Page 1: Service Manual
The Toro Company reserves the right to change product IMPORTANT: The IMPORTANT notice will give im- specifications or this publication without notice. portant instructions which must be followed to pre- vent damage to systems or components on the machine.
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Page 3: Table Of Contents
Table Of Contents Chapter 1 - - Safety Chapter 5 - - Electrical System General Safety Instructions ....1 -- 2 General Information .
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Page 5 Table Of Contents (Continued) Chapter 9 - - Operator Cab General Information ......9 -- 2 Service and Repairs .
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Page 7: General Safety Instructions 1
Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS ... . Before Operating ......While Operating .
Page 8: General Safety Instructions
General Safety Instructions The Groundsmaster 4000-D and 4010--D are tested and certified by Toro for compliance with existing safety WARNING standards and specifications. Although hazard control and accident prevention partially are dependent upon To reduce the potential for injury or death, the design and configuration of the machine, these fac- comply with the following safety instructions.
Page 9: While Operating
D. Stop engine and remove key from switch. C. After engine is started, release parking brake and E. Toro recommends that anytime the machine is keep foot off traction pedal. Machine must not move. parked (short or long term), the cutting decks should If movement is evident, the traction pedal linkage is be lowered to the ground.
Page 10: Maintenance And Service
5. Keep body and hands away from pin hole leaks in hy- timum performance and continued safety certification of draulic lines that eject high pressure hydraulic fluid. Use the machine, use genuine Toro replacement parts and cardboard or paper to find hydraulic leaks. Hydraulic accessories. Replacement parts and accessories made...
Page 11: Jacking Instructions
Jacking Instructions CAUTION When changing attachments, tires or perform- ing other service, use correct jacks and sup- ports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine.
Page 12: Safety And Instruction Decals
Safety and Instruction Decals Numerous safety and instruction decals are affixed to your Groundsmaster machine. If any decal becomes il- legible or damaged, install a new decal. Decal part num- bers are listed in your Parts Catalog. Safety Page 1 - - 6 Groundsmaster 4000--D/4010--D...
Page 13: Product Records
Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......MAINTENANCE ....... EQUIVALENTS AND CONVERSIONS .
Page 14: Equivalents And Conversions
Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 - - 2 Groundsmaster 4000--D/4010--D...
Page 15: Torque Specifications
For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
Page 16 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
Page 17 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series) Class 8.8 Bolts, Screws and Studs with Class 10.9 Bolts, Screws and Studs with Thread Size Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...
Page 18 Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Thread Size Square Head Hex Socket 7/16 -- 20 UNF 65 + 10 ft--lb 88 + 14 N--m Grade 5 1/4 -- 20 UNC 140 + 20 in--lb...
Page 19: General Information
Chapter 3 Kubota Diesel Engine Table of Contents SPECIFICATIONS ......GENERAL INFORMATION .
Page 20: Specifications
Specifications Item Description Make / Designation Kubota Model V2403--M--T--E3B: 4--Cycle, 4 Cylinder, Water Cooled, Turbocharged, Diesel Engine Bore 3.43 in (87.0 mm) Stroke 4.031 in (102.4 mm) Total Displacement 148.5 in (2434 cc) Firing Order 1 (closest to gear case end) -- 3 -- 4 (closest to flywheel end) -- 2 Combustion Chamber Spherical Type (E--TVCS) Compression Ratio...
Page 21: General Information
Authorized Toro Distributor. If no parts list is available, be prepared to provide your distrib- Most repairs and adjustments require tools which are utor with the Toro model and serial number of your ma- commonly available in many service shops. Special chine.
Page 22: Air Filter System
Service and Repairs Air Filter System RIGHT FRONT 12 to 15 in- -lb (1.4 to 1.6 N- -m) VACUATOR DIRECTION Figure 1 1. Air cleaner hose 7. Hose clamp 13. Flat washer (2 used) 2. Hose clamp 8. Air cleaner hose 14.
Page 23 Removal (Fig. 1) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Raise and support hood. 3. Remove air cleaner components as needed using Figure 1 as a guide. Installation (Fig.
Page 24: Exhaust System
Exhaust System 16 to 22 ft- -lb 16 to 22 ft- -lb (21 to 29 N- -m) (21 to 29 N- -m) 16 to 22 ft- -lb (21 to 29 N- -m) 13 ft- -lb (17.6 N- -m) RIGHT FRONT 16 to 22 ft- -lb (21 to 29 N- -m) Figure 5...
Page 25 Removal (Fig. 5) CAUTION The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and ex- haust system to cool before working on the muf- fler. 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch.
Page 26: Fuel System
Fuel System 36 35 RIGHT 18 17 16 135 to 165 ft- -lb FRONT (183 to 223 N- -m) 60 to 80 in- -lb (7 to 9 N- -m) Figure 7 1. Fuel tank 15. Retaining ring (2 used) 28. Phillips head screw (5 used) 2.
Page 27: Check Fuel Lines And Connections
Fuel Tank Installation (Fig. 7) DANGER 1. Install fuel tank using Figure 7 as a guide. A. Torque two (2) flange nuts (item 7) that secure the Because diesel fuel is highly flammable, use cau- fuel tank to the frame from 60 to 80 in- -lb (7 to 9 tion when storing or handling it.
Page 28: Radiator
Radiator RIGHT FRONT Figure 9 1. Radiator cap 22. Carriage screw (2 used) 43. Coolant reservoir 2. Foam strip (2 used) 23. 90 hydraulic fitting (2 used) 44. Tank bracket 3. Foam strip (2 used) 24. Cap screw (6 used) 45.
Page 29 Removal (Fig. 9) Installation (Fig. 9) 1. Park machine on a level surface, lower cutting 1. Remove all plugs placed during the removal proce- decks, stop engine, apply parking brake and remove dure. key from the ignition switch. 2. Carefully position radiator to the support frame. Se- 2.
Page 30: Engine
Engine RIGHT FRONT Loctite #242 29 to 33 ft- -lb 28 to 32 ft- -lb (40 to 44 N- -m) 28 to 32 ft- -lb (38 to 43 N- -m) (38 to 43 N- -m) Figure 10 1. Engine 11. Cap screw (8 used) 20.
Page 31: Engine Removal
Engine Removal (Fig. 10) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove battery from machine (see Battery Service in the Service and Repairs section of Chapter 5 -- Electri- cal System).
Page 32 8. Disconnect fuel supply hose from injection pump IMPORTANT: The hydraulic pump assembly can re- (Fig. 13). main in machine during engine removal. To prevent pump from shifting or falling, make sure to support 9. Remove throttle cable from engine (Figs. 13 and 14): pump assembly before mounting fasteners are re- moved.
Page 33: Engine Installation
15.Make sure all cable ties securing the wiring harness, fuel lines or hydraulic hoses to the engine are removed. RIGHT 16.Connect hoist or lift to the lift tabs on engine. FRONT 17.Remove flange nuts, rebound washers and cap screws securing the engine mounts to the engine sup- ports.
Page 34: General Information 4
7. Install fan motor and fan assembly (Fig. 15). 13.Connect wires and/or electrical connections to the following electrical components: A. Carefully position fan motor, fan and motor brack- et assembly to radiator. A. The temperature sender and alternator (Fig 11). B.
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Page 36: Spring Coupler
Spring Coupler RIGHT FRONT Loctite #242 29 to 33 ft- -lb (40 to 44 N- -m) 24 25 Loctite #242 28 to 32 ft- -lb 22 23 (38 to 43 N- -m) Figure 18 1. Spring coupler 10. Transport cylinder 18.
Page 37 Coupler Removal (Fig. 18) NOTE: The hydraulic pump assembly needs to be re- moved from engine before coupler can be removed. Engine Side Hydraulic Pump Side 1. If engine is in machine, support engine from below to prevent it from shifting. Remove the following: A.
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Page 39: Hydraulic Schematic 4
Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......Flush Hydraulic System ..... GENERAL INFORMATION .
Page 40 Specifications Item Description Piston (Traction) Pump Eaton Variable Displacement Piston Pump (Model 72400) Maximum Displacement (per revolution) 2.48 in (40.6 cc) System Relief Pressure: Forward 4000 PSI (274 bar) System Relief Pressure: Reverse 5000 PSI (343 bar) Charge Pressure 250 PSI (17 bar) Front Wheel Motors Eaton Fixed Displacement Piston Motors (Model 74318)
Page 41 General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Check Hydraulic Fluid The Groundsmaster hydraulic system is designed to op- erate on anti--wear hydraulic fluid.
Page 42: Relieving Hydraulic System Pressure
Traction Circuit Component Failure The traction circuit on Groundsmaster 4000--D and Once the Toro high flow hydraulic filter kit has been 4010--D machines is a closed loop system that includes placed in the circuit, raise and support the machine with the piston (traction) pump, two (2) front wheel motors all wheels off the ground.
Page 43 If the hose has an elbow at one end, tighten the swivel nut on that end before tightening the nut on the straight end of the hose. For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL).
Page 44 Hydraulic Hose and Tube Installation (O- -Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ C. Use a second wrench to tighten the nut to the cor- tube and the fitting are free of burrs, nicks, scratches or rect Flats From Wrench Resistance (F.F.W.R.).
Page 45 Hydraulic Fitting Installation (SAE Straight Thread O- -Ring Fitting into Component Port) Non- -Adjustable Fitting (Fig. 6) 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate meth- 1.
Page 46 Adjustable Fitting (Fig. 8) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is rec- ommended that the O--ring be replaced any time the connection is opened.
Page 47: Hydraulic Schematic
Hydraulic Schematic Groundsmaster 4000--D/4010--D Page 4 - - 9 Rev. A Hydraulic System...
Page 48: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams Hydraulic System Page 4 - - 10 Rev. A Groundsmaster 4000--D/4010--D...
Page 49 Traction Circuit: Low Speed (4WD) The traction circuit piston pump is a variable displace- Forward Direction ment pump that is directly coupled to the engine fly- When the Hi/Low switch is in the Low speed (4WD) posi- wheel. Pushing the traction pedal engages a hydraulic tion and the traction pedal is pushed in the forward direc- servo valve which controls the variable displacement tion, oil from the piston pump passes through the...
Page 50 Hydraulic System Page 4 - - 12 Rev. A Groundsmaster 4000--D/4010--D...
Page 51 Traction Circuit: Hi Speed (2WD) The traction circuit piston pump is a variable displace- Forward Direction ment pump that is directly coupled to the engine fly- With the Hi/Low speed switch in the Hi speed position wheel. Pushing the traction pedal engages a hydraulic (2WD), solenoid valve (SV) in the 4WD manifold is ener- servo valve which controls the variable displacement gized.
Page 52 Hydraulic System Page 4 - - 14 Rev. A Groundsmaster 4000--D/4010--D...
Page 53: Lower Cutting Deck
Lower Cutting Deck A four section gear pump is coupled to the piston (trac- Lower Right Cutting Deck tion) pump. The third gear pump section supplies hy- To lower the right wing deck, the front of the right console draulic flow to both the steering and lift/lower circuits. switch is pushed as an input to the TEC--5001 controller.
Page 54 Hydraulic System Page 4 - - 16 Rev. A Groundsmaster 4000--D/4010--D...
Page 55: Raise Cutting Deck
Raise Cutting Deck A four section gear pump is coupled to the piston (trac- Raise Right Cutting Deck tion) pump. The third gear pump section supplies hy- To raise the right deck, the rear of the right console draulic flow to both the steering and lift/lower circuits. switch is depressed as an input to the TEC--5001 con- Hydraulic flow from this pump section is delivered to the troller.
Page 56 Hydraulic System Page 4 - - 18 Rev. A Groundsmaster 4000--D/4010--D...
Page 57 A four section gear pump is coupled to the piston (trac- Deck motor case drain leakage returns to the hydraulic tion) pump. Hydraulic flow for the mow circuit is supplied reservoir. by two sections of the gear pump. The gear pump sec- PTO Circuit Relief tion closest to the piston (traction) pump supplies hy- draulic flow to the side cutting decks, while the next gear...
Page 58 Mow Circuit Cutting Deck Blade Braking When the operator turns the PTO switch OFF or if a deck is raised with the PTO switch ON, PTO manifold sole- noid valve (S) is de--energized causing bypass cartridge (LC1) to shift (refer to information in Mow Circuit in this section).
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Page 60 Hydraulic System Page 4 - - 22 Rev. A Groundsmaster 4000--D/4010--D...
Page 61: Steering Circuit
Steering Circuit A four section gear pump is coupled to the piston (trac- (V1) and out the L port. Pressure retracts the steering tion) pump. The third gear pump section supplies hy- cylinder piston for a left turn. The rotary meter ensures draulic flow to both the steering and lift/lower circuits.
Page 62 Hydraulic System Page 4 - - 24 Rev. A Groundsmaster 4000--D/4010--D...
Page 63: Engine Cooling Fan Circuit
Engine Cooling Fan Circuit A four section gear pump is coupled to the piston (trac- ing oil flow to return to the fan motor but in the reverse tion) pump. The gear pump section farthest from the pis- direction causing the motor and cooling fan to run in re- ton pump supplies hydraulic flow for the engine cooling verse.
Page 64: Special Tools
Special Tools Order special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Kit contains one each: 1000 PSI (70 bar), 5000 PSI (350 bar) and 10000 PSI (700 bar) gauges.
Page 65 3. FLOW METER: This meter measures actual oil flow in the operating circuit with a gauge rated from 4 to 40 GPM (20 to 150 LPM). Toro Part Number: AT40002 Figure 19 NOTE: This tester does not include hoses (see Hydrau- lic Hose Kit TOR6007 below).
Page 66 Toro Part Number: TOR6011 NOTE: This kit does not include hoses (see Hydraulic Hose Kit TOR6007 above). NOTE: Replacement filter element is Toro part number TOR6012. Filter element cannister tightening torque is 25 ft- -lb (34 N- -m). O- -Ring Kit The O--ring kit includes O--rings in a variety of sizes for face seal and port seal hydraulic connections.
Page 67: Measuring Container
Hydraulic Test Fitting Kit This kit includes a variety of O--ring Face Seal fittings to TORO TEST FITTING KIT (TOR4079) enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings.
Page 68: Troubleshooting
Troubleshooting The charts that follow contain suggestions that can be NOTE: When troubleshooting traction problems on used to assist in diagnosing hydraulic system perfor- your Groundsmaster, if a problem exists in both Low mance issues. The suggestions are not all--inclusive. (4WD) and Hi (2WD) speeds, consider a faulty compo- Also, consider that there may be more than one cause nent that affects the entire traction circuit (e.g.
Page 69 Traction Circuit Problems Problem Possible Cause Machine operates in one direction Traction control linkage is faulty. only. Traction relief valve is faulty. Traction pedal is sluggish. Traction control linkage is stuck or binding. Charge pressure is low. Piston (traction) pump servo control valve orifices are plugged or damaged.
Page 70: Mow Circuit Problems
Mow Circuit Problems Problem Possible Cause No cutting decks will operate. Electrical problem exists (see Chapter 5 -- Electrical System). NOTE: To engage the mow circuit, Gear pump is damaged (NOTE: other hydraulic circuits impacted as the seat must be occupied, the cut- well).
Page 71 Lift Circuit Problems Problem Possible Cause Cutting decks will not raise. Engine RPM is too low. NOTE: Seat must be occupied in or- Hydraulic oil level in reservoir is low. der to raise cutting decks. Solenoid valve (S1) in lift/lower manifold is faulty. Electrical problem exists (see Chapter 5 -- Electrical System).
Page 72: Steering Circuit Problems
Steering Circuit Problems Problem Possible Cause Steering inoperative or sluggish Steering components (e.g. tie rods, steering cylinder ends) are worn or binding. Steering cylinder is binding. Oil level in hydraulic reservoir is low (NOTE: other hydraulic sys- tems are affected as well). Steering relief valve in steering control valve is stuck or damaged.
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Page 74: Testing
Testing The most effective method for isolating problems in the 1. Clean machine thoroughly before disconnecting or hydraulic system is by using hydraulic test equipment disassembling any hydraulic components. Always keep such as pressure gauges and flow meters in the circuits in mind the need for cleanliness when working on hy- during various operational checks (see the Special draulic equipment.
Page 75 Which Hydraulic Tests Are Necessary? 2. If a cutting (mow) circuit problem exists, consider performing one or more of the following tests: Cutting Before beginning any hydraulic test, identify if the prob- Deck Circuit Pressure, PTO Relief Pressure, Cutting lem is related to the traction circuit, cutting (mow) circuit, Deck Motor Case Drain Leakage and/or Cutting Deck lift circuit, steering circuit or engine cooling fan circuit.
Page 76 Traction Circuit Charge Pressure (Using Pressure Gauge) FROM LIFT CONTROL MANIFOLD FROM FRONT DECK PRESSURE GAUGE CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT TO STEERING & LIFT CIRCUITS TO COOLING FAN CIRCUIT Hydraulic System Page 4 - - 38...
Page 77 Procedure for Traction Circuit Charge Pressure Test 8. Next, with the pressure gauge still connected to the charge pressure test port, take a gauge reading while 1. Make sure hydraulic oil is at normal operating tem- operating the machine in forward and reverse. Start the perature by operating the machine under load for engine and put throttle at high idle speed (2870 RPM).
Page 78 Traction Circuit Relief Pressure (Using Pressure Gauge) FORWARD TRACTION CIRCUIT RELIEF PRESSURE TEST SHOWN FROM LIFT CONTROL MANIFOLD PRESSURE GAUGE FROM FRONT DECK CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT TO STEERING &...
Page 79 Procedure for Traction Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine under load for approximately ten (10) minutes. Make sure the hydrau- lic tank is full. CAUTION Move machine to an open area, away from people and obstructions.
Page 80 Counterbalance Pressure (Using Pressure Gauge) PRESSURE GAUGE FROM PTO MANIFOLDS TO PTO (MOW) CIRCUIT FROM DECK MOTORS TO PTO (MOW) CIRCUIT FROM FRONT PTO MANIFOLD Hydraulic System Page 4 - - 42 Rev. A Groundsmaster 4000--D/4010--D...
Page 81: Adjustments 4
Procedure for Counterbalance Pressure Test D. Tighten lock nut to secure adjustment. Check counterbalance pressure and readjust as needed. 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine under load for 9. When testing is completed, disconnect pressure approximately ten (10) minutes.
Page 82 Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge) FROM LIFT CONTROL PRESSURE MANIFOLD GAUGE FROM FRONT DECK CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT TO STEERING &...
Page 83 Procedure for Traction Circuit Reducing Valve (PR) Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine under load for approximately ten (10) minutes. Make sure the hydrau- lic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off.
Page 84 Rear Traction Circuit (RV) Relief Pressure (Using Pressure Gauge) FROM LIFT CONTROL PRESSURE MANIFOLD GAUGE FROM FRONT DECK CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT TO STEERING &...
Page 85 Procedure for Rear Traction Circuit (RV) Relief Pres- B. To increase relief pressure setting, rotate adjust- sure Test ment socket in a clockwise direction. 1. Make sure hydraulic oil is at normal operating tem- C. To decrease pressure setting, rotate adjustment perature by operating the machine under load for socket in a counterclockwise direction.
Page 86 Piston (Traction) Pump Flow Test (Using Tester with Flow meter and Pressure Gauge) FROM LIFT CONTROL MANIFOLD TESTER FROM FRONT DECK CYLINDERS FROM STEERING VALVE PORT PB FROM STEERING VALVE PORT T FROM FRONT PTO MANIFOLD TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT TO STEERING &...
Page 87 Procedure for Piston (Traction) Pump Flow Test 7. Start engine and run at idle speed. Check for any hy- draulic leakage from tester and hose connections. Cor- This test measures piston (traction) pump output (flow). rect any leaks before proceeding. During this test, pump load is created at the flow meter using the adjustable load valve on the tester.
Page 88 Cutting Deck Circuit Pressure (Using Pressure Gauge) FRONT DECK CIRCUIT PRESSURE TEST SHOWN TRACTION CIRCUIT FLOW PRESSURE GAUGE Hydraulic System Page 4 - - 50 Groundsmaster 4000--D/4010--D...
Page 89 Procedure for Cutting Deck Circuit Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine under load for approximately ten (10) minutes. Make sure the hydrau- lic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off.
Page 90 PTO Relief Pressure (Using Tester with Pressure Gauge and Flow Meter) FRONT PTO RELIEF PRESSURE TEST SHOWN TRACTION CIRCUIT FLOW Hydraulic System Page 4 - - 52 Groundsmaster 4000--D/4010--D...
Page 91 Procedure for PTO Relief Pressure Test 8. Fully open tester flow control valve and disengage cutting decks. Shut off engine and record test results. If 1. Make sure hydraulic oil is at normal operating tem- specification is not met, adjust or clean relief valve in perature by operating the machine under load for deck manifold port (RV1).
Page 92 Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauge and Flow Meter) FRONT CUTTING DECK MOTOR CASE DRAIN LEAKAGE TEST SHOWN TRACTION CIRCUIT FLOW TESTER MEASURING CONTAINER Hydraulic System Page 4 - - 54 Groundsmaster 4000--D/4010--D...
Page 93 Procedure for Cutting Deck Motor Case Drain 5. Sit on seat and start the engine. Move throttle to high Leakage Test idle speed (2870 RPM). Move PTO switch to ON. NOTE: Over a period of time, a deck motor can wear in- 6.
Page 94 Cutting Deck Gear Pump Flow (Using Tester with Pressure Gauge and Flow Meter) FRONT DECK GEAR PUMP FLOW TEST SHOWN TRACTION CIRCUIT FLOW TESTER Hydraulic System Page 4 - - 56 Groundsmaster 4000--D/4010--D...
Page 95 Procedure for Cutting Deck Gear Pump Flow Test 7. Watch pressure gauge carefully while slowly closing the flow control valve until 2000 PSI (138 bar) is ob- NOTE: Over a period of time, the gears and wear plates tained. Verify with a phototac that the engine speed is in the pump can wear.
Page 96 Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) FROM PTO MANIFOLDS TO PTO (MOW) CIRCUIT FROM DECK MOTORS TO PTO (MOW) CIRCUIT FROM FRONT PTO MANIFOLD Hydraulic System Page 4 - - 58 Rev. A Groundsmaster 4000--D/4010--D...
Page 97 Procedure for Lift/Lower Circuit Relief Pressure B. To decrease pressure setting, remove cap on re- Test lief valve and turn the adjustment socket on the valve in a counterclockwise direction. A 1/8 turn on the NOTE: Before attempting to check or adjust lift/lower socket will make a measurable change in pressure circuit relief pressure, make sure that counterbalance setting.
Page 98 Steering Circuit Relief Pressure (Using Pressure Gauge) FROM PTO MANIFOLDS TO PTO (MOW) CIRCUIT FROM DECK MOTORS TO PTO (MOW) CIRCUIT FROM FRONT PTO MANIFOLD Hydraulic System Page 4 - - 60 Rev. A Groundsmaster 4000--D/4010--D...
Page 99: Service And Repairs 4
Procedure for Steering Circuit Relief Pressure Test 7. If pressure is incorrect, inspect steering relief valve in steering control valve (see Steering Control Valve in 1. Make sure hydraulic oil is at normal operating tem- the Service and Repairs section of this chapter). If relief perature by operating the machine under load for valve is operating properly and if lift/lower problems also approximately ten (10) minutes.
Page 100 Steering Cylinder Internal Leakage STEERING CYLINDER CYLINDER FULLY EXTENDED LOOK FOR LEAKAGE STEEL CAP STEERING WHEEL TURNED FOR RIGHT TURN 1350 STEERING CONTROL Hydraulic System Page 4 - - 62 Groundsmaster 4000--D/4010--D...
Page 101 Procedure for Steering Cylinder Internal Leakage 5. Place a drain pan under the steering cylinder. Re- Test move hydraulic hose from the fitting on the rod end of the steering cylinder. Install a steel plug in the disconnected NOTE: Steering circuit operation will be affected by hose.
Page 102 Steering and Lift/Lower Gear Pump Flow (Using Tester with Pressure Gauge and Flow Meter) TESTER FROM PTO MANIFOLDS TO PTO (MOW) CIRCUIT FROM DECK MOTORS TO PTO (MOW) CIRCUIT FROM FRONT PTO MANIFOLD Hydraulic System Page 4 - - 64 Rev.
Page 103 Procedure for Steering and Lift/Lower Gear Pump 5. Start the engine and move throttle to high idle speed Flow Test (2870 RPM). DO NOT engage the cutting decks. NOTE: Output from the steering and lift/lower gear 6. While watching pressure gauge on tester, slowly pump section is equally divided by a proportional valve close flow control valve until 1000 PSI (69 bar) is ob- to provide flow to the steering circuit and the lift circuit.
Page 104 Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac) FROM PTO MANIFOLDS PRESSURE GAUGE TO PTO (MOW) CIRCUIT FROM DECK MOTORS TO PTO (MOW) CIRCUIT FROM FRONT PTO MANIFOLD Hydraulic System Page 4 - - 66 Rev. A Groundsmaster 4000--D/4010--D...
Page 105 Procedure for Engine Cooling Fan Circuit Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine under load for approximately ten (10) minutes. Make sure the hydrau- lic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off.
Page 106 Engine Cooling Fan Circuit Gear Pump Flow (Using Tester with Pressure Gauge and Flow Meter) TESTER FROM PTO MANIFOLDS TO PTO (MOW) CIRCUIT FROM DECK MOTORS TO PTO (MOW) CIRCUIT FROM FRONT PTO MANIFOLD Hydraulic System Page 4 - - 68 Rev.
Page 107 Procedure for Engine Cooling Fan Circuit Gear 6. While watching tester pressure gauges, slowly close Pump Flow Test tester flow control valve until 1000 PSI (69 bar) is ob- tained on gauge. Verify engine speed continues to be 1. Make sure hydraulic oil is at normal operating tem- 2870 RPM.
Page 108: Adjustments
Adjustments Traction Linkage Adjustment RIGHT FRONT Figure 55 1. Traction pedal 11. Flat washer 21. Traction lever 2. Cap screw (4 used) 12. Compression spring 22. Lock nut 3. Hex nut 13. Spring retainer 23. Spacer 4. Pedal stop 14. Roll pin 24.
Page 109 4. With ignition switch in the ON position (engine not 7. Shut engine off. running), use Diagnostic Display to make sure that neu- 8. After adjustments have been made and all fasteners tral switch is closed when traction pedal is released to are tightened, make sure that traction rod does not con- the neutral detent position (see Diagnostic Display in the tact anything through both forward and reverse direc-...
Page 110: Service And Repairs
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- 1. Check oil level in the hydraulic reservoir and add cor- tem, park machine on a level surface, apply parking rect oil if necessary.
Page 111 Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time 6. Connect all hydraulic hoses, lines and components there is a severe component failure or the system is that were disconnected while draining system. contaminated. Contaminated oil may appear milky NOTE: Use only hydraulic fluids specified in the Opera- or black or may contain metal particles.
Page 112: Special Tools 5
IMPORTANT: If using a filter that is not the bi- -direc- 2. Raise and support machine so all wheels are off the tional Toro high flow filter, do not press the traction ground (see Jacking Instructions in Chapter 1 -- Safety).
Page 113: Adjustments 5
Charge Hydraulic System NOTE: When initially starting the hydraulic system with 11. After the hydraulic system starts to show signs of fill, new or rebuilt components such as motors, pumps or lift actuate a lift switch until the lift cylinder rod moves in and cylinders, it is important that the hydraulic system be out several times.
Page 114: Hydraulic Reservoir
Hydraulic Reservoir 30 to 40 in- -lb (3.4 to 4.5 N- -m) (minimum) RIGHT NOTE: HYDRAULIC COMPONENTS FRONT ATTACHED TO FRONT FRAME ARE NOT SHOWN IN ILLUSTRATION Figure 59 1. Hydraulic reservoir 12. Dipstick 22. Lock nut (3 used) 2. Petcock 13.
Page 115 NOTE: The front frame needs to be lowered from the Inspection main frame to allow clearance to remove the hydraulic 1. Clean hydraulic reservoir and suction strainer with reservoir from the machine. solvent. Removal (Fig. 59) 2. Inspect reservoir for leaks, cracks or other damage. 1.
Page 116: Hydraulic Oil Cooler
Hydraulic Oil Cooler RIGHT FRONT 12 ft- -lb (16 N- -m) Figure 60 1. Radiator 8. O- -ring 14. Flange nut (2 used) 2. RH radiator support 9. 90 hydraulic fitting (2 used) 15. Cap screw(2 used) 3. Top radiator support 10.
Page 117 Removal (Fig. 60) CAUTION CAUTION Use eye protection such as goggles when using compressed air. The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling 2. Dry inside of oil cooler using compressed air in the systems to cool before working on the oil cooler.
Page 118: Gear Pump
Gear Pump 103 to 118 ft- -lb (140 to 160 N- -m) Loctite #242 79 to 84 ft- -lb Loctite #242 (108 to 113 N- -m) 79 to 84 ft- -lb (108 to 113 N- -m) RIGHT 30 to 40 in- -lb FRONT (3.4 to 4.5 N- -m) Figure 61...
Page 119 Removal (Fig. 61) 2. Lubricate new O--rings (item 13) with clean hydraulic oil. Position O--rings on gear pump and pump spacer 1. Park machine on a level surface, lower cutting flanges. decks, stop engine, apply parking brake and remove key from the ignition switch. 3.
Page 120: Gear Pump Service
Gear Pump Service 33 ft- -lb (45 N- -m) Figure 62 1. Dust seal 10. Seal (8 used) 19. Body 2. Retaining ring 11. Idler gear 20. Body 3. Flange washer 12. Drive shaft 21. Drive gear 4. Shaft seal 13.
Page 121 IMPORTANT: Use caution when clamping gear NOTE: Pressure seals and back--up gaskets fit in pump in a vise to avoid distorting any pump compo- grooves machined into thrust plates. Body seals fit in nents. grooves machined in body faces. 3. Secure the front cover of the pump in a vise with the 2.
Page 122: Traction Circuit
Traction Circuit NOTE: Arrow on check valve points toward rear of machine RIGHT FRONT Figure 65 1. Piston (traction) pump 6. 4WD manifold 10. Check valve 2. Gear pump 7. Filter manifold 11. Forward traction pressure port 3. LH front wheel motor 8.
Page 123 Transport Cylinder A transport cylinder is included in the traction circuit to reduce traction pump control arm movement when op- erating in Hi speed (2WD). This reduced control arm RIGHT movement limits pump swash plate rotation to prevent FRONT excessive transport speed. The transport cylinder is at- tached to the forward, right side engine mount (Fig.
Page 124 Piston (Traction) Pump 103 to 118 ft- -lb (140 to 160 N- -m) Loctite #242 79 to 84 ft- -lb (108 to 113 N- -m) Loctite #242 79 to 84 ft- -lb (108 to 113 N- -m) RIGHT 30 to 40 in- -lb FRONT (3.4 to 4.5 N- -m) Figure 68...
Page 125 5. Disconnect wire harness connector from neutral 6. Connect wire harness connector to neutral switch on switch on piston pump. traction pump. 6. Read the General Precautions for Removing and 7. Remove plugs or caps from disconnected hydraulic Installing Hydraulic System Components at the begin- hoses and open ports of the pump assembly.
Page 126 Piston (Traction) Pump Service 40 to 48 in- -lb 4 to 6 ft- -lb (4.5 to 5.4 N- -m) (5 to 8 N- -m) 100 to 110 ft- -lb 40 to 48 in- -lb 25 to 28 ft- -lb (136 to 149 N- -m) (4.5 to 5.4 N- -m) (34 to 38 N- -m) 27 to 31 ft- -lb...
Page 127 Piston (Traction) Pump Service (Fig. 70) For service of the piston (traction) pump (including the servo control (item 28) assembly), see the Eaton Model 72400 Servo Controlled Piston Pump Repair Informa- tion at the end of this chapter. Groundsmaster 4000--D/4010--D Page 4 - - 89 Hydraulic System...
Page 128: Rear Axle Motor
Rear Axle Motor Arrow on side of motor case points up 59 to 73 ft- -lb (80 to 99 N- -m) RIGHT FRONT Figure 71 1. Axle motor 8. Gear (45T) 15. O- -ring 2. 90 hydraulic fitting (2 used) 9.
Page 129 Removal (Fig. 71) Installation (Fig. 71) 1. Park machine on a level surface, lower cutting IMPORTANT: Refer to Traction Circuit Component decks, stop engine, apply parking brake and remove Failure in the General Information section of this key from the ignition switch. chapter for information regarding the importance of removing contamination from the traction circuit.
Page 130: Front Wheel Motor
Front Wheel Motor Arrow on side of motor case points up RIGHT 75 to 85 ft- -lb FRONT (101 to 115 N- -m) Figure 72 1. Front wheel motor 9. Flange head screw (6 used per side) 17. Hydraulic fitting 2.
Page 131 Removal (Fig. 72) Installation (Fig. 72) 1. Park machine on a level surface, lower cutting IMPORTANT: If 90 fitting (item 10) was removed decks, stop engine, apply parking brake and remove from backplate of RH wheel motor, make sure that key from the ignition switch.
Page 132: Rear Axle And Front Wheel Motor Service
Rear Axle and Front Wheel Motor Service 15 to 18 ft- -lb (20 to 24 N- -m) Figure 73 1. Drive shaft 7. Cap screw (6 used) 13. Thrust bearing 2. Backplate (front motor shown) 8. Shaft seal 14. Roll pin (3 used) 3.
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Page 134 4WD Manifold RIGHT FRONT Figure 74 1. Frame assembly 8. Dust cap 14. Hydraulic fitting 2. 4WD manifold 9. Hydraulic fitting 15. Adapter 3. 90 hydraulic fitting 10. O- -ring 16. Hydraulic fitting 4. O- -ring 11. O- -ring 17. O- -ring 5.
Page 135 Removal (Fig. 74) Installation (Fig. 74) 1. Read the General Precautions for Removing and 1. If fittings were removed from manifold, lubricate and Installing Hydraulic System Components at the begin- place new O--rings onto fittings. Install fittings into man- ning of the Service and Repairs section of this chapter. ifold openings using marks made during the removal process to properly orientate fittings.
Page 136: Wd Manifold Service
4WD Manifold Service 35 ft- -lb REAR 50 ft- -lb (47 N- -m) (67 N- -m) DOWN 25 ft- -lb (34 N- -m) FRONT 20 ft- -lb (27 N- -m) PLUG TORQUE #4 Zero Leak: 20 ft- -lb (27 N- -m) 5 ft- -lb #6 Zero Leak: 25 ft- -lb (34 N- -m) (6.7 N- -m)
Page 137 4WD Manifold Service (Fig. 75) 7. The 4WD manifold includes three (3) orifice fittings (items 9 and 12). The 0.030 orifice (item 9) is positioned 1. Make sure the manifold is clean before removing any in the SV port under the solenoid cartridge valve. The of the cartridge valves.
Page 138 Traction (Flow Divider) Manifold RIGHT FRONT Figure 76 1. Traction manifold 8. O- -ring 14. O- -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.
Page 139 Removal (Fig. 76) Installation (Fig. 76) 1. Read the General Precautions for Removing and 1. If fittings were removed from manifold, lubricate and Installing Hydraulic System Components at the begin- place new O--rings onto fittings. Install fittings into man- ning of the Service and Repairs section of this chapter. ifold openings using marks made during the removal process to properly orientate fittings.
Page 140 Traction (Flow Divider) Manifold Service 50 ft- -lb 50 ft- -lb (67 N- -m) (67 N- -m) FRONT 20 ft- -lb (27 N- -m) 40 ft- -lb (54 N- -m) 198 in- -lb (22.4 N- -m) 20 ft- -lb (27 N- -m) 5 ft- -lb (6.7 N- -m) 20 ft- -lb...
Page 141 Traction Manifold Service (Fig. 77) NOTE: If the check valve (item 5) next to the pilot direc- tional valve (item 2) needs to be removed from manifold, remove directional valve first. When installing this check valve, install and torque check valve before installing di- rectional valve.
Page 142: Filter Manifold
Filter Manifold RIGHT FRONT Figure 78 1. Filter manifold 10. Hydraulic fitting 18. Hydraulic hose 2. 45 hydraulic fitting 11. O- -ring 19. Hydraulic tee fitting 3. Test nipple 12. O- -ring 20. 90 hydraulic fitting 4. Dust cap 13. 90 hydraulic fitting 21.
Page 143 Removal (Fig. 78) Installation (Fig. 78) 1. Read the General Precautions for Removing and 1. If fittings were removed from manifold, lubricate and Installing Hydraulic System Components at the begin- place new O--rings onto fittings. Install fittings into man- ning of the Service and Repairs section of this chapter. ifold openings using marks made during the removal process to properly orientate fittings.
Page 144: Filter Manifold Service
Filter Manifold Service 25 ft- -lb (34 N- -m) FRONT 25 ft- -lb (34 N- -m) 25 ft- -lb (34 N- -m) 30 ft- -lb (41 N- -m) 50 ft- -lb (67 N- -m) 30 ft- -lb (41 N- -m) FRONT Figure 79 1.
Page 145 Filter Manifold Service (Fig. 79) For filter manifold cartridge valve service procedures, see 4WD Manifold Service in this section. Refer to Fig- ure 79 for filter manifold cartridge valve and plug instal- lation torque. Groundsmaster 4000--D/4010--D Page 4 - - 107 Hydraulic System...
Page 146 Steering and Engine Cooling Fan Circuits GROUNDSMASTER 4000- -D RIGHT FRONT Figure 80 1. Gear pump 4. Fan motor 6. Steering circuit test port (GM4000) 2. Steering control valve 5. Steering cylinder 7. Fan circuit test port 3. Fan drive manifold Hydraulic System Page 4 - - 108 Groundsmaster 4000--D/4010--D...
Page 147 Figure 80 illustrates the components that are used in the GROUNDSMASTER 4010- -D Groundsmaster 4000--D steering and engine cooling fan circuits. The steering control valve hydraulic lines used on the Groundsmaster 4010--D are slightly differ- ent and are shown in Figure 81. Procedures for removal, installation and disassembly/assembly of these compo- nents are provided on the following pages of this sec- tion.
Page 148: Steering Control Valve
Steering Control Valve 16 to 20 ft- -lb (22 to 27 N- -m) RIGHT FRONT Figure 82 1. Hex nut 16. Parking brake switch 31. Flange head screw (4 used) 2. Flat washer 17. Cotter pin 32. Switch bracket 3. Steering wheel 18.
Page 149 Removal (Fig. 82) GROUNDSMASTER 4000- -D 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter.
Page 150: Steering Control Valve Service
Steering Control Valve Service 150 in- -lb (17 N- -m) 140 to 160 in- -lb (16 to 18 N- -m) Figure 85 1. Steering control valve housing 9. Cap screw (7 used) 17. Geroter drive 2. Dust seal 10. End cap 18.
Page 151 8. Put the thrust bearing and races into the housing. CAUTION The thrust bearing goes between the two races (Fig. 86). IMPORTANT: Do not damage the dust or quad seals The centering springs are under tension. Re- when installing the spool and sleeve assembly. move the retaining ring carefully.
Page 152: Steering Cylinder
Steering Cylinder See text for tightening procedure RIGHT See text for tightening FRONT procedure Figure 87 1. Steering cylinder 7. 90 hydraulic fitting 12. Axle washer 2. Ball joint 8. O- -ring 13. Slotted hex nut 3. Ball joint 9. O- -ring 14.
Page 153 Removal (Fig. 87) Installation (Fig. 87) 1. Park machine on a level surface, lower cutting 1. If removed, install ball joints into steering cylinder. decks, stop engine, apply parking brake and remove 2. If fittings were removed from steering cylinder, lubri- key from the ignition switch.
Page 154: Steering Cylinder Service
Steering Cylinder Service 45 to 55 ft- -lb (62 to 74 N- -m) Figure 88 1. Tube assembly 5. Retaining ring 9. Rod seal 2. Rod 6. Backup ring 10. O- -ring 3. Piston assembly 7. O- -ring 11. O- -ring 4.
Page 155 Disassembly (Fig. 88) Assembly (Fig. 88) 1. Pump oil out of cylinder into a drain pan by SLOWLY 1. Use a complete repair kit when rebuilding the cylin- moving rod and piston in and out of cylinder bore. Plug der. Put a coating of clean hydraulic oil on all new seals ports and clean outside of cylinder.
Page 156: Engine Cooling Fan Motor
Engine Cooling Fan Motor 27 to 33 ft- -lb (37 to 44 N- -m) 16 17 12 to 14 ft- -lb (17 to 18 N- -m) Loctite #242 RIGHT FRONT Figure 89 1. Hydraulic fan motor 8. Washer 15. Hydraulic hose 2.
Page 157 5. Remove four (4) cap screws (item 11) and washers IMPORTANT: Make sure to not damage the radiator used to secure fan to fan hub. Remove fan. or other machine components while installing the fan motor and bracket assembly. IMPORTANT: Make sure to not damage the radiator or other machine components while loosening and 5.
Page 158: Engine Cooling Fan Motor Service
Engine Cooling Fan Motor Service 33 ft- -lb (45 N- -m) Figure 91 1. Flange washer 7. Shaft seal 12. Idler gear 2. O- -ring 8. Backup gasket 13. Cap screw (4 used) 3. Front flange 9. Pressure seal 14. Dowel (2 used) 4.
Page 159 8. Remove and discard back--up gaskets and pressure seals from wear plates. 9. Turn front flange over, with seal side up. IMPORTANT: Make sure not to damage the front flange counter bore when removing the seals from the front flange. 10.Carefully remove dust seal, retaining ring, flange washer and shaft seal from the front flange (Fig.
Page 160 3. Place front flange, seal side down, on a flat surface. 10.Install locating dowels in body. Align marker line on the body and front flange. 4. Install the pressure seals, flat side outward, into the grooves in the wear plates. Follow by carefully placing IMPORTANT: Do not dislodge seals during installa- the backup gaskets, flat side outward, between the tion.
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Page 162: Fan Drive Manifold
Fan Drive Manifold RIGHT FRONT Figure 95 1. Fan drive manifold 10. Hydraulic fitting 19. 90 hydraulic fitting 2. O- -ring 11. Hydraulic hose 20. Hydraulic hose 3. Test fitting 12. Hydraulic hose 21. Hydraulic hose 4. Dust cap (2 used) 13.
Page 163 Removal (Fig. 95) Installation (Fig. 95) 1. Park machine on a level surface, lower cutting 1. If fittings were removed from manifold, lubricate and decks, stop engine, apply parking brake and remove place new O--rings onto fittings. Install fittings into man- key from the ignition switch.
Page 164: Fan Drive Manifold Service
Fan Drive Manifold Service 5 ft- -lb (6.7 N- -m) 5 ft- -lb (6.7 N- -m) FRONT 25 ft- -lb 50 ft- -lb (34 N- -m) (67 N- -m) 20 ft- -lb (27 N- -m) 25 ft- -lb (34 N- -m) 25 ft- -lb 25 ft- -lb (34 N- -m)
Page 165 Fan Drive Manifold Service (Fig. 97) For fan drive manifold cartridge valve service proce- dures, see 4WD Manifold Service in this section. Refer to Figure 97 for fan drive manifold cartridge valve and plug installation torque. Groundsmaster 4000--D/4010--D Page 4 - - 127 Hydraulic System...
Page 166: Pto Circuit
PTO Circuit RIGHT FRONT Figure 98 1. Gear pump 4. RH PTO manifold 7. Front PTO manifold 2. RH cutting deck motor 5. Front cutting deck motor 8. Filter manifold 3. LH cutting deck motor 6. LH PTO manifold 9. Oil cooler Figure 98 illustrates the components that are used in the Groundsmaster 4000--D and 4010--D PTO circuit.
Page 167 Cutting Deck Motor Removal 5. Secure motor to cutting deck with two (2) flange head screws (Fig. 99). 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove 6. Remove caps or plugs from fittings and hoses. Con- key from the ignition switch.
Page 168: Cutting Deck Motor Service
Cutting Deck Motor Service 33 to 40 ft- -lb (45 to 55 N- -m) Figure 101 1. Rear cover 6. Tab washer 11. Body 2. Drive gear 7. Spider hub 12. Idler gear 3. Seal 8. Pressure seal 13. Cap screw (4 used) 4.
Page 169 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 may be corrosive to gear finish. 7. Place the motor on its side and push on the rear bear- ing block to remove the bearing block and gear set (Fig.
Page 170 Assembly (Fig. 101) 8. Install dowel pins in body. NOTE: When assembling the motor, check the identifi- IMPORTANT: Do not dislodge O- -rings, pressure cation marks made during disassembly to make sure seals or back- -up rings during final assembly. the parts are properly aligned during assembly.
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Page 172: Pto Manifold
PTO Manifold 19 18 19 18 RIGHT FRONT Figure 106 1. Hydraulic PTO manifold (front deck) 10. Straight fitting 19. O- -ring 2. Quick fitting (1 used per manifold) 11. Cap screw (2 used per manifold) 20. 90 hydraulic fitting 3.
Page 173 Removal (Fig. 106) Installation (Fig. 106) 1. Read the General Precautions for Removing and 1. If fittings were removed from manifold, lubricate and Installing Hydraulic System Components at the begin- place new O--rings onto fittings. Install fittings into man- ning of the Service and Repairs section of this chapter. ifold openings using marks made during the removal process to properly orientate fittings.
Page 174: Pto Manifold Service
PTO Manifold Service 20 ft- -lb 5 ft- -lb (27 N- -m) (6.7 N- -m) 25 ft- -lb 20 ft- -lb (34 N- -m) (27 N- -m) 25 ft- -lb (34 N- -m) 20 ft- -lb (27 N- -m) 50 ft- -lb (67 N- -m) 20 ft- -lb (27 N- -m)
Page 175 PTO Manifold Service (Fig. 107) For PTO manifold solenoid and control valve service procedures, see 4WD Manifold Service in this section. Refer to Figure 107 for PTO manifold cartridge valve and plug installation torque. Groundsmaster 4000--D/4010--D Page 4 - - 137 Hydraulic System...
Page 176 Cutting Deck Lift/Lower Circuit RIGHT FRONT Figure 108 1. Front lift cylinder (2 used) 3. LH lift cylinder 5. Lift/lower manifold 2. RH lift cylinder 4. Fan drive manifold 6. Oil filter Figure 108 illustrates the components that are used in the Groundsmaster 4000--D and 4010--D cutting deck WARNING lift and lower circuits.
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Page 178 Lift/Lower Manifold RIGHT FRONT Figure 109 1. Lift/lower manifold 3. Washer head screw (2 used) 4. Splash shield 2. Flange head screw (2 used) Removal (Fig. 109) WARNING 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch.
Page 179 6. Disconnect hydraulic lines from manifold and put caps or plugs on open hydraulic lines and fittings. Label disconnected hydraulic lines for proper installation. 7. Remove lift/lower manifold using Figure 109 as a guide. IMPORTANT: The fitting in manifold port C2 in- cludes a .070 orifice to control the lowering speed of the front deck.
Page 180 Lift/Lower Manifold Service 25 ft- -lb (34 N- -m) 5 ft- -lb (6.7 N- -m) 20 ft- -lb 5 ft- -lb (27 N- -m) (6.7 N- -m) 20 ft- -lb (27 N- -m) 20 ft- -lb 25 ft- -lb (27 N- -m) (34 N- -m) 20 ft- -lb (27 N- -m)
Page 181 Lift/Lower Manifold Service (Fig. 112) WARNING If lift/lower manifold is attached to machine, make sure that cutting decks are fully lowered before loosening hydraulic lines, cartridge valves or plugs from lift/lower manifold. If decks are not fully lowered when manifold components are loosened, decks may drop unexpectedly.
Page 182 Side Deck Lift Cylinder RIGHT FRONT Figure 113 1. Lift arm assembly (LH shown) 5. Flange locking nut 9. Cylinder pin 2. Shoulder screw 6. 90 hydraulic fitting (2 used) 10. Spring pin 3. Pin assembly 7. O- -ring 11. Lock nut 4.
Page 183 Removal (Fig. 113) Installation (Fig. 113) 1. Park machine on a level surface, lower cutting 1. If fittings were removed from lift cylinder, lubricate decks, stop engine, apply parking brake and remove and place new O--rings onto fittings. Install fittings into key from the ignition switch.
Page 184 Front Deck Lift Cylinder RIGHT FRONT Figure 114 1. Lift cylinder 6. Flat washer 11. O- -ring 2. Pivot pin 7. Lock nut 12. 90 hydraulic fitting 3. Cotter pin (2 used per pin) 8. LH lift arm assembly 13. RH lift arm assembly 4.
Page 185 Removal (Fig. 114) Installation (Fig. 114) 1. Park machine on a level surface, lower cutting 1. If fittings were removed from lift cylinder, lubricate decks, stop engine, apply parking brake and remove and place new O--rings onto fittings. Install fittings into key from the ignition switch.
Page 186: Lift Cylinder Service
Lift Cylinder Service 100 to 120 ft- -lb (136 to 162 N- -m) SIDE DECK LIFT CYLINDER Figure 115 1. Barrel with clevis 7. Back- -up ring 12. Lock nut 2. Retaining ring 8. Head 13. Grease fitting 3. Shaft with clevis 9.
Page 187 Disassembly (Figs. 115 and 116) Assembly (Figs. 115 and 116) 1. Remove oil from lift cylinder into a drain pan by slowly 1. Make sure all cylinder components are clean before pumping the cylinder shaft. Plug both ports and clean assembly.
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Page 189: Component Testing 5
..... . . Toro Electronic Controllers (TEC) ....
Page 190: General Information
Groundsmaster 4000--D and 4010--D machines use two The controllers appear identical but they are different in (2) Toro Electronic Controllers (TEC) to manage ma- terms of the connectors and internal hardware. They are chine electrical functions. The controllers are micropro- arranged in ”master / slave”...
Page 191: Special Tools
Multimeter The multimeter can test electrical components and cir- cuits 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.
Page 192: Diagnostic Display
The Diagnostic Display (Fig. 4) can be connected to the wiring harness communication connector located under the controller cover to verify correct electrical functions of the machine. Toro Electronic Controller (TEC) inputs and outputs can be checked using the Diagnostic Dis- play.
Page 193 Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally. Figure 7 Groundsmaster 4000--D/4010--D Page 5 - - 5 Electrical System...
Page 194: Troubleshooting
NOTE: Use the Diagnostic Display (see Special Tools in this chapter) to test Toro Electronic Controller inputs and outputs when troubleshooting an electrical problem on your Groundsmaster. Diagnostic Display...
Page 195 4. Turn the ignition switch to the ON position, but do not start machine. TEC- -5002 MASTER NOTE: The red text on the Diagnostic Display overlay OVERLAY decal refers to input switches and the green text refers to TEC outputs. 5.
Page 196 Diagnostic Display Diagnostic Display TEC- -5002 Master Inputs LED Operation P BRAKE Parking brake released: LED ON Parking brake applied: LED OFF NEUTRAL Traction pedal in neutral: LED ON Traction pedal in forward or reverse: LED OFF SEAT Operator seat occupied: LED ON SWITCH Operator seat empty: LED OFF Hi/Lo speed switch in HI range: LED ON...
Page 197 Diagnostic Display Diagnostic Display TEC- -5001 Slave Inputs LED Operation C DECK Cutting deck lift switch for center deck in RAISE position: LED ON RAISE Lift switch for center deck NOT in RAISE position: LED OFF C DECK Cutting deck lift switch for center deck in LOWER position: LED ON LOWER Lift switch for center deck NOT in LOWER position: LED OFF L DECK...
Page 198 Diagnostic correctly illuminated, this indicates a TEC controller Display. problem. If this occurs, contact your Toro Distributor for assistance. 1. Park machine on a level surface, lower the cutting decks, stop the engine and engage the parking brake.
Page 199: Starting Problems
Starting Problems Problem Possible Causes No electrical power to machine (including gauges). The battery is discharged. The battery cables are loose or corroded. Fuse F3--1 (2 amp) to the ignition switch is faulty. Bad ground connection on machine. The ignition switch or circuit wiring is faulty. Starter solenoid clicks, but starter will not crank.
Page 200 Starting Problems (Continued) Problem Possible Causes Engine cranks, but does not start. The fuel tank is empty. The engine is not cranking fast enough. Fuse F5--1 (30 amp) is faulty preventing engine run solenoid pull coil from being energized. Fuse M1 (60 amp) is faulty preventing glow plug operation.
Page 201: General Run & Transport Problems
General Run and Transport Problems Engine continues to run, but should not, when the The engine run solenoid is faulty. ignition switch is turned off. The ignition switch or circuit wiring is faulty. Engine continues to run, but should not, when the The seat switch or circuit wiring is faulty.
Page 202: Cutting Deck Operating Problems
Cutting Deck Operating Problems The cutting decks remain engaged, but should not, The seat switch or circuit wiring is faulty. with no operator in the seat. The TEC--5001 controller is faulty. Cutting deck runs, but should not, when raised. Decks The deck position switch or circuit wiring is faulty.
Page 203: Cutting Deck Lift/Lower Problems
Cutting Deck Lift/Lower Problems Problem Possible Causes None of the cutting decks will lower. The Hi/Low speed switch is in the Hi speed position. Operator is not fully depressing the seat switch. TEC--5001 fuse(s) (F4--1, F4--2, F4--3, F4--4) are faulty. The seat switch or circuit wiring is faulty.
Page 204 Cutting Deck Lift/Lower Problems (Continued) Problem Possible Causes RH wing cutting deck will not raise or lower, but the The RH deck lift switch or circuit wiring is faulty. front and LH wing cutting decks will raise and lower. Fuse F4--3 is faulty. Lift control manifold solenoid coils S7, S8 or S9 or circuit wiring is faulty.
Page 205: Adjustments
Adjustments Cutting Deck Position Switches Adjustment 1. Park machine on a level surface with front cutting deck raised and side cutting decks lowered. Stop en- gine, engage parking brake and remove key from the ignition switch. 2. There should be from 0.070” to 0.130” (1.8 to 3.3 mm) clearance between the target surface end of posi- tion switch and the sensing plate on lift arm.
Page 206: Electrical System Quick Checks
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level battery terminals. 12.68 V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery 12.45 V 75% charged should be at a temperature of 60...
Page 207: Check Operation Of Interlock Switches
Replace any malfunctioning switches before op- NOTE: Use the Diagnostic Display (see Special Tools erating the machine. in this chapter) to test Toro Electronic Controller inputs and outputs before further troubleshooting of an electri- cal problem on your Groundsmaster. Groundsmaster 4000--D/4010--D...
Page 208: Component Testing
Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the CAUTION circuit (e.g. unplug the ignition switch connector before checking continuity on the switch). When testing electrical components for continu- NOTE: For engine component testing information, see ity with a multimeter (ohms setting), make sure the Kubota Workshop Manual, Diesel Engine, that power to the circuit has been disconnected.
Page 209: Fuses
Fuses The fuse blocks are located in the power center under Fuse Testing the hood on the right side of the machine (Fig. 17). Turn ignition switch to the ON position (do not start en- In addition to the fuses in the fuse blocks, a 40 amp fuse gine).
Page 210: Operator Cab Fuses (Groundsmaster 4010--D)
Operator Cab Fuses (Groundsmaster 4010- -D) The cab fuse blocks are located in the cab headliner (Fig. 19). Identification and Function (Figs. 19 and 20) Fuse F1--2 (15 Amp) protects the cab fan circuit. Fuse F1--3 (30 Amp) protects the air conditioner circuit. Fuse F2--1 (15 Amp) protects the windshield wiper/ washer circuit.
Page 211: Chapter 7 - - Chassis
Warning Lights Charge Indicator Light 3. Apply 12 VDC to terminals 1A and 2A (Fig. 22). The charge indicator light should come on when the igni- 4. Ground terminals 1B and 2B (Fig. 22). tion switch is in ON with the engine not running or with 5.
Page 212: Pto Switch
PTO Switch The PTO switch is located on the console arm (Fig. 23). 6. If PTO switch tests correctly and circuit problem still The PTO switch is pulled up to engage the PTO and exists, check wire harness (see Electrical Schematics pushed in to disengage the PTO.
Page 213: Cutting Deck Lift Switches
Cutting Deck Lift Switches The cutting deck lift switches are used as inputs for the 7. After testing is completed, connect wire harness TEC--5001 controller to raise or lower the cutting decks. connector to the lift switch. When the front of a lift switch is depressed and held, the 8.
Page 214: Hi/Low Speed And Headlight (Groundsmaster 4010--D) Switches
Hi/Low Speed and Headlight (Groundsmaster 4010- -D) Switches The Hi/Low speed and headlight switches (Ground- 6. After testing is completed, connect wire harness smaster 4010--D) are identical, two (2) position rocker connector to the switch. switches that are located on the control console. 7.
Page 215: Flow Divider And Engine Cooling Fan Switches
Flow Divider and Engine Cooling Fan Switches The flow divider and engine cooling fan switches are 6. If switch tests correctly and circuit problem still ex- identical, two (2) position rocker switches that are lo- ists, check wire harness (see Electrical Schematics and cated on the control console (Fig.
Page 216: Seat Switch
Seat Switch The seat switch is normally open and closes when the operator is on the seat. This switch is used as an input for the TEC--5002 controller. The seat switch and its electrical connector are located in the seat assembly. If the traction system or PTO switch is engaged when the operator raises out of the seat, the engine will stop.
Page 217: Parking Brake Switch
Parking Brake Switch The switch used for the parking brake is a normally open switch that is located under the steering tower cover (Fig. 32). The brake switch is used as an input for the TEC--5002 controller. When the parking brake is not ap- plied, the parking brake pawl depresses the switch plunger to close the switch.
Page 218: Windshield Wiper/Washer Switch
Windshield Wiper/Washer Switch (Groundsmaster 4010- -D) The windshield wiper/washer switch is used to control operation of the windshield wiper and washer pump on the Groundsmaster 4010--D. The windshield wiper/wa- sher switch is located in the cab headliner (Fig. 33). Testing 1.
Page 219: Air Conditioning Switch (Groundsmaster 4010--D)
Air Conditioning Switch (Groundsmaster 4010- -D) The air conditioning switch is used to control operation of the air conditioning system on the Groundsmaster 4010--D. The switch is located in the cab headliner (Fig. 35). Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch.
Page 220: Hour Meter
Hour Meter The hour meter is located on the outside of the console 7. Assemble console arm (see Console Arm Assembly arm. in the Service and Repairs section of Chapter 7 -- Chas- sis). Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch.
Page 221: Main Power, Glow And Operator Cab
Main Power, Glow and Operator Cab Power (Groundsmaster 4010- -D) Relays The main power, glow and operator cab power relays 8. Secure relay to mounting bracket and connect wire are located at the power center behind the operator seat harness connector to relay. Secure power center to tank (Fig.
Page 222: Start And Air Conditioning (Groundsmaster 4010--D) Relays
Start and Air Conditioning (Groundsmaster 4010- -D) Relays When energized by the TEC--5002 controller, the start nals 30 and 87A as +12 VDC is applied and removed relay is used to provide current to the engine starter mo- from terminal 85. tor solenoid.
Page 223: Toro Electronic Controllers (Tec)
Toro Electronic Controllers (TEC) Groundsmaster 4000--D and 4010--D machines use two IMPORTANT: Before performing welding on the ma- Toro Electronic Controllers (TEC) to control electrical chine, disconnect both positive and negative bat- system operation. The controllers are attached to the tery cables from the battery, disconnect wire operator platform under the controller cover (Figs.
Page 224: Hydraulic Valve Solenoids
Hydraulic Valve Solenoids RIGHT FRONT Figure 45 1. 4WD manifold 4. Front PTO manifold 6. RH PTO manifold 2. LH PTO manifold 5. Fan drive manifold 7. Lift/lower manifold 3. Traction manifold Several hydraulic solenoid valve coils are used on the NOTE: To assist in troubleshooting, identical solenoid hydraulic control manifolds of Groundsmaster 4000--D coils can be exchanged.
Page 225 Testing 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Locate hydraulic valve solenoid coil to be tested (Fig. 45). Disconnect wire harness connector from coil. 3.
Page 226: Traction Neutral Switch
Traction Neutral Switch The traction neutral switch is closed when the traction See the Eaton Model 72400 Servo Controlled Piston pedal is in the neutral position and opens when the pedal Pump Repair Information at the end of Chapter 4 -- Hy- is depressed in either direction (forward or reverse).
Page 227: Fuel Sender
Fuel Sender The fuel sender is located on top of the fuel tank. 7. Replace sender as necessary. Install sender into fuel tank. Testing 8. Connect wires to fuel sender. Apply skin--over 1. Make sure ignition switch is OFF. Remove key from grease (see Special Tools in this chapter) to sender ter- ignition switch.
Page 228: Fuel Gauge
Fuel Gauge The fuel gauge can be tested using a new gauge as a substitute or with the use of a DC voltage source and a variable resistance box. Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch.
Page 229: Fuel Pump
Fuel Pump The fuel pump is attached to the frame above the fuel water separator (Fig. 54). Operational Test 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake. 2. Remove fuse F1--1 (20 amp) (Fig. 55) from fuse block to prevent the engine from cranking.
Page 230: Temperature Sender
B. Screw sender into the water flange. Torque send- er from 16 to 20 ft- -lb (22 to 27 N- -m). C. Reconnect gray harness wire to sender. Apply skin--over grease (Toro Part No. 505--165) to sender terminal. 5. Fill engine cooling system.
Page 231: Temperature Gauge
Temperature Gauge The temperature gauge on the control panel indicates engine coolant temperature level during machine op- eration (Fig. 58). The changing resistance of the engine temperature sender signals the temperature gauge. The temperature gauge should display the first green segment when the ignition switch is turned to ON.
Page 232: Cutting Deck Position Switches
Cutting Deck Position Switches Three (3) cutting deck position switches are used on the Groundsmaster 4000--D and 4010--D. These switches are located on the traction unit frame (Figs. 59 and 60). The position switches are powered proximity switches that incorporate an internal reed switch and a LED. The deck position switches are used as inputs for the TEC--5001 controller to prevent deck operation when a cutting deck is raised.
Page 233 B. Make sure that ignition switch is OFF and discon- nect the switch connector from wire harness. C. Using a multimeter, verify that wire harness con- nector terminal for pink wire has 12 VDC when the ignition switch is ON. D.
Page 234: Engine Coolant And Hydraulic Oil Temperature Senders
Engine Coolant and Hydraulic Oil Temperature Senders The Groundsmaster 4000--D and 4010--D use two (2) 6. Check and fill system (coolant or hydraulic) to proper temperature senders as inputs for the TEC--5002 to level. identify if either the engine coolant or hydraulic oil tem- perature has reached an excessive level.
Page 235: Service And Repairs
(+) cable first. Coat battery posts and cable plosive, keep open flames and electrical sparks connectors with battery terminal protector (Toro Part No. away from the battery; do not smoke. Nausea 107--0392) or petroleum jelly to prevent corrosion.
Page 236: Battery Service
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes.
Page 237 Battery Testing A. Check the voltage across the battery terminals prior to testing the battery. If the voltage is less than 1. Conduct a hydrometer test of the battery electrolyte. 12.4 VDC, charge the battery before performing a load test. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps.
Page 238 Battery Charging CAUTION 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- Do not charge a frozen battery because it can ex- complished with a constant current battery charger plode and cause injury.
Page 239: General Information 6
Chapter 6 Axles, Planetaries and Brakes Table of Contents SPECIFICATIONS ......GENERAL INFORMATION .
Page 240 Specifications Item Specification Tire pressure (front and rear) 25 to 30 PSI (172 to 207 kPa) Rear wheel toe--in 0.125 in (3.18 mm) Planetary gear drive oil SAE 85W--140 wt. gear lube System gear lube capacity (each wheel) 16 fl. oz. (0.47 liters) Rear axle lubricant SAE 85W--140 wt.
Page 241: General Information
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Groundsmaster 4000--D/4010--D Page 6 - - 3 Axles, Planetaries and Brakes...
Page 242: Service And Repairs
Service and Repairs Brake Assembly 85 to 100 ft- -lb (115 to 135 N- -m) 75 to 85 ft- -lb (101 to 115 N- -m) RIGHT 75 to 85 ft- -lb FRONT (101 to 115 N- -m) Figure 1 1. Planetary assembly 7.
Page 243 Removal (Fig. 1) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch. 2. Drain oil from planetary wheel drive/brake assembly. CAUTION When removing front wheel, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor.
Page 244 2. Apply gasket sealant to sealing surfaces of new gas- ket (item 18). Apply gasket to brake assembly. 3. Install brake assembly onto machine, aligning splined brake shaft with input shaft on planetary wheel drive. 4. Secure brake assembly to planetary assembly with four (4) flange head screws (item 9).
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Page 246: Brake Inspection And Repair
Brake Inspection and Repair Figure 6 1. Brake housing (LH shown) 6. Hitch pin (2 used) 11. Rotating actuator 2. Seal 7. Stationary disc (4 used) 12. Extension spring (3 used) 3. Pull rod 8. Rotating disc (3 used) 13. Ball (3 used) 4.
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Page 248: Planetary Wheel Drive Assembly
Planetary Wheel Drive Assembly 85 to 100 ft- -lb (115 to 135 N- -m) 75 to 85 ft- -lb (101 to 115 N- -m) RIGHT 75 to 85 ft- -lb FRONT (101 to 115 N- -m) Figure 7 1. Planetary assembly 6.
Page 249 NOTE: The planetary wheel drive assembly can be ser- 2. Install brake assembly (see Brake Assembly Instal- viced with the planetary installed to machine (see Plane- lation in this section). tary Wheel Drive Service in this section). Use the 3. Install hydraulic wheel motor (see Front Wheel Mo- following procedure to remove and install planetary tors in the Service and Repairs section of Chapter 4 -- wheel drive assembly from machine.
Page 250: Planetary Wheel Drive Service
Planetary Wheel Drive Service 9 ft- -lb (12 N- -m) Figure 9 1. Spindle 9. Thrust washer 17. Drive shaft 2. Boot seal 10. Retaining ring (external) 18. Carrier assembly 3. Inner bearing cone 11. Ring gear 19. Socket head screw (16 used) 4.
Page 251 NOTE: The planetary wheel drive assembly can be ser- viced with the planetary installed to machine. If the spindle (item 1) needs to be removed from machine, see Planetary Wheel Drive Assembly Removal in this sec- tion. Disassembly (Figs. 9 and 10) 1.
Page 252 F. Lightly oil bearing journals on spindle shaft. Slide 3. Install carrier assembly (item 18) making sure that housing onto spindle (item 1) taking care to not dam- carrier gear teeth align with ring gear and spline on age seal or spindle. Make sure that bearing in hous- spindle shaft.
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Page 254: Rear Axle Assembly
Rear Axle Assembly RIGHT FRONT See text for tightening procedure Figure 11 1. Frame assembly 8. Rear axle assembly 15. Flange nut (10 used) 2. Cap screw (10 used) 9. Thrust washer (thin) 16. Rear bumper 3. Lock washer (6 used) 10.
Page 255 8. Remove cap screw and flange nut that secures front corner of 4WD hydraulic manifold to rear axle mount bracket. 9. If required, remove tie rod ends from steering arms on rear axle (Fig. 13). Remove the cotter pins and castle nuts from the tie rod ball joints.
Page 256 8. Install steering cylinder to axle assembly (see Steer- ing Cylinder Installation in the Service and Repairs sec- tion of Chapter 4 -- Hydraulic System). 9. Install hydraulic motor to axle assembly (see Rear Axle Motor Installation in the Service and Repairs sec- tion of Chapter 4 -- Hydraulic System).
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Page 258: Rear Axle Service
Rear Axle Service Figure 16 Axles, Planetaries and Brakes Page 6 - - 20 Groundsmaster 4000--D/4010--D...
Page 259 Figure 16 (Continued) 1. LH axle support 22. O- -ring 43. Collar 2. Flange bushing (2 used) 23. RH axle support 44. Bevel gear (17 tooth) 3. Axle vent 24. Input shaft assembly 45. Bevel gear shaft 4. O- -ring 25.
Page 260: Bevel Gear Case And Axle Case
Bevel Gear Case and Axle Case The following procedures assume the rear axle assem- 35 to 41 ft- -lb bly has been removed from the machine. (47 to 56 N- -m) Removal 1. Remove the mounting screws, nuts and lock wash- ers.
Page 261 5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gas- ket material from either mating surface (Fig. 20). 6. While holding the bevel gear case, tap the upper end 17 to 20 ft- -lb (23 to 27 N- -m) of the bevel gear shaft out of the upper bearing and up- per bevel gear.
Page 262 Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 22). Figure 22 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.
Page 263 5. Determine necessary quantity of support shims. 57 to 67 ft- -lb A. Lubricate the axle case support bushing with a (77 to 91 N- -m) thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during VERTICAL disassembly between axle case support and axle ENDPLAY...
Page 264: Differential Shafts
9. Remove the bevel gear case/axle case assembly NOTE: Axle bearing shims are available in 0.008 in. from the axle support. Coat a new O-ring with grease (0.2 mm), 0.012 in. (0.3 mm) and 0.020 in. (0.5 mm) and temporarily install the axle cover assembly. Position thickness.
Page 265: Axle Shafts
Axle Shafts The following procedures assume the rear axle assem- 17 to 20 ft- -lb bly has been removed from the machine. (23 to 27 N- -m) Removal 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig.
Page 266: Input Shaft/Pinion Gear
Input Shaft/Pinion Gear 35 to 41 ft- -lb (47 to 56 N- -m) 35 to 41 ft- -lb (47 to 56 N- -m) Figure 32 1. Nut (2 used) 8. Seal collar 15. Gear case 2. Lock washer (2 used) 9.
Page 267 5. Install a new stake washer. Install the lock nut finger tight. 6. Set the bearing preload by securing the bearing case in 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 lock nut until 4 to 6 in-lb (0.4 to 0.7 N--m) of 0.040 in.
Page 268: Differential Gear
Differential Gear The following procedures assume the rear axle assem- 35 to 41 ft- -lb bly has been removed from the machine. (47 to 56 N- -m) Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual).
Page 269 Inspection 1. Measure the differential side gear O.D. and the dif- ferential case I.D. to determine the side gear to case clearance (Fig. 39). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 in. (0.05 to 0.30 mm) SIDE GEAR O.D.
Page 270 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 N- -m). 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.
Page 271: Pinion Gear To Ring Gear Engagement
Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using PROFILE the gear contact pattern method as described in the fol- TOP LAND lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 43): Toe -- the portion of the tooth surface at the end to- LENGTHWISE wards the center.
Page 272 Gear Pattern Movement Summary Heel Contact Base 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. 46): A.
Page 273: General Information 7
Chapter 7 Chassis Table of Contents GENERAL INFORMATION ..... Operator’s Manual ......SERVICE AND REPAIRS .
Page 274: Service And Repairs
Service and Repairs Steering Tower RIGHT FRONT 16 to 20 ft- -lb (22 to 27 N- -m) Figure 1 1. Hex nut 15. Lock nut (2 used) 28. Steering column 2. Flat washer 16. Parking brake switch 29. Cap screw (2 used) 3.
Page 275 Disassembly (Fig. 1) Assembly (Fig. 1) 1. Park machine on a level surface, lower cutting 1. Assemble steering tower using Figure 1 as a guide. decks, stop engine, apply parking brake and remove A. Thrust washer(s) (item 24) on steering column key from the ignition switch.
Page 276: Front Deck Lift Arm
Front Deck Lift Arm RIGHT FRONT 60 to 70 ft- -lb (81 to 94 N- -m) 90 to 100 ft- -lb (123 to 135 N- -m) 150 to 175 ft- -lb (203 to 237 N- -m) Figure 2 1. Flange bushing 15.
Page 277 7. Install ball joint mount to ball joint with slotted hex nut. CAUTION Torque nut from 90 to 100 ft- -lb (123 to 135 N- -m) while aligning cotter pin holes. Install cotter pin. 8. Install front cutting deck (see Front Cutting Deck When changing attachments, tires or perform- Installation in Chapter 8 -- Cutting Decks).
Page 278: Side Deck Lift Arm
Side Deck Lift Arm 16 17 19 18 Loctite #242 9 10 Anti- -seize Lubricant 77 to 96 ft- -lb (105 to 130 N- -m) 30 33 RIGHT FRONT Figure 5 1. Lift arm (LH shown) 15. Slotted roll pin 28.
Page 279 Removal (Fig. 5) 5. Align lift cylinder with lift arm. Secure lift cylinder to lift arm with lift cylinder pin (item 3). 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove 6. Install side deck rear arm assembly (see Side Deck key from the ignition switch.
Page 280: Side Deck Rear Arm Assembly
Side Deck Rear Arm Assembly Loctite #271 35 36 270 to 330 in- -lb (31 to 37 N- -m) RIGHT FRONT Figure 8 1. Cutting deck (LH shown) 18. Pivot shaft 34. Lock nut 2. Deck mount (LH shown) 19. Retaining ring 35.
Page 281 Rear Arm Removal (Fig. 8) 10.Thoroughly pack spring with grease. Install spring shaft assembly into housing and secure plate with four 1. Park machine on a level surface, lower cutting (4) cap screws and lock nuts. decks, stop engine, apply parking brake and remove key from the ignition switch.
Page 282 Rear Arm Installation (Fig. 8) 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 lock nut. 3. Connect damper link to cutting deck with clevis pin and hair pin (Fig.
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Page 284: Lift Arm Joint Yoke
Lift Arm Joint Yoke 150 to 180 ft- -lb (203 to 244 N- -m) RIGHT FRONT Figure 11 1. Side cutting deck (LH shown) 8. Flat washer (8 used per mount) 15. Cap screw (8 used per mount) 2. Deck mount (LH shown) 9.
Page 285 Joint Yoke Disassembly 5. Install retaining rings to yoke and deck mount to se- cure bearings in place. 1. Remove retaining rings from yoke and deck mount. 6. Make sure that assembled joint yoke moves without IMPORTANT: Support yoke when removing cross binding.
Page 286: Console Arm
Console Arm RIGHT FRONT Figure 13 1. Flange nut (3 used) 16. Warning lamp (glow plug/temp) 31. Cap 2. Flange head screw (2 used) 17. PTO switch 32. Engine cooling fan control switch 3. Foam seal 18. Hole plug 33. Nut 4.
Page 287 Disassembly (Fig. 13) 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 2. Remove two (2) flange head screws (item 40) and then cover plate (item 39) from outside of console arm. Locate and retrieve two (2) spacers (item 38).
Page 288: Operator Seat
Operator Seat RIGHT FRONT Figure 15 1. Platform 14. Flat washer (2 used) 27. Seat and suspension assembly 2. Clevis pin (2 used) 15. Flat washer (4 used) 28. Cap screw 3. Hair pin (2 used) 16. R- -clamp (2 used) 29.
Page 289 Removal (Fig. 15) B. Secure console arm support (item 35) to coupler nut (item 38) with cap screw (item 37). 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove C. Place flat washer (item 20), seat belt latch (item key from the ignition switch.
Page 290: Operator Seat Service
Operator Seat Service Figure 18 1. Backrest cushion 11. Washer 21. Torx screw (5 used) 2. Seat cushion 12. Cap screw (2 used) 22. RH adjustment rail 3. Armrest cover 13. Seat 23. Rail stop 4. LH armrest 14. Nut 24.
Page 291 Disassembly (Fig. 18) 1. Disassemble operator seat as necessary using Fig- ures 18 and 19 as guides. Assembly (Fig. 18) 1. Assemble operator seat using Figures 18 and 19 as guides. 7 11 Figure 19 1. Operator seat 7. Flat washer 2.
Page 292: Operator Seat Suspension
Operator Seat Suspension RIGHT FRONT Figure 20 1. Cover 14. Washer (2 used) 27. Clamp (2 used) 2. Cover 15. Tether 28. Hose nipple 3. Level control 16. Rivet (2 used) 29. Screw 4. Air control valve 17. Washer (4 used) 30.
Page 293 NOTE: Most of the seat suspension components can be serviced with the seat suspension base mounted to the frame platform. If the air spring assembly (item 6) re- quires removal, the seat suspension base will have to be removed from the seat platform. Disassembly (Fig.
Page 294: Hood
Hood RIGHT FRONT Figure 23 1. Rear screen 18. Latch 34. Washer head screw (2 used) 2. Top screen 19. Latch cover 35. Cable tie 3. Screen assembly 20. Hood latch bracket 36. Flat washer (20 used) 4. Bulb seal 21.
Page 295 Removal 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove hood using Figure 23 as a guide. Installation 1. Install hood using Figure 23 as a guide. 2.
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Page 297: Specifications 8
Chapter 8 Cutting Decks Table of Contents SPECIFICATIONS ......GENERAL INFORMATION ..... Operator’s Manual .
Page 298: Specifications
Specifications MOUNTING: Cutting decks are supported by lift arms WIDTH OF CUT: Front deck provides 62” (1575 mm) controlled with individual lift switches. width of cut. Each side deck has 42” (1067 mm) width of cut. Total width of cut is 132” (3353 mm) with 7” (128 CONSTRUCTION: Deck chamber is welded 12 gauge mm) overlap.
Page 299: General Information
General Information CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop en- gine and remove key first. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine.
Page 300: Troubleshooting
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 deck weight, tire pressures, hydrau- conditions. Turf conditions such as excessive thatch, lic counterbalance settings and turf conditions.
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Page 302: Service And Repairs
Service and Repairs CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop en- gine and remove key from ignition switch first. Front Cutting Deck RIGHT FRONT 60 to 70 ft- -lb (81 to 94 N- -m) 90 to 100 ft- -lb (123 to 135 N- -m)
Page 303 Removal (Fig. 1) 1. Position machine on a clean, level surface. Lower cutting decks, stop engine, apply parking brake and re- move 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.
Page 304: Side Cutting Deck
Side Cutting Deck Thread locking Compound 35 36 270 to 330 in- -lb (31 to 37 N- -m) RIGHT FRONT Figure 5 1. Cutting deck (LH shown) 18. Pivot shaft 34. Lock nut (2 per spring) 2. Deck mount (LH shown) 19.
Page 305 Removal (Fig. 5) 1. Position machine on a clean, level surface. Lower cutting decks, stop engine, apply parking brake and re- move 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 System).
Page 306: Idler Assembly
Idler Assembly RIGHT FRONT Figure 9 1. Cutting deck (front shown) 10. Idler stop bolt 18. Retaining ring 2. Flange nut 11. Flange nut 19. Thrust washer 3. Flange nut 12. Cap screw 20. Bushing (2 used per idler) 4. Adjusting screw 13.
Page 307 Removal (Fig. 9) CAUTION 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. Be careful when installing the idler spring. The spring is under heavy load and may cause per- 2.
Page 308 Blade Spindles RIGHT FRONT Figure 11 1. Front cutting deck 3. LH cutting deck 5. Driven spindle 2. RH cutting deck 4. Drive spindle 6. Grease fitting location Page 8 - - 12 Cutting Decks Groundsmaster 4000--D/4010--D...
Page 309: Blade Spindles
Removal (Figs. 11 and 12) 4. Install drive belt to spindle pulleys and idler pulley. Adjust drive belt tension (see Idler Assembly Installation 1. Park machine on a level surface, lower cutting in this section). decks, stop engine, apply parking brake and remove key from the ignition switch.
Page 310: Blade Spindle Service
Blade Spindle Service 130 to 150 ft- -lb 130 to 150 ft- -lb (176 to 203 N- -m) (176 to 203 N- -m) DRIVE SPINDLE Figure 13 1. Lock nut 6. Hydraulic motor mount 10. Spacer set 2. Hardened washer 7.
Page 311 2. Install outer bearing spacer into top of spindle hous- ing. The spacer should fit against the snap ring. 3. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the outer bearing spacer previously installed, and the bottom bearing cup must contact the snap ring.
Page 312 Castor Forks and Wheels FRONT CUTTING DECK SIDE CUTTING DECK 60 to 80 ft- -lb (81 to 108 N- -m) CASTOR WHEEL 29 30 60 to 80 ft- -lb (81 to 108 N- -m) Figure 17 1. Castor arm (front deck) 13.
Page 313 Chapter 9 Operator Cab Table of Contents GENERAL INFORMATION ..... Operator’s Manual ......Electrical Components and Schematic .
Page 314: General Information
General Information The information in this chapter pertains to the operator cab on the Groundsmaster 4010--D. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster. Refer to the Opera- tor’s Manual for additional information when servicing the machine.
Page 315: Service And Repairs
Service and Repairs General Precautions for Removing and Installing Air Conditioning System Components 5. Put labels on disconnected lines and hoses for prop- CAUTION er installation after repairs are completed. 6. If compressor is removed from machine, keep com- pressor in the same orientation as the installed position. The air conditioning system is under high pres- This will prevent compressor oil from filling the compres- sure.
Page 316: Air Conditioning Compressor
Air Conditioning Compressor FRONT RIGHT Figure 1 1. Cap screw (3 used) 13. Idler plate bracket 25. Hex nut (2 used) 2. Lock washer (8 used) 14. Lock nut 26. Cap screw 3. Pulley 15. Cap screw (3 used) 27. Flat washer 4.
Page 317 5. Disconnect compressor electrical connector from 2. The clearance between the compressor mounting machine wire harness. flanges and pivot plate must be less than 0.004” (0.10 mm). If necessary, install shims between compressor 6. Read the General Precautions for Removing and flanges and pivot plate to adjust clearance.
Page 318: Roof Assembly
Roof Assembly FRONT Figure 3 1. Roof 7. Panel nut 12. Front spacer (2 used) 2. Screw (2 used) 8. Roof mount 13. Front fastener (2 used) 3. Flat washer (6 used) 9. Flange nut (2 used) 14. Rubber washer 4.
Page 319 To gain access to the heater core and air conditioning components that are located under the cab roof, the roof panel can be loosened, raised and supported. Removal (Fig. 3) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch.
Page 320: Air Conditioning Condenser Assembly
Air Conditioning Condenser Assembly Figure 5 1. Condenser cover 5. Carriage screw (2 used) 8. Bushing (4 used) 2. Lock nut (4 used) 6. Flat washer (8 used) 9. Mounting strap 3. Condenser fan 7. Roof 10. Button head screw (4 used) 4.
Page 321 8. Label and remove hoses from condenser coil. Imme- diately cap hoses and fittings to prevent moisture and contaminants from entering the system. 9. Remove condenser coil from roof using Figure 6 as a guide. NOTE: The replacement of the drier--receiver is recom- mended whenever the air conditioning system is opened (see Heater/Evaporator Assembly in this sec- tion).
Page 322: Heater/Evaporator Assembly
Heater/Evaporator Assembly Figure 7 1. Heater/evaporator assembly 5. Bottom cover 9. Drier- -receiver assembly 2. Top cover 6. Hose clamp (2 used) 10. Screw (8 used) 3. Flange head screw (2 used) 7. Speed nut (8 used) 11. Screw (5 used) 4.
Page 323 8. Have a certified air conditioning service technician CAUTION evacuate the air conditioning system completely, prop- erly recharge the system with R134a refrigerant and then leak test the system. A/C system capacity is 1.25 The air conditioning system is under high pres- pounds of R134a refrigerant.
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Page 325 Chapter 10 Foldout Drawings Table of Contents HYDRAULIC SCHEMATIC ..... ELECTRICAL SCHEMATICS Sheet 1 of 3 ....... . Sheet 2 of 3 .
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Page 327: Hydraulic Schematic
.070 .063 .035 .063 FRONT PTO MANIFOLD LIFT/LOWER TRACTION MANIFOLD MANIFOLD LH PTO MANIFOLD BYPASS VALVE MANIFOLD FAN DRIVE MANIFOLD FILTER MANIFOLD RH PTO MANIFOLD Groundsmaster 4000--D/4010--D Hydraulic Schematic Page 10 - - 3 Rev. A...
Page 328: Sheet 1 Of 3
STANDARD ON GM4010- -D (OPTIONAL ON GM4000- -D) Groundsmaster 4000--D/4010--D Electrical Schematic Sheet 1 of 3 All relays and solenoids are shown as de- - energized. All ground wires are black. NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON THREE (3) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER WILL BE IDENTIFIED.
Page 329: Sheet 2 Of 3
(BRAKE APPLIED) (NOT IN NEUTRAL) (SEAT UNOCCUPIED) ENGINE OIL PRESSURE (OPTIONAL KIT) ALTERNATOR (OPTIONAL KIT) Groundsmaster 4000--D/4010--D Electrical Schematic Sheet 2 of 3 All relays and solenoids are shown as de- - energized. All ground wires are black. NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON THREE (3) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER WILL BE IDENTIFIED.
Page 330: Sheet 3 Of 3
Groundsmaster 4000--D/4010--D Electrical Schematic Sheet 3 of 3 All relays and solenoids are shown as de- - energized. All ground wires are black. NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON THREE (3) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER WILL BE IDENTIFIED.
Page 331: Operator Cab
- -1 RESISTOR - -2 - -7 - -8 BLOWER FAN - -5 - -6 - -3 OR/BK FREEZE SWITCH 1F 3 30 A A/C - -4 BK/W BK/W OR/BK CONDENSER FAN BK/W P05- -H 56- -E AIR CONDITIONER CLUTCH BINARY SWITCH 1F 2 15 A HEATER...
Page 332 This page is intentionally blank. Page 10 - - 8...
Page 333: Platform Wire Harness
TO REAR HARNESS (OPTIONAL KIT) (OPTIONAL KIT) A/C CLUTCH & (OPTIONAL KIT) WS WASHER PUMP (OPTIONAL KIT) NOTE CLOCK POSITION NOTE CLOCK POSITION TO REAR HARNESS TEC- -5001 COMM PORT (NOT USED) TO REAR TO REAR HARNESS HARNESS Groundsmaster 4000--D/4010--D Platform Wire Harness Drawing Page 10 - - 9...
Page 334 TO REAR HARNESS TO REAR HARNESS VIOLET WHITE/YELLOW BLACK BLACK WHITE PINK GRAY PINK RED/WHITE BLACK/WHITE RED/WHITE RED/WHITE BLACK/WHITE BLACK/WHITE BLACK BLACK BLACK BLACK BLACK BROWN BLACK PINK/BLACK VIOLET BLACK BLACK PINK/BLACK BLACK RED/GREEN BLACK GREEN (OPTIONAL KIT) (OPTIONAL KIT) (OPTIONAL KIT) (OPTIONAL KIT) Groundsmaster 4000--D/4010--D...
Page 335 TO REAR TO REAR HARNESS HARNESS (NOT USED) GRAY/BLACK VIOLET/BLACK YELLOW/BLACK WHITE/YELLOW VIOLET PINK RED/GREEN BLACK BROWN/BLACK VIOLET PINK/GREEN BROWN/YELLOW TAN/WHITE BLUE/BLACK YELLOW/BLUE YELLOW/BLUE PINK GREEN/BLACK ORANGE/BLACK BLACK VIOLET/BLACK BLACK BLACK ORANGE/WHITE WHITE/BLUE WHITE/BLUE PINK/BLACK BLACK BLACK BLACK BLACK TAN/BLACK VIOLET/WHITE PINK/WHITE TAN/WHITE...
Page 336 FUSEBLOCKS MAXI FUSES TO PLATFORM HARNESS TO PLATFORM HARNESS TO PLATFORM HARNESS TO PLATFORM HARNESS Groundsmaster 4000--D/4010--D Rear Wire Harness Drawing Page 10 - - 12...
Page 337: Rear Wire Harness
BLACK VIOLET BLACK BLUE BLACK WHITE/BLACK BROWN/BLACK TAN/BLACK TO PLATFORM GRAY/BLACK HARNESS BLUE PINK/BLACK WHITE WHITE/ORANGE BLACK YELLOW TO PLATFORM PINK HARNESS VIOLET ORANGE BLACK BLACK WHITE/YELLOW RED/BLACK BLACK BROWN PINK RED/BLUE TO PLATFORM RED/GREEN HARNESS WHITE/BLACK BLACK BROWN/BLACK TAN/BLACK GRAY/BLACK PINK BLACK...
Page 338 FUSEBLOCKS TO CAB INTERCONNECT HARNESS Groundsmaster 4010--D Cab Wire Harness Drawing Page 10 - - 14...
Page 339: Cab Wire Harness
YELLOW GRAY ORANGE BROWN VIOLET PINK ORANGE/BLACK BLUE BLACK BLACK ORANGE ORANGE ORANGE BLACK BLACK WHITE/BLACK ORANGE/BLACK RED/WHITE BLACK BLACK GREEN WHITE/BLACK BLACK BLACK BLACK BLACK BLACK TO CAB INTERCONNECT BLACK BLACK HARNESS VIOLET WHITE VIOLET ORANGE VIOLET GRAY BROWN BROWN BLUE BLUE...
Page 340: Cab Interconnect Wire Harness
BLACK BLUE WHITE Groundsmaster 4010--D Cab Interconnect Wire Harness Page 10 - - 16...

This manual is also suitable for:

30446 30448 Groundsmaster 4010-d

Toro Groundsmaster 4000-D Service Manual

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Chapter 1 Safety

Chapter 2 -- Product Records and Maintenance

Chapter 3 Kubota Diesel Engine

Chapter 6 -- Axles, Planetaries and Brakes

Chapter 5 Electrical System

Chapter 7 - - Chassis

Chapter 6 Axles, Planetaries and Brakes

Chapter 3 -- Kubota Diesel Engine

Chapter 7 Chassis

Chapter 8 Cutting Decks

Chapter 4 -- Hydraulic System

Chapter 9

Chapter 10

Quick Links

Service Manual

Chapters

Troubleshooting

Related Manuals for Toro Groundsmaster 4000-D

Summary of Contents for Toro Groundsmaster 4000-D