Form No. 13202SL Rev F Groundsmaster® 4000-D & 4010-D (Models 30603, 30605, 30607, 30609, 30635 and 30636) © 2021—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision Date – 2014 A 03/2018 Incorporated Models 30635 and 30636. Added revision history. B 05/2018 Added VA02 series planetary information. C 02/2019 Updated Hydraulic, Electrical, Chassis and Operator Cab chapters. D 06/2019 Updated rear axle service drawings. E 06/2020 Updated Electrical chapter and Foldout drawing. F 01/2021 Corrected traction pump plumbing error.
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
NOTES NOTES Page 4 Groundsmaster® 4000-D & 4010-D 13202SL Rev F
Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing and repair of major systems and components on the Groundsmaster 4000−D (Models 30605 and 30609) and Groundsmaster 4010−D (Models 30603, 30607, 30635 and 30636). Refer to the Operator’s Manuals for installing, operating, maintenance, and adjustment instructions.
Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S. components) that may have been removed. • dimensions or settings that must be maintained for proper machine operation. • a specific fastener tightening sequence. • component orientation that may not be obvious.
Table of Contents Preface ................................................................................................................ 5 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Safety and Instructional Decals ....................................................................
Service and Repairs ................................................................................... 11–4 Appendix A ......................................................................................................A–1 Electrical Drawing Designations....................................................................A–3 Hydraulic Schematic ....................................................................................
Engine Wire Harness Diagram for Models 30607, 30609, 30636 (For machines serial number below 400000000) ................................................A–34 Engine Wire Harness Diagram (For machines serial numbers 400000001 to 403450000).............................................................................................A–35 Engine Wire Harness Diagram (For machines serial numbers 400000001 to 403450000).............................................................................................
Preface Page 10 Groundsmaster® 4000-D & 4010-D 13202SL Rev F
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Before Operating the Machine ........................................................................................................... 1–3 While Operating the Machine ............................................................................................................. 1–4 Maintenance and Service.................
Safety Instructions The Groundsmaster 4000-D and 4010−D are tested and certified by Toro for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.
Before Operating the Machine • Review and understand the contents of the Operator’s Manuals before starting and operating the machine. Become familiar with the controls and know how to stop the machine and engine quickly. Additional copies of the Operator’s Manuals are available at www.toro.com. • Never allow children to operate the machine. Never allow adults to operate the machine without proper instructions.
While Operating the Machine 1. Sit on the seat when starting and operating the machine. 2. Before starting the engine: A. Apply the parking brake. B. Make sure traction pedal is in neutral and the PTO switch is OFF (disengaged). 3. After engine is started, release parking brake and keep foot off traction pedal. Machine must not move. If movement is evident, there may be a problem with traction pedal calibration or the piston (traction) pump that needs to be corrected before using the machine. 4.
Maintenance and Service 1. Before servicing or making adjustments, lower decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 3. Never store the machine or fuel container inside where there is an open flame, such as near a water heater or furnace. 4.
Maintenance and Service (continued) 17. When welding on machine, disconnect all battery cables to prevent damage to machine electronic equipment. Disconnect negative battery cable first and positive cable last. Also, disconnect wire harness connector from both of the TEC controllers, disconnect and remove the engine ECM and disconnect the terminal connector from the alternator. Attach welder ground cable no more than two (2) feet (0.6 meters) from the welding location. 18.
Jacking Instructions CAUTION When changing attachments, tires or performing other service, use correct jacks and supports. 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. Always chock or block wheels. Use jack stands to support the raised machine.
Jacking the Rear End (Figure 2) 2 1 2 g274529 Figure 2 1. Rear axle jacking point 2. Rear tire 1. Set parking brake and chock both front tires to prevent the machine from moving. 2. Place jack securely under the center of rear axle. Jack rear of machine off the ground. 3. Once the machine is raised, use jack stands under the axle to support the machine.
Safety and Instructional Decals Numerous safety and instruction decals are affixed to the traction unit and cutting units of your Groundsmaster. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog. Order replacement decals from Authorized Toro Distributor.
Safety: Safety and Instructional Decals Page 1–10 Groundsmaster® 4000-D & 4010-D 13202SL Rev F
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Overall Dimensions............................................................................................................................ 2–2 Engine (Models 30603, 30605 and 30635) ........................................................................................
Specifications Overall Dimensions g279838 Figure 3 Groundsmaster 4000 Specifications and Maintenance: Specifications Page 2–2 Groundsmaster® 4000-D & 4010-D 13202SL Rev F
Overall Dimensions (continued) g279839 Figure 4 Groundsmaster 4010 Groundsmaster® 4000-D & 4010-D 13202SL Rev F Page 2–3 Specifications and Maintenance: Specifications
Engine (Models 30603, 30605 and 30635) Item Description Yanmar Model 4TNV84T−ZMTR: 4−Cycle, 4 Cylinder, Water Cooled, Turbocharged, Tier 4i Diesel Engine Make / Designation Bore 84 mm (3.307 in) Stroke 90 mm (3.543 in) Total Displacement 1995 cc (121.
Engine (Models 30607, 30609 and 30636) Item Description Make / Designation Yanmar Model 4TNV86CT−DTR: 4−Cycle, 4 Cylinder, Water Cooled, Turbocharged, Tier 4 Diesel Engine Bore 86 mm (3.386 in) Stroke 90 mm (3.543 in) Total Displacement 2090 cc (127.5 in³) Firing Order 1 (closest to flywheel end) − 3 − 4 (farthest from flywheel) − 2 Direction of Rotation Counterclockwise (viewed from flywheel) Fuel Diesel or Biodiesel (up to B7) Fuel with Ultra Low Sulfur Content Fuel Tank Capacity 79.
Hydraulic System Item Description Piston (Traction) Sauer−Danfoss Variable Displacement Axial Piston Pump Maximum Displacement (per revolution) 45 cc (2.75 in³) System Relief Pressure: Forward 300 bar (4350 PSI) System Relief Pressure: Reverse 345 bar (5000 PSI) Charge Pressure 17 bar (250 PSI) Front Wheel Motors Sauer−Danfoss 2−Position Axial Piston Motors Displacement (per revolution) 19.55 cc (1.19 in³) Maximum / 10.55 cc (0.
Axles, Planetaries and Brakes Item Description Tire pressure (front and rear) Rear wheel toe−in 172 to 207 kPa (25 to 30 PSI) 6 mm (0.250 in) Planetary Drive Lubricant SAE 85W−140 wt. Gear Lube Capacity (each wheel) 0.47 to 0.59 liters(16 to 20 fl. oz.) Rear axle lubricant SAE 85W−140 wt. gear lube System gear lube capacity Rear axle gear box lubricant 2.4 liters (80 fl. oz.) SAE 85W−140 wt. gear lube System gear lube capacity Wheel lug nut torque 0.5 liters (16 fl. oz.
Cutting Decks MOUNTING: Cutting decks are supported by lift arms controlled with individual lift switches. CONSTRUCTION: Deck chamber is welded steel construction reinforced with channels and plates. HEIGHT−OF−CUT RANGE: 25.4 mm to 127 mm (1 to 5 in) in 12.7 mm (1/2 in) increments. Center deck height− of−cut adjustment is achieved by changing spacers on castor wheels and adjusting length of deck support chains.
Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These torque specifications for the installation and tightening of the fasteners will apply to all the fasteners which do not have a specific requirement identified in this Service Manual.
Calculating the Torque Values When Using a Drive-Adapter Wrench g205924 Figure 5 Torque Conversion Factor = A / B 1. Torque wrench 3. A (effective length of torque wrench) 2. Drive-adapter wrench (crowsfoot) 4. B (effective length of torque wrench and drive-adapter wrench) Using a drive-adapter wrench (e.g.
Identifying the Fastener g206088 Figure 6 Inch Series Bolts and Screws 1. Grade 1 2. Grade 5 3. Grade 8 g206089 Figure 7 Metric Bolts and Screws 1. Class 8.8 2. Class 10.9 Fasteners with a Locking Feature IMPORTANT If a fastener with a locking feature or previously applied thread locking compound is reused, clean the fastener threads and apply new thread locker to the fastener during installation. Locking features are designed to create friction and prevent a fastener from loosening.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC # 8 - 36 UNF # 10 - 24 UNC # 10 - 32 UNF Grade 1, 5 and 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in-lb in-lb N∙cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 56 18 ± 2 30 ± 5 339 ± 56 SAE Grade 5 Bolts, Screws, Studs, and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Thread Size Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 ± 6 in-lb 644 ± 68 N∙cm 78 ± 8 in-lb 881 ± 90 N∙cm M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N∙cm 133 ± 14 in-lb 1503 ± 158 N∙cm M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N∙m 28 ± 3 ft-lb 38 ± 4 N∙m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb Thread Cutting Screws (Zinc Plated Steel) Type 1, Type 23 or Type F Thread Size Baseline Torque** No. 6 - 32 UNC 20 ± 5 in-lb No. 8 - 32 UNC 30 ± 5 in-lb No.
Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply. IMPORTANT Always follow manufacturers instructions when using or storing shop supplies.
GASKET COMPOUND Used to create a seal between mating parts. Gasket compounds may be used with or without the presence of a pre-formed gasket. Gasket compounds may be solvent or silicone based, and cure when exposed to air or designed to cure in an air-less environment (anaerobic). Most gasket compounds are designed to be applied to clean surfaces free of oil, chemical residue and previously used gaskets or gasket compounds.
Special Tools You can order these special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic Pressure Testing Kit Toro Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick disconnect fittings are provided to attach directly to the mating fittings on the machine test ports without the tools. A high-pressure hose is given for remote readings.
150 LPM (40 GPM) Hydraulic Tester Toro Part No. AT40002 Use this tester to test the hydraulic circuits and components for flow and pressure capacities. The tester flow measurement maximum is 151 LPM (40 GPM). This tester includes the following: Load Valve – Turn the valve to restrict the flow to create a simulated working load in the circuit. Pressure Gauge – A glycerine filled pressure gauge 0 to 34,500 kPa (0 to 5,000 psi) to provide operating circuit pressure.
Hydraulic Test Fitting Kit Toro Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system.
High Flow Hydraulic Filter Kit Toro Part Number: TOR6011 The high flow hydraulic filter kit is designed with large flow (150 LPM or 40 GPM) and high pressure (34,500 kPa or 5,000 psi) capabilities. This kit provides for bidirectional filtration which prevents filtered unwanted material from entering into the circuit regardless of the flow direction. If a component failure occurs in the closed-loop traction circuit, contamination from the damaged part will remain in the circuit until you remove it.
Remote Starter Switch After flushing the hydraulic system or replacing a hydraulic component (e.g. gear pump, piston pump, drive motor), it is necessary to prime the hydraulic pumps. A remote starter switch can be used for this purpose. A remote starter switch can be purchased locally or fabricated as follows. IMPORTANT: When using a remote starter switch, it is highly recommended to include a 20 amp in−line fuse between the battery and switch connector for circuit protection.
Dielectric Gel Toro Part No. 107-0342 Use the dielectric gel to prevent corrosion of unsealed connection terminals. To ensure complete coating of the terminals, liberally apply the gel to the component and wire harness connector, plug the connector into the component, unplug the connector, apply the gel to both surfaces again, and connect the harness connector to the component again. The connectors must be fully packed with gel for effective results.
Chapter 3 Troubleshooting Table of Contents GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems ............................. 3–2 General Hydraulic System Problems ..................................................................................................... 3–3 Traction Circuit Problems ...................................................................................................................... 3–4 Mow Circuit Problems...............................................
GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems 1. Gather Information • Information reported by the customer • Information observed by you • Establish the what, where and when of the issue 2. Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis • Narrow down the focus of the problem 3.
General Hydraulic System Problems The charts that follow contain suggestions that can be used to assist in diagnosing hydraulic system performance issues. The suggestions are not all−inclusive. Also, consider that there may be more than one cause for a machine problem. Review the hydraulic schematic and information on hydraulic system operation in the Hydraulic Flow Diagrams section of this Chapter. This information will be useful during the hydraulic troubleshooting process.
Traction Circuit Problems Problem Possible Cause Machine operates in one direction only. Piston (traction) pump by−pass valve is open or damaged. Traction relief valve is leaking or faulty. Piston (traction) pump servo control valve orifices or screens are plugged or damaged. Problem with TEC output to piston (traction) pump servo control exists (see Chapter 6: Electrical System (page 6–1)). Traction pedal response is sluggish. Traction pedal components are stuck or binding.
Mow Circuit Problems Problem Possible Cause None of the cutting decks will operate. Electrical problem exists that prevents PRV solenoid valve in PTO manifolds from being energized (see Chapter 6: Electrical System (page 6–1)) Note: To engage the mow circuit, the seat must be occupied, the cutting deck(s) must be fully lowered the traction speed must be in the LOW (mow) position and the PTO switch must be on. Front two (2) gear pump sections for mow circuits are worn or damaged.
Lift Circuit Problems Problem Possible Cause Cutting decks will not raise. Engine RPM is too low Note: Seat must be occupied in order to raise the cutting decks. Hydraulic oil level in reservoir is low (NOTE: Other hydraulic systems are affected as well). Solenoid valve (S1) in combination manifold is faulty. Electrical problem exists (see Chapter 6: Electrical System (page 6–1)). Lift arm pivots are binding. Lift/lower relief valve in combination manifold is stuck. Lift cylinder(s) is (are) damaged.
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 systems are affected as well). Steering relief valve (RV1) in combination manifold is stuck or damaged. The pressure compensator valve (EC) in combination manifold is stuck or damaged. Steering cylinder leaks internally.
Engine Cooling Fan Circuit Problems Problem Possible Cause Cooling fan runs only in forward direction (fan does not run in reverse direction) Solenoid cartridge valve (S10) in combination control manifold is faulty. Electrical problem exists that prevents combination control manifold solenoid valve (S10) operation (see Chapter 6: Electrical System (page 6–1)). Cooling fan does not rotate. Cooling fan motor is worn or damaged. Proportional relief valve (PRV) in combination manifold is stuck or damaged.
Operator Advisories CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Also, disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Appendix A (page A–1)). If the machine has any interlock switches by−passed, reconnect the switches for safety and efficient troubleshooting.
Fault Codes The list below identifies the fault codes that are generated by the TEC controller to identify an electrical system malfunction (fault) that occurred during machine operation. Use the InfoCenter Display for fault retrieval. Note: The following list of fault codes identifies electrical problems that typically will prevent normal machine operation. The InfoCenter Display will identify existing faults if they should occur. Fault codes 13 through 25 identify problems with inputs (e.g.
32 Brake/LH turn light output has open or short to ground 33 Forward piston (traction) pump output has open or short to ground 34 Reverse piston (traction) pump output has open or short to ground 35 Reverse engine cooling fan output (solenoid valve S10) has open or short to ground 36 Disable dual engine cooling fan output (solenoid valve S11) has open or short to ground 38 Center PTO output has open or short to ground 39 LH PTO output has open or short to ground 40 RH PTO output has open or s
Starting Problems Note: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. Problem Possible Cause No electrical power to machine. The battery is discharged. The battery cables are loose or corroded. Fuse F−D1 (2 Amp) is faulty. A faulty ground connection exists on machine. The ignition switch or circuit wiring is faulty. Starter solenoid clicks, but starter will not crank. The battery is discharged.
General Run and Transport Problems Note: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. Problem Possible Cause Engine continues to run, but should not, when the ignition switch is turned off. The ignition switch or circuit wiring is faulty. Machine continues to move without an InfoCenter Advisory, but should not, when the traction pedal is depressed with no operator in the seat.
Cutting Deck Operating Problems Note: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. Note: To engage the mow circuit, the operator must be in the operator seat, the traction speed must be in the LOW speed (mow) position, the PTO switch must be ON and the cutting deck(s) must be fully lowered and in float. Problem Possible Cause The cutting decks remain engaged, but should not, with no operator in the seat.
Cutting Deck Lift/Lower Problems Note: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. Note: To lower a cutting deck, the operator must be in the operator seat and the traction speed must be in the LOW speed (mow) position. To raise a cutting deck, the operator must be in the operator seat. Problem Possible Cause None of the cutting decks will lower. The HI/LOW speed switch is in the HI speed position.
Aftercut Appearance There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, uneven ground conditions, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the machine. Remember that the “effective” or actual height−of−cut depends on cutting deck weight, tire pressures, hydraulic counterbalance settings and turf conditions.
Chapter 4 Yanmar Diesel Engine Table of Contents General Information .............................................................................................................................. 4–2 Operator’s Manual ............................................................................................................................. 4–2 Yanmar Service and Troubleshooting Manuals .................................................................................. 4–2 Stopping the Engine..............
General Information This Chapter gives information about specifications and repair of the diesel engine used in Groundsmaster 4000−D and 4010−D machines. General maintenance procedures are described in your Operator’s Manual. Information on engine troubleshooting, testing, disassembly and reassembly is identified in the Yanmar Service Manual. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Yanmar Service Manual.
Engine Electronic Control Unit (ECU) 2 1 g274712 Figure 8 1. Electronic control unit (30603 / 30605 / 30635) 2. Alternator The Yanmar engine that powers your Groundsmaster uses an electronic control unit (ECU) for engine management and also to communicate with the machine TEC controllers and the operator Info Center display on the machine.
Engine Electronic Control Unit (ECU) (continued) If the engine ECU identifies that an engine problem exists, the engine speed may be reduced or the engine might stop. The Yanmar electronic tool and troubleshooting manual should be used to provide assistance in identifying the cause of the problem and the repairs that are necessary. Contact your Toro distributor for assistance in Yanmar engine troubleshooting.
Yanmar Engine: Models 30603, 30605 and 30635 g274714 Figure 10 The engine used on Groundsmaster models 30603, 30605 and 30635 is a Yanmar TNV Series, turbocharged, diesel engine that complies with EPA interim Tier 4 emission regulations. The T4i engine features include an electronic control unit (ECU) controlled direct fuel injection and electronic governor. An air heater in the intake system is used to assist starting the engine.
Yanmar Engine: Models 30607, 30609 and 30636 g274715 Figure 11 The engine used on Groundsmaster models 30607, 30609 and 30636 is a Yanmar TNV Series, turbocharged, diesel engine that complies with EPA Tier 4 final emission regulations.
Diesel Particulate Filter The diesel particulate filter (DPF) used on Yanmar Tier 4 compliant engines is designed to breakdown the hazardous elements in the exhaust and prevent the discharge of unburnt fuel or oil known as particulate matter or soot. The DPF includes a Diesel Oxidation Catalyst (DOC), a Soot Filter (SF), 2 temperature sensors, and a pressure differential sensor.
Regeneration (continued) Types of regeneration that are performed automatically (while the machine is operating) (continued) Assist Occurs because of prolonged operation at low engine speed, low engine load, or when the engine ECU detects the soot filter is becoming obstructed. The engine ECU adjusts the intake throttle to raise the exhaust temperature. For software 120-6372A thru O only: the InfoCenter displays the assist regeneration icon.
Regeneration (continued) Types of regeneration that are performed manually (while the machine is stationary) Type Conditions Description Parked Occurs when exhaust back pressure in the DPF increases due to continued soot buildup. May be caused by prolonged operation at low engine speed, low engine load, or the use of incorrect fuel or engine oil. Manually initiate a parked regeneration as soon as possible.
Soot Accumulation If the types of regeneration that are performed automatically (while the machine is operating) are bypassed or not allowed to complete before shutting off the engine, soot will continue to accumulate in the soot filter. When enough soot accumulates, the engine ECU will generate an engine fault to prompt a parked or recovery regeneration. In addition to an engine fault appearing on the InfoCenter, the engine output power will be reduced.
Service and Repairs Air Cleaner System 14 11 10 9 RIGHT 6 8 13 12 FRONT 15 4 2 7 6 3 5 1 14 16 VACUATOR DIRECTION 16 14 18 17 MODELS 30603, 30605 and 30635 MODELS 30607, 30609 and 30636 g274776 Figure 12 1. Air cleaner assembly 7. Cap screw (2 used) 13. Socket head screw (2 used) 2. Tank support 8. Lock nut (2 used) 14. Hose clamp 3. Indicator 9. Flat washer (2 used) 15. Air cleaner inlet hose 4. Adapter 10. Lock nut (2 used) 16. Hose clamp 5.
Removal (Figure 12) 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 12 as a guide. Installation (Figure 12) 2 4 1 3 5 g274777 Figure 13 Air cleaner housing 4. Air cleaner cover 2. Safety filter element 5. Vacuator valve 3. Air filter element 1. IMPORTANT Any leaks in the air cleaner system will cause serious engine damage.
Installation (Figure 12) (continued) 2 3 1.4 to 1.6 N·m (12 to 15 in−lb) 1 g274778 Figure 14 1. Air cleaner assembly 2. Service indicator 3. Adapter B. When installing air cleaner, orientate the vacuator valve on the air cleaner cover so that the valve is pointing in a downward position and between 5:00 to 7:00 (approximate clock position) when viewed from the end. C.
Fuel System 24 25 22 9 RIGHT 11 17 20 10 6 FRONT 5 21 26 27 28 29 30 31 23 19 32 7 8 7 18 13 34 35 26 16 12 33 14 36 15 4 7 to 9 N·m (60 to 80 in−lb) 4 38 37 3 2 1 g274779 Figure 15 1. Carriage screw (2 used) 14. Fuel sender 27. Lock nut (2 used) 2. Retaining ring (2 used) 15. Gasket 28. Spring (2 used) 3. Flat washer (2 used) 16. Fuel cap 29. Flat washer (2 used) 4. Flange nut (6 used) 17. Fuel supply hose 30. Socket head screw (2 used) 5. 6.
DANGER Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety−approved container and keep cap in place. Use diesel fuel for the engine only; not for any other purpose.
Fuel Tank Removal (Figure 15) (continued) 1 4 2 3 g274780 Figure 16 1. Fuel supply hose 3. Return hose 2. Vent hose 4. Fuel sender Note: Fuel sender may have two (2) wire harness terminals (shown in Figure 16) or a single harness connector. 4. Disconnect wire harness connections from the fuel sender (item 14). 5. Disconnect fuel supply, vent and return hoses from elbow fittings in top of tank (Figure 16). 6. Remove fuel tank using Figure 15 as a guide.
Radiator and Oil Cooler Assembly 31 30 27 RIGHT 28 3 26 FRONT 25 32 33 2 24 4 23 6 1 29 3 21 5 34 9 7 8 22 10 3 35 16 20 19 11 Thread Sealant 12 18 13 17 36 9 4 14 15 12 3 g274762 Figure 17 1. LH radiator support 13. Cap screw (2 used) 25. Air cleaner inlet hose 2. Cap screw (2 used) 14. Hose 26. Radiator/hydraulic oil cooler 3. Flange nut (12 used) 15. Coolant reservoir 27. Bulb seal 4. Hose clamp (3 used) 16. Tank mount 28. RH radiator support 5.
Removal (Figure 17) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. Open and support hood. CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Ethylene−glycol antifreeze is poisonous. Dispose of coolant properly or store it in a properly labeled container away from children and pets. 2.
Removal (Figure 17) (continued) RIGHT 3 1 FRONT 4 5 2 g274764 Figure 19 1. Radiator/oil cooler 4. Flange nut (6 used) 2. Motor and fan assembly 5. Lower radiator shroud 3. Cap screw (6 used) 4 1 5 2 3 6 g274765 Figure 20 1. Radiator/oil cooler 4. 90° fitting 2. Straight fitting 5. Hydraulic hose 3. Hydraulic tube 6. Hydraulic tube 6. Thoroughly clean hydraulic lines at lower radiator shroud (Figure 19) and oil cooler ports (Figure 20).
Removal (Figure 17) (continued) 7. Disconnect hood rods from hood and radiator supports (see Hood (page 8–41)). 8. Remove flange head screws (item 8) and flange nuts (item 6) that secure the radiator supports (items 1 and 28) to the frame. 9. Carefully raise radiator assembly with shrouds, fan motor assembly and supports from the machine. 10. Disassemble radiator/oil cooler assembly as needed using Figure 17 and Figure 19 as guides. 11.
Engine 16 22 14 MODEL 30603 SHOWN 15 13 1 12 11 7 18 11 19 9 2 7 5 17 20 11 6 10 21 RIGHT 9 FRONT 5 3 4 8 4 g274766 Figure 21 9. Engine mount bracket (2 used) 17. Wire harness bracket 1. Engine (model 30603 shown) 2. Cap screw (4 used) 10. Cap screw (14 used) 18. Cap screw (3 used) 3. Rebound washer (4 used) 11. Lock washer (18 used) 19. Wire harness bracket 4. Flange nut (12 used) 12. Cap screw (2 used) 20. Lock washer (2 used) 5. Engine mount (4 used) 13.
Engine Removal (Figure 21) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Disconnect negative battery cable from battery terminal and then disconnect positive cable from battery (see Battery Service (page 6–91)). 3. Raise and support hood. CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Ethylene−glycol antifreeze is poisonous.
Engine Removal (Figure 21) (continued) MODELS 30607, 30609 and 30636 2 4 6 5 1 3 g274768 Figure 23 1. Tier 4 engine 4. Hose clamp 2. Hose clamp 5. Fuel return hose 3. Fuel supply hose 6. Front lift bracket MODELS 30603, 30605 and 30635 1 5 3 4 2 g274769 Figure 24 1. Tier 4i engine 4. Hose clamp 2. Hose clamp 5. Fuel return hose 3. Fuel supply hose 9. Disconnect fuel supply and return hoses from engine (Figure 23 or Figure 24). Position fuel hoses away from engine. 10.
Engine Removal (Figure 21) (continued) RIGHT FRONT 1 3 2 g274770 Figure 25 1. 2. Radiator/oil cooler Tank Mount 3. Coolant reservoir 12. On Groundsmaster 4010−D machines: A. Remove air conditioning compressor from compressor mount (see Air Conditioning Compressor (page 10–5)). Position compressor away from engine taking care to not damage compressor or AC hoses. Support compressor to make sure it will not fall during engine removal. B. Disconnect coolant hoses from fittings on engine water flange.
Engine Removal (Figure 21) (continued) MACHINES WITH OPERATOR CAB 1 6 7 2 3 9 4 10 5 8 11 10 12 g274771 Figure 26 1. Exhaust pipe 7. Compressor mount 2. Flange screw (2 used) 8. Cap screw (2 used) Cap screw (4 used) 3. Flange nut 9. 4. Idler pulley 10. Lock washer 5. Carriage screw 11. Cap screw (3 used) 6. Exhaust bracket 12. Pulley CAUTION One person should operate lift or hoist while a second person guides the engine out of the machine.
Engine Installation (Figure 21) 1. Make sure that all parts removed from the engine during maintenance or rebuilding are installed to the engine. 2. If removed, install engine mount brackets to the engine using Figure 21 or Figure 26 as a guide. 3. Connect lift or hoist to the engine lift brackets. CAUTION One person should operate lift or hoist while a second person guides the engine into the machine.
Engine Installation (Figure 21) (continued) 14. Install air cleaner assembly to the engine (see Air Cleaner System (page 4–11)). 15. Connect coolant hoses to the radiator. Make sure radiator draincock is closed. Fill radiator and coolant reservoir with coolant. 16. Secure the wire harness, fuel lines and hydraulic hoses to the engine with cable ties as noted during engine removal. 17.
Spring Coupler RIGHT 7 FRONT 38 to 43 N·m (28 to 32 ft−lb) 3 2 1 6 5 40 to 44 N·m (29 to 33 ft−lb) 4 g274772 Figure 27 1. Cap screw (8 used) 4. Cap screw (8 used) 2. Washer (8 used) 5. Washer (8 used) 3. Flywheel plate 6. Spring coupler 7. Engine (model 30603/30605 shown) Coupler Removal (Figure 27) Note: The hydraulic pump assembly needs to be removed from engine before coupler can be removed. 1.
Coupler Installation (Figure 27) Engine Side Hydraulic Pump Side 1 2 g274773 Figure 28 1. Coupler 2. Engine flywheel 1. Position spring coupler to engine flywheel and align mounting holes. Make sure that coupling hub is away from engine flywheel (Figure 28). 2. Secure coupler to flywheel with eight (8) cap screws and washers. Torque cap screws in a crossing pattern from 40 to 44 N·m (29 to 33 ft−lb). 3. Position flywheel plate to engine.
Exhaust System (Models 30607, 30609 and 30636) 7 40 41 25 to 40 N·m (19 to 29 ft−lb) 39 37 8 35 16 31 18 31 29 36 38 26 17 34 25 22 11 32 10 34 28 5 27 16 30 27 20 15 25 12 33 18 4 9 16 23 18 14 1 18 3 18 23 15 44 21 23 16 13 RIGHT 42 19 6 24 FRONT 2 43 g274774 Figure 29 1. Gasket 16. Bolt (20 used) 31. Hose clip (2 used) 2. Exhaust assembly stay 17. DPF lifter 32. Hose 3. Exhaust assembly stay 18. DPF stiffener (5 used) 33. Bolt (3 used) 4.
Groundsmaster models that are powered by a diesel engine that complies with EPA Tier 4 emission regulations are equipped with an exhaust system that includes a diesel oxidation catalyst (DOC) and a diesel particulate filter (DPF). These exhaust components require service or component replacement at intervals identified in your Operator’s Manual.
Removal (Figure 29 and Figure 30) (continued) 4 3 5 6 2 1 g274775 Figure 30 1. Engine 4. Flange nut (4 used) 2. Exhaust pipe 5. Exhaust flange 3. Clamp assembly 6. Exhaust gasket 2. Remove exhaust system components from the engine as necessary using Figure 29 and Figure 30 as guides. Discard all removed gaskets (items 1 and 15 in Figure 29 or item 6 in Figure 30).
Chapter 5 Hydraulic System Table of Contents General Information .............................................................................................................................. 5–3 Operator’s Manual ............................................................................................................................. 5–3 Check Hydraulic Fluid ........................................................................................................................
Hydraulic Reservoir.......................................................................................................................... 5–93 Radiator and Oil Cooler Assembly ................................................................................................... 5–96 Gear Pump....................................................................................................................................... 5–97 Gear Pump Service............................................................
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 2 1 g274850 Figure 31 1. Hydraulic reservoir 2. Reservoir cap The Groundsmaster hydraulic system is designed to operate on anti−wear hydraulic fluid.
Towing Traction Unit 1 2 3 g274851 Figure 32 (For machines serial number below 400000000) 1. Piston pump 2. Relief valve (forward) 3. Relief valve (reverse) g278592 Figure 33 (For machines serial number above 400000000) 1. Relief valves IMPORTANT If towing limits are exceeded, severe damage to the piston (traction) pump may occur. If it becomes necessary to tow (or push) the machine, tow (or push) in a forward direction only and at a speed below 5 kph (3 mph).
Towing Traction Unit (continued) Before returning machine to service, tighten both of the relief valves until seated. Then, torque relief valves to 70 N·m (52 ft−lb). IMPORTANT If the machine must to be pushed or towed in reverse, the check valve in the rear traction manifold must also be bypassed.
Traction Circuit Component Failure The traction circuit on Groundsmaster 4000−D and 4010−D machines is a closed loop system that includes the piston (traction) pump, two (2) front wheel motors and the rear axle motor. If a component in the traction circuit should fail, debris and contamination from the failed component will circulate throughout the traction circuit. This contamination can damage other components in the circuit so it must be removed to prevent additional component failure.
Hydraulic Hoses The hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions, in addition to mishandling during operation and maintenance. These conditions can cause damage to the hose or deterioration to the hose material. Some hoses are more susceptible to these conditions than others. Examine all of the hydraulic hoses of the machine frequently and repair or replace them as necessary.
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) g212099 Figure 34 1. Tube or hose 2. Swivel nut 3. 4. O-ring Fitting body 1. Ensure that all the threads, the sealing surfaces of the hose/tube, and the fitting are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the face seal O-ring when you open the connection. Ensure that the O-ring is installed and correctly seated in the groove of the fitting.
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (continued) Hose/Tube Installation Torque Table Fitting Dash Size Hose/Tube Side Thread Size (inch)—threads per inch) Installation Torque 4 9/16—18 25 to 29 N∙m (18 to 22 ft-lb) 6 11/16—16 37 to 44 N∙m (27 to 33 ft-lb) 8 13/16—16 51 to 63 N∙m (37 to 47 ft-lb) 10 1—14 82 to 100 N∙m (60 to 74 ft-lb) 12 1–3/16—12 116 to 142 N∙m (85 to 105 ft-lb) 16 1–7/16—12 150 to 184 N∙m (110 to 136 ft-lb) 20 1–11/16—12 190 to 233 N∙m (140 to 172
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) Installing a Non-Adjustable Fitting g212226 Figure 36 1. Fitting 2. O-ring 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the O-ring when you open the connection. 3. Lightly lubricate the O-ring with clean hydraulic fluid.
Installing an Adjustable Fitting g212224 Figure 37 1. Locknut 2. Back-up washer 3. O-ring g212225 Figure 38 1. Step 1: clearance the lock nut 3. Step 3: align the fitting 2. Step 2: seat the back-up washer 4. Step 4: tighten the lock nut 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the O-ring when you open the connection. 3.
Installing an Adjustable Fitting (continued) 7. Tighten the fitting lock nut (Step 4 in Figure 38): A. Hold the fitting in the correct alignment with a wrench and use a torque wrench and tighten the lock nut to the recommended torque value within the specified range of torque values; refer to the Fitting Installation Torque Table (page 5–12). This tightening procedure requires a drive-adapter wrench (e.g.
Groundsmaster® 4000-D & 4010-D 13202SL Rev F Page 5–13 M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 P1 STEERING CONTROL VALVE P L 0.4 CID G T STEERING CYLINDER 1.29 1.29 CID CID G 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM E 6.1 CID 0.3 CID R 2.00” BORE 4.20” STROKE 0.
Hydraulic System: Hydraulic Flow Diagrams Page 5–14 M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow STEERING CONTROL VALVE P G T G 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM E 6.1 CID L STEERING CYLINDER 0.3 0.
Traction Circuit: LOW Speed (Mow) The traction circuit piston pump is a variable displacement pump that is directly coupled to the engine flywheel. This pump utilizes an integral electro−hydraulic servo piston assembly that controls the rate and direction of hydraulic flow. Pressing the traction pedal rotates a potentiometer that provides an input to the machine TEC controller.
Forward Direction (continued) then returns to the piston pump. Oil flow from front traction manifold port M2 is directed to drive the rear axle motor in the forward direction. Oil returning from the axle motor enters the rear traction manifold at the M8 port. Flow bypasses the PR cartridge through the CV check valve, out manifold port P2 and returns to the piston pump. When going down a hill, the tractor becomes an over− running load that drives the front wheel and rear axle motors.
Groundsmaster® 4000-D & 4010-D 13202SL Rev F Page 5–17 M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P1 G P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow STEERING CONTROL VALVE P G T G 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM E 6.1 CID L STEERING CYLINDER 0.
The traction circuit piston pump is a variable displacement pump that is directly coupled to the engine flywheel. This pump utilizes an integral electro−hydraulic servo piston assembly that controls the rate and direction of hydraulic flow. Pressing the traction pedal rotates a potentiometer that provides an input to the machine TEC controller.
Forward Direction (continued) When going down a hill, the tractor becomes an over− running load that drives the front wheel and rear axle motors. In this condition, the rear axle motor could lock up as the oil pumped from the motor increases pressure as it returns to the piston pump. To prevent rear wheel lock up, an adjustable relief valve (RV) in the rear traction manifold reduces rear axle motor pressure created in down hill, dynamic braking conditions.
Hydraulic System: Hydraulic Flow Diagrams Page 5–20 M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow P G T G 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM E 6.1 CID L STEERING CYLINDER 0.3 0.4 1.29 1.
A four section gear pump is coupled to the piston (traction) pump. The third gear pump section supplies hydraulic flow to the lift/lower circuit, the engine cooling fan circuit and the traction charge circuit. Each of the cutting decks (center, right and left) can be lowered independently with the use of three (3) switches on the armrest console. Pressing the front of a lift switch provides an input for the TEC controller to lower a cutting deck.
Lower Left Cutting Deck To lower the left wing deck, the front of the left console lift switch is pushed as an input to the TEC controller. The controller provides an electrical output to solenoid valves S1, S3 and S4 in the combination manifold. The energized solenoid valves shift to allow a passage for circuit oil flow to the left deck lift cylinder rod end. Shifted S1 allows gear pump section oil flow to be available for the lift/lower circuits.
Groundsmaster® 4000-D & 4010-D 13202SL Rev F Page 5–23 M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow P G T G 1.29 CID 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM E 6.1 CID L STEERING CYLINDER 0.3 0.4 1.
A four section gear pump is coupled to the piston (traction) pump (Figure 44). The third gear pump section supplies hydraulic flow to the lift/lower circuit, the engine cooling fan circuit and the traction charge circuit. A relief valve (RV2) located in the combination manifold limits lift/lower circuit pressure to 110 bar (1600 PSI).
Raise Right Cutting Deck To raise the right deck, the rear of the right console lift switch is depressed as an input to the TEC controller. The controller provides an electrical output to solenoid valves S1, S7 and S9 in the combination manifold. The energized solenoid valves shift to allow a passage for circuit oil flow to the barrel end of the right deck lift cylinder. Shifted S1 allows gear pump section oil flow to be available for the lift/lower circuits.
Hydraulic System: Hydraulic Flow Diagrams Page 5–26 M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow Mow (Front Deck Shown) STEERING CONTROL VALVE P L 0.4 CID G T STEERING CYLINDER 1.29 1.29 CID CID G 2.75 CID 14.
A four section gear pump is coupled to the piston (traction) pump. Hydraulic flow for the mow circuit is supplied by two sections of the gear pump. The gear pump section closest to the piston (traction) pump supplies hydraulic flow to the side cutting decks, while the next gear pump section supplies the front cutting deck. Each cutting deck is controlled by a hydraulic manifold equipped with a proportional relief valve (PRV), a pilot directional valve (PD), a logic valve (LC1) and a relief valve (RV).
PTO Circuit Relief M1 P1 PUMP G FLOW 3000 PSI .025 1.17 CID PD PRV LC1 RV M2 P2 600 PSI CD RIGHT DECK RETURN RETURN DECK MOTOR STALLED PRV ENERGIZED PRV AND LC1 SHIFTED g274969 Figure 46 Maximum mow circuit pressure is limited for each deck by proportional relief valve (PRV) in the PTO manifold. The center and left deck relief valves are set at 207 bar (3000 PSI) and the right deck relief valve is set at 138 bar (2000 PSI).
Mow Circuit Cutting Deck Blade Braking PUMP FLOW M1 P1 G 3000 PSI .025 1.17 CID PD PRV LC1 RV M2 P2 600 PSI RIGHT DECK CD RETURN RETURN PTO SWITCH OFF PRV NOT ENERGIZED LC1 SHIFTED g274970 Figure 47 PUMP FLOW M1 P1 G 3000 PSI .025 1.
Hydraulic System: Hydraulic Flow Diagrams Page 5–30 M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P1 G P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow P G 1.29 CID 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM T 0.3 0.4 1.
A four section gear pump is coupled to the piston (traction) pump. The fourth gear pump section (farthest from the piston pump) supplies hydraulic flow to the steering circuit, the engine cooling fan circuit and the traction charge circuit. Priority hydraulic flow from this gear pump section is provided to the steering circuit by the pressure compensator valve (EC) located in the combination manifold.
Left Turn When a left turn is made with the engine running, the turning of the steering wheel positions the steering control valve spool so that the load sense flow is blocked off. Without load sense flow, pressures on the ends of manifold compensator valve (EC) start to equalize causing (EC) to move toward its neutral position which allows the needed oil flow to the steering control valve.
Groundsmaster® 4000-D & 4010-D 13202SL Rev F Page 5–33 M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow STEERING CONTROL VALVE P G T G 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM E 6.1 CID L STEERING CYLINDER 0.
3 1 2 g274972 Figure 51 1. Piston (traction) pump 2. 4th 3. 3rd gear pump section gear pump section A four section gear pump is coupled to the piston (traction) pump (Figure 51). The fourth gear pump section (farthest from the piston pump) supplies hydraulic flow to the steering circuit, the engine cooling fan circuit and the traction charge circuit. The third gear pump section supplies hydraulic flow to the engine cooling fan circuit, the lift/lower circuit and the traction charge circuit.
When the engine is shut off, the over−running inertia load of the engine cooling fan blades keeps driving the fan motor and turns it into a pump. The check valve (CV1) in the combination manifold will open to keep the motor circuit full of oil so the fan motor will not cavitate. Forward Direction Fan Operation During normal, forward direction fan operation, circuit oil flow is sent through the de−energized solenoid valve (S10) in the combination manifold to rotate the cooling fan motor.
Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (see the Special Tools (page 2–17)Special Tools section in this Chapter). IMPORTANT All obvious areas such as hydraulic oil supply, oil filters, binding components, loose fasteners or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem.
Precautions for Hydraulic Testing (continued) 3. Put metal caps or plugs on any hydraulic lines left open or exposed during testing or removal of components. 4. The engine must be in good operating condition. Use a phototac to determine engine speed when performing a hydraulic test. Engine speed will affect the accuracy of the tester readings. See Engine (Models 30603, 30605 and 30635) (page 2–4) and Engine (Models 30607, 30609 and 30636) (page 2–5). 5.
Which Hydraulic Tests Are Necessary? (continued) 5. If a engine cooling fan circuit problem exists, consider performing one or more of the following tests: Engine Cooling Fan Circuit and/or Gear Pump Flow Tests.
Groundsmaster® 4000-D & 4010-D 13202SL Rev F TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD PRESSURE GAUGE Page 5–39 FROM OIL FILTER 0.3 CID FROM CENTER DECK PTO MANIFOLD 0.4 CID G 1.29 CID G 1.29 CID 14.3 GPM 14.3 GPM 4.4 GPM 2.75 CID .0315 TO COMBINATION MANIFOLD 3.3 GPM 250 PSI .0315 FROM COMBINATION MANIFOLD G G 5000 PSI 4350 PSI 30.5 GPM REAR TRACTION MANIFOLD ENGINE P1 FROM COMBINATION MANIFOLD OR1 T .050 CV PR RV 13.7 GPM 200 PSI 16.
The traction charge circuit is designed to replace loss of hydraulic fluid from the closed loop traction circuit. This test is used to make sure that traction charge pressure is correct. Procedure for Traction Circuit Charge Pressure Test CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting decks lowered and off.
Procedure for Traction Circuit Charge Pressure Test (continued) Note: If the gear pump section that supplies the charge circuit is worn or damaged, charge, steering, lift/ lower and engine cooling fan circuits may all be affected. 7. Next, with the pressure gauge still connected to the charge pressure test port, take a gauge reading while operating the machine in forward and reverse. Start the engine and put throttle at high idle speed.
Hydraulic System: Testing FROM OIL FILTER 0.3 CID G 0.4 CID 1.29 CID G 1.29 CID 14.3 GPM 14.3 GPM 4.4 GPM 2.75 CID .0315 TO COMBINATION MANIFOLD 3.3 GPM 250 PSI .0315 FROM COMBINATION MANIFOLD G G 5000 PSI 4350 PSI 30.5 GPM Page 5–42 REAR TRACTION MANIFOLD ENGINE P1 FROM COMBINATION MANIFOLD PRESSURE GAUGE TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD FROM CENTER DECK PTO MANIFOLD .050 T OR1 P2 CV2 CV1 CV PR RV 13.7 GPM 200 PSI 16.
Procedure for Traction Circuit Relief Pressure Test FRONT 2 1 g275055 Figure 55 1. Forward traction port 2. Forward relief valve 2 RIGHT FRONT 1 g275056 Figure 56 1. Reverse traction port 2. Reverse relief valve Note: The traction charge circuit is designed to replace loss of hydraulic fluid from the closed loop traction circuit. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1.
Procedure for Traction Circuit Relief Pressure Test (continued) CAUTION When performing the traction circuit relief pressure test, move machine to an open area, away from people and obstructions. 2. Drive machine to an open area, lower cutting decks, turn the engine off and apply the parking brake. 3. Connect a 700 bar (10,000 PSI) pressure gauge to traction circuit test port for function to be checked (Figure 55 or Figure 56). 4. Start engine and increase engine speed to high idle speed.
TO RESERVOIR Groundsmaster® 4000-D & 4010-D 13202SL Rev F TO STEERING CONTROL VALVE Page 5–45 EC CV2 4 PSI FROM GEAR PUMP FROM GEAR PUMP G4 CF LS G2 CH4 S10 M1 G P4 80 PSI OR1 .030” 0.51 CID S11 3250 PSI CH2 RV1 1350 PSI CV1 4 PSI PRV M2 G 60 PSI CV3 TO FRONT TRACTION VALVE CH1 OR3 .070 C3 S4 S2 C4 S1 PR 310 PSI S3 P3 RV3 OR2 .063 G3 3300 PSI TO RESERVOIR CH3 CV4 4 PSI OR5 .070 T OR9 .030 OR4 .040 S5 C2 3.08” STROKE 6.50” STROKE 1.125” ROD 1.
Procedure for Counterbalance Pressure Test 2 1 3 g275057 Figure 58 1. Combination manifold 2. Test port G1 3. Pressure reducing valve CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting decks lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. 2.
Procedure for Counterbalance Pressure Test (continued) 3 2 1 g275058 Figure 59 3. 1. Combination manifold 2. Pressure reducing valve Adjustment screw 6. The pressure reducing valve on the combination manifold is used to set the counterbalance pressure (Figure 59). If necessary, adjust pressure reducing valve: Note: Because of valve design, the pressure reducing valve can be adjusted with the engine running. Do not remove the pressure reducing valve from the hydraulic manifold for adjustment. A.
Hydraulic System: Testing Page 5–48 FROM OIL FILTER TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD FROM CENTER DECK PTO MANIFOLD 0.3 CID G 0.4 CID 1.29 CID G 1.29 CID 14.3 GPM 14.3 GPM 4.4 GPM 2.75 CID .0315 TO COMBINATION MANIFOLD 3.3 GPM 250 PSI .0315 FROM COMBINATION MANIFOLD G G 5000 PSI 4350 PSI 30.5 GPM REAR TRACTION MANIFOLD ENGINE P1 FROM COMBINATION MANIFOLD T OR1 .050 P2 CV2 CV1 CV PR RV PRESSURE GAUGE 200 PSI 16.
Procedure for Reverse Traction Circuit Reducing Valve (PR) Pressure Test Note: When in reverse, pressure reducing valve (PR) limits the pressure to the rear axle motor to 26 bar (380 PSI) so the rear wheels will not scuff the turf. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting decks lowered and off.
Procedure for Reverse Traction Circuit Reducing Valve (PR) Pressure Test (continued) 1 4 2 3 g275060 Figure 62 1. Rear traction manifold 3. Relief (RV) valve 2. #6 zero leak plug 4. Reducing (PR) valve 7. The pressure reducing (PR) valve is located on the rear side of the rear traction manifold (Figure 61 and Figure 62). If test pressure is incorrect, adjust pressure reducing (PR) valve (see Adjust Control Manifold Relief Valves (page 5–82)).
Groundsmaster® 4000-D & 4010-D 13202SL Rev F Page 5–51 FROM OIL FILTER TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD FROM CENTER DECK PTO MANIFOLD 0.3 CID G 0.4 CID 1.29 CID G 1.29 CID 14.3 GPM 14.3 GPM 4.4 GPM 2.75 CID .0315 TO COMBINATION MANIFOLD 3.3 GPM 250 PSI .0315 FROM COMBINATION MANIFOLD G G 5000 PSI 4350 PSI 30.5 GPM REAR TRACTION MANIFOLD ENGINE P1 FROM COMBINATION MANIFOLD T OR1 .050 P2 CV2 CV1 CV PR RV PRESSURE GAUGE 200 PSI 16.
Procedure for Rear Traction Circuit Relief Valve (RV) Pressure Test Note: Adjustable relief valve (RV) in the rear traction control manifold reduces rear axle motor pressure created in down hill, dynamic braking conditions to prevent rear wheel lock up. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting decks lowered and off.
Procedure for Rear Traction Circuit Relief Valve (RV) Pressure Test (continued) 1 4 2 3 g275060 Figure 65 1. Rear traction manifold 3. Relief (RV) valve 2. #6 zero leak plug 4. Reducing (PR) valve Note: If the rear traction circuit reducing valve (PR) pressure is excessive, operation of the rear traction relief valve (RV) may be affected. Before adjusting rear traction relief valve (RV), make sure that pressure reducing valve (PR) pressure is correct. 6.
Hydraulic System: Testing Page 5–54 FROM OIL FILTER TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD FROM CENTER DECK PTO MANIFOLD 0.3 CID G 0.4 CID 1.29 CID G 1.29 CID 14.3 GPM 14.3 GPM 4.4 GPM 2.75 CID .0315 TO COMBINATION MANIFOLD 3.3 GPM 250 PSI .0315 FROM COMBINATION MANIFOLD G 5000 PSI 4350 PSI 30.5 GPM G P1 REAR TRACTION MANIFOLD ENGINE FROM COMBINATION MANIFOLD T OR1 .050 P2 OR .
Procedure for Piston (Traction) Pump Flow Test This test measures piston (traction) pump output (flow). During this test, pump load is created at the flow meter using the adjustable load valve on the tester. Note: Before performing piston pump flow test, make sure that traction speed is set to 100% using the InfoCenter settings menu. IMPORTANT Traction circuit flow for the Groundsmaster 4000/4010 is approximately 113.5 LPM (30 GPM). Use 151.
Procedure for Piston (Traction) Pump Flow Test (continued) 4. Install tester with pressure gauge and flow meter in series between piston pump fitting and disconnected hose to allow flow from traction pump to tester. Use hydraulic hose kit (see Special Tools (page 2–17)) to connect tester to machine. Make sure that fitting and hose connections are properly tightened. Also, make sure the flow control valve on tester is fully open. 5. Start engine and adjust engine speed to high idle speed.
Groundsmaster® 4000-D & 4010-D 13202SL Rev F Page 5–57 M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 600 PSI .025 CD PRV 2000 PSI CD PRV 3000 PSI CD PRV 3000 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 P2 G P1 50 PSI CENTER DECK LC1 P2 G P1 0.3 CID 0.4 CID G TO COMBINATION MANIFOLD 1.29 CID G 1.29 CID 2.75 CID 14.3 GPM 14.3 GPM .0315 250 PSI .0315 TO COMBINATION MANIFOLD 3.
Procedure for Cutting Deck Circuit Pressure Test 2 1 g275064 Figure 69 1. PTO manifold (front) 2. Manifold test port CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting decks lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. 2.
Groundsmaster® 4000-D & 4010-D 13202SL Rev F 1.17 CID 1.17 CID 1.17 CID M2 M1 M2 M1 M2 M1 Page 5–59 600 PSI .025 600 PSI .025 600 PSI CD PRV 2000 PSI CD PRV 3000 PSI CD PRV 3000 PSI RIGHT DECK LC1 LEFT DECK LC1 P1 P2 G P1 P2 G 50 PSI CENTER DECK LC1 P2 G 0.3 CID 0.4 CID G TO COMBINATION MANIFOLD 1.29 CID G 1.29 CID 2.75 CID 14.3 GPM 14.3 GPM .0315 250 PSI .0315 TO COMBINATION MANIFOLD 3.
Procedure for PTO Relief Pressure Test RIGHT FRONT 3 1 2 g275065 Figure 71 1. 2. Center PTO manifold LH PTO manifold 3. RH PTO manifold LEFT PTO MANIFOLD SHOWN 2 1 g275066 Figure 72 1. 2. PTO manifold PRV valve CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting decks lowered and off.
Procedure for PTO Relief Pressure Test (continued) CAUTION Cutting deck blades will rotate when cutting decks are lowered with PTO switch in ON position. Keep away from cutting decks during test to prevent personal injury from rotating blades. Do not stand in front of the machine. 4. Start engine and increase engine speed to high idle speed. Release the parking brake. 5. Watch pressure gauge carefully while slowly closing the tester flow control valve to fully closed. 6.
Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauge and Flow Meter) CENTER CUTTING DECK MOTOR CASE DRAIN LEAKAGE TEST SHOWN M1 P1 1.17 CID .025 3000 PSI G PD PRV TESTER LC1 RV P2 600 PSI M2 CD CENTER DECK FROM STEERING CONTROL VALVE CAP M1 P1 G 3000 PSI .025 1.17 CID PD TO RESERVOIR PRV LC1 MEASURING CONTAINER RV P2 600 PSI M2 CD LEFT DECK M1 FROM SECOND GEAR PUMP SECTION .025 1.
Procedure for Cutting Deck Motor Case Drain Leakage Test Note: Over a period of time, a deck motor can wear internally. A worn motor may by−pass oil to its case drain causing the motor to be less efficient. Eventually, enough oil loss will cause the deck motor to stall under heavy cutting conditions. Continued operation with a worn, inefficient motor can generate excessive heat, cause damage to seals and other components in the hydraulic system and affect quality of cut.
Procedure for Cutting Deck Motor Case Drain Leakage Test (continued) CAUTION Cutting deck blades will rotate when cutting decks are lowered with PTO switch in ON position. Keep away from cutting decks during test to prevent personal injury from rotating blades. Do not stand in front of the machine. 4. Sit on seat and start the engine. With engine running, increase engine speed to high idle speed and release the parking brake. Engage the cutting decks. g031767 Figure 75 5.
Groundsmaster® 4000-D & 4010-D 13202SL Rev F Page 5–65 FROM LEFT AND RIGHT DECK PTO MANIFOLDS 0.3 CID P G 0.4 CID 6.1 CID T G 1.29 CID 1.29 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM E L STEERING CYLINDER 2.75 CID G4 CF LS G2 CH4 G EC CV2 4 PSI S10 M1 .0315 P4 250 PSI G G CH2 30.5 GPM CH1 5000 PSI 60 PSI CV3 S1 OR3 .070 G3 P2 CV2 M3 PR 380 PSI M8 T S5 13.7 GPM OR9 .030 OR4 .040 C2 200 PSI 16.8 GPM FRONT TRACTION MANIFOLD CH M1 CV4 CV 650 PSI RV CH2 OR .
Procedure for Lift/Lower Circuit Relief Pressure Test 2 1 3 4 g275068 Figure 77 1. Gear pump 3. Combination manifold 2. 3rd 4. Relief valve RV2 section test fitting 2 1 g275069 Figure 78 1. Combination manifold 2. Relief valve RV2 Note: Before attempting to check or adjust lift/lower circuit relief pressure, make sure that counterbalance pressure is correctly adjusted (see Counterbalance Pressure (Using Pressure Gauge) (page 5–45)).
Procedure for Lift/Lower Circuit Relief Pressure Test (continued) 3. Connect a 345 bar (5,000 PSI) pressure gauge to test fitting attached to tee fitting in third section of gear pump (Figure 77). 4. Sit on the seat and start the engine. With engine running, increase engine speed to high idle speed. 5. While sitting on the seat, depress the rear of one of the lift switches to fully raise the cutting deck. Momentarily hold the switch with the deck fully raised while watching the pressure gauge.
Hydraulic System: Testing Page 5–68 M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 P1 STEERING CONTROL VALVE P 0.3 CID G E L 0.4 CID 6.1 CID R 2.00” BORE 4.20” STROKE 0.625” ROD T STEERING CYLINDER 1.29 1.29 CID CID G 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.
The steering circuit relief pressure test should be performed to make sure that the steering circuit relief pressure is correct. Procedure for Steering Circuit Relief Pressure Test CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting deck lowered and off.
Procedure for Steering Circuit Relief Pressure Test (continued) 7. If pressure is incorrect, inspect steering relief valve in steering control valve (see Steering Control Valve Service (For machines serial number below: 400000000) (page 5–140)). If relief valve is operating properly and if lift/lower problems also exist, flow divider in fan manifold and/or gear pump (third section) should be suspected of wear and inefficiency.
Steering Cylinder Internal Leakage STEERING CYLINDER CYLINDER FULLY EXTENDED 2.00” BORE 4.20” STROKE 0.625” ROD LOOK FOR LEAKAGE STEEL CAP R L STEERING CONTROL VALVE STEERING WHEEL TURNED FOR RIGHT TURN 6.1 CID P E T TO RESERVOIR FROM COMBINATION MANIFOLD FROM COMBINATION MANIFOLD g275085 Figure 81 The steering cylinder internal leakage test should be performed if a steering problem is identified. This test will determine if the steering cylinder is faulty.
Procedure for Steering Cylinder Internal Leakage Test (continued) CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting decks lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. 2. Turn the steering wheel for a right turn so that the steering cylinder rod is fully extended. 3.
Groundsmaster® 4000-D & 4010-D 13202SL Rev F Page 5–73 FROM LEFT AND RIGHT DECK PTO MANIFOLDS FROM OIL FILTER P R 0.3 CID 6.1 CID E L 0.4 CID G 1.29 CID G 1.29 CID 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM T STEERING CYLINDER .0315 G4 CF LS G2 CH4 PRESSURE GAUGE TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD FROM CENTER DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD STEERING CONTROL VALVE 2.00” BORE 4.20” STROKE 0.625” ROD 250 PSI 80 PSI OR1 .030” P4 .
Procedure for Engine Cooling Fan Circuit Test 1 2 g275071 Figure 83 1. Upper hydraulic tube 2. Test port 2 3 1 g275072 Figure 84 1. 2. Combination manifold PRV solenoid 3. S11 solenoid CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting decks lowered and off.
Procedure for Engine Cooling Fan Circuit Test (continued) 4. Have a phototac available to identify cooling fan speed once engine is running. 5. Start engine and increase engine speed to high idle speed. Do not engage the cutting decks. 6. While monitoring the pressure gauge and using the phototac to identify the cooling fan speed, disconnect the wire harness connectors from the PRV solenoid (white/green and black wires) and S11 solenoid (violet and black wires) on combination manifold (Figure 84).
Engine Cooling Fan Motor Case Drain Leakage Test FAN MOTOR 0.51 CID TESTER MEASURING CONTAINER M1 M2 S10 CH4 PRV Working Pressure Low Pressure (Charge) Return or Suction Flow CV1 P4 FROM GEAR PUMP CH2 TO RESERVOIR 1 2 3 High Pressure Low Pressure Return or Suction Flow FRONT g284143 Figure 85 1. 2. Pressure tube Case drain tube Hydraulic System: Testing 3.
Procedure for Engine Cooling Fan Motor Case Drain Leakage Test Over a period of time, the motor can wear internally. This test measures case drain volume while restricting flow across the motor parts. Case drain volume under load of more than 12% of total motor flow indicates the gears and wear plates in the motor have worn. A worn motor may by-pass hydraulic fluid to its case drain causing the motor to be less efficient.
Procedure for Engine Cooling Fan Motor Case Drain Leakage Test (continued) CAUTION Cooling fan blades will rotate during the test procedure. Keep away from cooling fan blades during test to prevent personal injury from rotating blades. 11. Sit in the operator’s seat, start the engine and set the throttle to high idle speed. 12. While watching the tester pressure gauge, slowly close flow control valve on tester until a pressure of 138 bar (2000 PSI) is obtained.
TESTER Groundsmaster® 4000-D & 4010-D 13202SL Rev F Page 5–79 FROM MANIFOLD AND FAN MOTOR FROM MOW CIRCUIT FROM OIL FILTER TO LEFT DECK PTO MANIFOLD 0.4 CID CID G 0.3 TO CENTER DECK PTO MANIFOLD CID 1.29 G CID 1.29 14.3 GPM CID 2.75 TO COMBINATION MANIFOLD TO COMBINATION MANIFOLD 14.3 GPM 3.3 GPM .0315 250 PSI .0315 5000 PSI 4350 PSI FROM REAR AXLE MOTOR FROM CENTER DECK MANIFOLD G G GPM 30.
1 2 3 4 g275073 Figure 87 1. Front pump section (LH and RH PTO) 2. 2nd pump section (front PTO) 3. 3rd pump section (cooling fan, lift/lower and charge) 4. 4th pump section (steering, charge and cooling fan) The gear pump flow test should be performed to make sure that the mow, steering, lift/lower, cooling fan and traction charge circuits have adequate hydraulic flow. The front gear pump section provides hydraulic flow for the side cutting decks (Figure 87).
Procedure for Gear Pump Flow Test (continued) 6. Start engine and increase engine speed to high idle speed. Do not engage the cutting decks. IMPORTANT Do not fully restrict oil flow through tester. In this test, the flow tester is positioned before the relief valve. Pump damage can occur if the oil flow is fully restricted. 7. Watch pressure gauge carefully while slowly closing the flow control valve until 69 bar (1000 PSI) is obtained.
Adjustments Adjust Control Manifold Relief Valves 1 2 g275100 Figure 88 1. 2. Relief valve cap Adjustment socket Several of the hydraulic control manifolds on your Groundsmaster include adjustable relief valves. The following procedure can be used to adjust these relief valves. Refer to the Testing (page 5–36) section of this chapter for information on testing relief pressure. Note: Do not remove relief valve from the hydraulic manifold for adjustment. 1. Locate relief valve on control manifold. 2.
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, park machine on a level surface, apply parking brake, lower cutting decks or attachments and stop engine. Remove key from the ignition switch. 2. Clean machine before disconnecting, removing or disassembling any hydraulic components.
After Repair or Replacement of Components (continued) 7. After disconnecting or replacing any hydraulic components, operate machine functions slowly until air is out of system (see Charge Hydraulic System (page 5–91)). 8. Check for hydraulic oil leaks. Shut off engine and correct leaks if necessary. Check oil level in hydraulic reservoir and add correct oil if necessary.
Check Hydraulic Lines and Hoses WARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury.
Priming Hydraulic Pumps Whenever the hydraulic system is flushed, the hydraulic system is charged or hydraulic components are installed, it is important to properly prime the hydraulic pumps. Hydraulic pump priming ensures that the gear pump and piston (traction) pump have adequate oil during initial start−up and running. The pumps can be primed by using a remote starter switch (see Special Tools (page 2–17)) to crank engine which allows the pumps to prime.
Flush Hydraulic System IMPORTANT Flush the hydraulic system any time there is a severe component failure or the system is contaminated. Contaminated oil may appear milky or black or may contain metal particles. IMPORTANT If a component failure occurred in the closed loop traction circuit (e.g. piston pump or wheel motor), filtering the traction circuit is recommended. See Filtering Closed−Loop Traction Circuit (page 5–89). 1. Park machine on a level surface.
Flush Hydraulic System (continued) 8. Prime hydraulic pumps (see Priming Hydraulic Pumps (page 5–86)). 9. Start engine and let it run at low idle speed for a minimum of two (2) minutes. Increase engine speed to high idle for minimum of one (1) minute under no load. 10. Raise and lower cutting decks several times. Turn steering wheel fully left and right several times. 11. Shut off engine and check for hydraulic oil leaks. Check oil level in hydraulic reservoir and add correct amount of oil if necessary. 12.
Filtering Closed−Loop Traction Circuit Filtering of a closed−loop hydraulic system after a major component failure (e.g. traction (piston) pump or front wheel motor) is a requirement to prevent debris from transmitting throughout the system. If a closed−loop hydraulic system filtering tool is not used to ensure system cleanliness, repeat failures, as well as subsequent damage to other hydraulic components in the affected system, will occur.
Filtering Closed−Loop Traction Circuit (continued) CAUTION All wheels will be off the ground and rotating during this procedure. Make sure machine is well supported so it will not move and accidentally fall to prevent injuring anyone around machine. IMPORTANT While engaging the traction circuit, monitor the high flow hydraulic filter indicator. If the indicator should show red, either reduce traction pedal setting or reduce engine speed to decrease hydraulic flow through the filter. 7.
Charge Hydraulic System Note: When initially starting the hydraulic system with new or rebuilt components such as motors, pumps or lift cylinders, it is important that the hydraulic system be charged properly. Air must be purged from the system to reduce the chance of component damage. IMPORTANT Change hydraulic oil filters whenever hydraulic components are repaired or replaced. 1. Park machine on a level surface. Lower cutting decks, stop engine and apply parking brake.
Charge Hydraulic System (continued) C. Faulty charge relief valve. D. Faulty gear pump. 9. Once the lift cylinder does move in ten (10) to fifteen (15) seconds, proceed to step 10. 10. Operate the traction pedal in the forward and reverse directions. The wheels should rotate in the proper direction. A. If the wheels rotate in the wrong direction, stop engine and check for proper hydraulic hose and electrical connections at traction pump and motors. Correct as needed. B.
Hydraulic Reservoir 26 27 RIGHT 109 to 119 N·m (80 to 88 ft−lb) 30 FRONT 9 8 28 10 11 7 12 6 25 24 13 14 31 3 18 1 19 15 23 16 29 4 17 20 3 2 5 21 22 g275418 Figure 91 1. Hydraulic reservoir 12. Dipstick 23. Plug 2. Cap screw 13. Screen filter 24. Hose clamp 3. Recess bumper (2 used) 14. Tank strainer 25. Suction hose 4. Thin spacer 15. Cap screw 26. Hose clamp (4 used) 5. Flange nut 16. Flat washer 27. Hydraulic hose 6. Breather 17. Thick spacer 28.
Note: The operator platform needs to be raised from the main frame so that the hydraulic reservoir can be removed from the machine (see Operator Platform (page 8–28)). Removal (Figure 91) 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 (page 5–83). 3. Drain reservoir into a suitable container.
Installation (Figure 91) (continued) 1 3 FRONT 2 4 g275419 Figure 92 1. Hydraulic reservoir 3. Flat washer 2. Cap screw 4. Tank mount 2. Slide tank mount assembly (items 15, 16, 3, 17, 18 and 19) between frame and hydraulic reservoir and position bumper into slot on left side of reservoir. Align tank mount with hole in frame. Secure mount with cap screw and flat washer (Figure 92). 3. Install tank strainer into reservoir port and torque from 109 to 119 N·m (80 to 88 ft−lb). 4.
Radiator and Oil Cooler Assembly 31 30 27 28 26 3 25 32 33 2 24 23 4 6 1 29 3 21 5 34 9 7 8 22 3 20 10 35 16 11 19 Thread Sealant 12 18 13 17 36 RIGHT 9 4 14 FRONT 15 12 3 g275420 Figure 93 1. LH radiator support 13. Cap screw (2 used) 25. Air cleaner inlet hose 2. Cap screw (2 used) 14. Hose 26. Radiator/hydraulic oil cooler 3. Flange nut (12 used) 15. Coolant reservoir 27. Bulb seal 4. Hose clamp (3 used) 16. Tank mount 28. RH radiator support 5.
Gear Pump g275421 Figure 94 (For machines serial number below: 400000000) 1. Hose clamp (3 used) 10. Gear pump 19. 90º hydraulic fitting 2. Hose clamp (2 used) 11. O−ring 20. Test nipple (2 used) 3. Hydraulic hose 12. Hydraulic fitting 21. Straight hydraulic fitting (2 used) 4. Suction hose 13. 45º hydraulic fitting 22. Straight hydraulic fitting 5. Tee fitting 14. Hydraulic tee fitting (2 used) 23. 90º hydraulic fitting 6. Straight hydraulic fitting 15.
RIGHT 24 FRONT 15 20 13 20 19 18 26 1 23 9 6 11 16 14 10 9 8 17 15 25 27 21 12 2 4 5 1 3 1 7 2 g278628 Figure 95 (For machines serial number above: 400000000) 1. Hose clamp (3 used) 10. Gear pump 19. 90º hydraulic fitting 2. Hose clamp (2 used) 11. O−ring 20. Test nipple (2 used) 3. Hydraulic hose 12. Hydraulic fitting 21. Straight hydraulic fitting (2 used) 4. Suction hose 13. 45º hydraulic fitting 22. Straight hydraulic fitting 5. Tee fitting 14.
Removal (Figure 94 and Figure 95) (continued) 2. Raise and support machine to gain access to gear pump from the underside of the machine. 3. Drain the hydraulic reservoir. IMPORTANT Follow all local codes and regulations when recycling or disposing hydraulic fluid. 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 (page 5–83). 6.
Installation (Figure 94 and Figure 95) 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 Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–10)). 2. Make sure mounting and O−ring sealing surfaces on the gear pump and piston pump are clean. 3. Apply clean hydraulic oil to gear pump flange O−ring (item 11).
Installation (Figure 94 and Figure 95) (continued) 8. Fill piston pump housing through case drain (90º barbed fitting) with new hydraulic oil (Figure 97). This will ensure that internal pump components have adequate lubrication during initial operation. 9. Lower machine to ground. 10. Replace hydraulic filters and fill hydraulic reservoir with new hydraulic oil. 11. Prime hydraulic pumps (see Priming Hydraulic Pumps (page 5–86)). 12. Properly fill hydraulic system (see Charge Hydraulic System (page 5–91)).
Gear Pump Service 11 16 15 13 9 7 3 2 5 18 14 12 10 17 21 8 6 4 24 25 1 23 22 20 45 N·m (33 ft−lb) 19 g275424 Figure 98 1. Front cover 10. Thrust plate (7 used) 19. Body 2. Dowel pin (4 used) 11. Dowel pin (6 used) 20. Idler gear 3. Pressure seal 12. Splined connecting shaft (3 used) 21. Drive gear 4. Back−up gasket 13. Flange (3 used) 22. Rear body 5. Front thrust plate 14. Back−up gasket 23. Rear cover 6. Seal (8 used) 15. Pressure seal 24.
Disassembly (Figure 98) (continued) DIAGONAL LINE g275425 Figure 99 2. Use a marker to make a diagonal line across the gear pump for assembly purposes (Figure 99). IMPORTANT Use caution when clamping gear pump in a vise to avoid distorting any pump components. 3. Secure the front cover of the pump in a vise with the drive shaft pointing down. 4. Loosen the four (4) cap screws that secure pump assembly. 5. Remove pump from vise and remove fasteners. 6.
Assembly (Figure 98) 1 2 3 4 g275426 Figure 100 1. LH and RH PTO pump section 3. 2. Front PTO pump section 4. Cooling fan, lift/lower and charge pump section Steering, charge and cooling fan pump section 1. Apply clean hydraulic oil to all parts before assembling. Note: Pressure seals and back−up gaskets fit in grooves machined into thrust plates. Body seals fit in grooves machined in body faces. 2. Assemble pump sections starting at front cover end.
Piston (Traction) Pump g275427 Figure 101 (For machines serial number below: 400000000) 1. Hose clamp (3 used) 10. Gear pump 19. 90º hydraulic fitting 2. Hose clamp (2 used) 11. O−ring 20. Test nipple (2 used) 3. Hydraulic hose 12. Hydraulic fitting 21. Straight hydraulic fitting (2 used) 4. Suction hose 13. 45º hydraulic fitting 22. Straight hydraulic fitting 5. Tee fitting 14. Hydraulic tee fitting (2 used) 23. 90º hydraulic fitting 6. Straight hydraulic fitting 15.
RIGHT 24 FRONT 15 20 13 20 19 18 26 1 23 9 6 11 16 14 10 9 8 17 15 25 27 21 12 2 4 5 1 3 1 7 2 g278628 Figure 102 (For machines serial number above: 400000000) 1. Hose clamp (3 used) 10. Gear pump 19. 90º hydraulic fitting 2. Hose clamp (2 used) 11. O−ring 20. Test nipple (2 used) 3. Hydraulic hose 12. Hydraulic fitting 21. Straight hydraulic fitting (2 used) 4. Suction hose 13. 45º hydraulic fitting 22. Straight hydraulic fitting 5. Tee fitting 14.
Removal (Figure 101 and Figure 102) 2 3 1 FRONT g275428 Figure 103 1. Piston pump 2. Solenoid coil (forward) 3. Solenoid coil (reverse) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. To prevent contamination of hydraulic system during removal, thoroughly clean exterior of pump assembly. 3. Raise and support machine to gain access to pump assembly from the underside of machine. 4.
Removal (Figure 101 and Figure 102) (continued) To prevent draining the pumps, install plugs in piston pump case drain and gear pump suction port after gear pump is removed. Remove plugs before installing gear pump to piston pump 1 2 g275429 Figure 104 1. Piston pump case drain 2. Gear pump suction port 8. Remove gear pump from machine (see Gear Pump (page 5–97)). IMPORTANT Dry weight of piston (traction) pump is 90 pounds (41 kg).
Installation (Figure 101 and Figure 102) (continued) 2. Carefully raise piston pump into the machine, align pump input shaft to spring coupler on engine and position it to the engine flywheel plate. Support pump to prevent it from producing any side load into coupler and also to align pilot diameter of pump to flywheel plate bore. 3. While maintaining pump alignment with spring coupler and flywheel plate, install two (2) cap screws and washers to secure piston pump to engine.
Installation (Figure 101 and Figure 102) (continued) IMPORTANT Refer to Traction Circuit Component Failure in the General Information section of this chapter for information regarding the importance of removing contamination from the traction circuit. 11. Prime hydraulic pumps (see Priming Hydraulic Pumps (page 5–86)). 12. Properly fill hydraulic system (see Charge Hydraulic System (page 5–91)). 13. Stop engine and check for hydraulic oil leaks. Check hydraulic reservoir oil level.
Piston (Traction) Pump Service (For machines serial number below: 400000000) 51 43 52 42 45 53 41 42 46 44 45 46 47 48 42 55 42 41 39 49 37 50 34 7 35 3 2 8 30 44 36 33 15 13 40 38 1 14 25 3 34 7 29 2 31 6 33 32 29 25 10 54 10 10 24 28 4 23 16 11 5 18 17 27 26 20 12 21 19 22 9 10 g275431 Figure 106 Groundsmaster® 4000-D & 4010-D 13202SL Rev F Page 5–111 Hydraulic System: Service and Repairs
Piston (Traction) Pump Service (For machines serial number below: 400000000) (continued) Figure 106 (continued) 1. Screen (2 used) 20. Bearing 39. Seal carrier 2. Plug with O−ring (2 used) 21. Screw (4 used) 40. Retaining ring 3. Plug with O−ring (2 used) 22. Thrust plate 41. Coil nut (2 used) 4. Cylinder block assembly 23. Forward relief valve assembly 42. O−ring 5. Valve plate 24. Reverse relief valve assembly 43. Forward solenoid coil 6. Servo piston 25.
Piston (Traction) Pump Service (For machines serial number above: 400000000) g278631 Figure 107 1. Control kit (12 volt) 13. O-ring 25. Plug asm 2. Coil kit 14. Screw 26. O-ring 3. Charge relief kit 15. Plug asm 27. O-ring 4. 16. Nut-seal 28. Plug 5. Shaft 17. Screw 29. Plug 6. Bearing-ball 18. Gasket-control 30. Plug-thread, straight 7. Ring-retaining 19. Ring-locking 31. Screw 8. Ring-retaining 20. Screen 32. Pin-slotted 9. Seal-lip 21. Screw 33.
Rear Axle Motor 2 1 9 12 11 3 13 4 7 18 8 19 6 10 14 5 15 16 17 12.3 to 14.9 N·m (9 to 11 ft−lb) 20 21 RIGHT FRONT g275432 Figure 108 1. Rear axle motor 2. 90º hydraulic fitting (2 used) 3. 90º hydraulic fitting 4. 5. 8. Flat washer (2 used) 15. Dowel pin (2 used) 9. O−ring 16. Gasket 10. External snap ring (2 used) 17. External snap ring (2 used) Straight hydraulic fitting 11. Pinion gear (27T) 18. Gear (45T) 90º hydraulic fitting 12. Cap screw (6 used) 19.
Removal (Figure 108) (continued) Note: To ease installation, label the hydraulic lines to show their correct position on the axle motor. 6. Disconnect hydraulic lines from motor. Put caps or plugs on motor fittings and hydraulic line openings to prevent contamination. IMPORTANT Before loosening fasteners that secure rear axle motor, support motor to prevent it from falling during removal. 7. Remove motor from rear axle using Figure 108 as a guide. 8.
Front Wheel Motors 4 1 15 13 3 8 5 11 12 7 6 14 1 13 8 2 10 6 RIGHT 7 FRONT 9 g275433 Figure 109 1. Front wheel motor 6. Cap screw (2 used per motor) 11. 90º hydraulic fitting (2 used) 2. Internal retaining ring 7. Flat washer (2 used per motor) 12. Hydraulic connector 3. Splined brake shaft 8. O−ring 13. Hydraulic tee fitting (2 used) 9. LH brake assembly 14. 90º hydraulic fitting 10. Hydraulic tee fitting 15. Straight hydraulic fitting 4. RH brake assembly 5.
Removal (Figure 109) (continued) IMPORTANT Before loosening fasteners that secure wheel motor, support motor to prevent it from falling during removal. 5. Remove wheel motor using Figure 109 as a guide. 6. If hydraulic fittings are to be removed from wheel motor, mark fitting orientation to allow correct assembly. Remove fittings from motor and discard O−rings.
Rear Axle and Front Wheel Motor Service 1 2 3 4 5 6 8 7 9 10 12 13 11 14 16 24 15 25 17 16 20 21 22 23 21 18 19 g275434 Figure 110 1. Plug with O−ring 10. Dowel pin 19. Bearing 2. Minimum angle stop 11. Bearing 20. Retaining ring 3. Bias spring 12. Gasket 21. Retaining ring (2 used) 4. Servo piston 13. Valve plate 22. Seal 5. O−ring 14. Cylinder block kit 23. Support washer 6. O−ring 15. Swashplate 24. Plug with O−ring (2 used) 7.
Rear Axle and Front Wheel Motor Service (continued) REAR AXLE MOTOR FLUSHING VALVE 3 10 1 2 5 4 4 3 9 8 2 1 7 6 g275435 Figure 111 1. Plug 6. Plug 2. O−ring 7. O−ring 3. Centering spring 8. Centering spring 9. Orifice poppet 4. Spring retaining washer 5. Shift spool 10. Endcap Note: The front wheel motors on your Groundsmaster are identical (Figure 110).
Rear Traction Manifold 2 3 1 14 11 9 10 8 7 12 13 5 15 16 18 17 4 RIGHT FRONT 6 g275436 Figure 112 1. Front frame 7. 90º hydraulic fitting 13. O−ring 2. PTO manifold (center deck) 8. O−ring 14. O−ring 3. Front traction manifold 9. 45º hydraulic fitting 15. 45º hydraulic fitting 4. Rear traction manifold 10. O−ring 16. O−ring 5. Cap screw (2 used) 11. O−ring 17. O−ring 6. Flange nut (2 used) 12. Straight fitting 18.
Installation (Figure 112) 1. If fittings were removed from manifold, lubricate and place new O−rings onto fittings. Install fittings into manifold openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (page 5–8)). 2. Install hydraulic manifold to the frame using Figure 112 as a guide. 3. Remove caps and plugs from fittings and hydraulic lines.
Rear Traction Manifold Service 34 N·m (25 ft−lb) 3 2 67 N·m (50 ft−lb) 27 N·m (20 ft−lb) 4 1 7 156 N·m (115 ft−lb) 34 N·m (25 ft−lb) 5 6 g275437 Figure 113 1. Rear traction manifold body 4. #4 zero leak plug with O−ring 2. Relief valve (port RV) 5. #6 zero leak plug with O−ring 3. Pressure reducing valve (port PR) 6. Check valve (port CV) 7. Orifice (0.050) (port OR1) Note: The ports on the rear traction manifold are marked for easy identification of components.
Front Traction Manifold 2 9 10 5 11 8 7 12 4 11 1 16 15 13 14 19 17 18 3 6 RIGHT FRONT g275438 Figure 114 1. Front frame 8. Check fitting 15. Check adapter 2. PTO manifold (center deck) 9. O−ring 16. O−ring 3. Rear traction manifold 10. Hydraulic straight fitting 17. O−ring 4. Front traction manifold 11. O−ring 18. 45º hydraulic elbow 5. Cap screw (2 used) 12. 90º hydraulic elbow 19. O−ring 6. Flange nut (2 used) 13. O−ring 7. O−ring 14.
Removal (Figure 114) (continued) 4. Remove front traction manifold from the frame using Figure 114 as a guide. 5. If hydraulic fittings are to be removed from manifold, mark fitting orientation to allow correct assembly. Remove fittings from manifold and discard O−rings. Installation (Figure 114) 1. If fittings were removed from manifold, lubricate and place new O−rings onto fittings. Install fittings into manifold openings using marks made during the removal process to properly orientate fittings.
Front Traction Manifold Service 2 6 34 N·m (25 ft−lb) 4 27 N·m (20 ft−lb) 162 N−m (120 ft−lb) 1 UP 6 34 N·m (25 ft−lb) UP 34 N·m (25 ft−lb) 27 N·m (20 ft−lb) 2 6 34 N·m (25 ft−lb) 5 3 7 27 N·m (20 ft−lb) g275439 Figure 115 1. Flow divider valve (port HFD) 4. Front traction manifold 2. SAE #4 plug with O−ring 5. Check valve (ports CV1 and CV2) 3. Orifice (0.063) (port OR) 6. SAE #6 plug with O−ring 7.
Front Traction Manifold Service (Figure 115) (continued) IMPORTANT A flow control orifice is located beneath the plug in the front traction manifold port OR. If the orifice is removed from the manifold port, make sure to label its position for assembly purposes. When installing the orifice in the manifold, make sure that the orifice is properly tightened in the port.
Combination Manifold 5 1 RIGHT 4 FRONT 3 2 g275440 Figure 116 1. Combination manifold 3. Flat washer (3 used) 2. Flange nut (3 used) 4. Mount (3 used) 5. Spacer (3 used) Note: The ports on the combination manifold are marked for easy identification of components.
Removal (Figure 116) (continued) 14 2 1 13 2 11 12 2 2 3 4 10 7 6 9 8 5 g275441 Figure 117 1. Manifold 8. Straight fitting 2. 3. Straight fitting 9. Barbed 90º fitting Straight fitting 10. Hose clamp Hose 4. Straight fitting 11. 5. Oil filter 12. 90º fitting 6. Straight fitting 13. Test nipple 7. Straight fitting 14. Straight fitting 6. If hydraulic fittings are to be removed from manifold, mark fitting orientation to allow correct assembly (Figure 117).
Combination Manifold Service FRONT 27 N·m (20 ft−lb) 34 N·m (25 ft−lb) 27 N·m (20 ft−lb) UP 34 N·m (25 ft−lb) 34 N·m (25 ft−lb) 27 N·m (20 ft−lb) 12 13 27 N·m (20 ft−lb) 11 10 34 N·m (25 ft−lb) 9 14 8 15 8 27 N·m (20 ft−lb) 27 N·m (20 ft−lb) 16 5 34 N·m (25 ft−lb) 27 N·m (20 ft−lb) 7 17 18 2 6 19 5 27 N·m (20 ft−lb) 18 4 2 20 21 2 17 17 34 N·m (25 ft−lb) 22 2 3 4 34 N·m (25 ft−lb) 27 N·m (20 ft−lb) 2 1 5 27 N·m (20 ft−lb) g275442 Figure 118 1.
WARNING If combination manifold is attached to machine, make sure that cutting units are fully lowered before loosening hydraulic lines or cartridge valves from combination manifold. If cutting units are raised as components are loosened in manifold, cutting units may drop unexpectedly. Note: The combination manifold uses several zero leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening.
Combination Manifold Service (continued) 27 to 35 N·m (20 to 26 ft−lb) 12 to 14 N·m (9 to 11 ft−lb) 1 2 1 1 g275444 Figure 120 1. #6 hex head plug 2. #4 hex head plug For combination manifold cartridge valve service procedures, see Control Manifold Cartridge Valve Service (page 5–131). Refer to Figure 118, Figure 119 and Figure 120 for combination manifold cartridge valve and plug installation torque.
Control Manifold Cartridge Valve Service (continued) IMPORTANT Use care when handling the cartridge valve. Slight bending or distortion of the stem tube can cause binding and malfunction. When removing cartridge valve from manifold, make sure that deep well socket fully engages the valve base. 3. Remove cartridge valve from manifold using a deep socket wrench. Note correct location for O−rings, sealing rings and backup rings. Remove seal kit from cartridge valve and discard removed seals. 4.
Control Manifold Cartridge Valve Service (continued) 9. If problems still exist after assembly, remove valve and clean again or replace valve.
Steering Control Valve (For machines serial number below: 400000000) 1 2 3 6 28 to 35 N·m (20 to 26 ft−lb) 4 7 37 to 44 N·m (27 to 33 ft−lb) 5 8 10 9 17 11 19 18 10 20 12 13 14 7 15 RIGHT FRONT 16 g275445 Figure 121 1. Steering wheel cover 8. Steering shaft 15. Valve mount plate 2. Hex nut 9. Flange bushing 16. Steering control valve 3. Flat washer 10. Thrust washer (as needed) 17. Steering tower 4. Steering wheel 11. Cap screw (4 used) 18. Cap screw (2 used) 5.
Removal (Figure 121) (continued) Note: To ease installation, label the hydraulic lines to show their correct position on the steering control valve. 5. Remove hydraulic lines from steering control valve. 6. Remove steering control valve from machine using Figure 121 as a guide. 1 5 3 2 4 3 g275446 Figure 122 1. Steering control valve 4. 45º hydraulic fitting 2. 45º hydraulic fitting 5. Straight fitting 3. Straight fitting (2 used) 2 1 3 2 7 4 5 6 2 3 2 8 7 g275447 Figure 123 1.
Installation (Figure 121) 1. If fittings were removed from steering control valve, lubricate and place new O−rings onto fittings. Install fittings into port openings using marks made during the removal process to properly orientate fittings (Figure 122 and Figure 123). Tighten fittings (see Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–10)). 2. Install steering control valve using Figure 121 as a guide. 3.
Steering Control Valve (For machines serial number above: 400000000) g278210 Figure 124 1. Steering wheel cover 13. Carriage bolt (6 each) 25. Nut (2 each) 2. Hex nut 14. Nut (4 each) 26. Shoulder bolt (2 each) 3. Flat washer 15. Steering control valve 27. Brake link 4. Steering wheel 16. Lock washer (2 each) 28. Brake rod 5. Foam collar 17. Bolt (2 each) 29. Extension spring 6. Steering shaft 18. Switch nut 30. Brake plate 7. Bolt (4 each) 19. Switch 31.
Removal (Figure 124) 1. Park the machine on the level surface, lower cutting decks, stop engine, apply parking brake and remove the key from the ignition switch. 2. Remove the steering cover to allow access to the steering control valve. 3. Support the steering tower to prevent it from falling. 4. Read the General Precautions for Removing and Installing Hydraulic System Components (page 5–83). 5.
Removal (Figure 124) (continued) g278284 Figure 126 1. Steering control valve 6. O-ring 2. O-ring 7. 90º hydraulic fitting 3. Straight fitting 8. O-ring 4. O-ring 9. 5. O-ring 10. 45º hydraulic fitting O-ring Installation (Figure 124) 1. If the hydraulic fitting were removed from the steering valve, lubricate new O-ring with clean hydraulic fluid, position the O-rings to the fittings.
Steering Control Valve Service (For machines serial number below: 400000000) 18 8 17 11 7 5 16 3 19 1 6 9 4 2 20 10 15 21 12 13 14 23 16 to 18 N·m (140 to 160 in−lb) 17 N·m (150 in−lb) 22 g275448 Figure 127 1. Steering valve housing 9. Cap screw (7 used) 17. Geroter drive 2. Dust seal 10. End cap 18. Wear plate 3. O−ring 11. O−ring 19. Bearing race 4. Spool 12. Seal ring 20. Thrust bearing 5. Spring retaining ring 13. O−ring 21. Plug 6. Pin 14.
Steering Control Valve Service (For machines serial number above: 400000000) g278299 Figure 128 1. Pin bolt 2. Bolt (4 each) Distributor plate 17. Shaft seal 10. 3. 4. 9. Cardan shaft 18. Thrust washer (2 each) Washer (5 each) 11. Plug 19. Bearing End cover 12. Plug 20. Ring 5. Tube (2 each) 13. Spring 21. Spring set 6. Inner gearwheel 14. Relief valve 22. Spool 7. O-ring (3 each) 15. Dust sealing ring 23. Cross pin 8. Outer gearwheel 16. Housing 24.
Steering Cylinder 7 6 4 5 3 4 8 1 2 10 13 RIGHT 9 FRONT 12 11 108 to 113 N·m (79 to 84 ft−lb) g275449 Figure 129 1. Steering cylinder 6. Grease fitting 11. Slotted hex nut (2 used) 2. Ball joint 7. 90º hydraulic fitting (2 used) 12. Cotter pin (2 used) 3. Ball joint 8. Drive axle assembly 13. Bulkhead mount plate 4. Retaining ring (2 used) 9. Ball joint spacer 5. Grease fitting 10. Axle washer Removal (Figure 129) 1.
Removal (Figure 129) (continued) 4 3 1 2 5 g275450 Figure 130 1. Steering cylinder 4. 90º hydraulic fitting 2. Hydraulic hose 5. Bulkhead mount plate 3. Hydraulic hose 4. Remove hydraulic hoses from steering cylinder (Figure 130). 5. Remove cotter pins, slotted hex nuts, axle washer and ball joint spacer from the threaded ends of ball joints. Remove steering cylinder with ball joints from machine. 6.
Steering Cylinder Service 6 9 8 7 3 1 2 5 4 12 10 11 54 N·m (40 ft−lb) 1 8 9 2 10 12 3 11 4 7 6 5 g275451 Figure 131 1. 2. Barrel Rod 5. 6. Internal collar Backup ring 9. 10. Rod seal O−ring 3. Piston 7. 4. Head 8. O−ring 11. Piston seal Dust seal 12. Lock nut Disassembly (Figure 131) 1. Pump oil out of steering cylinder into a drain pan by slowly moving rod in and out of cylinder bore. After oil has been removed from cylinder, plug ports and clean outside of cylinder.
Disassembly (Figure 131) (continued) 4. Grasp end of rod and use a twisting and pulling motion to carefully extract rod, piston and head assembly from cylinder barrel. IMPORTANT Do not clamp vise jaws against rod surface; the rod will be damaged. 5. Securely mount rod, piston and head assembly into vise with soft jaws. 6. Remove lock nut and then piston from the rod. Slide head and then internal collar off the rod. 7. Remove and discard all seals and O−rings from the piston and the head.
Assembly (Figure 131) (continued) 10. Secure head in barrel by using a spanner wrench to install and tighten internal collar (item 5) into barrel.
Engine Cooling Fan Motor 6 26 RIGHT FRONT 16 15 1 27 17 to 18 N·m (12 to 14 ft−lb) 14 17 8 18 9 4 12 20 11 2 19 5 10 7 3 5 19 23 13 24 21 25 28 22 24 29 5 30 g275452 Figure 132 1. Hydraulic fan motor 11. Cap screw (4 used) 21. Hydraulic tube 2. O−ring 12. Washer (4 used) 22. Hydraulic tube 3. Fan bracket 13. Fan 23. Support shim 4. Hydraulic fitting (2 used) 14. Lock nut (2 used) 24. Bulkhead nut (2 used) Bulkhead nut 5. O−ring 15.
Removal (Figure 132) (continued) CAUTION The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool before removing fan motor. 3. Read the General Precautions for Removing and Installing Hydraulic System Components (page 5–83). 4. Thoroughly clean three (3) hydraulic tubes at lower radiator shroud. Disconnect hydraulic tubes and put caps or plugs on tubes to prevent contamination. Label disconnected hydraulic tubes for proper installation.
Removal (Figure 132) (continued) IMPORTANT Make sure to not damage the radiator or other machine components while loosening and removing the fan motor and bracket assembly. 8. Remove cooling fan motor and bracket assembly. A. To prevent contamination of hydraulic system, thoroughly clean exterior of fan motor and fittings. B. Disconnect three (3) hydraulic tubes from fan motor. Put caps or plugs on fittings and tubes to prevent contamination. Label hydraulic lines for proper assembly. C.
Installation (Figure 132) (continued) 10. Connect three (3) hydraulic tubes at lower radiator shroud (see Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (page 5–8)). 11. Lower and secure hood. 12. Make sure hydraulic tank is full. 13. Properly fill hydraulic system (see Charge Hydraulic System (page 5–91)).
Engine Cooling Fan Motor Service g275454 Figure 134 1. Flange washer 7. Shaft seal 13. 2. O−ring 8. Backup gasket 14. Dowel (2 used) 9. Pressure seal 15. Drive gear 16. Washer (4 used) 3. Front flange 4. Dust seal 10. Rear wear plate 5. Retaining ring 11. Body 6. Front wear plate 12. Idler gear Cap screw (4 used) Note: Internal components for a cooling fan motor are not available separately. Disassemble motor for cleaning, inspection and seal replacement only.
Disassembly (Figure 134) (continued) IMPORTANT Prevent damage when clamping the fan motor in a vise; clamp on the front flange only. Also, use a vise with soft jaws. 3. Clamp front flange of motor in a vise with soft jaws with the shaft end down. 4. Loosen cap screws from the rear of the body. 5. Remove motor from the vise. Turn motor so that the shaft end is facing down. Remove cap screws. 6. Carefully remove body. Lift body straight up to remove.
Inspection 1. Remove any nicks and burrs from all parts with emery cloth. CAUTION Use eye protection such as goggles when using compressed air. 2. Clean all parts with solvent. Dry all parts with compressed air. 3 4 1 2 2 4 3 g275457 Figure 137 1. Gear shaft spline 3. Gear teeth 2. Gear shaft 4. Gear face edge 3. Inspect drive gears and idler gears for the following (Figure 137): A. Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas.
Assembly (Figure 134) (continued) C. Install new dust seal into front flange. 3. Place front flange, seal side down, on a flat surface. 4. Install the pressure seals, flat side outward, into the grooves in the wear plates. Follow by carefully placing the backup gaskets, flat side outward, between the pressure seals and the grooves in the wear plate. 5. Apply a light coating of petroleum jelly to the exposed side of the front flange. 6. Lubricate the drive gear shaft with clean hydraulic oil.
Cutting Deck Motors 2 1 37 to 44 N·m (27 to 33 ft−lb) 5 6 4 7 3 g275458 Figure 138 1. Cutting deck motor 5. Spider hub 2. Flange screw (2 used) 6. Woodruff key 3. Nut 7. Spider 4. Tab washer Removal 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components (page 5–83). 3. Thoroughly clean exterior of deck motor and fittings.
Removal (continued) 6 2 5 7 1 3 4 8 9 10 g275459 Figure 139 1. Motor (center deck) 6. Hydraulic fitting 2. O−ring 7. O−ring 3. Hydraulic fitting 8. O−ring 4. O−ring 9. 5. O−ring 10. Hydraulic fitting O−ring 7. If hydraulic fittings are to be removed from motor, mark fitting orientation to allow correct assembly. Remove fittings from motor and discard O−rings (Figure 139). Installation 1. If fittings were removed from motor, lubricate and place new O−rings onto fittings.
Cutting Deck Motor Service (Sauer−Danfoss) 9 15 10 12 10 13 15 9 14 1 8 7 45 to 55 N·m (33 to 40 ft−lb) 2 15 6 11 5 8 4 3 g275460 Figure 140 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. Woodruff key 9. Back−up ring 14. Front flange 5. Nut O−ring 15. Dowel pin 10. Note: Internal components for a cutting deck motor are not available separately.
Disassembly (Figure 140) (continued) DIAGONAL MARK g275461 Figure 141 5. Take motor from the vise and remove cap screws. 6. Remove front flange from the body, then remove rear cover. Locate and remove dowel pins from body. IMPORTANT Mark the relative positions of the gear teeth and the bearing blocks so they can be reassembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. 1 2 g275462 Figure 142 1.
Disassembly (Figure 140) (continued) g275463 Figure 143 7. Place the motor on its side and push on the rear bearing block to remove the bearing block and gear set (Figure 142). 8. Carefully remove and discard O−rings, pressure seals and back−up rings (Figure 143) from motor. Do not cause any damage to the machined grooves during the removal process. IMPORTANT Make sure not to damage the counter bore when removing the shaft seal from the front plate. 9. Position front flange with seal side up.
Inspection (continued) 1 2 3 3 g275464 Figure 144 1. Drive gear 2. Idler gear 3. Bearing block 3. Inspect drive gear, idler gear and bearing blocks (Figure 144) for the following: A. Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas. Scoring, rough surfaces or wear on gear shafts indicates need for replacement. B. Gear teeth should be free of excessive scoring and wear. Any broken or nicked gear teeth must be replaced. C.
Assembly (Figure 140) (continued) 6. Position the motor body on its side. Carefully slide bearing block and gear assembly into the body cavity using identification marks made during disassembly. 7. Remove any excess lubrication from mating surfaces of body, rear cover and front flange. Make sure that these surfaces are clean and dry. 8. Install dowel pins in body. IMPORTANT Do not dislodge O−rings, pressure seals or back−up rings during final assembly. 9.
Cutting Deck Motor Service (Casappa) 17 2 14 11 9 10 15 6 3 7 1 16 13 14 2 8 45 to 55 N·m (33 to 40 ft−lb) 12 8 5 9 4 g275465 Figure 145 1. Flange washer 7. Shaft seal 13. 2. O−ring 8. Backup gasket 14. Dowel (4 used) 3. Front flange 9. Pressure seal 15. Drive gear Cap screw (4 used) 4. Dust seal 10. Rear wear plate 16. Washer (4 used) 5. Retaining ring 11. Body 17. Rear cover 6. Front wear plate 12.
Cutting Deck Motor Service (Casappa) (continued) 1 2 3 4 g275406 Figure 146 1. Dust seal 3. Flange washer 2. Retaining ring 4. Shaft seal Note: Internal components for a cutting deck motor are not available separately. Disassemble motor for cleaning, inspection and seal replacement only.
PTO Manifold 8 18 4 18 4 12 2 16 7 17 20 6 9 7 18 4 1 13 13 5 11 10 2 4 12 4 19 6 8 7 10 18 8 7 14 6 7 9 13 RIGHT 4 8 2 3 FRONT 12 7 15 8 g275407 Figure 147 1. Hydraulic PTO manifold (center deck) 8. 2. Quick fitting (1 used per manifold) 9. 3. Flange screw (2 used per manifold) 10. O−ring 15. 90º hydraulic fitting Hydraulic adapter 16. Hydraulic PTO manifold (RH deck) Straight fitting 17. Hex head plug 4. O−ring 11. Flange screw (2 used per manifold) 18.
Removal (Figure 147) (continued) 2. To prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of PTO manifold and fittings. 3. Disconnect wire harness connector from the proportional relief valve coil on the PTO manifold. 4. Disconnect hydraulic lines from manifold and put caps or plugs on open hydraulic lines and fittings. Label disconnected hydraulic lines for proper installation. 2 1 3 g275408 Figure 148 1. RH PTO manifold 2. Controller mount 3.
Installation (Figure 147) (continued) 5. Make sure hydraulic tank is full. Add correct oil if necessary before returning machine to service.
PTO Manifold Service 27 N·m (20 ft−lb) 5 10 34 N·m (25 ft−lb) 47 N·m (35 ft−lb) 9 27 N·m (20 ft−lb) 1 6 7 3 8 27 N·m (20 ft−lb) 6.7 N·m (5 ft−lb) 2 34 N·m (25 ft−lb) 4 g275409 Figure 149 1. PTO manifold body 5. Relief valve (port RV1) 9. 2. NWD SAE #4 plug with O−ring 6. Proportional relief valve (port PRV) 10. 3. Orifice (0.025) (port OR) 7. Solenoid coil 4. 6 zero leak plug with O−ring 8.
Note: The PTO manifold assembly includes zero leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening. The zero leak plugs also have an O−ring as a secondary seal. If zero leak plug removal is necessary, lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug: the impact will allow plug removal with less chance of damage to the socket head of the plug. 1 2 g275410 Figure 150 1. 2.
Side Deck Lift Cylinders 5 6 8 7 10 11 9 3 4 2 1 RIGHT FRONT g275411 Figure 151 1. Lift arm assembly (LH shown) 5. Lock nut 2. Shoulder screw 6. Flat washer 10. 90º hydraulic fitting 11. 90º hydraulic fitting 9. 3. Flange nut 7. Cylinder pin 4. Pin assembly 8. Spring pin Lift cylinder Removal (Figure 151) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2.
Removal (Figure 151) (continued) WARNING Make sure that side cutting deck is fully lowered before loosening hydraulic lines from side deck lift cylinder. If deck is not fully lowered as hydraulic lines are loosened, deck may drop unexpectedly. Note: To ease installation, label the hydraulic hoses to show their correct position on the lift cylinder. 4. Disconnect hydraulic hoses from lift cylinder. 5. Remove shoulder screw and flange nut that secure the pin assembly (item 4) to the lift arm.
Center Deck Lift Cylinders 1 6 RIGHT 7 FRONT 6 9 8 10 7 5 3 4 2 11 g275412 Figure 152 1. Front frame 5. Grease fitting 9. Lift cylinder (2 used) 2. Flange head screw 6. Cotter pin (2 used per pin) 10. RH lift arm assembly 11. LH lift arm assembly 3. Flange nut 7. Flat washer (4 used per pin) 4. Pin assembly 8. Clevis pin Removal (Figure 152) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2.
Removal (Figure 152) (continued) 2 3 4 1 g275413 Figure 153 1. Lift cylinder 3. Straight fitting 2. O−ring 4. O−ring 6. Remove one (1) cotter pin and two (2) flat washers from one end of the clevis pin (item 8) that secures barrel end of lift cylinder to front frame. Pull clevis pin from frame and cylinder barrel. 7. Remove lift cylinder from machine. 8. If necessary, remove hydraulic fitting from cylinder and discard O−rings (Figure 153). Installation (Figure 152) 1.
Lift Cylinder Service 1 136 to 162 N·m (100 to 120 ft−lb) 13 12 11 6 2 8 3 10 13 9 16 15 SIDE DECK LIFT CYLINDER 7 5 14 4 g275414 Figure 154 1. Barrel with clevis 7. Back−up ring 13. Grease fitting 2. Retaining ring 8. Head 14. Bushing 3. Shaft with clevis 9. O−ring 15. O−ring 4. Dust seal 10. Wear ring 16. Seal 5. 6. Rod seal O−ring 11. 12. Piston Lock nut 9 6 5 1 7 2 4 8 3 54 N·m (40 ft−lb) 12 11 10 CENTER DECK LIFT CYLINDER g275415 Figure 155 1.
Disassembly (Figure 154 and Figure 155) 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. IMPORTANT Prevent damage when clamping the cylinder in a vise; clamp on the clevis only. 2. Mount lift cylinder securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft jaws is recommended. 3. Loosen head from barrel: A.
Assembly (Figure 154 and Figure 155) (continued) 3. Mount shaft securely in a vise by clamping on the clevis of the shaft. Use of a vise with soft jaws is recommended. A. Coat shaft with clean hydraulic oil. B. Carefully slide head and then piston onto the shaft. Secure piston to shaft with lock nut. C. Torque lock nut to specification in Figure 154 (side deck cylinder) or Figure 155 (center deck cylinder). 4. Remove shaft assembly from vise.
Hydraulic System: Service and Repairs Page 5–176 Groundsmaster® 4000-D & 4010-D 13202SL Rev F
Chapter 6 Electrical System Table of Contents General Information .............................................................................................................................. 6–3 Operator's Manual.............................................................................................................................. 6–3 Toro Electronic Controllers (TEC).......................................................................................................
Resistor Module (Machines with Two−Post ROPS Extension Operator Fan Kit)............................... 6–86 Audio Alarm ..................................................................................................................................... 6–88 Service and Repairs ........................................................................................................................... 6–89 Battery Care...........................................................................................
General Information Operator's Manual The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your Greensmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine. Toro Electronic Controllers (TEC) 3 1 2 g275690 Figure 156 1. Front TEC controller 2. Rear TEC controller 3.
Yanmar Engine Electronic Control Unit (ECU) 2 1 g275700 Figure 157 1. Electronic control unit (model 30603 / 30605 / 30635) 2. Alternator 1 2 g275701 Figure 158 1. Electronic control unit (model 30607 / 30609 / 30636) 2. Alternator The Yanmar engine that powers the Groundsmaster 4000−D and 4010−D uses an electronic control unit (ECU) for engine management and also to communicate with the TEC controllers and the InfoCenter Display on the machine.
Yanmar Engine Electrical Components When servicing or troubleshooting the engine electrical components, use the correct engine service manual and troubleshooting manual. Also, the Yanmar SMARTASSIST− Direct electronic control diagnostics service system is available to support the error diagnosis and maintenance services of engine electrical control devices.
InfoCenter Display g280073 Figure 159 1. InfoCenter display 2. Control arm The InfoCenter Display used on your Groundsmaster is a LCD device that is located on the console. The InfoCenter provides information for the machine operator during machine operation, provides electrical system diagnostic assistance for technicians and allows inputs for adjustable machine settings. Power for the InfoCenter is available when energized by the main power relay (ignition switch in the RUN or START position).
KEY SWITCHED ON AFTER 5 SECONDS AFTER 5 SECONDS MAIN INFORMATION SCREEN % % g280062 Figure 160 Groundsmaster® 4000-D & 4010-D 13202SL Rev F Page 6–7 Electrical System: General Information
Splash Screen 2 T 12.6V 1 95.2 3 6 4 5 g275702 Figure 161 1. Battery voltage 4. Right button 2. Fuel gauge 5. Down button 3. Hour meter 6. Menu/back button 2 3 180 140 o 220 F 12.6V 1 0 RPM 4 7 5 6 g275703 Figure 162 1. Battery voltage 5. Right button 2. Hydraulic oil temperature 6. Down button 3. Fuel gauge 7. Menu/back button 4.
Main Information Screen 4 5 3 170 100 240 L 2 P 1 8 6 7 g275691 Figure 163 1. Parking brake applied 5. Fuel gauge 2. Traction speed 6. Right button 3. Coolant temperature 7. Down button 4. Fault indicator 8. Menu/back button 3 4 2 180 140 220 o 12.6V 2120 1 8 RPM 5 6 7 g275692 Figure 164 1. Battery voltage 5. Engine RPM 2. Hydraulic oil temperature 6. Right button 3. 4. Fault indicator Fuel gauge 7. 8.
Main Information Screen (continued) The main information screens will also display arrows whenever the cutting decks are either raising (up arrows) or lowering (down arrows). If controls are not selected properly to allow certain machine operations, an advisory will be displayed on the InfoCenter Display. Typically, an advisory can be eliminated with a change in controls by the operator. If a machine fault occurs during machine operation, the InfoCenter fault indicator will blink to notify the operator.
Faults Screen 1 Faults #39 −57.3 Ago Clear System Faults 2 5 3 5 4 3 g275694 Figure 166 1. 2. 3. Fault menu Fault items Move to menu items 4. 5. Choose menu item Back button The faults screen (Figure 166) will list all machine electrical faults that have occurred since the faults were last cleared from the InfoCenter. The faults will be identified by a fault number and when the fault occurred.
Service Screen 1 Hours Key On: 92.5 Hours Machine Run: 88.4 Hours PTO On: 63.7 Hours 2 5 3 5 4 3 g275695 Figure 167 1. 2. 3. Service menu Service items Move to menu items 4. 5. Choose menu item Back button The service screen (Figure 167) contains machine operational information including hours and counts. Values listed for these service menu items cannot be changed.
Service Screen (continued) • Fan − Oil identifies the number of times that hydraulic oil temperature caused the engine cooling fan speed to change. • Inlet identifies the temperature of the inlet air into the engine intake system. The protected menu items include the following: • DPF Regeneration provides the necessary procedure for stationary regeneration for the exhaust system DPF (diesel particulate filter) on machines with a Tier 4 engine (models 30607, 30609 and 30636).
Diagnostics Screen (continued) • Center Deck identifies machine requirements to allow the center deck to raise and lower. Inputs indicate the state of the center deck lift/lower switch. Qualifiers include the LOW range speed, seat switch and parking brake position. Identified outputs consist of master, raise and float solenoids. • Right Deck identifies machine requirements to allow the right deck to raise and lower. Inputs indicate the state of the right deck lift/lower switch.
Settings Screen 1 Settings Units: English Language: English LCD Backlight: 40% +/− 2 5 3 5 4 3 g275697 Figure 169 1. Settings menu 4. Change menu item 2. Settings items 5. Back button 3. Move to menu items 7 3 1 Settings Auto Idle: Mow Speed: Trans. Speed: + 2 6 PIN 20s 70 % 70 % − 5 4 6 5 4 g275698 Figure 170 1. 5. Settings menu Decrease setting 2. Settings items 6. Back button 3. Current setting 7. PIN activated 4.
Settings Screen (continued) To allow access to the protected menu items, enter the four (4) digit pin PIN using the center and right InfoCenter buttons. After PIN has been entered, a check mark should be visible above center InfoCenter button. Press center button and the InfoCenter display screen should indicate “PIN” in the upper right hand corner if the correct PIN number was entered. Use back button to return to Settings menu.
About Screen 1 About Model: SN: S/W Rev: 2 30607 313000103 120−6363C 5 3 5 4 3 g275699 Figure 171 1. 2. 3. About menu About items Move to menu items 4. 5. Choose menu item Back button The about screen (Figure 171) identifies the machine model number, serial number and software revisions for the TEC controllers, InfoCenter and engine electronic control unit (if available). The about screen also lists the CAN−bus status.
Adjustments Cutting Deck Position Switch Adjustment Adjustment 4 3 2 1 g275982 Figure 172 1. Front lift arm 3. Sensing plate 2. Position switch 4. Switch LED 3 2 1 4 5 g275983 Figure 173 (For machines serial number below 400000000) 1. Side lift arm (RH shown) 4. Switch LED 2. 3. Position switch Sensing plate 5.
Adjustment (continued) g278112 Figure 174 (For machines serial number above 400000000) 4. 5. 1. 2. Clearance Sensing plate 3. Side lift arm (LH shown) Position switch Switch LED 1. Park machine on a level surface with front cutting deck raised and side cutting decks lowered. Stop engine, engage parking brake and remove key from the ignition switch. 2. There should be from 1.8 to 3.3 mm (0.070 to 0.130 in) clearance between the target surface end of position switch and the sensing plate on lift arm.
Traction Pedal Adjustment 1 3 4 2 5 g275984 Figure 175 1. Traction pedal 4. Hex nut 2. Pedal position sensor 5. Rod end bearing 3. Spring shaft The traction pedal includes a neutral assembly that is used to adjust the traction neutral position (Figure 175). Traction pedal adjustment may be necessary to make sure that traction pedal movement provides the correct full reverse and full forward positions for the traction pedal position sensor.
Traction Pedal Adjustment (continued) B. Voltage in full forward should be from 3.5 to 4.5V (approximate). 5. If voltage range from full reverse to full forward is incorrect, adjustment of the spring shaft and rod end bearing is necessary (Figure 175). A. Remove steering cover to access traction pedal components (see Steering Tower (For machines serial number below: 400000000) (page 8–3)). B. Loosen hex nut that secures rod end bearing in spring shaft. C.
Traction Pedal Position Sensor Calibration 1 2 g275987 Figure 178 1. Traction pedal 2. Pedal position sensor IMPORTANT A properly installed and calibrated traction pedal position sensor is critical to accurate traction system response and for reliable sensor life. Use care when removing, installing and calibrating the traction pedal position sensor. Calibration of the traction pedal position sensor ensures that the TEC controller can identify the traction neutral, forward and reverse positions. 1.
Traction Pedal Position Sensor Calibration (continued) ADVISORY #172 Calibrate Teach Is Engaged g275988 Figure 179 4. Use the InfoCenter Display Service menu (see InfoCenter Display (page 6–6)) to obtain and select the Traction Pedal menu item. The InfoCenter display should indicate that the traction pedal calibration process is engaged (Figure 179). 5. Follow the prompts on the InfoCenter display screen to calibrate the traction pedal position sensor. The calibration steps are listed below: A.
Electrical System Quick Checks Battery Test (Open Circuit) Use a multimeter to measure the voltage between the battery terminals. Set multimeter to the DC volts setting. The battery should be at a temperature of 60º to 100º F (16º to 38º C). The ignition key should be off and all accessories turned off. Connect the positive (+) multimeter lead to the positive battery post and the negative (−) multimeter lead to the negative battery post. The multimeter will display battery voltage.
Check Operation of Interlock Switches CAUTION Do not disconnect safety switches. They are for the operator’s protection. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before operating the machine. Interlock switch operation is described in the Traction Unit Operator’s Manual. Your Groundsmaster is equipped with two (2) Toro Electronic Controllers (TEC) which monitor interlock switch operation.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before checking continuity on the switch). For engine component testing information, see the Yanmar Workshop Manual and Yanmar Troubleshooting Manual. CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected.
Ignition Switch STOP RUN 6 5 4 1 2 3 START REAR VIEW FRONT VIEW g275990 Figure 181 The ignition (key) switch is located on the control panel and has three (3) positions: STOP, RUN and START (Figure 181). The Toro Electronic Controller (TEC) monitors the operation of the ignition switch. Testing 1. Park machine on a level surface, lower cutting decks, engage parking brake and stop engine. Remove key from ignition switch. 2.
Fuses 3 2 1 g275991 Figure 182 1. Fuse block 2. 60 Amp fuse 3. Operator seat FRONT A B C D 1 2 3 4 5 g275992 Figure 183 The fuse block is located under the controller cover next to the operator seat (Figure 182). In addition to the fuses in the fuse block, a 60 Amp fuse is included in the wire harness to protect the power circuit for the operator cab. This fuse resides in a fuse holder near the fuse block (Figure 182).
Fuse Identification and Function (continued) Fuse A−5 (2 Amp) protects telematics circuit (if equipped). Fuse B−1 (7.5 Amp) protects power supply for the outputs of the front TEC controller. Fuse B−2 (7.5 Amp) protects power supply for the outputs of the rear TEC controller. Fuse B−3 (10 Amp) protects power supply to the engine ECU. Fuse B−4 (10 Amp) protects operator air−ride seat circuit. Fuse B−5 (10 Amp) protects beacon circuit (if equipped). Fuse C−1 (7.
Operator Cab Fuses (Groundsmaster 4010−D) 2 1 g275993 Figure 184 1. Cab headliner 2. F1 1 Cab fuse blocks F2 15 A 2 15 A 3 30A 15 A 4 g275994 Figure 185 g275995 Figure 186 The operator cab fuse blocks are located in the cab headliner (Figure 184).
Identification and Function (Figure 184 and Figure 185) for models 30603 and 30607 Fuse F1−1 (15 Amp) protects the cab work lights circuit. 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. Fuse F2−2 (15 Amp) protects the cab dome light circuit. Fuses F1−4, F2−3 and F2−4 are available for optional equipment.
Fusible Link Harness 1 2 g275996 Figure 187 1. 2. Starter motor Fusible link harness P02 TO MAIN HARNESS P01 STARTER B+ FUSIBLE LINK (14 GAUGE) FUSIBLE LINK (16 GAUGE) g275997 Figure 188 Your Groundsmaster uses two (2) fusible links for circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the wire harness (Figure 187). If either of these links should fail, current to the protected circuits will cease.
PTO Switch 1 2 g275998 Figure 189 1. Control arm 2. PTO switch The PTO switch is located on the control arm (Figure 189). The PTO switch is pulled up to engage the PTO and pushed in to disengage the PTO. The TEC controller monitors the position of the PTO switch (up or down). Using inputs from the PTO switch and other switches in the interlock system, the TEC controller controls the energizing of the hydraulic solenoid valves used to drive the cutting deck motors.
Testing (continued) 5. The switch terminals are marked as shown in Figure 190. The circuit logic of the PTO switch is shown in the chart below. With the use of a multimeter (ohms setting), the switch functions can be tested to determine whether continuity exists between the various terminals for each switch position. Verify continuity between switch terminals. Replace PTO switch if testing identifies that switch is faulty.
HI/LOW Speed, Engine Speed and Cutting Deck Lift Switches 4 3 1 2 5 g276000 Figure 191 1. HI/LOW speed switch 4. Center deck lift switch 2. Engine speed switch 5. LH deck lift switch 3. RH deck lift switch The HI/LOW, engine speed and cutting deck lift switches are all identical momentary switches. These switches are located on the control arm (Figure 191). The HI/LOW speed switch is used as an input for the TEC controller to select either the HI (transport) or LOW (mow) traction speed.
Testing (continued) BACK OF SWITCH g276001 Figure 192 5. The switch terminals are marked as shown in Figure 192. The circuit logic of the switch is shown in the chart below. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each position. Verify continuity between switch terminals. Replace switch if testing identifies a faulty switch.
Cruise Control Switch 2 1 g276002 Figure 193 1. Control arm 2. Cruise control switch The cruise control switch is used as an input for the TEC controller to maintain ground speed when engaged. The cruise control function is enabled when the switch is in the ON (center) position. Pressing the front of the switch to the momentary position sets the desired ground speed. The cruise control function is disengaged when the rear of the cruise control switch is depressed.
Testing (continued) 5. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each position. The switch terminals are marked as shown in Figure 194. The circuitry of the cruise control switch is shown in the chart below. Verify continuity between switch terminals.
Seat Switch 2 1 g276004 Figure 195 1. Seat switch electrical connector 2. Operator seat The seat switch is normally open and closes when the operator is on the seat. This switch is used as an input for the TEC controller. The seat switch and its electrical connector are located in the seat assembly. If the traction system or PTO switch is engaged when the operator raises out of the seat, an operator advisory will be displayed on the InfoCenter.
Parking Brake Switch 3.9 to 4.7 N·m (34 to 42 in−lb) 6 1 2 3 4 5 g276005 Figure 196 1. Lock nut 4. Carriage bolt 2. Parking brake switch 5. Parking brake rod 3. Switch plate 6. Steering tower cover The switch used for the parking brake is a normally open proximity switch that is located under the steering tower cover (Figure 196). The parking brake switch is an input for the TEC controller.
Switch Testing (continued) 8. Replace parking brake switch if necessary. 9. Correctly connect the wire harness connector to the parking brake switch after testing is completed. 10. Install front steering tower cover (see Steering Tower (For machines serial number below: 400000000) (page 8–3)). Switch Adjustment With the parking brake not applied (brake rod tab near the switch), there should be a 1.6 mm (0.062 in) gap between the switch and the brake rod tab.
Service Brake Switches 13 to 17 in−lb (1.5 to 1.9 N−m) 3 2 1 5 4 6 7 g276006 Figure 197 1. Flange screw (3 used) 5. Screw (2 per switch) 2. Cover 6. Switch nut (2 used) 3. Switch bracket 7. Clip (3 used) 4. Brake switch (2 used) The two (2) switches used for the service brakes are normally open switches that are located under the footrest panel (Figure 197). The service brake switches provide inputs for the TEC controller.
Adjustment Adjust the service brake switch so that the switch plunger always makes full contact with the brake pedal. Tighten fasteners from 1.5 to 1.9 N·m (13 to 17 in−lb).
Headlight Switch (Groundsmaster 4010−D) 2 1 g276007 Figure 198 1. 2. Control arm Headlight switch The Groundsmaster 4010−D headlight switch is a two (2) position rocker switch that is located on the inside of the control arm. The headlight switch allows the headlights and taillights to be turned on and off. Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 2. Disassemble control arm to gain access to headlight switch (see Control Arm (page 8–22)). 3.
Testing (continued) 6. After testing is completed, connect wire harness connector to the headlight switch. 7. Assemble control arm (see Control Arm (page 8–22)).
Windshield Wiper/Washer Switch (Groundsmaster 4010−D) 2 1 g276009 Figure 200 1. Cab headliner 2. Wiper/washer switch 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/washer switch is located in the cab headliner (Figure 200). Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 2. Remove switch plate from cab headliner. 3.
Testing (continued) 5. If switch tests correctly and circuit problem still exists, check wire harness (see Appendix A (page A–1)). 6. Connect the wire harness connector to the switch after testing. 7. Install switch plate to cab headliner after switch testing is complete.
Air Conditioning Switch (Groundsmaster 4010−D) 2 1 g276011 Figure 202 1. 2. Cab headliner Air conditioning switch 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 (Figure 202). Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 2. Remove switch plate from cab headliner. 3. Locate air conditioning switch and unplug wire harness connector from switch.
Testing (continued) 5. If switch tests correctly and circuit problem still exists, check wire harness (see Appendix A (page A–1)). 6. Connect the wire harness connector to the air conditioning switch after testing. 7. Install switch plate to cab headliner after switch testing is complete.
Turn Signal Switch (Groundsmaster 4010−D) 1 2 g276013 Figure 204 1. 2. Steering column Turn signal switch On Groundsmaster 4010−D machines, the turn signal switch is used as an input for the TEC controller to provide power for the turn signals. The switch is located on the steering tower (Figure 204). Testing 1. Before disconnecting the turn signal switch for testing, the switch and its circuit wiring should be tested as a TEC input with the InfoCenter Display (see InfoCenter Display (page 6–6)).
Testing (continued) SWITCH POSITION CLOSED CIRCUITS OPEN CIRCUITS RIGHT TURN 2 + 3 2 + 1 5 + 6 5 + 4 NEUTRAL NONE ALL LEFT TURN 2 + 1 2 + 3 5 + 4 5 + 6 6. Connect the harness connector to the switch after testing. 7. If switch tests correctly and circuit problem still exists, check wire harness (see Appendix A (page A–1)). 8. Install front steering tower cover (see Steering Tower (For machines serial number below: 400000000) (page 8–3)).
Flasher Switch (Groundsmaster 4010−D) 2 1 g276015 Figure 206 1. 2. Steering column Flasher switch On Groundsmaster 4010−D machines, the flasher switch is used as an input for the TEC controller to provide power for the four way flashers. The switch is located on the steering tower (Figure 206). Testing 1. Before disconnecting the flasher switch for testing, the switch and its circuit wiring should be tested as a TEC input with the InfoCenter Display (see InfoCenter Display (page 6–6)).
Testing (continued) SWITCH POSITION CLOSED CIRCUITS OPEN CIRCUITS ON (LIGHT END DEPRESSED) 2 + 3 2 + 1 5 + 6 5 + 4 OFF 2 + 1 2 + 3 5 + 4 5 + 6 6. Connect the harness connector to the switch after testing. 7. If switch tests correctly and circuit problem still exists, check wire harness (see Appendix A (page A–1)). 8. Install front steering tower cover (see Steering Tower (For machines serial number below: 400000000) (page 8–3)).
Traction Pedal Position Sensor 1 2 g276017 Figure 208 1. Traction pedal 2. Pedal position sensor The traction pedal position sensor is connected to the traction pedal assembly (Figure 208). This position sensor determines the neutral band for the traction pedal, the direction of travel desired by the operator and the traction speed. The position sensor is a single analog, dual digital signal electronic device.
Relays with Four (4) Terminals 4 3 2 1 g276018 Figure 209 1. Main power relay 3. Cab power relay 2. TEC power relay 4. Operator seat Your Groundsmaster uses a number of electrical relays that have four (4) terminals. A tag near the wire harness relay connector can be used to identify each relay. The main power relay is used to provide current to most of the fuse protected circuits (operator seat, InfoCenter display, power point and optional electric equipment).
MODELS 30603, 30605 AND 30635 2 4 1 3 g276019 Figure 210 1. Controller mount 3. Start relay 2. Engine ECU 4. Air heater relay MODELS 30607, 30609 AND 30636 4 2 1 3 g276020 Figure 211 1. Controller mount 3. Start relay 2. Engine ECU 4. Glow relay The main power, TEC power and cab power relays are located under the controller cover next to the operator seat (Figure 209).
Testing (continued) 86 87 30 85 85 30 86 87 g276021 Figure 212 5. Using a multimeter, verify that coil resistance between terminals 86 and 85 is approximately 72 ohms. 6. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as +12 VDC is applied and removed from terminal 85. 7. Disconnect voltage and test leads from the relay terminals. 8.
Relays with Five (5) Terminals MODELS 30603, 30605 AND 30635 2 3 4 1 g276022 Figure 213 1. Controller mount 3. Main relay 2. Engine ECU 4. Rack actuator relay MODELS 30607, 30609 AND 30636 3 2 1 g276023 Figure 214 1. Controller mount 2. Engine ECU 3. EGR relay Your Groundsmaster uses a number of electrical relays that have five (5) terminals. A tag near the wire harness relay connector can be used to identify each relay.
Testing 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. To make sure that machine operation does not occur unexpectedly, disconnect negative (−) cable from battery and then disconnect positive (+) cable from battery (see Battery Service (page 6–91)). 3. Locate relay that is to be tested. 4. Disconnect wire harness connector from relay. Remove relay from mounting bracket for testing.
Toro Electronic Controllers (TEC) 2 3 1 8 10 4 6 7 9 11 5 FRONT g276025 Figure 216 1. Controller cover 7. Carriage screw (8 used) 2. Screw (2 used) 8. Flange nut (8 used) 3. Flat washer (2 used) 9. Front TEC controller 4. Flange screw (2 used) 10. Rear TEC controller 5. Power mount 11. Operator platform 6. Relay mount 3 1 2 g276026 Figure 217 1. Front TEC controller 2. Rear TEC controller 3.
Toro Electronic Controllers (TEC) (continued) attached to the operator platform under the controller cover (Figure 216 and Figure 217). Logic power is provided to the controllers as long as the battery cables are connected to the battery. A pair of 2 Amp fuses (fuse D−1 for the front controller and fuse D−2 for the rear controller) provide circuit protection for this logic power to the controllers.
Toro Electronic Controllers (TEC) (continued) 12V POWER (7.5A FUSES) OUTPUTS (PWR 2) 12V LOGIC POWER (2 AMP FUSE) VOLTAGE OUT IGNITION SWITCH INPUTS OUTPUTS (PWR 3) OUTPUTS (PWR 4) DIGITAL INPUTS (OPEN/ CLOSED) COMM PORT CAN BUS GROUND ANALOG INPUTS (VARIABLE) g276027 Figure 218 The diagram in Figure 218 depicts the connection terminal functions for the TEC controllers.
Toro Electronic Controllers (TEC) (continued) IMPORTANT When testing for wire harness continuity at the connector for the TEC controller, take care to not damage the connector pins with multimeter test leads. If connector pins are enlarged or damaged during testing, connector repair will be necessary for proper machine operation.
Toro Electronic Controllers (TEC) (continued) If the wire harness connector is removed from the TEC controller for any reason, tighten the harness connector screw from 2.8 to 3.2 N·m (25 to 28 in-lb).
Hydraulic Solenoid Valve Coils 2 4 1 RIGHT FRONT 3 g276029 Figure 221 1. 2. Front PTO manifold RH PTO manifold 3. 4. LH PTO manifold Combination manifold Several hydraulic solenoid valve coils are used on the hydraulic control manifolds of Groundsmaster 4000−D and 4010−D machines. When energized by the TEC controller, these coils provide hydraulic circuit control. Solenoid valve coils with two (2) different resistance specifications are used on the 4000−D and 4010−D.
COIL DIAMETER COIL HEIGHT g276030 Figure 222 1 6.7 N·m (5 ft−lb) 2 3 4 LH PTO MANIFOLD SHOWN g276031 Figure 223 1. Hydraulic manifold 3. Solenoid coil 2. Cartridge valve 4. Nut 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 solenoid valve coil to be tested (Figure 221). Disconnect wire harness connector from coil. 3.
Testing (continued) Note: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value from the measured value of the component you are testing. 4. Using a multimeter (ohms setting), measure resistance between the two (2) connector terminals on the solenoid valve coil.
Piston (Traction) Pump Control Solenoid Coils 1 2 RIGHT FRONT 3 g276032 Figure 224 1. Piston pump 2. Forward solenoid coil 3. Reverse solenoid coil The piston (traction) pump uses an electronic control assembly for swash plate rotation. Electrical outputs from the machine TEC controller are provided to two (2) solenoid coils for pump control. The piston pump control assembly is attached to the left side of the piston pump (Figure 224).
Solenoid Coil Testing (continued) 2 1 2 3 2 1 2 3 g276033 Figure 225 1. 2. Solenoid coil O−ring 3. Coil nut 3. Using a multimeter (ohms setting), measure resistance between the two (2) connector terminals on the solenoid coil. Solenoid coil resistance should be 3.66 ohms. Note: Solenoid coil resistance should be measured with solenoid at approximately 20ºC (68ºF). Resistance may be slightly different than listed at different temperatures.
CAN−bus Termination Resistor Termination Resistor A B C g276034 Figure 226 System communication between electrical components on Groundsmaster 4000−D and 4010−D machines is accomplished on a CAN−bus communication system. Two (2) specially designed, twisted wires form the bus for the network used on the machine. These wires provide the data pathways between machine components. At the end of the twisted pair of bus wires near the InfoCenter display is a 120 ohm termination resistor.
Diode Assemblies 1 4 2 3 g276035 Figure 227 1. Diode assembly 3. Female terminal 2. Male terminal 4. End of diode body The Groundsmaster engine wire harness contains a diode assembly that is used for circuit protection from voltage spikes when the engine starter solenoid is de−energized. Groundsmaster models 30607, 30609 and 30636 use an additional diode assembly in the engine wire harness that protects the engine EGR circuit from reverse polarity.
Resistor Assembly 2 1 g276036 Figure 228 1. Resistor assembly 2. End of resistor body On Groundsmaster machines with an 80 Amp alternator (see Engine (Models 30603, 30605 and 30635) (page 2–4) and Engine (Models 30607, 30609 and 30636) (page 2–5)), the engine wire harness contains a resistor that is necessary for ignition switch operation. The resistor plugs into the wiring harness near the engine starter motor (see Appendix A (page A–1)).
Fuel Sender 3 1 2 g276037 Figure 229 1. Fuel sender 2. White (+) lead 3. Black (−) lead The fuel sender is attached to the top of the fuel tank. The resistance of the fuel sender increases as the fuel level in the fuel tank decreases. The TEC controller uses the fuel sender as an input to generate an output for the InfoCenter fuel gauge. Two (2) styles of fuel senders have been used on Groundsmaster 4000−D and 4010−D machines.
Testing (continued) TWO TERMINAL SENDER SINGLE CONNECTOR SENDER FULL POSITION EMPTY POSITION SLIDING FLOAT g276038 Figure 230 4. Remove screws and lock washers that secure the fuel sender to the fuel tank. 5. Carefully remove fuel sender and gasket from the fuel tank. Clean all fuel from the sender. Note: Before taking small resistance readings with a digital multimeter, short meter test leads together. The meter will display a small resistance value.
Fuel Pump (Models 30603, 30605 and 30635) 2 4 3 1 g276039 Figure 231 1. Fuel water separator 3. Pump inlet hose 2. Fuel pump 4. Pump discharge hose 1 4 3 2 g276040 Figure 232 1. Tier 4i engine 3. Fuel supply hose 2. Hose clamp 4. Fuel return hose The fuel pump is attached to the fuel tank support above the fuel water separator (Figure 231). Operational Test 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake. Raise hood to access fuel pump. 2.
Operational Test (continued) IMPORTANT When testing fuel pump output, do not turn ignition switch to the START position. 5. Collect fuel in the graduated cylinder by turning ignition switch to the RUN position. Allow pump to run for fifteen (15) seconds, then turn switch to OFF. 6. The amount of fuel collected in the graduated cylinder should be approximately 16 fl oz (475 ml) after fifteen (15) seconds. 7. Replace fuel pump as necessary.
Fuel Pump (Models 30607, 30609 and 30636) 2 3 4 1 g276041 Figure 233 1. Fuel water separator 3. Pump inlet hose 2. Fuel pump 4. Pump discharge 2 4 1 3 g276042 Figure 234 1. Tier 4 engine 3. Pump discharge hose 2. Hose clamp 4. Fuel return hose The fuel pump is attached to the fuel tank support above the fuel water separator (Figure 233). Operational Test 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake. Raise hood to access fuel pump. 2.
Operational Test (continued) IMPORTANT When testing fuel pump output, do not turn ignition switch to the START position. 5. Collect fuel in the graduated cylinder by turning ignition switch to the RUN position. Allow pump to run for thirty (30) seconds, then turn switch to OFF. 6. The amount of fuel collected in the graduated cylinder should be approximately 350 ml (11.8 fl oz) after thirty (30) seconds. 7. Replace fuel pump as necessary.
Cutting Deck Position Switches 4 3 2 1 g276043 Figure 235 1. Front lift arm 3. Sensing plate 2. Position switch 4. Switch LED 3 2 1 4 5 g276044 Figure 236 (For machines serial numbers below: 400000000) 1. Side lift arm (RH shown) 4. Switch LED 2. 3. Position switch Sensing plate 5.
g278112 Figure 237 (For machines serial numbers above: 400000000) 4. 5. 1. 2. Clearance Sensing plate 3. Side lift arm (LH shown) Position switch Switch LED 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 (Figure 235 and Figure 236). The position switches are powered proximity switches that incorporate an internal reed switch and a LED.
Testing (continued) 4. Start engine, fully raise cutting decks and then stop engine. Then, turn ignition switch to the RUN position (do not start engine) and check LED on cable end of position switches. Switch LED should not be illuminated when the cutting decks are fully raised. 5. If a position switch LED did not function correctly: A. Position cutting deck so sensing plate on the lift arm is near the position switch (front cutting deck raised and side cutting decks lowered). B.
Hydraulic Oil Temperature Sender RIGHT 1 FRONT 2 g276045 Figure 238 1. Rear axle motor 2. Oil temp sender g276046 Figure 239 The Groundsmaster 4000−D and 4010−D use a temperature sender as an input for the TEC controller to identify if the hydraulic oil temperature has reached an excessive level. The hydraulic oil temperature sender is attached to the bottom of the rear axle motor (Figure 238).
Testing (continued) CAUTION Handle the hot oil with extreme care to prevent personal injury or fire. Note: Prior to taking resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value from from the measured value of the component you are testing. 4.
Fan Speed Switch (Machines with Two−Post ROPS Extension Operator Fan Kit) 1 2 3 g276047 Figure 240 1. Fan speed switch 2. Control knob 3. Control panel The fan speed switch is attached to the overhead control panel (Figure 240). The switch is used to select the fan speed (off, low, medium, or high). Testing 1. Park the machine on a level surface, lower the cutting decks, and shut off the engine. Remove the key from the key switch. 2.
Testing (continued) 4. The switch terminals are identified in (Figure 241). With the use of a multimeter (ohms setting), test the switch functions to determine if continuity exists between only the terminals listed for each switch position. Check the continuity between the switch terminals. Switch Position Closed Circuits OFF L+H LOW B+C+L MEDIUM B+C+M HIGH B+C+H 5. Replace the fan speed switch if testing determines that the switch is damaged. 6.
Resistor Module (Machines with Two−Post ROPS Extension Operator Fan Kit) 1 2 3 g276049 Figure 242 1. Operator’s fan 2. Fan mount bracket 3. Resistor module The resistor module is attached to the rear of the fan mounting bracket (Figure 242). The resistor module is used for operation of the operator’s fan. Testing 1. Park the machine on a level surface, lower the cutting decks, and shut off the engine. Remove the key from the key switch. 2.
Testing (continued) 6 5 4 3 2 2 1 1 g276050 Figure 243 1. Pin 1 (Violet wire) 4. Pin 4 (Not used) 2. Pin 2 (Brown wire) 5. Motor pin 3. Pin 3 (Orange wire) 6. Resistor module 4. Use a multimeter to check that the resistance values of the resistor module as below (Figure 243). Test Point 1 Test Point 2 Expected Reading Motor Pin Pin 1 Less than 9 ohms Motor Pin Pin 2 Less than 6 ohms Motor Pin Pin 3 Less than 3 ohms 5. Replace the resistor module if it fails the test. 6.
Audio Alarm 4 3 1 2 g276051 Figure 244 1. Alarm top view 3. Positive (+) terminal 2. Alarm bottom view 4. Negative (−) terminal The audio alarm sounds to notify the operator when a machine problem exists. TEC controller detects the requirement for alarm and sends signals to InfoCenter. The InfoCenter provides the electrical current for the alarm. The alarm is attached to the control arm next to the operator seat. Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 2.
Service and Repairs Note: For engine component repair information (e.g. starter motor), refer to the Yanmar Workshop Manual that is correct for your Groundsmaster model. Battery Care 1. The top of the battery must be kept clean. lf the machine is stored in a location where temperatures are extremely high, the battery will discharge more rapidly than if the machine is stored in a location where temperatures are cool. WARNING Wear safety goggles and rubber gloves when working with electrolyte.
Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery and charge it fully (see Battery Service (page 6–91)). 2. Either store battery on a shelf or on the machine. 3. Leave battery cables disconnected if the battery is stored on the machine. 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5. To help prevent the battery from freezing, make sure it is fully charged (see Battery Service (page 6–91)).
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 caution to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries.
Battery Inspection and Maintenance 1. Check battery for cracks. Replace battery if cracked or leaking. 2. Check battery terminal posts for corrosion. Use wire brush to clean corrosion from posts. IMPORTANT Before cleaning the battery, tape or block vent holes to the filler caps and make sure the caps are on tightly. 3. Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler cap, overcharging, loose terminal post or overfilling.
Battery Testing (continued) Minimum Voltage Battery Temperature 9.6 70ºF (and up) 21ºC (and up) 9.5 60ºF 16ºC 9.4 50ºF 10ºC 9.3 40ºF 4ºC 9.1 30ºF -1ºC 8.9 20ºF -7ºC 8.7 10ºF -12ºC 8.5 0ºF -18ºC 2. If the battery electrolyte is accessible, the specific gravity of the electrolyte can be used to determine the battery condition. IMPORTANT Make sure the area around the cells is clean before opening the battery caps. A. Measure the specific gravity of each cell with a hydrometer.
Battery Charging To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which is readily available. CAUTION Follow the manufacturer’s instructions when using a battery charger. Note: Using specific gravity of the battery electrolyte is the most accurate method of determining battery condition. 1.
Battery Charging (continued) 3. Following the battery charger manufacturer’s instructions, connect the charger cables to the battery. Make sure a good connection is made. 4. Charge the battery following the battery charger manufacturer’s instructions. 5. While charging, occasionally check the battery. If the electrolyte is violently gassing or spewing or if the battery case feels hot to the touch, the charging rate must be lowered or temporarily stopped. 6.
Electrical System: Service and Repairs Page 6–96 Groundsmaster® 4000-D & 4010-D 13202SL Rev F
Chapter 7 Axles, Planetaries and Brakes Table of Contents General Information .............................................................................................................................. 7–2 Operator’s Manual ............................................................................................................................. 7–2 Adjustments...........................................................................................................................................
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, adjustment procedures, and general maintenance for your Greensmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Adjustments Planetary Drive Assembly Endplay (OPH−2 series planetary drives) A front planetary drive assembly that is properly operating should have no endplay. Any endplay in a planetary assembly indicates that there are potential problems with the planetary. Check planetary endplay at intervals specified in your Operator’s Manual. Endplay Checking Procedure 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch.
Service and Repairs Brake Assembly OPH−2 series planetary VA02 series planetary OPH−2 series planetary = 81 N·m (60 ft-lbs) VA02 series planetary = 101 to 115 N·m (75 to 85 ft-lbs) 19 4 15 13 3 5 20 11 12 14 1 13 8 2 10 RIGHT FRONT 22 6 17 7 16 9 115 to 135 N·m (85 to 100 ft-lb) 18 OPH−2 series planetary = 81 N·m (60 ft-lbs) VA02 series planetary = 101 to 115 N·m (75 to 85 ft-lbs) 21 g276509 Figure 247 1. Front wheel motor 9. LH brake assembly 17. Jam nut 2.
Removal (Figure 247) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch. 2. Drain oil from planetary drive and brake assembly; refer to traction unit Operator’s Manual. 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. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine.
Installation (Figure 247) (continued) 2. Apply gasket sealant (Loctite #2 or equivalent) to sealing surfaces of new gasket (item 18). Align gasket and secure brake assembly to planetary. • For OPH−2 series planetary drives: tighten screws to 81 N·m (60 ft−lb). • For VA02 series planetary drives: tighten screws from 101 to 115 N·m (75 to 85 ft−lb). 3. Secure hex on end of brake cable to pull rod on brake assembly. Brake cable end should be completely threaded onto pull rod before tightening jam nut. 4.
Brake Inspection and Repair 2 1 3 4 5 6 7 8 9 15 10 14 13 12 11 g276542 Figure 250 1. Brake housing (LH shown) 2. 3. 4. Clevis pin (2 used) 5. Link (2 used) 11. Rotating actuator 6. Hitch pin (2 used) Seal 7. Stationary disc (4 used) 12. Extension spring (3 used) Pull rod 8. Rotating disc (3 used) 13. Ball (3 used) Retaining ring 14. Plug Gasket 15. O−ring 9. 10. Brake Inspection and Repair (Figure 250) 1.
Planetary Drive Assembly OPH−2 series planetary = 81 N·m (60 ft-lbs) VA02 series planetary = 101 to 115 N·m (75 to 85 ft-lbs) OPH−2 series planetary VA02 series planetary 19 4 15 13 3 5 20 11 12 14 1 13 8 2 10 17 6 RIGHT 7 FRONT 16 9 OPH−2 series planetary = 81 N·m (60 ft-lbs) VA02 series planetary = 101 to 115 N·m (75 to 85 ft-lbs) 18 115 to 135 N·m (85 to 100 ft-lbs) 21 g276543 Figure 251 1. Front wheel motor 8. O−ring 15. Straight hydraulic fitting 2.
Removal (Figure 251) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch. 2. Drain the oil from the brake assembly and the Planetary drive; refer to the traction unit Operator’s Manual. 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. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine.
Installation (Figure 251) (continued) 5. Fill planetary drive with gear lube; refer to traction unit Operator’s Manual. A portion of the gear lube will pass into the brake assembly automatically. 6. Check and adjust the brake cables for proper brake operation. WARNING Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury. 7. Lower machine from jack stands. Tighten lug nuts from 115 to 135 N·m (85 to 100 ft−lb) in a crossing pattern.
OPH−2 Series Planetary Drive Service 2 13.3 to 16.3 N·m (118 to 144 in-lb) 3 4 7 8 9 11 1 12 13 14 5 15 16 6 10 28 21 13 27 26 17 25 24 23 22 20 OPH−2 series planetary 19 18 g276544 Figure 252 1. Spindle 11. Outer bearing cup 21. Thrust plug 2. Boot seal 12. Outer bearing cone 22. Thrust washer 3. Oil seal 13. O−ring 23. Retaining ring 4. Inner bearing cone 14. Thrust washer 24. Primary gear 5. Inner bearing cup 15. Retaining ring (external) 25. Drive shaft 6.
g276545 Figure 253 1. Spindle 15. Retaining ring (external) 2. Boot seal 16. Ring gear 3. Oil seal 17. Retaining ring (internal) 4. Inner bearing cone 18. Plug (2) 5. Inner bearing cup 19. O−ring (2) 6. Wheel stud (8) 20. End cap 7. Socket head screw (16) 21. Thrust plug 8. Lock washer (16) 22. Thrust washer 9. Housing 23. Retaining ring 10. Dowel pin (2) 24. Primary gear 11. Outer bearing cup 25. Drive shaft 12. Outer bearing cone 26. Primary carrier assy.
Disassembly (Figure 252 and Figure 253) (continued) 6. Remove drive shaft assembly (items 23, 24 and 25) If necessary, remove retaining ring and primary gear from shaft. 7. Remove primary carrier (item 26), secondary gear (item 27) and secondary carrier (item 28). Note: Steps 6 through 10 are necessary only if inspecting or replacing bearings and/or seals. IMPORTANT Do not reuse retaining ring (item 10) after it has been removed. 8. Remove retaining ring (item 15) and thrust washer (item 14).
Assembly (Figure 252 and Figure 253) (continued) Note: The planetary shim kit includes the retaining ring and several thrust washers with thickness in incremental steps of 0.10 mm (0.004 in). Refer to your Parts Catalog to identify the correct part number for the planetary shim kit. H. Measure thickness of thrust washer (item 14) that was removed during disassembly. Choose new thrust washer of equal thickness or the next available thickness from thrust washers in the shim kit. I.
Assembly (Figure 252 and Figure 253) (continued) WARNING Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury. 13. Remove jack stands and lower machine to ground. Tighten wheel lug nuts in a crossing pattern from 115 to 135 N·m (85 to 100 ft−lb)in a crossing pattern.
VA02 Series Planetary Drive Service 1 2 3 37 N·m (27 ft-lb) 5 VA02 series planetary 7 4 8 9 4 5 11 12 13 14 6 15 10 28 27 20 19 26 24 25 24 23 22 21 18 17 16 g276546 Figure 254 1. Spindle 11. O−ring 21. End cap 2. Boot seal 12. Spacer 22. Thrust plate 3. Lip seal 13. Locking washer 23. O−Ring 4. Inner bearing cup (2) 14. Lock nut 24. Retaining ring (2) 5. Inner bearing cone (2) 15. Ring gear 25. Primary gear 6. Wheel stud (8) 16. Retaining ring 26.
2 7 8 13 28 11 10 14 27 15 24 3 16 22 19, 20 1 26 23 17, 18 25 4 5 12 6 21 9 g276499 Figure 255 1. Spindle 15. Ring gear 2. Boot seal 16. Retaining ring 3. Lip seal 17. Plug 4. Inner bearing cup (2) 18. O−ring 5. Inner bearing cone (2) 19. Plug (2) 6. Wheel stud (8) 20. O−Ring (2) 7. Socket head screw (8) 21. End cap 8. Lock washer (8) 22. Thrust plate Housing 23. O−Ring Dowel pin (4) 24. Retaining ring (2) 9. 10. 11. O−ring 25. Primary gear 12.
Disassembly (continued) 7. Remove primary carrier and secondary carrier from ring gear. 8. Bend the locking washer tab away from the lock nut. Use a TMFS12 spanner socket to remove the 55 x 1.5 mm lock nut. Remove the locking washer and spacer. Discard the locking washer. 9. Carefully remove housing and bearing cones from spindle. 10. Remove and discard seals from housing. 11. If necessary, remove bearing cups from housing. 12.
Assembly (continued) 11. Align key on locking washer and install locking washer onto spindle shaft. IMPORTANT Perform the following steps without interruption. Once the thread locking compound is applied, you have only a few minutes before the curing process will influence the bearing lock nut torque. 12. Install the bearing lock nut: A. Apply high strength thread locking compound (Loctite 263 or equivalent) and install the lock nut. B. Tighten the lock nut to 150 N·m (110 ft−lb). C.
Assembly (continued) 20. Install front wheel assembly. 21. Fill planetary drive with gear lube; refer to traction unit Operator’s Manual. A portion of the gear lube will pass into the brake assembly automatically. 22. Test planetary drive operation. 23. Remove jack stands and lower machine to ground.
Rear Axle Assembly 18 19 5 8 6 7 22 28 4 16 5 15 27 17 1 3 12 24 20 29 14 25 27 9 10 23 13 11 1 RIGHT 26 FRONT 21 115 to 135 N·m (85 to 100 ft-lb) 184 to 223 N·m (135 to 165 ft-lb) 2 g276500 Figure 256 1. Plug with O−ring 11. Slotted hex nut (2 used) 21. Rear axle mount 2. Lug nut (5 used per wheel) 12. Washer 22. Rear axle assembly 3. Rear wheel assembly (2 used) 13. Cap screw (4 used) 23. Lock nut 4. Cap screw (2 used) 14. Lock washer (4 used) 24.
Removal (Figure 256) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 1 2 g276501 Figure 257 1. Center axle drain plug 2. Outside plug (2 used) 2 1 g276502 Figure 258 1. Gearbox drain plug 2. Gearbox fill plug 2. Drain oil from rear axle and axle gearbox (Figure 257 and Figure 258). 3. Chock front wheels and jack up rear of machine (see Jacking Instructions (page 1–7)).
Removal (Figure 256) (continued) 4 5 1 6 g276503 Figure 259 1. 2. 3. Tie rod Dust cover Cotter pin 4. 5. 6. Castle nut Tie rod end Steering arm (LH) 8. If required, remove tie rod ends from steering arms on rear axle (Figure 259). Remove the cotter pins and castle nuts from the tie rod ball joints. Use a ball joint fork and remove the tie rod ends from the axle steering arms. 9. Support rear axle to prevent it from falling.
Installation (Figure 256) (continued) 2. Secure rear axle to rear axle mount. A. Slide rear axle pin through rear axle mount and rear axle. Install washer and lock nut onto rear axle pin. B. Secure pivot pin to axle mount with washer head screw (Figure 260). C. Torque lock nut from 184 to 223 N·m (135 to 165 ft−lb). After tightening the lock nut, makes sure that the rear axle pivots freely. 3. Position rear axle with attached mount under machine.
Installation (Figure 256) (continued) 1 2 g276506 Figure 262 1. Steering stop bolt 2. Bevel gear case (LH) 11. Fill gearbox and rear axle with SAE 85W−140 weight gear lube (Figure 258 and Figure 261). Lubricant capacity is approximately 0.47 liters. (16 fl. oz) for the gearbox and 2.37 liters (80 fl. oz.) for the rear axle assembly. 12. Check rear wheel toe−in and adjust if necessary. 13. Check steering stop bolt adjustment. When the steering cylinder is fully extended (right turn), a gap of 1.
Rear Axle Service g276507 Figure 263 Axles, Planetaries and Brakes: Service and Repairs Page 7–26 Groundsmaster® 4000-D & 4010-D 13202SL Rev F
Rear Axle Service (continued) Figure 263 (continued) 1. LH axle support 23. RH axle support 45. Bevel gear shaft 2. Flange bushing (2 used) 24. Input shaft assembly 46. Axle case (LH shown) 3. Axle vent 25. Bolt (8 used) 47. Ball bearing 4. Filter 26. O−ring 48. Bevel gear (29 tooth) 5. Vent extension 27. Differential shaft (LH shown) 49. Shim set 6. Cap screw (4 used per gear case) 28. Shim set 50. Clip (2 used per axle case) 7. Shim set 29. Ball bearing 51.
Bevel Gear Case and Axle Case The following procedures assume the rear axle assembly has been removed from the machine. Removal 47 to 56 N·m (35 to 41 ft-lb) 1 5 6 4 2 3 47 to 56 N·m (35 to 41 ft-lb) g276508 Figure 264 1. Cap screw (4 used) 4. Axle support 2. Lock nut (2 used) 5. Bevel gear case/axle case assembly 3. Lock washer (2 used) 6. O-ring 1. Remove the mounting screws, nuts and lock washers.
Removal (continued) Threadlocking Compound 3 77 to 91 N·m (57 to 67 ft-lb) 2 4 1 g276511 Figure 266 1. Axle case 3. Screw (2 used) 2. Axle case support 4. Support shim 4. Remove the axle case support mounting screws, the axle case support and the support shims (Figure 266). 2 1 23 to 27 N·m (17 to 20 ft-lb) 3 4 Threadlocking Compound 5 14 7 15 11 6 13 9 12 10 23 to 27 N·m (17 to 20 ft-lb) g276512 Figure 267 1. Knuckle pin 2. Mounting screw (4 used) 10. 9.
Removal (continued) 5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gasket material from either mating surface (Figure 267). 6. While holding the bevel gear case, tap the upper end of the bevel gear shaft out of the upper bearing and upper bevel gear. 7. Pull the bevel gear case from the axle case and remove the upper bevel gear and collar from the gear case. 8. Remove the axle case cover screws, cover and the O-ring from the axle case. 9.
Installation 3 2 1 g276514 Figure 269 1. 2. Axle case Bevel gear case 3. Shaft seal 1. Coat new shaft seal with grease and install in axle case as shown (Figure 269). 7 8 6 5 3 2 1 4 g276515 Figure 270 1. Axle case cover 5. Upper bevel gear 2. Lower bevel gear 6. Collar 3. Bevel gear shaft 7. Upper bearing 4. Lower bearing 8. Knuckle pin 2. Install the lower bevel gear and bevel gear shaft in the axle case cover.
Installation (continued) 4. Install the knuckle pin. Use medium strength threadlocking compound and tighten the knuckle pin mounting screws from 23 to 27 N·m (17 to 20 ft-lb). 4 77 to 91 N·m (57 to 67 ft-lb) 1 VERTICAL ENDPLAY 6 5 2 3 g276516 Figure 271 1. Axle case support 4. Dial indicator 2. Axle case 5. Knuckle pin 3. Bevel gearcase 6. Support shim location 5. Determine necessary quantity of support shims. A.
Installation (continued) 3 2 1 4 5 g276517 Figure 272 1. Axle support 4. Dial indicator 2. Upper bevel gear 5. Axle bearing shims 3. Differential shaft gear 7. Temporarily install the bevel gear case/axle case assembly on the axle support. Position a dial indicator at the tooths center. Prevent the axle from turning and measure the upper bevel gear to differential shaft gear backlash (Figure 272). UPPER BEVEL GEAR BACKLASH: 0.10 to 0.40 mm (0.004 to 0.016 in) 8.
Installation (continued) Position a dial indicator at the tooths center. Prevent the axle from turning and measure the lower bevel gear to axle gear backlash (Figure 273). LOWER BEVEL GEAR BACKLASH: 0.10 to 0.40 mm (0.004 to 0.016 in) 10. Adjust backlash by increasing or reducing axle bearing shim thickness (see Axle Shafts (page 7–37)). Note: Axle bearing shims are available in 0.2 mm (0.008 in), 0.3 mm (0.012 in) and 0.5 mm (0.020 in) thickness. 11.
Differential Shafts 47 to 56 N·m (35 to 41 ft-lb) 1 5 6 4 2 3 7 47 to 56 N·m (35 to 41 ft-lb) g276519 Figure 274 1. Cap screw (4 used) 5. Bevel gear/axle case assembly 2. Lock nut (2 used) 6. O-ring 3. Lock washer (2 used) 7. Stud (2 used) 4. Axle support The following procedures assume the rear axle assembly has been removed from the machine. Removal IMPORTANT Do not interchange right and left differential shaft assemblies. 1. Remove the mounting screws, nuts and lock washers.
Removal (continued) 5. Inspect all gears, shafts, bearings and cases for damage and wear. Replace components as necessary. Installation 1. Press bearings onto differential shaft. Place correct combination of bearing shims in axle support and drive differential shaft and bearing assembly into axle support. 2. Install bevel gear and retaining ring. 3. Coat new O-ring with grease. Align differential shaft splines with differential gear assembly and slide differential shaft assembly onto axle support. 4.
Axle Shafts 1 4 23 to 27 N·m (17 to 20 ft-lb) 3 2 g276522 Figure 276 1. Axle case 3. Screw (6 used) 2. Axle cover assembly 4. O-ring 1 2 4 3 5 g276523 Figure 277 1. Bearing 4. Spacer 2. Bevel gear 5. Retaining ring 3. Shims The following procedures assume the rear axle assembly has been removed from the machine. Removal 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Figure 276). 2.
Installation 1 4 2 3 g276524 Figure 278 1. Axle shaft seal 3. Bearing 2. Axle cover 4. Axle shaft 1. Coat new axle shaft seal with grease and install in axle cover as shown (Figure 278). 2. Press the axle cover and bearing assembly onto the axle shaft. Press only on the inner race of the cover bearing (Figure 278). 3. Install retaining ring, spacer and correct combination of bearing shims. Install bevel gear and bearing. 4. Coat a new O-ring with grease and install the axle cover assembly.
Input Shaft/Pinion Gear 20 47 to 56 N·m (35 to 41 ft-lb) 1 22 19 2 3 17 18 16 4 8 6 21 5 23 9 10 15 10 14 9 13 7 11 47 to 56 N·m (35 to 41 ft-lb) 12 g276525 Figure 279 1. Nut (2 used) 2. Lock washer (2 used) 3. Stud (2 used) 9. Bearing 17. Cover plate 10. O-ring 18. Dowel pin (2 used) 11. Input shaft/pinion gear 19. Lock washer (6 used) 4. Lock nut 12. Bearing case 20. Cap screw (6 used) 5. Stake washer 13. Shim 21. Retaining ring (2 used) 6. Oil seal 14.
Installation (Figure 279) Note: When installing bearing cones onto the input shaft/pinion gear, press only on the inner race of the bearing cone. 1. If the inner bearing cone was removed, press a new bearing cone all the way onto the input shaft/pinion gear. 2. Place the shaft and bearing assembly in the bearing case and install the outer bearing cone. Note: The bearings must be completely seated. There should be no input shaft/pinion gear end play. 1 mm (0.040 in) 2 1 3 g276526 Figure 280 1.
Installation (Figure 279) (continued) 8. Use a depth gauge to measure the distance from the end face of the input shaft/pinion gear to the mating surface of the bearing case. Subtract the “Design Cone Center Distance” from this distance to determine initial shim thickness (Figure 281). DESIGN CONE CENTER DISTANCE (distance from mating surface of axle support to end face of pinion gear): 47.5 + 0.05 mm (1.870 + 0.002 in). Note: Bearing case shims are available in 0.1 mm (0.004 in) and 0.2 mm (0.
Differential Gear g276529 Figure 283 1. Gear case 5. Case screw (8 used) 2. Pinion gear 6. Differential gear 3. Axle support (left) 7. O-ring 4. Axle support (right) The following procedures assume the rear axle assembly has been removed from the machine. Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case and Axle Case (page 7–28)). IMPORTANT Do not interchange right and left differential shafts assemblies. 2.
Removal (continued) 2 1 g276530 Figure 284 1. Differential case 2. Spring pin 6. Drive the spring pin from the differential case with a punch and hammer. Discard the spring pin (Figure 284). Note: Mark and arrange all components so they can be reassembled in their original position. g276532 Figure 285 1. Differential pinion shaft 5. Side gear shims 2. Pinion gear 6. Ring gear 3. 4. Pinion washer Side gear 7. 8. Differential case Bolt/washer (8 used) 7.
Inspection 1 2 g276533 Figure 286 1. Side gear 2. Differential case 1. Measure the differential side gear O.D. and the differential case I.D. to determine the side gear to case clearance (Figure 286). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.05 to 0.30 mm (0.002 to 0.012 in) SIDE GEAR O.D. (Factory Spec.): 33.91 to 33.95 mm (1.335 to 1.337 in) DIFFERENTIAL CASE I.D. (Factory Spec.): 34.00 to 34.06 mm (1.339 to 1.
Inspection (continued) 1 2 g276534 Figure 287 1. 2. Pinion shaft Pinion gear 2. Measure the differential pinion shaft O.D. and the pinion gear I.D. to determine the pinion shaft to pinion gear clearance (Figure 287). Replace components as necessary. PINION SHAFT TO PINION GEAR CLEARANCE: 0.03 to 0.25 mm (0.001 to 0.010 in) PINION SHAFT O.D. (Factory Spec.): 13.97 to 13.10 mm (0.550 to 0.551 in) PINION GEAR I.D. (Factory Spec.): 13.10 to 14.02 mm (0.551 to 0.552 in) 3.
Installation (continued) 3 2 1 g276535 Figure 288 1. 2. Vise Differential gear case 3. Dial indicator 5. Secure the differential case in a soft jawed vise. Position a dial indicator on a tooth of the differential pinion gear. Press the pinion and side gear against the differential case and measure the pinion gear to side gear backlash (Figure 288). PINION GEAR TO SIDE GEAR BACKLASH: 0.10 to 0.40 mm (0.004 to 0.016 in) 6. Adjust backlash by increasing or reducing side gear shim thickness.
Installation (continued) 14. Install input shaft/pinion gear assembly (see Input Shaft/Pinion Gear (page 7–39)). 15. Coat new o-rings with grease, align differential shaft splines with differential gear assembly and slide differential shaft assemblies onto axle support. 16. Install bevel gear case/axle case assemblies (see Bevel Gear Case and Axle Case (page 7–28)).
Pinion Gear to Ring Gear Engagement PROFILE TOP LAND TOE HEEL LENGTHWISE BEARING ARC ROOT g276537 Figure 290 The final position of the pinion gear is verified by using the gear contact pattern method as described in the following procedure. GEAR TOOTH DEFINITIONS (Figure 290): Toe − the portion of the tooth surface at the end towards the center. Heel − the portion of the gear tooth at the outer end. Top Land − top surface of tooth. 1.
Pinion Gear to Ring Gear Engagement (continued) g276539 Figure 292 1. Input shaft/pinion gear 3. Differential gear case 2. Bearing case shims 4. Differential bearing shims 3. While applying a light load to the ring gear, rotate the pinion gear in the direction of forward travel until the ring gear has made one complete revolution. Ideal tooth contact observed on the ring gear should cover more than 35% of each tooth surface.
Gear Pattern Movement Summary Heel Contact Base Contact g276540 Figure 293 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 (Figure 293): A. Install thicker or additional bearing case shim(s) to move pinion shaft toward ring gear. B. Install thinner or remove differential bearing shim(s) to move ring gear backward. C.
Chapter 8 Chassis Table of Contents General Information .............................................................................................................................. 8–2 Operator’s Manual ............................................................................................................................. 8–2 Service and Repairs .............................................................................................................................
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, adjustment procedures, and general maintenance for your Greensmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Service and Repairs Steering Tower (For machines serial number below: 400000000) 2 1 3 28 to 35 N·m (20 to 26 ft−lb) 6 4 37 to 44 N·m (27 to 33 ft−lb) 7 5 8 10 9 17 11 19 20 12 18 10 13 14 7 20 15 16 RIGHT 22 21 FRONT 23 19 24 g276866 Figure 295 9. Flange bushing 1. Steering wheel cover 2. Hex nut 10. Thrust washer (as needed) 18. Cap screw (2 used) 3. Flat washer 11. Cap screw (4 used) 19. Pivot hub (3 used) 4. Steering wheel 12. Washer (4 used) 20.
Disassembly (Figure 295) 3 5 2 2 4 1 2 g276877 Figure 296 1. Operator platform 4. Clip (2 used) 2. Flange screw (10 used) 5. Rear cover 3. Front cover 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove steering tower covers to access steering tower components (Figure 296). 3. Disassemble steering tower as needed using Figure 295 as a guide.
Steering Tower (For machines serial number above: 400000000) g278210 Figure 297 1. Steering wheel cover 13. Carriage bolt (6 each) 25. Nut (2 each) 2. Hex nut 14. Nut (4 each) 26. Shoulder bolt (2 each) 3. Flat washer 15. Steering control valve 27. Brake link 4. Steering wheel 16. Lock washer (2 each) 28. Brake rod 5. Foam collar 17. Bolt (2 each) 29. Extension spring 6. Steering shaft 18. Switch nut 30. Brake plate 7. Bolt (4 each) 19. Switch 31.
Removal (Figure 297) (continued) 2. Remove steering tower covers to access steering tower components. 3. Remove the locknut and flat washer that secures the steering wheel to the steering tower. 4. Use a suitable puller to remove the steering wheel from the steering tower assembly. 5. Slide the rubber bellows up the steering tower to get access to the fasteners that secure the steering tower to the machine. 6. Support the steering control valve to prevent it from falling during the steering tower removal.
Center Deck Lift Arms 42 41 42 41 43 RIGHT 44 FRONT 123 to 135 N·m (90 to 100 ft−lb) 18 19 37 20 2 38 6 5 4 40 8 17 12 11 33 10 3 9 7 29 5 30 31 23 24 21 22 34 14 13 36 39 37 23 28 15 14 25 36 32 11 15 81 to 94 N·m (60 to 70 ft−lb) 12 27 26 203 to 237 N·m (150 to 175 ft−lb) 35 1 16 16 35 g276888 Figure 299 1. Center deck assembly 16. Cap screw (2 per mount) 31. Clevis rod end 2. Grease fitting 17. Sensor plate 32. Spring pin 3. Ball joint seal 18.
Removal (Figure 299) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove center cutting deck (see Center Cutting Deck (page 9–4)). CAUTION When changing attachments, tires or performing other service, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor.
Installation (Figure 299) (continued) 1 30.5 mm (1.200 in) 2 g276894 Figure 300 1. U−bolt 2. Height of cut chain 5. If height−of−cut chain u−bolt was removed from lift arm, assemble u−bolt so that threaded portion extends 30.5 mm (1.200 in) above lift arm mounting plate (Figure 300). This dimension is a starting point that might need additional adjustment for deck pitch correction (see step 12 below). Note: The lift arm ball joint (item 12) and jam nut (item 11) have left hand threads. 2 1 56.
Installation (Figure 299) (continued) 10. Lubricate lift arm grease fittings. 11. After assembly is completed, raise and lower the cutting deck to verify that hydraulic hoses and fittings do not contact anything. 12. Check height−of−cut and deck pitch adjustment (refer to Operator’s Manual).
Side Deck Lift Arms 33 13 34 13 33 35 1 Loctite #242 2 3 4 8 5 16 4 15 34 30 10 32 20 31 21 29 24 17 9 Antiseize Lubricant 7 6 11 13 15 14 12 105 to 130 N·m (77 to 96 ft−lb) 28 10 27 19 22 23 26 RIGHT 25 24 18 FRONT g276896 Figure 302 1. Lift cylinder pin 13. Flat washer (5 used per side) 25. Sensing plate 2. Slotted roll pin 14. Flange head screw (3 used per block) 26. Carriage screw (2 per plate) 3. Flange head screw 15. Grease fitting 27.
2 1 g276897 Figure 303 1. Front frame bore 2. Rear frame bore Note: Allowable clearance between lift arm pivot shaft (item 8) and front frame bore (Figure 303) is up to 0.64 mm (0.025 in). Allowable clearance between lift arm pivot shaft and rear frame bore is up to 1.78 mm (0.070 in). Removal (Figure 302) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2.
Removal (Figure 302) (continued) 6. Support lift arm and pull lift arm pivot shaft from lift arm and frame. Locate and remove thrust washers (item 10) during pivot shaft removal. Note location of thrust washers for assembly purposes. A. If pivot shaft is difficult to remove, fabricate a puller as shown in Figure 304. B. Attach puller to end of pivot shaft using bolt and flat washer. C. Drive pivot shaft from lift arm and frame with hammer. 7. Remove lift arm from machine. Installation (Figure 302) 1.
Side Deck Rear Arm Assembly Loctite #271 34 29 25 40 39 33 28 22 24 26 31 34 35 35 36 31 37 30 27 18 35 32 15 19 21 17 38 23 20 RIGHT 31 to 37 N·m (270 to 330 in−lb) 14 13 13 5 FRONT 12 4 11 3 6 9 8 1 2 16 10 41 7 43 42 g276899 Figure 305 For machines serial number below 400000000 1. Cutting deck (LH shown) 16. Plate 31. Damper rod end (2 per damper) 2. Deck mount (LH shown) 17. Lock nut (2 per arm) 32. Cap screw (2 per damper) 3. Cap screw 18. Pivot shaft 33.
g278125 Figure 306 For machines serial number above 400000000 1. Lock nut (2 each) 2. Plate 9. Flange bushing (2 each) 10. Bell crank (LH shown) Retaining ring 3. Bumper 11. 4. Flat washer (2 each) 12. LH rear arm 5. Bolt (2 each) 13. Spacer tube 6. 7. 8. Flat washer Lock nut Thrust washer (2 each) 14. 15. Flat washer Bolt Rear Arm Removal (Figure 305) 1 2 3 g276867 Figure 307 1. Lift arm (RH shown) 2. Rear arm 3. Damper 1.
Rear Arm Removal (Figure 305) (continued) 4. Remove lock nut (item 25) and lock washer (item 24) that secures rear arm pivot shaft. Slide pivot shaft from hub and rear arm. Remove rear arm assembly from machine. Rear Arm Disassembly (Figure 305) Disassemble rear arm assembly using Figure 305 as a guide. Rear Arm Assembly (Figure 305) 1. Slide large flat washer, spring, plastic bearing, second large flat washer and small flat washer onto spring shaft.
Rear Arm Assembly (Figure 305) (continued) 1 2 3 134.5 to 138.3 mm (5.295 to 5.445 in) 2 1 g276868 Figure 308 1. Rod end (2 used) 2. Jam nut (2 used) 3. Link tube 11. If damper link was disassembled, adjust the length of the link from 134.5 to 138.3 mm (5.295 to 5.445 in) (Figure 308). 12. If damper springs (item 37) were removed, tighten lock nuts so that bushings (item 36) are free to rotate. Rear Arm Installation (Figure 305) 1. Position rear arm assembly to cutting deck and frame. 2.
Rear Arm Installation (Figure 305) (continued) C. Measure from the inset bead of the rim (not the outer edge of the rim) to the straight edge at two locations as indicated in Figure 309. Rim and paint irregularities make the rim outer edge an unreliable point of measure. These two measurements should be the same within a tolerance of 3 mm (1/8 in). D. Rotate spring shaft (item 12) in rear arm assembly until correct dimension is attained. Shaft should rotate freely inside the assembly.
Lift Arm Joint Yoke 13 203 to 244 N·m (150 to 180 ft−lb) 14 12 21 17 11 11 9 10 1 20 18 18 5 19 6 8 3 RIGHT 16 2 4 15 FRONT 7 g276870 Figure 310 1. Side cutting deck (LH shown) 8. 15. Cap screw (8 used per mount) Joint yoke 16. Lock washer (8 used per mount) 10. Spacer 17. Rear arm assembly Lock nut 11. Thrust washer (0.125” thickness) 18. Spacer Plate 12. Hardened washer 19. Cap screw 6. Rubber plate 13. Cotter pin 20. Lock nut 7. Cap screw 14.
Removal (Figure 310) (continued) 1 3 4 2 5 5 g276871 Figure 311 Lift arm (RH shown) 4. Deck mount 2. Joint yoke 5. Cap screw/washers 3. Rear arm assembly 1. 3. Remove eight (8) cap screws, lock washers and flat washers that secure deck mount to cutting deck (Figure 311). 4. Remove cotter pin from joint yoke shaft. Make sure that deck mount is supported and remove slotted hex nut that secures joint yoke to lift arm.
Joint Yoke Assembly 1. Make sure that rubber plate (item 6) and plate (item 5) are positioned in bottom of deck mount. 2. Apply a coating of grease to bearing bores of yoke and deck mount. Also, apply grease to bearings and seal of bearing assembly. Make sure that all bearing rollers are properly seated in bearing cage. 3. Use a press to install cross and bearings into yoke. A. Press one bearing partially into yoke. IMPORTANT Take care when installing cross into bearing to avoid damaging bearing seal. B.
Control Arm 27 26 28 23 21 22 18 25 20 34 1 19 31 14 13 11 40 35 29 41 36 30 33 32 37 10 9 38 15 24 39 2 16 17 7 3 12 4 6 RIGHT 8 42 FRONT 5 43 g276872 Figure 312 1. Flange nut (3 used) 16. Flange head screw (6 used) 31. Cruise control switch 2. Flange head screw (2 used) 17. Flange nut (2 used) 32. Cover plate 3. Washer head screw (10 used) 18. Hole plug 33. Cap screw (2 used) 4. LH cover 19. Rivet (2 used) 34. Lift/lower switch (3 used) 5. Lock nut 20.
Disassembly (Figure 312) (continued) 3. At front of control arm, remove screw (item 29) and lock nut (item 5) that secure control arm covers to each other. 4. Remove five (5) washer head screws (item 3) that secure each cover to control arm panel. 5. Remove control arm covers from machine. As LH cover (item 4) is removed from control arm, unplug wire harness connector from headlight switch if equipped. 6. Remove electrical components from control arm as needed using Figure 312 as a guide. 7.
Traction Pedal 1 6 5 7 1.5 to 1.9 N·m (13 to 17 in−lb) 10 11 8 37 13 36 14 2 24 16 18 8 35 38 22 19 34 25 9 32 12 15 30 29 17 20 33 21 31 1 23 26 27 3 28 RIGHT 4 FRONT 8 g276874 Figure 314 (For machines serial numbers below 400000000) 1. Carriage bolt (6 used) 14. Cap screw 27. Bushing hub 2. Traction pedal 15. Flange nut (2 used) 28. Position sensor 3. Bushing 16. Lock washer 29. Capture plate 4. Operator platform 17. Flange mount bearing 30.
g278517 Figure 315 (For machines serial numbers above 400000000) 1. Carriage bolt (6 used) 14. Cap screw 27. Bushing hub 2. Traction pedal 15. Flange nut (2 used) 28. Position sensor 3. Bushing 16. Lock washer 29. Capture plate 4. Operator platform 17. Flange mount bearing 30. Standoff spacer (2 used) 5. Cap screw 18. Cover plate 31. Screw (2 used) 6. Rod end bearing 19. Butterfly plate 32. Spring shaft 7. Hex nut 20. Butterfly bracket 33. Flat washer 8.
IMPORTANT A properly installed and calibrated traction pedal position sensor is critical to accurate traction system response and for reliable sensor life. Use care when removing, installing and calibrating the traction pedal position sensor. Disassembly (Figure 314) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2.
Assembly (Figure 314) (continued) C. If traction pedal shaft (item 9) was removed, apply grease to the shaft areas that will be inside the bearings after assembly. D. Use a press to install roll pin (item 10). DO NOT damage flange mount bearing (item 17) or cover plate (item 18) when installing roll pin. Also, take care to not distort roll pin during assembly. E. Make sure that roll pin (item 10) is fully inside the butterfly groove of the shim plate (item 20).
Operator Platform 1 2 3 7 3 4 4 129 to 155 N·m (95 to 115 ft−lb) 6 5 5 6 RIGHT FRONT g276876 Figure 317 1. Operator platform 4. Center mount (4 used) 2. Cap screw (2 used) 5. Plain washer (4 used) 3. Flat washer (4 used) 6. Lock nut (4 used) Chassis: Service and Repairs Page 8–28 7.
5 2 3 2 4 1 2 g276878 Figure 318 1. Operator platform 4. Clip (2 used) 2. Flange screw (10 used) 5. Rear cover 3. Front cover Some service procedures (e.g. removing the hydraulic reservoir) require the operator platform to be raised. The following steps can be used to raise the platform. Disassembly (Figure 317) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2.
Disassembly (Figure 317) (continued) 6 2 7 5 1 3 4 g276880 Figure 320 1. Brake pedal (RH shown) 5. Spring 2. Cotter pin 6. Brake cable (RH shown) 3. Clevis pin 7. Brake cable jam nuts 4. Brake strap 2 1.5 to 1.9 N·m (13 to 17 in−lb) 3 1 5 4 6 7 g276881 Figure 321 1. Flange screw (3 used) 5. Screw (2 per switch) 2. Adjustment cover 6. Switch nut (2 used) 3. Switch bracket 7. Clip (3 used) 4. Brake switch (2 used) 5.
Disassembly (Figure 317) (continued) A. Remove operator cab from machine. B. Remove cable ties that secure operator cab coolant and air conditioner hoses in engine compartment to allow the operator platform to be raised. Note location of cable ties for assembly purposes. Note: If desired, operator seat can be removed from operator platform to reduce overall weight of operator platform assembly (see Operator Seat (page 8–32)). 9.
Operator Seat 38 8 9 7 37 25 31 21 5 6 1 2 12 4 10 6 13 3 32 28 11 15 35 14 16 33 27 17 34 19 36 23 20 22 27 30 18 4 26 28 RIGHT 27 FRONT 29 24 g276882 Figure 322 1. Carriage screw (5 used) 2. Support channel 15. Locking cotter pin 28. Cotter pin (2 used) 3. Support bracket 16. Latch rod 29. Clevis pin (2 used) 4. Flange nut (6 used) 17. Locking cotter pin (2 used) 30. Locking cotter pin (2 used) 5. Cap screw 18. Clevis pin (2 used) 31. Manual tube 6.
1 2 3 g276883 Figure 323 1. Operator seat 2. Seat switch connector 3. Suspension connector Removal (Figure 322) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Disconnect seat electrical connector from machine wire harness (Figure 323). 3. Support control arm assembly to prevent it from shifting. 4.
Removal (Figure 322) (continued) 1 3 4 25 N·m (18 ft−lb) 2 g276884 Figure 324 1. Seat 3. Screw (M8x12) (3 used) 2. Suspension assembly 4. Screw (M8x16) 8. Remove four (4) torx head screws that secure seat to seat suspension (Figure 324). Note that the screw near the seat adjustment handle is longer than the other three (3) screws. 9. Lift seat from seat suspension and remove from machine.
Installation (Figure 322) (continued) D. Fully tighten all fasteners to secure control arm assembly to seat. 4. Connect seat electrical connector to machine wire harness (Figure 323).
Operator Seat Service 21 1 7 6 2 13 5 28 12 21 22 26 25 11 30 29 24 4 16 18 14 17 3 23 9 8 19 27 10 20 15 g276885 Figure 325 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. 5. LH armrest Bushing (2 used) 14. 15. Nut Spring (2 used) 24. 25. Torx screw Torx screw (3 used) 6. Backrest 16. Magnet 26. Washer (3 used) 7. Plug (2 used) 17.
2 3 1 4 6 7 5 g276886 Figure 326 1. Operator seat 5. Flat washer 2. R−clamp (2 used) 6. Seat belt 3. Screw (2 used) 7. Cap screw 4. Manual tube Disassembly (Figure 325) Disassemble operator seat as necessary using Figure 325 and Figure 326 as guides. Assembly (Figure 325) Assemble operator seat using Figure 325 and Figure 326 as guides.
Operator Seat Suspension RIGHT 16 17 5 FRONT 2 18 33 19 1 20 24 22 25 23 21 3 39 14 12 7 35 28 30 6 15 38 27 31 4 13 36 8 29 9 10 26 33 11 34 37 32 g276887 Figure 327 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. Handle 5. Shock absorber 18. C−clip (4 used) 31. Bumper 6. Air spring 19. Pin (2 used) 32. Nut 7.
1 2 3 g276889 Figure 328 1. Operator seat 2. Seat switch connector 3. Suspension connector 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) requires removal, the seat suspension base will have to be removed from the seat platform. Disassembly (Figure 327) 1. Remove operator seat from seat suspension (see Operator Seat (page 8–32)). 2.
Disassembly (Figure 327) (continued) 3. If the air spring assembly (item 6) or base plate (item 37) requires removal, remove seat suspension from seat plate (Figure 329): A. Raise and support seat plate assembly. Support seat suspension to prevent it from falling. B. Remove four (4) cap screws, flat washers and flange nuts that secure seat suspension to seat plate. C. Remove seat suspension from machine. 4. Remove seat suspension components as needed using Figure 327 as a guide. Assembly (Figure 327) 1.
Hood 21 4 1 20 24 29 18 26 28 25 31 7 23 27 30 9 22 12 6 8 5 15 RIGHT 11 10 FRONT 14 2 3 17 16 19 13 g276891 Figure 330 1. Hood 12. Flexible draw latch (2 used) 23. Carriage bolt (2 used) 2. Screen assembly 13. Corner screen seal (2 used) 24. Plastic plug (43 used) 3. Bulb seal 14. Screw (8 used) 25. Foam seal (2 used) 4. Flange nut (2 used) 15. LH hood support 26. Flange nut (2 used) 5. Screen pivot (2 used) 16. Hood rod (2 used) 27. Screw (2 used) 6.
Removal (continued) A. Remove hair pins (item 6) that retain screen pivots to hood pivots. B. Slide hood assembly to disengage screen pivots from hood pivots and lift hood from machine. 3. Disassemble hood as needed using Figure 330 as a guide. Installation 1. Assemble hood using Figure 330 as a guide. 2. Install hood to machine: A. Position hood to machine and engage screen pivots to hood pivots. B. Install hair pins (item 6) to secure screen pivots to hood pivots. 3.
Installation (continued) A. Place shim that is from 9.5 to 11.1 mm (3/8 to 7/16 in) thick on top of frame (both RH and LH sides) near the sides of radiator/oil cooler (Figure 331 and Figure 332). B. Close hood so that it rests on shims and fasten the hood latches. C. Loosen hood pivots at frame to adjust vertical placement of pivots. Re−tighten hood pivot fasteners. D. Loosen screen pivots to allow hood latches to pull hood against radiator support. Re−tighten screen pivot fasteners. 4.
Chassis: Service and Repairs Page 8–44 Groundsmaster® 4000-D & 4010-D 13202SL Rev F
Chapter 9 Cutting Decks Table of Contents General Information .............................................................................................................................. 9–2 Operator’s Manual ............................................................................................................................. 9–2 Castor Wheel Tire Pressure ............................................................................................................... 9–2 Blade Stopping Time........
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, adjustment procedures, and general maintenance for your Greensmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine. Castor Wheel Tire Pressure Castor tires on the front and side decks should be inflated to 345 kPa (50 PSI).
Service and Repairs CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine and remove key from ignition switch first.
Center Cutting Deck RIGHT 123 to 135 N·m (90 to 100 ft−lb) FRONT 38 8 17 19 18 20 6 5 4 2 37 12 11 10 3 9 5 30 31 15 14 29 33 25 23 28 34 14 13 36 36 32 11 15 37 7 23 24 21 22 12 27 26 203 to 237 N·m (150 to 175 ft−lb) 35 1 16 16 35 g277079 Figure 333 1. Center deck assembly 14. Ball joint mount (2 used) 27. Hair pin (2 used) 2. Grease fitting 15. Flange nut (2 per mount) 28. Cap screw 3. Ball joint seal 16. Cap screw (2 per mount) 29. Spherical rod end 4.
Removal (Figure 333) (continued) 2. Remove spring pin (item 32) that secures damper (item 30) to cutting deck. Position damper away from cutting deck. Note: Removal of clevis pin from deck and height−of− cut chain is easier if deck is lifted slightly. 2 1 g277088 Figure 334 1. Hairpin and clevis pin 2. Height−of−cut chain 1 1 2 g277089 Figure 335 1. Groundsmaster® 4000-D & 4010-D 13202SL Rev F Flange head screw 2.
Removal (Figure 333) (continued) 2 1 3 g277090 Figure 336 1. Ball joint mount 2. Lift arm 3. Castor arm 3. Remove hairpin and clevis pin that secure the height−of−cut chain to the rear of the cutting deck (Figure 334). 4. Remove hydraulic motor from cutting deck (see Cutting Deck Motors (page 5–155)). 5. Remove cap screws, washers and lock nuts securing ball joint mounts (item 14) to center deck castor arms (Figure 336). 6. Slide the center cutting deck away from the traction unit.
Side Cutting Decks RIGHT FRONT 11 2 4 3 7 5 6 1 10 9 8 g277091 Figure 337 1. Cutting deck (LH shown) 5. Clevis pin 9. Lock washer (8 used per mount) 2. Flange head screw (2 used) 6. 3. Hydraulic deck motor 7. Hair pin 10. Flat washer (8 used per mount) Deck mount (LH shown) 11. Lift arm (LH shown) 4. Spider 8. Cap screw (8 used per mount) Removal (Figure 337) 1. Position machine on a clean, level surface.
Removal (Figure 337) (continued) 3 2 1 g277092 Figure 338 1. Flange head screw 2. Hydraulic motor 3. Deck mount screw 1 2 3 g277093 Figure 339 1. Lift arm (RH shown) 2. Rear arm assembly Cutting Decks: Service and Repairs 3.
Removal (Figure 337) (continued) 1 134 to 138 mm (5.295 to 5.445 in) 2 g277094 Figure 340 1. Damper link 2. Clevis pin 3. Remove hairpin and clevis pin that secure the damper link to the rear of the cutting deck (Figure 340). 4. Remove eight (8) cap screws, lock washers and flat washers that secure deck mount to cutting deck (Figure 338). 5. Raise lift arm enough to separate deck mount from cutting deck (Figure 339). 6. Slide the cutting deck away from the traction unit.
Idler Assembly 18 17 16 22 RIGHT 15 FRONT 14 20 5 21 7 20 19 8 11 1 24 6 19 13 23 18 10 12 9 8 7 5 4 2 19 3 22 2 4 10 g277095 Figure 341 Socket head screw 17. Idler arm 10. Idler stop bolt 18. Retaining ring Flange nut 11. Flange nut 19. Thrust washer Adjusting screw 12. Cap screw 20. Bushing (2 used per idler) 1. Cutting deck (front shown) 2. Flange nut 3. 4. 9. 5. Idler pulley 13. Spacer 21. Grease fitting 6.
Removal (Figure 341) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove deck covers from top of cutting deck. CAUTION Be careful when removing idler spring. The spring is under heavy load and may cause personal injury. 3. Use spring hook tool to unhook the idler spring (item 15) from the adjusting screw (item 4). 4. Remove drive belt(s) from deck pulleys. 5.
Installation (Figure 341) (continued) 3 1 2 3.2 to 4.6 mm (0.125 to 0.185 in) 82.6 to 95.2 mm (3.250 to 3.750 in) g277080 Figure 342 1. Idler stop bolt 2. Idler spring 3. Adjusting screw 4. With the idler arm tensioning the drive belt, the idler spring hook to hook length should be from 82.6 to 95.2 mm (3.250 to 3.750 in) (Figure 342). If necessary, disconnect spring and change position of adjusting screw.
Blade Spindle Assemblies 6 6 2 3 5 4 5 5 4 4 6 6 1 RIGHT FRONT 6 6 g277081 Figure 343 1. Center cutting deck 3. LH cutting deck 5. Driven spindle assembly 2. RH cutting deck 4. Drive spindle assembly 6.
5 3 1 2 6 4 7 9 8 120 to 146 N·m (88 to 108 ft−lb) 10 g277082 Figure 344 1. Deck (RH shown) 6. Washer 2. Driven spindle assembly 7. Cap screw 3. Drive spindle assembly 8. Blade 4. Flange nut 9. Anti−scalp cup 5. Drive belt 10. Blade bolt Removal (Figure 343 and Figure 344) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove covers from cutting deck to allow access to spindle assemblies. 3.
Installation (Figure 343 and Figure 344) 1. If screws were removed from spindle housing, press new screws into housing. Make sure that screw head is squarely seated against housing after installation. 2. Position spindle assembly on cutting deck noting orientation of grease fitting (Figure 343). Secure spindle assembly to deck with removed fasteners. 3. Install cutting blade, anti−scalp cup and blade bolt to spindle. Tighten blade bolt from 120 to 146 N·m (88 to 108 ft−lb). 4.
Blade Spindle Service 2 1 176 to 203 N·m (130 to 150 ft−lb) 176 to 203 N·m (130 to 150 ft−lb) 3 7 1 8 9 2 6 10 5 11 12 9 8 13 DRIVE SPINDLE 4 g277083 Figure 345 1. Lock nut 6. Hydraulic motor mount 11. Spindle housing 2. Hardened washer 7. O−ring 12. Grease fitting 3. Driven pulley (single shown) 8. Oil seal 13. Spindle shaft spacer 4. Spindle shaft 9. Bearing cup and cone 5. Drive pulley 10. Spacer set Disassembly (Figure 345) 1.
Disassembly (Figure 345) (continued) 1 4 2 5 3 1 g277084 Figure 346 1. Bearing 4. Inner bearing spacer 2. Spacer ring 5. Outer bearing spacer 3. Large snap ring 4. Allow the bearing cones, inner bearing spacer and spacer ring to drop out of the spindle housing (Figure 346). 5. Using an arbor press, remove both of the bearing cups and the outer bearing spacer from the housing. 6. The large snap ring can remain inside the spindle housing. Removal of this snap ring is very difficult.
Assembly (Figure 345) (continued) PRESS 4 3 1 6 2 5 g277085 Figure 347 1. Bearing cups 4. Arbor press 2. Large snap ring 5. Support 3. Outer bearing spacer 6. Arbor press base 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.
Assembly (Figure 345) (continued) 6. Slide spacer ring and inner bearing spacer into spindle housing, then install upper bearing cone and oil seal into top of housing. Note: The upper seal must have the lip facing in (down) (Figure 348). Also, upper seal should be flush or up to 1.5 mm (0.060 in) recessed into housing. 7. Inspect the spindle shaft and shaft spacer to make sure there are no burrs or nicks that could possibly damage the oil seals. Lubricate the shaft and spacer with grease. 8.
Castor Forks and Wheels CASTOR FORK SIDE CUTTING DECK 34 14 20 13 12 16 1 11 6 7 19 10 9 31 5 15 8 32 2 17 10 21 22 33 7 18 81 to 108 N·m (60 to 80 ft−lb) 6 5 4 3 CASTOR WHEEL 4 28 29 30 23 24 81 to 108 N·m (60 to 80 ft−lb) 23 25 26 27 g277087 Figure 349 1. Castor arm (center deck shown) 13. Compression spring 25. Wheel hub 2. Cap screw (5 used) 14. Cap 26. Wheel rim half 3. 4. Castor fork Cap screw 15. 16. Flat washer Lock nut (3 used per bracket) 27. 28.
Chapter 10 Operator Cab (For models 30603 and 30607) Table of Contents General Information ............................................................................................................................ 10–2 Operator’s Manual ........................................................................................................................... 10–2 Electrical Components and Schematic.............................................................................................
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, adjustment procedures, and general maintenance for your Greensmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Service and Repairs General Precautions for Removing and Installing the Air Conditioning System Components WARNING Do not let the refrigerant contact your skin or eyes as there is a possibility of serious injury. Always wear safety goggles or a face shield when you work with the air conditioning system components. CAUTION Loosening any air conditioning system fitting or component allows the pressurized refrigerant to escape, causing possible injury.
General Precautions for Removing and Installing the Air Conditioning System Components (continued) 8. Always use a DOT approved tank to store the used and recycled refrigerants. 9. The air conditioning system uses R134a refrigerant. Do not use other refrigerants in the system. Note: The capacity of the air conditioning system is 1.55 kg (3.43 lb) of R134a refrigerant. 10. The refrigerant containers (either full or empty) are under pressure and the pressure increases if you heat them.
Air Conditioning Compressor 21 7 8 1 2 15 5 6 13 14 16 4 3 9 2 19 18 20 10 3 17 11 12 RIGHT FRONT g277159 Figure 350 1. Cap screw (2 used) 8. 15. O−ring Exhaust pipe 2. Flat washer (4 used) 9. A/C compressor 16. Flange nut 3. Lock washer (6 used) 10. Cap screw (4 used) 17. Carriage screw 4. Hex nut (2 used) 11. Cap screw (2 used) 18. Idler pulley 5. Conduit 12. A/C compressor mount 19. Compressor drive belt 6. O−ring (2 used) 13.
Removal (Figure 350) (continued) 6. Disconnect compressor electrical connector from machine wire harness. 2 3 1 g277161 Figure 351 1. A/C compressor 2. Alternator 3. A/C compressor mount 7. Read the General Precautions for Removing and Installing the Air Conditioning System Components (page 10–3). CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. 8.
Removal (Figure 350) (continued) Note: The air conditioning compressor used on the Groundsmaster 4010−D is a Sanden model SD5H09. For air conditioning compressor repair procedures, see the Sanden SD Compressor Service Guide. Installation (Figure 350) New compressor installation requires flushing of the system which also removes all air conditioning system PAG oil. New compressors should be drained of air condition PAG oil into a clean and clear graduated container.
Roof Assembly 16 3 4 1 15 14 2 3 FRONT 7 5 4 8 13 6 4 2 12 9 3 4 11 10 10 9 g277162 Figure 352 1. Roof 7. Panel nut 13. Front fastener (2 used) 2. Screw (2 used) 8. Roof mount 14. Rubber washer 3. Flat washer (6 used) 9. Flange nut (2 used) 15. Cap screw 16. Hex nut (4 used) 4. Bushing (10 used) 10. Flange nut (4 used) 5. Rear fastener (2 used) 11. Headliner 6. Rear spacer (2 used) 12.
Removal (Figure 352) 5 3 6 1 8 7 2 4 1 FRONT g277163 Figure 353 1. Condensation drain hose (2 used) 5. A/C hose: compressor to condenser 2. 3. Heater valve A/C hose: evaporator to compressor 6. 7. A/C hose: condenser to drier Heater hose: thermostat to heater valve 4. Heater hose: heater valve to heater core 8. Heater hose: heater core to water pump 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2.
Air Conditioning Condenser Assembly 10 1 2 6 8 3 6 4 2 6 8 7 6 FRONT 9 5 g277164 Figure 354 1. Condenser cover 5. Carriage screw (2 used) 2. Lock nut (4 used) 6. Flat washer (8 used) 3. 4. Condenser fan Condenser coil assembly 7. 8. Roof Bushing (4 used) 9. 10. Mounting strap Button head screw (4 used) Removal (Figure 354) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2.
Removal (Figure 354) (continued) CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. 7. Have refrigerant evacuated from air conditioning system by a certified A/C service technician. 8. Label and remove hoses from condenser coil. Immediately cap hoses and fittings to prevent moisture and contaminants from entering the system.
Removal (Figure 354) (continued) 9. Remove condenser coil from roof using Figure 355 as a guide. Note: The replacement of the drier−receiver is recommended whenever the air conditioning system is opened (see Heater/Evaporator Assembly (page 10–13)). Installation (Figure 354) 1. Install condenser coil to roof using Figure 355 as a guide. 2. Remove caps that were placed on hoses and fittings during the removal process. Using labels placed during removal, properly secure hoses to condenser coil. 3.
Heater/Evaporator Assembly 2 16 12 10 1 9 15 13 14 13 11 7 6 4 8 12 3 5 g277166 Figure 356 1. Heater/evaporator assembly 7. Speed nut (8 used) 13. Expansion valve 2. Top cover 8. Panel nut (4 used) 14. Freeze switch 3. Flange head screw (2 used) 9. 4. Drier−receiver mount 5. 6. Drier−receiver assembly 15. Screw (2 used) 10. Screw (8 used) 16. Screw (12 used) Bottom cover 11. Screw (4 used) Hose clamp (2 used) 12. Blower fan assembly Removal (Figure 356) 1.
Removal (Figure 356) (continued) 5 3 6 1 8 7 2 4 1 FRONT g277167 Figure 357 1. Condensation drain hose (2 used) 5. A/C hose: compressor to condenser 2. 3. Heater valve A/C hose: evaporator to compressor 6. 7. A/C hose: condenser to drier Heater hose: thermostat to heater valve 4. Heater hose: heater valve to heater core 8. Heater hose: heater core to water pump 4. Read the General Precautions for Removing and Installing the Air Conditioning System Components (page 10–3).
Installation (Figure 356) 1. Assemble heater/evaporator assembly using Figure 356 as a guide. Make sure that expansion valve is covered with insulating tape to prevent condensation issues. 1 4 2 3 g277168 Figure 358 1. Fan resistor 3. Clamp 2. Blower fan assembly 4. Screw (2 used) 2. If removed, secure fan resistor to blower fan assembly (Figure 358). 3. Position heater/evaporator assembly into bottom cover in headliner. Secure top cover to bottom cover with removed screws. 4.
Windshield Wiper 8 1 7 9 2 3 4 10 5 6 11 12 13 g277160 Figure 359 1. Wiper motor 6. Cap (2 used) 11. Wiper arm assembly 2. Gasket 7. Washer 12. Wiper blade 3. Linkage bracket 8. Nut 13. Screw (2 used) 4. Lock washer 9. Flange nut (2 used) 5. Cap screw 10. Cover (2 used) Disassembly (Figure 359) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2.
Assembly (Figure 359) 1. Assemble windshield wiper components using Figure 359 as a guide. 2. If roof was raised, lower and secure roof assembly (see Roof Assembly (page 10–8)).
Operator Cab (For models 30603 and 30607): Service and Repairs Page 10–18 Groundsmaster® 4000-D & 4010-D 13202SL Rev F
Chapter 11 Operator Cab (For models 30635 and 30636) Table of Contents General Information ............................................................................................................................ 11–2 Traction Unit Operator’s Manual ...................................................................................................... 11–2 Electrical Components and Schematic.............................................................................................
General Information Traction Unit Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine. Electrical Components and Schematic Information regarding the electrical cab components (switches and relays) are included in Chapter 6: Electrical System (page 6–1).
Air Conditioning System Performance There are a number of factors that can affect the performance of the air conditioning system of your machine. To ensure the best system operation, inspect the following components: 1. Ensure that the heater control fully closes the heater valve in the cab headliner. 2. Ensure that the condenser and evaporator fins are clean. 3. Check that the refrigerant charge quantity and system operating pressures are correct. 4.
Service and Repairs General Precautions for Removing and Installing the Air Conditioning System Components WARNING Do not let the refrigerant contact your skin or eyes as there is a possibility of serious injury. Always wear safety goggles or a face shield when you work with the air conditioning system components. CAUTION Loosening any air conditioning system fitting or component allows the pressurized refrigerant to escape, causing possible injury.
General Precautions for Removing and Installing the Air Conditioning System Components (continued) 8. Always use a DOT approved tank to store the used and recycled refrigerants. 9. The air conditioning system uses R134a refrigerant. Do not use other refrigerants in the system. Note: The capacity of the air conditioning system is 1.55 kg (3.43 lb) of R134a refrigerant. 10. The refrigerant containers (either full or empty) are under pressure and the pressure increases if you heat them.
Air Conditioning Compressor g278801 Figure 360 1. Pulley 8. Idler pulley 15. O-ring 2. Lock washer (5 each) 9. Nut (6 each) 16. Elbow fitting 3. Bolt (3 each) 10. Compressor mount 17. Convoluted conduit 4. V-belt 11. Bolt (2 each) 18. Straight fitting (2 each) 5. Carriage bolt (5 each) 12. Compressor 19. Shim (4 each) 6. Carriage bolt 13. Washer (4 each) 20. Engine 7. Pulley mount 14. Nut (2 each) Removing the Air Conditioning Compressor (Figure 360) 1.
Removing the Air Conditioning Compressor (Figure 360) (continued) 2. Raise the hood to get access to the engine and air conditioning compressor. 3. Remove the exhaust pipe; refer to Exhaust System (Models 30607, 30609 and 30636) (page 4–30). 4. Loosen the flange nut that secures the idler pulley. Move the pulley to loosen A/C compressor drive belt. Remove the drive belt from A/C compressor pully. 5. Inspect the compressor drive belt for glazing or damage. Replace the belt if necessary. 6.
Installing the Air Conditioning Compressor (Figure 360) (continued) IMPORTANT After the compressor has been installed, make sure to rotate the compressor drive shaft several times to properly distribute oil in the compressor. Compressor damage due to oil slugging can occur if this procedure is not performed. 3. Manually rotate the compressor drive shaft at least ten (10) revolutions to make sure that no compressor oil is in the compressor cylinders. 4. Place drive belt onto compressor pulley. 5.
Roof Assembly g278816 Figure 361 1. Roof panel 6. Rear condenser seal 11. Front/rear cab strap (2 each) 2. Flange-head screw (16 each) 7. Left condenser seal 12. Flange nut (22 each) 3. Right condenser seal 8. Shoulder screw (22 each) 13. Headliner assembly 4. Condenser screen 9. Flat washer (22 each) 14. Side cab strap (2 each) 5. Front condenser seal 10. Condenser assembly Get access to the heater core and air conditioning components by removing the roof panel.
Removing the Roof Assembly (continued) 2. Release the 4 swell latches and lift the condenser screen (item 4 in Figure 361) from the roof assembly. 3. Remove the 16 flange-head screws (item 2 in Figure 361) that secure the condenser seals (items 3, 5, 6, and 7) to the roof and air conditioning condenser assembly. 4. Remove the 22 shoulder screws (item 8 in Figure 361), 22 flat washers, and 22 flange nuts that secure the roof and cab straps to the headliner. 5.
Heating and Air Conditioning Components g278839 Figure 362 1. Air conditioning binary switch 4. Air conditioning condenser assembly 7. Heat and air conditioning mixing box assembly 2. Air conditioning drier-receiver 5. Left intake air filter 8. Wiper motor assembly 3. Right intake air filter 6.
Heating and Air Conditioning Components (continued) g278838 Figure 363 1. Evaporator/heater cores 3. Air diverter assembly 2. Blower fan 4. Air conditioning freeze switch Get access to the cab heating and air conditioning components by removing the cab roof; refer to Roof Assembly (page 11–9). After you remove the cab roof, refer to Figure 362 and Figure 363 to identify the components used for heating and cooling the operator cab.
Air Conditioning Condenser Fan Assembly g278864 Figure 364 1. Cab frame 3. Air conditioning condenser assembly 2. Cab headliner assembly 4. Knob (2 each) Groundsmaster® 4000-D & 4010-D 13202SL Rev F Page 11–13 5.
Removing the Air Conditioning Condenser Fan Assembly g278865 Figure 365 1. Condenser fan (2 each) 2. Fan plug (2 each) 3. Knob (2 each) g278866 Figure 366 1. Screw (4 each per fan) 4. Plug (3 each) 2. Fan tab (4 each per fan) 5. Fan mount plate 3. Condenser fan (2 each) 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Installing the Air Conditioning Condenser Fan Assembly 1. If the condenser fan assembly was disassembled, secure the fans to the fan mount plate (Figure 366). 2. Raise and support the fan assembly to the cab frame. 3. Secure the fan assembly to the machine with the 2 knobs. 4. Connect the 2 condenser fan plugs to the wire harness connectors that are attached to the cab frame.
Air Conditioning Condenser Assembly g278919 Figure 367 1. Cab frame 5. Condenser fan assembly 2. Cab headliner assembly 6. Flange nut (4 each) 3. Air conditioning condenser assembly 7. Strip seal (2 each) 4. Knob (2 each) 8. Edge seal (2 each) Removing the Air Conditioning Condenser Assembly 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Removing the Air Conditioning Condenser Assembly (continued) CAUTION Loosening any air conditioning system fitting or component allows the pressurized refrigerant to escape, causing possible injury. Do not loosen any system fitting or component until a certified air conditioning service technician discharges the system completely. g278920 Figure 368 1. 2. Condenser core Lower leg (2 each) 7. 8. Left side wall Strip seal (2 each) 3. Hex nut (6 each) 9. Edge seal (2 each) 4. Front wall 10.
Installing the Air Conditioning Condenser Assembly 1. If the condenser assembly was disassembled, do as follows: A. To properly seal the condenser core, apply RTV sealant to all mating surfaces of walls, lower legs, and condenser core before assembly. B. Assemble all the condenser assembly components as shown in Figure 368. Note: Ensure that the strip and edge seals are in good condition after assembly. 2. Carefully lower the air conditioning condenser assembly through the headliner and onto the cab frame.
Mixing Box Assembly g278973 Figure 369 1. Mixing box 12. Hairpin 2. Mixing box cover 13. Flat washer 24. Tube support (2 each) 3. Cover insulation 14. Carriage screw (2 each) 25. Vent hose (2 each) 4. Rivet (19 each) 15. Support plate 26. Adapter (2 each) 5. Heater core/ air conditioning evaporator/fan assembly 16. Flange nut (4 each) 27. Hose clamp (2 each) 23. Vent hose (2 each) 6. Expansion valve 17. Flat washer (2 each) 28. Vent hose 7. O-ring (2 each) 18.
Removing the Mixing Box Assembly 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the roof panel from the top of the cab to get access to the mixing box assembly; refer to Removing the Roof Assembly (page 11–9). 3. Remove the cover from the mixing box assembly as follows: A. Carefully use a small prybar to raise the head of the pin in the center of each rivet that secures the mixing box cover. B.
Installing the Mixing Box Assembly g278974 Figure 370 1. Evaporator and heater core 5. Air diverter assembly 2. Blower fan 6. Air conditioning expansion valve 3. Air conditioning binary switch 7. Air conditioning freeze switch 4. Air conditioning drier-receiver 1. Install all the mixing box components that were removed (Figure 369 and Figure 370). Note: Ensure that the expansion valve is covered with insulating tape to prevent condensation issues. 2.
Installing the Mixing Box Assembly (continued) 6. Secure the cover to the mixing box assembly as follows: A. Position the mixing box cover to the mixing box. Ensure that the wire harness is routed through recess in side of the mixing box. B. With the rivet pin in a raised position, insert the rivets through the cover and into the hole in the mixing box. Press the pin into the rivet to secure the rivet in place. 7. Operate the heater system to ensure that there are no coolant leaks in the cab headliner. 8.
Heater and Air Conditioning Evaporator Cores g278977 Figure 371 1. Mixing box 10. Mount bracket (shown with fan) 2. Rivet (19 each) 11. Expansion valve 3. Mixing box cover 12. O-ring (2 each) 4. Cover insulation 13. Air conditioning evaporator core 5. Screw (5 each) 14. Heater core 6. Mount bracket cover 15. Double sided tape (2 each) 7. Cover gasket 16. Gasket (4 each) 8. Screw (2 each) 17. Condensation catch foam 9. Freeze switch 18.
Removing the Heater and Air Conditioning Evaporator Cores (continued) CAUTION Loosening any air conditioning system fitting or component allows the pressurized refrigerant to escape, causing possible injury. Do not loosen any system fitting or component until a certified air conditioning service technician discharges the system completely. 4. Have a certified air conditioning service technician evacuate the air conditioning system. 5.
Installing the Heater and Air Conditioning Evaporator Cores (continued) 5. Secure the cover to the mixing box assembly as follows: A. Position the mixing box cover to the mixing box. Ensure that the wire harness is routed through recess in side of the mixing box. B. With the rivet pin in a raised position, insert the rivets through cover and into the hole in the mixing box. Press the pin into the rivet to secure the rivet in place. 6.
Blower Fan g279105 Figure 372 1. Mixing box 5. Heater core/air conditioning evaporator assembly 9. Screw (6 each) 2. Rivet (19 each) 6. O-ring (2 each) 10. Freeze switch 3. Mixing box cover 7. Expansion valve 11. Screw (2 each) 4. Cover insulation 8. Blower fan 12. Air diverter assembly Note: The blower fan can be removed and installed with the mixing box (item 1 in Figure 372) attached to the cab headliner. Removing the Blower Fan 1.
Removing the Blower Fan (continued) CAUTION Loosening any air conditioning system fitting or component allows the pressurized refrigerant to escape, causing possible injury. Do not loosen any system fitting or component until a certified air conditioning service technician discharges the system completely. 4. Have a certified air conditioning service technician evacuate the refrigerant from the air conditioning system. 5. Disconnect both evaporator core swivel fittings from front ports of expansion valve.
Installing the Blower Fan 1. Position the blower fan to the heater core/air conditioning evaporator assembly and secure the fan with the 6 screws. 2. Carefully lower the heater core/air conditioning evaporator assembly with attached blower fan into the mixing box. 3. Connect the wire harness connectors to the freeze switch and blower fan assembly (Figure 373). 4. Secure the mixing box cover as follows: A. Position the mixing box cover to the mixing box.
Windshield Wiper Assembly g279149 Figure 374 1. Wiper blade 6. Cab headliner 11. Washer-head screw (2 each) 2. Bolt (2 each) 7. Washer plate 12. Wiper motor 3. Lock washer (2 each) 8. Wiper bracket 13. Bolt Washer-head screw (4 each) 14. Lock washer 4. Wiper arm assembly 9. 5. Flange nut (2 each) 10. Flange nut (4 each) Disassembling the Windshield Wiper Assembly 1.
Disassembling the Windshield Wiper Assembly (continued) 3. If necessary, remove the wiper arm assembly as follows: A. Disconnect the washer hose from the wiper assembly. B. Lift the caps at the top of the wiper arms and remove the flange nuts that secure the wiper arms to the wiper motor. C. Use a suitable puller to remove the tapered wiper arm sockets from the wiper motor shafts. 4.
Appendix A Foldout Drawings Table of Contents Electrical Drawing Designations.........................................................................................................A–3 Hydraulic Schematic .........................................................................................................................A–5 Electrical Schematic for Models 30605 and 30603/30635 (For machines serial number below 400000000)..................................................................................
Engine Wire Harness Diagram (For machines serial numbers 400000001 to 403450000)....................................................................................................................A–35 Engine Wire Harness Diagram (For machines serial numbers 400000001 to 403450000)....................................................................................................................A–36 Engine Wire Harness Diagram (For machines serial above 403450001)..........................................
Electrical Drawing Designations Note: A splice used in a wire harness will be identified on the wire harness diagram by SP. The manufacturing number of the splice is also identified on the wire harness diagram (e.g., SP01 is splice number 1). Wire Color The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter.
Foldout Drawings Page A–4 Groundsmaster® 4000-D & 4010-D 13202SL Rev F
Hydraulic Schematic 2.00” BORE 4.20” STROKE 0.625” ROD COOLING FAN MOTOR 0.51 CID STEERING CYLINDER G R M1 G M1 L STEERING CONTROL VALVE LEFT DECK 2.50” BORE 6.50” STROKE 1.125” ROD M2 C3 C4 C2 C5 OR5 .070 OR3 .070 S10 RIGHT DECK 2.50” BORE 6.50” STROKE 1.125” ROD CENTER DECK RAM CYLINDERS 1.50” BORE 3.08” STROKE C6 OR7 .070 P1 CH4 .025 1.17 CID 3250 PSI PRV G 3000 PSI S4 S9 6.
Electrical Schematic for Models 30605 and 30603/30635 (For machines serial number below 400000000) NOTE: WHEN A WIRE FROM THIS SCHEMATIC CONTINUES TO THE OPERATOR CAB, A REFERENCE NUMBER WILL BE LISTED. THE CAB SCHEMATIC WILL ALSO INCLUDE THE REFERENCE NUMBER. All relays and solenoids are shown as de−energized. All ground wires are black.
Electrical Schematic for Models 30605 and 30603/30635 (For machines serial number 400000001 to 403450000) g327813 Groundsmaster 4000-D/4010-D (For machines serial number 400000001 to 403450000), Drawing 122-0975 Rev C, Sheet 1 of 2 13202SL Rev F Page A–7
Electrical Schematic for Models 30605 and 30603/30635 (For machines serial number 400000001 to 403450000) g279724 Page A–8 13202SL Rev F Groundsmaster 4000-D/4010-D (For machines serial numbers 400000001 to 403450000), Drawing 122-0975 Rev C, Sheet 2 of 2
Electrical Schematic for Models 30605 and 30603/30635 (For machines serial number above 403450001) g327815 Groundsmaster 4000-D/4010-D (For machines serial numbers above 403450001), Drawing 122-1529 Rev A, Sheet 1 of 2 13202SL Rev F Page A–9
Electrical Schematic for Models 30605 and 30603/30635 (For machines serial number above 403450001) g279724 Page A–10 13202SL Rev F Groundsmaster 4000-D/4010-D (For machines serial numbers above 403450001), Drawing 122-1529 Rev A, Sheet 2 of 2
Electrical Schematic for Models 30609 and 30607/30636 (For machines serial number below 400000000) NOTE: WHEN A WIRE FROM THIS SCHEMATIC CONTINUES TO THE OPERATOR CAB, A REFERENCE NUMBER WILL BE LISTED. THE CAB SCHEMATIC WILL ALSO INCLUDE THE REFERENCE NUMBER. All relays and solenoids are shown as de−energized. All ground wires are black.
Electrical Schematic for Models 30609 and 30607/30636 (For machines serial numbers 400000001 to 403450000) g279723 Page A–12 13202SL Rev F Groundsmaster 4000-D/4010-D (For machines serial number 400000001 to 403450000), Drawing 122-0975 Rev C, Sheet 1 of 2
Electrical Schematic for Models 30609 and 30607/30636 (For machines serial numbers 400000001 to 403450000) g279724 Groundsmaster 4000-D/4010-D (For machines serial number 400000001 to 403450000), Drawing 122-0975 Rev C, Sheet 2 of 2 13202SL Rev F Page A–13
Electrical Schematic for Models 30609 and 30607/30636 (For machines serial numbers above 403450001) g327814 Page A–14 13202SL Rev F Groundsmaster 4000-D/4010-D (For machines serial number above 403450001), Drawing 122-1529 Rev A, Sheet 1 of 2
Electrical Schematic for Models 30609 and 30607/30636 (For machines serial numbers above 403450001) g279724 Groundsmaster 4000-D/4010-D (For machines serial number above 403450001), Drawing 122-1529 Rev A, Sheet 2 of 2 13202SL Rev F Page A–15
Electrical Schematic - Operator Cab (shown with lights for models 30603 and 30607) NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. 1 2 TO GROUND BLOCK 4 FROM OPERATOR PLATFORM WIRE HARNESS 3 TO OPERATOR PLATFORM WIRE HARNESS TO CAB WIRE HARNESS All relays and solenoids are shown as de−energized. All ground wires are black.
Electrical Schematic - Operator Cab (shown with lights for models 30635 and 30636) g279174 Operator Cab (shown with lights for models 30635 and 30636), Drawing 119-4388 Rev A, Sheet 1 of 1 13202SL Rev F Page A–17
Electrical Schematic - International Light Kits NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. 4 2 FROM OPERATOR PLATFORM WIRE HARNESS 3 TO OPERATOR PLATFORM WIRE HARNESS TO OPERATOR PLATFORM WIRE HARNESS TO CAB WIRE HARNESS 5 All relays and solenoids are shown as de−energized. All ground wires are black. NOTE: THE OPERATOR CAB SCHEMATIC SHOULD BE USED WITH THE ELECTRICAL SCHEMATIC FOR THE APPROPRIATE MODEL NUMBER WHICH IS ON A SEPARATE PAGE.
Platform Wire Harness Diagram (For machines serial number below 400000000) A B C D 1 2 3 4 5 g277237 Groundsmaster 4000-D/4010-D (For machines serial number below 400000000), Drawing Rev , Sheet 1 of 3 13202SL Rev F Page A–19
Platform Wire Harness Diagram (For machines serial number below 400000000) NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. NOTE: THE PLATFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, A REFERENCE NUMBER WILL BE IDENTIFIED.
Platform Wire Harness Diagram (For machines serial number below 400000000) NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. NOTE: THE PLATFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, A REFERENCE NUMBER WILL BE IDENTIFIED.
Platform Wire Harness Diagram (For machines serial numbers 400000000 to 403450000) g279263 Page A–22 13202SL Rev F Groundsmaster 4000-D/4010-D (For machines serial numbers 400000000 to 403450000), Drawing 122-0973 Rev D, Sheet 1 of 3
Platform Wire Harness Diagram (For machines serial numbers 400000000 to 403450000) g279264 Groundsmaster 4000-D/4010-D (For machines serial numbers 400000000 to 403450000), Drawing 122-0973 Rev D, Sheet 2 of 3 13202SL Rev F Page A–23
Platform Wire Harness Diagram (For machines serial numbers 400000000 to 403450000) g279265 Page A–24 13202SL Rev F Groundsmaster 4000-D/4010-D (For machines serial numbers 400000000 to 403450000), Drawing 122-0973 Rev D, Sheet 3 of 3
Platform Wire Harness Diagram (For machines serial numbers above 403450001) CV g327816 Groundsmaster 4000-D/4010-D (For machines serial numbers above 403450001), Drawing 122-1530 Rev A, Sheet 1 of 3 13202SL Rev F Page A–25
Platform Wire Harness Diagram (For machines serial numbers above 403450001) g327817 Page A–26 13202SL Rev F Groundsmaster 4000-D/4010-D (For machines serial numbers above 403450001), Drawing 122-1530 Rev A, Sheet 2 of 3
Platform Wire Harness Diagram (For machines serial numbers above 403450001) g327818 Groundsmaster 4000-D/4010-D (For machines serial numbers above 403450001), Drawing 122-1530 Rev A, Sheet 3 of 3 13202SL Rev F Page A–27
g326106 Page A–28 13202SL Rev F , Drawing Rev , Sheet
Rear Wire Harness Diagram (For machines serial number below 400000000) g277221 Groundsmaster 4000−D/4010−D (For machines serial number below 400000000), Drawing Rev , Sheet 1 of 2 13202SL Rev F Page A–29
Rear Wire Harness Diagram (For machines serial number below 400000000) NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
Rear Wire Harness Diagram (For machines serial number above 400000000) CV g279590 Groundsmaster 4000-D/4010-D (For machines serial number above 400000000), Drawing 122-0974 Rev B, Sheet 1 of 2 13202SL Rev F Page A–31
Rear Wire Harness Diagram (For machines serial number above 400000000) g279591 Page A–32 13202SL Rev F Groundsmaster 4000-D/4010-D (For machines serial number above 400000000), Drawing 122-0974 Rev B, Sheet 2 of 2
Engine Wire Harness Drawing for Models 30607, 30609, 30636 (For machines serial number below 400000000) g277223 Groundsmaster 4000−D/4010−D Models 30607, 30609, 30636 (For machines serial number below 400000000), Drawing Rev , Sheet 1 of 2 13202SL Rev F Page A–33
Engine Wire Harness Diagram for Models 30607, 30609, 30636 (For machines serial number below 400000000) NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
Engine Wire Harness Diagram (For machines serial numbers 400000001 to 403450000) g279588 Groundsmaster 4000-D/4010-D (For machines serial numbers 400000001 to 403450000), Drawing 122-0229 Rev C, Sheet 1 of 2 13202SL Rev F Page A–35
Engine Wire Harness Diagram (For machines serial numbers 400000001 to 403450000) g279589 Page A–36 13202SL Rev F Groundsmaster 4000-D/4010-D (For machines serial numbers 400000001 to 403450000), Drawing 122-0229 Rev C, Sheet 2 of 2
Engine Wire Harness Diagram (For machines serial above 403450001) CV g327819 Groundsmaster 4000-D/4010-D (For machines serial number above 403450001), Drawing 122-1569 Rev C, Sheet 1 of 2 13202SL Rev F Page A–37
Engine Wire Harness Diagram (For machines serial above 403450001) g327820 Page A–38 13202SL Rev F Groundsmaster 4000-D/4010-D (For machines serial number above 403450001), Drawing 122-1569 Rev C, Sheet 2 of 2
Engine Wire Harness Drawing for Models 30603, 30605, 30635 g277225 Groundsmaster 4000−D/4010−D for models 30603, 30605, 30635, Drawing Rev , Sheet 1 of 2 13202SL Rev F Page A–39
Engine Wire Harness Diagram for Models 30603, 30605, 30635 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
Operator Cab Wire Harness Diagram (For machines serial number below 400000000) g277227 Groundsmaster 4000-D/4010-D (For machines serial number below 400000000), Drawing Rev , Sheet 1 of 2 13202SL Rev F Page A–41
Operator Cab Wire Harness Diagram (For machines serial number below 400000000) NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
Operator Cab Wire Harness Diagram (For machines serial number above 400000000) g279586 Groundsmaster 4000-D/4010-D (For machines serial number above 400000000), Drawing 122-0723 Rev B, Sheet 1 of 2 13202SL Rev F Page A–43
Operator Cab Wire Harness Diagram (For machines serial number above 400000000) g279587 Page A–44 13202SL Rev F Groundsmaster 4000-D/4010-D (For machines serial number above 400000000), Drawing 122-0723 Rev B, Sheet 2 of 2
Operator Cab Interconnect Wire Harness NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
Wire Harness Diagram − Two−Post ROPS Extension (Models 30605 and 30609) 6 5 4 3 2 1 D D C C B B A A 6 5 4 3 2 1 g277230 Page A–46 13202SL Rev F Groundsmaster 4000 (Models 30605 and 30609), Drawing 122−0892 Rev B, Sheet 1 of 2
Wire Harness Diagram − Two−Post ROPS Extension (Models 30605 and 30609) 6 5 4 3 2 1 D D C C B B A A 6 5 4 3 2 1 g277231 Groundsmaster 4000 (Models 30605 and 30609), Drawing 122−0892 Rev B, Sheet 2 of 2 13202SL Rev F Page A–47
