Service Manual
Table Of Contents
- Title Page
- Revision History
- Reader Comments
- Preface
- Table of Contents
- 1 - Safety
- 2 - Product Records and Maintenance
- 3 - Kubota Diesel Engine
- Kubota Diesel Engine Service Manual
- 4 - Hydraulic System
- Specifications
- General Information
- Hydraulic Schematic
- Hydraulic Flow Diagrams
- Special Tools
- Troubleshooting
- Testing
- Traction Circuit Charge Pressure (Using Pressure Gauge)
- Traction Circuit Relief Pressure (Using Pressure Gauge)
- Counterbalance Pressure (Using Pressure Gauge)
- Rear Traction Circuit (RV) Relief Pressure (Using Pressure Gauge)
- Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge)
- Cutting Deck Circuit Pressure (Using Pressure Gauge)
- PTO Relief Pressure (Using Tester with Pressure Gauges and Flow Meter)
- Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauges and Flow
- Cutting Deck Gear Pump Flow
- Steering Circuit Relief Pressure
- Lift/Lower Circuit Relief Pressure
- Steering and Lift/Lower Gear Pump Flow
- Engine Cooling Fan Circuit
- Engine Cooling Fan Circuit Gear Pump Flow
- Adjustments
- Service and Repairs
- General Precautions for Removing and Installing Hydraulic System Components
- Check Hydraulic Lines and Hoses
- Flush Hydraulic System
- Charge Hydraulic System
- Hydraulic Reservoir
- Hydraulic Oil Cooler
- Gear Pump
- Gear Pump Service
- Traction Circuit
- Piston (Traction) Pump
- Piston (Traction) Pump Service
- Rear Axle Motor
- Front Wheel Motor
- Rear Axle and Front Wheel Motor Service
- 4WD Manifold
- 4WD Manifold Service
- Traction (Flow Divider) Manifold
- Traction (Flow Divider) Manifold Service
- Filter Manifold
- Filter Manifold Service
- Steering and Cooling Fan Circuits
- Steering Valve
- Steering Valve Service
- Steering Cylinder
- Steering Cylinder Service
- Engine Cooling Fan Motor
- Engine Cooling Fan Motor Service
- Fan Drive Manifold
- Fan Drive Manifold Service
- PTO Circuit
- Cutting Deck Motor
- Cutting Deck Motor Service
- PTO Manifold
- PTO Manifold Service
- Lift/Lower Circuit
- Lift/Lower Control Valve
- Lift/Lower Control Valve Service
- Side Deck Lift Cylinder
- Front Deck Lift Cylinder
- Lift Cylinder Service
- Counterbalance Manifold
- Counterbalance Manifold Service
- Eaton Piston Pump Repair Information
- Eaton Piston Motor Repair Information
- 5 - Electrical System
- General Information
- Special Tools
- Troubleshooting
- Electrical System Quick Checks
- Component Testing
- Ignition Switch
- Fuses
- Warning Lights
- PTO Switch
- Alarm Silence and Temperature Override Switches
- Transport / 4WD Switch
- Flow Divider Switch
- Cooling Fan Switch
- Seat Switch
- Parking Brake Switch
- Hour Meter
- Audio Alarm
- Glow and Power Relays
- Start, Engine Shutdown, Seat, PTO, PTO Overtemp, Alarm and Over Temperature Relays
- Hydraulic Valve Solenoids
- TEC-5002 Controller
- Fuel Sender
- Fuel Gauge
- Fuel Pump
- Glow Controller
- Temperature Sender
- Dual Temperature Switch
- Temperature Gauge
- Traction Neutral Switch
- Diode Assemblies
- Diode Circuit Board
- Fusible Link Harness
- Cutting Deck Position Switch
- Engine Coolant and Hydraulic Oil Temperature Senders
- Service and Repairs
- 6 - Axles, Planetaries and Brakes
- 7 - Chassis
- 8 - Cutting Decks
- 9 - Foldout Drawings
- Hydraulic Schematic
- Electrical Schematic
- Glow Plug Circuits
- Crank Circuits
- Run (Transport) Circuits
- Run (Mow) Circuits
- High Temperature Warning Cuircuits
- Over Temperature Shutdown Circuits
- Engine Wire Harness
- Engine Wire Harness Diagram
- Front Wire Harness
- Front Wire Harness Diagram
- Console Wire Harness
- Console Wire Harness DIagram
Groundsmaster 4000--D Hydraulic SystemPage 4 -- 69
Removal (Fig. 49)
1. Park machine on a level surface, lower cutting
decks, stop engine, apply parking brake and remove
key from the ignition switch.
2. Raiseseat and secure it with prop rod to gain access
to gear pump.
3. Drain the hydraulic reservoir.
4. To prevent contamination of hydraulic system during
removal, thoroughly clean exterior of pump and fittings.
5. Read the General Precautions for Removing and
Installing Hydraulic System Components at the begin-
ning of the Service and Repairs section of this chapter.
6. Disconnect hydraulic lines from pump and put caps
or plugs on open hydraulic lines and fittings. Label dis-
connected hydraulic lines for proper installation.
7. Support gear pump assembly to prevent it from fal-
ling.
8. Remove two (2) cap screws and washers securing
gear pump to piston pump. Remove gear pump, cou-
pler, spacer and O--rings from machine.
9. If hydraulic fittings are to be removed from gear
pump, mark fitting orientation to allow c orrect assembly.
Remove fittings from pump and discard O--rings.
Installation (Fig. 49)
1. If fittings were removed from gear pump, lubricate
and place new O--rings onto fittings. Install fittings into
pump openings using marks made during the removal
process to properly orientate fittings. Tighten fittings
(see Hydraulic Fitting Installation in the General Infor-
mation section of this chapter).
A. If 90
o
hydraulic suction fitting (item 8) was re-
moved, torque fitting nut from 103 to 118 ft--lb (140
to 160 N--m).
2. Lubricatenew O--rings(item 13) with clean hydraulic
oil. Position O--rings on gear pump and pump spacer
flanges.
3. Slide coupler onto the piston pump output shaft.
4. Positionpump spacer to gear pump. Align gear teeth
and slide gear pump input shaft into coupler. Secure
gear pump to piston pump w ith two (2) cap screws and
flat washers. Torque screws from 79 to 84 ft--lb (108 to
113 N--m).
5. Remove caps or plugs from hydraulic lines and fit-
tings.Installlinestogear pump(seeHydraulic Hoseand
Tube Installation in the General Information section of
this chapter).
6. Replace hydraulic filter and fill hydraulic reservoir
with new hydraulic oil.
7. Disconnect engine run solenoid electrical connector
to prevent engine from starting. Prime the hydraulic
pump by turning the ignition key switch to start and
cranking the engine for ten (10) seconds. Repeat crank-
ing procedure again.
8. Connect engine run solenoid electrical connector,
start the engine and check for proper operation.
9. Properly fill hydraulic system (see Charge Hydraulic
System in this section).
10.Stop engine and check for hydraulic oil leaks. Check
hydraulic reservoir oil level.
11.Lower and secure seat.
Hydraulic
System