be sus pected of wear and inefficiency If steering wheel continues to turn at end of cylinder travel with lower than normal effort steering cylinder or steering valve should be suspected of wear or damage Groundsmaster 4000 D Page 4 37 Hydraulic System Rev B TEST 8 Lift Lower Circuit Relief Pressure Using Pressure Gauge 2 O 9 z tr MOW CIRCUIT 12 1 FROM 3 2 NOTE LH DECK RAISE SHOWN LIFT LOWER CONTROL VALVE LH WING DECK LIFT CYL2 CYL4 RH WING 248 vy TRACTION CIRCUIT RESERVOIR FROM OIL FILTER Hydraulic System Rev B Page 4 38 DECK LIFT E TO Y RESERVOIR lt CHARGE CIRCUIT High Pressure Low Pressure Re
182. ge condi tions or mishandling during operation or maintenance These conditions can cause damage or premature dete rioration Some hoses are more susceptible to these conditions than others Inspect the hoses frequently for signs of deterioration or damage When replacing a hydraulic hose be sure that the hose is straight not twisted before tightening the fittings This can be done by observing the imprint on the hose Use two wrenches hold the hose straight with one and tighten the hose swivel nut onto the fitting with the other Hydraulic Fitting Installation O Ring Face Seal 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Make sure the O ring is installed and properly seated in the groove It is recommended that the O ring be replaced any time the connection is opened 3 Lubricate the O ring with a light coating of oil 4 Put the tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight 5 Mark the nut and fitting body Hold the body with a wrench Use another wrench to tighten the nutto the cor rect Flats From Finger Tight F F F T The markings on the nut and fitting body will verify that the connection has been tightened Size F F F T 4 1 4 in nominal hose or tubing 0 75 0 25 6 3 8 0 75 0 25 8 1 2 in 0 75 0 25 10 6 8 in 1 00 0 25 12 3 4 in 0 75 0 25 16 1 in 0 7
183. h cap screws rebound washers and flange head locking nuts 6 Secure fan shroud to the radiator with four cap screws flat washers and locknuts Make sure that clearance between shroud and fan is at least 180 4 6 mm at all points Groundsmaster 4000 D Page 3 17 Figure 15 3 Cap screw position 4 Dowel position 1 Coupling spacer 2 Shoulder bolt position Hydraulic Pump Side Engine Side Spring Center__y Coupling Figure 16 7 Install coolant reservoir bracket and reservoir to fan shroud 8 Connect throttle cable to the speed control lever with washer and lock nut Install cable to mounting bracket Fig 11 Adjust throttle cable see Operator s Manual 9 Connect fuel line to the injection pump Fig 11 10 Install traction cylinder assembly to engine adapter plate IMPORTANT Support hydraulic pump assembly to prevent it from falling and being damaged 11 Install hydraulic pump assembly to engine see Pump Assembly in Chapter 4 Hydraulic Systems 12 Connect two wires to neutral switch on traction pump 13 Connect wires and or electrical connections to the Kubota Diesel Engine Rev B 52 following electrical components A The temperature sender and alternator Fig 10 B The engine run solenoid and fuel pump Fig 12 C The high temperature shutdown switch and glow plug Fig 13 D Battery frame and wire harness gro
184. haft pinion gear Groundsmaster 4000 D Page 6 23 Axles Planetaries and Brakes Rev B Differential Gear The following procedures assume the rear axle assem bly has been removed from the machine Removal 1 Remove bevel gear case axle case assemblies see Bevel Gear Case Axle Case Assembly in this section of this manual IMPORTANT not interchange right and left dif ferential shafts assemblies 2 Mark and pull the differential shaft assemblies from the axle support 3 Remove input shaft pinion gear assembly shims and O ring from the axle support Fig 32 4 Remove the axle support case screws Separate the axle support halves and remove the O ring 5 Remove the differential gear assembly bearings and adjusting shims from the axle case 6 Drive the spring pin from the differential case with a punch and hammer Discard the spring pin Fig 33 NOTE Mark and arrange all components so they can be reassembled in their original position 7 Remove the differential pinion shaft pinion gears and pinion washers Remove the differential side gears and side gear shims Remove the ring gear only if it will be replaced Fig 34 NOTE Replacement ring gears are only available in matched ring and pinion sets Axles Planetaries and Brakes Rev B Page 6 24 35 to 41 ft Ib 47 to 56 35 to 41 ft Ib 47 to 56 Figure 32 1 Gear Case 5 Case screw 2 Pinion Gear 6 Differe
185. he piston traction pump is equipped with a by pass valve that needs to be turned 90 for towing See Operator s Manual for Towing Pro cedures See Operator s Manual for towing instructions in re verse Figure 6 1 By pass valve location Check Hydraulic Fluid The Groundsmaster 4000 D hydraulic system is de signed to operate on anti wear hydraulic fluid The res ervoir holds about 8 gallons 30 3 liters of hydraulic fluid Check level of hydraulic fluid daily See Opera tor s Manual for fluid level checking procedure and oil recommendations Hydraulic Figure 7 1 Hydraulic reservoir cap Groundsmaster 4000 D Page4 5 Hydraulic System Rev B Hydraulic Schematics UMOUS 05 666666022 eues 3531005 c 1 15 gt ISd 032 ox u e o T T ao ieu m 2 amp E 9 S 1 JNN n MOL _ J 02 peg 872 82
186. ic oil and install in gear pocket of middle body 12 Install rear adapter plate 24 in place on middle body 19 Check positioning mark on all sections of pump 13 Position rear body 26 onto rear adapter plate 24 Place wear plate 12 into the gear pocket with the pres sure seal and backup gasket against the rear adapter plate 14 Install key 22 in slot of drive gear shaft Dip slip fit gear 20 inclean hydraulic oil and slide on shaft and into gear pocket of rear body 26 Check key for proper alignment 15 Dip rear idler gear 25 in clean hydraulic oil and install in gear pocket of rear body 16 Position backplate 27 over shafts until dowel pins in body are engaged 17 Secure pump components with cap screws 3 Torque cap screws evenly in a crisscross pattern from 25 to 28 ft lb 34 to 38 N m 18 Place washer 2 over drive shaft into housing Liber ally oil shaft seal 1 and install over drive shaft carefully so that rubber sealing lips are not cut 19 Place 1 3 8 O D sleeve over shaft and press in shaft seal 200 in 5 08mm below surface of front plate 20 Install plug 7 and washer 9 into rear adapter plate 21 11 removed install plug 28 with o ring into back plate and torque from 21 to 24 ft Ib 29 to 33 N m 22 Install proportional valve 6 into backplate Torque plug from 21 to 24 ft Ib 29 to 33 N m Groundsmaster 4000 D 9 Ey This page is intention
187. ical System 5 22 Rev E 2 Alternator Figure 32 Groundsmaster 4000 D High Temperature Shutdown Switch The high temperature shutdown switch is located near the glow plug connection on the engine cylinder head Fig 33 There is a blue wire attached to the switch Make sure engine is cool before removing the temperature switch 1 Lower coolant level in the engine and remove the temperature shutdown switch 2 Put switch in a container of oil with a thermometer and slowly heat the oil Fig 34 Handle the hot with extreme to prevent personal injury or fire Figure 3 1 Temp shutdown switch 2 Glow plug connection 3 Check continuity of the switch with a multimeter ohms setting The temperature switch is normally open and should close between 225 to 235 F 107 to 113 C 26 gt on 4 Allow to cool while observing temperature Figure 34 temperature switch should open at about 219 F 104 C 5 Replace switch if necessary 6 Install switch to the water flange A Clean threads of cylinder head and switch thor oughly Apply thread sealant to the threads of the switch B Screw switch into the cylinder head and tighten C Connect blue wire to switch 7 Fill engine cooling system see Operator s Manual Groundsmaster 4000 D Page 5 23 Electrical System Temperature Gauge
188. is chapter Maintenance Maintenance procedures and recommended service in tervals for the Groundsmaster 4000 D are covered in the Operator s Manual Refer to that publication when performing regular equipment maintenance Chapter 2 Product Records and Maintenance ge 95 oo 58 Standard Torque for Dry Zinc Plated 3 Steel Fasteners Inch Series 4 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners 5 Other Torque Specifications 6 Conversion Factors 6 Groundsmaster 4000 D 2 1 Rev E Product Records and Maintenance Decimal and Millimeter Equivalents Equivalents and Conversions Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 03125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1 16 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 09375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17
189. is less than 12 4 VDC recharge the battery B If the battery has been charged apply a 150 amp load for 15 seconds to remove the surface charge Use a battery load tester following the manufactur er s instructions C Make sure battery terminals are free of corrosion D Measure the temperature of the center cell E Connect a battery load tester to the battery termi nals following the manufacturer s instructions Connect a digital multimeter to the battery terminals F Apply a test load of one half the Cranking Perfor mance see Battery Specifications rating of the bat tery for 15 seconds G Take a voltage reading at 15 seconds then re move the load Electrical System Page 5 30 H Using the table below determine the minimum voltage for the cell temperature reading Voltage Temperature 96 70 F 21 19 and up 9 5 609 15 69 9 4 50 F 10 0 C 9 3 40 F 4 496 EN 89 20 F 6 79C 12 29C 17 89C l If the test voltage is below the minimum replace the battery If the test voltage is at or above the mini mum return the battery to service 8 7 109F Groundsmaster 4000 D Charging To minimize possible damage to the battery and allow the battery to be fully charged the slow charging meth od is presented here This charging method can be ac complished with a constant current battery charger which is available in most shops Follow the manufacturer s instruc
190. ised machine If the ma chine is not properly supported by blocks or jack stands the machine may move or fall which may result in personal injury 3 Chock rear wheels and jack up front of machine see Jacking Instructions in Chapter 1 Safety Support ma chine with jack stands or solid wood blocks 4 Remove front wheel assembly 5 Remove hydraulic wheel motor see Front Wheel Motors in Service and Repairs section of Chapter 4 Hydraulic System 6 Remove brake assembly see Brake Assembly 7 Support planetary assembly to prevent it from falling Loosen and remove flange head screws that secure planetary assembly to frame Remove planetary as sembly from machine Planetary Wheel Drive Installation 1 Position planetary assembly to machine Install flange head screws that secure planetary assembly Torque screws from 75 to 85 ft lb 101 to 115 2 Install brake assembly see Brake Assembly 3 Install hydraulic wheel motor see Front Wheel Mo tors in Service and Repairs section of Chapter 4 Hy draulic System Groundsmaster 4000 D Page 6 9 Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury 4 Install wheel assembly Torque lug nuts from 85 to 100 ft lb 115 135 5 Lower machine from jack stands 6 Make sure drain plug is installed in bottom of brake assembly Fig 6 Fill planetary wheel driv
191. itch or circuit wiring are faulty A hydraulic problem exists see Troubleshooting section of Chapter 4 Hydraulic System The PTO switch or circuit wiring is faulty The operator is lifting off the seat switch The seat switch or circuit wiring is faulty The PTO switch or circuit wiring is faulty The deck position switch or circuit wiring is faulty Hydraulic valve solenoid s or circuit wiring is faulty A hydraulic problem exists see Troubleshooting section of Chapter 4 Hydraulic System Hydraulic valve solenoid coil is shorted Cutting deck position switch is faulty Groundsmaster 4000 D 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 to 100 F 16 to 38 C The ignition key should be off and all accessories turned off Connect the positive meter lead to the positive battery post and the negative meter lead to the nega tive battery post NOTE This test provides a relative condition of the bat tery Load testing of the battery will provide additional and more accurate information Check Operation of Interlock Switches 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 op
192. ivot hub Flange head screw Switch bracket Flange nut Cap screw Steering tower Phillips head screw Clevis pin Steering valve Steering wheel cover Front wire harness Snap ring location Groundsmaster 4000 D Disassembly Assembly 1 Park machine on a level surface lower cutting units 1 Assemble steering tower using Figure 1 as a guide stop engine engage parking brake and remove key Note Thrust washer s 24 on steering column are from the ignition switch used as needed to remove end play of steering shaft 2 Disassemble steering tower as needed using Figure 1 as a guide Groundsmaster 4000 D Page 7 3 Chassis Front Deck Lift Arm Ev GS 30 44s 60 to 70 ft Ib 81 to 94 fom Or N RIGHT FRONT Flange bushing Ball joint Lock nut Clevis pin Height of cut chain U bolt Hex nut Flat washer Lock nut Lock nut Grease fitting 45 Grease fitting Slotted roll pin Removal 150 to 175 ft lb 203 to 237 N m Figure 2 Lift arm pin Cotter pin Upper lift pin Grease fitting Lift cylinder Lock nut Pin Cap screw Flat washer Lift arm LH shown Jam nut Hair pin Ball joint mount 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove front cutting deck see Front Cutting Unit in Chapter 8 Cutting Units Chassis 7
193. l 6 Reconnect switch connector Parking Brake Switch The switch used for the parking brake is a normally closed switch The parking brake switch is located under the steering tower cover and opens when the parking brake lever is engaged 1 Make sure the engine is off Locate switch for testing 2 Disconnect electrical connector from the switch 3 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals 4 When the switch plunger is extended there should be continuity between the switch terminals 5 When the switch plunger is depressed there should be no continuity between the switch terminals 6 Reconnect switch connector Figure 16 1 Electrical connector 2 Seat switch Figure 17 1 Parking brake switch 2 Parking brake rod Groundsmaster 4000 D Page 5 13 3 Parking brake pawl Electrical System Electrical System Hour Meter The hour meter is located on the control console next to the operator seat 1 Connect the positive terminal of a 12 VDC source to the positive terminal of the hour meter 2 Connect the negative terminal of the voltage source to the other terminal of the hour meter 3 The hour meter should move a 1 10 of an hour in six minutes 4 Disconnect voltage source from the hour meter Audio Alarm The audio alarm for low engine oil pressure or high en gine coolant temperature is attached to the
194. l oil is clean If changing to biode gradable fluid repeat steps 1 through 14 again at least once and until the oil is clean 16 Assume normal operation and follow recommended maintenance intervals Groundsmaster 4000 D Charge Hydraulic System NOTE When initially starting the hydraulic system with new or rebuilt components such as motors pumps or lift cylinders it is important that the hydraulic system be charged properly Air must be purged from the system and its components to reduce the chance of damage IMPORTANT Change hydraulic oil filter whenever hydraulic components are repaired or replaced 1 Park machine on alevel surface Lower cutting units stop engine and engage parking brake Remove key from the ignition switch 2 Make sure all hydraulic connections lines and com ponents are secured tightly failure was severe or the system is con taminated flush and refill hydraulic system and tank see Flush Hydraulic System 4 Make sure hydraulic reservoir is full Add correct hy draulic oil if necessary see Operator s Manual 5 Disconnect engine run solenoid lead to prevent the engine from starting 6 Check control rod to the piston traction pump for proper adjustment binding or broken parts 7 Make sure traction pedal and lift control lever are in the neutral position Turn ignition key switch engage starter for fifteen 15 seconds to prime the traction and gear pum
195. large flat washer and small flat washer onto spring shaft Loosely secure components to shaft with one jam nut 2 Slide the straight bushing and plate onto other end of spring shaft 3 While holding flats on end of spring shaft rotate jam nut on other end of assembly until components are snug but spring is not compressed 4 Insert assembly into rear arm housing 5 From open end of rear arm housing insert a 3 4 socket onto spring shaft jam nut Tighten jam nut fully 6 Mount plate to rear arm housing with two cap screws and lock nuts Grasp end of spring shaft Push inward and pull outward on shaft to determine endplay in as sembly IMPORTANT All endplay must be removed from as sembly to allow proper operation and ensure long life 7 Loosen jam nut 1 2 turn at a time until all endplay in shaft is removed 8 Remove two cap screws and nuts securing plate to rear arm housing Remove spring shaft assembly from housing 9 Thread remaining jam nut onto end of spring shaft and tighten to lock adjustment 10 Thoroughly pack spring with grease Install spring shaft assembly into housing and secure plate with four cap screws and lock nuts 11 Thread rod end with jam nut into end of spring shaft Do not tighten jam nut at this time 12 rod ends 31 were removed from damper 30 ap ply thread locking compound to damper shaft threads before installing rod ends Secure damper to bellcrank and rear arm with ca
196. le terminal Multimeter Black Lead Continuity on Terminal T owe ves Electrical System 9 Diode Circuit Board The circuit board contains four diodes Fig 39 and is lo cated under the console housing The diodes are used for circuit protection from inductive voltage spikes that occur when a hydraulic valve solenoid is de energized Diode D1 is in the left cutting deck circuit D2 is in the Transport Mow circuit D3 is in the front cutting deck cir cuit and D4 is in the right cutting deck circuit Testing The diodes can be individually tested using a digital multimeter ohms setting and the table to the right If any of the diodes are damaged the diode circuit board must be replaced 51 D D3 CIRCUIT BOARD DIODE DIAGRAM Figure 39 Red Lead Black Lead on on Continuity Terminal Terminal Electrical System Page 5 26 Groundsmaster 4000 D Cutting Deck Position Switch The cutting deck position switches on the Groundsmas 4000 D are located on the traction unit frame Fig 40 and 41 and are normally open The position switch is a powered proximity switch that incorporates an inter nal reed switch and relay see schematic in Figure 42 The sensing plate is located on the cutting deck lift arm The switches for front and
197. lic fitting 15 Adapter 3 90 hydraulic fitting 10 O ring 16 Hydraulic fitting 4 O ring 11 O ring 17 O ring 5 O ring 12 90 hydraulic fitting 18 Cap screw 6 Quick fitting 13 O ring 19 Flange nut 7 O ring Hydraulic System Rev B Page 4 66 Groundsmaster 4000 D Removal NOTE The ports on the manifold are marked for easy identification of components Example P1 is a piston pump connection port and 2 is the location for the sole noid valve See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port 1 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 2 Disconnect electrical connector from the solenoid valve 3 Disconnect hydraulic lines from manifold and put caps or plugs on open hydraulic lines and fittings Label disconnected hydraulic lines for proper reassembly 4 Remove hydraulic manifold from the frame using Figure 49 as guide Groundsmaster 4000 D Page 4 67 Installation 1 Install hydraulic manifold to the frame using Figure 49 as guide 2 Remove caps and plugs from fittings and hoses Properly connect hydraulic lines to manifold 3 Connect electrical connector to the solenoid valve Hydraulic System Rev B 2 E S 5 gt Hydraulic Control Manifold Service 4 Wheel Drive EATON VICKERS MANIFOLD i 80 to 90 ft Ib
198. nals 30 and 87A Apply 12 VDC to terminal 85 The relay should make and break continuity between termi nals 30 and 87A as 12 VDC is applied and removed from terminal 85 5 Disconnect voltage and multimeter leads from the relay terminals Groundsmaster 4000 D Page 5 15 Electrical System Hydraulic Valve Solenoids There are four hydraulic valve solenoids on the Ground 5 Install new solenoid if necessary smaster 4000 D Fig 23 Testing of these solenoids be done with the solenoid on the hydraulic valve A Apply Loctite 242 or equivalent to threads on end of valve stem before installing nut NOTE Prior to taking small resistance readings with a digital multimeter short the meter test leads together B Torque solenoid nut to specification identified in The meter will display a small resistance value usually Figure 23 Over tightening may damage the sole 0 5 ohms or less This resistance is due to the internal noid or cause the valve to malfunction resistance of the meter and test leads Subtract this val ue from from the measured value of the component you 6 Reconnect electrical connector to the solenoid are testing 1 Make sure engine is off Disconnect hydraulic valve solenoid electrical connector Fig 22 2 Apply 12VDC source directly to the solenoid Listen for solenoid to switch on 3 Remove 12VDC source from the solenoid Listen for solenoid to switch off 4 Measure resistance betwe
199. native to using manifold port MP would be to disconnect the inlet hydraulic hose to the deck motor 4 Install tester in series with the the disconnected hose and hydraulic manifold port MP or motor inlet if hose was disconnected at deck motor 5 Make sure the flow control valve on the tester is fully open 6 Install tester in series with the hose and hydraulic fit ting Make sure the flow control valve on tester is fully open A CAUTION Keep away from decks during test to prevent per sonal injury from the cutting blades 7 Start engine and move throttle to full speed 2730 30 RPM Engage the cutting units 8 Watch pressure gauge carefully while slowly closing the flow control valve to fully closed 9 As the relief valve lifts system pressure should be approximately 3000 PSI for the front and left decks 2000 PSI for the right deck Groundsmaster 4000 D Page 4 33 10 Disengage cutting units Shut off engine If specifica tion is not met adjust or clean relief valve in deck man ifold port R1BY Adjust relief valve as follows NOTE Do not remove valve from the hydraulic man ifold for adjustment A Remove cap on relief valve with an allen wrench B To increase pressure setting turn the adjust ment screw on the valve in a clockwise direction A 1 8turn onthe screw will make a measurable change in relief pressure C To decrease pressure setting turn the adjust ment screw onthe v
200. nder and gasket from the fuel tank Clean EMPTY POSITION 4 any fuel from the sender NOTE Before taking small resistance readings with digital multimeter short meter test leads together The Figure 26 meter will display a small resistance value This internal resistance of the meter and test leads should be sub tracted from the measured value of the component Make sure sending unit is completely dry no fuel on it before testing Perform test away from the tank to prevent an explosion or fire from sparks 4 Check resistance of the sender with a multimeter A Resistance with the float in the full position should be 27 5 to 39 5 ohms B Resistance with the float in the empty position should be 240 to 260 ohms 5 Replace sender as necessary Reinstall sender into fuel tank Connect wires Electrical System Page 5 18 Groundsmaster 4000 D Fuel Gauge The fuel gauge can be tested using new gauge as a substitute or with the use of a DC voltage source and a variable resistance box Make sure the voltage source is turned OFF be fore connecting it to the electrical circuit to avoid electrical shock and prevent damaging the gauge VARIABLE RESISTANCE 1 Connect fuel gauge to the variable resistance and DC voltage source Fig 27 NOTE When reading the gauge test point there are two white dots on the gauge face below the edg
201. ng Instructions 1 4 Safety and Instruction Decals 1 5 Chapter 2 Product Records and Maintenance Product Records 2 1 Maintenance 2 1 Equivalents and Conversions 2 2 Torque Specifications 2 3 Chapter 3 Kubota Diesel Engine General Information 3 2 Specifications 3 3 Adjustments 3 4 Service and Repairs 3 6 KUBOTA WORKSHOP MANUAL DIESEL ENGINE V2003 T SERIES Chapter 4 Hydraulic System Specifications 4 2 General Information 4 3 Hydraulic Schematic 4 6 Hydraulic Flow Diagrams 4 8 Special Tools 4 18 Troubleshooting 4 20 TES REG 4 23 Adjustments 4 48 Service and Repairs 4 49 Groundsmaster 4000 D Chapter 5 Electrical System Chapter 7 Chassis Electrical Schematic Circuit Diagrams and Wire Harness Drawings Special Tools eure ders DER Troubleshooting 5 Electrical System Quick Checks t Component Testing EE Service and Repairs
202. ng and centering springs from the spool Reassembly Check all mating surfaces Replace any parts with scratches or burrs that could cause leakage Wash all metal parts in clean solvent Blow them dry with pressur ized air Do not wipe parts dry with paper towels or cloth Lint in a hydraulic system will cause damage NOTE Always use new seals and o rings when reassembling the steering control unit IMPORTANT During reassembly lubricate the new seals with petroleum jelly Also lubricate machined surfaces and bearings with clean hydraulic fluid 1 Install the quad seal A Put one of the bearing races and sleeve into the housing B Together the housing and bearing race create a groove into which the quad seal will be installed C Hold the bearing race tightly against the input end of the housing by pushing on the gerotor end of the sleeve D Fitthe quad seal into its seat through the input end of the housing Be sure the seal is not twisted E Remove the sleeve and bearing race 2 Lubricate and install the dust seal 3 Install the centering springs in the spool It is best to install the two flat pieces first Next install the curved pieces three at a time 4 Fit the retaining ring over the centering springs 5 Apply a light coating of clean hydraulic fluid to the spool and slide it into the sleeve Be sure the centering springs fit into the notches in the sleeve 6 Install the pin 7 Apply a ligh
203. ng screws nuts and lock wash ers Remove the bevel gear case axle case assembly and O ring from the axle support Fig 13 2 Mark both right and left bevel gear case axle case assemblies IMPORTANT Do not interchange right and left bevel gear case axle case assemblies 3 Remove the axle cover mounting screws Remove the axle cover from the axle case as an assembly Fig 14 4 Remove the axle case support mounting screws the axle case support and the support shims Fig 15 Groundsmaster 4000 D Page 6 15 35 to 41 ft Ib 47 to 56 N m 35 to 41 ft Ib 47 to 56 N m Figure 13 Cap screw 5 Bevel gear case axle Lock nut case assembly Lock washer 6 O ring Axle support Pons 17 to 20 ft lb 23 to 27 N m Figure 14 3 Mounting screw 4 O ring 1 Axle case 2 Axle cover assembly Threadlocking Compound 57 to 67 ft lb 77 to 91 Figure 15 3 Mounting screw 4 Support shim 1 Axle case 2 Axle case support Axles Planetaries and Brakes Rev B a 5 S a a 9 x lt 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 16 6 While holding the bevel gear case tap the upper end of the bevel gear shaft out of the upper bearing and up per bevel gear 7 Pull the bevel gear case from the axle case and
204. ng unit several times Readjust as required 5 After desired drop rate is attained tighten setscrew on valve to lock adjustment Hydraulic System Rev B Page 4 48 Groundsmaster 4000 D Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1 Before removing any parts from the hydraulic sys tem park machine on a level surface engage parking brake lower cutting units or attachments and stop en gine Remove key from the ignition switch 2 Clean machine before disconnecting removing or disassembling any hydraulic components Make sure hydraulic components hoses connections and fittings are cleaned thoroughly Always keep in mind the need for cleanliness when working on hydraulic equipment Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil Controls must be operated with the ignition switch in RUN and the engine OFF Make sure all electrically operated control valves are actuated Return ignition switch to OFF when pressure has been relieved Remove key from the ignition switch 3 Putcaps or plugs on any hydraulic lines hydraulic fit tings and components left open or exposed to prevent contamination 4 Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed 5 Note the position of hydraulic fittings especially el b
205. ngine 14 Adjust traction pedal to the neutral position see Op erator s Manual 15 Check operation ofthe traction interlock switch see Check Interlock System in Chapter 5 Electrical Sys tems 16 Remove blocks from frame and lower machine Re move chocks from remaining wheels 17 If the piston traction pump or a traction motor was replaced or rebuilt run the machine so all wheels turn slowly for 10 minutes 18 Operate machine by gradually increasing its work load to full over a 10 minute period 19 Stop the machine Check hydraulic reservoir and fill if necessary Check hydraulic components for leaks and tighten any loose connections Hydraulic System Rev B 2 5 gt 90 hydraulic fitting O ring O ring 90 hydraulic fitting O ring O ring Hydraulic fitting O ring Hydraulic fitting Hydraulic System Rev Figure 39 O ring Clamp Hydraulic T fitting O ring Hydraulic fitting Fitting cap Hydraulic fitting O ring Cap screw Page 4 52 Flat washer Engine Piston pump O ring Coupler Gear pump Spacer Cap screw Washer Groundsmaster 4000 D Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Raise seat and secure it with prop rod to gain acces
206. nternal surface of barrel for dam age deep scratches out of round etc Replace en tire cylinder if barrel is damaged Inspect piston rod and piston for evidence of excessive scoring pitting or wear Replace any damaged parts Assembly 1 Use a complete repair kit when rebuilding the cylin der Puta coating of clean hydraulic oil on all new seals and O rings Groundsmaster 4000 D 4 107 Rev E 2 Install new O rings and PTFE seal to the piston rod and new O ring U cup and wiper to gland 3 Lubricate shaft with clean hydraulic oil Slide gland and piston onto shaft Install and tighten lock nut 4 Put a coating of clean hydraulic oil on all cylinder parts to ease assembly 5 Slide piston rod assembly into cylinder tube 6 Mount lift cylinder in a vise with soft jaws Secure gland head in barrel A On cylinders without a retaining ring slot in the barrel Fig 82 use a spanner wrench to tighten gland into barrel On cylinders with a retaining ring Fig 83 align retaining ring hole in the head with the access slot in the barrel Insert the retaining ring hook into the hole and rotate head clockwise until the retaining ring is completely pulled into the barrel and the ring ends are covered Figure 83 1 Barrel 3 Retaining ring 2 Gland head Hydraulic System Rev B 9 Ey Hydraulic Reservoir Figure 84 1 Hydraulic reservoir
207. ntial gear 3 Axle support left 7 O ring 4 Axle support right Figure 33 1 Differential case 2 Spring pin 22 to 25 ft Ib 30 to 34 Threadlocking Compound Figure 34 1 Differential pinion shaft 5 Side gear shims 2 Pinion gear 6 Ring gear 3 Pinion washer 7 Differential case 4 Side gear Groundsmaster 4000 D Inspection 1 Measure the differential side gear O D and the dif ferential case 1 0 to determine the side gear to case clearance Fig 35 Replace components as necessary SIDE GEAR TO CASE CLEARANCE 0 002 to 0 012 in 0 05 to 0 30 mm SIDE GEAR O D Factory Spec 1 335 to 1 337 in 33 91 to 33 95 mm DIFFERENTIAL CASE 1 0 Factory Spec 1 339 to 1 341 in 34 00 to 34 06 mm 2 Measure the differential pinion shaft O D and the pinion gear I D to determine the pinion shaft to pinion gear clearance Fig 36 Replace components as nec essary PINION SHAFT TO PINION GEAR CLEARANCE 0 001 to 0 010 in 0 08 to 0 25 mm PINION SHAFT O D Factory Spec 1 Side gear 2 Differential case PINION GEAR 1 0 Factory Spec 0 551 to 0 552 in 13 10 to 14 02 mm 3 Inspect all gears shafts bearings cases and cov ers for damage and wear Replace components as nec essary 4 5 9 x Figure 36 1 Pinion shaft 2 Pinion gear Groundsmaster 4000 D Page 6 25 Axles Planetaries and Brakes Rev B
208. o Part No 505 165 which forms a light protective skin which helps waterproof electrical switches and contacts Electrical System Figure 2 Deck Proximity Switch Adjustment Tool The Deck Proximity Switch Adjustment Tool TOR4095 is designed to assist in the adjustment of the cutting deck position switches for cutting blade shutdown dur ing deck lift Figure 3 Groundsmaster 4000 D 5 3 Rev E Electrical System Troubleshooting For effective troubleshooting and repairs you must have a good understanding of the electrical circuits and components used this machine see Chapter 9 Electrical Diagrams Remove all jewelry especially rings and watches before doing any electrical trouble If the machine has any interlock switches by passed shooting or testing Disconnect the battery reconnect the switches for proper troubleshooting and cables unless the test requires battery voltage safety Starting Problems All electrical power is dead including gauges The battery charge is low The 10 amp fuse to the ignition switch is open Bad ground connection on machine The ignition switch or circuit wiring is faulty The fusible link from the battery is faulty Starter solenoid clicks but starter will not crank Low battery charge NOTE If the solenoid clicks the problem is not in the in ON Loose or corroded battery cables terlock circuit wiring Loose or corroded ground Faulty wiring at the sta
209. ocedure again 8 Connect engine run solenoid electrical connector start the engine and check for proper operation 9 Properly fill hydraulic system see Charge Hydraulic System 10 Stop engine and check for hydraulic oil leaks Check hydraulic reservoir oil level Hydraulic System Rev B 9 0 Se Piston Traction Pump Service 100 to 110 ft Ib 13610 149 N m gt 150 to 160 in Ib 17 to 18 N m 40 to 48 in Ib 4 5 to 5 4 N m 1 Jamnut 16 2 Retaining ring 17 3 Retaining ring 18 4 Seal washer 19 5 Socket head screw 20 6 Rotating kit assembly 21 7 Servo piston assembly 22 8 Piston follower 23 9 Cover plate 24 10 Cover plate 25 11 Camplate assembly 26 12 Thrust race 27 13 Thrust bearing 28 14 Bypass valve 29 15 Cap screw 30 Hydraulic System Rev B 27 to 31 ft lb 37 to 42 N m Figure 42 Relief valve Reverse Socket head screw Valve plate Pump housing Backplate assembly Drive shaft Nut Lock washer Washer Shaft seal Relief valve Forward Control arm Servo control assembly Washer Orifice plate 3 used Page 4 60 100 to 110 ft Ib 136 to 149 N m 4 to 6 ft Ib 5 to 8 N m 40 to 48 in Ib e e 4 5 10 5 4 que 5 to 48 in Ib 4 5 to 5 4 N m 31 Flat washer 32 Housing gasket 33 Cover plate gasket 34 Control assembly gasket 35 Plug 36 O ring 37
210. ol valve then through the T port and to the hydraulic reservoir The steering wheel and steering control valve return to the neutral position when turning is completed Right Turn When a right turn is made with the engine running the turning ofthe steering wheel positions the spool valve so that flow goes through the bottom of the spool Flow en tering the steering control valve at the P port goes through the spool and is routed to two places As in a left turn most of the flow through the valve is by passed out the PB port back to the oil filter and traction charge cir cuit Also like a left turn the remainder of the flow is drawn through rotary meter V1 but goes out port R Pressure extends the piston for a right turn The rotary meter ensures that the oil flow to the cylinder is propor tional to the amount of the turning on the steering wheel Fluid leaving the cylinder flows back through the spool valve then through the T port and to the hydraulic reser voir The steering wheel and steering control valve return to the neutral position when turning is completed STEERING CYLINDER PISTON MOVEMENT STEERING CONTROL NEUTRAL POSITION LEFT TURN STEERING CONTROL STEERING CONTROL RIGHT TURN Figure 8 Groundsmaster 4000 D 4 17 Hydraulic System Rev 2 o Ey Special Tools Order these tools from your Toro Distributor Hydraulic Pressure T
211. omponents is noted before screws are fully tightened add additional sup port shims Torque screws from 57 to 67 ft lb 77 to 91 Use dial indicator to measure vertical endplay of axle case Fig 20 AXLE CASE ASSEMBLY ENDPLAY 0 001 to 0 008 in 0 02 to 0 20 mm D Adjust endplay by increasing or reducing number of axle case support shims NOTE Axle case support shims are available in 0 004 in 0 1 mm 0 008 in 0 2 mm and 0 016 in 0 4 mm thickness 6 After correct support shims have been determined remove mounting screws apply heavy strength thread locking compound to screw threads reinstall screws and torque from 57 to 67 ft lb 77 to 91 N m IMPORTANT Correct engagement between bevel gears is critical to axle performance and durability 7 install the bevel gear case axle case as sembly on the axle support Position a dial indicator at the tooths center Prevent the axle from turning and measure the upper bevel gear to differential shaft gear backlash Fig 21 UPPER BEVEL GEAR BACKLASH 0 004 to 0 016 in 0 10 to 0 40 mm 8 Adjust backlash by increasing or reducing axle bear ing shim thickness see Differential Shafts in this section of this manual NOTE Axle bearing shims are available in 0 004 in 0 1 mm 0 008 in 0 2 mm and 0 020 in 0 5 mm thickness Axles Planetaries and Brakes Rev B Page 6 18 57 to 67 ft lb 77 to 91 N m V
212. oper greas ing of spindle housings 11 Attach a hand pump grease gun to grease fitting and fill housing cavity with grease until grease starts to come out of lower seal 12 Rotate spindle shaft to make sure that it turns freely 13 Secure drive spindle assembly to deck with flange head screws Driven spindle assemblies are attached to the deck with flange head screws and flange lock nuts 14 Install cutting blade anti scalp cup and bolt see Op erator s Manual Tighten blade bolt from 85 to 110 ft lb 115 to 149 15 Install drive belt and adjust belt tension see Opera tor s Manual 16 drive spindle was removed install hydraulic motor to cutting deck see Cutting Deck Motor Installation in the Service and Repairs Section of Chapter 4 Hydrau lic Systems Install belt covers to cutting deck Figure 10 1 Bearing cups 4 Arbor press 2 Large snap ring 5 Support 3 Large spacer 6 Arbor press base Figure 11 1 Bottom seal installation 2 Upper seal installation Cutting Units Cutting Units Castor Forks and Wheels FRONT CUTTING DECK SIDE CUTTING DECK 60 to 80 ft lb 81 to 108 60 to 80 ft Ib 81 to 108 Figure 12 1 Castor arm front deck 11 Retaining ring 21 Hairpin 2 Flange head screw 12 Cap washer 22 Cutting deck RH shown 3 Castor fork 13 Compression spring 23 Bearing 4 Capscrew 14 Cap 2
213. or 30 seconds then turn switch to OFF 7 The amount of fuel collected in the graduated cylin der should be approximately 11 75 fl oz 350 ml after 30 seconds 8 Replace fuel pump as necessary Install fuel hose to the water separator 9 Reconnect electrical connector to the fuel stop sole noid 10 Prime fuel system Electrical System 5 20 Rev E Figure 29 1 Fuel pump 3 Pump discharge hose 2 Water separator Fuel Pump Specifications Pump Capacity 23 5 fl oz min 695 ml min 228 kPa Max Current 0 9 amp Draw Groundsmaster 4000 D Glow Controller The glow controller is located under the console cover NOTE Refer to Chapter 9 Electrical Schematics and Diagrams when troubleshooting the controller Controller Operation 1 When the ignition switch is placed in the ON position the controller energizes the glow plugs and lights up the glow lamp for 10 seconds 2 When the ignition switch is held in the START posi tion the glow plugs will energize and the glow lamp will not light 3 When the ignition switch is released from START to ON the glow plugs will deenergize and the glow lamp will remain off Controller Checks 1 Make sure there is power from the battery 2 Disconnect electrical connector to the run solenoid to prevent the engine from starting 3 Place ignition switch in the ON position Verify the fol lowing while in the ON position A Glow indicator l
214. or additional differential bearing shim s to move ring gear forward C Repeat until proper tooth contact and pinion gear to ring gear backlash are correct Axles Planetaries and Brakes Rev B Page 6 28 Rev E Base Contact Sn Figure 42 Tip Contact Sn Figure 43 Groundsmaster 4000 D Chapter 7 TORO Chassis Table of Contents SERVICE AND REPAIRS 2 Steering Tower 2 Front Deck Lift Arm 4 Side Deck ift Arm Re dus 6 Side Deck Rear Arm Assembly 8 Lift Arm Yoke Joint 12 TEMA TTE 14 Groundsmaster 4000 D Page 7 1 Chassis Service and Repairs Steering Tower Hex nut Flat washer Steering wheel Foam collar Steering seal External snap ring 2 used Knob Steering tower cover Steering shaft Compression spring Cap Rod assembly Extension spring Tilt rod BON Chassis 18 to 22 ft Ib 25 to 29 N m Figure 1 Lock nut Parking brake switch Cotter pin Brake pawl Cotter pin Lock nut Nut insert Flange head screw Flange bushing Thrust washer Temperature gauge Warning lamp temp glow plug Warning lamp charge oil pressure Steering column Page7 2 Rev E 29 30 31 32 33 34 35 36 37 38 39 40 41 Cap screw P
215. or hardwood blocks under the frame as close to the wheels as possible to support the machine 11090 i Jacking the Rear End Fig 2 1 Place jack securely under the center of rear axle Figure 2 2 Chock both front tires Jack rear of machine off the 1 Rear axle jacking point 2 Rear tire ground 3 Use jack stands or blocks under the axle to support the machine Safety Page 1 4 Groundsmaster 4000 0 Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 4000 D If any decal becomes illegible or damaged install a new decal Part numbers are listed in your Parts Catalog Groundsmaster 4000 D Page 1 5 Safety This is intentionally blank Safety Page 1 6 Groundsmaster 4000 D TORO Table of Contents PRODUCT RECORDS 1 MAINTENANCE 1 EQUIVALENTS AND CONVERSIONS 2 Decimal and Millimeter Equivalents 2 U S to Metric Conversions 2 TORQUE SPECIFICATIONS 3 Fastener Identification 3 Product Records Insert Operator s Manual and Parts Catalog for your Groundsmaster 4000 D at the end of this chapter Addi tionally if any optional equipment or accessories have been installed to your machine insert the Installation In structions Operator s Manuals and Parts Catalogs for those options at the end of th
216. orrect position on the steering cylinder 3 Remove hydraulic hoses from steering cylinder 4 Remove cotter pins hex slotted nuts axle washer and ball joint spacer fromthe threaded ends of ball joints Fig 81 Remove steering cylinder with ball joints from machine Locate and retrieve ball joint spacers from top of axle assembly Groundsmaster 4000 D Page 4 105 Installation 1 Place a washer onto each ball joint Slide ram end ball joint through hole on steering arm Secure with axle washer and hex slotted nut Slide fixed end of cylinder through hole on axle Install spacer onto ball joint and secure with hex slotted nut Torque slotted nuts from 100 to 125 ft lbs 135 to 169 N m prior to inserting cotter pins 2 Install hydraulic hoses to steering cylinder 3 Fill reservoir with hydraulic fluid as required see Op erator s Manual 4 After assembly is completed operate steering cylin derto verify that hydraulic hoses and fittings are not con tacted by anything Hydraulic System Rev B 9 Oo Ey Steering Cylinder Service Figure 82 1 Butt and tube assembly 5 Lock nut 9 O ring 2 Shaft 6 O ring 10 U cup 3 Piston rod assembly 7 PTFE seal 11 Wiper 4 Gland head 8 O ring Hydraulic System Rev B 4 106 Rev E Groundsmaster 4000 D Disassembly 1 Pump oil out of cylinder into a drain pan by SLOWLY moving rod and piston in and out of cylinder bore Plug
217. ow check for restriction assembly 5 Poppet in pump intake line Check the lift cylinder for internal leakage If cylinder is not leaking adjust the relief valve by rotating clockwise If pressure is still too low pump or lift cylinder s should be suspected of wear damage or inefficiency Groundsmaster 4000 D Page 4 39 Hydraulic System Rev B TEST 9 Steering Lift Lower Gear Pump Flow Using Tester with Pressure Gauges and Flow Meter NOTE LIFT LOWER GEAR PUMP FLOW TEST SHOWN TO STEERING CIRCUIT TO LIFT LOWER CIRCUIT TO PTO MOW CIRCUIT TO PTO MOW CIRCUIT gt gt 12 12 248 FN 4 Pi SN YN SG RESERVOIR TRACTION CIRCUIT FROM OIL FILTER Hydraulic System Rev B Page 4 40 High Pressure Low Pressure Return Suction gt Groundsmaster 4000 D Procedure for Steering Lift Lower Gear Pump Flow Test Output from the steering and lift lower gear pump sec tion is equally divided by a proportional valve to provide flow to the steering circuit and the lift circuit To test gear pump flow testing of both circuits is required Total gear pump flow is the combined flow from the two circuits 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units l
218. ow fittings on hydraulic components before removal Mark parts if necessary to make sure they will be aligned properly when reinstalling hydraulic hoses and tubes Check Hydraulic Lines and Hoses Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is in jected into the skin it must be surgically re moved within a few hours by a doctor familiar with thistype of injury Gangrene may result from such an injury Groundsmaster 4000 D Page 4 49 After Repair or Replacement of Components 1 Check oil level inthe hydraulic reservoir and add cor rect oil if necessary Drain and refill hydraulic system reservoir and change oil filter if component failure was Severe or system is contaminated see Flush Hydraulic System 2 Lubricate O rings and seals with clean hydraulic oil before installing hydraulic components 3 Make sure caps or plugs are removed from the hy draulic tubes hydraulic fittings and components before reconnecting 4 Use proper tightening methods when installing hy draulic hoses and fittings see Hydraulic Fitting Installa tion 5 After repairs check control linkages or cables for proper adjustment binding or broken parts 6 After disconnecting or replacing any h
219. ower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Open engine hood on the machine Do not open radiator cap or drain coolant if the radiator or engine is hot Pressurized hot cool ant can escape and cause burns Ethylene glycol antifreeze is poisonous Dis pose of coolant properly or store it in a properly labeled container away from children and pets 3 Drain radiator into a suitable container using the ra diator drain The radiator drain hose is located near the engine oil filter 4 Disconnect hoses upper and lower from the radia tor 5 Remove air cleaner hose 6 Disconnect reservoir hose from the vent tube 7 Detach radiator shroud from the radiator by remov ing four flange head screws and flat washers Position shroud away from radiator 8 Remove screws flat washers and lock nuts securing the radiator to the support frame Pull radiator from the machine 9 Plug any radiator or hose openings to prevent con tamination Groundsmaster 4000 D Page 3 13 Installation 1 Remove any plugs used during the removal proce dure 2 Position radiator to the support frame Secure radia tor to the support frame with lock nuts flat washers and screws 3 Attach radiator shroud to the radiator with flange screws and flat washers Make sure that clearance be tween shroud and fan is at least 180 4 6 mm at all points 4 Connect reservoir hose
220. owered and off Make sure engine is off and the parking brake is engaged Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section IMPORTANT Make sure that the oil flow indicator arrow on the flow gauge is showing that the oil will flow from the pump through the tester and into the hydraulic hose 3 With the engine off and cutting units lowered install tester in series between the last gear pump section and one of the circuit hoses Fig 30 Make sure the tester flow control valve is OPEN IMPORTANT The pump is a positive displacement type If pump flow is completely restricted or stopped damage to the pump tester or other com ponents could occur 4 Startthe engine and move throttle to full speed 2730 30 RPM DO NOT engage the cutting units 5 While watching pressure gauges slowly close flow control valve until 1000 PSI is obtained on gauge Verify engine speed continues to be correct 2730 30 RPM GAUGE READING TO BE Flow approximately 3 5 GPM at 1000 PSI 6 Stop engine Remove tester and reinstall hose Complete steps 3 through 6 for other circuit hose Groundsmaster 4000 D Page 4 41 7 Ifthe total of the two flows is lower than 7 GPM or a pressure of 1000 PSI could not be obtained check for restriction in pump intake line If intake line is not re stricted remove gear pump and repair or repl
221. p screws and lock nuts Torque fas teners from 22 to 27 ft lb 30 to 37 13 damper link was disassembled adjust the length of the link to 5 370 075 13 6 cm 2 cm Fig 8 14 1 damper springs 37 were removed tighten lock nuts so that bushings 36 are free to rotate Groundsmaster 4000 D Page 7 9 Z Spring shaft Flat washer Bushing Compression spring Figure 8 2 Clevis pin Plate Coupler Roll pin Jam nut 0 Rod end Chassis Installation 1 Position rear arm assembly to cutting deck and frame 2 Slide pivot shaft through rear arm clevis and hub Se cure pivot shaft with lock washer and locknut 3 Connect damper link to cutting deck with clevis pin and hair pin Fig 8 4 Position spacers on both sides of rod end of rear arm assembly Secure rod end of rear arm to deck mount with cap screw and lock nut 5 Lubricate rear arm grease fittings see Operator s Manual 6 Align cutting deck to traction unit as follows A Make sure the machine is on a level hard sur face B Place a square or straight edge against the deck weldment that contains the castor fork assembly Fig 10 Do not use the castor fork assembly itself C Measure from the inset bead of the rim not the outer edge of the rim to the straight edge at two loca tions as indicated in Figure 10 Rim and paint irregu larities make the rim outer edge an unreli
222. pect front flange and rear cover for damage or wear Figure 68 1 Motor body 2 Bearing block amp gear set 2 5 gt Backup Ring Figure 69 Figure 70 1 Drive gear 3 Bearing block 2 Idler gear Groundsmaster 4000 D Page 4 87 Hydraulic System Rev B NOTE When reassembling the motor check the identi fication marks made during disassembly to make sure the parts are properly aligned during reassembly 1 Lubricate o rings pressure seals back up gaskets and seal grooves with a thin coat of petroleum jelly Lu bricate all other internal parts freely with clean hydraulic oil 2 Install new shaft seal into front flange Install snap ring into front flange 3 Install lubricated pressure seals into the grooves in the front flange and rear cover Follow by carefully plac ing the back up rings into the grooves 4 Install new o rings to the body 5 Lubricate gear faces and bearing surfaces of drive gear idler gear and bearing blocks Carefully assemble bearing blocks and gears noting identification marks made during disassembly 6 Position the motor body on its side Carefully slide bearing block and gear assembly into the body cavity using identification marks made during disassembly 7 Remove any excess lubrication from mating sur faces of body rear cover and front flange Make sure that these surfaces are clean and dry Hydraulic System Rev B P
223. pedal linkage is adjusted incorrectly therefore shut engine off and adjust until machine does not move when traction pedal is released 3 Do not run engine in a confined area without ade quate ventilation Exhaust fumes are hazardous and could possibly be deadly 4 Do not touch engine muffler or exhaust pipe while engine is running or soon after it is stopped These areas could be hot enough to cause burns Safety Page 1 2 death To reduce the potential for injury or death comply with the following safety instructions WARNING To reduce the potential for injury or death comply with the following safety instructions 3 Assure interlock switches are adjusted correctly so engine cannot be started unless traction pedal is in NEUTRAL and cutting units are DISENGAGED 4 Since diesel fuel is highly flammable handle it care fully A Use an approved fuel container B Do not remove fuel tank cap while engine is hot or running C Do not smoke while handling fuel D Fill fuel tank outdoors and only to within an inch of the top of the tank not the filler neck Do not overfill E Wipe up any spilled fuel 5 Before getting off the seat A Ensure that traction pedal is in neutral B Set parking brake C Disengage cutting units and wait for blades to stop D Stop engine and remove key from switch E Toro recommends that anytime the machine is parked short or long term the cutting units
224. perating hours and every 30 days if machine is in storage 6 Maintain cell level with distilled or demineralized wa ter Do not fill cells above the fill line Groundsmaster 4000 D 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 When working with batteries use extreme cau tion to avoid splashing or spilling electrolyte Electrolyte can destroy clothing and burn skin or eyes Always wear safety goggles and a face shield when working with batteries Electrolyte Specific Gravity Fully charged 1 265 corrected to 80 F 26 7 C Discharged less than 1 240 Battery Specifications BCI Group Size 24 650 CCA at 0 F 17 8 C Reserve Capacity of 110 minutes at 80 F 26 7 C Dimensions including terminal posts and caps Length 10 2 inches 25 9 cm Width 6 64 inches 16 9 cm Height 8 99 inches 22 8 cm Removal and Installation Fig 43 See Operator s Manual for battery removal and installa tion information NOTE Before connecting the negative ground cable connect a digital multimeter set to amps between the negative battery post and the negative ground cable connector The reading should be less than 0 1 amp If the reading is 0 1 amp or more the unit s electrical sys tem should be tested and repaired Inspection Maintenance and Testing 1
225. positions the oil grooves closest to respective dowel pin holes 10 Replace the backplate front plate or adapter plates if I D of bushings exceed 879 inch 22 33mm Bush ings are not available as separate items 11 Bushings in front plate and backup gasket side of adapter plates should be flush with face of plate 12 Check for scoring on face of backplate and adapter plates Replace if wear exceeds 0015 inch 038mm 13 Check bodies inside gear pockets for excessive scoring or wear 14 Replace bodies if 1 0 of gear pockets exceeds 2 100 inch 53 34mm Hydraulic System Rev B 2 o Ey is important that the relationship of the backplate adapter plates bodies wear plates and front plate is correct The two half moon cavities in the bodies must face away from the front plate or adapter plate The smaller half moon port cavity must be on the pressure side of the pump The side of the wear plate with mid section cut out must be on suction side of pump Suction side of backplate or adapter plate is always the side with larger port boss 1 Replace the wear plates pressure seals backup gaskets shaft seal and o rings as new parts During re assembly check the scribe mark on each part to make sure the parts are properly aligned 2 Install o rings 4 in groove of front plate 15 adapt er plates 23 24 and backplate 27 with a small amount of petroleum jelly to hol
226. ps 8 Reconnect engine run solenoid lead Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 9 Raise one front and one rear wheel off the ground and place support blocks under the frame Chock re maining wheels to prevent movement of the machine 10 Make sure traction pedal and lift control lever are in neutral Start engine and run it at low idle 1450 rpm The charge pump should pick up oil andfill the hydraulic system Ifthere is no indication offillin 30 seconds stop the engine and determine the cause Groundsmaster 4000 D Page 4 51 11 After the hydraulic system starts to show signs of fill actuate lift control lever until the lift cylinder rod moves in and out several times If the cylinder rod does not move after 10 to 15 seconds or the pump emits abnor mal sounds shut the engine off immediately and deter mine cause or problem Inspect for the following A Loose filter or suction lines B Blocked suction line C Faulty charge relief valve D Faulty gear pump 12 If cylinder does move in 10 to 15 seconds proceed to step 13 13 Operate the traction pedal in the forward and reverse directions The wheels off the ground should rotate in the proper direction A If the wheels rotate the wrong direction stop engine remove lines from bottom of piston traction pump and reverse the connections B If the wheels rotate in the proper direction stop e
227. pump 2 If adjustment is needed loosen lock nut and rotate the threaded end of the swivel until the lever is properly positioned 3 Tighten lock nut Recheck adjustment Figure 1 1 Run solenoid 3 Swivel 2 Solenoid lever run 4 Lock nut Figure 2 1 Run solenoid 3 Injection pump stop 2 Solenoid lever off Kubota Diesel Engine Rev B Page 3 4 Groundsmaster 4000 D 5 5 This is intentionally blank Groundsmaster 4000 D Page 3 5 Kubota Diesel Engine Rev B Service and Repairs Air Filter System rE N EA WE A 3 EVACUATOR DIRECTION Figure 3 1 Air cleaner hose 5 Air cleaner strap 9 Hose clamp 2 Hose clamp 6 Lock nut 10 Cap screw 3 Air cleaner assembly 7 Hose clamp 11 Flat washer 4 Indicator 8 Air cleaner hose Kubota Diesel Engine Rev B Page3 6 Groundsmaster 4000 D Removal 1 Remove air cleaner components as needed using Figure 3 as a guide Installation IMPORTANT Any leaks in the air filter system will cause serious engine damage Make sure daily that all air cleaner components are in good condition and are properly secured during reassembly 1 Reassemble air cleaner system using Figure 3 as a guide 2 When installing air cleaner hose 8 between air cleaner and turbo charger Fig 4 A Make sure that hose do
228. r ing ball joint mounts to front deck castor arms Fig 4 5 Slide the cutting unit away from the traction unit Installation 1 Position machine on a clean level surface Lower lift arms stop engine engage parking brake and remove key from the ignition switch 2 Position the front deck to the lift arms 3 Align ball joint mounts to front deck castor arms and secure with cap screws washers and lock nuts Fig 4 NOTE Installation of clevis pin to deck and height of cut chain is easier if deck is lifted slightly 4 Install clevis pin and hairpin that secure the height of cut chain to the rear of the cutting deck Fig 2 5 Install hydraulic motor to cutting deck see Cutting Deck Motor Installation in the Service and Repairs Sec tion of Chapter 4 Hydraulic Systems 6 Lubricate grease fittings on cutting deck and lift as sembly see Operator s Manual 1 Figure 2 1 Hairpin and clevis pin 2 Height of cut chain Flange head screw 1 Ball joint mount 2 Lift arm Groundsmaster 4000 D Page 8 7 Figure 3 2 Hydraulic motor Figure 4 3 Castor arm Cutting Units 2 2 5 o Side Cutting Unit a SS 595 oor Lock nut 6 Clevis Hair pin 5 7 rs gt x05 955 2555 025 ox Pe 5948 NALL Groundsmaster 4000 D
229. rade 1 Inch Series Bolts and Screws Figure 1 Groundsmaster 4000 D Page 2 3 As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be determined based on the aluminum or brass material strength fastener size length of thread en gagement etc The standard method of verifying torque shall be per formed by marking a line on the fastener head or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Class 8 8 Class 10 9 Metric Bolts and Screws Figure 2 Product Records and Maintenance 7 5 gt Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Grade 1 5 amp SAE Grade 1 Bolts Screws Studs amp SAE Grade 5 Bolts Screws Studs amp SAE Grade 8 Bolts Screws Studs amp Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 5 or Stronger Nuts ae 250 29 147 23 282 30 339 56 599 79 100 10 1125 100 140 15 1580 170 734 113 115 10 13
230. rator in the seat Traction neutral switch circuit wiring is faulty The engine stops during operation but is able to The operator is lifting off the seat switch restart The seat switch or circuit wiring is faulty The engine shutdown delay is faulty The ignition switch or circuit wiring is faulty Electrical System The engine kills when the traction pedal is depressed The operator is lifting off the seat switch The seat switch or circuit wiring is faulty Battery does not charge Loose corroded or broken wire s The fusible link to the battery is faulty Faulty alternator or dead battery Charge indicator lamp is faulty or burned out Charge indicator lamp wiring loose corroded or damaged Groundsmaster 4000 D 5 5 Electrical System Cutting Unit Operating Problems The cutting units remain engaged but should not with no operator in the seat Cutting units run but should not when raised Units shut off with PTO switch The seat switch or circuit wiring is faulty The deck position switch or circuit wiring is faulty Cutting units run but should not when raised Units do The deck position switch or circuit wiring and PTO not shut off with the PTO switch Cutting units run but should not when lowered with PTO switch in the OFF disengage position Cutting deck s do not operate PTO fuse blows when engaging cutting deck Electrical System Page 5 6 sw
231. rd then reverse GAUGE READING TO BE 200 to 300 PSI 7 If pressure is good under no load but drops below specification when under traction load the piston pump and or traction motor s should be suspected of wear and inefficiency When the pump and or traction mo tor s are worn or damaged the charge pump is not able to keep up with internal leakage in traction circuit com ponents Figure 14 1 Charge pressure port 2 Hydraulic reservoir cap 9 5 LA gt Groundsmaster 4000 D Page 4 25 Hydraulic System Rev B TEST 2 Traction Circuit Relief Pressure Forward Shown Using Pressure Gauge CHARGE gt CIRCUIT lt TO RESERVOIR TO gt CHARGE CIRCUIT V CASE DRAIN TO RESERVOIR _CHARGE CIRCUIT lt TO PTO MOW CIRCUIT lt d lt FILTER Working Pressure TO LIFT LOWER CIRCUIT zx ORAN Low Pressure 4 6 FROM Return Suction RESERVOIR TO STEERING n SERVO gt Flow Hydraulic System Rev B Page 4 26 Groundsmaster 4000 D Procedure for Traction Circuit Relief Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full A CAUTION Move machine to an open area away from people and obstructions 2 Drive machine to an open a
232. re that arrows on the side of motor case point upward 2 Align splines motor shaft and splined brake shaft Slide motor into brake assembly 3 Secure motor to brake assembly with cap screws and flat washers Tighten cap screws from 75 to 85 ft lb 101 to 115 N m 4 Remove plugs from ports Attach hydraulic hoses and tubes to wheel motor 5 Fill reservoir with hydraulic fluid as required see Op erator s Manual Hydraulic System Rev B 9 Oo Ey Rear Axle Front Wheel Motor Service 15 to 18 ft Ib 20 to 24 N m Figure 62 1 Drive shaft 7 Capscrew 13 Thrust bearing 2 Backplate front motor shown 8 Shaft seal 14 Roll pin 3 Housing assembly 9 Retaining ring 15 Roll pin 4 Rotating assembly 10 Thrust race 16 Bearing 5 Cam plate insert 11 O ring 17 Bearing 6 Retaining ring 12 Valve plate 18 Washer NOTE The front wheel motors are identical The rear axle motor has some differences from the front motors Service of the front and rear motors requires the same procedures Cleanliness is extremely important when repairing these motors Work in a clean area Before disconnect ing the lines clean port area of motor Thoroughly clean the outside of the motor After cleaning remove port plugs and drain oil Hydraulic System Rev B Page4 82 Disassembly 1 Clampthe drive shaft end ofthe piston motor in a pro tected jaw vise with the cap screws up Remove the six
233. re and flow capabilities open load valve completely in the tester to minimize the possibility of damaging components 6 Install fittings finger tight and far enough to make sure that they are not cross threaded before tightening them with a wrench 7 Position tester hoses to prevent rotating machine parts from contacting and damaging the hoses or tester 8 Check oil level in the hydraulic reservoir After con necting test equipment make sure tank is full 9 Check control linkages for improper adjustment binding or broken parts 10 All hydraulic tests should be made with the hydraulic oil at normal operating temperature 11 Before returning machine to use make sure that hy draulic reservoir has correct fluid level Hydraulic System Rev B 2 G a Ey TEST 1 Traction Circuit Charge Pressure Using Pressure Gauge CHARGE OIL FROM LIFT CIRCUIT CHARGE OIL FROM STEERING CIRCUIT SS eet ere a el a oe 20 er ene et es woe eles or ere wg eg RV G CASE DRAIN FROM PTO MOW CIRCUIT MOW CIRCUIT lt TO LIFT LOWER CIRCUIT ex 250 PSI P1 TO STEERING CIRCUIT R OIL COOLEI RETURN FROM PTO MOW CIRCUIT
234. rea lower cutting units turn the engine off and engage the parking brake Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section 3 Connect a 10 000 psi gauge to traction circuit test port for function to be checked Fig 16 4 Startthe engine and move throttle to full speed 2730 30 RPM Release parking brake 5 Sitonseat apply brakes fully and slowly depress the traction pedal in the appropriate direction While pu shing traction pedal look at pressure reading on gauge GAUGE READING TO BE Forward 4000 PSI Reverse 5000 PSI 6 If traction pressure is too low inspect traction pump relief valves Fig 17 Clean or replace valves as neces sary These cartridge type valves are factory set and are not adjustable If relief valves are in good condition traction pump or wheel motors should be suspected of wear and inefficiency Figure 15 1 Forward traction port 2 Left front wheel E E 55 gt 16 1 Reverse traction port 2 Right front wheel Figure 17 Forward relief valve 3 Traction pump 2 Reverse relief valve Groundsmaster 4000 D Page 4 27 Hydraulic System Rev B TEST 3 Cutting Deck Circuit Pressure Front Deck Shown ing Pressure Gauge Us Working Pressure HO1OMW 14 X930 HY E wa Low Pre
235. ring 12 Spider hoses and fittings are not contacted by moving compo 5 Flange head screw 13 Nut nents 6 O ring 14 Tab washer 7 Hydraulic adapter 15 Spider hub 8 O ring Groundsmaster 4000 D Page 4 85 Hydraulic System Rev B Cutting Deck Motor Service 33 to 40 ft Ib 45 to 55 N m Figure 66 1 Rear cover 7 Spider hub 12 Idler gear 2 Drive gear 8 Pressure seal 13 Cap screw 3 Seal 9 Back up ring 14 Front flange 4 Woodruff key 10 O ring 15 Dowel pin 5 Nut 11 Body 16 Snap ring 6 Tab washer Disassembly DIAGONAL MARK 1 Plug motor ports and clean the outside of the motor thoroughly After cleaning remove plugs and drain any oil out of the motor 2 Use a marker or scribe to make a diagonal mark across the front flange body and rear cover for reas sembly purposes Fig 67 IMPORTANT Avoid using excessive clamping pressure on the motor flange to prevent distorting the casting 3 Clamp mounting flange of motor in a vise with the Figure 67 shaft end down 4 Loosen cap screws on the rear cover 5 Take motor from the vise and remove cap screws 6 Remove front flange from the body then remove rear cover Locate and remove dowel pins from body Hydraulic System Rev B Page 4 86 Groundsmaster 4000 D IMPORTANT Mark the relative positions of the gear teeth and the bearing blocks so they can be re assembled in the same position Do not touch the gear surfaces as residue on hands ma
236. rter Faulty starter solenoid Faulty starter Nothing happens when start attempt is made Control The traction pedal is not in neutral position or the panel lights and gauges operate with the ignition neutral switch or circuit wiring is faulty switch in ON The cutting units are engaged Faulty ignition switch or circuit wiring Start relay or circuit wiring is faulty Starter solenoid or starter is faulty Engine starts but stops when the ignition switch is The fuel run solenoid is out of adjustment or circuit released from the START position wiring is faulty High temperature shutdown switch or circuit wiring is faulty Electrical System 5 4 Groundsmaster 4000 D Engine cranks but does not start Engine is not cranking fast enough Engine fuel stop solenoid circuit wiring or fuel pump is faulty The problem is not electrical see Chapter 3 Kubota Engine Starter cranks but should not when the traction pedal The traction neutral switch is out of adjustment is depressed tts ut EN The traction neutral switch or circuit wiring is faulty General Run and Transport Problems Engine continues to run but should not when the The engine fuel stop solenoid is stuck open ignition switch is turned off ee Tere Ignition switch or circuit wiring is faulty Engine continues to run but should not when the The seat sensor or circuit wiring is faulty traction pedal is engaged with no ope
237. rvice and Repairs section of this chapter 3 Disconnect hydraulic lines from deck motor Put caps or plugs on fittings and hoses to prevent contami nation Tag hydraulic lines for proper reassembly 4 Removetwoflange head screws that secure hydrau Figure 64 lic motor to motor mount Fig 64 1 Cutting deck motor 2 Flange head screw 5 Carefully remove hydraulic motor from cutting deck taking care notto damage spider hub attached to motor Locate and remove spider and mounting shim s if present from the deck Hydraulic Installation 1 Check for proper clearance between spider hub and spindle pulley Install motor to cutting deck without plac ing the spider in the spindle pulley The clearance be tween hub and pulley valleys should be from 830 to 930 21 1 to 23 6 mm If required use mounting shims between motor and motor mount to adjust clearance 2 Position spider in spindle pulley Place mounting shim s if required on deck Carefully install hydraulic motor to the cutting unit taking care not to damage spi der hub attached to motor 3 Secure motor to cutting deck with two flange head screws Fig 64 4 Remove caps or plugs from fittings and hoses Con Figure 65 nect hydraulic hoses to deck motor 1 Cutting deck motor 9 90 hydraulic fitting 2 O ring 10 Woodruff key 3 Hydraulic adapter 11 Shim if required 5 After assembly is completed verify that hydraulic 4 O
238. s to gear pump 3 Drain the hydraulic reservoir see Operator s Manu al 4 To prevent contamination of hydraulic system during removal thoroughly clean exterior of pump and fittings 5 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 6 Disconnect hydraulic lines from pump and put caps or plugs on open hydraulic lines and fittings Label dis connected hydraulic lines for proper reassembly 7 Support gear pump assembly to prevent it from fal ling 8 Remove two 2 cap screws and washers securing gear pump to piston pump Remove gear pump cou pler spacer and o rings from machine Groundsmaster 4000 D Page 4 53 Installation 1 Lubricate new o rings with clean hydraulic oil and position on pump 2 Slide coupler onto the piston pump output shaft 3 Position o rings and spacer to gear pump Align gear teeth and slide gear pump input shaft into coupler Secure gear pump to piston pump with two 2 cap screws and washers 4 Remove caps or plugs from hydraulic lines and fit tings Install lines to gear pump 5 Replace hydraulic filter and fill hydraulic reservoir with new hydraulic oil 6 Disconnect engine run solenoid electrical connector to prevent engine from starting Prime the hydraulic pump by turning the ignition key switch to start and crank the engine for 10 seconds Repeat cranking
239. s assume the rear axle assem bly has been removed from the machine Removal IMPORTANT not interchange right and left dif ferential shaft assemblies 1 Remove the mounting screws nuts and lock wash ers Remove the bevel gear case axle case assembly and O ring from the axle support Fig 23 2 Mark and pull the differential shaft assembly from the axle support 3 Remove the retaining ring and bevel gear Fig 24 4 Drive the differential shaft out of the bearings Re move the bearings and bearing shims 5 Inspect all gears shafts bearings and cases for damage and wear Replace components as necessary Installation 1 Press bearings onto differential shaft Place correct combination of bearing shims in axle support and drive differential shaft and bearing assembly into axle sup port 2 Install bevel gear and retaining ring 3 Coat new O ring with grease Align differential shaft splines with differential gear assembly and slide differ ential shaft assembly onto axle support 4 Install bevel gear case axle case assembly see Bevel Gear Case Axle Case Assembly in this section of this manual Axles Planetaries and Brakes Rev B Page 6 20 35 to 41 ft Ib 47 to 56 35 to 41 ft lb 47 to 56 N m Figure 23 1 screw 5 Bevel case 2 Lock nut assembly 3 Lock washer 6 O ring 4 Axle support 7 Stud Figure 24 1 Retaining ring 4 Bearing 2 Bev
240. scratches Inspect the shoes for a snug fit on the ball end of the pistons and a flat smooth surface that comes in contact with the cam plate Do not lap piston shoes 6 Examine the spider for wear in the pivot area 7 Examine the spider pivot to insure smoothness and no signs of wear 8 The polished finish on the shoe surface of the cam plate insert 5 should show no signs of scoring 9 Inspect the shaft for wear in the seal bearing and spline areas 10 Inspect thrust bearing 13 and races 10 for wear 11 Check the condition of the needle bearing 17 in housing and replace if necessary Reassembly 1 Clean all parts in suitable solvent and lubricate all in ternal parts with clean hydraulic oil before reassembly Groundsmaster 4000 D Page 4 83 2 If necessary install new needle bearing 17 hous ing 3 with numbered end of the bearing outward 3 Install retaining ring 9 on shaft Install thrust race 10 thrust bearing 13 and second thrust race 10 Secure with second retaining ring 9 4 Install shaftin housing Install washer 18 new shaft seal 8 and retaining ring 6 5 Install camplate insert 5 with the lettering side of in sert to the front of the housing Use petroleum jelly to hold in place during assembly 6 Install rotating assembly 4 into housing Make sure that piston shoes make contact with the camplate insert 7 Clamp motor assembly in a protected jaw vis
241. should be lowered to the ground This relieves pressure from the lift circuit and eliminates the risk of cutting units accidentally lowering to the ground F Do not park on slopes unless wheels are chocked or blocked Groundsmaster 4000 D Maintenance and Service 1 Before servicing or making adjustments lower decks stop engine set parking brake and remove key from the switch 2 Make sure machine is in safe operating condition by keeping all nuts bolts and screws tight 3 Never store the machine or fuel container inside where there is an open flame such as near a water heat er or furnace 4 Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition be fore applying pressure to the system 5 Keep body and hands away from pin hole leaks in hy draulic lines that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Hydraulic fluid escaping under pressure can penetrate skin and cause injury Fluid accidentally injected into the skin must be surgically removed within a few hours by a doc tor familiar with this form of injury or gangrene may re sult 6 Before disconnecting or performing any work on the hydraulic system all pressure in system must be re lieved by stopping engine and lowering cutting units to the ground 7 lf major repairs are ever needed or assistance is de sired contact an Authorized Toro Distributor 8 To reduc
242. sing Pressure Gauge CHARGE gt CIRCUIT lt TO RESERVOIR CIRCUIT V CASE DRAIN TO RESERVOIR _CHARGE CIRCUIT lt TO PTO MOW CIRCUIT lt d lt FILTER Working Pressure TO LIFT LOWER CIRCUIT gt Low Pressure lt FROM Return or Suction lt TAM Ae RESERVOIR TO STEERING CIRCUIT lt gt Flow Hydraulic System Rev B Page 4 44 Groundsmaster 4000 D Procedure for Rear Traction Circuit RV5 Relief Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Figure 33 1 2WD 4WD control manifold Prevent personal injury and or damage to equip 2 Relief valve test port ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section 3 Connect a 1000 PSI gauge to test port on 2WD AWD control manifold under radiator Fig 33 4 Start the engine and put throttle at full engine speed 2730 30 RPM 5 gt 5 Operate the machine 4WD with the cutting units lowered Drive down a slope in a forward direction de crease pressure on the tra
243. ssure Return or Suction RESERVOIR TRACTION CIRCUIT Y am 4 TO STEERING CIRCUIT m 5 o m o m LL A YOLOW 930 LNOYS V p Groundsmaster 4000 D Page 4 28 Hydraulic System Rev B Procedure for Cutting Deck Circuit Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section 3 Install test gauge with hydraulic hose attached to manifold test port for the deck to be tested Fig 18 19 and 20 Keep away from decks during test to prevent per sonal injury from the cutting blades 4 Start engine and move throttle to full speed 2730 30 RPM Engage the cutting units 5 Watch pressure gauge carefully while mowing with the machine 6 Cutting deck circuit pressure should be from 1000 to 3000 PSI and will vary depending on mowing condi tions 7 Disengage cutting units Shut off engine 8 Disconnect test gauge with hose from
244. t coating of petroleum jelly to the inner edge of the dust and quad seals Groundsmaster 4000 D Page 4 97 8 Put the thrust bearing and races into the housing The thrust bearing goes between the two races Fig 75 IMPORTANT Do not damage the dust or quad seals when installing the spool and sleeve assembly 9 Apply a light coating of clean hydraulic fluid to the spool and sleeve assembly and slide carefully the as sembly into the housing 10 Clamp the housing in a vise Use only enough clamp ing force to hold the housing securely 11 Lubricate and install a new o ring seal in the groove in the housing 12 Install the wear plate and align screw holes in the wear plate with threaded holes in the housing NOTE The holes in the wear plate are symmetrical 13 Install the geroter drive making sure the slot in the drive engages the pin 14 Lubricate and install new o ring in wear plate groove 15 Install the gerotor and align the screw holes 16 Lubricate and install new o ring in gerotor ring groove 17 Lubricate and install new o ring and seal ring in gero tor star groove 18 Install the spacer 19 Install the end cap and seven cap screws Tighten the cap screws in a crossing pattern from 140 to 160 in Ib 16 to 18 N m 20 Remove the steering control unit from the vise 21 Install the relief valve and plug Tighten the plug to 150 in Ib 17 N m Thrust Bearing Dust Seal and Race 2
245. tall servo piston follower 8 onto camplate dowel pin Install camplate 11 carefully onto bushing 44 coat bushing surface with hydraulic oil aligning servo piston follower 8 with slot servo piston assembly 7 11 Position housing in a horizontal position Holding camplate 11 in position with screw driver through con troller linkage passageway at the top of housing place rotating kitassembly 6 over shaft and into housing until pistons are against camplate 11 Make sure all parts are in housing completely and are properly positioned Return the pump to the vise with open end of housing up clamping housing on the outer portion of the flange 12 Install gasket 32 onto housing 13 If necessary press new bearing 45 and roll pin 38 in backplate 20 to dimension shown in Figure 43 Note Bearing should be installed with the numbered end out ward Roll pin should be installed with split oriented away from bearing 14 Install new o ring on relief valves 16 amp 26 Install relief valve in the cavity in backplate that it was removed and torque from 100 to 110 ft Ib 136 to 149 N m 15 Install new o ring on bypass valve 14 Install by pass valve 14 into backplate 20 Note Make sure paddle of bypass valve is perpendicular to relief valve axis prior to installing or damage could result 16 Apply a small amount of petroleum jelly to the steel side of valve plate 18 to hold in place for installation Alignin
246. tch 2 Remove eight flange head screws flat washers and lock nuts that secure deck mount to cutting deck 3 Remove cotter pin from yoke joint shaft Make sure that deck mount is supported and remove slotted hex nut that secures yoke joint to lift arm Take hardened washer and thrust washer from yoke joint shaft Raise lift arm enough to free yoke joint from lift arm Remove second thrust washer and spacer washer from yoke shaft Chassis Page 7 12 base mounts to deck mount 5 Lift yoke joint and base mounts from deck mount Re move shims plate and rubber pad from deck mount 6 Press yoke joint from base mounts Yoke Joint Disassembly 1 Remove snap rings from yoke Fig 12 IMPORTANT Support yoke when removing and installing cross and bearings to prevent yoke dam age 2 Use a press to remove cross and bearing assembly from yoke Groundsmaster 4000 D Yoke Joint Assembly 1 Apply a coating of grease to bearing bores of yoke 2 Press one bearing partially into yoke 3 Insert cross into yoke and bearing 4 Hold cross in alignment and press bearing in until it hits the yoke 5 Install snap ring to secure installed bearing 6 Place second bearing into yoke bore and onto cross shaft Press second bearing into yoke and install snap ring Installation 1 Press yoke joint to cutting deck base mounts with the angled edge of the mount assembled away from the joint Fig 12 The outside of the yoke
247. ting unit the appropriate lift lever on the lift lower control valve is pushed to allow valve shift in the lift lower control This valve change causes valve shift in the counterbalance manifold and oil flow to the rod end ofthe lift cylinder Higher hydraulic pressure against the rod end of the cylinder causes the shaft to retract and lower the cutting unit Oil from the piston end of the cylinder returns to the traction charge circuit When the lift lever is released the lift cylinder is held in position Groundsmaster 4000 D Page 4 11 To lower the front cutting unit the center lift lever on the lift lower control valve is pushed to allow valve shift in the lift lower control This valve change allows a passage for oil flow from the rod end ofthe front deck lift cylinder The weight of the cutting deck causes the lift cylinder to ex tend and lower the cutting unit Oil from the rod end of the cylinder is allowed to return to the traction charge cir cuit When the lift lever is released the lift cylinder is held in position The drop speed of the front cutting units is regulated by an adjustable flow control valve that is located in the hy draulic lines between the lift lower control valve and the front deck lift cylinders An adjustable counterbalance valve maintains back pressure on the side deck lift cylinders A relief valve lo cated in the lift lower control valve limits circuit pressure Excess circuit flow is routed
248. tions when us ing a battery charger NOTE Using specific gravity of the battery cells is the most accurate method of determining battery condition 1 Determine the battery charge level from either its specific gravity or open circuit voltage Open Circuit Voltage Battery Charge Level 100 75 50 25 0 Specific Gravity 1 265 1 225 1 190 1 155 1 120 2 Determine the charging time and rate using the manufacturer s battery charger instructions or the following table Battery Reserve Battery Charge Level Percent of Fully Charged Capacity ints 80 or less 3 8hrs 7 5hrs 11 3hrs 15 hrs amps amps 3 amps amps 5 3hrs 10 5 hrs 15 8 hrs 21 hrs 4 4amps 4amps 4 22 hrs 5 amps 171 to 11 5 hrs 17 3 hrs 23 hrs 250 e 6 amps 6 amps 6 amps above 12 hrs 18 hrs 24 hrs 250 10 amps Groundsmaster 4000 D 126 to 5 5 hrs 11 hrs 16 5 hrs 170 5 amps 5 5 amps 5 8 hrs 6 amps 6 hrs 0 amps 10 amps 10 amps Page 5 31 CAUTION Do not charge a frozen battery because it can ex plode and cause injury Let the battery warm to 60 F 15 5 C before connecting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are explosive keep open flame and elec trical spark away from the battery Do not smoke Na
249. to 94 2 Align lift cylinder with lift arm Slide pin through lift arm and cylinder end Secure pin with cap screw wash ers and lock nut 3 Install front wheel assembly 4 Lower machine to the ground 5 If height of cut chain u bolt was removed from lift arm assemble u bolt so that threaded portion extends 870 22 1 mm above mounting plate on lift arm Fig 3 6 If removed install ball joint to lift arm Distance from end of lift arm to center of ball joint should be from 2 210 to 2 390 56 1 to 60 7 mm Fig 4 Make sure that ball joint is horizontal and that stud is centered in ball joint Torque ball joint jam nut from 150 to 175 ft lb 203 to 237 N m Groundsmaster 4000 D Page7 5 7 Install ball joint mount to ball joint with slotted hex nut Torque nut from 150 to 175 ft lb 203 to 237 while aligning cotter pin holes Install cotter pin 8 Install front cutting deck see Front Cutting Unit in Chapter 8 Cutting Units 9 Lubricate lift arm grease fittings see Operator s Manual 10 After assembly is completed raise and lower the cut ting deck to verify that hydraulic hoses and fittings do not contact anything 11 Check height of cut and deck pitch adjustment see Operator s Manual Figure 3 1 U bolt 2 Height of cut chain 210 to 2 390 6 1 to 60 7 mm Figure 4 1 Lift arm 2 Ball joint Chassis Side Deck Lift Arm Thread locking Compound
250. to the vent tube 5 Connect hoses upper and lower to the radiator 6 Reinstall air cleaner hose 7 Make sure radiator drain is closed Fill radiator with coolant see Operator s Manual 8 Close and secure engine hood on the machine Kubota Diesel Engine Rev B s CON OO PON N 17 to 21 ft lb 23 to 28 5 N m a 35 to 43 ft lb 1010 12 ft lb 25 13 6 to 16 3 N m A 47 5 to 58 3 N m Engine Engine mount bracket RH shown Lock washer Cap screw Barb fitting Hose clamp Hose Fuel line Fuel filter Fuel line Coolant drain hose Hose clamp Cap screw Barb fitting female Coolant drain cock fitting Engine mount bracket RH shown Lock washer Kubota Diesel Engine Rev B Figure 9 Cap screw Lock washer Cap screw Cap screw Rubber engine mount Flange head locking nut Rebound washer Hose clamp Fuel line Coupler spacer Dowel Lock washer Shoulder bolt Cap screw Spring center coupling Plate pin Page 3 14 N Cap screw Pump adapter plate Lock washer Cap screw Traction cylinder assembly Cap screw O ring Cylinder piston Back up ring Retaining ring Seal Hydraulic fitting O ring O ring Shim plate Hydraulic hose Groundsmaster 4000 D Engine Removal 1 Park
251. to the wrong battery post could result in personal injury and or dam age to the electrical system 5 Position battery in machine Connect positive battery cable first and then negative battery cable Install bat tery strap and cover 6 Lower seat and hood 7 Fill fuel tank see Operator s Manual Kubota Diesel Engine Rev B 5 2 e Radiator 1 Radiator cap 2 Foam strip 3 Foam strip 4 Lower radiator hose 5 Upper radiator hose 6 Hose clamp 7 Radiator shroud 8 Lock nut 9 Radiator 10 Hose clamp 11 Reservoir hose 12 Flange head screw 13 Grommet 14 Flange nut 15 Retaining ring 16 Knob Kubota Diesel Engine Rev B Figure 8 17 Bulb seal 18 Radiator support assembly 19 Retaining ring 20 Oil cooler bracket 21 Oil cooler 22 Carriage screw 23 Hydraulic fitting 24 Flange head screw 25 Clamp 26 Flange nut 27 Oil cooler bracket RH shown 28 Flat washer 29 Foam plug 30 Lock nut 31 Foam strip 32 Lower radiator support Page 3 12 33 Flange head screw 34 Bulb seal 35 Grommet 36 Frame cover 37 Flange head screw 38 Plate 39 Flat washer 40 Knob 41 Shoulder bolt 42 Flat washer 43 Coolant reservoir 44 Coolant reservoir bracket 45 O ring 46 O ring 47 Air cleaner hose Groundsmaster 4000 D Removal 1 Park machine on a level surface l
252. trol and accident prevention par tially are dependent upon the design and configuration of the machine these factors are also dependent upon the awareness concern and proper training of the per sonnel involved in the operation transport mainte nance and storage of the machine Improper use or maintenance of the machine can result in injury or Before Operating 1 Read and understand the contents of the Operator s Manual before starting and operating the machine Be come familiar with the controls and know how to stop the machine and engine quickly A replacement Operator s Manual is available on the Internet at www Toro com or by sending the complete model and serial number to The Toro Company Attn Technical Publications 8111 Lyndale Avenue South Bloomington Minnesota 55420 1196 2 Keep all shields safety devices and decals in place If a shield safety device or decal is defective illegible or damaged repair or replace it before operating the machine Also tighten any loose nuts bolts or screws to ensure machine is in safe operating condition While Operating 1 Sit on the seat when starting and operating the ma chine 2 Before starting the engine A Engage the parking brake B Make sure traction pedal is in neutral and the PTO switch is OFF disengaged C After engine is started release parking brake and keep foot off traction pedal Machine must not move If movement is evident the traction
253. tting 3 Flange nut 12 Fitting cap 21 O ring 4 O ring 13 Adapter 22 O ring 5 Hydraulic fitting 14 Adapter 23 Adapter 6 O ring 15 Straight hydraulic fitting 24 O ring 7 O ring 16 Adapter 25 Hydraulic manifold RH deck 8 45 hydraulic fitting 17 O ring 26 Hydraulic manifold LH deck 9 Adapter 18 Hydraulic fitting Removal 3 Disconnect hydraulic lines from manifold and put NOTE The ports on the manifold are marked for easy identification of components Example SV1 is the deck solenoid valve and 1 is a gear pump connection port See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port 1 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 2 Disconnect electrical connector from the solenoid valve Hydraulic System Rev B Page 4 70 caps or plugs on open hydraulic lines and fittings Label disconnected hydraulic lines for proper reassembly 4 Remove hydraulic manifold from the frame using Figure 52 as guide Installation 1 Install hydraulic manifold to the frame using Figure 52 as guide 2 Remove caps and plugs from fittings and hoses Properly connect hydraulic lines to manifold 3 Connect electrical connector to the solenoid valve Groundsmaster 4000 D Hydraulic Control Manifold Service Deck Drive 30 to 35 ft lb ag 41 to 47 N m
254. turn or Suction gt Flow Groundsmaster 4000 D Procedure for Lift Lower Circuit Relief Pressure Test NOTE Before attempting to check or adjust lift pres sure make sure that counterbalance pressure is cor rectly adjusted 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Figure 28 1 Lift circuit port 2 Hydraulic reservoir cap Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section 3 Raise seat to gain access to hydraulic test fitting Connect a 5 000 psi gauge to lift circuit test port Fig 28 Route gauge hose to allow seat to be safely low ered Hydraulic 4 Sit onthe seat and start the engine Move throttle to full speed 2730 30 RPM 5 While sitting on the seat pull lift lever back to raise the cutting units Momentarily hold the lever with the lift cylinder at full extension while looking at the gauge GAUGE READING TO BE 1525 to 1575 PSI 6 Stop the engine If pressure is too high adjust relief Figure 29 valve in lift control valve by rotating counterclockwise 1 Control valve assembly 4 Spring Figure 29 If pressure is too l
255. ubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Maintenance Page2 2 Groundsmaster 4000 D 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 clearly identified and spe cified in this Service Manual These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Ser vice Manual The following factors shall be considered when applying torque cleanliness of the fastener use of a thread sealant e g Loctite degree of lubrication on the fastener presence of a prevailing torque feature hardness of the surface underneath the fastener s head or similar condition which affects the installation Fastener Identification Grade 5 G
256. und to the engine block Fig 14 E The starter Fig 14 and low oil pressure switch near starter 14 Install air cleaner assembly to the engine see Air Cleaner Installation 15 Install exhaust system to machine see Muffler Installation 16 Connect coolant hoses to the radiator Make sure ra diator drain is shut Fill radiator and reservoir with cool ant see Operator s Manual Kubota Diesel Engine Rev B Page 3 18 17 Check position of wires fuel lines hydraulic hoses and cables for proper clearance with rotating high tem perature and moving components 18 Position battery to machine Connect positive bat tery cable first and then negative battery cable Secure battery to machine with strap and cover 19 Check and adjust engine oil as needed see Opera tor s Manual 20 Check and adjust hydraulic oil as needed see Oper ator s Manual 21 Bleed fuel system see Operator s Manual 22 Operate hydraulic controls to properly fill hydraulic system see Charge Hydraulic System in Chapter 4 Hydraulic Systems Groundsmaster 4000 D TORO Table of Contents SPECIFICATIONS GENERAL INFORMATION Hydraulic Hoses Hydraulic Fitting Installation Towing Traction Unit Check Hydraulic Fluid HYDRAULIC SCHEMATICS Hydraulic Schematic S N below 220999999 Hydraulic Schematic S N above 230000000 HYDRAULIC FLOW DI
257. usea may result if the gases are inhaled Un plug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts 3 Following the manufacturer s instructions con nect the charger cables to the battery Make sure a good connection is made 4 Charge the battery following the manufacturer s instructions 5 Occasionally check the temperature of the battery electrolyte If the temperature exceeds 125 F 51 69 or the electrolyte is violently gassing or spewing the charging rate must be lowered or temporarily stopped 6 Three hours prior to the end of the charging mea sure the specific gravity of a battery cell once per hour The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0 003 change in specific gravity for three consecutive readings Electrical System 6 Lu This is intentionally blank Electrical System Page 5 32 Groundsmaster 4000 D Chapter 6 TORO Axles Planetaries and Brakes Table of Contents SPECIFICATIONS 2 Rear Axle Assembly 12 ADJUSTMENT 5 cee ig mei 3 Bevel Gear Case and Axle Case 15 SERVICE AND REPAIRS 4 Differential Shafts 20 Brake Assembly 4 Axle
258. valve on the hydraulic man ifold needs adjustment Cutting Units Page 8 4 Groundsmaster 4000 D This is intentionally blank 2 E o Groundsmaster 4000 D Page8 5 Cutting Units Service and Repairs Never install or work on the cutting units or lift arms with the engine running Always stop en gine and remove key first Front Cutting Unit ing 10 J 7 eec if P ope 7975 J Figure 1 1 Spider 9 joint 17 Clevis pin 2 Mounting shim if required 10 Jam nut 18 Lock nut 3 Hydraulic deck motor 11 Lift arm LH shown 19 Front cutting deck 4 Capscrew 12 Lock nut 20 Woodruff key 5 Washer 13 Flat washer 21 Spider hub 6 Cotter pin 14 Nut 22 Tab washer 7 Ball joint mount 15 U bolt 23 Nut 8 Hairpin 16 Height of cut chain Cutting Units Page8 6 Groundsmaster 4000 D Removal 1 Position machine on a clean level surface Lower cutting units stop engine engage parking brake and remove key from the ignition switch NOTE Removal of clevis pin from deck and height of cut chain is easier if deck is lifted slightly 2 Remove hairpin and clevis pin that secure the height of cut chain to the rear of the cutting deck Fig 2 3 Remove hydraulic motor from cutting deck see Cut ting Deck Motor Removal in the Service and Repairs Section of Chapter 4 Hydraulic Systems 4 Remove cap screws washers and lock nuts secu
259. ve PR 6 Pressure reducing valve PR is located on the lower front side of the 2WD 4WD control manifold Fig 37 Adjustment of this valve can be performed as follows NOTE Do not remove the valve from the hydraulic manifold for adjustment A To increase pressure setting remove cap on re ducing valve and turn the adjustment socket on the valve a clockwise direction 1 8 turn on the sock et will make a measurable change in pressure set ting B To decrease pressure setting remove cap onre ducing valve and turn the adjustment socket on the valve in a counterclockwise direction A 1 8 turn on the socket will make a measurable change in pres sure setting C Recheck pressure setting and readjust as need ed Groundsmaster 4000 D Page 4 47 Hydraulic System Rev B Adjustments Adjust Front Cutting Unit Lift Flow Control The front cutting unit lift circuit is equipped with an ad justable flow control valve used to adjust the rate at which the front deck lowers Adjust flow control valve as follows 1 Run machine to get hydraulic oil at operating temper atures Park machine on a level surface shut engine off and lower cutting units to the ground 2 Locate valve under front of machine Fig 38 3 Loosen setscrew on valve and rotate valve clock Figure 38 wise to slow down drop rate of front cutting unit 1 Front cutting unit flow control valve 4 Verify adjustment by raising and lowering cutti
260. w 3 Capscrew 18 Pivot shaft 33 Link tube 4 Locknut 19 Retaining ring 34 Lock nut 5 Clevis pin 20 Thrust washer 35 Flat washer 6 Hair pin 21 Flange bushing 36 Bushing 7 Spacer 22 Rear arm LH shown 37 Damper spring 8 Rodend 23 Lock nut 38 Lock nut 9 Jamnut 24 Lock washer 39 Carriage screw 10 Cap screw 25 Lock nut 40 Grease fitting 11 Straight bushing 26 Bumper pad 41 Jam nut 12 Spring shaft 27 Bumper bracket 42 Lock nut 13 Flat washer 28 Cap screw 43 Jam nut 14 Compression spring 29 Bell crank LH shown 44 Rod end 15 Plastic bearing 30 Damper 45 Plate Removal 3 Remove cap screw and lock nut that secures rod end of rear arm to cutting deck Locate and remove spacer 1 Park machine on a level surface lower cutting units from each side of rod end stop engine engage parking brake and remove key from the ignition switch 4 Remove lock nut and lock washer that secures rear arm pivot shaft Slide pivot shaft from hub and rear arm 2 Remove hair pin and clevis pin that connects damper Remove rear arm assembly from machine link to cutting deck Fig 8 Chassis Page 7 8 Groundsmaster 4000 D Disassembly 1 Disassemble rear arm assembly using Figure 7 as a guide Note early models use rear arm components as shown in Figure 9 On these models roll pin removal will allow coupler to be separated from spring shaft Assembly Figure 7 1 Slide large flat washer spring plastic bearing another
261. washers wiper seals and nylon poppets should be replaced as new items 2 Install new O rings 11 in proper grooves in spool bores 3 Install relief valve components 13 14 15 31 and 10 with new O ring 34 on plug assembly 32 4 Install plugs 6 with new back up washers 20 and O rings 7 5 Install plungers 33 and 28 IMPORTANT Check location and positioning of plungers during installation 6 Install new O rings 5 on seats 4 Install new back up washers 26 and O rings 25 on plugs 29 7 Install seats 4 new poppets 1 and plugs 29 8 Install plug 17 with new O ring 18 9 Install detent plunger 22 spring 21 disc 27 and plug 23 with new O ring 24 10 1 retaining ring 12 has been removed to replace spool spring 19 install washer 16 spring 19 spacer 2 and secure with retaining ring 12 11 Slide bushings 8 over spools Slide new O rings 11 over spools and position next to bushings Dip spools in clean hydraulic oil and install spool assemblies into proper location of body 12 Install spool caps 9 and tighten from 20 to 25 ft lb 27 to 33 N m 13 Install new wiper seals 3 Hydraulic System Rev B 9 Ey Steering Valve 18 to 22 ft Ib 25 to 29 N m gt 11 eee S gt 9 12 ae 13 11 Figure 73 1 Hex nut 11 O ring 21 Steering column assembly 2 Flat washer 12 Flang
262. ws hydraulic pressure to the rod end of the front deck lift cylinders causing the cylinders to retract As the cylinders retract the front deck raises Oil from the piston end of the cylin der returns to the hydraulic reservoir When the lift lever is released the lift cylinder is held in position An adjustable counterbalance valve maintains back pressure on the lift cylinders A relief valve located in the lift lower control valve limits circuit pressure Excess cir cuit flow is routed to the oil filter and then to the traction charge circuit Hydraulic System Rev B 2 o Ey uonong 10 lt lt 499q 10014 MOWN 000 2 AT ca 4 2 I 2 A J GAME C LW 5 x 3 4 Aires d 9X d S LN OHO T9 Q 5 OdSNVHL 44m O
263. xle Install thrust washers between axle boss and frame mount The thin ner thrust washer should be installed on the hydraulic motor end of the axle toward the rear of the machine With washers installed there should be 002 to 020 05 mm to 51 mm clearance between rear frame mount and axle mounting boss Add thrust washers if needed to adjust clearance 2 Install axle pivot pin to secure axle to rear frame mount Install washer and lock nut onto pivot pin Lock nut should be tightened enough to allow pivot pin to ro tate maximum 70 ft lb 94 Secure pivot pin with Figure 10 washer head screw Fig 11 1 Tie rod 4 Castle nut 52 2 Dust cover 5 Tie rod end 3 i LH Sa 3 If removed install the tie rod to rear axle Fig 10 2 5 Tighten ball joint castle nuts and install new cotter pins 98 6 lt 4 Position axle and rear mount under machine with jack Raise assembly to machine frame and align mounting holes of rear mount and machine frame 5 Secure rear mount to frame with six cap screws flat washers and flange nuts 6 Install cap screw and flange nut that secures front corner of 4WD hydraulic manifold to rear frame mount 7 f removed install the tie rod to rear axle Tighten ball Figure 11 joint castle nuts and install new cotter pins 1 Pivotpin 2 Washer head screw 8 Attach steering cylinder hydraulic tubes to rear frame mount with washers
264. y be corrosive to gear finish 7 Place the motor onits side and push on the rear bear ing block to remove the bearing block and gear set Fig 68 8 Carefully remove and discard o rings pressure seals and back up rings Fig 69 from motor Do not cause any damage to the machined grooves during the removal process IMPORTANT Make sure not to damage the counter bore when removing the shaft seal from the front plate 9 Position front flange with seal side up Remove snap ring and shaft seal Inspection 1 Remove any nicks and burrs from all motor compo nents with emery cloth A CAUTION Use eye protection such as goggles when using compressed air 2 Clean all motor components with solvent Dry all parts with compressed air 3 Inspect drive gear idler gear and bearing blocks Fig 70 for the following A Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas Scoring rough surfaces or wear on gear shafts indi cates need for replacement B Gear teeth should be free of excessive scoring and wear Any broken or nicked gear teeth must be replaced C Inspect gear face edge for sharpness Sharp edges of gears will mill into bearing blocks and thus must be replaced D Bearing areas of bearing blocks should not have excessive wear or scoring E Face of bearing blocks that are in contact with gears should be free of wear roughness or scoring 4 Ins
265. ydraulic com ponents operate machine functions slowly until air is out of system see Charge Hydraulic System 7 Checkfor hydraulic oil leaks Shut off engine and cor rectleaks if necessary Check oil levelin hydraulic reser voir and add correct oil if necessary IMPORTANT Check hydraulic lines and hoses daily for leaks kinked lines loose mounting supports wear loose fittings weather deterioration and chemical deterioration Make all necessary repairs before operating Hydraulic System Rev B 9 Ey Flush Hydraulic System IMPORTANT Flush the hydraulic system any time there is a severe component failure or the system is contaminated oil appears milky black or contains metal particles IMPORTANT Flush hydraulic system when chang Ing from petroleum base hydraulic fluid to a biode gradable fluid such as Mobil EAL 224H Operate machine under normal operating conditions for at least four 4 hours before draining 1 Park machine on alevel surface Lower cutting units stop engine and engage parking brake Remove key from the ignition switch Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil Controls must be operated with the ignition switch in OFF Remove key from the igni tion switch IMPORTANT Make sure to clean around any hy draulic connections that will be disconnected for draining 2 Drain hydraulic reservoir

caution

Contents

Download Pdf Manuals

Related Search

Related Contents